Case 580SK SM PDF

Case 580 Super K
Backhoe • Loader • Tractor

Service Manual
P.I.N. JJG0160001 and after
v 9.0
http://BestManuals.net
Best.Manuals@yahoo.com
580 Super K Loader Backhoe
P.I.N. JJG0160001 and after
Service Manual
Table of Contents
Description Section No Form No

General Tabl
Loctite Product Chart 8-98900
Section Index - General 8-17141
Torque Specifications 10001 8-71600
Fluids & Lubricants 10002 8-12271
Engines Tab 2
Section Index - Engine 8-17161
Engine Removal & Installation 2001 8-17560
Stall Tests 2002 8-12301
Detailed Engine Specifications 2402 8-24163
Cylinder Head & Valve Train 2415 8-24173
Cylinder Block 2425 8-24183
Lubrication System 2445 8-24193
Cooling System 2455 8-24203
Turbocharger 2465 8-25550
Turbocharger Failure Analysis 2565 9-78235
Fuel System Tab 3

Section Index - Fuel System 8-17190
Fuel System & Filters 3410 8-24212
Fuel Inj ectors 3413 8-24233
CAV Injection Pump (4-390) 3414 7-37131
Bosch Injection Pump (4T-390) 3415 7-37141
Electrical Tab 4
Section Index - Electrical 8-17200
Removal & Installation of Electrical Components 4001 8-17210
Specifications, Troubleshooting & Schematics 4002 8-17220
Batteries 4003 8-12350
Starter & Starter Selenoid 4004 8-11370
95 Ampere Alternator 4006 8-12381
65 Ampere Alternator 4007 8-15670
Instrument Cluster 4008 8-17230
Steering Tab 5
Section Index - Steering 8-17250
Removal & Installation of Steering Component 5001 8-17260
Specifications, Schematics & Troubleshooting 5002 8-17270
Steering Control Valve - Eaton 5004 8-12440
Steering Control Valve - Danfoss 5005 8-12450
Steering Cylinder 5006 8-17280
Front Axle - Two Wheel Drive 5007 8-12471
Front Axle - Four Wheel Drive 5008 8-17300
Description Section No Form No
Power Train Tab 6

Section Index - Power Train 8-17570
Removal & Installation of Components 6001 8-12501
Transmission Specifications & Schematic 6002 8-12512
Wheels & Tires 6003 8-12521
PTO 6019 7-37060
Rear Axles & Planetaries 6201 7-36980
Transfer Gearbox 6202 7-36990
Differential & Differential Lock 6203 7-37000
ForwardlReverse Valve 6204 7-37010
Torque Converter Charging Pump, Output Shaft
& Converter Housing 6205 7-37020
Transmi ssi on 6206 7-37030
Brakes Tab 7
Section Index - Brakes 8-17350
Parking Brake 7000 7-37040
Disc Brakes 7001 7-37050
Removal & Installation of Brake Components 7002 8-12540
Master Cylinder 7003 8-12570
Hydraulics TabS
Section Index - Hydraulics 8-12580
Removal & Installation of Hydraulic Components 8001 8-17580
Schematics, Specifications & Troubleshooting 8002 8-17530
Cleaning the Hydraulic System 8003 8-67390
Hydraulic Pump 8004 8-17400
Loader Control Valve 8005 8-17410
Cylinder 8006 8-17591
Backhoe Control Valve 8007 8-17430
Swing Sequence Valve 8008 8-12650
Three Point Hitch Control Valve 8009 8-67421
Double Selector Valve 8011 8-12670
Mounted Equipment Tab 9

Section Index - Mounted Equipment 8-12680
Pedals & Levers 9001 8-17540
Air Conditioning Troubleshooting &
Pressure Checks 9002 8-12700
Air Conditioning System 9003 8-12711
Loader 9004 8-17630
ROBS Cab & ROPS Canopy 9005 8-17470
Backhoe 9006 8-12741
Three Point Hitch 9008 8-12761
Seat & Seat Belts 9009 8-12770
Suspension Seat 9010 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
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1001
STANDARD TORQUE SPECIFICATIONS
TABLE OF CONTENTS
Torque Specifications - Decimal Torque Specifications - Steel Hydraullc

Hardware 1001-2 Fittings 1001-4
Torque Specifications - Metric Hardware ...1001-3 Torque Specifications - O-ring Face

Seal Fittings..... ....................1001-5
Printed in U.S.A.
CASE CORPORATION Bur 8-71600
Issued May 1988
1001-2
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special tor-
ques are not given. These torques apply to fasten-
ars with both UNC and UNF threads as received
from suppliers. dry. or when lubricated with engine
oil Not applicable if special graphites, rnotydisul-
fide greases. or other extreme pressure lubricants
are used.
8113608
1001-3
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following toques when special torques
are not given.
These values apply to fasteners with coarse

threads as received from supplier. plated or un-
plated. or when lubricated with engine oil. These
values do not apply if graphite or molydisulfide
grease or oil if used.
811359A
1001-4
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton
Hose ID Size Feet metres Hose ID Size Feet metres
37 Degree Flare Fittings Straight Threads with O-ring
1/4 in 7/16-20 6-12 8-16 1/4 in 7/16-20 12-19 16-25

6.4 mm 6.4 mm
5/16 in 1/2-20 8-16 11-21 5/16 in 1/2-20 16-25 22-23

7.9 mm 7.9 mm
3/8 in 9/16-18 10-25 14-33 3/8 in 9/16-18 25-40 34-54

9.5 mm 9.5 mm
1/2 in 3/4-16 15-42 20-56 1/2 in 3/4-16 42-67 57-90

12.7 mm 12.7 mm
5/8 in 7/8-14 25-58 34-78 5/8 in 7/8-14 58-92 79-124

15.9 mm 15.9 mm
3/4 in 1-1/16-12 40-80 54-108 3/4 in 1-1/16-12 80-128 108-174

19.0 mm 19.0 mm
l/8.in 1-3/16-12 60-100 81-135 7/8 in 1-3/16-12 100-160 136-216

22.2 mm 22.2 mm
1.0 in 1-5/16-12 75-117 102-158 1.0 in 1-5/16-12 117-187 159-253

25.4 mm 25.4 mm
1-1/4 in 1-5/8-12 125-165 169-223 1-1/4 in 1-5/8-12 165-264 224-357

31.8 mm 31.8 mm
1-1/2 in 1-7/8-12 210-250 285-338 1-1/2 in 1-7/8-12 250-400 339-542

38.1 mm 38.1 mm
Split Flange Mounting Bolts

Pound- Newton
Size Feet metres
5/16-18 15-20 20-27
3/8-16 20-25 26-33
7/16-14 35-45 47-61
1/2-13 55-65 74-88
5/8-11 140-150 190-203

8113618
1001-5
TORQUE SPECIFICATIONS - O-RING FACE SEAL FITTING
Nom.
SAE
Dash Thread Pound- Newton Thread Pound- Newton
Size Tube 00 Size Feet Metres Size Feet Metres
O-ring Face Seal End O-ring Boss End

Fitting or Locknut
-4 1/4 In 9/16-18 10-12 14-16 7/16-20 17-20 23-27
6.4 mm
-6 3/8 in 11/16-16 18-20 24-27 9/16-18 25-30 33-40

95 mm
-8 1/2 in 13/16-16 32-40 43-54 3/4-16 45-50 61-68

12.7 mm
-10 5/8 in 1-14 46-56 60-75 7/8-14 60-65 81-88

I 15.9 mm
I
-12 3/4 in 1-3/16-12 65-80 90-110 1-1/16-12 85-90 115-122

19.0 mm
I
-14 7/8 in 1-3/16-12 65-80 90-110 1-3/16-12 95-100 129-136

22.2 mm I
-16 1.0 in 1-7/16-12 92-105 125-140 1-5/16-12 115-125 156-169

25.4 mm
-20 1-1/4 in 1-11/16-12 125-140 170-190 1-5/8-12 150-160 203-217

31.8 mm
-24 1-1/2 in 2-12 150-180 200-254 1-7/8-12 190-200 258-271

38.1 mm
8871553
Section
1002
FLUIDS AND LUBRICANTS

Issued March 1991
1002-2
TABLE OF CONTENTS
CAPACITIES AND LUBRICANTS ... ....................................... 2
ENGINE OIL RECOMMENDATIONS . . 3
DIESEL FUEL . .. .4
CAPACITIES AND LUBRICANTS

Engine Oil
Capacity with Filter Change 11.6 U.S. quarts (11 litres)
Type of oil. See Engine Oil Recommendations on page 3
Engine Cooling System

Capacity without heater 17.2 U.S. quarts (16.3 litres)
Capacity with heater.. ... 17.9 U.S quarts (16.9 litres)
Type of coolant. Ethylene glycol and water mixed for lowest ambient temperature
At least SO/50 mix
Fuel Tank
Capacity 25 U.S. gallons (94.6 litres)
Capacity with auxiliary tank.................................. . 33 U.S. gallons (124.9 litres)
Type of fuel See Diesel fuel specifications on page 4
Hydraulic System
Hydraulic reservoir refill capacity 21.5 US. gallons (81.4 litres)
Type of oil Case TCH Fluid
Transmission
Capacity 47.6 U.S. quarts (45 litres)
Total System Capacity 57.1 U.S. quarts (54 litres)
Type of oiL............. Case Hy-Trans Plus (MS 1207)
Front Axle - Four Wheel Drive

Capacity of center bowl 7.4 quarts (7 Iitres)
Capacity of planetary (each) 1.1 U.S. quarts (1 litre)
Type of oil..... .. CaselH 135-H EP gear lube
Brake Reservoir
Type of fluid Case TCH Fluid
Conversion Formulas
Imperial quart = litres x 0.879877
Imperial gallon = litres x 0.219969
Bur 8-12271 Issued 3-91 Printed in U.S.A.

1002-3
ENGINE OIL RECOMMENDATIONS

Case IH No.1 Engine Oil is recommended for use 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 ca-
tergory CE.
654L9
See the chart below for recommended viscosity at ambient air temperature ranges.
NOTE: Do not put Performance Additives or other oil additive products in the engine
crankcase. The oil intervals given in this manual are according to tests with Case IH
lubricants.
AMBIENT AIR TEMPERATURE RANGES

Temperature Fahrenheit
, I I
I I I I I I • I
I
.
MUL TI-GRADE OIL
••
I I
•
I I
.
I I I
••
I I I
I
• •
.
SINGLE GRADE OIL
I
•• I
I
•
• •
• 737L9
I I I I I I I I I I I I
-34' _29' -23' -18' -12' -7" _1' 4' 10' 16" 21' 27" 32' 38' 43' -49'
Temperature Celsius

1002-4
DIESEL FUEL
Use NO.2 diesel fuel in the engine of Fuel Storage
this machine. The use of other fuels can
cause the loss of engine power and high If you keep fuel in storage for a period
fuel consumption. of time, you can get foreign material or
water in the fuel storage tank. Many
Invery cold temperatures, a mixture of engine problems are caused by water in
NO.1 and NO.2 diesel fuels is tempora- the fuel.
rily permitted. See the following Note.
Keep the fuel storage tank outside
NOTE: See your fuel dealer for and keep the fuel as cool as possible.
winter fuel requirements in your area. If Remove water from the storage con-
the temperature of the fuel is below the tainer at regular periods of time.
cloud point (wax appearance point), wax
crystals in the fuel will cause the engine
to lose power or not start.
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 Mate-
rials.
Specifications for Acceptable NO.2 Diesel Fuel
API gravity, minimum .. 34

Flash point, minimum. .. 140°F (60°C)
Cloud point (wax appearance point), maximum .. -5°F (-20°C) See Note above
Pour point. maximum -15°F (-26°C) See Note above
Distillation temperature. 90% point... 540 to 640°F (282 to 338°C)
Viscosity, at 100°F (88°C)
Centistokes . 2.0 to 43
Saybolt Seconds Universal................. .. 32 to 40
Cetane number, minimum 43 (45 to 55 for winter or high altitudes)
Water and sediment, by volume, maximum........................... .. 0.05 of 1%
Sulfur, by weight, maximum............... .. 0.5 of 1%
Copper strips corrosion, maximum .. No. 2
Ash, by weight, maximum................. .. 0.01 of 1%

Section
1024
SPECIFICATION DETAILS
IMPORTANT: This engine was made using the metric measurement system. All
measurements and checks must be made with metric tools to make sure of an
accurate reading when inspecting parts.
Copyright© 1991 J I Case Company

Rae 8-24162 Printed in U.S.A.
CASE CORPORATION June, 1983 (Revised January, 1991)
1024-2
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS. . 3
IDENTIFICATION MARKS
Crankshaft 4
Cylinder Block.... .. .4
Cylinder Head..... . ..4
ENGINE SPECIFICATION DETAILS

Cylinder Block... . .4
Service Cylinder Sleeve..... . 5
Piston....... . 5
Piston Pin 5
Piston Rings 6
Cylinder Head. .. ................... 6
Lifters .. ... 6
Connecting Rod . 7
Crankshaft. 8
Camshaft 9
Turbocharger 9
Gear Train 9
Rocker Arm Assembly. .............. 10
Intake Valve... .. 10
Exhaust Valve 10
Valve Springs.......... . 11
Valve Seat Installation Dimensions 11
SPECIAL TORQUES .. , 11-13
Rae 8-24162 Revised 1-91 Printed in U.S.A.

1024-3
RUN-IN INSTRUCTIONS
Engine Lubrication
Fill the engine crankcase with CO or CE service classification oil that has the correct viscosity rating for the ambient air
temperature. Install new oil filters, after the engine has been rebuilt.
Run-In Procedure for Rebuilt Engine
Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start Crank the
engine for 30 seconds until there is oil pressure, then reconnect the wire.
Step 2 Remove the air from the cooling system at the temperature sending unit.
Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks
Step 4 During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.
Run-In Procedure for Rebuilt Engines (With a Dynamometer)
The following procedure must be followed when using a 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 TIME ENGINE SPEED DYNAMOMETER SCALE LOAD

1 5 Minutes 1000 RPM 50
2 5 Minutes 1100 RPM 1/2
3 5 Minutes 2200 RPM Full
Run-In Procedure for Rebuilt Engines (Without a Dynamometer)
STEP TIME ENGINE SPEED LOAD

1 5 Minutes 1000 RPM No Load
2 5 Minutes 1100 RPM Light Load
Run-In Procedure (Agriculture Tractors)
For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours 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
Crankshaft
Letter N = Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV 0.2 rockwell any time
the crankshaft has been reconditioned.
Cylinder Block
Letter X = The cylinder block has been retaced and up to 0.25 mm has been removed. Use a thicker head gasket (DNa
notches).
Letter XX = The cylinder block has been refaced and up to 0.50 mm has been removed Use a thicker head gasket
(three notches).
Cylinder Head
Letter G = Thermostat passage in cylinder did not need to be machined
Letter M = Thermostat passage in cylinder head was machined.
Letter V = Valve seats have been machined.
Letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch)
Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed use a thicker head gasket (DNa
notches) .
Letter XXX = The cylinder block has been ref aced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.

Cylinder Block
Metric Value
Type.. . Non-Sleeved
Material Cast Iron
10 of Cylinder... . 102.00 to 102.04 mm
Maximum Service Limit . 102.116 mm
Cylinder Out of Round (Maximum) 0.038 mm
Cylinder Taper (Maximum) 0.076 mm
0.5 mm Oversize Piston
Machine Cylinder Bore to 102.40 to 102.44 mm
Hone to (Finished Diameter) 102.50 to 102.54 mm
Warpage (Maximum).................................................................. 0.075 mm
Maximum Material Removal 0.50 mm
Rae 8-24162 Revised 1-91 Printed in U.SA

1024-5
Service Cylinder Sleeve

Type Dry, Can Be Replaced
Material Cast Iron
Machine Cylinder Block Bore to 104485 to 104.515 mm
Installation.................. . . Press Fit
Machine Sleeve Bore to:
Standard Size Piston (Finished Diameter) ................................10200 to 102.04 mm
Machine Cylinder Bore to 10240 to 10244 mm
Machine Cylinder Bore to.. .. 102.90 to 102.94 mm
Hone to (Finished Diameter) .. 103.00 to 103.04 mm
Piston
Type Cam Ground
Material................... ...Aluminum alloy
OD at 12 mm From the Bottom, 90 Degrees Piston Pin
Standard Size Piston 101.873 to 101.887 mm
Minimum Service Limit. 101.823 mm
0.5 mm Oversize Piston 102.373 to 102.387 mm
Minimum Service Limit 102.823 mm
ID of Piston Pin Bore 40.006 to 40.012 mm
Maximum Service Limit 40.025 mm
Width of 1st Ring Groove (Top) .2465 to 2.485 mm
Width of 2nd Ring Groove (Intermediate) 2.425 to 2445 mm
Width of 3rd Ring Groove (Oil Ring) 4.040 to 4.060 mm
Protrusion Above Cylinder Block (Maximum) 0.660 mm
Piston Pin
Type Full Float
OD of Pin 39.997 to 40.003 mm

1024-6
Piston Rings
NO.1 Compression 4T-390 Engine Key Stone Type (Barrel Face)
End Gap in 102.02 10.... .. 0.4 to 0.70 mm
No.1. Compression 4-390 Engine Rectangular Type (Barrel Face)
End Gap in 102.02 10.................. . 0.25 to 0.55 mm
Maximum Service l.irnit.. 0.806 mm
Side Clearance 0.075 to 0.120 mm
Maximum Service Limit... 0.15 mm
NO.2 Compression. Rectangular Type (Tapper Face)
End Gap in 102.02 10. ................0.25 to 0.55 mm
NO.3 Oil Control Rings.. Two Piece
End Gap in 102.02 10 0.25 to 0.55 mm
Maximum Service Limit............................................... . 0.806 mm
Side Clearance. . 0 130 mm
Cylinder Head
Warpage (Maximum) 0.20 mm
Maximum Material Removal.......................... . 1.00 mm
Minimum Head Height .. 9375 mm
Engines Manufactured in U.S.A.:
Prior to Engine Serial Number 45511034 Injectior Nozzle 9 mm
Engine Serial Number 45511034 and After Injectior Nozzle 7 mm
Engines Manufactured in Darlington England:
Prior to Engine Serial Number 21092870 Injectior Nozzle 9 mm
Engine Serial Number 21092870 and After . Injector Nozzle 7 mm
Engines Manufactured in Neuss Germany:
Prior to Engine Serial Number 52107489 Injector Nozzle 9 mm
Engine Serial Number 52107489 and After Injector Nozzle 7 mm
Lifters
Material Hardened Iron
00 of Lifter 15.961 to 15.977 mm
Minimum Service Limit. . .. 15.960 mm
Bore Diameter in Block 16.000 to 16.030 mm
Maximum Service Limit. 16.055 mm
Rae 8-24162 Revised 1-91 Printed in USA.

1024-7
Connecting Rod
Bushing . Steel Backed Leaded Bronze
Bushing 10 Installed (Ream to Size)........................................................... ..40.053 to 40.067 mm
Bearing Liners...................... . Replaceable
Journal 10 Without Bearing Liners 72.987 to 73.013 mm
Bearing Oil Clearance . 0.038 to 0.116 mm
Maximum Service Limit..... . 0129 mm
Side Clearance...................................... . 0.100 to 0.300 mm
Maximum Service Limit ... 0330 mm
Connecting Rod Bend (Maximum)
Without Bushing. . . . 0.200 mm
With Bushing . 0150 mm
Connecting Rod Twist (Maximum)
Without Bushing. . ,.. . 0.500 mm
With Bushing . . 0.300 mm

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 . 68.987 to 69.013 mm
Maximum Service Lirnit.. . 68.962 mm
0.25 mm 00 Undersize, Grind to 68.737 to 68.763 mm
Maximum Service Limit........................................................... .. 68.712 mm
0.50 mm 00 Undersize, Grind to...................................... . 68.487 to 68.513 mm
Maximum Service Limit.. 68.462 mm
Maximum Service Limit............ . . 68.212 mm
1.00 mm 00 Undersize, Grind to....................... ...67.98 to 68.013 mm
Maximum Service Limit..................................... . 67.962 mm
Connecting Rod Journal Maximum Taper 0.013 mm
Journals Out of Round Maximum....................................... . 0050 mm
Undersize Main Bearing Liners For Service . 0.25,0.50,0.75 and 1.00 mm
Main Bearing Oil Clearance 0.041 to 0.119 mm
Maximum Service Limit 0 140 mm
Main Bearing Journal
00, Standard 82.987 to 83.013 mm
Maximum Service. Limit..... . 82.962 mm
0.25 mm 00 Undersize, Grind to . 82.737 to 82.763 mm
0.75 mm 00 Undersize, Grind to .......................................................................82.237 to 82.263 mm
Main Bearing Journal Bore 10 No Liners 87.982 to 88.018 mm
Main Journal Width:
1st, 2nd, 3rd, 5th .. 37.424 to 37.576 mm
4th 37.475 to 37.525 mm
Connect Rod Journals Width 38.950 to 39.050 mm

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 54.107 to 54.133 mm
Maximum Service Limit .. 54.146 mm
ID of NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm
10 of NO.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm
Width of No 1 Bushing 25.15 to 25.65 mm
Width of No.2, 3, 4 and 5 Service Bushing 1775 to 18.25 mm
Camshaft Bushing 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
Camshaft Thrust Clearance 0.130 to 0.340 mm
Camshaft Lobes:
Minimum Diameter at Peak Intake 47.265 mm
Minimum Diameter at Peak Exhaust 46.994 mm
Turbocharger
Horizontal Travel of Turbine Shaft 0.1 0 to 0.16 mm
Gear Train
Backlash:
Crankshaft Gear to Camshaft Gear 0.08 to 0.33 mm
Crankshaft Gear to Idler Gear 0.08 to 0.33 mm
Camshaft to Fuel Pump Gear 0.08 to 0.33 mm
Idler Gear to Oil Pump 0.08 to 0.33 mm
Camshaft to Auxiliary 0.08 to 0.33 mm
Maximum Service Limit (All Gears) 0.45 mm

1024-10
Rocker Arm Assembly

OD of Shaft . . 18.963 to 18.975 mm
Minimum Service Limit.............. . 18.938 mm
ID of Arm Bore.............................. .. 19.000 to 19.026 mm
Lubrication.. . Pressure From Oil Gallery
Shaft Oil Holes . Down
Intake Valve
Tappet Clearance (Cold) 0.254 mm
Face Angle 29 Degrees
Face Run-Out................. .. 0.038 mm
Valve Head Edge Thickness, Minimum........................... . 1.50 mm
Length 128.84 to 129.46 mm
OD of Stem . 7.960 to 7.980 mm
Minimum Service Limit . 7.940 mm
OD of Head 44870 to 45.130 mm
Seat Angle................................ . 30 Degrees
Seat Contact Width 1.32 to 1.92 mm
Seat Run-Out....... . 0.1 0 mm
Insert Height..................... .. 6.84 to 6.96 mm
OD of Insert......................... .. .47.063 to 47.089 mm
ID of Insert..................... Tapered
Valve Recession Below Head Surface 0.99 to 1.52 mm
Maximum Service Limit. .. 1.52 mm
ID of Valve Guide Bore 8.019 to 8.039 mm
Exhaust Valve
Face Run-Out. 0.038 mm
Valve Head Edge Thickness, Minimum......................................................................................................150 mm
OD of Head .41.870 to 42.130 mm
OD of Stem .. 7.960 to 7.980 mm
Length 128.74 to 129.36 mm
Insert Seat Angle.... .45 Degrees
Seat Contact Width .. 1.47 to 2.07 mm
Seat Run-Out. 0.10 mm
Insert Heigh!...... . 6.65 to 6.77 mm
OD of Insert........ . 43713 to 43.739 mm
ID of Insert... . Tapered
ID of Valve Guide Bore 8.019 to 8.039 mm
Rae 8·24162 Revised 1-91 Printed in U.S.A.
1024-11
Valve Springs
Free Length 55.63 mm
Total Coils. .. 7.25
Wire Diameter.......... .. . 4.830 to 4.930 mm
Compressed to 38.53 mm (Valve Open) 785 to 839 N
Maximum Service Limit . 765 N
Compressed to 49.25 mm (Valve Closed) 285 to 321 N
Minimum Service Limit 270 N
Valve Seat Installation Dimensions

Exhaust Seat
Diameter of Insert .43. 713 to 43.73 mm
Machine Insert Bore to...... . .. .....43.647 to 43663 mm
Depth of Bore. ..........1010 to .092 mm
Press Fit... ..0.05 to 0 102 mm
Intake Seat
Diameter of Insert 47.063 to 47.089 mm
Machine Bore to ..46.987 to 47.013 mm
Depth of Bore .. 10.30 to 10.50 mm
Press Fit....................... '''_ 0.05 to 0.102 mm
14 mm Valve Guide Installation Dimensions
Guide Diameter 14.026 to 14.038 mm
Machine Guide Bore to 13.987 to 14013 mm
Press Fit.. 013 to .051 mm
Installed Height (above top of valve guide boss on head) 11.25 to 11.75 mm
Guide Installed ID 819 to 8.39 mm
SPECIAL TORQUES
Metric Value
Aftercooler Bolts...... 21 to 27 Nm
Alternator Bracket Bolts (Lower) 21 to 27 Nm
Alternator Bracket Bolts (Upper) 21 to 27 Nm
Alternator Retaining Bolt 21 to 27 Nm
Balancer Counter Weight Bolts.................... .. 21 to 27 Nm
Balancer Mounting Bolts 167 to 183 Nm
Balancer Idler Gear .. 52 to 62 Nm
Belt Tensioner Bracket Bolts 21 to 27 Nm
Belt Tensioner Retaining Bolt. 39 to 47 Nm
Block Heater 11 to 13 Nm

1024-12
SPECIAL TORQUES (Cont'd)

Metric Valve
Camshaft Retaining Bolts 21 to 27 Nm
Coolant Inlet Bolts 39 to 47 Nm
Connecting Rod Bolts..................... 95 to 100 Nm

(Lubricate Threads with Engine Oil)
Cylinder Head Bolts 120 to 132 Nm
Engine Lift Bracket Bolts (Rear) 71 to 83 Nm
Exhaust Manifold Bolts 39 to 47 Nm
Fan Pulley Bracket Bolts .. .. 23 to 26 Nm
Fan Pulley Bolts 8.8..... ... 37 to 43 Nm
Fan Pulley Bolts 10.9.. . 52 to 62 Nm
Flywheel Housing Bolts . 54 to 66 Nm
Flywheel Retaining Bolts 130 to 144 Nm
Flywheel Housing Cover Bolts 21 to 27 Nm
Fuel Filter Inlet Bolt 29 to 35 Nm
Fuel Air Removal Bolt........ .. 5 to 7 Nm
Fuel Filter Inlet NuL....... 29 to 35 Nm
Fuel Line Fitting (High Pressure) 22 to 28 Nm
Fuel Line Fitting (Low Pressure) 22 to 28 Nm
Fuel Shutoff Solenoid.. .. 15 Nm
Front Cover Bolts.... 21 to 27 Nm
Front Housing Bolts 21 to 27 Nm
Injection Pump Drive Gear Nut 59 to 71 Nm
Injection Pump Lock Bolt (Lock Position) 8 Nm
Injection Pump Lock Bolt (Unlock Position) 20 Nm
Injection Pump Retaining Nuts 21 to 27 Nm
Injection Pump Bracket Bolts 21 to 27 Nm
Injector Leak Off Bolt. . .. .. 5 to 7 Nm
Injector Retaining NuL... .. 55 to 65 Nm
Rae 8-24162 Revised 1-91 Printed in U.S.A

1024-13
SPECIAL TORQUES (Cont'd)

Metric Valve
Intake Manifold Bolts.. 21 to 27 Nm
Intake Manifold Plug 115 to 135 Nm
Lifter Cover Bolts .. 21 to 27 Nm
Main Bearing Bolts 165 to 180 Nm

(Lubricate the Thread with Engine Oil)
Oil Fill Tube Bolts 39 to 47 Nm
Oil Pan Drain Plug 68 to 82 Nm
Oil Pan Heater Plug 108 to 132 Nm
Oil Pan Retaining Bolts 21 to 27 Nm
Oil Pump Retaining Bolts. 21 to 27 Nm
Oil Inlet Tube Bolts . 18 to 30 Nm
Oil Inlet Tube Brace.. ..21 to 27 Nm
Oil Filter Housing Bolts 21 to 27 Nm
Oil Relief Valve Plug 108 to 132 Nm
Primer Pump 21 to 27 Nm
Rear Seal Retaining Bolts 8 to 10 Nm
Rocker Arm Bolts 21 to 27 Nm
Starter Retaining Bolts 39 to 47 Nm
Tachometer Drive Retaining Bolts .. 2 to 4 Nm
Thermostat Housing Bolts 21 to 27 Nm
Timing Pin Retaining Bolts 4 to 6 Nm
Thrust Bearing Screws (Torx Head) ..4 to 6 Nm
Turbocharger Mounting Bolts 30 to 34 Nm
Turbocharger Drain Tube Bolts 21 to 27 Nm
Turbine Housing Bolts 9 to 13 Nm
Center Housing to Back Plate Bolts 5 to 7 Nm
Compressor Housing Bolts 5 to 7 Nm
Compressor Lock Nut... 13 to 1.5 Nm
Water Pump Mounting Bolts 21 to 27 Nm
Valve Cover Bolts.......................... 21 to 27 Nm

1024-14
NOTE: The J I Case Company reserves the right to make improvements in design or
changes in specifications at any time without incurring any obligation to install them
on units previously sold.
Rac 8-24162 Revised 1-91 Printed in U.S.A.

SECTION INDEX - ENGINE
Engine Removal and Installation................................................. . 2001
Stall Tests. .. 2002
Detailed Engine Specifications. . 2402
Cylinder Head and Valve Train..... . 2415
Cylinder Block. . 2425
Lubrication System... .. 2445
Cooling System .. 2455
Turbocharger............. ..2465
Turbocharger Failure Analysis 2565
CASE CORPORATION Rae 8-17161 Printed in U.S.A

August. 1992
2001-3
RADIATOR REMOVAL
Put identification tags on all disconnected hoses NOTE: During instal/ation the hood must be adjusted.
and wires. Close disconnected hoses and fittings with Put the hood in position. Install the hardware in the hood
caps and plugs. hinges. Do not tighten the hardware. Close the hood
and remove the plastic plugs for access to the hinge
NOTE: Cal/outs on the photographs are in the order hardware. Push the top of the hood to the rear as far as
of the procedure. possible and tighten the hinge hardware.
STEP 1
STEP 3
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).
Install a hose on the drain valve (7) and drain the ra-
STEP 2 diator.
Disconnect the upper and lower radiator hoses (8).
Remove the hardware from the fan shroud (9). (bolts,

lock washers, and flat washers)
NOTE: During installation fill the radiator completely and

the coolant reservoir with apprOXimately 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).

2001-4
STEP 4 STEP 6
Remove the strap (10) from the top of the radiator Remove the hardware (14) from each side of the
shroud. (bolt, lock washer, and flat washer). radiator shroud. (bolts, flat washers, and nuts).
Remove the top cover (11). (bolts, lock washers, and Remove the radiator shroud. The weight of the radiator
flat washers). shroud is approximately 50 pounds (23 kg).
Remove the upper and lower foam baffles (12). NOTE: During installation, push the top of the shroud
toward the rear of the machine and tighten the bolts for
the radiator shroud to 270 to 324 pound-feet (366 to 439
STEP 5 Nm).
STEP 7
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 of the radiator is the reverse of

removal.

2001-5
ENGINE REMOVAL
Do steps 1 through 6 of radiator removal. STEP 10
STEP 8
Remove the battery cover (18) from the left step. (cap
screws and lock washers).
The hydraulic reservoir holds approximately 25 U.S.
gallons (95 litres) of oil. Drain the oil from the hydraulic
reservoir (16). STEP 11
NOTE: During installation make sure the hydraulic re-

servoir is filled with oil. See Section 1002 for specifica-
tions.
STEP 9
Disconnect the ground cable(s) (19) from the batt-

ery(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).
Issued 3-91 Printed in U.S.A.

Bur 8-17560
2002-4
CHECK SHEET
1. _ (22301<Y2280-s-pe-cified) rpm (rim!ri)hydrauiiC stall speed
2. _ (2200 to 2300 specified) rpm (rimin) torque converter stall speed
3. _ (1550 to 1750 specified) rpm (rimin) hydraulic and torque converter stall speed
rpm (r/rnin)
1. 2230 to 2280 Torque converter, transmission, hydraulic system and engine ere probably good.
2. 2200 to 2300
3. 1550 to 1750
1. Above 2280 Engine problem. Check engine speeds. See specifications in Section 9001, Check the
2. Above 2300 timing of the fuel injection pump according to instructions in Section 3412.
3. Above 1750
1. Below 2230 Engine problem. Check engine speeds according to instructions in Section 9001. Check
2. Below 2200 the timing of the fuel injection pump according to instructions in Section 3412. Replace
3. Below 1550 the fuel and air filters.
1. Below 2230 Hydraulic system problem (s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve, Check the output of the pumps.
3. Below 1550
1. Above 2280 Hydraulic system problem (s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve. Check the output of the hydraulic pumps. Check for leakage in the loader
3. Above 1750 control valve.
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check the
2. Above 2300 transmission and torque converter.
3. Above 1750
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check
2. Below 2200 the transmission and torque converter.
3. Below 1550
D" •. 0 ~",.,,, .•
SECTION INDEX - ENGINE
Engine Removal and Installation . ................. 2001
Stall Tests 2002
Detailed Engine Specifications........ ...2402
Cylinder Head and Valve Train . ...... 2415
Cylinder Block . ..2425
Lubrication System . ..................... ................. .............................................................................................. ....2445
Cooling System ..... .. ..... 2455
Turbocharger . 2465
Turbocharger Failure Analysis.. . . .. 2565
CASE CORPORATION Rae 8-17161

Section
2001
ENGINE REMOVAL AND INSTALLATION

Issued March 1991
2001-2
TABLE OF CONTENTS
SPECIAL TOOLS 2
RADIATOR REMOVAL 3
ENGINE REMOVAL 5
REMOVING AND INSTALLING THE TORQUE CONVERTER 11
INSTALLING THE FRONT ENGINE SUPPORT.. 14
SPECIAL TOOLS
Order special tools from one of the following ad-
dresses:
In the U.S.A. and Canada:
Service Tools
P.O. Box 314
Owatonna, Minnesota 55060
In Europe:
VL Churchill Ltd.
P.O. Box 3, Daventry
Northants, NN11 4NF CAS-1690 Rotation Tool
England This tool is first used on page 12.
CAS-2081 Alignment Tool

This tool is first used on page 11.

2001-3
RADIATOR REMOVAL
Put identification tags on all disconnected hoses NOTE: During installation the hood must be adjusted.
and wires. Close disconnected hoses and fittings with Put the hood in position. Install the hardware in the hood
caps and plugs. hinges. Do not tighten the hardware. Close the hood
NOTE: Cal/outs on the photographs are in the order hardware. Push the top of the hood to the rear as far as
of the procedure. possible and tighten the hinge hardware.
STEP 1
STEP 3
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).
Install a hose on the drain valve (7) and drain the ra-
STEP 2 diator.
Remove the hardware from the fan shroud (9). (bolts,

lock washers, and flat washers)
NOTE: During installation fill the radiator completely and

the coolant reservoir with approximately 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.
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).

weight of the hood is approximately 75 pounds (34 kg).
Bur 8-17560 Issued 3-91 Printedin U.S.A.

2001-4
STEP 4 STEP 6
Remove the strap (10) from the top of the radiator Remove the hardware (14) from each side of the
shroud. (bolt, lock washer, and flat washer). radiator shroud. (bolts, flat washers, and nuts).
Remove the top cover (11). (bolts, lock washers, and Remove the radiator shroud. The weight of the radiator
flat washers). shroud is approximately 50 pounds (23 kg).
Remove the upper and lower foam baffles (12). NOTE: During installation, push the top of the shroud
toward the rear of the machine and tighten the bolts for
the radiator shroud to 270 to 324 pound-feet (366 to 439
STEP 5 Nm).
STEP 7
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 of the radiator is the reverse of

removal.

2001-5
ENGINE REMOVAL
Do steps 1 through 6 of radiator removal. STEP 10
STEP 8
Remove the battery cover (18) from the left step. (cap
screws and lock washers).
The hydraulic reservoir holds approximately 25 U.S.
gallons (95 litres) of oil. Drain the oil from the hydraulic
reservoir (16). STEP 11
NOTE: During installation make sure the hydraulic re-

servoir is filled with oil. See Section 1002 for specifica-
tions.
STEP 9
Disconnect the ground cable(s) (19) from the batt-

ery(s).
STEP 12
Disconnect the hose (17) from the bottom of the torque

converter to drain the oil from the torque converter.
Remove the bottom cover (20). (bolts, lock washers,

and flat washers).

2001-6
STEP 13 STEP 15
Disconnect the two hoses (21) from the RH side of the Disconnect the two hoses (27) from the LH side of the
oil cooler. pump. Remove the bolts and lock washers that fasten
the flange (28) on the RH side of the pump.
Disconnect the two tubes (22) from the LH side of the oil
cooler. Remove the pump (29). (Bolts, lock washers, and
hardened washers on the lower two bolts).
STEP 14 NOTE: During installation, remove and clean the

suction screen for the pump. Apply Molykote Type G to
the splines of the pump.
STEP 16
Remove the hardware (23) that fastens the condenser

to the oil cooler and radiator. (bolts, lock washers, and
flat washers - bottom three on each side).
Move the condenser (24) to the LH side out of the way.

Have another person help you remove the oil cooler Disconnect the two connectors (30).
and radiator (25). The weight of the oil cooler and
radiator is approximately 50 pounds (23 kg). Remove the hardware (31) from the adjusting straps.
(bolts, lock washers, flat washers, and nut - front
Remove the fan shroud (26). hardware has a weld nut).
Cut tie strap (32).

2001-7
STEP 17 STEP 19
Remove the hardware (33) that fastens the compressor Disconnect throttle rod (36).
to the bracket. (long bolt, flat washer, lock washer, and
nut). Remove the belt (34) and lay the compressor over Disconnect the wiring clamp (37).
the side of the frame.
Disconnect the wire from the oil pressure sender (38).
NOTE: During installation, adjust the drive belt ac-
cording to instructions in Section 9003. Disconnect the fuel shutoff wire (39).
If the machine has ether injection, disconnect the tube

STEP 18 (40) and the wire (41).
Disconnect the fuel lines (42).
STEP 20
Close the fuel shut off valve (35).
Remove the hardware from the muffler (43). (bolts, lock

washers, flat washers, and nuts)
Loosen the nuts on the muffler clamp (44). Remove the

muffler.
Disconnect the wires from the air restriction switch (45).

Then cut the tie straps which fasten the wire to the fuel
lines and put the wire out of the way.
Loosen the clamp (46) and remove the hose from the
turbocharger.
Remove the hardware that fastens the firewall (47).

(cap screws and flat washers). Remove the firewall (47)
and the air cleaner assembly. If the machine has ether
injection, disconnect the wire from the harness.
2001-8
STEP 21 STEP 23
Remove harness clamp (48). Disconnect the wires (54) from the starter.
Disconnect the wire (49) from the temperature sender. Disconnect the ground strap (55). (bolt and lock
Cut the tie straps that fasten the harness to the fuel washer).
lines.
Remove the hardware (56) for the engine mount. (bolt,
flat washer, and nut).
STEP 22
NOTE: During installation, tighten the nut to 135 to 165
pound-feet (183 to 224 Nm).
STEP 24
Remove harness clamp (50).
Remove harness clamp (51).
Disconnect the wires from the alternator (52).

Connect the lifting eye (57) to the rear of the engine
Loosen the clamp (53) and disconnect the heater hose. head.
NOTE: During installation, remove the lifting eye and put

in tool box.
Loosen the clamp (58) and disconnect the heater hose.
Remove the clamp (59).
Remove the hardware (60) for the engine mount. (bolt,

flat washer, and nut)
NOTE: During installation, tighten the nut to 135 to 165

pound-feet (183 to 224 Nm).

2001-9
STEP 25 STEP 27
Remove the clamp (61). Disconnect the hose (64) from the torque converter.
Disconnect the drive shaft (65) from the torque con-

STEP 26 verter. (bolts and straps)
NOTE: During installation, tighten the bolts to 288 to

348 pound-inches (33 to 40 Nm).
Loosen the clamps (66) on the hose.
STEP 28
Disconnect the tube (62) from the top of the filter head.
Disconnect the wire (63) from the sender on the filter

head.
Remove the hardware (67) for the front engine mount.

(bolts, flat washers, and self-locking nuts)
NOTE: During installation, tighten self-locking nuts to

360 to 420 pound-inches (41 to 47 Nm).

2001-10
STEP 29 NOTE: Installation of the engine is the reverse of

removal. Before starting the engine, do the following:
a. The turbocharger must be filled with oil. Discon-

nect the wire from the fuel shutoff solenoid. Actuate
the starter for 10 to 20 seconds to fill the turboch-
arger with oil. Connect the wire to the fuel shutoff
solenoid.
b. Check the oil level in the transaxle.
c. On machines with PTO, the torque converter

housing is filled with oil. To prevent leakage, the
starter and torque converter housing must be
Connect lifting equipment to the lifting eyes on the sealed. Use Loctite 504 on the torque converter
housing and form-in-place gasket material on the
engine. Carefully lift the engine slightly and move the
starter.
engine toward the front. Disconnect the hose (66)
shown in step 27. Make sure all hoses and wires are out
d. With PTO fill the torque converter housing with
of the way. Remove the engine from the machine.
approximately one U.S. quart (0.95 litres) of oil.
See Section 1002 for specifications.

2001-11
REMOVING AND INSTALLING THE TORQUE CONVERTER

NOTE: On machines with PTO, drain the oil from the STEP 33
torque converter housing.
STEP 30
Install the drive ring and the CAS-2018 alignmenttool.

Install the drive ring to get the least amount of
movement between the alignment tool and the drive
Remove the cap screws and lock washers that fasten ring.
the torque converter housing to the engine. Remove the
torque converter housing.
STEP 34
STEP 31
Install four cap screws and hardened washers.

Remove the cap screws and hardened washers that
fasten the drive ring to the flywheel.
STEP 35
STEP 32
Tighten the four cap screws evenly to 456 to 504

Remove the torque converter. pound-inches (52 to 57 Nm). Remove the CAS-2018
tool and install the remaining hardened washers and
NOTE: If the torque converter or the drive ring is being cap screws. Tighten the cap screws to the same torque
replaced, do the following steps. value.
2001-12
STEP 36 STEP 39
Hold the torque converter in place and install the cap Install the CAS-1690 tool to rotate the flywheel.
screws and lock washers.
STEP 40
STEP 37
Rotate the flywheel and read the dial indicator. The

Use a dial indicator to check the position of the torque torque converter must be centered within 0.004 inch
converter. (0.1 mm) so that the full indicated movement of the dial
indicator is 0.008 inch (0.2 mm) or less.
STEP 38
STEP 41
Remove the plastic plug at the left front of the flywheel

housing. When the torque converter is centered, tighten the cap
screws to 156 to 180 pound-inches (18 to 20 Nm).

2001-13
STEP 42 STEP 44
Remove the CAS-1690 tool and install the plastic plug. Install the cap screws and lock washers. Tighten the
cap screws to 456 to 540 pound-inches (52 to 61 Nm).
NOTE: On machines with PTa, Apply Loctite 504 to the
edge of the flywheel housing.
STEP 43
Install the torque converter housing so that the filter

head is horizontal.
IMPORTANT: DO NOT use extra force to push the

torque converter housing into place. Rotate the drive
yoke to align the shafts with the torque converter and
slide the torque converter housing against the engine.

2001-14
INSTALLING THE FRONT ENGINE SUPPORT

NOTE: If the front engine support was removed for STEP 47
any reason, the front engine support must be aligned
with the crankshaft of the engine. If the front engine
support is not aligned with the crankshaft of the engine,
the pump can be damaged.
STEP 45
FRONT ENGINE SUPPORT
Remove the plastic plug at the left front of the flywheel

housing.
STEP 48
B892300J
Install a bushing in each top hole in the front engine

support. Install the front engine support with the
hardware shown.
STEP 46
Install the CAS-1690 tool to rotate the flywheel.
STEP 49
Use a dial indicator to check the alignment of the front

engine support.
Rotate the flywheel and read the dial indicator. The front
engine support must be centered with the crankshaft
within 0.010 inch (0.25 mm).

2001-15
STEP 50 STEP 51
When the front engine support is centered, tighten the Remove the CAS-1690 tool and install the plastic plug.
cap screws to 66 to 79 pound-feet (89 to 107 Nm).

2002
STALL TEST
TABLE OF CONTENTS
Specifications 2002-2 Procedure to Heat Hydraulic and

Torque Converter Oil 2002-3
General Information 2002-2
Test Procedure .2002-3
Preparing the Machine for the Stall Test.. 2002-2
Check Sheet 2002-4

Issued March 1991
2002-2
SPECIFICATIONS
The specifications are the same for the naturally aspirated and turbocharged engines.
Low idle 850 to 900 rpm (r/rnin)
Full throttle (no load) 2330 to 2380 rpm (r/rnin)
Hydraulic stall speed (loader only) 2230 to 2280 rpm (r/rnin)
Torque converter stall speed 2200 to 2300 rpm (r/rnin)
Combined stall speed 1550 to 1750 rpm (r/min)
GENERAL INFORMATION
Do the stall test to find the cause of poor perfor- Use a photo tachometer or other tachometer of
mance. equal accuracy to get accurate results from the stall
test.
The engine is run at full throttle and the transmission
and hydraulic systems are engaged separately, and The engine, transmission and hydraulic system
then together. must be at operating temperature before doing the stall
test. Heat the oil according to instructions in this
Comparing the engine speeds from the stall test section.
with the check sheet on page 2002-4 will help to find the
cause of the problem. It can be necessary to check a
separate system to find the exact cause of the problem.
PREPARING THE MACHINE FOR THE STALL TEST

1. See Section 9001 and check the full throttle and low 4. Slowly increase the engine speed to full throttle.
idle speeds.
5. If the machine begins to move at any time,
2. Apply the parking brake. decrease the engine speed to low idle and stop the
engine.
3. With the engine running at low idle move the trans-
mission control lever to fourth gear and the direction 6. Adjust or repair the parking brake as required. See
control lever to FORWARD. Section 7002 or 9001 as required.

2002-3
PROCEDURE TO HEAT TORQUE CONVERTER AND HYDRAULIC OIL

1. Apply the parking brake. 6. With the engine running at low idle, move the trans-
mission control to fourth gear and the direction control
2. Start and run the engine at low idle. lever to FORWARD.
3. With the engine running at full throttle, hold the 7. Run the engine at full throttle for 15 seconds.
loader control lever in ROLLBACK for 15 seconds.
8. Decrease the engine speed to low idle and move
4. Return the loader control lever to NEUTRAL for 15 the direction control lever to NEUTRAL for 15 seconds
seconds.
9. Repeat steps 6 through 8 until the pointer in the
5. Repeat steps 3 and 4 until the temperature of the oil gauge for transmission oil temperature is in the center
is 125°F (52°C). The side of the reservoir will be very of the green zone or the lamps in the optional instru-
warm at this temperature. ment cluster are illuminated to the center of the green
zone of the gauge for transmission oil temperature.
TEST PROCEDURE
1. Prepare the machine for the stall test according to 7. Slow!y increase the engine speed to full throttle and
instructions in this section. read the tachometer. Write the reading on line 2 on the
check sheet.
2. Heat the oil according to instructions in this section.
8. With the transmission control lever in fourth gear,
3. Apply the parking brake and start the engine. the direction control lever in FORWARD, and the engine
running at full throttle. hold the loader control lever in
4. With the engine running at full throttle, hold the ROLLBACK and read the tachometer. Write the reading
loader control lever in ROLLBACK and read the tachom- on line 3 on the check sheet.
eter. Write the reading on line 1 on the check sheet.
9. Decrease the engine speed to low idle (two
5. Decrease the engine speed to low idle. minutes with turbocharger) and stop the engine.
6. Move the transmission control lever to fourth gear 10. See the check sheet to understand the results of
and the direction control lever to FORWARD. the stall test.

2002-4
CHECK SHEET
1. _ (2230 to 2280 specified) rpm (r/min) hydraulic stall speed
2. _ (2200 to 2300 specified) rpm (r/min) torque converter stall speed
3. _ (1550 to 1750 specified) rpm (r/min) hydraulic and torque converter stall speed
rpm (r/min)
1. 2230 to 2280 Torque converter, transmission, hydraulic system and engine are probably good.
2. 2200 to 2300
3. 1550 to 1750
1. Above 2280 Engine problem. Check engine speeds. See specifications in Section 9001. Check the
2. Above 2300 timing of the fuel injection pump according to instructions in Section 3412.
3. Above 1750
1. Below 2230 Engine problem. Check engine speeds according to instructions in Section 9001. Check
2. Below 2200 the timing of the fuel injection pump according to instructions in Section 3412. Replace
3. Below 1550 the fuel and air filters.
1. Below 2230 Hydraulic system problem(s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve. Check the output of the pumps.
3. Below 1550
1. Above 2280 Hydraulic system problem(s). See Section 8002. Check the setting of the main relief
2. 2200 to 2300 valve. Check the output of the hydraulic pumps. Check for leakage in the loader
3. Above 1750 control valve.
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check the
2. Above 2300 transmission and torque converter.
3. Above 1750
1. 2230 to 2280 Torque converter or transmission problems. See Section 6002 and check
2. Below 2200 the transmission and torque converter.
3. Below 1550

Section
2402
SPECIFICATION DETAILS
4-390 Diesel Engine

CASE CORPORATION June, 1983 (Revised February, 1992)
2402-2
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS 3
Crankshaft 4
Cylinder Block 4
Cylinder Head .4

Cylinder Block .4
Service Cylinder Sleeve 5
Piston 5
Piston Pin 5
Piston Rings 6
Cylinder Head 6
Lifters 6
Connecting Rod 7
Crankshaft 8
Camshaft 9
Turbocharger 9
Gear Train 9
Rocker Arm Assembly 10
Intake Valve 10
Exhaust Valve 10
Valve Springs 11
Valve Seat Installation Dimensions 11
SPECIAL TORQUES 11-13

2402-3
RUN-IN INSTRUCTIONS
Engine Lubrication
Fill the 4-390 engine crankcase with CC/SF, CD/SF, CE/SF or CF-4 service classification oil. Use the correct viscosity
rating for the ambient air temperature. Install new oil filters after the engine is rebuilt.
Fill the 4T390 and the 4TA 390 engine crankcase with CE/SF or CF-4 service classification oil. Use the correct viscosity
rating for the ambient air temperature. Install new oil filters after the engine is rebuilt.
Run-In Procedure for Rebuilt Engine
Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start. Crank the
engine for 30 seconds until there is oil pressure, then reconnect the wire.
Step 2 Remove the air from the cooling system at the temperature sending unit.
Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks.
Step 4 During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.
Run-In Procedure for Rebuilt Engines (with a Dynamometer)
The following procedure must 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 TIME ENGINE SPEED DYNAMOMETER SCALE LOAD

1 5 Minutes 1000 RPM 50
2 5 Minutes 1100 RPM 1/2
3 5 Minutes 2200 RPM Full
Run-In Procedure for Rebuilt Engines (without a Dynamometer)
STEP TIME ENGINE SPEED LOAD

1 5 Minutes 1000 RPM No Load
Run-In Procedure (Agriculture Equipment)

For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours DO NOT "lug" the engine.
Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the rated engine RPM
during early hours of life.
Run-In Procedure (Construction Equipment)
For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. The
engine must not be "lugged" below the Rated Engine RPM (Do not stall the engine more than 10 seconds).

2402-4
Crankshaft
Letter N = Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV 0.2 rockwell any time
the crankshaft has been reconditioned.
Cylinder Block
Letter X = The cylinder block has been refaced and up to 0.25 mm has been removed. Use a thicker head gasket (two
notches).
Letter XX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
Cylinder Head
Letter G = Thermostat passage in cylinder did not need to be machined.
Letter M = Thermostat passage in cylinder head was machined.
Letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch). This gasket is used for standard replacement, 0.5 mm oversize and 1.0 mm oversize bore.
Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed use a thicker head gasket (two
notches).
Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).

Cylinder Block
Metric Value
Type Non-Sleeved
Material Cast Iron
10 of Cylinder 102.00 to 102.04 mm
Cylinder Out of Round (Maximum) 0.038 mm
Cylinder Taper (Maximum) 0.076 mm
Machine Cylinder Bore to... .. 102.90 to 102.94 mm
Warpage (Maximum) 0.075 mm
Maximum Material Removal. 0.50 mm

2402-5
Service Cylinder Sleeve

Type , Dry, Can Be Replaced
Material .. , , , Cast Iron
Machine Cylinder Block Bore to ,104.485 to 104.515 mm
Installation Press Fit
Machine Sleeve Bore to:
Standard Size Piston (Finished Diameter) 102.00 to 102,04 mm
Hone to (Finished Diameter) 102.50 to 10254 mm
Hone to (Finished Diameter) 103,00 to 103.04 mm
Piston
Type : Cam Ground
Material Aluminum Alloy
00 at 12 mm From the Bottom, 90 Degrees Piston Pin
Standard Size Piston ,101.873 to 101.887 mm
Minimum Service Limit. , , 101.823 mm
Minimum Service Limit. , 102.823 mm
10 of Piston Pin Bore .40.006 to 40.012 mm
Width of 1st Ring Groove (Top) 2.465 to 2.485 mm
Width of 2nd Ring Groove (Intermediate) 2.425 to 2.445 mm
Width of 3rd Ring Groove (Oil Ring) , 4.040 to 4.060 mm
Protrusion Above Cylinder Block (Minimum) 0.280 mm
Piston Pin
Type Full Float
00 of Pin , 39.997 to 40.003 mm
Rae 8-24163 Revised 2·92 Printed in U.S.A.

2402-6
Piston Rings
NO.1 Compression 4T-390 Engine Key Stone Type (Barrel Face)
End Gap in 102.02 ID 0.4 to 0.70 mm
NO.1 Compression 4-390 Engine Rectangular Type (Barrel Face)
End Gap in 102.02 ID 0.25 to 0.55 mm
Maximum Service Limit....... .. 0.806 mm
Side Clearance.................... . 0.075 to 0.120 mm
NO.2 Compression Rectangular Type (Tapper Face)
End Gap in 102.021D 0.25 to 0.55 mm
Maximum Service Limit.. 015 mm
NO.3 Oil Control Rings Two Piece
End Gap in 102.02 ID 0.25 to 0.55 mm
Maximum Service Limit. . 0806 mm
Side Clearance 0.130 mm
Cylinder Head
Warpage (Maximum) . 0.20 mm
Maximum Material Removal.................. 1.00 mm
Minimum Head Height 93.75 mm
Engines Manufactured in U.S.A.:
Engines Manufactured in Darlington England:
Engines Manufactured in Neuss Germany:
Lifters
Material Hardened Iron
OD of Lifter 15.961 to 15.977 mm
Bore Diameter in Block 16.000 to 16.030 mm

2402-7
Connecting Rod
Bushing Steel Backed Leaded Bronze
Bushing ID Installed (Ream to Size) 40.053 to 40.067 mm
Bearing Liners Replaceable
Bearing Oil Clearance 0.038 to 0.116 mm
Connecting Rod Bend (Maximum)
Without Bushing 0200 mm
With Bushing 0150 mm
Connecting Rod Twist (Maximum)
Without Bushing 0500 mm
With Bushing 0.300 mm .
Connecting Rod Bolt Maximum 59.25

2402-8
Crankshaft
Type............................. . Hardened Steel, Balanced
Main Bearing Liners...... . Replaceable
End Clearance, Center Main Bearing Cap . 013 to 0.25 mm
Center Main Bearing Thrust Surface Thickness.. . 2.50 mm
Connecting Rod Journal
OD, Standard 68.987 to 69.013 mm
Maximum Service Limit.. . 68.962 mm
0.25 mm OD Undersize, Grind to......................................................... ..68.737 to 68.763 mm
Maximum Service Limit.... . 68.712 mm
0.50 mm OD Undersize, Grind to 68.487 to 68.513 mm
Maximum Service Limit........ .. 68.462 mm
1.00 mm OD Undersize, Grind to. .. . 67.987 to 68.013 mm
Maximum Service Limit.............................................. .. 67962 mm
Connecting Rod Journal Maximum Taper.................................................. .. 0.013 mm
Journals Out of Round Maximum 0.050 mm
Undersize Main Bearing Liners For Service 0.25,0.50, 0.75 and 1.00 mm
Main Bearing Journal
OD, Standard 82.987 to 83.013 mm
Main Journal Width:
tst, 2nd, 3rd, 5th.......................... . 37.424 to 37.576 mm
4th................................................... . 37.475 to 37.525 mm
Connect Rod Journals Width 38.950 to 39.050 mm
Main Bearing Bolt Maximum Length 119.25 mm

2402-9
Camshaft
Type................ . Hardened Iron
Bushing (Front Only) 1, Replaceable
Bushing Lubrication:
Front Bushing Pressure Lubricated
Intermediate Pressure Lubricated
Rear Pressure Lubricated
Oil Clearance 0.076 to 0.152 mm
10 of NO.1 Bushing, Installed 54.107 to 54.133 mm
10 of NO.1 Oversize (57.24 mm 00) Service Bushing 54.089 to 54.139 mm
10 of No.2, 3, 4 and 5 Service Bushing 54.089 to 54.139 mm
Width of No. 1 Bushing 25.15 to 25.65 mm
Width of No.2, 3, 4 and 5 Service Bushing 17.75 to 18.25 mm
Camshaft Bushing Journal 00 53.987 to 54.013 mm
Camshaft Bore Diameter in Block
NO.1 Bushing 57.222 to 57.258 mm
NO.1 Oversize Bushing, Machine to 57.722 to 57.758 mm
No.2, 3, 4 and 5, Less Bushings 54.089 to 54.139 mm
No.2, 3, 4 and 5 Oversize for Bushings, Machine to 57.222 to 57.258 mm
Camshaft Thrust Thickness 9.42 to 9.58 mm
Camshaft Lobes:
Minimum Diameter at Peak Intake 47.265 mm
Minimum Diameter at Peak Exhaust... 46.994 mm
Turbocharger
Horizontal Travel of Turbine Shaft 0.10 to 0.16 mm
Gear Train
Backlash:
Crankshaft Gear to Idler Gear 0.08 to 0.33 mm
Camshaft to Fuel Pump Gear 0.08 to 0.33 mm
Idler Gear to Oil Pump 0.08 to 0.33 mm
Camshaft to Auxiliary 0.08 to 0.33 mm
Maximum Service Limit (All Gears) 0.45 mm
Rae 8-24163 Revised2-92 Printedin U.S.A.

2402-10
Rocker Arm Assembly

00 of Shaft . 18.963 to 18.975 mm
Minimum Service Limit .. 18.938 mm
10 of Arm Bore 19.000 to 19.026 mm
Lubrication Pressure From Oil Gallery
Shaft Oil Holes Down
Intake Valve
Face Angle..................... . 29 Degrees
Face Run-Out.. 0.038 mm
Valve Head Edge Thickness, Minimum 1.50 mm
Length 128.84 to 129.46 mm
00 of Stem 7.960 to 7.980 mm
Minimum Service Limit.. 7.940 mm
00 of Head .44.870 to 45.130 mm
Seat Angle 30 Degrees
Seat Run-Out... 0.10 mm
Insert Height 6.84 to 6.96 mm
00 of Insert .47.063 to 47.089 mm
10 of Insert Tapered
10 of Valve Guide Bore 8.019 to 8.039 mm
Exhaust Valve
Face Run-Out 0.038 mm
Valve Head Edge Thickness, Minimum 1.50 mm
00 of Head 41.870 to 42.130 mm
00 of Stem 7.960 to 7.980 mm
Length 128.74 to 129.36 mm
Insert Seat Angle 45 Degrees
Seat Run-Out. 0.10 mm
Insert Height 6.65 to 6.77 mm
00 of Insert .43.713 to 43.739 mm
10 of Insert Tapered
Maximum Service Limit : 1.52 mm
10 of Valve Guide Bore 8.019 to 8.039 mm
2402-11
Valve Springs
Free Length , , ,' , ,.,.., , , , 55.63 mm
Total Coils ' ,' ' , ,' , , , 7.25
Wire Diameter, , , '.. , , , , , , . , .4.830 to 4.930 mm
Compressed to 38.53 mm , (Valve Open) 785 to 839 N
Maximum Service Limit , , , , 765 N
Compressed to 49.25 mm , (Valve Closed) 285 to 321 N
Minimum Service Limit , , ' 270 N
Valve Seat Installation Dimensions

Exhaust Seat
Diameter of Insert .' ,..43.713 to 43.73 mm
Machine Insert Bore to , , .43.647 to 43,663 mm
Depth of Bore , , 10.10 to .092 mm
Press Fit.. 0.05 to 0.102 mm
Intake Seat
Diameter of Insert .47.063 to 47.089 mm
Machine Bore to .46.987 to 47.013 mm
Depth of Bore . 10.30 to 10.50 mm
Press Fit................. 0.05 to 0.102 mm
Valve Guide Installation Dimensions

Valve Guide 00 , , 11.150 to 11.163 mm
Machine Guide Bore to 11.112 to 11.138 mm

Press Fit... 0.012 to 0.051 mm
Installed Height (above top of valve guide boss on head) "'"'''''''''''' """"'"'''''''''''''''' """ " " " " 11.25 to 11.75 mm
Guide Installed 10 8.19 to 8.39 mm

Guide Diameter 14.026 to 14.038 mm
Machine Guide Bore to 13.987 to 14.013 mm
Press Fit. , 013 to 051 mm
Installed Height (above top of valve guide boss on head) 11.25 to 11.75 mm
Guige Installed 10 , 8.19 to 8.39 mm
SPECIAL TORQUES Metric Value

Aftercooler Bolts , 21 to 27 Nm
Alternator Bracket Bolts (Lower) 21 to 27 Nm
Alternator Bracket Bolts (Upper) , , , 21 to 27 Nm
Alternator Retaining Bolt 21 to 27 Nm
Balancer Counter Weight Bolts 21 to 27 Nm
Balancer Mounting Bolts 167 to 183 Nm

Balancer Idler Gear 52 to 62 Nm
Rae 8-24163 Revised 2-92 Printed in U.S.A,

2402-12
Metric Valve
Belt Tensioner Retaining Bolt .39 to 47 Nm
Block Heater 11 to 13 Nm
Camshaft Retaining Bolts...... 21 to 27 Nm
Coolant Inlet Bolts 39 to 47 Nm
Connecting Rod Bolts 60 Nm Plus 60 Degrees

(Lubricate Threads with Engine Oil)
Cylinder Head Torque
Short Bolts 90 Nm Plus 90 Degrees
Long Bolts 120 Nm Plus 90 Degrees
Engine lift Bracket Bolts (Rear) 71 to 83 Nm
Exhaust Manifold Bolts 39 to 47 Nm
Fan Pulley Bracket Bolts 23 to 26 Nm
Fan Pulley Bolts

Grade 8.8 Size M8 37 to 43 Nm
Flywheel Housing Bolts 54 to 66 Nm
Flywheel Retaining Bolts................ 130 to 144 Nm
Flywheel Housing Cover Bolts 21 to 27 Nm
Fuel Filter Inlet Bolt 29 to 35 Nm
Fuel Air Removal Bolt 5 to 7 Nm
Fuel Filter Inlet Nut 29 to 35 Nm
Fuel Line Fitting (High Pressure) 22 to 28 Nm
Fuel line Fitting (Low Pressure) 22 to 28 Nm
Fuel Shutoff Solenoid 15 Nm
Front Cover Bolts 21 to 27 Nm
Front Housing Bolts 21 to 27 Nm
Injection Pump Drive Gear Nut.. 59 to 71 Nm
Injection Pump Retaining Nuts 21 to 27 Nm
Injection Pump Bracket Bolts 21 to 27 Nm
Injector Leak Off Bolt 5 to 7 Nm
Injector Retaining Nut. 55 to 65 Nm

2402-13
Metric Valve
Intake Manifold Bolts 21 to 27 Nm
Intake Manifold Plug 115 to 135 Nm
Lifter Cover Bolts 21 to 27 Nm
Main Bearing Bolts 80 Nm Plus 60 Degrees

(Lubricate the Thread with Engine Oil)
Oil Fill Tube Bolts 39 to 47 Nm
Oil Pan Heater Plug 108 to 132 Nm
Oil Pan Retaining Bolts 21 to 27 Nm
Oil Pump Retaining Bolts... . 21 to 27 Nm
Oil Inlet Tube Bolts 18 to 30 Nm
Oil Inlet Tube Brace 21 to 27 Nm
Oil Filter Housing Bolts 21 to 27 Nm
Oil Relief Valve Plug 108 to 132 Nm
Primer Pump 21 to 27 Nm
Rear Seal Retaining Bolts 8 to 10 Nm
Rocker Arm Bolts 21 to 27 Nm
Starter Retaining Bolts 39 to 47 Nm
Tachometer Drive Retaining Bolts 2 to 4 Nm
Timing Pin Retaining Bolts 4 to 6 Nm
Thrust Bearing Screws (Torx Head) .4 to 6 Nm
Turbocharger Mounting Bolts 30 to 34 Nm
Turbocharger Drain Tube Bolts 21 to 27 Nm
Turbine Housing Bolts 9 to 13 Nm
Center Housing to Back Plate Bolts 5 to 7 Nm
Compressor Housing Bolts 5 to 7 Nm
Compressor Lock NuL 13 to 15 Nm
Water Pump Mounting Bolts 21 to 27 Nm
Valve Cover Bolts 21 to 27 Nm

2402-14

Section
2415
CYLINDER HEAD AND VALVE TRAIN
4-390 Diesel Engine
IMPORTANT: This engine was made using the metric measurement system. NI

CASE CORPORATION June, 1983 (Revised February. 1992)
2415-2
TABLE OF CONTENTS
IDENTIFICATION MARKS 2
SPECIFICATIONS 3
SPECIAL TORQUES 4
SPECIAL TOOLS 5
CYLINDER HEAD REMOVAL 6-10
CYLINDER HEAD DiSASSEMBLy................. 11
CHECKING AND RESURFACING THE CYLINDER HEAD 12,13
VALVE GUIDE REPLACEMENT

14 mm Replacement Valve Guides 14
11 mm Replacement Valve Guides 15
INSPECTION OF THE VALVES AND VALVE SEATS 16-18
VALVE SEAT INSTALLATION.......................................... 19
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS 20-26
CYLINDER HEAD ASSEMBLy 27,28
ROCKER ARM DiSASSEMBLy .28,29
ROCKER ARM ASSEMBLy 29
CYLINDER HEAD INSTALLATION 30-34
LOCATING TOP CENTER 35
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE 35-39
THERMOSTAT SERViCE 39-40
letter G Thermostat passage in cylinder did not need to be machined.
letter M = Thermostat passage in cylinder head was machined.
letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes
(one notch).
Letter XX = The cylinder block has been refaced and up to 0.25 mm has been removed. Use a thicker head gasket (two
notches).
Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket
(three notches).
2415-3
SPECIFICATIONS
ENGINES MANUFACTURED IN USA
ENGINES MANUFACTURED IN DARLINGTON ENGLAND

Prior to Engine Serial Number 21092870..................... Injector Nozzle 9 mm
Engine Serial Number 21092870 and After Injectior Nozzle 7 mm
ENGINES MANUFACTURED IN NEUSS GERMANY

Prior to Engine Number 52107489 Injector Nozzle 9 mm
CYLINDER HEAD
Maximum Warpage 0.010 mm in any 50 mm diameter area or more than
0.075 mm overall end to end or side to side.
Maximum amount of material that can be removed during resurfacing 1.0 mm
Minimum total height of cylinder head 93.75 to 94.25 mm
CYLINDER HEAD MACHINING IDENTIFICATION MARKS

Total thickness of cylinder head material removed See Page 12
X on head indicates block resurfacing See Page 27
Von head indicates valves have been ground See Page 27
G on head indicates thermostat bore inspected See Page 40
M on head indicates thermostat bore machined See Page 40
14 MM REPLACEMENT VALVE GUIDE

Valve guide 00 14.026 to 14.038 mm
Bore cylinder head to 13.987 to 14.013 mm
Press fit 0.013 to 0.051 mm
Installed height above top of valve guide boss on cylinder head 11.25 to 11.75 mm
11 MM REPLACEMENT VALVE GUIDE

Installed height above top of valve guide boss on cylinder head 11.25 to 11.75 mm
EXHAUST VALVE INSERT

Diameter of insert .43.713 to 43.739 mm
Diameter of bore 43.647 to 43.663 mm
Depth of bore 10.10 to 10.30 mm
INTAKE VALVE INSERT

Diameter of insert .47.063 to 47.089 mm
Diameter of bore .46.987 to 47.013 mm
Depth of bore 10.30 to 10.50 mm
:

2415-4
SPECIAL TORQUES
Alternator bracket bolts 21 to 27 Nm
Belt tensioner bracket bolts (Allen head) 21 to 27 Nm
Belt tensioner bolt 39 to 47 Nm
Cylinder head bolts 120 to 132 Nm
Exhaust manifold bolts 39 to 47 Nm
Fan belt pulley bracket bolts 23 to 25 Nm
Fan belt pulley bolts

Grade 8.8 Size M8 26 to 31
Fuel filter housing nut 29 to 35 Nm
Injector leak off fitting 5 to 7 Nm
Injector cap nut 55 to 60 Nm
Intake manifold cover bolts 21 to 27 Nm
Lift bracket bolts (Rear) 71 to 83 Nm
Rocker arm bracket bolts 21 to 27 Nm
Thermostat housing bolts 21 to 27 Nm
Valve cover bolts 21 to 27 Nm

2415-5
SPECIAL TOOLS
B90288SJ
CAS-1066A Head Bolt Wrench
B9028B3J
This tool is first used on Page 36.
CAS-1694 Injector Bore Cleaner (For 9 mm injectors)
CAS-2155 Injector Bore Cleaner (For 7 mm injectors)
CAS-2162 Torque Angle Gauge

B902884J This tool first used on Page 31 .
CAS-1743 Valve Guide Reamer


2415-6
CYLINDER HEAD REMOVAL

STEP 1 STEP 4
'T68944
Lift the belt tensioner and remove the fan belt. Remove the belt tensioner bolts and the bracket.
STEP 2 STEP 5
i1
Remove the belt tensioner bolt and the belt tensioner. Remove the fan hub bracket bolts and the bracket.
STEP 3 STEP 6
Mc,iQ,I6~94g
Remove the fan hub bolts and the fan hub. Remove the bolts that hold the alternator and remove
the alternator.

2415-7
STEP 7 STEP 10
Remove the alternator bracket bolts and the bracket.
STEP 8 STEP 11
Remove the thermostat bolts and the housing as- Disconnect and remove the fuel lines.
sembly.
STEP 12
STEP 9 4T-390 ENGiNE
I,
Install protective covers on the injection pump outlet
To remove the turbocharger see section 2465 in the lines and the injection lines.
service manual.

2415-8
STEP 13 CAV INJECTION PUMP STEP 16
Remove the leak off fitting and gasket. Loosen the nut on the injectors.
NOTE: The injector must not rotate in the bore of the

STEP 14 BOSCH INJECTION PUMP cylinder head. This will damage the cylinder head.
STEP 17
Remove the leak off fitting and gaskets.
STEP 15 Remove the injectors from the cylinder head.
NOTE: Make sure the injector seal is removed from the

cylinder head.
STEP 18
15
Remove the leak off fittings, gaskets and the leak off
line.
Use a strap type wrench to remove the fuel filters.
NOTE: Some engines have a single fuel filter.

2415-9
STEP 19 STEP 22 BOSCH INJECTION PUMP
•. " •.•w •••• N•••••
T68983
Remove the fuel line fittings and the fuel line. Remove the inlet line.
STEP 20 STEP 23
:>.:,.;
T~8~9~j
Install a protective cover in the injection pump.
STEP 21 CAY INJECTION PUMP STEP 24
.~:..
. . ~~ ....-.:~
.
..------ ··':T68994
Remove the inlet line. Remove the valve bolts and the valve covers.

2415-10
STEP 25 STEP 28
.... ".-- ..•... ",...., .
Remove the intake manifold cover bolts and the intake Remove the lift bracket bolts and the lift bracket.
manifold cover.
STEP 29
STEP 26
Remove the cylinder head bolts and the cylinder head.

Remove the rocker arm bolts and the rocker arm as-
semblies.
STEP 30
STEP 27
~A#W T68~
Cover the cylinder bores and pistons. Clean all foreign
material from the cylinder head mounting surface.
Remove the push rods from the cylinder head.
NOTE: The cylinders and pistons must be covered to
prevent damage to the pistons and cylinder walls.

2415-11
CYLINDER HEAD DISASSEMBLY

STEP 31 STEP 34
687~8'
Put the cylinder head on a clean work surface. Remove the valve seals.
STEP 32 STEP 35
;::
.
.~~,~ ../-)
. -"(.
~
6~Q7':l()
...'.~:::w:..
Use a valve spring compressor to push down the valve
springs. Remove the valve keepers.
Remove the valves.
STEP 33
{" -. "t-
~ ~...&
Remove the valve spring retainers and the valve spring.

2415-12
CHECKING AND RESURFACING THE CYLINDER HEAD

STEP 36 STEP 38
.:.:.:
....pp
Clean the cylinder head completely. Remove carbon
and other deposits. Check for cracks and any other
B902888J
damage to the head.
Resurface the cylinder head in increments necessary to

STEP 37 straighten the surface and maintain surface finish ac-
cording to the following specifications:
A = 10 mm total amount of material removed.

B = 93.75 mm minimum total height of the cylinder
head.
C = Surface finish1.5 to 3.2 micrometers.
D = Use this area to stamp the total thickness of
cylinder head material removed in rnrn.
Check the cylinder head surface with a straight edge

and feeler gauge. Resurface the cylinder head if
warpage or erosion is more than 0.010 mm in any 50
mm diameter area or if there is more than 0.075 mm
overall end to end or side to side
Rae 8-24173 "levised 2-92 Printed in U.S.A

2415-13
".
STEP 39 STEP 40
Measure the bore gauge with a micrometer. If the

diameter of the valve guide at any depth is more than
8.089 mm, install a new valve guide. See Page 14for 14
mm valve guides and Page 15 for 11 mm valve guides.
B902889J
Measure the valve guide diameter at three depths with a

bore gauge.

2415-14
VALVE GUIDE REPLACEMENT

14 mm Replacement Valve Guides
There are two different diameters of replacement valve STEP 42
guides for your engine. You can get either 14 mm or 11
mm 00 replacement valve guides. Measure the re-
placement valve guides before you machine the
cylinder head.
Specifications
Installed height above top of valve guide boss
on cylinder head 11.25 to 11.75 mm
STEP 41
B902891J
Make a bushing 16.038 mm 10 x 11.25 to 11.75 mm

long. Install the bushing over the new valve guide. Press
the new valve guide into the cylinder head until the
press contacts the bushing.
STEP 43
Drill the valve guide bores to 13.987 to 14.013 mm

diameter.
Drill the new valve guides to a diameter of 8.0 mm.

Ream the new valve guides to a finished diameter of
8.019 to 8.039 rnrn.
2415-15
11 mm Replacement Valve Guides

Specifications STEP 45
Valve guide 00 11.150to 11.163 mm
Installed height above top of valve guide
boss on cylinder head 1125 to 11.75 mm
STEP 44
t
11.25 TO 11.75 mm
(\
DIAMETER OF
11.112 TO 11.138 mm
B902891J
Make a bushing 16.038 mm 10 x 11.25 to 11.75 mm

long Install the bushing over the new valve guide. Press
the new valve guide into the cylinder head until the
press contacts the bushing.
Drill the valve guide bores to 11.112 to 11.138 mm STEP 46

diameter.
Drill the valve guides to a diameter of 8.0 mm. Ream the

new valve guides to a finished diameter of 8.019 to
8.039 mm.

2415-16
INSPECTION OF THE VALVES AND VALVE SEATS

STEP 47 STEP 48 (Cont'd)
I FINE PiniNG
8902895J
NOTE: THIS IS A NORMAL CONDITION.
Small amounts of very fine pitting can be found on the

surfaces of the valve face or seat after the valves are
cleaned. These are normal and will not change the
engine performance. This fine pitting is caused by
normal oxidation procedure and can occur on any
engine during the run-in period. It is not necessary to
grind valves or seats if this fine pitting is found. because
pitting will generally occur after the engine has run for
STEP 48 several hours.
Check the valves for the following conditions.
VALVE STEM WITH A NARROW NECK
j
8902896J
8902893J
NOTE: GRIND OR REPLACE THE VALVE IF THIS CONDITION
OCCURS.
NOTE: REPLACE THE VALVE IF THIS CONDITION OCCURS.
This condition is generally caused by worn valve guides
This Condition Can Be Caused By: or bad seals on the valves. permitting oil to go by the
1. Valve does not have lubrication. valves. Low operating temperature is a secondary
2. Restriction in the water passages. cause. Worn piston rings and cylinder walls will also
3. Operating the engine under continued overload at permit too much oil to reach the combustion chamber.
too much engine RPM.
RUST OR PiniNG ON VALVE STEM
1
._-- GROOVE IN VALVE FACE
8902894J 8902897J
NOTE: REPLACE VALVE IF THIS CONDITION OCCURS.
NOTE: GRIND OR REPLACE VALVE IF THIS CONDITION

OCCURS.
This condition can be caused by using bad quality
engine oil or fuel and by not correctly keeping the
This condition can be caused by foreign material engine in storage.
entering the engine through the intake system or not
giving service to the air intake system.

2415-17
STEP 48 (Cont'd) STEP 49

/' 1. RUST OR PiniNG IN VALVE FACE INTAKE VALVES
• 7.960 TO 7.980 mm
NOTE: THIS CONDITION CAN BE CAUSED BY USING BAD

QUALITY ENGINE OIL OR FUEL.
DEEP BURNED VALVE FACE

• 7.960 TO 7.980 mm
B902901J
Check the intake valve stem diameter at three points

along the stem. If the stem diameter is less than 7.960
mm, the valve must be replaced.
EXHAUST VALVES
CONCAVE VALVE HEAD
• 7.960 TO 7.980 mm
These conditions are generally caused by running the
engine at very high engine temperatures, grinding the
valve face too thin or valve grinding that is not correct.
B902902J
Check the exhaust valve stem diameter at two points as

B902900J
shown. If the stem diameter is less that 7.960 mm or the
stem tip diameter is less than 7.960 mm, the valve must
be replaced.

2425-18
STEP 50
VALVE WITHOUT REPLACEABLE SEATS

1.52 mm MAX.
B902903J
Put the valves in the cylinder head and check to make

sure that the valve heads are recessed in the cylinder
head. The valves must not protrude from the head. If the
valve head is recessed more than 1.52 mm below the
cylinder head surface, the valve must be replaced or a
valve insert must be installed to make sure that there is
equal compression ratios between cylinders.

2415-19
VALVE SEAT INSTALLATION

STEP 51 STEP 52
Machine the cylinder head to the following specifica- Clean the recessed area in the cylinder head. Put the
tions for valve seats. new valve seats in dry ice for a minimum of one hour to
shrink the valve seats for easy installation. Use a driver
Exhaust Valve Seat Specifications: and install the valve seats.
Diameter of Valve Seat 43.713 to 43739 mm
A
Always wear gloves to prevent frostbite to
Diameter of Bore 43.647 to 43.663 mm your hands when handling frozen parts.
Depth of Bore 10.10 to 10.30 mm SM118A
Press Fit 0.05 to 0.092 mm
Intake Valve Seat Specifications:

STEP 53
Diameter of Valve Seat 47.063 to 47.089 mm
Diameter of Bore 46.987 to 47.013 mm
Depth of Bore 10.30 to 10.50 mm
Press Fit 0.05 to 0.102 mm
1. VALVE SEAT BORE
Use a center punch and stake the valve seats in three

positions. Grind the valve seats to the correct angle.
B902904J

2415-20
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS

STEP 54 STEP 55
VALVE AND SEAT GRINDING ANGLES
30 DEGREE VALVE
VALVE IDENTIFICATION
44 DEGREE
ANGLE
The 45 degree exhaust valves are smaller in diameter

than the intake valves.
The 30 degree intake valves are larger in diameter than

the exhaust valves.
45 DEGREE SEAT 30 DEGREE SEAT
B902905J
If dimension A and B is less than 1.5 mm the valve must

be replaced.
NOTE: Use a precision seat grinder. Take very light cuts

with the grinding stones so just enough metal is
removed to end up with a good smooth seat finish.

2415-21
STEP 56 STEP 58
30 DEGREE VALVES
45 DEGREE VALVES
Put a small amount of blue dye on the valve face. Install

the valve in the head and rotate the valve on the seat.
B902906J
STEP 57 Correct refacing of valves and seats will give a dye

pattern as shown.
NOTE: If the dye pattern is other than the patterns

shown, check the diagnosis of different dye patterns on
the following pages.
Remove the valve and look at the contact area on the

valve face and seat. The blue dye will be gone from the
valve face where the valve made contact with the seat.

2415-22
IF THE VALVE CONTACT AREA ON THE _ USE A 45 DEGREE ST~

SEAT LOOKS LIKE THIS (A SEAT THAT TO MAKE WIDER, THE
HAS BEEN GROUND).
SEAT CONTACT AREA ON THE VALVE

TO LOW
IF THE VALVE CONTACT AREA ON THE - USE A 45 DEGREE STl

SEAT LOOKS LIKE THIS. CONTACT AREA.
_ USE A 45 DEGREE 51
AND TO MAKE WIDER

TOO HIGH
IF THE VALVE CONTACT AREA ON THE _ THE VALVE MUST BE f

SEAT LOOKS LIKE THIS. VALVE SEAT MUST Sf
CAUSE MORE GRIN[
CHANGE THE LOWER l
Rae 8-24173 Revised 2-92

DIAGNOSIS OF DIFFERENT·DYE PATTERNS
45 Degree Exhaust valves
- CHECK THAT THE VALVE HEAD IS NOT - IF THE VALVE HEAD IS RE-
RECESSED MORE THAN 1.52 mm. BE- CESSED MORE THAN 1.52 rnm,
LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
INE TO LIFT THE - USE A 60 DEGREE STONE TO LIFT AND - CHECK THAT THE VALVE HEAD IS NOT _ IF THE VALVE HEAD IS RE-
NARROW THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm,
THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STAU A VALVE SEAT.
ONE TO LOWER _ USE A 30 DEGREE STONE TO NARROW _ CHECK THAT THE VALVE HEAD IS NOT _IF THE VALVE HEAD IS RE-
THE CONTACT THE UPPER CONTACT AREA, IN- RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
CREASED BY THE 45 DEGREE STONE. LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
IEPLACED AND A
! INSTALLED BE-
liNG WIU NOT
eONTACT POINT.
Printed in U.S.A.
2415-23
_ USE A 45 DEGREE STONE TO INCREASE - CHECK THAi

THE CONTACT AREA. RECESSED"
THE CYLINDI

TO NARROW
IF THE VAlVE CONTACT AREA ON THE -THE VALVE MUST BE RE-

VALVE SEAT LOOKS LIKE THIS. PLACED AND A VALVE SEATlN-
CONTACT AREA STALLED BECAUSE MORE
GRINDING WILL NOT CHANGE
THE LOWER CONTACT AREA.
_ USE A 30 DEGREE STONE TO LOWER _USEA60DE

THE UPPER CONTACT AREA. LOWER CON

TO WIDE.
IF THE VALVE CONTACT AREA ON THE - USE A 30 DEGREE STONE TO LOWER -USEA60DE
SEAT LOOKS LIKE THIS. THE UPPER CONTACT AREA. LOWER CON
CONTACT AREA

· THE VALVE HEAD IS NOT - CHECK THAT THE VALVE HEAD
ORE THAN 1.52 mm BELOW IS NOT RECESSED MORE THAN
:R HEAD SURFACE. 1.52 mm. REPLACE THE VALVE
AND INSTALL A VALVE SEAT.
iREE STONE TO LIFT THE _ IF THE VALVE HEAD IS RE-

ACT AREA. CESSED MORE THAN 1.52 mm.
REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
_ CHECK THAT THE VALVE HEAD IS NOT _ IF THE VALVE HEAD IS RE-
RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm.
STALL A VALVE SEAT.
B902908J
2415-24
IF THE VALVE CONTACT AREA ON THE _ USE A 30 DEGREE

SEAT LOOKS LIKE THIS (A SEAT THAT WIDER AND TO LO'
HAS BEEN GROUND). AREA.
<,

TO HIGH.
IF THE VALVE CONTACT AREA ON THE - THE VALVE MUST E

SEAT LOOKS LIKE THIS. VALVE SEAT IN!
MORE GRINDING \
THE LOWER CONTI
IF THE VALVE CONTACT AREA ON THE _ USE A 30 DEGREE

SEAT LOOKS UKE THIS (A SEAT THAT WIDER THE CONTA
HAS BEEN GROUND).
<,

TO NARROW
IF THE VALVE CONTACT AREA ON THE _ THE VALVE MUST e

SEAT LOOKS LIKE THIS. VALVE SEAT INS
MORE GRINDING \
THE LOWER CONTI
Rae 8-24173 Revised,

t STONE TO MAKE _ USE A 15 DEGREE STONE TO LOWER _ CHECK THAT THE VALVE HEAD IS NOT - IF THE VALVE HEAD IS RE-
~ER THE CONTACT THE UPPER CONTACT AREA. RECESSED MORE THAN 152 mm BELOW CESSED MORE THAN 152 mm,
STALL A VALVE SEAT.
E REPLACED AND A _ IFTHE VALVE HEAD IS RECESSED MORE

TALLED BECAUSE THAN 1.52 mm. REPLACE THE VALVE
"ILL NOT CHANGE AND INSTALL A VALVE SEAT.
,CTPOINT.
STONE TO MAKE _ CHECK THAT THE VALVE HEAD IS NOT

cr AREA. RECESSED MORE THAN 152 mm BELOW
THE CYLINDER HEAD SURFACE.
E REPLACED AND A
TALLED BECAUSE
VILL NOT CHANGE
,CTPOINT.
B902909J
-92 Printed in U.SA

-
2415-25
_1 DEGREE IN
THIS IS THE CORRECT SEAT CONTACT-THE CORRECT EXHAUST VALVE CON-
AREA ON THE VAlVE. TACT AREA ON THE SEAT WILL GIVE A
SEAT WIDTH OF 1.47 TO 2.07 mm.
30 DEGREE INTAKE VALVES ONLY

IF THE VAlVE CONTACT AREA ON THE - USE A 30 DEGREE STONE TO LIFT AND - USEA45DEG
SEAT LOOKS LIKE THIS (A SEAT THAT TO MAKE WIDER THE CONTACT AREA. TO NARROl1
HAS BEEN GROUND). AREA INCRE.
<, STONE.
SEAT CONTACT AREA ON THE VAlVE

TO LOW
IF THE VAlVE CONTACT AREA ON THE _ USE A 30 DEGREE STONE TO LIFT THE
SEAT lOOKS LIKE THIS. CONTACT AREA.
Rae 8-24173
Revised 2-92 Printed in U.S.A.
ERFERENCE ANGLE -CORRECT REFACING OF EXHAUST
- IF THE VALVE HEAD IS RE-
VALVES AND VALVE SEATS WILL GIVE A CESSED MORE THAN 1.52 mm
1 DEGREE INTERFERENCE ANGLE. THIS REPLACE THE VALVE AND IN-
ANGLE IS IMPORTANT BECAUSE THE STALL A VALVE SEAT.
ANGLE GIVES ASSISTANCE IN CUTTING
CARBON AND TO SEAT THE VALVES.
'OEOR 60 DEGREE STONE -CHECK THAT THE VALVE HEAD IS NOT - IF THE VALVE HEAD IS RE-
THE LOWER CONTACT RECESSED MORE THAN 152 mm. BE- CESSED MORE THAN 1.52 mm
ED BY THE 30 DEGREE LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
_ CHECK THAT THE VALVE HEAD IS NOT _ IF THE VALVE HEAD IS RE·
E OR 60 DEGREE STONE
RECESSED MORE THAN 152 mm BELOW CESSED MORE THAN 152 mm
'HE LOWER CONTACT
THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND'
STALL A VALVE SEAT.
B90291 OJ
2415-26
IF THE VALVE CONTACT AREA ON THE - USE A 15 DEGREE STOI

SEAT LOOKS LIKE THIS (A SEAT THAT THE UPPER CONTACT AI
HAS BEEN GROUND) .
....••.

TO WIOE
- 1 DEGREE INTERFEREN(
Rae 8-24173 Revised 2-92

"IE TO LOWER - USEA45 DEGREE OR 60 DEGREE STONE _ CHECK THAT THE VALVE HEAD IS NOT _IF THE VALVE HEAD IS RE-
~EA. TO LIFT THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm
STALL A VALVE SEAT.
iE TO LOWER - USEA45 DEGREE OR 60 DEGREE STONE _CHECK THAT THE VALVE HEAD IS NOT _IF THE VALVE HEAD IS RE-
lEA. TO LIFT THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
:E ANGLE _ CORRECT REFACING OF THE INTAKE

VALVE AND VALVE SEAT WILL GIVE A 1
DEGREE INTERFERENCE ANGLE. THIS
ANGLE IS IMPORTANT BECAUSE IT
GIVES ASSISTANCE IN CUTTING CAR-
BON AND TO SEAT THE VALVES.
B902911J
Printed in U.S.A.
2415-27
CYLINDER HEAD ASSEMBLY

STEP 59 STEP 62
904LO
If the cylinder head has been machined, mark the Install the valve spring the valve spring caps.
amount removed on the RH rear corner of the cylinder
head.
STEP 63
IMPORTANT: Do not machine more than 1.00 mm
from the cylinder head. The head height must not be
less than 93.75 mm.
STEP 60
-';.;I:;~.
. -
:,.
~
.
Push down the valve springs with a spring compressor.

Install the valve keepers.
,.,/.~,"
. L:,,-, T687~n
' •.. ~:~#,... ...z;•.••;."':~
NOTE: Always install new valve keepers when new caps

or valves are installed.
""'36
Apply lubrication to the valves. Install the valves in the
cylinder head. STEP 64
STEP 61
r ~: ...••••.
Remove the spring compressor and hit the end of the

valve stems with a soft hammer to seat the valve
keepers.
Install new valve seals.
2415-28
STEP 65
··)1:68728
Clean the injector bores with a bore cleaner Early Pro-
duction engines have 9 mm injectors and late produc-
tion engines have 7 mm injectors. See the following il-
lustration.
Use a CAS-1694 injector bore cleaner for heads that
have 9 mm injectors.
Use a CAS-2155 injector bore cleaner for heads that

have 7 mm injectors.
8903013J
7 mm Diameter Tip 9 mm Diameter Tip
ROCKER ARM DISASSEMBLY

STEP 67
305L91
Remove the snap ring, washer and rocker arm from the Use a micrometer and measure the rocker arm shaft for
shaft. out of round. Measure in three different locations
around the shaft. If the rocker arm shaft is less than
18.938 mm in diameter the rocker arm shaft assembly
must be replaced.
2415-29
STEP 68 STEP-:,w-·69
Measure the rocker arm with a bore gauge in three dif- Use a micrometer to measure the bore gauge. If the
ferent locations around the bore. diameter of the bore is more than 19.05 rnrn, the rocker
arm must be replaced.
ROCKER ARM ASSEMBLY
5. ROCKER ARM
309L91
STEP 70 STEP 71
Install the rocker arms on the rocker arm shaft with the Install the washers and the snap rings on the rocker arm
adjusting screws on same end as the large hole in the shaft.
bracket.

2415-30
CYLINDER HEAD INSTALLATION

STEP 72 STEP 74
Use the correctr tap and clean all head bolts holes of Install the cylinder head.
foreign material.
STEP 75
STEP 73
9171.91
Use the bolt length gauge to check the head bolt length.
Insallthe correct head gasket on the engine block, see If the head bolt length is more than the maximum length
below. on the gauge the bolt must be replaced.
Head Gasket Application

No Notches - Replacement Gaskett
2 Notches - 0.25 mm Oversize Gasket
3 Notches - 0.50 mm Oversize Gasket
918L91
IMPORTANT: Oversize thickness gaskets are used Check and replace all head bolts that have rust, pitting
when the cylinder block has been machined. narrowing and corrosion.

2415-31
STEP 77 STEP 79
B902915J
Put a small amount of engine oil on the head bolt

threads. Install the head bolts and washers. Tighten the
bolts a small amount.
NOTE: Do not torque the head bolts at this time.
STEP 78
Tighten the cylinder head bolts to the correct torque,

following the torque sequence shown above.
Use the following steps to get the correct torque.
Step 1 - torque to 41 Nm
Step 2 - torque to 90 Nm
Step 3 - torque bolts 3, 6, 11 and 14 to 120 Nm
STEP 80
Install the push rods and the rocker arm assembly.
Install the torque angle and tighten each head bolt an

additional 90 degrees.

2415-32
STEP 81
8902916J
T68834
Tighten the rocker shaft bracket bolt to a torque of 21 to
27 Nm.
STEP 82
Install the intake manifold bolts and tighten to a torque

of 21 to 27 Nm, following the torque sequence shown
above.
STEP 85
Install the intake manifold gasket and the intake man-

ifold.
STEP 83
Install the rear lift bracket and tighten the bolts to a

torque of 71 to 83 Nm.
Put Loctite liquid teflon on the intake manifold bolts

2415-33
CAY INJECTION PUMP STEP 89
Connect and tighten the inlet tube nuts. Install the inlet tube. Install a new o-ring on the filter
housing and install the filter housing.
STEP 87 BOSCH INJECTION PUMP NOTE: Some engines have single fuel filters.
STEP 90
Install the injection pump inlet tube.
Install the filter housing nut and tighten to a torque of 29

to 35 Nm.
STEP 91
Tighten the fuel outlet fitting to a torque of 29 to 35 Nm.
T68983
Install the lift pump outlet tube.

2415-34
STEP 92 STEP 95
Tighten the filter inlet fitting to a torque of 29 to 35 Nm. Install the seal and the front lift bracket.
STEP 96
STEP 93
Install the thermostat housing assembly and bolts.

For correct fuel filter installation see the fuel filter Tighten the bolts to a torque of 21 to 27 Nm.
section.
STEP 97
STEP 94
B902917J
Install the thermostat in the thermostat housing. The pin

in the thermostat must be at the top of the thermostat
housing.
NOTE: See page 39 to check the diameter of the ther-

mostat opening in cylinder head. T69
Install the manifold bolts and gasket on the cylinder
head. Tighten the bolts to a torque of 39 to 47 Nm,
follow the torque sequence shown above.
2415-35
LOCATING TOP CENTER

STEP 98 STEP 99
.··,·.'·.·,.·.'.·'·M·,"'·.·.·.·,·.·.,·~'"'" ·,,··, .w."_"" •••..•...

.... ·.·-.·,.••.••.•,·,w,·,.._ ..•. ··,•... ,
Install the engine rotating tool into the flywheel housing. While turning the engine, push the lock pin in. When the
Rotate the engine four revolutions to make sure the lock pin moves into the camshaft gear the engine will be
push rods are seated correctly. at top center.
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE

Cold Setting
STEP 100 STEP 101
:':".;;-'
\1
f'~~~
Check and adjust the intake and exhaust valves as the

arrows show below.
4 3 2 1
E E
B902918J
Number one cylinder top center compression stroke. Install the engine rotating tool. Move the engine a small
amount in each direction. Pull the lock pin out.
Valve Clearance, Cold: Intake Valves - 0.254 mm
Exhaust Valves - 0.508 mm

2415-36
STEP 102 STEP 104
Turn the engine one complete revolution. Put new seals on the injectors and install the injectors.
Check and adjust the intake and exhaust valves as the

arrows show below. STEP 105
3 2
E
8902919J
Number four cylinder top center compression stroke. Tighten the injector nut to a torque of 55 to 60 Nm.
Valve Clearance, Cold: Intake Valves - 0.254 mm

STEP 106
Exhaust Valves - 0.508 mm
8903013J Install the leak off line, fittings and gaskets Tighten the
fittings to a torque of 5 to 7 Nm.
7 mm Diameter Tip 9 mm Diameter Tip
Before you order new injectors or seals, you must deter-

mine which injectors were installed in your engine.

2415-37
STEP 107 STEP 110
Install the injector lines connect and tighten the injector Install the alternator and tighten the bolts.
line nut to the injection pump and injectors.
STEP 111
STEP 108
Install the fan belt pulley bracket and tighten the bolts to
Install the bracket and tighten. a torque of 23 to 25 Nm.
STEP 109 STEP 112
J>9l85
Install the alternator bracket and tighten the bolts to a Install the belt tensioner bracket and tighten the Allen
torque of 21 to 27 Nm. head bolts to a torque of 21 to 27 Nm.

2415-38
STEP 116
Install the fan belt pulley and tighten the bolts to a To install the turbocharger, see section 2465 in the
torque of: service manual.
Grade 8.8 Size M8 26 to 31 Nm STEP 117

Grade 8.8 Size M10 51 to 62 Nm Start and operate the engine. Check engine oil
Grade 10.9 Size MO 51 to 62 Nm pressure indicator to make sure of correct engine oil
pressure. Check the rocker arms to make sure that the
arms are receiving oil.
STEP 114
STEP 118
Install the belt tensioner and tighten the bolt to a torque

of 39 to 47 Nm.
Install new gaskets on the valve covers.
STEP 115
STEP 119
Lift the belt tensioner and install the fan belt.

Install new a-rings on the valve cover bolts.

2415-39
STEP 120
Install the valve cover bolts and tighten to a torque of 21

to 27 Nm.
THERMOSTAT SERVICE
STEP 121 STEP 123
2. Old Thermostat
1. New Thermostat
B902920J
8902922J
A new thermostat has been released for use in your
engine. If you removed an old thermostat from your If the cylinder head coolant passage is smaller than the
engine, do the following steps to install a new ther- 10 of the template, the coolant passage will have to be
mostat. made larger. Mark the 10 of the template on the cylinder
head.
STEP 122
STEP 124
8902921J
8902923J
Install the template that comes with the new thermostat
kit. Remove the template. Use a shop cloth in the coolant
passage to keep metal shavings out of the engine. Use
a rotary grinder to remove the material.
Rae 8-24173 Revised2-92 Printedin U.S.A.

2415-40
STEP 125 STEP 126
B902924J
Remove any metal shavings from the cylinder head.

Install the seal and new thermostat. Tighten the bolts to Mark the cylinder head on the intake side next to the
21 to 27 Nm. serial number as follows:
Stamp the letter "G" for cylinder heads that were in-
spected and did not need to be machined.
Stamp the letter "M" for cylinder heads that were

machined.

Section
2425
CYLINDER BLOCK
Crankshaft, Pistons, Rods, Sleeves, Camshaft,
Bearings, Seals and Flywheel
4-390 Diesel Engine
Copyright © 1992 J I Case Company

CASE CORPORATION Rae 8-24183 Printed in U.S.A.
June. 1983 (Revised February, 1992)
2425-2
TABLE OF CONTENTS
SPECIFICATIONS .. ..4-6
Special Torques ...........6
SPECIAL TOOLS ............ 7-8
FRONT Oil SEAL REPLACEMENT. 9-11
REAR Oil SEAL REPLACEMENT 12-15
FRONT OIL SEAL AND WEAR SLEEVE INSTALLATION . .... 15-17
REAR Oil SEAL AND WEAR SLEEVE INSTALLATION . . 18-21
REMOVAL OF PISTONS AND RODS . . 21-22
CYLINDER WALL INSPECTION 23-26
RECONDITIONING THE ENGINE CYLINDER BLOCK

Checking and Resurfacing the Cylinder Block. . 27
Reconditioning the Cylinder Block for Oversize Pistons . ....28
Reconditioning the Cylinder Block for Sleeves . ... 29-30
PISTON AND CONNECTING ROD DISASSEMBLY AND INSPECTION . ... 31-33
PISTON AND CONNECTING ROD ASSEMBLY AND INSTALLATION . ... 33-38
REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT .... . 38-41
CRANKSHAFT AND MAIN BEARINGS . . 41-45
CRANKSHAFT GEAR REMOVAL . . 46
CRANKSHAFT INSPECTION .46
CRANKSHAFT RECONDITIONING
Grinding a Crankshaft . .. 47
Crankshaft Rehardening . . .47
CRANKSHAFT GEAR INSTALLATION .48
CRANKSHAFT INSTALLATION 48-57

2425-3
CAMSHAFT
Removal 58-59
Camshaft Bore and Bushing Inspection 59-60
Camshaft Bushing Removal and Installation 60
Valve Lifter Inspection 61
Camshaft Disassembly and Inspection 62
Camshaft Gear Installation 63
Camshaft Installation 63-66
FLYWHEEL
Removal 66
Ring Gear Removal and Installation 67
Installation '" 67
TACHOMETER DRIVE, IF EQUIPPED

Removal and Disassembly 68
Assembly and Installation 68
EXPANSION PLUG REMOVAL AND INSTALLATION

60 mm Expansion Plugs 69
22.5 mm Expansion Plugs 72
18 mm Expansion Plugs 73-74
10 mm Expansion Plugs 74-75
CRANKCASE PRESSURE CHECK (BLOW BY)

Manometer Installation 76
Testing 77
Manometer Removal 78

2425-4
SPECIFICATIONS
CYLINDER BLOCK
ID of Cylinder , , 102.00 to 102.04 mm
Maximum Cylinder Out of Round............................... 0.038 mm

Maximum Cylinder Taper . , 0.076 mm
Maximum Warpage of Cylinder Block Surface ..More than 0,010 mm in any 50 mm diameter area or
more than 0.075 mm overall end to end or side to side
Maximum Amount of Material that can be Removed During Resurfacing , ." , 0.50 mm
Standard Piston Finish Housing of Cylinder Bore 102.00 to 102.116 mm
0.5 mm Oversize Piston Machine Cylinder Block Bore to 102.40 to 102.44 mm
0.5 mm Oversize Piston Finish Honing of Cylinder Block Bore , 102.50 to 102.54 mm
1.0 mm Oversize Piston Machine Cylinder Block Bore to 102.90 to 102.94 mm
1.0 mm Oversize Piston Finish Honing of Cylinder Block Bore 103.00 to 103.04 mm
CYLINDER SLEEVE
Machine Cylinder Block Bore to 104.485 to 104.515 mm
Machine Cylinder Sleeve Bore to 101.90 to 101.94 mm
Finish Honing Cylinder Sleeve to 102.00 to 102.04 mm
PISTON
OD 12 mm From the Bottom, 90 Degrees from Piston Pin 101.873 to 101.887 mm
Piston Clearance 0.113 to 0.293
ID of Piston Pin Bore 40.006 to 40.012 mm
PISTONS RINGS
No. 1 Compression
End Gap in 102.0210 Cylinder 0.25 to 0.55 mm
Side Clearance 0.075 to 0 120 mm
No. 2 Compression
NO.3 Oil Control Ring

Maximum Service Limit , 0806 mm

2425-5
PISTON PIN
00 of Pin. . 39.997 to 40.003 mm
CONNECTING ROD
Bushing 10 installed 40.053 to 40.067 mm

Bearing Oil Clearance 0.038 to 0.116 mm
Side Clearance 0 100 to 0.300 mm

Bolt (Maximum Length) 59.25 mm

CRANKSHAFT
End Clearance, Center Main Bearing Cap 0.041 to 0.119 mm
Center Main Bearing Thrust Surface Thickness 2.50 mm

Connecting Rod Journal Standard 00 68.987 to 69.013 mm

Connecting Rod Journal Maximum Taper 0.013 mm
Connecting Rod Journal Out of Round Maximum 0.050 mm

Main Bearing Journal Standard 00 82.987 to 83.013 mm


Maximum Service Limit. 88031 mm
Bolt (Maximum Length) 119.25 mm

2425-6
CAMSHAFT
10 of Bushing Installed 54.1 07 to 54.133 mm
10 of Camshaft Bore 54.089 to 54.139 mm
Maximum Service Limit...... 54.164 mm
00 of Each Carnshatt Bearing Surface...................................... .. 53.987 to 54.013 mm
Minimum Service Limit.................................................. . 0.4 70 mm
Cam Lobe Minimum Diameter At Peak
Intake 47.265 mm
Exhaust...................... . 46.994 mm
GEAR TRAIN BACKLASH
Maximum Service Limit (All Gears) .. 0.45 mm
SPECIAL TORQUES
Belt tensioner bolt 39 to 47 Nm
Camshaft plate bolts 21 to 27 Nm
Connecting rod bolts 60 Nm Plus 60 Degrees
Crankshaft pulley bolts 120 to 130 Nm
Fan Pulley Bolts
Grade 8.8 Size Size M10 51 to 62 Nm
Flywheel bolts 130 to 144 Nm
Flywheel housing bolts 54 to 66 Nm
Front cover bolts 21 to 27 Nm
Front housing bolts 21 to 27 Nm
Fuel inlet bolts 29 to 35 Nm
Fuel inlet nut. 29 to 35 Nm
Fuel outlet bolt 29 to 35 Nm
Injection pump nut 55 to 65 Nm
Injection pump lock bolt 6 to 8 Nm
Injection pump mounting nuts 21 to 27 Nm
Injection pump bracket bolts 21 to 27 Nm
Main bearing bolts 80 Nm Plus 50 Degrees
Oil suction tube bolts 18 to 30 Nm
Seal carrier bolts 8 to 10 Nm
Starter retaining bolts 39 to 47 Nm

2425-7
CAS-1690 Engine Rotating Tool

First used on Page 42.
CAS-1358 Ridge Reamer


2425-8
CAS-10900 Connecting Rod Pin Bushing

Removal and installation tool
Crankcase Pressure Check (Blow By)
CAS-1692A Manometer

2425-9
FRONT OIL SEAL REPLACEMENT

STEP 1 STEP 4
Lift the belt tensioner and remove the fan belt. Remove the front cover bolts and remove the front
cover.
STEP 2
STEP 5
Remove the tachometer drive, if equipped.

Clean the crankshaft seal surface with Loctite safety
solvent
STEP 3
IMPORTANT: The seal surface on the crankshaft must
be free of all oil and grease to prevent damage to the oil
seal.
STEP 6
Remove the bolts from the crankshaft pulley and

remove the crankshaft pulley.
Remove the seal and clean the seal surface with Loctite
safety solvent

2425-10
STEP 7 STEP 10
~;
Install the guide bolts and a new front cover gasket. Tighten the front cover bolts to a torque of 24 Nm.
Remove the installation tool.
STEP 8
STEP 11
Install the front cover bolts. Do not tighten the bolts.

Put Loctite 277 on the outside surface of the seal.
STEP 9 IMPORTANT: The crankshaft oil seal surface must not

have any oil, grease or foreign material on the sealing
surface.
STEP 12
Install the seal installation tool into the front cover with
the small diameter toward the engine. This will center
the front cover with the crankshaft.
Carefully install the protective sleeve and seal on the

crankshaft. Push the seal on the crankshaft until the
seal makes contact with the seal surface.

2425-11
STEP 13 STEP 16
Remove the protective sleeve. Install the crankshaft and the crankshaft pulley bolts.
Tighten the bolts to a torque of 120 to 130 Nm.
STEP 14
STEP 17
Install the installation tool and push the seal to the

correct depth. The seal will be at the correct depth when Install the tachometer drive, if equipped.
the outside diameter of the installation tool makes
contact with the front cover.
STEP 18
STEP 15
Remove the seal installation.

2425-12
REAR OIL SEAL REPLACEMENT

STEP 19 STEP 22
Remove the engine oil pan. See Section 2445 for oil pan Remove the bolts and the flywheel housing from the
removal. engine block.
STEP 20 STEP 23
Remove the bolts and the starter from the flywheel

housing.
STEP 24
STEP 21
Remove the biolts and the flywheel from the flywheel safety solvent.
housing.

2425-11
STEP 13 STEP 16
Remove the protective sleeve. Install the crankshaft and the crankshaft pulley bolts.
Tighten the bolts to a torque of 120 to 130 Nm.
STEP 14
STEP 17
Install the installation tool and push the seal to the

correct depth. The seal will be at the correct depth when Install the tachometer drive, if equipped.
the outside diameter of the installation tool makes
contact with the front cover.
STEP 18
STEP 15
Remove the seal installation.

2425-12
REAR OIL SEAL REPLACEMENT

STEP 19 STEP 22
Remove the engine oil pan. See Section 2445 for oil pan Remove the bolts and the flywheel housing from the
removal. engine block.
STEP 20 STEP 23
Remove the bolts and the starter from the flywheel Remove the seal carrier from the crankshaft.
housing.
STEP 24
STEP 21
Remove the biolts and the flywheel from the flywheel safety solvent.
housing.

2425-13
STEP 25 STEP 28
Clean the seal surface on the crankshaft with Loctite Install the seal installation tool into the seal carrier with
safety solvent. the small diameter toward the engine. This will center
the seal carrier to the crankshaft.
IMPORTANT: The crankshaft sealing surface must be
free of all oil and grease to prevent damage to the oil
seal. STEP 29
STEP 26
Tighten the seal carrier bolts to a torque of 8 to 10 Nm.
Install the guide bolts and a new seal carrier gasket. STEP 30
STEP 27
Remove the seal installation tool.
Install the seal carrier bolts and remove the guide bolts.
Do not tighten the seal carrier bolts.

2425-14
STEP 31
Install the seal and protective sleeve over the crank- Push the seal into the seal carrier until the outside
shaft until the outside diameter of the seal makes diameter of the seal installation tool makes contact with
contact with the seal carrier. seal carrier. Remove the installation tool.
STEP 32 STEP 35
Remove the protective sleeve Install the flywheel housing and tighten the bolts to a
STEP 33
STEP 36
•
Install the seal installation tool with the small diameter

toward the seal. Install the flywheel retaining bolts and tighten the bolts
to a torque of 130 to 144 Nm.

2425-15
STEP 37 STEP 38
Install the starter and tighten the bolts to a torque of 39 Install the engine oil pan. See Section 2445 for oil pan
to 47 Nm. installation.
FRONT OIL SEAL AND WEAR SLEEVE INSTALLATION

Used when crankshaft flange is worn and standard seal does not stop oil flow.
STEP 39
Lift the belt tensioner and remove the fan belt.
STEP 40·
Remove the bolts and the front cover.
Remove the tachometer drive, if equipped. STEP 43
STEP 41
Remove the oil seal and clean the seal surface with
Loctite safety solvent.
crankshaft pulley and

2425-16
STEP 44 STEP 47
Put Loctite 277 on the outside diameter of the seal Clean the crankshaft with Loctite safety solvent.
surface and install the seal in the front cover.
NOTE: The seal surface must be free of all oil and
grease to prevent damage to the oil seal.
STEP 45
STEP 48
Put the seal installation tool on the oil seal. The small
diameter of the seal installation tool must be toward the
seal. Install the wear sleeve on the crankshaft with the flange
toward the engine.
STEP 46
,
STEP 49
Push the seal into the cover until,the outside diameter of

the installation tool makes contact with the cover. Install the wear sleeve installation tool over the wear
sleeve. Push the wear sleeve on the crankshaft until the
flange makes contact with the face of the crankshaft
gear. Remove the installation tool.

2425-17
STEP 50 STEP 53
••.•.
s·
Install the guide bolts and a new front cover gasket. Install the crankshaft pulley and tighten the bolts to a
STEP 51
STEP 54
Carefully install the front cover.

Install the tachometer drive. if equipped.
STEP 55
Install the front cover bolts and tighten the bolts to a

torque of 21 to 27 Nm. Lift the belt tensioner and install the fan belt.

2425-18
REAR Oil SEAL AND WEAR SLEEVE INSTALLATION

Used when the crankshaft flange is worn and standard seal does not stop oil flow.
STEP 56 STEP 59
";:~';; ( '-;'
. Ttl8'147
.--.:.. • .• ·SM.••.••
Remove the engine oil pan See Section 2445 in the Remove the the bolts and flywheel housing.
service manual for oil pan removal
STEP 60
STEP 57
Remove the bolts and the seal carrier from the cran-
Remove the bolts and the starter from the flywheel kshaft.
housing.
STEP 61
STEP 58
Remove bolts and the flywheel safety solvent.

2425-19
STEP 62 STEP 65
Install the seal in the seal carrier. Put the wear sleeve on the crankshaft with the flange
toward the engine.
STEP 63
STEP 66
Install the seal installation tool. Push the seal into the
seal carrier until the outside diameter of the seal instal- Install the wear sleeve installation tool on the wear
lation tool makes contact with the seal carrier. sleeve.
STEP 64 STEP 67
Clean the crankshaft seal surface with Loctite safety Push the wear sleeve on the crankshaft until the flange
solvent. of the wear sleeve is even with the rear seal surface on
the crankshaft.
IMPORTANT: The wear sleeve flange must be even

with the rear seal surface of the crankshaft.

2425-20
STEP 68 STEP 71
Clean the seal surface with Loctite safety solvent. Install the seal carrier bolts and tighten the bolts to a
IMPORTANT: The crankshaft seal surface must be free
of all oil and grease to prevent damage to the seal.
STEP 72
STEP 69
Install the flywheel housing and tighten the bolts to a

Install the guide bolts and a new seal carrier gasket.
STEP 73
STEP 70
Install the flywheel and tighten to a torque of 130 to 144

Carefully install the seal carrier. Nm.

2425-21
STEP 74 STEP 75
Install the starter bolts and tighten the bolts to a torque Install the engine oil pan. See Section 2445 in the
of 39 to 47 Nm. service manual for oil pan installation.
REMOVAL OF PISTONS AND RODS

STEP 76 STEP 78
Remove the manifolds and cylinder head from the Check the side clearance of the piston connecting
engine. See Section 2415 of the service manual for rods. Replace the connecting rods if the side clearance
removal. is more than 0.330 mm.
STEP 79
1. RIDGE
Remove the engine oil pan and inlet tube. See Section
2445 of the service manual for removal. Remove the carbon from the top of the cylinder walls.
Check the cylinder walls for a ridge at the top of the ring
movement zone. A ridge will cause damage to the
piston when the piston is removed. A ridge will have to
be removed with a ridge reamer.
2425-22
STEP 80
Install a ridge reamer and remove the ridge from the Remove the rod cap.
cylinder walls.
STEP 84
STEP 81
T68776
'{Ji/;;- - _;;>.,
Remove the pistons from the top of the engine block.
Put a mark on each rod cap for cylinder identification.
STEP 82
Put an identification mark on each piston for assembly.

2425-23
CYLINDER WALL INSPECTION

STEP 85 Scoring on Cylinder Walls
Inspect the cylinder walls for the following conditions
Normal Wear
T2320
T10766
A smooth surface with some of the cross-hatch pattern
showing between the upper and lower limits of the ring
movement area shows normal wear. There will always
be a small amount of wear present because of com-
bustion pressure moving the top ring against the
cylinder wall.
Normal wear shows acceptable cylinder wall condi-

tions 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.

2425-24
Dusted Cylinder STEP 86
T68779
Measure the cylinder wall bore for taper as follows:
1. Measure the bore parallel to the crankshaft at the top

T40178
end of the ring travel zone.
Too much wear in the piston ring movement area
shows a dusting failure. 2. Measure the bore in the same position at the bottom
end of the ring travel zone.
A dusting failure will cause the following:
3. Measure the bore at right angles to the crankshaft at
1. Upper area of piston ring wall will show wear. the top end of the ring travel zone.
2. Too much piston ring groove wear. 4. Measure the bore in the same position at the bottom
end of the travel zone.
3. Too much piston ring side clearance.
Compare the results of the measurements (1) and (3)
4. Washed away areas of the piston ring lands where with (2) and (4), to find out if the bore has taper. To
the aluminum will be gone. measure use a inside micrometer, bore gauge or taper
gauge. If the taper is more than 0.076 mm, bore the
5. Piston rings will have too much face contact and cylinder. See reconditioning the cylinder block.
wear which can be seen as a reduction in radial
width and increase in end gap.
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.

2425-25
STEP 87 STEP 89
IMPORTANT: Before removing glaze, cover the cran-

kshaft journals with a clean cloth to prevent abrasives
and dirt caused by the cylinder hone from falling on the
crankshaft.
T68Z~~
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
Measure the cylinder wall bores for out-of-round as this work.
follows:
1. Measure the bore parallel to the crankshaft at the top Removing glaze can be done by using a cylinder hone
end of the ring travel. with 250 to 300 grit stone.
2. Measure the bore in the same position at the bottom Too much glaze (smooth surface) on cylinder walls of a
end of the ring travel. new engine or an engine with an overhaul is caused by
run-in procedure that is not correct.
3. Measure the bore at right angles to the crankshaft at
the top end of the ring travel. Glaze does not permit the piston rings to seat correctly
in the cylinder sleeves. This will cause too much oil con-
4. Measure the bore in the same position at the bottom sumption.
end of the ring travel.
Too much glaze on the cylinder walls can be prevented
Compare the measurements (1) and (3) to find the out- by giving your customer instructions in the correct run-
of-round wear at the top end of the bore. in procedure. See Section 2402 in the service manual
for the correct run-in procedure.
Compare the measurements (2) and (4) to find the out-
of-round wear at the bottom of the bore.
If out-of-round is more than 0.038 mm, bore the cylin-

ders. See reconditioning the cylinder block.
STEP 88
Measure the cylinder bores. See specifications on
Page 4. If the cylinder bore is more than 102.116 mm,
the cylinders must be bored. See reconditioning the
cylinder block.

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 NOTE: Clean the cylinder walls until a clean white cloth
hone and the stones free of foreign material. keeps completely clean, one cleaning operation is not
enough.
Start the hone at the top of the cylinder bore and actuate
the hone up and down until the correct cross-hatch IMPORTANT: Do not use gasoline, diesel fuel or
pattern is reached. The correct cross-hatch pattern is kerosene to clean cylinders because these materials
45 to 60 degrees from horizontal. will not remove the abrasives from the sleeve surface.
Use a 250 to 300 grit stone to reach the correct cylinder

bore finish of 0.4 to 0.8 micrometers.

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 B902936J
overall end to end or side to side.
Resurface the cylinder block in increments necessary
to straighten the surface and maintain the surface finish
according to the following specifications:
A = 0.25 mm first refacing.

0.35 mm second refacing.
0.50 mm total amount of material that can be
removed.
B = 322.90 to 323.10 mm standard

322.65 to 322.85 mm first refacing
322.40 to 322.60 mm second refacing
C = Surface finish 1.5 to 3.2 micrometers
o = Use this area to stamp an "X" when the first

refacing of 0.25 mm is done. Stamp a second "XX"
when the second refacing 0.50 mm total is done.
NOTE: When resurfacing the block it is always neces-

sary to machine the block to the specified dimensions.
There are 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.

2425-28
Reconditioning the Cylinder Block for Oversize Pistons
NOTE: Some of the following photographs show a STEP 96

cylinder block that has been cut in half for photographic
purposes.
STEP 95
Use a cylinder hone and hone the cylinder bores to the

For 0.5 mm oversize pistons, machine cylinder bores to following specifications. Use a lubricant/coolant with
10240 to 102.44 mm. the hone to keep the stones clean and cool.
For 1.0 mm oversize pistons, machine cylinder bores to Rough Honing - Use 80 to 150 grit stones to get a
102.90 to 102.94 mm. cross-hatch pattern of 45 to 60 degrees from
horizontal.
0.5 mm oversize piston - 102.475 to 102.695 mm

Finish Honing - Use 250 to 300 grit stones to get a

cross-hatch pattern of 45 to 60 degrees from
horizontal.

Finished cylinder bore must have a surface finish of 0.4

to 0.8 micrometers with a taper of less than 0.025 mm.

2425-29
Reconditioning the Cylinder Block for Sleeves

NOTE: Some of the following photographs show a STEP 99
cylinder block that has been cut in half for photographic
purposes.
STEP 97
Freeze the sleeves at -12 C for at least one hour. Push

0
the sleeves into the bore until the sleeve contacts the
ridge at the bottom of the bore.
L>.. Always wear gloves to prevent frostbite to

Put a mark on the cylinder bores 6.36 mm up from the •• your hands when handling frozen parts.
bottom. SM118A
STEP 98 STEP 100
Bore each cylinder to a diameter of 104.485 to 104.515 Cut the top of the sleeve flush to 0.025 mm above the
mm down to the mark. Boring must be done in four cylinder block surface.
steps with the final step taking a maximum of 0.125
mm. Let the block cool before the final step to prevent
distortion.

2425-30
STEP 101 STEP 103
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 dis-
tortion.
Use a cylinder hone and hone the cylinder bores to the
following specifications. Use a lubricant/coolant with
STEP 102 the hone to keep the stones clean and cool.
Break the top edge of the sleeve with a coarse stone. Rough Honing - Use 80 to 150 grit stones to get a
horizontal.
Standard piston - 101.975 to 102.015 mm
Finish Honing - Use 250 to 300 grit stones to get a

horizontal.
Standard piston - 102.00 to 102.04 mm
Finished cylinder bore must have a surface finish of 0.4

to 0.8 micrometers with a taper of less than 0.025 mm.

2425-31
PISTION AND CONNECTING ROD DISASSEMBLY AND INSTALLATION

STEP 104 STEP 106
3. RETAINING RING
364L91 T6881 0
Remove the retaining ring, piston pin and the con-
necting rod from the piston.
STEP 105
T68807
Measure the inside diameter of the connecting rod for
wear and out-of-round. If the inside diameter is more
than 40.092 mm the connecting rod bushing must be
365L91 replaced.
STEP 107
NOTE: The oil ring is a two piece ring.
705L91
To remove and install the connecting rod bushing use a

CAS-10900 connecting rod pin bushing removal and
installation tool.

2425-32
STEP 108
Measure the diameter of the piston pin. If the diameter Break an old piston ring in half and use the broken ring
is less than 39.990 mm the piston pin must be replaced. half to clean the piston ring grooves. Too much deposit
in the ring grooves can force the rings out and will cause
scoring.
STEP 109
STEP 112
Measure the piston pin bore. If the piston pin bore is

more than 40.025 mm the piston must be replaced.
Check the side clearance of the oil ring in the piston.
Insert a feeler gauge between the upper surface of a
STEP 110 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.
Check the side clearance of the first and second com-

pression rings. Replace the piston if the side clearance
is more than 0.15 rnrn.
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. Install the second compression ring. The piston ring
Replace the piston rings if the end gap is more than must be installed with the side marked TOP toward the
0806 mm. top of the piston to give good oil control.
STEP 116 STEP 118
. L.~";.<•.;•.>~>".d::,.s\ii/f~~~,§2Mti
Install the oil ring. Install the spring first and the oil ring Install the first compression ring on the piston. The
second. piston ring must be installed with the side marked TOP
toward the top of the piston to give good oil control.
NOTE: The spring must be between the oil ring and the
piston. NOTE: The top piston ring on the 4T-390 engine is a
key stone type ring.
2425-34
STEP 119 STEP 122
1. SPECIAL LAP
B902937J
The first compression ring. In a replacement set of

rings, must have a special lap design on the surface ---,_ ..-"'." ..."".. ,....
T6818-J,~
. ,:'.-.- ..
that contacts the cylinder wall. Apply lubrication to the pistons, piston rings and
cylinder walls, using clean engine oil.
STEP 120
STEP 123
137L91
Rotate the piston rings so that the ring ends are sepa- T68788
rated by 120 degrees. Install a ring compressor on the piston.
STEP 121 STEP 124
PISTON PIN
364L91 T68789
Install the connecting rod, piston pin and retaining rings Caref:Jlly push the piston down into the cylinder.
in the piston.
IMPORTANT: Make sure the arrow or the word FRONT
is toward the front of the engine.

2425-35
STEP 125 STEP 127
Measure the connecting rod journals on the crankshaft. Install the liners. The liner locks must be in alignment.
Each journal must be a minimum of 68.962 mm in
diameter. Measure the front and rear of each journal, NOTE: When installing the liners, make sure that the
checking for taper. If the taper is more than 0.013 mm or liner locks are in alignment. Use a sliding type
the journal is less than 68.962 rnrn, reconditioning of movement when installing the liners. Never push on the
the journals must be done. center of the liner locks.
STEP 126 STEP 128

k • ,.
T68783
The connecting rod journals must be checked again, Clean the connecting rod journals and the rod bearing
90 degrees from the first measurements for out- liners. Put a piece of plastigage on the crankshaft
of-round. If out-of-round is more than 0.050 mm, recon- journal.
ditioning of the journals must be done.

3425-36
STEP 129 STEP 131

I"
---.:J
Install the bearing caps. Lubricate the connecting rod bolts with clean engine oil
and tighten the bolts to a torque of 60 Nm.
NOTE: Make sure that the number on the bearing cap is
the same as the number on the connecting rod.
STEP 132
STEP 130
- 1. MAXIMUM LENGTH
59.25 mm -
Install the torque angle gauge. Position and lock the

holding rod. Move-the pointer to 60 degrees. Tighten
7L92 the bolt until the pointer is at 0 degrees.
Measure the length of the connecting rod bolts. If the
bolt length is more than 59.25 mm the bolt must be re- STEP 133
placed.
IMPORTANT: Each bolt length must be checked

before installation.
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.

2425-37
STEP 134 STEP 137
Apply lubrication to the bearing liners before installa- Install the torque angle gauge. Position and lock the
tion, using clean engine oil. holding rod. Turn the pointer to 60 degrees. Tighten the
bolt until the pointer is at 0 degrees.
STEP 135
STEP 138
_ 1. MAXIMUM LENGTH __
59.25 mm
7L92
Measure the length of the connecting rod bolts. If the

bolt length is more than 59.25 mm the bolt must be re- Install the engine oil inlet tube. See Section 2445 of the
placed. service manual for the inlet tube and the oil pan installa-
tion.
STEP 139
STEP 136
r
L
'~;l!
Use a dial indicator to check piston protrusion. The
piston protrusion must not be more than 0.660 mm plus
Lubricate the connecting rod bolts with clean engine oil any amount of material removed during resurfacing.
and tighten the bolts to a torque of 60 Nm.

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. Remove the bolts and main bearing cap.
2445 of the service manual.
NOTE: Remove only one cap at a time to prevent the
crankshaft from moving.
STEP 142
STEP 144
\,
Remove the bolts from the oil inlet tube. See Section
2445 of the service manual for the oil inlet tube removal.
Rae 8-24183
2425-39
STEP 145 STEP 148
~" • • • .T58~ '. 6L92
Put a new bearing liner on the crankshaft. Use a thin Measure the length of the main bearing bolts If the bolt
piece of plastic to push the bearing liner in position. length is more than 119.25 mm the bolt must be re-
placed.
STEP 146 IMPORTANT: Each bolt length 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.
holding rod. Turn the pointer to 50 degrees.Tighten the

2425-40
STEP 151 STEP 153
.•.. • ..- ~ • T688. 6L91
Remove the bearing cap and check the clearance Measure the length of the main bearing bolts. If the bolt
Clearance must be 0.041 to 0.140 mm. New liners must length is more than 119.25 mm the bolt must be re-
be installed if the clearance is more than 0.140 mm. placed.
NOTE: The crankshaft must be reconditioned if the IMPORTANT: Each bolt length must be checked
clearance is more than 0. 119 mm with the new liners. before installation.
STEP 152 STEP 154
Add lubrication to the bearing liners Add lubrication to the mounting bolts. Install the
bearing cap. mounting bolts and tighten to a torque of 80 Nm.
STEP 155


2425-41
STEP 156 STEP 157
-~, e" ,.
!<£?;&,17
Install a new oil inlet tube gasket. See Section 2445 of Install the oil pan. See Section 2445 of the service
the service manual for the installation of the oil inlet manual.
tube.
CRANKSHAFT AND MAIN BEARINGS

STEP 158 STEP 160
Remove the cylinder head. See Section 2415 of the Remove the oil pan. See Section 2445 in the service
service manual for cylinder head removal. manual for oil pan removal.
STEP 159 STEP 161
i
Remove the bolts and the crankshaft pulley. Remove the oil inlet tube bolts. See Section 2445 for the
oil inlet tube removal.

2425-42
STEP 162 STEP 164
Remove the tachometer, if equipped.
STEP 163
Turn the engine over with a engine rotating tool and

push the lock into the camshaft gear .
••
Remove the bolts and the front cover.
STEP 165 BOSCH INJECTION PUMP
Remove the injection pump and primer pump. See

Section 3415 in the service manual. .

2425-43
STEP 166 CAV INJECTION PUMP

rSTEP
/ 169
Remove the bolts that hold the camshaft thrust plate.
STEP 170
STEP 167
T69029
STEP 171
STEP 168
Remove the camshaft.

T69027
Raise the lifters and install pins to hold up the lifters.

2425-44
STEP 172 STEP 175
Remove the front housing Remove the bolts and the flywheel housing
STEP 173 STEP 176
Remove the bolts and the starter. Remove the bolts and the seal carrier.
STEP 174 STEP 177
Remove the bolts and the flywheel. Put a mark on each rod cap piston for assembly identifi-
cation

2425-45
STEP 178 STEP 181
Remove the bolts and the connecting rod bearing

caps
STEP 179 STEP 182
T68776
Remove the pistons and connecting rods.
STEP 180 STEP 183
Remove the main bearing liners from the engine.

2425-46
CRANKSHAFT GEAR REMOVAL

STEP 184 STEP 185
Pull the gear off the crankshaft. Remove the pin or woodruff key from the crankshaft.
CRANKSHAFT INSPECTION
STEP 186 STEP 188
T69070
Measure the main bearing journals to see if the journals Measure the connecting rod journals. Measure the front
are worn. Measure the front and rear of each journal. If and rear of each journal. Grind the journals if the taper is
the diameter is less than 82.962 mm grind the crank- more than 0.013 mm or if the diameter is less than
shaft journals. 68.962 mm.
STEP 187 STEP 189
.,..,.. ....•.,
Measure the main bearing journals, again, 90 degrees

f0.~fJ~':~.
Check the connecting rod journals again, 90 degrees
from the first measurements (Step 186) for out- from the first measurements (Step 188) for out-
of-round. If the out-of-round is more than 0.050 mm, of-round. Grind the journals if out-of-round is more than
grind the journals and use undersize liners. 0.050 mm.
NOTE: /f the crankshaft is bent, rep/ace the crankshaft.
2425-47
CRANKSHAFT RECONDITIONING
See crankshaft inspection on Page 46. If the crankshaft Grinding a Crankshaft
is worn or damaged, it is recommended that you have a
qualified engine shop regrind the crankshaft according Grind the crankshaft to the following specifications:
to the following instructions.
There are two hardening methods used to harden the

journals of the crankshaft. One hardening process is in-
duction hardening which hardens the journals to a
depth of 2.00 mm. The other hardening process is deep
nitroc which is a gas nitriding process This hardening
process hardens the journals to a very shallow depth.
Any time you grind a journal on a crankshaft that has
been deep nitroc hardened, you must reharden the B902940J
crankshaft.
A = Main Bearing Journals
Crankshafts hardened by the deep nitroc process are
stamped with the letter "N" on the pulley end (nose) of Standard diameter 82.987 to 83.013 mm
the crankshaft. Induction hardened crankshafts are not 0.25 mm undersize diameter 82.737 to 82.763 mm
identified. 0.50 mm undersize diameter 82.487 to 82.513 mm
0.75 mm undersize diameter 82.237 to 82.263 mm
B = Connecting Rod Journals
Standard diameter 68.987 to 69.013 mm

C = 1.23 to 1.27 mm radius smoothly blended to the

reground journal
Surface finish = 0.4 micrometers
Crankshaft Rehardening
Remember that any time you grind a crankshaft that

was hardened with the deep nitroc process, you must
reharden the crankshaft. Reharden the crankshaft to a
minimum hardness of 450 HV 0.2 Rockwell.

2425-48
CRANKSHAFT GEAR INSTALLATION

STEP 190 STEP 191
..,...
~,,~~_.>U"~_''',~''''','',,',.,.~ . '1'69075
Install the crankshaft gear pin or woodruff key. Heat the crankshaft gear for a minimum of 25 minutes
at 250°F (121°C). Use a bearing heater oven.
Install the heated gear on the crankshaft.
CRANKSHAFT INSTALLATION
STEP 192 STEP 193 .;.:-:.:,:.-
Install the bearing liners. The flanged bearing liner must

be installed on the second 'journal from the rear of the
block. The remainder of the bearing liners have no
flange.
STEP 194
1. Late Production Oil Spray Nozzle

2. Early Production Oil Spray Nozzle
Clean the oil spray nozzle with a small wire. If the nozzle
is damaged it must be replaced.
Add lubrication to the bearing liners.

oil.
2425-49
STEP 195 STEP 198
STEP 196
STEP 199
1. MAXIMUM LENGTH I ,
119.25 mm
Clean the main bearing journals and put a piece of plas- 6L92
tigage on the journals to check main bearing oil clear- Measure the length of the main bearing bolts. If the bolt
ance. length is more than 119.25 mm the bolt must be re-
placed.

I .
I
~ STEP 200
I.
; ':tJi
I
Install the liners in the bearing caps. Make sure the liner
locks are aligned. Use a sliding type movement when
installing the liners. Never push on the center of the
liners.
Install the main bearing cap bolts and tighten to a
torque of 80 Nm.
Rae 8-24183 Issued 2-92 Printed in U.S.A.

2425-50
STEP 201 STEP 204
Install the torque angle gauge. Position and lock the Add lubrication to the liner. Use clean engine oil.
STEP 205
1. MAXIMUM LENGTH
119.25mm
6L92
Measure the length of the main bearing bolts. If the bolt

length is more than 119.25 mm the bolt must be re-
Remove the main bearing caps. placed.

STEP 206
Check the main bearing oil clearance. Clearance must

be 0.041 to 0.140 mm. If the clearance is more than
0.140 mm, undersize bearing liners must be installed.
Install new undersize liners which will give a clearance
of 0.041 to 0.119 mm. Add lubrication to the cap bolts. Install the cap bolts
and tighten. Tighten to a torque of 80 Nm.
NOTE: If the clearance is more than O.140mm the cran-
kshaft must be reconditioned.

2425-51
STEP 207 STEP 209
Install the torque angle gauge. Position and lock the Install a new front housing gasket.
STEP 208
Install the front housing and tighten the bolts to a torque

of 21 to 27 Nm.
STEP 211
Put a dial indicator on the crankshaft gear. Check the

crankshaft end clearance. The end clearance must be ~
0.041 to 0.119 mm. If the clearance is more than 0.119 Add lubrication to the camshaft bearing journals. Use
mm, replace all the main bearing liners or the crank- clean engine oil.
shaft.
NOTE: To get an accurate reading, use a pry bar

between the crankshaft and the number two and
number four main bearing caps as shown above.

2425-52
STEP 212 STEP 215
Make sure the timing marks on the crankshaft and Put a dial indicator on the camshaft gear. Check the
camshaft are aligned. backlash between the camshaft gear and the crank-
shaft gear. Backlash must be 0.08 to 0.33 mm. If
backlash is more than 0.45 mm the gears must be re-
STEP
.~s-
213
. '.~ ~..:- placed .
NOTE : Too much backlash can also be caused by worn

camshaft bushings.
STEP 216
Install the camshaft thrust plate behind the camshaft

gear.
STEP 214
T69027
Remove the pins from the lifters.
STEP 217
Install the thrust plate bolts and tighten to a torque of 21

to 27 Nm.
Install the breather cover.

2425-53
STEP 218 STEP 221
Install a new gasket on the lifter cover. Install the injection pump and the hand primer pump.
See Section 3414 for CAV injection pum p and Section
3415 for Bosch injection pump
STEP 219
STEP 222
Install new seals on the lifter cover bolts.
Install a new front cover gasket.

STEP 220
STEP 223
Install the lifter cover bolts and tighten to a torque of 21

to 27 Nm.
Clean the crankshaft seal surface of all oil and grease
using Loctite safety solvent. See seal installation in this
section for the front crankshaft.

2425-54
STEP 224 STEP 227
T68788
Install the tachometer drive assembly, if equipped. Install a ring compressor on the piston.
NOTE: Make sure the piston rings are in the grooves

STEP 225 before tightening the ring compressor. Tighten the ring
compressor, a little at a time, making sure the rings are
free to be pushed in.
STEP 228
Clean the rear crankshaft seal of all foreign material,

using Loctite safety solvent. See seal installation in this
section for installing the rear crankshaft seal.
T68789
Carefully push the piston down into the block.
STEP 226
IMPORTANT: Make sure that the arrow or the word
FRONT is toward the front of the engine. Make sure the
correct connecting rod is in the correct cylinder.
Add lubrication to the cylinder walls and piston rings.

Use clean engine oil.
Rae 8-24183 Issued 2-92 Printed in U.S.A

2425-55
STEP 229 STEP 232
- 1. MAXIMUM LENGTH _
59.25 mm
7L92
Install the bearing liners on the connecting rods and rod Measure the length of the connecting rod bolts If the
caps bolt length is more than 59.25 mm the bolt must be re-
placed.
IMPORTANT: Make sure the liner locks are aligned
when installing the liners. Use a sliding type movement IMPORTANT: Each bolt length must be checked
when installing the liners Never push on the center of before installation.
the liners.
STEP 230 STEP 233

r
---...:
Clean the connecting rod journals and the bearing Tighten the connecting rods to a torque of 60 Nm.
liners. Put a piece of plastigage on the crankshaft jour-
nals.
STEP 234

Install the bearing caps. holding rod. Turn the pointer to 60 degrees.Tighten the
NOTE: Make sure the number on the bearing cap is
equal to the number on the connecting rod.

2425-56
STEP 235 STEP 238

r
----.:J
Remove the bearing caps and check the clearance. Add lubrication to the rod bolts. Install the rod bolts and
The clearance must be 0.038 to 0.129 rnrn. If the clear- tighten to a torque of 60 Nm.
ance is more than 0 129 rnrn, undersize bearing liners
must be installed and reconditioning of the bearing
journals must be done. Install new bearing liners which STEP 239
will give a clearance of 0.038 to 0.116 rnrn.
STEP 236

Add lubrication to the bearing liners. Use clean engine
oil.
STEP 240
STEP 237
-- 1. MAXIMUM LENGTH
59.25 mm -
7L92 Install a new oil inlet tube gasket. See Section 2445 for
Measure the length of the connecting rod bolts. If the oil inlet tube installation.
bolt length is more than 59.25 mm the bolt must be re-
placed.
before installation
2425-57
STEP 241 STEP 244
Install the engine oil pan. See Section 2445 for oil pan Install the crankshaft pulley and tighten the retaining
installation. bolts to a torque of 120 to 130 Nm.
STEP 245
Install the cylinder head. See Section 2415 for installing

the cylinder head.
STEP 243
Install the flywheel and tighten the retaining bolts to a


2425-58
CAMSHAFT
Removal
STEP 246 STEP 249
T69021
Lift the belt tensioner and remove the fan belt. Disconnect the fuel lines and remove the injection
pump. See Section 3414 for CAV injection pumps and
Section 3415 for Bosch injection pumps in the service
STEP 247 manual.
STEP 250
Remove the fan pulley bolts and the fan pulley.
STEP 248 Remove the bolts, lifter cover and breather cover.
STEP 251
Remove the cylinder head. See Section 2415 for

cylinder head removal.
Raise the lifters and install pins to hold up the lifters.

2425-59
STEP 252 STEP 254

r/
.f) , '.. .T6~.Q~;

Remove the bolts from the camshaft thrust plate. Remove the camshaft from the engine block.
STEP 253
Remove the camshaft thrust plate.
Camshaft Bore and Bushing Inspection

STEP 255 STEP 256
Remove the engine oil pan. See Section 2445 in the Measure the camshaft bores. Use a bore gauge. The
service manual. bores must be measured in two positions. Take a
second measurement 90 degrees from the first measu-
rement.
NOTE: The crankshaft and pistons have been removed

for photographic purposes. These parts do not have to
be removed to service the camshaft.

2425-60
STEP 257 STEP 258
If the bushing diarneter is more than 54.146 mm, the If the intermediate or the rear bores are more than
front camshaft bushing must be replaced. 54146 mm, disassemble the engine block and line
bore the bores. See specifications for machining di-
mensions
Camshaft Bushing Removal and Installation

STEP 260
T69053
Put a bushing puller in the engine block and pull the Install the bushing on the puller. Align the oil holes. Pull
bushing out of the cylinder block. Use tool CAS-14124. the bushing into the cylinder block until it is even with
the housing.

2425-61
.••• c, '-1: .. 1.'

.lIIIIII:tk 'l~
Remove the pins from the lifters and remove the lifters. Measure the outside diameter of the valve lifter stem.
Replace the valve lifters if the outside diameter of the
NOTE: The crankshaft and pistons have been removed lifter stem is less than 15.961 rnrn.
for photographic purposes.
STEP 265
STEP 262
T69055 Put clean engine oil on the lifters before installation

Measure the lifter bores. Use an expandable bore
gauge.
STEP 263
~
Install the lifters in the block and fasten in position with
the pins.
If the diameter ofthe lifter bore is more than 16.030 rnrn,
the engine block must be replaced.
Rae 8-24183 Issued 2-92 Printed in U.SA

2425-62
Camshaft Disassembly and Inspection

STEP 267 STEP 269
T69065
Press the gear off the camshaft. Measure the front and rear of each bearing surface on
the camshaft. Use a micrometer.
STEP 268
STEP 270
T69064
Remove the shaft key.
T69066
Each bearing surface must be measured in four posi-
tions. Measure the front and rear bearing surfaces
again, 90 degrees from the first measurement
NOTE: Replace the camshaft if the outside diameter of

any bearing surface is less than 53.962 mm.

2425-63
Camshaft Gear Installation

STEP 271 STEP 272
T69064
Install the shaft key Install the camshaft gear on the camshaft with the lock
pin hole down.
Heat the camshaft gear a minimum of 45 minutes at a.
temperature of 250°F (121°C). Use a bearing heater
oven.
Camshaft Installation
STEP 273 STEP 275
Lubricate the camshaft bearing surface with clean Install the camshaft thrust plate.
engine oil.
STEP 276
STEP 274
Install the camshaft thrust plate bolts and tighten to a

Align the timing marks on the camshaft with the timing torque of 21 to 27 Nm.
mark on the crankshaft.

2425-64
STEP 277 STEP 280
Check the camshaft end clearance with a dial indicator. Install the oil breather cover, if equipped.
The end clearance must not be more than 0.130 to
0.470 mm. If the clearance is more than 0.470 mm, the
camshaft thrust plate must be replaced. STEP 281
STEP 278
Install a new gasket on the lifter cover and install the

lifter cover.
Put a dial indicator on the camshaft gear and check the
gear backlash between the camshaft gear and the
crankshaft gear. Gear backlash must be 0.08 to 0.330 STEP 282
mm. The gears must be replaced if the clearance is
more than 0.45 mm.
NOTE: Too much gear clearance can also be caused

by worn camshaft bushings.
STEP 279
Install new seals on the lifter cover bolts and tighten the
bolts to a torque of 21 to 27 Nm.
T69027
Remove the pins from the lifters.
Rae 8-24183 Revised 2-92 Primed in U.S.A.

2425-65
STEP 283 STEP 286 CAV INJECTION PUMP
Install the cylinder head. See Section 2415 for cylinder See Section 3414 in the service manual to install the in-
head installation. jection pump fuel lines.
STEP 284 STEP 287 BOSCH INJECTION PUMP
If the engine oil pan was removed, see Section 2445 in See Section 3415 in the service manual to install the in-
the service manual for installation. jection pump fuel lines.
STEP
..••.....
285 STEP 288
Install the front crankshaft pulley and tighten the bolts to See Section 3413 in the service manual to install the fuel
a torque of 120 to 130 Nm. injectors.

2425-66
STEP 289 STEP 290
Install the fan pulley and bolts. Tighten the bolts to a Lift the belt tensioner and install the fan belt.
torque of:
Grade 10.9 SiZe M8 37 to 43
FLYWHEEL
Removal
STEP 291
Remove the bolts and the flywheel from the engine.

2425-67
Ring Gear Removal and Installation

NOTE: If your flywheel has a welded ring gear, DO NOT try to remove the ring gear. Use a complete new flywheel and ring
gear assembly.
STEP. 292
,~.
STEP 294
Remove the ring gear from the flywheel, using a drift Install the flywheel Tighten the retaining bolts to a
hammer. Work around the circumference of the ring torque of 130 to 144 Nm.
gear.
STEP 293
.··.·.·.-.,·
T69213
:.,.,.,.»W""*"'v~,-;.':
Heat the new ring gear, 400 to 450°F (204° to 232°C), in

0
oil or in an oven. Do not use a torch to heat the ring gear.
Install the ring gear on the flywheel.

2425-68
TACHOMETER DRIVE, IF EQUIPPED

Removal and Disassembly
STEP 295 STEP 297
883L91
Remove the tachometer drive Assemble thet achometer drive.
STEP 298
883L91
Disassemble the tachometer drive. Install the tachometer drive assembly. Rotate the tac-
hometer drive until the tachometer drive until the tac-
hometer drive is at the correct angle Tighten the cover
bolts.
::lac 8-24183 Revised 2-92 Printed in U.$A.

2425-69
EXPANSION PLUG REMOVAL AND INSTALLATION

60 mm Expansion Plug, Camshaft
NOTE: The flywheel and flywheel housing must be removed to replace the camshaft expansion plug.
STEP 299 STEP 301
Remove the expansion plug from the cylinder block. Apply Loctite 277 to the sealing surface of the expan-
sion plug.
STEP 300
STEP 302
Use Loctite safety solvent to clean the sealing surface

of all foreign material. Install the expansion plug into the cylinder block. Hit the
expansion plug in the center to lock the expansion plug
in position.

2425-70
58 mm Expansion Plugs
STEP 303 STEP 306
Remove the expansion plug from the cylinder block.
STEP 304 892LO
Clean the sealing surface of all foreign material

Install the expansion plug into the cylinder block, until
the top edge of the expansion plug is even with the
STEP 305 bottom edge of the chamfer.
""
2509"
Apply Loctite 277 to the sealing surface of the expan-
sion plug.

2425-71
STEP 307 STEP 310
STEP 308 892LO
Clean the sealing surface of all foreign material.

Install the expansion plug into the cylinder block until
STEP 309 bottom edge of the chamfer.

sion plug.

2425-72
22.5 mm Expansion Plug

STEP 311 STEP 314
893LO
l~.i,Q3
STEP 312
Install the expansion plug into the bore, until the top
edge of the expansion plug is even with the bottom
edge of the chamfer,
"~~~~
Clean the expansion plug bore of all foreign material,

use Loctite safety solvent
STEP 313

sion plug.
Rae 8-24183 Revised 2-92 Printed in U,S.A

2525-73
18 mm Expansion Plug
STEP 315 STEP 318
~cJi824a4ot ·::.T8~
Put a small amount of grease in the expansion plug. Use Loctite safety solvent to clean the sealing surface
of all foreign material.
STEP 316
STEP 319
Drill a small hole in the center of the expansion plug.

sion plug.
STEP 317
Install a screw in the expansion plug and remove the ex-

pansion plug from the cylinder block.

2425-74
STEP 320

bottom edge of the chamfer.
STEP 321 STEP 322
Put a small amount of grease in the expansion plug. Drill a small hole in the center of the expansion plug.

2425-75
STEP 323 STEP 325
Install a screw in the expansion plug and pull the expan- Apply Loctite 277 to the sealing surface of the expan-
sion plug out of the cylinder block. sion plug.
STEP 324 STEP 326

1. CHAMFER
3. EXPANSION PLUG 893LO

the top edge of the expansion plug is even to the
bottom edge of the chamfer.

2425-76
CRANKCASE PRESSURE CHECK (BLOW BY)

Manometer Installation
STEP 327 STEP 330
Remove the clamp and the breather hose. Turn each connector on the manometer one turn coun-
terclockwise.
STEP 331
Install the breather adapter with the four cylinder orifice.

Connect the tube from the breather adapter to one of
NOTE: Use the 0.221 inch for four cylinder engines. the connectors on the manometer.
STEP 329 STEP 332

,r~
Install the manometer. Push the button on the gauge and move the gauge up
or down, until the zero on the gauge and the liquid in the
tube are aligned.

2425-77
Testing
NOTE: Do the following steps to get the correct man- MANOMETER READING
ometer readings.
Inches of
Step 1 - Warm the engine to operating temperature. Water Umin
Step 2 - Operate the engine at the rated speed. 1 27

2 40
Step 3 - Use the hydraulics to apply a load to the engine 3 49
during the manometer test.
4 58
5 64
STEP 333 6 71
~._~.
7 '."
76
8 81
9 86
10 90
11 94
12 98
13 102
14 105
,15 109
16 112
Take a manometer reading from the engine. Add the 17 115
number of lowered inches to the number of raised 18 118
inches for the correct manometer reading. 19 121
See example below.
20 124
LOWERED INCHES + 1.5
RAISED INCHES 1.5
TOTAL 3.0 INCHES
See the chart for manometer reading and crankcase

pressure (Blow By) limits.

2425-78
Manometer Removal
Disconnect the tube from the connector. Remove the adapter from the breather tube.
STEP 335 STEP 338
Turn each connector on the manometer one turn clock- Install breather hose and the hose clamp.
wise.
STEP 336
~/
Remove the manometer.
Rae 8-24183 Revisd 2-92 Printed in U.S.A.

Section
2445
LUBRICATION SYSTEM
Oil Pan, Oil Pump, Oil Cooler
and Oil Filter Housing
4-390 Diesel Engine
CASE CORPORATION Copyright© 1992 J I Case Company

June. 1983 (Revised February. 1992)
2445-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 3
OIL PUMP
Removal 4
Disassembly and Assembly 5
Installation 6-7
OIL PRESSURE RELIEF VALVE 8
OIL FILTER HOUSING AND Oil COOLER

Removal 9
Installation _ 9
Oil PAN AND OIL INLET TUBE

Removal and Installation ; 10
SPECIFICATIONS
Oil Pressure
New Engine at Low or 800 rpm 1.9 to 3.0 Bar 28 to 43 PSI
at 1700 rpm 2.8 to 3.4 Bar 40 to 50 PSI
at High Idle or 2400 rpm 3.0 to 3.7 Bar 43 to 54 PSI
Used Engine low Idle (minimum) 0.7 Bar 10 PSI

High Idle (minimum) 2.1 Bar 30 PSI
Oil Pump Idler Gear to Crankshaft Gear Backlash 0.450 mm

Oil Pump Rotor Clearance 0.178 mm
Oil Pump Relief Valve Spring Specification (For 2 Hole Relief Valves)
Free Length 55.83 mm
Outside Diameter 14.02 mm
Assembled Height:
Compress to 44.98 mm 63 to 79 N
Spring Load Height:
Oil Pump Relief Valve Spring Specification (For 4 Hole Relief Valves)
Free Length 64.0 mm
Assembled Height:
Compress to 44.5 mm 87 N
Spring Load Height:
Compress to 41.25 mm 104.7 N

2445-3
SPECIAL TORQUES
Oil Pump Retaining Bolts.. 21 to 27 Nm
Front Cover Retaining Bolts 21 to 27 Nm
Crankshaft Pulley Retaining 80Its 120 to 130 Nm
Fan Pulley 8racket Retaining 80Its 23 to 25 Nm
Fan Pulley Bolts


Filter Housing Retaining Bolts 21 to 27 Nm
Oil Inlet Tube Retaining Bolts 18 to 30 Nm

2445-4
OIL PUMP
Removal
STEP 1 STEP 4
Lift the belt tensioner pulley and remove the fan belt. Remove the crankshaft pulley bolts and the pulley.
STEP 2 STEP 5
::1[§~~9~6
Remove the retaining bolts and fan belt pulley. Remove the front cover retaining bolts and remove the
front cover.
STEP 3
STEP 6
Remove the fan pulley bracket retaining bolts and fan

pulley bracket. Remove the oil pump bolts and the oil pump.

2445-5
Disassembly and Assembly
STEP 7 STEP 9
T68767 T68766
Put the oil pump on a clean work surface. Measure the clearance between the lobe on the gear
and the lobe on the pump body. If the clearance is
more than 0.178 mm the pump must be replaced.
STEP 8
Remove the back cover plate.

,>T68765
Install the back cover plate on the oil pump.
Rae 8-24193 Revised 2-92 Printed in U.SA.

2445-6
Installation
NOTE: If a new oil pump is installed it is necessary to STEP 13
install a new four hole relief valve and spring.
STEP 11
Clean the seal surface on the crankshaft with Loctite

Safety Solvent. Refer to Section 2425 in the service
manual for front cover installation.
Install the oil pump and tighten the bolts to a torque of

21 to 27 Nm. Follow the torque sequence above. STEP 14
NOTE: To prevent damage to the oil pump DO NOT

tighten the bolts to more than 27 Nm.
STEP 12
Install the tachometer drive assembly (if equipped).
STEP 15
Check the backlash between the oil pump idler gear

and the crankshaft. Put a dial indicator on the oil pump
idler gear. If the backlash is more than 0.450 mm the oil
pump must be replaced.
Install the fan pulley bracket. Install and tighten the

retaining bolts to a torque of 23 to 25 Nm.

2445-7
STEP 16 STEP 18
T689-16
" .
Install the fan pulley and the retaining bolts. Tighten the fan pulley retaining bolts to a torque of:
STEP 17 Grade 8.8 Size M10 " 51 to 62 Nm
Lift the fan belt tensioner pulley and install the fan belt.

2445-8
OIL PRESSURE RELIEF VALVE SERVICE

STEP 19
Use a valve spring tester and check the valve spring for the following specifications:
Bottom Mounted Relief Valve Top Mounted Relief Valve
1. PLUG 4. RELIEFVALVE
2. GASKET 5. OIL FILTER HOUSING
3. RELIEFVALVE SPRING
1. PLUG 4. RELIEF VALVE

Relief Valve Springs (For 4 Hole Relief Valves)
2. GASKET 5. OIL FILTER HOUSING
Free Length 64.0 mm
3. RELIEFVALVE SPRING
Assembled Height:
Compress to 44.5 mm 87 N
Relief Valve Springs (For 2 Hole Relief Valves) Spring Load Height:
Free Length 55.83 mm Compress to 41.25 mm 104.7 N
Assembled Height: Replace the valve spring if specifications are not met.
Spring Load Height:

2445-9
OIL FILTER HOUSING AND OIL COOLER

Removal
STEP 20 STEP 22
Remove the oil filter. Remove the oil cooler.
STEP 21 STEP 23
.'~
Remove the oil filter housing. Put the oil filter housing on a clean work surface and
remove the cold oil relief valve.
Installation
STEP 24 STEP 25
Repeat Steps 20 through 24 in reverse order and install

the oil cooler and filter housing. Remove the two
alignment bolts.
NOTE: On Installation, install new gaskets to the oil

cooler and oil filter housing. Tighten the oil filter housing
retaining bolts to a torque of 21 to 27 Nm.
Install two guide bolts 8M x 1.25 x 75 into the engine

block.
Rae 8-24193 Revised2-92 Printedin U.SA.

2445-10
OIL PAN AND OIL INLET TUBE

Removal and Installation
STEP 26 STEP 28
l
Remove the oil pan drain plug and drain the oil. Remove the oil inlet tube bolts.
NOTE: On Installation, tighten the oil pan drain plug to a NOTE: On Installation, tighten the oil inlet tube retaining
torque of 68 to 82 Nm. bolts to 21 to 27 Nm.
STEP 27 STEP 29
Remove the oil pan bolts. Clean all surfaces of foreign material.
NOTE: On Installation, tighten the oil pan retaining bolts

to a torque of 21 to 27 Nm. STEP 30
Repeat Steps 26 to 28 in reverse order to install the oil

inlet tube and oil pan.
NOTE: On Installation, install new gaskets to the oil pan

and oil inlet tube.

Section
2455
COOLING SYSTEM
Thermostat, Water Pump, Fan Pulley

and Belt Tensioner
4-390 Diesel Engine
CASE CORPORATION Copyright © 1992 J I Case Company

June. 1983 (Revised February, 1992)
2455-2
TABLE OF CONTENTS
SAFETY RULES 3
SPECIAL TORQUES..... .. 3
SPECIFICATIONS . 3
WATER PUMP
Removal 4
Installation 4
THERMOSTAT
Removal............... .. 5
Installation .. . . 6,7
COOLING INLET MANIFOLD

Removal...... .. 8
Installation 8,9
FAN PULLEY BRACKET

Removal.............. 10
Installation . 10,11
BELT TENSIONER
Removal 11,12
Installation .. 12,13
THERMOSTAT SERVICE. 14

2455-3
SAFETY RULES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS
AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY
OR DEATH. M171B
Add coolant to the radiator only when the engine is stopped or slowly
h idling. To avoid being scalded when the pressure-type filler cap is being
•• removed, turn the cap slowly to the first stop position to relieve pressure
before removing the cap. M346
To remove the system pressure, slowly turn the radiator Never put coolant in a hot engine. The engine block or
cap counterclockwise to the FIRST stop. This will cylinder head can get cracks because of the difference
permit a gradual release of pressure with little coolant in temperature between the metal and coolant.
loss.
How to Clean the Cooling System
Clean the cooling system a minimum of once each 3. Drain the radiator cleaner solution and flush the
year. In areas where the water has minerals, clean the system with clean water. Fill the system with
system more frequently. antifreeze and water and check the hoses, radiator
and water pump for leaks.
1. When the coolant is hot, open the radiator and
engine block drain valves. Close the valves after the NOTE: After the cooling system is completely filled, run
system is empty. the engine for approximately 20 minutes to remove air
from the cooling system. Check coolant level and add
2. Add a radiator cleaner and fill the system with clean coolant if necessary.
water. Use a good type of radiator cleaner. Follow
the instructions given with the radiator cleaner.
SPECIAL TORQUES
Water Pump Housing Bolts 21 to 27 Nm
Inlet Manifold Bolts 39 to 47 Nm
Fan Pulley Bracket Bolts 23 to 25 Nm

Fan Pulley Bolts .
Grade 109 Size M8 37 to 43 Nm
Grade 10.9 Size M10. ......................................................................................................... 51 to 62 Nm

Belt Tensioner Bolt 39 to 47 Nm
SPECIFICATIONS
Belt Tension
Spring Tension at 35 Degree Angle (Minimum) 24 Nm

2455-4
WATER PUMP
Removal
STEP 1 STEP 2
····T6§§'EJ9
Lift the belt tensioner pulley and remove the fan belt Remove the water pump bolts and the water pump.
Installation
STEP 3 STEP 5
Install a new a-ring into the water pump housing. Lift the belt tensioner pulley and install the fan belt
STEP 4
Install the water pump and tighten the water pump

retaining bolts to a torque of 21 to 27 Nrn.

2455-5
THERMOSTAT
Removal
STEP 6 STEP 9
Lift the belt tensioner pulley and remove the fan belt. Remove the thermostat bearing bolts and the ther-
mostat housing assembly
STEP 7 STEP 10
410L91
Remove the alternator bolts and the alternator. Disassemble the thermostat housing.
STEP 11
STEP 8
155666
Remove the bracket bolts and the alternator bracket. Check the thermostat for correct operation. Put the
thermostat in a container of hot water, approximately
175°F (83°C), at this temperature the thermostat should
start to open. Gradually heat the water to a temperature
of 203°F (95°C), the thermostat should be fully open at
this temperature. The thermostat must be replaced if it
does not meet this specification.
2455-6
Installation
410L91
1. THERMOSTAT HOUSING 3. SEAL
2. THERMOSTAT 4. LIFTING BRACKET
STEP 14
SM4
Install the template (1) as shown 410L91
Assemble the thermostat housing.

STEP 13
NOTE: Make sure the stepped side of the seal is
towards the thermostat housing.
STEP 15
24551
Check the cylinder head coolant passage. If the coolant

passage is smaller than the template, see Page XX.
Install the thermostat housing assembly Install and

tighten the bolts to a torque of 21 to 27 Nm.

2455-7
STEP 16 STEP 18
Install the alternator bracket and tighten the retaining Lift the belt tensioner pulley and install the fan belt.
STEP 17
Install the alternator and tighten the retaining bolts.

2455-8
COOLANT INLET MANIFOLD

Removal
STEP 19 STEP 21
Lift the belt tensioner pulley and remove the fan belt. Remove the coolant inlet manifold.
STEP 20
Remove the alternator retaining bolts and remove the

alternator.
Installation
STEP 22 STEP 23
Install a new a-ring and the coolant inlet manifold. Install the coolant inlet manifold retaining bolts and
tighten to a torque of 39 to 47 Nm.

2455-9
STEP 24 STEP 26
Install the alternator. Lift the belt tensioner pulley and install the fan belt.
STEP 25
Install and tighten the alternator retaining bolts.

2455-10
FAN PULLEY BRACKET

Removal
STEP 27 STEP 29
T68919
Lift the belt tensioner pulley and remove the fan belt. Remove the fan pulley bracket.
STEP 28
: 1-.
····i;T6891'6·
. ;'~-"~
.....••...•...
,'
Remove the fan pulley retaining bolts and fan pulley,
Installation
STEP 30 STEP 31
T68918
Install the fan pulley bracket and tighten the bolts to a Install the fan pulley and retaining bolts,
torque of 23 to 25 Nrn.

2455-11
STEP 32 STEP 33
Lift the belt tensioner pulley and install the fan belt. Tighten the fan pulley bolts to a torque of:
BELT TENSIONER
Removal
STEP 34
STEP 35
Lift the belt tensioner pulley and remove the fan belt.
SM5
",..;;
Use a precision type torque wrench to lift the belt

tensionerto a 45 degree angle. Lower the belt tensioner
to a 35 degree angle. The spring tension must not be
less than 24 Nm . If the spring tension is less than 24
Nm, the belt tensioner must be replaced.
2455-12
STEP 36 STEP 38
Remove the tensioner bolt and the belt tensioner. Remove the belt tensioner bolts and the bracket.
STEP 37
Remove the retaining bolts and fan belt pulley.
Installation
STEP 39 STEP 40
Install the tensioner bracket and tighten the Allen head Install the fan belt pulley and retaining bolts

2455-13
STEP 41 STEP 43
Tighten the fan belt pulley retaining bolts to a torque of:

STEP 42 Grade 10.9 Size M10 51 to 62 Nm
Lift the belt tensioner pulley and install the fan belt.

2455-14
THERMOSTAT SERVICE
STEP 44 STEP 47
2. OLD THERMOSTAT
1. NEW THERMOSTAT
309L91
312L91
A new thermostat has been released for use in your
engine. If you removed an old thermostat from your Remove the template. Use a shop cloth in the coolant
engine, do the following steps to install a new ther- passage to keep foreign material out of the engine. Use
mostat a rotary grinder to remove the material.
STEP 48
STEP 45
31391
Remove all foreign material from the cylinder head.

Install the seal and new thermostat. Tighten the bolts to
311L91 a torque of 21 to 27 Nm.
Install the template that comes with the new thermostat
kit STEP 49
STEP 46
314L91
Mark the cylinder head on the intake side next to the

serial number as follows:
Stamp the letter "Go for cylinder heads that were in-
spected and did not need to be machined.
Stamp the letter "M" for cylinder heads that were mach-
ined.
Rac 8-24203 Revised 2-92 Printed in U.S.A
Section
2465
TURBOCHARGER
Written In Clear
And
Simple
English
IMPORTANT: This Turbocharger was made using the Metric Measurement

system. All measurements and checks must be made with metric tools to make
sure of an accurate reading when inspecting parts.

June, 1984
2465-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 3
SPECIAL TOOLS 3
SERVICING THE TURBOCHARGER

Removal 4,5
Inspection 6
Disassembly 7-13
Inspection After Disassembly 13-14
Assembly 15-22
Installation 23,24
SPECIFICATIONS
Metric Value
Turbine Wheel Horizontal Movement 0.10 to 0.16 mm

2465-3
SPECIAL TORQUES
U.S. Value Metric Value
Turbine Housing Bolts 96 Ib inch 11 Nm
(1.1kgm)
Center Housing to Back Plate Bolts " 48 Ib inch 6 Nm

(0.6 kgm)
Compressor Housing Bolts , 48 Ib inch 6 Nm

(0.6 kgm)
Compressor Lock Nut 120 lb inch 14 Nm

(1.4 kgm)
Thrust Bearing Screws (Torx Head) 36 Ib inch 5 Nm

(0.5 kgm)
Turbocharger Mounting Nuts : 24 Ib ft 32 Nm

(3.2 kgm)
Drain Tube Bolts 18 Ib ft 24 Nm

(2.4 kgm)
SPECIAL TOOLS
CAS-10032 LB INCH TORQUE WRENCH

CAS-10033 LB FT TORQUE WRENCH
CAS-10066-1A DIAL INDICATOR

2465-4
SERVICING THE TURBOCHARGER

Removal
STEP 1 STEP 4
x, .!I
Turbocharger with the air cleaner and the exhaust Disconnect the oil supply tube.
pipe removed.
STEP 5
STEP 2
Disconnect the oil supply tube clamp from the

Loosen the air intake hose clamps. tu rbocharger.
STEP 3 STEP 6
Remove the air intake hose. Disconnect the oil drain tube.

2465-5
STEP 7 STEP 10
Remove the nuts that hold the turbochargerto the Clean the mounting surface on the turbocharger
exhaust manifold. and the exhaust manifold.
STEP 8 STEP 11
Clean the mounting surface on the turbocharger

, J
and the oil drain tube.
Remove the gasket.

2465-6
Inspection
STEP 12 STEP 13
Put the turbocharger on a clean work surface. Use a dial indicator to check the horizontal move-
ment of the turbine wheel assembly. The horizon-
tal movement must not be more than 0.10 to 0.16
mm. The turbocharger must be rebuilt if the move-
ment is more than 0.16 mm or less than 0.10 mm.

2465-7
Disassembly
STEP 14 STEP 17
Put a identification mark on the compressor hous- Remove the compressor housing clamp plates.
ing and back plate. This identification is to make
sure the parts are in the correct position at assem-
bly. STEP 18
STEP 15
Lift the assembly off the compressor housing.
Put a identification mark on the turbine housing STEP 19

and the back plate. This identification is to make
sure the parts are in the correct position at assem-
bly.
STEP 16
Make the tabs straight on the lock plate.
Remove the retaining bolts from the compressor

housing.
2465-8
STEP 20
Remove the retaining bolts from the lock plate. Put the turbine end of the center housing assembly
into the holding fixture.
STEP 21
STEP 24
Remove the lock plates and clamp plates from the

turbine housing. Use a double universal joint to remove the com-
pressor wheel lock nut. This procedure will pre-
vent the turbine shaft from bending.
STEP 22
STEP 25
'\
\
Lift the center housing assembly from the turbine

housing.
Remove the compressor wheel lock nut.
NOTE: The compressor wheel lock nut is left hand

thread.

2465-9
STEP 26 STEP 29
Remove the compressor wheel.
STEP 27
Remove the seal ring from the turbine shaft.
Lift the center housing from the turbine shaft. STEP 30
STEP 28
Turbocharger center housing.
Remove the heat shield.

2465-10
STEP 31 STEP 34
Make the tabs straight on the lock plate. Remove the center housing from the back plate.
STEP 32 STEP 35
Remove the retaining bolts from the center hous- Remove the oil baffle from the back plate.
ing.
STEP 36
STEP 33
Remove the seal from the back plate.

Remove the lock plates from the center housing.

2465-11
STEP 37 STEP 40
Remove the oil slinger from the back plate. Remove the torx head screws from the center
housing.
STEP 38
STEP 41
Remove the seal ring from the oil slinger.

Remove the thrust bearing.
STEP 39
STEP 42
Turbocharger center housing.

Remove the thrust collar.

2465-12
STEP 43
Remove the outer bearing retaining ring. Turn the center housing over and remove the outer
bearing retaining ring.
STEP 44
STEP 47
Use a wire hook and pull the bearing from the

center housing. Use a wire hook and pull the bearing from the
center housing.
STEP 45
STEP 48
Remove inner bearing retaining ring.

Remove the inner bearing retaining ring.

2465-13
STEP 49
Center housing disassembled.
Inspection After Disassembly

STEP 50 STEP 52
Replace the turbocharger if the outlet openings Replace the turbocharger if the turbine wheel is
show warpage or cracks. damaged or if the turbine shaft has grooves or
scratches.
STEP 51
STEP 53
Replace the turbocharger if the compressor hous-

ing shows damage caused by wheel friction. Replace the turbocharger if the back plate has
wheel friction wear.

2465-14
STEP 54 STEP 56
Inspect the compressor wheel for bent blades and Replace the turbocharger if the oil slinger shows
scratches. Replace the turbocharger if the wheel damage.
shows damage.
STEP 57
STEP 55
Inspect the center housing bearing surfaces for

Replace the turbocharger if the heat shield shows scoring or scratches. Replace the turbocharger if
damage. there is damage.

2465-15
Assembly
NOTE: Lubricate a/l bearings, seals and the tur-

bine shaft with clean engine oil before assembly.

2465-16
STEP 58 STEP 61
Install a new inner bearing retaining ring. The Turn the center housing over and install a new
round edge of the retaining ring must be toward inner bearing retaining ring. The round edgeofthe
the top. retaining ring must be toward the top.
STEP 59 STEP 62
Install a new center housing bearing. Install a new bearing in the center housing.
STEP 60 STEP 63
Install a new outer bearing retaining ring with the Install a new outer bearing retaining ring with the
round edge down. round edge down.

2465-17
STEP 64 STEP 67
Install the thrust collar with the large 00 down. Tighten the thrust bearing screws to a torque of 36
Ib inch (5 Nm)(O.5 kgm).
STEP 65
STEP 68
Install a new thrust bearing on the center housing.

Install the oil baffle on the center housing with the
cup side down.
STEP 66
STEP 69
Install new torx head screws in the center housing.

2465-18
STEP 70 STEP 73
Carefully install the oil slinger in the back plate. Install new lock plates and new mounting bolts.
STEP 71
Tighten the back plate mounting bolts to a torque

of 48 Ib inch (6 Nm)(O.6 kgm).
STEP 72
Install the center housing on the back plate. Make

sure the mark on the back plate and the center Bend the tabs on the lock plate.
housing are aligned.

2465-19
STEP 76 STEP 79
Install a new seal ring in the groove of the turbine Install the compressor wheel on the turbine shaft.
wheel.
STEP 80
STEP 77
Install a new compressor wheel lock nut.

Install the turbine wheel in the fixture and install
the heat shield on the turbine wheel. NOTE: The compressor wheel lock nut is left hand
thread.
STEP 78
STEP 81
Install the center housing on the turbine shaft. Be

careful not to damage the seal ring. Use a double universal joint socket to tighten the
lock nut on the compressor wheel. This procedure
will stop the turbine shaft from bending.

2465-20
STEP 82 STEP 84
Tighten the lock nut to a torque of 120 Ib inch (14

Nm)(1.4 kgm).
STEP 83
Carefully install the center housing on the turbine

housing. Make sure the mark on the turbine hous-
ing is in align with the mark on the center housing.
Remove the center housing assembly from the fix-

ture. STEP 85
Install the clamp plates and the new lock plates.

2465-21
STEP 86 STEP 89
Install the new turbine housing bolts and tighten to Install the compressor housing mounting plates.
a torque of 96 Ib inch (11 Nm)(1.1 kgm).
STEP 90
STEP 87
Install new lock washers and bolts in the compres-

Bend the tabs on the lock plates. sor housing. Tighten the bolts to a torque of 48 Ib
inch (6 Nm)(O.6 kgm).
STEP 88
STEP 91
Install the turbine housing assembly on the com-

pressor housing. Make sure the mark on the center Turbocharger completely assembled.
housing is in align with the mark on the compres-
sor housing.

2465-22
TUBINE SHAFT
CENTER HOUSING
Rae 8-25550
2465-23
Installation
STEP 95
Install a new gasket on the exhaust manifold. Install a new gasket on the oil drain tube.
STEP 93 STEP 96
Install the oil drain tube bolts.
STEP 94 STEP 97
""~.
!I'"
Install the turbocharger mounting nuts and tighten Tighten the oil drain tube bolts to a torque of 181b
to a torque of 24 Ib ft (32 Nm)(3.2 kgm). ft (24 Nm)(2.4 kgm).

2465-24
STEP 98 STEP 101
Install a tighten the bolt for the oil supply tube

clamp.
STEP 102
STEP 99
Turbocharger installed on engine.

Connect and tighten the oil supply tube to the
tu rbocharger.
STEP 100
Install the air intake hose.
NOTE: The J I Case Company reserves the right to make improvements in

design or changes in specifications at any time without incurring any obliga-
tion to install them on units previously sold.
Rac 8-25550 Issued 6-84 Printed in U.S.A.

Section
2565
TURBOCHARGER FAILURE ANALYSIS
J I Case Rae 9-78235 Printed in USA

A Tenneco Company
2565-2
CAUSES OF PREMATURE TURBOCHARGER FAILURE

Certain operating and maintenance conditions Push in the fuel shutoff control and press
can arise which could cause premature turbo- the start button. Run the engine (about 2 min.
charger failure. NOTE: The total solution to max.) at 1000 RPM until normal engine oil
the problem is not in repairing the failure, but pressure shows on the engine oil pressure
in determining the cause. Replacing a damaged gauge assuring proper lubrication to the tur-
turbocharger without determining the cause will bocharger.
frequently result in a repeat failure. 4. If the engine fires and stops, wait for the star-
ting motor to stop spinning before attempting
Lack of Lubricating Oil another start.
5. Do not use the starting motor longer than 30
This type of failure can occur when the a- seconds without interruption. Wait at least
mount of oil being supplied to the turbocharger 3 minutes between crankings so batteries
is insufficient to lubricate or cool bearing can recuperate and the starting motor can
and journal surfaces. cool.
6. Should the engine kill when operating under
Operating temperatures affect the volume load, immediately restart the engine to
of oil required by the turbocharger. As turbo- prevent over-heating caused by stopping the
charger speed or engine load increases, the flow of oil for turbocharger, cooling and
need for lubricating oil increases. NOTE: In- lubrication.
sufficient oil for periods as short as five sec-
onds can cause failure. This is why it is nec- Foreign Material or Dirt in the
essary to prime the turbocharger as part of
the everyday operating procedure. IMPOR- Lubricating System.
TANT: It is very important that adequate Operating the engine with contaminated oil
lubrication reaches the turbocharger bear- will cause damage to the turbocharger bear-
ings and throughout the engine before opera- ings if the particles are of sufficient quantity.
ting the engine at rated speed. If the particles are large enough, they can
clog the internal oil passages and starve the
Priming The Turbocharger bearings. This is another reason why it is im-
portant to change the engine crankcase oil and
1.Place the transmission range shift lever in oil filters at regular specified intervals.
"N" Neutral position.
Foreign Material in Exhaust or
2.Set the throttle lever not more than 1/3 open Air Intake Systems.
position (1000 RPM).
The rotating parts of the turbocharger can be
3.Push in the fuel shutoff control. Press starter damaged by particles introduced through the air
button until engine starts. IMPORTANT: Do intake, which makes proper maintenance of the
not increase throttle or apply load until nor- air cleaner system very important.
mal oil pressure shows on the engine oil
pressure gauge, assuring proper lubrication High Exhaust Temperature
to the turbocharger.
Excessive temperature in the exhaust system
IMPORTANT: In very cold weather, at oil will cause lubricating oil to coke in the center
filter change or when the tractor has been housing drain annulus at the turbine end. Oil
idle for several weeks or more, proceed as leakage, carbon deposits and eventual damage
follows to prime the turbocharger. to the back of the turbine wheel will result.
High exhaust temperature can also erode the
Pull out the fuel shutoff control, press the turbine housing creating pitting and deposits
start button and hold. Allow the engine to on the turbine wheel.
crank until the engine oil pressure gauge High exhaust temperature can be caused by
pointer reaches the green zone. Do not the turbocharger itself. Carbon build up on the
exceed 30 seconds cranking time. turbine wheel, if severe, will slow the rotating
assembly, reducing the amount of inlet air.
2565-3
TURBOCHARGER FAILURE ANALYSIS
NOTE: Following are discussion and examples

of damaged parts which are typical turbocharger
failures. In analyzing turbocharger failure it is
important to recognize what caused the failure.
Replacing of the parts will, of course, repair
the damage but, unless you can correct the
causes, a reoccurance of these problems can be
expected.
Turbine Contact Damage Compressor Contact Damage
Contact damage to the turbine usually means

there was bearing damage and/or shaft motion
caused by lack of lubricant or contaminated
oil. In this picture we see the turbine end
showing wheel rub from bearing failure as a
result of oil starvation.
Damage to bearings from contaminated lub-

ricant or from lack of lubricant will allow
motion of the shaft, permitting the compressor
wheel to contact the housing. Marking will be
visible on both the housing and the compres-
sor wheel. In these pictures we see the com-
pressor end showing wheel rub from bearing
failure as a result of oil starvation.
2565-4
Coked Center Housing Scored Bearing Surface
Coked (sludged) center housing failures are The bearing surfaces of this shaft were scored
generally caused by high exhaust temperatures due to dirty engine oil. Evidence of a contamina-
due to over-fueling, over-loading the engine, ted oil failure calls for careful, thorough exa-
dirty engine oil, or plugged oil return. Also mination of engine lube system.
examine bearings for sludge.
Scored Bearings
Scored Turbine Shaft
Scoring on the inside and outside surfaces

The scoring of this shaft was caused by a of the bearings is definitely attributed to
loose compressor wheel lock -nut. dirty engine oil.
2565-5
Scored Thrust Collar Compressor Damage - Hard
Scoring on the thrust collar caused by dirty

oil usually because engine oil and/or oil filters
were not changed at the recommended intervals.
Compressor Damage - Soft
Hard material such as a nut. wire. wrench

or bolt getting into the inlet will damage the
compressor blades as shown. The compressor
housing will be marked by the bits of foreign
material. If damage to blades is so extensive
that wheel balance is destroyed. some wheel-
to-housing contact damage may also be pre-
Soft material getting into the inlet will dam- sent.
age the compressor blades as shown. The
damage to this blade was caused by a shop
towel being left in the intake system.
2565-6
Compressor Blade Erosion Turbine Shaft Discoloration
Erosion of compressor blades from ingestion Discoloration of the turbine shaft is due to
of dust. Blades on one wheel are thinned while overheating caused by oil starvation. Lack of
the other wheel is almost completely worn lubrication generally is a matter of improper
away. Fine erosion of the inlet edges of the start-up or shut-down practices.
compressor wheel suggests sand or other fine
abrasive in the inlet system, entering through
a damaged air cleaner element or a leak in
inlet piping. There will generally be no dam- Backing Plate Wheel Rub
age to the turbine wheel or bearings unless the
problem was so severe that the rotating unit
became unbalanced.
Turbine Wheel Damage
Wheel rub against the backing plate can be

caused by a bent shaft or improper assembly.
Foreign material in the exhaust system will

cause chipped or broken turbine wheel blades.
Foreign material is usually something left by
accident in the exhaust manifold, or debris from
an engine component such as a valve which failed.
If damage is extreme, the turbine wheel balance
will be destroyed and further damage will occur.
If you find this problem checkout the engine.
2565-7
Blade Edges Lifted Bearing Damage
Blade edges of the compressor wheel lifted Engine bearing material imbedded in the
by improper removal of the compressor hous- bearing surfaces. Checkout the engine for
ing. Housing should not be pried off but lifted possible bearing failure.
straight off.
Bearing Failure
Turbtne Shaft & Bearings
Bearing failures occur in two separate

Turbine shaft and bearings showing effect of areas. Scoring on the inside as well as the
oil starvation. outside is attributed to dirty oil. Abrasive
wear can also cause erosion around the oil
holes in the bearings. A good bearing is shown
in the lower right for comparison.
2565-8
Fine Scratches on Shaft Bent or Broken Shaft
Fine scratches on both bearing journals are Bearing damage and extreme shaft motion
evidence that abrasive material has contamina- caused by lack of lubrication or abrasives in
ted the lubricating oil. the oil may eventually cause the shaft to bend
or even break. When this type of damage is
evident. check the bearings.
NOTE: The J I Case Company reserves the right to make improvements

in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
SECTION INDEX - FUEL SYSTEM
Fuel System and Filters 3410
Fuel Injection Pump 3412
Fuel Injectors 3413

Issued January 1991
Section
3410
FUEL SYSTEM AND FILTERS

Issued March 1991
3410-2
FILTER REPLACEMENT
NOTE: Some engines have MO fuel filters while others STEP 2
have single fuel filters. See the following photographs.
Remove and discard the rubber seals from the filter

Case engine with two fuel filters head.
STEP 3
Case engine with single fuel filter
Lubricate the new rubber seals with clean engine oil.

STEP 1
Install the rubber seals on the filter head.
STEP 4
Use a strap or clamp wrench to remove the filter or

filters.
Lubricate the gasket on the new filter with clean engine

oil. Turn the filter clockwise until the gasket makes
contact with the filter head. Use your hands to tighten
the filter an additional 1/2 to 3/4 of a turn.

3410-3
BLEEDING AIR FROM THE FUEL SYSTEM

STEP 5 4-390 ENGINE STEP 7 4T-390 ENGINE
1. Bleed Screw 1. Bleed Screw

2. Primer Pump 2. Primer Pump
Make sure there is fuel in the fuel tank. Loosen the bleed Make sure there is fuel in the fuel tank. Loosen the bleed
screw and actuate the primer pump. Tighten the bleed screw and actuate the primer pump. Tighten the bleed
screw when clear fuel with no air bubbles flows from the screw when clear fuel with no air bubbles flows from the
bleed screw. bleed screw.
NOTE: If the primer pump can not be actuated, rotate NOTE: If the primer pump can not be actuated, rotate
the engine until the primer pump can be actuated. the engine until the primer pump can be actuated.
STEP 6 4-390 ENGINE
1. Bleed Screw
2. Primer Pump
Put the key switch in the ON position. Loosen the bleed
screw on the fuel injection pump. Actuate the primer
pump. Tighten the bleed screw when clear fuel with no
air bubbles flows from the bleed screw.
NOTE: If the primer pump can not be actuated, rotate

the engine until the primer pump can be actuated.

3410-4
BLEEDING AIR FROM THE FUEL SYSTEM

STEP 5 4-390 ENGINE STEP 7 4T-390 ENGINE
1. Bleed Screw 1. Bleed Screw

2. Primer Pump 2. Primer Pump
Make sure there is fuel in the fuel tank. Loosen the bleed Make sure there is fuel in the fuel tank. Loosen the bleed
screw and actuate the primer pump Tighten the bleed screw and actuate the primer pump. Tighten the bleed
screw when clear fuel with no air bubbles flows from the screw when clear fuel with no air bubbles flows from the
bleed screw. bleed screw.
.NOTE: If the primer pump can not be actuated, rotate NOTE: If the primer pump can not be actuated, rotate
the engine until the primer pump can be actuated. the engine until the primer pump can be actuated.
STEP 6 4-390 ENGINE
1. Bleed Screw
2. Primer Pump
Put the key switch in the ON position. Loosen the bleed
screw on the fuel injection pump. Actuate the primer
pump. Tighten the bleed screw when clear fuel with no
air bubbles flows from the bleed screw.
NOTE: If the primer pump can not be actuated, rotate

the engine until the primer pump can be actuated.

Section
3413
FUEL INJECTORS
4-390 Diesel Engine
J'

June, 1983 (Revised February 1992)
3413-2
TABLE OF CONTENTS
SAFETY RULES 2
SPECiFiCATIONS..... .. 3
SPECIAL TOOLS 4
SPECIAL TORQUES 4
GENERAL INFORMATION 4
OPERATING PROCEDURES 5
LOCATING FAULTY INJECTORS

Locating Faulty Injectors at the Fuel Pump . 6
Locating Faulty Injectors at the Cylinder Head 6
INJECTORS
Removal 6,7
Installation .. .. . 7,8
FUEL INJECTOR TESTER. 9

Nozzle Tester Preparation 9
TESTING INJECTORS 10
Checking Opening Pressure................................ 10
Checking Seat Leakage 11
Spray Pattern 11
INJECTOR
Disassembly 12
Cleaning and Inspection 13
Assembly 14-16
Adjustments 16
INJECTOR SLEEVE (9 mm BORE TO 7 mm BORE)

Installation 17
SAFETY RULES
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT

SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS
SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS
AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY
OR DEATH. M171B
When testing or adjusting diesel fuel injectors, do not place your hands,
arms, or any other part of your body into the fuel injector spray.
Fuel s'prayfrom an injector has sufficient velocity to penetrate the skin and
cause serious infection or other reactions. If injured by fuel penetration,
see your doctor immediately. SM127A
Wash the injured part with boric acid solution, support the injured finger or hand with a splint and sling so the injured part
will remain absolutely at rest until a physician can examine it.
3413-3
SPECIFICATIONS
Engines Manufactured in Darlington, England:
Prior to Engine Serial Number 21092870 use 9 mm Injector Nozzles
Engine Serial Number 21092870 and after use 7 mm Injector Nozzles
Engines Manufactured in North America:

Engines Manufactured in Neuss, Germany:

Bosch Injectors
PART NUMBER
Assembly Nozzle Spray Angle Number of Spray Nozzle Size Opening Pressure
(Case) (Robert Bosch) Orifices Orifice Size
J914472 0433171067 155 Degrees 4 0.28 mm 9mm 220 to 228 Bar

(3190 to 3307 PSI)
J909476 0433171074 155 Degrees 4 0.29 mm 9 mm 245 to 253 Bar

(3553 to 3699 PSI)
J919300 155 Degrees 4 0.28 mm 7mm 220 to 228 Bar

(3190 to 3307 PSI)
CAY Injectors
PART NUMBER
Assembly Nozzle Spray Angle Number of Spray Nozzle Size Opening Pressure
(Case) (CAV) Orifices Orifice Size
J917661 ,
6801102 155 Degrees 4 0.29 mm 9mm 245 to 253 Bar
(3553 to 3669 PSI)

(3553 to 3699 PSI)

(3553 to 3669 PSI)
Valve Leakage Rate ,,, , No Leakage Permissible

Slight Moistening of Nozzle Tip Permissible
Maximimum Opening Pressure Variation between each Cylinder 10.34 Bar 150 PSI

3413-4
SPECIAL TOOLS
1. CAS-1066A WRENCH
SEE PAGE 7
2. CAS-1694 9 mm INJECTOR BORE CLEANING TOOL

3. CAS-2155 7 mm INJECTOR BORE CLEANING TOOL
SEE PAGE 7
SPECIAL TORQUES
Injector Retaining Nut 55 to 65 Nm

Leak Off Bolt : , 8 Nm
Nozzle Cap Nut 55 Nm
GENERAL INFORMATION
The fuel injector sends a measured amount of fuel to INJECTOR VALVE - The valve controls the flow of the
the combustion chamber from the injection pump. fuel from the injector.
Each quantity of fuel must be sent to the combustion
chamber in the form of fine particles. This will make sure VALVE STOP - The valve stop has two dowel pins which
that there is complete combustion and efficient engine hold the valve tip to the body. This will make a spray
performance pattern that is correct. Both faces of the valve stop have
a fine surface finish. The valve stop controls the
IMPORTANT: The injector tip end and the injector valve distance that the valve will move.
are a matched assembly. The two parts are made
smooth to fit together with accuracy. The injector tip or OPENING PRESSURE CONTROLSPRING - The spring
the injector valve cannot be replaced separately for controls the fuel pressure that is necessary to lift the
service. If it is necessary to replace either the valve or tip, valve from the seat.
replace the complete tip assembly.
SHIMS - The shims push down on the spring to keep a
IMPORTANT: Do not mix tip assemblies and bodies given pressure on the valve.
while the injectors are being disassembled.
INJECTOR TIP - The valve and the valve seat are in the
INJECTOR BODY - The body holds the injector parts in injector tip. There are orifices in the injector tip that
the correct position in the cylinder head. The body has a atomize the fuel for better combustion and separate the
high pressure channel and a leak off channel. The lower fuel spray to mix the fuel spray with air.
face of the body has a finished surface and has two
holes in the surface for locating dowel pins. NOZZLE SEAL - The seal is under the cap nut and stops
engine compression leakage.

3413-5
OPERATING PROCEDURES
The operation of the injector is easy and positive When the fuel delivery stops, the pressure against the
valve is decreased and the control spring immediately
A measured quantity of fuel under high pressure moves returns the valve to the seat. This removes the danger of
from the injection pump to the high pressure channel in leakage, after the measured amount of fuel has been
the injector body The fuel then moves through the valve released. The valve opens and closes vary rapidly with
stop channel and enters the pressure chamber which is a very clear noise.
around the valve in the injector tip.
A small amount of fuel leaks, during injection, through
When the pressure of the fuel against the valve is more the controlled clearance between the tip assembly and
than the set spring orifice, the valve is moved from the the injector body. This leakage adds lubrication to all
seat. This permits the fuel under high pressure to enter the moving parts in the injector. This fuel then moves
the injector tip. The fuel then moves through the spray through the leak off channel, leak off lines and returns to
orifices and to the combustion chamber. The fuel the fuel tank.
reaches the combustion chamber in an atomized
condition.
420L91
1. INLET 9. NOZZLE SEALING WASHER

2. LEAK OFF 10. SPRAY ORIFICE
3. LEAK OFF CHANNEL 11. INJECTOR TIP
4. EDGE FILTER (IF EQUIPPED) 12. INJECTOR VALVE
5. HIGH PRESSURE CHANNEL 13. VALVE STOP
6. INJECTOR BODY 14. SPRING SEAT
7. OPENING PRESSURE CONTROL SPRING 15. PRESSURE ADJUSTING SHIMS
8. CAP NUT

3413-6
LOCATING FAULTY INJECTORS
If there is a loss of power during engine operation, the

injectors can be faulty. Refer to the following
procedures to locate the faulty injectors:
Locating Faulty Injectors Locating Faulty Injectors

at the Fuel Pump at the Cylinder Head
STEP 2
!~
Loosen the tube nut on the fuel line. This will release the Loosen the tube nut on the fuel inlet line for the injector
fuel and the injector will not work. If this injector is faulty, at the cylinder head. If the injector is faulty, there will not
there will not be any difference in the engine perfor- be any difference in the engine performance Connect
mance. Connect and tighten the tube nut of the fuel line. ano tighten the tube on the fuel inlet line.
Repeat this procedure for the remaining injectors. Repeat this procedure for the remaining injectors.
INJECTOR
Removal
STEP 3 STEP 4
Clean the area around the fuel injectors.

3413-7
STEP 5 STEP 7
Remove the leak off bolt. Remove the fuel injector from the engine. Remove and
discard the sealing washer.
STEP 6
STEP 8
Repeat Steps 4 through 7 to remove the remaining in-

jectors.
Install the special wrench and a wrench on the flat

surface of the injector. Loosen the injector.
Installation
STEP 9 STEP 10
.~¥
lJ69231
Use the injector bore cleaning tool, see Special Tools Install a new seal on the injector and install the injector
page for correct size cleaning tool, to clean the injector in the cylinder head bore. The ball in the injector must
bore. Use compressed air to clean the injector bore. align with the slot in the cylinder head bore.
NOTE: Use only a 7 mm seal with a 7 mm injector and a

9 mm seal with a 9 mm injector.

3413-8
STEP 11 STEP 13
T78866 ~
Use the special wrench to tighten the injector retaining Remove the cap. Connect and tighten the injection line
nut to a torque of 55 to 65 Nm. to the injector.
STEP 12
-H,~I7i~60
Install the seal and the leak off screw and tighten the
leak off bolt to a torque of 8 Nm.
NOTE: Make sure the top of the gasket does not touch
the leak off line.

3413-9
FUEL INJECTOR TESTER

Fuel injectors must be checked on the tester when
making the following service operations
1. An injector that has been removed from the engine

for cleaning, must be checked on the tester before
the injector can be installed in the engine.
2. A new injector assembly must be checked on the

tester before the injector can be installed in the
engine.
3. All the injectors must be removed and checked on

the tester during an engine overhaul.
A Diesel Fuel Injection Nozzle Tester, OEM 1064, is
needed for checking and adjusting the injectors. The 4. An injector must be removed and checked on the
following instructions will work for all models of testers tester before the injector is disassembled, if the
except for descriptions on adjustments to the tester injector is the cause of engine performance that is
Operating instructions are given with the tester. not acceptable.
The tester is used to make the following checks
1. Check and adjust the injector opening pressure
2. Check the injector assembly for fuel leakage.
3. Check the injector for accurate spring pattern.
Nozzle Tester Preparation

1. Fill the reservoir with clean fuel. 3. Connect the injector to the tester.
2. Connect the correct connectors to the connection 4. To remove the air that is in the system, close the
tube pressure release valve and the gauge protection
valve, open the pump. Operate the pump rapidly to
remove the air from the system.

3413-10
TESTING INJECTORS
1
The injector must be cleaned before testing the injector. Connect the injector to the nozzle tester. The nozzle tip
Wash the body, nozzle tip and the cap nut in a solvent to must be facing down.
remove external dirt, grease and carbon deposits from
the cap, body and outside diameter of the tip. When testing or adjusting fuel injectors, do
IMPORTANT: Do not permit the wire brush to contact

I>.. not put your hands or arms in front of spray.
•• The spray will penetrate the skin causing
the tip (spray hole area) of the nozzle. serious personal injury. SM126A
Fuel from the spray orifices can enter clothing and skin,
causing serious damage. The tip must always be put in
a container to contain the spray.
Checking Opening Pressure

Close the pressure release valve and the gauge If the injectors do not meet the given opening pressure:
protection valve, operate the pump rapidly to flush the
injector. Open the gauge protection valve and raise the 1. New injectors can be adjusted to the given opening
pressure slowly until the injector valve opens (the pressure. Refer to Page 16.
gauge reading will fall quickly at this point). Check the
opening pressure against the Specifications, refer to 2. Injectors in use must be disassembled and cleaned.
Page 3. Refer to Page 12.
NOTE: There must not be more than 10.34 Bar (150 3. Check for broken or weak opening pressure control
PSI) difference between any of the injectors that have springs.
been removed from the engine.

3413-11
Checking Seat Leakage

Close the pressure release valve and the gauge 4. Open the pressure release valve and remove the
protection valve. Open the pump valve and operate the injector.
pump rapidly to flush the injector.
The following procedure must be followed if drops of
1. Dry the injector tip completely. Open the gauge fuel are seen on the nozzle tip.
protection valve.
1. Disassemble and clean the injector, refer to Pages
2. Lift the pressure at the injector to 6.9 Bar (100 PSI) 12.
under the opening pressure.
2. Assemble the injector, refer to Pages 14 through 16
3. Close the pump valve for five seconds and check
the nozzle tip (spray hole location). The nozzle leaks
if drops of fuel are seen on the nozzle tip. A small
amount of moisture on the nozzle tip is permitted
Spray Pattern
Close the pressure release valve and the gauge The injector will make a very clear noise when the test
protection valve. Open the pump valve and operate the stand is operated rapidly. This noise will not necessarily
tester at 60 strokes a minute, check the spray pattern. occur in the opeation of the injector in the engine. The
The nozzle must have a spray pattern that will atomize noise is an indication of good seat width and
the fuel. The nozzle must not have a solid spray pattern. interference angles This noise can change between
nozzles The noise in the nozzles must not be
compared for purpose of making nozzles acceptable
or not acceptable.
If this injector makes a solid type spray pattern, do the

following:
1. Check the orifices that are not open and check

orifices for scratches and heavy damage
2. Disassemble and clean the injector.
3. Check for pitting of the valve seat, wear of valve in-

terference angles, bent valve and distortion in the
SPRAY PATTERN THAT WILL ATOMIZE FUEL body. Replace the complete injector assembly if
there is distortion in the body. Under other condi-
tions, replace the tip assembly only.
SOLID TYPE SPRAY PATTERN
Rae 8-24233 Revised 2-92 Printed in U.S A

3413-12
INJECTOR
Disassembly
STEP 14 STEP 16
Put the injector in a soft faced vise with the two flat Remove the nozzle cap nut and disassemble the in-
surfaces towards the vise face. The tip of the injector jector.
must be up. Remove and discard the sealing washer
NOTE: The injector parts have tight tolerances. Dirt will
NOTE: Use a cleaning solution to remove carbon damage a smooth surface. Keep the work location and
deposits from the nozzle and holder assembly. tools clean. Disassemble and assemble all parts
carefully to prevent damage.
STEP 15
Use a small amount of force to turn the cap nut.
IMPORTANT: The nozzle is held in position with the cap

nut. To prevent damage to the dowel pins. valve stop
and holder body pressure face, the nozzle must not turn
with the cap nut. Wet the nozzle and holder assembly in
cleaning solution until the nozzle is free in the cap nut.
replace the valve stop assembly if there is damage to
the dowel pins or valve stop.

3413-13
Cleaning and Inspection

1. All parts must be put in a solvent to loosen the
carbon deposits.
2. Use the Nozzle Cleaning Kit, OEM 1068, to clean the

injectors A brass wire brush must be used to clean
the outside of the tip body. Use cleaning wires to
remove the carbon from the spray orifices. Use
cleaning wires that are 0.0127 to 0.0254 mm smaller
in diameter than the spray orifice. Put the cleaning
wire in a pin vise, the end of the wire must extend
o 79 mm past the tip of the pin vise. A longer length
of pin will hit the opposite s ide of the sac hole and will
break.
4. Clean all channels with compressed air Direct the
air through both ends of the nozzle tip assembly. All
Carbon deposits must be removed.
3 Use a stone to remove sharp edges from the end of

the wire. A small flat on one side of the wire will make
it easier to cut the carbon from the orifice. Put the 8
cleaning wire in the spray orifice and turn the wire 5. Make sure that the nozzle valve slides freely in the
until the wire is free Wash the body with clean nozzle body.
solvent and look at the tip. The nozzle tip must be
replaced if the orifice in the tip shows damage at the 6. Carefully clean the nozzle valve and the inside
edges. Damage to the orifice will change the spray diameter of the body to remove all dirt, varnish and
pattern. other foreign deposits.
7. The injector valve must be cleaned with a brush to

remove deposits from the seat location. Varnish
must be removed with a solvent and a cleaning pad
made of felt. Do not put the valve in a motor driven
lathe to clean the valve. This method can remove too
much material from the valve which can change
valve lift. Look at the valve for pitting or damage
which can cause leakage
8. Replace all parts that show damage.

3413-14
1. NOZZLE HOLDER
2. PRESSURE ADJUSTING SHIMS
3. OPENING PRESSURE CONTROL SPRING
4. SPRING SEAT
5. VALVE STOP
6. NOZZLE TIP ASSEMBLY
7. CAP NUT
421L91
NOTE: Clean all parts in clean diesel fuel before as-

sembly. STEP 18
STEP 17
"T69086
Install the opening pressure control spring into the
T69087 nozzle holder.
Install the pressure adjusting shims required to obtain
the correct opening pressure.
3413-15
STEP 19 STEP 22
T69085 T69083
Install the spring seat onto the pressure spring. The Align the dowel pins in the nozzle tip assembly with the
small diameter end of the spring seat must be toward dowel pins in the stop valve assembly. Install the nozzle
the pressure spring. tip assembly onto the stop valve assembly
,STEP
.
20 STEP 23
T69084 T69082
Install the valve stop assembly. Align the dowel pins in Add lubrication to the nozzle shoulder. Do not put
the valve stop with the dowel pin holes in the nozzle grease on the holder or on the threads of the cap nut.
holder. Install the cap nut over the end of the nozzle tip
assembly and turn the cap nut clockwise two or three
times
STEP 21
STEP 24
Put a small amount of clean fuel on the nozzle valve and

slide the nozzle valve up and down a number of times in T69080
the nozzle tip to make sure that there is free movement. Put the injector in a soft vise with the tip of the injector
up. The flat surface of the injector must be toward the
face of the vise. Tighten the nut to a torque of 55 Nm.

3413-16
STEP 25
1. INLET
2. LEAK OFF
3. LEAK OFF CHANNEL
4. EDGE FILTER (IF EQUIPPED)
5. HIGH PRESSURE CHANNEL
6. INJECTOR BODY
7. OPENING PRESSURE CONTROL SPRING
8. CAP NUT
9. NOZZLE SEALING WASHER
10. SPRAY ORIFICE
11. INJECTOR TIP
12. INJECTOR VALVE
_21 13. VALVE STOP
Check the fuel injector on the test stand, refer to Pages 14. SPRING SEAT
9 and 11. 15. PRESSURE ADJUSTING SHIMS
420L91
Adjustments
STEP 26 STEP 27
_"". om T69087
Remove the fuel injector from the nozzle tester. Put the Add pressure adjusting shims to increase the opening
injector in a soft faced vise. The flats of the injector pressure. Remove pressure adjusting shims to
holder must be toward the face of the vise. The injector decrease opening pressure. Do this until the correct
tip must be facing up. Loosen the cap nut. To pressure is reached.
disassemble the injector, refer to Page 12.
IMPORTANT: The opening pressure is changed by
about 3.79 Bar (55 PSI) for each 0.0254 mm of shim
thickness that is added or removed.
STEP 39
Assemble the fuel injector. Refer to Pages 14 through
16.
3413-17
INJECTOR SLEEVE
Installation
This sleeve must be used to change the 9 mm injector bore in the cylinder head to a 7 mm injector bore to use the 7 mm
injectors.
STEP 28 STEP 30
T78866
Use the injector bore cleaning tool, See Special Tools Use the special wrench and tighten the injector re-
page for correct size cleaning tool, clean the injector taining nut to a torque of 55 to 65 Nm.
bore. Use compressed air to clean the injector bore.
STEP 31
STEP 29
.#
J78860
Install the seal and the leak off screw and tighten the
leak off bolt to a torque of 8 Nm.
NOTE: Make sure the top of the gasket does not touch
35L92
the leak off line.
Install the sleeve on the injector. STEP 32

IMPORTANT: Do not install a sealing washer on the
injector when sleeve is used.
.~
Remove the dust cap. Connect and tighten the injection

line to the injector.
3413-18

Section
3414
CAV FUEL INJECTION PUMP
Pump Drive Gear, Fuel ShutOff
Primer Pump and Pump Timing
4-390 Diesel Engine
CASE CORPORATION Copyright © 1992 J I Case Company

February, 1991 (Revised February, 1992)
3414-2
TABLE OF CONTENTS
SPECIAL TOOLS .... .2
SPECIAL TORQUES . .... 2
TROUBLESHOOTING GUIDE .... 3
FUEL INJECTION PUMP

Removal . . 4,5
Installation . . ... 6,7
INJECTION PUMP GEAR

Removal. 8,9
Installation ................................................................................................................................. 10,11
FUEL INJECTION PUMP TIMING ... 11-14
FUEL SHUT-OFF SOLENOID

Removal and Disassembly ................... 14
Assembly and Installation ............. 14
PRIMER PUMP
Removal.. . 15
Installation 15
SPECIAL TOOLS
CAS-1690 ENGINE TURN OVER TOOL CAS-1691 A GEAR PULLER

FIRST USED ON PAGE 5 FIRST USED ON PAGE 5
SPECIAL TORQUES
Injection Pump Mounting Bolts 21 to 27 Nm
Injection Pump Nut 59 to 71 Nm
Fuel Line Inlet Bolt 22 to 28 Nm
Fuel Shutoff Solenoid 14 Nm
Leak Off Fitting 13 to 17 Nm

3414-3
TROUBLESHOOTING GUIDE
NOTE: It is assumed that the engine is in good working order and properly tuned, and that the electrical system has been
checked and repaired as necessary.
CAUSE AND REMEDY

Incorrect fuel in the fuel tank:
Drain tank, flush system and fill with correct fuel
Fuel tank empty or fuel tank vent blocked: .
Fill tank and bleed system, check tank vent (Refer to Section 3410)
Air in the fuel system:
Bleed fuel system, eliminate air leaks (Refer to Section 3410)
Pump rear support bracket loose:
Replace as necessary
, Voltage supply malfunction, stop solenoid defective:
Correct electrical faults, replace solenoid (Refer to Section 3414)
Fuel filter blocked:
Replace fuel filter (Refer to Section 3410)
Fuel supply lines blocked or resticted:
Check all fuel supply lines, flush or replace
Loose connection, injection lines leaking or broken:
Tighten the connection, eliminate the leak
Paraffin deposit in fuel filter:
Replace filter, use Diesel Fuel no.1 (Refer to Operators Manual)
Fuel injection pump timing incorrect:
Adjust timing
Injection nozzle faulty:
Repair or replace (Refer to Section 3413)
Engine air filter blocked:
Replace air filter element
Injection sequence does not correspond to firing order:
Install fuel injection lines in the correct order (Refer to Section 3414
Overflow fitting interchanged with inlet fitting:
Install fittings in correct positions (Refer to Section 3414)
Cold-start device malfunction (if equipped):
Check cold-start mechanism (if equipped)
Low or uneven engine compression:
Repair as necessary (Refer to Section 2425)
Fuel injection pump defective or cannot be adjusted:
Replace (Refer to Section 3414)

3414-4
-
FUEL INJECTION PUMP
Removal
STEP 1 STEP 4
Disconnect and install dust caps on the injection tubes Remove the tachometer drive assembly (if equipped).
and the fuel injection pump
STEP 5
STEP 2
Remove the nut and washer from the injection pump

Disconnect and install caps on the fuel inlet tubes and drive shaft.
the injection pump. Remove the tube.
STEP 3
Disconnect and install a dust cap on the fuel leak off

tube and the injection pump

3414-5
STEP 6 STEP 8
Loosen the injection pump retaining nuts and bracket

bolts.
STEP 9
Install the engine turn over tool, CAS 1690, and push in
on the lock pin. Turn the engine over until the lock pin
engages in the camshaft gear.
Install the gear puller, CAS 1691, and tighten the bolts
STEP 7 until the gear is loose on the pump shaft.
STEP 10
._ .••.••~ •...•...•.... ' ··_·~.·v,_, ,".-.y _ .•....-.""",..•.~"'".-...c"""' .,...;

2 .
Loosen the pump shaft lock bolt and move the slotted
washer off the lock bolt shoulder. Tighten the lock bolt
to a torque of 7 Nm.
Remove the retaining nuts and bracket bolts. Remove
NOTE: The slotted washer must be loose after the lock the injection pump and discard the gasket.
bolt had been tightened.
NOTE: Care must be taken when removing the pump
from the gear not to lose the key from the pump shaft. If
the key is not on the shaft, it is necessary to remove the
timing cover.

3414-6
Installation
STEP 11 STEP 14
Install a new gasket and install the injection pump Loosen the lock bolt on the injection pump, move the
slotted washer onto the lock bolt. Tighten the lock bolt
NOTE : Make sure the key in the injection pump shaft to a torque of 20 Nm.
and the slot in the drive gear are aligned.
NOTE : The slotted washer must not move after the
locking bolt has been dropped.
STEP 12
STEP 15
Install the nut and washer onto the injection pump shaft.
Tighten the nut to a torque of 59 to 71 Nm.
Pullout the lock pin from the camshaft gear.
STEP 13
Align the marks on the injection pump flange and front

housing. Install the pump retaining nuts and bracket
bolts. Tighten the nuts and bolt to a torque of 21 to 27
Nm
3414-7
STEP 16
Install the tachometer drive assembly (if equipped). Install the fuel inlet fitting with new sealing washers.
Tighten the fitting to a torque of 22 to 28 Nm.
NOTE: The nut on the injection pump and the tachom-
eter drive nut must be aligned.
STEP 19
STEP 17
~
Remove the caps. Install and tighten the tubes between
the fuel injectors and fuel injection pump.
Remove the dust caps. Connect and tighten the fuel
leak off tube.

3414-8
INJECTION PUMP GEAR

Removal
STEP 20 STEP 24
Lift the belt tensioner and remove the fan belt.
STEP 21
Remove the nut from the injection pump drive shaft
STEP 25
Remove the crankshaft pulley retaining bolts and cran-

kshaft pulley.
STEP 22
Remove the tachometer drive assembly (if equipped).
STEP 23
Remove the plug from the flywheel housing and install

the engine turn over tool. Turn the engine over until the
lock pin engages in the camshaft gear.
Remove the timing gear cover retaining bolts. Remove

the timing gear cover. Remove and discard the gasket.

3414-9
STEP 26 STEP 28
t~ LOCK
927A
Loosen the lock bolt and move the slotted washer off Remove the gear from the injection
the shoulder of the lock bolt. Tighten the lock bolt to a Remove the puller from the gear.
torque of 7 Nm.
NOTE: The slotted washer mustl be loose after the lock

bolt has been tightened.
STEP 27
Install the gear puller and tighten the bolts until the gear
is loose on the injection pump shaft.

3414-10
Installation
STEP 29 STEP 31
Loosen the pump shaft lock bolt, move the slotted

washer onto the lock bolt Tighten the lock bolt to a
torque of 20 Nm.
NOTE: The slotted washer must not move after the lock
bolt has been tightened.
STEP 32
T83414
LETIER A = CAV PUMP
Install the drive gear onto the injection pump drive shaft.
Make sure the correct letter on the drive gear and the
mark on the camshaft are aligned.
STEP 30
Pull out the lock pin from the camshaft gear.
STEP 33
T78828
Install the washer and nut onto the injection pump shaft
and tighten a small amount
Tighten the drive gear retaining nut to a torque of 59 to

71 Nm

3414-11
STEP 35
I~···
Clean the sealing surface of the crankshaft with Loctite Install the tachometer drive assembly (if equipped).
Solvent. Refer to Section 2425 to install the timing gear
front cover and oil seal.
STEP 36
INJECTION PUMP TIMING

STEP 37 STEP 38
Make sure the lock 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 on the shaft and the slot in
the drive gear are aligned.

3414-12
STEP 39 STEP 42
!~ UNLOCK
927.
J.
Install the injection pump shaft into the drive gear. Make Loosen the lock bolt on the injection pump. Move the
sure the slot in the drive gear and the key on the injec- slotted washer on the lock bolt. Tighten the lock bolt to a
tion pump are aligned. torque of 20 Nm.
NOTE: The slotted washer must not move after the lock
STEP 40 bolt has been tightened.
STEP 43
Install the nuts and bracket bolts that hold the injection
pump to the front cover.
Tighten the drive gear nut to a torque of 59 to 71 Nm.

STEP 41
Tighten the drive gear nut a small amount.

3414-13
STEP 44 STEP 46
Tighten the injection pump mounting bolts and bracket

STEP 47
Install the engine turn over tool, CAS 1691, push in on

the lock pin and turn the engine over until the lock pin
Pullout the lock pin from the camshaft gear.

STEP 45
STEP 48
Rotate the pump until the mark on the injection pump

flange and the mark on the front cover are aligned.
Connect and tighten the fuel leak off tube.

3414-14
STEP 49
Install the fuel inlet line, fitting and sealing washers

FUEL SHUTOFF SOLENOID

STEP 51 STEP 52
Remove the fuel shutoff solenoid from the injection Disassemble the fuel shutoff solenoid. Check the
pump. plunger and solenoid for scoring.
Assembly and Installation
STEP 53 STEP 54
Assemble the fuel shutoff solenoid. Install the fuel shutoff solenoid and tighten to a torque of
14 Nm.
3414-15
PRIMER PUMP
Removal
STEP 55 STEP 56
Disconnect and remove the fuel inlet line. Remove the primer pump bolts and the primer pump
from the cylinder block.
Installation
STEP 57 STEP 59
Install the primer pump and tighten the bolts that hold Tighten the inlet fitting to a torque of 22 to 28Nm.
the primer pump to the cylinder block.
STEP 58
Connect and tighten the fuel inlet line to the primer

pump.
NOTE: The J I Case Company reserves the right 10 make improvements in design or
Section
3415
BOSCH FUEL INJECTION PUMP
Pump Drive Gear, Fuel Shutoff Solenoid,
Primer Pump and Pump Timing
4-390 Diesel Engine

February, 1991 (Revised February, 1992)
3415-2
TABLE OF CONTENTS
SPECIAL TOOLS .2
SPECIAL TORQUES .............................. 2
TROUBLESHOOTING GUIDE ................. 3
FUEL INJECTION PUMP

Removal . 4-5
Installation . . 6-7
INJECTION PUMP GEAR

Removal . ...... 9
Installation .. 10-11
INJECTION PUMP TIMING .. 11

Removal and Disassembly .................................................................................................. 16
PRIMER PUMP
Removal . ..................... . 17
Installation . 18
TIMING LOCKING PIN

Removal . 18
Installation.... . . 19
SPECIAL TOOLS
CAS-1690 ENGINE TURNOVER TOOL
CAS-1691 A GEAR PULLER
SPECIAL TORQUES
Injection Pump Mounting Bolts........... . 21 to 27 Nm
Injection Pump Nut . 59 to 71 Nm
Fuel Line Inlet Bolt 22 to 28 Nm
Fuel Shut-off Solenoid 43 Nm
Leak Off Fitting .. 13 to 17 Nm
Injection Pump Lock Bolt, Lock Position 27 to 33 Nm
Injection Pump Lock Bolt, Unlock Position 12 to 14 Nm
Rac 7-37141 Revised 2-92 Printed in U.sA

3415-3
TROUBLESHOOTING GUIDE
NOTE: It is assumed that the engine is in good working order and properly tuned, and that the electrical system has been
checked and repaired as necessary.
CAUSE AND REMEDY

Incorrect fuel in the fuel tank:
Drain tank, flush system and fill with correct fuel
Fuel tank empty or fuel tank vent blocked:
Fill tank and bleed system, check tank vent (Refer to Section 3410)
Air in the fuel system:
Bleed fuel system, eliminate air leaks (Refer to Section 3410)
Pump rear support bracket loose:
Replace as necessary
Voltage supply malfunction, stop solenoid defective:
Correct electrical fau Its, replace solenoid (Refer to Section 3414)
Fuel filter blocked:
Replace fuel filter (Refer to Section 3410)
Fuel supply lines blocked or resticted:
Check all fuel supply lines, flush or replace
Loose connection, injection lines leaking or broken:
Tighten the connection, eliminate the leak
Paraffin deposit in fuel filter:
Replace filter, use Diesel Fuel no.1 (Refer to Operators Manual)
Fuel injection pump timing incorrect:
Adjust timing
Injection nozzle faulty:
Repair or replace (Refer to Section 34"13)
Engine air filter blocked:
Replace air filter element
Injection sequence does not correspond to firing order:
Install fuel injection lines in the correct order (Refer to Section 3414)
Overflow fitting interchanged with inlet fitting:
Install fittings in correct positions (Refer to Section 3414)
Cold-start device malfunction (if equipped):
Check cold-start mechanism (if equipped)
Low or uneven engine compression:
Repair as necessary (Refer to Section 2425)
Fuel injection pump defective or cannot be adjusted:
Replace (Refer to Section 3414)

3415-4
FUEL INJECTION PUMP

Removal
STEP 1 STEP 4
Clean the area around the fuel injection pump. Discon- Remove the tachometer drive assembly (if equipped).
nect and remove the fuel injector tubes.
STEP 5
STEP 2

Disconnect and remove the fuel inlet tube. drive shaft.
STEP 3
Remove the leak off fitting. Remove and discard the

scaling washers.

3415-5
STEP 6 STEP 8
Tighten the pump shaft lock bolt to a torque of 27 to 33

Nm.
STEP 9
'{;T78798
Install the engine turn over tool, and push in on the
locking pin. Turn the engine over until the locking pin
STEP 7 is loose from the pump shaft.
STEP 10
Jt,
Loosen the pump shaft lock bolt and remove the slotted
tab.
Remove the pump retaining nuts and bolt and remove

the pump.
IMPORTANT: Care must be taken when removing the

pump from the gear not to lose the key from the pump
shaft. If the key is not on the shaft, it is necessary to
remove the timing cover.

3415-6
Installation
STEP 11 STEP 14
Install a new gasket Install the injection pump Install Pull out the locking pin from the camshaft gear.
the injection pump washer and nut
NOTE: Make sure the key in the injection pump shaft STEP 15
and the slot in the drive gear are aligned.
STEP 12
Install the nut and washer on the injection pump shaft.

Tighten the nut to a torque of 59 to 71 Nm.
Align the marks on the injection pump flange and front

housing. Install the pump retaining nuts and bolt. Install STEP 16
the bolt into pump mounting bracket Tighten the nuts
and bolts to a torque of 21 to 27 Nm.
STEP 13
Install the tachometer drive assembly (if equipped).
NOTE: The nut on the injection pump and the tachom-

eter drive nut must be aligned.
',,;;1.
Install the slotted tab and tighten the lock bolt to a
3415-7
STEP 17 STEP 19
Remove the caps Install the leak off fitting and new Remove the caps. Install and tighten the tubes between
sealing washers. Tighten the fitting to a torque of 13 to the fuel injectors and fuel injection pump.
17 Nm.
STEP 18
Install the fuel inlet fitting with new sealing washers.

INJECTION PUMP GEAR'

Removal
STEP 20 STEP 21
Lift the belt tensioner and remove the fan belt. Remove the crankshaft pulley retaining bolts and cran-
kshaft pulley.

3415-8
STEP 22 STEP 24
·,··
I:
Remove the front cover bolts and the front cover.
STEP 23
Install the engine turn over toot and turn the engine over
until the locking pin engages the camshaft gear.
Loosen the nut on the injection pump shaft.

3415-9
STEP 25 STEP 27
?,1t
_'.>o_,~"~ __ "_",~__ .~.""~,

••••• • T7Sfr28·
"""""",,,,-,,._,,
shaft.
STEP 28
Loosen the lock bolt and remove the slotted tab.
STEP 26
is loose on the injection pump.
Tighten the lock bolt to a torque of 27 to 33 Nm.

3415-10
Installation
STEP 29 STEP 31
..... ",,_ .• _,,'0_. ~"~_' '_"""""_"'. 8906

Install the slotted tab and tighten the lock bolt to a
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 Pull the locking pin out of the camshaft gear.
pump shaft must be aligned.
STEP 33
STEP 30
. T78828 Tighten the drive gear nut to a torque of 59 to 71 Nm.

Install the washer and nut on the injection pump shaft.

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.

3415-12
STEP 37 STEP 40
Install the injection pump into the drive gear Make sure Install the slotted tab and tighten the lock bolt to a
the slot in the drive gear and the key on the pump shaft torque of 12 to 14 Nm.
are aligned,
STEP 41
STEP 38
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.

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
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.

3415-14
STEP 48 STEP 50
Push in on to the locking pin and turn the engine clock-

wise until the lock pin engages in the camshaft gear.
The dial indicator must read 1.8 mm. If the reading is
not correct continue to Step 51. If the reading is correct
go to Step 53.
STEP 51
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 injec-
tion 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.
3415-15
STEP 53 STEP 56
22
Tighten the bracket bolt and the nuts that hold the injec- Install the sealing washer and the leak off fitting. There
tion pump to the front cover to a torque of 21 to 27 Nrn. must be a sealing washer on each side of the leak off
line. Tighten the leak off fitting to a torque of 13 to 17
Nm.
STEP 54
STEP 57
Remove the dial indicator from the injection pump.
Install the inlet line. Install a sealing washer on each side

STEP 55 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 injec-

tors and the injection pump.

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.

STEP 61 STEP 62
Remove the fuel shut-off solenoid from the injection Disassemble the fuel shut-off. Check the plunger
pump. solenoid for scoring. Clean the orifice hole with a small
piece of wire.

3415-17

STEP 63 STEP 64
6
Assemble the fuel shut-off solenoid as shown. Install the fuel shut-off solenoid and tighten to a torque
of 43 Nm.
PRIMER PUMP
Removal
STEP 65 STEP 66
Remove the fuel inlet line. Remove the primer pump from the cylinder block.

3415-18
Installation
STEP 67 STEP 68
Tighten the bolts that hold the primer pump to the Tighten the inlet fitting to a torque of 32 Nm.
cylinder block.
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.

SECTION INDEX - ELECTRICAL
Removal and Installation of Electrical Components .4001
Electrical Specifications, Troubleshooting, and Schematics .4002
Batteries 4003
Starter and Starter Solenoid .4004
95 Ampere Alternator 4006
65 Ampere Alternator 4007
Instrument Cluster .4008
Bur 8-17200
CASE CORPORATION
Section
4001
REMOVAL AND INSTALLATION

OF ELECTRICAL COMPONENTS
Bur 8-17210 Printed in U.S.A.

CASE CORPORATION 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 50 pound-feet (68 Nm)
Crankshaft pulley cap screws 70 to 84 pound-feet (95 to 114 Nm)

4001-3
STARTER
Removal 9. Open the hood.
1. Park the machine on a level surface and apply the 10. Disconnect the wires and cables from the terminals
parking brake. on the starter.
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 11. Remove the two cap screws and lock washers that
negative battery cable from the battery. fasten the starter to the flywheel housing.
8. If the machine has two batteries. remove the 12. Remove the starter.
terminal nut. Remove the negative battery cable from
the terminal and move the negative battery cable away
from the battery. Make sure the jumper cable is in-
stalled on the terminal and start the terminal nut onto
the terminal.

4001-4
Installation 5. If the machine has only one battery, connect the

negative battery cable to the battery.
1. Put the starter in place on the flywheel housing.
2. Install the cap screws and lock washers that fasten

the starter to the flywheel housing. Make sure the
ground cable is installed under the upper cap screw.
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. Install the battery cover.
4. Close the hood. 8. Install the cap screws and lock washers that fasten
the battery cover to the machine.

4001-5
ALTERNATOR
Removal 9. Open the hood.
1. Park the machine on a level surface and apply the 10. Install a 1/2 inch breaker bar in the bracket for the
parking brake. tension pulley.

loader frame.
3. Raise the loader frame until the support strut is

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 11. Use the breaker bar to move the tension pulley just
negative battery cable from the battery. far enough to release the tension on the drive belt and
remove the drive belt from the alternator.
12. Move the rubber boot out of the way and discon-
nect the cable from the alternator.
8. If the machine has two batteries, remove the

terminal nut. Remove the negative battery cable from
the terminal and move the 'negative battery cable away
from the battery. Make sure the jumper cable is in-
13. Disconnect the wire from the alternator.
stalled on the terminal and start the terminal nut onto
the terminal.
14. Disconnect the connector from the alternator.

4001-6
15. Remove the cap screw and lock washer that fasten 6. Tighten the nut to 50 pound-feet (68 Nm).
the link to the bottom of the altnerator.
7. Remove the alternator from the vise.
8. Hold the alternator in alignment with the mounting

bracket and install the cap screw and the flat washer at
the top of the alternator. Do not tighten the cap screw.
9. Install the cap screw and lock washer that fasten

the link to the bottom of the alternator.
10. Tighten both of the cap screws.
11. Install the wire on the B + terminal.
12. Install the lock washer and the nut on the B + ter-
minal.
16. Hold the alternator and remove the cap screw and
lock washer at the top of the alternator.
13. Connect the connectors to the alternator.
17. Remove the alternator from the mounting bracket.
14. Use the breaker bar to move the tension pulley just
far enough to install the drive belt. Install the drive belt
18. Fasten the pulley of the alternator in a vise that has
on the alternator.
soft jaws.
15. Remove the breaker bar.
19. Remove the nut and lock washer from the shaft of
the alternator.
16. Close the hood.
20. Remove the alternator from the vise.

17. If the machine has only one battery, connect the
negative battery cable to the battery.
21. Hit the face of the pulley with a soft hammer to
loosen the tapered bushing in the pulley.
22. Remove the tapered bushing and pulley from the

shaft.
23. Remove the fan from the shaft.
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.

4001-7
18. If the machine has two batteries, remove the 19. Install the battery cover.
terminal nut from the terminal. Install the negative
battery cable on the terminal. Make sure the jumper 20. Install the cap screws and lock washers that fasten
cable is installed on the terminal. Install the terminal nut the battery cover to the machine.
on the terminal.
DRIVE BELT REPLACEMENT

1. Park the machine on a level surface and apply the 9. Remove the four cap screws, flat washers, and lock
parking brake. washers that fasten the coupling to the pulley on the
crankshaft.
loader frame. 10. Move the coupling toward the hydraulic pump.
3. Raise the loader frame until the support strut is 11. Remove the old drive belt.
12. Install the new drive belt on the pulley on the water
4. Stop the engine. pump and the pulley on the crankshaft.
5. Install the pin in the support strut. 13. Align the coupling with the pulley on the crankshaft.
6. Open the hood. 14. Install the cap screws, flat washers, and lock
washers that fasten the coupling to the pulley on the
7. Install a 1/2 inch breaker bar in the bracket for the crankshaft. Tighten the cap screws to 70 to 84 pound-
tension pulley. feet (95 to 114 Nm).
8. Use the breaker bar to move the tension pulley just 15. Use the breaker bar to move the tension pulley just
far enough to release the tension on the drive belt. far enough to install the drive belt. Install the drive belt
Remove the drive belt from the alternator. on the alternator.
16. Remove the breaker bar.
17. Close the hood.

4001-8
INSTRUMENT CLUSTER
Removal Gauge, Voltmeter, or Tachometer
1 . Remove the screws (16) that fasten the instrument
cluster to the instrument console.
1. Remove the instrument cluster from the instrument
console.
2. Pull the instrument cluster out of the instrument
console. 2. Remove the four screws (10) that fasten the cover
(17) and the retainer (18) to the body (11).
3. Disconnect the connectors for the wiring harness
from the instrument cluster 3. Remove the cover (17).
4. Remove the instrument cluster from the machine. 4. Remove the retainer (18).
Installation 5. Remove the screws (21) thatfasten the gauge (1,2,

or 15), voltmeter (14) or the tachometer (13) to the body
1. Connect the connectors for the wiring harness to (11) .
the instrument cluster.
6. Remove the gauge (1, 2, or 15), voltmeter (14), or
2. Install the instrument cluster in the instrument tachometer (13) from the body (11). If you are removing
console. 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
3. Install the screws (16) that fasten the instrument the clips (4) in the body (11).
cluster to the instrument console.
7. Install a new gauge (1, 2, or 15), voltmeter (14) or
Replacing a Bulb tachometer (13) in the body (11). If you are installing a
gauge (1, 2, or 15) or voltmeter (14), make sure the
1. Remove the instrument cluster from the instrument studs of the gauge (1, 2, or 15) or voltmeter (14) are
console. pushed into the clips (4) in the body (11).
2. Turn the socket (5) counterclockwise and remove 8. Install the screws (21) that fasten the gauge (1,2, or
the socket (5). 15), voltmeter (14), or tachometer (13) to the body (11).
3. Pull the bulb (3) from the socket (5) and install a 9. Install the retainer (18).
new bulb (3).
10. Install the cover (17).
4. Install the socket (5) and turn the socket (5) clock-
wise to hold the socket (5) in place. 11. Install the screws (10) that fasten the cover (17)
and the retainer (18) to the body (11).
5. Install the instrument cluster in the instrument
console. 12. Install the instrument cluster in the instrument
console.
Circuit Board
The circuit board does not normally cause any
problems. Use an ohmmeter to check the continuity of
the strips. Ifthere is no continuity in anyone of the strips,
the circuit board must be replaced.

4001-9
6. RUBBER
4.CUP
BOOT
2. OIL
TEMPERATURE
GAUGE
1. WATER
TEMPERATURE
GAUGE
18. RETAINER
20. IDENTIFICATION STRIP
17. COVER
B861764R
Bur 8-17210
Section
4002
ELECTRICAL SPECIFICATIONS, TROUBLESHOOTING,

AND SCHEMATICS

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

4002-3
SPECIFICATIONS
Electrical system, standard One 12 volt battery, negative ground
Electrical system, optional Two 12 volt batteries connected in parallel, negative ground
System voltage Approximately 12 volts
Batteries, standard
Production battery
J I Case part number 0132475
Group size 29H
Reserve capacity 160 minutes
Cold cranking capacity
At OaF (-17°C) 650 amperes
At -20°F (-29°C) 487 amperes
Load for Capacity (Load) Test. 325 amperes
Plates per cell 16
Approximate weight with electrolyte 56 pounds (25.4 kg)
Nonspill caps Not required on this machine
Replacement battery .
J I Case part number A180406 or BMF31 E
Group size 31
Reserve capacity , 170 minutes
At OaF (-1JOC) 700 amperes
At -20°F (-29°C) 520 amperes
Load for Capacity (Load) Test 350 amperes
Plates per cell 17
Batteries, optional
Production battery
J I Case part number 0128393 or BMF28SW
Group size 28
At OaF (-17°C) 525 amperes
At -20°F (-29°C) 390 amperes
Plates per cell , , , , , " .., , , ' ' , ,..,.'.. 12
Approximate weight with electrolyte , 44 pounds (19.9 kg)
Replacement battery
J I Case part number .0127414 or BMF28S
Group size ,' 28
At OaF (-1JOC) 525 amperes
At -20°F (-29°C) 390 amperes
Plates per cell ' 12
Alternator
Standard 12 volts, 65 amperes
Optional " 12 volts, 95 amperes
Voltage regulator solid state, not adjustable
Starter , 12 volt, solenoid actuated

4002-4
Starting, Charging, and Instrument Cluster Circuits

REF COLOR FROM TO WIRE GAUGE
o Red Battery Starter Cable

1A Red Battery Alternator 8
1B Red Starter Cab Relay 12
1C Red Battery Starter Relay 12
1D Red/lt Blue Cab Relay Key Switch (Batt.) 12
3 Orange/White Key Switch (Ign.) 10 Ampere Fuse 14
4 Orange/Black Key Switch (Ace.) Cab Relay 16
8 Yellow/White Key Switch (Momentary Grd.) Diode 14
19B Red/Black 15 Ampere Fuse Instrument Cluster 14
21A White/Red Key Switch (Start) Starter Relay 16
21 B White Starter Relay Starter Solenoid 12
22 White/Red Starter Relay and Neutral Alarm Harness Connector 16
Start Switch
23F White/Orange 10 Ampere Fuse Instrument Cluster and 16
Alarm Harness Connector
28 Gray/Orange Ether Injection Switch Ether Injection Solenoid 16
30 Black/Yellow Neutral Starter Switch Ground 12
31 P Yellow/Black Instrument Cluster Instrument Cluster and 18
Alarm Harness Connector
31 S Yellow/Red Alternator Tach Output Instrument Cluster 18
31T Yellow Coolant Temperature Sender Instrument Cluster 18
32F Orange/Blue Transmission Filter Switch Instrument Cluster 18
32T Yellow/Green Converter Temp Sender Instrument Cluster 18
33 Purple Master Cylinder Reservoir Instrument Cluster 18
34 Yellow/Ok Blue Alternator Instrument Cluster 18
36F Yellow/Orange Fuel Level Sender Instrument Cluster 18
36H Yellow/Purple Hydraulic Filter Switch Instrument Cluster 18
36P Yellow/Brown Parking Brake Switch Instrument Cluster and Alarm 18
Harness Connector
38 Yellow/Blue Air Filter Switch Instrument Cluster 18
41 Pink Instrument Cluster Driving Lamp Switch and Driving 12
Lamps

4002-5
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.
NOTE: Turn key switch to ON.
Terminal for wire 34 to ground Approximately Check the wire between the alternator and the in-
10 volts strument cluster. Check the instrument cluster on
page 4002-9.
NOTE: If the readings are good, see Section 4006 or 4007 and repair the alternator.
Battery terminal of starter solenoid to 12 volts Check the battery cable to the positive post of the
ground battery.
NOTE: Put the transmission control lever in NEUTRAL. Have another person hold the key switch in the START position.
Terminal for wire 21 B to ground 12 volts Check the starter relay (5), neutral start switch (6),
and the key switch (4).
NOTE: If the readings are good, see Section 4004 and check the starter.

4002-6
Terminal for wire 1D to ground 12 volts Bad circuit between the key switch (4) and the cab
relay. See page 4002-27.
NOTE: Disconnect the connector from the key switch. Turn the key switch to the ON position.
Check between the BAT terminal and Continuity Bad key switch (4).
the IGN terminal of the key switch
Check between the BAT terminal and Continuity Bad key switch (4).
the ACC terminal of the key switch
NOTE: Have another person hold the key switch in the START position.
Between the START terminal and the Continuity Bad key switch (4).
BAT terminal of the key switch
Terminal for wire 1C to ground 12 volts Check wire 1C between the starter relay (5) and
battery.
NOTE: Put the transmission control lever in NEUTRAL
Terminal for wire 22 to ground Continuity Bad circuit between the starter relay (5) and the
neutral start switch (6). Also check the neutral
start switch (6).
Terminal for wire 21A to ground 12 volts Check wire 21A between the starter relay (5) and
the key switch (4). Also check the key switch (4).
Terminal for wire 21 B to ground 12 volts Bad starter relay (5).
Terminal for wire 22 to ground 12 volts Bad circuit between the neutral start switch (6)
and the starter relay (5). Check the starter relay
(5).
Terminal for wire 30 to ground 12 volts Bad neutral start switch (6).

4002-7
NOTE: Disconnect the wires from the ether injection switch. Push down and hold the button.
Check between the terminals of the Continuity Bad ether injection switch.
ether injection switch.
NOTE: If the reading is good, check wire 21 A between the cold start button and the key switch (4). Also check ether
injection solenoid (8).
Ground terminal to ground Continuity Engine temperature too warm. Let the engine
cool. Check the ether injection temperature
switch (9).
NOTE: Disconnect wire 3 from the fuel shutoff solenoid (10). Have another person hold the key switch in the START
position and push in and hold the ether injection switch.
Terminal for wire 28 to ground 12 volts Bad circuit between the ether injection solenoid
and the ether injection switch (7). Also check the
ether injection switch (7).
NOTE: If the readings are good, replace the ether injection solenoid.
NOTE: Disconnect the wires from the ether injection temperature switch. Make sure the engine is cold.
Check between the terminals of the Continuity Bad ether injection temperature switch.
ether injection temperature switch
NOTE: Turn the key switch to ON.
Terminal for wire 3to ground 12 volts Check circuit between the fuel shutoff solenoid
and the key switch (4). Check the key switch (4).
NOTE: If the reading is good, replace the fuel shutoff solenoid.
Bur 8-17220 Issued 1-91 Printed in U.SA

4002-8
Terminal for wire 30 to ground Continuity Bad ground circuit.
Terminal for wire 33 to ground 12 volts Bad circuit between master cylinder reservoir
level switch and instrument cluster (14). Also
check the instrument cluster (14).
NOTE: If the readings are good, replace the master cylinder resetvoir level switch.
Check between the housing of the Continuity Bad ground connection between the coolant tem-
coolant temperature sender and the perature sender and the engine block.
engine block.
Terminal for wire 31T to ground 12 volts Check circuit between the coolant temperature
sender and instrument cluster (14). Also check
the instrument cluster (14).
NOTE: If the readings are good, replace the coolant temperature sender.
Check between the housing of the Continuity Bad ground connection between the converter
converter temperature sender and temperature sender and the converter housing.
the converter housing.
NOTE: Tum the key switch to ON.
Terminal for wire 32T to ground 12 volts Check the circuit between the converter tempera-
ture sender and the instrument cluster (14). Also
check the instrument cluster (14).
NOTE: If the readings are good, replace the converter temperature sender.

4002-9
NOTE: Disconnect the connector from the instrument cluster. Turn the key switch and driving lamp switch to ON. Apply
the parking brake.
Terminal T1 in connector to terminal Continuity Check the circuit between the connector and the
for wire 33 at the master cylinder re- master cylinder reservoir level switch (11). Also
servoir level switch (11) check the master cylinder reservoir level switch
(11) .
Terminal T2 in connector to ground 12 volts Check the circuit between the connector and the
key switch (4). Also check the 10 ampere fuse and
the key switch (4).
Terminal T3 in connector to ground Continuity Check the circuit between the connector and the
parking brake switch. Also check the parking
brake switch. See page 4002-19.
cab relay. Also check the 15 ampere fuse and cab
relay. See page 4002-27.
for wire 34 at alternator (2) alternator (2). Also check the alternator (2).
oil pressure switch. Also check the oil pressure
switch. See page 4002-19.
Terminal T8 in connector to terminal Continuity Check the circuit between the connector and air
for wire 38 at the air filter switch filter filter switch. Also check the air filter switch. See
switch. See page 4002-19 page 4002-19.
NOTE: Have another person hold the key switch in the momentary ground position, halfway between ON and START.
Terminal T8 in connector to ground Continuity Check the circuit from the connector through the
diode to the key switch (4). Also check the diode
in the circuit. See page 4002-19.
Terminal T9 in connector to ground 12 volts Check jumper wire from T2 to T9.
coolant temperature sender (12). Also check the
coolant temperature sender (12).
converter temperature sender (13). Also check
the converter temperature sender (13).
Continued on next page

4002-10
driving lamp switch. Also check the driving lamp
fuel level sender. Also check the fuel level sender.
See page 4002-19.
Terminal T15 in connector to ground Continuity Bad ground circuit.
for wire 36H at the hydraulic filter hydraulic filter switch. Also check the hydraulic
switch. See page 4002-19. filter switch. See page 4002-19.
Terminal T18 in connector to ground Continuity Check the circuit from the connector through the
in the circuit and the key switch (4). See page
4002-19 for the diode.
NOTE: Disconnect the tachometer wires from the instrument cluster.
Terminal for wire 31S to terminal for Continuity Check the circuit between the connector and the
wire 31 S at the alternator (2) alternator (2). Also check the alternator (2).
Terminal for wire 10 to ground Continuity Check wire 10 to ground.
Terminal for wire 23F to ground 12 volts Check the circuit between the connector and the
the key switch (4).
NOTE: Disconnect the wires for the transmission filter warning lamp from the instrument cluster.
Terminal for wire 32F to terminal for Continuity Check the circuit between the connector and the
wire 32F at the transmission filter transmission filter switch. Also check the trans-
switch mission filter switch. See page 4002-19.
Terminal for wire 23F to ground 12 volts Check the circuit between the connector and the
the key switch (4).
Terminal for wire 32F to ground Continuity Check the circuit from the connector through the
in the circuit and the key switch (4). See page
4002-19 for the diode.

CONNECTORS A.. B. C. AND 0
CONNECTOR G
Main chassis harness 10 side console Main chassis harness 10

harness IransaxJe harness
STARTING, CHARGING, AND INSTRUMENT CLUSTER

11 ill
4002-12
Warning Buzzer, Parking Brake, Backup Alarm, and Clutch Cutout

o Black Backup Alarm Pressure Switch Backup Alarm 14
o Black Backup Alarm Chassis Ground 14
8 YellowlWhite Key Switch (Momentary Grd) Diodes 14
10A Black/Orange Alarm Harness Connector Ground 14
12C Red Cab Relay 5 Ampere Fuse 12
13B2 Orange/Black Cab Relay 3 Ampere Fuse 16
13B3 Orange/Black Fuse Boom Lock Switch 16
13B4 Orange/Black Boom Lock Switch Boom Lock Solenoid 16
19E Red/Blue 15 Ampere Fuse Clutch Cutout Switch, Return- 14
To-O:- Magnetic Detent. and
Return- To-Dig Harness
22 White/Red Starter Relay and Neutral Start Alarm Harness Connector 16
Switch
22 Blue Alarm Harness Connector Parking Brake Relay 16
23F White/Orange 10 Ampere Fuse Instrument Cluster and Alarm 16
Harness Connector
23F Red Alarm Harness ':onnector Diode 16
23G RedlWhite Diode Parking Brake Relay 18
25 Orange/Blue Clutch Cutout Switch Loader Handle Harness 16
25 White/Blue Loader Handle Harness Transaxle Harness, Pin B of Con- 16
nector G
25 Gray Transaxle Harness, Pin B of Con- Clutch Cutout Solenoid 16
nector G
30 BlackiYeliow Clutch Cutout Solenoid Ground 12
30 Black Transaxle Harness, Pin C of Con- Ground 16
nector G
30 Black Return-To-Dig Harness Ground 16
30B6 Black Boom Lock Solenoid Ground 16
31 P Yellow/Black Oil Pressure Switch Instrument Cluster and Alarm 18
Harness Connector
31 P Green Alarm Harness Connector Diode 18
32F Orange/Blue Transmission Filter Switch Instrument Cluster 18
3QF 't'ellawlQrange Fuel Level Sender Instrument Cluster 18
36H YellowlPurpfe Hydraulic Filter Switch Instrument Cluster 18
36P Yellow/Brown Parking Brake Switch Instrument Cluster and Alarm 18
Harness Connector
36P White Alarm Harness Connector Parking Brake Relay 18
37 YellowlWhite Engine Temperature Switch Alarm Harness Connector 18
37 Brown Alarm Harness Connector Parking Brake Relay 18
38 Yellow/Blue Air Filter Switch Instrument Cluster 18
39A PurplelYeliow Warning Alarm (Positive) Alarm Harness Connector 18
39A Orange Alarm Harness Connector Parking Brake Relay 18
39B PurplelWhite Warning Alarm (Negative) Alarm Harness Connector 18
39B Purple Alarm Harness Connector Parking Brake Relay 18
41 Pink Light Switch Driving Lamps 12
51A RedlYeliow 5 Ampere Fuse Backup Alarm Pressure Switch 14
30 Black/Yellow Parking Brake Switch Ground 12
Bur 8-17220 Issued 1-91 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.
NOTE: Turn tne key switch to ON. If the warning buzzer does not sound, do the following checks.
Terminal for wire 39A to ground 12 Volts Check the circuit between the warning buzzer and
the key switch. Also check the 10 ampere fuse
and the key switch. See page 4002-11.
Terminal for wire 39B to ground Continuity Check the circuit between the warning buzzer and
the engine oil pressure switch (3). Also check the
engine oil pressure switch (3). Check the diode in
wire 31P.
NOTE: If the readings are good, replace the warning buzzer.
Terminal for wire 37 to ground 12 volts Check the circuit between the engine temperature
switch and the parking brake relay (6). Also check
the parking brake relay (6).
NOTE: If the readings are good, replace the engine temperature switch.
Bur 8-17220 Issued 1-91 Printed in U.S.A

4002-14
Check between the housing of the Continuity Bad ground connection between the oil pressure
oil pressure switch and the engine switch and the engine block.
block
Terminal for wire 31 P to ground 12 volts Check the circuit between the engine oil pressure
switch and the instrument cluster. Also check the
instrument cluster. See page 4002-11 .
NOTE: If the readings are good, replace the engine oil pressure switch.
Check between the housing of the Continuity Bad ground connection between the fuel level
fuel level sender and the machine sender and the machine frame.
frame
Terminal for wire 36F to ground 12 volts Check the circuit between the fuel level sender
and the instrument cluster. Also check the instru-
ment cluster. See page 4002-11.
NOTE: If the readings are good, replace the fuel level sender.
Terminal for wire 30 to ground Continuity Bad ground connection.
Terminal for wire 36P to ground 12 volts Check the circuit between the parking brake
NOTE: If the readings are good, replace the parking brake switch.

4002-15
NOTE: Make sure the transmission control lever is in NEUTRAL.
Terminal for wire 22 to ground Continuity Bad circuit between parking brake relay and the
neutral start switch. Also check the neutral start
switch. See page 4002-11 .
Terminal for wire 238 to ground 12 volts Check the circuit between the parking brake relay
and the key switch. Also check the 10 ampere
fuse and the key switch. See page 4002-11 .
Terminal for wire 39B to ground 12 volts Check wire 39B to the warning buzzer (1). Also
check the warning buzzer (1).
Terminal for wire 36P to ground 12 volts Bad parking brake relay.
Check between the housing of the Continuity Bad ground connection.

transmission filter switch and the
transmission housing
Terminal for wire 32F to ground 12 volts Check the circuit between the transmission filter
NOTE: If the readings are good, replace the transmission filter switch.
Check between the housing of the Continuity Bad ground connection.

hydraulic filter switch and the filter
housing
Terminal for wire 36H to ground 12 volts Check the circuit between the hydraulic filter
instrument cluster. See page 4002-11.
NOTE: If the readings are good, replace the hydraulic filter switch.

4002-16
Terminai for wire 30 to ground Continuity Bad ground connection.
Terminal for wire 38 to ground 12 volts Bad circuit between the air filter switch and the in-
strument cluster. Also check the instrument
cluster. See page 4002-11 .
Terminal for wire 51A to ground 12 volts Check the circuit between the backup alarm
pressure switch and the cab relay. Also check the
5 ampere fuse and the cab relay. See page 4002-
27.
NOTE: Start and run the engine at low idle. Have another person hold down both brake pedals and shift the trans-
mission into REVERSE.
Terminal for wire 0 to ground 12 volts Bad backup alarm pressure switch.
Negative terminal to ground Continuity Bad ground circuit.
NOTE: Start and run the engine at low idle. Have another person hold down both brake pedals and shift the trans-
mission into REVERSE.
Positive terminal to ground 12 volts Check the circuit between the the backup alarm
and the backup alarm pressure switch (10). Also
check the backup alarm pressure switch (10).
NOTE: If the readings are good, replace the backup alarm.

4002-17
Terminal for wire 19E to ground 12 volts Check the circuit between the clutch cutout switch
and the cab relay. Also check the 15 ampere fuse
and the cab relay. See page 4002-27.
NOTE: Push down and hold the clutch cutout switch.
Terminal 25 to ground 12 volts Bad clutch cutout switch.
NOTE: Turn the key switch to ON. Have another person push down and hold a clutch cutout switch.
Terminal for wire 25 to ground 12 volts Check the circuits between the clutch cutout
solenoid and the clutch cutout switch (12). Also
check the clutch cutout switch (12).
Terminal for wire 30 to ground Continuity Check the ground circuit 30.
NOTE: If the readings are good, replace the clutch cutout solenoid.
Terminal for wire 1383 to ground 12 volts Check the circuit between the boom lock switch
and the cab relay. See page 4002-27 for the cab
relay.
NOTE: Turn the boom lock switch ON.
Terminal for wire 1384 to ground 12 volts 8ad boom lock switch.

4002-18
Terminal for wire 30B6 to ground Continuity Bad ground circuit.
Terminal for wire 13B4 to ground 12 volts Check the circuit between the boom lock solenoid
valve and the boom lock switch (14). Also check
the boom lock switch (14).
NOTE: If the readings are good, replace the boom lock solenoid.
Terminal for wire 19E to ground 12 volts Check the circuit between the clutch cutout switch
and the cab relay. See page 4002-27.
NOTE: Push down and hold the clutch cutout switch.
Terminal 25 to ground 12 volts Bad clutch cutout switch.
Bur 8·17220 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
1B Red Starter Cab Relay 6

10 Red/Lt Blue Key Switch (Batt.) Cab Relay 12
10 Black/Orange Cab Relay Ground 12
12A Red/Black Cab Relay 25 Ampere Fuse 12
12B Red/Orange Cab Relay 10 Ampere and 15 Ampere Fuse 12
12C Red Cab Relay 5 Ampere Fuse 12
13B2 Orange/Black Cab Relay 3 Ampere Fuse 16
19A Red 25 Ampere Fuse Driving Lamp Switch 12
19B Red/Black 15 Ampere Fuse Stop, Flasher Switch, Turn Signal 14
Switch and Horn Button,
Instrument Cluster
190 RedlYellow 15 Ampere Fuse Rotating Beacon and Dipper 14
Lamp Switch, Flasher
19E Red/Blue 15 Ampere Fuse Clutch Cutout Switch, Return- 14
To-Dig Magnetic Detent, and
Return-To-Dig Harness
19E Red Return-To-Dig Harness Return-To-Dig Relay and Proxi- 16
mity Switch
30 Black/Yellow Turn Signal Indicator Lamps Ground 12
30 Black Return-to-Dig Relay and Proximity Ground
Switch
42R Ok BluelWhite Driving Lamp Switch Rear Working Lamp 12
44 Tan Stop Lamp Switch Brake Lamps 14
45L Ok BrownlYellow Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Turn Signal Switch Right Turn Signal Lamps 14
46 Ok Brown Flasher Switch Flasher (T1 Terminal) 14
47L Lt Brown/Yellow Left Turn Signal Switch Left Turn Signal Indicator 18
47R Lt Brown/Green Right Turn Signal Switch Right Turn Signal Indicator 18
48 Lt BrownlWhite Rotating Beacon Switch Rotating Beacon 14
53 Purple/Red Return-To-Dig and Auxiliary Loader Valve 16
Hydraulic Switch
54 Brown/Pink Return-To-Dig Relay Proximity Switch 16
64A Orange/Blue Turn Signal Switch and Horn Relay 16
Horn Button
64B Green/Red Horn Relay Horn 16

4002-21
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 a multimeter for the
tests.
Terminal for wire 19E to ground 12 volts Check the circuit between the return-to-dig relay
and the cab relay (7). Also check the 15 ampere
fuse on page 4002-19 and the cab relay (7).
NOTE: Disconnect the connector from the proximity switch (3).
Terminal for wire 54 to terminal for Continuity - Check wire 54.

wire 54 in connector for proximity
switch (3)
Terminal for wire 30 to ground Continuity Bad ground connection
Terminal for wire 53 to ground Approximately Check the circuit between the return-to-dig relay
12 volts and the magnetic detent (2). Also check the
magnetic detent (2).
NOTE: Disconnect the wires from the magnetic detent. Turn the key switch to ON.
Terminal in harness for wire 19E to 12 volts Check the circuit between the magnetic detent
ground and the cab relay (7). Also check the 15 ampere
Between the terminals of the Continuity Bad magnetic detent.

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

4002-22
NOTE: Disconnect the connector from the proximity switch.
Terminal for wire 30 in connector Continuity Bad ground circuit.

to ground
NOTE: Turn the key switch to ON .
.Terminal for wire 19E in connector 12 volts Check the circuit between the proximity switch
to ground and the cab relay (7). Also check the 15 ampere
Terminal for wire 54 in connector Approximately Check the circuit between the proximity switch
12 volts and the return-to-dig relay (1). Also check the
return-to-dig relay (1).
NOTE: 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. Have another person hold down the horn button.
Terminal for wire 64B to ground 12 volts Check the circuit between the horn and the horn
relay (5). Also check the horn relay (5) and the turn
signal switch and horn button (13).
NOTE: If the readings are good, install a new horn.

4002-23
Both terminals for wire 19B to 12 volts Check the circuit between the horn relay and the
ground cab relay (7). Also check the 15 ampere fuse and
the cab relay (7).
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.
Terminal for wire 53 to ground Approximately Check the circuit between the optional switch
10 volts relay and the magnetic detent (2). Also check the
magnetic detent (2).
Terminal for wire 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, 12 volts Bad cab relay.
or 12C and ground

4002-24
Terminal for wire 19A to ground 12 volts Check the circuit between the driving lamp switch
and the cab relay (7). Also check the 25 am pere
fuse and the cab relay (7).
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 in-
strument cluster. See page 4002-11.
Terminal for wire 19B to ground 12 volts Check the circuit between the stop lamp switch
and the cab relay (7). Also check the 15 am pere
NOTE: Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad stop lamp switch.
Terminal for wire 19B to ground 12 volts Check the circuit between the flasher switch and
the cab relay (7). Also check the 15 ampere fuse
and the cab relay (7).
NOTE: Turn the flasher switch ON.
Terminal for wire 46 to ground 12 volts Bad flasher switch.

4002-25
Terminal for wire 190 to ground 12 volts Check the circuit between the rotating beacon
switch and the cab relay (7). Also check the 15
ampere fuse and the cab relay (7).
NOTE: Turn the rotating beacon switch ON.
Terminal for wire 48 to ground 12 volts Bad rotating beacon switch.
Terminal for wire T3 to ground Continuity Bad ground connection.
Terminal T2 to ground 12 volts Check the circuit between the flasher and the cab
relay (7). Also check the 15 ampere fuse and the
cab relay (7).
NOTE: Make sure the turn signal switch is in the OFF position. Turn the flasher switch ON.
Terminal T1 to ground 12 volts Check the circuit between the flasher and the
flasher switch (10). Also check the flasher switch
(10).
Terminal T5 to ground Intermittent Bad flasher.

12 volts
Terminal T7 to ground Interm ittent Bad flasher.

12 volts

12 volts

12 volts

4002-26
Terminal for wire 19B to ground 12 volts Check the circuit between the turn signal switch
and the cab relay (7). Also check the 15 ampere
NOTE: Make sure the flasher switch is in the OFF position. Move the turn signal switch for a left turn.
Terminal for wire 45R to ground 12 volts Bad turn signal switch.
NOTE: Make sure the flasher switch is in the OFF position. Move the turn signal switch for a right turn.
Terminal for wire 45L to ground 12 volts Bad turn signal switch.
NOTE: If the readings are good but the turn signals still do not work, check the flasher (12).
Terminal for wire 64A to ground Approximately Ch8Ck wire 64A between the horn button and the
10 volts horn relay (5). Also check the horn relay (5).
NOTE: If the readings are good, install a new turn signal switch and horn button.
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 Check the circuit between the left turn signal indi-
12 volts cator lamp and the flasher (12). Also check the
flasher (12).
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 Check the circuit between the right turn signal in-
12 volts dicator lamp and the flasher (12). Also check the
flasher (12).

Bur 8-172~ Issued 1-91 Printed in U.S.A.
4002-28
FLOOD LAMP SWITCH, HIGH PRESSURE SWITCH,

AND AIR CONDITIONING COMPRESSOR CLUTCH
10 Red/Lt Blue Cab Relay 10 Ampere Fuse 12

12C Red Cab Relay 15 Ampere Fuse and 20 Ampere 12
Fuse
19C Red/White 20 Ampere Fuse Flood Lamp Switch 12
40A Black Lamps Ground 12
40B Blacx/white Lamps Ground 12
42C Ok Blue/Orange Flood Light Switch Rear Flood Lamps 12
42F Ok Blue Flood Light Switch Front Flood Lamps 12
42R Ok Blue/White Light Switch Rear Working Lamp 12
44 Tan Brake Switch Brake Lamps 14
45L OK Brown/Yellow Left Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Right Turn Signa! Switch Right Turn Signal Lamps 14
48 Lt Brown/White Rotating Beacon Switch Rotating Beacon 14
49 Gray 10 Ampere Fuse Dome Lamp 16
60 Orange/Brown Compressor Clutch Relay High Pressure Switch 16
60A Orange/Black Compressor Clutch Relay and High Pressure Switch 16
Low Pressure Switch
60B Orange/Green Compressor Clutch Relay Air Conditioning Compressor Clutch 16
61 Gray/White 15 Ampere Fuse Blower 14
63 Orange/Purple 15 Ampere Fuse Wipers 14

4002-29
Flood Lamp Switch, High Pressure Switch, and Air Conditioning Compressor
Clutch Circuit Checks
NOTE: The battery must be at full charge and al/ connections clean and tight before testing. Use a multimeter for the
tests.
NOTE: Put the key switch in the ON position. Turn the blower switch to HIGH and the air conditioning temperature switch
to COLD.
Terminal for wire 60 to ground 12 volts Bad circuit between the high pressure switch and
the air conditioning temperature switch.
NOTE: Disconnect the wires from the high pressure switch.
Between the terminals of the high Open High charge in the air conditioning system. See
pressure switch Section 9002. Bad high pressure switch.
o Air Conditioning Compressor Clutch

Ground wire of the air con- Continuity Bad ground wire.

ditioning clutch to ground
NOTE: Turn the key switch to ON. Turn the cab blower switch to HIGH and the air conditioning temperature switch to
COLD.
Terminal for 60B to ground 12 volts Check the circuit between the air conditioning
compressor clutch and the compressor clutch
relay. Also check the compressor clutch relay.
See page 4002-41 .
NOTE: If the readings are correct, replace the air conditioning compressor clutch.
Terminal for wire 19C to ground 12 volts Check the circuit between the flood lamp switch
relay.
NOTE: Turn the flood lamp switch to ON.
Terminal for wire 42F to ground 12 volts Bad flood lamp switch.
Terminal for wire 42C to ground 12 volts Bad flood lamp switch.
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, t

AIR CONDITIONING COMPRESSOR CLUTCH
Bur 8-17220 ISSUfld 1-91

4002-32
CAB HARNESS

40B Black/White Lamps Ground 12
42R Ok BluelWhite Light Switch Rear Flood Lamp 12
44 Tan Brake Switch Brake Lamps 14
45L OK Brown/Yellow Left Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Right Turn Signal Switch Right Turn Signal Lamps 14
49 Gray 10 Ampere Fuse Dome Lamp Switch 16
60 Orange/Brown Compressor Clutch Relay High Pressure Switch 16
60A Orange/Black Compressor Clutch Relay and High Pressure Switch 16
Low Pressure Switch
60B Orange/Green Compressor Clutch Relay Air Conditioning Compressor 16
Clutch
61 GraylWhite 15 Ampere Fuse Blower Switch 14
61B Gray/Black Dome Lamp Switch Dome Lamps 16
63 Orange/Purple 15 Ampere Fuse Wipers 14
63A Orange/Purple Front Wiper Switch Front Wiper Motor 16
66 Green Front Wiper Switch (Low) Front Wiper Motor (Low) 16
67 Red Front Wiper Switch (High) Front Wiper Motor (High) 16
69 Yellow Front Wiper Switch (Park) Front Wiper Motor (Park) 16
80 Black Rear Wiper Motor (Ground) Rear Wiper Park Switch 14
81 Gray Rear Wiper Switch (Low) Rear Wiper Motor (Low) 16
82 White Rear Wiper Switch (High) Rear Wiper Motor (High) 16
85 Orange/Green Blower Switch Air Conditioning Temperature 14
Switch
86 Lt Blue Blower Switch (Low) Resistor Board (Low) 14
87 Blue Blower Switch (Medium) Resistor Board (Medium) 14
88 Lt BluelWhite Blower Switch (High) Resistor Board (High) 14
Bur 8-17220 Issued 1-91 Printed in USA

4002-33
Cab Harness
NOTE: The battery must be at full charge and all connections clean and tight before testing. Use a multimetet for the
tests.
Terminal for wire 49 to ground 12 volts Check the circuit between the dome lamp switch
and the key switch. Also check the 10 ampere
fuse and the key switch. See page 4002-31 for the
10 ampere fuse and page 4002-11 for the key
switch.
NOTE: Put the dome lamp switch in the ON positior:
Terminal for wire 61 B to ground 12 volts Bad dome lamp switch.
Bulb Good Bad bulb.
Terminal for wire 40A to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to ON. Put the dome lamp switch (1) in the ON position.
Terminal for wire 61 B to ground 12 volts Check the circuit between the left dome lamp and
the dome lamp switch (1). Also check the dome
lamp switch (1).

4002-34
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Put the dome lamp switch (1) in the ON position.
Terminal for wire 61 B to ground 12 volts Check the circuit between the right dome lamp
and the dome lamp switch (1). Also check the
dome lamp switch (1).
Terminal for wire 85 to ground 12 volts Bad blower switch.
Terminal for wire 61 to ground 12 volts Bad circuit between the blower switch and the
cab relay. Also check the 15 ampere fuse and the
cab relay. See page 4002-27 for the cab relay.
NOTE: Turn the blower switch to LOW.
NOTE: Turn the blower switch to MEDIUM.
NOTE: Turn the blower switch to HIGH.
NOTE: Turn the key switch to ON. Turn the blower switch to HIGH.
Terminal for wire 88 to ground 12 volts Bad circuit between the blower motor and the
blower switch (4). Also check the blower switch
(4).
Bur 8·17220 Issued 1-91 Printedin U.S.A.

4002-35
NOTE: Turn the key switch to ON. Blower switch to LOW.
NOTE: Blower switch to MEDIUM.
NOTE: Disconnect the connector from the resistor board.
Between terminals 1 and 3 of the 3.8 ohms Bad resistor board.

resistor board
Terminal for wire 63 to ground 12 volts Check the circuit between the rear wiper switch
relay.
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 12 volts Bad rear wiper switch.

4002-36
NOTE: Make sure the rear wiper is not in the PARK position.
Terminal for wire 80 to ground Continuity Check the rear wiper park switch (9). Bad ground
circuit.
Terminal for wire 63 to ground 12 volts Check the circuit between the rear wiper motor
relay.
NOTE: Turn the rear wiper switch to HIGH.
and the rear wiper switch (7). Also check the rear
wiper switch (7).
NOTE: Turn the rear wiper switch to LOW.
and the rear wiper switch (7). Also check the rear
wiper switch (7).
NOTE: Disconnect the wires from the rear wiper park switch. Make sure the rear wiper is in the PARK position.
Between the terminals of the rear Open, Bad rear wiper park switch.
wiper park switch
NOTE: Move the wiper out of the PARK position.
Between the terminals of the rear Continuity Bad rear wiper park switch.
wiper park switch

4002-37
Terminal for wire 40B to ground Continuity Bad ground circuit.
NOTE: Turn the key switch to ON. Turn the blower switch to ON and the air conditioning temperature switch to COLD.
Terminal for wire 60 to ground 12 volts Bad circuit between the compressor clutch relay
and the air conditioning temperature switch (11).
Also check the air conditioning temperature
switch (11).
Terminal for wire 60A to ground 12 volts Bad low pressure switch (13) or high pressure
switch. Also check the low pressure switch (13)
and the high pressure switch. See page 4002-31
for the high pressure switch.
Terminal for wire 60B to ground 12 volts Bad compressor clutch relay.
NOTE: Turn the key switch to ON. Turn the blower switch to HIGH.
Terminal for wire 85 to ground 12 volts Bad circuit between the air conditioning tempera-
ture switch and the blower switch (4). Also check
the blower switch (4).
NOTE: Turn the air conditioning temperature switch all the way to COLD.
Terminal for wire 60 to ground 12 volts Bad air conditioning temperature switch.
Bulb Good Bad bulb.

4002-38
NOTE: Turn the key switch to ON. Turn the blower switch to HIGH and the air conditioning temperature switch to
cow.
Terminal for wire 60 to ground 12 volts Bad circuit between the low pressure switch and
the air conditioning thermostat switch.
NOTE: Disconnect the wires from the low pressure switch.
Between the terminals of the low Open Low charge in the air conditioning system. See
pressure switch Section 9002. Bad low pressure switch.
Terminal for wire 63 to ground 12 volts Check the circuit between the front wiper switch
relay.
Terminal for wire 69 to ground 12 volts Bad front wiper switch.
NOTE: Turn the front wiper switch to LOW.
NOTE: Turn the front wiper switch to HIGH.

4002-39
Terminal for wire 63A to ground 12 volts Check the circuit between the front wiper motor
relay.
Terminal for wire 69 to ground 12 volts Check the circuit between the front wiper motor
and the front wiper switch (7). Also check the front
wiper switch (7).
NOTE: Turn the front wiper switch to HIGH.
wiper switch (7).
NOTE: Turn the front wiper switch to LOW.
wiper switch (7).
NOTE: Turn the key switch and rotating beacon switch to ON.
Bulb Good Bad bulb.
Terminal for wire 48 to ground 12 volts Circuit between the rotating beacon and the
rotating beacon switch. Also check the rotating
beacon switch. See page 4002-27.
NOTE: /f the readings are good, rep/ace the rotating beacon.

4002-40
This page left blank.

4002-41
CONNECTOR
Connects one harT1
harness.
CAB HARNESS

41'UVc:.-""tL
CAB HARNESS (Continued)


40B Black/white Lamps Ground 12
41 Pink Driving Lamp Switch Driving Lamps and Rear Light 12
Harness
41T Pink Rear Light Harness Tail Lamps 16
42C Dk Blue/Orange Flood Lamp Switch Rear Flood Lamps 12
42F Dk Blue Flood Lamp Switch Front Flood Lamps 12
42R Dk BluelWhite Driving Lamp Switch Rear Work Lamps 12
45L DK Brown/Yellc': Turn Signal Switch Left Turn Signal Lamps 14
45R Dk Brown/Gree Turn Signal Switch Right Turn Signal Lamps 14
Bur 8-17220 Issued1-91 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.
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear LH work lamp and
the driVing lamp switch. Also check the driving
lamp switch. See page 4002-27.
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear LH flood lamp and
the flood lamp switch. Also check the flood lamp
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Turn the flood lamp switch to ON.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear RH flood lamp and

4002-44
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Turn the driving lamp switch to ON.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear RH work lamp and
the drivinq lamp switch. Also check the driving
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a left turn.
Terminal for wire 45L to ground Intermittent Bad circuit between the front left turn signal and
12 volts flasher lamp and turn signal switch. Also check
the turn signal switch. See page 4002-27.
Terminal 40A to ground Continuity Bad ground connection.
Bulb Good Bad bulb.
NOTE: Turn the key switcr: to ON. Turn the driving lamp switch to ON.
Terminal for wire 41 to ground 12 volts Bad circuit between the front LH marker lamp and
the driving lamp switch. Also check the driving

4002-45
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front LH driving lamp and
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
Bulb Good Bad bulb.
Terminal for wire 42F to ground 12 volts Bad circuit between the front RH flood lamp and

4002-46
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RH driving lamp and
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a right turn.
Terminal for wire 45R to ground Intermittent Bad circuit between the front RH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RH marker lamp and

4002-47
Terminal 40B to ground Continuity Bad ground connection.
Bulb Good Bad bulb.
Terminal for wire 41T to ground 12 volts Bad circuit between the LH tail lamp and the
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the LH brake lamp and the
stop lamp switch. Also check the stop lamp
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a left turn.
Terminal for wire 45L to ground Intermittent 12 volts Bad circuit between the rear LH turn signal and
flasher lamp and the turn signal switch. Also
check the turn signal switch. See page 4002-27.

4002-48
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Tum the driving lamp switch to ON.
Terminal for wire 41T to ground 12 volts Bad circuit between the RH tail lamp and the
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the RH brake lamp and the
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for a right tum.
Terminal for wire 45R to ground Intermittent Bad circuit between the rear RH turn signal and
12 volts flasher lamp and the turn signal switch. Also

4002-4
CAB HARNESS (COnt\nued)
I
~
Issued 1-91 Printed In u.s.~
BUr 8-17220
4002-50
CANOPY HARNESS

40B BlacklVYhite Lamps Ground 12
41 Pink Driving Lamp Switch Driving Lamps and Rear Light 12
Harness
42R Ok BluelWhite Driving Lamp Switch Rear Work Lamps 12
45L OK Brown/Yellow Turn Signal Switch Left Turn Signal Lamps 14
45R Ok Brown/Green Turn Signal Switch Right Turn Signal Lamps 14

4002-51
NOTE: The batteries must be at full charge and all connections clean and tight before testing. Use a multimeter for the
tests.
Bulb Good Bad bulb.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear LH work lamp and
Bulb Good Bad bulb.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear LH flood lamp and
Bulb Good Bad bulb.
Terminal for wire 42C to ground 12 volts Bad circuit between the rear RH flood lamp and

4002-52
Terminal for wire 40B to giOund Continuity Bad ground circuit.
Bulb Good Bad bulb.
Terminal for wire 42R to ground 12 volts Bad circuit between the rear RH work lamp and
Terminal for wire 40A to ground Continuity Bad ground circuit
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal fever for a left turn.
Terminal for wire 45L to ground Intermittent Bad circuit between the front LH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front LH driving lamp and

4002-53
Bulb Good Bad bulb.
Terminal for wire 42F to ground 12 volts Bad circuit between the front LH flood lamp and
Bulb Good Bad bulb.
Terminal for wire 42F to ground 12 volts Bad circuit between the front RH flood lamp and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the front RH driving lamp and

4002-54
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the tum signal lever for a right turn.
Terminal for wire 45R to ground Intermittent Bad circuit between the front RH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the LH tail lamp and the
Bulb Good Bad bulb.
NOTE: Tum the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the LH brake lamp and the

4002-55
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Make sure the flasher switch is OFF. Move the turn signal lever for a left turn.
Terminal for wire 45L to ground Intermittent Bad circuit between the rear LH turn signal and
Bulb Good Bad bulb.
Terminal for wire 41 to ground 12 volts Bad circuit between the RH tail lamp and the
Check Points Reading Possible Cause of Bad Reading.
Bulb Good Bad bulb.
NOTE: Turn the key switch to ON. Have another person push down and hold the brake pedals.
Terminal for wire 44 to ground 12 volts Bad circuit between the RH brake lamp and the

4002-56
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 Bad circuit between the rear RH turn signal and
Terminal for ground wire to Continuity Bad ground circuit.

ground
NOTE: Turn the key switch and rotating beacon switch to ON.
Bulb Good Bad bulb.
Terminal for wire 48 to ground 12 volts Circuit between the rotating beacon and the
rotating beacon switch. Also check the rotating
beacon switch. See page 4002-27.
NOTE: If the readings are good, replace the rotating beacon.

4002-57
4002-58
USING BOOSTER BATIERIES TO START THE ENGINE

1. Sit in the operators seat and have the other person
make the connections.
2. If using another machine for power, make sure the

two machines do not touch.
3. Connect the positive (+) jumper cable to the

positive (+) battery terminal.
4. Connect the negative (-) jumper cable to a good

Single Battery ground away from the battery.
5. Start the engine and have the other person discon-

nect the negative (-) jumper cable first and the positive
( +) jumper cable last.
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.

4002-59
ALPHABETICAL INDEX OF COMPONENTS

A K
Air Conditioning Compressor Clutch 29 Key Switch 6
Air Conditioning Indicator Lamp 37
Air Conditioning Temperature Switch 37 L
Air Filter Switch 16 LH Brake Lamp with Cab .47
Alternator 5 LH Brake Lamp with Canopy 54
LH Tail Lamp with Cab .47
B LH Tail Lamp with Canopy 54
Backup Alarm and Pressure Switch 16 Left Dome Lamp 33
Batteries 5 Left Turn Signal Indicator Lamp 26
Blower Motor and Blower Switch 34 Loader Valve Return-Te-Dig Magnetic Detent.. 21
Blower Resistor Board 35 Low Pressure Switch 38
Boom Lock Solenoid 18
Boom Lock Switch 17 M
Master Cylinder Reservoir Level Switch 8
C
Cab Relay 23 N
Clutch Cutout Solenoid 17 Neutral Start Switch 6
Clutch Cutout Switch - Loader Handle 18
Clutch Cutout Switch - Shift Handle 17 a
Compressor Clutch Relay 37 Optional Switch for Hand Held Hydraulic Attachments 23
Converter Temperature Sender 8
Coolant Temperature Sender 8 P
Parking Brake Relay 15
o Parking Brake Switch 14
Dome Lamp Switch 33 Proximity Switch 22
Driving Lamp Switch 24
R
E RH Brake Lamp with Cab 48
Engine Oil Pressure Switch 14 RH Brake Lamp with Canopy 55
Engine Temperature Switch 13 RH Tail Lamp with Cab 48
Ether Injection Solenoid 7 RH Tail Lamp with Canopy 55
Ether Injection Switch 7 Rear LH Flood Lamp with Cab .43
Ether Injection Temperature Switch : 7 Rear LH Flood Lamp with Canopy 51
• Rear LH Turn Signal and Flasher Lamp with Cab .47
F Rear LH Turn Signal and Flasher Lamp with Canopy 55
Flasher Switch 24 Rear LH Work Lamp with Cab 43
Flood Lamp Switch 29 Rear LH Work Lamp with Canopy 51
Front LH Driving Lamp with Cab .45 Rear RH Flood Lamp with Cab .43
Front LH Driving Lamp with Canopy 52 Rear RH Flood Lamp with Canopy 51
Front LH Flood Lamp with Cab 45 Rear RH Turn Signal and Flasher Lamp with Cab .48
Front LH Flood Lamp with Canopy 53 Rear RH Turn Signal and Flasher Lamp with Canopy 56
Front LH Marker Lamp 44 Rear RH Work Lamp with Cab 44
Front LH Tum Signal and Flasher Lamp with Cab 44 Rear RH Work Lamp with Canopy 52
Front LH Tum Signal and Flasher Lamp with Canopy 52 Rear Wiper Motor and Park Switch 36
Front RH Driving Lamp with Cab 46 Rear Wiper Switch 35
Front RH Driving Lamp with Canopy 53 Return- To-Dip Relay 21
Front RH Flood Lamp with Cab .45 Right Dome Lamp 34
Front RH Flood Lamp with Canopy 53 Right Tum Signal Indicator Lamp 26
Front RH Marker Lamp 46 Rotating Beacon with Canopy 56
Front RH Turn Signal and Flasher Lamp with Cab .46 Rotating Beacon with Cab 39
Front RH Tum Signal and Flasher Lamp with Canopy 54 Rotating Beacon Switch 25
Front Wiper Motor 39
Front Wiper Switch 38 S
Fuel Level Sender 14 Starter Relay 6
Fuel Shutoff Solenoid 7 Starter and Solenoid 5
Stop Lamp Switch 24
H
High Pressure Switch 29 T
Horn .22 Transmission Filter Switch 15
Horn Button 22 Turn Signal Switch .25
Horn Relay 23
Hydraulic Filter Switch 15 W
Warning Buzzer 13
Instrument Cluster 9

Section
4003
BATTERY(S)

CASE CORPORATION Issued November 1989
4003-2
TABLE OF CONTENTS
SPECIFICATIONS See Section 4001
BOOSTER BATIERIES.... See Section 4001
SAFETY RULES :. .. 3
SPECIAL TOOLS . 3
MAINTENANCE.. ..4
Electrolyte Level .4
Inspecting and Cleaning the Battery .4
NONSPILL CAPS.. . 5
BATIERY TEST 6
Visual Checks............... . 6
Specific Gravity Check. 6
Capacity (Load) Test.. 7
CHARGING A BATIERY. 8
PREPARING A DRY CHARGED BATIERY FOR USE....... . 9

4003-3
SAFETY RULES
SPECIAL TOOLS
'",-Order special tools from either of the following com-
parses;
"-
<,
In the U.S.A. and Canada

Service Tools
PO. Box 314
In Europe
VL Churchill ltd
Northants, NN11 4NF
England
The CAS-10147 tester is used to do the Capacity
(Load) Test. This tool is first used on page 4003-7.

4003-4
MAINTENANCE
Electrolyte Level NOTE: Add water only. DO NOT add electrolyte.
If the battery is a maintenance free battery, check Inspecting and Cleaning a Battery
the level of the electrolyte every 1000 hours of operation
or six months, whichever occurs first. For all other batte- If damage causes an electrolyte leak, replace the
ries, check the level of the electrolyte every 250 hours of battery.
operation.
If the battery in your machine has nons pill caps, see
NOTE: A maintenance free battery will have the Nonspill Caps on page 4003-5 and check the condition
words Maintenance Free on the decal on the top of the of the nonspill caps. See Specifications in Section 4002
battery. If the center part of the decal has been removed to find if the battery in your machine must have nonspill
for access to the battery caps, it is possible that the caps.
words Maintenance Free have been removed from the
decal. Inspect the battery at regular intervals for dirt, corro-
sion, and damage. Electrolyte and dirt on the top of the
Check the level of the electrolyte more often during battery can cause the battery to discharge by making a
hot weather. The use of a large amount of water by the passage for the current to flow.
battery can be caused by high battery temperature or a
voltage regulator setting that is too high. Keep the elec- If the battery must be cleaned, remove the battery
trolyte level above the top of the plates in the battery at from the battery carrier and clean the battery, cable ter-
all times to prevent damage to the battery. minals, and the battery carrier. When available, use
Case Battery Saver and Cleaner according to the in-
NOTE: On maintenance free batteries it is neces- structions on the container. Case Battery Saver and
sary to remove the center part of the decal for access to Cleaner also helps prevent corrosion. If Case Battery
the battery caps. Do not discard the center part of the Saver and Cleaner is not available, use baking soda
decaf. Install the center part of the decal after the battery and water as a cleaner. DO NOT permit any type of
caps have been installed. cleaner to enter the cells of the battery.
Ifthe level of the electrolyte is low, add distilled water Install the battery in the machine and make sure the
or other clean water until the electrolyte is just below the fasteners are tight. Apply Case Battery Saver and
cell opening. Do not add more water than is needed. Cleaner or Urethane Seal Coat to the cable terminals to
Too much water can cause bad performance, a short prevent corrosion. See the Parts Counter Catalog. DO
service life, and corrosion around the battery. NOT apply grease.

4003-5
NONSPILL CAPS
See Specifications in Section 4002 to find if the batt- The nonspill caps have a valve with a stem made of
ery(s) in your machine must have nonspill caps. lead and rubber. When the nons pill cap is turned
upside down, the weight of the lead holds the rubber
stem against the breather hole, preventing the loss of
electrolyte.
If the breather hole and valve are closed by foreign

material, pressure in the battery can become high
Do not operate the machine if the nonspill caps do enough to break the case of the battery. Always check
not work correctly or if the nonspill caps are not in place. the breather hole for foreign material when you check
Nonspill caps prevent electrolyte leakage which can the electrolyte level. If there is foreign material over the
cause personal injury and damage to the machine if the breather hole, turn the nons pill cap upside down and
machine turns over in an accident. clean the nonspill cap. Move the nonspill cap up and
down rapidly. You must be able to hear the movement
of the valve. If you cannot hear the valve, wash the
nonspill cap and loosen the valve. Move the nonspill
cap up and down rapidly to remove the water.
When you remove a nonspill cap, check the condi-

tion of the rubber gasket. If the rubber gasket is gone or
is damaged, install a new nonspill cap.
Missing or broken nonspill caps MUST be replaced

with new nonspill caps. DO NOT use any other type of
cap to replace nonspill caps.
B800305M
When you install a new battery, the new battery
MUST have nonspill caps. You can use the nons pill
caps from the old battery if the nonspill caps are in good
condition.

4003-6
BATTERY TEST
NOTE: To correctly test a battery, do each part of the
battery test until you know the condition of the battery.
Visual Checks
1 . Make sure the cable connections are clean and
tight. Clean foreign material from the top of the battery.
2. Inspect the battery case, battery posts, and cables

for damage.
3. Check the electrolyte level See page 4003-4
4. If you added water to the battery, the battery must

be charged for 15 minutes at 15 to 25 amperes to mix
the water with the electrolyte.
1. Temperature in OF 2. Temperature in °C
Specific Gravity Check Specific Gravity Chart
A hydrometer is used to check the specific gravity 4. Make a record of the corrected specific gravity
(weight) of the electrolyte. The specific gravity is an reading for each cell.
indication of the level of charge for each celt.
5. If the difference between the high reading and the
Hydrometers are made to show the correct specific low reading is .050 or more, charge the battery and
gravity when the temperature of the electrolyte is 80°F check the specific gravity again. If after charging, the
(26.JOC). difference is still .050 or more, install a new battery.
When you check the specific gravity, you must know 6. The corrected specific gravity reading shows the
the temperature of the electrolyte. If your hydrometer level of charge for the cell. The level of charge must be
does not have a thermometer, get a thermometer to at least 75% in each of the cells. In maintenance free
check the temperature of the electrolyte. The thermo- batteries the level of charge is at least 75% if the cor-
meter must indicate a high temperature of at least rected specific gravity reading is 1.240 or higher. In all
120°F (52°C). other batteries the level of charge is at least 75% if the
corrected specific gravity reading is 1.230 or higher.
1. Remove enough electrolyte from a cell so that the
float is free in the tube. 7. If the difference between the high reading and the
low reading is less than .050, and the level of charge is
NOTE: If the specific gravity cannot be checked at least 75% in all of the cells, do the Capacity (Load)
without first adding water to the cell, the battery must be Test.
charged for 15 minutes at 15 to 25 amperes to mix the
water with the electrolyte. Then check the specific 8. If the difference between the high reading and the
gravity. low reading is less than .050, but the level of charge is
less than 75% in any of the cells, charge the battery and
2. Read the float. check the specific gravity again. If after charging:
3. Read the thermometer If the reading is above 80°F a The level of charge is less than 75% in any of
(26.JOC)add specific gravity points to the reading for the cells, discard the battery.
specific gravity. If the reading is below 80°F (26SC)
subtract specific gravity points from the reading for b. The level of charge is at least 75% in all of the
specific gravity. See the following illustration and add or cells, do the Capacity (Load) Test.
subtract specific gravity points as needed.

4003-7
Capacity (Load) Test NOTE: Never apply a load for longer than 15 seconds.
After each 15 seconds, turn the load control knob to OFF
This test can be done using a variable load tester for at least one minute.
such as the Sun Electric VAT-33. Other test equipment
can be used. Connect the test equipment according to 4. Apply a 15 ampere load to the battery for 15
the instructions of the manufacturer of the equipment. seconds. Wait at least three minutes before applying
the load again.
1. The level of charge of the battery must be at least
75%. Do the Specific Gravity Check in this section 5. Check and make a record of the temperature of the
electrolyte.
2. Prepare the tester (Sun Electric VAT-33 shown) for
the test. 6. Find the correct load for this test in Specifications in
Section 4002.
a. Select the voltmeter range that will measure 1
to 18 volts. NOTE: The correct load is half of the cold cranking
amperes at OaF (-17"C).
b. Make sure the load control knob is in the OFF
position. 7. Turn the load control knob until the ammeter indi-
cates the specified load Keep the load for 15 seconds
c. Select the ammeter range that will measure 0 and read the voltmeter. Turn the load control knob to
to 1000 amperes. OFF.
d. Move the volt lead switch to the INT. position. 8. Compare the test reading and the temperature of
the electrolyte to the chart below.
3. Connect the tester to the battery as shown.
Temperature of Minimum Voltage
electrolyte
70°F (21°C) and above 9.6

60°F (16°C) . __ 9.5
50°F (1O°C) _ _ 9.4
40°F (4°C) 9.3
30°F (-1°C) 9.1
20°F (-7°C) 8.9
10°F (-12°C) 8.7
OaF (-18°C) 8.5
a. If the test result is equal to or more than the

voltage shown, the battery is in good condition.
b. If the test result is less than the voltage shown,

discard the battery.
B790499J
1. Load Control Knob 2. Ammeter Clamp

(Tip of Arrow Away
from Battery)

4003-8
CHARGING A BATTERY
The charging rate must be decreased if:
1. Too much gas causes the electrolyte to flow from

Before you charge the battery, check the level of the the cells.
electrolyte.
2. The temperature of the electrolyte rises above
It is difficult to give an exact charging rate because 125°F (52°C).
of the following variable conditions: (1) temperature of
the electrolyte, (2) level of charge, and (3) condition of NOTE: For the best charge, use the slow charging
the battery. Use the charging guide for the correct rates.
charging rate and time.
The battery is fully charged when, over a three hour
See Specifications in Section 4002 for the reserve period at a low charging rate, no cell is giving too much
capacity of the battery in this machine. gas, and the specific gravity does not change.
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under
Specifications Slow Charge Fast Charge
80 Minutes or Less 10 Hours at 5 Amperes 2.5 Hours at 20 Amperes

5 Hours at 10 Amperes 1.5 Hours at 30 Amperes
Above 80 to 125 Minutes 15 Hours at 5 Amperes 3.75 Hours at 20 Amperes

7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
Above 125 to 170 Minutes 20 Hours at 5 Amperes 5 Hours at 20 Amperes

10 Hours at 10 Amperes 2 Hours at 50 Amperes

*Initial rate for standard taper charger.
851285
NOTE: A maintenance free battery will have the words access to the battery caps, it is possible the words
Maintenance Free on the decal on the top of the battery. Maintenance Free will have been removed from the
If the center part of the decal has been removed to get decal.
Continued on next page
Bur 8-12350 Issued 11-89 Printed in U .SA

4003-9
CHARGING GUIDE FOR BATTERIES OTHER THAN

MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See

Reserve Capacity under
Specifications Slow Charge Fast Charge
80 Minutes or Less 10 Hours at 5 Amperes 2.5 Hours at 20 Amperes

5 Hours at 10 Amperes 1.5 Hours at 30 Amperes

7.5 Hours at 10 Amperes 1.5 Hours at 50 Amperes
Above 125 to 170 Minutes 20 Hours at 5 Amperes 5 Hours at 20 Amperes


Above 250 Minutes 24 Hours at 10 Amperes 6 Hours at 40 Amperes

4 Hours at 60 Amperes
*Initial rate for standard taper charger.
851286
PREPARING A DRY CHARGED BATTERY FOR USE

1. Remove the caps from the battery. 4. Connect a battery charger to the battery
2. Fill each cell to the top of the separators with elec- 5. Charge the battery at 30 amperes until the specific
trolyte. This will permit the volume of electrolyte to gravity is 1.250 or more and the temperature of the elec-
increase when heated by charging the battery. trolyte is at least 60°F (15'soC).
3. Install the caps on the battery. If the battery in your 6. If necessary, fill each cell with electrolyte until the
machine must have nonspill caps, install the nonspill electrolyte is just below split ring at the bottom ofthe cell
caps. See Specifications in Section 4002 to find if the opening.
battery in your machine must have nons pill caps.

4004
STARTER AND STARTER SOLENOID
TABLE OF CONTENTS
Removal and Installation See Section 4001 Disassembly 4004-7
Specifications 4004-2 Inspection 4004-11
Lubrication 4004-2 Brushes and Brush Springs 4004-11
No-Load Test 4004-2 Brush Helder 4004-11
General Information 4004-2 Armature 4004-11
Test Equipment 4004-2 Field Coil Test... .4004-12
Test Procedure 4004-3 Assembly 4004-14
Understanding No-Load Test Results 4004-S Starter Solenoid Test 4004-20

Issued June 1989
4004-2
SPECIFICATIONS
Case part number A 170746
No-Load Test at 80°F (26. 7°C)

Volts 11
Current draw 180 amperes maximum
Starter drive speed 3500 rpm (r/min) minimum
LUBRICATION
Interval When the starter is disassembled or each
time the engine is removed for repairs
Lubricant
Molykote-GN Use on shaft at pinion end of starter drive
Case multipurpose grease Use on bearings, gears,

idler gear shaft and spring.
NO-LOAD TEST
General Information Test Equipment
1. The No-Load Test is done with the starter removed The No-Load Test can be done using a Sun Electric
from the engine. VAT-33 Tester, an equivalent tester, or separate pieces
of test equipment.
2. Check to see if you can pull the gear on the starter
drive out of the starter drive housing. A hand held tachometer is needed to measure the
speed of the armature shaft.
3. Check to see if the starter drive can be turned. Pull
the gear on the starter drive out of the starter drive A remote starter button is needed to actuate the
housing. Turn the gear to turn the starter drive and the starter.
armature.
A fully charged 12 volt battery is needed to supply
4. If the starter drive cannot be turned, disassemble the electricity to turn the starter.
the starter and make repairs as needed. Then do the
No-Load Test.

4004-3
Test Procedure 3. Connect the positive battery cable to the battery

terminal on the starter solenoid and the negative battery
The illustrations in this procedure show the use of cable to the mounting flange of the starter.
the Sun Electric VAT-33 tester. Other test equipment
can be used. Connect the test equipment according to
this procedure and the manufacturer's instructions.
1. If the VAT-33 tester is being used:
a. Select the 0 to 100 ampere range.

1 3
b. Select the 18 to 40 volt range.
c. Move the volt lead switch to the EXT. position.
d. Turn the load control to the OFF position.

2
B831430J
1. Positive Battery Cable

2. Battery Terminal
3. Negative Bettery Cable
4. Connect the positive load cable to the positive post

of the battery. Connect the negative load cable to the
negative post.
2. Fasten the starter in a vise or use another method

to prevent the starter from moving. This must be done
to prevent personal injury.
B831431J
1. Positive Load Cable

2. Negative Load Cable

4004-4
5. Connect the red voltmeter lead to the motor 7. Fasten the ammeter clamp around the positive
terminal on the starter solenoid. battery cable so that the tip of the arrow is toward the
?tarter.
o
o 0
o
1
B831432J
1. Red Voltmeter Lead

2. Motor Terminal
B831434J
6. Connect the black voltmeter lead to the mounting
flange on the starter.
1. Ammeter Clamp
8. Connectthe leads from the remote starter button to

the Battery and Switch terminals.
B831433J
1. Black Voltmeter Lead
B831435J

4004-5
IMPORTANT: Steps 9, 10, and 11 must be done 2. Low armature shaft speed and high current draw
rapidly. Do not load the battery for more than 15 are indications of too much friction. Possible causes of
seconds at one time. After the battery has been loaded too much friction are:
for 15 seconds, let the starter cool for 60 seconds.
a. Tight, dirty, or worn bearings.
9. Actuate the remote starter button and turn the load
control until the voltmeter indicates 11 volts. b. A bent armature shaft.
c. Loose pole shoes (pole shoes make contact

with the armature).
d. A short circuit in the armature coil. Disas-

semble the starter. Use an armature tester to test
the armature. Use the instructions included with
the armature tester.
e. Damaged field coil. Do the test on page 4004-
I 12
3.. If the armature does not rotate and the current draw
is high, possible causes are:
a. Field terminal making contact with the field

frame. Inspect the insulators for the field terminal
b. Damaged field coil. Do the tests on page

4004-12.
c. Damaged bearings.
4. If the armature does not rotate and the current draw

is zero, possible causes are:
B831436J
a. An open field armature circuit. Disassemble
the starter and inspect the field coil connections.
1. Remote Starter Button
2. Load Control b. An open armature coil. Disassemble the
3. Voltmeter starter and check for burned commutator bars.
4. Ammeter Use an armature tester to test the armature. Use
5. Hand Held Tachometer the instructions included with the armature tester.
10. Look at the ammeter and make a record of the c. Brushes not making good contact with the
ammeter indication. commutator bars. Check for high insulation
between the commutator bars, broken brush
11. Use the hand held tachometer and check the springs, or worn brushes.
armature shaft speed. Make a record of armature shaft
speed. 5. Low armature shaft speed and low current draw are
indications of:
12. Release the remote starter button and turn the load
control to the OFF position. a. Dirt or corrosion on connections.
Understanding No-Load Test Results b. Damaged wiring.
1. If the current draw and the armature shaft speed c. Dirty commutator bars.
are within the ranges under Specifications, the starter is
good. d. All causes in step 4.

4004-6
6. High armature shaft speed and high current draw coil. Do the No-Load Test again to check for improve-
are indications of a short circuit in the field coil. It is diffi- ment in the operation of the starter.
cult to find a short circuit in a field coil. Install a new field

4004-7
DISASSEMBLY
STEP 1 STEP 4
Pull back the boot on the motor terminal and loosen and Remove the cover.
remove the nut and lock washer.
STEP 5
STEP 2
Hold the spring away from one of the brushes con-

Loosen and remove the screws that hold the cover. nected to the field coil and remove the brush from the
brush holder. Repeat this step for the other brush con-
nected to the field coil.
STEP 3
STEP 6
Loosen and remove the cap screws.
Remove the brush holder.

4004-8
STEP 7 STEP 10
Remove the field frame assembly. Remove the starter drive housing from the starter sole-
noid.
STEP 8
STEP 11
Remove the armature.

Push down the starter drive housing as shown to loosen
and remove the starter drive.
STEP 9
STEP 12
Fasten the starter solenoid in a vise and loosen and

remove the screws that hold the starter drive housing.
Remove the steel ball from the starter drive. If ne-
cessary, use a magnet.
Bur 8-11370 Issued6-89 Printedin U.S.A.

4004-9
STEP 13 STEP 16
Remove the O-ring from the groove in the starter drive Remove the bearing cage.
housing.
STEP 17
STEP 14
Remove the thrust washer.

Remove the spring.
STEP 18
STEP 15
Loosen and remove the screws that hold the cover.

Remove the idler gear.

4004-10
STEP 19 STEP 21
If necessary, use a hammer to loosen the cover. Remove the plunger.
STEP 20 STEP 22
,1.0M
Remove the cover. If necessry, remove the gasket from the cover.

4004-11
INSPECTION
All parts except the starter drive must be cleaned Armature
using mineral spirits and a brush or cloth. Use a clean,
dry cloth to clean the starter drive. 1. Test the armature on an armature tester. Use the
equipment manufacturer's instructions.
Brushes and Brush Springs
1. If the length of the brush fastened to the brush
holder is less than 7/16 inch (11 mm), a new brush
holder assembly must be used when the starter is as-
sembled.
2. If the length of a brush fastened to the field coil is

less than 7/16 inch (11 mm), a new field frame
assembly must be used when the starter is assembled.
3. Use a spring scale to check the tension of the brush

springs. Pull the brush spring up until the brush spring
is just above the brush holder. The scale indication
must be between 4 and 9 pounds (1.8 and 4.1 kg). If a
brush spring is not as specified, use a new brush spring 2. Put the armature on vee-blocks as shown and
when the starter is assembled. check the runout of the armature with a dial indicator.
The runout must not be more than .002 inch (0.05 mm).
Brush Holder
3. If -necessary, put the armature in a lathe and
remove enough material from the commutator to make
the runout less than .002 inch (0.05 mm).
1. Hold the leads of an ohmmeter against the frame

and the brush holders that have insulation between the
brush holder and frame.
4. Measure the diameter of the commutator. If the
2. If there was an indication of a complete circuit, diameter is less than 1.38 inch (35 mm), install a new ar-
install a new brush holder. mature.
5. If the depth of the groove between the commutator

bars is less than .008 inch (0.2 mm), cut the insulation
between the commutator bars to a depth of 1/64 to 1/32
inch (0.5 to 0.8 mm). Use sandpaper to remove the
rough edges from the commutator bars.
6. Check the bearings on the armature for free rota-

tion, rough balls, and damage to the inner race or outer
race. If a bearing is to be replaced, use a press and ac-
ceptable tools to remove and install the bearings.

4004-12
Field Coil Test
B610616M
3. Hold the leads of the ohmmeter against one of the

brushes and the end of the cable. The needle of the
1. Hold the leads of an ohmmeter against one of the ohmmeter must move.
brushes and the field frame. The needle of the
ohmmeter must not move. 4. If the needle of the ohmmeter did not move, install a
new field frame assembly.
2. If the needle of the ohmmeter moved, install a new
field frame assembly.

4004-13

4004-14
ASSEMBLY
STEP 23 STEP 26
Install the plunger in the starter solenoid. Install and tighten the screws.
STEP 24 STEP 27
If necessary, install a new gasket in the cover. Install the bearings in the bearing cage.
STEP 25 STEP 28
Install the cover. Lubricate the bearings and teeth of the idler gear with
the grease specified on page 4004-2.

4004-15
STEP 29 STEP 32
Install the thrust washer. Install the spring.
STEP 30 STEP 33
Install the bearing cage as shown. Install a new O-ring in the groove in the starter drive
housing. Lubricate the O-ring.
STEP 31
STEP 34
Install the idler gear.

Lubricate the open bearing on the starter drive with the
grease specified on page 4004-2.

4004-16
STEP 35 STEP 38
741M
Start the starter drive into the starter drive housing. Assemble the starter drive housing and starter sol-
enoid.
STEP 36
STEP 39
Push down the starter drive housing to push the starter

drive all the way into the starter drive housing. Install a lock washer, flat washer, and O-ring on the
screws that hold the starter drive housing. Lubricate the
O-rings.
STEP 37
STEP 40
Put a small amount of grease in the hole in the starter

drive and install the steel ball in the hole.
Install the screws in the starter drive housing.

4004-17
STEP 41 STEP 44
Fasten the starter solenoid in the vise and tighten the Use the springs to hold the brushes in the brush holder
screws that hold the starter drive housing. as shown.
STEP 42 STEP 45
Install the armature. Install the brush holder.
STEP 43 STEP 46
Install the field frame assembly. Put the springs on top of the brushes connected to the
brush holder.

4004-18
STEP 47 STEP 50
Install the brushes that are connected to the field coil. Install the cover and align the cover with the brush
holder.
STEP 48
STEP 51
Use a cap screw to align the brush holder with the field
frame assembly. Install the tighten the screws that hold the brush holder.
STEP 49 STEP 52
B330816M
Move the brush holder so that the brush holder is even Install a lock washer, flat washer, and O-ring on the cap
with the end of the armature. screws. Lubricate the O-rings.

4004-19
STEP 53 STEP 54
Install and tighten the cap screws. Install the cable, lock washer, and nut on the motor ter-
minal, and tighten the nut.
STEP 55
Pull the boot over the motor terminal.

4004-20
STARTER SOLENOID TEST

This test will check the condition of the pull-in 3. Connect a jumper wire to the battery terminal and
winding and the hold-in winding in the starter solenoid. the switch terminal in the starter solenoid housing. The
jumper wire must be made from No. 10 or larger wire.
The jumper cable connected to the starter mounting
flange and the motor terminal must have a common 4. Connect the jumper cable with the common con-
connection at the negative battery post. nection to the starter mounting flange and the motor
terminal in the starter solenoid housing.
Starter Solenoid Test Procedure
NOTE: Steps 5 and 7 must be done in a maximum of
1. Remove the rubber boot from the motor terminal. 15 seconds to prevent damage to the pull-in winding
Remove the nut and lock washer from the motor ter- and the hold-in winding.
minal. Then remove the wire from the motor terminal.
5. Connect the jumper cable with the common con-
2. Connect a jumper cable to the positive battery post nection to the negative battey post. The pinion gear on
of a fully charged 12 volt battery. Connect the other end the starter drive must come all the way out rapidly and
of the jumper cable to the battery terminal in the starter with force.
solenoid housing.
6. If the pinion gear did not come out rapidly and with
force, the pull-in winding is damaged. The complete
starter solenoid housing assembly must be replaced.
7. Disconnect the jumper cable from the motor

terminal in the starter solenoid housing. The pinion gear
on the starter drive must not move toward the starter
drive housing.
1. 12 Volt Battery B831438R 8. If the pinion gear started to move toward the starter
2. Starter drive housing, the hold-in winding is damaged. The
3. Battery Terminal complete starter solenoid housing assembly must be
4. Switch Terminal replaced.
5. Motor Terminal

Section
4006
95 AMPERE ALTERNATOR

4006-2
TABLE OF CONTENTS
SPECIFICATIONS 2
DiSASSEMBLy 3
INSPECTION OF BRUSHES 7
INSPECTION AND TESTING OF ROTOR 8
INSPECTION AND TESTING OF STATOR 9
TESTING THE CONDENSER 10
TESTING THE RECTIFIER BRIDGE 11
INSPECTION AND REPLACEMENT OF BEARINGS 12
ASSEMBLY 15
SPECIFICATIONS
12 Volt Alternator
Manufacturer Robert Bosch
Robert Bosch part number 0 120 484 011
Case part number A 187623
Output 14 volts at 95 amperes
Resistance of rotor winding 3.0 ohms
. Resistance of stator winding 0.05 to 0.06 ohms
Minimum brush length 0.55 inch (14 mm)
Special Torques
Nut that fastens the pulley to the rotor shaft 44 to 52 pound-feet (60 to 70 Nm)

4006-3
DISASSEMBLY
STEP 1 STEP 4
Fasten the pulley of the alternator in a vise that has soft

jaws. Loosen and remove the nut and lock washer. Remove the fan from the shaft.
STEP 2 STEP 5
Loosen and remove the screws and flat washers that

Hit the face of the pulley with a soft hammer to loosen fasten the voltage regulator and brush holder to the
the tapered bushing in the pulley. housing.
STEP 3 STEP 6
Remove the voltage regulator and brush holder.

Remove the tapered bushing and the pulley from the
shaft.

4006-4
STEP 7 STEP 10
Disconnect the lead for the capacitor. Loosen and remove the nut, flat washer, and fiber
washers from the B + terminal.
STEP 8
STEP 11
Loosen and remove the screw and remove the capa-

citor. Make an alignment mark on the cover, the stator, and
the housing.
STEP 9
STEP 12
Loosen and remove the nut, flat washer, and fiber

washers from the D + terminal. Loosen and remove the screws that fasten the cover,
stator, and housing together.

4006-5
STEP 13 STEP 16
Remove the cover and rotor from the stator and Loosen and remove the screws that fasten the rectifier
housing. bridge to the housing.
STEP 14 STEP 17
Loosen and remove the screws that fasten the bearing Remove the housing.
retainer to the cover. The rotor now can be removed.
STEP 18
STEP 15
Remove the insulator from the B + terminal.

Remove the rotor from the cover.

4006-6
STEP 19 STEP 20
Remove the insulator from the 0 + terminal. Remove the shield from the housing.

4006-7
INSPECTION OF BRUSHES
STEP 21 STEP 24
Use an ohmmeter and check the continuity from each To replace the brushes, use a soldering iron to remove
terminal and brush. If the reading is zero, replace the the original brushes. Install the springs and new
brush or voltage regulator and brush holder. brushes and use rosin core solder to solder the leads to
the terminals. Before soldering the terminal shown,
open the sleeve for the brush lead and then crimp the
STEP 22 sleeve.
STEP 25
Remove the shield.
STEP 23 Install the shield.
Measure the length of each brush. If the length of one

brush is less than 0.55 inch (14 mm) replace both
brushes or the voltage regulator and brush holder.
Bur 8-12381 Issued 1-91 Printed i'1 U.S.A.

4006-8
INSPECTION AND TESTING OF ROTOR

STEP 26 STEP 28
Touch the leads of the ohmmeter to the slip rings. The Use a dial indicator and measure the runout of each slip
reading must be 2.52 to 3.08 ohms. If the reading is not ring. If the runout is more than 0.002 inch (0.05 mm) a
as specified, a new rotor must be installed. new rotor must be used or use a lathe to remove
enough material until the runout is less than specified.
STEP 27
STEP 29
Touch the leads to each slip ring and the shaft. If a

reading shows continuity, a new rotor must be installed. Measure the diameter of the slip ring. The diameter
must not be less than 1.055 inch (26.8 mm).

4006-9
INSPECTION AND TESTING OF STATOR

STEP 30 STEP 33
Look for burned insulation on the coils of the stator. This
is an indication of a short circuit. Install a new stator.
STEP 31
Use a high watt soldering iron and rosin core soider to

solder the leads of the stator to the rectifier bridge.
Touch the leads of the ohmmeter to each lead from the

stator and the common connection. The readings must
be 0.05 to 0.06 ohm. If the readings are not as speci-
fied, a new stator must be installed.
STEP 32

stator and the frame. If a reading shows continuity, a
new stator must be installed.

4006-10
TESTING THE CONDENSER

STEP 34 STEP 35
Touch the terminal to the bracket to discharge the con-
denser.
Touch the leads of the ohmmeter to the condenser as

shown. The reading will increase and then return to zero
resistance as the condenser is charged. If there is no in-
dication of resistance, a new condenser must be in-
stalled. The condenser is used to reduce radio noise.

4006-11
TESTING THE RECTIFIER BRIDGE

STEP 36 NOTE: If the tester you are using has a diode test func-
tion, use the tester according to the instructions of the
manufacturer to check the positive and negative
diodes.
Touch the leads of the ohmmeter to a positive diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero reading.
Then test the other two positive diodes. If a positive
diode did not have readings as specified, the positive
diode is bad and a new rectifier bridge must be instal-
led.
STEP 37
Touch the leads of the ohmmeter to a negative diode

and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero reading.
Then test the other two negative diodes. If a negative
diode did not have readings as specified, the negative
diode is bad and a new rectifier bridge must be in-
stalled.

4006-12
INSPECTION AND REPLACEMENT OF BEARINGS

STEP 38 a. Use a suitable support between the front bearing
Inspect the bearings on the rotor. If the bearings are and the bearing retainer on the rotor shaft and
damaged, use the following procedure to replace the press the rotor shaft out of the front bearing and the
bearings. spacer.

4006-13
b. Remove the bearing retainer. e. Press the new front bearing onto the rotor shaft
until the front bearing stops moving.
c. Use a suitable support between the rear bearing

and the slip ring on the other end of the rotor shaft f. Press the spacer onto the rotor shaft until the
and press the rotor shaft out of the rear bearing. spacer stops moving.
d. Install the bearing retainer on the rotor shaft. g. Press the new rear bearing onto the other end of
the rotor shaft.

4006-14
B891870J

4006-15
ASSEMBLY
STEP 39 STEP 42
Install a new shield in the housing. Install the housing on the rectifier bridge.
STEP 40 STEP 43
Install the insulator on the 0 + terminal. Install and tighten the screws that fasten the rectifier
bridge to the housing.
STEP 41
STEP 44
Install the insulator on the B + terminal.

Install the fiber washers, flat washer, and nut on the B +
terminal.

4006-16
STEP 45 STEP 48
Check for a short circuit between the terminal and the Install the rotor in the cover.
housing. If there is continuity, the insulator is bad.
STEP 49
STEP 46
Install and tighten the screws that fasten the bearing

Install the fiber washers, flat washer, and nut on the D + retainer and rotor to the cover.
terminal.
STEP 50
STEP 47
Make sure the marks are in alignment and install the

Check for a short circuit between the terminal and the cover and rotor in the stator and housing.
housing. If there is continuity, the insulator is bad.

4006-17
STEP 51 STEP 54
Install and tighten the screws evenly that fasten the Install the voltage regulator and the brush holder. Be
housing, stator, and cover. careful not to damage the brushes.
STEP 52 STEP 55
Install the capacitor and tighten the screw. Install the screws and flat washers and tighten the
screws.
STEP 53
STEP 56
Connect the lead to the terminal.
Install the fan.

4006-18
STEP 57 STEP 59
Fasten the pulley in a vise with soft jaws. Tighten the nut
Install the pulley and the tapered bushing. to 44 to 52 pound-feet (60 to 70 Nm)
STEP 58
Install the lock washer and start the nut onto the shaft.

Section
4007
65 AMP ALTERNATOR A187873

CASE CORPORATION Issued July 1990
4007-2
TABLE OF CONTENTS
SPECiFiCATIONS 2
DISASSEMBLY 3
INSPECTION OF BRUSHES 8
INSPECTION AND TESTING OF ROTOR 9
INSPECTION AND TESTING OF STATOR 10
TESTING THE CONDENSER 11
TESTING THE RECTIFIER BRIDGE 12
ASSEMBLY 14
SPECIFICATIONS
Rated output. 14 volts at 65 amperes
Resistance of rotor winding 2.52 to 3.08 ohms
Maximum runout for slip rings 0.002 inch (0.05 mm)
Minimum diameter of slip rings 1.055 inch (26.8 mm)
Resistance of stator coils 0.09 to 0.11 ohms
Minimum length of brushes 0.27 inch (7 mm)
Torque for nut for pulley 44 to 55 pound-feet (60 to 70 Nm)

4007-3
DISASSEMBLY
STEP 1 STEP 4
Fasten the pulley in a vise that has soft jaws and loosen Remove the fan.
end remove the nut and lock washer.
STEP 5
STEP 2
M
.;:;::~..:.:: ....
Hold the voltage regulator and brush holder and loosen

Hit the pulley with a hammer to loosen the tapered and remove the screws.
bushing.
STEP 6
STEP 3
Remove the voltage regulator and brush holder.

Remove the pulley and tapered bushing.

4007-4
STEP 7 STEP 10
Make an alignment mark on the front and rear hous- Remove the front housing and rotor from the rear
ings. housing.
STEP 8 STEP 11
Loosen and remove the screws that hold the front and Loosen and remove the screws that hold the retainer for
rear housings together. the rotor.
STEP 9 STEP 12
Hold the stator and hit the front housing with a soft Remove the rotor.
hammer to separate the front housing from the stator.

4007-5
STEP 13 STEP 16
;1~~?07M
Use an acceptable puller and press the rotor out of the Loosen and remove the screw that holds the con-
spacer and bearing. denser.
STEP 14 STEP 17
Remove the retainer. Disconnect the lead from the condenser from the
terminal and remove the condenser.
STEP 15
STEP 18
Use an acceptable puller and driver and press the rotor .

out of the other bearing. Loosen and remove the two screws that hold the recti-
fier bridge.

4007-6
STEP 19 STEP 22
Loosen and remove the nut, lock washer and flat Remove the insulators from the D + terminal.
washer from the B + terminal.
STEP 23
STEP 20
Use a screwdriver and separate the stator from the rear

Remove the insulators from the B + terminal. housing.
STEP 21 STEP 24
Loosen and remove the nut, lock washer and flat Carefully remove the stator and rectifier bridge from the
washer from the D + terminal. rear housing.

4007-7
STEP 25 STEP 27
Turn the insulator off of the D + terminal. Use a screwdriver to start the cover for the slip rings out
of the rear housing.
STEP 26
STEP 28
Remove the insulator for the B + terminal.

Use an acceptable tool to remove the cover from the
rear housing.

4007-8
INSPECTION OF BRUSHES
STEP 29 STEP 32
Use an ohmmeter and check the continuity from each To replace the brushes, use a soldering iron to remove
terminal and brush. If the reading is zero, replace the the original brushes. Install the springs and new
brush or voltage regulator and brush holder. brushes and use rosin core solder to solder the leads to
the terminals. Before soldering the terminal shown,
open the sleeve for the brush lead and then crimp the
STEP 30 sleeve.
STEP 33
Remove the shield.
STEP 31 Install the shield.
Measure the length of each brush. If the length of one

brush is less than 0.27 inch (7 mm) replace both
brushes or the voltage regulator and brush holder.

4007-9
INSPECTION AND TESTING OF ROTOR

STEP 34 STEP 36
Touch the leads of the ohmmeter to the slip rings. The Use a dial indicator and measure the runout of each slip
reading must be 2.52 to 3.08 ohms. If the reading is not ring. If the runout is more than 0.002 inch (0.05 mm) a
as specified, a new rotor must be installed. new rotor must be used or use a lathe to remove
enough material until the runout is less than specified.
STEP 35
STEP 37
Touch the leads to each slip ring and the shaft. If a

reading shows continuity, a new rotor must be installed. Measure the diameter of the slip ring. The diameter
must not be less than 1.055 inch (26.8 mm).

4007-10
INSPECTION AND TESTING OF STATOR

STEP 38 STEP 41
Look for burned insulation on the coils of the stator. This
is an indication of a short circuit. Install a new stator.
STEP 39
Use a high watt soldering iron and rosin core solder to

solder the leads of the stator to the rectifier bridge.

stator and the common connection. The readings must
be 0.09 to 0.11 ohm. If the readings are not as speci-
fied, a new stator must be installed.
STEP 40

stator and the frame. If a reading shows continuity, a
new stator must be installed.

4007-11
TESTING THE CONDENSER

STEP 42 STEP 43
Touch the terminal to the bracket to discharge the con-
denser.
Touch the leads of the ohmmeter to the condenser as

shown. The reading will increase and then return to zero
resistance as the condenser is charged. If there is no in-
dication of resistance, a new condenser must be in-
stalled. The condenser is used to reduce radio noise.

4007-12
TESTING THE RECTIFIER BRIDGE

STEP 44 STEP 45
Touch the leads of the ohmmeter to a positive diode Touch the leads of the ohmmeter to a negative diode
and the heat sink as shown. Then reverse the leads. and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero reading. There must be a high reading and a low or zero reading.
Then test the other two positive diodes. If a positive Then test the other two negative diodes. If a negative
diode did not have readings as specified, the positive diode did not have readings as specified, the negative
diode is bad and a new rectifier bridge must be instal- diode is bad and a new rectifier bridge must be in-
led. stalled.
NOTE: If the tester you are using has a diode test func-
tion, use the tester according to the instructions of the
manufacturer to check the positive and negative
diodes.

Bur 8-15670 Issued7-90 Printedin U.S.A.
4007-14
ASSEMBLY
STEP 46 STEP 49
Align the boss on the cover with the notch in the rear Turn the insulator all the way onto the D + terminal.
housing.
STEP 50
STEP 47
Install the stator and rectifier bridge assembly in the

Use an acceptable driver and a small hammer and ca- rear housing.
refully drive the cover into the rear housing.
STEP 51
STEP 48
Pull the D + terminal and insulator into alignment with

Install the insulator for the B + terminal. the rear housing.

4007-15
STEP 52 STEP 55
Install and tighten the two screws that hold the rectifier Install the insulators on the B + terminal.
bridge.
STEP 56
STEP 53
Install the flat washer, lock washer and nut on the B +

Install the insulators on the 0 + terminal. terminal. Tighten the nut.
STEP 54 STEP 57
Install the flat washer, lock washer and nut on the 0 + Install the lead from the condenser on the B + terminal.
terminal. Tighten the nut.

4007-16
STEP 58 STEP 61
Install and tighten the screw that holds the condenser. Install the spacer with the smooth surface up.
STEP 59 STEP 62
Install the retainer with the smooth side up. Use an acceptable driver and press the bearing and
spacer all the way onto the shaft.
STEP 60
STEP 63
Install.the bearing.
Use an acceptable driver and press the other bearing
all the way onto the shaft.

4007-17
STEP 64 STEP 67
·.':1.~M
.-,-.'y~·.-.";';"',·;,.~"".M.·-~.·.·:
Install the rotor in the front housing. Install and tighten the screws that hold the alternator to-
gether.
STEP 65
STEP 68
Align the retainer with the front housing and install and
tighten the screws. Install the voltage regulator and brush holder.
STEP 66 STEP 69
Assemble the front and rear housings so that the align- Hold the voltage regulator and brush holder in place
ment marks are aligned. and install and tighten the screws.

4007-18
STEP 70 STEP 72
Install the fan. Install the lock washer and nut.
STEP 71 STEP 73
Install the pulley and tapered bushing. Fasten the pulley in a vise that has soft jaws and tighten
the nut to 44 to 50 pound-feet (60 to 70 Nm).

Section
4008
INSTRUMENT CLUSTER

Issued January 1991
4008-2
TABLE OF CONTENTS
INSTRUMENT CLUSTER 4
Removal and Installation .4
Replacing a Bulb .4
Gauge or Tachometer Removal and Installation ..4
Circuit Board 4
CHECKING THE WARNING LAMPS 5
Engine Oil Pressure 5
Alternator 5
Hydraulic Filter and Air Filter 5
CHECKING THE GAUGES 6
Water Temperature, Oil Temperature, or Fuel Level 6
Voltmeter 6
CHECKING THE TACHOMETER 7

4008-3
B901651J
1. Rubber Cover 6. Body 11. Tachometer

2. Socket 7. Water Temperature Gauge 12. Gasket
3. Bulb No. 194 8. Fuel Level Gauge 13. Identification Strip
4. Bulb No. 168 9. Oil Temperature Gauge 14. Cover
5. Gasket 10. Voltmeter 15. Retainer

4008-4
INSTRUMENT CLUSTER
Removal and Installation Gauqe or Tachometer

1. Remove the screws that fasten the instrument cluster
to the instrument panel. 1. R'emove the instrument cluster from the instrument
panel.
2. Pull the instrument cluster out of the instrument
panel.
2. Remove the four screws that fasten the cover and the
retainer to the body.
3. Disconnect the connectors for the wiring harness
from the instrument cluster. 3. Remove the cover and the retainer.
4. Remove the instrument cluster from the machine. 4. Remove the screws that fasten the gauge or the tac-
hometer to the body.
5. Connect the connectors for the wiring harness to the
instrument cluster 5. Remove the gauge or the tachometer from the body.
If you are removing a gauge, you must pull the studs of
6. Install the instrument cluster in the instrument panel. the gauge from the clips in the body.
7. Install the screws that fasten the instrument cluster to 6. Install the new gauge or the new tachometer in the
the instrument panel. body. If you are installing agauge, make sure the studs
of the gauge are pushed into the clips in the body.
Replacing a Bulb
7. Install the screws that fasten the gauge or the tac-
1. Remove the instrument cluster from the instrument hometer to the body.
panel.
8. Install the retainer and the cover.
2. Turn the socket counterclockwise and remove the
socket.
9. Install the screws that fasten the cover and the re-
tainer to the body.
3. Pull the bulb from the socket and install the new bulb.
10. Install the instrument cluster in the instrument panel.
4. Install the socket and turn the socket clockwise to
hold the socket in place. Circuit Board
5. Install the instrument cluster in the instrument panel. The circuit board does not normally cause any
problems. Use an ohmmeter to check the continuity of
the strips. If there is no continuity in anyone of the strips,
the circuit board must be replaced.

4008-5
CHECKING THE WARNING LAMPS

Engine Oil Pressure Hydraulic Filter and Air Filter
1. The warning lamp for engine oil pressure must illu- 1. Both warning lamps must illuminate when the key
minate when the key switch is in the RUN position and switch is turned half the distance between RUN and ST.
the engine is not running. If the warning lamp does not
illuminate: If one of the warning lamps will not illuminate, check
for:
a. Check for a bad bulb.
a. A bad bulb.
b Check for corrosion or bad connections at the
socket in the instrument cluster and at the switch b. Dirty connection at the instrument cluster.
for engine oil pressure.
c. An open circuit in a diode or in the wire between
c. Check the wire between the switch and the in- the diodes.
strument cluster.
d. An open circuit in the wire between a diode and
2. If the warning lamp illuminates when the engine is the instrument cluster.
running, the cause can be low engine oil pressure, or a
bad switch for the warning lamp. If neither of the warning lamps illuminate, check for:
Alternator a. A damaged wire between the instrument cluster

and the IGN terminal of the key switch.
1. The warning lamp for the alternator must illuminate
when the key switch is in the RUN position and the b. A damaged wire between the diodes and the
engine is not running.lf the warning lamp does not illu- GRD terminal of the key switch.
minate:
c. A bad key switch.
a. Check for a bad bulb.
2. Neither of the warning lamps must illuminate when
b. Check for corrosion or bad connections at the the engine is running.
socket in the instrument cluster and at the alter-
nator. If either warning lamp illuminates when the engine is
running, the cause can be:
c. Check for a damaged wire between the alter-
nator and the instrument panel. a. A dirty filter.
2. If the warning lamp illuminates when the engine is b. A bad switch for the warning lamp.
running, the cause is probably the alternator or voltage
regulator. See Section 4002 and check the alternator c. A short circuit in the wire between the switch and
and the voltage regulator. the warning lamp.
If both of the warning lamps illuminate when the

engine is running, the cause can be:
a. A bad key switch.
b. One of the warning lamps has illumninated for

one of the causes above, and the other warning
lamp has illuminated because of a bad diode.

4008-6
CHECKING THE GAUGES

Water Temperature, Oil Temperature, 2. If the gauge only works part of the time, the cause can
or Fuel Level be:
1. If the gauge does not work correctly: a. A bad connection at the sender.
a. Disconnect the wire from the sender. b. A bad connection at the instrument cluster.
b. Turn the key switch to RUN c. Bad connection in the connectors in the wiring
harness.
c. Hold the wire against the frame or the engine to
make a good ground connection. d. A short circuit or an open circuit in the wires
between the instrument cluster and the sender.
d. Have another person look at the gauge. If you
are checking the water temperature gauge or the e. A bad sender.
oil temperature gauge, the needle must move all
the way to the top of the gauge. If you are checking f. A bad gauge.
the fuel level gauge, the needle must go all the way
to the bottom of the gauge. Voltmeter
e.lfthe needle moved, the sender is bad and must 1. Connect the positive lead of a test voltmeter to the
be replaced. If the needle did not move, the gauge positive post of the battery. Connect the negative lead
is bad or there is an open circuit in the wires of the test voltmeter to the negative post of the battery. If
between the sender and the gauge. the machine has two batteries, make sure the leads are
connected to the same battery.
f. Install the wire on the sender.
2. Start the engine and run the engine at 1500 rpm
g. See page 4 and remove the instrument cluster (r/min).
from the instrument console and disconnect the
wiring harness from the instrument cluster. 3. Read the test voltmeter.
h. See the wiring schematic in Section 4002 for the 4. Read the voltmeter for the machine and compare the
location of the terminal in the connector on the reading with the reading of the test voltmeter.
wiring harness. Connect one lead of an ohmmeter
to the terminal in the connector. Connect the other
lead of the ohmmeter to a good ground connec-
tion.
i. If the ohmmeter did not indicate continuity, there

is a short circuit in the wires between the connector
and the sender. Repair or replace the wires. If the
ohmmeter indicated continuity, the wires are good
and the gauge must be replaced.
5. If the readings are within 1/2 volt, the voltmeter is

good.

4008-7
CHECKING THE TACHOMETER

1. Park the machine on a level surface and lower the 11 . Keep the positive lead of the voltmeter connected to
bucket to the floor. the middle terminai of the small connector. Connect the
negative lead of the voltmeter to the lower terminal
2. Stop the engine and apply the parking brake. (black and orange wire) of the small connector.
3. Remove the right side panel from the engine com- a. If the voltmeter indicated system voltage, do the
partment. next step.
4. Remove the connector from the W terminal of the al- b. If the voltmeter does not indicate system
ternator. voltage, repair or replace the wire between the
small connector and the ground connection near
5. Connect one of the leads of a voltmeter to the W the fuse blocks.
terminal in the alternator. Connect the other lead of the
voltmeter to a good ground connection on the engine. 12. Turn the key switch to the OFF position.
Adjust the voltmeter to indicate volts AC (alternating
current). 13 Connect one of the leads of an ohmmeter to the re-
maining terminal (yellow and red wire) in the small con-
6. Have another person start the engine while you look nector on the wiring harness.
at the voltmeter. The voltmeter must indicate a
minimum of six volts AC. Stop the engine. 14. Connect the other lead of the ohmmeter to the
terminal on the wire that was connected to the W
a. If the voltmeter indicated six volts or more, do the terminal of the alternator.
next step.
a. If the ohmmeter indicates continuity, the
b. If the voltmeter indicated less than six volts, see problem is in the tachometer, and the tachometer
Section 4006 or 4007 and replace the rectifier must be replaced.
bridge.
b. If the ohmmeter does not indicate continuity,
7. Remove the instrument cluster from the instrument see the wiring schematics in Section 4002 and
console. Make sure that the wiring harness is discon- check the continuity of wire 31S (yellow and red)
nected from the instrument cluster. through the main wiring harness and the side
console wiring harness. Repair or replace the wire
8. Turn the key switch to the RUN position. as necessary.
9. Adjust the voltmeter to indicate volts DC (direct cur-

rent).
10. Connect the positive lead of the voltmeter to the

middle terminal (white and orange wire) of the small
connector of the wiring harness. Connect the negative
lead of the voltmeter to a good ground connection.
a. If the voltmeter indicates system voltage, do the

next step.
b. If the voltmeter does not indicate system

voltage, repair or replace the wire between the
small connector and the fuse block.

SECTION INDEX - STEERING
Removal and Installation of Steering Components .. ...............................................................................................5001
Specifications, Schematic, and Troubleshooting ....................................................................................................5002
Steering Control Valve - Eaton ......... ........................................................................................................................ 5004
Steering Control Valve - Danfoss .............................................................................................................................5005
Steering Cylinder ........... ........................................................................................................................................... 5006
Front Axle - Two Wheel Drive ..................................................................................................................................5007
Front Axle - Four Wheel Drive ..................................................................................................................................5008

Section
5001

OF STEERING COMPONENTS

CASE CORPORATION
Issued January 1991
5001-2
TABLE OF CONTENTS
SPECiFiCATIONS..... .. .. . 3
SPECIAL TOOLS 4
STEERING CONTROL VALVE . 5
Removal.......... ..5
Installation........ . , ,. ... 8
STEERING COLUMN 10
Removal 10
Installation 14
STEERING CYLINDER, TVVOWHEEL DRIVE MACHINES 18
Removal...... . 18
Installation... . 18
STEERING CYLINDER, FOUR WHEEL DRIVE MACHINES 20
Removal.................................. ...20
Installation.... 21
FRONT AXLE - TVVOWHEEL DRiVE . ..24
Removal . .............. .. 24
Installation.. . ................ . 24
FRONT AXLE - FOUR WHEEL DRiVE . . 26
Removal . ............................ 26
Installation . .. 26

5001-3
SPECIFICATIONS
Special torques
Nut for the steering wheel 384 to 444 pound-inches (43 to 50 Nm)
Cap screws that fasten the steering cylinder

to the two wheel drive axle . . 580 to 696 pound-feet (786 to 944 Nm)
Capscrews that fasten the steering cylinder to fhe four wheel drive axle 66 to 79 pound-feet (90 to 107 Nm)
Nuts for the bolts that fasten the guard for the drive shaft to the frame ... 100 to 150 pound-feet (136 to 203 Nm)
Cap screws that hold the front drive shaft 504 to 576 pound-inches (58 to 65 Nm)
Wheel bolts for the two wheel drive front axle 115 to 150 pound-feet (156 to 203 Nm)
Wheel nuts for the four wheel drive front axle 200 to 260 pound-feet (270 to 352 Nm)
Nut that fastens the ball joint to the arm of the swivel housing
on the four wheel drive axle 170 pound-feet (230 Nm)

5001-4
SPECIAL TOOLS
dresses:
Service Tools
P.O. Box 314
VL Churchill Ltd
Northants, NN11 4NF
England B4095088M
CAS-10486 Puller
The tool shown is needed to remove the steering This tool is used to remove the ball joint for the steering
wheel. Make the tool in your shop. This tool is first used cylinder from the axle. This tool is first used on page 20.
on page 5.
4
6 7 B902174J B4097488M
CAS-2151 Wrench
Make from 1/4 in (6 mm) Cold Rolled Steel This tool is used to remove and install the tie rod This
1. 2 In (50 mm) tool is first used on page 20.
2. 1 In (25.4 mm)
3. 5/8 In (19 mm)
4. 3/8 In (9.5 mm)
5. 3/4 In (19 mm)
6. Two Holes, 7/32 In (5.5 mm)
7. Use No. 4 OrilJfor 1/4 - 24
Threads Metric Thread Optional
Two 10-32 x 1 In Screws Required

5001-5
STEERING CONTROL VALVE

Removal 6. Remove the three screws that hold the rear cover for
the steering column (5).
See the illustration on page 7.
1. Park the machine on a level surface and apply the

parking brake.
2. Lower the bucket to the floor and put the backhoe in

the transport position.
3. Remove the cover (1) from the steering wheel (2). The
cover (1) is held by the fit of an O-ring (3).
7. Remove the front and rear covers.
4. Loosen and remove the nut (4) that holds the steering
wheel (2) in place.
8. Disconnect the wiring for the turn signals.
5 Use the puller shown on page 4 to loosen and

remove the steering wheel (2).

5001-6
9. Open the access cover at the rear of the hood. This 11. Clean the hose connections at the steering control
will give you access to the hoses connected to the front valve (6).
of the steering control valve (6).
Jill""'" 12. Put identification tags on the hoses to the steering
control valve (6).
13. Three of the hoses at the steering control valve (6)

do not have swivel fittings. Find the end of each of the
hoses without swivel fittings and disconnect each hose
from the tube fitting. Install a cap on each hose and a
plug in each tube.
14. Disconnect the other two hoses from the fittings in

the steering control valve (6). Install a cap on each
fitting and a plug in each hose.
15. Loosen and remove the two cap screws (7) and lock
washers that hold the steering control valve (6) to the
10. Loosen and remove the three cap screws that hold bracket (8) for the steering column (5).
the access panel shown. Remove the access panel.
16. Loosen the nuts and lock washers on the bolts (9)
that fasten the plate (10) to the bracket (8) for the
steering column (5).
17. Push the steering column (5) down enough for

clearance to remove the two cap screws (11) and lock
washers that fasten the steering column (5) to the
steering control valve (6).
18. Hold the steering control valve (6) and remove the
cap screws (11) and lock washers.
19 Remove the steering control valve (6) and the three

hoses through the access hole.
20. Loosen and remove the three hoses and two fittings
from the steering control valve (6).

5001-7
2 STEERING WHEEL
12. DIRECTION
CONTROL LEVER
6. STEERING CONTROL VALVE
B902295J
Steering Control Valve Installation

5001-8
Installation 9. Install the front and rear covers.
1. Install the three hoses and two fittings in the steering

control valve (6).
2. Hold the steering control valve (6) in alignment with

the steering column (5)
3 Install the two cap screws (11) and lock washers that
fasten the steering column (5) to the steering control
valve (6). Tighten the cap screws (11).
4. Push the steering control valve (6) up and align the

steering column (5) with the bracket (8).
5 Tighten the nuts and lock washers on the bolts (9)

that fasten the plate (10) to the bracket (8) for the 10. Install and tighten the three screws that hold the rear
steering column (5). cover for the steering column (5).
6. Remove the caps from the two fittings in the steering

control valve (6) and remove the plugs from the two
hoses Connect the hoses to the fittings
7. Remove the caps from the three hoses in the steering

control valve (6) and remove the plugs from the tube fit-
tings. Connect the tube fittings to the hoses.
8. Connect the wiring for the turn signals.
11. Install the steering wheel (2) and install the nut (4).
Tighten the nut (4) to 384 to 444 pound-inches (43 to 50
Nm).
12. Install the cover (1) in the center of the steering

wheel (2).
13. Start the engine and run the engine at low idle.
14. Turn the steering wheel all the way to the right and
left several times to remove any air from the steering
system.
15. Stop the engine and check for oil leaks.
16. Check the level of the oil in the reservoir and add oil
as required.
17. Install the access panel.
18. Close the access cover at the rear of the hood.

5001-9
2. STEERING WHEEL
~ 5. STEERING COLUMN
B902295J

5001-10
STEERING COLUMN
Removal 6. Remove the three screws that hold the rear cover for
the steering column (5).
1. Park the machine on a level surface and apply the
parking brake.
2. Lower the bucket to the floor and put the backhoe in

the transport position.
3. Remove the cover (1) from the steering wheel (2). The
cover (1) is held by the fit of an O-ring (3).
7. Remove the front and rear covers.
4. Loosen and remove the nut (4) that holds the steering
wheel (2) in place.
8. Disconnect the wiring for the turn signals.
5 Use the puller shown on page 4 to loosen and

remove the steering wheel (2).

5001-11
2. STEERING WHEEL
-,
••••.'" 5. STEERING COLUMN
B902295J

5001-12
9. Loosen and remove the screws that hold the control 11. Remove the bulbs for the turn signals and discon-
console. nect the wiring from the lamp and warning flasher swit-
ches.
10 Remove the control console

12. Loosen and remove the two cap screws and locK
washers that fasten the steering column (5) to the
steering control valve.
13. Loosen and remove the nut (13) and lock washer
that fasten the power shuttle rod (14) for the power
shuttle to the sleeve (15). Move the power shuttle rod
(14) out of the way
14. Loosen the nut and bolt on the clamp (16) that holds
the roll pin (17) in the sleeve (15). Remove the clamp
(16).
15. Remove the roll pin (17) from the control rod (19)
and sleeve.
16. Remove the sleeve (15) from the control rod (19).
17. Loosen and remove the bolts (18), lock washers,

and nuts that fasten the bracket (8) for the steering
column (5) to the firewall.
18. Lift the bracket (8) for the steering column (5) and
pull the control rod (19) through the self-aligning
bearing at the left side of the firewall Remove the
bracket (8) and the control rod (19).
19. Loosen the nuts and lock washers on the bolts (9)
20. Remove the steering column (5) from the bracket

(8).

5001-13
NOTCH
B902308J

5001-14
Installation 11. Install the bulbs for the turn signals and connect the
wiring for the lamp and warning flasher switches.
1. Install the steering column (5) through the bracket
(8)
2. Tighten the nuts and lock washers on the bolts (9)

3. Install the bracket (8) for the steering column (5) and
install the control rod (19) through the self-aligning
bearing at the left side of the firewall.
4. Install the bolts (18), lock washers, and nuts that

fasten the bracket (8) for the steering column (5) to the
firewall. Tighten the nuts.
5 Install the sleeve (15) on the end of the control rod 12. Install the control console.
(19).
6. Align the hole in the sleeve (15) with the hole in the
control rod (19) and install the roll pin (17)
7. Install the clamp (16) over the sleeve (15) and tighten
the clamp (16).
8. Connect the power shuttle rod (14) for the power

shuttle to the sleeve (15) on the control rod (19). Install
the lock washer and nut (13) and tighten the nut (13).
9. If adjustment of the power shuttle linkage is required,

see Shuttle Control Linkage Adjustment in Section
9001.
13. Install the screws that hold the control console.
10 Install the two cap screws and lock washers that Tighten the screws.
fasten the steering column (5) to the steering control
valve. Tighten the cap screws.

5001-15
B90230BJ

5001-16
14. Connect the wiring for the turn signals. 16. Install and tighten the three screws that hold the rear
cover for the steering column (5).
15. Install the front and rear covers.

17. Install the steering wheel (2) and install the nut (4)
Tighten the nut (4) to 384 to 444 pound-inches (43 to 50
Nm).
18. Install the cover (1) in the center of the steering

wheel (2).

5001-17
2. STEERING WHEEL
5. STEERING COLUMN
B902295J

5001-18
STEERING CYLINDER, TWO WHEEL DRIVE MACHINES

Removal Installation
1. Clean the hose connections (1) at the steering 1, Install the steering cylinder (2) on the axle (11) and
cylinder (2). install the cap screws (9) and hardened washers (10),
2. Put an identification tag on one of the hoses (1). 2, Tighten the cap screws (9) to 580 to 696 pound-feet
(786 to 944 Nrn).
3. Disconnect the hoses (1) from the steering cylinder
(2), 3 Align the steering links (7) with the piston rod eyes
and install the pins (6),
4, Install a plug in each hose (1),
4, Install the bolts (5), lock washers (4), and nuts (3),
5. Loosen and remove the nuts (3), lock washers (4), Tighten the nuts (3),
and bolts (5) for the pins (6) that fasten the steering links
(7) to the piston rod eyes of the steering cylinder (2), 5, Remove the plugs from the hoses (1) and connect
the hoses (1) to the steering cylinder (2),
6, Drive the pins (6) out of the steering links (7) and the
piston rod eyes, Do not damage the grease fittings (8) 6 Lubricate the pins (6) for the steering links (7) with the
in the pins (6). grease specified in Section 1002,
7, Loosen and remove the cap screws (9) and 7, Check and adjust toe-in according to instructions in
hardened washers (10) that fasten the steering cylinder Section 5007,
(2) to the axle (11). There are access holes for the cap
screws (9) at each side of the front of the axle (11).
8. Remove the steering cylinder (2),
Bur 8-17260 Issued 1-91 Printed in U,SA

5001-19
2. STEERING
CYLINDER
7. STEERING LINK
8892200J
Bur 8-17260
5001-20
STEERING CYLINDER, FOUR WHEEL DRIVE MACHINES

Removal STEP 6
NOTE: The following photographs show the steering

cylinder being removed from the axle with the axle
removed from the machine. It is not necessary to
remove the axle from the machine to remove the
steering cylinder.
STEP 1
Clean the hose connections at the steering cylinder.
STEP 2
Fasten an identification tag to one of the hoses to the
steering cylinder
Remove the nut and remove the ball joint from the arm.
STEP 3
Disconnect the hoses from the steering cylinder. Install
a plug in each hose and a cap on each fitting.
STEP 7
Repeat steps 4, 5, and 6 for the other end of the axle
STEP 4
STEP 8
Remove the cotter pin from the ball joint and loosen the .:e9g§
nut several turns. Do not remove the nut at this time Install the CAS-2151 tool on the flats of the piston rod
and install a wrench on the tie rod. Prevent the piston
rod from turning and loosen the tie rod.
STEP 5
STEP 9
Install the CAS-1 0486 puller as shown and tighten the

screw. Remove the tie rod and ball joint assembly from the
piston rod.

5001-21
STEP 10 STEP 13
Loosen and remove the cap screws and lock washers Remove the steering cylinder from the axle.
that fasten the steering cylinder to the axle.
Installation
STEP 11
STEP 14
NOTE: The photograph shows a plug being removed

from the steering cylinder. A hose fitting will be installed Install the steering cylinder in the axle.
in your steering cylinder
Remove the hose fitting STEP 15
STEP 12
Install the cap screws and lock washers that fasten the
steering cylinder to the axle. Tighten the cap screws to
66 to 79 pound-feet (90 to 107 Nm).
Hit the steering cylinder with a soft hammer to drive the
steering cylinder out of the axle.

5001-22
STEP 16 STEP 19
B907621OM
NOTE: The photograph shows a plug being installed in Install the ball joint in the arm.
the steering cylinder. A hose fitting will be installed in
your steering cylinder.
STEP 20
Install the hose fitting.
STEP 17
Install the nut on the ball joint and tighten the nut to 170
pound-feet (230 Nm).
STEP 21
Install a new cotter pin in the nut and ball joint.
STEP 22
Repeat steps 19, 20, and 21 for the other end of the
STEP 18 axle.
Install the CAS-2151 tool on the flats of the piston rod

and install a wrench on the tie rod. Prevent the piston
rod from turning and tighten the tie rod.

5001-23
STEP 23 STEP 26
Connect the hoses to the fittings in the steering cylinder Stop the engine and check for oil leaks.
STEP 24 STEP 27
Start the engine and run the engine at low idle. Check the level of the oil in the reservoir and add oil as
required.
STEP 25
Turn the steering wheel all the way to the right and left
several times to remove any air from the steering
system.

5001-24
FRONT AXLE - TWO WHEEL DRIVE MACHINES

Removal 4. Start the pivot pin (2) into the frame, spacers (6) and
axle (5).
1. Raise the front wheels above the floor and use
suitable stands to hold the machine in place. 5. Drive the pivot pin (2) into the rear pivot of the axle (5)
but not through the rear pivot.
2. Loosen and remove the wheel bolts and remove the
wheels. 6 Install the thin spacer (6) between the rear of the axle
(5) and the frame. Use spacer (6) to remove any end
3. Fasten an identification tag to one of the hoses forthe play.
steering cylinder.
7. Drive the pivot pin (2) through the rear pivot and the
4. Disconnect the hoses from the fittings in the steering frame.
cylinder. Install a plug in each hose and a cap on each
fitting. 8. Install the flat washers (3) and snap ring (1) on the
tapered end of the pivot pin (2).
5. Remove the snap ring (1) from the rear of the pivot pin
(2) 9 Hit the pivot pin (2) to move the pivot pin (2) toward
the front of the machine as far as possible.
6. Remove the flat washers (3).
10. Check the end play between the frame and the snap
7. Loosen and remove the grease fitting (4) from the ring (1) on the pivot pin (2) at the front of the machine.
end of the pivot pin (2). Use flat washers (3) as required to remove any end
play.
8. Put a floor jack under the axle (5) to hold the axle (5) in
position. 11. Install a grease fitting (4) in each end of the pivot pin
(2). Tighten the grease fittings (4).
9. Drive the pivot pin (2) out of the frame and through
the hole in the counterweight. 12. Loosen and remove the plugs from the hoses and
the caps from the fittings for the steering cylinder.
10 Spacers (6) are used at the front and rear of the axle
(5), between the axle (5) and the frame. Lower the axle 13. Connect the hoses to the steering cylinder.
(5) and remove the spacers (6)
14. Install the wheels and wheel bolts. DO NOT use an
11. Remove the axle (5) from under the machine impact wrench to tighten the wheel bolts.
Installation 15. Tighten the wheel bolts to 115 to 150 pound-feet

(156 to 203 Nm).
1. Raise the axle (5) into alignment with the machine.
16 Remove the stands and lower the wheels to the
2. Loosen and remove the grease fitting (4) from the floor.
other end of the pivot pin (2). Install the pivot pin (2)
through the counterweight with the tapered end of the 17. Lubricate the pivot pin (2) for the axle (5).
pivot pin (2) toward the rear of the machine.
3. Install a thick spacer (6) and a thin spacer (6)

between the front of the axle (5) and the frame. Use
spacer (6) to remove any end play.

5001-25
B902461J

5001-26
FRONT AXLE - FOUR WHEEL DRIVE MACHINES

1. Loosen and remove the nuts. flat washers, and bolts 1. Raise the axle (4) into alignment with the frame.
that fasten the bar (1) to the guard (2) for the drive shaft
(3). Remove the bar (1). 2. Loosen and remove the grease fitting (8) from the
other end of the pivot pin (6). Install the pivot pin (6)
2. Put a floor jack under the guard (2) to hold the guard through the counterweight with the tapered end of the
(2) in position. pivot pin (6) toward the rear of the machine.
3. Loosen and remove the nuts and flat washers from 3. Install a thick spacer (9) and a thin spacer (9)
the bolts that fasten the guard (2) for the drive shaft (3) between the front of the axle (4) and the frame.
to the frame. Do not remove the bolts at this time.
4. Start the pivot pin (6) into the frame, spacers (9) and
4. Lower the guard (2) and remove the guard (2) from axle (4).
under the machine.
5 Drive the pivot pin (6) into the rear pivot of the axle (4)
5. Loosen and remove the cap screws that fasten the but not through the rear pivot.
drive shaft (3) to the flange on the trans axle and remove
the drive shaft (3). 6. Install the thin spacer (9) between the rear of the axle
(4) and the frame. Use spacers (9) as required for
6. Raise the front wheels above the floor and use minimum end play between the frame and the axle (4).
suitable stands to hold the machine in place.
7. Drive the pivot pin (6) through the rear pivot and the
7. Install blocks between the axle stops and the frame to frame.
prevent the axle (4) from tilting.
8. Install the flat washers (7) and snap ring (5) on the
8. Loosen and remove the wheel nuts and hardened tapered end of the pivot pin (6).
washers and remove the wheels.
9. Hit the pivot pin (6) to move the pivot pin (6) toward
9. Fasten an identification tag to one of the hoses for the the front of the machine as far as possible.
steering cylinder.
10. Check the end play between the frame and the snap
10. Disconnect the hoses from the fittings in the ring (5) on the pivot pin (6) at the front of the machine.
steering cylinder. Install a plug in each hose and a cap Use flat washers (7) as required to remove any end
on each fitting. play
11. Remove the snap ring (5) from the rear of the pivot 11. Install a grease fitting (8) in each end of the pivot pin
pin (6). (6). Tighten the grease fittings (8).
12. Remove the flat washers (7). 12. Loosen and remove the plugs from the hoses and
the caps from the fittings for the steering cylinder.
13. Loosen and remove the grease fitting (8) from the
end of the pivot pin (6). 13. Connect the hoses to the steering cylinder.
14. Put a floor jack under the axle (4) to hold the axle (4) 14. Install the wheels, hardened washers, and nuts. DO
in position. NOT use an impact wrench to tighten the nuts.
15. Drive the pivot pin (6) out of the frame and through 15. Tighten the nuts to 200 to 260 pound-feet (270 to
the hole in the counterweight. 352 Nm).
16. Spacers (9) are used at the front and rear of the axle 16. Remove the blocks from between the axle stops
(4), between the axle (4) and the frame. Lower the axle and the frame.
(4) and remove the spacers (9).
17. Remove the stands and lower the wheels to the
17. Remove the axle (4) from under the machine. floor.

5001-27
8. GREASE
FITTING
~19
6. PIVOT PIN • ~ 5. SNAP
_' ~ 1 RING
;\: 7. FLAT WASHER (USE

AS REQUIRED FOR
MINIMUM END PLAY)
7. FLAT .. :.~
WASHER ~ " ., .i:\:
~"\ \.",." ...
"\
C>~'~ . \
8. GREASE FITTING t:1 5. SNAP \
\
RING
\
\
TIGHTEN TO 200 TO 260 \
POUND-FEET (270 TO 352 Nm) \
\
@@ \
\
9. SPACER ~
~~ 9. SPACER (USE AS REQUIRED
~ FOR MINIMUM END PLAY)
,~
/~ TIGHTEN TO 504 TO 576
~ POUND-INCHES (58 TO 65 Nm)
B902368J

5001-28
18. Lubricate the pivot pin (6) for the axle (4). 22. Raise the guard (2) into alignment with the brackets
on the frame and install the bolts, flat washers, and
19. Install the drive shaft (3) and the cap screws that nuts. Remove the floor jack
fasten the drive shaft (3) to the flange on the transaxle.
23. Tighten the nuts to 100 to 150 pound-feet (136 to
20. Tighten the cap screws to 504 to 576 pound-inches 203 Nm).
(58 to 65 Nm).
24. Install the bar (1) on the guard (2) and install the
21. Use a floor jack and install the guard (2) under the bolts, flat washers, and nuts. Tighten the nuts.
drive shaft (3).

5001-29
8902368J

Section
5002
SPECIFICATIONS, SCHEMATIC AND TROUBLESHOOTING

5002-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TOOL 2
TROUBLESHOOTING PROCEDURE 3
CHECKING THE PRESSURE SETTING OF THE RELIEF VALVE .4
ADJUSTING THE PRESSURE SETTING OF THE RELIEF VALVE ..4
CHECKING PISTON PACKING FOR THE STEERING CYLINDER 5
SCHEMATiC 9
SPECIFICATIONS
Location of relief valve In inlet section of loader control valve
Pressure setting 2450 to 2600 psi at full throttle

(16 893 to 17 927 kPa, 169 to 179 bar)
SPECIAL TOOL
In the U.S. a~d Canada, order the tools from
Service Tools
P.O. Box 314
Owatonna. MN 55060
In Europe order the tools from
VL Churchill Ltd
PO. Box 3, Daventry
Northants, NN11 4NF
England.
CAS-1804 or CAS-10111 Pressure Fitting Kit


5002-3
TROUBLESHOOTING PROCEDURE
Check the machine for oil leaks and damaged or missing parts. Repair as required.
Add oil specified in Section 1002.
See Section 8002 for troubleshooting instructions.
Connect the hoses according to the schematic.
Does the steering control valve return to NEUTRAL

when the steering wheel is not being turned?
Replace or repair the steering control valve ac-

cording to instructions in Section 5004 or 5005.
Troubleshooting complete.
Repair as required according to instructions in

Section 5006.
Replace or repair the pump according to in-

structions in Section 8004.
Issued 1-91 Printedin U.S.A.

5002-4
CHECKING THE PRESSURE SETIING OF THE RELIEF VALVE

1. The oil must be at operating temperature. To heat the 5. Connect a 5000 psi (34473 kPa, 345 bar) gauge to
oil, do steps 2 through 4. the quick disconnect fitting in the pressure line from the
pump. The quick disconnect fitting is located just
2. With the engine running at full throttle, hold the loader forward of the battery box at the left side of the machine.
control lever in the ROLLBACK position for 15 seconds. The hose for the gauge must be long enough 'to read
the gauge from the operators seat.
3. Return the loader control lever to the NEUTRAL position
for 15 seconds. 6. With the engine running at full throttle, turn and hold
the steering wheel all the way to the right or to the left
4. Repeat steps 2 and 3 until the temperature of the oil is and read the gauge. Make a record of the reading.
125°F (51°C) or the side of the reservoir is very warm.
7. Decrease the engine speed to low idle for two
minutes and stop the engine.
8. If the reading was not between 2450 and 2600 psi (16
893 to 17 927 kPa, 169 to 179 bar), adjust the setting of
the relief valve.
ADJUSTING THE PRESSURE SETIING OF THE RELIEF VALVE

1. The relief valve is located in the inlet section of the 3. Prevent the adjusting screw from turning and tighten
loader control valve. the lock nut.
2. Loosen the lock nut on the adjusting screw and turn 4. Check the setting of the relief valve again.
the adjusting screw clockwise to increase the setting or
turn the adjusting screw counterclockwise to decrease
the setting.
CHECKING PISTON PACKING FOR THE STEERING CYLINDER

1. Apply the parking brake and lower the loader bucket 5. Start the engine and run the engine at full throttle.
to the floor.
6. Turn the steering wheel all the way to the right and
2. Turn the steering wheel all the way to the right and continue to turn the steering wheel to the right while
stop the engine. another person checks for leakage at the open fitting.
3. Disconnect the hose at the left side of the steering 7. If there is constant leakage, the piston packing is
cylinder. damaged and must be repaired. See Section 5006 for
repair instructions.
4. Install a plug in the hose. The thread size is 3/4-16.

5002-5
o STEERING CONTROL VALVE
Controls oil flow to the steering cylinder.
1. Inlet
2. Outlet
3. Pilot
4. Check Valve
5. Spool and Sleeve Assembly
6. Drive Unk
7. Gerotor
Controls the flow of oil to the steering cylinders.
B891058J

5002-6
INLET SECTION OF LOADER CONTROL VALVE

AND FLOW CONTROL VALVE
1. Inlet
2. To Steering Control Valve
3. Pilot Pressure Port
4. Relief Valve for
Steering System
5. Spring
6. Spool
Controls flow of oil and pressure for the steering system.
B891059J

5002-7
1. Backhoe Section
2. Loader Section
3. Outlet
4. Inlet
5. Drive Shaft
6. Coupling
Generates oil flow for the complete hydraulic system.
B891060J
Bur 8-17270 Issued 1·91 Printed in U.S.A.

5002-8
1. Inlet
2. To Reservoir
3. To Oil Cooler
4. From Steering Control Valve
5. Filter
6. Bypass Valve
7. Switch
8. Check Valve
Cleans oil returning to the reservoir.
B891 061 J

5002-9
DIRECTION OF FLOW
Shows direction of oil flow.
PILOT PRESSURE
Pressure used to control
another component.
CROSSOVER LINES
CONNECTING LINES
FILTER OR SCREEN
OIL COOLER
CHECK VALVE
DOUBLE ACTING CYLINDER

Section
5004
STEERING CONTROL VALVE - EATON

CASE CORPORATION
Issued October 1989
5004-2
TABLE OF CONTENTS
SPECfFICATIONS . . 2
SPECIAL TOOlS . .. 2
DiSASSEMBly................................... . .. 3
INSPECTION.............. ..9
ASSEMBLY ... . 12
SPECIFICATIONS
Rotor and stator clearance . ....................................... 0.005 inch (0.13 mm)
Special Torques
Allen head plug .. ................................................. 100 pound-inches (11 Nm)
Ferry head screws ..225 to 275 pound-inches (25 to 31 Nm)
SPECIAL TOOLS
dresses:
In the U.SA and Canada
Service Tools
PO. Box 314
Owatonna. Minnesota 55060
In Europe
VL Churchill Ltd.
PO. Box 3. Daventry
B785606M
Northants. NN11 4NF
England CAS-1239 Centering Spring Installation Tool
This tool is first used on page 5004-14.

5004-3
DISASSEMBLY
STEP 1 STEP 4
Put the steering control valve in the vise so the end plate Remove the end plate.
is up. Use a punch and hammer and hit the Ferry head
screws to make the Ferry head screws easier to
remove. STEP 5
STEP 2
Lift the metering gear set, spacer, drive shaft, and

spacer plate as an assembly from the body.
Loosen the Ferry head screws.

STEP 6
STEP 3
8523536M
Separate the metering gear set, spacer, drive shaft and
spacer plate.
Remove the Ferry head screws.
Bur 8-12440 Issued 10-89 Printed in ·U.S.A.

5004-4
STEP 10
B8471788M
Remove the rotor from the stator Remove and discard the O-ring from the body.
STEP 8 STEP 11
._;.,
.•.••.
>zfq". ""'?IT •••.•• ;;:~'.<,'- ,,".
'B877704M
Remove and discard the O-ring from the stator. Find the anticavitation valves in the body. Put identifica-
tion marks on the body for use during assembly.
STEP 9
STEP 12
B8472388M
Remove and discard the O-ring from the end plate. ......."'.." .."'.~..'0&'~~~.,,".",
•..".O_••. , ... ,,, •. V... ... . ..... ·77698M
Remove the springs, pins, and balls from the ports in
the body.

5004-5
STEP 13 STEP 16
8523923M
Remove the body of the steering control valve from the Remove the bearing.
vise. Push the spool and sleeve part of the way out of
the bottom of the body. Turn the sleeve and spool in
both directions and pull the sleeve and spool out of the STEP 17
body. The pin inside of the sleeve and spool can keep
the sleeve and spool from coming out of the body. If the
sleeve and spool cannot be pushed out of the body
easily, use a magnet to move the pin inside the spool
one way or the other.
STEP 14
8523925M
Remove the other washer.
STEP 18
Remove and discard the spacer from the spool.
STEP 15
8523927M
Use a punch to push the pin out of the sleeve and spool.
8523921M
Remove the washer.

5004-6
STEP 19 STEP 22
B523929M 1888M
Pull the spool straight out of the sleeve. Remove the Remove the Allen head plug from the body of the
centering springs. steering control valve.
STEP 20 STEP 23
Push the centering springs out of the spool. There are Install a No. 8-32 screw in the seat for the check valve.
four centering springs and two spacers Do not lose
any of the centering springs.
STEP 24
STEP 21
Use pliers to pull the seat out of the body of the steering
control valve.
Remove the seal from the gland.

5004-7
STEP 25
';;;:ijki0i.+iri,jwJ~~&3817M '". ".·,..".: .. ·~.>"-'";:.,.;"V;:; ..,;-;::.:J::-.·;·.· ;-;-.

B523935M
Remove the body of the steering control valve from the Remove the O-ring and backup ring from the bottom of
vise. Turn the body up and let the steel ball and retainer the gland. Discard the O-ring and backup ring.
fallout of the body
STEP 28
STEP 26
-..._._.- .. ,~._ ... ~~ ...~?Bs47C

:.~-;':;::., ..•...
. .;...: : . ..:.
8523820M Put the body in the vise with the gland up. Move the end
of the retaining ring out of the goove in the body.
Remove the retaining ring.
STEP 29
B523822M
Remove and discard the O-rings from the seat.
~-
The gland in the body of the steering control valve can
be difficult to remove. Remove the body of the steering
control valve from the vise. Put the body in a press with
the gland down. Put blocks under the body to hold the
body off the press table. Press the gland out of the
body.
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 STEP 32
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.
Inspect the check valve in the inlet port of the body.
Use this method until all rough places have been
Push the check valve in to see if the spring works cor-
removed. Make sure that the part is kept flat on the
rectly. If the check valve is worn or damaged, use a
emery cloth as the part is moved across the emery
complete new steering control valve.
cloth. Clean the parts in cleaning solvent to remove any
grit on the parts.
STEP 31
81758A88J
Inspect the Allen head plug, seat, steel ball, and

retainer for damage or wear. Use new parts as required.
STEP 34
B1757A88J
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.

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.

5004-11
2. END PLATE
6. STATOR
9. O-RING
8. METERING GEAR SET
27. WASHER
8871959J

5004-12
ASSEMBLY
STEP 38 STEP 41
1. LARGE
O-RING
'~~;*a8M 852384 1M
Install a new O-ring in the bore for the gland. Lubricate Install new O-rings on the seat for the check valve, Lub-
the O-ring with petroleum jelly. ricate the O-rings with petroleum jelly, The large O-ring
must be installed on the end of the seat that has
threads,
STEP 39
STEP 42
1588M
Put the body of the steering control valve in a vise with
the gland end up Drive the gland into the body of the ~,_ B§J3622M
steering control valve until the gland stops moving. Install the retainer in the bore for the check valve, Make
sure the retainer is flat in the bottom of the bore,
STEP 40
STEP 43
Use a screwdriver and punch to start the end of the re-

taining ring into the groove in the body. Push the re- Install the steel ball in the bore for the check valve,
taining ring into the groove in the body.
Bur 8-12440 Issued 10-89 Printed in U,S.A.

5004-13
STEP 44 STEP 47
_~
_,__~
__
,__
~.~_,~_~~_,__
._~, .. -.---··W·~__
sse.
. ,~
Install the seat for the check valve in the bore. The end Install the backup ring in the bottom of the gland. Use
of the seat with threads must be up. petroleum jelly to hold the backup ring in place
STEP 45
Apply a small amount of 242 Loctite on the threads of

the Allen head plug.
STEP 46 STEP 49
___ ,~,___ p1888M

.,_." .",.~
•.•"."..,~.'-"'-""""-"W'W"-"' ..~,... 1588M
Install and tighten the Allen head plug to 100 pound- Install the seal in the gland with the lip for the seal
inches (11 Nm). toward the outside of the body. Drive the seal into the
gland until the seal stops moving.

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 po-
sition. Turn the sleeve and move the sleeve on the spool
STEP 51 until the slots in the sleeve and spool for the centering
springs are in alignment.
STEP 54
8523635M
Put clean oil on the outside of the spool.
STEP 52
Install the tool shown on page 5004-2 through the slot
for the centering springs.
STEP 55
23637M
Install the spool in the sleeve. The spool must be in-
stalled straight into the sleeve. Turn the spool in both di-
rections as the spool is pushed into the sleeve.
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.
5004-15
STEP 56 STEP 59
B523919M
Push the centering springs into the spool. Move the tool Install a new spacer on the spool.
as necessary to put the centering springs in position.
STEP 60
STEP 57
8523728M
8523721M Put clean oil on the outside of the sleeve and spool.
Install the pin in the sleeve through the spool.
STEP 61
STEP 58
8523731M
Put clean oil on the bore in the body of the steering
Install the washer, bearing, and the other washer on the control valve.
spool.

5004-16
STEP 62 STEP 65
B877701M
The sleeve and spool must be installed straight into the Install the pins in the ports.
body of the steering control valve
STEP 66
STEP 63
Install the springs in the pins.

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. STEP 67
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.
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.

5004-17
STEP 68 STEP 71
B473688M B8480388M
Align the rotor and stator and push the rotor into the Install the spacer place on the stator. Turn the spacer
stator. plate to align the holes with the holes in the stator.
NOTE: The drive shaft must be in the rotor in the STEP 72

correct position. See step 69.
STEP 69
Put the body of the steering control valve in the vise.

Apply petroleum jelly on the a-ring for the body of the
.24:lj2 steering control valve. Install the a-ring in the groove in
Engage the teeth on the drive shaft in the teeth in the the body.
rotor so the slot in the end of the drive shaft is between
two teeth on the rotor.
STEP 73
STEP 70
Lower the drive shaft into the spool and engage the pin
B524117M with the slot in the drive shaft. DO NOT let the drive shaft
Check the position of the slot in the drive shaft again come out of the rotor. Turn the stator and spacer plate
and make sure the slot is in the correct position. to align these parts with the body.

5004-18
STEP 74 STEP 77
~. ~ B524128M
Install the spacer in the rotor on top of the drive shaft. Install the end plate on the metering gear set. Align the
holes in the end plate with the holes in the stator.
STEP 75
STEP 78
Put clean oil on the metering gear set, spacer plate, and
drive shaft assembly. Install the Ferry head screws.
STEP 76 STEP 79
B8472388M B8450288M
Put petroleum jelly on the O-ring for the end plate. Install Tighten the Ferry head screws to 100 to 150 pound-
the O-ring in the groove in the end plate. inches (11 to 17 Nm) in the sequence shown.

5004-19
STEP 80
Tighten the Ferry head screws to 225 to 275 pound-

inches (25 to 31 Nm) in the sequence shown in step 79

5004-20
1. INLET
CHECK VALVE
2. DRIVE SHAFT
SECTION A-A
8871967J
SECTION C-C
SECTION B-B

Section
5005
STEERING CONTROL VALVE - DANFOSS

Issued November 1989
5005-2
TABLE OF CONTENTS
SPECiFiCATIONS ..... . 2
SPECIAL TOOL ...........2
DISASSEMBLY ....3
INSPECTION . . 7
ASSEMBLY . 10
SPECIFICATIONS
Rotor and stator clearance .. ..0.005 inch (0.13 mm)
Special torques
Cap screws for fastening end plate. .. 212 to 319 pound-inches (24 to 36 Nm)
SPECIAL TOOL
dresses:
In the U.SA and Canada
Service Tools
P.O. Box 314
In Europe
VL Churchill Ltd.
PO Box 3, Daventry
B785606M
Northants, NN11 4NF
England CAS-1239 Centering Spring Tool
This tool is first used on page 5005-11.

5005-3
DISASSEMBL Y
STEP 1 STEP 4
__ """"'""'............ 870981 OM
Put the steering control valve in the vise so the end plate Remove and discard the O-ring from the stator
is up. Loosen the cap screws.
STEP 5
STEP 2
B709812M Remove the metering gear set and spacer from the
Remove the cap screws and flat washers One cap body.
screw has a guide pin.
STEP 6
STEP 3
Remove the drive shaft.

Remove the end plate

5005-4
STEP 7 STEP 10
i!t/ipI
C
; ···i<.O!lIJIl9834M
Remove the spacer plate. Remove and discard the O-ring from the body.
STEP 8 STEP 11
B710010M
Separate the metering gear set and spacer. Loosen the plug in the body.
STEP 9 STEP 12
Remove and discard the other O-ring from the stator. Remove the plug.

5005-5
STEP 13 STEP 16
B709912M B709920M
Remove the body of the steering control valve from the Remove the bearing,
vise. Turn the body up and let the steel balls, plungers,
and springs fall out of the body.
STEP 14
B710116M
B709916M Remove the other washer.
Push the spool and sleeve part of the way out of the
bottom of the body. Turn the sleeve and spool in both
directions and pull the sleeve and spool out of the body. STEP 18
The pin inside the spool can move out of the sleeve and
spool and keep the sleeve and spool from coming out
of the body, If the sleeve and spool cannot be pushed
out of the body easily, use a magnet to move the pin
inside the spool one way or the other,
STEP 15
B709926M
B709918M
Remove the washer.

5505-6
STEP 19 STEP 22
B709928M
Use a punch to push the pin out of the sleeve and spool. Use an acceptable tool through the bore of the body
and remove the inner seal. Discard the inner seal.
STEP 20
STEP 23
Pull the spool straight out of the sleeve. Turn the spool
in both directions as the spool is pulled out of the Remove the outer seal from the bore. Discard the outer
sleeve. seal.
STEP 21
B709932M
Push the centering springs out of the spool. There are
four centering springs. Do not lose any of the centering
springs.

5005-7
INSPECTION
Clean all parts in cleaning solvent. Put the parts on STEP 25
paper towels until the parts are dry. Do not use cloths to
wipe the parts dry.
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 t,./~710008M
check to see if the rough places have been removed.
Inspect the check valve in the inlet port of the body
Use this method until all rough places have been
Push the check valve in to see if the spring works cor-
removed. Make sure that the part is kept flat on the
rectly If the check valve is worn or damaged, use a
emery cloth as the part is moved across the emery
complete new steering control valve.
cloth Clean the parts in cleaning solvent to remove any
grit on the parts.
STEP 26
1. WASHER
STEP 24
Check the washers (1) and bearing (2) for damage or

wear. Use new parts as needed.
STEP 27
3. BALL 3. BALL
B871978R
If the spool (2), sleeve (3), or bore in the body (1) of the 1. SPRING
steering control valve is damaged or worn, use a
complete new steering control valve. The spool (2),
sleeve (3), or body of the steering control valve are not 2. PLUNGER
available separately
B709912A
Inspect the springs (1), plungers (2), and bs.lls (3) for
damage or wear. Use new parts as needed.

5005-8
8523912M
Use a feeler gauge to measure the clearance between
the rotor and stator. If clearance is more than 0.005 inch
(0.13 mm), a new metering gear set must be used.

5005-9
12. SPOOL
20. CENTERING
SPRINGS
17. O-RING
21. O-RING
B871956R

5005-10
ASSEMBLY
STEP 29 STEP 32
B710018M 8710030M
Lubricate the inner seal with clean oil. Use an acceptable driver and hammer and drive the
outer seal against the seat in the bore.
STEP 30
STEP 33
The inner seal is not difficult to install. Install the inner B710034M
seal through the opposite end of the bore shown in the Put clean oil on the inside of the sleeve.
photograph. Use your fingers to seat the inner seal
against the body. Make sure the lips of the inner seal
are toward the inside of the body STEP 34
STEP 31
8710036M
Put clean oil on the outside of the spool.
G!;f§;j ~028M
Install the outer seal in the body with the lips of the outer
seal toward the outside of the body.

5005-11
STEP 35 STEP 38
1. FLAT SPRING 1. FLAT SPRING
<r
2. CURVED SPRINGS
B871957R
B7101 02M Install the centering springs as shown in the illustration.

Install the spool in the sleeve. The spool must be in-
stalled straight into the sleeve. Turn the spool in both di-
rections as the spool is pushed into the sleeve. STEP 39
STEP 36
,.1Ql2Q~_
Put the two flat springs in the slot of the tool with the two
curved springs between the flat springs.
Put the spool and sleeve in a vise with soft jaws. Tighten
the vise just enough to hold the spool and sleeve in po- STEP 40
sition . Turn the sleeve and move the sleeve on the spool
until the slots in the sleeve and spool for the centering
springs are in alignment.
STEP 37
Use your thumb and finger to compress the centering

springs. Push the centering springs into the spool.
Move the tool as necessary to put the centering springs
in position.
Install the tool shown on page 5005-2 through the slot

for the centering springs.

5005-12
STEP 41 STEP 44
8710118M
Install the retaining ring, The retaining ring must be able Put clean oil on the outside of the sleeve and spool.
to rotate free of the centering springs.
STEP 45
STEP 42
;-.'-~':Z-~"-:>-;':'<~."~::<:$:~~~-"~'
8710126M
8710120M Install the pin in the sleeve and through the spool.
Install the washer, bearing, and the other washer on the
spool. See step 43.
STEP 46
Put clean oil in the bore in the body.
The washer with the chamfer must be installed nearest

the sleeve as shown in the illustration.

5005-13
STEP 47 STEP 50
B710128M
The sleeve and spool must be installed straight into the Tighten the plug
body of the steering contro Ivalve. The pin can move out
of the sleeve and spool. If the pin moves out of the
sleeve and spool, the pin can keep the sleeve and STEP 51
spool from being pushed into the body. Hold the sleeve
and spool in position in the body. Put the end of the
sleeve and spool on the bench and lower the body onto
the sleeve and spool.
STEP 48
Install one of the small steel balls
STEP 52
Put the body of the steering control valve in the vise.

Install the large steel ball.
STEP 49
Install the other small steel ball in the port shown.
Install the plug.

5005-14
STEP 53 STEP 56
B710218M
Install the spring and plunger. Apply petroleum jelly on each O-ring for the stator
Install an O-ring in the groove in each side of the stator.
STEP 54
STEP 57
Install the other spring and plunger. B710220M

Align the rotor and stator and install the rotor in the
stator.
STEP 55
STEP 58
Install the O-ring in the groove in the body.

B710224M
The drive shaft must be installed in the rotor in the
correct position. Engage the teeth on the drive shaft
and the teeth in the rotor so the slot in the end of the
drive shaft is between the two teeth on the rotor.

5005-15
STEP 59 STEP 61
8710228M 'B710232M
Install the spacer plate on the stator. Turn the spacer Put clean oil on the metering gear set. spacer plate, and
plate to align the holes with the holes in the stator. drive shaft assembly.
STEP 60 STEP 62
710212M
Hold the metering gear set, spacer plate, and drive Install the spacer in the rotor on top of the drive shaft.
shaft as an assembly in position over the body of the
steering control valve. Turn the metering gear set,
spacer plate, and drive shaft assembly to put the slot in STEP 63
the end of the drive shaft in alignment with the pin inside
the spool Lower the metering gear set, spacer plate,
and drive shaft assembly into position on the body.
Turn the metering gear set, spacer plate, and drive
shaft assembly a small amount in one direction or the
other until the slot inthe drive shaft is engaged with the
pin inside of the spool Turn the spacer plate and stator
to align the ho!es with the holes in the body.
709820M
Install the end plate. Align the holes in the end plate with
the holes in the stator.

5005-16
STEP 64 STEP 66
B709816M
Install the cap screw with the guide pin in the hole Tighten the cap screws to 100 to 150 pound-inches (11
shown. to 17 Nm) in the sequence shown.
STEP 65 STEP 67
B709812M
Install the remaining cap screws and flat washers. Tighten the cap screws to 212 to 319 pound-inches (24
to 36 Nm) in the sequence shown in step 66.

Section
5006
STEERING CYLINDER REPAIR

Issued January 1991
5006-2
TABLE OF CONTENTS
SPECIFICATIONS 3
TWO WHEEL DRIVE STEERING CYLINDER .4
Disassembly 4
Inspection 4
Assembly 6
FOUR WHEEL DRIVE STEERING CyLINDER 8
Disassembly 8
Inspection 9
Assembly 9

5006-3
SPECIFICATIONS
Two wheel drive steering cylinder tie rod nuts 324 to 504 pound-inches (37 to 57 Nm).

5006-4
TWO WHEEL DRIVE STEERING CYLINDER

Disassem bly 10. Remove the wear ring (12) from the piston (11).
Remove the seal (13) and backup ring (15) from the
1. Clean the outside of the steering cylinder (1). piston (11).
2. Fasten the steering cylinder (1) in a vise or other 11 . Remove the O-ring (9) and backup ring (14 ) from
holding equipment. Be careful to prevent damage to the outside of each gland (8). Remove the wiper (6) and
the tube (16) seal (7) from the bore of each gland (8).
3. One end of the piston rod (10) has two flat areas to Inspection
prevent the piston rod (10) from turning when the lock
nuts (3) for the rod eyes (2 and 17) are loosened. The 1. Discard the parts removed from the piston (11) and
rod eye (2) at the end of the piston rod (10) that has two the glands (8).
flat areas has LH threads. Prevent the piston rod (10)
from turning, loosen the lock nut (3), and turn the rod 2. Clean all parts in cleaning solvent.
eye (2) out of the piston rod (10).
3. Illuminate the inside of the tube (16). Inspect the
4. The rod eye (17) in the other end of the piston rod has inside of the tube (16) for deep grooves and other
RH threads. Prevent the piston rod (10) from turning, damage. If there is damage to the tube (16), a new tube
loosen the lock nut (3) and turn the rod eye (17) out of (16) must be used.
the piston rod (10).
4. Check to be sure that the piston rod (10) is straight. If
5. Loosen and remove the nut (4) from each tie rod (5) the piston rod (10) is not straight, install a new piston
and remove the tie rods (5) that hold the steering rod assembly (10 and 11).
cylinder (1) together.
5. Inspect the piston (11) for damage and wear. If the
6. Pull one end of the piston rod ("10)straight out of the piston (11) is damaged, or worn, a new piston rod
tube (16) until the piston (11) contacts the gland (8) assembly (10 and 11) must be used.
7. Use a soft hammer to drive the gland (8) out of the 6. Remove small scratches on the piston rod (10) and
tube (16) and pull the piston rod (10) straight out of the inside the tube (16) with emery cloth of medium grit.
tube (16) to prevent damage to the tube (16). Use the emery cloth with a rotary motion.
8. Remove the gland (8) from the piston rod (10). 7. Inspect both ends of the tube (16) for sharp edges
that will cut the gland O-rings (9) and remove the sharp
9. Use a soft hammer to drive the gland (8) out of the edges as necessary.
other end of the tube (16). Remove the gland (8 or 19).
8. Inspect both glands (8) for rust. Clean and remove
NOTE: The piston (11) cannot be removed from the rust as necessary.
piston rod (10). If the piston (11) or the piston rod (10) is
damaged, the piston rod assembly (10 and 11) must be
replaced.

Two Wheel Drive Steering Cylinder - Exploded View

5006-6
Assembly 5. Install a new wear ring (12) in the wide groove in the
piston (11).
6. Install a new backup ring (15) in the narrow grcAe in

the piston (11).
7. Install a new seal (13) on top of the backup ring (15).
8. Fasten the tube (16) in the vise or other holding

equipment. Be careful to prevent damage to the tube
8. GLAND
(16).
9. Lubricate the bore of the tube (16) with clean oil.
10. Lubricate the O-ring (9 and 17) on both glands (8 )

and the bore of both glands (8) with clean oil.
11. Remove any marks and sharp edges on the

8861554
chamfers at the end of the piston rod assembly (10 and
11). Make sure that the piston rod (10) is clean.
Gland
12. Lubricate the piston (11) with clean oil.

1. Install a new seal (7) into the bore of each gland (8).
13. Install one of the glands (8) in the tube (16).
The lips of the seal (7) must be toward the inside of the
steering cylinder (1). The seal (7) can be difficult to
14. Push the other gland (8) onto the piston rod
install. Do not damage the seal (7).
assembly (10).
15. Push the piston rod assembly (10) straight into the
2. Install a new wiper (6) into the bore of each gland (8).
tube (16), and through the gland (16) at the other end of
The lip of the wiper (6) must be toward the outside end
the tube (16).
of the gland (8).
16. Carefully start the other gland (8) into the tube (16).
3. Install a new backup ring (14) in the groove on each
gland (8).
17. Make sure the ports in both glands (8) are installed
correctly and drive the gland (8) into the tube (16).
4. Install a new O-ring (9) in the groove on each gland
(8). The O-ring (9) must be between the backup ring
18. Install the tie rods (5) and nuts (4). Tighten the nuts
(14) and the small end of the gland (8),
to 324 to 504 pound-inches (37 to 57 Nm).
19. The rod eye (2) for the end of the piston rod (10) that
has two flat areas has LH threads. Prevent the piston
rod (10) from turning, and turn the rod eye (2) into the
piston rod (10).
20. The rod eye (17) for the other end of the piston rod
(10) has RH threads. Prevent the piston rod from
turning, and turn the rod eye (17) into the piston rod
(10).
21. Do not tighten the lock nuts for the rod eyes (2 and
17) until after installation of the steering cylinder (1).
88861555
Piston

Two Wheel Drive Steering Cylinder - Exploded View

5006-8
FOUR WHEEL DRIVE STEERING CYLINDER

Disassembly 5. Remove the wiper (13), backup ring (12), and the
seal (11) from the closed end of the tube (10).
1. Fasten the tube (10) in a vise or other holding equip-
ment. Do not damage the tube (10). 6. Fasten the piston rod assembly (7) in a vise with soft
jaws
2. Separate the gland (5) from the tube (10).
7. Remove the wear rings (9), seal (8), and the backup
3. Remove the gland (5) from the piston rod assembly ring (14) from the piston rod assembly (7)
(7).
8. Remove the O-ring (6), wiper (2), backup ring (3),
4. Pull the piston rod assembly (7) straight out of the and the seal (4) from the gland (5).
tube (10) to prevent damage to the tube (10).
1. STEERING CYLINDER
7. PISTON ROD ASSEMBLY
8902049J
Four Wheel Drive Steering Cylinder - Exploded View

5006-9
Inspection 6. Install a new backup ring (14) in the center groove of

the piston rod assembly (7).
1. Discard the parts that were removed from the gland,
piston rod assembly, and the tube (10). 7. Install a new seal (8) on top of the backup ring (14) in
the center groove of the piston rod assembly (7).
2. Clean all parts in cleaning solvent.
8. Install a new wear ring (9) in the groove on each side
3 Inspect the gland, piston rod assembly, and the tube of the seal (8).
for damage and wear. These parts are not serviced se-
parately, if these parts need to be replaced. a new 9. Lubricate the seal (8) and wear rings (9) with clean oil.
steering cylinder must be used. Use a piston ring compression tool to hold the new
wear rings (9) in place.
Assembly
10. Start the tube (10) onto the piston rod assembly (7).
See the cross sectional view of the steering cylinder Push the tube (10) onto the piston rod assembly (7) until
on page 10. the compression tool is pushed off the piston rod
assembly (7). Be careful not to damage the wear rings
1. Install a new seal (4) in the gland (5). The lip of the (9) and the seal (8).
seal (4) must be toward the inside of the gland (5).
11. Fasten the tube (10) in a vise with soft jaws. Push the
2. Install a new backup ring (3) next to the gland (5). piston rod assembly (7) all the way into the tube (10).
3. Install a new wiper (2) in the gland (5). The lip of the 12. Lubricate the wiper (2), backup ring (3), seal (4),
wiper (2) must be toward the outside of the gland (5). and O-ring (6) on the gland (5) with clean oil.
4. Install a new O-ring (6) in the groove on the outside of 13. Install the gland (5) on the piston rod assembly (7)
the gland (5). and push the gland (5) against the tube (10).
5. Fasten the piston rod assembly (7) in a vise with soft

jaws.

5006-10
5. GLAND
8. SEAL
10. TUBE
B9020SOJ

Section
5007
FRONT AXLE, TWO WHEEL DRIVE.MACHINES

Issued January 1991
5007-2
TABLE OF CONTENTS
SPECIFICATIONS. 2
FRONT WHEEL BEARINGS 3
Removal and Disassembly . ......3
Inspection . ......5
Assembly and Installation . ....

7
Wheel Bearing Adjustment 10
SPLINDLE ................................ 11
Removal . ....11
Installation 16
KiNGPIN BEARINGS AND THRUST BEARINGS . . ...21
Removal . .....21
Installation. . 25
TOE-IN 30
Measuring Toe-In 30
Adjustment 30
SPECIFICATIONS
Service
Toe-In 0 to 3/16 inch (0 to 5 mm)

Clean and lubricate front wheel bearings After every 500 hours of operation
Wheel bearing grease Number 2 wheel bearing grease
Special Torques
Wheel bearing nut. . 75 to 85 pound-feet (101 to 115 Nm) with wheel turning.
Then loosen a maximum of 1/16 turn
Front wheel bolts 115 to 150 pound-feet (156 to 203 Nm)
Steering cylinder lock nuts 150 to 200 pound-feet (203 to 271 Nm)

5007-3
FRONT WHEEL BEARINGS

Removal and Disassembly STEP 4
STEP 1
r i'!!Y
Remove the cotter pin.
Raise the front wheel and put an acceptable support

under the front axle. STEP 5
STEP 2
Remove the nut.
Loosen and remove the wheel bolts. Remove the STEP 6

wheel.
STEP 3
Pull the hub toward you to remove the outer wheel

bearing from the spindle. It can be necessary to hit the
hub with a soft hammer.
Remove the cap
Bur 8-12471 Issued 1-91 Printed in U.SA.

5007-4
STEP 7 STEP 10
Remove the flat washer and wheel bearing. Use two prybars and remove the spindle seal.
STEP 8 STEP 11
Remove the hub. Remove the dirt and grease from the spindle.
STEP 9 STEP 12
Use a chisel to move the spindle seal away from the Put an acceptable driver on top of the wheel bearing.
spindle.

5007-5
STEP 13 STEP 15
Press the hub seal and wheel bearing out of the hub. Use a hammer and punch and remove the inner
bearing cup from the hub only if inspection indicates
the need for a new bearing cup or wheel bearing.
STEP 14
Inspection
1. Clean the wheel bearings in cleaning solvent to
remove all indications of grease from the wheel bear-
ings.
2. Check the bearing cups for scoring, flat areas, and

pitting.
3. Inspect the rollers in the wheel bearings for flat areas,

scoring and other damage. Also check the inner race
for wear and damage.
Use a hammer and punch and remove the outer
bearing cup from the hub only if inspection indicates
the need for a new bearing cup or wheel bearing.

5007-6

5007-7
Assembly and Installation STEP 19
STEP 16
Start the inner bearing cup into the hub.

B0213?9M
Fill each wheel bearing with the grease specified on
page 5007-2. STEP 20
STEP 17
Use an acceptable driver and press the bearing cup all

the way into the hub.
Start the outer bearing cup into the hub.

STEP 21
STEP 18
Put the other wheel bearing in the hub.
Use an acceptable driver and press the bearing cup all

the way into the hub.

5007-8
STEP 22 STEP 24
3. HUB SEAL
Press the hub seal into the hub until the hub seal stops
moving. Be careful not to damage the hub seal by
using too much pressure.
STEP 25
4. SPINDLE SEAL B891546J
The hub seal must be installed as shown in the illustra-

tion.
STEP 23
Drive the new spindle seal all the way onto the spindle.
Be careful not to damage the spindle seal.
STEP 26
Put the hub seal on an acceptable driver.
Fill the groove in the hub seal with wheel bearing

grease.

5007-9
STEP 27 STEP 30
Install the hub onto the spindle. Tighten the nut to 75 to 85 pound-feet (101 to 115 Nm)
and turn the hub at the same time. Then loosen the nut
to the first cotter pin hole.
STEP 28
STEP 31
Install the outer wheel bearing.
Install the cotter pin.

STEP 29
STEP 32
Install the flat washer and nut.
Install the cap

5007-10
STEP 33 Wheel Bearing Adjustment

The following photographs show the hub with the
wheel off. It is not necessary to remove the wheel from
the hub to adjust the wheel bearing
STEP 36
Install the wheel and wheel bolts. Do not use an impact

wrench to install the wheel bolts.
STEP 34
1 .•...•...
t·. ·•·..
. !">'::;u Remove the cap .
STEP 37
Remove the support from under the front axle and lower
the wheel to the floor.
STEP 35
Turn the wheel or hub and tighten the nut to 75 to 85
pound-feet (101 to 115 Nm). Then loosen the nut to the
first cotter pin hole.
STEP 38
Tighten the wheel bolts to 115 to 150 pound-feet (156 to

203 Nm).
Install a new cotter pin.

5007-11
STEP 39
Install the cap
SPINDLE
Removal STEP 42
STEP 40
Remove the cap.
Raise the front wheel off the floor and put an acceptable
support under the front axle. STEP 43
STEP 41
Remove the cotter pin.
Loosen and remove the wheel bolts. Remove the

wheel.

5007-12
STEP 44 STEP 47
Remove the nut. Remove the hub.
STEP 45 STEP 48
Pull the hub toward you to remove the outer wheel Loosen the nut on the lock pin.
bearing from the spindle. It can be necessary to hit the
hub with a soft hammer.
STEP 49
STEP 46
Remove the nut and lock washer.
Remove the flat washer and wheel bearing.

5007-13
STEP 50 STEP 53
Drive the lock pin out of the spindle. Remove the snap ring. The O-rings used between the
spacer and bearing will cause the snap ring to be diffi-
cult to remove.
STEP 51
STEP 54
Loosen the nuts on the bolts that hold the pivot pin for
the steering link.
Remove the spacer.
STEP 52
STEP 55
Drive the pivot pin out of the steering link.

Remove the O-ring.

5007-14
STEP 56 STEP 59
Remove the snap ring at the bottom of the king pin Drive the king pin toward the top to prevent damage to
the seal.
STEP 57
STEP 60
Remove the spacer.

Remove the spindle and thrust bearing.
STEP 58
STEP 61
Remove the O-ring.


5007-15
---
8891545J
36. COlTER
PIN

Bur 8-12471
5007-16
Installation STEP 65
STEP 62
Install the thrust bearing. Remember, the case must be

on top.
Put the thrust washer on the bottom boss.
STEP 63 STEP 66
Install the spindle. Align the spindle, thrust bearing, and thrust washer with
the front axle. Install the kingpin so that the notch for the
lock is toward the outside.
STEP 64
STEP 67
The case of the thrust bearing must be on top when the

thrust bearing is installed.
Hold the spindle and push the kingpin into place.

5007-17
STEP 68 STEP 71
Install the lock pin. Apply a small amount of grease to a spacer and install
the spacer so that the grease fitting is toward the center
of the machine.
STEP 69
STEP 72
Install the lock washer and nut but do not tighten the nut
now.
Install the snap ring. Hit the spacer and snap ring to
make sure that the snap ring is in the groove.
STEP 70
STEP 73
Install a new O-ring in the bottom boss. Use grease to

hold the O-ring in place.

5007-18
STEP 74 STEP 77
Install the spacer so that the grease fitting is toward the Tighten the nut that holds the lock pin.
center of the machine.
STEP 78
STEP 75
Align the steering link with the spindle and start the pivot
Install the snap ring. pin into the steering link.
STEP 76 STEP 79
••••
Hit the spacer and snap ring to make sure that the snap Drive the pivot pin into the steering link.
ring is in the groove.

5007-19
STEP 80 STEP 83
.~
,~
... ~.-
-.,;:..:.>>;
~?~
Tighten the nuts on the bolts that hold the pivot pin. Install the hub onto the spindle.
STEP 81 STEP 84
Drive the spindle seal all the way onto the spindle Be Install the outer wheel bearing.
careful not to damage the spindle seal.
STEP 85
STEP 82
Install the flat washer and nut

Fill the groove in the hub seal with the wheel bearing
grease specified on page 5007-2.

5007-20
STEP 86 STEP 89
Tighten the nut to 75 to 85 pound-feet (101 to 115 Nm) Install the wheel and wheel bolts. Do not use an impact
and turn the hub at the same time. Then loosen the nut wrench to install the wheel bolts.
to the first cotter pin hole.
STEP 90
STEP 87
Remove the support from under the front axle and lower
Install the cotter pin. the wheel to the floor.
STEP 88 STEP 91
Install the cap. Tighten the wheel bolts to 115 to 150 pound-feet (156 to
203 Nm).
STEP 92
Lubricate the bearings for the kingpin. Lubricate the tie
rod ends.
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
Remove the snap ring. The O-ring used between the

spacer and bearing will cause the snap ring to be diffi-
cult to remove.
Loosen and remove the wheel bolts. Remove the
wheel.
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.

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 Drive the bottom bearing out of the boss.
of the boss.

5007-24
2. GREASE
FITTING
B891545J
36. COTTER
PIN

5007-25
Installation STEP 112
STEP 109
Install the seal on an acceptable driver so that the lip is

toward the driver. The driver must have a larger
Clean the bores for the bearings. diameter that the seal.
STEP 110 STEP 113
Put a bearing on a driver that has a pilot end. The Drive the seal into the boss until the driver touches the
number on one end of the bearing must be toward the boss.
driver. The tape on the driver is 1/4 inch from the
bearing to help install the bearing to the correct depth.
STEP 114
STEP 111
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.

5007-26
STEP 115 STEP 118
Drive the bearing into the boss until the bearing is even Install the spindle.
with the bottom of the boss.
STEP 119
STEP 116
The case of the thrust bearing must be on top when the

Clean the bore in the spindle. thrust bearing is installed.
STEP 117 STEP 120
Install the thrust washer. Install the thrust bearing so that the case is on top.

5007-27
STEP 121 STEP 124
Align the spindle, thrust washer and thrust bearing with Install the lock washer and nut. Do not tighten the nut at
the front axle. Start the kingpin into the spindle so that this time.
the notch for the lock pin is toward the outside.
STEP 125
STEP 122
"
Use a soft hammer and drive the kingpin into the
spindle.
Install a new O-ring in the bottom boss. Use grease to
hold the O-ring.
STEP 126
STEP 123
Apply a small amount of grease to a spacer and install

Install the lock pin. the spacer so that the grease fitting is toward the center
of the machine.

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.

5007-29
STEP 133
Tighten the nut on the lock pin. Remove the support from under the front axle and lower
the wheel to the floor.
STEP 134
STEP 136
Install the wheel and wheel bolts. Do not use an impact

wrench to install the wheel bolts. Tighten the wheel nuts to 115 to 150 pound-feet (156 to
203 Nm).
STEP 137
Lubricate the bearings for the kingpins.

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
1. Raise the front of the machine until the front wheels the front of the tires.
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 2. Turn the piston rod as needed to increase or
for the other front wheel. decrease the toe-in.
4. Lower the front wheels to the floor. 3. When the toe-in is correct, tighten the lock nut
nearest the flat on the piston rod first to 150 to 200
5. Turn the steering wheel as needed to put the front pound-feet (203 to 271 Nm). Then tighten the other lock
wheels in the straight position. nut to 150 to 200 pound-feet (203 to 271 Nm).
6. Measure the distance between the marks at the

front and rear of the tires.
B ..
B861482R
1. Mark Around Center of Tire Measurement B Must Be Equal To or Up To 3/16

2. Steering Cylinder Inch (5 mm) Less Than Measurement A
3. Loosen Lock Nuts and Turn
Piston Rod as Required

Section
5008
FRONT AXLE - FOUR WHEEL DRIVE

Issued January 1991
5008-2
TABLE OF CONTENTS
SPECIFICATIONS 3
SPECIAL TOOLS 3
MEASURING TOE-I N . 4
DISASSEMBLY OF PLANETARy 5
INSPECTION OF PLANETARY PARTS 9
ASSEMBLY OF PLANETARy 11
REMOVAL AND DISASSEMBLY OF SWIVEL HOUSiNG 16
REPLACING A UNIVERSAL JOINT 19
ASSEMBLY AND INSTALLATION OF SWIVEL HOUSiNG 24
REMOVAL OF DIFFERENTIAL CARRIER 28
DISASSEMBLY OF DIFFERENTIAL CARRIER 30
DISASSEMBLY OF DIFFERENTIAL 33
INSPECTION OF DIFFERENTIAL PARTS 34
ASSEMBLY OF DIFFERENTIAL 36
ASSEMBLY OF DIFFERENTIAL CARRIER 39
INSTALLATION OF DIFFERENTIAL CARRIER 45
SPECIFICATIONS
Backlash for ring gear 0.008 to 0.010 inch (0.20 to 0.25 mm)
Rotating torque for pinion shaft without seal 10 to 20 pound-inches (1.1 to 2.3 Nm)
Gear lubricant . ............................................................. CaselH Gear Lube (85W-140)
Capacities
Center bowl 7.4 U.S. quarts (7 litres)
Planetary (each) 1.1 U.S. quart (1 litre)
Special torques
Studs for wheels 52 pound-feet (70 Nm)
Wheel nuts 200 to 240 pound-feet (270 to 325 Nm)
Allen screws for planetary cover with 242 Loctite 300 pound-inches (34 Nm)
Allen screws for carrier 59 pound-feet (80 Nm)
Nut for ball joint 125 to 135 pound-feet (169 to 180 Nm)
Cap screws for king pin 101 pound-feet (137 Nm)
Cap screw for lock for adjusting ring 84 pound-inches (9.5 Nm)
Cap screws for bearing caps 115 pound-feet (156 Nm)
Cap screws for differential case with 271 Loctite 52 pound-feet (70 Nm)
Cap screws for bearing caps 74 pound-feet (100 Nm)
Cap screws for steering cylinder 66 to 79 pound-feet (90 to 107 Nm)
Cap screws for hub for ring gear 184 pound-feet (299 Nm)

5008-3
SPECIAL TOOLS
The special tools shown on this page are required to
disassemble and assemble the planetaries and dif-
ferential.
In the US. and Canada, order the tools from
Service Tools
P.O. Box 314
Owatonna, MN 55060
VL Churchill Ltd B4097388M

P.O. Box 3, Daventry CAS-1840B Spanner Wrench. Shown in use in step
Northants NN11 4NF 150.
England
B4086.290M
B875432M CAS-2151 Wrench For Pinion Nut. Shown in use in step
1. CAS-1839-1 Gauge Tube 156.
2. CAS-1839-2 Gauge Block
3. CAS-1668 Metric Feeler Gauge
4. CAS-1596A-3 Pilot
5. CAS-1596A-4 Handle
6. 7116-A9 Stud
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.

5008-4
B4094188M B40974B8M
CAS-1842 Wheel Stud Removal and Installation. CAS-2151 Wrench to loosen and tighten tie rods for
Shown in use in step 3. steering cylinder. Shown in use in step 139.
'B4t068ssM , ...,:B4095oeaM
CAS-1980 V-Blade. Used to support coupling when CAS-1 0468 Puller. Used to remove ball joint from swivel
replacing a universal joint. First used in step 74. housing. Used in step 57.
MEASURING TOE-IN
A
B870171J
1. Mark Around Center of Tire Measurement B Must Be Equal To Or Up To

2. Steering Cylinder 3/16 Inch (5 mm) Less Than Measurement A
3. Loosen Clamps and Tum Piston Rod as Required

5008-5
DISASSEMBLY OF PLANETARY
STEP 1 STEP 5
Raise the wheel(s) off the floor and use suitable
supports to hold the machine in place
STEP 2
Remove the nuts and hardened washers and remove
the wheel(s).
STEP 3
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.

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.
Remove the ring gear.

STEP 10
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.

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 snap rings.

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 Remove the bearing cups and seal as required.
careful not to lose the needles.
STEP 22
Remove the Allen head screws and remove the cover.

5008-9
INSPECTION OF PLANETARY PARTS

1. Clean all parts in cleaning solvent. 4. Inspect the teeth of the pinion gears, sun gear and
ring gear for wear, pitting, scoring and other damage.
2. Inspect the bearing cup and the rollers in the wheel Use new parts as required.
bearings for flat areas, pitting, scoring and other
damage. Also check the inner race for damage. If any of 5. Inspect the needles for the pinion gears for flat areas,
these defects are found, a new wheel bearing and pitting, scoring and other damage. If any of these
bearing cup must be installed. defects are found, also inspect the bore of the pinion
gears and use new parts as required.
3. Inspect the pinion shafts for wear and damage.
6. Inspect the splines on the axle shaft and sun gear for
wear and damage.

5008-10
1. Me Shaft 8. Retaining Ring 15. Sun Gear 22. Carrier

2. Seal 9. Hub 16. Snap Ring 23. Allen Head Screw
3. Bearing 10. Ring Gear 17. Retainer 24. Flanged Stud
4. Bearing Cup 11. Bushing 18. Pinion Gear 25. Plug
5. Planetary Housing 12. Cap Screw 19. Needles 26. Pinion Shaft
6. Dowel Pin 13. Washer 20. Thrust Washer 27. Cover
7. Stud 14. Spacer 21. Thrust Button
5008-11
ASSEMBLY OF PLANETARY
STEP 25 STEP 28
Press the pinion shafts into the carrier until the inner end
of the pinion shafts are 1.350 to 1.450 inch (34.3 to 36.8
mm) from the machined surface on the carrier.
STEP 29
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.

5008-12
STEP 31 STEP 34
Install 30 needles in each pinion gear using petroleum Make sure that the threads in the pinion shafts are free
jelly to hold the needles in place. of lubricant.
STEP 32 STEP 35
Install the pinion gears so that the thrust washer is Apply 242 Loctite to the threads in the pinion shafts.
toward the carrier
STEP 36
STEP 33
Install the cover and Allen head screws and tighten the
Install the retainer and snap rings. Allen head screws to 300 pound-inches (34 Nm).

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.

5008-14
STEP 43 STEP 46
Align the large diameter bushing with the large hole in Install the thrust washer and spacer.
the swivel housing and install the ring gear.
STEP 47
STEP 44
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 gasket material to the planetary

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

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 pound-

feet (80 Nm).

5008-16
REMOVAL AND DISASSEMBLY OF SWIVEL HOUSING

STEP 54 STEP 58
Do the necessary steps under Disassembly of Plane-
tary for access to the swivel housing,
STEP 55
···B90762tGM
Remove the nut and remove the ball joint from the
swivel housing,
Slide the inner wheel bearing off the swivel housing, STEP 59
STEP 56
Loosen the cap screws that hold the top king pin,
Remove the cotter pin and loosen but do not remove STEP 60
the nut.
STEP 57
Remove the top king pin. Be careful not to damage the

shims,
Use the CAS-10468 puller to loosen the ball joint.

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 67
STEP 64
Use a suitable puller and remove the seal.

Remove the axle shaft.

5008-18
STEP 68 STEP 71
90763'1 OM
Use a suitable puller and remove the bushing. Use a hammer and a chisel that has a long taper to start
the bushing off the bottom king pin.
STEP 69
STEP 72
Use a suitable puller and remove the seal from the

swivel housing 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.

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
STEP 77
Use the CAS-1980 V-block to support the coupling.

Adjust the Allen screws in the V-block to hold the Remove the long axle shaft (or short axle shaft) from the
coupling level and use additional support as required. coupling.
Use a suitable driver and press the bottom bearing cap
against the V-block.
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 Remove the cross.
bearing cap out of the yoke as far as possible.
STEP 83
STEP 80
Use a suitable driver and press the bearing cap out of

the yoke.
STEP 84
STEP 81
Press a bearing cap into the yoke 1/4 inch (3 mm) from
Press the other bearing cap out of the yoke as far as the top of the yoke.
possible.

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
STEP 89
Press the other bearing cap into the yoke 3/8 inch (9
mm) from the top of the yoke. Use a suitable driver and press a bearing cap into the
yoke so that a snap ring can be installed.
STEP 87
STEP 90
Carefully raise the cross into the bearing cap so that the
cross is in both bearing caps. Install a snap ring.

5008-22
STEP 91 STEP 95
Repeat steps 89 and 90 for the other bearing cap.
STEP 92
Carefully raise the cross into the top bearing cap so that
the cross is in both bearing caps.
Use the V-block to support the coupling and press a

bearing cap into the coupling even with the 00 of the STEP 96
coupling.
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.
STEP 98
Use a suitable driver and press the other bearing cap Repeat steps 96 and 97 for the other bearing cap.
into the coupling 1/4 inch (3 mm) from the top of the
coupling.

5008-23
B902646J
1. Top fVng Pin 4. One Piece Bushing 7. Seal

2. Shim 5. Swivel Housing 8. Two Piece Bushing
3. Seal 6. Bushing 9. Bottom fVng Pin

5008-24
ASSEMBLY AND INSTALLATION OF SWIVEL HOUSING

STEP 99 STEP 102
Drive the bushing into the bore until the bushing is 5/16 Use a suitable driver and drive the seal all the way into
inch (8 mm) beyond the end of the bore. Then install the bore.
seal
STEP 103
STEP 100 Repeat step 102 for the bottom seal.
STEP 104
Install the bushing for the top king pin on a driver that
has a pilot and drive the bushing all the way into the
bore. Install the axle shaft.
STEP 101 STEP 105

Repeat step 100 for the bottom bushing.
Install the swivel housing.

5008-25
STEP 106 STEP 111

If the old swivel housing is being installed and no new
bushings for the king pins were installed, do steps 107
through 109.
STEP 107
Install the top king pin without shims.
STEP 112
Measure the the thickness of the shims removed with
Install the top king pin, shims and cap screws and lock the top and bottom king pins and install these shims
washers or self-locking cap screws. and two additional 0.014 inch (0.35 mm) shims on the
bottom king pin.
STEP 108
STEP 113
Tighten the cap screws to 101 pound-feet (137 Nm).

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.

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 thick-
ness of the shims to be installed on each king pin. If the
shims cannot be divided equally, install the thickest
shim set on the top king pin.
STEP 119
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.

5008-27
STEP 122 STEP 125
Tighten the cap screws to 101 pound-feet (134 Nrn). Install the ball joint and nut.
STEP 126
STEP 123
Tighten the nut to 125 to 135 pound-feet (169 to 180

Install the top king pin, shims, cap screws and lock Nm).
washers.
STEP 127
STEP 124
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
Tighten the cap screws to 101 pound-feet (134 Nm). nearest notch with the hole.
STEP 128
Lubricate the king pins.
STEP 129
Assemble the planetary according to instructions in this
section.
5008-28
REMOVAL OF DIFFERENTIAL CARRIER

STEP 130 STEP 134
Drain the lubricant from the center bowl.
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.

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
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 differen-

tial carrier.

5008-30
DISASSEMBLY OF DIFFERENTIAL CARRIER

STEP 145 STEP 148
Typical Illustration Remove the cap screw and lock that hold each ad-
Fasten the differential carrier in a repair stand. justing ring.
STEP 146 STEP 149
Prevent the pinion shaft from turning and measure the Remove the cap screws.
backlash of the ring gear. Record the reading.
STEP 150
STEP 147
Loosen both adjusting rings

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

5008-31
STEP 151 STEP 155
~,
Remove both bearing caps. Use a narrow chisel to push the nut out of the pinion
shaft.
STEP 152
STEP 156
Remove the adjusting rings, bearing cups and differen-

tial. Use the yoke and CAS-2151 tool to remove the pinion
nut.
STEP 153
If the bearing cups are to be used again, fasten an iden- STEP 157
tification tag to one bearing cup for correct installation.
STEP 154
Remove the washer.
Remove the seal and cover.

5008-32
STEP 158 STEP 161
Use a soft hammer and drive the pinion shaft out of the Remove the shim.
outer bearing.
STEP 162
STEP 159
Remove the bearing cups only if inspection indicates

Remove the flat washers and spacer. Discard the the need for new parts. A spacer is used between the
spacer. The spacer MUST NOT be used again. differential carrier and the inner bearing cup. Do not
lose the spacer.
STEP 160
Press the pinion shaft out of the inner bearing.

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.

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. 4. Inspect the teeth of the pinion gears and pinion shaft,
and side gears for the differential for pitting, scoring
2. Inspect the bearing cup and the rollers in the and other damage. Also inspect the thrust surfaces and
bearings for flat areas, pitting, scoring and other the bore of each pinion gear. Check the splines in the
damage. Also check the inner race for damage. If any of side gears for wear. Use new parts as required.
these defects are found, a new bearing and bearing
cup must be installed. 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.

5008-35
15
B902647J
1. Cover 7. Spacer 12. Lock 17. Thrust Washer

2. Seal 8. Bearing Cup 13. Shim 18. Side Gear
3. Pinion Nut 9. Differential Carrier 14. Pinion Gear 19. Pinion Gear
4. Washer 10. Adjusting Ring 15. Ring Gear 20. Pinion Shaft
5. Bearing 11. Bearing Cap 16. Case Half 21. Dowel Pin
6. Flat Washer
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 Install the thrust washers and pinion gears on the pinion
shaft with gear lubricant shaft.

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. Assemble the case halves.

5008-38
STEP 184 STEP 185
Make sure that the mounting surfaces for the ring gear Use the press to prevent the differential from turning
are clean and install the ring gear. and install and tighten the cap screws to 52 pound-feet
(70 Nm).

5008-39
ASSEMBLY OF DIFFERENTIAL CARRIER
STEP 186 STEP 189
. .
~~~~~,M.
If new bearing cups are being installed in the differential Install the gauge block assembly, bearings and handle.
carrier, make sure that the spacer is installed in the bore Tighten the handle until the bearings become difficult to
for the inner bearing cup. turn.
STEP 187 STEP 190
Use a suitable driver and drive the bearing cup(s) into Install the gauge tube, bearing caps with marks aligned
the differential carrier. and the cap screws.
STEP 188 STEP 191

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

5008-40
STEP 192 STEP 195
Use the metric feeler gauge and measure the space Remove the cap screws, bearing caps, gauge tube,
between the gauge block and the gauge tube. Write the handle, gauge block assembly and the bearings.
measurement on line b in step 194
STEP 196
STEP 193
Install the shim with the thickness specified in step 194.

Write the number on the end of the pinion shaft on line d The chamfer on the ID of the shim must be towards the
in step 194. 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 thick-
ness of the shim to be installed on the pinion shaft.
Example
a. 109.75 mm a. 109.75 mm
b.+ mm b. + 0.45 mm
c. mm c. 110.20 mm
d. - mm d. -107.45 mm
e. mm e. 2.75 mm
use 2.70 mm
Use a suitable driver and press the inner bearing
thick shim
against the shim.

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 Install a new pinion nut.
MUST NOT be used again.
STEP 203
STEP 200
Use the yoke and the CAS-2151 wrench and tighten the
Install the pinion shaft and the outer bearing. pinion nut to 50 pound-feet (68 Nm).

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 dif-
ferential 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.
Use a suitable driver and drive the cover onto the pinion
shaft
STEP 206
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.
Install the differential carrier and lubricate the bearings
with gear lubricant. The ring gear must be next to the leg
with the identification mark.

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 marks Tighten both adjusting rings while making sure that
aligned and the cap screws. there is clearance (backlash) between the ring gear and
pinion gear.
STEP 212
STEP 215
Tighten the cap screws to pull the bearing caps against

the differential carrier. Use a dial indicator and check for end play.

5008-44
STEP 216 STEP 222

If there is end play, tighten the adjusting ring on the
tooth side of the ring gear until there is no end play.
STEP 217
If there is no end play, loosen the adjusting ring on the
backface side of the ring gear to make sure that there is
clearance between the ring gear and pinion gear and
tighten the opposite adjusting ring until there is no end
play.
STEP 218
When there is no end play, tighten each adjusting ring
one notch.
If there is not enough backlash, loosen the adjusting
STEP 219 ring on the backface side of the ring gear one notch and
tighten the opposite adjusting ring one notch. Check
the backlash again. Continue with this step until the
backlash is correct.
STEP 223
Use the dial indicator and check the backlash for the
ring gear at 90 degree intervals. If the readings are not
equal, adjust the backlash at the position that had the
smallest reading. ''''';.;.'.''-" . ",1,
"'307tv1
~'"
STEP 220
, :
If there is too much backlash, loosen the adjusting ring

If the original ring gear and pinion gear are being used, on the tooth side of the ring gear one notch and tighten
the backlash must be equal to the measurement made the opposite adjusting ring one notch. Check the
during disassembly. backlash again. Continue with this step until the
backlash is correct.
3TEP 221
If a new ring gear and pinion gear are being used. the
backlash must be 0.008 to 0.020 inch (0.15 to 0.25
mm).

5008-45
STEP 224 STEP 225
When the backlash is correct, tighten the cap screws to Install the lock, cap screw and lock washer that hold
115 pound-feet (156 Nm). each adjusting ring. Tighten the cap screws to 84
pound-inches (9 Nm).
INSTALLATION OF DIFFERENTIAL CARRIER

STEP 226 STEP 228
Apply form-in-place gasket material.
STEP 227
STEP 229
Install the differential carrier.

Install the steering cylinder.

5008-46
STEP 230 STEP 234
s.~
Install and tighten the cap screws to 66 to 79 pound- Install the king pins, shims, cap screws and lock
feet (90 to 107 Nm). washers.
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.
STEP 233
Install the planetary and axle assembly. It can be neces-

sary to have another person turn the pinion shaft.

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.

SECTION INDEX - POWER TRAIN
Removal and Installation of Power Train Components . ...6001
Transmission Specifications and Schematic.... . 6002
Wheels and Tires .... . 6003
PTO . .6019
Rear Axles and Planetaries 6201
Transfer Gearbox 6202
Differential and Differential Lock . .....6203
Forward/Reverse Valve . ..6204
Torque Converter Charging Pump, Output Shaft, And Converter Housing 6205
Transmission. . 6206

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)
Cap screws that fasten the torque converter

housing to the flywheel housing... . . . ....360 to 420 pound-inches (40 to 47 Nm)
Cap screws that fasten the drive ring to the torque converter .456 to 504 pound-inches (52 to 57 Nm)
Cap screws that fasten the drive ring to the flywheel 156 to 180 pound-inches (18 to 20 Nm)
Wheel nuts for the rear wheels 320 to 380 pound-feet (434 to 515 Nm)
Nuts for the bolts that fasten the transaxle to the frame 520 to 640 pound-feet (705 to 868 Nm)
Nuts for the bolts that fasten the guard for the drive shaft to the frame ... 100 to 150 pound-feet (136 to 203 Nm)
Oil refill capacity for the transaxle 47.6 U.S. quarts (45 litres)
SPECIAL TOOLS
dresses:
In the U.8A and Canada
Service Tools
P.O. Box 314
Vl Churchill Ltd
Northants, NN11 4NF
England B897521OM
CAS-2018 Alignment Tool
This tool is shown in use in step 19.
6001-3
REMOVING THE TORQUE CONVERTER HOUSING AND TORQUE CONVERTER

STEP 1 STEP 5
Park the machine on a level surface. Put the backhoe in
the transport position and lower the loader bucket to the
floor.
STEP 2
Loosen and remove the nuts and flat washers from the
bolts that fasten the guard to the frame. Do not remove
the bolts at this time.
Drain the oil from the transaxle. The trans axle holds ap- STEP 6
proximately 47.6 U.S. quarts (45Iitres).lfequipped with
a PTa, drain the oil from the torque converter housing.
STEP 3
If the machine has four wheel drive and a PTa, do steps
4 through 8. If the machine has a PTa only, do steps 4
through 7.
STEP 4
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.

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 Loosen the clamps at each end of the hose on the
front drive shaft. suction tube and remove the suction tube.
STEP 9 STEP 12
If equipped with a PTO, loosen and remove the Ferry Loosen and remove the nut, lock washer, and wire from
head screws and clamps that fasten the drive shaft to the switch for the filter warning lamp.
the torque converter and remove the drive shaft.
STEP 13
STEP 10
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.

6001-5
STEP 15 STEP 17
Loosen and remove the torque converter housing.
NOTE: The following photographs show removing the

torque converter with the engine removed. The pro-
cedure is the same with the engine in the machine.
STEP 16
Hold the torque converter and remove the cap screws

and hardened washers and remove the torque con-
verter.
STEP 18
If necessary, loosen and remove the cap screws, flat
Loosen the cap screws that hold the torque converter. washers, and the drive ring from the torque converter.
4. HARDENED WASHER
~..-..-
2. CAP SCREW ~
7. TORQUE
~ CONVERTER
2. CAP c? ~ 3. FLAT HOUSING
SCREW WASHER B891515J

6001-6
INSTALLING THE TORQUE CONVERTER AND TORQUE CONVERTER HOUSING
STEP 19 STEP 22
Install the drive ring and the CAS-2018 alignment tool. Tighten the cap screws to 156 to 180 pound-inches (18
Install the drive ring to get the least amount of to 20 Nm).
movement between the alignment tool and the drive
ring. STEP 23
If equipped with a PTO, apply Loctite 515 all the way
STEP 20 around the edge of the flywheel housing.
STEP 24
Install a 10 mm - 1.5 x 4 inch (100 mm) stud in the
middle hole on each side of the flywheel housing.
STEP 25
Install the torque converter housing so that the suction
tube and filter are on the horizontal centerline.
STEP 26
Move the torque converter housing forward.
IMPORTANT: DO NOT use extra force to push the

torque converter housing into place. If the torque con-
Install four cap screws and flat washers and tighten the
verter housing does not easily slide into contact with the
flywheel housing, the parts are not correctly aligned.
Then install and tighten the remainder of the cap
screws.
STEP 27
Install the cap screws and lock washers that hold the
STEP 21
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.
6001-7
STEP 29 STEP 31
1.7/8-14
THREAD
Install the rear drive shaft, clamps, and the Ferry head
screws. Tighten the Ferry head screws to 156 to 216
pound-inches (18 to 24 Nm).
NOTE: If the hardware for the transaxle was loosened to

remove the rear drive shaft, tighten the hardware ac-
cording to the torque specifications in step 69.
STEP 32
If equipped with a PTO, install the drive shaft, clamps,
and the Ferry head screws. Tighten the Ferry head
screws to 156 to 216 pound-inches (18 to 24 Nm).
STEP 33
If the machine has four wheel drive, do steps 34 through
STEP 30 38. If the machine has a PTO but no four wheel drive, do
steps 35 through 38.
STEP 34
Install the suction tube and tighten each clamp on the

hose.
Install the front drive shaft and cap screws. Tighten the

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 Install and tighten the drain plug in the transaxle (and
remove the floor jack from under the machine. 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).

6001-9
REMOVING THE TRANSAXLE

STEP 42 STEP 45
Raise the wheels off of the floor high enough to remove Loosen and remove the bolts, flat washers. and nuts
the transaxle from under the machine. Put suitable that fasten the bar to the guard for the drive shaft.
stands under the frame at the rear of the machine and Remove the bar.
under the front axle.
STEP 46
STEP 43
Loosen and remove the nuts and flat washers from the
Drain the oil from the transaxle. The trans axle holds ap- bolts that fasten the guard to the frame. Do not remove
proximately 47.6 U.S. quarts (45 litres). the bolts at this time.
STEP 44 STEP 47
If the machine has four wheel drive and a PTO, do steps
45 through 49. If the machine has a PTO only, do steps
45 through 48.
Put a floor jack under the guard.

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 If the machine has four wheel drive, disconnect the
the torque converter and remove the drive shaft. control rod from the lever at the transaxle.
STEP 51 STEP 54
Loosen and remove the Ferry head screws and clamps Loosen and remove the nuts from the bolts that fasten
that fasten the rear drive shaft to the torque converter. the clamp and spacer for the parking brake cable to the
Remove the rear drive shaft. bracket on the transaxle. Remove the bolts, clamp, and
spacer.
6001-11
STEP 55 STEP 57
Slide the boot up the parking brake cable. Loosen the Loosen and remove the cap screws and flat washers
jam nut and turn the parking brake cable counterclock- that fasten the guard for the hose on the suction tube
wise out of the transaxle. and remove the guard. Loosen each clamp on the hose
on the suction tube and slide the hose upward to dis-
connect the hose.
STEP 56
STEP 58
If the machine is equipped with a cab and has a
floormat, remove the floormat.
STEP 59
Remove the operators seat.
STEP 60
Loosen and remove the screws that hold the rear floor
plate and remove the rear floor plate.
STEP 61
Remove the cotter pins and clevis pins that fasten the
control rods to the levers on the transaxle.
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.

6001-12
STEP 62 STEP 65
Disconnect the brake hose from each side of the trans- Install a transmission jack under the transaxle.
axle. Install a plug in each hose and a cap on each
fitting. Disconnect the tube from the fitting at the top left
side of the transaxle. Install a plug in the tube and a cap STEP 66
on the fitting. Disconnect the spring from the lever at the
top right side of the transaxle so that the tube will be free
of the transax/e.
STEP 63
Disconnect the tube from the right side of the transaxle.
Install a plug in the tube and a cap on the fitting.
STEP 64
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.

6001-13
890240SJ
Bur 8-12501
6001-14
INSTALLING THE TRANSAXLE

STEP 68 STEP 71
·-······w·,·-·
B9075614M
Put the trans axle under the machine and raise the trans- If used, install the straps and align the straps with the
axle into position. blocks in the frame. Install the cap screws that hold the
straps and tighten the cap screws.
STEP 69
STEP 72
Connect the tube to the right side of the transaxle.
STEP 73
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).
Connect the brake hose to each side of the transaxle.

STEP 70 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.

6001-15
STEP 74 STEP 79
Connect the control rod to the spring, Connect the hose Install the clevis pins and cotter pins that fasten the
to the tee fitling, Connect the connector for the wiring control rods to the levers on the transaxle.
harness, Install the clevis pin and cotter pin that fasten
the power shuttle rod to the control valve,
STEP 80
STEP 75
Install the rear floor plate. Install the screws that hold the
rear floor plate and tighten the screws,
STEP 76
Install the operators seat.
STEP 77
If the machine is equipped with a cab and has a
floormat, install the floormat.
STEP 78
Turn the jam nut onto the parking brake cable until the
jam nut is flush with the flats on the threads. Turn the
parking brake cable clockwise into the transaxle until
the jam nut contacts the transaxle. Prevent the parking
brake cable from turning and tighten the jam nut.
STEP 81
Install the hose for the suction tube and tighten the
clamps on the hose, Install the guard and install the cap
screws and flat washers. Tighten the cap screws.
Install the boot over the jam nut and parking brake
cable. Install the bolts, clamp, spacer, and nuts that
fasten the parking brake cable to the bracket on the
transaxle. Tighten the nuts.

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
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
STEP 85
If equipped with a PTO, install the drive shaft, clamps, Raise the guard into alignment with the brackets on the
and Fetty head screws that hold the drive shaft. frame and install the bolts. Lower the floor jack and
remove the floor jack from under the machine.
6001-17
STEP 90 STEP 92
Install the flat washers and nuts on the bolts. Tighten the Install and tighten the drain plug in the transaxle.
bolts to 100 to 150 pound-feet (136 to 203 Nm).
STEP 93
STEP 91 Fill the transaxle to the correct level. If the oil drained
from the transaxle is to be used again, the oil must be
filtered before being returned to the transaxle.
STEP 94
Remove the air from the brakes according to the in-
structions in Section 7002.
STEP 95
Adjust the shift linkage for the transmission and the
power shuttle according to the instructions in Section
9001.
Install the bar on the guard for the drive shaft. Install the
bolts, flat washers, and nuts and tighten the nuts.

6001-18
REPLACING A UNIVERSAL JOINT

NOTE: This procedure shows the removal of a uni- STEP 99
versal joint for the rear drive shaft. The procedure is the
same for all drive shafts used on this machine.
STEP 96
Remove the cross from the shaft
STEP 100
Remove the snap rings. Repeat steps 97, 98, and 99 to remove the cross from
the yoke.
STEP 97
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. Start a bearing cap into the yoke. DO NOT press the
bearing cap all the way in.
STEP 98
STEP 102
Remove the bearing cap. If necessary, use pliers to

remove the bearing cap.
Install the cross in the yoke.
6001-19
STEP 103 STEP 106
Install the cross in the bearing cap. Be careful not to Install a snap ring in the groove.
move the needles.
STEP 107
STEP 104
Press the other bearing cap all the way into the yoke.
Press the other bearing cap a short distance into the
yoke. Carefully raise the cross into the top bearing cap
and press the bearing cap into the yoke. STEP 108
STEP 105
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.

6001-20
STEP 109 STEP 112
Start a bearing cap into the shaft. DO NOT press the Press the other bearing cap a short distance into the
bearing cap all the way in. shaft. Carefully raise the cross into the bearing cap and
press the bearing cap into the shaft.
STEP 110
STEP 113
Install the cross in the shaft with the grease fitting up as

shown. Use the driver and press the bearing cap into the shaft
until the groove for the snap ring can be seen.
STEP 111
STEP 114
Install the cross in the bearing cap being careful not to

move the needles. Install a snap ring.
STEP 115
Repeat steps 113 and 114 for the other bearing cap.

Section
6002
SPECIFICATIONS, SCHEMATIC AND TROUBLESHOOTING

CASE CORPORATION Issued March 1991
6002-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TOOLS 3
SCHEMATIC OF TRANSMISSION HYDRAUliC SYSTEM 4
TROUBLESHOOTING 5
Problem: Machine Will Not Move 5
Problem: Loss of Power 6
Problem: Oil in Transmission Too Hot 7
Problem: Clutch Discs Wear Too Fast or Are Burned 7
Problem: Brake Discs Wear Too Fast 7
Problem: Pinion Shaft Failure 7
CHECKING CLUTCH PRESSURE 9
CHECKING OUTPUT OF CHARGING PUMP AND SETTING OF CHARGE PRESSURE REliEF VALVE 9
CHECKING CONVERTER IN PRESSURE AND FLOW 10
CHECKING CONVERTER OUT PRESSURE AND FLOW 11
CHECKING BRAKE COOLING FLOW 11
CHECKING LUBRICATION FLOW AND PRESSURE FOR CLUTCHES 12
CHECKING LUBRICATION FLOW FOR PINION SHAFT 12
SPECIFICATIONS
Output of charging pump 15 to 17 U.S. gpm at 80 to 140 psi at 2200 rpm
(57 to 64 Umin at 551 to 965 kPa, 5.5 to 9.6 bar at 2200 r/rnin)
Charge pump relief valve 350 to 430 psi at 2200 rpm

(2413 to 2965 kPa, 24 to 30 bar at 2200 r/rnin)
Neutral pressure 75 to 135 psi at 2200 rpm

(517 to 930 kPa, 5.2 to 9.3 bar at 2200 r/rnin)
Forward and reverse clutch 175 to 230 psi at 2200 rpm

(1082 to 1586 kPa, 11 to 16 bar at 2200 r/rnin)
Flow Specifications
Torque converter in 5 to 7 U.S. gpm at 50 to 100 psi at 2200 rpm

(19 to 26.5 Umin at 345 to 689 kPa, 3.4 to 7 bar at 2200 r/rnin)
Torque converter out... Within 1/2 U.S gpm of torque converter in at 30 to 80 psi
(1.9 Umin of torque converter in at 207 to 551 kPa, 2.1 to 5.5 bar at 2200 r/min)
Brake cooling 5 to 7 U.S. gpm at 10 to 30 psi

(19 to 26.5 Umin at 69 to 207, 0.7 to 2.1 bar at 2200 r/rrun)
Clutch lubrication 5 to 7 U.S. gpm at 45 to 90 psi at 2200 rpm

(19 to 26.5 Umin at 310 to 620 kPa, 3.1 to 6.2 bar at 2200 r/rnin)

6002-3
SPECIAL TOOLS
In the U.S. and Canada, order the tools from
Service Tools
P.O. Box 314
Owatonna, MN
55060
VL Churchill Ltd.
Northants NN11 4NF
B877558
England
CAS-1B04 or 10111 Pressure Fitting Kit
B4218289M
CAS-10280 Flowmeter CAS-2026 Special Fitting Kit
B877168
CAS-1BOBor 10106 Flowmeter Fitting Kit

6002-4
1. Clutch Lubrication Oil 6. Accumulator 11. Pressure Regulator Valve 15. Brake Cooling Oil
2. Reverse Clutch 7. Clutch Cutout Valve 12. Charging Pump 16. PTO Control Valve
3. Forward CLutch 8. Dual Regulator Valve 13. Torque Converter 17. PTO Clutch
4. Spool 9. Filter 14. Oil Cooler 18. Pinion Lubricaion Oil
5. Modulator Valve 10. Torque Converter
Relief Valve

6002-5
TROUBLESHOOTING
Problem: Machine Will Not Move
Troubleshooting complete. Find cause of

loss of oil.
Check the setting of the torque converter

relief valve and repair as required.
There can be a problem in the torque con-

verter housing or the torque converter.
Repair as required.
If the drive shaft turned with the direction

control lever in NEUTRAl but did not turn in
forward or reverse, the problem is in the
transaxle.
Check the pressure for the forward and

reverse clutches.
The clutch cutout solenoid is not working

correctly. Repair as required.
The dual regulator valve in the transmis-

sion control valve is not working correctly.
Remove the parts and repair as required.
Check the output of charging pump and

the setting of the charge pressure relief
valve and repair as required.
The problem can be broken parts in the

transaxle. Repair as required.
The problem can also be caused by bad

seals for the clutch piston. bad sealing
rings on the shaft or a worn wear sleeve in
the bore for the shaft.

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 transmis-

sion control valve can also cause the
problem. Remove the parts and repair as
required.
If the pressure for the forward and reverse

clutches is less than before, the problem is
in the clutch for the PTO.
The loss of pressure can be caused by

bad seals in the clutch, bad sealing rings
on the shaft or a worn wear sleeve in the
rear bore for the shaft for the PTO. 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 spe-
cified, the problem can be the clutch
cutout solenoid or the control valve. Repair
as required.

6002-7
Problem: Oil In Transmission Too Hot

Check torque converter in pressure and NO Remove and inspect the parts of the
flow. Is the pressure and flow as specified? ~ 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 lubrica-

tion 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

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 trans-
axle. 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.

6002-9
CHECKING CLUTCH PRESSURE

Equipment Required
CAS-10111 or CAS-1804 pressure fitting kit
Test Procedure
Parking brake applied.
Shift lever in NEUTRAL.
Oil at operating temperature.
400 psi (2758 kPa, 27 bar) gauge connected to

FORWARD port.
Engine running at 2200 rpm (r/min).
Move direction control lever to FORWARD.
Read gauge and record the reading.
See page 2 for the specification.
Repeat the procedure at the REVERSE port.
CHECKING OUTPUT OF CHARGING PUMP AND SETTING OF

CHARGE PRESSURE.RELIEF VALVE
Equipment Required
CAS-10106 or CAS-1808 flowmeter fitting kit.
CAS-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.
With the engine running at 2200 rpm (r/min), slowly
Parking brake applied. close load valve until the pressure stops increasing and
record the reading.
Load valve for flowmeter open.
See page 2 for specifications.

6002-10
CHECKING CONVERTER IN PRESSURE AND FLOW

Equipment Required
CAS-1 01 06 or CAS-1808 flowmeter fitting kit.
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. Tube replaced
with hose for late production.
Engine running at 2200 rpm (r/min).
Read the flow gauge and the pressure gauge and

See page 2 for the specifications.

6002-11
CHECKING CONVERTER OUT PRESSURE AND FLOW

Equipment Required
Test Procedure
Parking brake applied. Bottom of torque converter housing
Engine running at 2200 rpm (r/rnin).
Read the flow gauge and record the reading.
See page 2 for the specification.
CHECKING BRAKE COOLING FLOW

Equipment Required
Test Procedure
Read the flow gauge and the pressure gauge and


6002-12
CHECKING LUBRICATION FLOW AND PRESSURE FOR CLUTCHES

Equipment Required
CAS-1 01 06 or CAS-1808 flowmeter fitting kit.
CAS-10111 or CAS-1804 pressure fitting kit
CAS-2026 special fitting kit
Test Procedure
Connect the inlet of the flowmeter to port 1.
Connect the outlet of the flowmeter to port 2.
Connect a 100 psi (670 kPa, 6.7 bar) gauge to port 3
Load valve for flowmeter open
Engine running at 2200 rpm (rzmin).
Read the flow gauge and record the reading.
Read the pressure gauge and record the reading
LUBRICATION FLOW FOR PINION SHAFT

An estimate of the lubrication flow can be made from
known flow readings as shown in the following
example. The specified flow is 1-1/2 to 2 U.S. gpm (5.7
to 7.6 Umin).
U.S. gpm Umin
flow for torque converter in 6.6 25

flow for clutch lubrication + 5.8 + 22
12.4 47
pump output 14.4 54.5

answer from above -12.4 - 47.0
lubrication flow for pinion shaft 2.0 7.5

Section
6003
WHEELS AND TIRES

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)

Section
6019
HYDRAULIC PTO
J I Case Company
CASE CORPORATION Don 7-37060 Printed in U.S.A.
December 1990
OUl ~:h:~
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SPECIAL TOOLS 3
SHOP EQUIPMENT TOOLS 3
PTa HOUSING
Removal 4
Installation 5
PTa INPUT SHAFT (PRIMARY)

Removal and Disassembly 6
PTO CLUTCH
Removal 7
Disassembly 8
Inspection ,9
Assembly 10
Cross Sectional Drawing of the PTa Clutch 13
Installation 14
PTO VALVE
Removal 14
Disassembly 15
Assembly 16
Cross Sectional Drawing of the PTa Valve 17
Installation 18
INPUT AND OUTPUT SHAFTS

Removal 19
Installation 21
SPECIFICATIONS
Lubrication Hy-Tran Plus (MS1207)
Input Shaft End Play 0.025 to 0.127 mm 0.001 to 0.005 inch
Output Shaft End Play.......... 0.025 to 0.127 mm 0.001 to 0.005 inch
Clutch Friction Plate Thickness 2.45 to 2.60 mm 0.096 to 0.102 inch
Clutch Separator Plate Thickness 2.11 to 2.31 mm 0.083 to 0.091 inch
SPECIAL TORQUES
PTO Housing Retaining Bolts 195 to 250 Nm 145 to 185 Ib ft
PTO Valve Retaining Bolts 73 to 87 Nm 54 to 64 Ib ft
PTO Clutch Hub Retaining Bolt 101 to 113 Nm 75 to 83 Ib ft
Don 7-37060 Issued 12-90 Printed in U.S.A

6019-3
SPECIAL TOOLS
1. CLUTCH SPRING COMPRESSOR 2. SEAL EXPANDER/PROTECTOR

CAS 1992 CAS 2001
First Used on Page 8 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 4. PRIMER 'N' 8500637
2. TORQUE WRENCH OEM 6480 5. DIAL GAUGE OEM 1030-1
3. SEALANT B17555 LOCmE 515 6. IMPACT HAMMER OEM 4251
Don 7-37060 Issued 12-90 Printed in U.S.A.

6019-4
PTO HOUSING
Removal
STEP 1
Park the machine on level ground and apply the parking

brake.
STEP 2
Lower the bucket to ground level.
STEP 3
~. :".
~,
~
Install 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 was removed for

photographic purposes only.

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).

6019-6
P.T.G. INPUT SHAFT (PRIMARY)

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 and discard the oil seal from the housing.
Remove the shaft and bearing with a soft hammer.
STEP 18
NOTE: If the PTO housing has been removed it will not
be necessary to remove the end cover. Remove the Examine all parts and replace if necessary.
seal and outer bearing snap ring. Use a soft hammer
and drive the input shaft iotweto out of the end cover.
1. SHAFT
2. SNAP RING INP580
3. BEARING
4. SEAL

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 21 STEP 24
Refer to Steps 1 to 7 and remove the PTO housing from
the transaxle.
STEP 22
029626
030215
Remove the three bolts (1) and shroud (2) from the
housing.
STEP 23
Remove the bolt (1) and clutch assembly (2) from the
input shaft. Remove and discard the two rubber seals
(3) from the input shsft.
030217
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 25 STEP 28
029817 C26827
Remove the snap ring (1) backing plate (2) four clutch Turn the clutch housing over, shock the housing against
plates (3) and four separate plates (4) in alternate order a wooden block to remove the piston (1).
from the housing.
STEP 29
STEP 26
C26829
Remove and discard the o-rings and seals (1) from the
Install the clutch assembly and special tool CAS 1992 piston.
(1) into a press and compress the spring. Remove the
snap ring (2). STEP 30
STEP 27
D30223
Remove the snap ring (1), brake plate (2), springs (3),
brake assembly (4) and inner brake plate (5) from the
Release the pressure and remove the retainer (1) and clutch housing.
spring (2).

6019-9
STEP 31 STEP 32
C27202
Remove the three piston pins (1) and discard the Remove the needle roller bearing (1) and clutch
a-rings (2). assembly retaining washer (2) from the housing.
Inspection
STEP 33 STEP 35
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)

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 C26829
housing (3). Install the o-rings and seals (1) onto the clutch piston.
STEP 37 STEP 40
808132
Install new o-rings (1) onto the three piston brake pins Lubricate and install the piston into the housing. Push in
(2). Install the pins. the piston equally from all sides until fully installed.
NOTE: 00 not use a driver or press to install the piston

into the clutch housing.

6019-12
STEP 41 STEP 43
ll30221
Install the clutch housing into a press. Install the piston Install new rubber seals (1) onto the input shaft.
return spring and retainer. Compress the spring with the
special tool CAS 1992 (1) and install the snap ring (2). NOTE: The larger diameter seal is installed first.
STEP 42
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).

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

6019-14
Installation
STEP 44 STEP 46
029626
Install the PTO clutch assembly (1), and retaining bolt Install the shroud (1) and retaining bolts (2). Tighten the
(2). Tighten the bolt to a torque of 101 to 113 Nm (75 to bolts.
83 Ib ft).
STEP 47
STEP 45
Install the PTO housing. Refer to Steps 8 to 13.
030217
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
Remove the bolts and valve assembly. Discard the

o-rings (1).
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 51 STEP 54
808019 B08027
Remove the spring (1), detent (2) and ball (3) from the Remove the spool (1) from the valve body.
valve body.
STEP 55
STEP 52
Wash all parts in cleaning solvent and dry using
compressed air
STEP 56
Replace any part that shows signs of wear or damage.
B08021
Remove the snap ring (1) retaining the end cap.

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.

6019-17
Cross Sectional Drawing of the PTO Valve
1. SPOOL
2. VALVE BODY
3. BALL
4. VALVE
5. SECONDARY SPRING
6. RETURN SPRING
7. PRIMARY SPRING
8. SNAP RING
9. END CAP
10. DETENT GUIDE
11. DETENT SPRING
12. SCREW
13. NUT
14. WASHER
15. SEAL WASHER
PTOV580

6019-18
Installation
STEP 58 STEP 59
Install new o-rings (1) to the valve body. Install the valve
and tighten the retaining bolts to a torque of 73 to 87 Nm
(54 to 64 Ib tt).

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.

6019-20
STEP 66 STEP 67
029814
808425
Remove the snap ring from the housing and install the Examine the bearings, gears, snap rings, rear bearing
impact hammer OEM 4251 (1). Remove the input shaft cup (1) and seal sleeve (2) for wear and damage.
and front bearing cone. Discard the two seals from the Replace if necessary.
input shaft.
Don 7-37060 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 68 STEP 69
C21727 C21730
Use the special tool CAS 2001 to expand and install the Install the special tool CAS 2005-3 to compress the
new seals (1) onto the input shaft. seals to the correct diameter.
IMPORTANT: Soak the seals in Hy-Tran Plus before IMPORTANT: The correct seal operating size can only
installation. be obtained by using the special tools.

6019-22
STEP 70 STEP 73
D29636
Install the input shaft, front bearing cone and snap ring. Install the rear bearing cone and snap ring.
Install the inpact hammer and seat the bearing cone
against the snap ring (1). STEP 74
STEP 71
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
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
029802 end play measures 0.025 to 0.127 mm (0.001 to 0.005
Install the gear and output shaft into the PTa housing. inch).

6019-23
STEP 76 STEP 77
Install the clutch and PTO valve assemblies. Refer to

Steps 44 and 58.
STEP 78
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

Don 7-36980 Printed in U.S.A.
CASE CORPORATION
December 1990
6201-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SPECIAL TOOLS 3
TOOLS TO BE MADE 4
SERVICING THE REAR AXLES AND PLANETARIES

Removal 5
Disassembly 6
Inspection 9
Assembly 10
Installation 15
SPECIFICATIONS
Lubrication
Transmission Oil. Hy-Tran Plus (MS 1207)
Axle Shaft Bearing Rolling Torque 3.4 to 5.7 Nm 30 to 50 Ib inches
SPECIAL TORQUES
Rear Axles To Transmission Case 326 to 353 Nm 240 to 260 Ib ft

6201-3
SPECIAL TOOLS
1. SEAL INSTALLATION TOOL FOR REAR AXLE 2. lOCKNUT SOCKET FOR REAR AXLE SHAFT NUT
CAS 2007 CAS 2006
1. TORQUE WRENCH
OEM 6475
2. SEALANT B500642 lOCTITE 324

ACTIVATOR B500622 lOCTITE 707
KIT PART NUMBER B500621
3.BEARING OVEN OEM 8014
5. ALIGNMENT STUD SET

CAS 1995

6201-4
TOOLS TO BE MADE
AXLE BEARING PRE-LOAD SETIING TOOL
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)
7.36980 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 STEP 4
machine to service the rear axles and planetaries.
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.

6201-6
Disassembly
STEP 5 STEP 8
, .~
Remove the snap rings from the three planet gear pins, Remove the planet gear carrier assembly from the axle
housing.
STEP 6
STEP 9
C13206
Remove the steel plate.

Use a suitable drift punch to move the tab on the lock
STEP 7 washer away from the ring nut.
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.

6201-7
STEP 11 STEP 14
~.-'.
Remove and discard the lock washer. Use a lever to remove the shaft seal from the rear axle
case.
STEP 12
STEP 15

Remove the axle shaft from the rear axle case.
STEP 13
STEP 16
Ale.
BOIl520
Put the rear axle in a horizontal position and remove the
inner bearing from the axle shaft. Install the puller, OEM 1108, and remove the bearing
from the axle shaft.

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.
Remove the separator.
NOTE: Remove the bottom thrust washer with the gears
to retain the loose bearing rollers.

6201-9
STEP 23 STEP 24
013 014
Remove the bottom rollers. Remove the planet gear from the bottom washer.
Inspection
STEP 25
STEP 28
Clean all parts in cleaning solvent and dry in
compressed air. DO NOT permit the bearings to rotate
when drying.
STEP 26
A35
Check the 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 STEP 29
root. Replace the planet gears in sets only.
STEP 27
A3S
h #
Check the ring gear and axle case for cracks or other
damage. Replace as necessary.
Check the planet gear pins and the splines in the carrier
for wear or damage and replace if necessary. NOTE: The ring gear and axle housing cannot be
serviced separately.
NOTE: The Flat side of the pin faces outvvard.
6201-10
Assembly
EA2583

6201-11
STEP 30 $TEP 33
Clean the faces of the rear axle case and the trans axle
housing.
STEP 31
3. BEARING 51252
Putthe axle case in a horizontal position. Install the axle

shaft, assembly and seal installer CAS 2007 into the
axle housing.
Lubricate the new oil seal (1), with clean transmission
oil. Install the seal onto the axle shaft so that the lip is STEP 34
toward the flange (2), (groove inward).
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).

6201-12
STEP 35 STEP 36
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.

6201-13
STEP 39 STEP 41
EC3227A
Use the Specia Iy made tool bolted across the Lubricate the bearing rollers with petroleum jelly and
centerline of the axle, with the nut in the center. Use a install the bottom set.
torque wrench to measure the rolling torque at the nut,
"
with the axle resting on the axle flange (measure the STEP 42
rolling torque with no bearing preload). Make a note of
the rolling torque. Tighten the nut using the Special tool
(CAS 2006). While rotating the axle housing, preload
the bearings to 3.4 to 5.7 Nm (30 to 50 Ib in) above the
measurement noted with no bearing preload. Loosen
the ring nut and hit the inner end of the axle shaft with a
soft hammer if the rolling torque is incorrect. Repeat the
setting procedure.
NOTE: When the bearing pre-load is correct, move a

tab on the lock washer into one of the slots in the ring
nut.
011
STEP 40 Install the separator.
STEP 43
Lubricate the surface of the bottom washer with

petroleum jelly and install a planet gear on to the
washer. Install the top set of bearing rollers.

6201-14
STEP 44 STEP 47
DB
Install the 'D' washer to the top of the planet gear. Install the planet gear carrier assembly into the axle
Repeat the procedure for the remaining two planet housing.
gears.
STEP 48
STEP 45
C13208
C13222 Install the snap ring onto the axle shaft.

Install the snap ring onto the planet carrier.
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
Clean the surface of the rear axle housing and apply

712B9GA Activator CAS 8500622 (Loctite 707).
aean the surface of the transaxle housing and apply
Sealant CAS 8500642 (Loctite 324). STEP 53'
IMPORTANT: Do not get sealant onto the brake Install the two alignment studs CAS 1995.
surfaces.

6201-16
STEP 54 STEP 56
Use suitable lifting equipment to install the rear axle Install the remaining two bolts and washers then evenly
onto the transaxle housing. tighten all the bolts to a torque of 326 to 353 Nm (240 to
260 Ib ft).
STEP 57
Install the transaxle into the machine.
STEP 58
STEP 55
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.

Section
6202
TRANSFER GEARBOX

December 1990
6202-2
TABLE OF CONTENTS
SPECIAL TORQUES 2
TRANSFER GEARBOX
Removal 3
Disassembly 3
Inspection 6
Assembly 7
Installation 10
SPECIAL TORQUES
Transfer Gearbox to Parking Brake Housing 77 to 100 Nm 57 to 74 Ib ft
1. TORQUE WRENCH (OEM 6475) 2. SEALANT 817555 (LOCnTE 515)

+ PRIMER 'N' 8500637

6202-3
SERVICING THE TRANSFER GEARBOX

Removal
NOTE: It is not necessary to remove the transaxle from STEP 5
the machine to service the transfer gearbox. The
transaxle shown was removed for photographic
purposes only.
STEP 1
To prevent excessive loss of oil from the transaxle raise

the front of the machine and support on axle stands.
STEP 2
Remove the drive shaft. Refer to Section 6001.
STEP 3 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.

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 the shift rod seal
housing.
STEP 14
Remove the two pads from the shift fork.
Remove the snap ring from the yoke.

6202-5
STEP 15 STEP 18
Use a hydraulic press to remove the yoke from the Remove the bearing retainer snap ring from the
housing in the direction shown. housing.
STEP 16 STEP 19
Remove the snap ring from the yoke. Use a hydraulic press to remove the bearing from the
housing.
STEP 17
Remove and discard the seal.

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.

6202-7
Assembly
3. SNAP RING
5. SHIFT ROD
6. HOUSING
8. SHIFT COLlAR
EA2S87

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 Rotate the shift lever to the correct position. Align the
level with the housing. holes and install the roll pins.
STEP 31 STEP 34
Install the shift fork so the detent groove is aligned with Install the two pads into the shift fork.
the hole in the housing.

6202-10
STEP 35 STEP 37
~::.
Install the shift collar onto the two pads with the flat side Install a new o-ring onto the plug.
of the collar faces inward. Align the splines and slide
the collar over the yoke. STEP 38
STEP 36
Install and tighten the plug.
Install the detent plunger and spring. STEP 39
Check the movement of the shift collar by moving the

shift rod. Make sure the detent plunger holds the shift
fork in the engaged and disengaged positions. Rotate
the yoke and repeat the test.
Installation
STEP 40 STEP 41
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' Install the transfer gearbox onto the park brake housing.
8500637 to the transfer gearbox housing.
Don 7-36990 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.
STEP 46
Install the five bolts and washers and evenly tighten to a
torque of 77 to 100 Nm (57 to 74 Ib ft). Add oil of the correct type to the transmission until the
level reaches the full mark on the dipstick.

"
Section
6203
DIFFERENTIAL AND DIFFERENTIAL LOCK

CASE CORPORATION December 1990
6203-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SERVICING THE DIFFERENTIAL AND DIFFERENTIAL LOCK

Removal........ 4
Disassembly , , 6
Inspection....... 9
Assembly ,....................................................................................................................... 10
Installation.............................................................................................................................. 13
SPECIFICATIONS
Lubrication
Transmission OiL Hy-Tran Plus (MS 1207)
SPECIAL TORQUES
Rear Axles To Transmission Case 326 to 353 Nm 240 to 260 Ib ft
Differential Bearing Carrier Bolts 73 to 87 Nm 54 to 64 Ib ft
(Tighten While Rotating The Differential)
Differential Lock Cage To Carrier 73 to 87 Nm 54 to 64 Ib ft
Differential Carrier To Crown Wheel. 126 to 153 Nm 93 to 113 Ib ft

6203-3
1. TORQUE WRENCH (OEM 6475)
4. DEPTH GAUGE (OEM 1013)
2. SEALANT CAS B17555 (LOCTITE 515) AND

PRIMER 'N' B500637
5. BEARING OVEN (OEM 8014)
6. THREAD SEALANT
LOCTITE 680
3. DIAL GAUGE AND MAGNETIC BLOCK

(OEM 1030-1)
NOTE: Any reference to left or right hand is as seen from the operator's seat looking forward.

6203-4
SERVICING THE DIFFERENTIAL AND DIFFERENTIAL LOCK
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 STEP 6

reaction pins from the left side of the transmission
housing. Refer to Section 7001 for the correct
procedure.
NOTE: Do not remove the brake piston.
Disconnect the return spring from the top of the

differential lock selector lever.

6203-5
STEP 7 STEP 10
Use a punch to remove the pin from the differential lock Remove the nuts, bolts, washers and setscrews from
selector fork and lever. the rear cover plate.
STEP 8 STEP 11
Remove the differential lock lever from the transmission Remove the rear cover plate.
housing.
STEP 12
STEP 9
..•. .~
Use a block of wood to support the differential.

Remove the sun shaft and differential lock selector
assembly.

6203-6
STEP 13 STEP 15
Remove the four bolts and washers from the right hand Repeat the procedure for the differential bearing carrier
differential bearing carrier. on the left hand side.
STEP 14 STEP 16'

~?
Remove the differential bearing carrier and shims from Carefully remove the differential.
the transmission case.
Disassembly
STEP 17 STEP 18
Put the differential assembly on a clean work surface. Remove the bolts which hold the differential lock cage
to the differential carrier.

6203-7
STEP 19 STEP 22
..... ,;;;..;:.
F21
Remove the differential lock cage. Install two 12mm bolts into the threaded holes in the
differential carrier. Evenly tighten the bolts to push the
STEP 20 crown wheel from the differential carrier.
STEP 23
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.

6203-8
STEP 25 STEP 28
..d., G16
Remove the planetary gear pin from the differential Put the differential lock selector and sun shaft on a
carrier. clean work area.
STEP 26 STEP 29
Remove the two planetary gears. Remove the selector fork and pads.
STEP 27 STEP 30
·.G19
Remove the second side gear. Remove the selector from the sun shaft.

6203-9
Inspection
STEP 31 STEP 34

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.

6203-10
EA2586B

6203-11
STEP 37 STEP 40
Lubricate the differential lock selector with clean Install the left hand side gear into the differential carrier.
transmission oil then slide it onto the inner splines on
the sun shaft. Make sure that the selector teeth are
away from the sun gear. STEP 41
STEP 38
Install the two planet gears.
Install the two pads into the selector fork. Use STEP 42
petroleum jelly to hold them in position.
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.

6203-12
STEP 43 STEP 46
G36
Install a new grooved pin into the differential carrier and Apply (Loctite 680) to the threads and install the twelve
planet gear pin. 12mm bolts and new hardened washers into the
differential carrier and crown wheel.
STEP 44
STEP 47
Install two guide studs into opposite holes in the crown F24
wheel. Evenly tighten the bolts to a torque of 126 to 153 Nm (93

to 113 Ib ft).
STEP 45
STEP 48
F3S
Heat the crown wheel in a bearing oven to a maximum
temperature of 302°F (150°C) and install the crown Install the right hand side gear and lubricate the gears
wheel onto the differential carrier. When the parts are with clean transmission oil.
cool, remove the guide studs.
h WARNING: Always wear heat protective

••• gloves when touching heated parts.

6203-13
STEP 49 STEP 51
~':
Install the differential lock cage onto the differential Evenly tighten the bolts to a torque of 73 to 87 Nm (54 to
carrier. 64 Ib ft). Lubricate the bearing with clean transmission
oil.
STEP 50
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 Install new inner and outer o-rings onto the tube nut.
the top of the transmission housing.

6203-14
STEP 54 STEP 57
w~:,
",.
Install the tube nut into the transmission housing. Install the four 1Omm bolts and new hardened washers.
STEP
, 55 STEP 58
~
Install the differential into the transmission housing, so Evenly tighten the bolts to a torque of 73 to 87 Nm (54 to
thatthe crown wheel teeth are pointing to the right hand 64 Ib ft).
side of the housing.
STEP 59
STEP 56
Install the left hand bearing carrier without shims.

Install the right hand bearing carrier without shims.
NOTE: Make sure the hole for the differential lock

control rod is properly aligned.

6203-15
STEP 60 STEP 62
Install two bolts and new hardened washers into Using a depth gauge, measure the distance from the
opposite holes then remove the wood block from under face of the carrier to the transxaxle mounting face,
the differential. through the measuring holes. If the difference in the
measurements is 0.13mm (0.005 in.) or less, take the
STEP 61 average of the two measurements. If the difference is
greater than 0.13mm, disassemble and check for
proper bearing seating. Subtract the carrier flange
thickness from this figure and add the aero-set constant
of 0.065mm (0.0026 in.) to the measured gap. This is
the shim pack required for the correct bearing preload.
STEP 63
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 Remove the two bolts, washers and the left hand
seated. Continue this procedure until there is no change bearing carrier. Fit the total shim thickness onto the
in bolt torque. bearing carrier and install the bearing carrier.
STEP 64
Install the bolts and washers onto the bearing carrier.

6203-16
STEP 65 STEP 67
While rotating the differential, evenly tighten the bolts to Remove any old joint material from the rear cover plate
a torque of 73 to 87 Nm (54 to 64 Ib ft). The bearings and the joint face of the transmission housing. Make
are now correctly pre-loaded. sure both faces are free of oil.
STEP 66 STEP 68
Use a dial gauge on the edge of a crown wheel tooth to Apply a continuous bead of CAS 817555 (Loctite 515)
measure the amount of backlash between the crown onto the joint face of the transmission housing. Apply
wheel and the pinion. This must be between 0.15 to Primer 'N' 8500637 onto the mounting face of the
0.30 mm (0.006 to 0.012 inch). To change the amount cover.
of backlash, move some of the shims from the left hand
bearing carrier to the right hand bearing carrier, without STEP 69
changing the total shim pack thickness. For each 0.076
mm (0.003 inch) of shim thickness moved, the
backlash will change by approximately 0.05 mm (0.002
inch).
After moving the shims. rotate the differential and
evenly tighten the bearing carrier bolts to a torque of 73
to 87 Nm (54 to 64 Ib ft).
Check the ring gear to pinion shaft contact pattern.
Refer to Section 6206
Install the rear cover plate onto the transmission

housing

6203-17
STEP 70 STEP 73
Install the nuts, bolts, washers and setscrews and Install a new pin into the selector fork and lever.
evenly tighten to a torque of 221 to 250 Nm (160 to 185
Ib ft). STEP 74
STEP 71
Connect the return spring to the selector lever.
Install the sun shaft and differential lock selector STEP 75

assembly into the right hand side of the differential.
Make sure that the selector fork is at the rear.
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.

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.

Section
6204
FORWARD / REVERSE VALVE

December 1990
6204-2
TABLE OF CONTENTS
SPECIFICATIONS _ 2
SPECIAL TORQUES 2
FORWARD/REVERSE VALVE
Disassembly 3
Inspection 5
Assembly 6
SPECIFICATIONS
Transmission Lubricating Oil Hy-Trans Plus (to MS 1207)
Spool Detent Spring Free Length 37.26 mm 1.467 inch
Regulator Spring Free Length 58.65 mm 2.309 inch
Modulation Spool Inner Spring Free Length 70.55 mm 2.777 inch
Modulation Spool Outer Spring Free Length 77.60 mm 3.055 inch
SPECIAL TORQUES
Forward/Reverse Spool Plug 31 to 34 Nm 23 to 25 Ib ft
Detent Plug 16 to 18 Nm 12 to 13 Ib ft
Accumulator Piston Plug 31 to 34 Nm 23 to 25 Ib ft
Pressure Regulator Piston Plug 42 to 45 Nm 31 to 33 Ib ft
Solenoid Valve 17 to 20 Nm 13 to 15 Ib ft
Coil Cover Nut.. 0.8 to 1.0 Nm 0.5 to 0.75 Ib ft
Neutral Start Switch 20 to 27 Nm 15 to 20 Ib ft

1. TORQUE WRENCH
OEM 6479

6204-3
Disassembly
STEP 1 STEP 4".".".. --y".' •
Remove the connecting wires and neutral start switch Remove the solenoid valve (1) from the valve body and
(1) from the valve body. Discard the a-ring from the discard the o-rings (2).
switch.
STEP 5
STEP 2
Remove the allen plugs from the top of the valve body
and discard the a-rings.
STEP 3
Remove the 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) IMPORTANT: Machines equipped with PTO have a
from the solenoid valve. Discard the a-rings. special hexagon plug (A) to keep the pressure regulator
piston activated for PTO operation with the transmission
control lever in neutral. Remove the plug and
components as in Step 5, discard the a-ring from the
plug.

6204-4
STEP 6 STEP 9
Remove the allen plug (1), accumulator piston (2),

secondary spring (3) and primary spring (4). Discard
'~~7r
Remove the allen plug (1) and forward/reverse spool
"i1Jons
(2). Discard the ring (3) from the spool and o-ring from
the o-ring on the plug. the plug.
STEP 7 STEP 10
030111 030117
Remove the allen plug from the opposite end of the Remove and discard the oil seal (1) from the bore of the
same bore and remove the modulation pressure forward/reverse spool.
regulator spool (1) Discard the o-ring (2) from the plug.
STEP 8
Remove the allen plug (1), spring (2) and detent (3).
Discard the o-ring (4).

6204-5
Inspection
STEP 11 STEP 13
Clean all parts in cleaning solvent. Dry using

compressed air. DO NOT use cloths.
STEP 12
Inspect all the components for wear and replace if

necessary. Replace the valve assembly if there is any
damage to the surfaces of the bores and spools.
FRYOR
Make sure the oil restrictor (1) is clean. Remove

obstructions with compressed air or a soft wire.

6204-6
Assembly
1. BODY 9. PIN
2. SWITCH 10. SPOOL
3. PLUG 11. ACCUMU
12. MODULA~TOR PISTON
4. O-RING
13 SE OR SPOOL
5. Oil RESTRICTOR . LECTOR SPOOL
6. SOLENOID 14. RING
7. REGULATO VAlVE ASSEMBLY
15. DETENT
8. SPRING R PISTON
16. SEAL

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.

6204-8
STEP 20 STEP 23
000110 000106
Install a new a-ring (1) onto the plug. Install the primary Install a new o-ring (1), cover (2), o-ring (3) and nut (4).
spring (2), secondary spring (3) and accumulator Tighten the nut to a torque of 0.8 to 1.0 Nm (0.6 to 0.71b
piston (4). Install and tighten the plug. ft)
STEP 21 STEP 24
000119 000105
Install a new o-ring (1) onto the plug. Install the Install new o-rings onto the plugs. Install and tighten the
regulator spool (2), pin (3), spring (4) pressure regulator plugs.
piston (5). Install and tighten the plug.
STEP 25
STEP 22
D30233
030107 Install a new o-ring onto the neutral start switch. Install
Install new a-rings (1) onto the solenoid valve 2. Install and tighten to a torque of 20 to 27 Nm (15 to 20) Ib ft.
and tighten the valve to a torque of 20 Nm (15 Ib ft). Install the wires and tighten the screws.

Section
6205
TORQUE CONVERTER CHARGING PUMP, OUTPUT SHAFT,
AND CONVERTER HOUSING

December 1990
6205-2
TABLE OF CONTENTS
SPECIAL TORQUES 2
SERVICING THE CHARGING PUMP

Removal 3
Disassembly 4
Inspection 5
Assembly 6
Installation 8
SERVICING THE OUTPUT SHAFT

Removal 9
Inspection.................................... 10
Installation 11
SERVICING THE TORQUE CONVERTER HOUSiNG 13
SPECIAL TORQUES
Charging Pump Retaining Bolts 23 to 30 Nm 17 to 22 Ibs ft
Output Shaft Locknut 217 to 271 Nm 160 to 200 Ibs ft

6205-3
SERVICING THE CHARGING PUMP

Removal
STEP 1 STEP 4
Remove the torque converter housing from the

machine. Refer to Section 6200.
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

6205-4
Disassembly
STEP 5 STEP 8
X13
Loosen the internal hexagon screw that holds the stator Remove the drive gear.
support to the pump body.
STEP 9
STEP 6
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
Remove and discard the seal from the pump body.

Xll
For easy assembly, make a mark on the pump body,

driven gear and drive gear.

6205-5
Inspection
STEP 11 STEP 12
X22
1. Clean all the parts in cleaning solvent and dry in If a new converter support bushing (1) is installed, make
compressed air. sure that it fits against the internal shoulders (2) as
2. Only the seal and two bushings are available shown.
separately as service parts. If there is damage to
any other part of the charging pump, you must
install a new assembly.
3. Check the two gears for wear and damage.
4. Check the body and converter support for pitting,
scoring, cracks and wear.
5. There is only a small amount of clearance
between the parts of the charging pump. It is
possible for the parts to look good but still be
worn enough for the charging pump to be
replaced. If troubleshooting shows that there is
not enough flow from the charging pump, install a
new assembly.
NOTE: Low charge pump pressure could be caused by

the charge regulator valve stuck open.

6205-6
Assembly
62056

6205-7
STEP 13 STEP 17
Before assembly, lubricate all the parts with clean

transmission oil.
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.

6205-8
Installation
STEP 19 STEP 21
;, X1
Lubricate and install a new o-ring seal into the torque Install the four retaining bolts and new flat washers and
converter housing. evenly tighten to a torque of 23 to 30 Nm (17 to 22 Ib ft).
STEP 20 STEP 22
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.

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
Remove and discard the oil seal from the outer face of
Hold the coupling in a vice and remove the locknut and the torque converter housing.
washer.
STEP 28
NOTE: The coupling is shown out of the vice for
photographic purposes. When removing or installing Remove the output shaft bearing snap ring from the
the drive coupling nut, clamp the coupling in the vice torque converter housing.
and not the input shaft. This will prevent possible
damage to the shaft and splines. STEP 29
STEP 25
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.

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.

6205-11
Installati on
6205138

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 Install the washer and lock nut. Hold the coupling in a
coverter housing and install the snap ring. vise and tighten the lock nut to a torque of 217 to 271
Nm (160 to 200 Ibs ft).

6205-13
SERVICING THE TORQUE CONVERTER HOUSING
62115130

6205-14
STEP 41 STEP 44
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.
Use a magnet to remove the steel ball.
STEP 42
STEP 45
Remove the plug for the charging pump relief valve.

Use a suitable wood or plastic dowel to remove the
STEP 43 relief valve cartridge.
NOTE: If there is any damage, a new cartridge must be

installed.
STEP 46
Remove the spring.
Replace the o-ring and lubricate with clean

transmission oil.

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.

Remove the filter bypass valve from the right hand side
STEP 49 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.

Section
6206
TRANSMISSION

CASE CORPORATION Don 7·37030 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 ................................................................................................................................................................ 11
Disassembly ......................................................................................................................................................... 11
Inspection ............................................................................................................................................................. 14
Assembly .............................................................................................................................................................. 15
Installation ............................................................................................................................................................. 19
SERVICING THE PINION SHAFT

Disassembly ............................................................................................................................................................ 19
Inspection ............................................................................................................................................................. 25
Assembly .............................................................................................................................................................. 26
Checking Ring Gear and Pinion Tooth Contact .................................................................................................. 37
SERVICING THE GEAR SHIFTERS

Removal ................................................................................................................................................................ 39
Disassembly ......................................................................................................................................................... 40
Inspection ............................................................................................................................................................. 41
Assembly .............................................................................................................................................................. 42
Installation ............................................................................................................................................................. 43
Adjustment ........................................................................................................................................................... 44
REMOVAL AND INSTALLATION OF THE MAGNETIC SPEED SENSOR .................................................................. .44
INSTALLATION OF TRANSAXLE REAR COVER .........................................................................................................45
SPECIFICATIONS
Lubricating Oil ...........................................................................................................................Hy-Tran Plus (MS 1207)
SPECIAL TORQUES
Transmission End Cover BoiL .......................................................... 195 to 250 Nm 145 to 185 Ib ft
Pinion Shaft End Bolt.. ....................................................................... 251 to 280 Nm 185 to 205 Ib ft
Transmission Rear Cover Bolts ......................................................... 195 to 250 Nm 145 to 185 Ib ft
Gear Shift Rail Retaining Bolts ............................................................... 44 to 58 Nm 33 to 43 Ib ft
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 4. SEAL EXPANDER/PROTECTOR SHUTTLE SHAFT

CAS 1998 CAS 1999
2. SEAL COMPRESSOR SET 5. PINION SHAFT MASTER BEARING CONE

CAS 2005-1 CAS 2019
3. CLUTCH PACK SPRING COMPRESSOR 6. TRANSMISSION BEARING RACE RETAINER

CAS 1992 CAS 2008

6206-4
4. DIAL GAUGE WITH MAGNETIC BASE (OEM 1030)
2. SEALANT B17555 (LOCTITE 515)

AND PRIMER 'N' B500637
5. METRIC FEELER GAUGE (OEM 1024)
3. BEARING OVEN (OEM 8014)

6206-5

Removal
NOTE: To service the transmission the transaxle must STEP 4
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 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 and

assembly. Refer to Section 7000.
..,:. -.... -.;,
Remove the spacer and splined park brake hub.

6206-6
STEP 6 STEP 8
...... ..,
Remove the two bolts and plate from the end of the gear
shift rail.
STEP 7
__ ·~.~c
Remove the three blanking plugs from the end cover
and insert a 38 mm (1.5 inch) spacer into each hole.
Install and tighten the bolts evenly to separate the end
Remove the retaining bolts and washers from the cover from the transmission housing.
transmission end cover.
STEP 9
".- ~ :.:~.
Remove the bearing cone from the end of the pinion

shaft.

6206-7
STEP 10
Use suitable lifting equipment and remove the

transmission end cover.
SERVICING THE INTERMEDIATE SHAFT

Removal
STEP 11 STEP 13
Follow steps 1 to 10 to remove the transmission end
cover.
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.

6206-8
Disassembly
STEP 14 STEP
, 17
C124Q6
Mark the gears for easier assembly. Remove the second gear and spacer.
STEP 15 STEP 18
C1'22ll6
Use a press and remove the bearing cone (1), fourth Remove the second bearing cone and first gear.
drive gear (2) and spacer(3).
STEP 16
Remove the third gear.

6206-9
Inspection
STEP 19
Clean all parts in cleaning solvent and dry using

while drying. Check all the parts for wear and damage
and replace if necessary.
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.

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 i~!

e
1. SHOULDER
shaft must be at the fourth gear end.
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 22 STEP 23
Install the intermediate shaft the transmission Make sure the synchromesh hub, needle bearing and
housing. thrust washer is against the pinion shaft and install the
snap ring.
NOTE: Uft up the 3rd and 4th gear synchromesh hub to
allow installation of the intermediate shaft. STEP 24
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 31 STEP 32
N17 036
Remove the roller bearing (1), spacer (2) and second Remove the thrust bearing (1).
roller bearing (3).

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

STEP 35 (CAS 1992) to push the piston return spring and washer
away from the snap ring. Remove the snap ring.
STEP 38
030
Remove the clutch backing plate.
024
Remove the washer.

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 016
piston: Remove and discard the four sealing rings. Remove the
bearing cone (1), snap ring, thrust washer, thrust
Outer hole - forward piston bearing (2) and gear (3). Repeat STEPS 31 to 42 and
Inner hole - reverse piston disassemble the reverse clutch.
Middle hole - for lubrication
NOTE: Do not use levers to remove the piston. The

piston can be easily damaged by levers.

6206-14
Inspection
STEP 44 STEP 48
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 STEP 49
Check the piston for wear or damage and replace if
necessary.
STEP 46
08
Check the drive gear for damage and replace if

necessary. Look for cracks at the root of the teeth. Use
a hone to remove any small protrusions from the
··03 splines.
Check the friction plates for wear or damage and
replace if necessary. STEP 50
STEP 47
Check the shuttle shaft and replace the assembly if

05 there is wear or damage.
Check the steel wear plates for wear or damage and
replace if necessary.

6206-15
Assembly
620619

6206-16
NOTE: Before assembly, use compressed air to make STEP 54

sure that all the oil holes are clear.
STEP 51
Lubricate all the parts with clean transmission oil before

assembly. Put the seal rings for the piston and shuttle
shaft in warm transmission oil for several minutes to
prevent damage during assembly.
STEP 52
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.

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
STEP 58 plates in the clutch pack.
STEP 61
I P16
Put the shuttle shaft assembly into a press. Use the

special tool (CAS 1992) to push the piston return spring 030
and special washer below the snap ring groove. Install Install the backing plate so that the small diameter is
the snap ring. outward.
STEP 59 STEP 62
Install a steel clutch plate. Install the snap ring.

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. NOTE: Put the sealing rings in clean transmission oil
STEP 64
STEP 67
Install a roller bearing (1), spacer (2) and second roller

bearing (3). Compress the seal ring by hand and then install the seal
compressor, CAS 2005-1.
STEP 65
NOTE: Only by using the seal compressor, CAS 2005-1,
Repeat Steps 51 to 64 and assemble the reverse can the seals be compressed to the correct working
clutch. Install the gear, thrust bearing, thrust washer, size.
snap ring and bearing cone.

6206-19
Installation
STEP 68 STEP 69
2. WEAR SLEEVE
Install the shuttle shaft.
62066 NOTE: The second driven gear will have to be raised

slightly to allow the shuttle shaft to locate into the bore in
Check the wear sleeve in the transmission case for the transmission case.
damage or wear marks. If necessary, replace the wear
sleeve making sure that the oil holes are aligned with the STEP 70
holes in the top of the transmission case.
Follow STEPS 126 to 135 on servicing the pinion shaft.
SERVICING THE PINION SHAFT

Disassembly
NOTE: To prevent damage to the pinion shaft and STEP 72
crown wheel, remove the axles, differential and ~<
lubrication tube. Support the pinion shaft before starting
disassembly.
STEP 71
Remove the baffle plate.
;~
Remove the intermediate shaft. Refer to STEP 12.

6206-20
STEP 73 STEP 76
Remove the forward gear from the shuttle shaft. Remove the thrust washer (1) and needle bearing(2).
STEP 74 STEP 77
Loosen the two gear shift lever pivot bushings (1). Remove the fourth driven gear.
STEP 75 STEP 78
:~~'
,.:J ",$ .•.•
Pull the gear shift rail up from its locating bore in the Remove the washer.
transmission case. Rotate the assembly counter-
clockwise and lift the rail and shift forks clear of the
pinion shaft.

6206-21
STEP 79 STEP 82
Remove the synchromesh unit outer cup. Remove the hub.
STEP 80 STEP 83
Remove the bearing. Remove the needle bearing and synchromesh inner
cup.
STEP 81
Remove the synchromesh unit.

6206-22
STEP 84 STEP 87
Remove the third driven gear. Remove the thrust washer (1) and needle bearing (2).
STEP 85 STEP 88
Remove the needle bearing (1) and thrust washer (2). Remove the shuttle shaft.
STEP 86 NOTE: litt up the second driven gear to allow the shuttle
shaft to be lifted out of the transmission case.
STEP 89
>'
Remove the snap ring.
Remove the second driven gear.

6206-23
STEP 90 STEP 93
'.' ,
Remove the synchromesh assembly. Remove the needle bearing and thrust washer.
STEP 91 STEP 94
t.. .~
Remove the needle bearing. Remove the first driven gear with spacer.
STEP 92 STEP 95
:S.
h
£1:12121
Remove the synchromesh hub. Remove the two roller bearings.

6206-24
STEP 96 STEP 98
1
Remove the thrust washer, needle bearing and second Use a soft drift to remove the pinion bearing cup and
thrust washer. shims from the differential housing.
STEP 97 NOTE: Tie the shim pack together for easy assembly.
Remove the pinion shaft support and the pinion shaft

from the differential housing.

6206-25
Inspection
STEP 99 STEP 102
Clean all the parts in cleaning solvent and dry using

while drying.
STEP 100
Q20
Check both pinion bearings for free, smooth action. If a

new pinion bearing cone is used, install a new bearing
cup into the transmission housing.
IMPORTANT: The pinion shaft and crown wheel are a

PIS matched set and cannot be replaced separately. If there
Check the operation of the synchromesh units and is damage to either part, install a new set.
replace as necessary.
STEP 101
PIS
Check all the gears, parking brake hub and

synchromesh hubs for wear and damage. Look for
cracks at the root of teeth and splines.

6206-26
Assembly
Issued 12-90 Printed in U.S.A

6206-27
STEP 103 STEP 104
NOTE1: During the manufacture of early built transaxles

the numbers stamped on the ring gears and pinion shaft
include the thickness of the pinion inner bearing cup.
The bearing cup width must be added to this number
when calculating the shim pack thickness.
NOTE 2: If the original ring gear and pinion shaft are to

be used, assemble the pinion shaft using the original
shim pack, removed during disassembly.
NOTE 3: If the ring gear and pinion shaft are to be

replaced and the mounting dimension is stamped on
the rear face of the housing, the pinion mounting Install the shim pack and pinion bearing cup into the
distance shim pack is calculated as follows: transmission case from the differential side. Make sure
all the shims are against the shoulder.
STEP 105
Install the pinion shaft.
STEP 1106
1. Subtract the dimension etched on the ring gear from

the dimension etched on the transmission housing rear
face.
IMPORTANT: !fthere are no numbers stamped on the

transmission rear face, use the constant of 181.46 mm. .~ ~,
Pull the pinion shaft to seat on its bearing and support
2. Then subtract the bearing growth dimension of 0.04 the end with a block of wood.
mm.
Example:
Differential Mounting dimension constant
or number stamped on housing 181.46 mm
Dimension Etched on Ring Gear 179.86 mm
Bearing Growth Constant 0.04 mm
Required Shim Pack 1.56 mm
6206-28
STEP 107 STEP 110
62067
If a new front pinion bearing was installed, replace the Install the master bearing cone (CAS 2019) onto the
bearing cup in the transmission end cover. pinion shaft.
STEP 108 STEP 111
Install the end cover. Install the splined parking hub and spacer.
STEP 112
STEP 109
.~ -,--.. Install the setting washer (CAS 1998) (1) and bolt. Do
Install the retaining bolts and tighten to a torque of 195 not install any shims.
to 250 Nm (145 to 185 Ib ft).

6206-29
STEP 113 Using a depth gauge measure the distance from the
face of the setup washer to the end of the counters haft
(A) through both holes. If the difference in the two
measurements is 0.08mm (0.003 inch) or less take the
average of the two measurements. If the difference is
greater than 0.08 mm disassemble and check for
proper bearing seating, burrs or foreign material.
Subtract the setup washer thickness (8) and add the
aero-set constant of 0.17 mm (0.0067 inch) to the
measured gap. This is the shim pack thickness (C).
STEP 115
Rotate the transmission housing onto its rear flange and

To correctly seat the bearings, rotate the shaft while put a support under the pinion shaft.
tightening the bolt.
STEP 116
STEP 114
Remove the bolt from the end of the pinion shaft.
Remove the setting washer, shims, spacer and brake
hub. Remove the master bearing and transmission end
cover. Fasten the shims together and store safely.
STEP 117
i
Install the thrust washer, needle bearing and second
thrust washer.
NOTE: The bevelled side of the 1st thrust washer must

be towards the pinion gear.
STEP 118
,
IB~
in:C12121
Install the two roller bearings.

6206-30
STEP 119 STEP 122
Install the first driven gear and spacer with the splined Install the needle bearing.
hub outward.
STEP 123
NOTE: When installed the spacer must be level with the
end of the first gear.
STEP 120
Install the synchromesh assembly.
STEP 124
Install the thrust washer first and then the needle

bearing.
STEP 121
Install the second driven gear with the splined hub

inward.
Install the synchromesh hub.
Don 7~3"7030 Issued 12-90 Printed in U.S.A

6206-31
STEP 125 STEP 128
Slightly raise the second gear (1) and Install the shuttle Install the thrust washer (1) and needle bearing (2).
shaft.
STEP 129
NOTE: When installing the shuttle shaft be sure not to
bind the shaft in the wear sleeve or damage to the seal
rings and wear sleeves will occur.
STEP 126
Install the third driven gear with the splined hub

outward.
STEP 130
Install the needle bearing and thrust washer
STEP 127
Install the synchromesh inner cup (1) and needle

bearing (2).
Install the snap ring.

6206-32
STEP 131 STEP 132
Install the hub (1) and synchromesh unit (2) onto the Install the needle bearing (1) and the synchromesh
pinion shaft. outer cup (2).
STEP 133
Install the washer onto the 3rd and 4th gear

synchromesh.

6206-33
STEP 134 STEP 137
,.
Install the fourth driven gear with the splines facing Install the shuttle shaft forward gear.
inward.
STEP 138
STEP 135
-. ,-,'
Install the baffle plate (1) and intermediate shaft.
Install the needle bearing (1) and thrust washer (2).
NOTE: Raise the third and fourth gear synchromesh
STEP 136 hub slightly, to allow easy installation of the intermediate
shaft.
STEP 139
Install the gear shift selector forks and shift rail. Push
the shift rail into its locating bore in the transmission
housing. .,:..} elL
Make sure the third and fourth gear synchromesh hub,
needle bearing and thrust washer are properly seated.
Install the snap ring.

6206-34
TRANSMISSION
-..-
••••~i

Don 7-37030
6206-35

Installation
STEP 140 STEP 143
Clean the surfaces of the end cover and the Put the pinion shaft bearing into a bearing oven (OEM
transmission case. 8014) and heat to a temperature of 302°F (150°C).
Install the bearing and brake hub onto the pinion shaft.
STEP 141
NOTE: Wear heat protective gloves.
STEP 144
Mounting surfaces must be clean and free of oil. Apply

a continuous bead of 817555 (Loctite 515) onto the
mounting face of the end cover. Apply Primer 'N'
8500637 to the mounting face of the transaxle. Install Install the spacer, new shim pack, as calculated in
the cover and torque the bolts to 195 to 250 Nm (145 to STEP 114. Install the washer and bolt. Tigten the bolt to
185Ibft). a torque of 251 to 280 Nm (185 to 205 Ib ft).
STEP 142 STEP 145
Install the shift rail retaining plate and two bolts and Install the bearing cup and spacer onto the
tighten to a torque of 44 to 58 Nm (33 to 43 Ib ft). intermediate shaft.
6206-36
STEP 146 STEP 149
,- ~.:;;~
Install the Special Tool CAS 2008 (1). Use a micrometer to determine the required shim pack
thickness.
NOTE: No shims have been installed at this time.
STEP 150
STEP 147
Install the shims, spacer and bearing race retaining tool

Install a bolt (2) and jam nut and lock it onto the end of (CAS 2008). Check the end play and add or subtract
the intermediate shaft. shims as required until the end play measures 0.03 to
0.13 mm (0.001 to 0.005 inch).
STEP 148
STEP 151
Install a 'C' clamp onto the end of the shuttle shaft and
repeat STEPS 145 to 150 and adjust the end play on the
shuttle (input) shaft. The end play must be 0.03 to 0.13
mm (0.001 to 0.005 inch).
STEP 152
Refer to Step 180 and adjust the selector shaft pivot

bushes
'0" •
Install a dial gauge and check the end play. End play
must be 0.03 to 0.13 mm (0.001 to 0.005 inch).

6206-37
STEP 153 STEP 154
Refer to Section 6203 and install the differential

assembly.
NOTE: Make sure the lubrication tube is clear of the ring

gear. Adjust if necessary.
Install the lubricating tube (1) against the pinion head

(2) and tighten the fitting.
CHECKING FOR CORRECT PINION TO CROWN WHEEL TOOTH CONTACT

STEP 155 NOTE: The contact patterns of the crown wheel teeth
that are shown are approximate shapes. The gear teeth
contact patterns can change from the illustrations, but
the same general shape must be seen. The tooth
contact pattern can change in a used gear set because
of wear of the parts. Try to get a contact pattern that is
similar to the illustrations to get the best results.
CORRECT TOOTH CONTACT PATTERN
Put Prussian Blue or red lead on the crown wheel teeth.

on the convex side. Turn the pinion in the forward
direction (clockwise) while holding pressure against the
crown gear to cause a braking force. See the contact
patterns in the following illustrations.
RC627
Correct adjustment is made when the pattern and size

of the tooth contact area (both horizontal and vertical) is
as shown.

6206-38
STEP 155 (Continued)
Pinion in too far Contact Pattern
Move the pinion shaft away from the

crown wheel to correct this pattern.
RC625
Correct this type of pattern by removing shims from

under the pinion shaft inner bearing cone. Refer to Step
103.
'll 2. PINION SHAFT
Pinion out too far Contact Pattern
Move the piruon shaft towards the

crown wheel to correct this pattern.
RC625
Correct this type of pattern by adding shims under the

pinion shaft inner bearing cone. Refer to Step 103.
STEP 156
Refer to Section 6203 and adjust the backlash between

the crown wheel and pinion gear.
NOTE : The backlash has only a small effect on the

contact pattern.

6206-39
SERVICING THE GEAR SHIFTERS

Removal
STEP 157 STEP 160
Refer to STEPS 1 to 13 to remove the transmission end

cover, and intermediate shaft.
NOTE: The gear shifters can be serviced with the

transmission gears installed. In this case the pivot
bushes have to be removed first before the gear
selector shafts.
STEP 158
+ ""IT :
till
Loosen the two pivot bushes.
STEP 161
."Z;.
.;o':!llo.
Remove the oil baffle plate.
STEP 159
i~~~
Pull the gear shift rail up from its locating bore in the
transmission case. Rotate the assembly counter
clockwise and lift the rail and gear shifter forks clear of
the pinion shaft.
D29422
Mark the levers and shafts for easy assembly. Remove

the levers.

6206-40
STEP 162 STEP 163
Remove the pivot bushing from the transaxle and Remove the selector shaft from the transaxle and
discard the o-ring. discard the o-ring seal.
STEP 164
Repeat STEPS 162 and 163 to remove the second gear

pivot bushing and selector shaft.
Disassembly
STEP 165 STEP 166
Of;
Cover the detent holes on the the shift forks and Remove the detent ball and spring.
carefully pull the shift fork from the shift rail.
NOTE: Put marks on the two shift forks for easy

installation.

6206-41
Inspection
STEP 167 STEP 169
Q14
Check the bushings (1) in the shift forks for wear or Check the detent grooves on the shift rail for wear or
damage and replace as necessary. damage and replace if necessary.
STEP
,..
168 STEP 170
029420
Check the roller bearing (2) on the shift fork and replace Check the gear selector shafts, levers and pivot
if necessary. Install a new snap ring to hold the roller in bushing for wear or damage and replace if necessary.
position.

6206-42
Assembly
1. BUSH
STEP 171 STEP 172
,;~.
Install a shift fork onto the shift rail as marked during Use a suitable tool to compress the detent spring, and
disassembly, and install the detent spring and ball. push the detent ball below the diameter of the shift rail.
Push the shift fork onto the shift rail.
NOTE: Always wear eye protection when installing
detent springs and balls. NOTE: The threaded end of the shift rail is installed into
the transmission end cover.
STEP 173
Repeat STEPS 171 and 172 and install the second gear
shift fork.
6206-43
Installation
STEP 174 STEP 177
Install a new a-ring (1). Install the selectors into the

transmission housing as marked on removal.
STEP 175
Install the levers as marked on removal until the

clamping bolt (1) is level with the groove (2) in the
selector shaft. Tighten the clamping bolts.
Install a new a-ring. Install the pivot bushings into the
transmission housing. NOTE: If new selectors or levers are installed, first make
sure the transaxle is in the horizontal position. Install the
STEP 176 levers onto the selector shafts in the horizontal position
with the lever ends pointing towards the axle housing.
Remove the lever and turn in a clockwise direction one
spline. Install the lever and tighten the locking bolt.
NOTE: The pivot bushings end play can only be

adjusted after the transmission end cover has been
installed.
Install the gear shift forks and rail assembly. Locate the
shift forks over the two synchromesh units and push the
shift rail into its locating bore in the transmission
housing.

6206-44
STEP 178 STEP 179
Refer to STEPS 138 and 139 and install the baffle plate Refer to STEPS 140 to 151 and install the transmission
intermediate shaft, and snap ring. end cover.
Adjustment
STEP 180
Install a dial gauge onto the the end of the gear selector
shafts. Loosen the pivot bushing lock nut (1) and adjust
the pivot bushing (2) until the selector shaft end play
measures 1.0 to 1.5 mm (0.040 to 0.060 inches).
Tighten the lock nut.
REMOVAL AND INSTALLATION OF THE MAGNETIC SPEED SENSOR

STEP 181 STEP 183
On some transmissions a magnetic speed sensor is

fitted in the top of the transmission case above the ring
gear. Disconnect the electrical connectors.
STEP 182
y ~~
Install the speed sensor by hand until it contacts the ring

gear. Loosen the sensor 0.75 of one turn and tighten the
locking nut. Connect the electrical connections.
NOTE: If the rear cover had been removed. Adjust the

gap between the ring gear and speed sensor with a
Loosen the locknut and remove the speed sensor. feeler gauge OEM 1024 until the gap measures 0.25 mm
(0.010 inch).

6206-45
INSTALLATION OF TRANSAXLE REAR COVER

STEP 184 STEP 187
Remove old sealant material and oil from the Refer to Section 6201 and install the Rear Axles.
transmission rear housing and cover.
STEP 188
STEP 185
Refer to Section 7000 and install the Parking Brake and
Housing.
STEP 189
Refer to Section 6202 and install the Transfer Gearbox

or end cover.
STEP 190
Refer to Section 6200 and install the Transmission into

the machine. Add Hy-Tran Plus Transmission oil up to
the FULL mark on the dipstick.
Apply B17555 (Loctite 515) to the transmission rear
housing. Apply Primer 'N' B500637 to the transmission STEP 191
rear cover.
Test machine for correct operation. Check and add
. STEP 186 transmission oil if required.
::w·
Install the rear cover and tighten all the bolts to a torque
of 195 to 250 Nm (145 to 185 Ib ft).

SECTION INDEX - BRAKES

Parking Brake 7000
Disc Brakes 7001
Removal and Installation of Brake Components 7002
Master Cylinder 7003

Section
7000
PARKING BRAKE
Copyright © 1990 J I case Company

Don 7-37040 Printed in U.S.A
CASE CORPORATION December 1990
7000-2
TABLE OF CONTENTS
SPECIFICATIONS , 2
SPECIAL TORQUES 2
SERVICING THE PARKING BRAKE

Removal .. . 3
Disassembly 4
Inspection 6
Assembly 7
Installation 10
SPECIFICATIONS
BRAKE FRICTION PLATE THICKNESS
New 5.5 to 6.3 mm 0.216 to 0.248 inch
Wear Limit 4.2 to 4.8 mm 0.165 to 0.189 inch
NOTE: This machine was designed using the metric measuring system. Afl checks and settings must be made using
metric tools.
SPECIAL TORQUES
Brake Housing Mounting Bolts 77 to 100 Nm 57 to 74 Ib ft
Transfer Gearbox - Cover Plate Mounting Bolts 77 to 100 Nm 57 to 74 Ib ft
2. GASKET ELIMINATOR 817555 (LOCTlTE 515)

+ PRIMER 'N' 8500637
Don 7.37040 Issued 12-90 Printed in U.S.A.

7000-3
SERVICING THE PARKING BRAKE

Removal
NOTE: It is not necessary to remove the transaxle from STEP 6
the machine to service the parking brake. The transaxle
shown was removed for photographic purposes only.
STEP 1
To prevent excessive loss of oil from transaxle raise the

front of the machine and support on axle stands.
STEP 2
Remove the input and front drive shafts (4 WD

Machines). Refer to Section 6001.
STEP 3 Remove the brake actuator tube nut from the brake
housing. Remove and discard the o-ring.
Disconnect the parking brake operating cable. Refer to
Section 9001. STEP 7
STEP 4
C1Z309
Remove the parking brake housing retaining bolts and

washers. .
Remove the five bolts that hold the transfer gearbox (4 STEP 8
WD Machines) or the cover plate to the parking brake
housing.
STEP 5
Remove the housing and guide the actuator pin from

the brake housing.
Remove the transfer gearbox or cover plate.

7000-4
Disassembly
STEP 9 STEP 12
",
Remove the steel wear plate. Remove the friction disc.
STEP 10 STEP 13
Remove the friction disc. Remove the wear plate.
STEP 11 STEP 14
Remove the brake actuator assembly. Remove the three reaction pins.

7000-5
STEP 15 STEP 18
.:y.;,:':'.: {(::.:: . ,.,/K9

nut from the bolt in the brake actuator Separate the two actuator'pl~tes.
STEP 19
STEP 16
K15
KloRemovethefour steel balls.

Remove the bolt.
STEP 17
Disconnect the two springs from the actuator plate.

7000-6
Inspection
STEP 20 STEP 22
Clean all parts with cleaning solvent and dry with

compressed air.
STEP 21
Check the wear'f6r~~~i,distortion a~d

cracks around locating lugs and replace if necessary.
STEP 23
Check the two friction plates for wear or damage and

replace if necessary.
.. ·.: .. T.. .• /..; . ..(',. 1?7

)r •.••
Check the steel balls and both actuator plates for wear
or damage. and replace if necessary.
Don 7.37040 Issued 12-90 Printedin U.S.A.

7000-7
Assembly
9. PARKING BRAKE HOUSING

:. 1.01L SEAl
11. O-RING
5. STEEL WEAR PLATE
"2. TUBE NUT
10. REACTION PIN

3. ACTUATOR PLATE
a.SPRING .4
4. FRICTION PLATE 7. STEEL BAll •• 0
6. ACTUATOR PLATE
\
·8. SPRING 12. ACTUATOR PLATE
\ UNKAGE
4. FRICTION PLATE
5. STEEL WEAR PLATE
EA2584

7000-8
STEP 24 STEP 27
Install the bolt through the actuator levers and plate.

Make sure the two bolt heads are on opposite sides of
the actuator plates.
STEP 28
Install the top actuator plate onto the bottom plate.
STEP 26 Install and tighten the nut.
STEP 29
Install the two springs.
Install the reaction pins into the transmission end cover.

7000-9
STEP 30 STEP 33
Install the wear plate onto the reaction pins. Install the second friction disc.
STEP 31 STEP 34
Install the friction disc. Install the second wear plate.
STEP 32
Install the actuator assembly.

7000-10
Installation
STEP 35 STEP 38
..... ,.......................•... ,............... .:.;.;.:.:.:.:.:.: ... :.:.:.:.;.:.:.:.:.:.::::::::::.;
the input shaft seal in the parking brake Guide the parking brake housing onto the brake
housing. Fit the new seal so that the flat face is outward reaction pins. Install and tighten the bolts to a torque of
and level with the outer face on the housing. 77 to 110 Nm (57 to 81 Ib ft).
STEP 36 STEP 39
Clean the mounting surfaces on the transaxle and

parking brake housings. Apply a continuous bead of
B17555 (Loctite 515) onto the face of the transmission
end cover. Apply Primer 'N' to the face of the parking
brake housing.
STEP 37
Install a new o-ring and install and tighten the actuator

tube nut.
STEP 40
Clean the surfaces of the transfer gearbox

housing/cover plate. Apply a continous bead of
"::::::::::':::::::::::x:::::::::';': 817555 (Loctite 515) onto the joint lace of the parking
Position the actuator pin and guide it through the hole in brake housing. Apply Primer 'N' 8500637 to the face of
the parking brake housing. the transfer gearbox housing.

7000-11
STEP 41 STEP 43
Connect and adjust the parking brake operating cable.

Refer to Section 9001.
STEP 44
Install the input and front drive shaft (4 WD

MACHINES). Refer to Section 6001.
STEP 45
Lower the machine to the ground.
Install the transfer gearbox or end cover onto the STEP 46

parking brake housing.
Add oil of the correct type to the transmission until the
STEP 42 level reaches the full mark on the dipstick.
:.:.:.:~.:.:.:.:.:.:.:.'.'."" ...
Install and evenly tighten the five bolts and washers to

the correct torque.
Don 7.37040 Issued 12-90 Printed in U.SA

Section
7001
DISC BRAKES

December 1990
7001-2
TABLE OF CONTENTS
SPECIFICATIONS 2
SPECIAL TORQUES 2
SERVICING THE DISC BRAKES

Removal 3
Inspection 5
Installation 6
SPECIFICATIONS
BRAKES FRICTION PLATE THICKNESS
New 6.25 to 6.40 mm 0.246 to 0.252 inches
Wear Limit 475 to 4.90 mm 0.187 to 0.193 inches
SPECIAL TORQUES
Rear Axle Retaining Bolts 326 to 353 Nm 240 to 260 Ib ft
3. SEALANT 8500642 LOCTITE 324

ACTIVATOR 8500622 LOCTITE 707
KIT PART NUM8ER 8500621
1. ALIGNMENT STUDS CAS 1995

7001-3
Removal
NOTE: Any reference to left and right hand is as seen STEP 3
from the operators seat looking forward.
NOTE: Servicing of the disc brakes can only be done

with the transaxfe removed from the machine. Refer to
Section 6001.
STEP 1
Remove the two guide studs.
STEP 4
Remove two opposite retaining bolts from the rear axle

and install guide studs.
STEP 2
STEP 5
Use suitable lifting equipment to support the rear axle.

Remove the remaining retaining bolts, and remove the
rear axle assembly from the transaxle housing.
Remove the friction plate.

7001-4
STEP 6 STEP 8
.•···.ii~13
Remove the sun shaft. Remove the brake piston (1) by injecting compressed
air through the brake hose port (2).
STEP 7
STEP 9
Remove the three reaction pins.
Remove and discard the inner and outer o-rings from

the grooves (1) on the piston.

Inspection
STEP 13
compressed air. Do not use cloths.
Check the brake piston for wear, pitting, or other
damage. Replace if necessary. Check the brake
cylinder bore in the transaxle housing.
C14
Replace the three reaction pin springs if the plunger

movement is easy. A weak reaction plunger spring will
cause wear and warpage to the friction plates.
Inspect the two snap rings of each reaction pin for
tightness. If the snap rings are loose, the friction and
backing plates will not separate quickly when the brake
pedal is released. Check the eyes of the two snap rings
C8 are 180 apart. Replace the snap rings if necessary.
0
Check the friction plate for wear, scoring, warpage and

damage to the splined teeth and replace if necessary.
D30132
Check the brake backing plate for wear and damage

and replace if necessary. Remove small scoring or
grooves with a hone or fine grade emery cloth.
7001-6
Installation
8902564
1. TRANSMISSION HOUSING
2. PISTON SEALS
3. PISTON
4. FRICTION DISC
5. BACKING PLATE
6. REACTION PIN

7001-7
STEP 14 STEP 16
.>.. )?~13
Remove the old jointing material from the face of the Evenly install the brake piston into the cylinder bore and
trans axle and axle case. align the lugs with the reaction pin holes.
STEP 15 STEP 17
Lubricate the two new inner and outer piston o-rings Lubricate and install the three reaction pins so the
with petroleum jelly and install into the grooves (1) of the plungers are outward and the snap rings are on the
brake piston. outside of the lugs on the brake piston.

7001-8
STEP 18 STEP 21
.•...
Install the sun shaft. Install the brake backing plate so the large side is
towards the friction plate.
STEP 22
4. STRAIGHT EDGE
Put a straight edge across the end of the plunger of the \:::~:::'
reaction pin and measure the distance from the Install the two guide studs into the trans axle housing.
machined surface of the transmission case to the end
of the plunger. The measurement must be 2 mm (0.079 STEP 23
inch). Adjust the position of the snap rings if the
distance is incorrect. Make sure the edges of the two
snap rings are 180 apart. Repeat the procedure for the
0
other two reaction pins.
STEP 20
71289GA
Make sure the joint faces are clean. Apply sealant

8500642 (Loctite 324) to the face on the transaxle.
Lubricate and install the friction plate.

7001-9
STEP 24 STEP 27
.i:-;'-· .r •• ;;;: ,-.-.- •• '.
Apply activator 8500622 (Loctite 707) to the face on the Tighten all the bolts to 326 to 353 Nm (240 to 260 Ibs ft).
axle housing.
STEP 28
STEP 25
Install the transaxle into the machine. Refer to Section
6001.
STEP 29
Fill the transmission with Hy-Tran Plus oil, to the FULL

mark on the dipstick.
IMPORTANT: If new brake friction discs and new

Hy-Tran Plus are installed in the transaxfe, a special
additive must be added to the transmission fluid. The
additive 8191443 soaks into the brake linings and
prevents excessive brake chatter. Add one quart of
Use suitable lifting equipment and install the rear axle additive to the transmission fluid while circulating the oil
onto the transaxle housing. at operating temperature. DO NOT add 8191443 to
machines that have factory fiJIfluid in the transaxfe.
STEP 26
STEP 30
Remove the air from the brake system. Refer to Secian

7002.
Install some of the retaining bolts and washers before

removing the guide studs.
NOTE: When the axle and transmission housings are

joined, the mounting bolts must be fuJlytorqued within 3
to 5 minutes.

7001-10
STEP 29 STEP 30
Fill the transmission with Hy-Tran Plus oil, to the FULL Remove the air from the brake system. Refer to Secian
mark on the dipstick. 7002.

Section
7002
REMOVAL AND INSTALLATION OF BRAKE COMPONENTS

CASE CORPORATION Issued November 1989
7002-2
TABLE OF CONTENTS
MASTER CYLINDER. . . 2
Removal . . 2
Installation . . 2
REMOVING AIR FROM THE BRAKE SySTEM . . .4
PARKING BRAKE . .See Section 7000
DISC BRAKE . .... See Section 7001
SPECIFICATIONS
Type of oil.. .. Case TCH Fluid
Capacity
Reservoir... . 16 fluid ounces (473 ml)
System.. '" 32 fluid ounces (946 ml)
MASTER CYLINDER
Removal 11. Remove the master cylinder (1) from the frame.
1. Park the machine on a level surface 12 Install caps on the tubes (6 and 7).
2. Lower the loader bucket to the floor and stop the Installation
engine.
1. If a new master cylinder (1) is being installed, fill the
3. Apply the parking brake. master cylinder with clean Case TCH fluid.
4. Open the access cover above the master cylinder 2. Hold the master cylinder (1) in alignment with the
(1) . holes in the frame and install the bolts (10), lock
washers (9), and nuts (8) that fasten the master cylinder
5. Remove any dirt from the master cylinder (1) and the (1) to the frame.
area around the master cylinder (1).
3 Connect the tubes (4, 6 and 7) to the master cylinder
6. Remove the clevis pin (2) that fastens the clevis (3) on (1 )
the master cylinder (1) to the brake pedal
4. Install the clevis pin (2) that fastens the clevis (3) to
7. Disconnect the tube (4) for the master cylinder reser- the brake pedal.
voir (5) from the master cylinder (1).
5 See step 20 in Section 7003, page 7003-4, and
8. Drain the fluid from the master cylinder reservoir (5). adjust the master cylinder (1).
9 Disconnect the tubes (6 and 7) from the master 6. Fill the master cylinder reservoir (5) with Case TCH
cylinder (1). fluid until the fluid level is at the full mark.
10. Loosen and remove the nuts (8). lock washers (9), 7. See page 7002-4 and remove the air from the brake
and bolts (10) that fasten the master cylinder (1) to the system.
frame.
8. Check for leakage at the master cylinder (1).

7002-3
6. TUBE
4. TUBE
8891712J
Master Cylinder Installation
Bur 8-12540
7002-4
REMOVING AIR FROM THE BRAKE SYSTEM

1. Two persons are required, one to actuate the master 4 When the brake pedal touches the floor plate, hold
cylinder and the other to open and close the air removal the brake pedal in place and have the other person
screw on the transaxle. tighten the air removal screw.
2. Move the brake pedal down and up several times to 5. Repeat steps 2, 3, and 4 until there are no bubbles in
increase the pressure in the brake system. the fluid coming from the air removal screw.
3. When the brake pedal feels "hard", continue to push 6. Fill the master cylinder reservoir with Case TCH fluid.
against the pedal and have another person open the air
removal screw at the transaxle

Section
7003
MASTER CYLINDER

CASE CORPORATION
7003-2
TABLE OF CONTENTS
REMOVING AIR FROM THE BRAKE SYSTEM .. . .. See Section 7002
MASTER CYLINDER.. . 2
Removal and Installation ...... See Section 7002
Disassem bly . . 2
Inspection . ... .4
Assembly . ......4
SPECIFICATIONS
Type of oil.... . Case TCH Fluid
Master cylinder
Girling part number ...... A6315
Case part number.......... . 8143162
MASTER CYLINDER
Disassembly 12. Hit the open end of the master cylinder against a
piece of wood to move the piston assembly to the end
1. Clean the outside of the master cylinder. of the master cylinder.
2 Fasten the body (6) of the master cylinder in the 13. Pull the piston assembly from the master cylinder
vise.
14. There is a small tab in the spring seat (12) that
3. Remove the flow valve adapter (1) from the master holds the spring seat (12) on the piston (13). Use a
cylinder. screwdriver to lift up the tab.
4. Remove the flow valve (3) from the master cylinder 15. Remove the check valve assembly from the piston
(13).
5. Remove the ball (5) from the master cylinder.
16. Remove the seal (14) from the piston (13).
6 Remove the gasket (2) from the flow valve adapter
(1) . 17. Disconnect the check valve seat (10) from the
spring seat (12).
7. Remove the flow valve seal (4) from the flow valve
(3). 18 Remove the spring (11) from the spring seat (12).
8 Loosen the lock nut. Remove the clevis and lock 19. Remove the check valve seat (10) from the check
nut from the push rod (15). valve piston (8).
9. Remove the boot (18) from the body (6). 20 Remove the wave spring (9) from the check valve
piston (8).
10. Remove the snap ring (17) from the body (6).
21 Remove the check valve seal (7) from the check
11. Remove the push rod (15) and washer (16) from valve piston (8)
the body (6).
Bur 8·12570 Issued 11·89 Primed in U.S.A

7003-3
B870122R
Master Cylinder
Bur 8-12570 Issued 11 -89 Printed in U.S.A

7003-4
Inspection 13 Install the ball (5) in the body (6).
1. Inspect the bores in the body (6) for scoring, pitting, 14. Lubricate the flow valve seal (4) and the flow valve
or other damage. If the bores in the body (6) are (3) with clean hydraulic oil. Install the flow valve (3) in the
damaged a new master cylinder must be used. bore in the master cylinder. The flow valve (3) must be
centered in the bore of the master cylinder.
2. Check the tab in the spring seat (12). Push the tab
down a small amount so that the tab will engage the 15. Install a new gasket (2) on the flow valve adapter
end ofthe piston (8) to hold the check valve assembly in (1) .
place. If the tab is broken, use a new master cylinder.
16. Carefully start the flow valve adapter (1) into the
3. Inspect the flow valve (3), ball (5), check valve bore in the master cylinder by hand If the flow valve
piston (8), piston (13), and the push rod (15) for adapter (1) cannot be turned into the master cylinder
scoring, pitting, or other damage If the flow valve (3), completely by hand remove the flow valve adapter (1)
ball (5), check valve piston (8), piston (13) or the push from the master cylinder and make sure that the flow
rod (15) are damaged a new master cylinder must be valve (3) is in the center of the bore in the master
used. cylinder.
Assembly 17. Repeat step 16 until the flow valve adapter (1) can
be turned completely into the master cylinder by hand.
1. Install the check valve seal (7) on the check valve
piston (8). 18. Tighten the flow valve adapter (1) to 30 to 34
pound-feet (41 to 47 Nm)
2. Install the spring (11) on the spring seat (10).
19. See Section 7002 and install the master cylinder on
3. Install the check valve assembly in the spring (11). the machine.
Engage the stem of the check valve piston (8) in the
spring seat (12). 20 Depress the brake pedal to stroke the piston (13) in
the master cylinder. Release the brake pedal and allow
4. Install the check valve assembly on the piston (13). the piston to return. Adjust the push rod to piston clear-
Push the check valve assembly onto the piston (13) ance to .025 to 050 inch (0.6 to 1.3 mm). Turn the clevis
until the tab in the spring seat (12) engages the end of clockwise to shorten or counterclockwise to lengthen.
the piston (13). Tighten the lock nut against the clevis. See the illustra-
tion below.
5. Install the seal (14) on the piston (13)
6. Lubricate the bore of the body (6) with clean hyd-

raulic fluid.
7. Install the piston assembly into the bore of the body

(6).
8. Push the piston assembly into the bore until the --->
push rod (15) and washer (16) can be installed
9. Install the push rod (15) and washer (16).
10 Install the snap ring (17)

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.

7003-5
8870122R
Master Cylinder
Bur 8-12570 Issued 11-89 Printed in U:S.A.

SECTION INDEX - HYDRAULICS
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

Section
8001

OF HYDRAULIC COMPONENTS
CASE CORPORATION

Issued March 1991
8001-2
TABLE OF CONTENTS
OIL COOLER .. . 3
Removal , ......................
, : 3
Installation , , , , , .4
HYDRAULIC PUMP , 6
Removal 6
Installation 8
LOADER CONTROL VALVE ,... 10
Removal , ,." ,........................... . , , 10
Installation........ ... 10
BACKHOE CONTROL VALVE...... ... 11
Removal 11
Installation . . 11
SWING SEQUENCE VALVE. . 13
Removal , , 13
Installation 13
SWING SEQUENCE VALVE ADJUSTMENT................... . 14
THREE-POINT HITCH CONTROL VALVE.................... .15
Removal , , 15
Installation , , 15

8001-3
OIL COOLER
Removal STEP 3
STEP 1
Remove the bolt, lock washer, and flat washer which

fasten the strap (1) to the top of the radiator shroud.
Park the machine on a level surface. Raise the loader Remove the strap (1).
and lock the support strut (1) to hold up the loader.
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 Remove the bolts, lock washers, and nuts which fasten
the hood hinges (2). the mounting brackets (1) to each side of the oil cooler.

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
hardware. Push the top of the hood to the rear as far as
possible and tighten the hinge hardware.

8001-4
STEP 5 STEP 8
8907
Remove the bolts, flat washers, and nuts which fasten Disconnect the two hoses (1) from the RH side of the oil
the radiator shroud (1) to the machine frame. Remove cooler. Put identification tags on the hoses (1). Discon-
the radiator shroud (1), The weight of the radiator nect the two tubes (2) from the LH side of the oil cooler.
shroud (1) is approximately 50 pounds (23 kg). Install caps on the fittings and plugs in the hoses and
tubes. Stop the vacuum pump.
NOTE: During installation, tighten the bolts for the
radiator shroud (1) to 270 to 324 pound-feet (366 to 439
Nm). STEP 9
STEP 6
"';'!~~7'4703M'
Remove the bolts, lock washers, and flat washers
which fasten the condenser (1) and the oil cooler (2) to
.90[:~~;!ef the radiator (3). Move the condenser (1) to the LH side
Remove the bolts, lock washers, and flat washers from out of the way. Remove the oil cooler (2).
the bottom cover (1). Remove the bottom cover (1).
Installation
STEP 7
Connect a vacuum pump to the hydraulic reservoir Installation of the oil cooler is the reverse of removal.
Start the vacuum pump.

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

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 Install a hose on the drain valve (2) and drain the ra-
,
and lock the support strut (1) to hold up the loader. diator.

STEP 11
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
neck.
Remove the bolts, flat washers, spacers, lock washers,

and nuts which fasten the hood cables (2) to the sides
of the radiator shroud.
Remove the bolts, flat washers, and lock washers from

the hood hinges (3).

weight of the hood is approximately 100 pounds (45
kg).
Remove the bolt, lock washer, and flat washer which
NOTE: During installation the hood must be adjusted. fasten the strap (1) to the top of the radiator shroud.
Put the hood in position. Install the hardware in the hood Remove the strap (1).
hinges. Do not tighten the hardware. Close the hood
and remove the plastic plugs for access to the hinge Remove the bolts, lock washers, and flat washers from
hardware. Push the top of the hood to the rear as far as the top cover (2). Remove the top cover (2).
possible and tighten the hinge hardware.
Remove the upper and lower foam baffles (3).
8001-7
STEP 14 STEP 17
Remove the bolts, lock washers, and nuts which fasten The hydraulic reservoir holds approximately 25 U.S
the mounting brackets (1) to each side of the oil cooler. gallons (95 litres) of oil. Remove the drain plug (1) and
drain the oil from the hydraulic reservoir.
STEP 15 NOTE: During installation make sure the hydraulic re-

setvou is filled with oil. See Section 1002 for specifica-
tions.
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).
B90?~,~~Ji
NOTE: During installation, tighten the bolts for the Disconnect the two hoses (1) from the RH side of the oil
radiator shroud (1) to 270 to 324 pound-feet (366 to 439 cooler. Put identification tags on the hoses (1). Discon-
Nm). nect the two tubes (2) from the LH side of the oil cooler.
Install caps on the fittings and plugs in the hoses and
STEP 16 tubes.
.,
,!~9071~e'M
Remove the bolts, lock washers, and flat washers from
the bottom cover (1). Remove the bottom cover (1).
8001-8
STEP 19 STEP 20
B9074717M
Remove the bolts, lock washers, and flat washers Disconnect the two hoses (1) from the LH side of the
which fasten the condenser (1) to the oil cooler (2) and hydraulic pump (2). Remove the bolts and lock
radiator (3). Move the condenser (1) to the LH side out washers that fasten the flange (3) on the RH side of the
of the way. Have another person help you remove the hydraulic pump (2)
oil cooler (2) and radiator (3). The weight of the oil
cooler (2) and radiator (3) is approximately 50 pounds Remove the bolts, lock washers, and hardened
(23 kg). washers (The hardened washers are on the bottom two
bolts only.) which fasten the hydraulic pump (2) to the
Remove the fan shroud (4). front engine support. Remove the hydraulic pump (2).
Installation
Installation of the hydraulic pump is the reverse of
removal.
NOTE: During installation, remove and clean the

suction screen for the hydraulic pump. Apply Molykote
Type G to the splines of the hydraulic pump.

8001-9
4. SUCTION
SCREEN
B902373J

Bur 8-17580
8001-10
LOADER CONTROL VALVE

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
3. Lower the loader bucket to the floor. the loader control valve to the mounting brackets.
4. Stop the engine. 3 Remove the lifting equipment from the loader control
valve.
5. Move the loader control lever in all directions to
release the pressure from the hydraulic circuits. 4. Connect the vacuum pump to the hydraulic reservoir.
Start the vacuum pump
6 Remove the bolts, lock washers, and flat washers
which fasten the cover for the loader control valve to the 5. Connect the tubes and hoses to the fittings on the
RH step frame. Remove the cover for the loader control loader control valve.
valve.
6. Stop the vacuum pump.
7. Find the wires for the return-to-dig switch on the
loader control valve. Disconnect the wires from the 7. Connect the linkage to the loader control valve.
return-to-dig switch.
8. Connect the wires to the return-to-dig switch on the
8. Fasten identification tags to the loader linkage at the loader control valve.
loader control valve.
9. Start and run the engine at low idle. Move the loader
9. Disconnect the linkage from the loader control valve. control lever to raise the loader completely. Continue to
hold the loader control lever in the RAISE position for 30
10. Clean the loader control valve and the area around seconds.
the loader control valve. Fasten identification tags to the
tubes and hoses at the loader control valve. 10. Lower the loader bucket to the floor. Stop the
engine.
11. Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump. 11. Check for oil leakage at the loader control valve.
12. Disconnect the tubes and hoses from the fittings in 12. Check the oil level in the hydraulic reservoir. Add oil
the loader control valve. Install caps on the fittings and as required. See Section 1002 for specifications.
plugs in the hoses and tubes Stop the vacuum pump.
13. Put the cover for the loader control valve in position
13. Connect suitable lifting equipment to the loader on the RH step frame. Install the bolts, lock washers,
control valve. The weights of loader control valves avail- and flat washers which fasten the cover to the RH step
able on this machine are approximately 57 to 72 frame.
pounds (26 to 33 kg).
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.

8001-11
BACKHOE CONTROL VALVE

Removal 18. Remove the backhoe control valve from the
machine.
1. Park the machine on a level surface.
Installation
2. Lower the loader bucket to the floor.
1. If the fittings were removed from the backhoe control
3. If the machine is equipped with an Extendahoe, valve, if a new backhoe control valve is being used, or if
install the Extendahoe lock pin. the dipper or boom section of the backhoe control valve
has been replaced, do the following steps:
4. If the backhoe is not in the transport position, put the
backhoe in the transport position. a. Make sure that a restrictor is installed in the A
port of the dipper section of the backhoe control
5. Lower the stabilizers until the stabilizers just touch the valve. The restrictor must be installed so that the
floor 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.
c. Lubricate the O-rings with clean hydraulic oil.
8. Move each backhoe control lever in both directions
until all hydraulic pressure has been removed from the d. Install the fittings in the backhoe control valve.
backhoe hydraulic circuits.
2 Put the backhoe control valve in position on the
9. Clean the backhoe control valve and the area around mounting bracket. Make sure that the rubber mount is
the backhoe control valve. Fasten identification tags to in position in the mounting bracket.
the hoses and tubes at the backhoe control valve.
3. Install the cap screw, lock washer, and spacers that
10. Connect a vacuum pump to the hydraulic reservoir fasten the backhoe control valve to the mounting
Start the vacuum pump bracket. Make sure that the spacers are in position
between the backhoe control valve and the mounting
11 . Disconnect the hoses and tubes from the backhoe bracket.
control valve. Install caps on the fittings and plugs in the
hoses and tubes.Stop the vacuum pump. 4. Connect the linkage to the spools in the backhoe
control valve.
12. Disconnect the tube for the B port of the swing
section from the fitting in the swing sequence valve. 5. Connect the vacuum pump to the hydraulic reservoir.
Start the vacuum pump.
13. Fasten identification tags to the linkage for the
backhoe control valve. 6. Connect the tube to the fitting in the swing sequence
valve and to the B port in the swing section of the
14. Disconnect the linkage from the spools in the backhoe control valve.
backhoe control valve.
7. Connect the remaining tubes and the hoses to the
15. The weights of backhoe control valves available on fittings in the backhoe control valve. Stop the vacuum
this machine are approximately 115 to 130 pounds (52 pump.
to 59 kg). Have another person help with steps 16
through 18. 8. Start the engine and run the engine at low idle.
16. Hold the backhoe control valve in place and remove 9. Slowly extend and retract each cylinder several times
the bolts, lock washers, and nuts that fasten the LH side to remove any air from the backhoe hydraulic circuits.
of the backhoe control valve to the mounting bracket.
10. Stop the engine.
17. Remove the cap screw, lock washer, and spacers
that fasten the RH side of the backhoe control valve to 11. Check for oil leakage at the backhoe control valve.
the mounting bracket.
12. Check the oil level in the hydraulic reservoir. Add oil
as required. See Section 1002 for specifications.
8001-12

8001-13
SWING SEQUENCE VALVE

Removal 14 Remove the swing sequence valve from the
machine.
Installation
1. Hold the swing sequence valve in position on the
3. If the backhoe is not in the transport position, put the mounting bracket. Install the cap screws that fasten the
backhoe in the transport position. swing sequence valve to the mounting bracket.
4. Stop the engine and apply the parking brake. 2. Turn the spool so that when the yoke is installed on
the spool, the holes will be aligned vertically. Put the
5. Install the swing lock pin. yoke in position on the spool. Install the clevis pin and
the cotter pin to fasten the yoke to the spool.
6. Move the swing control pedals or levers in both direc-
tions to remove any pressure in the swing hydraulic 3. Connect the tube to the B port in the swing section of
circuit. the backhoe control valve and to the fitting in the bottom
of the swing sequence valve.
7. Clean the swing sequence valve and the area around
the swing sequence valve. Fasten identification tags to 4. Connect the remaining tubes and the hoses to the
the hoses and tubes for the swing sequence valve. fittings in the swing sequence valve.
8. Disconnect the tube from the B port in the swing 5. Remove the swing lock pin.
section of the backhoe control valve and from the fitting
in the bottom of the swing sequence valve. 6. Start and run the engine at low idle.
9 Install caps on the fittings in the backhoe control 7. Slowly and completely swing the backhoe to the left
valve and the swing sequence valve. and then to the right several times to remove any air
from the swing hydraulic circuit.
10. Disconnect the remaining tubes and hoses from the
swing sequence valve. 8. Stop the engine.
11. Use caps or plugs to close all openings in order to 9. Check for oil leakage at the swing sequence valve.
keep dirt out of the hydraulic system.
10. Check the oil level in the hydraulic reservoir. Add oil
12. Remove the cotter pin and clevis pin that fasten the as required. See Section 1002 for specifications.
yoke on the linkage to the spool in the swing sequence
valve. 11. See Swing Sequence Valve Adjustment on page 14.
Adjust the swing sequence valve as required.
13. Hold the swing sequence valve in position on the
mounting bracket. The weight of the swing sequence
valve is approximately 20 pounds (9 kg). Loosen and
remove the cap screws that fasten the swing sequence
valve to the mounting bracket.

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 LENGTHEN CONTROL ROD TO INCREASE THE
on the control rod. 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

8001-15
THREE-POINT HITCH CONTROL VALVE

Removal 12. Remove the three-point hitch control valve from the
machine.
Installation
1. If the fittings were removed from the three-point hitch
3 Lower any rear attachments to the floor. control valve, or a new three-point hitch control valve is
being used, install new O-rings on the fittings, and lubri-
4. Stop the engine and apply the parking brake. cate the O-rings with clean hydraulic oil. Install the
fittings in the three-point hitch control valve.
5. Move all control levers forthe three-point hitch in both
directions to remove any pressure in the hydraulic 2. Put the three-point hitch control valve in place on the
circuit mounting bracket. Install the bolts, lock washers, and
nuts that fasten the three-point hitch control valve to the
6. Clean the three-point hitch control valve and the area mounting bracket
around the three-point hitch control valve.
3. Connect the linkage to the spool eyes in the three-
7. Fasten identification tags to the hoses at the three- point hitch control valve.
point hitch control valve.
4. Connect the hoses to the fittings in the three-point
8. Disconnect the hoses from the fittings at the three- hitch control valve.
point hitch control valve.
5. Start and run the engine at low idle.
9 Use caps or plugs to close all openings in order to
keep dirt out of the hydraulic system. 6. Move all control levers for the three-point hitch slowly
in both directions to remove any air from the hydraulic
10. Disconnect the linkage from the spool eyes at the circuits.
three-point hitch control valve.
7. Lower any rear attachments to the floor. Stop the
11 . Hold the three-point hitch control valve in place and engine.
remove the bolts, lock washers, and nuts that fasten the
three-point hitch control valve to the mounting bracket. 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.

8001-16

Section
8002
HYDRAULIC SCHEMATICS, SPECIFICATIONS

AND TROUBLESHOOTING

CASE CORPORATION
Issued March 1991
8002-2
TABLE OF CONTENTS
SPECiFiCATIONS." , , , ,., ' , 3
SPECIAL TOOLS .., , , .4
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN ALL CiRCUiTS 5
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN A SINGLE CIRCUIT 6
MAIN RELIEF VALVE , 7
CHECKING OUTPUT OF PUMP WITH FLOWMETER 8
CIRCUIT RELIEF VALVES FOR LOADER AND BACKHOE CONTROL VALVES , , , 11
CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE 12
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

8002-3
SPECIFICATIONS
Output of Pump
Rear section (Loader and Steering) 24 U.S. gpm at 2000 psi at 2000 rpm
(90.8 Umin at 13 789 kPa, 138 bar at 2000 r/min)
Front section (Backhoe) 9 U.S. gpm at 2000 psi at 2000 rpm

(34 Umin at 13 789 kPa, 138 bar at 2000 r/rnin)
Main relief valve for Loader Backhoe 2500 to 2600 psi (17237 to 17 927 kPa, 172 to 179 bar)
Main relief valve for Three Point Hitch 2488 to 2588 psi (17 154 to 17 844 kPa, 171 to 178 bar)
Relief valve in piston of boom cylinder 4600 to 4800 psi (31 716 to 33095 kPa, 317 to 330 bar)
Circuit Relief Valves
Boom A port 2050 to 2250 psi (14 135 to 15574 kPa, 141 to 155 bar)
Boom B port 4000 to 4100 psi (27580 to 28 268 kPa, 276 to 283 bar)
Dipper and bucket A and B ports 2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar)
Swing A and B ports 2050 to 2250 psi (14135 to 15 514 kPa, 141 to 155 bar)
Swing sequence valve 4000 to 4100 psi (27580 to 28268 kPa, 276 to 283 bar)
Loader bucket A and B ports 2950 to 3150 psi (20340 to 21 719 kPa, 203 to 217 bar)
Three point hitch lift B port 2650 to 2750 psi (18271 to 18 960 kPa, 183 to 190 bar)

8002-4
SPECIAL TOOLS
dresses:
Service Tools
P.O. Box 314
In Europe:
VL Churchill Ltd.
P.O. Box 3, Daventry CAS-1804 or CAS-10111 Pressure Fitting Kit
Northants, NN11 4NF This tool is first used on page 7.
England
CAS-1205 Test Block

OEM 1239 or CAS-10280 Flowmeter

CAS-10090 Hand Pump

CAS-1808 or CAS-1 0106 Flowmeter Fitting Kit

CAS-1913 Hand Pump

8002-5
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN ALL CIRCUITS

Check the machine for leaks and repair as
required.
NOTE: The main relief valve controls the

pressure in the loader and backhoe cir- Adjust the main relief valve according to in-
cuits. structions in this section.
Do the flowmeter test according to instruc- Troubleshooting complete.

tions in this section.

8002-6
TROUBLESHOOTING PROCEDURE FOR PROBLEM IN A SINGLE CIRCUIT

Check the machine for oil leaks and
missing or damaged parts.
Check the operation of the circuit that has Check the spool travel. See Section 8005
the problem. Does the cylinder(s) move in and 8007 as required for specifications for
both directions? spool travel. Is the spool travel correct?
YES
Adjust the linkage as required to meet the
, specification for spool travel.
There can be internal wear or damage to

the control valve. Repair or replace as re-
quired.
Check the O-ring on the plug for the load
check valve in the loader or backhoe
control valve. Is the O-ring good? Replace the O-ring.
Check the O-ring on the end of the circuit Replace the O-ring.
relief valve or plug. Is the O-ring good?
If used, check setting of the circuit relief Adjust the setting of the circuit relief valve
valve. Is the setting correct? according to instructions in this section.
Check the piston packing for the cylinder. NOTE: Boom cylinder only. A check
Is the piston packing good? valve is installed in the piston. The problem
in the boom circuit can be the check valve
and not the piston packing.
Repair or replace the cylinder as required.
There is some wear or damage in the

control valve. Repair as required.

8002-7
MAIN RELIEF VALVE
Equipment Required 5. Continue to hold the loader control lever in the RAISE
position and read the pressure gauge. Stop the engine.
o to 3000 psi (20 684 kPa, 207 bar) pressure gauge.
6. Compare the reading with the specification on page
Pressure Check 3. If the reading is not correct, adjust the main relief
valve.
1. Park the machine on a level surface. Put the backhoe
in the transport position and lower the loader bucket to Adjusting Main Relief Valve
the floor.
1. The main relief valve is in the outlet section of the
2. Heat the oil to operating temperature. loader control valve. Loosen the lock nut on the main
relief valve. Turn the adjusting screw clockwise to
3. See the illustration. Connect the pressure gauge to increase the pressure and counterclockwise to
the quick disconnect fitting at Test Port 1. decrease the pressure.
4. Run the engine at full throttle. Hold the loader control 2. Check the pressure again.
lever in the RAISE position until the loader stops moving.
3. When the pressure is correct, tighten the lock nut.
3. HYDRAULIC PUMP
4. FROM RESERVOIR
B901795J

8002-8
CHECKING OUTPUT OF PUMP WITH FLOWMETER

Equipment Required 4. Run the engine at 2000 rpm (r/min). Open the load
valve on the flowmeter. Read the flow gauge. Record
CAS-10106 or CAS-1808 flowmeter fitting kit the flow reading.
OEM 1239 or CAS-10280 Flowmeter 5. Keep the engine running at 2000 rpm (r/rnin). Slowly
close the load valve until the pressure is 2000 psi (13
Checking the Output of the 789 kPa, 138 bar). Read the flow gauge and record the
Loader (Rear) Section reading.
1. Park the machine on a level surface. Put the backhoe 6. Decrease the engine speed to low idle and stop the
in the transport position and lower the loader bucket to engine.
the floor. Stop the engine.
7. The pump efficiency is found by dividing the flow
2. See the illustration. Connect the flowmeter into the reading at 2000 psi (13 789 kPa, 138 bar) by the flow
circuit. reading at 0 psi (0 kPa, 0 bar). The answer multiplied by
100 is the percent efficiency of the pump. If the effi-
3. Heat the oil to operating temperature by closing the ciency is less than 70%, repair or replace the pump.
load valve on the flowmeter until the pressure gauge
reads 1000 psi (6895 kPa, 69 bar). Run the engine at
full throttle until the temperature is 125°F (52°C).

8002-9
1. CAP. 1-5/16-12
FLARE THREAD
3. HYDRAULIC PUMP
6. CONNECT FLOWMETER
OUTLET TO TUBE
1-5/16-12 FLARE THREAD
•• 01
7. TO INLET OF
5. OEM 1239 OR
CAS-10280 FLOWMETER
B901796J

8002-10
Checking the Output of the Backhoe 4. Run the engine at 2000 rpm (r/min). Open the load
or Three Point Hitch (Front) Section valve on the flowmeter. Read the flow gauge. Record
the ~Iow reading.
1. Park the machine on a level surface. Put the backhoe
in the transport position and lower the loader bucket to 5. Keep the engine running at 2000 rpm (r/min). Slowly
the floor. Stop the engine. close the load valve until the pressure is 2000 psi (13
789 kPa, 138 bar). Read the flow gauge and record the
2. See the illustration. Connect the flowmeter into the reading.
circuit.
6. Decrease the engine speed to low idle and stop the
3. Heat the oil to operating temperature by closing the engine.
load valve on the flowmeter until the pressure gauge
reads 1000 psi (6895 kPa, 69 bar). Run the engine at 7. The pump efficiency is found by dividing the flow
full throttle until the temperature is 125°F (52°C). reading at 2000 psi (13 789 kPa, 138 bar) by the flow
reading at 0 psi (0 kPa, 0 bar). The answer multiplied by
100 is the percent efficiency of the pump. If the effi-
ciency is less than 70%, repair or replace the pump.
2. HYDRAULIC PUMP
3. FROM RESERVOIR
6. TO SWING SECTION OF
.!}~, .... -~..
BACKHOE CONTROL VALVE _'!. ..... :: :':.- ~ •• 0
'!) . . - ~
~ ~-
B901797J
4. OEM 1239 OR
CAS-10280 FLOWMETER

8002-11
CIRCUIT RELIEF VALVES FOR LOADER AND BACKHOE CONTROL VALVES

Equipment Required 3. Actuate the handle on the hand pump and record the
highest pressure reading. Check the pressure setting
CAS-10111 or CAS-1804 Pressure fitting kit 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
1. Connect the hand pump to the test block. pressure setting.
2. Install the circuit relief valve in the test block. 3. Check the pressure setting again. When the pressure
setting is correct, tighten the lock nut.
1 2 3 5
1 2 4 5
Backhoe:
1. Bucket A and B Ports. 2950 to 3150 psi
(20340 to 21 719 kPa, 203 to 217 bar)
B901824J 2. Dipper A and B Ports. 2950 to 3150 psi
(20340 to 21 719 kPa, 203 to 217 bar)
3. Boom A Port. 2050 to 2250 psi
Loader: (14 135 to 15514 kPa, 141 to 155 bar)
1. Bucket A and B Ports Circuit Relief Valve 4. Boom B Port. 4000 to 4100 psi
2950 to 3150 psi (20 340 to 21 719 kPa, (27 580 to 28 269 kPa, 276 to 283 bar)
203 to 217 bar) 5. Swing A and B Ports. 2050 to 2250 psi
(14 135 to 15514 kPa, 141 to 155 bar)

8002-12
CIRCUIT RELIEF VALVE FOR THE THREE POINT HITCH CONTROL VALVE
Equipment Required
CAS-10111 or CAS-1804 Pressure fitting kit
CAS-10095 Multi gauge
CAS-10090 Hand pump
Pressure Check
Attachment on the floor.
Loosen filler cap on reservoir to relieve pressure in re-

servoir.
Disconnect hose from S-port of the lift section.
Connect the correct fitting 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. 3. Prevent the adjusting screw from turning and tighten
the lock nut.
2. Turn the adjusting screw clockwise to increase the
setting or turn the adjusting screw counterclockwise to 4. Check the setting again.
decrease the setting.
Bur B-17530 Issued 3-91 Printed in U.S.A.

8002-13
Supplies oil flow for the complete hydraulic system.

Controls flow of oil to the cylinders
movement of control levers.
1. Inlet
2. Outlet
4. From Steering Control Valve (I
5. To Bucket Cylinders
6. To Lift Cylinders
7. To Clam Cylinders
8 Main Relief Valve
9. Steering Relief Valve
10. Flow Control Valve
11. Circuit Relief Valve
12. Load Check Valve
13. Spool
14. Check Valve
IE
for the loader by
BUCKET SECTION
LIFT SECTlm
Jilot)
INLET SECTION
t LOADER CONTROL VALVE
Controls flow of oil to the cylinders for the loader by
1. Inlet BUCKET SECTION

2. Outlet
4. From Steering Control Valve (Pilot)
5. To Bucket Cylinders INLET SECTION
6. To Uft Cylinders
7. To Clam Cylinders
8. Main Relief Valve
9. Steering Relief Valve
10. Flow Control Valve
13. Spool
14. Check Valve
®
8002-14
LIFT SECTION CLAM SECTION OUTLET SECTION
B891~
Bur 8-17530
Issued 3-91 Printed in U~
8002-15
1. Inlet
2. Outlet
3. Pilot
4. Check Valve
5. Spool and Sleeve Assembly
6. Drive Unk
7. Gerotor
Controls oil flow to the steering cylinder.
8891058J

8002-16
1. Inlet
2. To Resetvoi:
3. To Oil Cooler
4. From Steering Control Valve
5. Filter
6. Bypass Valve
7. Switch
8. Check Valve
Cleans oil returning to the reservoir.
B891 061 J

Bur 8-17530
8002-1·
Controls flow of oil to cylinders for backhoe hy

control levers.
1. Inlet
2. Outlet
3. To Swing Cylinders
4. To Boom Cylinder
5. To Left Stabilizer Cylinder
6. To Right Stabilizer Cylinder
7 To Dipper Cylinder
B To Bucket Cylinder
9 To Extension Cylinder
12 10. Anticavitation Valve
13. Check Valve
14. Spool
15 Regeneration Valve
14 L I
12
14
@
12
Bur 8-17530
Issued 3-91 Printed in U
7
1110Vnl110.111 of
SWING SECTION LEFT AND RIGHT

BOOM SECTION
STABILIZER SECTIONS
INLET SECTION
.SA
1002-1"
VE
shoo by
DIPPER AND
BUCKET SECTION EXTENSION SECTION
OUTLET SECTION
B891299A
led in U
o THREE POINT HITCH CaNT,
Controls flow of oil to cylinders for three c

1. inlet
2. Outlet
3. t» Implement
9
4. t» Tilt Cylinder
5. To Pitch Cylinder
6. To litt Cylinder
8. Circuit Relief - Anticavitation Valve
9. Load Check Valve
10. Spool
Corrrols flow of oil to cylinders for three point hitch by
1. inlet
2. Outlet
3. t» Implement
4. to Tilt Cylinder
5. To Pitch Cylinder INLET-OUTLET AND
6. To Uft Cylinder IMPLEMENT SECTIO~
B. Circuit Relief - Anticavitation Valve
9. Load Check Valve
10. Spool
PI
8002-18
~OL VALVE
oint hitch by
INLET-OUTLET AND
IMPLEMENT SECTION
TILT AND PITCH SEC'
Bur 8-17530
8002-18
LIFT SECTION
-- TILT AND PITCH SECTIONS
8891300
Bur 8-17530
Issued 3-9'
8002-19
1. Spool
2. Check Valve
3. Orifice
Actuated by cam to slow the speed of the swing

motion of the backhoe.
CD
CD
B891301J

8002-20
This Page Left Blank

8002-2
DIRECTION OF FLOW
PILOT PRESSURE
Pressure used to control another component.
CROSSOVER LINES
CONNECTING LINES
FILTER OR SCREEN
OIL COOLER
CHECK VALVE
Permits oil flow in one direction only.
Loader Backhoe Schematic

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 coc
RESERVOIR
inted in U.S.A.
STEERINC
DIRECTION OF FLOW
PILOT PRESSURE
Pressure used to control another component.
CROSSOVER LINES
CONNECTING LINES
-0- TEST PORT 2

FILTER OR SCREEN
OIL COOLER
CHECK VALVE
Permits oil flow in one direction only.

8891303
Loader Three Point Hitch Schematic
Bur 6-17530
Issued 3-91 Prinlr.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 Flushing Water From

the Hydraulic System 8003-6
Types of Contamination 8003-3
CASE CORPORATION
8-67390 Printed in U.S.A.

Issued March 1987
B003-2
PORTABLE FILTER
The Portable Filter and Fitting Kit are available
from Service Tools in the United States or from
Jobborn Manfaucturing Co. in Canada. See Spe-
cial Tools in Section 1001 for correct address.
The part number of the Portable Filter is CAS-

10162A and for the Fitting Kit the part number is
CAS-1050B.
S06126
Fitting Kit
806127
Portable Filter
8003-3
GENERAL INFORMATION
Contamination in the hydraulic system is a 1. Cylinder rod seals leak.
major cause of the malfunction of hydraulic com-
ponents. Contamination is any foreign material in 2. Control valve spools do not return to NEUTRAL.
the hydraulic oil. Contamination can enter the hy-
draulic system in several ways. 3. Movement of control valve spools is difficult.
1. When you drain the oil or disconnect any line. 4. Hydraulic oil becomes too hot.
2. When you disassemble a component. 5. Pump gears, housing, and other parts wear
rapidly.
3. From normal wear of the hydraulic compo-
nents. 6. Relief valves or check valves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of components that have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraul ic systems operate with some con-
tamination. The design of the components in this If your machine has any of these problems,
hydraulic system permits efficient operation with a check the hydraulic oil for contamination. See
small amount of contamination. An increase in this Types of Contamination below. If you find contam-
amount of contamination will cause problems in ination, use the Portable Filter to clean the hydrau-
the hydraulic system. The following list includes lic system.
some of these problems.
TYPES OF CONTAMINATION
There are two types of contamination, micro- 2. Visible contamination is foreign material that
scopic and visible. can be found by sight, touch, or odor. Visible con-
tamination can cause a sudden failure of a compo-
1. Microscopic contamination occurs when very nent. Examples of visible contamination.
fine particles of foreign material are in suspension
in the hydraulic oil. These particles are too small to a. Particles of metal or dirt in the oil.
see or feel. Microscopic contamination can be
found by identification of the following problems b. Air in the oil.
or by testi ng in a laboratory. Examples of the prob-
lems: c. The oil is dark and thick.
a. Cylinder rod seals leak. d. The oil has the odor of burned oil.
b. Control valve spools do not return to NEU- e. Water in the oil. See page 8003-6.
TRAL.
c. The hydraulic system has a high operating

temperature.
8003-4
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter shown on page 8. Loosen and remove the drain plug from the
8003-2 by doing the following steps: reservoi r.
a. Remove all the hydraulic oil from the inlet 9. See the fitting kit shown on page 8003-2. Install
and outlet hoses for the portable filter. the valve in the hole for the drain plug. Make sure
that the valve is closed.
b. Remove the filter element from the porta-
ble filter. 10. Stop the vacuum pump.
c. Remove all hydraulic oil from the portable 11. Connect the inlet hose for the portable filter to
filter. the valve that is installed in the hole for the drain
plug.
d. Clean the inside of the housing forthe filter
element. 12. Disconnect the vacuum pump from the filler
cap opening on the hydraulic reservoir.
e. Install a new filter element.
13. Install the outlet hose for the portable filter in
2. You must know whether the contamination is the hydraulic reservoir.
microscopic or visible. See Types of Contamina-
tion on page 8003-3. 14. Open the valve that is installed in the hole for
the drain plug.
3. If the contamination is microscopic:
15. Move the switch for the portable filter to the ON
a. Check the maintenance schedule for the position. Start and run the engine at 1500 rpm
machine to learn if the hydraulic oil must be (r/min).
changed. If needed, change the hydraulic oil.
See Section 8001. Change the hydraulic filter. 16. Run the portable filter for 10 minutes.
b. Do steps 6 th rough 38. 17. Continue to run the portable filter.
4. If the contamination is visible: 18. Increase the engine speed to full throttle. Heat
the oil to operating temperature by doing the fol-
a. Change the hydraulic oil and hydraulic fil- lowing steps:
ter. See Section 8001. Remove and clean the
hydraulic pump suction screen. a. Hold the bucket control lever in the ROLL-
BACK position for 15 seconds.
b. Do steps 5 through 38.
b. Return the bucketcontrolleverto NEUTRAL
5. Check the amount of contamination in the hy- for 30 seconds.
draulic system by doing the following steps.
c. Repeat steps 18a and 18b unti I the oil in the
a. Disassemble one cylinder in two different hydraulic system is at operating temperature.
circuits. Check for damage to seals, scoring of
the cylinder wall, etc. Repair the cylinders as 19. Continue to run the engine at full throttle. Con-
necessary. tinue to run the portable filter.
b. If, in your judgment, the damage to the 20. Operate each hydraulic circuit to completely
cylinders was caused by severe contamination extend and retract the cylinders. Continue to oper-
and is not the result of normal wear, it is neces- ate each hydraulic circuit two times, one after the
sary to remove, clean and repair valves, pump, other, for 45 minutes.
lines, cylinders, hydraulic reservoir, etc. in the
hydraulic system. 21. Decrease the engi ne speed to low idle.
6. Loosen and remove the filler cap from the

reservoir.
7. Connect a vacuum pump to the filler cap open-

ing. Start the vacuum pump.
8003-5
22. Continue to run the portable filter for 10 min- 31. Install the drain plug.
utes.
32. Stop the vacuum pump. Disconnect the vacu-
23. Stop the portable filter. um pump from the hydraulic reservoir.
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. 35. Install a new hydraulic filter element on the
machine.
27. Disconnect the inlet hose for the portable fi Iter
from the valve. 36. Check the oil level in the hydraulic reservoir.
Add oil as required. See Section 8001.
28. Connect a vacuum pump to the fill cap open-
ing of the hydraulic reservoir. 37. Start the engine. Check for oil leakage around
the new hydraulic filter. ~
29. Start the vacuum pump.
30. Remove the valve from the hole for the drain
plug.
8003-6
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/rnin). 11. Disconnect the line from the rod end and
closed end of each cylinder.
2. Completely retract the cylinders of all attach-
ments on the machine. 12. Be sure all control levers are in the NEUTRAL
position.
IMPORTANT: Check the oil level in the hydraulic.

reservoir frequently while doing step 14.
3. Any attachment or part of an attachment that is
raised must be supported to prevent the attach- 14. Move each control lever in both directions un-
ment from falling. til oil begins to flow from the open line. Hold the
control lever in place until clean oil flows from the
4. Loosen and remove the filler cap from the open line.
reservoir.
5. Drain the hydraulic oil from the reservoir.
16. Connect the line to the CLOSED end of each
a. The reservoir holds approximately 21 U.S. cylinder.
gallons (79.5 litres) of hydraulic oil.
b. Have available acceptable equipment to
drain the hydraulic oil. 18. Completely extend all cylinders. As the piston
rod comes out of the cylinder, oil will be pushed out
c. Remove the drain plug from the bottom of of the rod end of the cylinder.
the reservoir.
19. Support the loader frame so that the loader
6. Remove the hydraulic oil filter from the ma- frame will stay in the RAISED position.
chine.
7. Install a new hydraulic oil filter on the machine.
21. Connect the lines to the rod end of the cylin-
8. Install the drain plug in the bottom of the reser- ders.
voir.
22. Fill the reservoir to the correct level.
9. Fill the hydraulic reservoir with 21 U.S. gallons
(79.5 Iitres) of Case TCH Fluid. 23. Install the filler cap for the reservoir.
10. Move each control lever in both directions to

release pressure in the circuits.
Section
8004
HYDRAULIC PUMP
CASE CORPORATION

Issued January 1991
8004-2
TABLE OF CONTENTS
SPECiFiCATIONS 2
DiSASSEMBLy . . 3
INSPECTION ...................... . .7
ASSEMBLY .. . 9
SPECIFICATIONS
Manufacturer Commercial Shearing
Rotation Counterclockwise as seen from shaft end
Wear specifications See Inspection
Special torques
Cap screws that hold the' sections together 250 pound-feet (339 Nm)
Weight 80 pounds (36 kg)

8004-3
DISASSEMBLY
STEP 1 STEP 4
Clean the outside of the hydraulic pump. Fasten the Remove the quad ring.
hydraulic pump in a vise with soft jaws. Make alignment
marks on each section of the hydraulic pump.
STEP 5
STEP 2
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.

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.

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.

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.

8004-7
INSPECTION
Discard all seals and quad rings, Clean all parts in STEP 26
cleaning solvent. Check all machined surfaces for
damage or wear,
STEP 24
8525018M
Measure the thickness of the thrust plates. If the thick-
ness of a thrust plate is less than 0.247 inch (6.27 mm),
install a new thrust plate.
Measure the amount of wear caused by the gear teeth

in the gear housing. If the wear is more than 0.005 inch STEP 27
(0.13 mm), use a new gear housing.
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.

8004-8
8. CAP SCREW
6. END COVER
5. QUAD
RING
7. FLAT WASHER
16. QUAD
12. DRIVE GEAR
RING
28. DRIVEN GEAR

22. SEAL
13. QUAD
RING
31. DRIVE B901880J

END COVER

8004-9
ASSEMBLY
STEP 28 STEP 31
Install new quad rings in the grooves in the gear hous- Press a new bearing into the drive end cover until the
ings. Use petroleum jelly to hold the quad rings in place. snap ring can be installed in the groove.
STEP 29 STEP 32
Install a new oil seal in the drive end cover. Install the snap ring.
STEP 30 STEP 33
Press the oil seal into the drive end cover. Install new seals in each thrust plate.

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 Install the driven gear.
grooves as shown above.

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
STEP 44
Install the carrier.

Install the drive gear
STEP 42
STEP 45
Install the gear housing.

Install the driven gear.

8004-12
STEP 46 STEP 48
l
Install the thrust plate with the seal up as shown. Install the cap screws and flat washers. Tighten the cap
screws evenly to 250 pound-feet (339 Nm).
STEP 47
Install the end cover.

8004-13
12. QUAD RING

6. DRIVE 14. THRUST PLATE
3. OIL SEAL 5. QUAD GEAR
RING 13. DRIVE
GEAR
15. BUSHING
16. FLAT
WASHER
24. DRIVE
END COVER
18. END
23. GEAR 21. CARRIER
22. DOWEL COVER
HOUSING PIN
19. GEAR
8901881J
HOUSING
Bur 8·17400 Issued 1-91 Printed in U.S.A

Section
8005
CASE CORPORATION
Bur 8·17410 Printed in U.S.A.

Issued January 1991
8005-2
TABLE OF CONTENTS
SPECiFiCATIONS....... .. . 3
SPECIAL TOOLS.. . 4
SEPARATING THE VALVE SECTIONS 5
ASSEMBLING THE VALVE SECTIONS 6
OUTLET SECTION.. .. 7
Disassembly 7
Exploded View 8
Assembly 8
Cross Section........ . 9
INLET SECTION . 10
Disassembly.. . ,. . . 10
Inspection... . 11
Exploded View.. . 12
Assembly.... .. . . 13
Cross Section . . 14
BUCKET SECTION...... .15
Disassembly............ . .15
Exploded View....................................................................................... . 19
Inspection .. .. . 20
Assembly '" .20
Cross Section . .. .. " 25
LIFT SECTION 26
Disassembly 26
Exploded View. . 29
Inspection................ 30
Assembly 30
Cross Section 34
CLAM SECTION 35
Disassembly 35
Exploded View 37
Inspection 38
Assembly 38
Cross Section 41
CIRCUIT RELIEF VALVE 42
Dissasembly 42
Inspection . .......43
Assembly 43

8005-3
SPECIFICATIONS
Manufacturer . ..... J I Case
Pressure Settings . . See Section 8002
Ports and Spools

Spool travel, neutral to pressure 0.390 inch (9.9 mm)
Spool travel. neutral to float . . 0.680 inch (17.2 mm)
Spool moved into the body . ... pressure at A port
SpOOl moved out of the body .. ............ pressure at B port
Inlet. outlet, and power beyond ports 1-5/16-12, straight thread
Threads in steering pilot port . ...................................... 9/16 - 18, straight thread
Threads in steering outlet port . .. 3/4 - 16 straight thread
Threads in A and B ports . .. 7/8 - 14, straight thread
Special torque
Nuts that fasten the valve sections together 20 to 30 pound-feet (27 to 41 Nm)
Main relief valve 35 to 40 pound-feet (47 to 54 Nm)
Circuit relief valves.................... .. 65 to 85 pound-feet (88 to 155 Nm)
Plug for outlet section ............................................................ 30 to 40 pound-feet (41 to 54 Nm)
Spool cap or detent housing 20 to 30 pound-feet (27 to 41 Nm)
Allen head screws for bucket spool Tightenscrews evenly to 15 to 30 pound-inches

(2 to 3 Nm). Then tighten the Allen head screws
evenly to 50 to 60 pound-inches (6 to 7 Nm).
Circuit relief valve body 96 to 144 pound-inches (11 to 16 Nm)
Weight approximately 70 pounds (32 kg)

8005-4
SPECIAL TOOLS
dresses:
Service Tools
PO. Box 314
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.

8005-5
SEPARATING THE VALVE SECTIONS

STEP 1 STEP 4
Clean the outside of the loader control valve. Write a Remove the shims.
number on each section of the loader control valve.
STEP 5
STEP 2
Remove the remainder of the sections and shims.

Loosen and remove the nuts that fasten the sections to-
gether.
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 STEP 10
Inspect the O-rings in the valve sections. Replace the
O-rings as necessary Use petroleum jelly to hold the
O-rings in place as the valve sections are assembled
STEP 8
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 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).
Install the shims.

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.
STEP 17
Loosen the plug in the other end of the outlet section. Do not disassemble the main relief valve. None of the
internal parts of the main relief valve are available for
service.
STEP 14
Remove the plug

8005-8
STEP 19
Install the spring.
STEP 20
6. MAIN
RELIEF
VALVE
Install a new O-ring on the plug. Lubricate the O-ring
B870012J
with clean hydraulic oil. Install the plug. Tighten the plug
Outlet Section
to 30 to 40 pound-feet (41 to 54 Nm).
Assembly
STEP 18 STEP 21
Install new O-rings and a new backup ring on the main

Install the poppet.
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).

8005-9
5. OUTLET SECTION
6. MAIN RELIEF VALVE
2. O-RING
3. SPRING
B861799J
Outlet Section

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
Fasten the steering relief valve in the vise with soft jaws.
Prevent the adjusting screw from turning and loosen the
Remove the spring. lock nut. Make a count of the number of turns needed to
remove the adjusting screw from the body.

8005-11
STEP 28 Inspection
STEP 29
4. a-RING
B628924M
.~ ..'
Remove the steering relief valve from the vise and 4. a-RING
separate the parts. B628928M
Inspect the seat in the end of the body If the seat is
damaged, use a press to replace the seat. Replace the
O-rings and backup ring on the body and adjusting
screw.
STEP 30
Inspect the orifice in the orifice plug. Make sure the
orifice is clean.
STEP 31
Inspect the spool and spring. Use new parts as neces-
sary.

8005-12
4. BODY
6. O-RING
B870013J
Inlet Section

8005-13
Assembly STEP 35
STEP 32
Install a new O-ring on the plug. Lubricate the O-ring on

.·B628924M the plug. Lubricate the O-ring with clean hydraulic oil.
Lubricate the new O-ring on the adjusting screw. Install the plug in the inlet section
Assemble the parts of the steering relief valve.
STEP 36
STEP 33
Install the spring in the other end of the inlet section

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. 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.

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

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.

8005-16
STEP 45 STEP 48
Remove the spring. Pull the spool from the body.
STEP 46
STEP 49
Remove the detent washer. .:~~,S23~M

Remove the O-ring, retainer, spring washers, and other
O-ring from the spool.
STEP 47
STEP 50
Remove the coil and terminal.
Remove the detent housing.

8005-17
STEP 51 STEP 54
8415238M
See Special Tools in this section. Install the spring com- Loosen and remove the circuit relief valve from the
pressing plates to compress the centering spring. body.
STEP 52 STEP 55
B415240M
Loosen and remove the stud. See Special Tools in this section. Use the tool to pull the
load check plug, spring, and poppet from the body.
STEP 53
STEP 56
Repeat steps 54 and 55 to remove the other circuit relief
valve.
STEP 57
'i8415242M
Release the spring tension and separate the centering
spring and spring seats.
Use a prybar to remove the wiper.
Bur 8-17410 Issued 1-91 Printed in U,S.A

8005-18
STEP 58 STEP 59
See page 42 for disassembly, inspection, and
assembly of the circuit relief valves.
Remove the O-ring from the spool bore.

8005-19
B901919J
Bucket Section
Bur 8-17410
8005-20
Inspection STEP 63
STEP 60
B9073305M
Replace the O-ring and backup rings on the load check
B415232J plug.
Remove and discard the O-ring from the terminal.
STEP 64
STEP 61 Inspect the spool and spool bore for wear and damage.
If either part is worn or damaged. use a complete new
bucket section.
STEP 65
Use an ohmmeter to check the coil and terminal for
continuity and for a short circuit. If the terminal is
damaged. use a soldering iron to replace the terminal. If
the coil is damaged, remove the terminal from the old
coil and install the terminal on the new coil.
STEP 66
Discard the O-rings and gasket.
Inspect the rubber plug in the cap. Replace the rubber

Assembly
plug as necessary.
STEP 67
See page 42 for disassembly. inspection. and
assembly of the circuit relief valves.
STEP 62
STEP 68
B9073309M
Inspect the poppet. spring, and load check plug. Use
new parts as necessary.
Install a new O-ring in the groove of the spool bore.

8005-21
STEP 69 STEP 72
B415242M
Use the tool to install the load check plug, spring, and Assemble the spring and spring seats. Use the spring
poppet. The groove in the load check plug must be compressing plates to compress the spring.
toward the spool bore.
STEP 73
STEP 70
B415243M
Install the spring and spring seats on the spool.
Lubricate the O-rings and backup ring on the circuit
relief valve. Install the circuit relief valve.
STEP 74
STEP 71
B415201M
Apply 242 Loctite to the threads of the stud. Install the
628630M stud in the spool.
Tighten the circuit relief valve to 65 to 85 pound-feet (88
to 155 Nrn).

8005-22
STEP 75 STEP 78
B415238M "'B415202M
Remove the spring compressing plates. Push the parts against the detent housing.
STEP 76 STEP 79
Install the detent housing. Lubricate the spool, spool bore. and the O-rings with
clean hydraulic oil. Install the spool into the bore.
STEP 77
STEP 80
B4t5235M
Install the O-rings, spring washers, and retainer.
Install the coil and terminal on the stud.

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
Install the washer. 15113M

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 pound- Use a hollow sleeve and a hammer to push the wiper
inches (2 to 3 Nm). Then tighten the Allen screws to 50 into the body.
to 60 pound-inches (6 to 7 Nrn).
STEP 90
STEP 88
Install new O-rings in the bucket section.

Lubricate the wiper with clean hydraulic oil. Install the
wiper with the lip up.

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 95
II
STEP 92
Remove the eight steel balls.
Fasten the lift section in the vise with soft jaws. Loosen
and remove the plug. STEP 96
IIi
... :,(,=;::: ...."
STEP 93
Remove the spacer.
Remove the detent spring.

8005-27
STEP 97 STEP 100
B415424M
Loosen and remove the detent housing. See page 4 for the spring compressing plates Fasten
the spring compressing plates to compress the cen-
tering spring.
STEP 98
STEP 101
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.

8005-28
STEP 103 STEP 106
B415430M
Release the tension on the centering spring and Remove the wiper from the spool bore.
separate the centering spring and spring seats.
STEP 107
STEP 104

Loosen and remove the plug from the body.
STEP 108
STEP 105 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.

8005-29
Lift Section
8005-30
Inspection STEP 113

Inspect the stud, spacer, steel balls, and ball retainer
STEP 109 for damage and wear. Install new parts as necessary.
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. ~1' . ,,;,§41?414t'lt
Use the tool shown on page 4 to install the load check
STEP 111 plug, spring, and load check poppet. The groove in the
Inspect the spool and spool bore for wear and damage. loade check plug must be in alignment with the work
If either part is worn or damaged, use a complete new port.
lift section
STEP 116
STEP 112
B415420M
Replace the O-rings and backup ring on the plug.

8005-31
STEP 117 STEP 120
B41~5430M B415424M
Assemble the centering spring and spring seats. Use Remove the spring compressing plates.
the spring compressing plates shown on page 4 to
compress the centering spring.
STEP 121
STEP 118
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
Lubricate the spool, spool bore, and the O-rings with

clean hydraulic oil. Install the spool into the spool bore.
B4t5426M
Apply 242 Loctite (blue) to the threads of stud. Install
the stud in spool. Tighten the stud.

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
STEP 127
Apply No. 2 molydisu\fide grease to the groove in the

spacer. Apply No.2 molydisulfide grease to the flat side of the
ball retainer.
STEP 125
STEP 128
Install the spacer so that the groove in the spacer is up.

Install the ball retainer with the flat side down.

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
STEP 133
Install the plug.

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
B901922J
Bur 8-17410 Lift Section Issued 1-91 Printed in U.S.A
8005-35
CLAM SECTION
Disassembly STEP 137
STEP 134
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.

8005-36
STEP 140 STEP 143
Remove the spring and spring seats from the spool. Use a prybar to remove the wiper from the other end of
Release the spring tension and separate the spring, the spool bore.
spring seats, and washer.
STEP 144
STEP 141

Loosen and remove the plug.
STEP 145
STEP 142 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.

8005-37
B901923J
Clam Spool
Bur 8-17410
8005-38
Inspection Assembly
STEP 146 STEP 150
·B9073309M
Inspect the load check poppet, spring, and load check Install a new O-ring in the groove of the spool bore.
plug. Use new parts as necessary.
STEP 151
STEP 147
B9073305M Lubricate the O-ring and backup rings on the load

Replace the O-ring and backup rings on the load check check plug. Use the tool to install the load check plug,
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.
M
STEP 149
Lubricate the O-rings and backup ring on the plug.
Inspect the spool bore for wear and damage. If the
Install the plug. Tighten the plug to 65 to 85 pound-feet
spool or spool bore is damaged, use a complete new
(88 to 155 Nm).
clam section.
8005-39
STEP 153 STEP 156
i ' ,-:'B628624M
Assemble the spring, spring seats, and washer. Use Tighten the cap screw
the spring compressing plates shown in Special Tools
to compress the spring.
STEP 157
STEP 154
';':'~~~M
Release the tension of the spring and remove the spring
B628539M compressing plates.
Apply 242 Loctite to the threads of the cap screw.
STEP 158
STEP 155
B628622M Install the retainer and a new O-ring on the spool.

Install the cap screw to fasten the spring to the spool.

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

Install the spool cap. into the bore.
STEP 161
\OO28844M
Tighten the spool cap to 20 to 30 pound-feet (27 to 41
Nm).

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

8005-42
CIRCUIT RELIEF VALVE

STEP 164
Move the circuit relief valve in the vise. Fasten the

poppet seat in the vise. Loosen the body from the
Fasten the circuit relief valve in the vise with soft jaws. poppet seat.
Loosen the lock nut. Loosen and remove the adjusting
screw and lock nut.
STEP 166
NOTE: If you disassemble more than one relief valve,
keep the parts for each relief valve together. This pro-
cedure will prevent mixing the parts during assembly.
B628606M
Remove the relief valve from the vise. Separate the
parts of the relief valve.

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.
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.

8006
CYLINDERS
TABLE OF CONTENTS
Specifications 2 Lift Cylinder for the Three-Point Hitch 12
Special Tools.... 3 Disassembly........ 12
Loader Bucket and Lift. Backhoe Extension, Inspection .. 12

Bucket. Swing, Clam. Stabilizer and
Dipper Cylinders. . 4 Assembly. . 12
Disassembly.. ..4 Tilt Cylinder for the Three-Point Hitch 16
Inspection .. .. ... 4 Disassembly... .. 16
Assembly............ 4 Inspection 16
Boom Cylinder. . .. 8 Assembly. . 16
Disassembly. . ... 8 Pitch Cylinder for the Three-Point Hitch 20
Inspection. .. . 8 Disassembly......... .. 20
Assembly. . 8 Inspection. .. 20
Assembly 20
CASE CORPORATION
Rae 8-17591 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 .. 269 to 339 pound-feet (365 to 460 Nm)
Lift cylinder 269 to 339 pound-feet (365 to 460 Nm)
Clam cylinder...... ..661 to 819 pound-feet (895 to 1110 Nm)
Three-point hitch cylinders

Lift cylinder . 200 to 220 pound-feet (271 to 298 Nm)
Tilt cylinder.............................................. 200 to 220 pound-feet (271 to 298 Nm)
Pitch cylinder 169 to 192 pound-feet (230 to 260 Nm)
Backhoe cylinders
Extension cylinder..................... 269 to 339 pound-feet (365 to 460 Nm)
Bucket cylinder ..661 to 819 pound-feet (895 to 1110 Nm)
Swing cylinder .. 325 to 365 pound-feet (440 to 495 Nm)
Stabilizer cylinder................ . 661 to 819 pound-feet (895 to 1110 Nm)
Boom cylinder ..1314 to 1609 pound-feet (1780 to 2180 Nm)
Dipper cylinder.......................... . , 2443 to 2841 pound-feet (3310 to 3850 Nm)
Torque for all glands . ........ 100 to 400 pound-feet (135 to 542 Nm)
Cylinder weights (approximate)
Loader cylinders
Bucket cylinder . ... 40 pounds (19 kg)
Lift cylinder.................. . ... 60 pounds (27 kg)
Clam cylinder.................. . ... 33 pounds (15 kg)
Three-point hitch cylinders

Lift cylinder...... . .......... 29 pounds (13 kg)
Tilt cylinder. . ..23 pounds (10.4 kg)
Pitch cylinder .. . . .. 30 pounds (13.6 kg)
Backhoe cylinders
Extension cylinder 82 pounds (37 kg)
Bucket cylinder . 98 pounds (45 kg)
Swing cylinder 70 pounds (32 kg)
Stabilizer cylinder......................... 99 pounds (45 kg)
Boom cylinder.......................... 170 pounds (77 kg)
Dipper cylinder 155 pounds (70 kg)
Revised 8-92 Printed in USA

Rae 8-17591
8006-3
SPECIAL TOOLS
Order special tools from one of the following ad- The tool shown is used to install the seal in the
dresses: glands of the cylinders. This tool is first used on page
8006-4
Service Tools
PO Box 314
In Europe
VL Churchill Ltd
Northants, NN11 4NF
England
This tool is used to remove and install the gland on

B505802M
Case cylinders. The part number on the gland wrench is
CAS-1 456 This tool is first used on page 8006-4 1. CAS-1659 For One Inch (25 mm) Rods
2. CAS-1660 For 1-1/4 and 1-1/2 Inch
(32 and 38 mm) Rods
3. CAS-1758 For 2 Inch (50 mm) Rods
The torque multiplier is used to loosen and tighten

the piston cap screw. Use the torque multiplier ac-
cording to the instructions of the manufacturer. The part
number of the torque multiplier is CAS-1 039. This tool is
first used on page 8006-4.
B786441M
8795329M
Revised 8-92 Printed in U.S.A

gae 8-17591
8006-4
LOADER BUCKET AND LIFT, BACKHOE EXTENSION, BUCKET, SWING,

CLAM, STABILIZER, AND DIPPER CYLINDERS
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 (6)
removed with the cylinder, remove the hoses from the
cylinder. 5. Remove small scratches on the piston rod (6) or
inside the tube (1) with emery cloth of medium grit. Use
1. Fasten the tube (1) in a vise or other holding equip- the emery cloth with a rotary motion.
ment. Be careful to prevent damage to the tube (1).
6. Inspect the bushing (18) and seal (19). if equipped.
2 Loosen and remove the lock screw (2) from the in the piston rod eye (5) and the closed end of the tube
gland (3) and tube (1). (1), replace as required
3. Use the gland wrench shown on page 8006-3 to 7. Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1). rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8 Inspect the gland end of the tube (1) for share
prevent damage to the tube (1). edges that will cut the gland O-ring (12). remove as re-
quired.
5. Fasten the piston rod eye (5) in a vise and put a
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear If the
a shop cloth between the support and the piston rod (6) piston (4) is damaged or worn. a new piston (4) must be
to prevent damage to the piston rod (6). used.
6. Loosen and remove the cap screw (7) and Assembly

hardened washer (8) that holds the piston (4). Use the
torque multiplier shown on page 8006-3 for cap screws NOTE: If a new gland (3) is being installed, put the
that have a high torque value. part number of the cylinder on the new gland (3)
7. Remove the piston (4) from the piston rod (6). 1. Install the bushing (17) in the gland (3).
8. Remove the gland (3) from the piston rod (6). 2. Install the wide seal (15) in the gland. The wide seal
(15) is to be installed so that the Iips of the wi de seal (15)
9. Remove the seal (9), backup ring (10), and wear are toward the small end of the gland (3). The wide seal
ring (11) from the piston (4). (15) can be difficult to install. Use the tool shown on
page 8006-3
10. Remove the O-ring (12), backup ring (13), wiper
(14), wide seal (15), narrow seal (16), and bushing (17) 3. Install a new wiper (14) in the gland (3). The lips of
from the gland (3). the wiper (14) must be toward the large end of the gland
(3).
Inspection
4. Install the narrow seal (16) in the gland (3) The side
1. Clean the piston (4), gland (3), piston rod (6), tube of the narrow seal (16) with the groove must be toward
(1), hardened washer (8), and cap screw (7) in cleaning the small end of the gland (3).
solvent.
5. Install a new backup ring (13) in the groove on the
2. Discard the parts that were removed from the outside of the gland (3). If both sides of the backup ring
piston (4) and the gland (3). (13) are not flat, the side that is not flat must be toward
the small end of the gland (3)_
inside of the tube (1) for deep grooves and other 6. Install the O-ring (12) next to the backup ring (13) in
damage. If there is damage to the tube (1), a new tube the groove on the outside of the gland (3). The O-ring
(1) must be used. (12) must be toward the small end of the gland (3).
Revised 8-92 Printed in U.SA

Rae 8-17591
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. 18 Install a new seal (9) on top of the backup ring (10)
on the outside of the piston (4)
8. Remove any marks and sharp edges on the chamfer
at the end of the piston rod (6). 19. Fasten the tube (1) in a vise or other holding equip-
ment. Be careful to prevent damage to the tube (1)
9 Lubricate the bore of the gland (3) with clean oil.
20 Lubricate the inside of tne tube (1) and tne ois.on (4)
10 Push the gland (3) onto the piston rod (6). If neces- with clean oil.
sary, use a soft hammer to drive the gland (3) onto
the piston rod (6). 21 Push the piston (4) straiqh: in.o .ne lube (1)
11. Put a support below and near the end of the piston 22 When the piston (4) is in he smooth oar: 0' the tube
rod (6). Use a shop cloth between the support and (1). start the gland (3) in:o 'he .ube (1\
the piston rod (6) to prevent damage to the piston
(4). 23 Lubricate the O-ring (12) or, .he gland (3) \VI:hclean
oil
12. Put the piston (4) on the end of the piston rod (6)
24. Tighten the gland (3) :0 10010 400 oounc-tee: (135
13. Put the hardened washer (8) on the cap screw (7). to 542 Nm) If the lock screw (2) holes becorre
aligned In this torcue range. Install .he lock screw
14. Clean the threads on the end of the piston rod and (2). Tighten the lock screw (2) :0 20 occno-vicnes
the threads of the cap screw using Loctite cleaning (2.3 Nm) Ii :he lock scre\' (2) holes are no: alignec
solvent. Allow to dry. Apply Loctite 242 to the piston do steps 25 through 27
rod threads 1/4 inch from the open end of the piston
rod so that there is 1/2 inch of Loctite 242 on the 25. Tighten the gland (3) to 100;0400 ocund-teet 1135
piston rod threads. DO NOT apply Loctite to the first to 542 Nm)
1/4 inch of the piston rod threads.
26. Use a No 26 drill and drill a hole half in the gland(3)
15. Install the cap screw (7). Tighten the cap screw (7) and half in the tube (1). Drill to a deeth of 7'16 irch
to the torque value on page 8006-2 for the cylinder (11 mm) Do not drill in line with a hole in he gland
that is being repaired A torque multiplier can be (3) for the gland wrench
used to help tighten the cap screw.
27. Install the lock screw (2). Tighten the lock screw (2)
16. Install a new wear ring (11) in the end groove on the to 20 pound-inches (23 Nm)
outside of the piston (4).
If the hoses were removed with the cylinder. install new
17. Install a new backup ring (10) in the center groove a-rings. if equipped on the hose fittings Lubricate the
on the outside of the piston (4). a-rings with clean oil. Install the hoses

8006-7
12. a-RING
13. BACKUP RING
5. PISTON ROD EYE
16. NARROW SEAL 17. BUSHING
Rod End of Cylinder
1. TUBE BB91512J
8. HARDENED
WASHER
7. CAP SCREW
Closed End of Cylinder
Revised 8-92 Printed in USA.

Rac 8·,7591
8006-8
BOOM CYLINDER
Disassembly 3 Illuminate the inside of the tube (1). Inspect the inside
of the tube (1) for deep grooves and other damage. If
Clean the outside of the cylinder. If the hoses were there is damage to the tube (1), a new tube (1) must be
removed with the cylinder, remove the hoses from the used.
cylinder.
4. Check to be sure that the piston rod (6) is straight If
1. Fasten the tube (1) in a vise or other holding equip- the piston rod (6) is not straight, install a new piston rod
ment. Be careful to prevent damage to the tube (1). (6).
2. Loosen and remove the lock screw (2) from the gland 5. Remove small scratches on the piston rod (6) or
(3) and tube (1). inside the tube (1) with emery cloth of medium grit. Use
the emery cloth with a rotary motion
3. Use the gland wrench shown on page 8090-3 to
loosen and remove the gland (3) from the tube (1). 6 Inspect the bushing (20) and seal (21). if equipped in
the piston rod eye (5) and the closed end of the tube (1).
4. Pull the piston rod (6) straight out of the tube (1) to and replace as required.
prevent damage to the tube (1).
7. Inspect the gland (3) for rust and clean and remove
5. Fasten the piston rod eye (5) in a vise and put a rust as required.
support below the piston rod (6) near the piston (4). Use
a shop cloth between the support and the piston rod (6) 8 Inspectthe gland end of the tube (1) for sharp edges
to prevent damage to the piston rod (6). that will cut the gland O-ring (14) and remove as re-
quired.
6. Loosen and remove the cap screw (7) and hardened
washer (8) that holds the piston (4). Use the torque mul- 9. Inspect the piston (4) for damage and wear If the
tiplier shown on page 8090-3 for cap screws that have a piston (4) is damaged orworn. a new piston (4) must be
high torque value. used.
7. Remove the piston (4) from the piston rod (6). Assembly
8. Remove the gland (3) from the piston rod (6). NOTE: If a new gland (3) is being instal/ed, put the
part number of the cylinder on the new gland (3).
NOTE: If the boom cylinder is being disassembled for
repair because of poor performance and the seals (10) 1. Install the bushing (16) in the gland (3).
on the piston (4) are good, replace the check valve (12)
and the O-ring (13). If the seals (10) are damaged, do 2. Install the narrow seal (17) in the gland (3). The side
the next step. of the narrow seal (17) with the groove must be toward
the small end of the gland (3).
9. Remove the wear ring (9), seals (10), and the backup
rings (11) from the piston (4) 3. Install the wide seal (18) in the gland (3). The wide
seal (18) is to be installed so that the lips of the wide
10. Remove the O-ring (14), backup ring (15), wiper seal (18) are toward the small end of the gland (3) The
(19), wide seal (18), narrow seal (17), and bushing (16) wide seal (18) can be difficult to install. Use the tool
from the gland (3). shown on page 8009-3.
Inspection 4. Install a new wiper (19) in the gland (3) The lips of the
wiper (19) must be toward the outside of the gland (3).
1. Clean the piston (4), gland (3), piston rod (6), tube
(1), hardened washer (8) and cap screw (7) in cleaning 5 Install a new backup ring (15) in the groove on the
solvent. outside of the gland (3). If both sides of the backup ring
(15) are not flat, the side that is not flat must be toward
2. Discard the parts that were removed from the piston the small end of the gland (3).
(4) and the gland (3).
Rae 8-17591 Revised 8-92 Printed in US.A

8006-9

8006-10
6. Install the a-ring (14) next to the backup ring (15) in 17 Install a new backup ring (11) in each groove on the
the groove on the outside of the gland (3). The a-ring outside ends of the piston (4)
(14) must be toward the small end of the gland (3).
18 Install a new seal (10) over each backup ring (11) on
7 Fasten the piston rod eye (5) in the vise. the outside ends of the piston (4)
8. Remove any marks and sharp edges on the chamfer 19 Fasten the tube (1) in a vise or other holding equip-
at the end of the piston rod (6) ment. Be careful to prevent damage to the tube (1).
9. Lubricate the bore of the gland (3) and the piston rod 20 Lubricate the inside of the tube (1) and the piston (4)
(6) with clean oil with clean oil
10 Push the gland (3) onto the piston rod (6). If neces- 21. Push the piston (4) straiqrn into the tube (1)
the piston rod (6). 22. When the piston (4) is in the smooth par; of the tube
(1) start the gland (3) into the tube (1)
11. Put a support below and near the end of the piston
rod (6). Use a shop cloth between the support and 23. Lubricate the a-ring (14) on the gland (3) with clean
the piston rod (6) to prevent damage to the piston oil.
(4)
24 Tighten the gland (3) to 100 to 400 pound-feet (135
12. Put the piston (4) on the end of the piston rod (6) to 542 Nm) If the lock screw (2) holes become
aligned in this torque range install the lock screw
13. Put the hardened washer (8) on the cap screw (7). (2) Tighten the lock screw (2) to 20 pound- inches
(23 Nm) If the lock screw (2) holes are not aligned
14. Clean the threads on the end of the piston rod and do steps 25 through 27
the threads of the cap screw using Loctite cleaning
solvent. Allow to dry. Apply Loctite 242 to the piston 25. Tighten the gland (3) to 100 to 400 pound-feet (135
rod threads 1/4 inch from the open end of the piston to 542 Nm).
rod so that there is 1/2 inch of Loctite 242 on the
piston rod threads. DO NOT apply Loctite to the first 26. Use a No. 26 drill and drill a hole half in the gland (3)
1/4 inch of the piston rod threads. and half in the tube (1). Drill to a depth of 7/16 inch
(11 mm). Do not drill in line with a hole in the gland
15. Install the cap screw (7). Tighten the cap screw (7) (3) for the gland wrench
to the torque value on page 8006-2 for the cylinder
that is being repaired A torque multiplier can be 27. Install the lock screw (2) Tighten the lock screw (2)
used to help tighten the cap screw (7). to 20 pound-inches (23 Nm)
16. Install a new wear ring (9) in the groove in the center 28. If the hoses were removed with the cylinder, install
of the piston (4) new a-rings. if equipped, on the hose fittings. Lub-i-
cate the a-rings with clean oil. Install the hoses.
Rae 8-17591 Revised 8-92 Printed in U.sA

8006-11
5. PISTON ROD EYE
1. TUBE
21. SEAL
B891539J
Rae 8-17591 Revised 8-92 Printed in USA.

8006-12
LIFT CYLINDER FOR THREE-POINT HITCH

the piston rod (6) is not straight. install a new piston rod
Clean the outside of the cylinder. If the hoses were (6).
6. Inspect the bushing (18) and seal (19), if equipped.
2. Loosen and remove the lock screw (2) from the in the piston rod eye (5) and the closed end of the tube
gland (3) and tube (1). (1). Replace as required.
3. Use the gland wrench shown on page 8006-3 to 7. Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1). rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8. Inspect the gland end of the tube (1) for sharp
prevent damage to the tube (1). edges that will cut the gland O-ring (12). Remove as re-
quired.
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear. If the

that have a high torque value. part number of the cylinder on the new gland (3).
7. Remove the piston (4) from the piston rod (6). 1. Install the bushing (17) in the gland (3).
8. Remove the gland (3) from the piston rod (6). 2. Install the wide seal (15) in the gland. The wide seal
(15) is to be installed so that the lips of the wide seal (15)
9. Remove the seal (9), backup ring (10), and wear are toward the small end of the gland (3). The wide seal
ring (11) from the piston (4) (15) can be difficult to install Use the tool shown on
page 8006-3.
10. Remove the O-ring (12), backup ring (13), wiper
(14), wide seal (15), narrow seal (16), and bushing (17) 3. Install a new wiper (14) in the gland (3) The lips of
(3)
Inspection
4. Install the narrow seal (16) in the gland (3). The side
1. Clean the piston (4), gland (3), piston rod (6). tube of the narrow seal (16) with the groove must be toward
solvent.
(1) must be used. (12) must be toward the small end of the gland (3).

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
at the end of the piston rod (6) 19 Fasten the tube (1) In a vise or other holding equip-
ment. Be careful to prevent damage to the tube (1)
9. Lubricate the bore of the gland (3) with clean oil
20. Lubricate the inside of the tube (1) and the piston (4)
10. Push the gland (3) on to the piston rod (6). If neces- with clean oil
the piston rod (6). 21 Push the piston (4) s raiqh: into the tube (1).
11. Put a support below and near the end of the piston 22 When the piston (4) is In the smooth cart of the tube
rod (6). Use a shop cloth between the support and (1) start the gland (3) into the tube (1)
(4). 23. Lubricate the a-ring (12) on the gland (3) with clean
ali
12 Put the piston (4) on the end of the piston rod (6)
24 Tighten the glar:d (3) ;0 100 to 400 pound-feet (135
13. Put the hardened washer (8) on the cap screw (7). IO 542 NIT,) I' the lock screw (2) holes oecorr-e
aligned in tt"',istoroue range install the lock screw
14. Clean the threads on the end of the piston rod and (2). Tighten the lock screw (2) :0 20 pound-Inches
the threads of the cap screw using l.octite cleaning (23 Nm) I' tne lock screw (2) holes are no: aligned
solvent Allow to dry. Apply Loctite 242 to the piston do stecs 25 :hroLgh 27
rod threads 1/4 inch from the open end of the piston
rod so that there is 1/2 inch of Loctite 242 on the 2S 7ighten the gland (3) to 100 to 400 pound-tee: (135
piston rod threads DO NOT apply Loctite to the first to 542 Nrn)
1/4 inch of the piston rod threads
26 Use a No. 26 drill and drill a hole half in the gland (3)
15. Install the cap screw (7) Tighten the cap screw (7) and hal' in the tube (1) Drill to a death a' 7/16 inch
to the TOrque value on page 8006-2 for the cylinder (11 rr:r-) Do no: drill in line with a hole in the gland
that is being repaired A toraue multiplier can be f3) 'or the glar.c wrencr;
used to help .ighten the cap screw.
27 l"1s:al,the lock screw (2) Tighten the lock screw (2)
16 Install a new wear ring (11) in the end groove a the :020 cound-inches (2.3 Nm).
outside of the piston (4)
Ii the hoses were removed with the cylinder. install new
17. Install a new backup ring (10) in the center groove a-rings. ii equipped on the hose fittings. Lubricate the
on the outside of the piston (4) O-rings with clean 0'1. Install the hoses
Rac 8-17591 RCVlscC 8-92 p"..,:::::: ,~ :.; s ,'".

8006-15
12. O-RING
6. PISTON ROD
18. BUSHING
17. BUSHING 15. WIDE 16. NARROW

SEAL SEAL
Rod End of Cylinder
19. GREASE
4. FinING
18. BUSHING
S8S1S25J
8.HARDENED 7. CAP SCREW
WASHER
Rae 8-17591 Revised 8-92 Printed in U .SA

8006-16
TILT CYLINDER FOR THE THREE-POINT HITCH

6 Inspect the bushing (17) and seal, if equipped, in
2. Loosen and remove the lock screw (2) from the the piston rod eye (5) and the closed end of the tube (1).
gland (3) and tube (1). Replace as required.
3 Use the gland wrench shown on page 8006-3 to 7. Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1) rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8 Inspect the gland end of the tube (1) for sharp
prevent damage to the tube (1). edges that will cut the gland O-ring (12). Remove as re-
quired.
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear. If he

that have a high torque value part number of the cylinder on the new gland (3).
7. Remove the piston (4) from the piston rod (6). 1. Install the wide seal (15) in the gland. The wide seal
(15) is to be installed sothatthe lips of the wide seal (15)
8. Remove the gland (3) from the piston rod (6) are toward the small end o' the gland (3). The wide seal
(15) can be difficult to install. Use the tool shown on
9. Remove the seal (9), backup ring (10). and wear page 8006-3
ring (11) from the piston (4).
2. Install a new wiper (14) in the gland (3). The lips of
10 Remove the O-ring (12), backup ring (13), wiper the wiper (14) must be toward the large end of the gland
(14), wide seal (15), narrow seal (16), and bushing (17) (3) .
from the gland (3).
3. Install the narrow seal (16) in the gland (3). The side
Inspection of the narrow seal (16) with the groove must be toward
1. Clean the piston (4), gland (3), piston rod (6), tube
(1), hardened washer (8), and cap screw (7) in cleaning 4 Install a new backup ring (13) in the groove on the
solvent. outside of the gland (3). If both sides of the backup ring
(13) are not flat, the side that is not flat must be toward
2. Discard the parts that were removed from the the small end of the gland (3).
piston (4) and the gland (3).
5. Install the O-ring (12) next to the backup ring (13) in
3 Illuminate the inside of the tube (1). Inspect the the groove on the outside of the gland (3). The O-ring
inside of the tube (1) for deep grooves and other (12) must be toward the small end of the gland (3).
damage. If there is damage to the tube (1), a new tube
(1) must be used. 6. Fasten the piston rod eye (5) in the vise
=lac 8-17591 ReVised 8-92 Pwlted In US.A

8006-17
19 GREASE FITTING
~
Revised 8-92 Printed in U.S.A

Rae 8-17591
8006-18
7 Remove any marks and sharp edges on the chamfer 18. Fasten the tube (1) in a vise or other holding equip-
at the end of the piston rod (6) ment. Be careful to prevent damage to the tube (1)
8. Lubricate the bore of the gland (3) with clean oil 19 Lubricate the piston (4) and the inside of the tube (1)
with clean oil.
9. Push the gland (3) on to the piston rod (6) If neces-
sary, use a soft hammer to drive the gland (3) onto 20 Push the piston (4) straight into the tube (1)
the piston rod (6).
21. When the piston (4) is in the smooth part of the tube
10 Put a support below and near the end of the piston (1), start the gland (3) into the tube (1)
rod (6). Use a shop cloth between the support and
the piston rod (6) to prevent damage to the piston 22 Lubricate the O-ring (12) on the gland (3) with clean
(4). oil
11. Put the piston (4) on the end of the piston rod (6) 23 Tighten the gland (3) to 100 to 400 pound-feet (135
to 542 Nm) If the lock screw (2) holes become
12 Put the hardened washer (8) on the cap screw (7). aligned in this torque range install the lock screw
(2). Tighten the lock screw (2) to 20 pound-Inches
13. Clean the threads on the end of the piston rod and (2.3 Nm) If the lock screw (2) holes are not aligned.
the threads of the cap screw usmq Loctite cleaning do steps 24 through 26
solvent. Allow to dry Apply Loctite 242 to the piston
rod threads 1/4 inch from the open end of the piston 24. Tighten the gland (3) to 100 tc 400 oounc-tee: (135
rod so that there is 1/2 inch of Loctite 242 on the to 542 Nrn).
piston rod threads. DO NOT apply Loctite to the first
1/4 inch of the piston rod threads. 25 Use a No. 26 drill and drill a hole hal' In the gland (3)
and half in the tube (1) Drill to a death of 7/16 inch
14. Install the cap screw (7) Tighten the cap screw (7) (11 mm). Do not drill in line With a hole in the gland
to the torque value on page 8006-2 for the cylinder (3) for the gland wrench
that is being repaired A torque multiplier can be
used to help tighten the cap screw. When a torque 26 Install the lock screw (2) Tighten the lock screw (2)
multiplier IS used. a chain must be used to hold the to 20 pound-Inches (23 Nm)
piston rod (6) in position Use a shop cloth and a
metal protector between the piston rod (6) and the If the hoses were removed With the cylinder. install new
chain O-rings If equipped on the hose :ittings. Lubricate the
O-rings with clean oil Install the hoses
15. Install a new wear ring (11) In .be end groove on the
16. Install a new backup ring (10) in the center groove

17. Install a new seal (9) on too of the backuo ring (10)
Rae 8-17591 =<CVISCC 8-92 P~IC"tCC '" U S c;

8006-19
5. PISTON ROD EYE
6. PISTON
15. WIDE 16. NARROW ROD
18. SNAP
SEAL SEAL
RING
Rod End of Cylinder
9. SEAL
8. HARDENED 7. CAP SCREW 17. BUSHING

WASHER

8006-20
PITCH CYLINDER FOR THE THREE-POINT HITCH

6 Inspect the bushing (18) and seal, if equipped, in
2 Loosen and remove the lock screw (2) from the the piston rod eye (5) and the closed end of the tube (1).
gland (3) and tube (1). Replace as required.
3 Use the gland wrench shown on page 8006-3 to 7 Inspect the gland (3) for rust and clean and remove
loosen and remove the gland (3) from the tube (1) rust as required.
4. Pull the piston rod (6) straight out of the tube (1) to 8. Inspect the gland end of the tube (1) for share
prevent damage to the tube (1). edges that will cut the gland O-ring (12). remove as re-
quired.
5 Fasten the piston rod eye (5) in a vise and put a
support below the piston rod (6) near the piston (4). Use 9. Inspect the piston (4) for damage and wear. If the
a shop cloth between the support and the piston rod (6) piston (4) is damaged or worn. a new piston (4) rnus: be
to prevent damage to the piston rod (6). used

torque multiplier shown on page 8006-3 for cap screws NOTE: If a new g/e.nd (3) is beif'Q ir.sralled. put the
that have a high torque value. pan number of the cylinder on the new gland (3).
7. Remove the piston (4) 'rom the piston rod (6). 1. Install the bushing (17) in .he gland (3).
8 Remove the gland (3) from the piston rod (6) 2. lnstall the wide seal (15) in the gland. The wide seal
(15) is to be installed so that the lips of the wide seal (i5)
9 Remove the seal (9), backup ring (10). and wear are toward the small end of the gland (3). The wide seal
ring (11) from the piston (4). (15) can be difficult to install. Use the tool shown on
page 8006-3
10 Remove the O-ring (12). backup ring (13). wiper
(14), wide seal (15). narrow seal (16), and bushing (17) 3. Install a new wiper (14) in the gland (3). The lips of
(3)
Inspection
4. Install the narrow seal (16) in the gland (3) The side
1. Clean the piston (4), gland (3), piston rod (6), tube of the narrow seal (16) with the groove must be toward
solvent.
3. Illuminate the inside of the tube (1) Inspect the
(1) must be used. (12) must be toward the small end of the gland (3)
.~CVISCC 8-92 "'~;ri[CC !n USA

Bur 8-15790
8006-21
19. SNAP
RING
B891629J

8006-22
on the outside of the piston (4).
at the end of the piston rod (6). 19 Fasten the tube (1) in a vise or other holding equip-
ment Be careful to orevent damage to the tube (1).
9. Lubricate the bore of the gland (3) with clean oil
20. Lubricate the inside of the tube (1) and the piston (4)
10 Push the gland (3) onto the piston rod (6). If neces- with clean oil
the piston rod (6). 21 Push the piston (4) straight 1"1(0 tre tube (1)
11. Put a support below and near the end of the piston 22. When the cis.on (4) is in the srnoo.n pan of the tube
rod (6). Use a shop cloth between the support and (1) star; the gland (3) into the tube (1)
(4). 23 Lubricate the O-ring (12) on the giand (3\ with clean
oil.
12. Put the piston (4) on the end of the piston rod (6)
24 Tighten the gland (3) to 100 :0 400 ;:::OLnc-'eet : 135
13 Put the hardened washer (8) on the cap screw (7). to 542 Nm) I: the lock screw '2: holes become
aligned in 'his toroue range ins.ar me lock screw
14. Clean the threads on the end of the piston rod and (2). 7ighten the icck screw :2) :0 20 co.r.o-mches
the threads of the cap screw usmq Lac ire cleaning (23 NI) I': 2 lee- screw ~2:'"'ces are no: alqnec.
solvent. Allow to dry Apply Loctite 242 to the piston do s.eos 25 throL.:gh 27
rod threads 1/4 inch from :he open end of the piston
rod so tha there is 1/2 inch of Loctue 242 on the 25 7ighte the glanc (3) :0 1 oo .c 400 ooi.r-o-reet : 135
piston rod threads 00 NOT apoly Loctite to the first :0 542 Nm)
1/4 inch of the piston rod threads
26 Use a a 26 dr:1 and cr'll a "',012 1"2:' " Te gl2.rC (3)
15. Install the cap screw (7). Tighten the cap screw (7) and :,alf!'l :,2 t\.:Oe:1. Orl:l:O 2. deo:'" of 7 16 Ir,c~,
to the torque value on page 8006-2 for the cylinder (11 rnrn) 00 no: drl;i -n line V/!;i" 2 :,0:0 ir the giand
that is being repaired. A torque rnultiolier can be (3) for t e glanc \'/re'lC';
used to help tighten the cao screw.
27 Install the lac" screw (2) ilgr,:er :"Ie lccx screw (2)
16. Install a new wear ring (11) in the end groove on the to 20 oound-mcr-es 123 N'T
Ii the hoses were .err.oveo wi.h the cyunoer. instau new
17. Install a new backup ring (10) in the center groove O-rrngs I: ecuipped on :he hose :::;ings L.;brlca:c .no
on the outside of the piston (4) 0-,1ngs witr clear. cil. I::stall 'he hoses
~ac 8-17591 Rcv!scc 8-92

8006-23
13
6. PISTON ROD
5. PISTON ROD EYE
15. WIDE 17. BUSHING

SEAL
Rod End of Cylinder
20. GREASE
4. PISTON FITTING
1. TUBE
Revised 8-92 Printed in U.S.A.

Bur 8-17590
Section
8007
BACKHOE CONTROL VALVE
CASE CORPORATION

Issued January 1991
8007-2
TABLE OF CONTENTS
SPECiFiCATIONS.... . 3
SPECIAL TOOLS.. .4
EXPLODED VIEW OF BACKHOE CONTROL VALVE.......... . 5
SEPARATING THE VALVE SECTIONS................................................................................. . 6
ASSEMBLING THE VALVE SECTIONS. . 7
INLET SECTION .. 8
Disassembly. 8
Assembly. .. 10
OUTLET SECTION......... 12
Disassembly............... . .............................12
Assembly........... ...14
SWING AND BOOM SECTION . ..16
Disassembly............. . 16
Assembly............................. .. . 22
STABILIZER SECTION . . 28
Disassembly 28
Assembly..... .. . 32
BUCKET, DIPPER, AND EXTENDABLE DIPPER SECTIONS..................... 37
Disassembly............................................................................. . 37
Assembly 41
CIRCUIT RELIEF VALVE 46
Disassembly .46
Inspection .... . 47
Assembly 48
INSPECTION 49

8007-3
SPECIFICATIONS
Manufacturer , . J I Case
Pressure settings , ,................... ,See Section 8002
Ports and Spools
Spool travel, neutral to pressure , , 0.45 inch (11.5 mm)
Spool moved into the body pressure at A port
Spool moved out of the body . .. pressure at B port
Threads in inlet and outlet ports , 1-5/16 - 12, straight thread
Threads in inlet and swing section port , . ........ ,.. 7/8 - 14, straight thread
Threads in A and B ports of stabilizer 3/4 - 16, straight thread
Threads in A and B ports of other sections 1-1/16 - 12, straight thread
Special torques
Nuts that fasten the valve sections together 20 to 30 pound-feet (27 to 41 Nm)
Circuit relief valves for swing, boom, stabilizer, and dipper sections
or plugs for load check valves 65 to 80 pound-feet (88 to 108 Nm)
Circuit relief valves for bucket or extendable dipper sections 65 to 85 pound-feet

(88 to 155 Nm)
Spool cap 20 to 30 pound-feet (27 to 41 Nm)
Weight , approximately 130 pounds (59 kg)

8007-4
SPECIAL TOOLS
dresses:
In the U.S.A and Canada
Service Tools
P.O. Box 314
In Europe
VL Churchill Ltd.
Northants, NN11 4NF
BB61843J
England
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. The 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-147-2. This tool is first
used on page 16.

8007-5
B870187J
Exploded View of Backhoe Control Valve
Bur 8-17430
8007-6

STEP 1 STEP 4
Clean the backhoe control valve and put the valve on a Remove the shims.
clean bench. Write numbers on each section of the
valve.
STEP 5
STEP 2
Remove the remainder of the sections and shims.
Loosen and remove the nuts from the studs.

STEP 6
~.'
STEP 3
Remove the studs from the outlet section.

B630304M
Remove the inlet section.

8007-7

STEP 7 STEP 10
Install new O-rings in each section. Use the numbers on each valve section as a guide and
install the valve sections and shims.
STEP 8
STEP 11
Install the studs in the outlet section. 0044M

-,..-,.;,..,,;,.,
,._,
Install the nuts. Tighten the nuts to 20 to 30 pound-feet

(27 to 41 Nm).
STEP 9
Install the shims on the studs.

8007-8
INLET SECTION
Disassembly STEP 14
STEP 12
Remove the spring.
Fasten the inlet sections in a vise with soft jaws. Loosen

the plug. STEP 15
STEP 13
Remove the poppet.
Remove the plug STEP 16

See Inspection on page 49 and inspect the parts of the
inlet section.

8007-9
B870188J

8007-10
Assembly STEP 19
STEP 17
;B630320M
with clean hydraulic oil. Install the plug.
Install the poppet.
STEP 18
Install the spring.

8007-11
6. BODY
B861844J
3. SPRING
Inlet Section

8007-12
OUTLET SECTION
Disassembly STEP 23
STEP 20
Fasten the outlet section in the vise with soft jaws.
Loosen and remove the plug.
STEP 21
Remove the piston.
STEP .24
1. OUTLET SECTION
Remove the spring.
STEP 22
Remove the spool.

Remove the O-ring from the bore for the spool.
STEP 25
See page 49 and inspect the parts of the outlet section.

8007-13
B870189J
7. PLUG
Outlet Section
Issued 1-91 Printeo in U.S.A.

Bur 8-17430
8007-14
Assembly STEP 29
STEP 26
See the illustration on page 12 and install a new O-ring
in the bore for the spool.
STEP 27
Install the spring.
STEP 30
Install the piston.
STEP 28
0414M
with clean hydraulic oil. Install the plug.

8007-15
3. PISTON
5. O-RING
B871846J
6. SPRING
Outlet Section

8007-16
SWING AND BOOM SECTION

Disassembly STEP 34
STEP 31
'B62~2M
Use the spring compressing plates shown on page 4 to
compress the spring.
Fasten the section in the vise with soft jaws. Loosen and
remove the cap.
STEP 35
STEP 32
Remove the snap ring from the spool.
Pull the spool, retainer, and O-ring from the body.

STEP 36
STEP 33
Release the spring tension and separate the spring

seats and spring.

8007-17
STEP 37 STEP 40
Repeat steps 37,38, and 39 to remove the circuit relief
valve from the A port.
STEP 41
Loosen the circuit relief valve.
STEP 38
Removethewiperfrom theA portend of the spool bore.
STEP 42
Remove the circuit relief valve.
STEP 39
Remove the a-ring from the bore.
NOTE: Steps 43 through 46 are for the swing section

only. The boom section does not have this check valve
assembly.
STEP 43
Use the tool shown on page 4 to remove the load check

plug, spring and poppet.
Loosen the check valve body in the swing section.
Bur 8·17430 Issued 1·91 Printed in U.S.A.

8007-18
STEP 44 STEP 47
Remove the check valve body. Loosen the plug.
STEP 45 STEP 48
Remove the spring. Remove the plug.
STEP 46 STEP 49
Remove the plunger. Remove the spring and poppet.

8007-19
STEP 50 STEP 52
Repeat steps 47,48, and 49 to remove the other plug, See page 49 and inspect the parts of the swing section.
spring, and poppet.
STEP 51
See page 46 for the disassembly and assembly of the
circuit relief valves.

8007-20
22. SPOOL
20. BODY
16. CAP
B901902J
Swing Section
8007-21
22. SPOOL
/'
20. BODY
B901903J
Boom Section
8007-22
Assembly STEP 56
STEP 53
Install the plunger in the body.

8630614M
.•.... ,
':"-'.";'. ;
Install the poppet and spring in the body.

STEP 57
STEP 54
Install the spring.

0512M
with clean hydraulic oil. Install the plug. STEP 58
STEP 55
Repeat steps 53 and 54 to install the other poppet,
spring, and plug.
NOTE: Steps 56 through 59 are for the swing section

only. The boom section does not have this check valve
assembly.
Install a new O-ring and backup ring on the check valve

body.

8007-23
STEP 59 STEP 62
Lubricate the O-ring and backup ring with clean oil.

Install the check valve body
STEP 63
STEP 60
Lubricate the O-ring and backup rings on the load

Install a new O-ring in the A port end of the spool bore. check plug. Install the poppet, spring, and load check
plug. Make sure that the groove in the load check plug
is toward the spool bore.
STEP 61
STEP 64
Lubricate the O-rings and backup rings on the circuit


8007-24
STEP 65 STEP 69
Tighten the circuit relief valve to 65 to 80 pound-feet (88 Release the spring tension and remove the spring com-
to 108 Nm). pressing plates.
STEP 66 STEP 70
Repeat steps 61 through 65 to install the other load
check plug and circuit relief valve.
STEP 67
Lubricate the O-ring with clean oil. Carefully install the

retainer and O-ring. Do not cut the O-ring on the spool.
STEP 71
Assemble the spring seats and spring. Use the spring
compressing plates to compress the spring.
STEP 68
Lubricate the spool and spool bore with clean oil. Install
the spool.
B629344M
Install the spring and spring seats on the spool. Install
the snap ring.
8007-25
STEP 72 STEP 74
Install the cap. Move the body in the vise so that the spool eye is up.
Lubricate the wiper with clean oil. Install the wiper with
the lip up.
STEP 73
STEP 75
Tighten the cap to 20 to 30 pound-feet (27 to 41 Nm).

~t2M
into the body.

8007-26
22. SPOOL 11. CIRCUIT RELIEF VALVE
4. a-RING
23. A PORT
20. BODY
24. B PORT
4. a-RING
4. a-RING
19. RETAINER
6. SPRING 13. POPPET
18. SPRING SEAT
16. CAP 11. CIRCUIT RELIEF VALVE
17. SNAP RING B901904J
Swing Section
8007-27
22. SPOOL 11. CIRCUIT RELIEF VALVE
4. a-RING
23. A PORT
6. SPRING
13. POPPET
20. BODY
24. B PORT
4. O-RING 14. PLUG

19. RETAINER
6. SPRING 13. POPPET
17. SNAP RING
11. CIRCUIT RELIEF VALVE
B90190SJ
Boom Section
8007-28
STABILIZER SECTION
Disassembly STEP 79
STEP 76
B629342M
remove the cap.
STEP 80
STEP 77
Pull the spool, retainer, and O-ring from the body.

STEP 81
STEP 78

seats and spring.

8007-29
STEP 82 STEP 85
Loosen the plug. Remove the check valve.
STEP 83 STEP 86
Remove the plug. Remove the spool from the body.
STEP 84 STEP 87
Loosen the check valve in the other end of the body. Remove the wiper from the spool bore.

8007-30
STEP 88 STEP 90
Remove the O-ring from the bore. Remove the spring.
STEP 89 STEP 91
Fasten the check valve in the vise with soft jaws. Loosen Remove the plunger.
and remove the plug.
STEP 92
See page 49 and inspect the parts of the stabilizer
section.

8007-31
Stabilizer Section
8007-32
Assembly STEP 96,
STEP 93
Lubricate the O-ring on the plug. Install the plug in the

',B631008M body.
Install new O-rings (1) and backup rings (2) on the body
of the check valve, Install a new O-ring on the plug.
STEP 97
STEP 94
Install a new O-ring in the A port end of the spool bore.
Fasten the body of the check valve in the vise with soft
jaws. Install the plunger. STEP 98
STEP 95
Lubricate the spool with clean oil. Install the spool in the
body.
Install the spring.

8007-33
STEP 99 STEP 102
:'j!;, 'i - J,OM

Lubricate the O-rings and backup rings on the check Lubricate the O-rings and backup ring on the plug.
valve. Install the check valve Install the plug,
STEP 100 STEP 103
Tighten the check valve to 65 to 80 pound-feet (88 to

108 Nrn).
STEP 104
STEP 101
9302M
Assemble the spring seats and spring. Use the spring
Install new O-rings and a backup ring on the plug, compressing plates to compress the spring.

8007-34
STEP 105 STEP 108
Install the spring and spring seats on the spool. Install Lubricate the spool and spool bore with clean oil. Install
the snap ring. the spool.
STEP 106 STEP 109
Release the spring tension and remove the spring com- Install the cap.
pressing plates.
STEP 110
STEP 107
Tighten the cap to 20 to 30 pound-feet (27 to 41 Nm).

Lubricate the O-ring with clean oil. Carefully install the
retainer and O-ring. Do not cut the O-ring on the spool.

8007-35
STEP 111 1. PLUG
2. a-RING
3. SPRING
.M
Move the body in the vise so that the spool eye is up.
5. BODY
the lip up.
STEP 112
8861849J
Check Valve

into the body.

8007-36
15. SPOOL
17. A PORT
2. O-RING
18. B PORT
12. RETAINER
3. SPRING
11. SPRING SEAT
B861850J
9. CAP
10. SNAP
RING
Stabilizer Section

8007-37
BUCKET, DIPPER, AND EXTENDABLE DIPPER SECTIONS

NOTE: The bucket and dipper sections have circuit

relief valves at the A port and B port. The extendable
dipper section has plugs in place of the circuit relief
valves. The following photographs show the dipper
section.
STEP 113
B629342M
STEP 117
remove the cap.
STEP 114
'B629344M
STEP 118
Pull the spool, retainer, and O-ring from the body
STEP 115

seats and spring.

8007-38
STEP 119 STEP 123
Loosen the circuit relief valve. Remove the wiper from the A port end of the spool bore.
STEP 120 STEP 124
Remove the circuit relief valve. Remove the O-ring from the bore.
STEP 121 STEP 125

See page 46 for the disassembly and assembly of the
circuit relief valves.
STEP 126
See page 49 and inspect the parts of the section.
Use the tool shown on page 4 to remove the load check

plug, spring, and poppet.
STEP 122
Repeat steps 119. 120. and 121 to remove the circuit
relief valve, load check plug, spring. and poppet from
the A port.

8007-39
8901906J
Bucket and Dipper Section

8007-40
B901907J
Extendable Dipper Section

8007-41
Assembly STEP 130
STEP 127
Lubricate the O-ring and backup rings on the load

check plug. Install the poppet, spring, and load check
Install a new O-ring in the A port end of the spool bore. plug. Make sure that the groove in the load check plug
is toward the spool bore.
STEP 128
STEP 131
Install a new O-ring and new backup rings on the load

check plug. Lubricate the O-rings and backup rings on the circuit
STEP 129
STEP 132
Install the spring and poppet on the load check plug.

08021\1
Tighten the circuit relief valve to 65 to 85 pound-feet (88
to 155 Nm).

8007-42
STEP 133 STEP 137

Repeat steps 128 through 132 to install the other load
check plug and circuit relief valve.
STEP 134
Lubricate the a-ring with clean oil. Carefully install the

retainer and a-ring. Do not cut the a-ring on the spool.
Assemble the spring seats and spring. Use the spring STEP 138
compressing plates to compress the spring.
STEP 135
Lubricate the spool and spool bore with clean oil. Install
the spool.
Install the spring and spring seats on the spool. Install STEP 139
the snap ring.
STEP 136
Install the cap.
Release the spring tension and remove the spring com-

pressing plates.

8007-43
STEP 140 STEP 142

into the body.
STEP 141
Move the body in the vise so that the spool eye is up.
the lip up.

8007-44
19. SPOOL
4. O-RING
20. A PORT
12. POPPET
17. BODY
21. B PORT
4. O-RING
16. RETAINER
15. SPRING SEAT
6. SPRING j.!;,
14. SNAP RING
13. CAP
6901908.1
15. SPRING SEAT
Bucket and Dipper Section

8007-45
13. SPOOL
1. PLUG
2. a-RING
14. A PORT
15. B PORT
1. PLUG
7. CAP
B901909J
9. SPRING SEAT
Extendable Dipper Section

8007-46
CIRCUIT RELIEF VALVE

STEP 143
Fasten the circuit relief valve in the vise with soft jaws.
Loosen the lock nut. Loosen and remove the adjusting
screw and lock nut.
NOTE: If you disassemble more than one circuit relief

valve, keep the parts for each relief valve together. This
procedure will prevent mixing the parts during as-
sembly.
STEP 144
B628730M
Remove the circuit relief valve from the vise. Separate
the parts of the circuit relief valve. Some circuit relief
valves have a spring and pin and some circuit relief
valves have two springs.
Move the circuit relief valve in the vise. Fasten the

poppet seat in the vise. Loosen the body from the
poppet seat.

8007-47
3. BODY
Inspection STEP 147
STEP 146
Inspect the parts of the circuit relief valve. All of the
repair parts are available in a kit. If any of the parts are
damaged, replace all the parts in the kit.
"""W,s.B628734M
Replace the O-rings and backup ring on the parts of the
circuit relief valve.

8007-48
Assembly STEP 150
STEP 148

B628606M
STEP 151
the pressure setting of the circuit relief valve before the
relief valve is installed in the section.
B628730M
Lubricate the O-rings on the parts of the relief valve.
Assemble the parts into the body.
STEP 149

Tighten the body to 96 to 144 pound-inches (11 to 16
Nm).

8007-49
INSPECTION
STEP 152 STEP 155
Discard all O-rings. backup rings, and wipers. Inspect the spools and spool bores. Use a new section
if the spool or bore is damaged.
STEP 153
Clean all parts in cleaning solvent. STEP 156
Inspect the poppets. Use new parts as necessary
STEP 154
STEP 157
Inspect all machined surfaces.
B861853J
Inspect the seat inside the inlet section. If the seat is

damaged, use a 21/32 inch (17 mm) diameter drill and
drill the seat to a depth of 11/32 inch (8.7 mm). A thin
shell of the seat will stay in the inlet section. Remove this
thin shell. Remove all metal chips from the inlet section

Section
8008
SWING SEQUENCE VALVE
CASE CORPORATION

Issued in November 1989
8008-2
TABLE OF CONTENTS
SPECIFICATIONS. . 2
DISASSEMBLY ................. 3
INSPECTION . . 7
EXPLODED VIEW OF SWING SEQUENCE VALVE........ . ...... 8
ASSEMBLY . . 9
CROSS SECTION VIEW OF SWING SEQUENCE VALVE . . 14
SPECIFICATIONS
Manufacturer . . J I Case
Pressure settings . ..... .. See Section 8002
Ports..... 7/8 - 14, straight thread
Special Torques
Relief valves ... .. 65 to 85 pound-feet (88 to 155 Nm)
Spool cap . ..20 to 30 pound-feet (27 to 41 Nm)
Relief valve body .. .. 8 to 12 pound-feet (11 to 16 Nm)
Weight . .. approximately 20 pounds (9 kg)

8008-3
DISASSEMBL Y
Clean the outside of the swing sequence valve STEP 4
Fasten the swing sequence valve in the vise with soft
jaws.
STEP 1
Loosen one of the relief valves.
B629022M
STEP 5
Loosen the spool cap The springs will push against the
spool cap as the spool cap is loosened.
STEP 2
Remove the relief valve.
STEP 6
Remove the spool cap.
STEP 3
B629130M
Fasten an identification tag to the relief valve.
Pull the spool tram the body.

8008-4
STEP 7 STEP 10
Loosen and remove the other relief valve. Remove the O-ring from the body.
STEP 8 STEP 11
·B629130M
Fasten an identification tag to the relief valve. Loosen the plug.
STEP 9 STEP 12
Remove the wiper from the other end of the body. Remove the plug from the body.

8008-5
STEP 13 STEP 16
Loosen the plug inside the bore. Remove the spring.
STEP 14 STEP 17
8629142M
Remove the plug. Remove the O-ring and retainer from the spool.
STEP 15 STEP 18
Remove the plunger from the opposite end of the body. Remove the springs from the spool.

8008-6
STEP 21
B629101M
Loosen and remove the Allen head screw and spring Loosen the vise. Fasten the poppet seat in the vise.
seat from the spool. Loosen the body from the poppet seat.
STEP 20 STEP 22
B628606M
Fasten the relief valve in the vise with soft jaws. Loosen Remove the relief valve from the vise. Separate the
the lock nut from the adjusting screw. Remove the parts of the relief valve.
adjusting screw and lock nut.
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.

8008-7
INSPECTION
1. Replace the O-ring on the plug. 3. Replace the O-rings and backup ring on the parts of
the relief valves.
B629140M
2. a-RING
B628734M
2. Inspect the parts of the relief valves. All repair parts in
the relief valves are available in a kit. If any of the parts
are damaged, replace all the parts in the kit. 4. Inspect the springs. If the springs are damaged,
install new springs.
5. Inspect the spool and spool bore. If the parts are

damaged or worn, use a new swing sequence valve.
6. Inspect the plunger. If the plunger is damaged or

worn, install a new plunger.
Bur 8-12650 Issued 11·89 Printed in U.S.A

8008-8
12. O-RING
20. SPOOL
13. PLUNGER 19. WIPER
B891691J
Swing Sequence Valve

8008-9
ASSEMBLY
STEP 23 STEP 26
the pressure setting of each relief valve in a test block
before the relief valve is installed in the swing sequence
valve.
STEP 27
B628606M
Lubricate the O-rings on the parts of the relief valve.
Assemble the parts in the body.
STEP 24
Fasten the body in the vise with soft jaws. Install the
spring and plunger in the body.
STEP 28
,,\~BB28602M
Tighten the body to 8 to 12 pound-feet (11 to 16 Nm).
STEP 25
Lubricate the O-ring on the plug with clean hydraulic oil.
Install the plug in the bore for the relief valve.
STEP 29
Tighten the plug to 15 to 20 pound-feet (20 to 27 Nm).

8008-10
STEP 30 STEP 33
8629036M
Lubricate the O-ring on the plug with clean hydraulic oil. Lubricate the O-rings and backup ring on one of the
Install the plug. relief valves with clean hydraulic oil. Install the relief
valve.
STEP 31
STEP 34
Tighten the plug to 60 to 70 pound-feet (81 to 95 Nm). 038M

Tighten the relief valve to 65 to 85 pound-feet (88 to 155
Nm).
STEP 32
STEP 35
Install a new O-ring in the spool bore.
Lubricate the O-rings and backup ring on the other

relief valve with clean hydraulic oil. Install the relief
valve.

8008-11
STEP 36 STEP 39
M M
Tighten the relief valve to 65 to 85 pound-feet (88 to 155 Move the body in the vise so that a rod can be installed
Nm). through the hole in the end of the spool. Fasten the
body in the vise with the end of the spool in contact with
the vise.
STEP 37
STEP 40
Fasten the body in the vise with soft jaws as shown

above.
Install a new O-ring on the spool.
STEP 38
STEP 41
.- ..••...
Lubricate the spool with clean hydraulic oil. Install the

spool in the body. Install the retainer. Make sure the shoulder on the
retainer is down.

8008-12
STEP 42 STEP 45
Install the three springs on the spool. Move the swing sequence valve in the vise so that the
spool is not in contact the the vise. Remove the rod from
the end of the spool.
STEP 43
STEP 46
_<6#$·
.. ::.,:~-'.:/~..:~~"'~"
~
\;"
8629242M
Install the spring seat on the springs. Push down on the
spring seat to compress the springs. Install the Allen
head screw. Tighten the spool cap. The spool cap must be
tightened to a torque of 20 to 30 pound-feet (27 to 41
Nm).
STEP 44
STEP 47
Install the spool cap. Do not tighten the spool cap at this
time.
Install a new wiper on the spool. The lips of the wiper
must be up

8008-13
STEP 48
1. ADJUSTING
SCREW
j
2. BODY
,70128M
into the body until the top of the wiper is even with the
surface of the housing.
3. SPRING 8. O-RING
OR
PIN
_ 9. O-RING
4. SPRING
5. POPPET
SEAT
10. O-RING
11. BACKUP
RING
13. POPPET
12. O-RING B861803M
Relief Valve

8008-14
1. O-RING
6. PLUG
8. SPRING
9. PLUNGER
15.
14 SPRINGS
10. RELIEF
VALVE
B891692J
.
SWing Se quence Valve - Cross Section

8009
THREE-POINT HITCH CONTROL VALVE
TABLE OF CONTENTS
Specifications 8009-2 Exploded View 8009-18
Special Tools 8009-2 Assembly 8009-19
Separating the Valve Sections 8009-3 Inlet/Outlet and Auxiliary Section 8009-22
Assembling the Valve Sections 8009-5 Disassembly 8009-22
Lift Section 8009-6 Exploded View 8009-26
Disassembly 8009-6 Assembly 8009-27
Exploded View 8009-10 Inspection 8009-30
Assem bly 8009-11 Relief Valves 8009-31
Tilt and Pitch Sections 8009-15 Disassembly 8009-31
Disassembly 8009-15 Inspection 8009-32
Assembly 8009-32
CASE CORPORATION
Bu r 8-67421 Printed in U.S.A.

Issued February 1968
8009-2
SPECIFICATIONS
Manufacturer Rexroth
Weight " " 20 pounds (9 kg)
Special Torques
Detent stud 17 to 21 pound-feet (23 to 28 N m, 2 to 3 kg/m)
Self-locking nuts on suds that

hold sections together 17 to 21 pound-feet (23 to 28 N rn, 2 to 3 kg/m)
Plugs and relief valves 50 to 60 pound-feet (60 to 80 N m, 7 to 8 kg/m)
Allen screws for spool caps

and retainers 60 to 80 pound-inches (7 to 9 N m, 0.7 to 0.9 kg/m)
SPECIAL TOOLS
786802
The spring compressing plates are used to

compress the centering springs for removal and
installation. The part number of the tool is CAS-
1147-2. See Section 1001 for information about
ordering the special tool.
8009-3

STEP 1
Clean the outside of the three-point control valve.
STEP 2
721606
Remove the lift section.
721802 STEP 6
Write numbers on each section.
STEP 3
,21810
Remove the pitch section.
721804 STEP 7
Loosen the studs that fasten the valve sections
together.
STEP 4
Remove the tilt section.
721806
Remove the studs and self-locking nuts.

8009-4
INLET/OUTLET /
AND AUXILIARY
SECTION
8871897
Three Point Hitch Control Valve

8009-5

STEP 8 STEP 11
i216'~ 721820
Replace the O-rings in each section of the control Install the pitch section.
valve.
STEP 12
STEP 9
721822
721816 Install the lift section.

Remove the self-locking nuts from the studs. In-
stall the studs in the inlet/outlet and auxiliary sec- STEP 13
tion.
STEP 10
Make sure that the control valve is on a flat surface.

Install the self-locking nuts. Tighten the self-lock-
721818 ing nuts to 17 to 21 pound-feet (23 to 28 N m, 2 to 3
Install the tilt section. kg/m).
8009-6
LIFT SECTION
Disassembly STEP 17
STEP 14
721832
Remove the large steel ball.

721826
Fasten the lift section in the vise with soft jaws. STEP 18
Loosen the Allen head screws.
STEP 15
Remove the three small steel balls.
STEP 19
Remove the Allen head screws and spool cap.
STEP 16
721836
Remove the spring.
721830
There is a spring and detent balls inside the detent

sleeve. Use a punch to compress the spring and
remove the detent sleeve.
8009-7
STEP 20 STEP 23
721902
Remove the retainer. Remove the plug.
STEP 21 STEP 24
721910
Pull the spool and detent housing from the body. Loosen the Allen head screws in the retainer.
STEP 22 STEP 25
721906 i21g12
Loosen the plug in the body. Remove the Allen head screws, retainer, and wiper.
8009-8
STEP 26 STEP 29
721914 721928
Remove the O-ring. Loosen the plug for the load check valve. It can be
necessary to loosen the fitti ng to get access to the
STEP 27 plug.
Loosen the circuit relief valve from the body.
STEP 28 Remove the plug.
STEP 31
721926
Remove the circuit relief valve.

721934
Remove the spring.

8009-9
STEP 32 STEP 35
i00802
Remove the poppet. Loosen and remove the detent stud from the spool.
STEP 33 STEP 36
700840 700838
Remove the sleeve, O-ring, and detent housing Release the spring tension and separate the spring
from the spool. seats from the spring.
STEP 34
700844
Install the spring compressing plates shown on

page 8009-2.
8009-10
-SPOOL
8871898
Lift Section
8009-11
Assembly STEP 41
STEP 37
See page 8009-30. Inspect the parts of the lift sec-
tion.
STEP 38
700804
Install the detent housing on the spool. Lubricate

the a-ring with clean oil. Carefully install the 0-
ring into the detent housing.
STEP 42
700338
Assemble the spring seats and spring. Use the tool

shown on page 8009-2 to compress the spring.
STEP 39
700806
Install the sleeve into the detent housing.
7008:2
Install the spring seats and spring on the spool.

Tighten the detent stud to 17 to 21 pound-feet (23
to 28 N rn, 2 to 3 kg/m).
STEP 40
Install the poppet in the body.
700844
Remove the tool from the spool.

8009-12
STEP 44
-,
721926
Install the spring in the poppet. Lubricate the a-rings and backup ring on the cir-
cuit relief valve. Install the circuit relief valve.
STEP 45
STEP 48
721930
Lubricate the a-ring with clean oil. Install the plug.

Lubricate the a-rings and backup ring on the plug.
STEP 46 Install the plug.
STEP 49
721928
Tighten the plug.

72200.
Tighten the plug to 50 to 60 pound-feet (68 to 80

Nm,7 to 8 kg/m).
8009-13
STEP 50 STEP 53
721904 7?2006
Lubricate the spool and O-ring on the detent hous- Install the three steel balls in the holes in the detent
ing with clean oil. Install the spool and detent hous- stud. Apply petroleum jelly to the steel balls to hold
ing in the body. the steel balls in position.
STEP 51 STEP 54
721902 721632
Install the retainer. Install the large steel ball in the end of the detent
stud.
STEP 52
STEP 55
721836
Install the spring. 721830
Use a punch to push in the steel ball and install the

detent sleeve. Make sure the large steel ball is
pushed past the small steel balls.
8009-14
STEP 56 STEP 59
721828 7220'6
Install the spool cap. Install the wiper on the spool.
STEP 57 STEP 60
722010 7220' 8
Tighten the Allen head screws to 60 to 80 pound- Install the retainer. Tighten the Allen head screws
inches (7 to 9 N rn, 0.7 to 0.9 kg/m). to 60 to 80 pound-inches (7 to 9 Nm, 0.7 to 0.9
kg/m).
STEP 58
7220'"
Lubricate the O-ring with clean oil. Install the 0-

ring on the spool.
8009-15
TILT AND PITCH SECTIONS

Disassembly STEP 64
STEP 61
722028
Loosen the plug from the body.

722022
Fasten the section in the vise with soft jaws. Loos- STEP 65
en the Allen head screws in the spool cap.
STEP 62
722030
Remove the plug.
STEP 66
STEP 63
722032
Loosen the Allen head screws from the retainer.
722026
Pull the spool, O-ring, and wiper from the body.

8009-16
STEP 67 STEP 70
722034 722106
Remove the Allen head screws, retainer, and wiper. Loosen the plug for the load check valve.
STEP 68
-~
722036
Remove the O-ring. Remove the plug.
STEP 72
722037 722"0
Loosen and remove the plug. Remove the spring from the body.
8009-17
STEP 73 STEP 76
72211 4 70083"
Remove the poppet. Loosen and remove the Allen head screw from the
spool.
STEP 74
STEP 77
700828
Remove the O-ring, wiper, and retainer from the 700638
spool. Release the spring tension and separate the spring

seats and spring.
STEP 75
700832
Use the tool shown on page 8009-2 to compress the

spring.
8009-18
6871899
Tilt and Pitch Sections

8009-19
Assembly STEP 81
See page 8009-30. Inspect the parts of the tilt

or pitch section.
STEP 78
700826
Lubricate the O-ring and spool with clean oil. In-

stall the retainer. Carefully install the wiper and 0-
ring. Push the retainer, wiper, and O-ring against
the spring seat.
iOO838
Assemble the spring seats and spring. Use the tool STEP 82
STEP 79
72211~
700834 STEP 83
STEP 80
i22"O
Install the spring.
700832

8009-20
STEP 84
722108 722030
Lubricate the O-ring with clean oil. Install the plug. Lubricate the O-rings and backup ring on the plug.
Install the plug in the body. Tighten the plug to 50
STEP 85 to 60 pound-feet (68 to 80 N rn, 7 to 8 kg/m).
STEP 88
Tighten the plug.

722116
STEP 86 Lubricate the spool and O-ring with clean oil. In-
stall the spool in the body.
STEP 89
722037
Lubricatethe O-rings and backup ring on the plug.

to 60 pound-feet (68 to 80 N m, 7 to 8 kg/m). 722118
Install the spool cap.

STEP 90
722120
Tighten the Allen head screws to 60 to 80 pound-

inches (7 to 9 N m, 0.7 to 0.9 kg/m).
STEP 91

ring on the spool.
Install the wiper on the spool.

8009-22
INLET/OUTLET AND AUXiliARY SECTION

Disassembly
STEP 95
722302
Loosen the plug from the body.

722130
Fasten the section in the vise with soft jaws. Loos- STEP 99
~.~
en the Allen head screws in the spool cap. 1~~,- •
...
STEP 96
' ,
722306
Remove the plug.
722134 STEP 100

STEP 97
72230e
Loosen the relief valve.
722136
Pull the spool, O-ring, and wiper from the body.

8009-23
STEP 101 STEP 104
722310 i22316
Remove the relief valve. Remove the O-ring.
722312 722318
Loosen the Allen head screw from the retainer. Loosen the plug.
STEP 103 STEP 106
722314 722322
Remove the Allen head screws, retainer, and wiper. Remove the plug.
8009-24
STEP 107 STEP 110
72232' 722330
Loosen the plug for the load check valve. Remove the poppet.
STEP 108 'STEP 111
722326 700825
Remove the plug. Remove the O-ring, wiper, and retainer from the
spool.
STEP 109
722328
Remove the spring from the body. 700832
Use the tool shown on page 8009-2 to compress the

spring.
8009-25
STEP 113 STEP 114
700834 700838
Loosen and remove the Allen head screw from the Release the spring tension and separate the spring
spool. seats and spring.
8009-26
-SPOOL
8871900
Inlet/Outlet and Auxiliary Sections

8009-27
Assembly STEP 118
See page BOOS-3D. Inspect the parts of the inlet!

outlet and auxiliary section.
STEP 115
700828
Lubricate the a-ring and spool with clean oil. In-

stall the retainer. Carefully install the wiper and 0-
ring. Push the retainer, wiper, and a-ring against
the spring seat.
;00838
Assemble the spring seats and spring. Use the tool

STEP 116
70083' STEP 120

STEP 117
722328
Install the spring.
700832

8009-28
STEP 121 STEP 124
722326 722310
Lubricate the a-ring with clean oil. Install the plug. Lubricate the a-rings and backup ring on the relief
valve. Install the relief valve in the body. Tighten the
STEP 122 retiet valve to so to so pound-feet (68 t080 N m, 7 to
8 kg/m).
STEP 125
Tighten the plug.
722304

to 60 pound-feet (68 to 80 N rn, 7 to 8 kg/m).
STEP 126
722320

to 60 pound-feet (68 to 80 N m, 7 to 8 kg/m).
722136
Lubricate the spool and O-ring with clean oil. In-

stall the spool in the body.
8009-29
STEP 127 STEP 130
72213~
Install the spool cap. Install the wiper on the spool.
STEP 128 STEP 131
722132
Tighten the Allen head screws to 60 to 80 pound- tnstau the retainer and Allen head screws. Tighten
inches (7 to 9 N m, 0.7 to 0.9 kg/m). the Allen head screws to 60 to 80 pound-inches (7
to 9 N m, 0.7 to 0.9 kg/m).
STEP 129
722332

ri ng on the spool.
8009-30
INSPECTION
Discard all O-rings, backup rings, and wipers. STEP 133
Clean all parts in cleaning solvent. Inspect the
spools and spool bores for wear and damage. Use a
new valve section if the spools or spool bores are
damaged.
STEP 132
O-RINGS
700824
Install new O-rings and backup ring on the plugs.
STEP 134
700842
Install a new O-ring in the detent housing for the lift

spool.
700826
Install a new O-ring on the plug for the load check

valves.
8009-31
RELIEF VALVES
STEP 135
;01518
Loosen the body from the housing.

700506
Fasten the relief valve in the vise with soft jaws. STEP 139
Remove the cover.
STEP 136
701520
Remove the body.
700510 STEP 140

Loosen the lock nut.
STEP 137
701616
Separate the parts of the relief valve.
i00512
Remove the adjusting screw and lock nut. Make a

count of the number of turns needed to remove the
adjusting screw. Record this count.
8009-32
Inspection STEP 143
Remove and discard the O-rings and backup

rings. Inspect the seal on the bottom of the adjust-
ing nut. Replace the adjusting nut if the seat is
damaged.
STEP 141
O-RINGS
i01614
Install new O-rings and backup ring on the body.
BODY Assembly
PLUNGER STEP 144
701616
Inspect the parts ofthe relief valve. The spri ngs, 0-

rings, and backup rings are available for service. If
any of the other parts are damaged, usea new relief
valve.
STEP 142
701520
Install the piston, plunger, spring, and body in the

housing.
STEP 145
O-RINGS
701610
Install new O-rings and backup ring on the hous-

ing.
701518
Tighten the body.

8009-33
STEP 146 STEP 148
700512 700506
Install the poppet, spring, adjusting screw, and Tighten the lock nut and install the cover.
lock nut in the body.
After the three point hitch control valve is as-
STEP 147 sembled and installed, see Section 8002 and check
the pressure setti ng of the relief valves.
700510
Turn the adjusting screw into the body the same

number of turns needed to remove the adjusting
screw.
Section
8011
DOUBLE SELECTOR VALVE
CASE CORPORATION

8011-2
TABLE OF CONTENTS
SPECiFiCATIONS 2
DOUBLE SELECTOR VALVE 3
Disassembly 3
Inspection , , 4
Assembly 6
SPECIFICATIONS
Special torques
Retainer. 108 to 132 pound-inches (12 to 15 Nm)
Allen head screws 108 to 132 pound-inches (12 to 15 Nm)

8011-3
DOUBLE SELECTOR VALVE

Disassembly STEP 4
STEP 1
Remove the retainer and sleeve assembly from the

B8971702M spool.
Fasten the body of the double selector valve in a vise.
Loosen and remove the Allen Head screws that fasten
the cap to the body. STEP 5
STEP 2
Remove the plate from the body.
Remove the cap from the body. STEP 6
STEP 3
Remove the double selector valve from the vise.

Remove the spool from the body.
,__ B897171OM
Hold the spool in place and loosen the retainer.

8011-4
STEP 7 Inspection
STEP 9
Remove and discard the seal from each end of the bore
of the body. B8971728M
Inspect the spool for damage or wear. If the spool is
damaged or worn a new double selector valve must be
STEP 8 used.
STEP 10
Inspect the spool bore in the body for damage or wear.
If the spool bore is damaged or worn a new double
selector valve must be used.
STEP 11
Push the retainer, balls, and spring from the sleeve.
Inspect the sleeve, balls, spring, and retainer for

damage or wear. Use new parts as required.
STEP 12
Inspect the cap, plate, and knob for damage or wear.
Use new parts as required

8011-5
2. CAP
7. SPOOL
10. BODY
Double Selector Valve - Exploded View
Bur 8-12670
Issued 11·89 Printed in U.S.A.
8011-6
Assembly STEP 16
STEP 13
B8971734M
Put the spring and balls in the retainer as shown in the il-
lustration on page 5. Push the retainer assembly into STEP 17
the sleeve.
STEP 14
Apply 271 Loctite to the threads in the spool.
STEP 18
Install new seals in the bore of the body. Lubricate the
seals with clean hydraulic oil.
STEP 15
._----""'.{.~."-.~
.. ~
,.~
B8971720M
Keep the spool from turning and install and tighten the
retainer assembly to 108 to 132 pound-inches (12 to 15
Nm).
Lubricate the spool with clean hydraulic oil. Install the

spool in the body.

8011-7
STEP 19 STEP 20
88971704
Install the cap Install and tighten the Allen head screws to 108 to 132
pound-inches (12 to 15 Nm)

8011-8
3. SLEEVE
7. SPOOL
10. BODY
11. KNOB
8891755
Double Selector Valve - Cross Section

SECTION INDEX - MOUNTED EQUIPMENT
Pedals and Levers 9001
Air Conditioning Troubleshooting and Pressure Checks . .9002
Air Conditioning System _ _ . ....9003
Loader . _.9004
ROPS Cab and ROPS Canopy . .9005
Backhoe - Integral .9006
Backhoe - Demountable. ...9007
Three Point Hitch..... 9008
Seat and Seat Belts .....................................• . ..9009
Suspension Seat ... . _ 9010
CASE CORPORATION

Section
9001
PEDALS AND LEVERS
CASE CORPORATION

Issued March 1991
9001-2
TABLE OF CONTENTS
SPECiFiCATIONS , , , 3
SPECIAL TOOLS 4
ADJUSTMENT FOR RETURN-TO-DIG , , ,5
ADJUSTMENT OF ANTI ROLLBACK .. 6
THROTILE LINKAGE ADJUSTMENT... . 8
THROTILE LEVER ADJUSTMENT , 8
BRAKE PEDAL ADJUSTMENT.. _ 10
Checking Brake Pedal Height ' 10
Brake Pedal Height Adjustment 10
Free Travel Adjustment., , , , 10
Brake Switch Adjustment ,.. 10
PARKING BRAKE ADJUSTMENT , , , 12
SHUTILE CONTROL LINKAGE ADJUSTMENT 14
SHIFT LINKAGE ADJUSTMENT FOR TRANSAXLE 15
DIFFERENT\AllOCK PEDAL ADJUSTMENT , 16
SHIFT LINKAGE FOR TRANSFER CASE 17
LOADER LIFT CONTROL INSTALLATION 18
LOADER BUCKET CONTROL INSTALLATION 19
CLAM CONTROL INSTALLATION 20
ADJUSTMENT OF THE BACKHOE CONTROL LEVERS 21
ADJUSTMENT OF THE SWING SEQUENCE VALVE L1NKAGE.. 24
BOOM LATCH INSTALLATION .., , 25
THREE POINT HITCH CONTROL LEVER INSTALLATION (IF EQUIPPED) 26
ADJUSTMENT OF THE HOOD SEE SECTION 2001

9001-3
SPECIFICATIONS
Clearance between the switch and the inner bucket
link for return-to-dig..................................... . 0012 to 0.027 (0.3 to 0.7 mm)
Center to center length of the yoke and rollback rod

for anti rollback adjustment... . . 14 inches (355 mm)
Number of teeth on the flywheel. . . 159
Engine speeds
Low idle ,.. . ...............................................850 to 900 rpm (r/min)
High idle (no load) . . 2330 to 2380 rpm (r/min)
Low idle and high idle override. .. 1/16 to 1/8 inch (1.5 to 3.0 mm)
Brake pedal height . .. 7-1/4 to 7-1/2 inches (185 to 190 mm)
Brake pedal free travel . .. " 0.06 to 0.18 inch (1.5 to 4.6 mm)
Angle of backhoe control levers .71 to 73 degrees
Maximum clearance of cam follower for the swing sequence valve 0.02 inch (0.5 mm)
Alignment of cam follower on cam for the swing sequence valve must be centered within 0.08 inch (2 mm)
Special torques
Nut that fastens clamp for shuttle control linkage 156 to 180 pound-inches (18 to 20 Nm)
Screw that fastens boot for the shift control lever 12 to 24 pound-inches (1.4 to 2.7 Nm)
Cap screw that fastens the bumper to the swing tower 274 to 318 pound-inches (31 to 36 Nm)

9001-4
SPECIAL TOOLS
Order special tools from one of the following ad- The special tool shown is used to check the engine
dresses: rpm (r/rnin).
In the U.S.A. and Canada The tool must be programmed for the number of
Service Tools teeth on the flywheel. The 580 Super K loader backhoe
P.O. Box 314 has 159 teeth on the flywheel.
Install the magnetic sensor into the threaded hole in
In Europe the flywheel housing. Turn the magnetic sensor clock-
VL Churchill Ltd. wise until the sensor contacts the flywheel, then turn the
P.O. Box 3, Daventry sensor counterclockwise 1/2 to 3/4 of a turn and tighten
Northants, NN11 4NF the lock nut. This tool is first used on page 8.
England
CAS-10ll8

9001-5
ADJUSTMENT FOR RETURN-TO-DIG

1. Park the machine on a level surface and apply the 9. Slowly move the switch rearward until the LED illu-
parking brake. minates.
2. Lower the loader frame and put the bucket flat on

the floor or in the correct digging position.
3. Stop the engine.
4. Clean the switch so the LED at the wire end of the

switch can be seen,
5, Move the inner RH bucket link all the way to the

right.
6. There must be 0.012 to 0027 inches (0.3 to 0.7

mm) clearance between the switch and the inner
bucket link.
10. Hold the switch in position and tighten the nuts for
the switch.
11. Start the engine. Raise the loader frame all the way
and dump the bucket completely.
12. Increase the engine speed to full throttle.
13. Put the loader control lever in the RETURN-TO-DIG po-

sition. The loader frame will lower to the floor and the
bucket will roll back,
14. Check the position of the bucket on the floor,
15. If the bucket is not in the correct position, do steps

7 Turn the key switch to the ON position. 16 through 19.
8. Loosen the nuts for the switch, and move the switch 16. Loosen the nuts for the switch.
all the way forward in the mounting slot.
17. Move the switch rearward if the bucket did not roll
back far enough.
18. Move the switch forward if the bucket rolled back

too far,
19. Repeat steps 11 through 18 until the bucket returns

to the correct position.
Bur 8-17540 Issued 3-91 Printed in U.S,A.

9001-6
ADJUSTMENT OF ANTI ROLLBACK

1. Check to see that the yoke (1) and rollback rod (2) are 5. Raise the loader frame all the way.
adjusted to a length of 14 inches (355 mm) from the
center of the hole in the end of the rollback rod (2) to the 6. Look at the side cutting edge of the bucket.
center of the clevis pin in the yoke (1).
7. The side cutting edge must be approximately level.
2. Raise the loader frame until the pivot pin for the
bucket is 45 inches (1143 mm) from the floor. 8. If the side cutting edge is not in the specified position,
increase the length between the yoke (1) and the
3. Roll the bucket all the way back. rollback rod (2) to increase the amount of rollback.
Shorten the length between the yoke (1) and the
4. Check to see that the rollback rod (2) and the rollback rollback rod (2) to decrease the amount of rollback.
pivot block (3) are engaged completely without any free
travel in the pivot joints. Adjust the length of the yoke (1)
and the rollback rod (2) as required.
Bur B-17540 Issued 3-91 Printed in U.S.A.

9001-7
2. ROLLBACK ROD
B902737J

9001-8
THROTTLE LINKAGE ADJUSTMENT

1. Disconnect the throttle rod (1) from the lever (2) on 6. Have another person push the accelerator pedal
the fuel injection pump. (6) down until the accelerator pedal (6) is against the
stop bolt (7).
2. Use a photo tachometer or other tachometer of
equal accuracy and check the engine speeds If the 7. Check the position of the lever (2) on the fuel injec-
engine speeds are not equal to the specifications in this tion pump. Adjust the stop bolt (7) so there is 1/16 to 1/8
section, adjust the engine speeds as required. See inch (1.5 to 3.0 mm) of override as shown.
Special Tools in this section.
NOTE: Adjustment of high idle must be done by an

authorized Case service person.
3. Connect the throttle rod (1) to the lever (2) on the

fuel injection pump.
4, Make sure that the throttle lever (3) is in the low idle
position.
5. Check the position of the lever (2) on the fuel injec-

tion pump. Adjust the clevis (4) at the cross shaft (5)
until there is 1/16 to 1/8 inch (1.5 to 3.0 mm) of override
as shown.
8. Release the accelerator pedal (6).
9. Move the throttle lever (3) to the full throttle position.

The accelerator pedal (6) must be against the stop bolt
(7) before the throttle lever (3) reaches the end of the
slot in the mounting bracket (8). Adjust the cable (9) at
the throttle lever (3) as required.
10. Check to see that the high and low idle engine
speeds are as specified in this section.
THROTTLE LEVER ADJUSTMENT

Move the throttle lever (3) to the high idle position setting after the throttle lever (3) has been released, the
and then to the low idle position. The throttle lever (3) throttle lever (3) must be adjusted. Loosen or tighten
must move smoothly and hold the setting for the throttle the nut (10) as necessary until the throttle lever (3)
lever (3) when the throttle lever (3) is released. If the works correctly.
throttle lever (3) does not move smoothly or hold the

9001-9
3. THROTTLE
LEVER
B902738J

9001-10
BRAKE PEDAL ADJUSTMENT

Checking Brake Pedal Height Free Travel Adjustment
1 . Remove the rubber pads (1 and 2) from the brake NOTE: Free travel is the distance which the brake
pedals (3 and 4). pedal can move before the push rod makes contact with
the outer piston in the master cylinders.
2. Disengage the brake pedal lock (5) if the brake
pedal lock (5) is engaged. 1. Measure the free travel at the rear edge of each
brake pedal (3 and 4) as shown. The free travel must be
3. If equipped with a floormat, remove the floormat 0.06 to 0.18 inch (1.5 to 4.6 rnrn).
from the floor plate.
2. To increase or decrease the free travel, loosen the
4. Measure the distance from the floor plate to the rear lock nut (8) at each clevis (9) and turn the push rod as
edge of each brake pedal (3 and 4) as shown. The necessary to get the correct free travel. Tighten the lock
brake pedals (3 and 4) must be 7-1/4 to 7-1/2 inches nut (8).
(185 to 190 mm) above the floor plate with the brake
pedals (3 and 4) in the released position. Brake Switch Adjustment
Brake Pedal Height Adjustment 1. Loosen the lock nut (10) for the cap screw (11) that
actuates the brake switch (12). Adjust the cap screw
1. Loosen the lock nuts (6) on the stop bolt (7). (11) so the brake switch (12) is not damaged with the
brake pedal (3 and 4) in the released position. Tighten
2. Turn the stop bolt (7) clockwise or counterclock- the lock nut (10).
wise as required until the rear edge of each brake pedal
(3 or 4) is 7-1/4 to 7-1/2 inches (185 to 190 mm) above 2. The brake switch (12) must actuate when the brake
the floor plate. pedal (3 or 4) is applied.
3. Tighten the lock nuts (6) on the stop bolt (7).
4. Repeat steps 1 through 3 for the other brake pedal

(3 or 4).

9001-12
PARKING BRAKE ADJUSTMENT
The parking brake must prevent the machine from 3. Check the adjustment by trying to move the
moving forward with the transmission in third gear and machine with the parking brake applied.
the engine running at 1500 rpm (r/rnin).
To adjust the parking brake, do the following steps.
1. Release the parking brake.
4. Repeat steps 1, 2, and 3 until the parking brake is

adjusted correctly.
NOTE: If you can not get the correct adjustment by

turning the knob, adjust the parking brake cable at the
2. Turn the knob on the parking brake lever clockwise transaxle. See page 13.
several turns to increase the tension. Turn the knob
counterclockwise several turns to decrease the 5. If the parking brake will not prevent the machine
tension. from moving, the problem can be in the cable or the
parking brake mechanism. Repair the cable or the
parking brake mechanism as required.
NOTE: If your parking brake is equipped with a

parking brake switch, the parking brake switch cannot
be adjusted.

9001-13
1. BOOT. USED ON
TWO WHEEL DRIVE
MACHINES
NOTE: To adjust the parking brake cable, loosen

the lock nut and turn the end of the parking brake
cable as necessary to loosen or tighten the parking
brake cable.
B902739J
Parking Brake Cable Installation

9001-14
SHUTILE CONTROL LINKAGE ADJUSTMENT

1. Remove the cotter pin (6) and pin (5) that fasten the 3. Adjust the length of the control rod (3) at the yoke
control rod (3) to the control spool on the transaxle. (4) as required until the control rod (3) can be con-
nected to the control spool on the transaxle with the
2. Make sure that the pin in the shuttle control lever (1) control lever in the NEUTRAL position.
is in the NEUTRAL position between the tabs on the
detent plate (2). 4. Put the control rod (3) in position on the control
spool. Install the pin (5) and cotter pin (6) that fasten the
control rod (3) to the control spool on the transaxle.
NOTE: SHUTTLE CONTROL LEVER AD-

JUSTMENT: Put the Shuttle Control Lever
(1) in the NEUTRAL position between the
tabs on the Detent Plate (2). Lock in place
with the Locking Co/lars (7) on the Control
Link (8).
3. CONTROL ROD
B902740J

9001-15
SHIFT LINKAGE ADJUSTMENT FOR TRANSAXLE

NOTE: With the shift plates (1) and the transmission
in neutral detent, adjust the yokes (2) on the shift
rods (3) so the yokes (2) can be installed on the
levers (4) at the transmission without moving the
levers (4).
5. SHIFT LEVER
3. FIRST AND SECOND

GEAR SHIFT ROD 3. THIRD AND FOURTH
GEAR SHIFT ROD
6902741J

9001-16
DIFFERENTIAL LOCK PEDAL ADJUSTMENT

1. Make sure that the stop on the pedal (1) is against 2. Adjust the ball joint (2) on the control rod (3) until all
the bottom of the floor plate. free travel is removed from the pedal (i), then tighten
the ball joint (2) one additional turn.
• 3. CONTROL ROD
2. BALL JOINT •.
B902764J

9001-17
'<;
8902743J
Shift Linkage for Transfer Case
Bur 8-17540

9001-18
B902744J
Loader Lift Control Installation

9001-19
\
\
\
,
,,
Loader Bucket Control Installation

9001-20
I
I
I
B902746J
Clam Control Installation

9001-21
ADJUSTMENT OF THE BACKHOE CONTROL LEVERS

1. All control levers (1) must be in alignment and 2. All control levers (1) must be within 71 to 73
centered in the slots in the control tower (2). degrees from the floor plate as seen from the right side
of the backhoe. See the illustration below.
1. CONTROL LEVERS
2. CONTROL TOWER
71 TO 73 DEGREES
FLOOR PLATE RIGHT SIDE SHOWN B891234J

9001-22
•
•
1. EXTENDAHOE
(IF USED)
3. BOOM 4. DIPPER
5. BUCKET
•
6. RH STABILIZER
8. LH SWING
B902747J
Backhoe Controls with Foot Swing

9001-23
4. BOOM AND SWING
6. SWING
5 BOOM
11. EXTENDAHOE CONTROL

PIVOT (MOUNTED ON RH
SIDE OF BACKHOE
3. DIPPER
CONTROL TOWER)
I
NOTE: These parts
rotated 180 degrees.
10. EXTENDAHOE CONTROL

PEDAL (IF EQl!JIPPED)
B902748J
Backhoe Controls with Hand Swing

9001-24
ADJISTMENT OF THE SWING SEQUENCE VALVE LINKAGE

NOTE: In the following instructions, "right" and "left"
are as seen from the backhoe operators seat.
1. Swing the swing tower completely to the right.
2. Loosen the jam nuts at the yoke and at the ball joint
on the control rod.
3 . Turn the control rod clockwise or counterclockwise

until the cam follower will turn freely. The cam follower
must still touch the cam or be within 0.02 inch (0.5 mm)
from the cam.
4. After step 3 has been completed, turn the control rod

clockwise (looking at the control rod from the rear of the
tractor) 1/4 to 1/2 turn to shorten the control rod.
4. CAM
FOLLOWER 5. Make sure that the clevis pin that fastens the yoke on
the control rod to the spool eye in the swing sequence
valve is in the vertical position. If the clevis pin is not
vertical after the jam nuts are tightened on the control
rod, the control rod or the spool can be damaged.
6. Tighten the jam nuts at the yoke and at the ball joint
on the control rod.
5. CAM
7. Start and run the engine at approximately 1/4 throttle.
8. Swing the backhoe completely to the left and then to

the right. The amount of cushion should be equal on
8902375J both sides. If necessary, shorten the control rod to
increase left cushion or lengthen the control rod to
increase right cushion. The only adjustment available is
to divide the amount of cushion equally between sides.

9001-25
B902765J
Boom Latch Installation

9001-26
B902411J
Three Point Hitch Control Lever Installation (If Equipped)

9002
AIR CONDITIONING TROUBLESHOOTING
AND PRESSURE CHECKS
TABLE OF CONTENTS
Safety Rules 9002-2 Troubleshooting 9002-5
Special Tools 9002-2 System Checks 9002-7
Illustration 9002-3 Pressure Testing 9002-13
Operation 9002-4
CASE CORPORATION

9002-2
SAFETY RULES
SPECIAL TOOLS
Order special tools from one of the following The tools shown below are used to service the air
addresses: conditioning system. The tools are available separately
or in a kit. The part number of the kit is CAS-10023.
In the U.S.A. and Canada Parts from this kit are first used on page 9002-10.
Service Tools
P.O. Box 314
In Europe
VL Churchill Ltd
Northants, NN114 NF
England
The tool shown below is used to check for leaks in

the air conditioning system. The part number is CAS-
10028. This tool is first used on page 9002-12.
131238
9002-3
----------~-------
f
5
861485
::::::::::::::
Low Pressure Gas 1. Typical Expansion Valve
~,','>:
4. Compressor
High Pressure Gas 2. Temperature Sensor 5. Condenser
- - Low Pressure Liquid 3. Evaporator 6. Receiver-Drier
- High Pressure Liquid
9002-4
OPERATION
The air conditioning system includes five major corrosion of internal components of the air condi-
components: condenser, evaporator, compressor, tioning system. The receiver-drier is also a refriger-
expansion valve, and receiver-drier. These compo- ant reservoir for the air conditioning system.
nents are connected by tubes and hoses to operate
as a closed system. The air conditioning system is The refrigerant, still in a liquid from, flows to the
charged with R12 refrigerant. expansion valve. The expansion valve causes a re-
striction in the flow of refrigerant to the evaporator.
The compressor receives the refrigerant in gas Because of this restriction, the refrigerant flowing
form. The compressor then compresses the refriger- out of the expansion valve is under less pressure
ant and sends the refrigerant, still in gas form, to the than the refrigerant flowing in. As refrigerant flows
condenser. The condenser uses air flow from the through the evaporator, the refrigerant takes -heat
radiator fan to remove heat from the refrigerant. As from the air around the evaporator. The combination
heat is removed, the refrigerant changes into a liq- of increased heat and decreased pressure causes
uid. evaporation of the refrigerant. The evaporation
causes the air flowing over the evaporation coil to
The liquid refrigerant flows from the condenser become very cool. The cooled air is then used to
to the receiver-drier. The receiver-drier is a con- keep the operators cab cool.
tainer filled with a drying material which removes
moisture that has entered the air conditioning sys- The refrigerant, in a gas form again, flows back
tem. Moisture must be removed in order to prevent to the compressor, and the cycle is repeated.
9002-5
TROUBLESHOOTING
Problem
No Cooling
I COMPRES~OR RUNS I COMPRESSOR DOES NOT RUN
MECHANICAL
See mechanical Compressor Check, page 9002-
7.
ELECTRICAL
See Blower and Compressor Clutch Check, page
9002-8.
REFRIGERATION
See Visual and Leak Check, page 9002-11.
INTERNAL SYSTEM PRCJBLEM

See Pressure Testing page, 9002-13.
9002-6
9002-7
SYSTEM CHECKS
9002-9
Blower and Compressor Clutch Check (Continued)

9002-10
Cab Temperature Check
Air Louvers 1. Make sure ports are fully open for most effi-
cient air conditioning operation.
2. Check blower; blower must be operating.
Air Conditioning 1. Feel the air conditioning hoses. The high

pressure hose (small line) must be warmer
than the low pressure hose (large line).
2. If no temperature difference, the system is

low on refrigerant, there is a restriction in
system, or compressor is not operating cor-
rectly.
1. Put a thermometer in the air duct and run

Duct Temperature compressor for five minutes to make temper-
ature stable.
2. Duct temperature must be below 50° F (10° C)

if system is operating at maximum efficiency.
NOTE: Ambient temperature must be 70 -

90°F (21 - 32°C).
3. If temperature is above 50°F (10° C), system

is low on refrigerant, there is restriction in
system, or compressor has malfunction.
9002-12
9002-13
PRESSURE TESTING
Manifold Gauge Set indicate both psi (kPa) pressure and inches of mer-
cury.
The manifold gauge set is the most important
tool used to service the air conditioning system. The
manifold gauge set is used to learn the high and low During normal operation the low pressure
pressures of the system, the correct refrigerant gauge must always indicate from 7 to 30 psi (48 to
charge, system diagnosis, and operating efficiency. 207 kPa) after the system has run 10 to 15 minutes.
The manifold gauge set can read both the high (dis-
charge) and low (suction) sides at the same time, HIGH PRESSURE GAUGE - The high side
since pressures must be compared in order to make gauge is a pressure gauge used to indicate pres-
a diagnosis of system operation. sures in the high side of the system. The gauge must
indicate from 0 - 400 psi (0 - 2758 kPa) minimum.
LOW PRESSURE GAUGE - The low pressure
gauge is a compound gauge. All air conditioning During normal operation, the high pressure
systems can, under some conditions, change from a gauge will normally indicate from 120 to 270 psi (827
pressure into a vacuum on the low side. For this to 1861 kPa), including correction for ambient air
reason, it is necessary that a gauge be used that will temperatures, see pressure - temperature chart.
Pressure - Temperature Chart

Pressure- Temperature Chart
I
Normal High Pressure Reading Ambient Temperature
150 - 170 psi 80° F (26.7° C)

(1034 - 1172 kPa)
175 -185 psi I 90° F (32.2° C)

(1206 -1275 kPa)
195 - 205 psi 95° F (35° C)

(1344 - 1413 kPa)
210 - 230 psi 100° F (37.8° C)

(1447 - 1585 kPa)
230 - 250 psi 105° F (40.7°C)

(1585 - 1723 kPa)
250 - 270 psi 110°F (43°C)

(1723 - 1861 kPa)
NOTE: Ambient temperature is the tempera-

ture of the air around the machine. Connect the
manifold gauge set according to the instructions in
Section 9003, page 9003-7 to do the following pres-
sure tests.
9002-14
Problem - No Cooling
1. LOW PRESSURE GAUGE READING IN A VACUUM

2. HIGH PRESSURE GAUGE READING BELOW PRESSURE-
TEMPERATURE CHART
Indications of Low Refrigerant Charge

1. Test system for leaks. see page 9002-12. It
a. Sight glass clear - no bubbles can be necessary to add some refrigerant
charge, see Section 9003.
b. Discharge air from evaporator warm.
2. Discharge system of refrigerant, see Section

9003.
3. Repair system leaks as necessary. See Air

and Moisture Removal in Section 9003.
4. Check compressor oil level, see Section

9003.
5. Remove air and moisture from the system,

see Section 9003.
6. Charge system with new refrigerant, see Sec-

tion 9003.
9002-15
Problem - No Cooling
1. LOW PRESSURE GAUGE READING ABOVE 30 PSI (207 kPaj

2. HIGH PRESSURE GAUGE READING ABOVE PRESSURE-
TEMPERATURE CHART
Indications of Air in System
a. Bubbles in sight glass. 1. Discharge refrigerant from system, See Sec-

tion 9003.
2. Replace receiver-drier if drying material is

full of moisture and removal procedure can-
not remove moisture from receiver-drier.

see Section 9003.

tion 9003.
Indications of a Problem
in Condenser Operation
1. Inspect for loose or worn compressor belt
a. Bubbles in sight glass at intervals. and fan belts.
b. Line between condenser and evaporator

inlet very hot.
2. Inspect condenser and radiator for restric-
c. Discharge air from evaporator warm. tions in air passages.
(Continued on next page)

9002-16
Indications of a Problem in Condenser Operation (Continued)
3.
-
Check system for too much refrigerant.
a. Discharge refrigerant until bubbles can

be seen in sight glass and gauge pres-
sure is below normal.
b. Add refrigerant until bubbles cannot be

seen in sight glass and gauges indicate
normal pressures, see Section 9003.
4. Remove and inspect condenser for restric-

tion caused by oil.
a. Use compressed air to remove oil from

condenser.
b. Replace receiver-drier.
c. Remove air and moisture and charge sys-

tem, see Section 9003.
in Expansion Valve Operation
1. Remove cab trim panels and headliners, see
a. Discharge air from evaporator warm. Section 9003. Inspect temperature sensing
contact to evaporator outlet for looseness or
b. Much condensation on suction hose at corrosion.
compressor.
c. Much condensation on evaporator out-

let. 2. Clean contact surface between temperature
sensing bulb and evaporator outlet, see Sec-
tion 9003.
3. Fasten temperature sensing bulb to evapora-

tor outlet and tighten.
4. Fill the area between temperature sensing

bulb and evaporator outlet with lithium base
grease to make a better conductor.

9002-17
Indications of a Problem in
Expansion Valve Operation (Continued)
5. Install the insulation putty in the original po-

sition.
6. Discharge the system and remove expansion

valve, see Section 9003.
7. Test expansion valve and replace or adjust as

necessary, see Section 9003.
8. Replace expansion valve, remove air and

moisture, and charge system, see Section
9003.
9002-18
Problem - Not Enough Cooling
1. LOW PRESSURE GAUGE READING NORMAL.

7 TO 30 PSI (48 TO 207 kPa)
2. HIGH PRESSURE GAUGE READING NORMAL.
ACCORDING TO PRESSURE-TEMPERATURE CHART
Indications of Air In System
-
a. Sight glass free of bubbles or bubbles 1. Test system for leaks, see page 9002-12.
can be seen only at intervals. Possible leak has let air enter; check com-
pressor seal carefully, see Section 9003.
b. Suction line warm to your hand.
c. Evaporator discharge air only a little

cool. 2. Discharge system of refrigerant. See Section
9003.
3. Repair system leaks as necessary, see Dis-

charging the System in Section 9003.
4. Replace receiver-drier if drying material is

full of moisture and removal procedure can-
not remove moisture from receiver-drier.
5. Check compressor oil level, see Section

9003.

9002-19
Indications of Air in System (Continued)

see Section 9003.

tion 9003.
1. LOW PRESSURE GAUGE READING BELOW 7 PSI (48 kPaj

TEMPERATURE CHART
Indications of Low Refrigerant Charge 1. Test system for leaks. System has a loss of
refrigerant.
a. Bubbles in sight glass.
NOTE: Normally. the system will have a
b. Discharge air from evaporator only a lit- loss of 1/2 to 1 ounce (14.7 - 29.5 ml) of
tle cool. refrigerant between seasons.
a. If leak is found, do Step 2.
b. If no leak is found, do Step 6.
2. Discharge system of refrigerant. See Section

9003.

9002-20
Indications of Low Refrigerant Charge (Continued)
3. Repair system leaks as necessary. See Dis-

charging the System in Section 9003.
4. Check compressor oil level. See Section

9003.

see Section 9003.

tion 9003.
Indications of High Pressure Restriction 1. Discharge the system.
a. Discharge air from evaporator only a little

cool.
2. Remove and replace part which has restric-
b. Condensation or frost on receiver-drier. tion.
c. Liquid line to receiver-drier cool, with

frost or condensation.
see Section 9003.

tion 9003.
Indications of a Problem 1. Expansion valve inlet which has condensa-

in Expansion Valve Operation tion or frost is an indication of a restriction in
the expansion valve.
a. Discharge air from evaporator only a little
cool. a. Discharge the system. See Section 9003.
b. Condensation or frost on expansion b. Remove expansion valve and clean or re-

valve inlet. place. See Section 9003.
c. Inlet end of expansion valve is warm. c. Remove air and moisture and charge sys-
tem. See Section 9003.

9002-21
in Expansion Valve Operation (Continued)
2. Inlet end of expansion valve is warm, indicat-

ing expansion valve is not completely open.
a. Discharge system. Test expansion valve

and adjust or replace. See Section 9003.
b. Install expansion valve, remove air and

moisture. and charge system, see Sec-
tion 9003.
c. Clean contact surface between tempera-

ture sensing and evaporator outlet. See
Section 9003.
d. Fill the area between temperature sens-

ing bulb and evaporator outlet with lith-
ium base grease to make a better con-
ductor.
e. Install the insulation putty in the original

position.
9002-22
1. LOW PRESSURE GAUGE READING ABOVE 30 PSI (207 kPaj

TEMPERATURE CHART
Indications of a Problem 1. Separate the compressor from the system.

in Compressor Operation See Section 9003.
a. System is fully charged; no bubbles in

sight glass.
• 2. Internal leak in compressor is indicated. Re-
b. Evaporator discharge air only a little move compressor from machine. Possible
cool. causes are:
a. Leakage at valves.
b. Leakage at head gasket
c. Pistons, rings, or cylinders have wear

or scoring.
3. Check and make a record of compressor oil

level before doing service work. See Section
9003.
4. Repair or replace compressor as necessary.

See Section 9003.
(Continued
I
on next page)
9002-23
in Compressor Operation (Continued)
5. Replace receiver-drier if:
a. The system has been opened for repairs

two times.
b. Receiver-drier operated two or more sea-

sons.
c. Disassembly of compressor showed fine

particles of drying material (normally
yellow or brown particles).
6. Fill compressor with new refrigeration oil ac-

cording to instructions in Section 9003. In-
stall compressor in machine.
7. Remove air ana moisture from the system,

see Section 9003. Charge system.
8. Operate system and check refrigerant

charge. See Section 9003.
9002-24
1. LOW PRESSURE GAUGE READING ABOVE 30 PSI (207 kPa)

TEMPERATURE CHART
in Condenser Operation
1. Inspect for loose or worn fan and compressor
belts.
a. Bubbles in sight glass at intervals.
b. Liquid line very hot.

2. Inspect condenser and radiator for restric-
c. Discharge air from evaporator warm. tions in air passages.
3. Check system for too much refrigerant.
a. Remove refrigerant until there are

bubbles in sight glass and gauge pres-
sure is below normal.
b. Add refrigerant until there are no bubbles

in sight glass and gauge pressures are
normal. See Section 9003.
c. If there is still a problem, do step 4.

9002-25
in Condenser Operation (Continued)
•
4. Remove and inspect condenser for restric-
tions caused by oil.
a. Discharge system, see Section 9003.
b. Use compressed air to remove oil from

condenser.
c. Replace the receiver-drier.
d. Remove air and moisture from the sys-

tem and charge system, see Section
9003.
-
Indications of Air in System
1. Discharge refrigerant from system, see Sec-
a. Bubbles in sight glass. tion 9003.
2. Replace receiver-drier if drying material is full of

moisture and removal procedure cannot re-
move moisture from receiver-drier.

see Section 9003.
4. Charge system with new refrigerant. See

Section 9003.
9002-26
Problem - Erratic Cooling
1. LOW PRESSURE GAUGE READING NORMAL.

7 TO 30 PSI (48 TO 207 kPa)
2. HIGH PRESSURE GAUGE READING NORMAL.
ACCORDING TO PRESSURE-TEMPERATURE CHART
Moisture in the System

1. Discharge system of refrigerant. If too much
a. Cooling is acceptable during cool part of moisture enters the orifice of the expansion
day, but not acceptable during hot part of valve, the freezinq of this moisture can stop
day. refrigerant flow. See Section 9003.
2. Replace receiver-drier. Drying material is full

of moisture.
3. Remove air and moisture from the system.

See Section 9003.
NOTE: Vacuum pump must run for at least

2 to 3 hours to remove a large amount of
moisture.

tion 9003.
9002-27
Problem - Erratic Cooling
1. LOW PRESSURE GAUGE READING BELOW 7 PSI (48 kPa)

TEMPERATURE CHART
in Expansion Valve Operation 1. Expansion valve inlet which has condensa-
tion or frost is an indication of a restriction in
a. Discharge air from evaporator only a little the expansion valve.
cool.
a. Discharge the system. See Section 9003.
b. Condensation or frost on expansion
valve inlet. b. Remove expansion valve and clean or re-
place. See Section 9003.
c. Inlet end of expansion valve is warm.
c. Remove air and moisture and charge sys-
tem. See Section 9003.
2. Inlet end of expansion valve is warm, indicat-

ing expansion valve is not completely open.
a. Discharge system. Test expansion valve

and adjust or replace. See Section 9003.
b. Install expansion valve, remove air and

moisture. and charge system. See Sec-
tion 9003.
c. Clean contact surface between tempera-

ture sensing bulb and evaporator outlet.
See Section 9003.

9002-28
Indications of a Problem in
Expansion Valve Operation (Continued)
d. Continue performance test for possible

other problems.
e. Fasten temperature sensing bulb to eva-

porator outlet and tighten securely.
f. Fill the area between temperaturesensing

bulb and evaporator outlet with lithium
base grease to make a better conductor.
g. Install the insulation putty in the original

position.
Problem - Noise in System
1. LOW PRESSURE GAUGE READING NORMAL, 7 TO 30 PSI

(48 TO 207 kPa)
•
TEMPERATURE CHART
I
Indications of Too Much
-
Refrigerant in System
a. Sight glass clear. 1. Remove refrigerant from the system until

bubbles show in the sight glass and gauge
b. Discharge air from evaporator cool. readings are below normal.
c. Compressor makes noise.
2. Add new refrigerant until bubbles do not

show and gauge readings are normal. See
Section 9003.
Section
9003
AIR CONDITIONING SYSTEM
CASE CORPORATION

Issued January 1991
9003-2
TABLE OF CONTENTS
SPECIFICATIONS 3
SPECIAL TOOLS 3
ADJUSTMENT OF DRIVE BELT 5
LUBRICATION OF COMPRESSOR 5
General Information 5
Lubricant 5
Oil Level Check . .. 5
Oil Level for a New Compressor . . 7
DISCHARGING THE AIR CONDITIONING SYSTEM 8
REMOVING AIR AND MOISTURE FROM THE AIR CONDITIONING SySTEM 9
CHARGING THE AIR CONDITIONING SySTEM 10
REMOVING THE COMPRESSOR 12
REPLACING THE COIL OR CLUTCH ASSEMBLY 14
REPLACING THE SEAL 19
REPLACING THE VALVE PLATE AND GASKETS 24
INSTALLING THE COMPRESSOR 27
REPLACING THE AIR CONDITIONING CONTROL 28
REPLACING THE EXPANSION VALVE 28
REPLACING THE EVAPORATOR 30
REPLACING THE CONDENSER 34

9003-3
SPECIFICATIONS
Compressor Manufacturer Sanyo-Sanden Corporation
Lubricant. Suniso-5GS or equivalent
Coil
Resistance 2.B to 3.3 ohms at BO°F (27°C)
Current draw 3.6 to 4.2 amperes at 12 volts
Torque
Cap screws for end cap 264 to 300 pound-inches (30 to 34 Nm)
Nut for clutch plate 300 to 360 pound-inches (34 to 40 Nrn.)
Refrigerant , , , , , , R-12 refrigerant

System capacity ' 80 U.S. ounces (2.26 kg)
SPECIAL TOOLS
The tools shown are required to service the air con- It is a scientifically proven fact that one of the con-
ditioning system (finding leaks, charging the air con- tributing factors to the depletion of the ozone layer is the
ditioning system, checking the charge of the air con- use of CFCs.
ditioning system, and repairing the compressor).
You will se an addition to the equipment required to
In the U.S.A. and Canada, order the tools from: service the air conditioning system. This new piece of
Service Tools equipment is an R-12 refrigerant recovery/recycling
P.O. Box 314 system. This equipment will permit you to discharge an
Owatonna, MN 55060 air conditioning system without allowing the refrigerant
to escape into the atmosphere and help to cause the
In Europe order the tools from: depletion of the ozone layer This piece of equipment
VL Churchill ltd will also permit the recycling of the refrigerant for future
P.O. Box 3, Daventry use.
Northants NN11 4NF
England These special tools are required to safely discharge
and charge the air conditioning system.
Introduction
The use of chlorofluorocarbons (CFCs) such as R-
12 refrigerant used in mobile air conditioning systems
has become a worldwide concern. The concern is
about the depletion of the earth's ozone layer. The
ozone layer is a shield that protects man, beast, and
field from the harmful effects of ultraviolet rays from the
sun. Ultraviolet rays are believed to be a cause of skin
cancer and could also destroy the earth's entire food
chain,

9003-4
The tool shown is a vacuum pump that is used to

remove air and moisture from the air conditioning
system. The part number of the vacuum pump is CAS-
10027. Not shown in use
B4041990E
CD ...•-~a3M
OEM-1396 Refrigerant/Recovery/Recycling ~t.1)'i$~~;;;"::7~., ..
1. CAS-10023-1 Gauge Manifold

2. CAS-10023-2 Goggles
3. CAS-10023-4 Thermometer
4. CAS-10023-5 Control Valve
NOTE: The other parts shown are not required.
The tools shown above are used to charge and
check the charge of the air conditioning system. The
tools are available as a kit or separately. The part
number of the kit is CAS-10023. Some parts shown in
use.
···>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.
9003-5
ADJUSTMENT OF DRIVE BELT

Check the tension of the drive belt after every 250 To adjust the tension of the drive belt:
hours of operation. If a new drive belt is installed, check
the tension of the drive belt after the first 20 hours of 1. Loosen slightly the nuts on the bolts that hold the
operation. compressor.
The correct tension for a new drive belt is 65 to 75 2. Use a prybar near the front of the compressor to
pounds (29 to 34 kg) measured with a belt tension tighten the drive belt, then tighten the nuts.
gauge.
3. Use a belt tension gauge and check the tension of
The correct tension for a drive belt used more than the drive belt.
20 hours is 55 to 65 pounds (20 to 23 kg) measured with
a belt tension gauge. 4. Repeat steps 1, 2, and 3 as required.
LUBRICATION OF COMPRESSOR
General Information 1. Connect the hoses from the R-12 refrigerant re-
covery/recycling system to the manifold. Make sure
Because the air conditioning system is a closed that both valves in the gauge manifold are closed.
system, the compressor will not need regular oil level
checks or oil changes.
An oil change is necessary only when the air con-

ditioning 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 in-
stalled.
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. Stop the engine.

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.

B840536J
1. Point Must Be Toward Left
7. Connect the charge-discharge hose (yellow) to the Side Of Machine. Stop On
fitting on the side of the R-12 refrigerant recovery/recy- Dipstick Must Touch
cling system. The Compressor
8. Put the angle gauge from the tool kit shown on 12. Read the degrees on the angle gauge and the
page 9003-2 on the front or rear mounting flange. notches in the dipstick.
Adjust the level on the angle gauge until the bubble is
between the marks. Tighten the wing nut. 13. Compare the readings with the chart and add oil as
required. Add oil in amounts less than 1 U.S. fluid
ounce (30 mL) and check the level again. The oil must
be that which is specified on page 9003-3.
Angle Gauge Oil Level

Reading Notches
0 2-4
10 4-5
70 5-6
14. Charge the air conditioning system according to in-

structions 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.

9003-7
Oil Level for a New Compressor 3. Fill the new compressor with the new oil equal to
the amount drained from the old compressor plus 1
1. Drain the oil from the old compressor into a mea- U.S. fluid ounce (30 mL) of new oil.
suring container.
4. Install and tighten the filler plug.
2. Drain the oil from the new compressor into a
CLEAN measuring container. 5. No oil level check will be needed after the com-
pressor has been installed.

9003-8
DISCHARGING THE AIR CONDITIONING SYSTEM

The air conditioning system must be discharged 5. Loosen and remove the cap from the low pressure
before beginning the removal of any component of the port.
air conditioning system.
7. Connect the charge-discharge hose (yellow) to the

fitting on the side of the R-12 refrigerant recovery/recy-
cling 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 dis-
charged.
LOW HIGH
PRESSURE PRESSURE
GAUGE GAUGE
1. Connect the hoses from the R-12 refrigerant re-
covery/recycling system to the gauge manifold.
2. Make sure that each valve in the gauge manifold is

closed.
CHARGE-
DISCHARGE
~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 dis- b. Connect the hose from the low pressure gauge
charged and opened for service, air enters the air con- to the low pressure port.
ditioning system before the openings can be closed.
The air carries moisture which can cause damage to 2. Make sure that the valves in the gauge manifold are
the air conditioning system. It is necessary to remove open.
the air and moisture before the air conditioning system
is charged with new refrigerant.
Replace the receiver-drier before removing the air

and moisture if:
a. The air conditioning system has been opened

before.
b. 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 parti-

cles of the drying material inside the compressor.
3. Connect the charge-discharge hose from the
NOTE: Make sure the hoses from the R-12 refrigerant gauge manifold to the vacuum pump.
recoverylrecycling system are connected to the gauge
manifold. 4. Run the vacuum pump for a minimum of 30
minutes. The low pressure gauge must indicate a
1. If the hoses from the gauge manifold have been vacuum of 28 to 29 inches of mercury (95 to 100 kPa)
disconnected from the compressor: 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.
LOW HIGH
PRESSURE PRESSURE
GAUGE GAUGE 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. Stop the vacuum pump.
c. If the reading of the low pressure gauge in-

HIGH creases 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.
6. Before disconnecting the vacuum pump, make

B891255J
sure that the valves for the low pressure and high
pressure gauges have been closed.
a. Connect the hose from the high pressure
gauge to the high pressure port.

9003-10
CHARGING THE AIR CONDITIONING SYSTEM

General Information
LOW HIGH
PRESSURE PRESSURE
Charge the air conditioning system only when there GAUGE GAUGE
is no indication of leaks,
If the air conditioning system has been discharged,

air and moisture must be removed from the air con-
ditioning system according to instructions in this
section before the air conditioning system can be
charged.
If refrigerant is being added to a charged air con-

ditioning system, removal of air and moisture is not ne-
cessary,
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 com-
pressor,
Use the procedure that follows to correctly charge

the air conditioning system. B891255J
Charging Procedure
b. Loosen and remove the cap from the high
1, If the air conditioning system is to receive a pressure port.
complete charge of refrigerant, remove air and
moisture from the air conditioning system according to c. Connect the hose from the high pressure
instructions in this section, Then continue the pro- gauge to the high pressure port.
cedure at step 3.
d. Loosen and remove the cap from the low
NOTE: Make sure the hoses from the R-12 refrigerant pressure port.
recovery/recycling system are connected to the gauge
manifold. e, Connect the hose from the low pressure gauge
to the low pressure port.
2, If you are only adding refrigerant:
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.

(r/min).
10. Turn the air conditioning control to the COLD posi-

3. Install the control valve on the container of re-
frigerant. tion.
11. Turn the knob for the blower to the HI position.
12. Continue to charge the air conditioning system

until 80 ounces (2.26 kg) of refrigerant is in the air con-
ditioning 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 con-

tainer.
4. Connect the charge-discharge hose from the d. Install the control valve on the new container.
gauge manifold to the control valve.
14. Open the valve for the low pressure gauge and the
control valve on the container of refrigerant.
15. Read the low pressure gauge and the high

pressure gauge. The air conditioning system is cor-
rectly charged when:
a. The indication of the 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.

9003-12
Ambient Temperature* High Pressure Indication 16. If the high pressure reading is too high:
80°F (26.7°C) 150 to 170 psi

a. Close the control valve for the refrigerant con-
(1034 to 1172 kPa,
tainer.
10.3 to 11.7 bar)
b. Disconnect the charge-discharge hose from

90°F (32ZC) 175 to 185 psi
the control valve.
(1206 to 1275 kPa,
12.1 to 12.7 bar)
c. Slowly open the valve for the high pressure
gauge to decrease the high pressure to the correct
95°F (35°C) 195 to 205 psi
value.
(1344 to 1413 kPa,
13.4 to 14.1 bar)
d. Close the valve for the high pressure gauge
when the reading is correct.
100°F (37.8°C) 210 to 230 psi
(1447 to 1585 kPa,
17. After the air conditioning system has the correct
14.4 to 15.8 bar)
charge, stop the engine.
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)
*The temperature of the air around the machine.
18. Disconnect the hoses from the low and high

pressure ports.
19. Install the cap on the low and high pressure ports.
REMOVING THE COMPRESSOR

1. Discharge the air conditioning system according to 6. Remove the bolt and flat washer.
instructions in this section.
7. Loosen and remove the nut, lock washer and flat
2. Disconnect the hoses from the compressor. washers from the bolt that holds the compressor.
3. Install a plug in each hose. 8. Hold the compressor and remove the bolt and
remove the compressor from the machine.
4. Disconnect the wire from the wiring harness.
5. Loosen and remove the nut and lock washer from

the .bolt at the top of the adjustment strap.

9003-13
Issued 1-91 Printed in USA

Bur 8·12711
9003-14
REPLACING THE COIL OR CLUTCH ASSEMBLY

NOTE: Special tools are from kit CAS-10747 STEP 4
shown on page 9003-4.
STEP 1
Remove the shield from the bore of the pulley.
Fasten the compressor in a vise. Loosen and remove STEP 5

the three cap screws and lock washers from the cover
on the clutch. Remove the cover. Loosen and remove
the nut that holds the clutch plate.
STEP 2
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.

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.

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 Install the wire behind the clamp and tighten the screw.
bottom of the coil engages the hole in the front of the
compressor.

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.

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
STEP 29
Drive the clutch plate all the way onto the shaft.
If the gap is more than .032 inch (0.81 mm) or less than
.016 inch (0.41 mm), remove the clutch plate and add
STEP 27 or remove shims as required to get the correct gap.
STEP 30
Install the cover on the clutch.
Install and tighten the nut to 300 to 360 pound-inches

(34 to 40 Nm).

9003-19
REPLACING THE SEAL

STEP 31 STEP 34
Fasten the compressor in a vise. Remove the cover Drive the bottom of the Woodruff key into the keyway.
from the clutch. Loosen and remove the nut that holds
the clutch plate.
STEP 35
STEP 32
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.

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
STEP 41
Remove the snap ring that holds the seal seat.

Install the seal tool and engage the notches in the seal
tool with the tabs on the seal.
STEP 39
STEP 42
Remove the seal seat.
Remove the seal.

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.

Install the new a-ring in the bottom groove in the bore
for the seal.
NOTE: DO NOT touch the sealing surface of the
carbon ring. Body salts and acids will damage the
sealing surface. STEP 48
STEP 45
Carefully remove the seal seat from the container.
Install the seal on the seal tool. NOTE: DO NOT touch the sealing surface of the seal
seat. Body salts and acids will damage the sealing
surface.

9003-22
STEP 49 STEP 52
Lubricate the sealing surface of the seal seat with refri- Drive the felt seal into the bore until the metal is even
geration oil and install the seal seat. with the top of the bore.
STEP 50 STEP 53
Instail the snap ring so that the chamfer on the ID will be B414508M
on top. Remove the protector.
STEP 51 STEP 54
Install the new felt seal. Install the Woodruff key. If pliers are used as shown, use
a piece of metal as a protector between the pliers and
shaft to prevent damage to the shaft.

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.

9003-24
REPLACING THE VALVE PLATE AND GASKETS

STEP 59 STEP 63
Remove the dirt and grease from the compressor.
STEP 60
Remove the gasket from the valve plate.
Fasten the compressor in a vise and loosen and STEP 64

remove the cap screws that hold the end cap.
STEP 61
Loosen the valve plate.
STEP 65
Hit the end cap to loosen the end cap.
STEP 62
Remove the valve plate.
Remove the end cap.

9003-25
STEP 66 STEP 69
If the gaskets are being replaced, remove the other Install the end cap.
gasket from the valve plate. Be careful not to damage
the valves.
STEP 70
STEP 67
.:.....
4a43M·
:
Install and tighten every other cap screw to 264 to 300

•. : •...••• ->;., •.••• pound-inches (30 to 34 Nm) until all cap screws have
Install the new gaskets on the valve plate. The gaskets been tightened.
will only fit one way.
STEP 71
STEP 68 Loosen and remove the filler plug and drain the oil into a
measuring container.
STEP 72
Fill the compressor with the same amount of NEW refri-
geration oil.
STEP 73
Install and tighten the filler plug.
Install the valve plate.

9003-26
B1245A88J

9003-27
INSTALLING THE COMPRESSOR
'I . Align the compressor with the mounting bracket 6. Adjustthe drive belt according to instructions in this
and install the bolt and flat washer. section.
2. Install the flat washer, lock washer and nut on the 7. Loosen and remove the plugs from the hoses.
bolt.
8. Connect the hoses to the compressor
3. Install the drive belt on the pulley.
9. Connect the wiring to the wiring harness
4. Align the adjusting strap with the compressor and
install the bolt and flat washer. 10. Charge the air conditioning system according to in-
5. Install the lock washer and nut on the bolt.

9003-28
REPLACING THE AIR CONDITIONING CONTROL

1. Remove the evaporator according to instructions in 6. Route the tube for the new air conditioning control
this section. the same way as the original.
2. Loosen and remove the nut that holds the air con- 7. Connect the wiring to the air conditioning control.
ditioning control.
8. Install the air conditioning control in the mounting
3. Remove the air conditioning control from the plate.
mounting plate.
9. Install and tighten the nut that holds the air con-
4. Disconnect the wiring from the air conditioning ditioning control.
control.
10. Install the evaporator according to instructions in
5. Completely remove the air conditioning control. this section.
REPLACING THE EXPANSION VALVE

1. Discharge the air conditioning system according to 8. Disengage the vertical cover from the frame begin-
instructions in this section. ning at the top and remove the vertical cover.
2. Turn the temperature control to HOT. 9. Disengage the left vertical cover beginning at the
top and remove the vertical cover.
3. Drain one U.S. gallon (4 litres) of coolant from the
radiator. NOTE: The front headliner MUST be removed first.
4. Remove the knobs from the switches, air con- 10. Hold the front headliner in place and loosen and
ditioning control and temperature control. remove the screws at the front of the front headliner and
the screws on each side including the screw at the
5. Loosen and remove the screws that hold the junction of the front and rear headliners.
control panel.
11. Lower the front headliner onto the control.
6. Disengage the control panel from the vertical cover
and disconnect the wiring from the cab lamp switch. 12. Loosen the clamp on the front drain hoses.
7. Loosen and remove the screws that hold the 13. Remove the hoses from the drain pan.
bottom of the vertical cover.

9003-29
14. Loosen and remove the screw from the left and 23. Install new insulation tape around the expansion
right rear sides of the rear headliner. valve.
15. Hold the rear headliner in place and loosen and 24. Carefully raise the rear headliner and engage the
remove the screws from the left and right sides of the rear headliner with the slot at the rear of the roof.
rear headliner.
25. Hold the rear headliner in place and install a screw
16 Carefully lower the rear headliner behind the seat. in the center hole on the right and left sides of the rear
headliner.
17. Remove the insulation from the expansion valve.
26. Install and tighten the screw at the left and right rear
sides of the rear headliner.
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
33. Install the right vertical cover.
18. Loosen completely the connections at the rear of
the expansion valve 34. Install and tighten the screw at the bottom of the
right vertical cover.
19. Loosen completely the connections at the front of
the expansion valve and remove the expansion valve. 35. Connect the wires to the cab lamp switch in the
control panel and engage the control panel with the
20. Install new O-rings on the fittings on the tubes and right vertical cover.
the fittings on the evaporator.
36. Install and tighten the screws that hold the control
panel.
21. Lubricate the O-rings with refrigeration oil.
22. Install the expansion valve and tighten the connec- 37. Install the knobs for the switches and the air con-
tions with force equal to 240 to 300 pound-inches (27 to ditioning and temperature controls.
34 Nm).

9003-30
REPLACING THE EVAPORATOR

1. Discharge the air conditioning system according to 19. Remove the insulation for the connections to the
instructions in this section. expansion valve and evaporator.
2. Turn the temperature control to HOT. 20. Disconnect the tubes from the expansion valve and
evaporator .
3. Drain one U.S. gallon (4 litres) of coolant from the
radiator. 21. Loosen the cap screws that hold the evaporator.
4. Remove the knobs from the switches, air con- 22. Carefully remove the evaporator and remove the
ditioning control and temperature control. temperature sensor and tube for the air conditioning
control from the evaporator.
5. Loosen and remove the screws that hold the
control panel.
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 begin-

ning at the top and remove the vertical cover.
9. Disengage the left vertical cover beginning at the

top and remove the vertical cover.
B861647M
IMPORTANT: The front headliner must be removed

first. 23. Remove any remaining insulation from the expan-
sion valve and the connections to the evaporator.
10. Hold the front headliner in place and loosen and
remove the screws at the front of the headliner and the 24. Remove the clamp that holds the temperature
screws on each side including the screw at the junction sensor.
of the front and rear headliners.
25. Disconnect the expansion valve and equalizer tube
11. Lower the front headliner onto the control console. from the evaporator.
12. Loosen the clamp on the front drain hoses. 26. Connect the expansion valve to the new evapo-
rator.
13. Remove the front drain hoses from the drain pan.
27. Connect the equalizer tube to the outlet tube of the
14. Loosen and remove the screw from the left and evaporator.
right rear sides of the rear headliner.
28. Apply a small amount of grease between the tem-
15. Hold the rear headliner in place and loosen and perature sensor and the outlet tube.
remove the screws from the lett and right sides of the
rear headliner. 29. Install the clamp that holds the temperature
sensor.
16. Carefully lower the rear headliner behind the seat.
30. Apply new insulation tapes to the tubes at each end
17. Loosen both clamps on the hoses connected to of the evaporator, the inlet and outlet tubes, and the ex-
the heater. pansion valve and the equalizer tubes.
18. Slide the hoses to the rear.

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 eva- 40. Install and tighten the screw at the left and right rear
porator as shown. 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 eva- 48. Install and tighten the screws at the bottom of the
porator right vertical cover.
34. Connect the tubes to the expansion valve and eva- 49. Connect the wires to the cab lamp switch and
porator. engage the control panel with the right vertical cover.
35. Apply new insulation tape to the connections. 50. Install and tighten the screws that hold the control
panel.
36. Slide the hoses onto the tubes from the heater.
51. Install the knobs for the switches and the air con-
37. Tighten the clamps for both hoses. ditioning and temperature controls.
38. Carefully raise the rear headliner and engage the 52. Fill the radiator to the correct level.
rear headliner with the slot at the rear of the roof.
39. Hold the rear headliner in place and install a screw structions in this section.
in the center hole on the right and left sides of the rear
headliner.

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 21. Tighten the cap screws.
instructions in this section.
22. Install the mounting brackets and bolts and lock
2. Have another person hold the hood in position. washers and nuts.
3. Make an alignment mark at the top and rear of each 23. Tighten the nuts.
pivot bracket for the hood.
24. Loosen and remove the plug from each hose.
4. Loosen and remove the nut, lock washer, spacer,
flat washer and bolt that fasten each cable to the 25. Connect the hoses to the condenser.
radiator shroud.
26. Install the guard and cap screws.
5. Loosen and remove the front and rear cap screws
that hold each pivot bracket. 27. Tighten the cap screws.
6. Remove the hood from the machine. 28. Install the radiator shroud.
7. Put blocks between the radiator and pump to hold 29. Install the bolts and flat washers, and nuts that hold
the radiator in place with the radiator shroud or the radiator shroud.
mounting brackets removed.
30. Install the bracket and cap screw at the top of the
8. Loosen and remove the self-locking nut, bolt and radiator.
flat washer from each oil cooler mount.
31. Tighten the cap screw.
9. Loosen and remove the cap screw and bracket at
the top of the radiator. 32. Have another person push and hold the top of the
radiator shroud all the way to the rear.
10. Loosen and remove the nuts and bolts that hold the
radiator shroud. 33. Tighten the nuts.
11. Remove the radiator shroud. 34. Install a bolt and flat washer and self-locking nut in
each oil cooler mount.
12. Loosen and remove the cap screws that hold the
guard at the bottom of the condenser. 35. Tighten the self-locking nuts.
13. Remove the guard. 36. Remove the blocks from below the radiator.
14. Disconnect the hoses from the condenser. 37. Make sure that the pivot brackets are all the way on
the pivots for the hood.
15. Install and tighten a plug in each hose.
38. Install the hood.
16. Loosen and remove the nuts and lock washers
from the bolts that hold the mounting brackets. 39. Install the cap screws that hold the pivot brackets.
17. Remove the mounting brackets and the bolts. 40. Align each pivot bracket with the alignment marks
and tighten the cap screws.
18. Loosen and remove all but the top cap screws that
hold the condenser. 41. Close the hood. The top rear of the hood must be
even with the frame.
19. Hold the condenser in place and remove the top
cap screws and remove the condenser. 42. If the top of the hood is too high, check to see if the
sides of the hood are touching the frame. To correct this
20 Hold the condenser in place and install the flat problem, move the pivot brackets forward.
washers, lock washers and cap screws.

9003-35
3. O-RING
3. O-RING
3. O-RING
3. O-RING
B891259J

Bur 8-12711
9003-36
43. If the top of the hood is too high and the sound of 44. When the hood can be closed and is in the correct
metal hitting metal is heard at the front of the hood, the position, tighten the nuts on the bolts that hold the
radiator shroud is not in the correct position. To correct radiator shroud to 270 to 324 pound-feet (366 to 439
this problem, the top of the radiator shroud must be Nm).
moved farther to the rear.

9003-37
3. O-RING
3. O-RING
3. O-RING
8891259J

Bur 8-12711
9004
LOADER
TABLE OF CONTENTS
REPLACEMENT OF CUTIING EDGE FOR EXPLODED VIEWS

STANDARD BUCKETS 2
loader Frame 9
REPLACEMENT OF CUTIING EDGE FOR
CLAM BUCKET. 4 Lift Cylinder Hydraulic Installation 10
REPLACEMENT OF TOOTH SHANK 6 Bucket Cylinder Hydraulic Installation 11
REPLACEMENT OF TOOTH POINT 6 Antirollback Linkage 12
REMOVAL OF lOADER FRAME 7 Clam Cylinder Circuit... 13
INSTALLATION OF LOADER FRAME 8 Clam Cylinder Hydraulic Installation 14
Installation of Front Counterweight 15
Installation of Rear Counterweight 16
CASE CORPORATION
Copyright © J I Case Company
Issued March 1991
9004-2
REPLACEMENT OF CUTTING EDGE FOR STANDARD BUCKETS

1. If the bucket is not removed from the machine, raise 8. Put the cutting edge in place and use C-clamps to
the bucket to a suitable height and use suitable hold the cutting edge in place. See the illustration forthe
supports to hold the loader frame and bucket in place. 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 dis-
tortion to a minimum when removing the cutting edge.
4. When removing the bottom rear weld for the cutting

edge DO NOT cut through the floor of the bucket.
5. If removing the cutting edge from a short lip bucket,

remove the gusset from each side of the bucket.
B902762J
1. Short Up Bucket - 25-3/16 In (639 mm)

2. Long Up Bucket - 27 In (687 mm)
9. Use E-7018 welding rod and weld the cutting edge to

the bucket.
1. Gusset 10. When welding the floor of the bucket the top of the
6. If removing the cutting edge from a short lip bucket, cutting edge:
cut through each corner of the cutting edge 1-13/16 (45
mm) to the rear from the front edge of the floor of the a. Start at one end of the bucket and weld toward
bucket. the center until one welding rod is used.
7. Use a grinder to remove any welds or extra metal on
the bucket that will prevent the new cutting edge from b. Start at the center of the bucket and weld in both
fitting correctly. directions from center until one welding rod is
used.
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.

9004-3
Weld Specifications for Weld Specifications for

Long Lip Bucket Short Lip Bucket
1. 1/4 In (6 mm) Fillet 1. 1/4 In (6 mm) Fillet

2. Fill Corners 2. Fill Corners
3. Fill Groove 3. 3/16 In (5 mm) Fillet
4. 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

9004-4
REPLACEMENT OF CUTTING EDGE FOR CLAM BUCKET

1. If the bucket is not removed from the machine, raise 7. Put the cutting edge in place and use C-clamps to
the bucket to a suitable height and use suitable hold the cutting edge in place. See the illustration for the
supports to hold the loader frame and bucket in place. correct position of the cutting edge.
2. If equipped with bucket teeth, use carbon arc rod to

remove the bucket teeth.

remove the welds that hold the cutting edge. Keep dis-
tortion to a minimum when removing the cutting edge.
4. When removing the bottom rear weld for the cutting

edge DO NOT cut through the floor of the bucket.
5. Cut through each corner of the bucket and cutting

edge in the area shown.
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
a. Start at one end of the bucket and weld toward
6. Use a grinder to remove any welds or extra metal on the center until one welding rod is used.
the bucket that will prevent the new cutting edge from
fitting correctly. 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.

9004-5
Weld Specifications for Clam Bucket
1. 1/4 Inch (6 mm) Fillet

2. Fill Corner
3. Fill Groove

9004-6
REPLACEMENT OF TOOTH SHANK

1. Use carbon arc rod or an acetylene cutting torch to 4. See the following illustration for weld specifications
remove the welds that hold the tooth shank in place. 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 B902019J
1. Short Up Bucket - 15-1/8 In (384 mm) 1. 3/8 Inch (10 mm) Fillet. Weld Around Each Corner
Long Up Bucket - 8-1/4 In (208 mm) 3/8 Inch (10 mm). Weld Two Times
2. Short Up Bucket - 14-9/16 In (370 mm) 2. 2-1/2 Inches (63 mm)
Long Up Bucket - 8 In (203 mm) 3. 3/8 Inch (10 mm) Fillet. Weld Both Sides and Rear
3. Put Tooth Shank as Close to Corner as Possible of Tooth Shank Weld Two Times
and Keep Corner of the Tooth Point Even With Outer 4. 3/8 In (10 mm) Fillet. Two Times
Surface of Cutting Edge 5. Bent Area of Tooth Point
REPLACEMENT OF TOOTH POINT

1. Heat the part of the tooth point that has been 5. Heat the part of the tooth point that will be pressed
pressed into the hole on each side of the tooth shank. into the hole on each side of the tooth shank.
2. Bend the tooth point out of the dent on each side of 6. Have another person hold the tooth point against
the tooth shank. the tooth shank.
3. Use a pair of pliers to remove the tooth point from 7. Use an suitable tool and drive the heated part of the
the tooth shank. tooth point into the dent on each side of the tooth shank.
4. Install a new tooth point on the tooth shank.

9004-7
REMOVING THE LOADER FRAME

1. Raise the loader frame until the pivot pins for the 13. Remove the tie straps that fasten the wiring
piston rod eye ot the lift cylinders are above the hood. harness to the tubes on the loader frame. Put the wiring
Stop the engine. harness out of the way.
2. Fasten suitable lifting equipment to the loader 14. Remove the cotter pin and flat washer that fasten
frame to hold the loader frame in place. the actuator rod for antirollback to the bellcrank for the
right bucket cylinder.
3. Remove the outer snap ring that hold the pivot pins
for the piston rod eyes ot the lift cylinders. 15. Remove the actuator rod. Be careful not to lose the
spring or other flat washer.
4. Use suitable drivers and drive the pivot pins out of
the loader frame. DO NOT remove the drivers now. 16. If equipped with a clam bucket, move the clam
control lever in either direction to relieve any pressure in
5. Disconnect the lifting equipment and lower the the clam circuit.
bucket to the floor.
17. Disconnect the tubes to the clam cylinders from the
6. Hold the right lift cylinder and remove the driver and hoses on the left side of the machine. Fasten an identi-
lower the lift cylinder onto the front axle. fication tag to one hose.
7. Hold the left lift cylinder and remove the driver and 18. Install a cap on each hose and a plug in each tube.
lower the lift cylinder onto the front axle. Flat washers
are used between the strut and the loader frame; be 19. Remove the snap ring and flat washer from the
careful not to lose the flat washers. It is not necessary to right end of the pivot shaft.
remove the strut.
20. Fasten suitable lifting equipment to the loader
8. Move the loader control lever to the right or left to frame to hold the loader frame in place.
relieve any pressure in the bucket circuit.
21. Use a suitable driver and drive the pivot shaft out of
9. Disconnect the tubes to the bucket cylinders from the loader frame.
the hoses on the right side of the loader frame. Fasten
an identification tag to one of the hoses. 22. Belleville springs are used between the loader
frame and the machine. Raise the loader frame and
10. Install a cap on each hose and a cap on each tube. remove the Belleville springs.
11. Disconnect the wiring from the switch for return- 23. Raise the loader frame until the loader frame is free
to-dig. of the machine.
12. Loosen and remove the bolt, flat washer and nut 24. Carefully move the machine out of the loader
that holds the clamp for the wiring harness. frame.

9004-8
INSTALLATION OF LOADER FRAME

1. Carefully move the machine into the loader frame. 14. Connect the tubes to the bucket cylinders to the
hoses on the right side of the machine.
2. Lower the loader frame into alignment with the
frame. 15. Move the loader control lever to FLOAT.
3. Install the Belleville springs between the frame and 16. Remove the snap ring and flat washer from both
loader arm as shown. pivot pins for the piston rod eyes of the lift cylinders.
Then install the large snap ring on each pivot pin.
17. Start the pivot pin tor tne left piston rod eye into the
loader frame and install the flat washer used between
1. BELLEVILLE SPRING. the strut and loader frame.
THIS SIDE TOWARD MACHINE
18. Start the pivot pin into the strut.
19. Align the piston rod with the strut and start the pivot
pin into the piston rod eye.
B891353J 20. Drive the pivot pin into the piston rod eye.
21. Install the other flat washer between the strut and
4. Align the loader frame and Belleville springs with loader frame and drive the pivot pin all the way into the
the frame. loader frame.
5. Start the pivot shaft into the loader frame from the 22. Install the flat washer and snap ring on the pivot
left side of the machine. pin.
6. Drive the pivot shaft all the way into the loader 23. Start the pivot pin for the other lift cylinder into the
frame. loader frame.
7. Install the flat washer and snap ring. 24. Align the piston rod eye with the loader frame and
drive the pivot pin all the way into the loader frame.
8. If equipped with a clam bucket, connect the hoses
to the tubes on the left side of the machine. 25. Install the flat washer and snap ring on the pivot
pin.
9. Install the actuator rod and spring in the actuator
tube for the antirollback mechanism. 26. Lubricate the pivot pins for the piston rod eyes of
the lift cylinders and the pivot shaft.
10. Engage the actuator rod with the bellcrank and
install the flat washer and cotter pin. 27. With the engine running at low idle, extend and
retract the bucket cylinders and clam cylinders, if
11. Connect the wiring harness to the switch for return- equipped, three times to remove any air from the cir-
to-dig. cuits.
12. Install the nut, bolt and flat washer that hold the
clamp for the wiring harness for the switch.
13. Install tie straps to hold the wiring harness in place.

9004-9
Loader Frame

9004-10
B902720J
Lift Cylinder Hydraulic Installation

9004-11
B902721J
Bucket Cylinder Hydraulic Installation

9004-12
B902719J
Antirollback Linkage

9004-13
I· der Circuit
Clam CYln

9004-~4
. III U.S.p..·
?rlllteO
_17630
Sur 8
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
Section
9005
ROPS CAB AND ROPS CANOPY
CASE CORPORATION

Issued January 1991 .
9005-2
TABLE OF CONTENTS
SPECIAL TOOL . . 2
TORQUE SPECiFiCATIONS _ 3
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY 3
MAINTENANCE AND INSPECTION OF THE ROPS CAB OR ROPS CANOPY 3
IllUSTRATION OF ROPS CANOPY INSTALLATION .4
ILLUSTRATION OF SEAT INSTALLATION 5
REMOVAL AND INSTALLATION OF ROPS CAB 6
REMOVAL AND INSTALLATION OF ROPS CANOPY 14
REMOVAL AND INSTALLATION OF HEATER _ 15
REMOVAL AND INSTALLATION OF TEMPERATURE CONTROL 17
SPECIAL TOOL
The tool shown is needed to remove the steering
wheel. Make the tool in your shop. Shown in use in step
5.
4
6 7 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

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 (43 to 50 Nm)
Bolt for rear POD mount 220 to 264 pound-feet (298 to 358 Nm)
Bolt for front center POD mount... 220 to 264 pound-feet (298 to 358 Nm)
Seat and seat belt torques See page 5
POSSIBLE DAMAGE TO THE ROPS CAB OR RaPS CANOPY

If the machine has rolled over or the ROPS cab or After an accident, check for damage to the ROPS
ROPS canopy has been in some type of accident (such cab or ROPS canopy, the operators seat, the seat belt,
as hitting an overhead object during transport), you and all accessories, wiring etc., in the ROPS cab or
must replace the ROPS cab or ROPS canopy to get as ROPS canopy. Before operating the machine again, all
much protection as you had originally. 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 neces-
sary, tighten the cap screws and nuts to the correct
torque.
See illustration on page 5. Check the operators seat

and the mounting parts for the seat belt. Make sure that
all nuts and cap screws are tight. Replace parts that are
worn or damaged.

9005-4
sur 8_17470
9005-5
@
,
B870363R

9005-6
REMOVAL AND INSTALLATION OF ROPS CAB

STEP 1 STEP 5
If the machine has air conditioning. discharge the air
conditioning system according to instructions in
Section 9003.
NOTE: After installation, charge the air conditioning

system according to instructions in Section 9003.
STEP 2
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 ra-

diator.
Use the puller shown on page 2 to loosen and remove
STEP 3 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

~
Remove the front and rear covers.

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.

Remove the cap screws that hold the front of the ROPS
cab.
STEP 10
STEP 13
Remove the control console.
Remove the cap screws that hold the seat and remove
the seat.

9005-8
STEP 14 STEP 17
Remove the self-locking nut and shoulder bolt that Begin at the top and remove the vertical cover.
holds the cable for the left door.
STEP 18
STEP 15
Remove the screws and the bottom cover.

Remove the self-locking nut that holds rod for the door
cylinder.
STEP 19
Remove the screws that hold the guard for the instru-
STEP 16 ment console and remove the guard.
STEP 20
Remove the two screws at the bottom of the vertical

cover.
Remove the screws that hold the instrument cluster.

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
STEP 25
Disconnect the wiring harness.

Remove the knobs.
STEP 23
STEP 26
Remove the nut that holds the key switch. Remove the
key switch from the panel. Remove the screws that hold the cover.

9005-10
STEP 27 STEP 30
Disconnect the wiring from the cab lamp switch and Disconnect the wiring from the switches.
lamp for air conditioning.
NOTE: Top, five wire plug; bottom front, four wire plug;
bottom rear, three wire plug.
STEP 28
STEP 31
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.

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 Loosen the set screw that holds the handle.
instrument console.
STEP 38
STEP 35
Slide the boot through the opening.

Drive the knob off the lever.

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 Remove the clevis and cotter pins that hold the shift
a cap screw at the top of the support. linkage.
STEP 41 STEP 44
Remove the nut, lock washer and bolt. Remove the hardware that holds the clamp, ROPS cab
only, and move the support out of the way.

9005-13
STEP 45 STEP 48
.~
~~~
Disconnect the heater hoses and air conditioning 1. Hardened Washer
hoses, if equipped. Install caps and plugs on the air
conditioning hoses and tubes. Remove the hardware at the side supports.
NOTE: During instal/ation, tighten the cap screws to

STEP 46 600 to 720 pound-feet (813 to 796 Nm).
STEP 49
Remove the cap screws all around the bottom.
Remove the plugs, cap screws and retainers.

STEP 47
STEP 50
1. Hardened Washer
Fasten suitable lifting equipment to the roof and care-
Remove the hardware at the front supports. fully remove the ROPS cab.
NOTE: During instal/ation, tighten the nuts to 220 to 264 STEP 51

pound-feet (298 to 358 Nm). Install the ROPS cab in the reverse of removal.

9005-14
REMOVAL AND INSTALLATION OF ROPS CANOPY

1. Remove the hardware that holds the seat and 7. Remove the hardware at the front supports.
remove the seat.
NOTE: During installation, tighten the nuts to 220 to 264
NOTE: During instal/ation, tighten the cap screws to 80 pound-feet (298 to 358 Nm).
to 96 pound-feet (109 to 130 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 plate and

support for both fenders.
8. Remove the hardware at the side supports.
NOTE: During installation, tighten the cap screws to

B902117J 600 to 720 pound-feet (813 to 796 Nm).
9. Carefully raise and remove the ROPS canopy.

5. Fasten suitable lifting equipment to 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 8, If equipped with air conditioning, loosen the clamp
U,S. gallon (4 litres) of coolant from the radiator, on each front drain hose and remove the drain hoses
from the drain pan,
NOTE: During installation, return the coolant to the ra-
diator. 9, Hold the rear headliner in place and remove all
screws that hold the rear headliner. Lower the rear
2, Remove the knobs from the control panel. headliner behind the seat.
3, Remove the screws that hold the control panel. Dis- 10, Disconnect the yellow wire from the wiring harness,
connect the wires from the switch for the cab lamp and
the lamp for air conditioning, 11 . Hold the blower assembly in place and remove the
five cap screws that hold the blower mount and remove
4, Remove the screws at the bottom of the vertical cover the blower assembly,
and remove the vertical cover beginning at the top,
12, Loosen the clamps on the hoses at the heater and
5, Remove the screws at the bottom of the left vertical remove the hoses,
cover and remove the left vertical cover beginning at the
top, 13, Hold the heater in place and remove the cap screws
that hold the heater and remove the heater,
6. Hold the front headliner in place and remove all
screws that hold the front headliner, 14, Install the heater in reverse of removal.
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 8. Disconnect the wiring from the switches.
U.S. gallon (4 litres) of coolant from the radiator.
NOTE: Top, five wire plug; bottom front, four wire plug;
NOTE: During installation, return the coolant to the ra- bottom rear, three wire plug.
diator.
9. Loosen the top clamp and remove the hose from the
2. Remove the knobs from the control panel. temperature control.
3. Remove the screws that hold the control panel. Dis- 10. Remove the screws that hold the temperature
connect the wires from the switch for the cab lamp and control.
the lamp for air conditioning.
NOTE: During installation, make sure that the two
4. Remove the screws at the bottom of the vertical cover ground wires are installed with the bottom screw.
and remove the vertical cover beginning at the top.
11. Loosen the bottom clamp and remove the tempera-
5. Remove the screws that hold the switch panel. ture control.
6. Remove the nut that holds the air conditioning NOTE: During installation, make sure that the tempera-
control. ture control is aligned with the control panel.
7. Remove the screws that hold the switch mount. 12. Install the temperature control in the reverse of
removal.

Section
9006
BACKHOE
CASE CORPORATION
Issued March 1991
9006-2
TABLE OF CONTENTS
REMOVAL OF SWING TOWER" , , , , , , , , , , " ,.3
INSTALLATION OF SWING TOWER " ,.., , , '' , , ,., ,..', 4
REMOVAL OF BOOM ,., '., ,' ..,..' , ' ', ",., " , " , ,.., ,., 5
INSTALLATION OF BOOM , , , ,.., ",., , ,." ,..,., ',., ' , 6
REMOVAL OF DiPPER ".,., .." , , , , , "." ..,."" , 6
INSTALLATION OF DIPPER , , 7
REMOVAL OF DIPPER EXTENSION,., , ", , , " " , 7
INSTALLATION OF DIPPER EXTENSiON , , , 8
REPLACING WEAR PLATES FOR DIPPER WITH EXTENDABLE DiPPER., ,.., , ,., , 8
CUTIING EDGES
Universal and Heavy Duty Buckets .., ', ,..'" ,' "." , " ..""""'''' .,., ,"""" ,.', " , , ' " ..,..9
High Capacity Buckets " " , ,., , " .. , , " "", .. ,."., ' , ,10
Standard Duty Trenching Buckets ,..,..,'., ,,' ," , ' ,., , ", ,." , 11
BUCKET TEETH
Replacing a Tooth Point..; , , , ' , , , ', 12
Replacing a Tooth Shank, ,.,..,,.." ' ' ', ,., , , " ,' ,..,' ' ..,." ,.. ,..' , ,.' , , 12
EXPLODED VIEWS
Stabilizer Installation .,., , , , '., 14
Stabilizer Cylinder Hydraulic Installation ,.., ,.., , , 15
Swing Tower and Swing Cylinder Installation , , , 16
Sequence Valve Linkage .." , " .., , , , , 17
Swing Cylinder Hydraulic Installation , , , ', ,.." , , 18
Boom latch Installation , , 19
Boom and Dipper Installation ,., ,., ', 20
Boom Cylinder Hydraulic Installation , , , ' 21
Dipper Cylinder Hydraulic Installation , 22
Quick Coupler and Bucket Installation , , ", , ,., , , 23
Bucket Cylinder Hydraulic Installation Without Extendable Dipper 24
Extendable Dipper Installation , , " " , 25
Extension Cylinder Hydraulic Installation, , , , , , , , 26
Bucket Cylinder Hydraulic Installation With Extendable Dipper , , .27
Auxiliary Hydraulic Installation With Extendable Dipper , 28
Bur 8-12741 Issued 3-91 Printed in U.S,A

9006-3
REMOVAL OF SWING TOWER

1. Remove all dirt from the hose connections at the 18. Loosen and remove the cap screws, hardened
backhoe control valve. washers and spacers that hold the pivot pins for the
boom.
(r/min). 19 Remove the pivot pins for the boom.
3. Hold the bucket control lever in the LOAD position until NOTE: Flat washers are installed between the boom
the bucket stops moving. and swing tower to center the boom in the swing tower.
4. Extend the dipper and boom as far as possible in the 20. Carefully move the machine away from the boom.
space that is available and lower the bucket to the floor.
21. Remove the snap ring and flat washer(s) from one
5 Fasten suitable lifting equipment to the boom and end of the pivot pins for the piston rod eyes of the swing
dipper pivot area to prevent the boom and dipper from cylinders.
falling when the boom is free of the swing tower.
22. Use a hammer or hydraulic ram and a suitable
6. Move the control levers for the backhoe in either di- driver and remove the pivot pins from the swing tower.
rection to relieve any pressure in the circuits.
23. Remove a snap ring and flat washer(s) from one
7. Disconnect the hoses from the backhoe control valve end of the pivot pin for the boom latch.
one at a time and fasten an identification tag to each
hose. 24. Loosen the set screw in the boom latch and drive
the pivot pin out of the swing tower and remove the
8. Install a cap on each fitting and a plug in each hose. driver.
9 Loosen and remove the self-locking nuts and flat 25. Move the boom latch out of the way
washers that hold the vertical clamps near the center of
the swing tower. 26. Loosen and remove the self-locking nut and flat
washer from the bolt that holds the cam on the top pivot
10. Remove the bolts and the clamps. pin for the swing tower.
11. Loosen and remove the self-locking nuts, flat 27. Remove the bolt and flat washers used as spacers
washers, bolts and the horizontal clamp at the rear of Record the amount of flat washers used for use during
the swing tower. installation.
12. Write a number on each clamp ring so that the 28. Remove the snap ring and flat washer from the
hoses will be installed in the correct notch during instal- bottom of the the bottom pivot pin for the swing tower.
lation.
29. Fasten suitable lifting equipment to the swing tower.
13. Fasten suitable lifting equipment to the boom
cylinder to hold the boom cylinder while the pivot pin is 30. Use a hammer or hydraulic ram and a suitable
being removed. driver and remove the bottom pivot pin.
14. Remove the snap ring and flat washer(s) from one 31. Remove the snap ring and flat washer that hold the
end of the pivot pin for the boom cylinder. top pivot pin for the swing tower.
15. Drive the pivot pin out of the swing tower and 32 Drive the top pivot pin out of the swing tower.
remove the driver.
33. Remove the swing tower from the frame.
16. Lower the boom cylinder until the boom cylinder
touches the boom and remove the lifting equipment. 34. Remove the thrust washer from the swing tower or
the bottom support for the swing tower.
17. Use other suitable lifting equipment to hold the
boom when the pivot pins for the boom are removed.

9006-4
INSTALLATION OF SWING TOWER

1. Installation of the swing tower is the reverse of 3. Lubricate all pivot pins with molydisulfide grease.
removal.
4. With the engine running at 1000 rpm (r/rnin), slowly
2. The bottom pivot pin for the swing tower must be in- operate the bucket, dipper, extension, if equipped, and
stalled so that the grease fitting is on top. boom cylinders through four complete cycles to
remove any air from the circuits.

9006-5
REMOVAL OF BOOM
1. With the engine running at low idle, hold the bucket 17. Remove the snap ring and flat washer from one end
control lever in the LOAD position until the bucket stops of the pivot pin for the piston rod eye of the boom
moving. cylinder.
2. Put the boom and dipper in a suitable position for 18. Drive the pivot pin out of the boom.
removal of these parts with the bucket on the floor.
19. Move the boom cylinder toward the machine and
3. With the engine stopped, move the dipper control use a chain to hold the boom cylinder out of the way.
lever in either direction to relieve any pressure in the cir-
cuits. 20. Disconnect the hoses from the dipper cylinder from
the tubes inside the boom.
4. Fasten suitable lifting equipment to the dipper
cylinder to hold the dipper cylinder for removal of the 21 . Install and tighten a plug in each tube and a cap on
pivot pin for the piston rod eye. each hose.
5 Remove the snap ring and flat washer that hold the 22. Fasten lifting equipment to the dipper cylinder for
pivot pin for the piston rod eye of the dipper cylinder. removal of the dipper cylinder.
6. Drive the pivot pin out of the dipper and remove the 23. Remove the snap ring and flat washer from one end
driver. of the pivot pin for the dipper cylinder.
7. Raise the dipper cylinder for access to the hoses 24. Drive the pivot pin out of the boom and remove the
inside the boom driver.
8. Disconnect the hoses from the bucket cylinder at the 25. Remove the dipper cylinder.
tubes inside the boom and fasten an identification tag
to one hose. 26. Lower the boom to the floor and use the lifting
equipment to hold the boom when the pivot pins for the
9. Install and tighten a plug in each tube and a cap on boom are removed.
each hose.
27. Disconnect the hoses at the bottom of the boom
10. If equipped with an extendable dipper, disconnect from the tubes inside the boom one at a time and fasten
the hoses from the extension cylinder and the tubes an identification tag to each hose.
inside the boom and fasten an identification tag to one
hose. 28. Install and tighten a plug in each tube and a cap on
each hose.
11. Install a plug in each tube and a cap on each hose.
29. Loosen and remove the cap screw, hardened
12. Fasten the lifting equipment to the dipper. washer and spacer that hold each pivot pin for the
boom.
13. Loosen and remove the self-locking nut and
hardened washer that hold the pivot pin for the dipper. 30. Remove the pivot pins for the boom.
14. Drive the pivot pin out of the dipper and remove the NOTE: Flat washers are installed between the boom
driver. and swing tower to center the boom in the swing tower.
15. Move the dipper out of the way. 31. Remove the boom and check for flat washers being
used between the swing tower and the boom.
16. Fasten the lifting equipment to the boom.

9006-6
INSTALLATION OF BOOM
1. Install new seals at all pivot points. 4. Tighten the self-locking nut for the pivot pin for the
dipper to 500 to 550 pound-feet (678 to 746 Nm).
2. Installation is the reverse of removal.
5. Lubricate the pivot pins with molydisulfide grease.
3. For original or new booms, measure the distance
between the ears of the boom at the dipper pivot point 6. With the engine running at 1000 rpm (r/rnin), slowly
and record the measurement. Before installing the self- operate the bucket, dipper, and extension, if equipped,
locking nut, install flat washers on the pivot pin that will cylinders through four complete cycles to remove any
pull the ears of the boom together 1/16 to 1/8 inch (1 to air from the circuits.
3 mm).
REMOVAL OF DIPPER
1. With the engine running at 1000 rpm (r/rnin) use the 11. Raise the dipper cylinder for access to the hose
backhoe controls as required so that the bucket teeth connections inside the boom.
are just off the floor and below the pivot pin for the
bucket. 12. Disconnect the hoses from the bucket cylinder at
the tubes inside the boom and fasten an identification
2. Remove the Klik pin from the pivot pin for the bucket. tag to one hose.
3. Remove the pivot pin for the bucket. 13. Install and tighten a plug in each tube and a cap on
each hose.
4. Use the boom, dipper and bucket controls as
required to disengage the coupler from the bucket. 14. If equipped with an extendable dipper, disconnect
the hoses from the extension cylinder at the tubes
5. Move the bucket out of the way. inside the boom and fasten an identification tag to one
hose.
6. Retract the bucket cylinder and put the boom and
dipper in a suitable position for removal of the dipper. 15. Install and tighten a plug in each tube and a cap on
each hose. Thread size is 1-1/16-12.
7. With the engine stopped, move the bucket control
lever and the extension control lever, if equipped, in 16. Fasten the lifting equipment to the dipper to hold
both directions to relieve any pressure in the circuits. and remove the dipper.
8. Fasten suitable lifting equipment to the dipper 17. Loosen and remove the self-locking nut and
cylinder. hardened washer(s) from the pivot pin for the dipper.
9. Remove a snap ring and flat washer from one end of 18. Drive the pivot pin out of the dipper.
the pivot pin for the piston rod eye of the dipper cylinder.
19. Remove the dipper.
10. Drive the pivot pin out of the dipper.

9006-7
INSTALLATION OF DIPPER
1. Install new seals in the bores for the pivot pin for the 4. Tighten the self-locking nut for the pivot pin for the
dipper. dipper to 500 to 550 pound-feet (678 to 746 Nm).
2. Installation is the reverse of removal. 5. Lubricate the pivot pins with molydisulfide grease.
3. Before installing the dipper, measure the distance 6. With the engine running at 1000 rpm (r/min), slowly
between the ears of the boom at the dipper pivot and operate the bucket cylinder and the extension cylinder,
record the measurement. Before installing the self- if equipped, through four complete cycles to remove
locking nut, install flat washers on the pivot pin so that any air from the circuits.
the ears of the boom will be pulled together 1/16 to 1/8
inch (1 to 3 mm) when the self-locking nut is tightened.
REMOVAL OF DIPPER EXTENSION

1. With the engine running at 1000 rpm (rim in) use the 10. Drive the pivot pin out of the guide links.
backhoe controls as required so that the bucket teeth
are just off the floor and below the pivot pin for the 11. Slowly remove the driver and lower a guide link and
bucket. then the coupler and the other guide link.
2. Remove the Klik pin from the pivot pin for the bucket. 12. Remove the snap ring and flat washer from each
end of the pivot pin for the guide links and the piston rod
3. Remove the pivot pin for the bucket. eye of the extension cylinder.
4. Use the boom, dipper and bucket controls as 13. Remove the guide link and flat washer from each
required to disengage the coupler from the bucket. end of the pivot pin.
5. Move the bucket out of the way. 14. Drive the pivot pin out of the dipper extension and
remove the driver.
6. Completely extend the dipper and raise or lower the
boom so that the end of the dipper is approximately 3 NOTE: The weight of the dipper extension and the
feet (1 m) above the floor. coupler is approximately 395 pounds (179 kg). The
length of the dipper extension is approximately 5-112
7. Completely retract the bucket cylinder and stop the feet (1.7 my.
engine.
15. Fasten suitable lifting equipment to the dipper ex-
8. Put a block under the bucket cylinder to hold the tension approximately two feet (0.6 m) from the bucket
bucket cylinder when the pivot pin for the piston rod eye end of the dipper extension to hold and remove the
is removed. dipper extension.
9. Remove a snap ring and flat washer from one end of 16. Install a bar through the hole for the pivot pin for the
the pivot pin for the piston rod eye of the bucket bucket and loosen the lifting equipment and pull the
cylinder. dipper extension off the dipper. Repeat this step until
the dipper extension is free of the dipper. Be careful
because the dipper extension can be out of balance on
the lifting equipment.

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 ex-
tension in place.
REPLACING THE WEAR PLATES FOR DIPPER WITH EXTENDABLE DIPPER

1. Remove the dipper extension according to instruc- 7. Install the shim(s), wear plates, retainers and cap
tions in this section. screws. Tighten the cap screws to 480 to 540 pound-
inches (54 to 61 Nm).
2. Loosen and remove the cap screws, flat washers,
side wear plates only, retainers, wear plate(s) and 8. Select shim(s) for the side wear plates so that the
shim(s). side wear plates will be even with or or up to 0.030 inch
(0.8 mm) beyond the rails on the dipper.
3. Remove the grease from the sides and bottom of the
dipper. 9. Install the shim(s), wear plates, retainers, flat
washers and cap screws. Tighten the cap screws to
4. Select shims for the bottom wear plate so that the 480 to 540 pound-inches (54 to 61 Nm).
bottom wear plate will be even with or up to 0.030 inch
(0.8 mm) beyond rails on the dipper. 10. Apply molydisulfide grease to the rails on the
dipper.
5. Install the shim(s), wear plates, retainers and cap
screws. Tighten the cap screws to 480 to 540 pound- 11 . Remove the grease from the inside of the dipper ex-
inches (54 to 61 Nm). tension.
6. Select shim(s) for the top wear plate so that the 12. Install the dipper extension according to instruc-
distance from the bottom of the bottom wear plate and tions in this section.
the top of the top wear plate is 9-3/16 inch (233 mm).

9006-9
CUTTING EDGES
Universal and Heavy Duty Buckets 6. See the following illustration and install the corner
bucket teeth and weld the bucket teeth in place. Use
Replacing Bottom Cutting Edge E7018 welding rod.
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 B861750R
inside of the bucket except the bottom of the bucket to

the bottom cutting edge. Use E7018 welding rod and 1. 1/2 Inch (14 mm)
weld the bottom cutting edge in place. 2. 7/8 Inch (20 mm) No Weld
3. No Weld, Top Only
4. First Weld. 7/16 Inch (10 mm) Flare
\
Bevel Weld
Second Weld. 7/16 Inch (10 mm)
Fillet Weld.
5. Bottom All Around 5/16 Inch (8 mm)
Fillet. Weld Two Times
6. 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
Replacing Side Cutting Edge
1. Universal Bucket - 5 79 Inches (147 mm)
Heavy Duty Bucket - 5-15/16 Inches (151 mm)
2. Universal Bucket - 1.73 Inch (44 mm)
remove the welds that hold the side cutting edge.
Heavy Duty Bucket - 1-7/8 Inch (47 mm)
3. 7/16 Inch (10 mm) Fillet Top and Bottom
2. Use a grinder and remove any welds still on the
4. Fill Groove Return Wear Plates and
bucket and any extra metal so that the new side cutting
Bottom Cutting Edge
edge will fit the bucket.
5. 1/4 Inch (6 mm) Fillet All Around.
6. Two Pass 1/4 Inch (6 mm) Weld To Fill Void.
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.
Bur 8-12741 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 1. Remove all welds that hold the side cutting edge in
acetylene cutting torch to remove the welds. place. Use carbon arc rod or an acetylene cutting torch
to remove the welds.
2. Remove all welds that hold the bottom cutting edge
in place. Use carbon arc rod or an acetylene cutting 2. Remove the side cutting edge from the bucket.
torch to remove welds.
3. Use a grinder to remove any welds still on the bucket
3. Cut through each corner of the bottom cutting edge and any extra metal so that the new side cutting edge
and bucket. will fit the bucket.
4. Remove the cutting edge from the bucket. 4. Put the side cutting edge in place and use a C-c1amp
to hold the side cutting edge in place.
5. Use a grinder to remove any welds still on the bucket.
Remove any extra metal so that the new cutting edge 5. Use E7018 welding rod and weld the side cutting
will fit the bucket. edge to the bucket with a 3/16 inch (5 mm) fillet weld all
6 Put the new bottom cutting edge in place and use C-
clamps to hold the bottom cutting edge in place.
7. See the following illustration for weld locations and

specifications. Use E7018 welding rod and weld the
bottom cutting edge to the bucket.
B902037J
1. 1-7/8 Inch (48 mm)

4. Groove Weld. Weld Two Times
5. 1-7/16 Inch (37 mm)

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 1. Remove the welds that hold the side cutting edge.
acetylene cutting torch to remove the welds. Use carbon arc rod or an acetylene cutting torch
IMPORTANT: When removing the bottom weld at the 2. Remove the side cutting edge.
rear of the bottom cutting edge, do not cut through the
bottom of the bucket. 3. Use a grinder to remove any welds still on the bucket
and any extra metal so that the new side cutting edge
2. Use carbon arc rod or an acetylene cutting torch to will fit the bucket.
remove the welds that hold the bottom cutting edge.
4. Use C-clamps to hold the side cutting edge on the
3. Cut through each corner of the bucket to the rear of bucket.
the bottom cutting edge.
5. Use E7018 welding rod and weld the side cutting
4. Remove the bottom cutting edge from the bucket. edge to the bucket with a 3/16 inch (5 mm) fillet weld all
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.
6. Use C-c1amps to hold the bottom cutting edge on the

bucket.
7. See the following illustration for weld locations and

specifications. Use E7018 welding rod and weld the
bottom cutting edge to the bucket.
1. 1-7/16 Inches (36.5 mm) B902089J

3. Fill Groove
4. 1-3/16 Inches (30 mm)
BurB-12741 Issued 3-91 Printed in U.S.A.

9006-12
BUCKET TEETH
Replacing a Tooth Point 5. Universal and heavy duty buckets only. See the fol-
lowing illustration for the weld specifications for the
1. Use a hammer and punch to remove the flex pin from corner bucket teeth. Use E7018 welding rod and weld
the tooth point. the tooth shanks in place.
2. Install the flex pin so that the shoulders are toward the
cutting edge.
3. Install a new tooth point and drive a new flex pin into
the tooth point.
Replacing a Tooth Shank

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 illus-

trations on the following page for correct location of the
bucket teeth.
B861750R
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 1. 11/16 Inch (17 mm)
welding rod to weld the tooth shanks in place. 2. 7/8 Inch (20 mm) No Weld
3. No Weld, Top Only
4. First Weld. 7/16 Inch (10 mm) Flare Bevel Weld.
Second Weld. 7/16 Inch (10 mm) Fillet Weld.
5. Bottom All Around 5/16 Inch (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

9006-13
B872455J
1. Center Tooth 5. 16 In (406 mm) Bucket - 7.0 In (177.9 mm)

2. 0.50 In (12.7 mm) 24 In (610 mm) Bucket - 10.98 In (279 mm)
3. 18 In (457 mm) Bucket - 5.18 In (131.5 mm) 30 In (762 mm) Bucket - 14.0 In (355.7 mm)
24 In (610 mm) Bucket - 7.13 In (181 mm) 36 In (914 mm) Bucket - 22.44 In (570 mm)
30 In (762 mm) Bucket - 8.86 In (225.1 mm) 6. 36 In (914 mm) Bucket - 17.0 In (432 mm)
36 In (914 mm) Bucket - 7.64 In (194 mm) 7. 24 In (610 mm) Bucket - 16.34 In (415 mm)
4. 18 In (457 mm) Bucket - 10.83 In (275 mm) 30 In (762 mm) Bucket - 20.65 In (524.4 mm)
36 In (914 mm) Bucket - 11.57 In (294 mm) 36 In (914 mm) Bucket - 27.83 In (707 mm)
Tooth Location for High Tooth Location for Standard Duty

Capacity Buckets Trenching Buckets
1 B90203BJ 1 B902038J
1. Centerline 1. Centerline
2. Center Tooth 2. Center Tooth
3. 24 In (610 mm) Bucket - 4.3 In (109 mm) 3. 18 In (457 mm) Bucket - 3.56 In (90 mm)
30 In (762 mm) Bucket - 6.8 In (173 mm) 4. 24 In (610 mm) Bucket - 5.4 In (137 mm)
4. Put Tooth Shank as Near Corner as 5. Put Tooth Shank as Near Corner as
Possible and Keep Tooth Point Possible and Keep Tooth Point
0.5 In (12.7 mm) Outside of Cutting Edge 0.5 In (12.7 mm) Outside of Cutting Edge,
All Buckets Except 12 in (305 mm) Bucket
Which Is Even with Outside of Cutting Edge

9006-14
.......... , .
8902834J

9006-15
B902704J
Stabilizer Cylinder Hydraulic Installation

9006-16
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.

9006-17

Bur 8-12741
9006-18
B902B36J

9006-19
•
1. Tighten to 264 To 305 Pound-Inches (31 to 36 Nm)
B892343J
After Putting Backhoe in Transport Position Three Times

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

9006-21

9006-22
Dipper Cylinder Hydraulic Installation

9006-23
B902839J

Bur 8-12741
9006-24
\\'.'
6902958.1
ut
BuCKet cylinder \-IydrauliC Installation Witoo 8dendable Dipper
ISsued 3-91 printed in U.S.A
Bur 8_12741
9006-25
1. Wear Plate 8902713J

2. 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

9006-28
B902B40J
1. To Extension Cylinder
Printed in U.S.A
Issued 3-91
Bur B-12741
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

9008-3
REMOVING THE THREE-POINT HITCH

1. The attachment can stay on the three-point hitch. 9. Loosen and remove the nuts, lock washers and bolts
Lower the attachment to the floor. that hold the mounting bracket and remove the
mounting bracket assembly.
2. Move the control levers in either direction to relieve
any pressure in the circuits. 10. Raise the rear wheels off the floor and use accept-
able supports to hold the machine in place.
3. Disconnect all hoses from the three-point hitch
control valve one at a time and and fasten an identifica- 11. Loosen and remove the wheel nuts and the wheels.
tion tag to each hose.
12. Fasten acceptable lifting equipment to the three-
4. Install caps on the fittings and plugs in the hoses. point hitch to hold the three-point hitch in place when
the bolts are removed.
5. For machines with a ROPS cab, loosen and remove
the nuts, lock washers, flat washers and bolts that hold 13. Loosen and remove the nuts, hardened washers
the top closure panel. and bolts that hold the three-point hitch.
6. Remove the top closure panel. IMPORTANT: Before the engine can be started, the
inlet and outlet hoses must be connected together. To
7. For machines with a ROPS canopy, loosen and connect the hoses together, use tube union 218-854.
remove the nuts, lock washers and bolts that hold the
cover and remove the cover. 14. Move the machine away from the three-point hitch.
8. Fasten acceptable lifting equipment to the mounting IMPORTANT: If the three-point hitch is not to be in-
bracket for the control levers and the three point hitch stalled again, the rear counterweight or backhoe must
control valve. be installed before the machine can be used.
INSTALLING THE THREE-POINT HITCH

1. Move the machine into alignment with the three-point 8. Install the cover or top closure panel and the bolts,
hitch. flat washers, lock washers and nuts. Tighten the nuts.
2. Install the hardened washers and bolts and the 9. Connect the hoses to the three-point hitch control
hardened washers and nuts. valve.
3. Tighten the nuts to 380 to 455 pound-feet (515 to 615 10. With the engine running at low idle, operate each
N m). cylinder through three complete cycles to remove any
air from the circuits.
4. Install the rear wheels and the wheel nuts. Do not use
an impact wrench to install the wheel nuts. 11. Stop the engine and check for oil leaks.
5. Tighten the wheel nuts to 320 to 380 pound-feet (435 12. Check the level of the oil in the reservoir and add oil
to 515 N m). as required
6. Lower the wheels to the floor.
7. Align the mounting bracket assembly with the three-

point hitch and install the bolts, lock washers and nuts.
Tighten the nuts.

9008-4
Bur 8-12761
Issued 3-91 .
Printed in U.S.A
9008-5
B902761J

Bur 8-12761
9008-6

Section
9009
SEAT AND SEAT BELT
© 1996 Case Corporation Bur 8-12770 Printed in U.S.A.

9009-2
TABLE OF CONTENTS
STANDARD SEAT INSTALLATION ... 3
EXPLODED VIEW OF STANDARD SEAT. .. . 4
SUSPENSION SEAT INSTALLATION .................. . 5
EXPLODED VIEW OF SEAT SUPPORT .... . 6

9009-3
B891367J

Standard Seat Installation
Bur 8-12770 lssuec 11-89 Printed in USA

9009-4
5. BACK
CUSHION
B870238R
Standard Seat
Issued 11·89 Printed in U.S.A.

Bur 8·12770
9009-5
""
B891368J

Suspension Seat Installation

9009-6
2. SWIVEL LEVER
7. HEIGHT ADJUSTER
B 5. SLIDE TUBE BELLOWS

4. SHAFT
B891369J
Seat Support

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

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 shaft.
remove the knob.
STEP 6
STEP 3
Loosen and remove the cap screws that hold the seat.
Use a prybar and remove the cover.

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 ab-
sorber and remove the pivot pin.
Remove the springs.
STEP 9
STEP 12
Remove an E-ring from the pivot pin that holds the

shock absorber and remove the pivot pin and the shock The adjuster rod is threaded into the bottom of the
absorber. spring seat. Install the punch through the hole in the
adjuster rod and turn the adjuster rod out of the spring
seat.

9010-5
STEP 13 STEP 17
Remove the spring seat.
STEP 14
Loosen and remove the cap screws that hold the base.
STEP 18
Remove the springs.
STEP 15
Remove the cotter pins and pivot pins that fasten the
housing to the base.
STEP 16
Remove the base.
Remove the housing.

9010-6
2. SHOCK ABSORBER
4. ADJUSTER SPRING
f 11. COTTER PIN
B870242R

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 Install the springs.
housing.

9010-8
STEP 27 STEP 30
Install and tighten the self-locking nut on the bottom of Install the seat.
the adjuster rod.
STEP 31
STEP 28
Install and tighten the cap screws that hold the seat.
Install the shock absorber, pivot pin and E-ring ..
STEP 32
STEP 29
Raise the boot and install the shaft.

Align the piston rod eye with the brackets and install the
pivot pin and E-ring.

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
STEP 36
Install the cover.

Fasten the boot to the slide.

9010-10
2. SEAT BACKREST
3. SEAT CUSHION
14. LH COVER
10. BOOT

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Case 580 Super K

Backhoe • Loader • Tractor

Description Section No Form No

Fuel System Tab 3

Power Train Tab 6

Mounted Equipment Tab 9

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

Detailed Engi ne Specifications ................................................................................................................................1024

CASE CORPORATION Bur 8-16230 Printed in U.S.A.

Torque Specifications - Decimal Torque Specifications - Steel Hydraullc

Torque Specifications - Metric Hardware ...1001-3 Torque Specifications - O-ring Face

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

TORQUE SPECIFICATIONS - METRIC HARDWARE

These values apply to fasteners with coarse

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fittings Straight Threads with O-ring

1/4 in 7/16-20 6-12 8-16 1/4 in 7/16-20 12-19 16-25

5/16 in 1/2-20 8-16 11-21 5/16 in 1/2-20 16-25 22-23

3/8 in 9/16-18 10-25 14-33 3/8 in 9/16-18 25-40 34-54

1/2 in 3/4-16 15-42 20-56 1/2 in 3/4-16 42-67 57-90

5/8 in 7/8-14 25-58 34-78 5/8 in 7/8-14 58-92 79-124

3/4 in 1-1/16-12 40-80 54-108 3/4 in 1-1/16-12 80-128 108-174

l/8.in 1-3/16-12 60-100 81-135 7/8 in 1-3/16-12 100-160 136-216

1.0 in 1-5/16-12 75-117 102-158 1.0 in 1-5/16-12 117-187 159-253

1-1/4 in 1-5/8-12 125-165 169-223 1-1/4 in 1-5/8-12 165-264 224-357

1-1/2 in 1-7/8-12 210-250 285-338 1-1/2 in 1-7/8-12 250-400 339-542

Split Flange Mounting Bolts

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

TORQUE SPECIFICATIONS - O-RING FACE SEAL FITTING

O-ring Face Seal End O-ring Boss End

-6 3/8 in 11/16-16 18-20 24-27 9/16-18 25-30 33-40

-8 1/2 in 13/16-16 32-40 43-54 3/4-16 45-50 61-68

-10 5/8 in 1-14 46-56 60-75 7/8-14 60-65 81-88

-12 3/4 in 1-3/16-12 65-80 90-110 1-1/16-12 85-90 115-122

-14 7/8 in 1-3/16-12 65-80 90-110 1-3/16-12 95-100 129-136

-16 1.0 in 1-7/16-12 92-105 125-140 1-5/16-12 115-125 156-169

-20 1-1/4 in 1-11/16-12 125-140 170-190 1-5/8-12 150-160 203-217

-24 1-1/2 in 2-12 150-180 200-254 1-7/8-12 190-200 258-271

FLUIDS AND LUBRICANTS

CASE CORPORATION Bur 8-12271 Printed in U.S.A.

ENGINE OIL RECOMMENDATIONS . . 3

CAPACITIES AND LUBRICANTS

Engine Cooling System

Front Axle - Four Wheel Drive

Bur 8-12271 Issued 3-91 Printed in U.S.A.

ENGINE OIL RECOMMENDATIONS

If Case IH No.1 Multi-Viscosity or Single

AMBIENT AIR TEMPERATURE RANGES

Bur 8-12271 Issued 3-91 Printed in U.S.A.

The diesel fuel used in this machine

Specifications for Acceptable NO.2 Diesel Fuel

API gravity, minimum .. 34

Bur 8-12271 Issued 3-91 Printed in U.S.A.

Copyright© 1991 J I Case Company

ENGINE SPECIFICATION DETAILS

Service Cylinder Sleeve..... . 5

Cylinder Head. .. ................... 6

Rocker Arm Assembly. .............. 10

Valve Seat Installation Dimensions 11