580L Manual Servicio

2000
Section
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION Copyright © 1999 Case Corporation
3350 South Service Road Printed in U.S.A.
Hamilton, ON L7N 3M6 CANADA Bur 7-49651 Issued May, 1995 (Revised March, 2000)
2000-2
TABLE OF CONTENTS
RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLING THE FRONT ENGINE SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bur 7-49651 Revised 3-00 Printed in U.S.A.

2000-3
RADIATOR REMOVAL
Put identification tags on all disconnected hoses and STEP 4
wires. Close disconnected hoses and fittings with
caps and plugs.
STEP 1
BP9502286
Have another per s on hel p wi th the followin g

procedure.
A. Open the hood.
BP9502285
Park the machine on a level surface. Raise the loader B. Remove the retainers from the hood struts (1)
and lock the support strut (1) to hold the loader. Stop and disconnect the hood struts from the stud.
the engine and apply the parking brake.
C. Hold the hood in place and disconnect the
hood cable from the radiator shroud on the
STEP 2 other side of the machine.
D. Carefully lower the hood back to the closed
position.
4
2
STEP 5
1
3
BP9502315
Remove the caps screws (1), upper (2) and lower

bumpers (3), and the grille (4) from the front of the
machine.
STEP 3 BP9502288
Remove the bolts, washers, and nuts from the pivot Drive the pivot tubes out of the hood pivot point.
point on the hood. Remove the hood from the machine.

2000-4
STEP 6 STEP 8
BP9502290 BP9502290
Slowly remove the radiator cap. Install a hose on the Loosen the clamp (1) and disconnect the lower
drain valve and drain the radiator into a clean radiator hose.
container that holds approximately 17 litres (18 U.S.
quarts). STEP 9
NOTE: During installation, fill the radiator and
coolant reservoir completely. See Section 1002 for
coolant specifications. Start and run the engine until
1
the coolant is at operating temperature. Stop the
engine and check for leakage. When the coolant is
cold, check the coolant reservoir level. Add coolant
as required.
STEP 7
1
1 2
BP9502291
Remove the bolts (1), spacers, washers, and coolant

reservoir from the machine.
NOTE: During installation tighten the bolts to a
torque of 5 to 6 Nm (45 to 55 pound-feet).
BP9502292
Disconnect the overflow hose (1) from the radiator

neck. Loosen the clamp and disconnect the upper
radiator hose (2).

2000-5
STEP 10 STEP 12
2
3
BP9502293 BP9502293
Remove the hardware from the fan shroud. Move the Use a sharp knife and cut the warning decal (1).
fan shroud away from the radiator. Remove the cap screws that fasten the lower
brackets (2) to the radiator. Remove the hardware
NOTE: During installation tighten the cap screws to
and the lower brackets (2) from the radiator shroud.
a torque of 26 to 31 Nm (19 to 23 pound-feet).
Remove the cap screws and flat washers that fasten
the upper brackets (3) to the radiator. Remove the
STEP 11 cap screws and flat washers (4) that fastens the
condenser if equipped and oil cooler to the radiator.
Lift the radiator straight up and remove the radiator
from the machine
1 NOTE: Installation of the radiator is the reverse of
1 removal.
2
BP9502314
Remove the cap screws (1) and pump guard (2) from
the machine.

2000-6
ENGINE REMOVAL
Put identification tags on all disconnected hoses and STEP 3
wires. Close disconnected hoses and fittings with
caps and plugs.
STEP 1
B9410098
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
BP9502285 from the battery. Make sure the jumper cable is
Park the machine on a level surface. Raise the loader installed on the terminal and start the terminal nut
and lock the support strut to hold the loader. onto the terminal.
STEP 2 STEP 4
Drain the oil from the hydraulic reservoir.
NOTE: During installation fill the hydraulic reservoir
with the oil specified in section 1002 of this manual.
STEP 5
4
2
1
PHOTO_ID_NUMB 3
BP9410097
Remove the battery cover from the right step. If the

machine has only one batter y, disconnect the
negative battery cable from the battery.
BP9502315
Remove the caps screws (1), upper (2) and lower

bumpers (3), and the grille (4) from the front of the
machine.
STEP 6
Remove the bolts, washers, and nuts from the pivot
point on the hood.

2000-7
STEP 7 STEP 9
BP9502286 BP9502290
Have another per so n hel p with the followin g Slowly remove the radiator cap. Install a hose on the
procedure. drain valve and drain the radiator into a clean
container that holds approximately 17 litres (18 U.S.
A. Open the hood.
quarts).
B. Remove the retainers from the hood struts (1)
NOTE: During installation, fill the radiator and
and disconnect the hood struts from the stud.
coolant reservoir completely with coolant. See
C. Hold the hood in place and disconnect the Section 1002 for coolant specifications. Start and run
hood cable from the radiator shroud on the the engine until the coolant is at operating
other side of the machine. temperature. Stop the engine and check for leakage.
When the coolant is cold, check the coolant reservoir
D. Carefully lower the hood back to the closed
level. Add coolant as required.
position.
STEP 10
STEP 8
1 2
BP9502292
BP9502288
Disconnect the overflow hose (1) from the radiator
Drive the pivot tubes out of the hood pivot point.
neck. Loosen the clamp and disconnect the upper
Remove the hood from the machine.
radiator hose (2).

2000-8
STEP 11 STEP 14
1
1
1
2
BP9502290 BP9502314
Loosen the clamp (1) and disconnect the lower Remove the cap screws (1) and pump guard (2) from
radiator hose. the machine.
NOTE: If the machine is equipped with air
STEP 12 conditioning and a baffle plate with a slot for the drier
hose, go to step 24. If the machine is equipped with
air conditioning and a baffle plate with out a slot for
1 the drier hose, do steps 20 through 22 to keep from
discharging the air conditioning system. For
machines without air conditioning, do steps 15
through 19.
STEP 15
BP9502291
Remove the bolts (1), spacers, washers, and coolant

reservoir from the machine.
NOTE: During installation tighten the bolts to a
torque of 5 to 6 Nm (45 to 55 pound-feet).
STEP 13
BP9502294
Loosen and remove the cap screws, flat washers,

and if equipped, lock washers that fasten the baffle
plate to the front of the machine.
BP9502293
Remove the hardware from the fan shroud. Move the

fan shroud away from the radiator.

2000-9
STEP 16 STEP 21
Loosen and remove the cap screws, flat washers,
and if equipped, lock washers that fasten the baffle
plate to the front of the machine.
STEP 22
Move the baffle plate and drier for access to the
hoses on the left side of the oil cooler.
STEP 23
Go to Step 27.
NOTE: Do steps 24 and 25 for machines with air
conditioning and a baffle plate with a slot.
BP9502313
Disconnect the hoses from the oil cooler.

STEP 24
STEP 17
1
2
2
BP9503103
Remove the self-locking nut and clamp from the

BP9503100
drier.
Remove the studs (1). Remove the bolts (2) and nuts
that fasten the radiator shroud to the frame. NOTE: During installation tighten the self locking nut
to a torque of 26 to 31 Nm (19 to 23 pound-feet).
NOTE: During installation tighten the studs (1) to a
torque of 52 to 61 Nm (38 to 45 pound-feet). Tighten
the bolts (2) to a torque of 434 to 515 Nm (320 to 380
pound-feet).
STEP 18
Remove the radiator shroud, radiator, and oil cooler
as an assembly.
STEP 19
Go to step 34.
NOTE: Do steps 20 through 22 for machine with air
conditioning and a baffle plate without a slot.
STEP 20
Remove all straps that hold the hose for the air
conditioning system drier from the front of the
machine back to the cab. It is important to have as
much hose as possible at the front of the machine to
do the next step.

2000-10
STEP 25 STEP 27
3
2
BP9503104 BP9502293
Remove the cap screws, flat washers, and if Use a sharp knife and cut the warning decal (1).
equipped, lock washers that fasten the baffle plate to Remove the cap screws that fasten the lower
the front of the machine. Remove the baffle plate brackets (2) to the radiator. Remove the hardware
from the drier and the machine. and the lower brackets (2) from the radiator shroud.
the upper brackets (3) to the radiator.
NOTE: Do the remaining steps for all machines.
STEP 26 STEP 28
1
2 2
BP9503106
BP9503100
Put a block under the oil cooler to hold the radiator,
Remove the studs (1) from the frame. Remove the
oil cooler, and condenser in place when the radiator
bolts and nuts (2) that fasten the radiator shroud to
shroud is removed.
the frame.
STEP 29
Remove the radiator shroud from the radiator, oil
cooler, and condenser.

2000-11
STEP 30 STEP 33
BP9503108 BP9503110
Disconnect the electrical connector for the drier. Pull the foam baffle away from the condenser.
NOTE: Apply adhesive to the baffle during the
STEP 31 installation procedure before installing the baffle.
STEP 34
BP9503109
Disconnect the hoses from the oil cooler on both

sides of the oil cooler.
BP9503111
For machines with a slot in the baffle plate, move the

STEP 32 condenser and drier assembly out of the way as
shown. For machines without a slot in the baffle
plate, have another pers on help to move the
condenser, baffle plate, and drier assembly away
from the radiator and oil cooler assembly and fasten
the assembly out of the way.
BP9503107

the condenser and oil cooler to the radiator.

2000-12
STEP 35 STEP 38
3
1
1
BP9503112 BP9503116
Remove the radiator and oil cooler. Remove the fan Disconnect the electrical connector (1). Remove the
shroud (1) from the fan. tie strap (2). Remove the hardware (3) from the
adjusting straps.
STEP 36
STEP 39
BP9502312
Disconnect the hoses (1) from the LH side of the BP9503114
pump. Remove the bolts and lock washers that Remove the hardware that fastens the compressor to
fasten the flange (2) on the RH side of the pump. the bracket.
STEP 37 STEP 40
BP9502311 BP9503120
Loosen and remove the cap screws that fasten the Remove the belt and lay the compressor over the
pump to the pump mounting bracket. side of the frame.
NOTE: Do steps 38 through 40 for machines with air NOTE: During installation, adjust the drive belt
conditioning. according the instructions in Section 9003.

2000-13
STEP 41 STEP 44
4
3 1
BP9502309 BP9502303
Loosen the clamp for the exhaust pipe at the muffler. If the machine has ether injection, remove the tie
Remove the exhaust pipe from the muffler. straps (1) and sleeve (2) from the tube (3) and wire
(4). Disconnect the tube (3) and the wire (4).
STEP 42
STEP 45
4
1 1
3
2
3
2
BP9502308
Remove the tie strap (1). Disconnect the electrical BP9502304
connectors (2) for the air restriction indicator. Loosen Disconnect the throttle rod (1). Disconnect the wiring
the clamp (3) on the air cleaner hose. Disconnect the clamp (2). Disconnect the wire from the oil pressure
hose from the air cleaner. sender (3). Disconnect the fuel shutoff wire (4).
STEP 43 STEP 46
BP9502306 BP9502302
Remove the cap screws and flat washers that fasten Disconnect the fuel lines (1) and (2).
the cover to uprights. Remove the cover and air
cleaner as an assembly.

2000-14
STEP 47 STEP 49
1
1
2
BP9502301 BP9502296
Disconnect the heater hose (1). Remove the harness clamps (1). Disconnect the
wires (2) from the alternator.
STEP 48
STEP 50
BP9502298
Disconnect the coolant temperature sender (1) and BP9502297
coolant temperature switch (2). Loosen the clamp and disconnect the heater hose.

2000-15
STEP 51 STEP 53
BP9502316 BP9502305
Disconnect the ground strap (1). Disconnect the Connect lifting equipment to the lifting eyes on the
wires (2) from the starter. engine to hold the engine in place.
NOTE: There are six cap screws with lock washers
STEP 52 that fasten the torque converter to the flywheel. The
engine must be rotated to align each cap screw with
the access hole in the flywheel housing at the left
side of the engine.
STEP 54
Remove the plastic plug from the flywheel housing.
Remove the hose from the bracket and remove the
cover and gasket from the access hole for the cap
screws.
STEP 55
BP9502310
Remove the bolts, flat washers, and nuts from the

front engine mount.
NOTE: During installation, tighten the self-locking
nuts to 41 to 47 Nm (360 to 420 pound-inches).
BP9502299
Install the CAS-1690 tool to turn the flywheel for

access to the cap screws.

2000-16
STEP 56 STEP 57
Loosen and remove the 12 cap screws and flat
washers that fasten the transmission to the engine.
Move the heater hose and clamps out of the way.
STEP 58
Move the engine forward and raise the engine.
Remove the engine from the machine.
NOTE: Installation of the engine is the reverse of
removal.
IMPORTANT: Before starting the engine. do the
following.
BP9502300 1. See section 1002 Fluids and Lubricants in this
Loosen and remove all six cap screws and lock manual for the correct type and quantities
washers that fasten the torque conver ter to the needed to replace lost or drained fluids and
flywheel. lubricants before starting the engine.
NOTE: Be careful during installation when installing 2. The turbocharger must be filled with oil.
the cap screws and lock washers that fasten the Dis connect the wire fr om the fuel shutoff
torque converter to the flywheel. Tighten the cap solenoid. Actuate the starter for 10 to 20 seconds
screws to 52 to 57 Nm (38 to 42 pound-feet). to fill the turbocharger with oil. Connect the wire
to the fuel shutoff solenoid.
3. The hydraulic pump must be filled with oil. Do
the following procedure to fill the hydraulic pump
with oil:
A. Fill the hydraulic reservoir Make sure the oil
level in the hydraulic reservoir is correct.
B. Remove the cap from the hydraulic reservoir.
C. Use a nozzle and shop air to pressurize the
hydraulic reservoir. Wrap a shop cloth around
the end of the hose at the nozzle.
NOTE: 34.5 kPa (5 psi) to 69.0 kPa (10 psi) is all that
is required to move the oil. Pressure above 69.0 kPa
(10 psi) can damage the hydraulic reservoir.
D. Have another person start and run the engine
at low idle while shop air is being applied to
the hydraulic reservoir.

2000-17
4
1
2
BC00E068
1. RADIATOR 3. COOLANT RECOVERY BOTTLE 5. OIL COOLER

2. FAN SHROUD 4. BAFFLE 6. AIR CONDITIONING CONDENSER
RADIATOR INSTALLATION

2000-18
4 5
6
2
6 B9503082T
B9503082T
8 5
7 B9503082T
B9503082T
B9503082T
1. RADIATOR SHROUD 3. NUT 5. CAP SCREW 7. GROMMET

2. BOLT, RADIATOR SHROUD 4. BRACKET, RADIATOR 6. FLAT WASHER, SPECIAL 8. SPACER
TO CHASSIS FRAME SHROUD TO RADIATOR
RADIATOR SHROUD

2000-19
6
5
7
6
8
BC00F052
1. ENGINE MOUNT 3. HARDENED WASHER 5. BOLT 7. INSULATOR

2. CAP SCREW 4. SPACER 6. HARDENED WASHER 8. HARDENED WASHER
9. SELF-LOCKING NUT
FRONT ENGINE MOUNT INSTALLATION

2000-20
INSTALLING THE FRONT ENGINE SUPPORT

NOTE: If the front engine support was removed for STEP 3
any reason, the front engine support must be aligned
with the crankshaft for the engine. If the front engine
support is not aligned with the crankshaft of the
engine, the pump can be damaged.
STEP 1
B8976018M
Remove the plastic plug at the left front of the

flywheel housing.
STEP 4
BC00F052
Install a spacer in each top hole in the front engine

support. Install the front engine support with the
hardware shown.
B8976015M
STEP 2
Install the CAS-1690 tool to rotate the flywheel.
B897003M
Use a dial indicator to check the alignment of the

front engine support.

2000-21
STEP 5 STEP 7
B8976003M B8976018M
Rotate the flywheel and read the dial indicator. The Remove the CAS-1690 tool and install the plastic
front engine suppor t must be centered with the plug.
crankshaft within 0.25 mm (0.010 inch). If you are
unable to center the engine suppor t within the
specifications, you must replace the front engine
support.
STEP 6
B8976006M
When the front engine support is centered, tighten

the cap screws to 89 to 107 Nm (66 to 79
pound-feet).

2000-22
NOTES

Section
4003
4003
BATTERY(S)
CASE CORPORATION
700 STATE STREET
RACINE, WI 53404 U.S.A.
3350 SOUTH SERVICE ROAD Bur 7-49440 Printed in U.S.A.
BURLINGTON, ON L7N 3M6 CANADA Issued May 1995
4003-2
TABLE OF CONTENTS
SAFETY RULES .......................................................................................................................................................... 3
SPECIAL TOOLS ........................................................................................................................................................ 3
MAINTENANCE .......................................................................................................................................................... 4
Electrolyte Level ...................................................................................................................................................... 4
Inspecting and Cleaning a Battery .............................................................................................................................. 4
NONSPILL CAPS ........................................................................................................................................................ 5
BATTERY TEST .......................................................................................................................................................... 6

Visual Checks ......................................................................................................................................................... 6
Specific Gravity Check .............................................................................................................................................. 6
Capacity (Load) Test .................................................................................................................................................................. 7
CHARGING A BATTERY ............................................................................................................................................................... 8
PREPARING A DRY CHARGED BATTERY FOR USE ................................................................................................................... 9
NOTE: Case Corporation 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.
Bur 7-49440 Issued 3-95 Printed in U.S.A

Template Name: SM_2_col Alt= to hide template information
Template Date: 1994_04_05 Alt+ to display template information
4003-3
SAFETY RULES
Never try to charge the battery if the electrolyte in the If the battery(s) in this machine must have nonspill
battery is frozen. caps, do not operate the machine if the nonspill caps
47-83A do not work correctly, or if the nonspill caps are not in
place.
48-99A
Never cause sparks to occur or smoke near batteries

that are charging or have been recently charged.
13-8A Battery acid causes severe burns. Batteries contain
sulfuric acid. Avoid contact with skin, eyes, or clothing.
Antidote: EXTERNAL-Flush with water. INTERNAL-
Drink large quantities of water or milk. Follow with milk
Disconnect the ground cable first when the battery of magnesia, beaten egg, or vegetable oil. Call physi-
cables are disconnected from the battery. cian immediately. Eyes: Flush with water for 15 min-
Connect the ground cable last when the battery cables utes and get prompt medical attention.
are connected to the battery.
47-55A Batteries produce explosive gases. Keep sparks,
flame, and cigarettes away. Ventilate when charging or
using in enclosed area. Always shield eyes when work-
ing near batteries.
Some batteries have a ventilation tube. If there is
battery acid in the ventilation tube, this battery acid can Keep out of reach of children.
be released when the battery is turned upside down. If D-47-53A
you turn the battery upside down, make sure that the
end of the ventilation tube is away from you and away
from any other people in the area. Battery acid can
cause severe burns.
48-57B
SPECIAL TOOLS
B795328M
The CAS-10147 tester is used to do the Capacity (Load)

Test. This tool is first used on page 4003-7.
Bur 7-49440 Issued 5-95 Printed in U.S.A.

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

4003-5
NONSPILL CAPS
See Specifications in Section 4002 to find if the battery(s) The nonspill caps have a valve with a stem made of
in your machine must have nonspill caps. lead and rubber. When the nonspill cap is turned up-
side down, the weight of the lead holds the rubber
WARNING: If the battery(s) in this machine must stem against the breather hole, preventing the loss of
have nonspill caps, do not operate the machine if the electrolyte.
nonspill caps do not work correctly or if the nonspill
caps are not in place. If the breather hole and valve are closed by foreign mate-
48-99A
rial, pressure in the battery can become high enough to break
the case of the battery. Always check the breather hole for for-
Do not operate the machine if the nonspill caps do not work eign material when you check the electrolyte level. If there is
correctly or if the nonspill caps are not in place. Nonspill caps foreign material over the breather hole, turn the nonspill cap
prevent electrolyte leakage which can cause personal injury upside down and clean the nonspill cap. Move the nonspill cap
and damage to the machine if the machine turns over in an ac- up and down rapidly. You must be able to hear the movement
cident. 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 condition 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 re-
place nonspill caps.
When you install a new battery, the new battery MUST

have nonspill caps. You can use the nonspill caps from the old
battery if the nonspill caps are in good condition.
B800305M

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

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

charged for 15 minutes at 15 to 25 amperes to mix the
water with the electrolyte.
Specific Gravity Check B790863J
A hydrometer is used to check the specific gravity (weight)

of the electrolyte. The specific gravity is an indication of the 1. Temperature in °F 2. Temperature in °C
level of charge for each cell. Specific Gravity Chart
Hydrometers are made to show the correct specific gravity 4. Make a record of the corrected specific gravity reading for
when the temperature of the electrolyte is 80°F (26.7°C). each cell.
When you check the specific gravity, you must know the 5. If the difference between the high reading and the low
temperature of the electrolyte. If your hydrometer does not reading is 0.050 or more, charge the battery and check
have a thermometer, get a thermometer to check the temper- the specific gravity again. If after charging, the difference
ature of the electrolyte. The thermometer must indicate a high is still 0.050 or more, install a new battery.
temperature of at least 120°F (52°C).
6. The corrected specific gravity reading shows the level of
1. Remove enough electrolyte from a cell so that the float is charge for the cell. The level of charge must be at least
free in the tube. 75% in each of the cells. In maintenance free batteries
NOTE: If the specific gravity cannot be checked without first the level of charge is at least 75% if the corrected specific
gravity reading is 1.240 or higher. In all other batteries the
adding water to the cell, the battery must be charged for 15
level of charge is at least 75% if the corrected specific
minutes at 15 to 25 amperes to mix the water with the electro- gravity reading is 1.230 or higher.
lyte. Then check the specific gravity.
7. If the difference between the high reading and the low
2. Read the float. reading is less than 0.050, and the level of charge is at
least 75% in all of the cells, do the Capacity (Load) Test.
3. Read the thermometer. If the reading is above 80°F
(26.7°C) add specific gravity points to the reading for 8. If the difference between the high reading and the low
specific gravity. If the reading is below 80°F (26.5°C) reading is less than 0.050, but the level of charge is less
subtract specific gravity points from the reading for than 75% in any of the cells, charge the battery and
specific gravity. See the following illustration and add or check the specific gravity again. If after charging:
subtract specific gravity points as needed.
A. The level of charge is less than 75% in any of the
cells, discard the battery.
B. The level of charge is at least 75% in all of the cells,

do the Capacity (Load) Test.

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 such as for at least one minute.
the Sun Electric VAT-33. Other test equipment can be used.
Connect the test equipment according to the instructions of 4. Apply a 15 ampere load to the battery for 15 seconds.
the manufacturer of the equipment. 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 0°F (-17°C).
B. Make sure the load control knob is in the OFF
position. 7. Turn the load control knob until the ammeter indicates the
specified load. Keep the load for 15 seconds and read the
C. Select the ammeter range that will measure 0 to voltmeter. Turn the load control knob to OFF.
1000 amperes.
8. Compare the test reading and the temperature of the
D. Move the volt lead switch to the INT. position. electrolyte to the chart below.
3. Connect the tester to the battery as shown. Temperature of Minimum

electrolyte Voltage
70°F (21°C) and above ................................................... 9.6
60°F (16°C) .................................................................... 9.5
2 50°F (10°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
0°F (-18°C) ..................................................................... 8.5
1
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
Before you charge the battery, check the level of the elec- The charging rate must be decreased if:
trolyte.
1. Too much gas causes the electrolyte to flow from the
It is difficult to give an exact charging rate because of the cells.
following variable conditions: (1) temperature of the electro-
lyte, (2) level of charge, and (3) condition of the battery. Use 2. The temperature of the electrolyte rises above 125°F
the charging guide for the correct charging rate and time. (52°C).
NOTE: For the best charge, use the slow charging rates.
See Specifications in Section 4002 for the reserve capac-
ity of the battery in this machine. The battery is fully charged when, over a three hour period
at a low charging rate, no cell is giving too much gas, and the
specific gravity does not change.
CHARGING GUIDE FOR MAINTENANCE FREE BATTERIES
Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity - See Reserve

Capacity under Specifications 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
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

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
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 electrolyte. 5. Charge the battery at 30 amperes until the specific
This will permit the volume of electrolyte to increase gravity is 1.250 or more and the temperature of the
when heated by charging the battery. electrolyte is at least 60°F (15.5°C).
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 of the cell
caps. See Specifications in Section 4002 to find if the opening.
battery in your machine must have nonspill caps.

4003-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
LUBRICATION ........................................................................................................................................................ 3
NO-LOAD TEST ...................................................................................................................................................... 3

General Information ............................................................................................................................................. 3
Test Equipment .................................................................................................................................................... 3
Test Procedure .................................................................................................................................................... 4
Understanding No-Load Test Results .................................................................................................................. 6
DISASSEMBLY ....................................................................................................................................................... 7
INSPECTION ......................................................................................................................................................... 11
Brushes and Brush Springs ............................................................................................................................... 11
Brush Holder ...................................................................................................................................................... 11
Armature ............................................................................................................................................................ 11
Field Coil Test .................................................................................................................................................... 12
ASSEMBLY ........................................................................................................................................................... 14
STARTER SOLENOID TEST ................................................................................................................................ 20

Starter Solenoid Test Procedure ........................................................................................................................ 20

4003-3
SPECIFICATIONS
Manufacturer ................................................................................................................................................... Denso
Nippondenso part number .................................................................................................................... 128000-0212
Case part number ................................................................................................................................... 1987559C1
No-Load Test at 80°F (26.7°C)
Volts ................................................................................................................................................................... 11
Current draw .................................................................................................................... 220 amperes maximum
Starter drive speed ...................................................................................................... 4200 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.
NOTE: The photos and illustrations in this section are typical. Your starter will have a device to keep you from jump
starting the machine on the switch terminal of the starter. See page 13 for correct illustration of your starter.
NO-LOAD TEST
General Information Test Equipment

1. The No-Load Test is done with the starter The No-Load Test can be done using a Sun
removed from the engine. Electric VAT-33 Tester, an equivalent tester, or
separate pieces of test equipment.
2. Check to see if you can pull the gear on the
starter drive out of the starter drive housing. A hand held tachometer is needed to measure
the speed of the armature shaft.
3. Check to see if the starter drive can be turned.
Pull the gear on the starter drive out of the starter A remote starter button is needed to actuate the
drive housing. Turn the gear clockwise to turn the starter.
star ter drive and the armature. Much force
A fully charged 12 volt battery is needed to supply
should be required to turn the gear. Turn the gear
the electricity to turn the starter.
counterclockwise; less force should be required
to turn the gear as the clutch will be slipping.
4. If the starter drive cannot be turned, disassemble
the starter and make repairs as needed. Then do
the No-Load Test.

4003-4
Test Procedure 3. Connect the positive battery cable to the battery

terminal on the starter solenoid and the negative
The illustrations in this procedure show the use of batter y cable to the mounting flange of the
the Sun Electric VAT-33 tester. Other test equipment starter.
can be used. Connect the test equipment according
to this procedure and the manufacturer’s instructions.
1. If the VAT-33 tester is being used:
A. Select the 0 to 100 ampere range.
B. Select the 18 to 40 volt range.
C. Move the volt lead switch to the EXT. 1 3
position.
D. Turn the load control to the OFF position.
B831430J
1. POSITIVE BATTERY CABLE
2. BATTERY TERMINAL
3. NEGATIVE BATTERY CABLE
4. Connect the positive load cable to the positive

post of the battery. Connect the negative load
cable to the negative post.
B795328M
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.
1
B831431J
1. POSITIVE LOAD CABLE
2. NEGATIVE LOAD CABLE

4003-5
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 starter.
B831432J
1. RED VOLTMETER LEAD
2. MOTOR TERMINAL
6. Connect the black voltmeter lead to the mounting

flange on the starter.
B831434J
1. AMMETER CLAMP
8. Connect the leads from the remote starter button

to the battery and switch terminals of the starter.
B831433J
1. BLACK VOLTMETER LEAD
1 2
B831435J
1. REMOTE STARTER BUTTON
2. BATTERY TERMINAL
3. SWITCH TERMINAL

4003-6
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
seconds at one time. After the battery has been causes of too much friction are:
loaded for 15 seconds, let the starter cool for 60
A. Tight, dirty, or worn bearings.
seconds.
B. A bent armature shaft.
9. Actuate the remote starter button and turn the
load control until the voltmeter indicates 11 volts. C. Loose pole shoes (pole shoes make contact
with the armature).
D. A short circuit in the armature coil.
4 3 Disassemble the starter. Use an armature
2 t e s t e r t o t e s t t h e a r m a t u r e. U s e t h e
instructions included with the armature
tester.
E. Damaged field coil. Do the test on page 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 12.
C. Damaged bearings.
1
4. If the armature does not rotate and the current
draw is zero, possible causes are:
A. An open field coil circuit. Disassemble the
star ter and inspect the field coil
connections.
5
B. An open armature coil. Disassemble the
starter and check for burned commutator
bars. Use an armature tester to test the
armature. Use the instructions included with
the armature tester.
B831436J
1. REMOTE STARTER BUTTON C. Brushes not making good contact with the
2. LOAD CONTROL commutator bars. Check for high insulation
3. VOLTMETER between the commutator bars, broken brush
4. AMMETER
springs, or worn brushes.
5. HAND HELD TACHOMETER
10. Look at the ammeter and record the ammeter 5. Low armature shaft speed and low current draw
indication. are indications of:
11. Use the hand held tachometer and check the A. Dirt or corrosion on connections.
armature shaft speed. Record the armature shaft B. Damaged wiring.
speed.
C. Dirty commutator bars.
12. Release the remote starter button and turn the
load control to the OFF position. D. All causes in step 4.
6. High armature shaft speed and high current draw
Understanding No-Load Test are indications of a short circuit in the field coil. It
is difficult to find a short circuit in a field coil.
Results Install a new field coil. Do the No-Load Test
1. If the current draw and the armature shaft speed again to check for improvement in the operation
are within the ranges under Specifications, the of the starter.
starter is good.

4003-7
DISASSEMBLY
STEP 1 STEP 4
B330731M B330735M
Pull back the boot on the motor terminal. Loosen and Remove the cover.
remove the nut and lock washer.
STEP 5
STEP 2
B330736M
B330732M Hold the spring away from one of the brushes

Loosen and remove the screws that hold the cover. connected to the field coil. Remove the brush from
the brush holder. Repeat this step for the other
brush.
STEP 3
STEP 6
B330733M
Loosen and remove the thru bolts.

B330737M
Remove the brush holder.

4003-8
STEP 7 STEP 10
B330738M B330741M
Remove the field frame assembly. Remove the starter drive housing from the starter
solenoid.
STEP 8
STEP 11
B330739M
Remove the armature. B330743M
Push down the starter drive housing as shown to

loosen and remove the starter drive.
STEP 9
STEP 12
B330740M
Fasten the starter solenoid in a vise and loosen and

remove the screws that hold the star ter drive B330744M
housing. Remove the steel ball from the star ter drive. If
necessary, use a magnet.

4003-9
STEP 13 STEP 16
B330701M B330704M
Remove the O-ring from the groove in the starter Remove the bearing cage.
drive housing.
STEP 17
STEP 14
B330705M
B330702M Remove the thrust washer.

Remove the spring.
STEP 18
STEP 15
B330706M
B330703M Loosen and remove the screws that hold the cover.
Remove the idler gear.

4003-10
STEP 19 STEP 21
B330707M B330709M
If necessary, use a hammer to loosen the cover. Remove the plunger.
STEP 20 STEP 22
B330708M B330710M
Remove the cover. If necessary, remove the gasket from the cover.

4003-11
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 2. Put the armature on vee-blocks as shown and
check the runout of the commutator with a dial
1. If the length of the brush fastened to the brush
indicator. The runout must not be more than 0.05
holder is less than13 mm (0.51 inch), a new
mm (0.002 inch).
brush holder assembly must be installed when
the starter is assembled.
2. If the length of a brush fastened to the field coil is
less than 13 mm (0.51 inch), a new field frame
assembly must be installed 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 3.5 and 4.5 kg
(7.7 and 9.9 pounds). If tension of a brush spring
is not as specified, install a new brush spring
when the starter is assembled.
B834918M
3. If necessary, put the armature in a lathe and

Brush Holder remove enough material from the commutator to
1. Hold the leads of an ohmmeter against the frame make the runout less than 0.05 mm (0.002 inch).
and the brush holders that have insulation 4. Measure the diameter of the commutator. If the
between the brush holder and frame. diameter is less than 42 mm (1.65 inch), install a
new armature.
B313142M
2. If ohmmeter indicates continuity, install a new

B313141M
brush holder.
5. If the depth of the groove between the
commutator bars is less than 0.2 mm (0.008
inch), cut the insulation between the commutator
bars to a depth of 0.7 to 0.9 mm (0.0276 to
0.0354 inch). Use fine grit sandpaper to remove
the rough edges from the commutator bars.

4003-12
6. Check the bearings on the armature for free
rotation, rough balls, and damage to the inner
race or outer race. If a bearing is to be replaced,
use a press and acceptable tools to remove and
install the bearing.

4003-13
2
1 3 4
5 6
7
9 5
8
12
10 16 14
13
11 17
15
14
18
27 19
20
21
28
23
22
27
25
24
25
26 31
29 30
32
5
3 2
BS98E108
1. SCREW 9. BEARING CAGE 17. PLUNGER 25. FIELD FRAME ASSEMBLY
2. LOCK WASHER 10. IDLER GEAR 18. SCREW 26. BRUSH HOLDER
3. FLAT WASHER 11. STARTER SOLENOID ASSEMBLY 19. LOCK WASHER 27. BEARING
4. STARTER DRIVE HOUSING 12. ROLLER 20. GASKET 28. ARMATURE
5. O-RING 13. THRUST WASHER 21. SOLENOID COVER 29. COVER
6. STARTER DRIVE 14. NUT 22. SCREW 30. SCREW
7. STEEL BALL 15. LOCK WASHER 23. WASHER 31. LOCK WASHER
8. SPRING 16. SPRING WASHER 24. BRUSH 32. THRU BOLT

4003-14
Field Coil Test
1. Hold the leads of an ohmmeter against one lead

o f t h e f i e l d c o i l an d t he f i e l d f ra m e. T h e
ohmmeter must indicate an open circuit (infinity).
B610614M
2. If the ohmmeter does not indicate an open

circuit, install a new field frame assembly.
3. Hold the leads of the ohmmeter against one of
the br ushes and the end of the cable. The
ohmmeter must indicate continuity.
4. Hold the leads of the ohmmeter against the other
brush and the end of the cable. The ohmmeter
must indicate continuity.
B610616M
5. If the ohmmeter does not indicate continuity,

install a new field frame assembly.

4003-15
ASSEMBLY STEP 26
STEP 23
B330712M
Install and tighten the screws to 2.65 to 4.61 Nm (23

to 41 lb-in).
B330709M
Install the plunger in the starter solenoid.

STEP 27
STEP 24
B330714M
Install the rollers in the bearing cage.

B330711M
If necessary, install a new gasket in the cover.

STEP 28
STEP 25
B330715M
Lubricate the rollers and teeth of the idler gear with

B330708M Case Multipurpose Grease.
Install the cover.

4003-16
STEP 29 STEP 32
B330834M B330837M
Install the thrust washer. Install the spring.
STEP 30 STEP 33
B330704M B330838M
Install the bearing cage as shown. Install a new O-ring in the groove in the starter drive
housing. Lubricate the O-ring with grease.
STEP 31
STEP 34
B330703
Install the idler gear. B330841M
Lubricate the open bearing on the starter drive with

Case Multipurpose Grease.

4003-17
STEP 35 STEP 38
B330802M B330741M
Start the starter drive into the starter drive housing. Assemble the star ter drive housing and star ter
solenoid.
STEP 36
STEP 39
B330803M
Push down the starter drive housing to push the B330805M
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 with grease.
STEP 37
STEP 40
B330804M
Put a small amount of grease in the hole in the

starter drive and install the steel ball in the hole. B330807M
Install the screws in the starter drive housing.

4003-18
STEP 41 STEP 44
B330740M B330808M
Fasten the starter solenoid in the vise and tighten the Use the springs to hold the brushes in the brush
screws that hold the starter drive housing. Tighten holder as shown.
the screws to 6.86 to 11.8 Nm (5 to 9 lb-ft).
STEP 45
STEP 42
B330809M
B330739M Install the brush holder.

Install the armature.
STEP 46
STEP 43
B330810M
B330738M Put the springs on top of the brushes connected to

Install the field frame assembly. the brush holder.

4003-19
STEP 47 STEP 50
B330811M B330814M
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
B330812M
Use a thru bolt to align the brush holder with the field B330732M
frame assembly and the holes for the thru bolt in the Install and tighten the cover retaining screws.
starter solenoid assembly.
STEP 52
STEP 49
B330816M
B330813M Install a lock washer, flat washer, and O-ring on the

Move the brush holder so that the holder is even with thru screws. Lubricate the O-rings with grease.
the end of the armature.

4003-20
STEP 53
STEP 54
B330818M
Install and tighten the thru bolts to 10.8 to 17.6 Nm (8 B330731M
to 13 lb-ft). Install the cable, lock washer, and nut on the motor
terminal. Tighten the nut to 17.6 to 25.5 Nm (13 to 19
lb-ft).
STEP 55
Pull the boot over the motor terminal.

4003-21
STARTER SOLENOID TEST 3. Connect a jumper wire to the battery terminal

This test will check the condition of the pull-in winding and the switch terminal on the starter solenoid
and the hold-in winding in the starter solenoid. housing. The jumper wire must be made from
No. 10 AWG or larger wire.
The jumper cable connected to the star ter
mounting flange and the motor terminal must have a 4. Connect the jumper cable with the common
common connection at the negative battery post. connection 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 and the hold-in winding.
terminal. Then remove the wire from the motor 5. Connect the jumper cable with the common
terminal. connection to the negative battery post. The
2. Connect a jumper cable to the positive battery pinion gear on the starter drive must come all the
post of a fully charged 12 volt battery. Connect way out rapidly and with force.
the other end of the jumper cable to the battery 6. If the pinion gear did not come out rapidly and
terminal on the starter solenoid housing. with force, the pull-in winding is damaged. The
complete starter solenoid housing assembly
must be replaced.
2
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.
3 1
8. If the pinion gear started to move toward the
5 star ter drive housing, the hold-in winding is
4 damaged. The complete starter solenoid housing
assembly must be replaced.
B831438R
1. 12 VOLT BATTERY
2. STARTER
3. BATTERY TERMINAL
4. SWITCH TERMINAL
5. MOTOR TERMINAL

4003-22

5002-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
SPECIAL TOOLS .................................................................................................................................................... 2
DISASSEMBLY ....................................................................................................................................................... 3
INSPECTION ........................................................................................................................................................... 8
ASSEMBLY ........................................................................................................................................................... 10
SPECIFICATIONS
Rotor and Stator clearance........................................................................................................0.13 mm (0.005 inch)
Special torques
Allen Head Plug ....................................................................................................... 11 Nm (100 pound-inches)

Ferry Head Screws .............................................................................. 25 to 31 Nm (225 to 275 pound-inches)
SPECIAL TOOLS
B785606M
CAS-1239 CENTERING SPRING TOOL

This tool is first used on page 12.

5002-3
DISASSEMBLY
STEP 1 STEP 4
BP9503067 BP9503070
Put the steering control valve in the vise so that the Lift the metering gear set, the spacer, the drive
end plate is up. Remove the Ferry head screws. shaft, and the spacer plate as an assembly from
the body.
STEP 2
STEP 5
3
2
BP9503068
Remove the end plate. BP9503071
Separate the metering gear set (1), the spacer (2),

the drive shaft (3), and the spacer plate (4).
STEP 3
STEP 6
BP9503069
Remove the O-ring from the stator of the metering

gear set. BP9503072
Remove the O-ring from the spacer plate.

5002-4
STEP 7 STEP 10
B8460988M B523917M
Remove and discard the O-ring from the body. Push the sleeve and spool part of the way out of
the bottom of the body. Turn the sleeve and spool
in both directions as you push the sleeve and spool
STEP 8 out of the body. If the pin inside of the sleeve and
spool prevents the sleeve and spool from coming
1 out of the body, use a magnet to move the pin one
way or the other.
STEP 11
B877704M
Find the anticavitation valves (1) in the body. Put

identification marks on the body for use during
assembly.
BP9503073
STEP 9
Remove and discard the seal from the spool. It is
possible that the seal stayed with the body. If so,
remove the seal from the body.
STEP 12
B877698M
Remove the 4 springs, the pins, and the balls from

the ports in the body.
B523921M
Remove the thrust washer.

5002-5
STEP 13 STEP 16
B523923M B523929M
Remove the thrust bearing. Pull the spool straight out of the sleeve. Remove
the centering springs.
STEP 14
STEP 17
B523925M
Remove the other thrust washer. B523929M
Push the centering springs out of the spool. There

are four centering springs and two spacers. Be
STEP 15 careful so that you do not lose any of the parts.
STEP 18
B523927M
Use a punch to push the pin out of the sleeve and

spool.
B8461288M
Remove the seal from the gland.

5002-6
STEP 19 STEP 22
B8461888M B523817M
Remove the Allen head plug from the body of the Remove the body of the steering control valve from
steering control valve. the vise. Turn the body so that the steel ball and
the retainer fall from the body.
STEP 20
STEP 23
B8462788M
Install a No. 8-32 screw in the seat for the check B523820M
valve.
STEP 21
B523822M
Remove and discard the O-rings from the seat.

B8463088M
Use pliers to pull the seat out of the body of the

steering control valve.

5002-7
STEP 24 STEP 26
B8470288M B8471188M
Put the body in the vise so that the gland is up. Remove and discard the O-ring from the bore for
Disengage the end of the retaining ring from the the gland.
groove in the body. Remove the retaining ring.
STEP 25
B523826M
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 so that the gland is down. Put blocks
under the body to hold the body off the press table.
Press the gland from the body.

5002-8
INSPECTION
Use cleaning solvent to clean all parts. Put the STEP 28
parts on paper towels until the parts are dry. Do
not use cloths to wipe the parts dry.
C h e ck a l l m a c h i n e d s u r fa c e s fo r we a r o r
damage. If there are rough places on the ends of
the stator and rotor or on the machined surfaces
1
on the body, end plate, or spacer plate, use 600
grit emery cloth to make the surfaces smooth. Put
the emery cloth on a flat surface. If the emery cloth
is new, move a piece of steel across the emery
cloth six times to remove the sharp pieces of grit.
Move the rotor, stator, body, end plate, or spacer
across the emery cloth six times. Then check to
see if the rough places have been removed. Use
B1757A88J
this method until all rough places are gone. Make
Inspect the check valve (1) in the inlet port of the
sure that you keep the part flat on the emery cloth
body. Push in the check valve (1) to make sure that
as you move the part across the emery cloth. Use
the spring works correctly. If the check valve (1) is
cleaning solvent to remove any grit from the parts.
worn or damaged, use a complete new steering
control valve.
STEP 27
STEP 29
3
2
2
1
1 4
3
B1758A88J
Inspect the Allen head plug (1), the seat (2), the
steel ball (3), and the retainer (4) for damage or
B1757A88J
wear. Use new parts as required.
If the spool (1), the sleeve (2), or the bore in the
body (3) of the steering control valve is damaged
or wor n, use a complete new steering control
valve. The spool (1), the sleeve (2), and the body
(3) of the steering control valve are not available
separately.

5002-9
STEP 30 STEP 32
2
1
B1759A88J B8473288M
Inspect the thr ust washers (1) and the thrust Use a feeler gauge to measure the clearance
bearing (2) for damage or wear. Use new parts as between the rotor and the stator. If the clearance is
required. more than 0.13 mm (0.005 inch), a new metering
gear set must be used.
STEP 31
Inspect the springs, the pins, and the balls of the STEP 33
anticavitation valve for damage or wear. Use new
parts as required.
B1760A88J
Inspect the gland (1) for damage or wear. Use a

new gland if required.

5002-10
ASSEMBLY
STEP 34 STEP 37
1
B8471188M B523841M
Install a new O-ring in the bore for the gland. Use Install new O-rings on the seat for the check valve.
petroleum jelly to lubricate the O-ring. Use petroleum jelly to lubricate the new O-rings.
Install the larger O-ring (1) on the tapped end of
STEP 35 the seat.
STEP 38
B8461588M
Put the body of the steering control valve in the

vise so that the gland end is up. Drive the gland B523622M
into the body of the steering control valve until the Install the retainer in the bore for the check valve.
gland stops moving. Make sure that the retainer is flat in the bottom of
the bore.
STEP 36
STEP 39
B8470588M
Use a screwdriver and a punch to start the end of B8463688M
the retaining ring into the groove in the body. Push Install the steel ball in the bore for the check valve.
the retaining ring into the groove in the body.
5002-11
STEP 40 STEP 43
B8463388M B8461588M
Install the seat for the check valve in the bore. The Install the seal in the gland so that the lip is toward
tapped end of the seat must be up. the outside of the body. Drive the seal into the
gland until the seal stops moving.
STEP 41
STEP 44
B8462488M
Apply a small amount of 242 Loctite to the threads B523633M
of the Allen head plug. Use clean hydraulic oil to lubricate the inside of the
sleeve.
STEP 42
STEP 45
B8461888M
Install the Allen head plug. Tighten the Allen head B523635M
plug to a torque of 11 Nm (100 pound-inches). Use clean hydraulic oil to lubricate the outside of
the spool.

5002-12
STEP 46 STEP 48
B523637M B523641M
Install the spool in the sleeve. The spool must be Install the tool shown on page 2 through the slots
installed straight into the sleeve. Turn the spool in for the centering springs.
both directions as the spool is pushed into the
sleeve.
STEP 49
STEP 47
B523643M
Assemble the centering springs in sets of three.

B523639M Put the two sets of centering springs in the end of
Put the spool and the sleeve in the vise with soft the tool so that the notched corners are toward the
jaws. Tighten the vise just enough to hold the sleeve. Use your thumb and finger to compress the
spool in position. There are slots in the sleeve and centering springs.
the spool. The purpose of these slots is to hold the
centering springs. Move the sleeve on the spool
until the slots in the sleeve and the spool are in
alignment.

5002-13
STEP 50 STEP 53
B523717M BP9503073
Push the centering springs into the spool. Move Install a new seal on the spool.
the tool as necessary to put the centering springs
in position.
STEP 54
STEP 51
BP9503075
Use clean hydraulic oil to lubricate the outside of

B523721M the sleeve. Use clean hydraulic oil to lubricate the
Install the pin in the sleeve and through the spool. bore in the body. Install the sleeve and the spool
straight into the body.
STEP 52
B523723M
Install the thrust washer, the thrust bearing, and

the other thrust washer on the spool.

5002-14
STEP 55 STEP 58
B524108M B877701M
The pin can move out of the sleeve and the spool. Install the pins in the ports.
If the pin moves out of the sleeve and the spool,
the pin can keep the sleeve and the spool from
being pushed into the body. Hold the sleeve and STEP 59
the spool in position in the body. Put the end of the
sleeve and the spool on the bench. Lower the body
onto the sleeve and the spool as shown.
STEP 56
B877700M
Install the springs in the pins.
STEP 60
B877702M
Find the ports with identification marks. Install the

balls in the ports.
STEP 57
BP9503077
Put the body of the steering control valve in the

vise. Install a new O-ring in the groove in the body.
B877700M
Install the springs.

5002-15
STEP 61 STEP 63
2
1
2
2
BP9503076 B8480388M
Install the drive shaft in the metering gear set. The Install the spacer plate on the stator so that the O-
teeth on the drive shaft must engage the teeth in ring is toward the stator. Turn the spacer plate as
the rotor so that the slot (1) in the end of the drive necessary to align the holes with the holes in the
shaft is centered between two lobes (2) on the stator.
rotor.
STEP 64
STEP 62
BP9503078
BP9503072 Lower the drive shaft into the spool so that the pin
Install a new O-ring in the groove in the spacer in the spool engages the slot in the drive shaft. DO
plate. NOT let the drive shaft come out of the rotor. Turn
the stator and the spacer plate as necessary to
align these parts with the body.

5002-16
STEP 65 STEP 68
BP9503079 BP9503082
Install the spacer in the rotor so that the spacer is Install the end plate on the metering gear set.
on top of the drive shaft. Align the holes in the end plate with the holes in
the stator.
STEP 66 STEP 69
BP9503080
BP9503083
Put clean hydraulic oil on the metering gear set, Install the Ferry head screws.
the spacer plate, and the drive shaft.
STEP 70
STEP 67
1 7
5 4
3 2
6
BP9503086
BP950308
Tighten the Ferry head screws to a torque of 11 to
17 Nm (100 to 150 pound-inches) in the sequence
Install a new O-ring in the groove in the stator.
shown. Then tighten the Ferry head screws to a
final torque of 25 to 31 Nm (225 to 275 pound-
inches) in the sequence shown.

5002-17
1 6
8 2
3
9
8 4
10 3 6
11
3
12 7
5
28
11 16
17
18
13 19
10
3
18
21 14
3
20 15
22
25 20
23
24 26
BS98F283
1. FERRY HEAD SCREWS 8. SPRING 15. ALLEN HEAD PLUG 22. SEAL
2. END PLATE 9. PIN 16. PIN 23. 0-RING
3. O-RING 10. BALL 17. SLEEVE 24. GLAND
4. SPACER 11. SPACER PLATE 18. CENTERING SPRING 25. RETAINING RING
5. ROTOR 12. BODY 19. SPOOL 26. SEAL
6. STATOR 13. RETAINER 20. THRUST WASHER 27. METERING GEAR SET
7. DRIVE SHAFT 14. SEAT 21. THRUST BEARING 28. RELIEF VALVE DO NOT REMOVE

5002-18

5003-2
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

5003-3
SPECIFICATIONS
Two wheel drive steering cylinder tie rod nuts .................................... 37 to 57 Nm (324 to 504 pound-inches)
Four wheel drive steering cylinder cap screws .....................................................................120 Nm (89 pound-feet)
Nut for ball joint....................................................................................................................300 Nm (221 pound-feet)
Jam nut for tie rod................................................................................................................250 Nm (184 pound-feet)

5003-4
TWO WHEEL DRIVE STEERING CYLINDER

Disassembly 10.Remove the wear ring (12) from the piston (11).
Remove the seal (13) and backup ring (15) from
1. Clean the outside of the steering cylinder (1). the piston (11).
2. Fasten the steering cylinder (1) in a vise or 11.Remove the O-ring (9) and backup ring (14)
other holding equipment. Be careful to prevent from the outside of each gland (8). Remove the
damage to the tube. (16). wiper (6) and seal (7) from the bore of each
gland (8).
3. One end of the piston rod (10) has two flat
ar eas to pr eve nt the pi st on r od ( 10) fro m Inspection
turning when the lock nuts (3) for the rod eyes
(2 and 17) are loosened. the rod eye (2) at the 1. Discard the parts removed from the piston (11)
end of the piston rod (10) that has two flat and the glands (8).
areas has LH threads. Prevent the piston rod
(10) from turning, loosen the lock nut (3), and 2. Clean all parts in cleaning solvent.
turn the rod eye (2) out of the piston rod (10).
3. Illuminate the inside of the tube (16). Inspect
4. The rod eye (17) in the other end of the piston the inside of the tube (16) for deep grooves and
rod has RH threads. Prevent the piston rod (10) other damage. If there is damage to the tube
from turning, loosen the lock nut (3) and turn (16), a new tube (16) must be used.
the rod eye (17) out of the piston rod (10).
4. Check to be sure that the piston rod (10) is
5. Loosen and remove the nut (4) from each tie straight. If the piston rod (10) is not straight,
rod (5) and remove the tie rods (5) that hold the install a new piston rod assembly (10 and 11).
steering cylinder (1) together.
5. Inspect the piston (11) for damage and wear. If
6. Pull one end of the piston rod (10) out of the the piston (11) is damaged, or wor n, a new
tube (16) until the piston (11) contacts the piston rod assembly (10 and 11) must be used.
gland (8).
6. Remove the small scratches on the piston rod
7. Use a soft hammer to drive the gland (8) out of (10) and inside the tube (16) with emery cloth
the tube (16) and pull the pis ton rod (10) of medium grit. Use emery cloth with a rotary
straight out of the tube (16) to prevent damage motion.
to the tube (16).
7. Inspect both ends of the tube (16) for sharp
8. Remove the gland (8) from the piston rod (10). edges that will cut the gland O-rings (9) and
remove the sharp edges as necessary.
9. Use a soft hammer to drive the gland (8) out of
the other end of the tube (16). Remove the 8. Inspect both glands (8) for rust. Clean and
gland (8). remove rust as necessary.
NOTE: The piston (11) cannot be removed from the

piston rod (10). If the piston (11) or the piston rod
(10) is damaged, the piston rod assembly (10 and
11) must be replaced.

5003-5
3
2 1
5
6
14
9 10
11
7
8
12
16 15
13
14
8
7
6 4
3 17
B892228J
1. STEERING CYLINDER 6. WIPER 11. PISTON 15. BACKUP RING

2. ROD EYE 7. SEAL 12. WEAR RING 16. TUBE
3. LOCK NUT 8. GLAND 13. SEAL 17. ROD EYE
4. NUTS 9. O-RING 14. BACKUP RING
5. TIE RODS 10. PISTON ROD
Two Wheel Drive Steering Cylinder - Exploded View

5003-6
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
14 groove in the piston (11).
9
7. Install a new seal (13) on top of the backup ring
(15).
8. Fasten the tube (16) in the vise or other holding
6 equipment. Be careful to prevent damage to the
tube (16).
8 9. Lubricated the bore of the tube (16) with clean
7 oil.
10.Lubricate the O-ring (9) on both glands (8) and
the bore of both glands (8) with clean oil.
11.Remove any marks and sharp edges on the
chamfers at the end of the piston rod assembly
B861554 (10 and 11). Make sure that the piston rod (10)
is clean.
Gland
6. WIPER 9. O-RING 12.Lubricate the piston (11) with clean oil.
7. SEAL 14. BACKUP RING
8. GLAND 13.Install one of the glands (8) in the tube (16).
14.Push the other gland (8) onto the piston rod
1. Install a new seal (7) into the bore of each assembly.
gland (8). The lips of the seal (7) must be
toward the inside of the steering cylinder (1). 15.Push the piston rod assembly (10) straight into
The seal (7) can be difficult to install. Do not the tube (16), and through the gland (8) at the
damage the seal (7). other end of the tube (16).
2. Install a new wiper (6) into the bore of each 16.Carefully start the other gland (8) into the tube
gland (8). The lip of the wiper (6) must be (16).
toward the outside end of the gland (8). 17.Make sure the ports in both glands (8) are
3. Install a new backup ring (14) in the groove on installed correctly and drive the gland (8) into
each gland (8). the tube (16).
4. Install a new O-ring (9) in the groove on each 18.Install the tie rods (5) and nuts (4). tighten the
gland (8). The O-ring (9) must be between the nuts to 324 to 504 pound-inches (37 to 57 Nm).
backup ring (14) and the small end of the gland 19.The rod eye (2) for the end of the piston rod
(8). (10) that has two flat areas has LH threads.
Prevent the piston rod (10) from turning, and
12 turn the rod eye (2) into the piston rod (10).
15 13
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).
11
21.Do not tighten the lock nuts for the rod eyes (2
and 17) until after installation of the steering
cylinder (1).
B861555
Piston
11. PISTON 13. SEAL
12. WEAR RING 15. BACKUP RING

5003-7
3
2 1
5
6
14
9 10
11
7
8
12
16
15
13
14
8
7
6 4
3 17
B892228J
1. STEERING CYLINDER 6. WIPER 11. PISTON 15. BACKUP RING

2. ROD EYE 7. SEAL 12. WEAR RING 16. TUBE
3. LOCK NUT 8. GLAND 13. SEAL 17. ROD EYE
4. NUTS 9. O-RING 14. BACKUP RING
5. TIE RODS 10. PISTON ROD
Two Wheel Drive Steering Cylinder - Exploded View

5003-8
FOUR WHEEL DRIVE STEERING CYLINDER

Disassembly 6. Remove the wiper (13), backup ring (12), and
the seal (11) from the closed end of the tube
1. Remove the tie rod ball joint assembly (16). (10).
2. Fasten the tube (10) in a vise or other holding 7. Fasten the piston rod assembly (7) in a vise
equipment. Do not damage the tube (10). with soft jaws.
3. Separate the gland (5) from the tube (10). 8. Remove the wear rings (9), seal (8), and the
backup ring (14) from the piston rod assembly
4. Remove the gland (5) from the piston rod
(7).
assembly (7).
9. Remove the O-ring (6), wiper (2), backup ring
5. Pull the piston rod assembly (7) straight out of
(3), and the seal (4) from the gland (5).
the tube (10) to prevent damage to the tube
(10).
16
11 1
15
3 16
2 5
8 9
11
4
6 7
9 14
10
4
12
13
BS98F284
1. STEERING CYLINDER 5. GLAND 9. WEAR RING 13. WIPER

2. WIPER 6. O-RING 10. TUBE 14. BACKUP RING
3. BACKUP RING 7. PISTON ROD ASSEMBLY 11. NUT 15. CAP SCREW
4. SEAL 8. SEAL 12. BACKUP RING 16. TIE ROD BALL JOINT ASSEMBLY
Four Wheel Drive Steering Cylinder - Exploded View

5003-9
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
2. Clean all parts in cleaning solvent. assembly (7).
3. Inspect the gland, piston rod assembly, and the 8. Install a new wear ring (9) in the groove on
tube for damage and wear. these parts are not each side of the seal (8).
serviced separately, if these parts need to be
replaced, a new steering cylinder must be used. 9. Lubricate the seal (8) and wear rings (9) with
clean oil. Use a piston ring compression tool to
hold the new wear rings (9) in place.
Assembly 10.Start the tube (10) onto the piston rod assembly
(7). Push the tube (10) onto the piston rod
See the cross sectional view of the steering assembly (7) until the compression tool is
cylinder on page 10. pushed off the piston rod assembly (7). be
careful not to damage the wear rings (9) and
1. Install a new seal (4) in the gland (5). The lip of the seal (8).
the seal (4) must be toward the inside of the
gland (5). 11.Fasten the tube (10) in a vise with soft jaws.
Push the piston rod assembly (7) all the way
2. Install a new backup ring (3) next to the gland into the tube (10).
(5).
12.Lubricate the wiper (2), backup ring (3), seal
3. Install a new wiper (2) in the gland (5). the lip of (4), and O-ring (6) on the gland (5) with clean
the wiper (2) must be toward the outside of the oil.
gland (5).
13.Install the gland (5) on the piston rod assembly
4. Install a new O-ring (6) in the groove on the (7) and push the gland (5) against the tube
gland (5). (10).
5. Fasten the piston rod assembly (7) in a vise 14.Install the tie rod ball joint assembly (16).
with soft jaws. Tighten the ball joint assembly (16) to a torque
of 300 Nm (221 pound-feet).

5003-10
1. STEERING CYLINDER
2 2. WIPER
3. BACKUP RING
3 4. SEAL
5 5. GLAND
6. O-RING
4 7. PISTON ROD ASSEMBLY
8. SEAL
9. WEAR RING
10. TUBE
11. SEAL
12. BACKUP RING
13. WIPER
14. BACKUP RING
6
9
14
8
9
10
11
12
13
B902050J
Four Wheel Drive Steering Cylinder - Cross Sectional View

5005-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 2
FRONT WHEEL BEARINGS ................................................................................................................................... 3

Removal and Disassembly .................................................................................................................................. 3
Inspection ............................................................................................................................................................. 5
Assembly and Installation .................................................................................................................................... 7
Wheel Bearing Adjustment ................................................................................................................................ 10
SPINDLE ............................................................................................................................................................... 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 5 mm (0 to 3/16 inch)
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 ............................................... 101 to 115 Nm (75 to 85 pound-feet) with wheel turning.
Then loosen a maximum of 1/16 turn.
Front wheel bolts ........................................................................... 156 to 203 Nm (115 to 150 pound-feet)
Steering cylinder lock nuts ............................................................. 203 to 271 Nm (150 to 200 pound-feet)

5005-3
FRONT WHEEL BEARINGS
Removal and Disassembly STEP 4
STEP 1
B633503M
Remove the cotter pin.

B633543M
Raise the front wheel and place an acceptable

support under the front axle.
STEP 5
STEP 2
B633505M
Remove the nut.

B634107M
Loosen and remove the wheel bolts. Remove the STEP 6

wheel.
STEP 3
B633507M
Pull the hub toward you to remove the outer wheel

bearing from the spindle. It may be necessary to
B633501M
hit the hub with a soft hammer.
Remove the cap.

5005-4
STEP 7 STEP 10
B633509M B633515M
Remove the flat washer and the wheel bearing. Use two prybars to remove the spindle seal.
STEP 8 STEP 11
B633511M B633517M
Remove the hub. Remove any dirt and grease from the spindle.
STEP 9 STEP 12
B633513M B021321M
Use a chisel to move the spindle seal away from Place an acceptable driver on top of the wheel
the spindle. bearing.

5005-5
STEP 13 STEP 15
B021322M B021326M
Press the hub seal and the wheel bearing out of If inspection indicates the need for a new bearing
the hub. cup or wheel bearing, use a hammer and a punch
to remove the inner bearing cup from the hub.
STEP 14
Inspection
1. Clean the wheel bearings in cleaning solvent to
remove all grease from the wheel bearings. Use
new parts as required.
2. Check the bearing cups for scoring, flat areas,

and pitting. Use new parts as required.
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 new
parts as required.
B021325M
If inspection indicates the need for a new bearing

cup or wheel bearing, use a hammer and a punch
to remove the outer bearing cup from the hub.

5005-6
1 2
3
4
2 5
6
9
7
11 10
21
12
13 22
14 20
15 24 25
16 19
17
18
23
26
27
29
28
32
30 33
31 34
35
36
B891545J
1. FRONT AXLE 10. LOCK WASHER 19. LOCK PIN 28. BEARING CUP
2. GREASE FITTING 11. STEERING LINK 20. BUSHING 29. WHEEL BEARING
3. SNAP RING 12. BOLT 21. THRUST BEARING 30. HUB
4. SPACER 13. SEAL 22. NUT 31. BEARING CUP
5. O-RING 14. BEARING 23. THRUST WASHER 32. FLAT WASHER
6. KINGPIN 15. O-RING 24. SPINDLE 33. NUT
7. BEARING 16. SPACER 25. LOCK WASHER 34. CAP
8. NUT 17. SNAP RING 26. SPINDLE SEAL 35. WHEEL BEARING
9. PIVOT PIN 18. GREASE FITTING 27. HUB SEAL 36. COTTER PIN

5005-7
Assembly and Installation STEP 19
STEP 16
B021340M
Start the inner bearing cup into the hub.
B021329M
Fill each wheel bearing with the grease specified STEP 20

on page 2.
STEP 17
B021418M
Use an acceptable driver to press the bearing cup

all the way into the hub.
B021332M
Start the outer bearing cup into the hub. STEP 21
STEP 18
B021420M
Put the inner wheel bearing in the hub.
B021336M
Use an acceptable driver to press the bearing cup

all the way into the hub.

5005-8
STEP 22 STEP 24
2 3
B021426M
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
B891546J
1. SPINDLE 3. HUB SEAL
2. HUB 4. SPINDLE SEAL
The hub seal must be installed as shown in the

illustration.
STEP 23
B633519M
Drive the new spindle seal all the way onto the
spindle. Be careful not to damage the spindle seal.
STEP 26
B021423M
Put the hub seal on an acceptable driver.
B633925M
Fill the groove in the hub seal with wheel bearing

grease.

5005-9
STEP 27 STEP 30
B633927M B633933M
Install the hub onto the spindle. Tighten the nut to a torque of 101 to 115 Nm (75 to
85 pound-feet) and turn the hub at the same time.
Then loosen the nut to the first cotter pin hole.
STEP 28
STEP 31
B633929M
Install the outer wheel bearing.

B633936M
Install the cotter pin.

STEP 29
STEP 32
B633931M
Install the flat washer and the nut.

B634104M
Install the cap.

5005-10
STEP 33 Wheel Bearing Adjustment
The following photographs show the hub with
the wheel removed. It is not necessary to remove
the wheel from the hub to adjust the wheel
bearing.
STEP 36
B634107M
Install the wheel and the wheel bolts. Do not use

an impact wrench to install the wheel bolts.
STEP 34
B633501M
Remove the cap.
STEP 37
B633543M
Remove the support from under the front axle and

lower the wheel to the floor.
STEP 35
B633933M
Remove the cotter pin. Turn the wheel or the hub

while you tighten the nut to a torque of 101 to 115
Nm (75 to 85 pound-feet). Then loosen the nut to
the first cotter pin hole.
B634108M
Tighten the wheel bolts to a torque of 156 to 203

Nm (115 to 150 pound-feet).

5005-11
STEP 38 STEP 39
B633936M B634104M
Install a new cotter pin. Install the cap.
SPINDLE
Removal STEP 42
STEP 40
B633501M
Remove the cap.

B633543M
Raise the front wheel off the floor and place an

acceptable support under the front axle
STEP 43
STEP 41
B633503M
Remove the cotter pin.
B634107M
Loosen and remove the wheel bolts. Remove the

wheel.
5005-12
STEP 44 STEP 47
B633505M B633511M
Remove the nut. Remove the hub.
STEP 45 STEP 48
B633507M B633521M
Pull the hub toward you to remove the outer wheel Loosen the nut on the lock pin.
bearing from the spindle. It may be necessary to
hit the hub with a soft hammer.
STEP 49
STEP 46
B633525M
Remove the nut and the lock washer.

B633509M
Remove the flat washer and the wheel bearing.

5005-13
STEP 50 STEP 53
B633528M B633644M
Drive the lock pin out of the spindle. Remove the snap ring. The O-ring used between
the spacer and the bearing will make the snap ring
difficult to remove.
STEP 51
STEP 54
B633640M
Loosen the nuts on the bolts that hold the pivot pin
for the steering link. B633602M
Remove the spacer.
STEP 52
STEP 55
B633642M
Drive the pivot pin out of the steering link. B633604M
Remove the O-ring.

5005-14
STEP 56 STEP 59
B633606M B633612M
Remove the snap ring at the bottom of the kingpin. Drive the kingpin toward the top to prevent damage
to the seal.
STEP 57
STEP 60
B633608M
Remove the spacer. B633614M
Remove the spindle and the thrust bearing.
STEP 58
STEP 61
B633610M
Remove the O-ring. B633616M
Remove the thrust washer.

5005-15
1 2
3
4
2
5
9 6
7
8
11 10
21
12
13 22
14 20
15 24 25
16 19
17
18
23
26
27
29
28 32
30 33
34
31
35
36
B891545J

5005-16
Installation STEP 65
STEP 62
B634020M
Install the thrust bearing. Remember, the metal

shield must be on top.
B634013M
Put the thrust washer on the bottom boss.

STEP 66
STEP 63
B634022M
Align the spindle, the thrust bearing, and the thrust

B634016M washer with the front axle. Install the kingpin so
Install the spindle. that the notch for the lock is toward the outside.
STEP 64 STEP 67
B634018M B634024M
The metal shield on the thrust bearing must be on Hold the spindle and push the kingpin into position.
top when the thrust bearing is installed.

5005-17
STEP 68 STEP 71
B634026M B633904M
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
B633525M
Install the lock washer and the nut but do not

tighten the nut now. B633907M
Install the snap ring. Hit the spacer and the snap
r ing to make sure that the snap r ing is in the
STEP 70 groove.
STEP 73
B633902M
Install a new O-r ing in the bottom boss. Use

grease to hold the O-ring in position.
B633909M
Install a new O-ring in the top boss.

5005-18
STEP 74 STEP 77
B633911M B633917M
Install the spacer so that the grease fitting is Tighten the nut that holds the lock pin.
STEP 78
STEP 75
B633919M
B633913M Align the steering link with the spindle and start the
Install the snap ring. pivot pin into the steering link.
STEP 76 STEP 79
B633915M B633921M
Hit the spacer and the snap ring to make sure that Drive the pivot pin into the steering link.
the snap ring is in the groove.

5005-19
STEP 80 STEP 83
B633923M B633927M
Tighten the nuts on the bolts that hold the pivot Install the hub onto the spindle.
pin.
STEP 84
STEP 81
B633929M
B633519M Install the outer wheel bearing.

Drive the spindle seal all the way onto the spindle.
Be careful not to damage the spindle seal.
STEP 85
STEP 82
B633931M
Install the flat washer and the nut.

B633925M
Fill the groove in the hub seal with the wheel

bearing grease specified on page 2.

5005-20
STEP 86 STEP 89
B633933M B634107M
Tighten the nut to a torque of 101 to 115 Nm (75 to Install the wheel and the wheel bolts. Do not use
85 pound-feet) and turn the hub at the same time. an impact wrench to install the wheel bolts.
Then loosen the nut to the first cotter pin hole.
STEP 90
STEP 87
B633543M
Remove the support from under the front axle and

B633936M
Install the cotter pin.
STEP 91
STEP 88
B634108M
B634104M Tighten the wheel bolts to a torque of 156 to 203

Install the cap. Nm (115 to 150 pound-feet).
STEP 92
Lubricate the bearings for the kingpin. Lubricate
the tie rod ends.

5005-21
KINGPIN BEARINGS AND THRUST BEARINGS

Removal STEP 96
STEP 93
B633834M
Drive the lock pin out of the spindle.

B633543M
Raise the front wheel and put an acceptable STEP 97

support under the front axle.
STEP 94
B633732M
Remove the snap ring. The O-ring used between

the spacer and the bearing will make the snap ring
B634107M
difficult to remove.
Loosen and remove the wheel bolts. Remove the
wheel.
STEP 98
STEP 95
B633734M
B633830M Remove the spacer.

Loosen and remove the nut and the lock washer
from the lock pin.
5005-22
STEP 99 STEP 102
B633736M B633808M
Remove the O-ring. Remove the O-ring.
STEP 100 STEP 103
B633804M B633810M
Remove the snap ring at the bottom of the kingpin. Drive the kingpin out of the spindle.
STEP 101 STEP 104
B633806M B633812M
Remove the spacer. Remove the spindle and the thrust bearing and put
the spindle out of the way.

5005-23
STEP 105 STEP 107
B633706M B633710M
Remove the thrust washer. Remove the seal.
STEP 106 STEP 108
B633708M B633712M
Use an acceptable driver to drive the top bearing Drive the bottom bearing out of the boss.
out of the boss.

5005-24
1 2
3
4
2 5
6
9
7
11 10
21
12
13 22
14 20
15 24 25
16 19
17
18
23
26
27
29
28
32
30 33
31 34
35
36
B891545J

5005-25
Installation STEP 112
STEP 109
B633721M
Install the seal on an acceptable driver so that the

B633714M lip is toward the driver. The driver must have a
Clean the bores for the bearings. larger diameter than the seal.
STEP 110
STEP 113
B633717M
B633723M
Put a bearing on a driver that has a pilot end.
Drive the seal into the bottom boss until the driver
There is a number on one end of the bearing.
touches the boss.
Make sure that the end with the number is toward
the driver. Put tape on the driver 6.4 mm (1/4 inch)
from the bearing to help install the bearing to the STEP 114
correct depth.
STEP 111
B633725M
Put a bearing on an acceptable driver. There is a

number on one end of the bearing. Make sure that
B633719M
the end 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.
5005-26
STEP 115 STEP 118
B633727M B633818M
Dr ive the bear ing into the top boss un til the Install the spindle.
bearing is even with the bottom of the boss.
STEP 119
STEP 116
B633820M
B633814M The metal shield on the thrust bearing must be on

Clean the bore in the spindle. top when the thrust bearing is installed.
STEP 117 STEP 120
B633816M B633822M
Install the thrust washer. Install the thrust bearing so that the metal shield is
on top.

5005-27
STEP 121 STEP 124
B633824M B633525M
Align the spindle, the thrust washer, and the thrust Install the lock washer and the nut. Do not tighten
bearing with the front axle. Start the kingpin into the nut at this time.
the spindle so that the notch for the lock pin is
toward the outside.
STEP 125
STEP 122
B633808M
Install a new O-r ing in the bottom boss. Use

B633826M grease to hold the O-ring.
Use a soft hammer to drive the kingpin into the
spindle.
STEP 126
STEP 123
B633836M
Apply a small amount of grease to a spacer and

B633828M install the spacer so that the grease fitting is
Install the lock pin. toward the center of the machine.

5005-28
STEP 127 STEP 130
B634002M B634007M
Install a snap ring. Install the spacer so that the grease fitting is
STEP 128
STEP 131
B634004M
Hit the spacer and the snap ring to make sure that B634009M
the snap ring is in the groove. Install the snap ring.
STEP 129 STEP 132
B634005M B634011M
Install a new O-ring in the top boss. Hit the spacer and the snap ring to make sure that
the snap ring is in the groove.

5005-29
STEP 133 STEP 135
B633832M B633543M
Tighten the nut on the lock pin. Remove the support from under the front axle and
STEP 134
STEP 136
B634107M
Install the wheel and the wheel bolts. Do not use B634108M
an impact wrench to install the wheel bolts. Tighten the wheel nuts to a torque of 156 to 203
STEP 137
Lubricate the bearings for the kingpins.

5005-30
TOE-IN
Measuring Toe-In 7. The measurement at the rear of the tires must
be 0 to 5 mm (0 to 3/16 inch) more than the
1. Raise the front of the machine until the front measurement at the front of the tires.
wheels are free of the floor.
Adjustment
2. Hold a tool that has a sharp point against the
center of the tire tread. 1. Loosen the lock nut at each end of the piston
rod for the steering cylinder.
3. Hold the tool in one place and rotate the wheel
to make a fine line around the tire. Repeat this 2. Turn the piston rod as needed to increase or
procedure for the other wheel. decrease the toe-in.
4. Lower the front wheels to the floor. 3. When the toe-in is correct, first tighten the lock
nut nearest the flat on the piston rod to a torque
5. Turn the steering wheel as needed to put the of 203 to 271 Nm (150 to 200 pound-feet). Then
front wheels in the straight position. tighten the other lock nut to a torque of 203 to
271 Nm (150 to 200 pound-feet).
6. Measure the distance between the marks at the
front and the rear of the tires.
B
1 1
3 3
A
B861482R
1. MARK AROUND CENTER OF TIRE 3. LOOSEN LOCK NUTS AND TURN PISTON ROD AS REQUIRED.
2. STEERING CYLINDER
NOTE: Measurement B Must Be Equal To or Up To 5 mm (3/16 Inch) Less Than Measurement A.

Section
6007
CLARK POWERSHIFT TRANSMISSION
6007
CASE CORPORATION
700 State Street
CASE CANADA CORPORATION

© 1998 Case Corporation
450 Sherman Avenue Printed in U.S.A.
Hamilton, ON L8N 4C4 CANADA Bur 7-10440 December, 1998
6007-2
TABLE OF CONTENTS
SPECIAL TOOLS .................................................................................................................................................... 3
SPECIFICATIONS ................................................................................................................................................... 5
SPECIAL TORQUES ............................................................................................................................................... 5
CLEANING AND INSPECTION ............................................................................................................................... 6

Cleaning ............................................................................................................................................................... 6
Bearings ............................................................................................................................................................... 6
Housings .............................................................................................................................................................. 6
Inspection ............................................................................................................................................................. 6
Bearings ............................................................................................................................................................... 6
Oil Seals, Gaskets, etc. ........................................................................................................................................ 6
Gears and Shafts ................................................................................................................................................. 6
Housing, Covers, etc. ........................................................................................................................................... 6
DISASSEMBLY T16000 TRANSMISSION .............................................................................................................. 7

Exploded View of Torque Converter - Drive Plate - and Internal Charge Pump .................................................12
Exploded View of Converter Housing ................................................................................................................. 13
Exploded View of Control Valve Mounting Assembly ......................................................................................... 14
Exploded View of Rear Transmission Housing................................................................................................... 22
Disassembly Forward High Clutch ..................................................................................................................... 23
Disassembly Forward Low Clutch ...................................................................................................................... 26
Exploded View of Forward Low and Forward High Clutch ..................................................................................31
Reassembly Forward Low Clutch ...................................................................................................................... 32
Reassembly Forward High Clutch ..................................................................................................................... 36
Disassembly First Clutch ................................................................................................................................... 39
Disassembly Reverse Clutch ............................................................................................................................. 42
Exploded View of Reverse - First Gear - Drive Clutch........................................................................................ 47
Reassembly Reverse Clutch .............................................................................................................................. 48
Reassembly First Clutch .................................................................................................................................... 52
Disassembly 2nd Clutch Drum ........................................................................................................................... 55
Exploded View of Second Gear Clutch ...............................................................................................................60
Resassembly 2nd Clutch Drum ......................................................................................................................... 61
Disassembly Output Shaft ................................................................................................................................. 65
Disassembly Disconnect Shaft .......................................................................................................................... 73
Exploded View of Output and Disconnect Shaft Clutch ......................................................................................74
Reassembly Disconnect Shaft ........................................................................................................................... 75
Disassembly Input Shaft .................................................................................................................................... 76
Exploded View of Input - Pump Drive Shaft........................................................................................................ 78
Reassembly Input Shaft ..................................................................................................................................... 79
Reassembly Converter Housing ........................................................................................................................ 80
Reassembly T16000 Transmission .................................................................................................................... 89
Disassembly Of The Transmission Control Valve .............................................................................................. 96
Assembly Of The Transmission Control Valve .................................................................................................. 96
Exploded View of Transmission Control Valve ...................................................................................................97

6007-3
SPECIAL TOOLS
T he fo ll owi ng s p ec ia l too l s ar e r equi re d t o

disassemble and assemble the Clark Powershift
Transmission.
BK98D134
CAS2585 Transmission Yoke Holding Bracket
BK98D180
CAS2582 Transmission Cover Lifting Bracket
BK98J179
CAS2586 - Clutch Spring Compressor
BK98J183
CAS2384 - 2 3/8 inch Hex Socket

6007-4
CAS40050 - L Series Loader/Backhoe Transmission
Tool Kit Consists of:
CAS2582 - Transmission Cover Lifting Bracket

CAS2583 - Transmission Test Adapter Set
CAS2584 - 2 3/8 inch Hex Socket
CAS2585 - Transmission Yoke Holding Bracket
CAS2586 - Clutch Spring Compressor
CAS2587 - Stack Lifting Bracket
CAS2588 - Transmission Mounting Bracket Set
CAS2589 - Transmission Mounting Bracket Set
BK98D137
CAS2590 - Transmission Nest Plate
CAS2587 - Stack Lifting Bracket
CAS2591 - Engine Support Bar
BK98J178
CAS2590 - Transmission Nest Plate

6007-5
SPECIFICATIONS
Type ...............................................................................................................................Gearbox Clark Hurth T16000
Weight.........................................................................................................................................260 kg (573 pounds)
Gearbox capacity (with filter) ............................................................................................. 14 litres (14.8 U.S. quarts)
Total circuit capacity .......................................................................................................... 21 litres (22.2 U.S. quarts)
Oil type ............................................................................................................................. Case MS 1214 Trans-XHD
SPECIAL TORQUES
Output flanges ...............................................................................................339 to 407 Nm (250 to 300 pound-feet)
Filter torque ...........................................................................................................30 to 38 Nm (22 to 28 pound-feet)
Control valve
Control valve mounting screws................................................................. 20 to 25 Nm (177 to 221 pound-inches)
Cover mounting screws ................................................................................ 7 to 12 Nm (62 to 106 pound-inches)
Connector nut to cover ..............................................................................................6 to 8 Nm (4 to 6 pound-feet)
Air breather .............................................................................................. 34 to 41 Nm (300 to 362 pound-inches)
Charge pump mounting screws .................................................................... 20 to 25 Nm (177 to 221 pound-inches)
Torque converter drive plate mounting screws ............................................. 18 to 32 Nm (159 to 283 pound-inches)
Transmission case to converter housing mounting screws........................... 40 to 50 Nm (354 to 442 pound-inches)
Filter adapter mounting screws .................................................................... 40 to 50 Nm (354 to 442 pound-inches)
Torque tables for plugs (O-ring ports)

Torque
Size Nm pound-feet
M10 x 1 8 - 10 5.9 - 7.4
M22 x 1.5 48 - 60 35.4 - 44.2
M33 x 2 112 - 140 82.5 - 103.2
Torque tables for pipe plugs

Torque
Size Nm pound-feet
M22 x 1.5 48 - 60 35.4 - 44.2
UNI 7707

6007-6
CLEANING AND INSPECTION
Cleaning Inspection
Clean all par ts thoroughly using solvent type The importance of careful and thorough inspection of
cleaning fluid. It is recommended that par ts be all parts cannot be overstressed. Replacement of all
immersed in cleaning fluid and moved up and down par ts showing indication of wear or stress will
slowly until all old lubricant and foreign material is eliminate costly and avoidable failures at a later date.
dissolved and parts are thoroughly cleaned.
Bearings
Bearings Carefully inspect all rollers, cages and cups for wear,
Remove bearings from cleaning fluid and strike flat chipping, or nicks to determine fitness of bearings for
against a block of wood to dislodge solidified further use. Do not replace a bearing cone or cup
particles of lubricant. Immerse again in cleaning fluid individually without replacing the mating cup or cone
to flush out particles. Repeat above operation until at the same time. After inspection, dip bearings in
bearings are thoroughly clean. Dry bearings using Automatic Transmission Fluid and wrap in clean lint
moisture-free compressed air. Be careful to direct air free cloth or paper to protect them until installed.
stream across bearing to avoid spinning. Do not spin
bearings when drying. Bearings may be rotated Oil Seals, Gaskets, etc.
slowly by hand to facilitate drying process.
Replacement of spring load oil seals, O-rings, metal
sealing rings, gaskets, and snap rings is more
Housings e c o no m i c a l wh e n u n i t i s d i s a s s e m bl e d t h a n
Clean interior and exterior of housings, bearing caps, premature overhaul to replace these parts at a future
etc., thoroughly. Cast parts may be cleaned in hot time. Further loss of lubricant through a worn seal
solution tanks with mild alkali solutions providing may result in failure of other more expensive parts of
these parts do not have ground or polished surfaces. the assembly. Sealing members should be handled
Parts should remain in solution long enough to be carefully, particularly when being installed. Cutting,
thoroughly cleaned and heated. This will aid the scratching, or curling under of lip of seal seriously
evaporation of the cleaning solution and rinse water. impairs its efficiency. When assembling new metal
Parts cleaned in solution tanks must be thoroughly type sealing rings, same should be lubricated with
rinsed with clean water to remove all traces of alkali. coat of chassis grease to stabilize rings in their
Cast parts may also be cleaned with steam cleaner. grooves for ease of assembly of mating members.
All par ts cleaned must be thoroughly dried Lubricate all O-rings and seals with recommended
immediately by using moisture-free compressed air type Automatic Transmission Fluid before assembly.
or soft, lint free absorbent wiping rags free of
abrasive mater ials such as metal fillings, Gears and Shafts
contaminated oil, or lapping compound.
Examine teeth on all gears carefully for wear, pitting,
chipping, nicks, cracks, or scores. If gear teeth show
spots where case hardening is worn through or
cracked, replace with new gear. Small nicks may be
removed with suitable hone. Inspect shafts and quills
to make certain they are not sprung, bent, or splines
twisted, and that shafts are true.
Housing, Covers, etc.

Inspect housings, covers and bearing caps to be
certain they are thoroughly clean and that mating
surfaces, bearing bores, etc., are free from nicks or
burrs. Check all parts carefully for evidence of cracks
or condition which would cause subsequent oil leaks
or failures.

6007-7
DISASSEMBLY T16000 TRANSMISSION

STEP 1 STEP 4
BK98J176 BK98J172
Remove the oil filter. Remove the drive plate screws, strap, cap screw, and
spacer.
STEP 2
STEP 5
BK98J174
Remove the filter adapter screws. CK97D005
Remove the drive plates.
STEP 3
STEP 6
BK98J173
Remove the filter adapter with O-ring. BK98J177
Remove the torque converter as an assembly.

6007-8
STEP 7 STEP 10
2
BK98J171 BK98J164
Remove the charging pump screws. Install the CAS2585 (1) on the flange as shown. Use
the CAS2584 (2) to loosen and remove the nut from
the upper output flange. Remove the CAS2585 (1)
STEP 8 from the flange.
STEP 11
BK98J169
Use a pry bars to remove charging pump.
BK98J163
STEP 9 Remove the washer and O-ring.
STEP 12
CK97D009
Remove the charging pump as an assembly, remove

O-ring.
BK98J162
Remove the upper output flange.

6007-9
STEP 13 STEP 16
CK97D013 CK97D016
Remove the air breather. Remove the control valve protection cover and
gasket.
STEP 14
STEP 17
CK97D014
Remove the control valve protection cover mounting CK97D017
screws. Remove the control valve mounting screws.
STEP 15 STEP 18
CK97D015 CK97D018
Remove the wiring connector mounting nut. Remove the control valve as an assembly. Remove
the bypass valve spool and spring.

6007-10
STEP 19 STEP 22
CK97D024 BK98J157
Remove the converter housing to transmission case Find the output shaft rear bearing retaining ring.
screws and lockwashers.
STEP 23
STEP 20
BK98J156
BK98J161 Co nn ec t ac c ep ta bl e l i fti ng e qu ip me nt t o th e
Remove the transmission case plug. CAS2582. Use spreading type snap ring pliers and
spread the ears on output shaft rear bear ing
retaining ring. Hold the snap ring open and tap on
STEP 21 output shaft and transmission case to remove the
case from the conver ter hous ing. Lift the
transmission case from the converter housing using
the CAS2582 lifting bracket.
BK98J158
Install the CAS2582 transmission cover lifting bracket

as shown.

6007-11
STEP 24 STEP 27
BK98J155 BK98J153
Remove the transmission case to converter housing Loosen and remove the Allen head screws that
gasket. fasten the suction tube to the converter housing.
STEP 25 STEP 28
BK98J154 BK98J152
Remove the O-rings from the converter housing. Remove the O-ring from the suction tube.
STEP 26 STEP 29
CK97D047 BK98J151
Remove the oil baffle to converter housing screws. Remove the suction tube.
Do not remove the oil baffle from the output shaft.

6007-12
10
9
2
1
8
7
4 6
3
2
1
BS99D150
1. CAP SCREW 6. BUSHING
2. LOCK WASHER 7. TORQUE CONVERTER ASSEMBLY
3. BUSHING PLATE 8. SEAL
4. DRIVE PLATE ASSEMBLY 9. CHARGE PUMP ASSEMBLY
5. FACE PLATE 10. PUMP SEAL
Exploded View of Torque Converter - Drive Plate - and Internal Charge Pump

6007-13
4
4
5 7
5
8
3 3
5
4 2 7
2 8
5 4
4 10
5 5
4 8
5 7 8
4
4 7
5 5
5
4
5
5 9
5
4
5
5 4
5 5
4
5 4
8
11 7
13
1
5 8
6 4 7
12
BS99D108
1. CONVERTER HOUSING 6. HOUSING SEAL 11. FILTER ADAPTER
2. BALL 7. CAP SCREW 12. FILTER
3. DETENT SPRING 8. LOCK WASHER 13. GASKET
4. PLUG 9. OIL HOUSING (1 PIECE)
5. O-RING 10. SUCTION TUBE
Exploded View of Converter Housing

6007-14
2
3
5
8
7
BS99D102
1. VALVE ASSEMBLY 5. BREATHER
2. SOCKET HEAD CAP SCREW 6. NUT
3. COVER SEAL 7. O-RING
4. HOUSING 8. WIRE HARNESS
Exploded View of Control Valve Mounting Assembly

6007-15
STEP 30 STEP 33
CK97D030 CK97D033
Remove the output shaft sealing rings. Output shaft rear bearing removed.
STEP 31 STEP 34
CK97D031 CK97D034
Remove the output shaft rear bearing retaining ring. Use a bearing puller to remove 2nd shaft rear
bearing.
STEP 32
STEP 35
CK97D032
Use a bearing puller to remove the output shaft rear CK97D035
bearing. 2nd shaft rear bearing removed.

6007-16
STEP 36 STEP 39
CK97D036 CK97D039
Use a bearing puller to remove the input shaft rear Use a bearing puller to remove the reverse and 1st
bearing. shaft rear bearing.
STEP 37 STEP 40
CK97D037 CK97D040
Input shaft rear bearing removed. Reverse and 1st shaft rear bearing removed.
STEP 38 STEP 41
CK97D038 CK97D041
Remove the reverse and 1st shaft sealing rings. Remove the forward low and forward high shaft
sealing rings.

6007-17
STEP 42 STEP 45
CK97D042 BK98J131
Use a bearing puller to remove the forward low and Install the shaft holding forks (part of CAS2587 tool)
forward high shaft rear bearing. in position on the shafts as shown.
STEP 43 STEP 46
CK97D043 BK98J132
Forward low and forward high shaft rear bearing Install the pins in the shaft holding forks (part of
removed. CAS2587 tool) as shown.
STEP 44 STEP 47
BK98J130 BK98J133
Install the CAS2587 in position on the shafts. Install the nut (part of CAS2587 tool) as shown.

6007-18
STEP 48 STEP 51
BK98J134 BK98J136
Install the cap screw (par t of CAS2587 tool) as Lower the shafts until the output shaft starts into the
shown. cup (1) (part of CAS2590).
STEP 49 STEP 52
BK98J147 BK98J135
Connecting acceptable lifting equipment to the Completely lower the shafts into the CAS2590
CAS2587. Lift the shafts out of the conver ter nesting plate. Remove the lifting equipment and the
housing. CAS2587 from the shafts.
STEP 50 STEP 53
1
BK98J111 CK97D056
Align the shafts with the CAS2590 nesting plate. Remove the safety valve plug, spring and ball.
Start the input shaft into the CAS2590 as shown. Put
the cup (1) (part of the CAS2590) for the output shaft
in position on the CAS2590.

6007-19
STEP 54 STEP 57
CK97D057 BK98J140
Remove the by-pass plug, spring and ball. Remove the lower output flange.
STEP 55 STEP 58
BK98J139 BK98J141
Install the CAS2585 on the flange. Use the CAS2584 Hit the output shaft with a soft hammer. Remove the
to loosen the nut on the lower output flange. Remove output shaft.
the CAS2585 from the flange. Remove the nut from
the lower output flange.
STEP 59
STEP 56
BK98J142
Remove the output shaft front bearing retainer ring.

BK98J138
Remove the washer and O-ring.

6007-20
STEP 60 STEP 62
BK98J143 BK98J120
Hit the output shaft bearing with a soft hammer. Remove the forward low and high clutch shaft from
Remove the output shaft bearing. the CAS2590 nesting plate. Place the forward low
and high clutch shaft on a clean bench.
STEP 61
STEP 63
BK98J143
Use an acceptable driver and remove the output BK98J121
shaft bearing cup from the converter housing. Remove the reverse and first clutch shaft from the
CAS2590 nesting plate. Place the reverse and first
clutch shaft on a clean bench.

6007-21
STEP 64 STEP 66
BK98J122 BK98J125
Remove the input shaft from the CAS2590 nesting Remove the second clutch shaft from the CAS2590
plate. Place the input shaft on a clean bench. nesting plate. Place the second clutch shaft on a
clean bench.
STEP 65
BK98J123
Remove the output shaft and oil baffle from the

CAS2590 nesting plate. Place the output shaft and
oil baffle on a clean bench.

6007-22
6
4
3
3
10 4
11 4
9
3
10 4
3
8
13
11
3
4
4 3
4
3
3
4
3
2 5
12
1 3
BS99D107
❁❁❁❁❁
1. TRANSMISSION HOUSING 6. COVER 11. LOCK WASHER

2. PIN 7. RETAINING RING 12. SNAP RING
3. PLUG 8. PLUG SEAL 13. BUSHING
4. O-RING 9. HOUSING SEAL
5. DRAIN PLUG 10. CAP SCREW
Exploded View of Rear Transmission Housing

6007-23
Disassembly Forward High Clutch STEP 69
STEP 67
CK97D061
Remove the clutch gear.
CK97D059
Remove the thrust washer and thrust bearing. STEP 70
STEP 68
CK97D062
Remove the clutch gear inner needle bearing.
CK97D060
Remove the clutch gear outer needle bearing.

6007-24
STEP 71 STEP 74
CK97D063 CK97D066
Remove the thrust washer and thrust bearing. Remove the clutch disc backing plate.
STEP 72 STEP 75
CK97D064 CK97D067
Remove the backing plate retaining ring. Remove one outer half disc.
STEP 73 STEP 76
CK97D065 CK97D068
Remove the clutch plate spacer. Remove the inner and outer discs.

6007-25
STEP 77 STEP 79
CK97D069 CK97D072
Remove one outer half disc. Remove the clutch spring spacer.
STEP 78 STEP 80
BK98J127 CK97D073
Use the CAS2586 clutch spring compressor tool. Remove the clutch piston spring retainer.
Compress the spring to remove spring retainer snap
ring. Remove the spring retainer snap ring.

6007-26
STEP 81 Disassembly Forward Low Clutch
STEP 84
CK97D074
Remove the clutch piston spring.
CK87D077
STEP 82 Use a bearing puller to remove the front bearing and
gear.
STEP 85
CK97D075
Remove the clutch piston wear plate.
STEP 83 CK97D078
Remove the front bearing and gear.
STEP 86
CK97D076
Remove the clutch piston assembly.
CK97D079
Remove the gear retainer ring.

6007-27
STEP 87 STEP 90
CK97D080 CK97D083
Use a bearing puller to remove the clutch gear and Remove the spacer.
outer bearing.
STEP 91
STEP 88
CK97D084
CK97D081 Remove the backing plate retaining ring.

Clutch gear and outer bearing removed.
STEP 92
STEP 89
CK97D085
CK97D082 Remove the clutch disc backing plate.

Remove the spacer snap ring.

6007-28
STEP 93 STEP 95
CK97D086 CK97D088
Use a bearing puller to remove the clutch gear inner Remove one outer half disc.
bearing
STEP 94
CK97D087
Clutch gear inner bearing removed.

6007-29
STEP 96 STEP 98
CK97D089 CK97D091
Remove the inner and outer discs. Remove the clutch gear inner bearing locating ring.
STEP 97 STEP 99
CK97D090 BK98J127
Remove one outer half disc. Use the CAS2586 clutch spring compressor tool.
Compress the spring to remove spring retainer snap
ring. Remove the spring retainer snap ring.

6007-30
STEP 100 STEP 102
CK97D094 CK97D096
Remove the clutch piston spring retainer. Remove the clutch piston wear plate.
STEP 101 STEP 103
CK97D095 CK97D097
Remove the clutch piston spring. Remove the clutch piston assembly.

6007-31
9
8
13 9
15 8
13 9
9 10
11
8
10
12
8 7
8
13 6
8 5
8 4
14
3
2
1
2
2
3 8 13
4 16
5 11 17
6 18
7 19
8 18
10 17
16
12
8
12 8 9
BS99D106
1. SHAFT DRUM 8. RETAINING RING 15. FORWARD DRIVEN GEAR
2. SEAL 9. EXTERNAL FRICTION DISC 16. THRUST WASHER
3. RING 10. INTERNAL FRICTION DISC 17. THRUST BEARINGR
4. PISTON 11. BACKING PLATE 18. NEEDLE BEARING
5. WEAR RING 12. SPACER 19. FORWARD HIGH GEAR
6. SPRING 13. BALL BEARING
7. SPRING SEAT 14. FORWARD/REVERSE GEAR
Exploded View of Forward Low and Forward High Clutch

6007-32
Reassembly Forward Low Clutch STEP 106
STEP 104
CK97D100
Install the clutch piston wear plate on the piston.
CK97D098
Install the clutch piston outer seal. STEP 107
NOTE: Ring must be sized before installing in clutch

drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with outer
diameter of piston.
STEP 105
CK97D101
Install the clutch piston spring.
STEP 108
CK97D099
Install the clutch piston inner seal. Install the clutch

piston in the clutch drum. Be careful not to damage
sealing rings.
CK97D102
Install the clutch piston spring retainer.

6007-33
STEP 109 STEP 112
CK97D103 CK97D106
Install the clutch spring retainer snap ring. Install one steel disc. Alternate friction and steel
discs until the proper amount of discs are installed.
The first and last discs are steel.
STEP 110
STEP 113
BK98J127
Use the CAS2586 clutch spring compressor tool.

Compress the spring ans install the spring retainer CK97D107
snap ring. Be sure ring is in full position in groove. Install one outer half disc with the friction material
down.
STEP 111
STEP 114
CK97D105
Install one outer half disc, with friction material away CK97D108
from the piston. Install the backing plate.

6007-34
STEP 115 STEP 118
CK97D109 CK97D112
Install the backing plate snap ring. Install the inner bearing snap ring.
STEP 116 STEP 119
CK97D110 CK97D113
Install the spacer. Install the clutch gear inner bearing.
STEP 117 STEP 120
CK97D111 CK97D114
Install the spacer snap ring. Use an acceptable tools and drive the inner bearing
into place.

6007-35
STEP 121 STEP 124
CK97D115 CK97D118
Install the clutch gear bearing locating rings. Use acceptable tools and drive the outer bearing into
place.
STEP 122
STEP 125
CK97D116
Install the clutch gear sealing ring. Install the clutch CK97D119
gear in the clutch drum. Align the splines on the Install the outer bearing snap ring.
clutch gear with internal teeth of the steel discs. Do
not force this operation. The gear splines must be in
full position with internal teeth of all the inner discs. STEP 126
STEP 123
CK97D120
Install the front gear.
CK97D117
Install the clutch gear outer bearing. Be sure that the

bearing shield is on the outside.

6007-36
STEP 127 STEP 129
CK97D121 CK97D123
Warm the front bearing to 120°C (248°F) and install Install the piston inner seal. Install the clutch piston in
the bearing. the clutch drum. Be careful not to damage the
sealing rings.
Reassembly Forward High Clutch STEP 130
STEP 128
CK97D124
Install the clutch piston wear plate on the piston.

CK97D122
Install the clutch outer seal. STEP 131

diameter of piston.
CK97D125
Install the clutch piston return spring.

6007-37
STEP 132 STEP 135
CK97D126 BK98J127
Install the piston return spring retainer. Use the CAS2586 clutch spring compressor tool.
Compress the spring and install the spring retainer
snap ring. Be sure ring is in full position in groove.
STEP 133
STEP 136
CK97D127
Install the spring retainer spacer.

CK97D130
Install one outer half disc with the friction material

STEP 134 away from the piston.
STEP 137
CK97D128
Install the clutch spring retainer snap ring.
CK97D131
Install one steel disc. Alternate friction and steel

discs until the proper amount of discs are installed.
The first and last discs are steel.

6007-38
STEP 138 STEP 141
CK97D132 CK97D135
Install one outer half disc with the friction material Install the backing plate spacer retainer ring.
down.
STEP 142
STEP 139
CK97D136
CK97D133 Install the thrust washer and the thrust bearing.

Install the backing plate.
STEP 143
STEP 140
CK97D137
CK97D134 Install the clutch gear inner needle bearing.

Install the backing plate spacer.

6007-39
STEP 144 STEP 146
CK97D138 CK97D140
Install the clutch gear in the clutch drum. Align the Install the thrust washer and the thrust bearing.
splines on the clutch gear with internal teeth of the
steel discs. Do not force this operation. The gear
splines must be in full position with the internal teeth Disassembly First Clutch
of all the inner discs.
STEP 147
STEP 145
CK97D143
CK97D139
Remove the clutch gear bearing retainer ring.
Install the clutch gear outer needle bearing.

6007-40
STEP 148 STEP 151
CK97D144 CK97D147
Use a bearing puller to remove the clutch gear and Remove the backing plate.
the outer bearing.
STEP 152
STEP 149
CK97D148
CK97D145 Remove the modulation spring.

STEP 153
STEP 150
CK97D149
CK97D146 Use a bearing puller to remove the clutch gear inner

Remove the backing plate retainer ring. bearing.

6007-41
STEP 154 STEP 157
CK97D150 CK97D153
Clutch gear inner bearing removed. Remove one outer half disc.
STEP 155 STEP 158
CK97D151 BK98J127
Compress the clutch piston belleville washer spring.
Remove the spring snap ring.
STEP 156
IMPORTANT: Force of disc spring is 3280 N (737
pound-force)!
STEP 159
CK97D152
Remove the inner and outer discs.
CK97D155
Spring retainer ring removed.

6007-42
STEP 160 Disassembly Reverse Clutch
STEP 163
CK97D156
Remove the disc belleville washer spring.
CK97D159
STEP 161 Use a bearing puller to remove the gear and the front
bearing.
STEP 164
CK97D157
Remove the clutch piston wear sleeve.
STEP 162 CK97D160
Gear and front bearing removed.
CK97D158
Remove the clutch piston assembly.

6007-43
STEP 165 STEP 168
CK97D161 CK97D164
Remove the clutch gear bearing retaining ring. Remove the spacer snap ring.
STEP 166 STEP 169
CK97D162 CK97D165
Use a bearing puller to remove the clutch gear and Remove the spacer.
the clutch gear outer bearing.
STEP 170
STEP 167
CK97D166
CK97D163 Remove the backing plate retaining ring.


6007-44
STEP 171 STEP 173
CK97D167 CK97D169
Remove the clutch disc backing plate. Clutch gear inner bearing removed.
STEP 172 STEP 174
CK97D168 CK97D170
Use a bearing puller to remove the clutch gear inner Remove one outer half disc.
bearing.

6007-45
STEP 175 STEP 177
CK97D171 CK97D173
Remove the inner and outer discs. Remove the inner bearing locating ring.
STEP 176 STEP 178
CK97D172 BK98J127
Compress the spring to remove the spring retainer
snap ring.

6007-46
STEP 179 STEP 182
CK97D175 CK97D178
Remove the spring retainer snap ring. Remove the clutch piston wear plate.
STEP 180 STEP 183
CK97D176 CK97D179
Remove the clutch piston spring retainer. Remove the clutch piston assembly.
STEP 181
CK97D177
Remove the clutch piston spring.

6007-47
8 13
8
14
8
13
15 8
13
9
9
8
10
10
16
11
8 5
8 17 4
3
2
1
2
2 13
3 8
11 8
4 13
5 12 8
6 18
7 10 8
8
13
10
9
BS99D105
1. SHAFT DRUM 8. RETAINING RING 15. REVERSE DRIVEN GEAR
2. SEAL 9. EXTERNAL FRICTION DISC 16. BELLVILLE SPRING
3. RING 10. INTERNAL FRICTION DISC 17. CLUTCH DISC SPACER
4. PISTON 11. BACKING PLATE 18. FIRST CLUTCH GEAR
5. WEAR RING 12. SPACER
6. SPRING 13. BALL BEARING
7. SPRING SEAT 14. FORWARD/REVERSE GEAR
Exploded View of Reverse - First Gear - Drive Clutch

6007-48
Reassembly Reverse Clutch STEP 186
STEP 184
CK97D182
Install the piston wear plate on the piston.
CK97D180
Install the clutch piston outer seal. STEP 187

diameter of piston.
STEP 185
CK97D183
STEP 188
CK97D181

the sealing rings.
CK97D184
Install the clutch piston spring retainer.

6007-49
STEP 189 STEP 192
CK97D185 CK97D188
Install the clutch spring retainer snap ring. Install one steel disc. Alternate the friction and the
steel discs until the proper amount of discs are
installed. The first and last discs are steel.
STEP 190
STEP 193
BK97J127

Compress the spring and install the spring retainer CK97D189
snap ring. Be sure the ring is in full position in the Install one outer half disc with the friction material
groove. down.
STEP 191 STEP 194
CK97D187 CK97D190
Install one outer half disc, with the friction material Install the backing plate.
away from the piston.

6007-50
STEP 195 STEP 198
CK97D191 CK97D194
Install the backing plate snap ring. Install the inner bearing snap ring.
STEP 196 STEP 199
CK97D192 CK97D195
Install the spacer. Install the clutch gear inner bearing.
STEP 197 STEP 200
CK97D193 CK97D196
Install the spacer snap ring. Use acceptable tools and drive the bearing into
place.

6007-51
STEP 201 STEP 203
CK97D197 CK97D199
Install the clutch gear bearing locating rings. Install the clutch gear outer bearing.
Caution : Be sure that bearing shield is on

STEP 202 ! the outside.
STEP 204
CK97D198
Install clutch gear sealing ring. Install clutch gear in

clutch drum. Align splines on clutch gear with internal
teeth of steel discs. Do not force this operation. Gear CK97D200
splines must be in full position with internal teeth of
Use acceptable tools and drive the outer bearing into
all inner discs.
place.
STEP 205
CK97D201
Install the outer bearing snap ring.

6007-52
STEP 206 Reassembly First Clutch
STEP 208
CK97D202
Install the front gear.
CK97D204
STEP 207 Install the clutch piston outer seal.

diameter of piston.
STEP 209
CK97D203
Warm the front bearing to 120°C (248°F) and install

the bearing.
CK97D205
Install the piston inner seal. Install the clutch piston in

the clutch drum. Be careful not to damage the
sealing rings.

6007-53
STEP 210 STEP 213
CK97D206 BK98J127
Install the clutch piston wear sleeve. Use the CAS2586 clutch spring compressor tool.
Compress the spring and install the spring retainer
ring. Be sure the ring is in full position in the groove.
STEP 211
STEP 214
CK97D207
Install the piston return disc springs. Install the first

spring with the large diameter of the bevel toward the CK97D210
wear sleeve. Alternate the position of the remaining Install one outer half disc with the friction material
eleven (11) springs. away from the piston.
STEP 212 STEP 215
CK97D208 CK97D211
Install the disc belleville washer spring retainer ring. Install one steel disc. Alternate the friction and the
steel discs until the proper amount of the discs are
installed. The first and the last discs are steel.

6007-54
STEP 216 STEP 219
CK97D212 CK97D215
Install one outer half disc with the friction material Install the backing plate snap ring.
down.
STEP 220
STEP 217
CK97D216
CK97D213 Install the clutch disc hub inner bearing.

Install the modulation spring with the large diameter
up to the backing plate.
STEP 221
STEP 218
CK97D217
Use acceptable tools and drive the inner bearing into

CK97D214 place.
Install the backing plate.

6007-55
STEP 222 STEP 225
CK97D218 CK97D221
Install the clutch hub bearing locating rings. Install Install the outer bearing retaining ring.
the clutch gear in the clutch drum. Align the splines
on the clutch gear with the internal teeth of the steel
discs. Do not force this operation. The gear splines STEP 226
must be in full position with the internal teeth of all
the steel discs.
STEP 223
CK97D222
Install the clutch shaft sealing rings.
CK97D219 Disassembly 2nd Clutch Drum

Install the clutch hub outer bearing. Be sure that the
bearing shield is on the outside.
STEP 227
STEP 224
BK98J128
Use acceptable tools and remove the upper output

CK97D220
gear from the 2nd shaft.
Use acceptable tools and drive the outer bearing into
the clutch hub.

6007-56
STEP 228 STEP 231
CK97D224 CK97D227
Remove the gear from the 2nd shaft. Use a bearing puller to remove the clutch hub and
the front bearing.
STEP 229
STEP 232
CK97D225
Remove the gear retaining ring. CK97D228
Remove the clutch shaft front bearing.
STEP 230
STEP 233
CK97D226
Remove the clutch shaft sealing rings. CK97D229
Remove the bearing washer.

6007-57
STEP 234 STEP 237
CK97D230 CK97D233
Remove the clutch hub and the outer bearing. Remove the backing plate snap ring.
STEP 235 STEP 238
CK97D231 CK97D234
Use a bearing puller to remove the clutch hub inner Remove the backing plate.
bearing.
STEP 239
STEP 236
CK97D235
CK97D232 Remove the modulation spring.

Remove the clutch hub inner bearing.

6007-58
STEP 240 STEP 242
CK97D236 CK97D238
Remove one outer half disc. Remove one outer half disc.
STEP 241 STEP 243
CK97D237 CK97D239
Remove the inner and outer discs. Use the CAS2586 clutch spring compressor tool.
snap ring. Remove the spring retainer snap ring.

6007-59
STEP 244 STEP 247
CK97D240 CK97D243
Remove the spring retaining ring. Remove the piston wear plate.
STEP 245 STEP 248
CK97D241 CK97D244
Remove the spring retainer. Remove the clutch piston assembly.
STEP 246
CK97D242
Remove the clutch piston return spring.

6007-60
14
8
13 8
15
13
2 9
10
10
9
12
11
7
13
1
2
3
4
5
6
7 21
8 20
19
18
13
17
16
8
BS99D104
1. SHAFT DRUM 8. RETAINING RING 15. BEARING SUPPORT RING
2. SEAL 9. EXTERNAL FRICTION DISC 16. LOWER OUTPUT DRIVE GEAR
3. PISTON RING 10. INTERNAL FRICTION DISC 17. UPPER OUTPUT GEAR
4. PISTON 11. BACKING PLATE 18. FLANGE
5. WEAR RING 12. SPACER 19. O-RING
6. SPRING 13. BALL BEARING 20. SPECIAL WASHER
7. SPRING SEAT 14. SECOND CLUTCH GEAR 21. NUT
Exploded View of Second Gear Clutch

6007-61
Resassembly 2nd Clutch Drum STEP 251
STEP 249
CK97D247
Install the piston wear plate.
CK97D245
Install the piston outer seal. STEP 252

diameter of piston.
STEP 250
CK97D248
Install the piston return spring.
STEP 253
CK97D246

sealing rings.
CK97D249
Install the spring retainer.

6007-62
STEP 254 STEP 257
CK97D250 CK97D253
Install the spring retainer snap ring. Install one steel disc. Alternate the friction and the
steel discs until the proper amount of discs are
installed. The first and the last discs are steel.
STEP 255
STEP 258
BK98J127

Compress the spring to install the spring retainer CK97D254
snap ring. Install the spring retainer snap ring. Be Install one outer half disc with the friction material
sure the ring is in the full position in the groove. down.
STEP 256 STEP 259
CK97D252 CK97D255
Install one outer half disc with the friction material Install the modulator spring with large diameter up to
away from the piston. the backing plate.

6007-63
STEP 260 STEP 263
CK97D256 CK97D259
Install the backing plate. Use acceptable tools and drive the clutch gear inner
bearing into place.
STEP 261
STEP 264
CK97D257
Install the backing plate retainer ring. CK97D260
Install the clutch hub bearing locating rings. Install

the clutch gear in the clutch drum. Align the splines
STEP 262 on the clutch gear with the internal teeth of the steel
discs. Do not force this operation. The gear splines
must be in full position with the internal teeth of all
the steel discs.
STEP 265
CK97D258
Install the clutch hub inner bearing.
CK97D261
Install the clutch hub outer bearing.

6007-64
STEP 269
Caution : Be sure that bearing shield is on
! the outside.
STEP 266
CK97D265
Install the clutch shaft sealing rings.
STEP 270
CK97D262
Use accetable tools and drive the outer bearing into

place.
STEP 267
CK97D266
Install the gear retaining ring.
STEP 271
CK97D263
Install the bearing washer.
STEP 268
CK97D267
Install the lower output gear on the shaft.
CK97D264
Warm the front bearing to 120°C (248°F), install the

bearing.

6007-65
STEP 272 STEP 274
CK97D268 CK97D271
Install the upper output gear on the shaft. Remove the output shaft sealing rings.
STEP 275
Disassembly Output Shaft
NOTE: The following photo is for reference only. The
oil baffle is one piece and should be removed as one
piece.
STEP 273
CK97D272
Remove the output shaft gear retaining ring.
STEP 276
CK97D270
Remove the oil baffle.
CK97D273
Use acceptable tools and press output gear from the

shaft.

6007-66
STEP 277 STEP 280
CK97D274 CK97D278
Remove the output gear. Remove the backing plate spacer.
STEP 278 STEP 281
CK97D276 CK97D279
Remove the gear retaining ring. Remove the backing plate.
STEP 279 STEP 282
CK97D277 CK97D280
Remove the backing plate snap ring. Remove one outer half disc.

6007-67
STEP 283 STEP 285
CK97D281 BK98J127
Remove the inner and outer discs. Use the CAS2586 clutch spring compressor tool.
snap ring. Remove the spring retainer snap ring.
STEP 284
STEP 286
CK97D282
Remove one outer half disc.

CK97D284
Remove the spring retaining ring.

6007-68
STEP 287 STEP 289
CK97D285 CK97D287
Remove the spring retainer. Remove the piston wear plate.
STEP 288 STEP 290
CK97D286 CK97D288
Remove the clutch piston spring. Remove the piston assembly.

6007-69
Reassembly Output Shaft STEP 293
STEP 291
CK97D291
Install the piston wear plate on the piston.
CK97D289
Install the piston outer seal. STEP 294

diameter of piston.
STEP 292
CK97D292
CK97D290

the sealing rings.

6007-70
STEP 295 STEP 297
CK97D293 CK97D295
Install the spring retainer. Install one outer half disc with the friction material
away from the piston.
STEP 296
STEP 298
BK98J127
Use the CAS2586 clutch spring compressor tool. CK97D296
Compress the spring to install the spring retainer Install one steel disc. Alternate the friction and steel
snap ring. Be sure the ring is in full position in the discs until the proper amount of discs are installed.
groove. The first and last discs are steel.

6007-71
STEP 299 STEP 301
CK97D297 CK97D299
Install one half disc with the friction material down Install the backing plate spacer.
STEP 300 STEP 302
CK97D298 CK97D300
Install the backing plate. Install the backing plate snap ring.

6007-72
STEP 303 STEP 305
CK97D302 CK97D304
Install the output gear retaining ring. Install the output gear retaining ring.
STEP 304 STEP 306
CK97D303 CK97D305
Install the lower output gear. Install the output shaft sealing rings.

6007-73
STEP 307 STEP 310
CK97D306
CK97D310
Install the oil baffle on the output shaft.
Remove the front bearing retaining ring.
Disassembly Disconnect Shaft STEP 311

STEP 308
CK97D311
Remove the clutch hub from shaft.

CK97D308
Use a bearing puller to remove the disconnect shaft

front bearing. STEP 312
STEP 309
CK97D312
Remove the clutch hub locating ring from the shaft.
CK97D309
Remove the front bearing.

6007-74
11
8
12
15
8
16
8
13
17
19 18
4
20
10 5
6
10 7
8
10
9
2
9 8
13
8
9
8 14
1
2
3
BS99D103
1. FRONT OUTPUT SHAFT DRUM 8. RETAINING RING 15. FRONT OUTPUT SHAFT
2. SEAL 9. EXTERNAL FRICTION RING 16. DISCONNECT HUB
3. RING 10. INTERNAL FRICTION RING 17. FLANGE
4. PISTON 11. BACKING PLATE 18. O-RING
5. WEAR RING 12. BUSHING 19. WASHER
6. SPRING 13. BALL BEARING 20. NUT
7. SPRING SEAT 14. LOWER OUTPUT GEAR
Exploded View of Output and Disconnect Shaft Clutch

6007-75
Reassembly Disconnect Shaft STEP 316
STEP 313
CK97D316
Install the front bearing retaining ring.
CK97D313
Install the bushing if necessary. STEP 317
STEP 314
CK97D317
Install the front bearing on the shaft.
CK97D314
Install the clutch hub locating ring. STEP 318
STEP 315
CK97D318
Use acceptable tools and drive the bearing on the

shaft.
CK97D315
Install the clutch hub on the shaft.

6007-76
Disassembly Input Shaft STEP 321
STEP 319
CK97D329
Remove the forward low gear retaining ring.
CK97D327
Remove the input shaft rear sealing ring. STEP 322
STEP 320
CK97D330
Remove the input shaft front sealing ring.
CK97D328
Remove the forward high gear retaining ring.

6007-77
STEP 323 STEP 326
CK97D331 CK97D334
Use a bearing puller to remove the input shaft front Remove the forward low gear retaining ring.
bearing.
STEP 327
STEP 324
CK97D335
CK97D332 Use acceptable tools and remove the forward low

Remove the input shaft front bearing. gear from the shaft.
STEP 325
CK97D333
Remove the input shaft front bearing retaining ring.

6007-78
6
3
3
5
3
4
2
BS99D149
1. INPUT SHAFT 4. BALL BEARING
2. SEAL 5. FORWARD LOW GEAR
3. RETAINING RING 6. FORWARD HIGH GEAR
Exploded View of Input - Pump Drive Shaft

6007-79
Reassembly Input Shaft STEP 331
STEP 328
CK97D339
Install the input shaft front bearing retaining ring.
CK97D336
Install the forward low gear retaining ring. STEP 332
STEP 329
CK97D340
Install the input shaft front sealing ring.
CK97D337
Install the forward low gearon the shaft. STEP 333
STEP 330
CK97D341
Warm the input shaft front bearing to 120°C (248°F),

CK97D338
Install the forward low gear retaining ring.

6007-80
STEP 334 STEP 337
CK97D342 CK97D345
Turn the shaft and install the input shaft forward high Install the by-pass valve ball spring and plug.
gear retaining ring.
STEP 338
STEP 335
CK97D346
CK97D343 Install the output shaft front oil seal.

Install the input shaft rear sealing ring.
STEP 339
Reassembly Converter Housing
STEP 336
CK97D347
Use acceptable tools and drive the seal into place.
NOTE: Using caution as not to damage any of the

CK97D344
shaft sealing rings.
Install the safety valve ball spring and plug.

6007-81
STEP 340 STEP 343
BK98J146 CK97D351
Use acceptable tools and drive the output shaft

Install the disconnect shaft assembly in the converter
bearing cup in the converter housing.
housing. Use acceptable tools and spread the
bearing retaining ring. Drive the shaft into place. Be
STEP 341 sure the ring is in the groove.
STEP 344
BK98J125
Install the output shaft bearing.

CK97D351
STEP 342 Install the lower output flange in place on the output
shaft.
STEP 345
BK98J142
Install the output shaft front bearing retainer ring.
BK98J138
Install the washer and O-ring.

6007-82
STEP 346 STEP 348
BK98J139 BK98J124
Start the nut on the lower output flange. Install the Put the cup in position in the CAS2590 nesting plate.
CAS2585 on the flange. Use the CAS2584 to tighten
the nut on the lower output flange to a torque of 339
to 407 Nm (250 to 300 pound-feet). Remove the STEP 349
CAS2585 from the flange.
STEP 347
BK98J123
Put the output shaft and oil baffle in position in the

CAS2590 nesting plate.
BK98J125
Put the second clutch shaft in position in the


6007-83
STEP 350 STEP 352
BK98J122 BK98J120
Put the input shaft in position in the CAS2590 nesting Put the forward low and high clutch shaft in position
plate. in the CAS2590 nesting plate.
STEP 351 STEP 353
BK98J121 BK98J130
Put the reverse and first clutch shaft in poisition in the Put the CAS2587 in position on the shafts.

6007-84
STEP 354 STEP 356
BK98J131 BK98J133
Put the shaft holding forks (part of CAS2587 tool) in Install the nut (part of CAS2587 tool) as shown.
position on the shafts as shown.
STEP 357
STEP 355
BK98J134
BK98J132 Install the cap screw (par t of CAS2587 tool) as

Install the pins in the shaft holding forks (part of shown.
CAS2587 tool) as shown.

6007-85
STEP 358 STEP 360
2
BK98J135 BK98J148
Co nne c t ac c ep ta bl e l if ti ng e qu ip me nt t o th e When the shafts are nearing the converter housing it

CAS2587. may be necessary to rotate the lower ouput flange (1)
back and forth slightly . This will allow the splines of
the disconnect shaft (3) and the output shaft (2) to
STEP 359 mesh smoothly as the shafts are being lowered into
the converter housing.
STEP 361
BK98J147
Move the shafts out of the CAS2590 nesting plate

and into position over the converter housing. Begin
lowering the shafts very slowly into the converter
housing. BK98J134
After the shafts are installed in the converter housing,

remove the cap screw from the CAS2587 tool.

6007-86
STEP 362 STEP 364
BK98J133 BK98J131
Remove the nut from the CAS2587 tool. Remove the shaft holding forks from the CAS2587
tool.
STEP 363
STEP 365
BK98J132
BK98J130
Remove the pins from the shaft holding forks of the
CAS2587 tool. Remove the CAS2587 from the shafts.

6007-87
STEP 366 STEP 369
CK97D354 CK97D356
Install the baffle plate, mounting screws, washers Install the O-ring on the suction tube.
and nuts. Apply Loctite 243 to the threads of the
screws and tighten the nuts to a torque of 40 to 50
Nm (354 to 442 pound-inches). STEP 370
STEP 367
CK97D357
Install the suction tube retainer, mounting screws and

CK97D355
lockwashers. Apply Loctite 243 to the threads of the
screws and tighten the screws to a torque of 40 to 50
Install the oil baffle, mounting screws and washers.
Nm (354 to 442 pound-inches).
Apply Loctite 243 to the threads of the screws and
tighten the screws to a torque of 40 to 50 Nm (354 to
442 pound-inches). STEP 371
STEP 368
CK97D358
Install the O-rings in the converter housing.

BK98J151
Put the suction tube in position on the housing.

6007-88
STEP 372 STEP 375
CK97D359 CK97D362
Install the output shaft rear bearing retaining ring. Warm the reverse and 1st shaft rear bearing to
120°C (248°F), install the bearing.
STEP 373
STEP 376
CK97D360
Install the forward high gear. CK97D363
Warm the input shaft rear bearing to 120°C (248°F),

STEP 374
STEP 377
CK97D361
War m the upper output rear bearing to 120°C

(248°F), install the bearing. CK97D364
Warm the forward low and high shaft rear bearing to

120°C (248°F), install the bearing.

6007-89
STEP 378 Reassembly T16000 Transmission
STEP 381
CK97D365
Warm the lower output shaft rear bearing to 120°C

(248°F), install the bearing.
CK97D368
Remove the lower output bore plug. Attach the

STEP 379 CAS2582 transmission cover lifting bracket to the
transmission case. Use acceptable lifting equipment
an d pos i tio n the tra ns mi ss i on c as e ove r th e
converter housing. Lower the transmission case
slowly onto the converter housing.
STEP 382
CK97D366
Install the output shaft rear bearing retaining ring.
STEP 380
CK97D369
Using spreading type snap ring pliers, spread the

ears on output shaft rear bearing retaining ring.
While holding the snap r ing open, use a soft
hammmer and carefully tap the transmission case
into place on the converter housing.
CK97D367
Install the gasket and clutch pressure O-rings (4) into

the O-ring grooves.

6007-90
STEP 383 STEP 385
1
1
CK97D370 CK97D372
Drive the dowel pin (1) into the transmission case Using spreading type snap ring pliers, spread the
and converter housing. ears on the output shaft rear bearing retaining ring.
Hold the snap ring open. Using a lifting eye (1) or
M12 screw , pry or lift the output shaft until the
STEP 384 retaining ring is installed in the groove on the shaft.
Make sure the retaining ring is completely installed in
the groove.
STEP 386
CK97D371
Install the transmission case to converter housing

mounting screws and lockwashers. Tighten the
mounting screws to a torque of 40 to 50 Nm (354 to
442 pound-inches).
CK97D373
Install the hole plug and gasket.

6007-91
STEP 387 STEP 389
CK97D374 CK97D376
Tighten the plug to a torque of 14 to 20 Nm (120 to Position the upper output seal.
180 pound-inches).
STEP 390
STEP 388
CK97D377
CK97D375 Use acceptable tools and drive the seal into place.
Position the lower output bore plug. Use acceptable
tools and drive the bore plug into place.

6007-92
STEP 391 STEP 393
CK97D378 BD99D001
Install the upper output flange, O-ring, washer and Install the O-ring on the pump hole cover . Install the
nut and tighten the nut to a torque of 339-407 Nm pump hole cover into the transmission case. Install
(250 to 300 pound-feet). the pump hole cover retaining ring into the retaining
ring groove.
STEP 392
STEP 394
CK97D379
Install the pump drive shaft assembly into the CK97D383
housing. Install the pump and O-ring into the conver ter
housing.

6007-93
STEP 395 STEP 397
CK97D384 CK97D386
Install the pump mounting screws and lockwashers. Install the drive plates on the converter.
Tighten the screws to a torque of 20 to 25 Nm (177 to
221 pound-inches).
STEP 398
STEP 396
CK97D387
Install the drive plates screws and lockwashers.

CK97D385 Tighten the screws to a torque of 18 to 32 Nm (159 to
Install the converter assembly on the input shaft. 283 pound-inches).
Rotate the converter while pushing the converter
towards the transmission until the tangs on the
converter shaft are aligned with the grooves of the STEP 399
pump shaft. After the tangs are aligned with the
grooves, the converter will slide into place.
CK97D388
Install the filter adapter, O-ring, lockwashers and

mounting screws.

6007-94
STEP 400 STEP 402
CK97D389 CK97D012
Tighten the screws to a torque of 40 to 50 Nm (354 to Install the output shaft front flange, O-ring, washer
442 pound-inches). and nut. Install the CAS2584 on the flange. Use the
CAS2584 and tighten the nut to a torque of 339 to
407 Nm (250 to 300 pound-feet).
STEP 401
STEP 403
CK97D390
Install the oil filter and tighten to a torque of 30 to 38

Nm (265 to 336 pound-inches). CK97D393
Install the by-pass valve spool into solenoid housing

and the spring into transmission case. Position the
control valve on the transmission case.

6007-95
STEP 404 STEP 407
CK97D394 CK97D397
Install control the valve mounting screws and Install the air breather and tighten to a torque of 34 to
lockwashers. Tighten the screws to a torque of 20 to 41 Nm (300 to 362 pound-inches).
25 Nm (177 to 221 pound-inches).
STEP 408
STEP 405
CK97D398
CK97D395 Install the wiring connector nut and tighten to a

Position the wiring connector in the valve protection torque of 6 to 8 Nm (53 to 70 pound-inches).
cover.
STEP 406
CK97D396
Install the gasket and the valve protection cover

mounting screws. Tighten the screws to a torque of 7
to 12 Nm (62 to 106 pound-inches).

6007-96
Disassembly Of The Transmission Assembly Of The Transmission

Control Valve Control Valve
STEP 409 STEP 416

Remove the transmission control valve from the
Lubricate new O-rings (2) with clean transmission oil.
transmission.
Install the O-rings (2) on the wire harness (1) and the
valve sensor (3). Install the valve sensor (3) into the
STEP 410 control valve. Make sure the notch in the sensor (3) is
aligned in the transmission valve body.
Mark the electrical connectors (9) for each solenoid
valve (6) and mar k the solenoid valve (6) for
STEP 417
reference during assembly. Mark the connector (9)
for the solenoid module (7) for reference during
Install the bypass valve spool (4) and spring (5) into
assembly.
the transmission control valve.
STEP 411 STEP 418

Remove the connectors (9) from the solenoid valves
Using the reference marks made during disassembly,
(6) and the solenoid module (7).
install the solenoid valves (6) and the solenoid
module (7) into the control valve.
STEP 412
STEP 419
Loosen and remove the bail screws (10). Remove the
valve bail (8) from the control valve.
Install the valve bail (8) onto the control valve. Install
and tighten the bail screws (10).
STEP 413
STEP 420
Remove the solenoid valves (6) and the solenoid
module (7) from the control valve.
Using the reference marks made during disassembly,
install the harness connectors (9) onto the solenoid
STEP 414 valves (7) and the solenoid module (7).
Remove the bypass valve spool (4) and spring (5)

STEP 421
form the control valve.
Ins tall th e tran smi ss io n c ontr ol valve o n th e
STEP 415 transmission.
Remove the valve sensor (3) and valve harness (1)

from the control valve. Remove and discard the O-
rings (2).

6007-97
6
10
9
6
5
4
3
2
2
BS99d109
1. VALVE HARNESS 6. SOLENOID VALVE
2. O-RING 7. SOLENOID MODULE
3. VALVE SENSOR 8. VALVE BAIL
4. BYPASS VALVE SPOOL 9. WIRE CONNECTORS
5. BYPASS VALVE SPRING 10. BAIL SCREWS
Exploded View of Transmission Control Valve

Section
7003
7003
MASTER CYLINDER
CASE CORPORATION
700 STATE STREET
7003-2
TABLE OF CONTENTS
MASTER CYLINDER ..................................................................................................................................................................... 2
Disassembly ............................................................................................................................................................................. 2
Inspection ................................................................................................................................................................................. 4
Assembly .................................................................................................................................................................................. 4
NOTE: The Case Corporation 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.
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 of the
1. Clean the outside of the master cylinder. master cylinder.
2. Fasten the body (6) of the master cylinder is the vise. 13. Pull the piston assembly from the master cylinder.
3. Remove the flow valve adapter (1) from the master 14. There is a small tab in the spring seat (12) that holds the
cylinder. spring seat (12) on the piston (13). Use a screwdriver to
left up the tab.
4. Remove the flow valve (3) fro 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
7. Remove the flow valve seal (4) fro the flow valve (3). (12).
8. Loosen the lock nut. Remove the clevis and lock nut from 18. Remove the spring (11) from the spring seat (12).
the push rod (15).
19. Remove the check valve seat (10) fro the check valve
9. Remove the boot (18) from the body (6). piston (8).
10. Remove the snap ring (17) from the body (6). 20. Remove the wave spring (9) from the check valve piston
(8).
11. Remove the push rod (15) and washer (16) from the body
(6). 21. Remove the check valve seal (7) from the check valve
piston (8).

7003-3
3
4
5 6
8
9
10
11
12
13
14
17 15
16
18
B9502283T
1. Flow Valve Adapter 6. Body 11. Spring 16. Washer

2. Gasket 7. Check Valve Seal 12. Spring Seat 17. Snap Ring
3. Flow Valve 8. Check Valve Piston 13. Piston 18. Boot
4. Flow Valve Seal 9. Wave Spring 14. Seal
5. Ball 10. Check Valve Seat 15. Push Rod
Master Cylinder

7003-4
Inspection 14. Lubricate the flow valve seal (4) and the flow valve (3)
with clean hydraulic oil. Install the flow valve (3) in the
1. Inspect the bores in the body (6) for scoring, pitting, or bore in the master cylinder. The flow valve (3) must be
other damage. If the bores in the body (6) are damaged a centered in the bore of the master cylinder.
new master cylinder must be used.
15. Install a new gasket (2) on the flow valve adapter (1).
2. Check the tab in the spring seat (12). Push the tab down
a small amount so that the tab will engage the end of the 16. Carefully start the flow valve adapter (1) into the bore in
piston (8). to hold the check valve assembly in place. If the master cylinder by hand. If the flow valve adapter (1)
the tab is broken, use a new master cylinder. cannot be turned into the master cylinder completely by
hand remove the flow valve adapter (1) from the master
3. Inspect the flow valve (3), ball (5). check valve piston (8), cylinder and make sure that the flow valve (3) is in the
piston (13), and the push rod (15) for scoring, pitting, or center of the bore in the master cylinder.
other damage. If the flow valve (3), ball (5), check valve
piston (8), piston (13) or the push rod (15) are damage a 17. Repeat step 16 until the flow valve adapter (1) can be
new master cylinder must be used. turned completely into the master cylinder by hand.
18. Tighten the flow adapter (1) to 30 to 40 pound-feet (41 to

Assembly 47 Nm).
1. Install the check valve seal (7) on the check valve piston 19. See Section 7002 and install the master cylinder on the
(8). machine.
2. Install the spring (11) on the spring seat (10). 20. Depress the brake pedal and allow the piston to return.
Adjust the push rod to piston clearance to 0.025 to 0.050
3. Instal the check valve assembly in the spring (11). inch (0.6 to 1.3 mm). Turn the clevis clockwise to shorten
Engage the stem of the check valve piston (8) in the or counterclockwise to lengthen. Tighten the lock nut
spring seat (12). against the clevis. See the illustration below.
4. Install the check valve assembly on the piston (13). Push
the check valve assembly onto the piston (13) until the
tab in the spring seat (12) engages the end of the piston
(13).
0.025 to 0.05 Inch
(0.6 to 1.3 mm)
5. Install the seal (14) on the piston (13).
6. Lubricate the bore of the body (6) with clean hydraulic

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. B870123R
9. Install the push rod (15) and washer (16).

1. 0.025 to 0.050 INCH (0.6 to 1.3 mm)
10. Install the snap ring (17).
11. Install the boot (18).
12. Install the lock nut and clevis on the push rod (15). Do not
tighten the lock nut on the push rod at this time.
13. Install the ball (5) in the body (6).

7003-5
3
4
5 6
8
9
10
11
12
13
14
17 15
16
18
B9502283T
1. Flow Valve Adapter 6. Body 11. Spring 16. Washer

2. Gasket 7. Check Valve Seal 12. Spring Seat 17. Snap Ring
3. Flow Valve 8. Check Valve Piston 13. Piston 18. Boot
4. Flow Valve Seal 9. Wave Spring 14. Seal
5. Ball 10. Check Valve Seat 15. Push Rod
Master Cylinder

Section
8003
8003
CLEANING THE HYDRAULIC SYSTEM
CASE CORPORATION
700 STATE STREET
8003-2
TABLE OF CONTENTS
PORTABLE FILTER ..................................................................................................................................................... 3
GENERAL INFORMATION ............................................................................................................................................ 4
TYPES OF CONTAMINATION ....................................................................................................................................... 4
CLEANING THE HYDRAULIC SYSTEM .......................................................................................................................... 5
FLUSHING WATER FROM THE HYDRAULIC SYSTEM .................................................................................................... 7
NOTE: The Case Corporation 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.

8003-3
SPECIAL TOOLS
806128
The part number for the Fitting Kit is CAS-10508.
806127
The part number for the Portable Filter is CAS-10162A.

8003-4
GENERAL INFORMATION
Contamination in the hydraulic system is a major cause of 1. Cylinder rod seals leak.
the malfunction of hydraulic components. Contamination is
any foreign material in the hydraulic oil. Contamination can 2. Control valve spools do not return to neutral.
enter the hydraulic 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 components.
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
All hydraulic systems operate with some contamination. power.
The design of the components in this hydraulic system
per mits efficient operation with a small amount of If your machine has any of these problems, check the
contamination. An increase in this amount of contamination hydraulic oil for contamination. See Types of Contamination
can cause problems in the hydraulic system. The following list below. If you find contamination, use the Portable Filter to
includes some of these problems. clean the hydraulic system.
TYPES OF CONTAMINATION
There are two types of contamination, microscopic and 3. Visible contamination is foreign material that can be
visible. found by sight, touch, or odor. Visible contamination can
cause a sudden failure of components. Examples of
1. Microscopic contamination occurs when very fine visible contamination:
particles of foreign material are in suspension in the
hydraulic oil. a. Particles of metal or dirt in the oil.
2. These particles are too small to see or feel. Microscopic b. Air in the oil.
contamination can be found by identification of the
following problems or by testing in a laboratory. Examples c. The oil is dark and thick.
of the problems:
d. The oil has the odor of burned oil.
a. Cylinder rod seal leak.
e. Water in the oil. See page 7.
b. Control valve spools do not return to NEUTRAL.
c. The hydraulic system has a high operating

temperature.

8003-5
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter on page 3 by doing the 8. See the fitting kit shown on page 3. Install the valve in the
following steps: hole for the drain plug. Make sure that the valve is closed.
a. Remove all the hydraulic oil from the inlet and outlet 9. Stop the vacuum pump.
hoses for the portable filter.
10. Connect the inlet hose for the portable filter to the valve
b. Remove the filter element from the portable filter. that is installed in the hole for the drain plug.
c. Remove all hydraulic oil from the portable filter. 11. Disconnect the vacuum pump from the filler cap opening
on the hydraulic reservoir.
d. Clean the inside of the housing for the filter
element. 12. Install the outlet hose for the portable filter in the
hydraulic reservoir.
2. You must know whether the contamination is microscopic
or visible. See Types of Contamination on page 4. 13. Open the valve that is installed in the hole for the drain
plug.
3. If the contamination is microscopic:
14. Move the switch for the portable filter to the ON position.
a. Check the maintenance schedule for the machine to Start and run the engine at 1500 rpm (r/min).
lear n if the hydraulic oil must be changed. If
needed, change the hydraulic oil. See Section 1002 15. Run the portable filter for 10 minutes.
for specifications. Change the hydraulic filter.
16. Continue to run the portable filter. Increase the engine
b. Do steps 6 through 38. s p e e d t o f u l l t h r o t t l e. H e a t t h e o i l t o o p e r a t i n g
temperature by doing the following steps:
4. If the contamination is visible:
a. Hold the bucket control lever in the ROLLBACK
a. Change the hydraulic oil and hydraulic filter. See position for 15 seconds.
Section 1002 for oil specifications.
b. Return the bucket control lever to NEUTRAL for 30
b. Do steps 5 through 38. seconds.
5. Check the amount of contamination in the hydraulic c. Repeat steps 17a through 18b until the oil in the
system by doing the following steps: hydraulic system is at operating temperature.
a. Disassemble one cylinder in two different circuits. 17. Continue to run the engine at full throttle. Continue to run
Check for damage to seals, scoring of the cylinder the portable filter.
wall, etc. Repair the cylinders as necessary.
18. Operate each hydraulic circuit to completely extend and
b. If, in your judgment, the damage to the cylinders retract the cylinders. Continue to operate each hydraulic
was caused by severe contamination and is not the circuit two times, one after the other, for 45 minutes.
result of normal wear, it is necessary to remove,
clean and repair valves, pump, lines, cylinders, 19. Decrease the engine speed to low idle.
hydraulic reservoir, etc. in the hydraulic system.
20. Continue to run the portable filter for 10 minutes.
6. Connect a vacuum pump to the hydraulic reservoir air
breather hose. Start the vacuum pump. 21. Stop the portable filter.
7. Loosen and remove the drain plug from the reservoir. 22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.

8003-6
24. Close the valve that is installed in the hole for the drain 30. Stop the vacuum pump. Disconnect the vacuum pump
plug. from the hydraulic reservoir.
25. Disconnect the inlet hose for the portable filter from the 31. Remove the hydraulic filter element from the machine.
valve.
32. Install a new hydraulic filter element on the machine.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir. 33. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
27. Start the vacuum pump.
34. Start the engine. Check for oil leakage around the new
28. Remove the valve from the hole for the drain plug. hydraulic filter.
29. Install the drain plug. 35. Stop the engine.

8003-7
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/min). 9. Move each control lever in both directions to release
pressure in the hydraulic circuits.
2. Completely retract the cylinders of all attachments on the
machine. 10. Disconnect the line from the rod end and closed end of
each cylinder.
WARNING: If retracting the cylinder rods 11. Be sure all control levers are in the NEUTRAL position.
causes the attachment to be raised, block
! the attachment in place before proceeding to
the next step!
12. Start the engine and run the engine at low idle.
39-4 IMPORTANT: C h e ck t h e o i l l eve l i n t h e hy d ra u l i c

reser voir frequently while doing step 14. Have another
NOTE: Any attachment or part of an attachment that is person hold a container under the hydraulic lines while
raised must be supported with acceptable equipment to you do step 14.
prevent the attachment from falling.
13. Slowly move each control lever in both directions until oil
3. Loosen and remove the filler cap from the reservoir. begins to flow from the open line. Hold the control lever in
place until clean oil flows from the open line.
4. Drain the hydraulic oil from the reservoir.
14. Stop the engine.
a. The reservoir holds approximately 15 U.S. gallons
(56.8 litres) of hydraulic oil. NOTE: Any attachment or part of an attachment that is
raised must be supported with acceptable equipment to
b. Have available acceptable equipment to drain the prevent the attachment from falling.
hydraulic oil.
15. Connect the line to the CLOSED end of each cylinder.
c. Remove the drain plug from the bottom of the
reservoir. 16. Start the engine and run the engine at low idle.
5. Remove the hydraulic oil filter from the machine. 17. Slowly and completely extend all cylinders. As the piston
rod comes out of the cylinder, oil will be pushed out of the
6. Install a new hydraulic oil filter on the machine. rod end of the cylinder.
7. Install the drain plug in the bottom of the reservoir. 18. Support the loader frame so that the loader frame will
stay in the RAISED position.
8. Fill the hydraulic reservoir with 14.4 U.S. gallons (54.5
litres) of Case TCH Fluid. 19. Stop the engine.
20. Connect the lines to the rod end of the cylinders.
21. Check the oil level in the hydraulic reservoir. Add oil as
required. See Section 1002 for specifications.
22. Install the filler cap for the reservoir.

8005-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................................................................................... 3
SPECIAL TOOLS .................................................................................................................................................... 4
SEPARATING THE VALVE SECTIONS ................................................................................................................. 5
ASSEMBLING THE VALVE SECTIONS ................................................................................................................. 6
OUTLET SECTION ................................................................................................................................................. 8

Disassembly ......................................................................................................................................................... 8
Assembly ............................................................................................................................................................. 9
INLET SECTION ................................................................................................................................................... 11

Disassembly ....................................................................................................................................................... 11
Inspection ........................................................................................................................................................... 12
Assembly ........................................................................................................................................................... 13
CLAM SECTION .................................................................................................................................................... 15

Disassembly ....................................................................................................................................................... 15
Assembly ........................................................................................................................................................... 18
LIFT SECTION ...................................................................................................................................................... 23

Disassembly ....................................................................................................................................................... 23
Assembly ........................................................................................................................................................... 26
BUCKET SECTION ............................................................................................................................................... 31

Disassembly ....................................................................................................................................................... 31
Assembly ........................................................................................................................................................... 36
INSPECTION ......................................................................................................................................................... 42
CIRCUIT RELIEF VALVE ...................................................................................................................................... 43

Disassembly ....................................................................................................................................................... 43
Inspection ........................................................................................................................................................... 44
Assembly ........................................................................................................................................................... 45

8005-3
SPECIFICATIONS
Manufacturer .................................................................................................................................. Case Corporation
Pressure Settings ......................................................................................................................... See Section 8002
Ports and Spools

Spool travel, neutral to pressure .................................................................................... 0.39 inch (9.9 mm)
Spool travel, neutral to float ......................................................................................... 0.68 inch (17.3 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 ................................................................................ 7/8 - 14, 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 115 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)
Circuit relief valve body ................................................................... 96 to 144 pound-inches (11 to 16 Nm)
Weight ......................................................................................................... approximately 70 pounds (32 kg)

8005-4
SPECIAL TOOLS
B786802M 1
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. This tool is first used on page 15. 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 16.

8005-5
SEPARATING THE VALVE SECTIONS

STEP 1 STEP 4
BP9502178 BP9502182
Clean the outside of the loader control valve. Put Remove the shims.
identification numbers on the sections of the loader
control valve.
STEP 5
STEP 2
BP9502183
Remove the remainder of the sections and the
BP9502179 shims.
Remove the nuts from the studs.
STEP 6
STEP 3
BP9502184
BP9502181 Remove the studs.
Remove the outlet section.

8005-6
ASSEMBLING THE VALVE SECTIONS

STEP 7 STEP 10
BP9502187 BP9502186
Install new O-rings in each section. Use the numbers on the sections as guides to
install the remainder of the sections and shims.
STEP 8
STEP 11
BP9502184
Install the studs in the inlet section. BP9502180
Install the nuts on the studs. Tighten the nuts to a
torque of 20 to 30 pound-feet (27 to 41 Nm).
STEP 9
BP9502185
Install the shims.

8005-7
3 4
5
2
6 4
3
7 4
4
3
3
4 7
4
3
9 3
10
8
2
3
4
11
4
B9505026T
1. Inlet Section 4. O-Ring 7. Stud 10. Main Relief Valve

2. Nut 5. Bucket Section 8. Clam Section 11. Plug
3. Shim 6. Lift Section 9. Outlet Section

8005-8
OUTLET SECTION
Disassembly STEP 15
STEP 12
BP9502191
Remove the poppet.
BP9502188
Fasten the outlet section in the vise with soft jaws. STEP 16
Remove the main relief valve. Do not disassemble the main relief valve. None of
the inter nal par ts of the main relief valve are
available for service.
STEP 13
BP9502189
Remove the load check plug.
STEP 14
BP9502190
Remove the spring.

8005-9
Assembly STEP 20
STEP 17
BP9502194
Install new O-rings and a new backup ring on the
m ai n r el i e f val ve. Us e c l ea n hy dra u l ic o i l t o
BP9502191
lubricate the O-rings and the backup ring.
Install the poppet.
STEP 21
STEP 18
BP9502193
BP9502190
Install the main relief valve. Tighten the main relief
Install the spring. valve to a torque of 35 to 40 pound-feet (47 to 54
Nm).
STEP 19
BP9502192
In s ta l l a new O - r i n g o n th e p l u g . U s e c l e a n
hydraulic oil to lubricate the O-ring. Install the plug.
Tighten the plug to a torque of 30 to 40 pound-feet
(41 to 54 Nm).

8005-10
1
2
B9505027T
1. Body 3. Poppet 5. Spring

2. Main Relief Valve 4. O-Ring 6. Load Check Plug
Outlet Section

8005-11
INLET SECTION
Disassembly STEP 25
STEP 22
BP9502283
Remove the spool.
BP9502280
Fasten the inlet section in the vise with soft jaws. STEP 26
Remove the relief valve.
STEP 23
B628922M
Fasten the relief valve in the vise with soft jaws.
Prevent the adjusting screw from turning while you
loosen the lock nut. Remove the adjusting screw
BP9502281
from the body. As you remove the adjusting screw
Remove the inner spring and the outer spring. from the body, count the number of turns required.
Record the number of turns so that you will be able
to install the adjusting screw to approximately the
STEP 24 same setting.
BP9502282
Remove the plug from the other end of the inlet
section.

8005-12
STEP 27 Inspection
STEP 28
4
3
B628924M
Remove the relief valve from the vise and separate 2
the parts. 5 3 3
B628928M
Inspect the seat (1) in the end of the body (2). If
the seat (1) is damaged, use a press to replace the
seat (1). Replace the O-rings (3) and the backup
ring (4) on the body (2) and the adjusting screw
(5).
STEP 29
Inspect the orifice in the orifice plug. Make sure
that the orifice is clean.
STEP 30
Inspect the spool and the springs. Use new parts
as necessary.

8005-13
Assembly STEP 34
STEP 31
BP9502282
I ns ta l l a new O - r i n g o n th e p l u g . U s e c l e a n
B628924M
Use clean hydraulic oil to lubricate the O-ring on
the adjusting screw. Assemble the par ts of the STEP 35
relief valve.
STEP 32
BP9502281
Install the inner spring and the outer spring in the
other end of the inlet section.
B628922M
Fasten the body in the vise with soft jaws. Tighten STEP 36
the adjusting screw the same number of turns that
you r eco rded in step 26 under Dis ass embly.
Tighten the lock nut.
STEP 33
BP9502284
Use clean hydraulic oil to lubricate the new O-rings
and the backup ring on the relief valve. Install the
relief valve. Tighten the relief valve to a torque of
65 to 85 pound-feet (88 to 115 Nm).
BP9502283
Install the spool.
8005-14
6
14
2
13
12
11
10
9
1
4
4
3
B9505028T
1. Body 4. O-Ring 7. Inner Spring 10. Relief Valve Body 13. Adjusting Screw
2. Orifice Plug 5. Plug 8. Backup Ring 11. Poppet 14. Lock Nut
3. Spool 6. Outer Spring 9. Seat 12. Spring
Inlet Section

8005-15
CLAM SECTION
Disassembly STEP 40
STEP 37
BP9502110
Use the spring compressing plates shown on page
4 to compress the spring.
BP9502195
Fasten the clam section in the vise with soft jaws.
Remove the spool cap. STEP 41
STEP 38
BP9502111
Remove the snap ring from the spool. Release the
spring tension and remove the spring compressing
BP9502196
plates.
Pull the spool, the retainer, and the O-ring from the
body.
STEP 42
STEP 39
BP9502112
Remove the spring seat.
B628532M
Remove the O-ring and the retainer from the spool.

8005-16
STEP 43 STEP 46
BP9502113 BP9502197
Remove the spring. Remove the plug from the end of the section.
STEP 44 STEP 47
BP9502114 BP9502198
Remove the two spacers. Use the tool shown on page 4 to remove the load
check plug.
STEP 45
STEP 48
BP9502115
Remove the other spring seat. BP9502199
Remove the spring.

8005-17
STEP 49 STEP 53
BP9502200 BP9502203
Remove the poppet. Remove the poppet.
STEP 54
STEP 50 Repeat steps 51 through 53 to remove the other
Repeat steps 46 through 49 to remove the other
plug, spring, and poppet.
plug, load check plug, spring, and poppet.
STEP 55
STEP 51
BP9502204
BP9502201 Use a prybar to remove the wiper from the A port
Remove the plug for the anticavitation valve. end of the spool bore.
STEP 56
STEP 52
BP9502205
BP9502202
Remove the O-ring from the spool bore.
Remove the spring.
STEP 57
Inspect the parts of the clam section according to
the instructions under Inspection on page 42.
8005-18
Assembly STEP 61
STEP 58
BP9502201
BP9502206
Install a new O-ring in the A port end of the spool
bore. STEP 62
Repeat steps 59 through 61 to install the other
poppet, spring, and plug.
STEP 59
STEP 63
1 2
2
BP9502203
Install the poppet for one of the anticavitation BP9502128
valves.
Install a new O-ring (1) and new backup rings (2)
on the load check plug.
STEP 60
STEP 64
BP9502202
Install the spring. BP9502130
Install the load check spring and the load check
poppet in the load check plug.
8005-19
STEP 65 STEP 67
BP9502209 BP9502210
Use clean hydraulic oil to lubricate the O-ring and Use clean hydraulic oil to lubricate the backup ring
the backup rings on the load check plug. Use the and the O-rings on each plug. Install the plugs in
tool shown on page 4 to install the load check the ends of the section. Tighten each plug to a
poppet, spring, and plug. Make sure that one end torque of 65 to 80 pound-feet (88 to 108 Nm).
of the groove in the load check plug is toward the
spool bore. Repeat the procedure to install the
load check parts in the other end of the section. STEP 68
STEP 66
2
1
2
BP9502115
Install the spring seat on the spool.
BP9502177
Install a new backup ring (1) and new O-rings (2) STEP 69
on each plug.
BP9502114
Install the two spacers.

8005-20
STEP 70 STEP 73
BP9502113 BP9502111
Put the spring into position on the spring seat. Install the snap ring. Release the spring tension
and remove the spring compressing plates.
STEP 71
STEP 74
BP9502112
Put the other spring seat into position in the spring. B628532M
Use clean hydraulic oil to lubricate a new O-ring.
Install the retainer and the O-ring. Be careful so
STEP 72 that you do not cut the O-ring on the spool.
STEP 75
BP9502110
4 to compress the spring. Make sure that the two
spacers do not fall from the spool. BP9502211
Use clean hydraulic oil to lubricate the spool and
the spool bore. Install the spool.

8005-21
STEP 76 STEP 78
BP9502212 BP9502214
Install the cap. Tighten the cap to a torque of 20 to Use a hollow sleeve and a hammer to push the
30 pound-feet (27 to 41 Nm). wiper into the spool bore. Push only on the outside
edge of the wiper. Push the wiper in until the
outside edge is even with the end of the spool
STEP 77 bore.
BP9502213
Move the section in the vise so that the spool eye
is up. Use clean hydraulic oil to lubricate the wiper.
Install the wiper so that the lip is up.

8005-22
3
7
7
3
3 8
7
9 4
5
3
10 1 5
4
3
2
3 4
3
11
3 5
12 13
4
7 2
4
7
8
12 3
7
14
6 3
15
B9505029T
1. Body 5. Poppet 9. Wiper 13. Spacer

2. Anticavitation Plug 6. Plug 10. Spool 14. Snap Ring
3. O-Ring 7. Backup Ring 11. Retainer 15. Spool Cap
4. Spring 8. Load Check Plug 12. Spring Seat
Clam Section

8005-23
LIFT SECTION
Disassembly STEP 82
STEP 79
BP9502218
Remove the eight steel balls.
BP9502215
Fasten the lift section in the vise with soft jaws. STEP 83
Remove the detent plug.
STEP 80
BP9502219
Remove the spacer.
BP9502216 STEP 84
Remove the detent spring.
STEP 81
BP9502220
Remove the detent housing.
BP9502217
Remove the ball retainer.

8005-24
STEP 85 STEP 88
BP9502221 BP9502231
Pull the spool, the retainer, and the O-ring from the Remove the stud.
body.
STEP 89
STEP 86
2
1
BP9502232
BP9502229 Remove the spring and the spring seats from the
Remove the O-ring (1) and the retainer (2) from the spool.
spool.
STEP 90
STEP 87
BP9502233
BP9502230 Release the tension on the spring and separate
Use the spring compressing plates shown on page the spring and the spring seats.

8005-25
STEP 91 STEP 94
BP9502222 BP9502225
Remove the plug from the end of the section. Remove the poppet.
STEP 95
plug, load check plug, spring, and poppet.
STEP 96
BP9502223
Use the tool shown on page 4 to remove the load
check plug.
BP9502226
STEP 93 Use a prybar to remove the wiper from the A port

end of the spool bore.
STEP 97
BP9502224
Remove the spring.
BP9502227
Remove the O-ring from the spool bore.
STEP 98
Inspect the parts of the lift section according to the
instructions under Inspection on page 42.
8005-26
Assembly STEP 102
STEP 99
BP9502234
Use clean hydraulic oil to lubricate the O-ring and
the backup rings on the load check plug. Use the
BP9502228
tool shown on page 4 to install the load check
Install a new O-ring in the A port end of the spool poppet, spring, and plug. Make sure that one end
bore. of the groove in the load check plug is toward the
load check parts in the other end of the section.
STEP 100
2
1 STEP 103
2 2
1
2
BP9502128
on the load check plug. BP9502177
Install a new backup ring (1) and new O-rings (2)
on each plug.
STEP 101
BP9502130

8005-27
STEP 104 STEP 107
BP9502235 BP9502231
Use clean oil to lubricate the backup ring and the Apply Loctite 242 (blue) to the threads of the stud.
O-rings on each plug. Install the plugs in the ends Install the stud in the spool.
of the section. Tighten each plug to a torque of 65
to 85 pound-feet (88 to 115 Nm).
STEP 108
STEP 105
BP9502230
BP9502233 Remove the spring compressing plates.
Assemble the spring and the spring seats. Use the
spring compressing plates shown on page 4 to STEP 109
compress the spring.
2
STEP 106 1
BP9502229
Use clean hydraulic oil to lubricate a new O-ring.
Install the retainer (2) and a new O-ring (1) on the
BP9502232 spool. Be careful so that you do not cut the O-ring
(1) on the spool.
Install the spring and the spring seats on the spool.

8005-28
STEP 110 STEP 113
BP9502221 BP9502238
Use clean hydraulic oil to lubricate the spool and Install the eight steel balls in the groove of the
the spool bore. Install the spool. spacer. Make sure that there is even spacing
between the balls.
STEP 111
STEP 114
BP9502236
Move the lift section in the vise so that the spring BP9502239
end of the spool is up. Install the detent housing. Apply No. 2 molydisulfide grease to the flat side of
the ball retainer. Install the ball retainer so that the
flat side is down.
STEP 112
STEP 115
BP9502237
Apply No. 2 molydisulfide grease to the groove in
the spacer. Install the spacer so that the groove in BP9502240
the spacer is up. Install the detent spring.

8005-29
STEP 116 STEP 118
BP9502241 BP9502243
If the rubber plug was removed from the hole in the Use a hollow sleeve and a hammer to push the
detent plug, install the rubber plug. Use a new wiper into the spool bore. Push only on the outside
rubber plug if necessary. Install the detent plug. edge of the wiper. Push the wiper in until the
outside edge is even with the end of the spool
bore.
STEP 117
BP9502242
Move the section in the vise so that the spool eye
is up. Use clean hydraulic oil to lubricate the wiper.

8005-30
3
4
3
3 5
10
8 4
3 6
7
11
6
1
11
12 3
7
13 9 6
4
5
14
15 4 3
16
2
17
18 19
B9505030
1. Body 6. Spring 11. Spring Seat 16. Ball Retainer

2. Plug 7. Poppet 12. Stud 17. Detent Spring
3. O-Ring 8. Wiper 13. Detent Housing 18. Detent Plug
4. Backup Ring 9. Retainer 14. Spacer 19. Rubber Plug
5. Load Check Plug 10. Spool 15. Balls
Lift Section

8005-31
BUCKET SECTION
Disassembly STEP 122
STEP 119
BP9502271
Remove the rubber plug from the detent plug.
BP9502244
Remove the tie strap which fastens the wire to the STEP 123
detent housing.
STEP 120
BP9502247
Remove the detent coil.
BP9502245 STEP 124

Remove the sealing material from the slot in the
detent housing.
STEP 121
BP9502249
Remove the snap ring.
BP9502246
Remove the detent plug.

8005-32
STEP 125 STEP 128
BP9502250 BP9502252
Remove the detent washer. Pull the spool, the retainer, and the O-ring from the
body.
STEP 126
STEP 129
2
1
BP9502251
Remove the washer spring. BP9502264
Remove the O-ring (1) and the retainer (2) from the
spool.
STEP 127
STEP 130
BP9502248
Remove the detent housing.
BP9502265

8005-33
STEP 131 STEP 134
BP9502266 BP9502253
Remove the stud. Remove the circuit relief valves from the ends of
the section.
STEP 132
STEP 135
BP9502267
Remove the spring and the spring seats from the BP9502254
spool. Use the tool shown on page 4 to remove the load
check plug.
STEP 133
STEP 136
BP9502268
Release the tension on the spring and separate BP9502255
the spring and the spring seats. Remove the spring.

8005-34
STEP 137 STEP 141
BP9502256 BP9502259
Remove the poppet. Remove the poppet.
STEP 142
Repeat steps 135 through 137 to remove the load
plug, spring, and poppet.
check plug, spring, and poppet from the other end
of the section.
STEP 143
STEP 139
BP9502204
Use a prybar to remove the wiper from the A port
BP9502257 end of the spool bore.
Remove the plug for the anticavitation valve.
STEP 144
STEP 140
BP9502205
BP9502258 Remove the O-ring from the spool bore.
Remove the spring.

8005-35
STEP 145 STEP 146
Inspect the parts of the bucket section according to See page 43 for the disassembly of the circuit
the instructions under Inspection on page 42. relief valves.

8005-36
Assembly STEP 150
STEP 147
BP9502261
BP9502206
Install a new O-ring in the A port end of the spool
bore. STEP 151
Repeat steps 148 through 150 to install the other
poppet, spring, and plug.
STEP 148
STEP 152
2
1
2
BP9502259
Install the poppet for one of the anticavitation BP9502128
valves.
on the load check plug.
STEP 149
STEP 153
BP9502260
Install the spring. BP9502130
8005-37
STEP 154 STEP 156
BP9502262 BP9502263
Use clean hydraulic oil to lubricate the O-ring and Use clean hydraulic oil to lubricate the backup ring
the backup rings on the load check plug. Use the and the O-rings on each circuit relief valve. Install
tool shown on page 4 to install the load check the circuit relief valves in the ends of the section.
poppet, spring, and plug. Make sure that one end Tighten each circuit relief valve to a torque of 65 to
of the groove in the load check plug is toward the 80 pound-feet (88 to 108 Nm).
load check parts in the other end of the section.
STEP 157
STEP 155
2
1
2
BP9502268
BP9502127 Assemble the spring and the spring seats. Use the
spring compressing plates shown on page 4 to
Install a new backup ring (1) and new O-rings (2)
compress the spring.
on each circuit relief valve.
STEP 158
BP9502267
Install the spring and the spring seats on the spool.

8005-38
STEP 159 STEP 162
BP9502266 BP9502252
Apply Loctite 242 (blue) to the threads of the stud. Use clean hydraulic oil to lubricate the spool and
Install the stud in the spool. the spool bore. Install the spool.
STEP 160 STEP 163
BP9502265 BP9502269
Remove the spring compressing plates. Install a new O-ring in the detent housing.
STEP 161 STEP 164
2
1
BP9502264 BP9502248
Use clean hydraulic oil to lubricate a new O-ring. Install the detent housing.
Install the retainer (2) and a new O-ring (1) on the
spool. Be careful so that you do not cut the O-ring
(1) on the spool.

8005-39
STEP 165 STEP 168
BP9502273 BP9502272
Move the bucket section in the vise so that the Install the rubber plug in the detent plug. Use a
detent housing is up. Install the washer spring. new rubber plug if necessary.
STEP 166 STEP 169
BP9502274 BP9502270
Install the detent washer. Push down the detent Install a new O-ring on the detent plug.
washer while you install the snap ring in the groove
in the stud.
STEP 170
STEP 167
BP9502276
Install the detent plug.
BP9502275
Install the detent coil. Make sure that the wire goes
into the slot in the detent housing.

8005-40
STEP 171 STEP 174
BP9502277 BP9502117
Tighten the detent plug to a torque of 20 to 30 Move the section in the vise so that the spool eye
pound-feet (27 to 41 Nm). is up. Use clean hydraulic oil to lubricate the wiper.
NOTE: Either the detent plug or the detent housing
can turn as you tighten the detent plug.
STEP 175
STEP 172
BP9502118
Use a hollow sleeve and a hammer to push the
BP9502278 wiper into the spool bore. Push only on the outside
Use a new tie strap to fasten the wire to the detent edge of the wiper. Push the wiper in until the
housing. outside edge is even with the end of the spool
bore.
STEP 173
BP9502279
Use Loctite 595 or equivalent sealing material to fill
the slot in the detent housing. Make sure that the
area around the wire is completely sealed.

8005-41
4
8
5
12
4
5
6
6 7
7
12 6
1 5
13 9
7 6
5
14 9
5
15 10
16
7
17 5 6
5 4
18 3
5
19
2
20
11
B9505031T
1. Body 6. Spring 11. Spool 16. Detent Washer

2. Circuit Relief Valve 7. Poppet 12. Spring Seat 17. Snap Ring
3. Load Check Plug 8. Wiper 13. Stud 18. Detent Coil
4. Backup Ring 9. Anticavitation Plug 14. Detent Housing 19. Detent Plug
5. O-Ring 10. Retainer 15. Washer Spring 20. Rubber Plug
Bucket Section

8005-42
INSPECTION
STEP 176 STEP 179
Discard all O-rings, backup rings, and wipers. Inspect the poppets. Use new parts as necessary.
STEP 177 STEP 180

Use cleaning solvent to clean all parts. Inspect all machined surfaces.
STEP 178
Inspect the spool and the spool bores. If the spool
or the spool bore is damaged, use a new section.

8005-43
CIRCUIT RELIEF VALVE

Disassembly STEP 183
STEP 181
B628606M
Remove the circuit relief valve from the vise.
Separate the parts of the circuit relief valve.
B628644M
Fasten the circuit relief valve in the vise with soft
jaws. Loosen the lock nut. Remove the adjusting
screw and the 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 assembly.
STEP 182
B628604M
Move the circuit relief valve in the vise so that the
poppet seat is fastened in the vise. Loosen the
body from the poppet seat.

8005-44
6
3
4 7
8
5
4
6
B870017J
1. Lock Nut 4. O-Ring 7. Poppet
2. Adjusting Screw 5. Spring Seat 8. Poppet Seat
3. Body 6. Spring 9. Backup Ring
Inspection 1
3
STEP 184
Inspect the parts of the circuit relief valve. The lock
nut, the adjusting screw, the two external O-rings,
2
and the backup ring are the only parts available
separately. If any other parts are damaged, order a
new circuit relief valve.
1
2 B628734M
1. External O-Ring 3. Backup Ring
2. Internal O-Ring

8005-45
Assembly STEP 188

See the procedure in Section 8002. Check and
adjust the pressure setting of the circuit relief valve
STEP 185 before you install the circuit relief valve in the
section.
2 1
B628606M 3
4
Use clean oil to lubricate the O-rings on the parts
of the circuit relief valve. Assemble the parts into 6
the body.
STEP 186
6
4
8
9
4
7
B861803J
B628602M 1. Lock Nut 6. Spring

2. Adjusting Screw 7. Poppet
Fasten the poppet seat in the vise with soft jaws.
3. Body 8. Poppet Seat
Tighten the body to a torque of 96 to 144 pound-
4. O-Ring 9. Backup Ring
inches (11 to 16 Nm).
5. Spring Seat
STEP 187
B628644M
Install the adjusting screw and the lock nut in the
body.
Section
8008
AUXILIARY CONTROL VALVE
8008
CASE CORPORATION
700 State Street

Hamilton, ON L8N 4C4 CANADA Bur 7-14550 Issued December 1998
8008-2
TABLE OF CONTENTS
SEPARATING THE VALVE SECTIONS .................................................................................................................. 3
Disassembly........................................................................................................................................................... 3
Inspection............................................................................................................................................................... 3
Assembly ............................................................................................................................................................... 3
HAND HELD AUXILIARY SECTION ......................................................................................................................... 4

Disassembly........................................................................................................................................................... 4
Flow Control ......................................................................................................................................................... 4
Load Check ..........................................................................................................................................................4
Spool .................................................................................................................................................................... 4
Assembly ............................................................................................................................................................... 6
Spool .................................................................................................................................................................... 6
Load Check ..........................................................................................................................................................6
Flow Control ......................................................................................................................................................... 6

8008-3
SEPARATING THE VALVE SECTIONS

Disassembly Assembly
1. Clean the outside of the auxiliary control valve. 1. Install new O-rings on the sections (4) and inlet/
Put identification numbers on the sections of the outlet cover (3).
auxiliary control valve.
2. Put the cover/power beyond section (5) on the
2. Remove the nuts (1) from the studs (2). studs (2).
3. Remove the inlet/outlet section (3). 3. Put the hand held auxiliary section (4) on the
cover/power beyond section (5).
4. Remove the hand held auxiliary section (4).
4. Put the inlet/outlet section (3) on the hand held
5. Remove the studs (2) from the cover/power
auxiliary section (4).
beyond section (5).
5. Install the nuts (1) on the studs (2). Tighten the
6. Remove the O-rings (7) from the sections (3 and
nuts to 26 to 40 Nm (35 to 55 pound-feet).
4) and/or the cover/power beyond section (5).
Inspection
1. Remove and discard the O-rings (6) from the
valve sections.
2. Inspect the orifice (7) in the inlet/outlet section
(3). Use a new orifice as required.
3 6
GS99J801
1. NUTS (3) 4. HAND HELD AUXILIARY SECTION 6. O-RINGS (4)

2. STUDS (3) 5. COVER POWER BEYOND SECTION 7. ORIFICE
3. INLET/OUTLET SECTION

8008-4
HAND HELD AUXILIARY SECTION

Disassembly Load Check
14. Remove the load check plug (18), spring (19), and
Flow Control poppet (20) from the hand held auxiliary section
1. Fasten the hand held auxiliary section (1) in a (1).
vise with soft jaws. 15. Remove and discard the O-ring (21) and backup
2. Loosen the plug (2) for the flow control. Remove ring (22) from the load check plug (18).
the plug (2), compression nut (3), thin bearing
race (4), thrust bearing (5), thick bearing race Spool
(6), and rod assembly (7).
16. Remove the snap ring (23), spring retainer (24),
3. Hold the rod assembly at the roll pin (8) end and spring (25), ball retainer (26), eight balls (27), and
pull the rod assembly from the plug (2) and spacer (28) from the detent housing (29).
compression nut (3) assembly. Do not lose the
17. Loosen and remove the Allen head screws (30) flat
thin bearing race (4), thrust bearing (5), or thick
washers (31), and detent housing (29) from the
bearing race (6) from the rod assembly (7).
backhoe auxiliary section (1).
4. Remove the thin bearing race (4), thrust bearing
18. Hold the detent shaft (32) and pull the spool (33),
(5), and thick bearing race (6) from the rod
0-ring (34), retainer (35), upper spring seat (36),
assembly (7).
spring (37), spool stop (38), and lower spring seat
5. Remove the compression nut (3) from the plug (39) from the hand held auxiliary section (1).
(2).
19. Remove the wiper (40) and O-ring (41) from the
6. Remove and discard the seal (9) from the hand held auxiliary section (1).
compression nut (3).
20. Loosen and remove the detent shaft (32), upper
7. Remove and discard the O-ring (10) from the OD spring seat (36), spring (37), spool stop (38), and
of the plug (2). lower spring seat (39) from the spool (33).
8. Remove and discard the five O-rings (11) from 21. Remove the O-ring (42) from the detent shaft (32).
the ID of the plug (2).
22. Remove and discard the O-rings (43 and 44) from
9. Remove the spool (12) and spring (13) from the the hand held auxiliary section (1).
hand held auxiliary section (1). Be careful not to
lose the shuttle (14) from the spool (12).
10. Remove the shuffle (14) from the spool (12).
11. Remove the retaining ring (15) from the end of
the spool (12).
12. Remove the plug (16) from the spool (12).
13. Remove and discard the O-ring (17) from the
plug (16).

8008-5
2
10
9 4
3 5
6
11
15 16
17
7 14
41 13
12
33 8
40
20
21
1
43
18
44
19
22
42
34
35 36
37
38
39 25
32 24
23
29
31
30 28 27 26
GS99J802
1. BACKHOE AUXILIARY 9. SEAL 18. LOAD CHECK PLUG 27. BALLS (8) 36. UPPER SPRING SEAT
SECTION 10. O-RING 19. SPRING 28. SPACER 37. SPRING
2. PLUG 11. O-RINGS (5) 20. POPPET 29. DETENT HOUSING 38. SPOOL STOP
3. COMPRESSION NUT 12. SPOOL 21. O-RING 30. ALLEN HEAD SCREWS 39. LOWER SPRING SEAT
4. BEARING RACE 13. SPRING 22. BACKUP RING 31. FLAT WASHERS 40. WIPER
5. THRUST BEARING 14. SHUTTLE 23. SNAP RING 32. DETENT SHAFT 41. O-RING
6. BEARING RACE 15. RETAINING RING 24. SPRING RETAINER 33. SPOOL 42. O-RING
7. ROD ASSEMBLY 16. PLUG 25. SPRING 34. O-RING 43. O-RING
8. PIN 17. O-RING 26. BALL RETAINER 35. RETAINER 44. O-RING
HAND HELD AUXILIARY SECTION DISASSEMBLY

8008-6
Assembly Flow Control

13. Install a new O-ring (17) on the plug (16).
Spool
14. Lubricate the O-ring (17) and the plug (16) with
1. Install new O-rings (34, 41, 43 and 44) in the clean oil. Install the plug (16) in the spool (12).
hand held auxiliary section (1). Lubricate the O-
rings (34, 41, 43, and 44) with clean hydraulic oil. 15. Install the retaining ring (15).
2. Install a new O-ring (42) on the detent shaft (32). 16. Lubricate the shuttle (14) with clean oil. Install the
shuttle in the spool (12).
3. Put the retainer (35), upper spring seat (36),
spring (37), spool stop (38) and lower spring seat 17. Install the spring (13) on the shuttle (14) in the
(39) on the detent shaft (32). spool (12).
4. Apply a small amount of Loctite 242 to the 18. Lubricate the spool (12) with clean oil. Install the
threads of the detent shaft (32). spool (12) in the hand held auxiliary section (1).
5. Install the detent shaft (32) in the spool (33). 19. Install five new O-rings (11) in the ID of the plug (2).
Tighten the detent shaft (32) to a torque equal to Lubricate the O-rings (11) with clean oil.
12 to 16 Nm (102 to 142 pound-inches). 20. Install a new O-ring (10) on the OD of the plug (2).
6. Lubricate the spool (33) with clean oil. 21. Install a new seal (9) in the compression nut (3).
7. Install the spool (33) in the hand held auxiliary 22. Install the compression nut (9) in the plug (2).
section (1). Be careful not to damage the O-rings
(34 and 41). 23. Install the thin bearing race (4), thrust bearing (5),
and thick bearing race (6) on the rod assembly (7).
8. Put the detent housing (29) in place on the hand
held auxiliary section (1). Install the Allen head 24. Apply clean oil to the rod assembly (7). Install the
screws (30) and flat washers (31) that fasten the rod assembly (7), thick bearing race (6), thrust
detent housing (29) to the hand held auxiliary bearing (5), and the thin bearing race (4) in the plug
section (1). Tighten the Allen head screws (30) to (2) compression nut (3) assembly.
5 to 6.8 Nm (44 to 60 pound-feet) 25. Install the plug (2) in the hand held auxiliary section
9. Put the spacer (28), eight balls (27), ball retainer (1). Make sure the roll pin (8) on the rod assembly
(26), spring (25), and spring retainer (24) on the (7) engages the slot in the spool (12).
detent shaft (32). Install the snap ring. 26. Tighten the plug (2) to a torque equal to 41 to 47
Load Check
10. Install a new backup ring (22) and O-ring (21) on
the load check plug (18).
11. Put the spring (19) and poppet (20) on the load
check plug (18).
12. Install the load check plug (18) in the hand held
auxiliary section (1).

8008-7
2
10
9 4
3 5
6
11
15 16
17
7 14
41 13
12
33 8
40
20
21
1
43
18
44
19
22
42
34
35 36
37
38
39 25
32 24
23
29
31
30 28 27 26
GS99J802
1. BACKHOE AUXILIARY 9. SEAL 18. LOAD CHECK PLUG 27. BALLS (8) 36. UPPER SPRING SEAT
SECTION 10. O-RING 19. SPRING 28. SPACER 37. SPRING
2. PLUG 11. O-RINGS (5) 20. POPPET 29. DETENT HOUSING 38. SPOOL STOP
3. COMPRESSION NUT 12. SPOOL 21. O-RING 30. ALLEN HEAD SCREWS 39. LOWER SPRING SEAT
4. BEARING RACE 13. SPRING 22. BACKUP RING 31. FLAT WASHERS 40. WIPER
5. THRUST BEARING 14. SHUTTLE 23. SNAP RING 32. DETENT SHAFT 41. O-RING
6. BEARING RACE 15. RETAINING RING 24. SPRING RETAINER 33. SPOOL 42. O-RING
7. ROD ASSEMBLY 16. PLUG 25. SPRING 34. O-RING 43. O-RING
8. PIN 17. O-RING 26. BALL RETAINER 35. RETAINER 44. O-RING
HAND HELD AUXILIARY SECTION ASSEMBLY

Section
8010
SOLENOID VALVES FOR MACHINES

WITH OPTIONAL RIDE CONTROL
8010
CASE CORPORATION
700 State Street

Hamilton, ON L8N 4C4 CANADA Bur 7-14560 Issued December 1998
8010-2
TABLE OF CONTENTS
DISASSEMBLY ...................................................................................................................................................... 3
ASSEMBLY ............................................................................................................................................................. 5

8010-3
SOLENOID VALVES FOR MACHINES WITH OPTIONAL RIDE CONTROL

Disassembly Assembly
1. Fasten the solenoid valve in a vise with soft jaws. 1. Install a new O-ring (11) on the plug (6), see
Loosen and remove the Allen head screws (12), illustration on page 4.
see illustration on page 4.
2. Install a new O-ring (11) on the plunger (5).
2. Remove the cover (13).
3. Lubricate the O-ring (11) on the plug (6) with
3. Remove the coil (14). clean hydraulic oil. Install the plug (6) in the body
(1). Tighten the plug (6) to 34 to 45 kg (25 to 33
4. Remove the long spacer (2). pound-feet).
5. Remove the spring (3). 4. Remove the body (1) from the vise. Install the
valve plate shuttle (8) and spring (10) in the body
6. Remove the short spacer (4). (1).
7. Remove the plunger (5). 5. Fasten the body (1) in the vise with soft jaws.
Install the spring (7).
8. Remove the spring (7).
6. Lubricate the O-ring (11) on the plunger (5) with
9. Remove the body (1) from the vise. Remove the clean oil. Install the plunger (5).
valve plate shuttle (8) and spring (10) from the
body (1). 7. Install the short spacer (4).
10. Loosen and remove the plug (6) from the 8. Install the spring (3).
opposite end of the body (1).
9. Install the long spacer (2).
11. Remove and discard the O-ring (11) from the
plunger (5). 10. Install the coil (14).
12. Remove and discard the O-ring (11) from the 11. Install the cover (13).
plug (6).
12. Install the Allen head screws (12). Tighten the
Allen head screws (12) to 650 to 813 Nm (40 to
50 pound-inches).

8010-4
12
2
7
9 13
8
3
14
10 4
1
5
11 11
GS99J800
1. BODY 5. PLUNGER 9. VALVE WASHER 13. COVER
2. LONG SPACER 6. PLUG 10. SPRING 14. COIL
3. SPRING 7. SPRING 11. O-RING
4. SHORT SPACER 8. VALVE PLATE SHUTTLE 12. ALLEN HEAD SCREWS
SOLENOID VALVE DISASSEMBLY

9002
Section
9002
AIR CONDITIONER TROUBLE SHOOTING
FOR SYSTEMS WITH R-134a REFRIGERANT
(Visual and Operating)
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July 1995
9002-2
TABLE OF CONTENTS
SAFETY PROCEDURES .............................................................................................................................................. 3
SPECIAL TOOLS ........................................................................................................................................................ 4
TROUBLESHOOTING ............................................................................................................................................... 5-7
EXTERNAL COMPRESSOR CHECK ............................................................................................................................ 8,9
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK .......................................................................................... 10-13
CAB TEMPERATURE CHECK ................................................................................................................................. 14,15
VISUAL REFRIGERANT CHECK ................................................................................................................................. 16
CAB HEATER CHECK ............................................................................................................................................... 17
EVAPORATOR AND PLENUM CHECK ..................................................................................................................... 18,19
PRESSURE SWITCH CHECK ..................................................................................................................................... 20
AIR CONDITIONING CONTROL SWITCH CHECK .......................................................................................................... 21

Current Check ....................................................................................................................................................... 21
Sensing Line Check ............................................................................................................................................... 21
previously sold.

9002-3
SAFETY PROCEDURES
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
Refrigerant R-134a is the most stable, and easiest to work 3. Keep refrigerant containers in the correct upright position.
with of the refrigerants now used in air conditioner systems. Always keep refrigerant containers away from heat and
Refrigerant R-134a does not contain any chlorofluorocarbons sunlight. The pressure in a container will increase with
(CFC’s) which are harmful to the earth’s ozone layer. heat.
Safety procedures must be followed when working with 4. Always reclaim the refrigerant from the system if you are
Refrigerant R-134a to prevent possible personal injury. going to weld or steam clean near the air conditioner
system.
1. Always wear safety goggles when doing any service work
near an air conditioner system. Liquid refrigerant getting 5. Always check the temperature and pressure of the air
into the eyes can cause serious injury. Do the following if conditioner system before reclaiming refrigerant and
you get refrigerant in or near your eyes: when you test the system.
A. Flush your eyes with water for 15 minutes. 6. Dangerous gas can form when refrigerant comes in
contact with an open flame. Never permit fumes to be
B. See a family physician immediately inhaled.
2. A drop of liquid refrigerant on your skin may cause 7. Never leak test with compressed air or flame testers.
frostbite. Open the fitting carefully and slowly when it is Te s t s h a ve i n d i c a t e d t h a t , a t p r e s s u r e s a b o ve
necessary to service the air conditioner system. Your skin atmospheric, and with air concentrations greater than
must be treated for frostbite or a physician must be seen 60% by volume, R-134a can form a combustible gas.
if you get refrigerant on your skin.

9002-4
SPECIAL TOOLS
A22094 299L7B
REFRIGERANT RECOVERY, 9 INCH STEM TYPE THERMOMETER

RECYCLING AND CHARGING 0 TO 250° F CAS-10248
STATION OEM-1418
A22090
299L7A ELECTRONIC LEAK DETECTOR OEM-1437
SAFETY GOGGLES
CAS-10073-3
299L7C
BELT TENSION TOOL

CAS-10808

9002-5
TROUBLESHOOTING
1. Perform a visual inspection of the machine. Check the C. Are there any sharp bends or kinks in the hoses?
following and correct as necessary:
D. Are compressor clutch and pressure switch leads
A. Are the compressor and fan drive belts in place and plugged into the harness?
at the correct tension?
E. Are there heavy accumulations of oil or oily dust
B. Are grille screens, radiator, and condenser around the fittings, indicating refrigerant leakage?
unobstructed?
PROBLEM
NO COOLING
COMPRESSOR RUNS COMPRESSOR DOES NOT RUN
MECHANICAL
See External Compressor Check Page 8
ELECTRICAL
See Blower and Compressor

Clutch Check Page 10
REFRIGERANT
See Visual Refrigerant Check Page 16
INTERNAL SYSTEM PROBLEM
See Gauges and Testing Section 9003

9002-6
TROUBLESHOOTING
PROBLEM
NOT ENOUGH COOLING
MECHANICAL
ELECTRICAL
See Blower and Compressor

Clutch Check Page 10
REFRIGERANT
See Visual Refrigerant Check Page 16

9002-7
TROUBLESHOOTING
PROBLEM
INTERMITTENT COOLING
MECHANICAL
ELECTRICAL
See Blower Switch Check Page 11.

See Blower Motor Check Page 10.
See Compressor Clutch Check Page 10.
See Cutoff Relay Check Page 12.
PROBLEM
SYSTEM MAKES NOISE
MECHANICAL
See External Compressor Check Page 8.

See Blower Motor Check Page 10.
ELECTRICAL
See Compressor Clutch Check Page 10.

9002-8
EXTERNAL COMPRESSOR CHECK
Compressor
and Fan Loose or broken drive belts -
1 Belts Adjust the tension on a new
belt at 95 to 115 lbs (422 to 516
N) and at 90 to 110 lbs (400 to
489 N) after a minimum of ten
minutes run-in time on the belt.
Belt tension on a used belt
2 must be 90 to 110 lbs (400 to
489 N).
Too much belt wear - Replace a

BP9503119
worn belt, because a worn belt
1. Belt Tension Tool 2. Compressor Belt
will cause too much slip.
Compressor
Mounting Loose bracket mounting bolts -
Brackets Tighten the bolts to the correct
torque.
Brackets have breaks or cracks

- Replace the brackets.
BP9503114
Compressor The compressor belt will slip on

1 Clutch the compressor pulley if there
is a compressor seizure.
Remove the compressor for
service or replacement. See
Section 9005 of this ser vice
manual.
Remove the dust cover and

3 check the air gap on the
2 compressor clutch. The gap
BP9503115 between the front plate and
1. Belt 3. Compressor pulley assembly must be 0.41
2. Air Gap to 0.79 mm. See Section 9005
of this manual.
Use a socket wrench to slowly

rotate the compressor clock-
w is e. C om pres s or rot ati on
s h o ul d b e s m o ot h a n d no t
(Continued on next page) require much effort.

9002-9
(External Compressor Check Continued)
1 Pulley and Belt

Alignment The compressor pulley and the
fan pulley must be aligned
within 1/16 inch (1.6 mm) of
2 each other. Use a straight edge
to ch eck p ul ley al ig nme nt.
Adjust the compressor
mounting bracket if needed.
The drive belt should be
located in the forward clutch
groove.
BP9503115
1. Compressor Pulley 2. Fan Pulley

9002-10
BLOWER MOTOR AND COMPRESSOR CLUTCH CHECK
1 Keyed Power Turn on the ignition and the

Blower Fuse blower switch. Adjust the air
(25 Ampere) conditioner control to high.
2
Remove the cover panel at the
right-hand side of the loader
control console.
BP9504001
Check to see if the blower fuse
1. Cab Power Relay 2. Blower Fuse - 25 Amp is failed. Check the voltage at
the cab power relay. The cab
power relay is relay No. 2 on
the decal on the cover panel.
(Continued on next page)

9002-11
(Blower and compressor clutch check continued)
Blower Switch Check the switch operation.

The switch must give three
1 different blower speeds - Low
(I), Medium(II), and High(III).
BP9504002
1. Blower Switch
Check for loose connections or
The following is a list of the terminals on the blower switch. wires that have damage.
Repair or replace wires as
“B” Battery - power from fuse block. necessary.
“L” Low Speed - to blower motor resistor.
“M” Medium Speed - to blower motor resistor.
“H” High Speed - to blower motor.
“C” Compressor Clutch - to air conditioning switch.
The blower switch is connected
to the blower motor through a
resistor on low and medium
speed. See Section 4001 and
check the resistor if the blower
does not operate on low and
medium speed. The resistance
value for low speed is 0.504 to
0.616 ohms and for medium
speed the resistance value is
0.144 to 0.176 ohms.Test the
black wire harness if the blower
does not operate on high
speed. See Section 4001 in
A22091 this manual for blower switch
troubleshooting to test the high
speed switch position.

9002-12
Blower Motor Check the voltage at the blower

motor. Make repairs or replace
items as necessary.
A22101
Air Conditioner The compressor clutch must
Control Switch engage when the air
conditioner control switch is
tur ned fully on. The blower
1 switch must be on because
e le ct r i ca l pow er is c om in g
through the blower switch. See
Air Conditioner Control Switch
check in this section.
Test th e c irc ui ts of the ai r

conditioner control switch if the
BP9504003
compressor clutch does not
1. Air Conditioner Control Switch engage.
Cutoff Relay Check the relay for the

compressor clutch shutdown.
1 The clutch will not operate if
the system pr essure is too
2 high, above 385 PSI (2653
kPa), or too low, below 6 PSI
(41 kPa). The pres sure
indicator lamp will illuminate
when the relay is actuated. The
relay must be reset to operate
the compressor clutch if it has
been actuated. The power to
the relay must be interrupted to
BP9504002 reset the relay. Tur n the air
1. Air Conditioner Indicator Lamp conditioner control to the off
2. Air Conditioner Control Switch position to start the
compressor if the relay has

9002-13
High and Low Che ck the vo ltage at the

Pressure switches.
Switches
1. No voltage at switch -
break in wire from air
conditioner control switch.
2. Current through switch -

switch is ba d. See
Pressure Switch Check in
this section.
BP9503105 3. System pressure is too low

or too high.
Compressor The compressor clutch must

Clutch disengage when the wire lead
to the clutch is disconnected.
The current draw of the clutch

coil field must be 3.6 to 4.2
amperes at 12 volts. See
Section 9005 of this ser vice
manual.
BP9504004

9002-14
CAB TEMPERATURE CHECK
Air Louvers Close the recirculation louvers.
1
Make sure the cab discharge
louvers and defroster louvers
are open.
Make sure the blower control is

set on high and the air
BP9504005 conditioner temperature control
1. Air Discharge Louvers is on maximum.
BP9504006
1. Recirculation Louvers Air Conditioner Carefully feel the air
Hose Check conditioner hoses. The high
pressure hose must be warmer
than the low pressure hose.
2 If there is no temperature dif-

ference between the hoses -
1. The system is low on

refrigerant.
2. There is a restriction in the

system.
BP9504007
1. High Pressure Hose 2. Low Pressure Hose
3. The compressor is not
operating.

9002-15
(Cab temperature check continued)
Louver
Temperature Record the ambient tempera-
ture reading from a ther-
mometer placed in front of the
grille screen.
Put a thermometer in the

center air discharge louver and
r u n t h e c o m p r e s s or fo r 1 0
minutes to make sure the
system has stability.
BP9504008
C om p ar e t h e t he r m o me t er
reading and ambient
temperature reading to the
chart. If the reading is higher
than the values in the chart:
1. The system may need

refrigerant. Refer to
Section 9003.
2. There is restriction in the

system.
3. The compressor is not

operating.
4. The heater control valve is

leaking.
5. Evaporator air is by-

passing the core.
6. Evaporator core may be

plugged.
7. Expansion valve mal-

functioning.
AMBIENT TEMPERATURE CENTER LOUVER

TEMPERATURE
80°×F (27 °C).................................................55 to 63° F (13 to 17 °C)

90°×F (32 °C).................................................62 to 70° F (17 to 21 °C)
100°×F (38 °C)...............................................69 to 77° F (21 to 25 °C)
110°×F (43 °C)...............................................73 to 81×°F (23 to 27°C)
120°×F (49 °C)...............................................78 to 86×°F (26 to 30°C)

9002-16
VISUAL REFRIGERANT CHECK
Compressor Make sure that all hose

Hoses connections are tight.
C h e ck h o s e s fo r b e n d s o r
cracks. Replace all hoses that
have damage.
BP9504007
Leak Finding Stop the engine.

Check
1
WARNING: When refrigerant comes in

contact with an open flame, it can form
! dangerous gas. Never breathe these fumes.
SM109B
A22090
1. Electronic Leak Detector

Use electronic leak detector
OEM-1437 to inspect all
connections for leaking
refrigerant. The cab headliner
must be rem oved to detect
leaks around the expansion
valve.
NOTE: When checking the

compressor seal for a leak,
remove the dust cover and
rotate the clutch shaft
clockwise.
Repair all leaks and recharge

the system. See Section 9004.

9002-17
CAB HEATER CHECK
Heater Hoses Make sure the heater control is

in the off position. Feel the
heater hoses to see if they are
hot. The hoses may be hot due
1 to heat from air flow around the
2
engine.
The heater control valve in the

cab is not working if the hoses
are hot from engine coolant.
BP9410049
1. Heater Return Valve 2. Heater Hose
Heater Control Close the heater return valve at
Valve th e eng i ne. Tu r n th e va lve
clockwise to stop the flow of
coolant through the heater
core.
1
Check the temperature of the
cab heater hoses again.
Check the cab air louver

temperature.
BP9504009
1. Heater Control Valve
If it increases, check the
position of the heater control
valve. It should be completely
closed.
Replace the valve if the control

knob is at the OFF stop and
leakage is detected through the
valve.

9002-18
EVAPORATOR AND PLENUM CHECK
Evaporator Core R emove the h ead li ne r a nd

remove the evaporator core.
Check the fins on the evapora-

tor. All the fins that have bends
or damage must be made
straight.
BP9504010 Ke e p t h e eva p o r a t o r c o r e
1. Evaporator Core clean. If the core is dry, use
compressed air or a vacuum. If
the core is wet, flush the core
with water using a hose without
pressure.
If th e eva po ra to r c ore i s
ex t r e m e l y d i r t y, c h e ck t h e
condition of the air filter. Also
review the manner of operation
of the machine. Do not operate
the machine with doors and/or
windows open and with the
recirculation louver open. This
can allow dirt to be sucked into
the evaporator core and cause
it to become plugged.
Plenum Sealing Correct plenum sealing will

permit air through the
evaporator but not around the
evaporator.
1 See Section 9005 in this

manual for plenum sealing.
BP9504011
1. Plenum

9002-19
(Evaporator and plenum check continued)
Filters Keep the air filter elements

clean to provide maximum air
flow into the operator cab.
BP9504012
1. Filters

9002-20
PRESSURE SWITCH CHECK

The low pressure switch is located in the roof of the cab in the Normal operating conditions will see 26 to 51 PSI (180 to 355
low pressure tube to the evaporator.The high pressure switch kPa) on the low side of the system. The low pressure switch
is located at the front of the tractor and behind the grille. is open whenever the pressure is above 2 to 6 PSI (14 to 41
kPa). Below this the switch closes and sends a signal to the
relay to disengage the compressor clutch.
STEP 1
Check both terminals of the low pressure switch with a test
E ngin e O F F, key sw itc h O N, blowe r sw itc h O N, and lamp. If voltage is available at both terminals and pressure is
temperature control switch turned fully clockwise. not below 2 PSI (14 kPa), replace the switch.
NOTE: With the engine OFF, system pressure will
equalize on both sides of system to approximately 75 PSI STEP 3
(520 kPa) at room temperature.
Both pressure switches should remain in the open position.
To check system pressure, refer to Section 9003 in this

manual.
STEP 2
BP9503105
High pressure switch located at condenser.
Check for 12 VDC at high pressure switch. If no voltage,

check temperature control switch. Refer to Air Conditioner
Control Switch in this section.
Check both terminals of high pressure switch with a test

lamp. If voltage is present at both terminals and pressure is
BP9504013 not above 385 PSI (2 654 kPa), replace the switch.
Low pressure switch located in cab roof.
Check for 12 VDC at low pressure switch with a test lamp. If

no voltage, check temperature control switch. Refer to Air
Conditioner Control Switch Check in this section.

9002-21
AIR CONDITIONING CONTROL SWITCH CHECK

Current Check Sensing Line Check
The temperature control switch is located in the panel on the STEP 2
right-hand center cab post.
T h e t e m p e r a t u r e c o n t r o l sw i t c h s e n s e s eva p o ra t o r 2
temperature and controls current flow for compressor clutch
operation. 1
The switch interrupts current flow to the clutch at 33° F to 37°

F (0.6° C to 2.8° C) and will allow the clutch to energize at
42° to 70° F (5.6° C to 21° C) depending on switch position.
If the temperature control switch malfunctions, replace it.
STEP 1 T97352
1. Container of Ice and Water
2. Sensing Line
Engine OFF, key switch ON, and blower switch ON.

1
Turn temperature control switch fully clockwise. Remove
sensing tube from evaporator.
Place end of sensing tube in a container with ice and water

mixture.
STEP 3
BP9504003
1. Temperature Control Switch
Engine OFF, key switch ON, and blower switch ON.

1
Turn temperature control switch fully clockwise.
Check voltage at temperature control switch terminal with

orange/green wire No. 85. If voltage is less than 5, check
blower switch.
Check Voltage at temperature control switch terminal with

orange/brown wire No. 60. If less than 5 volts, replace
BP9504003
temperature control switch.
1. Temperature Control Switch
When the sensing tube has cooled to the temperature of the

ice and water mixture, the temperature control switch should
interrupt the current flow to the compressor.
Check for current at temperature control switch terminal with

the No. 60 and No. 85 wires. Use a test lamp connected to a
good ground.
If current is not interrupted, replace the temperature control

switch.

9003
Section
9003
AIR CONDITIONER SYSTEM

GAUGES AND TESTING
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July 1995
9003-2
TABLE OF CONTENTS
SPECIAL TOOLS ........................................................................................................................................................ 2
PRESSURE - TEMPERATURE CHART .......................................................................................................................... 4
A/C RECOVERY AND CHARGING STATION CONNECTIONS ........................................................................................... 5
PROBLEM - NO COOLING ....................................................................................................................................... 7-10
PROBLEM - NOT ENOUGH COOLING ..................................................................................................................... 11-19
PROBLEM - INTERMITTENT COOLING ................................................................................................................... 20,21
PROBLEM - NOISE IN SYSTEM .................................................................................................................................. 22
previously sold.
SPECIAL TOOLS
A22094
Refrigerant Recovery, Recycling and Charging Station OEM-1418

9003-3
SAFETY PROCEDURES

!
OR DEATH. M171B
Safety procedures must be followed when working with 4. Always reclaim the refrigerant from the system, if you are
system.
B. See a family physician immediately. inhaled.
2. A drop of liquid refrigerant on your skin may cause 7. Never leak test with compressed air or flame testers.

9003-4
PRESSURE - TEMPERATURE CHART
SOLID DRIVE FAN VISCOUS FAN
AMBIENT NORMAL LOW NORMAL HIGH NORMAL LOW NORMAL HIGH

TEMPERATURE SIDE PRESSURE SIDE PRESSURE SIDE PRESSUIRE SIDE PRESSURE
80×°F(27°C) 26 to 36 PSI 200 to 240 23 to 33 PSI 205 to 255 PSI

(180 to 250 kPa) (1 378 to 1 654 kPa) (158 to 227 kPa) (1 412 to 1 757 kPa)
90°F (32°C) 33 to 43 PSI 230 to 270 PSI 30 to 40 PSI 245 to 295 PSI
The pressure-temperature chart is based on the following

conditions:
1. Engine operating at 1500 RPM.
2. No engine load.
3. Fan speed control in High position.
4. Door open.
5. Thermostat on maximum setting ten minutes after

startup.
6. Maximum fresh air mode.
7. Side panels at hood installed.
8. Heater valve at engine shut off.

9003-5
A/C RECOVERY AND CHARGING STATION CONNECTIONS

STEP 1
WARNING: Always wear safety goggles
when working with liquid refrigerant. Liquid
! re fr i ge ra nt in y ou r ey es c ou l d c au s e
blindness. SM0105A
STEP 3
BP9504007
Clean the external surfaces of the compressor and hoses.
Remove the caps from the service ports on the suction and
pressure hoses.
WARNING: Do not steam clean any air

conditioning parts while the system is Make sure the charging station manifold gauge valves are in
! charged. The heat will cause the refrigerant the closed position.
to rise to a pressure that could cause the
system to explode. SM104A
STEP 4
STEP 2
BP9505002
Start the and run the engine at 1500 RPM. Operate the air
BP9505001 conditioner system at maximum cooling setting and blower
Connect the hoses from the test gauges to the service ports. speed for 10 minutes with the cab door open. Observe the
test gauges and check the chart on page 4 against the gauge
Connect the hose from the low pressure gauge to the port on readings.
the suction hose.
Connect the hose from the high pressure gauge to the port on
the discharge hose.

9003-6
LOW PRESSURE HIGH PRESSURE SEE

PROBLEM GAUGE GAUGE PAGE
NO COOLING VERY LOW VERY LOW 7
NO COOLING HIGH HIGH 8-10
NOT ENOUGH COOLING NORMAL TO SLIGHTLY HIGH NORMAL 11-12
NOT ENOUGH COOLING LOW LOW 13-15
NOT ENOUGH COOLING HIGH LOW 16
NOT ENOUGH COOLING HIGH HIGH 17-18
NOT ENOUGH COOLING LOW NORMAL 19
INTERMITTENT COOLING LOW HIGH 20
INTERMITTENT COOLING LOW LOW 21
NOISE IN SYSTEM NORMAL TO HIGH HIGH 22

9003-7
PROBLEM - NO COOLING
See pressure - temperature

VERY LOW VERY LOW chart on Page 4.
476L7
No Refrigerant - Indications: 1. Leak test the system. See Section 9002 in this manual.
A. Discharge air from evaporator warm. 2. Remove any remaining refrigerant from the system. See
Section 9004 in this manual.
B. Compressor does not run, or cycles off rapidly after
start up. 3. Repair system leaks as needed. Follow the given repair
procedure.
4. Check level of oil in the compressor - possible for

compressor to have an oil loss. See Section 9005 in this
manual.
5. Remove air and moisture from the system. See Section

9004 in this manual.
6. Charge the system with new refrigerant. See Section

7. Continue performance test for other possible problems.

9003-8
PROBLEM - NO COOLING

HIGH HIGH chart on Page 4.
476L7
Condenser Malfunctioning - Indications: 1. Check for loose or worn compressor belt and proper
engine fan operation.
A. Liquid line very hot.
2. Check to see that condenser, radiator, and grille screen
B. Discharge air from evaporator warm. are clean and that hood and radiator seals are in place.
3. Remove and check condenser for oil.
A. Remove refrigerant from the system. See Section

B. Check compressor for proper oil level.
C. Replace receiver-drier.
D. Remove moisture and charge the system. See

4. Continue the performance test for other possible

problems.
(Continued on next page).

9003-9
(No
No Cooling - Continued
Continued)
Expansion Valve Malfunctioning - Indications: 1. Check the expansion valve. Remove the headliner.
Disconnect the low pressure cutout switch.
A. Discharge air from evaporator warm.
2. Test the expansion valve:
B. Much condensation on suction hose.
A. Remove insulation material from the top of the
C. Much condensation on evaporator outlet. valve. With engine running and air conditioner on
maximum cooling, cool the top of the valve with ice
and check for low pressure gauge decrease.
3. Allow the top of the expansion valve to warm. The valve

should open and the pressure should rise at the low
pressure gauge. Repeat Step 2. If there is little or no
decrease in the low pressure gauge, go to Step 5.
4. Replace all the expansion valve insulation material.
5. If the expansion valve did not operate correctly, remove

refrigerant from the system and remove the expansion
valve. See Section 9005 in this manual.
6. Install a new expansion valve, remove air and moisture

and charge the system. See Section 9004 in this manual.
7. Connect the low pressure cutout switch.

9003-10
(No Cooling - Continued)
Expansion Valve Malfunctioning - Indications: 1. Leak test system to see if it is possible that a leak has
permitted air to enter. See Section 9002 in this manual.
A. Suction line warm to your hand.
2. Remove refrigerant from the system. See Section 9004 in
B. Discharge air from evaporator only a little cool. this manual.
3. Repair leaks as needed.
4. Replace receiver-drier. The moisture removing material in

the receiver-drier could be full to capacity with moisture.
5. Check the oil level in the compressor - It is possible for

the compressor to lose oil. See Section 9005 in this
manual.



9003-11
PROBLEM - NOT ENOUGH COOLING
NORMAL TO See pressure - temperature

SLIGHTLY NORMAL chart on Page 4.
HIGH
476L7
Heater Control Valve not working - Indications: 1. The heater control valve is not closed if the hoses are hot.
A. Discharge air from evaporator only a little cool. 2. Shut off coolant flow to heater core.
B. Heater hoses to cab are warmer than ambient 3. Check air duct for temperature change.
temperature.
4. Inspect and repair heater control valve. See Section 9002
in this manual.
Air or moisture in the system - Indications: 1. Leak test the system to see if it is possible that a leak has
permitted air to enter. See Section 9002 of this manual.
A. Suction line warm to your hand.
2. Remove refrigerant from system. See Section 9004 of
B. Discharge air from the evaporator only a little cool. this manual.
3. Repair leaks as needed.
(Continued on next page) (Continued on next page)

9003-12
(Not Enough Cooling - Continued) (Air in the system - Continued)
4. Replace receiver-drier. The moisture removing material in

the receiver-drier could be full to capacity with moisture.
5. Check the oil level in the compressor - It is possible for

the compressor to lose oil. See Section 9005 in this
manual.


T he r m o st a t S en s i ng Tu b e L ow on C h ar ge o r o ut o f 1. Inspect and repair the thermostat sensing tube. See

Calibration - Indications: Section 9002 in this manual.
A. Excessive or incorrect compressor cycling.
B. Compressor clutch not engaging.

9003-13

LOW LOW chart on Page 4.
476L7
Not Enough Refrigerant- Indications: 1. Leak test the system to see if the system has a loss of
refrigerant.
A. Discharge air from the evaporator cool or warm - not
cold. A. If you find a leak, go to step 2.
B. If you do not find a leak, go to step 7.
2. Remove refrigerant from the system. See Section 9004 of

this manual.
3. Repair system leaks as needed.
4. Check oil level in the compressor. It is possible for the

compressor to lose oil. See Section 9005 in this manual.



problems.

9003-14
(Not Enough Cooling - Continued)
High Side Restrictions - Indications: 1. Remove the refrigerant from the system. The restriction in
the receiver-drier must be removed.
A. Discharge air from evaporator only a little cool.
2. Remove and replace part with restriction.
B. Condensation or frost on receiver-drier.
C. Liquid line to receiver-drier cool, with frost or 9004 in this manual.
condensation.
Expansion Valve not Operating - Indications: 1. Expansion valve inlet with condensation or frost is an
indication of a restriction in the expansion valve.
A. Discharge air from evaporator warm or cool - not
cold. A. Remove refrigerant from system. See Section 9004
in this manual.
B. Condensation or frost on expansion valve inlet.
B. Remove and replace expansion valve. See Section
C. Inlet end of expansion valve is warm. 9005 in this manual.
C. Remove air and moisture and charge the system.

See Section 9004 in this manual.
D. Continue performance test for possible other

problems.

9003-15
(Expansion Valve Not Operating - Continued)
2. Inlet end of expansion valve is cold - indication the valve

is not completely open.
A. Disconnect the low pressure cutout switch with the

engine running and the air conditioner on maximum
cooling. Cool the top of the valve with ice and check
for low pressure gauge decrease. The flow of air
from the blower motor must continue through the
evaporator core.
B. Allow the top of the expansion valve to warm. The

valve should open and the pressure should rise at
the low pressure gauge. Repeat step A.
C. If little or no decrease is shown in the low pressure

gauge reading, the expansion valve must be
replaced.
D. Remove refrigerant from the system, replace the

expansion valve, remove air and moisture and
charge the system. See Section 9004 in this
manual.
E. Connect the low pressure cutout switch. Replace all

the insulation material.
F. Continue performance test for other possible

problems.

9003-16

HIGH LOW chart on Page 4.
476L7
Compressor turning but not pumping properly - Indications: 1. Remove refrigerant from system. See Section 9004 in this
manual.
A. System is fully charged.
2. Before you start to repair the compressor, check and
B. Cool discharge air from evaporator. record the compressor oil level. See Section 9005 in this
manual.
3. Remove the compressor from the tractor because there is

indication of an internal leak in the compressor.
4. Repair or replace the compressor as necessary. See

5. Replace the receiver-drier if:
A. System has been opened before.
B. Receiver-drier has been used two or more years.
C. Disassembly of compressor shows small particles

of moisture removing material (gold or brown
particles). See Section 9005 for receiver-drier
replacement.
6. Fill the compressor with new refrigerant oil as shown in

Section 9005 and install compressor in tractor.



problems.

9003-17

HIGH HIGH chart on Page 4.
476L7
Condenser Not Operating - Indications: 1. Check for loose or worn compressor belt and proper
engine fan operation.
A. Liquid line very hot.
2. Check to see that condenser, radiator, and grille screen
B. Discharge air from evaporator is warm. are clean and not damaged, and that hood and radiator
seals are in place.
3. Remove and inspect the condenser for oil collecting in the

tubes. See Section 9005 in this manual.
A. Remove refrigerant from system. See Section 9004

in this manual.
B. Check the compressor for proper oil level.
C. Replace receiver-drier. See Section 9005 in this

manual.
D. Remove air and moisture and charge the system.

See Section 9004 in this manual.

problems.

9003-18
(Not Enough Cooling - Continued)
Air in the System - Indications: 1. Remove the refrigerant from the system. See Section
A. Warm discharge air from the evaporator.
2. Replace the receiver-drier. The moisture removing
material could be full to capacity with moisture.



9003-19

LOW NORMAL chart on Page 4.
476L7
Thermostat Sensing Tube Not Functioning - Indications: 1. Check for proper positioning of sensing tube in the core.
A. Evaporator outlet cold or iced. 2. Sensing tube could be out of calibration. Replace the
sensing tube if necessary. See Section 9002 in this
B. Continuous Compressor operation. manual.
3. Check to see that evaporator seals are clean and

undamaged.

9003-20
PROBLEM - INTERMITTENT COOLING

LOW HIGH chart on Page 4.
476L7
Moisture in the system - Indications: 1. Remove refrigerant from the system. Too much moisture
gets into the expansion valve orifice and will freeze and
A. System cools well during cool part of the day, but stop the refrigerant flow. See Section 9004 in this manual.
does not cool during hot part of the day.
2. Replace receiver-drier. The moisture removing material
could be full to capacity with moisture. See Section 9005
in this manual.

9004 in this manual. The time needed to remove a large
amount of moisture will be two to three hours minimum.

5. Continue performance test for possible other problems.

9003-21
PROBLEM - INTERMITTENT COOLING

LOW LOW chart on Page 4.
476L7
Expansion Valve Not Operating - Indications: 1. Frost on outlet line of expansion valve may be an
indication of a restriction in the valve.
A. Discharge air from evaporator only cool.
A. Remove insulation material from the top of the
B. Condensation or frost on expansion valve outlet to valve. Disconnect the low pressure output switch
evaporator. with the engine running and the air conditioner on
maximum cooling. Cool the top of the valve with ice
and check for low pressure gauge decrease. The
flow of air from the blower motor must continue
through the evaporator core.
B. Allow the top of the expansion valve to warm. The

valve should open and the pressure should rise at
the low pressure gauge. Repeat Step A.
C. If there is little or no decrease shown on the low

pressure gauge, the expansion valve must be
replaced.
D. Remove refrigerant from the system, replace the

expansion valve, remove air and moisture, and
charge the system. See Sections 9004 and 9005 in
this manual.
E. Connect the low pressure cutout switch. Replace all

the insulation material.
F. Continue Performance test for possible other

problems.

9003-22
PROBLEM - NOISE IN SYSTEM
NORMAL See pressure - temperature

TO HIGH HIGH chart on Page 4.
476L7
To much Refrigerant in System - Indications: 1. Remove refrigerant from system. See Section 9004 in this
manual.
A. Cool discharge air from evaporator.
2. Remove moisture and charge system. See Section 9004
B. Compressor makes noise. in this manual.
3. Continue performance test for possible other problem.

Section
9004
9004
AIR CONDITIONER SYSTEM SERVICE
Refrigerant Recovery,
Compressor Removal, And
System Evacuation and Recharging
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July,1995
9004-2
TABLE OF CONTENTS
SPECIFICATIONS ....................................................................................................................................................... 2
SPECIAL TOOLS ........................................................................................................................................................ 3
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY ............................................................................................... 4
COMPRESSOR REMOVAL ........................................................................................................................................... 6
COMPRESSOR INSTALLATION .................................................................................................................................... 7
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING ...................................................................................... 8
PRESSURE - TEMPERATURE CHART ........................................................................................................................ 11
sold.
SPECIFICATIONS
U.S. Standard Value Metric Value
Air Conditioning System Refrigerant Capacity ............................................................ 4 lbs 1.82 kg

9004-3
SAFETY PROCEDURES

!
OR DEATH. M171B
Safety procedures must be followed when working with 4. Always reclaim the refrigerant from the system, if you are
system.
B. See a family physician immediately. inhaled.
2. A drop of liquid refrigerant on your skin can cause 7. Never leak test with compressed air or flame testers.
SPECIAL TOOLS
A22094 299L7A
REFRIGERANT RECOVERY, RECYCLING AND SAFETY GOGGLES CAS-10073-3

RECHARGING STATION OEM-1418

9004-4
AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY

Recovered refrigerant passes through an oil separator and a filter-drier before entering the refrigerant tank. The moisture
indicator will turn green when dry refrigerant passes over it.
If possible, run the air conditioning system for a few minutes before starting the recovery process. Turn the system off before
proceeding.
STEP 1 STEP 3
BP9504007 A22114
Clean the external surfaces of the compressor and hoses. Open the high and low valves.
Remove the caps from the service ports on the suction and
pressure hoses.
STEP 4
STEP 2
A22107
Make certain the refrigerant tank gas and liquid valves are
BP9505001 open.
With the charging station manifold gauge valves in the closed
position, connect the hoses from the test gauges to the
service ports.
Connect the hose from the low pressure gauge to the port on
the suction hose.
Connect the hose from the high pressure gauge to the port on
the discharge hose.

9004-5
STEP 5 STEP 7
A22112 A22110
Connect the main power plug to a 115 volt AC outlet. Move Slowly open the oil drain valve and drain the oil into the
the main power switch to the ON position and depress the reservoir. When the oil stops draining, close the oil drain
recovery start switch. valve completely.
The compressor will shut OFF automatically when recovery is

complete. Wait for 5 minutes and observe the manifold
STEP 8
pressure gauges for a pressure rise. If the pressure rises
above 0 PSI, depress the hold/cont switch then wait for the
compressor to automatically shut OFF.
STEP 6
A22111
Fill the A/C compressor with fresh oil equal to the amount in
the reservoir. See Section 9005.
STEP 9
A22108
Drain the oil separator of A/C system oil. Open the air purge
valve long enough to let some compressor discharge
pressure back into the separator.
BP9504007
Remove the hoses from the service ports and install the
caps.

9004-6
COMPRESSOR REMOVAL
STEP 10 STEP 13
BP9503118 BP9503114
Disconnect the low pressure line from the suction port and Push the compressor down toward the engine. Remove the
the high pressure line from the discharge por t on the compressor belt.
compressor. Immediately install protective caps on open
ports.
STEP 14
STEP 11
BP9503114
Remove the compressor pivot bolt, nut, washers, and lock
BP9504004 washer.
Disconnect the compressor clutch wire from the engine
harness assembly.
STEP 15
STEP 12 Remove the compressor from the tractor. See Section 9005 in
this manual to service the compressor.
BP9503116
Remove the compressor adjusting bolt, lock washer, and
washer.

9004-7
COMPRESSOR INSTALLATION
STEP 16 STEP 18
BP9503114 BP9503119
Install the compressor on the tractor. Install three washers on Adjust the belt tension. See Section 9005 in this service
the pivot bolt. Install the pivot bolt and washers into the rear manual.
of the compressor. Install a washer, lock washer, and nut on
the pivot bolt. Tighten the nut.
STEP 19
STEP 17
BP9504004
Connect the compressor clutch wire to the engine harness
BP9503113 assembly.
Install the drive belt on the tractor. Install the bolt, lock
washer, and washer into the compressor adjusting strap.

9004-8
STEP 20 STEP 21
BP9504007 BP9504007
Carefully remove the protective cap and connect the high Carefully remove the protective cap and connect the low
pressure line to the discharge port on the compressor. Make pressure line to the suction port on the compressor. Make
sure O-ring is in place. sure O-ring is in place.
AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING

IMPORTANT: Replace the receiver-drier if one or more Connect the hose from the high pressure gauge to the port on
of the following conditions occurs before you remove the the discharge hose.
air and moisture from the system.
Removal of air and moisture from the system is necessary
1. The system has been opened for service before. after refrigerant has been removed from the system or after
2. Receiver-drier has operated two or more years. the system has been opened for maintenance. Air enters the
system when the system is opened. Air has moisture that
3. Disassembly of compressor shows small particles of must be removed to prevent damage to system components.
moisture removing material (gold or brown particles).
Air and moisture are removed from the system by a vacuum
4. Large system leak (broken hose, break in line). pump. A vacuum pump is the only equipment made to lower
5. Too much air or moisture in system. the pressure enough to change the moisture to vapor that can
be removed from the system.
6. Removal of compressor caused the system to be open
(uncapped) longer than 5 minutes. NOTE: Refer to the manufacturers user manual for
additional information.
STEP 22
STEP 23
BP9505001
With the charging station manifold gauge valves in the closed A22113
position, connect the hoses from the test gauges to the Connect the main power plug to a 115 volt AC outlet. Move
service ports. the main power switch to the ON position. If the Program and
Vacuum do not appear at the top of the display, press the
Connect the hose from the low pressure gauge to the port on Vacuum key. Program a minimum of 45 minutes and press the
the suction hose. Enter key. T he display will flash once indicating the
programmed data has been accepted.
9004-9
STEP 24 STEP 27
A22115 A22107
Press the Charge key. Program and Charge will appear on Open the red (vapor) and blue (liquid) valves on the tank.
the display.
STEP 28
STEP 25
A22123
A22113 Press the Vacuum key. Automatic will show on the display
Program 4.0 lbs and press the Enter key. The display will and after a slight delay, the vacuum pump will start. The
flash once indicating the programmed data has been display will show the amount of time programmed and begin a
accepted. countdown to zero.
When the programmed time has elapsed, an automatic hold

STEP 26 occurs. Check the low pressure gauge to see that the A/C
system maintains 28 to 29-1/2 inches of mercury (Hg). The
low pressure gauge must not increase faster than one inch of
mercury (Hg) in 15 minutes. If the system will not hold
vacuum, a leak exists that must be corrected before
recharging can begin. See Section 9002 in this manual for a
leak test.
A22114
Fully open the low and high pressure valves.

9004-10
STEP 29 STEP 31
A22116 BP9505002
Pr ess the Char ge key to begin refrigerant charging. Start the engine and run at 1500 RPM. Operate the air
Automatic and Charge will appear on the display. The display conditioner system at maximum cooling setting and blower
shows the programmed amount and counts down to zero as speed with the doors and windows open.
charging proceeds. When charging is completed, the display
shows CPL. NOTE: The compressor will not operate if the system
pressure is too low or too high. The pressure indicator
lamp will illuminate when the relay is actuated by low or
STEP 30 high pressure and the compressor clutch will disengage.
To restart the compressor, the air conditioner control or
blower switch must be turned to the OFF position and
then to the ON position.
STEP 32
A22117
Completely close the high and low pressure manifold valves.
A22117
Completely close the high and low pressure manifold valves.
Observe the pressure gauge readings to determine that the
correct amount of refrigerant has entered the system. See the
char t on page 9004-11 for temperature and pressure
variations.

9004-11
STEP 33 STEP 34
BP9505001 BP9504007
Stop the engine, close any open valves, and carefully remove Install the caps on the service por ts on the suction and
the manifold gauge hoses. discharge hoses.
PRESSURE - TEMPERATURE CHART

SOLID DRIVE FAN VISCOUS FAN
AMBIENT NORMAL LOW NORMAL HIGH NORMAL LOW NORMAL HIGH
TEMPERATURE SIDE PRESSURE SIDE PRESSURE SIDE PRESSURE SIDE PRESSURE
80×°F(27°C) 26 to 36 PSI 200 to 240 PSI 23 to 33 PSI 205 to 255 PSI
The pressure-temperature chart is based on the following 5. Thermostat on maximum setting ten minutes after
conditions: startup.
1. Engine operating at 1500 RPM. 6. Maximum fresh air mode.
2. No engine load. 7. Side panels at hood installed.
3. Fan speed control at High position. 8. Heater valve at engine shut off.
4. Door open.

Section
9005
9005
AIR CONDITIONER COMPONENT SERVICE
CASE CORPORATION
700 STATE STREET
BURLINGTON, ON L7N 3M6 CANADA Issued July,1995
9005-2
TABLE OF CONTENTS
SPECIAL TOOLS ........................................................................................................................................................ 4
COMPRESSOR BELT CHECK AND ADJUSTMENT .......................................................................................................... 5
COMPRESSOR OIL LEVEL CHECK ............................................................................................................................... 6
COMPRESSOR REPAIR .............................................................................................................................................. 8

Clutch Disassembly .................................................................................................................................................. 8
Clutch Assembly .................................................................................................................................................... 11
EXPANSION VALVE TESTING .................................................................................................................................... 15
EVAPORATOR AND EXPANSION VALVE .................................................................................................................... 16
CONDENSER, RECEIVER-DRIER, AND TUBES ............................................................................................................ 18
EVAPORATOR CORE REMOVAL ................................................................................................................................ 20
EVAPORATOR CORE INSTALLATION ......................................................................................................................... 22
sold.

9005-3
SAFETY PROCEDURES

!
OR DEATH. M171B
Safety procedures must be followed when working with
4. Always reclaim the refrigerant from the system, if you are
Refrigerant R-134a to prevent possible personal injury.
going to weld or steam clean near the air conditioner
system.
near an air conditioner system. Liquid refrigerant getting
5. Always check the temperature and pressure of the air
into the eyes can cause serious injury. Do the following if
conditioner system before reclaiming refrigerant and
you get refrigerant in or near your eyes:
when you test the system.
A. Flush your eyes with water for 15 minutes.
6. Dangerous gas can form when refrigerant comes in
B. See a family physician immediately
inhaled.
2. A drop of liquid refrigerant on your skin can cause
frostbite. Open the fitting carefully and slowly when it is
7. Never leak test with compressed air or flame testers.
necessary to service the air conditioner system. Your skin
Te s t s h a ve i n d i c a t e d t h a t , a t p r e s s u r e s a b o ve
must be treated for frostbite or a physician must be seen
atmospheric, and with air concentrations greater than
60% by volume, R-134a can form a combustible gas.

9005-4
SPECIAL TOOLS
299L7A T81574
SAFETY GOGGLES CAS-10073-3 COMPRESSOR SERVICE TOOL SET CAS10747A. ALSO

USE CAS2332 PULLER JAW SET.
A22094
REFRIGERANT RECOVERY, RECYCLING AND RECHARGE

OEM1418

9005-5
COMPRESSOR BELT CHECK AND ADJUSTMENT

Check interval ......................... Every 250 hours of operation
NOTE: Check the belt tension after the first 10 hours of

operation and then use the regular check interval.
BP9503113
To adjust the belt tension, loosen the compressor adjusting
bolts and pivot bolt. Apply pressure to the compressor until
the correct tension for the belt is reached. Tighten the
compressor adjusting bolts and pivot bolt.
BP9503119
Measure the compressor belt for correct tension using a belt
tension gage. Check the belt to the following specifications.
Belt Tension ................................ 45 to 55 lbs (200 to 245 N)
! WARNING: ** Rotating fan and belts. Contact can injure. Keep clear! ** M150A

9005-6
COMPRESSOR OIL LEVEL CHECK

Check the oil level in the compressor when any of the STEP 3
following has occurred:
A. Broken refrigerant hose.
B. Large refrigerant leak.
C. Compressor leak.
D. Damage to system components.
E. New compressor installed.
Use the following procedure to check the compressor oil
level.
STEP 1 7791288
Check the mounting angle of the compressor. Put the angle
gauge from the service tool set across the flat surfaces of the
two front mounting ears. Adjust the gauge so that the bubble
is between the center marks. Read the mounting angle to the
nearest degree mark. Make a note of the degree reading for
reference later.
STEP 4
BP9505002
Start the engine and run at 1500 RPM maximum. Operate the
air conditioner for 10 to 15 minutes at maximum cooling and
high blower speed.
STEP 2
BP9505113
Remove the oil filler plug.
BP9505001
Stop the engine. Connect the compres sor to the air
conditioner charging, recover y, and recycling station.
Discharge the system. See Section 9004 in this service
manual for complete instructions.
NOTE: Wear safety goggles when working with

refrigerant.

9005-7
STEP 5 STEP 7
Remove the dipstick. Count the oil level marks on the
dipstick. Use the following table to find the correct oil level for
the mounting angle of the compressor.
COMPRESSOR OIL LEVELS
MOUNTING ANGLE DIPSTICK

(DEGREES) READING
0 4 to 6
10 6 to 8
103L7 20 7 to 9
Remove the dust cover and use a wrench to rotate the clutch
clockwise until the internal parts are in the position shown 30 8 to 10
above. This will permit the dipstick to be inserted all the way.
40 9 to 11
50 9 to 11
STEP 6
60 9 to 12
90 9 to 12
STEP 8
If the oil level is not correct, add or subtract oil to the correct
level as shown in the above chart.
IMPORTANT: Use only SP-20 PAG oil.
STEP 9
85010
BP9505114
Put the dipstick in the oil filler hole to the stop position. Make
sure the dipstick is inserted all the way to the stop. Install a new O-ring on the oil filler plug. Install the plug and
tighten to a torque of 11 to 18 pound-feet (15 to 24 Nm).
NOTE: The illustration shows the front view of the
compressor with the dust cover removed.

9005-8
COMPRESSOR REPAIR
Clutch Disassembly
STEP 10 STEP 13
A21250 A21253
See Section 9004 in this service manual for compressor Remove the retaining nut for the front plate. Use the special
removal. Clean the external surfaces of the compressor spanner wrench from the service tool set to keep the plate
before doing any work on the compressor. and shaft from turning.
STEP 11 STEP 14
A21251 A21254
Remove the mounting bolts for the clutch dust cover. Install the special puller from the service tool set on the clutch
front plate.
STEP 12
STEP 15
A21252
Remove the clutch dust cover. A21255
Turn the center screw to pull the clutch front plate.

9005-9
STEP 16 STEP 19
A21256 A21260
Remove the shim(s) from the shaft. Remove the external snap ring for the bearing and pulley
assembly.
STEP 17
STEP 20
A21257
Remove the bearing dust cover. Be careful not to bend the A21261
dust cover. Install the special puller internal collars into the groove in the
pulley. Install the special tool onto the shaft. Tighten the
mounting screws finger tight.
STEP 18
STEP 21
A21258
Remove the key from the rotor shaft.
A21262
Turn the center screw on the puller.

9005-10
STEP 22 STEP 25
A21263 A21266
Remove the pulley and bearing assembly. Remove the clutch coil assembly.
STEP 23 STEP 26
A21265 A21267
Remove the snap ring for the clutch coil assembly. Remove the internal snap ring and remove the bearing from
the pulley.
STEP 24
A21264
Disconnect the clip for the lead wire.

9005-11
Clutch Assembly
1016L93
STEP 27 STEP 28
102L7 A21266
Use an ammeter, voltmeter, and a 12 volt battery to check the Install the clutch coil assembly. Align the detent ball and
amperage of the clutch coil. The current draw must be 3.6 to socket on the coil and housing.
4.2 amperes at 12 volts.
A reading of more than 4.2 amperes indicates a short within
the coil.
No amperage reading indicates an open circuit in the coil.
Replace the clutch coil if the amperage reading is not correct.

9005-12
STEP 29 STEP 32
A21264 A21268
Install the clip for the coil lead wire. Put the pulley and the bearing assembly on the front housing
hub. Install a driver on the pulley assembly. Make sure that
the tool is on the inner race of the bearing.
STEP 30
STEP 33
A21265
Install the snap ring for the clutch coil assembly.
A21268
Support the compressor on the four mounting ears at the
STEP 31 compressor rear. Use a a hammer to tap the pulley assembly
onto the front housing hub. As the pulley is tapped onto the
hub you can hear the difference in sound when the pulley is
fully installed. Make sure the bearing is against the bottom of
the hub.
A21267
Install the bearing in the pulley and install the internal snap
ring.

9005-13
STEP 34 STEP 37
A21260 A21270
Install the external snap ring on the front housing hub. Gently tap the dust cover until it is seated.
STEP 35 STEP 38
A21259 A21256
Install the key in the rotor shaft. Install the shim(s) on the rotor shaft.
STEP 36 STEP 39
A21269 A21271
Place the bearing dust cover in the bore. Place the driver Install the front plate on the rotor shaft. Make sure the keyway
from the special tool kit over the dust cover. in the plate is aligned with the key in the shaft. Install the
driver over the shaft.

9005-14
STEP 40 STEP 42
A21272 T97256
Use a hammer to tap the plate onto the shaft. Make sure the Use a feeler gauge to measure the gap between the front
plate is against the clutch shims. As the plate is tapped onto plate and pulley assembly. The gap must be 0.016 to 0.031
the shaft you can hear the difference in the sound when the inch (0.41 to 0.79 mm). The gap must be even all the way
plate is fully installed. around the plate. If necessary , lightly lift , or push down on
the plate to make the gap even.
STEP 41 NOTE: If the gap does not meet the above

specifications, remove the front plate and add or subtract
clutch shims as required.
STEP 43
A21253
Install the nut on the rotor shaft. Use the spanner wrench and
a torque wrench to tighten the nut to a torque of 11 to 15
pound-feet (15 to 20 Nm).
A21252
Install the dust cover.
STEP 44
A21251
I ns t a ll t he s i x b o l ts t ha t ho l d t h e d u st c over to t he
compressor. Tighten to 5 to 8 pound-feet (7 to 11 Nm).
9005-15
EXPANSION VALVE TESTING

The following test is to be made with the expansion valve STEP 48
mounted in the system. No repair, cleaning or adjustment is
recommended for the valve.
STEP 45
BP95F001
Watch the low pressure gauge as ice is applied onto the cap
of the expansion valve.
The pressure must start to lower. When the pressure reaches
BP9504011 4 PSI (28 kPa), the low pressure indicator will illuminate and
Remove headliner. the compressor will stop. The relay must be reset after the
compressor has stopped before the system will operate. To
reset the relay, turn the air conditioner to the OFF position
STEP 46 and then back to the desired temperature setting.
STEP 49
Warm the expansion valve and watch the low pressure
gauge.
Within minutes, the expansion valve will open and the
pressure must rise at the low pressure gauge. The pressure
will rise to a range of 45 to 75 PSI (310 to 520 kPa).
STEP 50
If the pressure does not rise per step 49, the valve is not
BP95F002 operating. Replace the valve.
Install low pressure hose from OEM-1418 to the low pressure
service port. Close both manifold valves.
STEP 47
Make sure the flow of air continues through the evaporator
core. Start the engine and run at 1500 RPM.Turn the Blower
Switch to the HIGH position, and with the temperature control
valve turned fully clockwise, check the low pressure gauge
reading.
The low pressure reading will range from 26 to 51 PSI (180 to
355 kPa) when the compressor is operating

9005-16
EVAPORATOR AND EXPANSION VALVE

The refrigerant must be reclaimed from the system and all the Connect the suction hose to the evaporator outlet. Install an
black insulation must be removed from the fittings and O-ring between the fittings.
expansion valve before the evaporator core or the expansion
valve are replaced. NOTE: Tighten all the connections. Use two wrenches
to prevent damage to the parts when tightening tubes
The expansion valve must be installed with the sensor toward
and hoses. Always replace O-rings and put clean
the top of the tractor. The port nearest to the IN mark must
refrigerant oil on the O-rings.
point away from the evaporator core. Connect the evaporator
core fittings to the expansion valve. Install O-rings between
NOTE: SP-20 PAG OIL must be added whenever a
the evaporator core and the expansion valve.
component is replaced. Refer to the chart below for
Connect the expansion valve to the evaporator inlet tube. recommended quantities.
Install an O-ring between the expansion valve inlet and the
pressure hose from the receiver-drier. COMPONENT OIL AMOUNT
FL OZ CC
Evaporator 1.5 to 1.7 45 to 50
Condenser 1.2 to 1.3 35 to 40
Receiver-Drier 0.7 to 0.8 20 to 25
Hoses (Normal Length) 0.3 to 0.7 10 to 20

9005-17
BT95F024
3
1
6
5
7 4
2
8
5
9
11
10
BT95F024
BT95F024
1. Evaporator Core 5. O-Ring 9. Cap

2. Expansion Valve 6. Suction Hose 10. A/C Control Switch and
3. O-Ring 7. Pressure Hose Sensing Line
4. O-Ring 8. Low Pressure Switch 11. Left-Hand Air Duct

9005-18
CONDENSER, RECEIVER-DRIER, AND TUBES

C. When the expansion valve is replaced (because of
WARNING: ** Do not steam clean any air corrosion caused by moisture in the system).
conditioner system parts while the system is
charged. The heat will cause the refrigerant D. When the receiver-drier or inlet and outlet lines feel
! to rise to a pressure that could cause the cool to your hand when the system is operating.
system to explode.** This condition is an indication of too much moisture
SM104A in the system.
The receiver-drier must be installed with the inlet connected
Keep the condenser fins clean and straight to make sure to the hose from the condenser and the outlet connected to
there is maximum flow through the condenser and radiator at the tube going to the evaporator. Always install new O-rings
all times. Use compressed air or a rigid brush to clean the when you connect the receiver-drier to the system.
condenser. Also check and clean the grille screen and
radiator. Maximum air flow will prevent the engine from Use the two hand, two wrench method to prevent damage to
getting too hot and will give the most efficient operation of the the tubes and fittings when you loosen or tighten the tube
air conditioner system. connections.
Always replace the O-rings when you separate connections to
IMPORTANT: Because the condenser fins bend easily, make sure you get a good tight seal when you make the
be careful when you clean the condenser. connections again. Apply clean refrigerant oil onto the O-
Replace the receiver-drier every other time the system is rings.
opened for repair or service. Replace the receiver-drier each
time the system is opened under the following conditions:
A. In an area where there is high moisture content in
the air.
B. If the system has been open for a long period of
time because of a leak (broken hoses, loose
connections) that has permitted air and moisture to
enter the system.

9005-19
5
3
8
1
7
6
BT95F023
BT95F023
1. Condenser 5. Receiver-Drier
2. High Pressure Switch 6. Hose - Compressor to Cab
3. Hose - Receiver-Drier to Cab 7. Hose - Compressor to Condenser
4. Hose - Condenser to Receiver-Drier 8. Compressor

9005-20
EVAPORATOR CORE REMOVAL

STEP 51 STEP 54
Carefully remove the four nuts that hold the housing to the
roof of the cab and lower the housing including the blower,
heater core, and air conditioner evaporator to the front dash
and steering wheel area.
NOTE: Be careful not to kink the the air conditioner

lines, as this could cause premature failure of the hoses.
STEP 55
BP9504009
Remove the screws that hold the cover on the right-hand
center post. Then remove the cover and the control panel.
STEP 52
1
BP95F001
If the insulation (1) has not been removed, remove it now
from the expansion valve and the evaporator lines.
To test the valve see Expansion Valve Testing in this section.
Discharge the A/C system to remove the evaporator core.
See Section 9004 of this manual.
BP9504011 STEP 56
Remove headliner
STEP 53
1
4
1
2
3 BP95F001
Disconnect the air conditioner suction and discharge lines (1)
at the expansion valve. Remove and discard the O-rings. Cap
1 and plug the lines to prevent dirt and moisture from entering
BP95F002
the system.
Remove the hose clamps (1) and disconnect the four drain
hoses (2) at the housing. Disconnect the low pressure switch
(3). Remove the bolts (4) retaining the air ducts and remove
the air ducts. Disconnect the blower.

9005-21
STEP 57 STEP 58
3 Remove the evaporator core from the housing and put the
evaporator on a clean bench. Remove the expansion valve
from the evaporator core. It can be necessary to use a back-
up wrench to prevent damage to the tubes. Remove and
2 discard the O-rings from between the expansion valve and
4 the evaporator core lines.
1
BT95F129
1. 2 inches (50 mm)
2. 4 inches (100 mm)
3. 2 inches (50 mm)
4. 12 inches (300 mm)
Remove the thermostat probe for the air conditioner control

that is put into the evaporator core.

9005-22
EVAPORATOR CORE INSTALLATION

STEP 59 STEP 64
Put new O-rings on the evaporator core lines. Lubricate the
O-rings with clean refrigerant oil.
STEP 60
BP95F001
1 Connect the air conditioner discharge and suction lines to the
expansion valve. Wrap the valve and the lines with insulation.
BP95F001
STEP 65
Install the expansion valve (1). Tighten the fittings to a torque
Install the evaporator core in the housing with the heater
of 18 to 25 lb ft (25 to 34 Nm). It can be necessary to use a
core. Be sure the foam insulation strips are in place to seal
backup wrench to prevent damage to the evaporator tubes.
the plenum around the evaporator so air is forced through the
evaporator and the heater core.
STEP 61
Install the evaporator core in the housing
STEP 66
STEP 62 Raise the housing into place, including the blower, heater
core and air conditioner evaporator. Fasten with four nuts to
3 the roof. Be sure the top insulation strip is in place.
2
STEP 67
4
1
1
4
2
3
BT95F129
1. 2 inches (50 mm) 1
BP95F002I
BP95F002
2. 4 inches (100 mm)
3. 2 inches (50 mm) Connect the blower. Install the hose clamps (1) and the air
4. 12 inches (300 mm) ducts using bolts (4). Make sure the seals on the air ducts are
in place. Connect the low pressure switch (3). Connect the
Install the thermostat probe for the air conditioner. four drain hoses (2) to the housing and tape in place to the air
ducts. Connect the blower. Make sure the seals are in place
when installing air ducts.
STEP 63
Install new O-rings on the discharge and suction lines at the
expansion valve. Lubricate the O-rings with clean refrigerant
oil.
9005-23
STEP 68 STEP 69
BP9504006 BP9504002
Install headliner. Install the control panel and the cover on the center post

580L Manual Servicio

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2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Have another per s on hel p wi th the followin g

Remove the caps screws (1), upper (2) and lower

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Remove the bolts (1), spacers, washers, and coolant

Disconnect the overflow hose (1) from the radiator

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Bur 7-49651 Revised 3-00 Printed in U.S.A.

If the machine has two batteries, remove the terminal

Remove the battery cover from the right step. If the

Remove the caps screws (1), upper (2) and lower

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Remove the bolts (1), spacers, washers, and coolant

Loosen and remove the cap screws, flat washers,

Remove the hardware from the fan shroud. Move the

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Disconnect the hoses from the oil cooler.

Remove the self-locking nut and clamp from the

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Disconnect the hoses from the oil cooler on both

For machines with a slot in the baffle plate, move the

Remove the cap screws and flat washers that fasten

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Disconnect the hoses (1) from the LH side of the BP9503114

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Remove the tie strap (1). Disconnect the electrical BP9502304

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Disconnect the coolant temperature sender (1) and BP9502297

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Remove the bolts, flat washers, and nuts from the

Install the CAS-1690 tool to turn the flywheel for

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Bur 7-49651 Revised 3-00 Printed in U.S.A.

1. RADIATOR 3. COOLANT RECOVERY BOTTLE 5. OIL COOLER

Bur 7-49651 Revised 3-00 Printed in U.S.A.

1. RADIATOR SHROUD 3. NUT 5. CAP SCREW 7. GROMMET

Bur 7-49651 Revised 3-00 Printed in U.S.A.

1. ENGINE MOUNT 3. HARDENED WASHER 5. BOLT 7. INSULATOR

FRONT ENGINE MOUNT INSTALLATION

Bur 7-49651 Revised 3-00 Printed in U.S.A.

INSTALLING THE FRONT ENGINE SUPPORT

Remove the plastic plug at the left front of the

Install a spacer in each top hole in the front engine

Use a dial indicator to check the alignment of the

Bur 7-49651 Revised 3-00 Printed in U.S.A.

When the front engine support is centered, tighten

Bur 7-49651 Revised 3-00 Printed in U.S.A.

Bur 7-49651 Revised 3-00 Printed in U.S.A.

SPECIAL TOOLS ........................................................................................................................................................ 3

NONSPILL CAPS ........................................................................................................................................................ 5

BATTERY TEST .......................................................................................................................................................... 6

CHARGING A BATTERY ............................................................................................................................................................... 8

PREPARING A DRY CHARGED BATTERY FOR USE ................................................................................................................... 9

Bur 7-49440 Issued 3-95 Printed in U.S.A

Never cause sparks to occur or smoke near batteries

The CAS-10147 tester is used to do the Capacity (Load)

Bur 7-49440 Issued 5-95 Printed in U.S.A.

Bur 7-49440 Issued 5-95 Printed in U.S.A.

When you remove a nonspill cap, check the condition of

Missing or broken nonspill caps MUST be replaced with