SALES INC. WITHOUT THE AUTHORIZATION OF ORS. J.I. CASE AND IT'S SUCCESSORS HE QUALITY OR ACCURACY OF THIS MANUAL.

Transcription

1 of 3 SALES INC. WITHOUT THE AUTHORIZATION OF ORS. J.I. CASE AND IT'S SUCCESSORS HE QUALITY OR ACCURACY OF THIS MANUAL. ONTAINED AND USED HEREIN ARE THOSE OF OTHERS, PTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CA-S-450C C

2 450C/455C CRAWLERS Service Manual Table of Contents Description General llilillllllllllll!llllll!lill&.. I I Iii Iii Iii Safety Rules, Service Manual Introduction, and Torque Specifications General Engine Specifications Section No. Tab Tab 2 Form No a :1r1m.CAV Injection Pump Tab Electrical Wiring Schematics Alternator, Delco-Remy Alternator, Bosch Track and Suspension Tab Tab Idler, Track Adjuster, and Recoil Housing Carrier Rollers I Reprinted I CASE CORPORATION Rae Copyright 1992 Case Company Printed in U.S.A. August, 1992

3 Description Section No. Form No. Power Train Tab 6 Modulator Valve Brakes I I 1111 Wet Brakes Hydraulics Tab 8 Mounted Equipment Tab 9 C-Frame and Blade for Dozer Machines ROPS Canopy Rae Printed in U.S.A. August, 1992

4 Section 1001 SAFETY RULES SERVICE MANUAL INTRODUCTION AND TORQUE SPECIFICATIONS Safety Rules Service Manual Introduction Product Identification Number (PIN) and Serial Numbers Torque Specifications Written In Clear And Simple English CASE CORPORATION Printed in U.S.A. Issued December 1984

5 -1002 MAINTENANCE AND LUBRICATION ' Fluids and Lubricants Engine Oil Recommendations Diesel Fuel... ~ Engine Run-In Period Run-In Maintenance Schedule Maintenance Schedule Case Corporation BurS Printed in U.S.A. Issued February 1988

6 2000 ENGINE STALL TESTS Stall Tests Specifications Procedure to Heat the Oil Torque Converter Test No. 1 - Torque Converter and Hydraulic Stall Together Test No. 2 -Torque Converter Stall Test No. 3- Hydraulic Stall Hydraulic System CASE CORPORATION BurS Printed in U.S.A. Issued February 1988

7 ENGINE REMOVAL In this procedure the engine and torque converter are removed as an assembly. 1. Park the machine on a level surface. 2. Lower rear mounted equipment to the floor. 6. If the machine has a front counterweight, the weight of the front counterweight is approximately 930 pounds (421 kg). Use the floor jack and remove the counterweight Raise the blade and use acceptable supports to hold the blade in place Lower the blade to the floor The weight of the rear guard is approximately 60 pounds (27 kg). Use a floor jack a~d remove the rear guard Remove the engine side panels. 5. The weight of the front guard is approximately 30 pounds (15 kg). Use a floor jack and remove the front guard

8 RUN-IN INSTRUCTIONS... 3 IDENTIFICATION MARKS Crankshaft... 4 Cylinder Block... 4 Cylinder Head... 4 ENGINE SPECIFICATION DETAILS Cylinder Block... 4 Service Cylinder Sleeve... 5 Piston... 5 Piston Pin... 5 Piston Rings... 6 Cylinder Head... 6 Lifters... 6 Connecting Rod... 7 Crankshaft... :... :... 8 Camshaft... 9 Turbocharger... 9 Gear Train... 9 Rocker Arm Assembly... 1 O Intake Valve... 1 O Exhaust Valve Valve Springs Valve Seat Installation Dimensions SPECIAL TORQUES Rae Revised 2-92 Printed in U.S.A.

9 IDENTIFICATION MARKS... 2 SPECIFICATIONS... 3 SPECIAL TORQUES... 4 SPECIAL TOOLS... 5 CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY CHECKING AND RESURFACING THE CYLINDER HEAD... 12,13 VALVE GUIDE REPLACEMENT 14 mm Replacement Valve Guides mm Replacement Valve Guides INSPECTION OF THE VALVES AND VALVE SEATS VALVE SEAT INSTALLATION REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS CYLINDER HEAD ASSEMBLY... 27,28 ROCKER ARM DISASSEMBLY... 28,29 ROCKER ARM ASSEMBLY CYLINDER HEAD INSTALLATION LOCATING TOP CENTER ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE THERMOSTAT SERVICE IDENTIFICATION MARKS Letter G = Thermostat passage in cylinder did not need to be machined. Letter M = Thermostat passage in cylinder head was machined. Letter V = Valve seats have been machined. Letter X = The cylinders in the cylinder block have been bored oversize. Use a head gasket with oversize cylinder holes (one notch). Letter XX = The cylinder block has been refaced and up to O.25 mm has been removed. Use a thicker head gasket (two notches). Letter XXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker head gasket (three notches). Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head. Rae Revised 2-92 Printed in U.S.A

10 SPECIFICATIONS ENGINES MANUFACTURED IN U.S.A. Prior to Engine Serial Number Injector Nozzle 9 mm Engine Serial Number and After... Injector Nozzle 7 mm ENGINES MANUFACTURED IN DARLINGTON ENGLAND Prior to Engine Serial Number Injector Nozzle 9 mm Engine Serial Number and After... lnjectior Nozzle 7 mm ENGINES MANUFACTURED IN NEUSS GERMANY Prior to Engine Number Injector Nozzle 9 mm Engine Serial Number and After... Injector Nozzle 7 mm CYLINDER HEAD Maximum Warpage mm in any 50 mm diameter area or more than mm overall end to end or side to side. Maximum amount of material that can be removed during resurfacing mm Minimum total height of cylinder head to mm CYLINDER HEAD MACHINING IDENTIFICATION MARKS Total thickness of cylinder head material removed... See Page 12 X on head indicates block resurfacing... See Page 27 V on head indicates valves have been ground... See Page 27 G on head indicates thermostat bore inspected... See Page 40 Mon head indicates thermostat bore machined... See Page MM REPLACEMENT VALVE GUIDE Valve guide OD to mm Bore cylinder head to to mm Press fit to mm Installed height above top of valve guide boss on cylinder head to mm 11 MM REPLACEMENT VALVE GUIDE Valve guide OD to mm Bore cylinder head to to mm Press fit to mm Installed height above top of valve guide boss on cylinder head to mm EXHAUST VALVE INSERT Diameter of insert to mm Diameter of bore to mm Depth of bore to mm Press fit to mm INTAKE VALVE INSERT Diameter of insert to mm Diameter of bore to 47.o'13 mm Depth of bore to mm Press fit to mm Rae Revised 2-92 Printed in U.S.A.

11 SPECIFICATIONS Special Torques... :... 6 SPECIAL TOOLS FRONT OIL SEAL REPLACEMENT REAR OIL SEAL REPLACEMENT FRONT OIL SEAL AND WEAR SLEEVE INSTALLATION REAR OIL SEAL AND WEAR SLEEVE INSTALLATION REMOVAL OF PISTONS AND RODS CYLINDER WALL INSPECTION RECONDITIONING THE ENGINE CYLINDER BLOCK Checking and Resurfacing the Cylinder Block Reconditioning the Cylinder Block for Oversize Pistons Reconditioning the Cylinder Block for Sleeves PISTON AND CONNECTING ROD DISASSEMBLY AND INSPECTION PISTON AND CONNECTING ROD ASSEMBLY AND INSTALLATION REPLACEMENT OF THE MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT CRANKSHAFT AND MAIN BEARINGS CRANKSHAFT GEAR REMOVAL CRANKSHAFT INSPECTION CRANKSHAFT RECONDITIONING Grinding a Crankshaft Crankshaft Rehardening CRANKSHAFT GEAR INSTALLATION CRANKSHAFT INSTALLATION Rae Revised 2-92 Printed in U.S.A.

12 CAMSHAFT Removal Camshaft Bore and Bushing Inspection Camshaft Bushing Removal and lnstallation Valve Lifter Inspection Camshaft Disassembly and Inspection Camshaft Gear lnstallation Camshaft Installation..., FLY\/1/HEEL Removal Ring Gear Removal and Installation Installation TACHOMETER DRIVE, IF EQUIPPED Removal and Disassembly Assembly and Installation EXPANSION PLUG REMOVAL AND INSTALLATION 60 mm Expansion Plugs mm Expansion Plugs mm Expansion Plugs mm Expansion Plugs mm Expansion Plugs mm Expansion Plugs CRANKCASE PRESSURE CHECK (BLOW BY) Manometer Installation Testing Manometer Removal Rae Revised 2-92 Printed in U.S.A..

13 SPECIFICATIONS... 2 SPECIAL TORQUES... 3 OIL PUMP Removal... 4 Disassembly and Assembly Installation OIL PRESSURE RELIEF VALVE... 8 OIL FILTER HOUSING AND OIL COOLER Removal... 9 Installation OIL PAN AND OIL INLET TUBE Removal and Installation O SPECIFICATIONS Oil Pressure New Engine at Low or 800 rpm to 3.0 Bar at 1700 rpm to 3.4 Bar at High Idle or 2400 rpm to 3.7 Bar Used Engine Low Idle (minimum) Bar High Idle (minimum) Bar 28 to 43 PSI 40 to 50 PSI 43 to 54 PSI 10 PSI 30 PSI Oil Pump Idler Gear to Crankshaft Gear Backlash mm Oil Pump Rotor Clearance mm Oil Pump Relief Valve Spring Specification (For 2 Hole Relief Valves) Free Length mm Outside Diameter mm Assembled Height: Compress to mm to 79 N Spring Load Height: Compress to mm to 113 N Oil Pump Relief Valve Spring Specification (For 4 Hole Relief Valves) Free Length mm Outside Diameter mm Assembled Height: Compress to 44.5 mm N Spring Load Height: Compress to mm N Rae B Revised 2-92 Printed in U.S A

14 SAFETY RULES... 3 SPECIAL TORQUES SPECIFICATIONS WATER PUMP Removal... 4 Installation THERMOSTAT Removal... 5 Installation , 7 COOLING INLET MANIFOLD Removal... 8 Installation... 8,9 FAN PULLEY BRACKET Removal Installation , 11 BELT TENSIONER Removal... 11,12 Installation , 13 THERMOSTAT SERVICE Rae Revised 2-92 Printed in U.S.A.

15 SPECIFICATIONS... 2 SPECIAL TORQUES... 3 SPECIAL TOOLS... 3 SERVICING THE TURBOCHARGER Removal ,5 Inspection Disassembly Inspection After Disassembly Assembly Installation... 23,24 SPECIFICATIONS Metric Value Turbine Wheel Horizontal Movement to 0.16 mm Rae Issued 6-84 Printed in U.S.A.

16 3001 FUEL LINES, FUEL TANKS, AND ENGINE CONTROLS Specifications Throttle Linkage Adjustment Illustration - Throttle Linkage Illustration - Fuel Lines Removing Air From the Fuel System Replacement of the Fuel Filters Removing Water From the Fuel System Illustration - Fuel Tank Written In Clear And Simple English CASE CORPORATION Printed in U.S.A. Issued December 1984

17 SAFETY RULES... 2 SPECIFICATIONS... 3 SPECIAL TOOLS... 4 SPECIAL TORQUES... 4 GENERAL INFORMATION... 4 OPERATING PROCEDURES... 5 LOCATING FAULTY INJECTORS Locating Faulty Injectors at the Fuel Pump... 6 Locating Faulty Injectors at the Cylinder Head... 6 INJECTORS Removal... 6, 7 Installation... 7,8 FUEL INJECTOR.TESTER... 9 Nozzle Tester Preparation... 9 TESTING INJECTORS Checking Opening Pressure Checking Seat Leakage Spray Pattern INJECTOR Disassembly Cleaning and Inspection Assembly Adjustments INJECTOR SLEEVE (9 mm BORE TO 7 mm BORE) Installation SAFETY RULES A THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. M171B When testing or adjusting diesel fuel injectors, do not place your hands, arms, or any other part of your body into the fuel injector spray. Fuel spray from an injector has sufficient velocity to penetrate the skin and cause serious infection or other reactions. If injured by fuel penetration, see your doctor immediately. SM127A Wash the injured part with boric acid solution, support the injured finger or hand with a splint and sling so the injured part will remain absolutely at rest until a physician can examine it. Rae Revised 2-92 Printed in U.S.A.

18 SPECIAL TOOLS... 2 SPECIAL TORQUES... 2 TROUBLESHOOTING GUIDE... 3 FUEL INJECTION PUMP Removal... 4,5 Installation... 6,7 INJECTION PUMP GEAR Removal... 8,9 Installation o, 11 FUEL INJECTION PUMP TIMING FUEL SHUT-OFF SOLENOID Removal and Disassembly... : Assembly and Installation PRIMER PUMP Removal Installation SPECIAL TOOLS CAS-1690 ENGINE TURN OVER TOOL FIRST USED ON PAGE 5 CAS-1691 A GEAR PULLER FIRST USED ON PAGE 5 SPECIAL TORQUES Injection Pump Mounting Bolts to 27 Nm Injection Pump Nut to 71 Nm Fuel Line Inlet Bolt to 28 Nm Fuel Shutoff Solenoid Nm Leak Off Fitting to 17 Nm Injection Pump Lock Bolt (Lock Position)... 7 Nm Injection Pump Lock Bolt (Unlock Position) Nm Rae Revised 2-92 Printed in U.S.A.

19 SPECIAL TOOLS... 2 SPECIAL TORQUES... 2 TROUBLESHOOTING GUIDE... 3 FUEL INJECTION PUMP Removal Installation... : INJECTION PUMP GEAR Removal... 9 Installation INJECTION PUMP TIMING FUEL SHUT-OFF SOLENOID Removal and Disassembly Assembly and Installation PRIMER PUMP Removal Installation TIMING LOCKING PIN Removal Installation SPECIAL TOOLS CAS-1690 ENGINE TURNOVER TOOL SPECIAL TORQUES CAS-1691A GEAR PULLER Injection Pump Mounting Bolts to 27 Nm Injection Pump Nut to 71 Nm Fuel Line Inlet Bolt... : to 28 Nm Fuel Shut-off Solenoid Nm Leak Off Fitting to 17 Nm Injection Pump Lock Bolt, Lock Position to 33 Nm Injection Pump Lock Bolt, Unlock Position to 14 Nm NOTE: The case corporat10n 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. Rae Revised 2-92 Printed in U.S.A.

20 SPECIFICATIONS... 3 USING BOOSTER BATIERIES TO START THE ENGINE... 4 Booster Battery Connections to the Batteries...4 TROUBLESHOOTING CHART... 5 Battery... 5 Alternator... 6 Starter... 7 TROUBLESHOOTING THE CHARGING CIRCUIT FOR THE DELCO-REMY ALTERNATOR... 8 General Inspection... 8 Checking Voltage at the Alternator... 8 Charging Circuit Check... 9 Alternator and Voltage Regulator Test TROUBLESHOOTING THE CHARGING CIRCUIT FOR THE BOSCH ALTERNATOR General Inspection Checking Voltage at the Alternator Charging Circuit Check Alternator and Voltage Regulator Test..., TROUBLESHOOTING THE STARTING CIRCUIT General Inspection Starter Check Starting Circuit Check...: TROUBLESHOOTING THE RETURN-TO-DIG CIRCUIT Bur Issued 7-91 Printed in U.S.A.

21 4004 INDICATORS AND GAUGES Checking the Accuracy of the Gauges Alternator Gauges (Ammeter) Engine Oil Pressure Gauge Transmission Oil Pressure Gauge Water Temperature Gauge Gauge for Torque Converter Oil Temperature Hourmeter Illustrations of Indicators and Gauges CASE CORPORATION BurB Printed in U.S.A. Issued February 1988

22 4005 BATTERY(S) Specifications... See Section 4002 Booster Batt~ries... See Section 4002 Safety Rules Maintenance Electrolyte Level Inspecting and Cleaning the Battery Nonsplll Caps Battery Test Visual Checks Specific Gravity Check Capacity (Load) Test Charging A Battery Preparing a Dry Charged Battery For Use Written In Clear. And Simple English CASE CORPORATION Printed in U.S.A. Issued November 1985 Reprinted March 1986 (1845C)

23 4006 STARTER AND STARTER SOLENOID Specifications Lubrication No-Load Test Disassembly Inspection Brushes and Brush Springs Brush Holder... 4: Armature Field Coil Test Assembly Illustration of Starter Starter Solenoid Test CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

24 4007 ALTERNATOR DELCO-REMY Specifications Stator Test Charging Circuit and Alternator Rotor Removal Inspection Installation Resistance Test Disassembly Test For Short Circuit Rectifier Bridge Test Assembly Diode Trio Test CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

25 SPECIFICATIONS DISASSEMBLY INSPECTION OF BRUSHES INSPECTION AND TESTING OF ROTOR INSPECTION AND TESTING OF STATOR TESTING THE CONDENSER TESTING THE RECTIFIER BRIDGE SPECIFICATIONS Rated output volts at 65 amperes Resistance of rotor winding to 3.08 ohms Maximum runout for slip rings mm (0.002 inch) Minimum diameter of slip rings mm (1.055 inch) Resistance of stator coils to 0.11 ohms Minimum length of brushes... 7 mm (0.27 inch) Torque for nut for pulley to 70 Nm (44 to 55 pound-feet Bur Issued 7-90 Printed in U.S.A.

26 SPECIFICATIONS... 3 NO LOAD TEST... 4 General Information... 4 Test Equipment... 4 Test Procedure... 4 Understanding Test Results... 5 STARTER SOLENOID TESTS... 6 General Information... 6 Hold-in Coil Test Pull-in Coil Test STARTER... 8 Disassembly... 8 Inspection Brush Holder and Brushes Replacing Bushings Cover Shift Lever Housing Starter Drive Housing Field Coil Test Replacing the Field Coil Assembly Checking Pinion Clearance STARTER SOLENOID Disassembly Assembly Bur Issued Printed in U.S.A.

27 SPECIAL TOOL... 3 INTRODUCTION... 3 PIN AND BUSHING WEAR FOR SEALED TRACK....4 PIN AND BUSHING WEAR FOR CASE LUBRICATED TRACK... 5 TRACK LINK WEAR... 6 TRACK SHOE WEAR... 7 TRACK AND CARRIER ROLLER WEAR... 8 IDLER WEAR WEAR CHART FOR PIN AND BUSHING WEAR (PITCH EXTENSION) FOR SEALED TRACK WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR FOR SEALED TRACK WEAR CHART FOR VERTICAL BUSHING WEAR FOR SEALED TRACK WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR FOR CASE LUBRICATED TRACK WEAR CHART FOR VERTICAL BUSHING WEAR FOR CASE LUBRICATED TRACK WEAR CHART FOR TRACK LINK WEAR WEAR CHART FOR ONE BAR TRACK SHOE WEAR WEAR CHART FOR THREE BAR TRACK SHOE WEAR WEAR CHART FOR TRACK ROLLER WEAR WEAR CHART FOR CARRIER ROLLER WEAR WEAR CHART FOR IDLER WEAR TRACK COMPONENT APPRAISAL FORM Bur Issued 7-91 Printed in U.S.A.

28 SPECIFICATIONS... 3 SPECIAL TOOLS... 3 TRACK... 5 Removal... 5 Disassembly... 7 Assembly...? Installation... 7 Track Adjustment TRACK FRAME Removal Installation CROSS SHAFT INSTALLATION Bur Issued 7-91 Printed in U.S.A.

29 SPECIFICATIONS... 3 SPECIAL TOOLS... 3 IDLER RECONDITIONING... 4 IDLER... 5 Removal... 6 Installation... 6 Disassembly... 8 Inspection Assembly of Face Seals... 1 O Assembly LEAKAGE TEST TRACK ADJUSTER Removal Installation Disassembly Inspection Assembly RECOIL HOUSING General Information Removal lnstallation DESTROYING THE OLD RECOIL HOUSING Bur Issued 7-91 Printed in US.A.

30 5509 SPROCKET Specifications Special Tool General Information Removing a Sprocket Installing a Sprocket CASE CORPORATION BurS Printed in U.S.A. Issued February 1988

31 SPECIFICATIONS... 2 SPECIAL TOOLS... 3 RECONDITIONING SPECIFICATIONS... 4 REMOVAL DISASSEMBLY... 5 INSPECTION... 7 ASSEMBLY... 9 LEAKAGE TEST INSTALLATION SPECIFICATIONS Lubricant....,... Case Gear Lube Amount U.S. fluid ounces (290 ml) End travel for shaft to inch {1.13 to 1.47 mm) Special torques Cap screws for retainer pound-inches (49 Nm) Cap screws for end cap pound-inches {49 Nm) Nut for bolt that holds carrier roller to 96 pound-feet (109 to 130 Nm Bur Issued 1-90 Printed in U SA

32 SPECIFICATIONS... 2 SPECIAL TOOLS... 3 RECONDITIONING SPECIFICATIONS...4 REMOVAL DISASSEMBLY... 5 INSPECTION... 8 ASSEMBLY... 9 LEAKAGE TEST INSTALLATION SPECIFICATIONS Lubricant.... Case Gear Lube Amount U.S. fluid ounces (219 ml) End travel for shaft to inch (0.3 to 0.9 mm) Special torque Nuts for bolts that hold track rollers to 180 pound-feet (203 to 244 Nm) Bur Issued 1-90 Printed in U.S.A

33 6002 SPECIFICATIONS AND TROUBLESHOOTING Specifications Test No. 2 - Pressure Regulator Valve Special Tools Test No. 3 - Forward and Reverse Correcting High Torque Converter Clutches Temperature Test No. 4 - High and Low Clutches Transmission Troubleshooting Understanding Test Results General Information U.S. Measure Check Sheet Checks To Do Before Testing Metric Measure Check Sheet Test No. 1 - Charging Pump CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

34 6003 TRANSMISSION OPERATION FOR MACHINES BEFORE PIN GBE Illustration of Transmission Hydraulic Circuit General Information Operation Transmission in Neutral Transmission in Low Range, Forward and High Track Speed Clutches Engaged Making a 90 Degree Turn to the Right Using the Right Brake Pedal Transmission in Low Range, Reverse and Low Track Speed Clutches Engaged o CASE CORPORATION BurS Printed in U.S.A. Issued February 1988

35 6005 CHARGING PUMP Specifications Disassembly Removal Inspection Installation Assembly Illustration of Charging Pump Written In Clear And Simple English CASE CORPORATION Printed in U.S.A. Issued December 1984

36 6007 TRANSMISSION CONTROL VALVE G REMOVAL... 3 INSPECTION... 9 INSTALLATION... 3 ASSEMBLY DISASSEMBLY... 4 CASE CORPORATION Bur Copyright If) 1991 CASE CORPORATION Printed in U.SA Issued July 1991

37 REMOVAL... 4 INSTALLATION... 4 DISASSEMBLY... 5 INSPECTION... 7 ASSEMBLY... 8 EXPLODED VIEW OF TRANSMISSION CONTROL VALVE Bur Issued 7-91 Printed in US.A

38 6008 MODULATOR VALVE Specifications Removal Installation Inspection Disassembly Assembly CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

39 6010 TORQUE CONVERTER Specifications Torque Converter Special Torques Removal Installation Disassembly Inspection Assembly Illustration of Torque Converter Written In Clear And SimP..le English CASE CORPORATION Printed in U.S.A. Issued December 1984

40 6016 TRANSMISSION WITH DRY BRAKES Specifications Special Tools Illustration of Transmission Hydraulic Circuit Removing the Transmission Installing the Transmission Illustration of Front and Rear Covers., Illustration of Range Housing Illustration of Track Speed Shaft, Main Shaft, Pinion Shaft and Gears Illustration of Clutches Inspection Disassembling the Transmission Assembling the Transmission (Installation of Components and Adjustments) Adjustment of Pinion Shaft Location... Begins at step 20 Adjustment of End Travel of Track Speed Shafts... Begins at step 66 Adjustment of End Travel of Main Shaft... Begins at step 96 Adjustment of End Travel of Pinion Shafts... Begins at step 129 Adjustment of Final Drive Gear Backlash... Begins at step 162 Pinion Shaft Disassembly and Assembly Main Shaft Disassembly Assembly Forward and Reverse Clutches Disassembly Assembly Track Speed Shaft Disassembly Assembly High and Low Clutches Disassembly Assembly Checking Clutch Oil Leakage With a Hand Pump CASE CORPORATION Bur Copyright 1991 CASE CORPORATION Printed in U.S.A. Issued July 1991

41 6016 TRANSMISSION WITH WET BRAKES Specifications Special Tools Removing the Transmission Installing the Transmission Exploded Views of Transmission through Inspection Disassembling the Transmission Assembling the Transmission Main Shaft Disassembly Forward and Reverse Clutches Disassembly Assembly Track Speed Shaft Disassembly Assembly High and Low Clutches Disassembly Assembly Checking Clutch Oil Leakage With a Hand Pump Assembly CASE CORPORATION Bur Copyright 1991 CASE CORPORATION Printed in U.S.A. Issued July 1991

42 SPECIFICATIONS... 3 SPECIAL TOOLS... 4 REMOVING A FINAL DRIVE... 5 INSTALLING A FINAL DRIVE... 6 DISASSEMBLING A FINAL DRIVE... 8 EXPLODED VIEW OF FINAL DRIVE INSPECTION OF FINAL DRIVE PARTS ASSEMBLING A FINAL DRIVE SPECIFICATIONS Rotating torque for sprocket shaft without face seal and bull gear installed to 40 lb in (4 to 4.5 Nm) Rotating torque for input shaft (bevel gear) to 40 lb in (4 to 4.5 Nm) Backlash for ring and pinion to inch (0.15 to 0.30 mm) Capacity for final drive 450E and 550E Models U.S. quarts (7.0 litres) Capacity for final drive 850E and 855E Models U.S. quarts (5.7 litres) Lubricant..... Case 135H EP gear lubricant Special torques Cap screws, main frame and seat frame to final drive. All threads cleaned with Loctite Primer T. Use 242 Loctite on threads and bottom of head on cap screws. Tighten to 180 lb ft (244 Nm) and then tighten 1/4 turn. Self-locking nuts, final drive to transmission to 98 lb ft (116 to 132 Nm) Cap screws, retainer on input shaft to 98 lb ft (116 to 132 Nm) Cap screws, retainer on sprocket shaft to 139 lb ft (170 to 190 Nm) Ferry head screws, cover for input and sprocket shafts to 98 lb ft (102 to 132 Nm) Ferry head screws, bottom cover to 98 lb ft (102 to 132 Nm) Rae Revisd 9-92 Printed in U S A

43 6018 TRANSMISSION CONTROLS Adjusting the Transmission Controls Illustration of Transmission Controls Written In Clear And Simp.Je English CASE CORPORATION Printed in U.S.A. Issued December 1984

44 6021 DRIVE SHAFT Removal Disassembly Installation Assembly Illustration of Drive Shaft Written In Clear And Simple English CASE CORPORATION Printed in U.S.A. Issued December 1984

45 7001 DRY BRAKES Brakes Master Cylinder Removing a Brake Housing Assembly Removal and Brake Mounting Plate Installation Installing a Brake Mounting Plate and Brake Housing Assembly Disassembly Exploded View of Brake Inspection Disassembling a Brake Housing Assembly Assembly Removing Air From the Brake System Assembling a Brake Housing Assembly Brake Pedal Adjustment Brake Cylinder Brake Adjustment Disassembly Parking Brake Inspection Minor Adjustment Assembly Major Adjustment Illustration of Brake Pedal and Master Cylinder Mounting Illustration of Brake Line Connections With Clutch Cutout CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

46 7001 BRAKES Specifications Special Tools Brake Adjustment Removing Air From a Brake System Disassembling a Brake Exploded View of Brake Inspection Assembling a Brake Inspection Assembly Master Cylinder Removal Installation Disassembly Inspection Assembly Brake Cylinder Disassembly CASE CORPORATION Bur Copyright 1991 CASE CORPORATION Printed in U.S.A. Issued July 1991

47 7007 Illustration of Clutch Cutout Exploded View of Clutch Cutout Valve Valve Installation Disassembly Removal Inspection Installation Assembly I Written In Clear And Simple. English 1 CASE CORPORATION Printed in U.S.A. Issued December 1984

48 8002 HYDRAULIC SYSTEM SPECIFICATIONS, SCHEMATICS, MAINTENANCE, TROUBLESHOOTING, AND PRESSURE CHECKS Specifications Special Tools Loader Hydraulic Diagram Dozer Hydraulic Diagram Ripper Hydraulic Diagram Backhoe Supply and Return Circuits on Dozer Machines Backhoe Supply and Return Circuits on Loader Machines Backhoe Hydraulic Diagram Troubleshooting O Problem: Bad Performance in a Single Circuit Boom Down and Swing Problems Stabilizer Problems Bad Performance in All Circuits Bad Performance in the Backhoe Circuits; Loader or Dozer Circuits Work Correctly Oil in the Hydraulic System Becomes Too Hot Problem in the Hydraulic: Pump Problem in the Equipment Control Valve Problem in the Cylinders Problem in the Hoses and Fittings Hydraulic System Maintenance and Fittings Oil Level Check Changing the Hydraulic Oil Hydraulic Filter Main Relief Valve General Information Pressure Setting Check Loader or Loader With Backhoe Dozer Without Backhoe Dozer With Backhoe Pressure Setting Adjustment Loader Machines and Dozer Machines Without Backhoe Dozer Machines With Backhoe Testing the Circuit Relief Valves With a Hand Pump General Information Checking the Pressure Setting Adjusting the Circuit Relief Valves Equipment Control Valve Backhoe Control Valve Flowmeter Tests General Information Test No. 1 - Output of the Hydraulic Pump Test No. 2 - Loader Circuit Leakage Test Test No. 3 - Blade Circuit Leakage Test Test No. 4 - Backhoe Circuit Leakage Test U.S. Measure Flowmeter Check Sheet Metric Measure Flowmeter Check Sheet CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

49 8003 CLEANING THE HYDRAULIC SYSTEM Portable Filter Cleaning the Hydraulic System General Information Types of Contamination Flushing Water From the Hydraulic System Written In Clear And Simple English CASE CORPORATION Printed in U.S.A., Issued December 1984

50 8005 HYDRAULIC PUMP Specifications Exploded View of Pump Removal Disassembly Installation Preparing the Hydraulic Pump for Use Inspection Assembly Written In Clear And Simple English CASE CORPORATION Printed in U.S.A. Issued December 1984

51 8007 EQUIPMENT CONTROL VALVE Specifications Special Tool Schematic of Dozer Control Valve Schematic of Loader Control Valve Removal Installation... ; Illustration of Equipment Control Valves O Dozer Control Valve Separating the Sections Assembling the Sections Loader Control Valve Separating the Sections Assembling the Sections Inlet/Outlet Section Disassembly Assembly Illustration of the Lift Section Lift Section Disassembly Assembly Illustration of Tilt and Angle Section Illustration of Clam and Auxiliary Section Tilt, Angle, Clam and Auxiliary Sections Disassembly Assembly Illustration of Bucket Section Bucket Section Disassembly Assembly Illustration of Main Relief Valve Main Relief Valve Disassembly Assembly Illustration of Circuit Relief Valve and Circuit Relief and Anticavltatlon Valve Circuit Relief Valve and Circuit Relief and Anticavitatlon Valve Disassembly Assembly Inspection CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

52 Park the machine on a level surface. REMOVAL 7. Remove the front cover. 2. Lower the front and rear mounted equipment to the floor. 3. Stop the engine and apply the parking brake. 4. Move the control levers in all directions to release any pressure from the hydraulic system. 5. Loosen and remove the cap screws and lock washers that fasten the access door to the right side of the machine. Remove the access door. 8. Disconnect the control lever linkage from the spools. 6. Loosen the cap screws that fasten the front cover in place. Remove the bottom cap screw. aa 9. Disconnect the tubes and hoses from the fittings in the equipment control valve. Install plugs in the tubes and hoses. Install caps on the fittings

53 8090 CYLINDERS Specifications Torque for Steel Hydraulic Fittings Bushing Replacement for All Cylinders Removal Special Tools Removal Loader Lift Cylinder Loader Bucket Cylinder Clam Cylinder Blade Lift Cylinder Blade Tilt Cylinder Blade Angle Cylinder Ripper Cylinder Backhoe Boom Cylinder Backhoe Dipper Cylinder Backhoe Bucket Cylinder Backhoe Stabilizer Cylinder Installation Installation (all cylinders) All Cylinders Except Backhoe Swing Cylinders Exploded View Disassembly Inspection Assembly Backhoe Swing Cylinder Exploded View Disassembly Inspection Assembly Backhoe Swing Cylinder Backhoe Extension Cylinder CASE CORPORJ\ TION Rae Copyright 1992 CASE CORPORATION Printed in U.S.A. May, 1992

54 SPECIFICATIONS... 3 SPECIAL TOOLS... 3 SEPARATING THE VALVE SECTIONS...:...4 ASSEMBLING THE VALVE SECTIONS... 6 INSPECTION DISASSEMBLY OF INLET SECTION ASSEMBLY OF INLET SECTION DISASSEMBLY OF OUTLET SECTION ASSEMBLY OF OUTLET SECTION DISASSEMBLY OF ALL WORKING SECTIONS ASSEMBLY OF ALL WORKING SECTIONS Bur Issued 7-91 Printed in US A

55 8109 STABILIZER CONTROL VALVE Specifications... _ Illustration of Stabilizer Control Valve Special Tools. : Disassembly Operation Inspection Removal Assembly Installation Written In Clear And Simple English CASE CORPORATION Printed in U.S.A. Issued December 1984

56 9010 LOADER Illustration of Standard Bucket Return-To-Dig Adjustment Standard Bucket Loader Frame Illustration of Clam Bucket Removal Clam Bucket Installation Standard Bucket Teeth - Early Illustrations Production Machines Loader Frame and Lift Cylinders Heavy Duty Bucket Teeth - Early Production Machines Loader Frame, Bucket Cylinder and Linkage Welding of Bucket Teeth Lift Cylinder Circuit Standard Bucket Teeth - Late Production Machines Bucket Cylinder Circuit Illustration of Return-To-Dig Installation Clam Cylinder Circuit From Equipment For Early Production Machines Control Valve to Clam Bucket Illustration of Return-To-Dig Installation Clam Bucket Circuit For Late Production Machines Counterweight Control Lever Installation CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

57 9020 C-FRAME AND BLADE FOR DOZER MACHINES Removing the C-frame and Blade Removing the C-frame from the Blade Removing the Mounting Beam from the Blade Replacing Bushings in the C-frame Replacing Bushings in the Mounting Frame Installing the Mounting Beam on the Blade Installing the Blade on the C-frame Installing the C-frame and Blade Removing and Replacing the Blade Cutting Edge Trunnion Holder for the Lift Cylinder Removal Installation Illustrations C-frame, Lift Cylinders, and Angle Cylinders Blade Lift Hydraulic Circuit Tilt and Angle Hydraulic Circuits - From Valve to Blade Tilt and Angle Hydraulic Circuits on Blade Counterweights Control Lever Installation CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

58 9031 RIPPER Illustration of Ripper Installing the Ripper... : and Mounting Parts Illustration of Ripper Hydraulic Circuit Removing the Ripper Clamp Installation CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

59 9061 ROPS CANOPY AND OPERATORS SEATS Damage to the ROPS Canopy Seat Used on Machines With Backhoe Maintenance and Inspection of ROPS Canopy Suspension Seat Mounting ROPS Canopy Suspension Seat Removal Suspension Seat Installation Adjusting the Suspension Seat Illustrations Seat Lubrication ROPS Canopy Removing the Torsion Bar Brush Guards and Side Screens Installing the Torsion Bar Standard Seat Removing the Shock Absorber Installing the Shock Absorber CASE CORPORATION Bur Printed in U.S.A. Issued February 1988

60 Backhoe Removal Backhoe Installation Swing Tower Removal Installation Pivot Bushings and Bearing Washer , Separating the Swing Tower from the Mounting Frame Replacing the Bearing Washer Replacing the Pivot Bushing Fastening the Swing Tower to the Mounting Frame Boom Removal Installation Dipper Removal Installation Dipper Extension Removal Installation Replacing Wear Strips for the Dipper Extension Guide Blocks Cutting Edges Bottom Cutting Edge Removal and Installation Side Cutting Edge Removal and Installation..., Bucket Teeth Replacement of Tooth Shank Replacement of Tooth Point Illustrations of Parts of the Backhoe Mounting Arms and Tension Rods Stabilizer Installation Stabilizer Cylinder Hydraulic Installation Mounting Frame, Swing Cylinders, and Swing Tower Swing Cylinder Hydraulic Installation Transport Lock Mechanism Boom, Dipper, and Bucket Boom Cylinder Hydraulic Installation Dipper Cylinder Hydraulic Installation Bucket Cylinder Hydraulic Installation Without Extendable Dipper Bucket Cylinder Hydraulic Installation With Extendable Dipper Extendable Dipper Extension Cylinder Hydraulic Installation Control Tower and Cover Backhoe Controls Without Extendable Dipper Backhoe Controls With Extendable Dipper