970/1 070 TRACTOR SERVICE MANUAL '

Transcription

1 970/1 070 TRACTOR SERVICE MANUAL '

2 TRACTORS SERIES SECTION DESCRIPTION FORM GENERAL NUMBE~ General Specifications Tractors General Specifications Tractors Lubrication Tractors (Prior to SN ) Lubrication Tractors (Starting with SN ) Lubrication Tractors Detailed Specifications BD Engine Detailed Specifications BD Engine Fuel System - Diesel..., Hydraulic System......'.. ' Steering System Power Train Brake System ENGINES - GASOLINE Cylinder Head and Valves...,.... Engine Block Assembly Governor ENGINES - DIESEL Engine Diagnosis Engine Tune-Up.... Cylinder Head, Valve Train and Camshaft Cylinder Block, Sleeves, Pistons and Rods Splitting Tractor between Engine and Torque Tube Crankshaft, Main Bearings, Flywheel and Oil Seals Lubrication System, Oil Pump and Oil Flow Diagrams Cooling System ENGINES - GASOLINE & DIESEL Air Intake System Reconditioning Engine Cylinder Block FUEL SYSTEM Carburetor.... Diesel Fuel System and Filters Robert Bosch Fuel Injection Pumps.... Roosa Master Fuel Injectors..., Repairing Polyethylene Fuel Tanks.... Repairing Cast Nylon Fuel Tanks ".

3 RUN-IN INSTRUCTIONS... 3,4 DETAILED ENGINE SPECIFICATIONS Cylinder Sleeves... 5 Piston... 5 Piston Rings... 5 Oil Ring... 5 Piston Pin... 5 Connecting Rod...:... 6 Crankshaft... 6,7 Camshaft... 7 Valve Push Rod Lifters... 7 Gear Train... 7,8 Oil Pump... 8 Cylinder Head... 8 Intake Valve... 8 Exhaust Valve... 9 Intake and Exhaust Valve Guides... 9 Valve Spring... 9 Rocker Arm Assembly SPECIAL TORQUES GENERAL TORQUE SPECIFICATION TABLE... 12

4 RUN-IN INSTRUCTIONS... 3,4.- DETAILED ENGINE SPECIFICATIONS Cylinder Sleeves Piston... 5 Piston Rings... 5 Oil Ring... 5 Piston Pin... 5 Connecting Rod... 6 Crankshaft... 6,7 Camshaft... 7 Valve Push Rod Lifters Gear Train... 7,8 Oil Pump... 8 Cylinder Head... 8 Intake Valve... 8 Exhaust Valve... 9 Intake and Exhaust Valve Guides... 9 Valve Spring... 9 Rocker Arm Assembly SPECIAL TORQUES GENERAL TORQUE SPECIFICATION TABLE... 12

5 Power Shift (Continued) Reverse Lockout Spring: Decimal System Free length to 1.852" Wire dia " Spring O.D " No. of coils (7.5 active) Compress to.625" (15.875mm) to 20.9 lbs. Pressure Regulator Spring: Free length " Wire dia " Spring O.D " No. of coils (9 active) Compress to 1.00" (25.4mm) to 16.5 lbs. Modulator Primary Spring: Free length " Wire dia " Spring O.D.... Work in.437" bore No. of coils (12.5 active) Compress to 1.20" (30.48mm) to 10.4 Ibs. Modulator Secondary Spring: Free length... 76" Wire dia " Spring O.D " No. of coils... 8 (6 active) Compress to.43" (10.92mm) to 1.4 lbs. Detent Spring: Free length " Wire dia " Spring O.D " No. of coils (7.5 active) Compress to.67" (17.02mm) lbs. Lube Oil Spring: Free length " Wire dia " Spring O.D " No. of coils (14 active) Compress to.97" (24.64mm) to 10.7 lbs. Metric System to mm 1.575mm mm 76.1 to 93 N 34.8mm mm mm 60 to 73 N 40.89mm mm 1l.lmm 38.3 to 46.3 N 19.3mm.559mm 6.731mm 5.3 to 6.2 N 27.18mm 1.676mm mm 133 N 42.93mm 1.016mm 7.925mm 39.6 to 47.6 N

6 CHECKING COMPRESSION PRESSURE (continued) 6. Two common types of compression gauge equipment used are the remote control and the ignition switch operation type. A. When using the remote control type of compression tester, Figure 1, make sure the v"oires are correctly attached to the starter terminals. Incorrect a ttaching of the wires will cause damage to the testing equipment, Figure 1. STA RTER SOLENOID \ Figure 1 "- ( 18mm ) ADAPTER B. When using the ignition switch operation type of compression tester, Figure 2, be sure the carburetor throttle plate (butterfly) valve is held in the wide open position. Drain the carburetor to prevent fuel from entering the cylinders. COMPRESSION GAUGE Figure 2 COMPRESSION ADAPTER ( 18mm) 7. It is very important that all cylinder pressures be approximately alike. For the allowable compression pressure variation, refer to the chart below. 8. If the compression reading is below these figures, leaking valves or excessive ring clearance is indicated. NO Tt To make a simple check when a compression leak is indicated, squirt a small amount (a teaspoon) of oil into the cylinder and recheck the compression. If the pressure rises to near normal, compression loss is past the rings. Very little change in compression indicates leakage past the valves. A low pressure reading will cause difficulty In starting particularly at low temperatures. NOTt Always take a second set of readings for an accurate check. This will also indicate how much the loss of cranking speed, due to battery discharge, is affecting the compression pressure reading. 9. Before installing the spark plugs, clean them thoroughly and check them for burned electrodes or cracked insulation. Replace them if necessary. Regap all plugs to.025" setting, Figure Replace all spark plug gaskets, Figure 3, before installing for proper seating and sealing. Install the spark plugs finger tight. Using the exact size spark plug wtench or a thin wall deep socket, torque the spark plugs 32 to 35 ft. Ibs. ( 18mm ) SPARK PLUG ROUND FEELER GAUGE Will GIVE~GA'KET A MORE ACCURATE READING ~ Figure 3 ENGINE SPEED NORMAL COMPRESSION PRESSURE ALLOWABLE VARIATION BETWEEN CYLINDERS CHANKING Approximately 150 RPM 140 PSI* 15 PSI * A 4% reduction in PSI must be allowed for every 1000 ft. above sea level.

7 Camshaft, Bushings, Lifters and Timing Gears (Removal, Inspection) Camshaft, Bushings, Lifters and Timing Gears (Installation) Crankshaft and Bearing Liners (Inspection, Assembly) Crankshaft, Pistons and Connecting Rods (Removal, Disassembly, Inspection) Cylinder Sleeves (Inspection) Engine Lubricating Oil and Coolant Systems..,... 8,9 Flywheel, Seal Retainer, Oil Pan and Oil Pump (Removal) Flywheel, Seal Retainer, Oil Pan and Oil Pump (Installation) Locating Top Dead Center..., Oil Pump Piston, Connecting Rod and Piston Rings (Assembly) Piston and Cylinder Sleeves (Inspection) Special Torques... 7 Specifications Timing Gear Cover... 16

8 SPECIAL TOOLS... 3,4 SPECIFICATIONS FOR TOOLS WHICH MUST BE MADE CYLINDER HEAD RECONDITIONING Cylinder Head Assembly... 19,20 Cylinder Head Inspection... 7 Cylinder Head Installation... 20,21 Cylinder Head Torquing - Cold or Initial Torque Cylinder Head Torquing - Hot Diagnosis of Various Valve Bluing Patterns Expansion Plug Replacement... 9 Locating Top Dead Center : Manifold Stud Replacement... 9 Refacing Valves and Valve Seats Removal ,6 Rocker Arm Assembly Valve Bluing... : Valve Guide Replacement Valve Inspection Valve Seat Inspection Valve Seat Replacement Valve Tappet Adjustment - Cold Setting Valve Tappet Adjustment - Hot Setting with Engine Stopped CAMSHAFT Backlash - Camshaft to Crankshaft Backlash - Camshaft to Idler Gear Backlash - Idler Gear to Injection Pump Bushing Replacement - Front... 32,33 Bushing Replacement - Intermediate... 32,33 Bushing Replacement - Rear... 33,34 Camshaft - Assembly... 36,37 Camshaft - Installation... 37,38 Camshaft - Removal Idler Gear - Inspection... 38,39 Idler Gear - Installation Valve Lifters - Inspection Valve Lifters - Replacement... 35

9 SPECIAL TOOLS...:.. 3 CYLINDER BLOCK, SLEEVES, PISTONS AND RODS Checking Connecting Rod Journals... 14,15 Checking Ring Gap Checking Sleeve Protrusion Connecting Rod Bearing Replacement Connecting Rod Bushing Replacement...: Connecting Rod Inspection..: Cylinder Sleeve Inspection... 6,7 Piston Inspection Piston Installation Sleeve Deglazing... 8 Sleeve Installation... 9,10 Sleeve Removal... 9

10 SPECIAL TOOLS...' 3 FRONT OIL SEAL REPLACEMENT REAR OIL SEAL REPLACEMENT OVERSIZE REAR OIL SEAL AND WEAR SLEEVE INSTALLATION... 9,10 REPLACEMENT OF MAIN BEARINGS WITHOUT REMOVING CRANKSHAFT Bearing Liner Installation Bearing Liner Removal...:... 11,12 Checking Main Bearing Oil Clearance... 12,13 Installation of Front Main Bearing with Oil Pump... 13,14 Removal of Main Bearing Caps CRANKSHAFT AND MAIN BEARINGS Checking Connecting Rod Bearing Oil Clearance Checking Main Bearing Oil Clearance Checking Crankshaft Gear Backlash Checking Crankshaft End Play Cleaning and Replacing Oil Nozzles Crankshaft Assembly Crankshaft Inspection Crankshaft Installation Installation of Connecting Rod Bearing Caps Installation of Front Mounted Oil Pumps... 23,24 Installation of Main Bearing Caps Main Bearing Cap Replacement Piston and Connecting Rod Installation... 25,26 Reassembling External Engine Parts Removal of Crankshaft Thrust Bearing Inspection and Installation FLYWHEEL... 30,31

11 2046 LUBRICATION SYSTEM Oil Pump, Heat Exchanger and Oil Flow Diagrams OIL FLOW DIAGRAMS... 2,3 SPECIAL TOOLS... 4 OIL PUMP - SINGLE GEAR Removal ,5 Inspection Installation...,... 8,9 HEAT EXCHANGER WITH SINGLE FILTER HEAT EXCHANGER WITH DUAL FILTER J I Case Rae PRINTED IN U.S.A. A Tenneco Company

12 SPECIFICATIONS... 2 SAFETY PRECAUTIONS '"... 3 CLEANING THE COOLING SYSTEM... 3 WATER MANIFOLD REPLACEMENT Installation... 4,5 Removal... 4 THERMOSTAT REPLACEMENT Inspection... : Installation... ~... 6,7 Removal... 5,6 WATER PUMP REPLACEMENT Removal... :... 7,8 Inspection... 8 Water Pump Repair Installation SPECI FICATIO NS Type..... Pressurized thermostat controlled by-pass: Forced Circulation. Pump type...,... Vane type impeller Radiator cap PSI (0.984 kg/cm2) Thermostat... Start to open at approximately 1750F (790C.) Fully Open at 2020F. (94 C) Cold weather coolant... '" Reputable top brand "High Boiling Point" Anti-Freeze

13 RECONDITIONING THE LOWER COUNTERBORE AREA FOR THE CYLINDER SLEEVE Using The Power Tool With Bore Cutter and Chamfer Cutter Trouble Shooting The Lower Bore Power Tool Using The Hand Tool With Chamfer Cutter Lower Bore Bushings and Bore Diameter Specifications... 6 and 14 Chamfer Cutter Setting... '.'. : RECONDITIONING THE UPPER COUNTERBORE AREA FOR THE CYLINDER SLEEVE Rae Issued 8-78 Printed in U.S.A.

14 SERIES SECTION TRACTORS DESCRIPTION HYDRAULICS Hydraulic Oil Filters.... Dual Hydraulic Pump... ".... Dual Remote Valve.... Flow Divider - PTO Control Valve.... Draft-O-System.... Break-Away Couplings and Portable Cylinders.... STEERING Steering Column and Pump-Valve (Starting wi SN )... '.'.. Steering Column and Hand Pump (Prior to SN )...,.... Steering Control Valve.... Hydrostatic Steering Actuator.... Steering Axles.... POWER TRAIN Trouble Shooting RPS-34 Power Shift.... RPS-34 Power Shift(Prior to SN ).... RPS-34 Power Shift (Starting w/sn ).... Single Reduction Final Drive and Transmission " & 15" Traction Clutches and Pedals - Mechanical Shift.... Torque Limiter Clutch(Starting w/sn ).... Hydraulic PTO.... FORM J I Case A Tenneco Company Rae Printed in U.S.A

15 4014 DUAL REMOTE VALVE Remote Valve, Removal and Installation... 2 Remote Valve, Disassembly... 4 Remote Valve, Inspection... 6 Remote Valve, Assembly... 8 Testing Pilot Operated Relief Valve with A Hand Pump S PECI FICATIONS Pilot operated relief valve setting Cranking PSI Main Relief PSI to to to to to : to to to to to to to to to 2250 NOTE: See page 6 for the spring specifications Special Torques Valve end cover bolts to 40 ft. lbs. J I Case Rae PRINTED IN U.S.A. A Tenneco Company

16 45 DRAFT-O-MATIC HYDRAULIC SYSTEM Specifica tions Draft-O-Matk Arms, Lift Links and Turnbuckle Link (770, 870 and 970 Tractors) Draft-O-Matic Arms, Lift Links and Turnbuckle Link (1070 Tractors) Draft-O-Matic Arms, Lift Links and Turnbuckle Link (1070 Heavy Duty, 1090, 1170 and 1175 Tractors) Lower Draft-O-Matic Sensing Linkage Upper Draft-O-Matic Sensing Linkage Rockshaft Housing and Components Draft-O-Matic Control Valve Draft-O-Matic Adjustments Draft-O-Matic Check-Out Procedure Draft-O-Matic Test Fixture SPECIFICATIONS Draft Control rod assembly pre-adjusted to /16" Draft-O-Matic control valve spool travel /32" Draft arms free travel at top of lift /2" Draft-O-Matic and Hand Lever Pull lbs. Rockshaft R.H. bushing LD " Rockshaft L.H. bushing LD " Rockshaft oil clearance " to.005" Spring Specifications Control valve spring specifications... Refer to Page Special Torques Cross Bar Retaining Nuts ft. lbs. Link "H" to draft control shaft bolt to 18 ft. Ibs. Draft-O-Matic control rod assembly to piston rod arm and link "F" bolts to 18 ft. lbs. Draft-O-Matic control valve to rockshaft housing bolts to 18 ft. lbs. Rockshaft housing cover bolts to 18 ft. lbs. Rockshaft piston rod retainer bolts to 40 ft. lbs. Piston rod arm set screws to 50 ft. lbs. Cam lock bolts to 300 ft. lbs. Lower sensing rod to vertical draft sensing shaft bolt to 18 ft. lbs. Lower sensing rod rear jam nut to 50 ft. lbs. J I Case e RAG. A Tenneco Company PRINTED IN U.SA

17 4019 BREAK-AWAY COUPLINGS AND PORTABLE HYDRAULIC CYLINDERS Break-away couplings ASAE Standard Break-away Couplings /4" x 8" and 4" x 8" Hydraulic cylinders with mechanical stop " x 8" and 4" x 8" hydraulic cylinders with hydraulic and collar locking limit stop " x 8" and 4" x 8" hydraulic cylinders with hydraulic and clamp type locking limit stop Portable cylinder jack pad and base J I Case Rae A Tenneco Company PRINTED IN U.S.A

18 Seclion 5010 TILTING AND TELESCOPING STEERING COLUMN WITH STEERING PUMP-VALVE Adjustable Steering Column & Steering Pump, Removal Adjustable Steering Column & Steering Pump, Installation Steering Pump, Disassembly Steering Pump, Assembly SPECIFICATIONS Spring Specifications... See Page Steering Column Mounting Studs In. Lbs. Steering Wheel Retaining Nut Ft. Lbs. Steering Wheel Lock Knob Nut Ft. Lbs. Steering Pump Commutator to Commutator Ring Thickness Difference " Max. Rotor to Stator Clearance " Max. Rotor to Stator Thickness Difference " Max. Vane Height " Min. Vane Spring Free Height " Min. Upper Cover Needle Bearing Press Fit Dimension /1.30" J I Case Rae PRINTED IN U.S.A. A Tenneco Company

19 5010 RIGID AND ADJUSTABLE STEERING COLUMNS WITH HAND PUMP (Prior to Tractor SN ) Rigid Steering Column Adjustable Steering Column Steering Column Tilt Adjustment Manual Steering Pump SPECIFICATIONS Steering Column Mounting Studs In. Lbs. Steering Column Mounting Stud Jam Nuts Ft. Lbs. Steering Wheel Retaining Nut Ft. Lbs. Steering Wheel Lock Knob Nut Ft. Lbs. Manual Steering Pump Steering Shaft to Body Clearance " Max. Rotor to Stator Clearance " Max. Vane Height " Min. Vane spring free height " Min. J I Case Rae PRINTED IN U.S.A. A Tenneco Company

20 62 POWER SHIFT TRANSMISSION Prior to tractor SN General Inspection... : Power Shift Service Procedure Introduction Inching Pedal and Linkage Power Shift Control Valve and Lubrication Oil Relief Valve Power Shift Control Valve Power Shift and Housing Planetary Output Shaft C-2 and C-3 Clutch Pack Planetary Carrier Assembly C-1 and C-4 Power Shift Clutches Power Shift Piston Seals and Wires Torque Limiter Clutch Shuttle Valve Kit, Parts removal and installation thru Transmission Top Cover modification with new control valve ,63-33 Power Shift Fixture C-2,C-3 Clutch Pack Assembly Adapter Special Torques Power shift valve cover bolts to 35 ft. lbs. Tube fittings and locknuts... 4 to 6 ft. Ibs. Reverse lockout tube nuts '" to 131 in. lbs. Selector spool detent spring plug to 30 ft. Ibs. Retard needle hex nuts... 5 to 7 ft. lbs. Test port pipe plugs... 7 to 10 ft. lbs. Pilot valve plugs to 15 ft. Ibs. Shuttle valve plug to 20 ft. lbs. Inching spool plug to 20 ft. Ibs. Selector spool retainer cover bolts... 7 to 9 ft. lbs. Reverse lockout plug to 25 ft. lbs. Power Shift housing rear nuts to 485 ft. lbs. Drilled plugs (oil tubes) in. lbs. more than thread torque.' Oil distributor cover bolts to 42 ft. lbs. C-3 hub to oil distributor hub capscrews... 9 to 11 ft. lbs. C-2 thru C-3 hub capscrews (use locktite) to 50 ft. lbs. C-l and C-4 carrier bolts to 54 ft. lbs. Torque limiter bolts... '" to 96 ft. lbs. Power Shift housing bolts 3/4" to 324 ft. lbs. Power Shift housing bolts 1/2" to 96 ft. lbs. J I Case Rae PRINTED IN U.S.A. A Tenneco Company

21 SPECIAL TOOLS... 4 GENERAL SPECiFiCATIONS... '" SPECIAL TORQUES... 5 GENERAL INFORMATION... '"...,... 6 SERVICING RPS-34 POWER SHIFT Power Shift Removal Rebuilding and Installing Oil Distributor Carrier and Mainshaft Disassembling Ring Gear, (C-3) Clutch Hub and Clutch Plates, (C-2) and (C-3) Piston Carrier and (C-2) Clutch Hub and Clutch Plates... 22,23 Rebuilding (C-2) and (C-3) Piston Carrier - Prior to Transmission SN10Q Rebuilding (C-2) and (C-3) Piston Carrier - Transmission SN and After Rebuilding (C-3) Clutch Hub Assembling (C-3) Clutch Hub and Clutch Plates, Ring Gear and (C-2) and (C-3) Piston Carrier Rebuilding (C-2) Clutch Hub and Clutch Plates... 39,40 Installing (C-2) Clutch Hub Assembly Into Planetary Ring Gear Assembly Planetary Ring Gear Assembly Installation... 44,45 Rebuilding Power Shift Planetary Installing Power Shift Planetary Rebuilding {C-4) Clutch Assembly Assembling (C-4) Clutch Plates Installing (C-4) Clutch Assembly Installing (C-1) Clutch Plates Installing PTO Shaft Drive Gear and Support Bushing..._ Installing (C-1) and (C-4) Oil Suppy Tubes Installing Transmission Top Cover and Power Shift Control VAlve Rae Printed in U.S.A.

22 64 SINGLE REDUCTION FINAL DRIVE AND TRANSMISSION Specifications Special torques Service procedure Removal Sequence General inspection General assembly Introduction Shift sequence Mechanical Shift ( tractors) Mechanical Shift ( tractors) Mechanical Shift (1090 tractors) Power Shift ( tractors) Power Shift ( tractors) Power Stift (1090 tractors) Transmission Top Cover (Mechanical Shift) (Power Shift) Shifter Assembly (Mechanical Shift) (Power Shift) Range Shafts (Mechanical Shift tractors) (Mechanical Shift tractors) Sliding Gear Shaft (Mechanical Shift) (Power Shift) Rear Axle and Final Drives ( Tractors) ( tractors) Differential Assembly ( tractors) ( tractors) (1090 tractors) Counter Shaft and Reverse Idler (Mechanical Shift) Countershaft (Power Shift) Transmission Adjustments Tools J I Case Rae PRINTED IN U.S.A. A Tenneco Company

23 aa 14" AND 15" TRACTION CLUTCHES AND LINKAGE MECHANICAL SHIFT CI utch Pedal and Linkage 66-2 Clutch Release and Housing " Clutch Assembly " Clutch Assembly SPECIFICATIONS Clutch Free Pedal /8" Center of Pedal Pad to firewall /16" 14" Clutch Release lever screw to face of pressure plate " 15" Clutch Release lever screw to face of pressure plate " Clutch Pedal 14" Clutch Cover 15" Clutch Cover Return Spring Springs Springs Free Length 3.4" 2.5" 2.84" Spring O.D. 1" 1.10" to 1.13" 1.365" to 1.385" No. of Coils Spring Rate to lbs. 145 to 155 lbs. 190 to 200 lbs. at length of 5.16" " 1.94" Rae

24 6045 HYDRAULIC PTO Specifications...: PTO Assembly PTO Clutch st Idler Shaft PTO Brake nd Idler Shaft Dual Speed Output Shaft Single Speed Output Shaft Hydraulic Pick-Up Tube Oil Filler Cap & Tube and Oil Breather PTO Adjustments & Tests SPECIFICATIONS PTO housing oil breather service interval...:... every 200 hours PTO hand lever adjustment... 5 Lbs. pull at lever Free travel of "Case" flow divider valve spool... 75" Clutch plates used on tractors... 4 each Clutch plates used on and 1090 tractors (Prior Trans. SIN )... 6 each Clutch plates used on 970 and 1070 tractors (SIN and after)... 7 each Clutch plates used on 1170 and 1175 tractors... ~... 7 each Special Torques Second idler shaft retaining bolt (Jay-Loc Type) ft. lbs. Second idler shaft retaining (12 Pt. capscrews) (Wire-locked) in. lbs. PTO shield stud nuts ft. lbs. Hydraulic pick-up tube bolts ft. lbs. J I Case Rae PRINTED IN U.S.A. A Tenneco Company

25 J.I. Case Service Manual 970 & 1070 All Models Volume 3 of 3 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF J.I. CASE OR IT S SUCCESSORS. J.I. CASE AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CA-S-970+TM

26 SERIES SECTION TRACTORS DESCRIPTION FORM a BRAKES Brake Master Cylinders and Pedals.... Power Assist Brake Unit and Pedals.... Power Assist Brake Valve with Adjustable Relief Valve.... Differential and Parking Brake ELECTRICAL Tractor Wiring Diagram - Spark Igntion (Prior to SN ).... Tractor Wiring Diagram - Diesel (Prior to SN ).... Tractor Wiring Diagram.. (Starting W/SN ).... Cab Wiring Diagram (Starting W/SN ).... Cab Wiring Diagram (Prior to SN ).... Starting or Cranking Motors.... Battery Servicing and Testing.... Prestolite Alternator Systems.... Delco-Remy Alternator Systems.... Delco-Remy Alternator System.... Distributor Ignition Systems.... ACCESSORIES Cab Sealing and Recirculation.... Trouble Shooting - Air Conditioning System.... Gauging and Testing - Air Conditioning System.... Compressor Isolation, Removal, Installation and Evacuation System Discharging, Evacuation and Charging.... Servicing Air Conditioning Components.... Seat Adjustments (Swivel and Non Swivel) HOW IT WORKS Hydraulic Testing, Steering - Power Brakes.... Hydraulic Testing, Power Shift, Remotes and PTO.... Hydraulic System.... Dual Pump - Flow Divider Valve.... Dual Remote System.... Draft-O-Matic System.... Power Steering - Power Brakes.... Power Shift Transmission... ~.... Hydraulic PTO.... Air Conditioning System , J I Case A Tenneco Company e Rae Pnnted In U.S.A

27 72 HYDRAULIC BRAKE MASTER CYLINDERS AND PEDALS Brake Pedals 72-2 Hydraulic Brake Master Cylinders Removal, Inspection, Installation and Bleeding Hydraulic Brake Master Cylinders Disassembly, Inspection ana Assembly SPECIFICATIONS Type Fluid Case TCH or Type A-ATF Fluid Level /2" below filter neck Brake Free Pedal ApFlroximately 1/8" Brake Tube Nuts to 15 ft. lbs. torque Brake Pedal Shoulder bolts to 95 ft. lbs. torque Rac. Form

28 73 POWER ASSIST BRAKE UNIT AND PEDALS Brake Pedals Power Assist Brake Unit 73-4 Power Assist Cover Assembly Power Assist Valve and Cylinder Assembly 73-8 SPECIFICATIONS Brake free pedal. Approximately 3/4" Brake tube nuts. Brake fitting bolts Brake pedal shoulder bolts 13to 15 ft. lbs. torque 30 to 33 ft. Ibs. torque 80 to 95 ft. Ibs. torque Spring Description Free No. of O.D. Rate Length Coils in Lbs. At Length Pressure Control (19).566" 6.375" 9.1 to " Pressure Control (45).590" " 4.8 to " Pressure Regulating (13).665" 6.594" 7.5 to " Pressure Relief (30) 1. 25" 5.985" to 1.115" 119 to " Influx Pressure (inner) (42).969" 7.555" 52.5 to " Influx Pressure (outer) (43) 1.12 to 1.21" 5.985" to 1.115" 119 to " Sump Relief Valve (38).78" 6.375" 1.0 to " Sump Relief Valve (44).654" 8.437".31 to.37.60" Brake Piston (21).65" 6.437" 15.1 to " Boost Spool (29) 1.75" " 8.1 to 9.9 1" J e I Case Rae A Tenneco Company PRINTED IN U.S.A.

29 7012 DIFFERENTIAL AND PARKING_BRAKES Brake Linkage and Slave Cylinder Seven Inch Differential Brakes Eight Inch Differential Brakes Parking Brake SPECIFICATIONS Hydraulic Brake System Case TCH Oil CAUTION DO NOT USE BRAKE FLUID Hydraulic Power Assist Brake System Case TFD Fluid Brake lever free travel " at the slave cylinder with running clearance taken up by hand lever Free O.D. No. Coils Load Length Length Lever Return Spring (1) P ".875" to 60 Ibs. 7.08" Cam Adjusting Spring (16) P ".54" Ibs. 2.72" Self Adjusting Spring (11) P ".18" Ills. 1.95" J I Case Rae PRINTED IN U-SA A Tenneco Company

30 8012 STARTING OR CRANKING MOTORS T ABLE OF CONTENTS General Starter Inspection Starter No Load Test Field Coil Tests... _ Armature Tests Checking Pinion Clearance Solenoid Switch Tests Starter or Cranking Motor Specifications Delco-Remy Solenoid Specifications - Delco-Remy Starter or Cranking Motor Specifications Prestolite Solenoid Specifications Prestolite J lease Rae PRINTED IN U SA A Tenneco Company

31 8014 PRESTOLITE ALTERNATOR SYSTEMS T ABLE OF CONTENTS Prestolite Alternator Charging Systems Precautions to be observed when Servicing the Systems Prestolite Alternator Rotor Inspecting and Testing Testing Rectifier Diodes Stator Ground and Open Tests Checking Alternator Resistor ~-~ Regulator Output Test , Alternator Output Test Alternator Specifications Voltage Regulator Specifications... -' J I Case Rae PRI~~7ED IN U.S.A. A Tenneco Company

32 8114 DELCO-REMY 10-SI SERIES ALTERNATOR SYSTEM DELCO-REMY PART NO. LOCATION REFER TO SPECIFICATIONS Delco-Remy Alternator Charging System Precautions to be Observed when Servicing Alternator System ~ Checking Indicator Lamp Operation Charging System Checks Disassembly and Testing Assembly Alternator Bench Output Check Checking Alternator System Resistor SPECIFICATIONS RATED HOT FIELD CURRENT COLD OUTPUT - OUTPUT 80 Deg. F. 75 Deg. F. CASE DELCO- 160 Deg. F. PART NO. REMY NO. AMPS VOLTS AMPS RPM VOLTS AMPS A A A J I Case A Tenneco Company e Rae PRINTED IN U.S.A.

33 8115 DELCO-REMY 10-SI SERIES ALTERNATOR SYSTEM DELCO-REMY PART LOCATION REFER TO SPECIFICATIONS Delco-Remy Alternator Charging System... 2 Precautions to be Observed when Servicing Alternator System....4 Checking Indicator Lamp Operation... 6 Charging System Checks... 8 Disassembly and Testing... : Assembly Alternator Bench Output Check Checking Alternator System Resistor SPECIFICATIONS FIELD CURRENT COLD OUTPUT RATED HOT 80 Deg. F. 75 Deg. F. OUTPUT 160 Deg. F. CASE DELCO- PART NO. REMY NO. AMPS VOLTS AMPS RPM VOLTS AMPS A A A A J I Case Rae PRINTED IN U.S.A. A Tenneco Company

34 8S DISTRIBUTOR IGNITION SYSTEMS Distributors, Introduction Contact Points Cap Rotor Coil Polarity Distriburor Static and Running Ignition Timing... -:... 83"7 Spark Plugs, Specfications Rea t Range... " Electrode Condition High Tension Spark Plug and Coil Leads Checking Ignition Coil Resistor Distributor Specifications Ignition Coil Specifications Static and Running Ignition Timing Chart Roc_ Form

35 92a CAB SEALING AND RECIRCULATION FOR MAXIMUM AIR CONDITIONING EFFICIENCY TROUBLE SHOOTING CAB SEALING AND CIRCULATION Problems Corrections Dust & Dirt Conditions inside of cab... 92a-2 thru 92a-4 Dust & Dirt Conditions in the plenum area... 92a-5 i Evaporator freeze up in high humidity locations... 92a-6 i Increasing cab air recirculation for better cooling... 92a-7 thru 92a-12 Sealing 70 Series Cabs, prior to Cab SN a-2 Re-Calibrating Air Conditioning Temperature Control... 92a-6 Cab Air Recirculation Modification Cab SN thru SN a- 7 Cab Air Recirculation Modification Cab SN thru SN a-9 J I Case Rae PRINTED IN U.S.A. A Tenneco Company

36 9025 COMPRESSOR ISOLATION, REMOVAL, INSTALLATION AND EVACUATION DISCHARGING, EVACUATION AND CHARGING THE AIR CONDITIONING SYSTEM Safety Precautions... 2 Special Tools Compressor Servicing Compressor Isolation and Removal Compressor Installation and Evacuation Air Conditioning System Servicing Discharging the Air Conditioning System System Evacuation... 13,14 Charging the System with Refrigerant J lease Rae PRINTED IN U.S.A. A Tenneco Company

37 Safety Precautions... 3 Special Tools... 4,5 Compressor Belt Alignment and Tension Adjustment Two Wheel Drive Tractors... 6 Four Wheel Drive Tractors w/rotary Type Compressor... 7 Four Wheel Drive Tractors wi Piston Type Compressor... 8 Compressor Oil Level Check Rotary Type Compressors... 9 Piston Type Compressors Servicing the Rotary Type Compressor Shaft Seal Replacement Clutch Electrical Check Clutch and Pulley Replacement..., Front and Rear Head to Body "0" Ring Replacement Servicing the Piston Type Compressor Clutch Replacement Seal Replacement Clutch Electrical Check Reed Valve and Gasket Replacement... 34,35 Base Plate Gasket Replacement Rear Cover "0" Ring Replacement Condenser, Receiver-Drier and Tubing... 38,39 Evaporator, Thermostatic Expansion Valve and Self-Sealing Couplings... 40,41 Temperature Control Switch Probe Routing Fittings Required for Testing TEV Valve Testing and Adjusting TEV Valve., TEV Valve Cleaning and Inspection Servicing the Cab Blower Assembly Blower Housing Removal Blower Housing and Motor Disassembly... 49,50 Blower Housing and Motor Assembly Blower Housing Installation Sealing the Cab Plenum... :... '" Cab Roof Panel and Air Valve Cleaning the Cab Air Filter Element Oil Level Dipstick Template ~...

38 ROTARY TYPE COMPRESSOR OIL LEVEL CHECK Generally the compressor oil level should be checked only when there is evidence of a major loss of system oil such as might be caused by: 1. A broken refrigerant hose. 2. A severe refrigerant leak. 3. A badly leaking compressor seal. 4. Damage to system components. There are two ways of checking the compressor oil -level; vehicle check-compressor connected to AIC system, and bench check-compressor removed from vehicle. VEHICLE CHECK 1. Run the system for 10 minutes at 2000 Engine RPM with controls set for maximum cooling and high blower speed. 2. Turn off engine and momentarily crack open compressor drain plug, letting a slight a mount of oil to drain out. 3. Retighten compressor drain plug. 4. Then, again slightly crack open the drain plug. A. If oil appears the second time, the compressor has an adequate supply of oil. B. If oil does not appear the second time, it will be necessary to remove compressor from the vehicle and perform bench check. NOTE: The oil may appear foamy. This is considered normal. BENCH CHECK 1. COMPRESSOR OPERATIONAL - Before removing compressor from vehicle, run the system for 10 minutes at 1500 Engine RPM with controls set for maximum cooling and high blower speed. Turn off engine and remove compressor from vehicle, refer to Section 9025 for discharging the system. Place compressor in a horizontal position, with the drain plug downward. Remove drain plug and drain the oil into a clean container, measure and discard the oil. A. If the amount of oil drained was 4 ozs. or more, add the same amount of new refrigerant oil (525 viscosity). B. If the amount of oil drained was less than 4 ozs., add 6 ozs. of new refrigerant oil (525 viscosity). IMPORT ANT: The compressor manufacture recommends when adding or changing oil, use only Delco # or an equivalent 525 viscosity oil. BENCH CHECK (Cont'd) 2. COMPRESSOR NOT OPERATIONAL - Remove compressor from vehicle, refer to Section 9025 for discharging the system. Place compressor in a horizontal position, with the drain plug downward. Remove drain plug and drain the oil into a clean container, measure and discard the oil. A. If the amount of oil drained was 2 ozs. or more, add the same amount of new refrigerant oil (525 viscosity). B. If the amount of oil drained was less than 2 ozs., add 6 OZS. of new refrigerant 0,;, (525 viscosity). NOTE: If an overhauled or field repair I,: compressor is being installed, add one add tional ounce of new refrigerant oil to the (.~ mounts specified above. If a new compressor I'; being installed, add 6 ozs. of new refrigerarn oil. If the drained oil contained chips or other fo! eign material, replace the receiver-drier and flush or ieplace all system parts. Add additionai oil in the following amounts for any system components being replaced. Evaporator... 3 fluid oz Condenser... 1 fluid oz, Receiver-Drier fluid oz.

39 111 HYDRAULIC TESTING (Power Shift - Dual Remotes - PTO Clutch) Testing and Adjusting Power Shift Retard Valves Power Shift Pressure Checks C-l,C-2,C-4 Clutch Modulation Checking Relief Valve (Flow Divider and PTO Control Valve) Power Shift Clutch Pressures... : Power Shift Clutch Isolation Fittings Required for checking 16 GPM Pump Section Hook-up for testing 16 GPM Pump Section GPM Pump Tests PTO and Power Shift Clutch Pressure Regulator Tests Power Shift, Remote and PTO Clutch Leakage Tests Remote and PTO Circuit Leakage Tests - Mechanical Shift... 11i -12 Power Shift, Dual Remotes, PTO, Check Sheet J I Case Rae PRINTED IN U.S.A. A Tenneco Company

40 Seclion 141 DRAFT-O-MATIC HYDRAULIC SYSTEM HOW IT WORKS Introduction Operation of the Draft-O-Matic Control Sensing Linkage Increase in implement load... Decrease in implement load Oil Flow - Lifting Position.... Oil Flow - Holding Position. Oil Flow - Lowering Position Oil Flow - Floating Position J I Case Rae A Tenneco Company PRINTED IN U.S.A.

41 151 HOW IT WORKS POWER STEERING AND POWER "BRAKES Steering and Power Brake Systems (Introduction) Power Brake Valve Assembly OIL FLOWS Engine Running - No Steering - Brakes Not Applied Right Brake Applied - No Steering - Engine Not Running Left Brake Applied - No Steering - Engine Running Left Turn - Brakes Not Applied - Engine Running..." Right Turn - Brakes Not Applied - Engine Not Running Rae. Form

42 161 POWER SHIFT HOW IT WORKS Introduction Power Shift (1) Low Power Shift (2) Intermediate Power Shift (3) High Power Shift (R) Reverse Power Shift - Inching Pedal Fully Depressed Power Shift- Inching - Inching Pedal Partially Depressed Specifications Power Shift Input to output ratio (1) Low 1.67 to 1 (2) Intermediate 1.25 to 1 (3) High 1 to 1 (R) Reverse 1 to 1 Power Shift Clutches Operating oil pressure 180 to 200 PSI Power Shift Lubrication Operating oil pressure 55 to 65 PSI Rae. Form

43 19010 AIR CONDITIONING THEORY OF OPERATION Specific a tions... : Safety Precautions... 3 Simplified Explanation of Air Conditioning... 4 Basic Principles of Air Conditioning (Refrigeration)... 6 Temperature-Pressure Relation Chart (For Refrigerant 12) Basic Components of Our Refrigeration System Compressor Drive Clutch... ~..., Compressor Lubrication Stabilized Cab Air Temperature High Cab Air Temperature Low Cab Air Temperature J I Case Rae PRINTED IN U.S.A. A Tenneco Company