J.I. Case Service Manual 1150D & 1155D Crawler Volume 1 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-1150D+
SERIES/SECTION 1150D/1155D CRAWLERS TABLE OF CONTENTS SECTION NO. FORM'NO. 1 GENERAL Safety Rules, Service Manl,Jal Introduction, and Torque Specifications............... 1001 Maintenance and Lubrication... 1002 General Engine Specifications......... 1010 Detailed Engine Specifications......... 1320 2 ENGINE Engine Stall Tests, Engine Removal and Installation, Engine Accessories (Radiator, Air Cleaner, Mufflers, Ether Injection System, Turbocharger).. ~. 2000 Engine Tune-Up......... 2002 Cylinder Head, Valve Train, and Camshaft 2015 Cylinder Block, Sleeves, Pistons, and Rods 2025 Crankshaft, Main Bearings, Flywheel, and Oil Seals.. 2035 Lubrication System......... 2046 Cooling System..... 2055 Engine Troubleshooting.. 2201 Reconditioning the Engine Block... 2290 Turbocharger Failur-e Analysis... 2565 3 FUEL SYSTEM Fuel Tank, Fuel Lines, and Engine Controls.... 3001 Fuel System and Filters........... 3010 Robert Bosch Fuel Injection Pump...... 3012 17 mm Fuel Injectors... 3213 4 ELECTRICAL Electrical System Specifications and Troubleshooting.. 4002 Wiring Diagrams................. 4003 Gauges......... 0 4004 Batteries...... 0... 4005 Starter and Starter Solenoid............ 4006 Alternator................. 4007 5 TRACK AND SUSPENSION Case Lubricated Track.................. 5504 Track, Track Frame, and Suspension...... 5506 Idler, Track Adjuster, and Recoil Housing..... 5508- Sprockets................... 5509 Carrier Rollers.............."...... 5510 Track Rollers.................,. 551:1 8-25220 8-20040 9-76379 8-22560 9-76176 9-76187 8-22780 9-76337 8-20110 8-21170 9-78235 9-75297 9-74937 8-20240 8-42190 CASE CORPORATION -R1 Printed in U.S.A.
SERIES/SECTION SECTION NO. -. 6 POWER TRAIN Transmission Maintenance and Troubleshooting...... 6002 Transmission Diagrams and Operation..... 6003 Charging Pump.................... 6005 Transmission Control Valve.............. 6007 Torque Converter.................. -6010 Transmission.............. 6016 Final Drives............. 6017 Transmission Controls.............. 6018 Drive Shaft.................. 6021 7 BRAKES Brakes.......... 7001 8 HYDRAULICS Hydraulic System Specifications, Diagrams, Maintenance Troubleshooting, and Pressure Checks 8002 Cleaning the Hydraulic System........ 8003 Pump.............. 8005 Equipment Control Valve...... 8007 Selector Valve....... 8021- Cyli nders........... 8090. 9 MOUNTED EQUIPMENT Air Conditioning Troubleshooting......... 9002 Air Conditioning System........ 9003 Loader.............. 9010' Dozer Blade................ 9020- Ripper.............. 9031 Cab and Canopy......... 9061 Operators Seats and Seat Belts........... 9064 Decals, Painting, and Noise Control........ 920t Winch............. 9300 FORM NO, 9-6786~ 8:-41280
Contents of Revision -R1 Table of Contents 8-42190 Section 5504 Assembly Instructions REVISION NO.1 FOR 11500/11550 SERVICE MANUAL 1. Remove and discard the Table of Contents from your manual. 2. Put the contents of this revision into your manual. 3. Keep this sheet as a record of the revision. Summary of Revision Coverage of Case Lubricated Track (CL T) added. J I Case -Rl Printed in U.S.A.
PRODUCT IDENTIFICATION NUMBER (PIN) AND SERIAL NUMBER'S 1001~5 NOTE: A serial number plate is also on some components such as the starter, alternator, pump, etc. DOZER BLADE TRANSMISSION PRODUCT IDENTIFICATION NUMBER 830943
2055-4 STEP 1 WATER MANIFOLD REPLACEMENT Removal Installation STEP 4 REMOVE TURBO-CHARGER AND INTAKE elbow (IF EQUIPPED,. INSTALL NEW WATER MANIFOLD GASKETS. STEP 2 STEP 5 REMOVE EXHAUST MANIFOLD AND GASKETS. INSTALL WATER MANIFOLD AND TORQUE RE TAINING BOLTS 35 TO 42 FT. LBS. STEP 3 STEP 6 REMOVE WATER MANIFOLD AND GASKETS. I, _ INSTALL NEW EXHAUST MANIFOLD GASKETS.
2290-34 Turn the main shaft of the tool clockwise to make sure that the tool is centered and turns freely. Put the tool in position again, if necessary, and make sure that the cutter just makes contact with the counterbore surface. Loosen the depth control collar one mark. One mark on the collar is 0.001" (0.0254 mm). Tighten the screw on the collar. Turn the main shaft clockwise. Push down on the handle. Loosen the screw in the depth control collar. Loosen the collar one mark. Tighten the screw in the collar. Turn the main shaft again and continue to loosen the collar one mark at a time until the complete counterbore surface has been machined. Do not try and cut more than 0.001" (0.0254 mm) at a time or the machined surface will become too rough. NOTE: To find the correct counterbore depth, remove the tool and install the cylinder sleeve to check the sleeve protrusion. Rae 8-21170 Printed in U.S.A.
4002-17 9. Check for electrical system voltage at test point C. a. If the voltmeter indication was electrical system voltage, go to step 10. b. If there was no indication of voltage, the wire between the ammeter and 80 ampere circuit breaker is damaged. Make repairs as required. 10. Connect jumper wire to the BAT and switch terminals on the starter solenoid. a. If the starter ran, go to step 12. b. If the starter did not run, go to step 11. 11. Connect the jumper wire to the BAT and MO TOR terminals on the starter solenoid. a. If the starter ran, the starter solenoid is the problem. Install a new starter solenoid. b. If the starter did not run, the starter is the problem. Repair or replace the starter as required. 12. Disconnect the starter button wiring harness from the rear wiring harness. 13. The orange wire from test point 0 is spliced to the orange wire in the rear wiring harness. Check for electrical system voltage at test point D. a. If the voltmeter indication was electrical system voltage, go to step 14. b. If there was no indication of voltage, the wire between the plug and ammeter is damaged. Repair as required. 17. Have another person push in and hold the star-' ter button while you check for electrical system voltage at test point E. If there was no indication bf voltage, the wire between the plug and switch terminal is damaged. Make repairs as required. Checking for Voltage Loss in the Starting Circuit General Information The photographs in the following tests show the use of a voltmeter that is part of a Sun Electric VAT -33 tester. A voltmeter that is not a part of other test equipment can also be used for these tests! DO NOT run the starter for more than 30 seconds at one time. After the starter has run for 30 seconds, let the starter cool for two minutes before running the starter again. Specifications Minimum voltage while starter is running... 18 volts Maximum voltage loss Positive battery cable and starter solenoid........5 volt Each cable...........4 volt Starter solenoid..........1 volt Each connection....0 volt Test No.1 - Voltage Loss in Complete Starting Circuit 1. If the machine is a loader, raise the loader frame and lower the strut onto the lift cylinder. 14. Connect the leads of an ohmmeter to the terminals in the plug on the starter button.wiring harness. 15. Push the starter button in and look at the ohmmeter. a. If the needle of the ohmmeter moved to the right, go to step 16. b. If the needle of the ohmmeter did not move, the starter button or the starter button wiring harness is the problem. Make repairs as required. 16. Connect the starter button wiring harness and rear wiring harness together.
4002-18 2. Select a volt range that will measure 24 volts. 5. Connect the black lead of the voltmeter to the negative post of the front battery. 404429 404417 3. Move the volt lead switch to the EXT. position. 6. Pull out the fuel shutoff control until the fuel shutoff control stops moving. 404430 4. Connect the red lead of the voltmeter to the positive post of the rear b"attery. 7. Turn the master disconnect switch to the ON position. 404415 404543
4006-31 4. Install the oil wick. Assembly 1. I nstall the starter d rive in the sh ift lever housing. Be sure the shift lever is engaged with the starter drive. 5. Fill the oil wick with SAE 20 engine oil. Install the plug into the starter drive housing. 912312 2. I nstall the fiber thrust washers on the armature shaft. Apply a thin layer of grease on the armature shaft and splines. 912419 6. Install the O-ring on the starter drive housing. 912508 3. Install the shift lever housing and starter drive on the armature shaft. Make sure the splines on the armature shaft engage the splines in the bore ofthe starter drive. 912504 912311
4006-32 4. Install the metal thrust washer on the armature shaft. 7. As you push the field frame onto the armature, use your fingers to put the brushes in position on the commutator. Be careful to avoid damage to the O-ring as you push the field frame against the shift lever housing. 912310 5. Install the starter drive housrng on me armature shaft. Make sure to align the alignment marks. 912905 8. I nstall the cap screws and lock washers to fasten the shift lever housing to the field frame. 912309 6. I nstall the Allen head screws. Tighten the Allen head screws to the specification on page 4006-2. 912907 9. Install a new gasket on the end cap. 912908
4006-47 13. Carefully remove the end cap from the field frame and commutator. 16. Loosen and remove the cap screws and lock washers that hold the shift lever housing in pla~e. 'OO'3~ 100137 14. Remove the thrust washer from the armature shaft. 17. Remove the field frame from the shift lever housing. 1. Thrust Washer 100135 100138 15. Remove the armature from the field frame. 18. Remove the thrust washer from the shift lever housing..... ",'."... 1. Armature 100136 100139
4006-48 19. Loosen and remove the Allen screws that hold the starter drive housing in place. 22. Remove the snap ring from the shaft for the shift lever. 1. AI/en Head Screws 100140 20. Remove the starter drive housing from the shift lever housing. 23. Use a hammer and punch to remove the shaft from the shift lever housing. 100142 21. Remove the starter drive and quad ring from the starter drive housi 24. Remove the O-rings from the shaft. 009311 1. Quad Ring 100143 2. Starter Drive
4006-66 9 8 @K 6 :w.@ 5 20 ~ 4 @~ 26 18 27 ~28 @25 ~29 e 28 4 30 17 o 31. @@41 c 30. I c 42 /~j)7 -; c-~ ~ 43,,-- 31~ ~ ~ V@. 25 ~ 30/~~ 25 /'28 @(j 25 28 1. 2. 3. 4. 5. 6. 7. B. 9. 10. 11. Cap Screw Starter Solenoid Plunger Flat Washer Boot Inner Spring Seat Spring Outer Spring Seat Snap Ring Bushing Cup Plug 12. 13. 14. 15. 16. 17. lb. 19. 20. 21. 22. Oil Wick 23. Starter Drive Housing 24. Short Allen Screw (1) 25. Long Allen Screw (5) 26. Quad Ring 27. Plug 2B. O-Ring 29. Self-Locking Nut 30. Shift Lever 31. Starter Drive 32. Brake Washer 33. Shaft 34. Shift Lever Housing 35. Lock Washer 36. Seal 37. Field Frame 3B. Nut 39. Connector 40. Insulator 41. Gasket 42. Screw 43. Field Coil 810189A Insulator Pole Shoe Insulator Thrust Washer Armature Brush Holder Brush (4) Rubber Bushing End Cap Ground Wire