Case 580k SM

Case 580 K
Backhoe • Loader • Tractor

Service Manual
Phase 1 - prior to Serial Number JJG0020000
v 4.0
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580K Loader Backhoe
TABLE OF CONTENTS
SERIES/SECTION SECTION NO. FORM NO.
1 GENERAL
Safety Rules, Service Manual Introduction, and Torque
Specifications .................................................. 1001 8-66910
General Engine Specifications . ................................... 1010 8-28800
Detailed Engine Specifications ...... . ....... .. ........... . ........ 1024 8-24161
General Machine Specifications ................................... 1210 8-66921
Maintenance and Lubrication ..................................... 1212 8-66931
2 ENGINE
Removal and Installation of the Engine, Radiator,
Power Shuttle, Torque Converter, and Front Engine
Support . ...................................................... . 2000 8-67151
Engine Accessories (Air Cleaning System, Spark Arresting
Muffler, Ether Injection System Turbocharger
Removal/Installation) ........................................... 2001 8-67160
Stall Tests ....................................................... 2002 8-67170
Cylinder Head and Valve Train .................................... 2415 8-24171
Cylinder Block, Pistons , Rods, Camshaft, Main Bearings,
Oil Seals, and Flywheel ......................................... 2425 8-24181
Lubrication System ............................................... 2445 8-24191
Cooling System ..........................•....................... 2455 8-24201
Turbocharger Disassembly/Assembly . ... ................. . ........ 2465 8-25550
Turbocharger Failure Analysis ........ . .......... .. ............... 2565 9-78235
3 FUEL SYSTEM
Engine Controls, Fuel Lines, and Fuel Tank ........................ 3001 8-67180
Fuel System and Filters ............ . .......... ...... .............. 3410 8-24211
Fuel Injection Pump and Drive Gear ............................... 3412 8-27080
Fuel Injectors .................................................... 3413 8-24231
4 ELECTRICAL
Removal and I nstallation of Electrical Components ...•............. 4000 8-67190
Electrical Specifications and Troubleshooting ...................... 4002 8-67201
Electrical Schematics ...................................•......•.. 4003 8-67211
Instrument Cluster ............................................ •.. 4004 8-67230
Battery .......................................................... 4005 8-44360
Starter and Starter Solenoid ....................................... 4006 8-42910
Alternator ........... . .. . ......................................... 4019 8-42851
5 STEERING
Removal and Installation of Steering Components .................. 5000 8-67240
Optional Tilt and Telescoping Steering Column ............. .. .... . 5001 8-72800
Steering Specifications and Troubleshooting .. .. . .... .. .. ... .... ...
5002 8-67250
Steering Control Valve - Eaton . .... ....... . .............. ....... .. 5007 8-67261
Steering Control Valve - Danfoss .................................. 5008 8-71560
Steering Cylinder ................................................. 5010 8-67271
Front Axle - Two Wheel Drive ...•.................• • . . ......... ... 5021 8-67281
Front Axle - Four Wheel Drive ....... ........ .......• ... .. ..... .... 5022 8-67291
J I Case
A Tenneco Company
SERIES/SECTION SECTION NO. FORM NO.
6 POWER TRAIN
Removal and Installation of Power Train Components .. . .. ...... . .. 6200 8-67301
Maintenance ........ . ... ...... . .. .. .. ...... ... ... .. . ... .. ... . .... 6201 8-67311
Power Shuttle Operation and Troubleshooting . ......... ... ....... . 6202 8-67320
Power Shuttle ......................... .... ........ ........... .... 6210 8-44810
Controls ...................... .... ... ..... .. .. ........ .... '.. ..... 6211 8-67331
Transfer Gear Box . .. ... . ... . . ........ . ............... .... ........ 6216 8-23451
Transaxle and Differential Lock, Wet Brake . ......... . . ...... .. . .. . . 6217 8-67550
Wheels and Tires .... .. . .............. ...... ..... ... .. ........ ... . 6229 8-67341
7 BRAKES
Brakes (Brake Pedals to Transaxle) ... ....... .. .... ................ 7106 8-67351
Differential Brakes, Wet Brakes ........ .. .... . ... '" ...... , . . ...... 7125 8-67560
8 HYDRAULICS
Removal and Installation of Hydraulic Components .. . ... . .... ...... 8000 8-67361
Maintenance ................................... ... .... .. .. .. . .... 8001 8-67370
Hydraulic Schematics, Specifications and Troubleshooting ........• 8002 8-67381
Cleaning the Hydraulic System . . .......... , . . ................. .... 8003 8-67390
Hydraulic Pump - Sections fastened together with studs ...... . ..... 8005 8-67401
Hydraulic Pump - Sections fasten together with cap screws ......... 8006 8-71570
Loader Control Valve .. . .••..........................•..•......... 8007 8-67410
Three Point Hitch Control Valve ..........................•........ 8009 8-67421
Cylinders .. .... ..•.... .•• .• • ............. .. ......... . ........... 8090 8-67431
Backhoe Control Valve .... ................ . ...................... 8107 8-67441
Swing Sequence Valve . •. ... .. ..•.......••... • ••.•.••.•........... 8108 8-67450
9 MOUNTING EQUIPMENT
Air Conditioning Troubleshooting ..... .. . . . ..... ............•. • .. . 9002 8-67460
Air Conditioning System • ........... . ...............•...•......... 9003 8-67470
Loader ........ .......... ..................•...•..•............... 9010 8-67480
Three Point Hitch .... • ................ .. ......................... 9033 8-67491
ROPS Cab and ROPS Canopy ...............•.•....•....•......•.. 9061 8-67501
Seat and Seat Belts ... .. . .•........... ....• ........ .•.. ........... 9064 8-67510
Suspension Seat ..•....••....••.•....•.•...•.......•..•..•....... 9065 8-67520
Backhoe ..•............•..•..•.................................•. 9100 8-67531
-1-
GENERAL
1001
SAFETY RULES
SERVICE MANUAL INTRODUCTION AND
TORQUE SPECIFICATIONS
TABLE OF CONTENTS
Safety Rules ................ . .......... 1001-2 Grade 8.8 Bolts, Nuts, and Studs ..... . 1001-6
Service Manual Introduction ............ 1001-4 Grade 10.5 Bolts, Nuts, and Studs ..... 1001-6
Torque Specifications .... .. ... .. . . . ... . 1001-5 Grade 12.8 Bolts, Nuts, and Studs ..... 1001-6
Grade 5 Bolts, Nuts, and Studs ........ 1001-5 Steel Hydraulic Fittings .. .. .......... . 1001-7
Grade 8 Bolts, Nuts, and Studs . ....... 1001-5 Split Flange Mounting Bolts ........... 1001-7
J I Case 8-66910
A Tenneco Company
1001-2
SAFETY RULES
ThIS symbol means A TrENT/ONI BECOME ALERT! YOUR SAFETY

/').. IS INVOL VED. The message that follows the symbol contains Impor-
. . tant Information about safety. Carefully read the message. Make sure
you fully understand the causes of possible injury or death. 1-1-C
IMPORTANT: To prevent injury on the job, A WARNING: Read operator's manual to

follow the Warning , Caution, and Danger notes in . . faml7iarize yourself with control lever functions.
this section and other sections throughout this 46-27
manual. Follow the instructions carefully.
WARNING: Operate tractor and equip-
The procedures recommended and shown in A ment controls from the seat position only.
this manua l are good , effective service methods. . . Any other method could result in serious
However, all possible procedures and service haz- tnjury.
ards may not be covered. Therefore, if you use a 48-55
tool or procedure not recommended , you must
make sure that the method you select is a safe A WARNING: This is a one man machine,
'"7lethod . . . no riders allowed. 35-8
Put the warn ing tag shown below on the key for WARNING: If you wear clothing that Is
the key switch when you are servicing or repairing too loose or do not use the correct safety
this machine. One warning tag is on every new equipment for your job, you can be Injl:1red.
machine. You can buy additional warning tags , A Always wear clothing that will not catch on
part number 331-4614, from Service Parts Supply. . . objects. Extra safety equipment that can
be required includes hard hat, safety
shoes, ear protection, eye or face protec-
tion, heavy gloves and reflector clothing.
4S-3-A
ReJson _ _ __
Se e Other Side
750213
780449
DANGER: Engine exhaust fumes can

A WARNING: Operate controls from the
. . operator's seat only. 35-7
cause death . If It IS necessary to start the
engine in a closed place. remove the ex-
/').. haust fumes from the area with an exhaust WARNING: When working in the area of
. . pipe extension. If you do not have an ex- A the fan belt with the engine running, avoid
haust pIpe extension. open the doors and . . loose clothing if possible, and use extreme
get outside air into the area. caudon. 354
48-56
1001-3
WARNING: Whenever the bucket must

h
be raised to aid in servicing. block the
"loader arms in place wIth lift cylinder sup-
port strut or a suitable safety stand.
23-7 -8
1. Lift Cylinder Support Strut 866554
WARNING: When dOing checks and

h tests on the equipment hydraulics, '01-
.. low the procedures as they are written.
DO NOT change the procedure. 47-44
WARNING: When putting the hydraulic

cylinders on this machine through the
necessary cycles to check operation or
to remove air from a circuit, make sure
al/ people are out of the way. 47-45 CAUTION: Use suitable floor (service)
- - - --- - - - - - -
WARNING: Use insulated gloves or
h jacks or chain hoists to raise wheels or
A mittens when working with hot parts.

47-41A
. . track off the floor. Always block machine in
place with sUitable safety stands. 40-7-A
WARNING: DO NOT, for any reason, CAUTION: Some components of this

weld the following parts: h machine are very heavy. Use suitable lifting
Front axle . . equipment or additional help as instructed in
this service manual. 40-10
Stabilizer leg
Cast stabilizer foot
h
Swing tower
. . Boom
Boom latch
Standard dipper
Dipper extension
Backhoe bucket links
Welding will cause failure of the part and
result in personal injury. 50·29
1001-4
SERVICE MANUAL INTRODUCTION

This service manual has been prepared with Table of Contents
the latest service information available. Trouble-
shooting, removal, disassembly, inspection and in- A Table of Contents is in the front of this man-
stallation procedures, and complete specifications ual. The Table of Contents shows the main divi-
and tightening references can be found in most sions and the sections that are in each division. The
sections. Some sections have drawings but no writ- individual sections, where necessary, have a Table
ten procedure because the job is so easily done. of Contents on the cover or second page of that
This service manual is one of the most important section .
tools available to the service technician .
Page Numbers
Right, Left, Front, and Rear
All page numbers are made of two numbers
T he terms right-hand and left-hand and front separated by a dash , such as 4002-9. The number
and rear as used in this manual indicate the right before the dash is the section number. The number
and left sides , and front and rear of the machine as following the dash is the page number in that sec-
seen from the operator's seat for correct operation tion . Page numbers will be found at the upper right
of the machine or attachment. or left of each page.
Illustrations
Illustrations are put as near as possible to the
text and are to be used as part of the text.
Special Tools
Special tools are needed to remove and install ,
disassemble and assemble, check, and adjust some
67~
components parts of this machine. Some special
5 . SJ 8 tools can be easily made locally and the necessary
information to make the tool is in this service man-
ual. Other special tools are more difficult to make
locally and are available from Service Tools in the
811 546
U.S. and from Jobborn Manufacturing in Canada.
1. Righ t Side-Backhoe 5. Front-Backhoe Use these tools according to the instructions in this
2. Left Side -Backhoe 6. Rear-Backhoe service manual for your personal safety and to do
3. Left Side-Machine 7. Rear-Machine the job correctly.
4. Right Side-Machine 8. Front-Machine
Order special tools from either of the following
Text companies:
If the service manual is for more than one ma- Service Tools
chine or different models of components (plane- P.O. Box 314
tary axles , gear boxes, control valves , etc.) the Owatonna, Minnesota 55060
procedures have the steps necessary to service
each model. Jobborn Manufacturing Co.
97 Frid Street
Hamilton, Ontario L8P 4M3
Canada
1001-5
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special tor- Grade 8 Bolts, Nuts, and Studs
ques are not given. These torques apply to fasten-
ers with both UNC and UNF threads as received
from suppliers, dry, or when lubricated with engine
0 <E> @ I \
oil. Not applicable if special graphites, moly-disul- Pound- Newton Kilogram

Size Feet metres metres
fide greases, or other extreme pressure lubricants
are used. 1/4 In 12-15 16-20 1.7-2.1
6.4mm
Grade 5 Bolts, Nuts, and Studs 5/16 in 24-29 33-39 3.3-4.0
7.9mm
0 0 @ 3/8 in 45-54 61 -73 6.2-7.5
9.5mm
Pound- Newton Kilogram
Size Feet metres metres 7/16 In 70-84 135-114 9.7-11 .6
11.1mm
1/4 In 9-11 12-15 1.2-1.5 112 in 110-132 149-179 15.2-18.2
6.4 mm 12.7 mm
9/16 in 160-192 ~~ 17-260 22.1-26.5
5/16 In 17-21 23-28 2.4-2.9
14.3 mm
7.9mm
5/8 in 220-264 ~~98-358 30.4-36.5
3/8 In 35-42 48-57 4.8-5 .8 15.9 mm
9.5mm 3/4 in 380-456 515-618 52 .5-63 .0
19.0 mm
7/16 In 54-64 73-87 7.5-8.8
7/8 in 600-720 E: 14-976 83.0-99.5
11.1 mm
22.2 mm
1/2 In 80-96 109-130 11.1-13.3 1.0 In 900-1080 1nO-1465 124-149
12.7 mm 25.4 mm
1-1/8 In 1280-1440 17'36-1953 177-199
9/16 In 110-132 149-179 15.2-18.2 28.6 mm
14.3 mm
1-1/4 in 1820-2000 24168-2712 252-277
31 .8 mm
5/8 In 150-180 203-244 20.8-24.9
15.9 mm 1-3/8 In 2380-2720 3~~ 27-3688 329-376
34.9 mm
3/4 In 270-324 366-439 37.3-44.8 1-1/2 in 3160-3560 4285-4827 437-492
19.0 mm 38.1 mm
7/8 In 400-480 542-651 55.3-66.4

22.2 mm
1.0 In 580-696 787-944 80.2-96.2

25.4 mm
1-1/8 In 800-880 1085-11$3 111-122

28.6 mm
1-1/4 In 1120-1240 1519-1681 155-171

31.8 mm
1-3/8 In 1460-1680 1980-2278 202-232

34.9 mm
1-1/2 In 1940-2200 2631-2983 268-304

38.1 mm
811360A
1001 -6
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when spec ial tor- Grade 10.9 Bolts, Nuts, and Studs
ques are not given .
These values apply to fasteners with coarse

th reads as received from supplier, plated or un- Pound-
e Newton Kilogram
metres
plated, or when lubricated with engine oil. These Size Feet metres
values do not apply if graphite or moly-disulfide
grease or oil is used. M4 3-4 4-5 0.4-0.5
0.15 in
Grade 8.8 Bolts, Nuts, and Studs
Pound -
e Newton Kilogram
MS
0.19 in
M6
7-8
11-13
9.5-1 1
15-17.5
1.0-1 .1
1.5-1.8
Size Feet metres metres 0.23 in
M4 2-3 3-4 0.3-0.4 . M8 27-32 37-43 3.7-4.4

0.15 in 0.31 in
M5 5-6 6.5-8 0.7-0.8 M10 54-64 73-87 7.5-8.8

0.19 in 0.39 in
M6 8-9 10.5-12 1.1-1 .2 M12 93-112 125-150 12.9-15.5

0.23 in 0.46 in
M8 19-23 26-31 2.6-3.2 M14 149-179 200-245 20.6-24.7

0.31 in 0.55 in
M1 0 38-45 52-61 5.3-6.2 M16 230-280 310-380 31 .8-38.7

0.39 in 0.62 in
M1 2 66-79 90-107 9.1-10.9 M20 450-540 610-730 62 .2-74.7

0.46 in 0.78 in
M14 106-127 144-172 14.7-17.6 M24 780-940 1050-1275 108-130

0.55 in 0.94 in
M1 6 160-200 217-271 22.1-27.7 M30 1470-1770 2000-2400 203-245

0.62 in 1.17 in
M20 320-380 434-515 44.2-52.5 M36 2580-3090 3500-4200 357-427

0.78 in 1.40 in
M24 500-600 675-815 69.1-83.0

0.94 in
Grade 12.9 Bolts, Nuts, and Studs
M30
1.17 in
M36
920-1100
1600-1950
1250-1500
2175-2600
127-152
221-270
e
Usually the torque values specified fo r grade 10.9
fasteners can be used satisfactorily on grade 12.9
1.40 in
fasteners.
811359
1001-7
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube 00 Thread Pound- Newton Kilogram Tube 00 Thread Pound- Newton Kilogram
Hose 10 Size Feet metres metres Hose 10 Size Feet metres metres
37 Degree Flare Fittings Straight Threads with O-ring

1/4 In 7/16-20 6-12 8-16 0.8-1 .7 1/4 in 7/16-20 12-19 16-25 1.7-2.6
6.4mm 6.4 mm
5/16 in 1/2-20 8-16 11-21 1.1-2.2 5/16 in 1/2-20 16-2!5 22-33 2.2-3.5
7.9 mm 7.9mm
3/8 In 9/16-18 10-25 14-33 1.4-3.5 3/8 In 9/16-18 25-40 34-54 3.5-5.5
9.5mm 9.5 mm
1/2 In 3/4-16 15-42 20-56 2.1-5 .8 1/2 in 3/4-16 42-6j7 57-90 5.8-9.3
12.7 mm 12.7 mm
5/8 In 7/8-14 25-58 34-78 3.5-8.0 5/ 8 in 7/8-14 58-9~~ 79-124 8.0-12.7
15.9 mm 15.9 mm
3/4 In 1-1/16-12 40-80 54-108 5.5-11.1 3/4 In 1-1/16-12 80-128 108-174 11.1-17.8
19.0 mm 19.0 mm
7/8 In 1-3/16-12 60-100 81-135 8.3-13 .9 7/8 in 1-3/16-12 100-160 136-216 13.8-22.1
22.2 mm 22.2 mm
1.0 In 1-5/16-12 75-117 102-158 10.4-16.2 1.0 in 1-5/16-12 117-187 159-253 16.2-25.9
25.4 mm 25.4 mm
1-1/4 In 1-5/8-12 125-165 169-223 17.3-22.8 1-1/4 In 1-5/8-12 165-264 224-357 22.8-36.5
31.8 mm 31 .8 mm
1-1/2 in 1-7/8-12 210-250 285-338 29.0-34.6 1-1/2 in 1-7/8-12 250-400 339-542 34.6-55.3
38.1 mm 38.1 mm
Split Flange Mounting Bolts

Pound- Newton Ki logram
Size Feet metres metres
5/16-18 15-20 20-27 2.1-2 .8
3/8-16 20-25 26-33 2.8-3.5
7/16-14 35-45 47-61 4.7-6.2
1/2-13 55-65 74-88 7.6-9.0
5/8-11 140-150 190-203 19.4-20.7

811361A
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Section
1010
GENERAL ENGINE SPECIFICATIONIS
IMPORTANT: This engine was made using the measurement system. All
measurements and checks must be made with metric tools to make sum of an
accurate reading when inspecting parts.
J 1Case Rae 8-28800

A Tenneco Company
1010-2
ENGINE SPECIFICATIONS
General
Type . .. .............................. ... ... ........... . .. .. 4 Cylinder, 4 Stroke Cycle , Valve-In-Head
Firing Order .. ......... .. .... . ... ........ . .... ...... . . .. .. .... ...... . ..... . .. ....... . ....... . 1,3,4,2
Bore .. .... ........ ............. .... ... .. . .. .......... . .. . ..... .......... . .. . .. . ... ..... . . .. 102 mm
Stroke . ...... . . ... .... . ............ .......... ..... . .... . .. ..... . ..... .... .. . ... ... .... .. . ... 120 mm
Piston Displacement .... . , .... . .. ..... . .. . . . ... ........ . . . ... . . .. .. . . ... . .. ..... . ..... . ... 3.92 Litres
Compression Ratio . ... ......... .. ... . ... . . ... .. .. ............ . . . ..... . ....... .... .. . . . .. . .. 17.0 to 1
No Load Governed Speed ... . . .. .. ....... .. .. . ... ........ . ... . ........ . ...... . . . ... 2345 to 2440 RPM
Rated Engine Speed ....... . . .. .. ...... . . . ... ....... ... .. .. .... .... .. . .... .. .... ... 2305 to 2385 RPM
Engine Idle Speed .... . ... ........ .. . ... . . .. ............... . ... .. .... . .... . .. .... . ... 850 to 900 RPM
Valve Tappet Clearance (Exhaust)(Cold) . ......... ..... .... . .......... .. .. ... .... .. ........ 0.508 mm
(Intake)(Cold) .......... .... ............................. .. ........ 0.254 mm
Thermostat Operating Range ... . .... ......... . ... . .. .... ........... . . . 181 0 F to 203 0 F (83 0 C to 95 0 C)
Piston and Connecting Rods

Rings Per Piston ... . ... . .... .... .... ........ . ..... . .. . ... ... .. . ........ . . ... . . ... ......... . . . . . .. . 3
Number of Compression Rings . .. . .. . . .... ... ... . ... ............. . .. . .... .. ... . . ..... . . .. . . . .... ... 2
Number of Oil Rings (two piece) ............................ . . .. . . ... . ... ... .. ... . . .. . .... .. .... .. . 1
Type of Pins . .. . . . . .. . .. . ... .. . .. : .... . . . . .. ...... . ......... ... . ... .. . . .... .. ............. Full Float
Type Bearings . ... . . .............. . . .... .. . . . ................... .... . .. ... Steel Back Leaded Bronze
Main Bearings
Number of Bearings ...... . .. . .... ................. .. . .... ... .. . . ........ . . .. . . .. .. .. . . ........ . . .. 5
Type of Bearings ..... . .. ........ .. ....... . . ..... . ....... ... . . .. . ......... . . . . . .. .... ... Replaceable
Engine Lubricating System

Oil Pressure ....... ...... .... ..... . . . . ... . ............ . . 42 to 54 PSI (290 to 372 kPa)(2.90 to 3.72 bar)
with Engine Warm at Rated Engine Speed
Type of System . . . . ......... ... .. ... ..... .. . .. . . ...... . . ...... . .... .. Pressure and Spray Lubrication
Oil Pump .... ... .. .... . ........... . ........ ... ... ......... ... . . . .. . .. ..... .. .. . . .... . .. . . Rotor Type
Oil Filter ... . . ... . . .............. . ... . .. ..... . ..... . . .. ... . . .. . . .... .......... Full Flow Turn on Type
Oil Capacity (with filter) ...... . ....... . ... ..... ... .. . . . . .... .. . ....... . ......... 11 Quarts (10.4 litres)
(without filter) .. ... . .. ... . ........... .... ... ........ .... .. .. ... . .. . . 10 Quarts (9.5 litres)
Fuel System
Fuel Inject:on Pump ...... . .... ......... .... .. . ...... .. .... .... .... . .... . . . . .. . . .. ·.· · ·· ········ CAV
Pump Timing ..... .. . ... . . ....... ... .... .. . ... ... . ... ... .. ... .......... ... ..... .. . .... ... Top Center
Fuel Injectors ... . . .. ...... .. . . . . . ... .. ......... .. ... . ...... ... Bosch 17 mm Opening Pressure (New)
3190 to 3310 PSI (21 994 to 22 821 kPa) (220 to 228 Bar)
Governor . .... ...... . ... . . .... ......... .. ...... .. . . ...... Variable Speed, a Part of the Injection Pump
First Stage Fuel Filter ... .. .. . . ..... ...... . ... ... ......... ... .. .. . .. ..... .. . ... . ... ... . . Turn on Type
Second Stage Fuel Filter ....... . . . ... . . . . .. . . . .. ... .. .. . . . . . ... . .. . . . . ...... .... ... . .. . Turn on Type
Lift Pump ........ .......... . ... . . ..... ... .... .. . . .... .... ... 5 to 7 PSI (34 to 48 kPa)(0 .34 to 0.48 Bar)
NOTE: The J I Case Company reserves the right to make improvements in

design or changes in specifications at any time without incurring any obliga-
tion to install them on units previously sold .
Rac 8-28800
Section
1024
SPECIFICATION DETAILS
Written In Clear
And
Simple
English
IMPORTANT: This engine was made using the metric measurement system.
All measurements and checks must be made with metric tools to make sure of
an accurate reading when inspecting parts.
J I Case Rae 8- 24161

A Tenneco Company
1024-2
TABLE OF CONTENTS
RUN - IN INSTRUCTIONS . .. . ... . . .. . . . . .. ... .. ... . .. . .. .. . ... .. . ... . .. .. . . . . ... . . . . . . . . . . . ... . .... 3
ENGINE SPECIFICATION DETAILS

Cy lind er Bloc k . ... . ..... . . . . .. ... . . .. ... . .. . . . . .. . .. .. . . . .. . . .. .... . . ..... . ... .. . ... .. . . . ... .. .. 4
Se rvice Cy linder Sleeve . . . . . ... . . .. . . . . . ...... . ... . . . .... ... .. .. ... ... . .. . .. .. .. . . . .. . .. . . . . . . .. . 4
Piston .. .. . . .. . .. . . .... .. .... . . . ... . ... .. ... . .. . . .... . . ......... . . ... .. . . . . . . . . .. . . . . . . . . . .. . . . . 4
Pi sto n Pin .. . . . . . . . .. . . .. . .. . .. ...... . . .. . . . .. . . . . .. . . . .. .. ... ... . ... . . .. .... . . . . . .. . . ... . . . . ... 4
Pisto n Rings . . .... . . . . . ....•. . . . ... . .. . . . ... .. . . . . .. . . . . . .. . .. . ...... . . ... . .... . .. ... .. . . .. . . .. . 5
Cy lind er Head .. . . .... . . .... . . .. .. .. . . . ... . .. . . .. .. . .. . .. . . . . .. ... . ... . .. . . . . . . ... . . . . .•. . .. . . .. 5
Tappets .. . .... . . .. . ....... .... .. . . .. . . . . . . ... . .. . .. . . .... . .. .. . . . . . . . . ... . .. . .. .. ... .. . . . .. . .. . 5
Co nn ecti ng Rod . . . . . ... . . .. . .. . . ... . .. .. . . . . . . .. . ... . ... . . ... . . . .. . . . . .. . ...... .. . .. .... ....... . 5
Cranksh aft ... .. ...... . . . . . . . . . . . . . ... ... . .. . .. ... . . . . . . . . . . . . . .. . . . .. . . . .. . .. .. . ... . .. . . . .. . . . . . 6
Cams haft .... . . ..... .. . . .... .... . . . . .. . .. . . . ... . . . .. .. .. ... ... . . .. . . .. .... . .. . .... . . .. . . . .. . . . .. 7
Va lve Pus h Rod Lifters . ... .. . . . . . . . . . .... .. ... . ..... . . . .. . .. . . . .. . ... . .... .. .... . . .. . .. . .... . . . . . 7
Gea r Train . . .... . . . .. ... . .. .. . .. . . ... . . . .. .. .. .. . . . .. ..... . . . . . .. . . . . . . . .. . .... . . ... . . . ...... . . . 7
Rocker Arm Assemb ly ... . .. . . . . . . .. . .. . . .. . . . . . . . . . .. ... . .. ...... . . . . . . . . . . ... .. . . .... . . . . . . ... . 7
Turboc harger . .. . . .. . . . . . .. . .. . . . .. . .. .. . . .. . . . . .. . .. . . . . . . .... . .... . .... . . . . ... . .. . ... . .. . . . . . . 7
Intake Va lve . . . . . . ........ . .... . . . .... . . . .. . . . .. . . . . .... . . . . ... .... . . . . ... . .. . . . . . . . .. .. . .. ... . . . 8
Exha ust Valve . . . ... . .. .. . . .... ... ... ......... . . .. . . . . . . .. .. . .. .. ... . . ... . . . . .. . . .. . .. . . . . .. ... . . 8
Valve Springs . . .. . . . . . . . . ... .. . . . . . .. .... . . . . ... .. . . . . .. . . . .. . . . ... .. . ...... . . . . . . ... . . . . . .... . . 8
SPEC IAL T ORQ UES .. . .. .. .. ... .... .. .. .. .. .. ........ . ..... ..... .. ... ....... . ... ... .... .. .... . 9- 11
Rae 8-24161
1024-3
RUN-IN INSTRUCTIONS
Engine Lubrication
Fill the engine crankcase with CC or CD service classification oil that has t he correct viscosity rating fo r the
ambient air temperature . Install new oil filters, after the engine has been reb uilt.
Run-In Procedure For Rebuilt Engine

Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start.
Crank the engine for 30 seconds until there is oil pressure, then reconnect the wire .
Step 2 Remove the air from the coo lin g system at the temperature sending unit.
Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks.
Step 4 During the Run-In, continue to check the oil pressure , coolant leve l, and coolant temperature .
Run-In Procedure For Rebuilt Engines (With A Dynamometer)

The following procedure must be followed when using a PTO dynamometer to Run-In the engine . The
dynamometer will control the engine load at each speed and will remove stress on new parts during Run-In .
During the Run-In , continue to check the oil pressure, coolant level and coolant temperature .
STEP TIME ENGINE SPEED DYNAMOMETER SCALE LOAD

1 5 Minutes 1000 RPM 50
2 5 Minutes 1100 RPM 1/ 2
3 5 Minutes 2200 RPM Full
Run-In Procedure for Rebuilt Engines (Without A Dynamomelter)

STEP TIME ENGINE SPEED LOAD
1 5 Minutes 1000 RPM I'Jo Load
2 5 Minutes 1100 RPM Light Load
3 5 Minutes 2200 RPM Light Load
Run-In Procedure (Agriculture Tractors)

For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours DO NOT "lug "
the engine. Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the
rated engine RPM during early hours of life.
Run-In Procedure (Construction Equipment)

For the first 8 hours, operate the engine at full throttle maintaining a normal load . DO NOT "baby" the engine,
but avoid converter or hydraulic stall. The engine must not be "lugged" below the Rated Engine RPM (Do not
stall the engine more than 10 seconds) .
Rae 8-24161
1024-4
ENGINE SPECIFICATION DETAILS

Cylinder Block Metric Value
Type ...... .. .. .... ..... .. . .... . . ............. • ...... ...... ...... .......... . ....... .. . . Non-Sleeved
Material .. . ....... . ......... . ........ .. ....... .. . ............ .. • .. . .... ... ...... .... .. ... .. Cast Iron
10 of Cylinder ....... .. ... .. ... ... . ............... .. ........ . ... .. . ........... . .. 102.00 to 102.04 mm
Maximum Service Limit .. .. ................. .. .... .. ... ............ .. .... . ..... .. .. .. . . 102.116 mm
Cylinder Out of Round (Maximum) .............. . .... .. .......................... ...... .. .. 0.038 mm
Cylinder Taper (Maximum) ........ .... ........ ........... .... .. .. .......... . .. . ........... 0.076 mm
0.5 mm Oversize Piston
Machine Cylinder Bore to .......... . ....... . ................................... 102.50 to 102.54 mm
Machine Cylinder Bore to ........... . ..................... .. ....... . ... ... ..... 103.00 to 103.04 mm
Service Cylinder Sleeve

Type ......... . ........ .... . . .................... .. . . ..... .. ............. . ... . Dry , Can Be Replaced
Material .. . .. ... . .. ............... . . .... ...... ............. . . . . ... . ... ..... ... . ............ Cast I ron
Machine Cylinder Block Bore to ............. . ... . ... . . . . ..... . .. . .... .. . . ..... 104.500 to 104.515 mm
Installation .................. . ..... ....... ..... .... . .. ...... ... . .. .................. . ...... Press Fit
Machine Sleeve Bore to:
Standard Size Piston ....... . ................... ... ............... . .. . .. .. ... .. 102.00 to 102.04 mm
0.5 mm Oversize Piston .. . . ...... .... .......... .. ............................ .. 102.50 to 102.54 mm
1.0 mm Oversize Piston ... ...... . .... ........ ..........•......... ... ... .. ..... . 103.00 to 103.04 mm
Piston
Type ........ .. . ........... . ........................................... ... .... ......... Cam Ground
Material .. . ..... ...... ..... . ..................... . .. . ... . .. .......... . .............. . Aluminum alloy
00 at 12 mm From the Bottom, 90 Degrees Piston Pin
Standard Size Piston .......... .. .... . .... ........ .. .... .... ......... ........ 101 .873 to 101 .887 mm
Minimum Service Limit ... . ... . ...... . ... . ......... . ................................. 101 .823 mm
0.5 mm Oversize Piston .. ... ... .... . ...... ................ ....... . ..... ..... 102.373 to 102.387 mm
Minimum Service Limit . ..... .... ........ .. . .. ....... .. . ........... ... ...... . .... . ... 101.323 mm
1.0 mm Oversize Piston ................. .. .. ... ........................ .. ... 102.873 to 102.887 mm
Minimum Service Limit .................•......... . ... .. ............ . ........ . ... . ... 102.823 mm
10 of Piston Pin Bore .. ..... . .. . . .... . ............ .. ............................. 40.006 to 40 .012 mm
Maximum Service Limit ......... .... ....... ......... . ... . ............ ........ .. .... ..... 40.025 mm
Width of 1st Ring Groove (Top) ...... ...... .. ....... ... . .. ..... . ....... . . ..... ..... 2.465 to 2.485 mm
Width of 2nd Ring Groove (Intermediate) ...... . .. ....... . . . ...... .. . .. ... . ......... 2.425 to 2.445 mm
Width of 3rd Ring Groove (Oil Ring) .......... ........ . . ....... . ... ... .. . .. •.. .. .... 4.040 to 4.060 mm
Protrusion Above Cylinder Block (Maximum) .. . .... . ... ..... ................ . ...... . .... ... 0.660 mm
Piston Pin
Type .. . .. ............. .. .. .... ........ ... ...... .. .. ........ ... . ..... . ... .. ... ........ . .... Full Float
00 of Pin . ... ... .... ..... ...... ...... . .... ... . ............ . .... . . .. ...... .. ..... 39.997 to 40 .003 mm
Minimum Service Limit .. . .. ... . . . .. . .. ... .. ...... .. . . . .. .... . ................. . . .. ..... 39.990 mm
Rae 8-24161
1024-5
Piston Rings
No . 1 Compression 4T-390 Engine .......... . ............................ Key Stone Type (Barrel Face)
End Gap in 102.02 10 ... ... ..... . ..... ......... .. .. . .. ........•..................... 0.4 to 0.70 mm
No.1 Compression 4-390 Engine . .. . . ... . . ....... .. ................... Rectangular Type (Barrel Face)
End Gap in 102.0210 ... ...... . ... . ........... ... . ................................. 0.25 to 0.55 mm
Maximum Service Limit ...... .. .. . .... ........ ... . .. . . ........ . . .. .... . ....... ... .... . . 0.806 mm
Side Clearance .. .... ...... . . ........ . .... ... ... . ........ .. ... ... . ......... . .. . . . 0.075 to 0.120 mm
Maximum Service Limit .................................... . .............. .. ........... . 0.15 mm
No.2 Compression ... . ........ . . .......... . .. .... . ................ . . Rectangular Type (Tapper Face)
End Gap in 102.02 ID ................... . ............................ . ........ . .... 0.25 to 0.55 mm
Maximum Service Limit ..... ........... . . . ........................ . . . .. .. . ............. 0.806 mm
Side Clearance ........... . ............ .. .................... . .... .. ............. 0.075 to 0.120 mm
Maximum Service Limit ................ ... .... . ......... ........... ... . ...... . ....... .. . 0.15 mm
NO.3 Oil Control Rings .... ..... ....... ....... ....... . .. . . ........ .. .. ........ .. ...... .. . . Two Piece
End Gap in 102.02 10 .... .... .......... . . ...... ....... .. .. ... . .... .... ...... .. ..... 0.25 to 0.55 mm
Max imum Serv ice Limit .. ....... . ............•..... .. ....... ........... . .. ...... ... .... 0.806 mm
Side Clearance .............. . . ... .................... ...... . . .... ......... .. . ........... 0.130 mm
Cylinder Head
Warpage (Maximum) ........... ......... .. . ........ ... .. .. ... . ......... .. ...... . ........... 0.20 mm
Lifters
Material .. . .... . .................................. . ................................... Hardened Iron
00 of Lifter .... ............ .. . ... .. .. ... ... ........... ........... .... ... . . ... . 15.961 to 15.977 mm
Minimum Service Limit ............. . . .. .... ... . . .......... .... ... ..... . . . ......... . .. 15.960 mm
Bore Diameter in Block ... . ......... .. . . ...... . . . ....... .. .... .. .... . .. .. . ... .. 16.000 to 16.030 mm
Maximum Service Limit .. .. ....... . ....... .... .. ....... ... ......... ..... . . . . ........ .. 16.055 mm
Connecting Rod
Bushing . ... . . ... . ...... .. ...... . ........... .. ........ . .. . ..... ... .. .... Steel Backed Leaded Bronze
Bushing 10 Installed (Ream to Size) ......... . .... . . . .. . . ... ....... . . . ............ 40.053 to 40.067 mm
Maximum Service Limit .. ......... .......... . ........................................... 40 .092 mm
Bearing Liners . ............. ....... ...... ..... ..... .. ....... . .............. ........... .. Replaceable
Journal 10 Without Bearing Liners .. .... ............. . . .. . ... . .. . .. . ............. 72.987 to 73.013 mm
Bearing Oi l Clearance ......................... . ............. . ..... .. . . .. ........ . . 0.038 to 0.116 mm
Maximum Service Limit . . ... . .. ... ... ... . ......... ........ .•. ...... . ..... . .......... . . ... 0.129 mm
Sid e Clearance ........ . .................. . ...... .. . . ........... . ........ . .. ... .. .. 0.100 to 0.300 mm
Maximum Service Limit .. . .......... . ............ . .. .... .. . . .. . . . ... . ....... ............. 0.330 mm
Connecting Rod Bend (Maximum)
Without Bushing ..... ....... ..... ....... . ....... ........ .. .. ... . .. . .. . .................. 0.200 mm
With Bushing .. . . .... .... . ... ..... .. ..... . .... . .. .. . .... .... ......... ................... 0.150 mm
Connecting Rod Twist (Maximum)
Without Bushing . . .. . ... ...... . ........... ... . ... ... . . . .... . .. . ......... . ............... 0.500 mm
With Bushing .... . .. ... .. .. . .... ........ ..... . . ......... .. ........... ..... ............ . . 0.300 mm
Rae 8-24161
1024-6
Crankshaft
Ty pe .. ..... . ..... . .. .. ... . ........... . . . . . ..... . •. ...... .. ... .... . .... .... Hardened Steel , Balanced
Main Bearing Liners . ... . .. ... ... .. ......... ..... . ........ .. ... .. ... . . . . ... . .. ... . ... .. . Replaceabl e
End Clearance, Center Main Bearing Cap .. . .. . ..... ... . . ....... . .... . .. ... . .. ..... . 0.041 to 0.119 mm
Center Main Bearing Thrust Surface Thickness . .... ... .... ....... .. ... . ... . . . .. ... . ....... .. . 2.50 mm
Connecting Rod Journal
00, Standard ....... .. . ....... .. . ........... . ........... .. .... .. . ............. 68.987 to 69.013 mm
Minimum Service Limit .. . . .. . .............. . . . . . ... . . . .. .......... .. ... . ............ . 68 .962 mm
0.25 mm 00 Undersize, G rind to . ..... ......... ... . . . .. . . .. . .. . . ... .... ... . .. .. 68 .737 to 68 .763 mm
Minimum Servi ce Limit . . .... .......... ............ .. .... ..... ... .. . . .. . . .... .. ... .. . . 68 .712 mm
0.50 mm 00 Undersize, Grind to .... . ...... .... .... .. . ... . ....... . ......... . . . . 68.487 to 68 .51 3 mm
Minimum Service Limit ...... ... . .. ....... . ... ... ... . ..... . . ... . . ......... . ........... 68.462 mm
0.75 mm 00 Undersize, Grind to . .. . . . . .. ..... . .. .. ......... ... .. .. ... .... . . ... 68 .237 to 68 .263 mm
Minimum Service Limit ... ... .. .... . ......... . ... .... ... ... . .. . .. . ..... . .. .. ..... . . ... 68 .212 mm
1.00 mm 00 Undersize, Grind to .. . .. ....................... . ........ . . .. . . .. .. 67 .987 to 68 .013 mm
Minimum Service Limit .. .. .... ...... .. . ............. ... ... .... ...... ... . . ... . . . .. .... 67 .962 mm
Connecting Rod Journal Maximum Taper .... . . . . .. .. ..... . ..... .... . .. . . . ...... ... . . ....... 0.013 mm
Journals Out of Round Maximum .... . . . .. . . . ......... . ... . ..... . .... ... . .... . ..... . ... ..... 0.050 mm
Undersize Main Bearing Liners For Service ...... .... ... . .. ............. ... 0.25 , 0.50 , 0.75 and 1.00 mm
Main Beari ng O il Clearance .... ... .... . . . .... ....... . . . ... . . . . .. . .. .. .... .. .. . ..... 0.041 to 0.119 mm
Maximum Service Limit . . . . .... ....... .... . .. ... . ...... .... .. .. . ...... . ... . . ........... . . 0.140 mm
Main Bearing Journal
00 , Standard . .... . . ... ... . .. . ... .......... . .... . . . .. . . .. ... . ... .... . .. . ..... . 82 .987 to 83.013 mm
Minimum Service Limit ......... .. . . . .. . . . ....... . .... .... ....... .. .... ...... . ........ 82 .962 mm
0.25 mm 00 Undersize, Grind to .... .. .. . ...... .. . . ... ............... .. ... ... .. 82 .737 to 82 .763 mm
Minimum Service Limit . ... ... .... . ........ ... ... .... .... .. ........ ..... .. ... . .. .. .. . . 82 .712 mm
0.50 mm 00 Undersize, Grind to .... .. . ........ . ...... ... .. . ... . ...... ......... 82.487 to 82 .513 mm
Minimum Service Limit .. . . ... .... .. . . . .... ... . . .... . . .. . .... ........... . . ... . .. . ... . . 82.462 mm
0.75 mm 00 Und ersize , Grind to ...... . .... . .... . ...... .. . . .. ... ....... ... .. ... 82 .237 to 82 .263 mm
Minim um Service Limit ...... .... . .. . . . ........... . ... . ... . .. ... . ....... .. .......... . . 82 .212 mm
1.00 mm 00 Undersize, Grind to ... .. .... . .... .... . .... .. . . ...... . . . ...... .. .. . 81 .987 to 82 .013 mm
Minimum Service Limit ...... . . ... . . . .... .. . ... ... ... . .. . ....... . ....... ... . ..... . . . .. 81 .962 mm
Main Bearing Journal Bore 10 No Liners . .. ... ... . .. . .... ..... . .. .... . .. . . ........ 87 .982 to 88.018 mm
Maximum Service Limit ............. . . .. . .... . .. . .... .. . .... . ....... . .. ....... . . . . .... . . 88.031 mm
Main Journal Width:
1st , 2nd , 3rd, 5th . ... .. . . .. . . . . . . ........ .... . . ... . . . . . . ..... . . . . ..... ....... .. 37.424 to 37 .576 mm
4th ... ................ . .............. .. . .. . ... . .... . . . ... ... . . .. .... . . . . ... . .. 37.475 to 37.525 mm
Connect Rod Journals Width ... ......... . . . . .. ... ... .. .. . . ... . .. . ... . . . .. . ...... 38 .950 to 39 .050 mm
Rae 8-24161
1024-7
Camshaft
Type ..... . ... . .. . ... . .. . ..................... .. . ........ ... . ..... . ............. . . . . .. Hardened Iron
Bushing (Fro nt On ly) . . ..... .. ... . . ..... . . . . . . ... . ... . . . ... . . .. . . . . . . . .......... . . .... 1, Replaceable
Bushi ng Lu brication :
Fron t Bushing ....... . ...... .. . .... .. . .. . .. . ....... . .... . . .. . .. . . ...... .. . . . . . . Pressure Lubricated
Intermedi ate .. ... . .......... . ........ .. . . . ......... .. ....... . . ... . . . .. . .... ... Pressure Lubricated
Rea r ............. ..... .. ... . . .. . .. ... ...... .......... .... .. .. ... . .. ........... Pressure Lubricated
Oil Clearance ...... . .... . . .. ...... .. . .. . . . . . .... ......... ......... . . ..... . .... .. .. 0.076 to 0.152 mm
10 of No. 1 Bushing ........ .. .... ... .. .. .. . .. ... . . .. . ..... . ...... . . .. . ... ..... .. 54 .107 to 54.133 mm
Maxim um Service Limit .......... . .. ... . . . .... .. .. ... . . . . ........ ...... ....... . .... . . .. . 54.146 mm
10 of No . 1 Oversize (57 .24 _l1J m 00) Service Bushing .... . .. ... . ... . . . . . . . . .... .... 54.089 to 54.139 mm
Maxi mum Service Li mit .. .. . . . . . .. ...... . .... . . .... . . ....... . . ... .... . .. . . . . . ....... .. . . 54.146 mm
10 of No . 2, 3, 4 and 5 Service Bushing .. . . . .... . . . .. . .......... .... .. . . .... ... .. . 54.089 to 54.139 mm
Maximum Service Li mit ... . .. ..... ... . ... ... ... . ... .. .... ... . , ... . . .... . ... . ........ . ... 54.146 mm
Width of No. 1 Bushing .. . ... .. ... .... . ... . . ... . ........... . ... . . .. .... . ...... . ... . 25 .15 to 25.65 mm
Width of No. 2, 3, 4 and 5 Service Bushing ........ ... .. .... . .... . ...... .. ........... 17.75 to 18.25 mm
Camshaft Bushing Journa l 00 ........ ...... . . .. ... . ....... . ... . . . . .............. 53 .987 to 54 .013 mm
Camshaft Bore ~iameter in Block
No.1 Bushing ........... . . .. . ... ... ..... .. . . ... ......... . . . ... .... . ..... .. . .. 57.222 to 57.258 mm
No.1 Ove rsize Bushing , Machine to .. ..... . ......... ... . ......... . . . . . ... .. .... 57.722 to 57.758 mm
No. 2, 3, 4 and 5, Less Bushings . ... . . . ..... ....... . . . ....... . ... ... .. ... . . ..... 54.089 to 54.139 mm
No. 2, 3, 4 and 5 Oversize for Bushings , Machine to . . .. . . .. . . . .. ... . ....... ...... 57 .222 to 57 .258 mm
Camshaft Thrust Thickness ..... . ........ .. ....... .. . . .. . ... . .... . . . ....... .. . ... .. .. 9.42 to 9.58 mm
Minimum Service Limit . ... .. ... ... . . .. ... .. . . ..... .. ............ . .. ...... .. .... . .... ... .. 9.34 mm
Cam shaft T h rust Clearance . . . ... . . . ... . .. . . . .......... ... . . . .. . ....... .. . . . . .. . ... 0.130 to 0.340 mm
Maxi mum Se rvice Limit . .. .. . ...... ... ... ... .. . ...... . ... ..... . ...... ............... . .... 0.470 mm
Turbocharger
Horizontal Travel of Turbine Shaft .. ........... .. . .. . ... ... . . ..... . ... ...... . . ... ... . . 0.10 to 0.16 mm
Gear Train
Backlash :
Crankshaft Gear to Camshaft Gear .. . ....... .... . .. ..... ... . . .... . ....... . ... . ... . . 0.08 to 0.33 mm
Crankshaft Gear to Idler Gear ... .. ... . . .. . . . . . . . ... .... .. ..... . .... . .. .. .......... . 0.08 to 0.33 mm
Camshaft to Fuel Pump Gear .... .. .. . ... ...... . ..... .. ..... ..... ... ...... ... ....... 0.08 to 0.33 mm
Idl er Gear to Oil Pump ....... . . . ..... . ... . .... . .... . ... .... .... .. . . .. . ...... . ...... 0.08 to 0.33 mm
Camshaft to Auxilia ry . . .. . ....... . . . ..... . .. . ...... . .. . ....... . . . . .. .... . . ... .. . ... 0.08 to 0.33 mm
Maximum Service Limit (All Gears) . . .... .. . . .. ........... . .......... .. .. ... ....... . ..... 0.45 mm
Rocker Arm Assembly

00 of Shaft .... ..... ......... . . . ... ... .... .. . . ... . . ....... . . .. .... .. . ... .. ...... '18.963 to 18.975 mm
Minim um Service Lim it . .. . . .. . . . . .. . .............. .. .... .. . ........... . .. . .. ..... . ..... 18.938 mm
10 of Arm Bore ....... . . . .. .. .. .. .. . . ....... .. .. .. . .. . ..... . .. .......... .. .... . .. 19.000 to 19.026 mm
Maxi mum Service Limit .. .. ... .... . .. ..... . ... .. . .......... ... .. . ....... . . . .. . ..... ..... 19.051 mm
Lubri cation .... . .. . .............. .. . .. ... ... .. ................ .. . . ... . .... . Pressure From Oil Gallery
Rae 8-24161
1024-8
Intake Valve
Tappet Clearance (Cold) ..... . .. ... ... .. .... . .. . . . .. . ... . .. . . . ... .. ........ . .... . . .. .. . .. . . 0.254 mm
Face Angl e . . ..... . . ..... .. . ... . . . .. . . .. . .. . .. . .. . ..... . ...... .... ... .. ..... . . . . ..... . . . . 29 Degrees
Face Run -Out . .. .... .. ... . . ... ... . ... .. . . . . . .... . ...... . . . . ... ...... ...... . ... .... . . . .... . 0.038 mm
Valve Head Edge Thickness, Minimum ... ...... ... . .... .. . .. .... ... .. .. . .. . . . .. .............. 1.50 mm
Length ... . ... .. .. .. .... . . ... .... .... ....... . ..... . ........ . . . .... . . .. .... .... . . 128.84 to 129.46 mm
00 of Stem .. ..... .... . ... . . ... .. .. .. .... . . ... ... .. .. . . . ....... . ..... . ....... . ... . 7.960 to 7.980 mm
Minimum Service Limit . ...... . .. ... .. . . . ... . . .... . . ... . . .... . ..... ... .. ... . . . ........... 7.940 mm
00 of Head ... . . . .... ....... .. . .. . . ... . ... . . . . . .... . ......... . . . . .. .. .. . . . . . .... 44 .870 to 45 .130 mm
Seat Angl e . .. ....... .. .. ....... .. .... . . .... .. .... . ...... .. .. . .... . .. .... . .... . . .. .... . . . 30 Degrees
Seat Contact Width .. .... .... .. ... . ..... .... . . ............ . . . .. . ... ...... . .. . .. . . ... . 1.32 to 1.92 mm
Seat Run-Out . . .. . . . ...... . .. . . . ... . . ... ..... . . . . .. .. . . . . . ... ... . . . .. . . . . . . ......... . .. . . .. 0.10 mm
Insert Height . ... ....... ... .. .... . . .. ......... . .... .. .. .... .... ... .. ...... . . ......... 6.84 to 6.96 mm
00 of Insert ... .. . . . ... ... ...... . . . .. . . ......... . . . ..... .• . • ... . .... . ...... . ... . 47 .063 to 47.089 mm
10 of Insert ... . ...... ... . .... ...... .... . ..... . . . .. . . .. ..... . ....... .. ...... ... . ... .. . .. . . . .. Tapered
Valve Recession Below Head Surface .. . ... . ............... . . . . .. ... . ........ .. ..... .. 0.99 to 1.52 mm
Maximum Service Limit . ... ..... . ..... ...... . .. ...... . ... . . . . .. ....... . . ... . . . . . ....... . .. 1.52 mm
10 of Valve Guide Bore ........ . .... . . .. . ....... . . . .... .. ... . . .... . ... .. . .. . . .. .... 8.01 9 to 8.039 mm
Maximum Service Limit .... ... ...... . ... . ........ . .... . . ... .... . .. . . .. .... . ... . . . .. . . .... 8089 mm
Exhaust Valve
Tappet Clearance (Cold) .... . . . . . ..... . . . . . . . . ...... . . . . .... . ....... . .. . . . .. . ...... . . ... . .. 0.508 mm
Face Ang le . . . ..... ... . . . .. . ... . . .. ... . ...... . . . .. . ........ . .. ....... . . . . .... .. .. ... . . . . . 44 Degrees
Face Run-Out ....... . ..... . .. .. . ......... .... . ... . . . .... .... . . . ............... .. ... . ....... 0.038 mm
Valve Head Edge Thickness , Minimum . . . ..... .. .. . . .... ... .. .. .. ... ........ . .......... . . . .. . 1.50 mm
00 of Head ...... ......... .. .... .. .......................... ........ .. . .. ... .. .. 41 .870 to 42 .130 mm
00 of Stem ... ...... . .......... .. .. .. . ............... . ......•... .. .. . . . .. . . .... . . . 7.960 to 7.980 mm
Minimum Service Limit ......... . . .. ....... .. .. . . . . ........ . . . .. .. ..... .. . .. . ... . . .. . . .. . 7.940 mm
Length .. .. .. . .... . .. . . . ... .... .. .. .. . ... .. . . . . .... .. . .. ..... .. ......... .. . .. . .. 128.74 to 129.36 mm
Insert Seat Angle . . . . ...... . . . ....... . . .. ..... .. ........ . ...... .. .. . . ... ... . ... .. . ..... .. 45 Degrees
Seat Contact Width .. . . . ........ .. .. .... . ....... . . . ..... . . . . . ..... . ... ... ..... . . .... . 1.47 to 2.07 mm
Seat Run-Out . . .... . . .. .. .. . .. . .. .. ... .. . . . . .... . . . .. . ..... ... . ... . . . .... ... ... .. . .. . .. . . .. 0 10 mm
Insert Height . .... ... ....... . ... . ... ... . ...... ... ... .... .... ....... .. .. . .. . ... ...... . 6.65 to 6.77 mm
00 of Insert . . ... .... .. . . .. . . ... . . . . ..... ... ... .. . .... .. . .. ... .... ... . . . . . . ..... 43.713 to 43.739 mm
10 of Insert . .. . .. ... .. ..... . .... . .. . . .. .. .. .. .. . .... . . .......... ... .. ... .. .. .. .... . ... . . ... . Tapered
Valve Recession Below Head Surface ........ . ..... . .. . ...... ... .... . ........ ..... .. .. 0.99 to 1.52 mm
Maximum Service Limit .... .. ..... .... ........... .. .... . . ........ ... .. .. . . .. . ........ . .. .. 1.52 mm
lOaf Valve Guide Bore .. ... ............ . . . . . ........... .. .. ... ... .. . . . .... ... . . .. . 8.019 to 8.039 mm
Maximum Service Limit . ... . . . . ....... . . .. . . . ... . .. .... . . . .. ..... .. ...... ... . . . . . . . . . .. . . 8.089 mm
Valve Springs
Free Length ........ . . . .... .. ......... ..... ... ..... .......... . .. . . . .......... . ..... . .... ... 55.63 mm
Total Coils . . . .. ... .... . .. .... .. . ... . . .. ...... . .. . .. . ......... . ... . ............ ... ..... . ... . . ... 7.25
Wire Diameter .............. . . . . ....... .... . . . ........ . ... . ....... . ... . .. . .. ...... . 4.830 to 4.930 mm
Compressed to 38.53 mm . ... . ..... ... . . ...... .. ..... . .. .. ...... .. ..... .... (Valve Open) 785 to 839 N
Minimum Service Limit .... ........ .. . .. . ... . . . . .... . ..... . .. .. ... . .... .. ...... ... ........... 765 N
Compressed to 49.25 mm . . .... . . . .. ... .............. .... . . ... .. ... .... .. . (Valve Closed) 285 to 321 N
Minimum Service Limit . . .. . . ..... . . ..... . .... . ..... ... . . . . . . . .. .. ... . . . . ..... . ..... .. .... . .. 270 N
1024-9
SPECIAL TORQUES
U.S. Value Metric Value
A lternato r Bracket Bolts (Lower) ... ............ ... . ....... . . ... . . 18 Ib ft 24 Nm
(2.4 kgm)
Alternator Bracket Bolts (Upper) . ...... . ....... .. ...... .... . ..... 18 Ib ft 24 Nm
(2.4 kgm)
Alternator Retai ning Bolt .... ....... ....... . ............ .. .... ... 18 Ib ft 24 Nm
(2.4 kgm)
Belt Tensioner Bracket Bolts ...... ......... .... ........ ........ .. 18 Ib ft 24 Nm
(2 .4 kgm)
Belt Tensioner Reta ining Bolt ...... .. . ... ... . . . . . .. .. ... ....... .. 32 Ib ft 43 Nm
(4.3 kgm)
Camshaft Retaining Bolts ..... .... .. ...... .. .............. .... .. . 18 Ib ft 24 Nm
(2.4 kgm)
Connecting Rod Bolts . ....... . . .......... .. .. ...... . ............ 74 Ib ft 100 Nm
(Lubricate Threads With Engine Oil) (10.0 kgm)
Exhaust Manifold Bolts ........... . ... .. .. ........ ............. .. 32 Ib ft 43 Nm
(4 .3 kgm)
Fan Pulley Bracket Bolts ..... ....................... .... . ..... . .. 18 Ib ft 24 Nm
(2.4 kgm)
Fan Pulley Bolts . .. .............. . .. . . .. . .... ..... ...... ......... 18 Ib ft 24 Nm
(2.4 kgm)
Flywheel Housing Bolts ... .................. . ..... . ........ ...... 44 Ib ft 60 Nm
(6.0 kgm)
Flywheel Retaining Bolts ....................................... 101 Ib ft 137 Nm
(13.7 kgm)
Flywheel Housing Cover Bolts ................... . . .. .. . ..... .... 18 Ib ft 24 Nm
(2.4 kgm)
Fuel Filter Inlet Bolt . ............... ... .. ... . ..... . . ..... ........ 24 Ib ft 32 Nm
(3 .2 kgm)
Fuel Air Removal Bolt . . .... . . . . ... .... ............ . ........... . . . 4 Ib ft 6 Nm
(0.6 kgm)
Fu el Filter Inl et Nut ........ . . .. .. ..... .. . . . . . .. ... ... ...... . . ... . 24 Ib ft 32 Nm
(3 .2 kgm)
Fuel Line Fitting (High Pressure) ..... . . ...... ..... .. ......... .. . . 18 Ib ft 24 Nm
(2.4 kgm)
Fue l Line Fitting (Low Pressure) ... . . ........... .. .. .............. 18 Ib ft 24 Nm
(2.4 kgm)
Front Cover Bolts ..... . . ... .. .. . ... .... . ........ . . . ... . ..... . .. . 18 Ib ft 24 Nm
(2 .4 kgm)
Front Housing Bolts ....... . . . ... . ..... . . ... ..... ........ .. .. . . .. 18 Ib ft 24 Nm
(2.4 kgm)
Cylinder Head Bolts .......... ... ... ... ...... . . ..... . ...... ... .. . 93 Ib ft 126 Nm
(12 .6 kgm)
Inj ection Pump Drive Gear Nut .. ........ ... ... ........ ... ... ..... 48 Ib ft 65 Nm
(6.5 kgm)
Inj ection Pump Lock Bolt ................. . ........ ...... ........ 22 Ib ft 30 Nm
(3.0 kgm)
Rae 8· 24161
1024-10
SPECIAL TORQUES (CONT'O)

U .S. Value Metric Value
Injection Pump Retaining Nuts ........... . ...... . ................ 18 Ib ft 24 Nm
(2.4 kgm)
Injection Pump Bracket Bolts .. ......... .. ..... .. .. .. .. .. .... . . .. 18 Ib ft 24 Nm
(2.4 kgm)
Inj ector Leak off Bolt ........... ......... ... .. .... .... ... . ... .. ... 6 Ib ft 8 Nm
(0.8 kgm)
In jector Retaining Nut ..... ... . .... . ... ........ ... . . ......... .... 44 Ib ft 60 Nm
(6.0 kgm)
Intake Manifold Bolts ... ........ ........ .. ............ . ........ .. 18 Ib ft 24 Nm
(2.4 kgm)
Intake Manifold Plug ........ ... ......... ...... . .... . . . . ...... . .. 92 Ib ft 125 Nm
(12.5 kgm)
Engine Lift Bracket Bolts (Rear) .............. . ... . ..... .... . . .... 57 Ib ft 77 Nm
(7 .7 kgm)
Main Bearing Bolts . ...... .... ........ ... ..•............. . .. . ... 129 Ib ft 175 Nm
(Lubricate The Threads With Engine Oil) (17 .5 kgm)
Oil Fill Tube Bolts ...... ....... . .... .. .. .. . ........... . .. .... . .. . 32 Ib ft 43 Nm
(4 .3 kgm)
Oil Pan Drain Plug ................... .... .... . .. .. .. .... . ....... 55 Ib ft 75 Nm
(7.5 kgm)
Oil Pan Heater Plug .. .. .. . ....... . ... .. ..... .. . ......... ........ 90 Ib ft 122 Nm
(12 .2 kgm)
Oil Pan Retaining Bolts .... . ... ... .. .... . . .. ... . ... . ..... ..... .. . 18 Ib ft 24 Nm
(2.4 kgm)
Oil Pump Retaining Bolts ... . ...... ....... . .... . ........ ... ..... . 181b ft 24 Nm
(2.4 kgm)
Oil I nlet Tube Bolts ... . . . .. ... . ... ..... . .... .. ..... . . ..... . ..... . 18 Ib ft 24 Nm
(2.4 kgm)
Oil Inlet Tube Brace ....................................... .. .. . . 18 Ib ft 24 Nm
(2.4 kgm)
Oil Filter Housing Bolts ................ .. .. . ...... . .... ... . .. .. . . 18 Ib ft 24 Nm
(2.4 kgm)
Rear Seal Retaining Bolts . .. . . . ...... . ... .. .... .. ...... ...•.... . . . 7 Ib ft 9 Nm
(0.9 kgm)
Rocker Arm Bolts ... . .... .. .... .. .. . .. . . .... . ..... ............ . . 18 Ib ft 24 Nm
(2.4 kgm)
Starter Retaining Bolts .......... . . . ..... ....... . ........... . . . . . 32 Ib ft 43 Nm
(4.3 kgm)
Tachometer Drive Retaining Bolts . .. . ... . ..... ... .. ...... ....... . . 2 Ib ft 3 Nm
(03 kgm)
Lifter Cover Bolts . .. . . . .... .. ........ . .. .. . . .. . .. . . . .. ....... ... 18 Ib ft 24 Nm
(2.4 kgm)
Thermostat Housing Bolts ....... . ... ... . . .. . ....... ........... .. 18 Ib ft 24 Nm
(2.4 kgm)
Timing Pin Retaining Bolts .. ... ... . ... .... . . . . ... . . .... . .. . .. . .. .. 4 Ib ft 5 Nm
(0 .5 kgm)
Fuel Shutoff Solenoid .. ......... . ... ... . .. . ... ........ . .. .... . .. 10 Ib ft 15 Nm
(1.5 kgm)
1024-11
SPECIAL TORQUES (CONT'O)

Turbocharger Mounting Bolts ..... .. ...... . . ... .. ..... .. . .. ...... 24 Ib ft 32 Nm
(3 .2 kgm)
Turbocharger Drain Tube Bolts ....... ... . ............... .. . .. . .. 181b ft 24 Nm
(24 kgm)
Turbin e Housing Bolts ................. .. ... .... ...... . .. .. ... 96 Ib inch 11Nm
(1 .1 kgm)
Center Housing to Back Plate Bolts ..... .. . . .. .. .. . .. . .... . ... . 48 Ib inch 6 Nm
(0 .6 kgm)
Compressor Housing Bolts . .. . . ..... . ................... . .. ... 48 Ib inch 6Nm
(0.6 kgm)
Compressor Lock Nut .. . .. . ...................... . . . . . .... . . 120 Ib inch 14 Nm
(14 kgm)
Thrust Bearing Screws (Torx Head) . . ..... ...... ........ . . .. .. 36 Ib inch 5Nm
(0.5 kgm)
Water Pump Mounting Bolts . .. .. . ... . ... .... . .. ........... . ..... 18 Ib ft 24 Nm
(24 kgm)
Coolant Inlet Bolts . .... ... .... .. ... .. . . . . . ... .......... .. ....... 32 Ib ft 43 Nm
(4 .3 kgm)
Valve Cover Bolts ....... . . ... ... . ... .. .. . . .... . .. .. ...... . . . .. .. 18 Ib ft 24 Nm
(24 kgm)
This Page is Blank

tion to install them on units previously sOld.
1210
GENERAL MACHINE SPECIFICATIONS
TABLE OF CONTENTS
Product Identification Number Dimensions .... ........................ 1210-5

and Serial Numbers .. . .. .. ........ . .. 1210-2
Cooling System . .. . .... . ............... 1210-3
Electrical System . . . . ................ . . . 1210-3
J I Case Bur 8-66921

A Tenneco Compan y
1210-2
PRODUCT IDENTIFICATION AND

SERIAL NUMBERS
Write your machine Model number, Product Identification Number (PIN),
and Serial numbers on the lines provided .
Make a record of the numbers. Keep the record and your Manufacturer's
Statement of Origin in a safe place. If the machine is stolen , report the numbers
to your local law enforcement agency.
Model/PIN Number ROPS Cab
ModeINumber __~5~8~0~K~______ SI N _____________
Product Identification Number ROPS Canopy
Engine
866555
SI N ______________
SI N ____________________
1210-3
COOLING SYSTEM
Capacity
With heater . ...... .. .... .... . ..... .. . . .. .. ........ ....... ... ...... . . · . .. 17.9 U.S. quarts (16 .9 litres)
Without heater .. ..... ............ ..... . . .... .. . . ....... .... .. . . .. . ..... 17.2 U.S . quarts (16.3 litres)
Pressure cap . . .. .... . . .... . .. ... ... .... ... ..... . ............. . . . .. . ..... 15 psi (103 kPa , 1.05 kg/ cm2)
Thermostat
Temperature rating ..... . . .. . .. ..... .. .. . ........... ... .. ... . . . . ... .. .. ... . ..... . . . .. 190° F (88° C)
Operating temperature .. ...... ..... . . . ... ... ...... . .... . Begins to open at 181 to 187° F (83 to 86°C) ,
completel y o pen at 203° F (95° C)
ELECTRICAL SYSTEM
Standard electrical system ...... .... . .......... .... .. ..... ........ one 12 vo lt battery , negative ground
Optional electrical system ........ . . . .. ... .. . two 12 volt batteries connected in parallel, negative ground
System voltage ... . .. . . ...... . ... . . .. ... .. .. .. .. . .... .. . ..... . ..... . ..... . . .. . . approximately 12 volts
Battery, standard electrica l system

NOTE: The specifications are the same for the production battery and the replacement battery.
J I Case part number, production battery . .. . .. . . . .. . .... .............. .. ...... A 76482 or BMF31 EW
J I Case part number, replaceme nt battery .. ... .... . .. .... ...... .. ........... . .. A 145205 or BMF31 E
Group size ............... ... ...... . . . . .......... ..... . . .. . . . . .. . . . ........ . ... . . . .... . ..... .. .. 31
Reserve capacity ... . . . . .. . . ..... ..... . . . .. . ............... ..... . . .... . . ........ . ..... . 170 minutes
Cold cranking capacity
At 0° F (-17°C) .... . ... .. .. ............ . . .. ... .... ... .... ... . .. . ......... . . .. .. . .. . . . 700 amperes
At -20° F (-29° C) .. . . . ...... . . ... ... ............. .. .. . .. . ... . ....... . ......... .. . .. .. 520 amperes
Load fo r load (capacity) test ..... .. .. .... . .. ... . .. .. ...... .. .. ..... .. ..... . . .. .. . .... . . 350 amperes
Plates per cell . . .... . .. ..... .. . ............ . . . . .. ... ..... ..... ...... . ... . . .. . ... ... .... . .... . ... 17
Approximate weight with electrolyte . . . ........... . ....... . ..... . ..... ..... . .... 60 pounds (25.8 kg)
Nonspill caps ....... .. ... . . .... . . ...... ...... .. .. ... ..... . . . ......... . . not required on this machine
Battery, optional electrical system

J I Case part number, production battery . . . ... ............ ...... . .. ... .. ...... D128383 or BMF28SW
J I Case part number, replacement battery ..... ... .. ....... .. . ... ... .. . ........ . D127414 or BMF28S
Group size . . ...... .. ........ . . ....... ... .......... . . . ..... .. . ...... .. .............. . ....... .. .. 28
Reserve capacity . ..... . . . .... ...... . ... .......... .... . .. . .... .... . .. ....... ... .. ...... 110 mi nutes
Cold crankin g capacity
At O° F (-1JOC) .... . . . . .. ... .. ...... . .. ... . . ... .. ..... ................. ......... . . .. 525 amperes
At-20°F (-29° C) .......... ... .. ...... . ... ... ..... ...... . . . .. . ... . . .... .. ..... .. .... 390 amperes
Load for load (capacity ) test .. ...... . ..... . . . . . ........ .. ... .. . .... . ... . ...... ... . ... .. 263 amperes
Plates per cell . ... ..... .. ....... ..... .... ... .... .......... . .... . . . . . . . ... ... .. .. . .. ... ..... .. . .. 12
Approximate weight with electrolyte . .................. .. ... .... . .... .... .. . .... 44 pounds (19.9 kg)
Alternator .. . . . .. .. . ...... ............. .. .. ... .... . .... .. .. . .. ... . ... .. . ...... ... . . 12 volt, 65 ampere
Voltage regulator .. . ...... ... ...... . . . . .... ... .... . . , .. .. .. ... .. ... ..... . ... solid state, not adjustable
Starter . ..... .. ....... ... . . .. ...... .. ..... ... . . ... . .. . . . . . ...... ....... .. ... 12 vo lt, solenoid actuated
1210-4
Fuses
Main fuse panel for machines with fuse block located on the engine
The main fuse panel is mounted on the right side of the engine below the starter.
1. Starter magnetic switch and the key switch ..... .. .... . .. ....... .. ... ..... ... . ....... . . 30 amperes
2. Chassis magnetic switch .. ... .. .......... ............. ......................... . .. .. . 30 amperes
3. Chassis magnetic switch ...... .... . .... . .... .. .. .... .............. . . ... . ... . . . .. .... . 30 amperes
4. Not used
Accessories fuse panel

The accessories fuse panel is mounted behind an access door at the bottom of the instrument console .
1. Fuel shutoff solenoid for machines with fuse block located on the engine, tachometer
instrument cluster. and warning buzzer . .. ... ...... . .......... .. .. .. . .. . . . ....... .... . . 10 amperes
2. Standard lamps .. ... ...... .. ... .. .. ... ....... .... .. . ... ... .. . .. .. ....... ... . . .. .... .. 25 amperes
3. Stop lamp, turn signal lamps, flasher, and horn ..... . . .. ... ..... ..... . . ... . .. .. . . . ..... 10 amperes
4. Beacon (i f equipped) .. .... .... . . .. .... .. . ... ...... . .. . . .. ... . .. ... ...... . .. .... .. . .. . 15 amperes
5. Flood lamps (if equipped) ....... ... .. ....... ...... .... . . .. .... ... ....... . .. . .. ...... . 20 amperes
6. Return-to-dig and the clutch cutout ... .. .. . ........ ................................... 15 amperes
7. Wipers (if equipped) . ... . ................................. . ............. . ..... ... .. .. 15 amperes
8. Blower (if equipped) . ....... . .. . .. ....... . . . ...... . . .. . ...... . .... .. . . .. . ..... .. .. . .. 15 amperes
9. Backup alarm (if equipped) ... .......... . . .... ... ... . .... .. .. . .. . . ... . . . . ... ... . .. .. ... 5 amperes
10. Not used
11. Cab lamps (if equipped) ... . ..... .. . .. .. .. .. ....... . .............. .. ..... . ...... . ... .. 10 amperes
1210-5
Lamps Bulb Numbers

ROPS Canopy
Head lamps . .. . .... ...... . ... . .. . .. . . ... .... ... ... .... . . ..... ... . . J I Case part number 91946C1
Flood lamps ... . .... . .... . . .. . ... . ... .................... ..... .. .. . J I Case part number 91947C1
Stop and tail lamps . .. .. . . . . ... . . ....... . ... .. . . . ... . .... ..... .. .. ....... . ... . . .. . . .... . No. 1157
Flasher and turn signal lamps .... .. ..... ... .. ..... .... . ..... .. . . . . ... ... .. . . . . ... . .. .. .. No. 1156
ROPS Cab
Head lamps, sealed beam ... .. . . . .. ..... .... .. . . . . .. .. ........ ..... J I Case part number 91946C1
Head lamps, replaceable bulb . . . . ... . .... . .. .... . . . . ..... ... ... . . J I Case part number 1312210C1
Flood lamps, sealed beam . .. ........ . ... . .. . . .. . ..... . . .. .... . . . .. . J I Case part number 91947C1
Flood lamps, replaceab le bulb .. .. ..... . . . ..... . . . .. . ... . .. .... ... J I Case part number 131221 0C1
Rea r t urn signal lamps . .. .. . .. ..... . ... .. ... . ....... ... ..... ... . .. . . .. .. .. . .. .. . ..... . .. No. 1156
Stop and tail lamps . . .. .. . . . . . .. .. ....... .... . ... .. . . ... .... .. .. . ... .. .. ... .... .. . . . .. .. No. 1157
Front warning lamps . ... ... . .. .. . .. .. .. ... . .. ... ... ... ..... ..... . ... . ....... .. . ... . . .. .. No. 1157
Dome lamps ... . .... . .... . . . ... . .. ..... . .. . .. .. ... .. . . . . ..... ... .. .... .. .... . ...... . ... . . No. 211
Turn indicator lamps ....... . . . . . .... ... . .. ... . ......... .. ... . . . . . . ..... . . . .... . ...... . ... . . No. 168
Instrument Panel
Warn ing lamps (top) ...... . . ... ... ... . . ... . .. .... . . . .. ..... . . ..... .. . .. . . ... .. . ... . ... . . . No. 168
Instrument lamps (bottom) . . ... ... .. ... . .. .. . .. . ... . .. . . . . . . . . .. . . .. ...... . .... .. . . . ..... No. 194
Rotatin g beacon . . . .. . ...... . .. ... . . .. .. ... . . . .. .. .. .. . .. . . ... . . .. . ... .... .. .. .. . . ... . . . .. No. 4416
DIMENSIONS
1
2
:~·------------------------------------3------------------------------ 8701 04
1. Transport Height ...... ..... .... . ......... .. .. .. ...... ... . .. . 129.5 Inches (3289 mm)
2. Height, ROPS Cab or ROPS Canopy ... ...... .. ... .... ... .105.5 Inches (2680 mm )
3. Length
With Standard Ba ckhoe ... .... . ... .. ..... .......... ....... ... ......... .. ...... ... 272.2 Inches (6914 mm )
With Extendahoe .......... ... .............. ............ .... . ... ..... .. .. .. .. .... ...... . 277.6 Inches (7051 mm )
With Three -Point Hitch Without Attachment ... ........ .. . ... ... " .... . . ... 203.2 Inches (5161 mm )
4. Width ....... . .... .... ......... ........ .. ... .. .. .. ...... .. .. ..... ... .... . _.. . ... 82 Inches (2083 mm )
This Page is Blank
1212
FLUIDS AND LUBRICANTS AND
MAINTENANCE SCHEDULE
TABLE OF CONTENTS
Fluids and Lubricants . .... . .... .. . .. . ... 1212-2 Run-in Maintenance Schedull~ ...... . . .. 1212-5
Support Strut for Loader Lift Arm . . . . . . .. 1212-3 Maintenance Schedule . .. .... . ... . . .... 1212-6
Engine Oil Recommendations ... ........ 1212-4 Diesel Fuel . ... .. ... ... .... . ..... . ..... 1212-10
Engine Run-In Period . . .... . . . ...... . . .. 1212-5
A Tenneco Company
1212-2
FLUIDS AND LUBRICANTS

ENGINE CRANKCASE
Capacity - with filter change . .... ........ . ... . 11 .6 U.S. quarts (1 1 litres)
Type of oil ............. See Engine Oil Recommendations, page 1212-4
FUEL TANK
Capacity ... . ... .. ...... . . .. . . ............ .. 2S U.S. gallons (94 .6 li tres)
Type of fuel . ...... . . . ... . . See Diesel Fuel Specifications, page 1212-10
ENGINE COOLING SYSTEM

Capacity - with heater . .. . . . .. . ... ..... . .... 17.9 U.S. quarts (1 6.9 lit res)
without heater .. .. . . .... .. .. . ... 17.2 U.S. quarts (1 6.3 lit res)
Type of coolant .. . .. . . .. Ethylene glycol type antifreeze and water that is
mixed SO% ethylene glycol and SO% water
HYDRAULIC SYSTEM RESERVOIR

Refill capacity - with filter change .. .. ... ... 21.S U.S . gallons (81.4 lit res)
without filter change . . .. . .. .. 21 U.S. gallons (79.S litres)
Type of fluid ... ... . .. ... . .... Case TCH Fluid or SAE 10W-30 engine oil
with API classification CC
POWER SHUTTLE
Capacity .... . .. . . . . . .. .. ... ... ...... . .... . . . .. 8 U.S. quarts (7.6 lit res)
Type of f luid . . . . . . .......... . . . .. . . .... .. . .. .. . ... .. . Case TCH Fluid
Alternate fluid . . .. .... . .............. ... .. .... . .... Type C3 fluid (10W)
TRANSAXLE
Dry capacity . . . .. . ........... . ... . . .. .. . . ... 22 U.S. quarts (20.8 litres)
Refill capacity . . .. . .. ... . . . .... . ....... . .. , 20.S U.S. quarts (1 9.4 litres)
Type of fluid ... . .. . .... . . . ... . .. . . . . . . Case Transaxle Fluid (MS 1317)
Alternate fluid .. ... . ... .. . . ...... .. . .. ... . . . . ... ...... .. . . .. . ... None
TRANSFER CASE
Capacity ... . .. . . . ............ . . .... . .. .. . .. . .... .. 1 U.S. pint (O.S litre)
Type of lubricant . . . .. . .... . ... .. .. . .. . ... Case IH 13S-H EP Gear Lube
Alternate .. . .. .. .. . ..... . .. . ............. .. ... API GL-S (SAE 8SW-140)
FRONT DRIVE AXLE

Capacity of the center bowl . . . . ...... . . . .. . .. . . 7.4 U.S. qua rts (7 litres)
Capacity of each planetary . . . ..... . . . .... ..... 1.1 U.S. quarts (1.0 litres)
Type of lub ricant .. . .... . ... . ... . .. . ... .. . Case IH 13S-H EP Gear Lube
BATTERIES
Type of fluid .. . . ... ............... Add drinking water or distilled water
FRONT WHEEL BEARINGS , TWO WHEEL DRIVE

Type of lubricant ...... . .... . ..... . .... Number 2 wheel bearing grease
BRAKE MASTER CYLINDER RESERVOIR

Type of fluid ....... . ....... . .... . .. .... . . .. . ......... Case TCH Fluid
Al ternate ...... . .................... • ........ . ...... . ... .. ..... . None
GREASE FITTINGS
Type of lubricant ......................... Case IH molydisu lfide grease
1212-3
SUPPORT STRUT FOR LOADER LIFT ARMS

WARNING : If you service the machine with the loader lift arms
raised, always use the support strut.
1. Empty the loader bucket, raise the loader lift arms to maximum
height and stop the engine.
h
2. Remove the rear pin from the support strut and lower the sup-
. . port strut onto the cylinder rod.
3. Install the rear pin in the support strut.
4. Slowly lower the lift arms onto the support strut.
If you do not follow this procedure, you can cause serious injury or
death if the loader lift arms are lowered by accident. 50-32
Supporting Loader Lowering Loader

Lift Arms Lift Arms
1. Remove the rear pin. 1. Raise loader lift arms and re-
move rear pin .
866550
2. Raise the loader.
2. Raise the support strut up to the
3. Lower the lift arms onto the sup- storage position and install the rear
port strut. Install the rear pin . pin.
1212-4
ENGINE OIL RECOMMENDATIONS

Case International No. 1 Engine Oil is recommended for use in your Case
engine. To select the correct grade of oil, see the chart below.
If Case International multi-grade engine oil is not available, Case Interna-

t ional single grade engine oil can be used .
API Classifications
Eng ines with turbochargers use API CC/ CD or CD oil.
Engines without turbochargers use API CC or CC/ CD oil.
NOTE: Do not put "Performance Additives" or other oil additive products

in the engine crankcase. The oil change interval given in this manual is accord-
ing to tests with Case lubricants. It is recommended that you use the Case
Systemgard ™ Lubricant Analysis System.
Recommended Engine Oil Grades

Temperature Fahrenheit
_30° -20° -10° 0° 10° 20° 30° 40° 50° 60° 70" 80" goo 100°
-34° _29° _23° _18° _12° _7° _1 ° 4° 10° 16° 21 " 27° 32° 38°
Temperature Celsius 840639
NOTE: When the temperature is below -10 0 F (-25 0 C j, use the optional oil
pan heater and the optional engine coolant heater to increase the temperature
of the engine before you start.
1212-5
ENGINE RUN-IN PERIOD

During the first 20 hours of operation for a new machine, or a machine with a
rebu ilt engine , make sure you do the following:
1. Operate the machine with normal loads fo r the first 8 hours.
2. Keep the engine at normal operating temperatures .
3. Do not run the engine at idle speeds for long periods of times.
4. See the Run- In Maintenance Schedule on this page for additional infor-
mation .
RUN-IN MAINTENANCE SCHEDULE

Th e follow ing items are to be done during the Run-I n Period and are in
addition to the items in the Maintenance Schedule on the following page.
- EVERY TWO HOURS OF OPERATION UNTIL BOLTS STAY TIGHT-
Check the tightness of the rear wheel bolts . . .. . ..... . . ... .. . Section 6229
Chec k th e tig htness of the front wheel bolts . . . . . ... . . ... ... . Sectio n 6229
- - - - - - AFTER FIRST 20 HOURS OF OPERATION---- - -
Have your Case dealer do the After

Delivery Check ... . ... . . .... . ........ ...... . . See the Operators Manual
- - - - - - - AFTER 50 HOURS OF OPERATION-------
Tighten nuts on bolts that hold transaxle . . ... ..... .. . ....... Section 1260
- -- - - AFTER FIRST 100 HOURS OF OPERATION-----
Tighten all hose clamps
Replace the in-line fuel filter .. ...... ...... . .. .. ... . ... . .... . Section 3001
Check the foot brake adjustment . .... .... .. .. . ...... ... . . . . Section 7106
1212-6
MAINTENANCE SCHEDULE
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«:0 SER VICE POINTS
r-8~___A_ir_C_I_e_a_ne_r_' _' ______________________~:~~:~:~~:__+-~-+_2_00_1~ ~

r-2_8~__H~y_d_ra~u_li_C_F_il_te_r_"_'__________________~~~:~~:~:.~:__~~-+8~0~0~1 As
29 Brake Master Cylinder Fluid Level ::::::: 7106 Required
:=2=5:===E=ng=i=n=e=O=i=I=Le=v=e~I====================~:::~::~::~==:=~~=:=~~~c=J 10
HOURS
13 Loader Pivot Points (14 Fitti ng s)
Backhoe Pivot Points (27 Fittings)
Three Point Hitch (8 Fittings) Not Shown :r~:
30 Front Axle Pivot Points (10 Fitti ngs)
2-Wheel Drive
30 Front Axle Pivot Po ints (6 Fittings)
4-Wheel Drive
o50
4- 1n- 1 Bucket Pivot Points (6 Fittings) HOURS
Not Shown
26 First Stage Fuel Fi lter 3410
19 Power Shuttle Oi I Level 6201
24 Coolant Reservoir Fluid Level
7 Hydrauli c Reservoir Fluid Level 8001
8 Air Cleaner Dust Val ve 2001
3 Backhoe Swing Pedal Pi vots (2 Fittings)
(If Equipped)
16
14
Transaxle Control Lever Pivot (1 -2 Fitti ngs)
Rear Axle Bearings (2 Fittings) e
100
31 Ti re Pressure and Condit ion 6229 HOURS
6 Fo ur Speed Transaxle Oil Level 6201
17 Transfer Case O il Level (4-Wheel Drive ) 6201
10 Spark Arrester Muffler ~}:~ 2001
' Every 10 hours of operation or each day, whichever occurs first.
" Service the air cleaner elements if the air cleaner warning lamp illuminates.
"*Service the hydraulic filter element if the hydraulic filter warn ing lamp
illumi nates.
1212-7
(2) (2) (2)
(1) (3)
(1) (2) (2) (1 ) (2) (2) (1) (2) (2) (2) (2) (2)
GREASE FITTINGS
CAUTION: Never grease, oil or perform any maintenance with the

h. engme running unless so mstructed in the operator's manual or
. . service manual. If the attachment must be raised in order to perform
the operatIOn, block up the attachment securely. 18-8
Lubricate the machine according to the intervals given in the maintenance

schedule unless you operate the machine in severe conditions. If you operate
the machine in severe conditions, lubricate the machine more frequently.
861810
Remove all dirt from the grease fittings before you lubricate.
1212-8
5
SERVICE POINTS
Seat Post (1 ittingl

'v (0
If~:~
(0ri~'
34 Battery
m~I 4005
11 Air Conditioning Drive Belt "ension :~:t~ 19003
17 Transfer Case Breather"
If 6201
21 Engine Crankcase Oil
ft: ~
32 Engine Oil Filter ~~~I~ 250
22 Front Drive Axle Oil Level " II 16201 HOURS
22 Front Drive Axle Breather" rt 6201
29 Brake Master Cylinder Fluid Level ~f: 171 06
11 Cab Air Conditioning ~:::
12 Radiator Coolant Level ~:::
27 Fuel Tank ~t::
:~j~j~j:
20 Drive Shaft U-Joints and Spline
(3-6 Fittings)
4 ROPS Canopy or ROPS Cab mf~: B061
0500
26 Fu el Filters (T hree) m:I 3410 HOURS
23 Front Wheel Bearings' mf~ 15021
28 Hydraulic Filter m{: 8001
34 Battery Fluid Level ~t) 4005
2 Cab Air Filterl s m:f: 9061
18 Power Shuttle Fluid I::r:: 16201
18 Power Shuttle Screen tt::: 6201
C
1000
33 Hydra ulic Reservoir Fluid I::::: 8001 HOURS
15 Four-Speed Transaxle Oil 6201
22 Front Drive Axle Oil 6201
17 Transfer Case Oil" 6201
9 Engine Valve Adjustment 12415
•...
mmm
12 Engine Coolant tt
2000
:~j~j~j
35 Air Cleaner Elements
2001 HOURS
(I nner and Outer)
' Two wheel drive machines.

" Four wheel drive machines.
"'Every 2000 hours of operation or each year.
*' " One filter on Delux cabs with heater, and two filters on Delux cabs with
heater and air conditioning.
1212-9
861811
1212-10
DIESEL FUEL
Use No . 2 diesel fuel in the engine Fuel Storage
of this machine. The use of other
fuels can cause the loss of engine If you keep fuel in storage for a
power and high fuel consumption. period of time , you can get foreign
material or water in the fuel storage
In very cold temperatures , a mix- tank. Many engine problems are
ture of No.1 and No. 2 diesel fuels is caused by water in the fuel.
temporarily permitted . See the fol-
lowing Note. Keep the fuel storage tank outside
and keep the fuel as cool as possible.
NOTE: See your fuel dealer for Remove water from the storage con-
winter fuel requirements in your area. tainer at regular periods of time .
If the temperature of the fuel lowers
below the cloud paint (wax appear- Fill the fuel tank at the end of the
ance paint), wax crystals in the fuel daily operating period to prevent
will cause the engine to lose power condensation in the fuel tank .
or not start.
The diesel fuel used in this ma-

chine must meet the specifications
in the chart below or Specification
0975-81 of the American Society for
Testing and Materials.
Specifications for Acceptable No. 2 Diesel Fuel
API gravity. minimum . .. ....... . ....... . ..• .. .. . . • ... .................... . 34

Flash point . minimum .. . ....... . .... . .. . .... . .. . . ..... .. . ........ 140°F (60° C)
Cloud point (wax appearance point ). maxi mum ... . .. .•..... -5 ° F (-20°C) See Note above .
Pour point, maximum ... . .. . . . ........ .. ..... . ... • .. -15° F (-26° C) See Note above .
Distillation temperature. 90% point . ... . .. .. • .. . . . ........ 540 to 640° F (282 to 338° C)
Viscosity . at 100° F (38° C)
Centistokes • .... . . . •....... . ............. . ........ .... ..... ..... . 2.0 to 4.3
Saybolt Seconds Universal .... . .... . . . . • ......... . . . .. .... . . .......... 32 to 40
Cetane number, minimum . ....... . . . .. ..•..... . 43 (45 to 55 for winter or high altitudes)
Water and sediment, by vo lume, maximum ..•. .. .... . .. .. .. . ... .. ........ .05 of 1%
Sulfur, by weight , maximum . . ...........•. .. ....... .. .. .... . ... .. .. .. .50 of 1%
Copper strip corrosion , maximum . . . . • ....• .. .... •. ......... ... ... • ...... .. No. 2
Ash , by weight , maximum . .. .. . .. .. .. .....• , ... .. ..... . ... .. ..... . . .. .01 of 1%
WARNING: Engine fuel is flammable and can cause a fire or an

h.explosion. Do not fill the fuel tank or service the fuel system near an
. . open flame, welding, burning cigars and cigarettes, etc. 84·100
This Page is Blank
- 2-
ENGINE
2000
REMOVAL AND INSTALLATION OF THE ENGINE,
RADIATOR, POWER SHUTTLE, TORQUE CONVERTER,
AND FRONT ENGINE SUPPORT
TABLE OF CONTENTS
Special Tools . . . .... . .. . . . ...... ....... 2000-2 Engine ...... . ... .... .. . .. . . .. .. ... . .. 2000-15
Illustration of Radiator Shroud and Removal ..... .. . .... .. .. . . . ..... . .. . 2000-15

Front Cover Installation . .... . ... . .... . 2000-3
Installation . .... ..... ... .. .. . .. . .. . . . 2000-27
Illustration of Radiator Installation . ..... . 2000-4
Power Shuttle and Torque Converter .. . 2000-41
Radiator . .. . .. .. .... . ........ .. .. .. .... 2000-5
Removal . .. . . . ........... . ... .. . .... 2000-41
Removal . . . . . .. . . . .... .. ... . . .... .... 2000-5
Installation ... ......... ... ...... .. . . . 2000-42
Installation ... .. .... ... . ... . ... . . . . . " 2000-9
Installing the Front Engine Support . .... 2000-44
Illustration of Engine Installation .. .. . . . 2000-14
A T en n eco Company
2000-2
SPECIAL TOOLS
7864 41
The tool shown below is used to turn the fly-

wh ee l. The tool is available from Service Tools in
th e Uni ted States and Jobborn Manufacturing Co .
in Canada. See Special Tools in Section 1001 for
th e correct address . The part number of the tool is
CAS-1690 .
2000-3
2
..v
I
~
If-Al/ I
8
--- ---®~
1. Shroud 5. Bottom Co ver

2. Radiator Retaining Bracket 6. Bumper
3. Top Cover, Used on Machines 7. Counterweight, Used on Machines
With an Air Conditioner With Extendable Dipper
4. Top Cover, Used on Machines 8. Cap Screw
Without an Air Conditioner 9. Bolt, Tighten to 270 to 324 Pound-
Feet (366 to 439 N m, 37 to 45 kg / my
Radiator Shroud and Front Cover Installation

2000-4
CLAMP
RECOVERY
BOTTLE HOSE
TOP
RADIATOR
HOSE
CLAMP __ ~
ot
CLAMP
870106
Radiator Installation
2000-5
RADIATOR
Removal STEPS
STEP 1
Park the machine on a level surface.
STEP 2
Apply the parking brake.
STEP 3
630140
Loosen and remove the bolts, spacers , flat wash-

ers, and nuts that fasten the hold down straps to the
shroud.
STEP9
866552
Remove the pin that holds the strut in place and

lower the strut onto the lift cylinder.
STEP 4
Raise the loader frame until the strut is against the
end of the lift cylinder.
STEPS
630136
Loosen and remove the bolts, flat washers and lock

washers that fasten the hood mounting bracket to
the frame .
STEP 10
Pull the hood straight forward and remove the
hood from the machine.
Install the pin in the strut.
STEP 6
Raise the hood.
STEP 7
Have another person hold the hood in position.
2000-6
STEP 11 STEP 15
630036 627930
Install a hose on the drain valve of the radiator. Remove the top cover from the machine.
STEP 12 STEP 16
Loosen and remove the cap from the radiator.
STEP 13
Drain the cooling system . There is approximately 5
gallons (19 litres) of coolant in the machine.
STEP 14
Loosen and remove the bolts , flat washers, and

self-locking nuts that fasten the oil cooler and radi-
ator assembly to the shroud .
STEP 17
627928
Loosen and remove the cap screws, flat washers ,

and lock washers that fasten the top cover to the
bottom cover.
Loosen and remove the cap screw and lock washer

that fastens the radiator retaining bracket to the
shroud.
2000-7
STEP 18 STEP 21
628004 628308
Remove the radiator retaining bracket from the Install a wooden block between the pump and oil
radiator. cooler to support the oil cooler.
STEP 19 STEP 22
If the machine is not equipped with air conditioning
go to step 28. If the machine is equipped with air
conditioning do steps 23 through 27.
NOTE: The following photos show a machine

with the bumper and bottom cover removed. It is
not necessary to remove the bumper or the bottom
cover from the machine.
STEP 23
Loosen and remove the bolt, washers, and nuts that

fasten the shroud to the frame.
STEP 20
628 122

that fasten the clamp on the hose from the air con-
ditioning condenser to the radiator.
628008
Remove the shroud from the machine.

2000-8
STEP 24 STEP 27
628126 628314
Loosen and remove the bolts, lock washers, and Remove the bolts from the fan shroud.
nuts that fasten the mounting brackets to the oil
cooler and air conditioning co ndenser. Remove STEP 28
the moun ting brackets .
STEP 25
628102
Loosen the clamps on the lower radiator hose.
628206 STEP 29
Loosen and remove the cap screws, lock washers , Remove the lower radiator hose from the machine.
and flat washers that fasten the air conditioning
condenser to the oil cooler and radiator. STEP 30
STEP 26
628104
Loosen the clamps on the top radiator hose.

628210
Pull the air conditioning condenser away from the STEP 31

oil cooler and fasten the condenser out of the way. Remove the top radiator hose from the machine.
2000-9
STEP 32 STEP 36
628312 626320
Loosen and remove the cap screws, lock washers, Remove the radiator from the machine.
and flat washers that fasten the oil cooler to the
radiator. NOTE: 00 not force the oil cooler forward when
removing the radiator or damage to the oil cooler
STEP 33 can result.
Disconnect the hose for the coolant reservoir bot-
tl e from the radiator. Installation
STEP 34 STEP 1
628320
Loosen and remove the cap screws , lock washers , Put the radiator in position on the machine.
and flat washers that fasten the fan shroud to the
radiator. NOTE: 00 not force the oil cooler forward when
removing the radiator or damage to the oil cooler
STEP 35 can result.
Move the fan shroud away from the radiator.
2000-10
STEP 2 STEP 6
628206
Put the fan shroud in position on the radiator . In- I nstall the cap screws , lock washers, and flat wash-
stall t he cap screws , lock washers, flat washers, ers that fasten the condenser to the oil cooler and
and clamps that fasten the fan shroud to the radia- radiator assem bl y.
tor.
STEP 7
STEP 3
Connect the hose for the coolant reservoir bottle to
the top of the radiator.
STEP 4
If the machine is not equipped with air condition-
ing go to step 9. If the machine is equipped with air
cond itioning do steps 5 through 8.
STEPS
6281 26
Put the mounting brackets in position on the oil

cooler. I nstall the bolts, lock washers, and nuts that
fasten the mounting brackets to the condenser and
the oi l coo ler.
STEP 8
628210
Put the condenser in position on the oil cooler.
628 122
I nstall the cap screw and lock washer that fastens

the clamp on the hose from the air condit ionin g
condenser to the radiator .
2000-11
STEP 9 STEP 12
628008
Put the shroud in position on the machine. Make Install the cap screw and lock washer that fastens
sure that the mounting brackets on the oil cooler the radiator retaining bracket to the shroud.
are on top of the tabs on the shroud. Make sure that
the rubber insulators are in position on the mount- STEP 13
ing brackets .
STEP 10
628001
Move the shroud as far as possible toward the rear

of the machine. Hold the shroud and tighten the
628001 bolts to 270 to 324 pound-feet (366 to 439 N m, 37 to
Install the bolts, flat washers, and nuts that fasten 45 kg / m) .
the shroud to the frame. Do not tighten the nuts on
the bolts at this time. STEP 14
Remove the wooden block from under the oil
STEP 11 cooler.
628004
Put the radiator retaining bracket in position on the

radiator and shroud .
2000-12
STEP 15 STEP 20
628038
I nstall the bolts , flat washers , and self-locking nuts I nstall the cap screws , flat washers , and lock wash-
t hat fasten the oil cooler and radiator assembly to ers that fasten the top cover to the bottom cove r.
the sh rou d.
STEP 21
STEP 16 Have another person help you put the hood in posi-
Close the drain valve in the radiator and fill the tion on the machine. Align the holes in the hinges
rad iator with coolant. See Section 1212 for coolant with the holes in the fram e.
specifications .
STEP 22
STEP 17
I nstall the cap on the radiator.
STEP 18
Fill the recovery bottle to the FU LL mark.
STEP 19
620136
I nstall the bolts, flat washers and lock washers that

fasten the hinges to the frame . Do not tighten the
bolts at this time.
STEP 23
Lower the hood so that the rubber bumpers are on
the air cleaner bracket.
Put the top cover in position on the machine.
2000-13
STEP 24 STEP 28
Remove the plast ic plugs from the bottom of the Start and run the eng ine at idle until the engine is at
hood for access to the hinge mounting bolts . operating temperature. Check for coolant leaks.
STEP 25 STEP 29
Push the hood toward the rear of the machine as far Stop the engine.
as possible . Tighten the hinge mounting bolts.
STEP 30
STEP 26 Check the level of coolant in the recovery bottle .
Raise the hood. Add coolant as required .
STEP 27 STEP 31
Close the hood.
Install the bolts, spacers , flat washers , and nuts

that fasten the hold down straps to the shroud.
2000-14
870107
1. Bolts 5. Nut (Tighten to 80 to 96 8. Cap Screw (Tighten to

2. Insulator Pount-Feet (108 to 130 N m. 66 to 79 Pound-Feet
3. Hardened Washer 11 to 13 kg / m) (90 to 107 N m. 9 to 11 kg / m)
4. Nut ( Tighten to 135 to 165 6. Bolt 9. Ring Dowel
Pound-Feet (183 to 224 N m. 7. Lock Washer 10. Flat Washer
19 to 22 kg/ m )
Engine Installation
2000-15
ENGINE
Removal STEP 6
Ra ise the hood .
In the following procedure, the engine and
power shuttle will be removed as a unit. STEP 7
Have another person hold the hood in position.
STEP 1
Park the machine on a level surface. STEPS
STEP 2
Apply the parking brake .
STEP 3
630140
Loosen and remove the bolts , spacers, flat wash-

ers, and nuts tha t fasten the hold down straps to the
shroud .
STEP9
STEP 4
STEPS
630136
Loosen and remove the bolts, flat washers , and

lock washers that fasten the hood mounting bracket
to the frame.
STEP 10
Have another pe rson help yo u pull the hood straight
forward and remove the hood from the machine.
I nstall the pin in the strut.

2000-16
STEP 11 STEP 17
630036 627930
Install a hose on the drain valve of the radiator. Remove the to p cover from the machine.
STEP 12 STEP 18
Loosen and remove the cap from the radiator.
STEP 13
Dra in the cool ing system. There is approximately 5
gallons (19 litres ) of coolant in the machine.
STEP 14
See Section 8001 . Drain the oil from the hydraulic
reservoir.
STEP 15
Put a container under the drain plug in the power
shuttle. The power shuttle contains 8 U.S . qua rts
(7.6 litres) of Case TCH Fluid . Remove the dipstick 628102
for the power shuttle. Loosen and remove the drain
Loosen the clamps on the lower radiator hose.
plug from the power shuttle. Drain the oil from the
power shuttle.
STEP 19
Remove the lower radiator hose from the machine.
STEP 16
STEP 20
627928
Loosen and remove the cap screws, flat washers, 628104

Loosen the clamps on the top radiator hose.
bottom cover.
STEP 21
Remove the top radiator hose from the mach in e.
2000-17
STEP 22 STEP 27
If the machine is equipped with air conditioning,
see Section 9003 and discharge the air condition-
ing system . Disconnect the hoses from the bottom
of the condenser.
STEP 23
Disconnect the tubes from the bottom of the oil
cooler.
STEP 24
Loosen and remove the cap screws , lock washers ,

and flange mounting brackets that fasten the flange
fitting on the inlet hose to the equipment pump.
STEP 28
628001
Loosen and remove the bolts , washers, and nuts

that fasten the shroud to the frame.
STEP 25
Have another person help you remove the shroud,
radiator, and oil cooler as an assembly.
STEP 26
629420

fittings on the hoses to the equipment pump.
STEP 29
Fasten acceptable lifting equipment to the equip-
ment pump . The weight of the equipment is ap-
proximately 80 pounds (36 kg).
629416
Loosen the clamp that fastens the inlet hose to the

equipment pump . Move the clamp out of the way.
2000-1 8
STEP 30 STEP 33
Remove the muffler from the engine.
STEP 34
629422
Loosen and remove the cap screws , flat washers ,

and lock was hers that fasten the equipment pump
to the en gin e mounting brack et.
Remove the cover from the battery box .
STEP 31
STEP 35
629424
Pull the equipment pump toward the front of the

mac hine an d remove th e equipment pump from the Disconnect the ground strap from the negative bat-
mach ine. tery post.
STEP 32 STEP 36
Loosen th e self-locking nuts on the U-bolts that Disconnect the ground strap from the engine .
fasten the muffler to the engine .
2000-19
STEP 37 STEP 40
62951 4 632426
Disconnect the wires from the battery post on the If the machine is equipped with an air conditioner,
starter. loosen and remove the cap screws and lock wash-
ers that fasten the receiver-drier and mounting
STEP 38 bracket to the eng in e. Move the receiver-drier out
of the way.
STEP 41
629518
Disconnect the wire from the tab on the starter

solenoid on the starter.
629524
STEP 39 Disconnect the wire from the battery terminal on

the alternator.
STEP 42
629520
If the machine is equipped with a fuse panel on the

engine, loosen and remove the cap screw that
fastens the fuse mounting bracket to the engine.
Remove the fuse mounting bracket from the engine. Disconnect th e wire plugs from the alternator.
2000-20
STEP 43 STEP 46
629530 629536
Disconnect the wire from the engine temperature Disconnect the wire from the horn.
sw itch.
STEP 44
629532 Remove the tie straps that fasten the wiring har-
Disconnect the wire from the engine temperature ness to the hose for the equipment pump and the
sen der. Move the wiring harness for the right side horn mounting bracket.
of the engine out of the way.
STEP 48
STEP 45
866734 Disconnect the wire from the engine oil pressure

If the machine is equipped with a heater, discon- sender.
nect th e heater hose from the fitting on the water
pump. Install a plug in the hose and a cap on the
fitting .
2000-21
STEP 49 STEP 52
629620
Disconnect the wire from the fuel shutoff solenoid Disconnect the tube fo r the ether injection system
on the fuel injection pump. from the intake manifold .
STEP 50 STEP 53
If the machine is not equipped with an air condi-
tioner, go to step 62 . If the mach ine is equipped
with an air conditioner do steps 54 through 61 .
STEP 54
Disconnect the wires from the air restriction indi-

cator switch .
STEP 51
Find the clamp on the hose for the compressor on

the air cleaner mounting bracket. Loosen and re-
move the bolt, flat washer, lock washer, and nut
that fastens the clamp for the compressor.
629614

that fastens the clamp on the wiring harness to the
engine . Remove the clamp from the wiring harness
from the engine. Move the wiring harness for the
left side of the engine out of the way.
2000-22
STEP 55 STEP 59
Remove the self-locking nut, flat washer, and bolt
that fastens the compressor to the hinge.
STEP 60
Remove the compressor from the mounting
bracket.
STEP 61
Move the compressor out of the way .
STEP 62
628216
Disconnect the wire connector for the compressor

from the wiring harness.
STEP 56
For the machi nes without tu rbocharger, loosen the

clamp that fastens the air cleaner hose to the in-
take manifold. Remove the air cleaner hose from
the intake manifold . Put a cover over the opening
for the intake manifold.
STEP 63
632424
For the machines with turbocharger, di sco nn ect
Loosen the nut on the bolt that fastens the com-
the air cleaner hose from the turbocharger. Put a
pressor to the adjusting bracket. Loosen the self-
cover over the opening in the turbocharger.
locking nut on the bolt in the hinge.
STEP 64
STEP 57
Move the compressor toward th e engine . Remove
the belt from the pulley on the compressor.
STEP 58
Disconnect the wire connector for the ether injec-

t ion system to the engine temperature switch on
the intake manifo ld.
632424
Remo ve the bolt, flat washer, and nut that fastens

the compressor to the adjusting bracket.
2000-23
STEP 65 STEP 68
Find the wire connector for the ether injection sys-
tem to the wiring harness. Disconnect the wire
connector for the ether injection system from the
wiring harness.
STEP 66
Close the fuel sh utoff valve in the bottom of the fuel

tank.
STEP 69
866726
If the machine is equipped with a heater, discon-
nect the heater hose from the fitting in the water
manifold. Install a cap on the fitting and a plug in
the hose.
STEP 67
--~
629630
Disconnect the tube from the hand primer pump.
STEP 70
Disconnect the throttle linkage from the arm on the

fuel injection pump.
629708
I nstall a cap on the fitting and a cap on the fuel line.

2000-24
STEP 71 STEP 74
629632
Loosen the clamp on the hose for the fuel return Loosen and remove the cap screws and straps that
line. Disconnect the hose. fasten the drive shaft to the power shuttle.
STEP 72 STEP 75
Remove the drive shaft from the machine.
STEP 76
629636
Loosen and remove the bolts , flat washers , lock

washers, and nuts that fasten the air cleaner and
mounting bracket to the frame . 629714
Disconnect the wiring connector for the fuel level

STEP 73 sender from the wiring harness.
STEP 77
629704
Remove th e air cleaner and mounting bracket from

the machine.
Disconnect the wires from the switch tor the back-
up alarm.
2000-25
STEP 78 STEP 81
6297 18
Loosen and remove the nut and lock washer that Disconnect the wiring harness.
hold the linkage to the control arm.
STEP 82
STEP 79
629724 Disconnect the wiring harness from the neutral

Disconnect the wiring harness for the clutch cutout start switch .
solenoid .
STEP 83
STEP 80
Disconnect the wiring harnesses and electric con-

Loosen and remove the nut, lock washers, and wire nector shown.
from the sender for the oil temperature gauge.
2000-26
STEP 84 STEP 87
629808 63241 7
Fasten identification tags to the hoses at the power If the machine is equipped with a heater, find the
shuttl e. Disconnect the top and bottom hoses from clamp that fastens the heater hose to the torque
t he power shuttle. converter housing. Loosen and remove the cap
screw and lock washer that fastens the clamp on
STEP 85 the hose to the torque converter housing . Move the
In stall caps on the fittings and plugs in the hoses. heater hose out of the way.
STEP 86 STEP 88
632 4~2 63241 5
Find the wires for the return-to-dig switch on the If the machine is equipped with an air conditioner,
loader control valve. Disconnect the wires from the find the clamp that fastens the air conditioner hose
return-to-dig switch on the loader control valve. to the torque converter housing . Loosen and re-
move the cap screw and lock washer that fastens
the clamp on the hose to the torque converter hous-
ing. Move the air conditioner hose out of the way.
STEP 89
Connect acceptable lifting equ ipment to the en-
gine. See step 92 photo .
2000-27
STEP 90 STEP 93
629534 630008
Loosen and remove the bolts , flat washers , and Lift the front of the engine overthe frame and move
nuts that fasten the front engine support to the the engine and power shuttle forward .
frame .
STEP 94
STEP 91
Remove the engine and power shuttle from the

Loosen and remove the bolts , flat washers, and machine.
nuts that fasten the rear of the engine to the frame.
Installation
STEP 92
STEP 1
Carefully lift the engine and power shuttle .

Put the engine and power shuttle in position over
the frame.
2000-28
STEP 2 STEP 7
Lower the power shuttle and carefu lly move the Install the bolts , flat washers , and nuts that fasten
engine and power shuttle toward the rear of the the rear of the engine to the frame.
machine.
STEPS
STEP 3 Tighten the nuts to 135 to 165 pound-feet (183 to
Make sure that the spacers are in place on the 223 N m, 19 to 22 kg/ m) .
frame for the rear engine mounts.
STEP 9
STEP 4
If the machine is equipped with an air conditioner
make sure that the hoses for the compressor, and
the receiver-drier are out of the way before lower-
ing the eng ine into the frame.
STEPS
Make su re that the engine wiring harness is routed
over the rear of the engine .
STEPS
I nstall the bolts , flat washers, and nuts that fasten

the front engine support to the frame.
STEP 10
Tighten the bolts to 80 to 96 pound-feet (108 to 130
N m, 11 to 13 kg/m).
STEP 11
Disconnect the lifting equipment from the engine
and remove the lifting equipment.
630012
Lower the engine and power shuttle into the frame. NOTE: It is recommended that you remove and
clean the suction strainer for the hydraulic pump.
2000-29
STEP 12 STEP 15
Make sure that the drain plug is installed in the
power shuttle.
STEP 16
632422
Connect the wires to the return-to-dig switch on
the loader control valve .
STEP 13 629808
Connect the top and bottom hose to the fittings in

the power shuttle.
STEP 17
63241 7
If the machine is equipped with a heater, put the

heater hose in position on the torque converter
housing . Install the cap screw and lock washer that
fastens the clamp on the heater hose to the torque
converter housing. 630142
Connect the wiring harnesses and electric con-

STEP 14 nector shown.
STEP 18
If the machine is equipped with an air conditioner,

put the hose to the air conditioner compressor in
position on the torque converter housing. Install 629806
the cap screw and lock washer that fastens the Connect the wiring harness to the neutral start
clamp on the hose for the air conditioner compres- switch.
sor to the torque converter housing.
2000-30
STEP 19 STEP 22
629718
Connect the wiring harness. Put the linkage in position on the control arm. In-
stall the nut and lock washer that holds the lin-
STEP 20 kage to the control arm.
STEP 23
629726
Put the wire in position on the sender for the oil

te mperature gauge. I nstall the lock washer and nut 629718
that fastens the wire to the oil temperature gauge. Connect the wires to the backup alarm switch.
STEP 21 STEP 24
629724 629714
Connect the wiring harness for the clutch cutout Connect the wire connector for the fuel level send -
solenoid. er to the wiring harness.
2000-31
STEP 25 STEP 29
Put the drive shaft in position on the transaxle. If the machine is equ ipped with an air conditioner,
make sure that the clamp on the air conditioner
STEP 26 hose is installed on the air cleaner mounting
bracket.
STEP 30
I nstall the cap screw and straps that fasten th e

drive shaft to the power shuttle. Tighten the cap
screws to 156 to 216 pound-inches (18 to 24 Nm,
1.8 to 2.4 kg/m).
629632
STEP 27 Install the hose for the fuel return line and tighten
the clamp .
STEP 31
Put the air cleaner and mounting bracket in posi-

tion on the machine.
629630
STEP 28 Connect the tube to the hand primer pump.
STEP 32
Install the bolts, flat washers , and nuts that fasten

the air cleaner and mounting bracket to the frame.
Open the fuel shutoff valve in the bottom of the fuel

tank.
2000-32
STEP 33 STEP 37
~- For machines with turbocharger, connect the air
cleaner hose to the turbocharger.
STEP 38
629626
Connect the throttle linkage to the arm on the fuel

injection pump.
STEP 34
629622
For machines without turbocharger, connect the

air cleaner hose to the intake manifold .
STEP 39
Put the wiring harness in position on the left side of
the engine.
STEP 40
If the machine is not equipped with an air condi -
tioner go to step 48. If the machine is equipped with
an air co nditioner do steps 41 through 47.
STEP 41
866726 Put the compressor in position on the mounting
If the machine is equipped with a heater, connect bracket.
the heater hose to the fitting in the water manifold .
STEP 42
•
629624 632409
Connect the wiring connector for the ether injec- Install the bolt, flat washers, lock washer, and nut
tion system to the engine temperature switch on that fasten the compressor to the hinge. Do not
the intake manifold . tighten the nut on the bolt at this time.
STEP 36 STEP 43
Find the wire connector for the ether injection sys- Push the compressor toward the engine. Put the
tem to the wiring harness. Connect the wire con- belt on the clutch on the compressor.
nector to r the ether inject ion system to the wire
harness .
2000-33
STEP 44 STEP 48
632424 62821 6
Install the bolt, flat washer, lock washer, and nut Connect the wire connector for the compressor to
that fastens the compressor to the adjusting bracket. the wiring harness.
Do not tighten the nut on the bolt at this time.
STEP 49
STEP 45
Use a prybar to tighten the belt. Adjust the belt to
the specifications in Section 9003 .
STEP 46
Connect the tube for the ether injection system to

the intake manifold .
STEP 50
632424
Tighten the nut on the bolt that fastens the com-

pressor to the adjusting bracket.
STEP 47
629618
Connect the wires to the air restriction indicator

switch.
632409
Tighten the nut on the bolt that fastens the com-

presso r to th e hinge.
2000-34
STEP 51 STEP 54
62953G
Put the engine wiring harness in position on the left Connect the wire connector for the horn to the
side of the engine. Install the cap screw and lock wiring harness.
washer that fastens the clamp on the wiring har-
ness to the engine.
STEP 52
629604
I nstall the tie straps that fasten the wiring harness

629612 to the hose for the equipment pump and the horn
Connect the wiring to the fuel shutoff solenoid on mounting bracket.
the fuel injection pump.
STEP 56
STEP 53
866734
If the machine is equipped with a heater, connect

Connect the wire to the engine oil pressure sender. the heater hose to the fitting on the water pump .
2000-35
STEP 57 STEP 61
Put the wiring harness in position on the right side

of the engine.
STEP 58
Connect the wire to the battery terminal on the

alternator.
STEP 62
629532 If the machine is equipped with an air conditioner,
Connect the wire for the engine temperature send- install the cap screws and lock washers that fasten
er. the receiver-drier and mounting bracket to the en-
gine.
STEP 59
STEP 63
~'""'PIE"'"~-
Connect the wire for the engine temperature switch.

If the machine is equipped with a fuse panel on the
engine, put the fuse mounting bracket in position
STEP 60 on the engine. Install the cap screw that fastens the
fuse mounting bracket to the engine.
Connect the wire plugs to the alternator.

2000-36
STEP 64 STEP 67
629518 629510
Put t he wire in pos ition on the tab on the starter Connect t he ground strap to the negative battery
sol enoid . Tighten the screw that fastens the wire to post.
the starter solenoid.
STEP 68
STEP 65
629508
629514 Install the cover on the battery box.

Put the wires in position on the battery terminal on
the starter. Install the nut that fastens the wires to STEP 69
the battery terminal on the starter.
STEP 66
Put the muffler in position on the engine. Tighten

the self-locking nuts on the U-bolt that fastens the
6295 12 muffler to the exhaust manifold .
Connect the ground strap to the engine.
2000-37
STEP 70 STEP 73
Fasten lifting equipment to the equipment pump . Put the flange fittings on the hoses in position on
Put the equipment pump in position on the ma- the equipment pump . Install the cap screws, lock
chine. Apply Molykote Type G to the splined shaft. washers, and flange mounting brackets that fasten
the flange fittings on the hoses to the equipment
pump.
STEP 74
6294 24
Engage the splined shaft in the coupling on the

engine . If the splined shaft on the equipment pump
will not engage the splines in the coupling, use tool 629418
CAS-1690, shown on page 2000-2 , and turn the I nstall the cap screws, lock washers , and flange
flywheel until the splined shaft on the equipment mounting brackets that fasten the flange fitting on
pump engages the coupling . the inlet hose to the hydraulic pump.
STEP 72 STEP 75
I nstall the cap screws and lock washers in the top

Put the clamp in position on the inlet hose. Tighten
holes. Install the cap screws, flat washers, and lock
the clamp.
washers in the bottom holes that fasten the equip-
ment pump to the engine mounting bracket.
2000-38
STEP 76 STEP 83
Install the shroud, radiator, and oil cooler as an Install the cap on the radiator.
assembly.
STEP 84
STEP 77 Fill the recovery bottle to the FULL mark.
I nstall the bolts, flat washers, and nuts to fasten the
shroud to the frame. Move the shroud toward the STEP 85
rear of the machine as far as possible. Tighten the See Section 8001 . Fill the hydraulic reservoir.
nuts to 270 to 324 pound-feet (366 to 439 N m, 37 to
45 kg/m) . STEP 86
If the machine is equipped with a turbocharger, go
STEP 78 to step 92. If the machine is not equipped with a
turbocharger do steps 87 through 91 .
STEP 87
Fill the power shuttle with 3 U.S. quarts (3Iitres) of
Case TCH fluid.
STEP 88
Have another 4 U.S . quarts (4 litres) of Case TCH
fluid ready for the power shuttle.
STEP 89
Start the engine and run the engine at 1000 rpm
(r/min).
628104
STEP 90
Connect the top radiator hose to the engine and
Immediately add the 4 U.S . quarts (4Iitres) of Case
radiator.
TCH fluid to the power sh uttle .
STEP 79
STEP 91
With the engine running , check the fluid level for
the power shuttle. If necessary, add fluid to raise
the fluid level to the FULL mark on the dipstick. Go
to step 101 .
STEP 92
Fill the power shuttle with 3 U.S. quarts (3Iitres) of
Case TCH fluid .
STEP 93
Connect the bottom radiator hose to the engine

and radiator.
STEP 80
Connect the tubes to the bottom of the oil cooler.
STEP 81
If the machine is equipped with air condit ioning ,
connect the hoses to the bottom of the condenser.
Disconnect the wire from the fuel shutoff solenoid
STEP 82 on the fuel injection pump.
Close the drain valve on the radiator. Fill the radia-
tor with coolant . If new coolant is being used, see STEP 94
Section 1212 for the mixture. Turn the key switch to the START position and run
the starter motor for approximately 10 seconds.
2000-39
STEP 95 STEP 103

Turn the key switch to the OFF position .
STEP 96
627928
Install the cap screws, flat washers , and lock wash-

ers that fasten the top cover to the bottom cover.
6296 12
Connect the wire to the fuel shutoff solenoid on the STEP 104
fuel injection pump . See Section 9003. Charge the air conditioning sys-
tem .
STEP 97
Have another 4 U.S . quarts (4 litres) of Case TCH STEP 105
Fluid ready for the power shuttle . Have another person help you put the hood in posi-
tion on the machine. Align the holes in the hinges
STEP 98 with the holes in the frame.
Start and run the engine at 1000 rpm (r/ min).
STEP 106
STEP 99
Immediately add 4 U.S. quarts (4 litres) of Case
TCH Fluid to the power shuttle.
STEP 100
With the engine running , check the fluid level for
the power shuttle. If necessary, add fluid to raise
the fluid level to the FULL mark on the dipstick.
STEP 101
Stop the engin e and check for oil leaks.
STEP 102
630136
I nstall the bolts, flat washers , and lock washers that

fasten the hinges to the frame. Do not tighten the
bolts at this time.
STEP 107
STEP 108
Remove the plastic plugs from the bottom of the
hood for access to the hinge mounting bolts.
627930 STEP 109

Put the top cover in position on the machine. Push the hood toward the rear of the machine as far
as possible. Tighten the hinge mounting bolts.
2000-40
STEP 110 STEP 112

Ope n the hood . Start and run the engine at idle until the engine is at
operating temperature. Check for coolan t leaks.
STEP 111
STEP 113
Stop the engine.
STEP 114
Check the level of coolant in the rec overy bottl e.
Add coolant as required.
STEP 115
Close the hood .
I nstall the bolts , spacers , fla t washe rs, and nuts to

fasten the hold down straps to the shro ud .
2000-41
POWER SHUTTLE AND TORQUE CONVERTER

Removal STEP 6
NOTE: Use this procedure to remove and in-

stall the power shuttle and torque converter after
the engine, power shuttle, and torque converter
have been removed from the machine as a unit. See
Section 6200 for the procedure to remove and in-
stall the power shuttle and torque converter with
the engine installed in the machine.
STEP 1
Remove the plug, if equipped , from the bottom of
the torque converter housing.
STEP 2
Look through the hole in the bottom of the torque
Loosen and remove the cap screws and lock wash-
converter housing. Use tool CAS-1690 (see Spe-
ers that hold the power shuttle to the torque con-
cial Tools in this section) and turn the flywheel unti l
verter housing.
you see the plug in the torque converter.
STEP 7
STEP 3
Put a container under the hole in the torque con-
verter housing . Loosen and remove the plug from
the torque converter and let the oil drain into the
containe r.
STEP 4
Pull the power shL;ttle to the rear and remove the

power shuttle from the torque converter housing.
STEP 8
629904
If the machine is not equipped with a heater, loos-

en and remove the cap screw and lock washer that
holds the bracket for the fill tube to the torque
converter housing.
STEP 5
Connect acceptable lifting equipment to the power
shuttle.
329018
Loosen and remove ali but two cap screws and lock
washers that hold the torque converter housing to
the flywheel housing .
2000-42
STEP 9 STEP 12
629928 329104
Hold the flywheel housing in place and remove the Hold the torque converter and remove the remain-
remaining cap screws and lock washers that fasten ing cap screw and flat washer. Remove the torque
the torque converter housing to the flywheel hous- converter.
ing .
Installation
STEP 10
NOTE: If the flex plate for the torque conver-
ter needs to be replaced, see Section 6210 for in -
structions.
STEP 1
329022
Hold the torque converter housing and hit the tor-

que converter housing with a soft hammer. Re-
move the torque converter housing.
STEP 11 629924
Install the plug in the torque converter.
329144R
Loosen and remove all but one cap screw and flat
washer that hold the flex plate for the torque con- 329104
verter. Hold the. tnrnllA r.nnvArtA r ::Inri flAX nl::ltA ::10::1 i n!':t thA
flywhee
2000-43
STEP 3 STEP 6
329342
Tighten the cap screws to 13 to 15 pound -feet (18 Tighten the cap screws to 30 to 35 pound-feet (40
to 20 N m, 1.8 to 2.0 kg/ m). to 47 N m, 4 to 5 kg/ m).
STEP 4 STEP 7
Install the plug, if equipped, in the torque conver-
ter housing .
STEPS
Connect lifting equipment to the power shuttle and

start the power shuttle into the torque converter . If
necessary. Use tool CAS-1690 (see Special Tools
in this section) and turn the flywheel to align the
Put the torque converter housing in position on the splines on the power shuttle and the tangs on the
flywheel housing as shown. Install the cap screws hub of the torque converter with the gear in the
and lock washers . Do not install the cap screw and power shuttle . Push the power shuttle into place.
lock washer that holds the bracket for the fill tube. DO NOT use the cap screws to pull the power
If the machine is equipped with an air conditioner, shutt le into place .
do not install the cap screw and lock washer that
fastens the clamp on the hose for the air condi-
tioner to the torque converter housing .
2000-44
STEP 8 STEP 9
62991 2 629904
Install the cap screws and lock washers. Tighten If the machine is not equipped with an air condi-
the cap screws to 54 to 64 pound-feet (73 to 87 N m, tioner, install the cap screw and lock washer that
7.5 to 8.8 kg/ m). holds the bracket for the fill tube to the torque
converter housing. Tighten the cap screw to 30 to
35 pound-feet (40 to 47 N m, 4 to 5 kg/ m) .
INSTALLING THE FRONT ENGINE SUPPORT

NOTE: Make sure that the ring dowels are in STEP 2
the fro nt engine support before the front engine
support is installed on the engine.
STEP 1
Put t he f ront engine support in position on the
engine .
I nstall the cap screws and lock washers that fasten

the front engine support to the engine. Tighten the
cap screws to 66 to 79 pound-feet (80 to 107 N m , 9
to 11 kg / m) .
I I
ENGINE ACCESSORIES
TABLE OF CONTENTS
Air Cleaning System ... ................. 2001-2 Illustration of Air Cleaner Installation
With Turbocharger ... .. . . ... . .... .. 2001-8
General .............................. 2001-2
Illustration of Ai r Cleaner .. . .. . ....... 2001-9
Cap for the Air Cleaner ............... 2001-2
Spark Arresting Muffler ................ 2001-10
Precleaner (If Equipped) .......... .. .. 2001-2
Radiator ..................... See Section 2000
Dust Valve ................ . .. .... .. .. 2001-2
Ether Injection System ................. 2001-12
Service Interval ...................... 2001-2
General Informati on ................. 2001-12
Pri mary Element ..................... 2001-3
Operating Procedure .....•.......... 2001-12
Secondary Element ......... . ......... 2001 -4
Troubleshooting .................... 2001-12
Cleaning the Primary
Element ........................... 2001-5 Illustration of Ether Injection System .. 2001-14
Checking the Switch for the Turbocharger ....... .. ................ 2001-15

Air Filter Warning Lamp ............ 2001-6
Removal ............................ 2001-15
Illustration of Air Cleaner Installation
Without Turbocharger .............. 2001-7 Installation ................... ....... 2001-15
Illustration of Turbocharger
Installation ......... .. ............. 2001-16 •
J I Case 8-67160
A Tenneco Company
2001 -2
AIR CLEANING SYSTEM

General
The shelf life of a new air cleaner element is five
years. Do not install a new element that is more
tha n five years old. The date of manufacture is on
t he end cap of the element.
Replace both elements after one year in the

machine.
Do not remove the elements from the machine

to check for restriction ; always follow the recom-
mendati ons in this section .
Each time the air cleaning system is serviced,

make sure that all hose connections and flanges
are air tight. Replace all damaged parts.
Cap for the Air Cleaner

The cap fo r the air cleaner prevents coarse
particles from entering the intake pipe .
Check the cap and clean as required . Clean the

dust and dirt from the cap with compressed air. To
clean oil and grease from the cap, wash the cap in
hot water with a small amount of detergent.
870327
Precleaner (If Equipped)
Check the precleaner bowl and remove the
dust as required . Dust Valve
STEP 1 Check the dust valve every 50 hours of opera-

Loosen the nut and remove the cap from the bowl. tion or each week . Make sure that there is no ob-
struction inside the valve .
STEP 2
Remove the bowl and clean with a damp cloth . Service Interval
STEP 3 The air cleaner needs service when the airfilter

Install the bowl on the base. warning lamp illuminates.
STEP 4 Check the condition of the air cleaner warning

Install the cap and tighten the nut. lamp each day before you operate the machine.
Start and run the engine at full throttle. If the air
filter warning lamp illuminates, clean or replace the
primary element in the air cleaner.
After the primary element has been cleaned

and installed, or a new primary element has been
installed , the condition of the secondary element
must be checked . Start and run the engine at full
throttle. If the air filter warning lamp illuminates,
the secondary element must be replaced.
2001-3
Primary Element STEP 6
Replace the primary element after three wash-

ings or after the element has been in the machine
for one year. To service the primary element do the
following:
STEP 1
Open the hood.
STEP 2
Install a clean primary element or a new primary

element. Make sure the primary element is seated
in the body of the air cleaner. Install and tighten the
wing nut.
STEP 7
Loosen the clamp that fastens the cover to the body

of the air cleaner.
STEP 3
Remove the cover from the body of the air cleaner.
STEP 4
I
Use a clean damp cloth and clean the inside of the

cover.
STEPS
Remove the wing nut that holds the primary filter in

the body of the air cleaner. Remove the primary
element from the body of the air cleaner. See
Cleaning the Primary Element in this section , or
replace the primary element.
STEPS
Put the cover in position on the body of the air
body of the air cleaner.
cleaner and tighten the clamp that holds the cover
in position .
2001-4
STEP 9 STEP3
Start the engine and check the air filter warning Remove the cover from the body of the air cleaner.
lamp . If the air filter warning lamp is still illumi-
nated , see Secondary Element in this section and STEP 4
replace the secondary element.
Secondary Element
Do not clean the secondary element.
Replace the secondary element when anyone

of the following cond itions occur:
1. When the primary element has been cleaned

th ree times .
2. When vis ual inspection shows damage to the

secondary element.
Remove the wing nut that holds the primary ele-
3. When the air f ilter warning lamp illuminates
ment in the body of the air cleaner. Remove the
after t he primary element has been cleaned or a
primary element from the body of the air cleaner.
new primary element has been installed .
STEPS
If the secondary f ilter must be replaced, do the
foll owin g:
STEP 1
Open the hood .
STEP 2
Remove the wing nut that holds the secondary

element in the body of the air cleaner. Remove the
secondary element from the body of the ai r cleaner.
STEP 6
body of the air cleaner.
Loosen the clamp that fastens the cover to the body
of the air cleaner.
2001-5
STEP 7 STEP 10
866566
Install the new secondary element in the body of Put the cover in position on the body with the dust
the air cleaner. Make sure that the secondary ele- valve down and tighten the clamp that holds the
ment is seated in the body of the air cleaner. Install cover in position. '
and tighten the wing nut that holds the secondary
element in the body of the air cleaner. STEP 11
Start the engine and check the air filter warn ing
STEP 8 lamp. If the air filter warning lamp is still illumi-
nated , see Checking the Switch for the A ir Filter
Warning Lamp on the next page.
Cleaning the Primary Element

It is recommended that the primary element be
cleaned by washing . Washing will remove more dirt
than other methods of cleaning.
Wash the primary element in Case Filter Ele-

ment Cleaner, part number A40910 . Do not use the
primary elemen t until t he primary element is dry.
Do not use compressed ai r to dry the primary ele-
ment.
Install a clean primary element or a new primary
The use of compressed ai r to clean the primary
element. Make sure the primary element is seated
element is permitted when washing is not possible .
in the body of the air cleaner. Install and tighten the
Use not more than 30 psi (206 kPa) of compressed
wing nut that holds the primary element in the body
air at the nozzle and keep the nozzle 1 inch (25 mm)
of the air cleaner.
or more from the element .
STEP 9
Check the primary element after the primary
element is clean and dry. Use a lamp inside the
primary element and look for holes or bent metal
covering. If there are holes or if the metal covering
is bent, install a new primary element.
NOTE: Check a new primary element the same

way. Do not use a new primary element that is
damaged.

cover.
2001-6
Checking the Switch for the STEPS

Air Filter Warning Lamp Turn the vacuum control until the ohmmeter indi-
cates a complete circuit.
STEP 1
Remove the switch. STEPS
Read the manometer.
STEP 2
Connect the switch to a manomete r. STEP 7
The indication must be 22 to 28 inches of water (5 .5
STEP 3 to 7.0 kPa) .
Connect the leads of an ohmmeter to the terminals
on the switch . STEPS
If the switch does not close at the specified vacu -
STEP 4 um, install a new switch.
Actuate the manometer.
2001-7
PRECLEANER
~AP_g,.
(IF USED)
1--=
"'-- -
f lI
I O
II I I
la(b
Iii
6
870328
.
Air Clean er Installation Without Tur b 0 charger
2001-8
t
AIR CLEANER
870329
Air Cleaner Installation With Turbocharger
2001-9
Y ELEMENT
~_DUST
~ VALVE
Air Cleaner
• 870330
2001-10
SPARK ARRESTING MUFFLER

The laws of some states and provinces make it
necessary to install a spark arresting muffler on
t his machine. If this machine has a spark arresting
muffl.er, two pipe plugs are located on the side of
the muffler.
If the machine has a spark arresting muffler,

the replacement muffler must be a spark arresting
muffler.
Clean the spark arresting muffler every 100

hours of operation.
STEP 1 _ EXHAUST PIPE

STEP 2
Disconnect the wire from the fuel shutoff solenoid
in the fuel injection pump.
STEP 3
Remove one of the pipe plugs from the muffler. If a
new pi pe plug is needed , the pipe plug must be
brass . SPARK
ARRESTING
MUFFLER
STEP 4
Have another person close the end of the muffler
with a wooden block.
STEP 5
Hold the key switch in the start position for 30
seconds to remove the carbon from the muffler.
STEP 6
Install the pipe plug in the muffler.
"-
~
MUFFLER
STEP 7 V -CLAMP
Remove the other pipe plug and repeat steps 4 and •
5 to complete the procedure . 1ft:- ADAPTER
STEP 8 ~
Install the other pipe plug in the muffler.
II
STEP 9 ~-GASKET
Connect the wi re to the fuel shutoff solenoid in the
8 70331
fuel injection pump.
Muffler and Exhaust System
Without Turbocharge r
2001-11
870332
Muffler and Exhaust System With Turbocharger

2001-12
ETHER INJECTION SYSTEM

General Information STEP 2
Remove the nozzle from the in t ake manifo ld.
The ether injection system gives assistance in Check and clean the orifice in the nozzle.
starting the engine during cold weather.
STEP 3
The ether injection system includes an ether Make sure that the fittings are tight.
injection valve, a thermostat , a can of ether starting
fluid, a nozzle, a cold start button, and the neces- STEP 4
sary tubing and wiring . Check for loose or broken wires and for corrosion
on the terminals.
Each time the cold start button is pushed and
released , a measured amount of ether is put into STEPS
the intake manifold of the engine. I nstall a new can of ether starting fluid .
Operating Procedure STEP 6

You will need another person to help you do steps 7
STEP 1 through 16.
STEP 7
STEP 2 Disconnect the tube from the nozzle.
Put the transmission control in NEUTRAL.
STEPS
STEP 3 Hold the end of the tube away from your face .
Turn the key switch to START .
STEP 9
STEP 4 Turn the key switch to the START position.
Continue to hold the key switch in the START posi-
tion and push and release the cold start button . STEP 10
Push and release the cold start button.
STEPS
If the engine does not start within 20 seconds turn STEP 11
the key switch to the OFF position . When step 10 is comp leted , check the end of the
tube for the odor of ether. If there is an odor of
STEP 6 ether, then the injection system is working cor-
Wa it two minutes for the starter motorto cool. Then rectly.
repeat steps 3, 4, and 5.
STEP 12
STEP 7 If there is no odor of ether at the end of the tube,
Do not push the cold start button after the engine disconnect the wire for the ether injection valve
starts. from the wire in the wiring harness.
Troubleshooting STEP 13
Make sure that the key switch is in the ON position .
WARNING: Do not make repairs to the Push in and hold the cold start button .
h ether injectIOn system near an open flame
. . or while smoking. Ether burns east/yo STEP 14
47-29 Use a voltmeter to check for electrical system volt-
age at the wire in the wiring harness.
The ether injection system is equipped with a
thermostat. The thermostat will keep the ether in- STEP1S
jection system from working when the engine is If there is electrical system voltage at the wire ,
warm. Before you begin troubleshooting the ether continue with step 17.
injection system, make sure that the engine is cool.
STEP 1
Check the tube between the ether injections valve
and the nozzle for damage.
2001-13
STEP 16 STEP 19
If there is no electrical system voltage at the wire, If the ohmmeter does not show a complete circuit
use the voltmeter to check for electrical system through the thermostat, check to make sure that
voltage through the cold start button and the key the ground connection at the mounting bolt for the
switch ST terminal. See Section 4003 for the wiring thermostat is clean and tight.
diagram.
STEP 20
STEP 17 If the ground connection is good, install a new
Find the wire that is connected between the ther- thermostat.
mostat and the ether injection valve . Cut this wire
half way between the thermostat and the ether STEP 21
injection valve . If the ohmmeter shows a complete circuit through
the thermostat, the ether injection va lve is proba-
STEP 18 ble damaged. I nstall a new ether inject ion valve .
Connect the leads of an ohmmeter between the end
of the wire that is connected to the thermostat and
a good engine ground . The ohmmeter must show a
complete circuit through the thermostat.
2001-14
~
~~ '20LD ST ART BUTTON
.o"~,,w )
~"~ A
NOZZLE
~TARTING
AN OF ETHER
- FLUID
~-THER.OSTAT
I
B
REPLACEMENT -
CAP
"TO MAINHARNESS
WIRING
870333
. . n System
Ether Injectlo
2001-15
TURBOCHARGER
Removal STEP 9
Loosen the clamp on the hose for the air cleaner.
STEP 1
Park the machine on a level surface . STEP 10
Remove the hose from the turbocharger.
STEP 2
Apply the parking brake. STEP 11
Remove the cap screws, lock washers, and flat
STEP 3 washers that fasten the elbow to the mounting
bracket.
STEP 12
Remove the c lamp that fastens the elbow to the
turbocharger.
STEP 13
Remove' the elbow from the turbocharger.
STEP 14
See Section 2465 (Turbocharger) for additional
information .
Installation
Remove t he pin that ho lds th e strut in place and
STEP 1
Put the elbow in position on the turbocharger.
STEP 4
STEP 2
Ra ise the loader frame unti l the strut is against the
Install the clamp that fastens the elbow to the t ur-
bocharger.
STEP S
STEP 3
I nstall the flat washers, lock washers , and cap
screws that fasten the elbow to the mou nting
bracket.
STEP4
Put the air cleaner hose in position on the turbo-
charger.
STEPS
Tighten the clamp that fastens the air cleaner hose
to the turbocharger.
STEP 6
Put the muffler in positio n on the turbocharger.
In stall the pin in the strut.
STEP 7
STEP 6 Tighten the clamp that fastens t he muffler to the
Raise the hood . turbocharger.
STEP 7 STEP 8
Loosen the nuts on the clamp tha t fasten the muf- Lower the hood .
fler to the turbocharger.
STEP 9
STEP 8 Do steps 10 thro ugh 13 for priming the turbochar-
Remove the muffler from the turbocharger. ger with oil .
2001-16
STEP 10 STEP 12
Disconnect the electric wire from the fuel shutoff Turn the key switch to the OFF position.
solenoid on the fuel injection pump.
STEP 13
STEP 11 Connect the electric wire to the fuel shutoff sole-
Turn the key switch to the START position and run noid on the fuel injection pump.
the starter motor for approximately 10 seconds.
o
I / TO THE MUFFLER
~
~ "
870334
Turbocharger Installation
2002
ENGINE STALL TESTS
TABLE OF CONTENTS
General Information .. .............. .. . . 2002-2 Test No.1 - Torque Converter Stall . . .. .. 2002-3
Specifications .. ....... ................. 2002-2 Test No.2 - Hydraulic Stall . ....... . .... . 2002-4
Procedure to Heat the 011 .. ...... ... ... . 2002-2
J I Case 8-67170
A Tenneco Compan y
2002-2
GENERAL INFORMATION
During the stall tests the engine is run at full Do both tests. Use a photo tachometer or other
throttle and works against the torque converter, the tachometer of equal accuracy to get accurate re-
hydraulic system, or both the torque converter and sults from the tests. If the oil in the engine, torque
hydraulic system. The results of the tests will show converter and hydraulic system is cold, heat the oil
you if the cause for bad performance is in anyone accordi ng to the instructions below.
or more of the following parts: (1) engine , (2) tor-
que converter or power shuttle, (3) hydraulic sys-
tem.
SPECIFICATIONS
Low idle ......... . . . . ...... ....... .. ............... .. ....... .. ... . ..... .. . .... 850 to 900 rpm (r/min)
Full throttle (no load) ......... .. .. ..... ...................................... 2330 to 2370 rpm (r/min)
Torque converter stall speed ... ................... . .. ....... .................. ... . ... 2100 rpm (r/min)
Hydraulic stall speed (Loader only) ......................... .. ........................ 2230 rpm (r/ min)
Oil temperature ... . . .... . . ...... ...... .. .. . ..... .. ....... ... . . ...... . . . ........ . ...... .. ... See below
PROCEDURE TO HEAT THE OIL

Torque Converter Oil 3. Run the engine at full throttle for 15 seconds.
1. Check the parking brake to be sure that the 4. Decrease the engine speed to low idle and put
parking brake will prevent the machine from mov- the direction control lever in Neutral.
ing while the torque converter oil is being heated .
5. Run the engine at low idle for 15 seconds.
a. Engage the parking brake.
6. Repeat steps 2 through 5 until the needle in the
b. Start the engine and run the engine at low oil temperature gauge is in the center of the green
idle. zone on the gauge.
c. Put the shift lever for the transmission in Hydraulic Oil

fourth (4th) gear.
1. Engage the parking brake.
d. Put the direction control lever in the For-
ward position. 2. Start the engine and run the engine at full
throttle.
e. Slow ly increase the engine speed to full
throttle. If the parking brake does not prevent 3. Hold the loader control lever in the Rollback
the machine from moving , stop the engine im- position for 15 seconds.
mediately.
4. Return the loadercontrolleverto neutral for 15
f. Adjust the parking brake according to the seconds.
instructions in Section 7106.
5. Repeat steps 2 through 4 until the temperature
g. Repeat steps 1a through 1f until the park- of the hydraulic oil is 125 0 F (5P C) . If a thermome-
ing brake will prevent the machine from mov- ter is not available, feel the side of the hydraulic
ing with the engine running at full throttle . reservoir. The side of the hydraulic reservoir must
be very warm .
2. With the transmission in fourth gear and the
power shuttle in forward, slowly increase the en-
gine speed to full throttle.
2002-3
TEST NO.1 - TORQUE CONVERTER STALL

1. Engage the parking brake. a. If the engine speed was 600 to 700 rpm
(r/min) below the specified engine speed , the
2. Start the engine and run the engine at low idle. problem is the one way clutch in the torque
converter. A new torque converter must be
3. Put the shift lever for the transmission in fourth installed.
(4th) gear.
b. If the engine speed was 200 to 300 rpm
4. Put the direction control lever in the Forward (r/min) below the specified engine speed , the
position. problem is in the engine.
5. Slowly increase the engine speed to full throt- NOTE: If the engine is bad, engine speed in
tle. Test No. 2 probably was below specified en-
gine speed also.
6. Look at the tachometer and make a record of
the engine speed. 3. If the engine speed forTest No.1 was above the
specified engine speed and the engine speed for
7. Decrease the engine speed to low idle, then Test No. 2 was within specifications, the problem is
stop the engine. in the torque converter or power shuttle.
Understanding the Results of a. See Section 6202 for troubleshooting in-

the Test structions for the power shuttle .
b. If there was the sound of metal hitting met-

1. If the engine speed was as specified, the en- al coming from the torque converter, the blades
gine, torque converter, and the power shuttle are in the torque converter are damaged. A new
good. torque converter must be installed .
2. If the engine speed forTest No.1 was below the

specified engine speed and the engine speed for
Test No. 2 was within specifications, the problem is
probably in the power shuttle or torque converter.
2002-4
TEST NO.2 - HYDRAULIC STALL

1. Engage the parking brake. Understanding the Results of
the Test
2. Start the engine and run the engine at low idle.
1. If the engine speed was below the specified
3. Hold the loader control lever in the In position. engine speed the problem can be in the hydraulic
system or the engine.
4. Increase the engine speed to full throttle.
a. Check the setting of the main relief valve
5. Look at the tachometer and make a record of according to instructions in Section 8002 .
the engine speed.
b. If the main relief valve setting is correct,
6. Return the loader control lever to neutral. the problem is in the engine.
7. Decrease the engine speed to low idle, then 2. If the engine speed is above the specified en-
stop the engine. gine speed, the problem is probably in the hydrau-
lic system, especially if the engine speed in Test
No . 1 was within specifications. See Section 8002
for troubleshooting instructions.
Section
2415
CYLINDER HEAD AND VALVE TRAIN
Written In Clear
And
Simple
English
All measurements and the checks must be made with metric tools to make sure
of an accurate reading when inspecting parts.
J I Case Rae 8- 241 71

A Tenneco Co mpany
2415-2
TABLE OF CONTENTS
SPECIFICATIONS .... . ... ........ .. .... ..... ....... . . .. ...... .................. . ... .. ... . ... . .... 3
SPECIAL TORQUES ....................................... .. .. . . . . . . ... . .... ....... ... ... . ....... 4
SPECIAL TOOLS . .... ... .. ... ...... . ... . . . ... ... . ... ... ..... .... ......... .... . .•.... • .... •. ...... 5
SERVICING THE CYLINDER HEAD AND VALVE TRAIN

Cy linder Head Removal ........ . ... .... . ... . .... ......... . .... . . . ... .. ... ....... ....... .. . . ... 6-16
Cy linder Head Disassembly . ..... . . . .. .. ...... .. ............................ . ....... ......... 17-19
Cy linder Head Assembly .................................... .. . ... ... .. .. .. .... .... ... .. .. ... 32,33
Rocker Arm Disassembly ... . .. ....... . . . . .... . ...... . . ..... . .. .. .............. . .... .....•. . . 34,35
Rocker Arm Assembly . ... ....... . ....... ..... . ..... . .... ...................... .... . ... . ... . .. .. 36
Cylind er Head Installation ..................... . .. .. . ..... .. ... . .... ... . ............. . .. ... .. 37-43
VALVE GUIDE REPLACEMENT . .................................................................. 20
INSPECTION OF THE VALVE AND VALVE SEATS .................. ....... .................... . 21-23
VALVE SEAT INSTALLATION ............................ ........... .. .. ... .. .. .................. 24
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS ................... .. .. .... .. .. 25,26
DIAGNOSIS OF DIFFERENT DYE PATTERNS ............ ........ ............... . .. .. ......... . 27-31
LOCATING TOP CENTER .. .. ....................... .................. .... . . .. .. ................. 43
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE .. ........ ....... ......... .. ... ....... 44-49
Rae 8-24171
2415-3
SPECIFICATIONS
Valve Guide Installation Specifications:
Valve Guide Diameter .. .. . ... . . . .. . .. ....... . .. . ..... .. ....... . .... .. . . ... . ... 14.026 to 14.038 mm
Diameter of Bore . ... ... . .... . . .. ......... .. ........ . . . . ... ... ... .. .. .. . . . .. .. . 13.987 to 14.013 mm
Press Fit .. . .. . . .. . . . . . .. ... . ......... . ...... . .. .. ... .. ... . .. . .... . .. .. .... .. ... . 0.013 to 0.051 mm
Installed Height .. .... .. . . ... .. .. ..... ..... . . ... . .... . .. . .. ... ... . .. .. .. . . . . ..... 11.25 to 11 .75 mm
Exhaust Valve Insert Specifications:
Diameter of Insert .. . . . .... . .. . .... ........ . . .. .. .. . .. . ... . .. ... .. . ..... . ..... . 43.713 to 43.739 mm
Diameter of Bore .. .. ... . ... . .. . .. .. . . .. .. ... . . . .. ... .. . . . .. . . . ... . .. . .. . .. . .. . 43.647 to 43.663 mm
Depth of Bore ... . . . . . . .. . ... . .. .. ...... .... . . . . .... . ... . ... . ... .... ... .. .. . . .. .. 10.10 to 10.30 mm
Press Fit ... ... . . .. . .. . . . . . .. . . .. .. . ..... . .... . . ..... .. ... . ... .. .... .. .... ........ 0.05 to 0.092 mm
Intake Valve Insert Specifications:
Diameter of Insert . . .. .. . .. .... . . . . ... . ... .. . . ...... ... . . . . .. . .. .... . . . . . . . . .. . 47.063 to 47 .089 mm
Diameter of Bore .. ......... . . .. ...... .. ... . .... . . . . . .. . . . . .. . . .. . .. . ... . ... . . . 46.987 to 47.01 3 mm
Depth of Bore . . .... . . .. ... . . .... ...... . ... .. . . ... . . .... ... .... . .... . . .. .... . . . . . 10.30 to 10.50 mm
Press Fit . .... .. . . . .. ... . ....... . .. .. .. .... . . .. .. . .. . . . . .. .. .... . . ... .. . . . . . .. ... . 0.05 to 0.1 02 mm
Rae 8-24 171

2415-4
SPECIAL TORQUES
Bel t Tensioner Bracket Bolts (Allen head) . .. .. ....... . ... . ........ 18 Ib ft 24 Nm
(2.4 kgm)
Belt Tensioner Bolt .. . . .... . ... . . . .. ..... . . .... . ....... . . .. .. . .. . 32 Ib ft 43 Nm

(4.3 kgm)
Exhaust Manifold Bolts ........ .... ... .... .. . .... .... ...... .. . . .. 32 Ib ft 43 Nm
(4 .3 kgm)
Fan Belt Pulley Bracket Bolts ... .. ... . ..... . . . .. . ... .. . . .. . .. .. . . 18 Ib ft 24 Nm

(2.4 kgm)
Fan Belt Pulley Bolts . .. .. .. .. .. . ..... .. ... ...... ... .... .. . .. .. . . 18 Ib ft 24 Nm

(2.4 kgm)
Fuel Filter Housing Nut ... . . . ...... .. . .. ...... . ... . ........ . .... . 24 Ib ft 32 Nm
(3 .2 kgm)
Injector Leak Off Fitting ....... ... . . . .. . ...... .. . .. ........ . . . . ... 4 Ib ft 6 Nm

(0.6 kgm)
Injector Cap Nut ....................... . . .. . .... ....... ... . 41 to 44 Ib ft 55 to 60 Nm

(5.5 to 6.0 kgm)
Cylinder Head Bolts . ...... . ... ... .... .. ... .. . . . ... . . . .. .. ... . ... 93 Ib ft 126 Nm
(12.6 kgm)
Intake Manifold Cover Bolts ... . ... ...... .. . . ...... . . . . .. .. .. .. ... 18 Ib ft 24 Nm

(2.4 kgm)
Rocker Arm Bracket Bolts . . ... . . ... ....... ... .... .. ... . .. . .... .. 18 Ib ft 24 Nm
(2.4 kgm)
Valve Cover Bolts . .. .. .... . ............. .. .. .. ..... . ....... . .. . . 18 Ib ft 24 Nm

(2.4 kgm)
Thermostat Housing Bolts . . . .. .. ... . .. . . ... .. .. . . .... .... . .. .. .. 18 Ib ft 24 Nm

(2.4 kgm)
Alternator Bracket Bolts .... . . .. .. .. ... . . ..... . ... . ...... .... .. .. 18 Ib ft 24 Nm

(2.4 kgm)
Lift Bracket Bolts (Rear) ... . .... . ..... . . .. .. .. ..... ... . . .. .... ... 57 Ib ft 77 Nm
(7.7 kgm)
2415-5
SPECIAL TOOLS
VALVE ADJUSTING TOOL
CAS-10240 VALVE SPRING COMPRESSOR
CAS-1357 VALVE SPRING TESTER
DEPTH MICROMETER
CAS-1 0064-1 M
CAS-10087 BORE GAUGE SET
o TO 25MM MICROMETER
CAS-10285M
VALVE GUIDE CLEANER

CAS-1066A WRENCH
CAS-1694 INJECTION
BORE CLEANER
TORQUE WRENCH LB FT
TORQUE WRENCH INCH POUND
~~'~...~~ .
:''''\.'~ .
~" ·_V"\
... . .. .
THREAD SEALANT WITH TEFLON - B17503 6 ml TUBE CAS-1690 ENGINE TURN OVER TOOL
CAS-1066A WRENCH
2415-6
SERVICING THE CYLINDER HEAD AND VALVE TRAIN

Cylinder Head Removal
STEP 1 STEP 4
Lift the belt tensioner and remove the fan belt. Remove the fan hub bolts .
STEP 2
'-u
.•
•• '
Remove the belt tensioner bo lt. Remove the fan hub.
Remove the belt tensioner. Remove the allen head bolts from the belt ten -
sioner bracket.
2415-7
STEP 10
"
Remove the belt tensioner bracket. Remove the bolts that hold the alternator and re-
move the alternator.
STEP 11
~.
Remove the bracket bolts .
Remove the alternator bracket bolts .
Remove the fan hub bracket.

Remove the alternator bracket.
2415-8
STEP 13 STEP 16
Remove the thermostat housing bolts . Remove the exhaust manifold bolts.
STEP 14 STEP 17
'#"'0\
•
Remove the thermostat housing assembly. Remove the exhaust manifold .
STEP 15 4T-390 ENGINE STEP 18

-----"----.
To remove the turbocharger see section 2465 in Remove the exhaust manifold gaskets and clean
the service manual. the exhaust manifold mounting surface .
2415-9
STEP 19 STEP 22
Disconnect the fuel supply line from the injectors. Disconnect the fuel line from the fuel injection
pump .
STEP 20
STEP 23
,
Install a protective cover over each injector inlet \
and the injection lines. Remove the fuel lines.
STEP 21
STEP 24
~
\.
l~
- '" , --r -
Remove the bolts and clamps that hold the fuel I
lines. Install protective covers on the injection pump out-
let lines and the injection lines. .
2415-10
STEP 25 STEP 28 4T-390 ENGINE
'II,
..;.~ L .
Use two wrenches too loosen the leak off fitting on Remove the leak off fitting and gaskets.
th e injection pump .
STEP 29
STEP 26
r
.'\\~
~ :" >~~~'~-~~
1 ' ''
......-
.
Remove the bolt that holds the clamp for the leak
Rem ove the leak off fitting and gasket. off line.

I
Loosen the leak off fitting and on the injection Loosen the leak off fittings on the fuel injectors.
pu mp.
2415-1 1
STEP 31 STEP 34
Remove the leak off fittings and gaskets. Remove the injectors f rom the cylinder head.
NOTE: Make sure the injector seal is removed

STEP 32 from the cylinder head.
STEP 35
Remove the leak off line.
STEP 33 Use a strap type wrench to remove the fuel filters.
STEP 36
Loosen the nut on the injectors.
NOTE: The injector must not rotate in the bore of

th e cy linder head, this will damage the cylinder Disconnect the fuel line nut on the lift pump.
head.
2415-12
STEP 37
Loosen the fuel line fitting on the filter head . Remove the nut that holds the fuel filter housing.
STEP 38 STEP 41
y:.' ..
Remove the fuel line fitting and gaskets. Remove the fuel filter housing.
NOTE: There are two gaskets on the fuel line fit-

ting. one on each side of the fuel line. STEP 42
STEP 39
Remove the fuel filter inlet fitting.
Remove the fuel line.

2415-13
STEP 43 STEP 46 4-390 ENGINE
I
w r
-tikI •
Loosen the filter outlet fitting. Remove the inlet line.
Remove the filter outlet fitting and gaskets. Disconnect the nut on t he injection pump inlet line.
NOTE: There are two gaskets on the filter outlet

fitting, one on each side of the fuel line.
STEP 45
\: 4-390
I:: ENGINE .;)1.
Remove the inlet line.
Disconnect the two nuts on the injection pump

inlet line.
2415-14
STEP 49 STEP 52
Install a protective cover in the injection pump . Remove intake manifold cover bolts.
STEP 50 STEP 53
Remove the valve cover bolts. Remove the intake manifold cover.
STEP 51
Remove the valve covers . Remove the rocker arm bolts .

2415-15
STEP 55
I j 1
Remove the rocker arm assemblies . Remove the cylinder head bo lts.
STEP 56 STEP 59
Remove the push rods from the cylinder head. Remove the cylinder head .
STEP 60
STEP 57
..,11
..".
Remove the lift bracket bolts and the lift bracket. '.
Remove the cylinder head gasket.
2415-16
STEP 61
Cover the cylinder bores and pistons. Clean all

foreign material from the cylinder head mounting
surface.
NOTE: The cylinders and pistons must be covered

to prevent damage to the pistons and cylinder
walls.
2415-17
Cylinder Head Disassembly

STEP 62 STEP 65
Put the cylinder head on a clean work surface. Remove the valve spring retainers.
STEP 63 STEP 66
_"i!""""'~
Use a valve spring compressor to push down the Remove the valve springs.
valve springs.
STEP 67
STEP 64
.. J
.- ' -
Push down the valve springs and remove the valve
keepers.
Remove the valve seals .
2415-18
STEP 68 STEP 70
Remove the valves. Check the cylinder head surface for warpage. Use
a straight edge and fee ler gauge. Clean the ma-
chined surface of the head . Use a heavy, accurate
STEP 69 straight edge to check for warpage at each side
and between all cylinders. Also, check for end-to-
end warpage in six positions or more.
IMPORTANT: If the measurement is more than

0.762mm, the cylinder head must be machined or
replaced. Replace the cylinder head if the head
height is less than 93.80 mm, after the head is
machined.
STEP 71
Clean the cylinder head completely, removing car-

bon and other deposits. Check for cracks and any
sign of damage in the area of the fire ring contact.
Check the valve guides in three positions with a

bore gauge.
2415-19
STEP 72
Check the bore gauge with a micrometer.
NOTE: If the diameter is more than B.OB9mm, a

valve guide must be installed.
2415-20
VALVE GUIDE REPLACEMENT
Valve Guide Installation Specifications: STEP 74

Valve Guide Outside
Diameter ... . . ...... ... . 14.026 to 14.038 mm
Diameter of Bore . ..... ... . 13.987 to 14.013 mm
Press Fit .. .. .. .. . . ..... .... . 0.013 to 0.051 mm
In stalled Height . . . .. .. . ..... 11 .25 to 11 .75 mm
STEP 73
TOP OF VALVE GUIDE
/
CYLINDER HEAD SURFACE
11.25 TO 11.75 mm
Make a bushing 16.038 mm minimum diameter ID x

11.25 to 11 .75 mm long. Install the bushing over the
valve guide. Push the valve guides into the cylinder
head until the bushing makes contact with the cyl-
inder head surface .
STEP 75
___ 13.987 to 14.013 mm
Ream the new valve guides to a diameter of 8.029

mm ± 0.010 mm with a reamer.
Machine the bore to a diameter of 13.987 to 14.013

mm .
2415-21
INSPECTION OF THE VALVES AND VALVE SEATS

STEP 76
r
STEP 77 (Cont'd)
"NE POTT'.G
D]
NOTE: THIS IS A NORMAL CONDITION.
Small amounts of very fine pitting can be found on

the surfaces of the valve face or seat after the
valves are cleaned. These are normal and will not
change the engine performance. This fine pitting is
Clean the valves with a power driven wire brush. caused by normal oxidation procedure and can
Do not scratch the valve stems. occur on any engine during the run-in period . It is
not necessary to grind valves or seats if this fine
pitting is found, because pitting will generally oc-
STEP 77 cur after the engine is run for several hours.
Check the valves for the following conditions.
VALVE STEM WITH A NARROW NECK HEAVY CARBON AND VARNISH DEPOSITS
~~;;;;;;;;:;;;~l~==:JO[[] 1
NOTE: REPLACE THE VALVE IF THIS CONDITION oc-

CURS .
NOTE: GRIND OR REPLACE THE VAI_VE IF THIS CONDI-
TION OCCURS.
This Condition Can be Caused by:
1. Valve does not have lubrication .
This condition is generally caused by worn valve
2. Restriction in the water passages.
guides or bad seals on the valves, permitting oil to
3. Operating the engine under continued overload
r
go by the valves. Low operating temperature is a
at too much engine RPM .
secondary cause. Worn piston rings and cylinder
walls will also permit too much oil to reach the
GROOVE ,. VALVE FACE
combustion chamber.
RUST OR PITTING ON VALVE STEM

11]
.. .. -, 1
r . ..... .. .
-
/ •• ;...,;,.. ._~ ... ...r' ..' . . . . "
NOTE: GRIND OR REPLACE VALVE IF THIS CONDITION

OCCURS.
NOTE: REPLACE VALVE IF THIS CONDITION OCCURS.
This condition can be caused by foreign material
entering the engine through the intake system or This condition can be caused by using bad quality
not giving service to the air intake system. engine oil or fuel and by not correctly keeping the
engine in storage.
r
2415-22
STEP 77 (Cont'd) STEP 78

RUST OR "HONG IN VALVE FACE II] INTAKE VALVES
_ _ _ _7.960 TO 7.980 mm
NOTE: THIS CONDITION CAN BE CAUSED BY USING BAD

QUALITY ENGINE OIL OR FUEL.
DEEP BURNED VALVE FACE
L _ _ _ _ 7.960 TO 7.980 mm
Check the intake valve stem diameter at three

points along the stem . If the stem diameter is less
than 7.960 mm , the valve must be replaced .
CONCAVE VALVE HEAD

EXHAUST VALVES
NOTE: IF EITHER OF THESE CONDITIONS OCCUR , RE·

PLACE THE VALVES.
_ - - - 7.960 TO 7.980 mm
These conditions are generally caused by running
the engine at very high engine temperatures,
grinding the valve face too thin or valve grinding
that is not correct.
WORN RETAINER GROOVE
1Y Check the exhaust valve stem diameter at two
/~
pOints as shown . If the stem diameter is less than
7.960 mm or the stem tip diameter is less than 7.960
mm, the valve must be replaced .
WORN STEM TIP
NOTE: IF EITHER OF THESE CONDITIONS OCCUR , RE·

PLACE THE VALVE.
Rae 8· 2417 1
2415-23
STEP 79
EXHAUST VALVE WITHOUT REPLACEABLE SEATS
1.52 mm MAX.
INTAKE VALVES WITHOUT REPLACEABLE SEATS
Put the valves in the cylinder head and check to see

if the valve heads are recessed in the cylinder head.
If the valve head is recessed more than 1.52 mm
below the cylinder head surface, the valve must be
replaced or a valve insert must be installed to make
sure that there is equal compression ratios be-
tween cylinders.
241 5-24
VALVE SEAT INSTALLATION

STEP 80 STEP 81
Mach ine the cylinder head to the following specifi-

cation s for valve seats .
Exhaust Valve Seat Specifications:
Diameter of Valve Seat . ... 43.713 to 43.739 mm h CAUTION:Always wear gloves to prevent
Diameter of Bore ... . . .. ... 43.647 to 43.663 mm . . frostbite to your hands when handling
Depth of Bore .. .. . . . . .. . .. . . 10.10 to 10.30 mm frozen parts.
Press Fit .. . . . ....... . . . .... . . 0.05 to 0.092 mm
Intake Valve Seat Specifications: STEP 82
Diameter of Valve Seat . . .. 47.063 to 47.089 mm

Diameter of Bore . . . . . . .. .. 46.987 to 47.013 mm
Depth of Bore . . ...... . . ... . . 10.30 to 10.50 mm
Press Fit . .. . . ... . . ..... . .. . .. 0.05 to 0.102 mm
VALVE
/SEAT
/ BORE
Use a center punch and stake the valve seats in

three positions . Grind the valve seats to the correct
angle .
2415-25
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS

STEP 83 STEP 84
VALVE AND SEAT GRINDING ANGLES
VALVE IDENTIFICATION
The 45 degree exhaust valves are smaller in diame- 44 DEGREE ' " r-
ter than the intake valves. ANGLE '\..
\ "
The 30 degree intake valves are larger in diameter

than the exhaust valves.
30DEG~"""'"
~
ANGLE,REE
---,....,,-~~-
45 DEGREE SEAT 30 DEGREE SEAT
If dimension A and B is less than 1.5 mm the valve

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

light cuts with the grinding stones so just enough
metal is removed to end up with a good smooth
seat finish.
Rae 8- 24171
2415-26
STEP 85 STEP 87
VALVE BLUE DYE

30 DEGREE VALVES
45 DEGREE VALVES
I
.l ",. . f¥
Put a small amount of blue dye on the valve face .
Install the valve in the head and rotate the valve on
the seat.
Correct refacing of valves and seats will give a dye

STEP 86 pattern as shown.
NOTE: If the dye pattern is other than the patterns

shown, check the diagnosis o f different dye pat-
terns on the foJ/owing pages.
Remove the valve and look at the contact area on

the valve face and seat. The blue dye will be gone
from the valve face where the valve made contact
with the seat.
Rae 8-24171
2415··27
DIAGNOSIS OF DIFFERENT DYE PATTERNS

45 Degree Exhaust valves
IF THE VALVE CONTACT AREA ON THE ~ USE A 45 D lEE STONE TO LIFT AND ~ USE A 60 DEGREE STONE TO NARROW ~ CHECK THAT THE VALVE HEAD IS NOT ~ IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT TO MAKE VI R, THE CONTACT AREA. THE LOWER CONTACT AREA, IN- RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
HAS BEEN GROUND). CREASED BY THE 45 DEGREE STONE. LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
SEAT CONTACT AREA ON THE VALVE

TO LOW
~NTACTAREA IF THE VALVE CONTACT AREA ON THE

SEAT LOOKS LIKE THIS.
----. USE A 45 [
CONTACT
'lEE STONE TO LIFT THE
A.
----. USE A 60 DEGRE E STONE TO LIFT AND
NARROW THE LOWER CONTACT AREA.
~ CHECK THAT THE VALVE HEAD IS NOT
RECESSED MORE THAN 1.52 mm BELOW
THE CYLINDER HEAD SURFACE.
~ IF THE VALVE HEAD IS RE-
CESSED MORE THAN 1.52 mm,
REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
IF THE VALVE CONTACT AREA ON THE ----. USE A 45 I ,REE STONE TO LOWER ----. USE A 30 DEGREE STONE TO NARROW ---.. CHECK THAT THE VALVE HEAD IS NOT ~ IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT AND TO M WIDER, THE CONTACT THE UPPER CONTACT AREA, IN- RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm ,
HAS BEEN GROUND). CREASED BY THE 45 DEGREE STONE . LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
It~
~
STALL A VALVE SEAT.

TOO HIGH
/ CONTACT AREA
IF THE VALVE CONTACT AREA ON THE
SEAT LOOKS LIKE THIS.
~ THE VALVE
VALVE SEJ
CAUSE MI
CHANGE T
1ST BE REPLACED AND A
lUST BE INSTALLED BE-
GRINDING WILL NOT
.OWER CONTACT POINT.
Rae 8-24171
2415-28
IF THE VALVE CONTACT AREA ON THE ~ USE A 45 DEGRE i ONE TO INCREASE ~ CHECK THAT THE VALVE HEAD IS NOT ~ CHECK THAT THE VALVE HEAD
SEAT LOOKS LIKE THIS (A SEAT THAT THE CONTACT J ~. RECESSED MORE THAN 1.52 mm BELOW IS NOT RECESSED MORE THAN
HAS BEEN GROUND.) THE CYLINDER HEAD SURFACE. 1.52 mm, REPLACE THE VALVE
-=======
~ =======
AND INSTALL A VALVE SEAT.
' - = - - - - 1 .52 mm-

TO NARROW
IF THE VALVE CONTACT AREA ON THE ~THE VALVE M BE RE-

VALVE SEAT LOOKS LIKE THIS. PLACED AND A V E SEATlN-
CONTACT AREA STALLED BEC ,E MORE
GRINDING WILL r CHANGE
THE LOWER cor :T AREA.
IF THE VALVE CONTACT AREA ON THE ~ USE A 30 DEGR STONE TO LOWER ----+ USE A 60 DEGREE STONE TO LIFT THE ~ CHECK THAT THE VALVE HEAD IS NOT ~ IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT THE UPPER CO" :T AREA. LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
HAS BEEN GROUND). LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
_ ~L
STALL A VALVE SEAT.

TO WIDE.
W
~
IF THE VALVE CONTACT AREA ON THE ~ USE A 30 DEGR STONE TO LOWER ----+ USE A 60 DEGREE STONE TO LIFT THE ~ CHECK THAT THE VALVE HEAD IS NOT ~ IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS. THE UPPER CON :T AREA. LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm,
CONTACT AREA THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
'-0::----1.52 mm-
2415-29
IF THE VALVE CONTACT AREA ON THE ~ USE A 30 DEGI STONE TO MAKE ~ USE A 15 DEGREE STONE TO LOWER ~ CHECK THAT THE VALVE HEAD IS NOT ~ IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT WIDER AND TO fER THE CONTACT THE UPPER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm,
HAS BEEN GROUND). AREA. THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
~ STALL A VALVE SEAT.

TO HIGH.
IF THE VALVE CONTACT AREA ON THE ~ THE VALVE MUS : REPLACED AND A ~ IF THE VALVE HEAD IS RECESSED MORE
SEAT LOOKS LIKE THIS. VALVE SEAT rALLED BECAUSE THAN 1.52 mm, REPLACE THE VALVE
MORE GRINDIN' riLL NOT CHANGE AND INSTALL A VALVE SEAT.
THE LOWER COl CT POINT.
IF THE VALVE CONTACT AREA ON THE ~ USE A 30 DEGF STONE TO MAKE ~CHECK THAT THE VALVE HEAD IS NOT
SEAT LOOKS LIKE THIS (A SEAT THAT WIDER THE CON :T AREA. RECESSED MORE THAN 1.52 mm BELOW
HAS BEEN GROUND). THE CYLINDER HEAD SURFACE .
"-.,..,

TO NARROW
~,
CONTACT AREA
IF THE VALVE CONTACT AREA ON THE ~ THE VALVE MUS' : REPLACED AND A
SEAT LOOKS LIKE THIS. VALVE SEAT I 'ALLED BECAUSE
MORE GRINDIN( ILL NOT CHANGE
THE LOWER COli :T POINT.
Rae 8-241
2415-30
THIS IS THE CORRECT SEAT CONTACT ..... THE CORRECT EXHAUST VALVE CON- ~ 1 DEGREE INTERFERENCE ANGLE ~ CORRECT REFACING OF EXHAUST ~ IF THE VALVE HEAD IS RE-
AREA ON THE VALVE. TACT AREA ON THE SEAT WILL GIVE A VALVES AND VALVE SEATS WILL GIVE A CESSED MORE THAN 1.52 mm
SEAT WIDTH OF 1.47 TO 2.07 mm. 1 DEGREE INTERFERENCE ANGLE. THIS REPLACE THE VALVE AND IN-
, ANGLE IS IMPORTANT BECAUSE THE STALL A VALVE SEAT.
ANGLE GIVES ASSISTANCE IN CUTTING
/ CARBON AND TO SEAT THE VALVES.
/
"
'i, ~/
CONTACT AREA
30 DEGREE INTAKE VALVES ONLY

IF THE VALVE CONTACT AREA ON THE ~ USE A 30 DEGREE ONE TO LIFT AND ~ USE A 45 DEGREE OR 60 DEGREE STONE ~CHECK THAT THE VALVE HEAD IS NOT ~ IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT TO MAKE WIDER· CONTACT AREA. TO NARROW THE LOWER CONTACT RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm
HAS BEEN GROUND). AREA INCREASED BY THE 30 DEGREE LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STONE. STALL A VALVE SEAT.

TO LOW
IF THE VALVE CONTACT AREA ON THE ~ USE A 30 DEGREE ONE TO LIFT THE ~ USE A 45 DEGREE OR 60 DEGRE£ STONE ~ CHECK THAT THE VALVE HEAD IS NOT ~ IF THE VALVE HEAD IS RE·
~~ACTAREA
SEAT LOOKS LIKE THIS. CONTACT AREA. TO NARROW THE LOWER CONTACT RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm
AREA. THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND·
STALL A VALVE SEAT.
"'-=:---1.52 mm -
2415-31
IF THE VALVE CONTACT AREA ON THE - - . USE A 15 DEGRE TONE TO LOWER - - . USEA45 DEGREE OR60DEGREESTONE - - . CHECK THAT THE VALVE HEAD IS NOT - - ' I F THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT THE UPPER CO NT . AREA. TO LIFT THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm
HAS BEEN GROUND). THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
"'" STALL A VALVE SEAT.
'-=---1.52 mm -

TO WIDE
'i, CONTACT AREA

IF THE VALVE CONTACT AREA ON THE
VALVE SEAT LOOKS LIKE THIS.
- - . USE A 15 DEGRE
THE UPPER CONT
TONE TO LOWER
. AREA.
- - . USE A 45 DEGREE OR 60 DEGREE STONE - - . CHECK THAT THE VALVE HEAD IS NOT - - . IF THE VALVE HEAD IS RE-
TO LIFT THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm, BE-
LOW THE CYLINDER HEAD SURFACE.
CESSED MORE THAN 1.52 mm,
REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
THIS IS THE CORRECT SEAT CONTACT THE CORRECT VALVE CONTACT AREA - - . 1 DEGREE INTERI ENCE ANGLE - - . CORRECT REFACING OF THE INTAKE
AREA ON THE VALVE. ON THE SEAT WILL GIVE A SEAT WIDTH VALVE AND VALVE SEAT WILL GIVE A 1
OF 1.32 TO 1.92 mm. DEGREE INTERFERENCE ANGLE. THIS
ANGLE IS IMPORTANT BECAUSE IT
~'
GIVES ASSISTANCE IN CUTTING CAR-
BON AND TO SEAT THE VALVES.
~~ACTAREA -~
2415-32
Cylinder Head Assembly

STEP 88 STEP 90
LETTER v,
~ ~
If you grind the valve seats mark the cylinder head Apply lubrication to the valves. Install the valves in
with the letter " V". the cylinder head.
STEP 89 STEP 91
LETTER X
I
Mark the cylinder head with the letter "X" to indi- Install new valve seals.
cate the following:
X - Oversize Bore STEP 92

XX - Oversize Bore
0.25 mm machined from the cylinder head
or the cyl inder block surface .
XXX - Oversize Bore
0.25 mm machined from the cylinder head
surface.
0.25 mm machined from th e cylinder block
surface.
Check the valve springs with a valve spring tester.

The springs must have these specifications:
Free Length .......... .. ..... ... .. . .. 55.63 mm

Outside Diameter . . ...... .. ..... .... 33.81 mm
Wire Diameter ............... ..... .... 4.88 mm
Number of Coils ..... . ...... ... ........... 7.25
Compresst049.25.mm .. 64t0721b(285t0321 N)
Rae 8-2 417 1

2415-33
STEP 93 STEP 96
4 .A III>
., .....
Install the valve springs. Remove the spring compressor and hit the end of
the valve stems with a soft hammer to seat the valve
keepers.
STEP 94
STEP 97
Install the valve spring caps.
Clean the injector bores with a bore cleaner.

STEP 95
4iIlV@ ,.~ ,m.. ,

Push down the valve springs with a spring com-
pressor. Install the valve keepers.
NOTE: Always install new valve keepers when

new valves are installed.
Rae 8- 24 171
2415-34
Rocker Arm Disassembly

STEP 98 STEP 101
Put the ro ck er arm assembly on a clean work sur- Remove the rocker arms.
face .
STEP 102 ,-
STE P 99
. .-.. .
- •
-,
I
4 .~
"-
Use a micrometer and measure the rocker arm
Remove the snap rings. shaft for out of round. Measure in three different
locations around the shaft. If the rocker arm shaft
is less than 18.938 mm in diameter t he rocker arm
STEP 100 shaft assembly must be replaced.
STEP 103
Remove the washers .
Measure the rocker arm with a bore gauge in three

different locations around th e bore.
Rae 8- 24171
2415-35
STEP 104
"
Use a micrometer to measure the bore gauge. If the
diameter of the bore is more than 19.05 mm , the
rocker arm must be replaced.
Rae 8-24171
2415-36
Rocker Arm Assembly

SNAP RING WASHER
~ / ROCKER ARM
()) @ ~/ ROCKER ARM SHAFT
~ ~/ ROCKER ARM
~
/ eJ@/___ WASHER
().. SNAP RING
STEP 105 STEP 107
LARGE HOLE
Install the rocker arms on the rocker arm shaft with Install the snap rings in the groove on the rocker
the adjusting screws on same end as the large hole arm shaft.
in the bracket.
STEP 106
\,...•
Install the washers on the rocker arm shaft.

-
Rae 8- 2417 1
2415-37
Cylinder Head Installation

STEP 108 STEP 110
Use the correct tap and clean all head bolt holes of Install the cylinder head.
foreign material.
STEP 109
Put a small amount of engine oil on the head bolt

Install the correct head gasket on the engine block, threads . Install the head bolts and wa shers.
see below . Tighten the bolts a small amount.
NOTE: Do not torque the head bolts at this time.
£/0 [b0 [bOo 2b~
°0°0°0°0°°
o
00
000
° ° °
STEP 112
NOTCHES/
Head Gasket Application
No Notches - Standard Gasket

1 Notch - 1.00 mm oversize bore
2 Notches - 1.00 mm oversize bore and
0.25 mm oversize thickness
3 Notches - 1.00 mm oversize bore and Install the push rods in the cylinder head .
0.50 mm oversize thickness
Rae 8-24171
2415-38
STEP 113 STEP 116
Install the rocker arm assembly.

Tighten the rocker shaft bracket bolt to a torque of
STEP 114 18 Ib ft (24 Nm)(2.4 kgm) .
STEP 117
Put a small amount of oil on the threads of the

rocker arm head bolt.
STEP 115
Install a new intake manifold gasket.
STEP 118
Install the intake manifold.

Tighten the cylinder head bolts to the correct tor-
que, following the torque sequence shown above.
Use the following steps to get the correct torque.
Step 1 - torque to 30 Ib ft (41 Nm)(4.1 kgm)
Rae 8-24171
2415-39
STEP 119 STEP 121
.........
I.
Put loctite liquid teflon on the intake manifold Install the rear lift bracket.
bolts.
STEP 122
STEP 120
BOLT TORQUE SEQUENCE
~ FAN
Install the rear lift bracket bolts and tighten to a

torque of 57 Ib ft (77 Nm)(7".7 kgm) .
STEP 123
, ~
Install the intake manifold bolts and tighten to a

torque of 18 Ib ft (24 Nm)(2.4 kgm). following the
torque seq uence shown in the inset.
.. ~ J.
Remove the dust covers from the injection pump
inlet.
Rae 8-24171
2415-40
STEP 124 4-390 ENGINE STEP 127 4T-390 ENGINE
#",
Install the injection pump inlet tube Connect and tighten t he inlet tube.
STEP 125 4-390 ENGINE STEP 128
Connect and tighten the inlet tube nuts. Install the filter outlet fitting and gaskets. Install
one gasket on each side of the tube .
,.
STEP 126 4T-390 ENGINE
I; STEP 129
, t""-
Install the injection pump inlet tube.

Tighten the fuel outlet fitting to a torque of 24 Ib ft
(32 Nm)(3.2 kgm).
Rae 8-241 71
2415-41
STEP 130 STEP 133
&
Install the filter inlet tube. Install the lift pump outlet tube.
STEP 131 STEP 134
Install a new o-ring on the filter housing and install Install the filter housing inlet tube gaskets and
the filter housing. fitting. Install a gasket on each side of the tube.
STEP 132 STEP 135

~
.*:,
.. ri.f •
Install the filter housing nut and tighten to a torque Tighten the filter inlet fitting to a torque of 24 Ib ft
of 24 Ib ft (32 Nm)(3.2 kgm) . (32 Nm)(3.2 kgm).
Rae 8-24171
2415-42
STEP 136 STEP 139
For correct fuel filter installation see the fuel filter Install the front lift bracket.
section.
STEP 140
STEP 137
Install the thermostat housing assembly and bolts.

Install the thermostat in the thermostat housing . Tighten the bolts to a torque of 18 Ib ft (24 Nm) (2.4
The pin in the thermostat must be at the top of the kgm).
thermostat housi ng .
STEP 141
STEP 138
Install the bolts into the exhaust manifold. Install

Install a new seal in the thermostat housing . the exhaust manifold gaskets on the bolts.
Rae 8-24171
24 15-43
STEP 142
I
Install the manifold on the cylinder head. Tighten
the bolts to a torque of 32 Ib ft (43 Nm)(4.3 kgm),
follow the torque sequence shown above.
LOCATING TOP CENTER

STEP 143 STEP 144
Install the engine turn over tool into the flywheel While turning the engine with the turn over tool,
housing . Turn the engine over four revolutions to push the lock pin in . When the lock pin moves into
make sure the push rods are seated correctly. the camshaft gear the engine will be at top center.
Rae 8-24171
2415-44
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE

Cold Setting
STEP 145 STEP 146
.. ~
/
J
•
('
(
,
~.", g!l//('
Check and adjust the intake and exhaust valves as

the arrows show below.
FAN
4 3 2 1
I E I
•
Number one cylinder top center compression
stroke Install the engine turn over tool. Move the engine a
small amount in each direction . Pul l the lock pin
Valve Clearance, Cold: I ntake Valves - 0.010 inch out.
(0.254 mm)
Exhaust Valves - 0.020 inch
(0.508 mm)
Rae 8-24171
2415-45
STEP 147 STEP 148
Turn the engine one complete revolution. Put new seals on the injectors and install the injec-
tors .
Check and adjust the intake and exhaust valves as
the arrows show below.
FANt STEP 149
4 3 2 1
~~~~
..........
""""
Number four cylinder top center compression
stroke .
Valve Clearance, Cold: Intake Valves - 0.010 inch

(0.254
Exhaust Valves - 0.020
mm)
inch
. ~
Tighten the injector nut to a torque of 41 to 441b ft
(0.508 mm) (55 to 60 Nm)(5.5 to 6.0 kgm).
STEP 150
Install the leak off line.
Rae 8-24171
2415-46
STEP 151 STEP 154
Install the leak off line tittings and gaskets. Tighten Remove the protective covers from the injection
the fitting to a torque of 4 Ib ft (6 Nm)(O.6 kgm). pump and injectors. Install the injector lines.
STEP 152 STEP 155
Install the leak off fitting and gaskets on the injec- Connect the injector line nut to the injection pump
tion pump. and tighten .
STEP 153 STEP 156
Tighten the leak off fitting. Connect the injector li ne nut to ttle injector and
tighten .
Rae 8-24 171

24 15-47
STEP 157 STEP 160
J.
,'. u~., f~, ".,~_::"", ,-, ';,j:.,"'I:j:::'·" :", '~ ~, ""',,%; - ,, ' ._ '
Put loctite liquid teflon on the injection line bracket Tighten the bracket bolts to a torque of 18 Ib ft (24
bolts . Nm)(2.4 kgm).
STEP 158 STEP 161
Install the fuel line bracket. Install the alternator bracket and tighten the bolts
to a torque of 18 Ib ft (24 Nm)(2.4 kgm).
STEP 159
STEP 162
"
"-"'-',,,,., ,~
. .: ., .
, '" ",';~ '--; .'.--. , ,

,w'>"-'· "'-""_.'
.X<
.:l/~:"')}Y'
"'\""
.. .:
Install the bracket and tighten.

Install the alternator and tighten the bolts .
Rae 8-24171
2415-48
STEP 163 STEP 166
.."",.....
Install the fan belt pulley bracket and tighten the Install the belt tensioner and tighten the bolt to a
bolts to a torque of 18 Ib ft (24 Nm)(2.4 kgm). torque of 32 Ib ft (43 Nm)(4.3 kgm).
STEP 164 STEP 167
Install the belt tens ioner bracket and tighten the Lift the be lt tensioner and install the· fan belt.
allen head bolts to a torque of 18 Ib ft (24 Nm)(2.4
kgm).
STEP 168 4T-390 ENGINE
STEP 165
L _ __
To install the turbocharger, see section 2465 in the

service manual.
Install the fan belt pulley and tighten the bolts to a
torque of 18 Ib ft (24 Nm) (2.4 kgm).
Hac 8-241 71
2415-49
STEP 169 ~TEP 171;.."

Start and operate the engine. Check engine oil
pressure indicator to make sure of correct engine
oil pressure . Check the rocker arms to make sure
that the arms are receiving oil.
, ' .
STEP 170 "'" ....

'"">;', .•, - '
, ,
'""~." ~ .-
....
Install new o-rings on the valve cover bolts.
'. ",,,,
STEP 172
%
,',
" :;";'"
,=-.,~
,',
":'" 9!.
~
Install new gaskets on the valve covers.
Install the valve cover bolts and tighten to a torque

of 18 Ib ft (24 Nm)(2.4 kgm).
Rae 8-24171
This Page is Blank

tion to install them on units previously sold.
•
•
CYLINDER BLOCK
Crankshaft, Pistons, Rods, Sleeves, Camshaft,
Bearings, Seals and Flywheel
Written In Clear
And
Simple
English
Rae 8-24181
J I Case
A Tp n npr.n l,nm niln V
2425-2
TABLE OF CONTENTS
SPECIFICATIONS • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4-5
SPECIAL TORQUES .. .. ..... .......... .. ..... . .......... . .. . .... . .. . . .. . ... .. ........ .. . ....... 5-6
SPECIAL TOOLS . .... ....... .. . ... .... .... ................. ... ...... ............. . ....... . . ... . . 7-9
SERVICING THE ENGINE BLOCK

Front Oil Seal Replacement . .. ....... . . . . .... .. .... ... . . ........... . . .. .. ... . ................ 10-14
Rear Oil Seal Replacement ..................................... .. .. .. ............. . .. ........ 14-19
Front Oil Seal and Wear Sleeve Installation . . . ... . .......... .. ............... . ......... ....... 20-23
Rear Oil Seal and Wear Sleeve Installation ................................... .. .. ... . . . . ..... . 24-28
Removal of Pistons and Rods ....... ... .. ... . . ............................................... 29 ,30
Cylinder Wall Inspection .... . .. . ......................................................... . .. . 31-34
RECONDITIONING THE 4-390 CYLINDER BLOCK

Recond itionin g the Cylinder Block for Oversize Pistons . .... ........ ...... . . . .... . . ... . . ...... . ... 35
Reconditioning the 4-390 Cylinder Block for Sleeves ...... • ....... ..•.. . .... .. •. ....... . . . ... .. 36 ,37
Piston and Connecting Rod Disassembly and Inspection ............ . ......... . ............ .. .. 38-40
Piston Assem bly ...... ..... .. ....... . ........ ... . .... .. .... . .. ...... . ......... . . . . ........ .. 41-45
REPLACEMENT OF MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT

Removal ... . . ....... ....... ......... . .... . .................. . ...... . . ......... . . ..... . .. . . ... 46 ,47
Installation .. . ................................................................. . ... . . .. ...... 47,48
CRANKSHAFT AND MAIN BEARINGS

Removal ................. ... .......................... . ................. . .. . .. . ..... . ....... 49-56
Gear Removal .... ........ .... ... .. ............ . ... ... . .. ... .... .... .. ... . ...... .. ....... . ..... . 56
Inspection ... ... . .......... ... . ....... . ....................................... . ..... . .......... 57
Gear Installation .. . ............. . .......... . .................................................. . 58
Installation ......... . .. . . .. ... ............................... . .......... . ..... . .. .. . . .. ... .. 59-68
Rae 8-2418 1
2425-3
TABLE OF CONTENTS (Continued)

CAMSHAFT
Removal .. . . .. ..... . . . . ... . .. . . . ..... .. ...... ... ... .. . . . . . . .. ... . .... .. . ..... ... .. . ... ... . . . 68-71
Bore Inspection .. . ............. .. . . . ... . .. . . .......................... . . .... . .. . .. . . ... .. . .. 71-72
Bushing Removal and Installation .. .. . ... . . ... . . . . . .. . . . .. . . . .... ...... . . .. ... .. ... . . ....... .. .. 72
Valve Li fter Inspection ............ . ...... . . . ...... . .. .... . ... . ... . . .. .. .. . . .... .. ..... ... .... 72 ,73
Disassembly and In spection ... . .. ... .... . . .. . . ... . ... . . . .. .. ..... • .. . ........ . .. . . .. . . .. ..... 73,74
Gea r Installation .. .. .. . ..... . ... . .......... . . ...... . . . ... . .. .. . . ... .. . .. . .. . ... .... . .. ..... . ... 74
Installati on . . ....... . ... . ....... . .... .... . ........................ . .. .. . . .. . . . . . .. . . ... . ... . 75-80
FLYWHEEL
Removal . .. ........... ... .... . . .. ... .. .. . .. ... . ... .. . . ...... . . .. ... ... . ...... . . .. . ......... .... 81
Ring Gea r Removal and Installation ... . ....... . .. . . .. ... . ..... . . .... . . . ..... .. ....... .. ... ... .. . 81
Installation .. .. . ... . ... ..... .. . . . . ..... ... . . . ........... . ...... .. . . .. . .. . .... .. ...... .. . .. . .. . . 81
TACHOMETER DRIVE
Removal and Disassembly .. • ..... .•. . . .................. . ...... .. . .. ... . ...... .. .. . .. . ....... .. 82
Assembly and Installation . .. . .... . . .. . . . .... . . .. .. . . .... . .. . ... . .. . . .. . . ..... . . . .. . . .... ... ... .. 83
Rae 8-24181
2425-4
SPECIFICATIONS
CYLINDER BLOCK
ID of Cylinder . .... . ... .... .. . ........ . . .................. ......... ........ . ... 102.00 to 102.04 mm
Maximum Service Limit ...... .... ...... . ... . ................. . ... ......... . ... . . . ...... 102.116 mm
Maximum Cylinder Out of Round ... ... ....... ......... . .. .. . . .... ... .. . .... .. . . ......... . 0.038 mm
Maximum Cylinder Taper .......... .... . .... ....... ..... . .......... .. ... . .. .. .. . ... . ..... 0.076 mm
Machine Cylinder Block Bore to ............. .... .. .. .................... .. . . . 102.50 to 102.59 mm
Machine Cylinder Block Bore to ..... . ................................. . ... ... 103.00 to 103.04 mm
CYLINDER SLEEVE
Machine Cylinder Block Bore to . . . ......... . . . .. .......... . ..... . ..... . .. .. . 104.500 to 104.515 mm
Machine Cylinder Sleeve Bore to ... ......... ... .. . . .. ... . .... . . ............... . 102.00 to 102.04 mm
PISTON
OD 12 mm From the Bottom , 90 Degrees from Piston Pin ...... ... ..... . ..... . . 101.873 to 101.887 mm
Minimum Service Limit . ... .... . .............. ... .. ...... . .. ...... .. . . .. .. .. .. .. .. ... 101.823 mm
ID of Piston Pin Bore ..... . ... . .................................. . ...... ... . ... 40.006 to 40.012 mm
Maximum Service Limit ... ....... ........... .... . .... . ....... ..... . . . ................. 40 .025 mm
PISTONS RINGS
No.1 Compression
End Gap in 102.02 ID Cylinder . .. ............ . ................................ . ... 0.25 to 0.55 mm
Maximum Service Limit . ..... ............................................... .. .... .. . 0.806 mm
Side Clearance .......... ... . ... ... .............. .. ...... .. .. ...... . .... .. ..... 0.075 to 0.120 mm
Maximum Service Limit .. ... .......................... . .. . ..... .. ....... . ... . ... . ..... 0.15 mm
No.2 Compression
End Gap in 102.02 ID Cylinder . .. .. .. . ..... ... ................ ...... ..... . .......... 0.25 to 0.55 mm
Maximum Service Limit ... .... . . . . ......................................... ..... ... .. 0.806 mm
Side Clearance ... ... ........... .... .. .. . . . .... . ... ...... .. .................... 0.075 to 0.1 20 mm
Maximum Service Limit .... ..... •. .... .................. . . ................ . . . ..... .... 0.15 mm
No. 3 Oil Control Ring
End Gap in 102.02 ID Cylinder . ... ... . ... .. ..................... .. ........... . . ... 0.25 to 0.55 mm
Maximum Service Limit ......... .. ... . ............................ .. ................ . 0.806 mm
Protrusion Above Cylinder Block (Maximum) .................................... ..... . . . . 0.660 mm
PISTON PIN
OD of Pin .. .. ... ... ... ................................ .. .. ..... ............... 39.997 to 40.003 mm
Minimum Service Limit ..... .. ................. . . ...... . . .. ....... ... . ....... ... . ..... 39.990 mm
CONNECTING ROD
Bushing ID Installed ................... . ................... . .. . ...... . ......... 40 .053 to 40 .067 mm
Maximum Service Limit .. ... . ...... . .... ........................ .. . ............. ..... . 40.092 mm
Journal ID Without Bearing Liners ...... . ........ .. ... ... .. ... ......... .. ...... 72.987 to 73.013 mm
Bearing Oil Clearance ............................. .. . . ......................... . 0.038 to 0.116 mm
Maximum Service Limit ...................................... .. ........................ 0.129 mm
Side Clearance .............. . ... .. .......... ..... .. .................. . .......... 0.100 to 0.300 mm
Maximum Service Limit .... ...................... . ....... . ........... . . .. .............. 0.330 mm
Rae 8-24181
2425-5
SPECIFICATIONS (Continued)
CRANKSHAFT
End Clearance , Center Main Bearing Cap . . ... . . ... . .. . .. . .. .. . .. . . .... ... . .... . . . 0.041 to 0.119 mm
Center Ma in Bearin g Th rust Surface Thickness . ... . ... .. ..... .. .. .. .. ... .. ................. 2.50 mm
Connecting Rod Journal Standard 00 . .. . . .. . ..... . .. . .... .. . ... . .. . . . ..... . .. . 68 .987 to 69 .013 mm
Maximum Service Limit .. .... .. ..... ...... ... .. . ..... ... ..... . ........... . .. ... . . .. . .. 68 .962 mm
0.25 mm 00 Undersize, Grind to .... . . ... .. . ... .. . .. ...... ... . . . . ........ . ... 68.737 to 68 .763 mm
0.50 mm 00 Undersize, Grind to ... . . .. . ...... . .. . . .. . . ...... . ...... .... .. . . . 68.487 to 68.513 mm
0.75 mm 00 Undersize, Grind to ... . . ... . .. ... .. .. . ... . . .. . .. . . . .... ........ . 68. 237 to 68.263 mm
100 m lTl 00 Undersize, Grind to . .. . . .. .. . . ..... .. . .. .. . . ..... .... ... .. ... . . . . 67 .987 to 68 .01 3 mm
Connecting Rod J ournal Max ilTlum Taper . .. . .. . .. .. . ....... . .. .. . .. . .......... . .. . .. . ... . 0.013 mm
Connecting Rod Journal Out of Round Maximum . . .. .. . . .. . .. . ... . . .. . .... . . . . . . .. . .. . ... 0.050 mm
Main Bearing Oil Clearance . . .. ... ... ........ . .... . ... .. ........ .. ... . . ... . . ..... 0.041 to 0.119 mm
Max imulTl Service Limit .. . .. .. ... ... . . . . .. . ... .. ... . . .. . . .... . . . . . ... .. . .. . .... . .. .. . . . 0.140 mm
Mai n Bea ring Jo urn al Standard 00 ... .. . .. .... . . .. . . . . . .... . ...... .. .......... 82 .987 to 83 .013 mm
Max im um Serv ice Limi t . .. . ... ..... .... .. . ..... . .. .. . . ... . . .. . . ... . . . . ... . . . .. .. . . . .. . 82.962 mm
0.25 mm 00 Und ersize, Grind to ... . .. . ........ . .. .. . .. . ....... .. ...... . . . . . . 82 .737 to 82.763 mm
0.50 mm 00 Undersize, Grind to . ... . ... .. .... .. . . ....... . . .. .... .... . ....... 82 .487 to 82.513 mm
1.00 mm 00 Undersize, Grind to .. .... .. . .. . . . ... . . . . ... . ... ......... .. . . ... . 81 .987 to 82 .013 mm
Main Bearing Journal Bore 10 No Liners . ...... . .. . . ..... .. . . .... . . . . .. .. .. . . ... 87 .982 to 88.018 mm
Max imu m Serv ice Limit . ...... . ..... . . . ...... . . . .... .. ............. ............ ... .... 88 .031 mm
CAMSHAFT
10 of Bu shing In stalled ... . ... ..... .. . .... . .... . ......... . . . . . . . . . .. ... .. . . .. .. 54.089 to 54.151 mm
Maximum Service Limi t ..... ......... ... . ... ... . .. .. . . . . . ... . . .... .... . . . ............. 54 .151 mm
10 of Cam shaft Bo re ....... . . .. ............ .. .. .. .. .... . .......... . . .. . .• . .... 54.089 to 54 .139 mm
Max imum Service Limit ... ........ ...... ... ..... .. .. .......... .. ............. . .... ... . 54 .164 mm
00 of Each Camshaft Bearing Surface ... . ... .. . . ....... . ......... . ..... . . ..... 53 .987 to 54 .013 mm
Min ilTl um Servi ce Lim it .. ..... ... ....... . ............ .. ...... .... ..... . ....... ... .... . 53 .962 mm
Camshaft Th rust C learan ce .... ....... . ....... . . .. ..... . . ...... . .... . ..... .... . . .. . 9.42 to 9.58 mm
Minimum Service Limit . ... .. ... . ... . . . . . . . ... . . . . ... ..... .. . .... . .. .... .......... . .. . . . 9.34 mm
GEAR TRAIN BACKLASH
C ranksh aft Gea r to Camshaft Gear . ........ . ..... .......... .. . ... . . . . . . .. .. ... . . . . . 0.08 to 0.33 mm
Maximu m Servi ce Limit (All Gears) . .. .. ..... ...... ..... . .. . ... . ......................... 0.45 mm
SPECIAL TORQUES
Belt Tens io ner Bolt ......... ... . .. . . ... .. . .. . . ... . .. .. .... .. .. ... 32 Ib ft 43 Nm
(4 .3 kgm)
Camsh aft Plate Bo lts ... . . . • . . . . .... • ...... . . .. .. ... .. .. . .. . .. . . . 18 Ib ft 24 Nm

(2.4 kgm)
Co nn ectin g Rod Bolts ... . ....... . . .. . . .. . ..... . . . ... . ... .. ... . .. 74 Ib ft 100 Nm
(10 .0 kgm )
Crankshaft Pull ey Bo lts . .. . ....... ... .... . . .... .. . . . .......... .. 101 Ib ft 137 Nm
(13 .7 kgm)
Fan Pulley Bracket Bo lts ...... .. .... ... ..... .. ....... ..... .. . ... . 18 Ib ft 24 Nm
(2.4 kgm)
Fan Pulley Bolts ........ . ........ . ............... ...... .. . ...... . 18 Ib ft 24 Nm

(2.4 kgm)
Rae 8-24181
2425-6
SPECIAL TORQUES (Continued)
Flyw heel Bolts . .. .... . . . . .... . . . .. .. . ..... . . . . . .... . . . .. . . . . . . . 101 Ib ft 137 Nm

(13.7 kgm )
Flywheel Housing Bolts . .. .. . ........ .. . . ...... . . . . . ... . .. . . .... . 44 Ib ft 60 Nm

(6 .0 kgm)
Fuel I nlet Nut ... . .. . .... . . .. .. .. .. .. .. . ..... ... . . . ... . . . .. .. .. . . 24 Ib ft 32 Nm

(3.2 kgm)
Injection Pump Nut . .... . .. .. .. . . . . . . . . . . ..... . .. . . . .... . . . . . .... 48 Ib ft 65 Nm

(6.5 kgm )
Injection Pump Lock Bolt . .. .. . . ...... . . ... . ....... . ... . . ... . . . . . 22 Ib ft 30 Nm

(3.0 kgm )
Injection Pump Mounting Nuts . .. . .. ... .... . . . .... . .. ... . .. ... . .. 18 Ib ft 24 Nm

(2.4 kgm)
Injection Pump Bracket Bolts . . . . .. ... . . .... .... ........ . . . .. . .. . 181b ft 24 Nm

(2.4 kgm)
Fro nt Cover Bolts .. ..... . ........... . . . . . . .. .. . . .... .... . . .. . ... 18 Ib ft 24 Nm

(2 .4 kgm)
Front Housing Bolts .... . .. . . .. . . . .. . . . . . .... .. . .. . . .. . . . . . . . . .. . 18 Ib ft 24 Nm

(2.4 kgm )
Cylinder Head Bolts . .. . ... . .... . . .. .. .. .. . ........... . ....... ... 93 Ib ft 126 Nm

(1 2.6 kgm)
Main Bearing Bolts . .. ........ . . . . . . . . . .. . . . . . . .. ... . . .. . . ... ... 129 Ib ft 175 Nm

(17.5 kgm )
Oi l Suction Tube Bolts . ... . . ... . .... .... . ... .... . . . . . ... .. . .. . . . 18 Ib ft 24 Nm
(2 .4 kgm )
Seal Carrier Bolts . . . . . ... . .... ... . ... . . .. . .. .. . ... . .. .. . .. . . . .. . . 7 Ib ft 9 Nm

(0.9 kgm)
Starter Retaining Bolts . . .. .. . . .... . . . .. . . ... ...... . .. .. .... . .. .. 32 Ib ft 43 Nm

(4.3 kgm )
Fuel Inlet Bolts . . ... ..... . ... . .. . .. .... . .... . . . . . .... .. . . . . . . . . . . 24 Ib ft 32 Nm

(3.2 kgm)
Fuel Outlet Bolt . . . ... . . . . ... ... . ... .. .. ...... . . . . . . ... ... .. . ... . 24 Ib ft 32 Nm
(3.2 kgm )
Rae 8-24181
2425-7
SPECIAL TOOLS
Crankshaft Seals and Wear Sleeve
WEAR SLEEVE INSTALLATION TOOL

/ ' (INCLUDED IN KIT)
/oo/,O INSTALLATION TOOL
IN SEAL KIT,
PROTECTIVE
SLEEVE
~
;,~
I /
INSTALLATION TOOL
(INCLUDED IN SEAL KIT) WEAR SLEEVE IINSTALLATION TOOL
(INCLUDED IN KIT)
PROTECTIVE SLEEVE
REAR SEAL KIT FRONT SEAL KIT
TORQUE WRENCH LB FT
Cylinder Block and Cylinder
CAS-1690 ENGINE TURN OVER TOOL CAS-10056M

OUTSIDE MICROMETER
CAS··10063M
CAS-1358 RIDGE REAMER
INSIDE MICROMETER
Rae 8-24181
2425-8
SPECIAL TOOLS (Continued)
Cylinder Block and Cylinder (Continued)
o mm TO 125 mm
BORE AND TAPER GAUGE
FEELEB GAUGE
(METRIC)
CYLINDER HONE
CAS-1 0064-1 M
DEPTH GAUGE
80 TO 150 GRIT STONE
250 TO 300 GRIT STONE
Pistons, Connecting Rods, Connecting Rod Bearings and Main Bearln!~s
CAS-10063M
INSIDE MICROMETER TORQUE WRENCH LB FT
CAS-10133
BEARING OVEN/ HEATER
CAS-10056M OUTSIDE MICROMETER
CAS-1 0066-1 A
DIAL INDICATOR
Rae 8-24181
2425-9
SPECIAL TOOLS (Continued)
Camshaft
CAS-10063M
INSIDE MICROMETER
CAS-1 0066-1 A
DIAL INDICATOR
CAS-1 0056M
OUTSIDE MICROMETER
CAS-10133
BEARING OVEN/ HEATER
"" TORQUE WRENCH LB FT
CAS-1063
BUSHING PULLER
Flywheel
TORQUE WRENCH LB FT
Rae 8-24181
2425-10
SERVICING THE ENGINE BLOCK

Front Oil Seal Replacement
STEP 1 STEP 4
!
,, •
•
(-
Case 4-390 Engine. Remove the tachometer drive.
STEP 2 STEP 5
.,,'.
.' '·,w.
,oW" .' .
·>c·-
•
,
J. " ..
,.
.,.0.,.
•
.'
,-~
'W"',
Case 4T-390 Engine. Remove the bolts from the crankshaft pulley and
remove the crankshaft pulley.
STEP 3
STEP 6
" """"";;.-
.'
•
1
Lift the belt tensioner and remove the fan belt.
Remove the front cover bolts and remove the front
cover.
Rae 8- 24181
2425-11
STEP 7 STEP 10
Clean th e mounting surfaces of all foreign materi- Clean the seal surface with loctite safety solvent .
al.
STEP 8
~ \l
"' , Install two guide bolts (M8 x 1.25 x 75 mm).

Clean the crankshaft seal surface with loctite safe-
ty solvent.
IMPORTANT: The seal surface on the crankshaft

must be free of all oil and grease to prevent dam-
age to the oil seal.
STEP 9
Install a new front cover 9asket.
Remove the seal from the front cover.
Rae 8-24 181

2425-12
STEP 13
Install the front cover . Tighten the front cover bolts to a torque of 18 Ib ft
(24 Nm)(2.4 kgm).
STEP 17
Install the front cover bolts. Do not tighten the

bolts. Remove the installation tool.
STEP 15 $TEP 18
Install the seal insta llation tool into the front cover Put loctite 277 on the outside surfacl3 of the seal.
with the small diameter toward the engine. This
will center the front cover with the crankshaft.
Rae 8-24181
2425-13
STEP 19 STEP 22
J
Carefully install the protective sleeve and seal on Remove the seal installati on tool.
the crankshaft. Push the seal on the crankshaft
until the seal makes contact with the seal surface.
STEP 23
,STEP 201
Install the crankshaft pulley.
Remove the protective sleeve.
STEP 21
fffi
•ii~ Install the crankshaft pulley bolts . Tighten the
JiM . bolts to a torque of 1011b 1t (137 Nm)(13.7 kgm).
Insta!1 the installation tool and push the seal to the
correct depth . The seal will be at the correct depth
when the outside diam eter of the installation tool
makes contact with the front cover.
Ra e 8-24181
2425-14
STEP 25 STEP 26
,. "",
•
...
( . • J
Install the tachometer drive. Lift the belt tensioner and install the fan belt.
Rear Oil Seal Replacement

P 27
•
(\
Remove the engine oil pan. See Section 2445 for oil Remove the starter from the flywheel housing .
pan removal.
STEP
STEP 28
1
r~
- ,
• •
>.
" \. ~
f Remove the bolts from the flywheel.
Remove the bolts that hold the starter to the fly-
wheel housing .
Rae 8-24181
2425-15
STEP 31 STEP 34
'1
Remove the flywheel from the flywheel housing. Remove the bolts from the seal carrier.
STEP 32 STEP 35
Remove the bolts from the flywheel housing.

.. \.
Remove the seal carrier from the crankshaft.
STEP 33 STEP 36
Remove the flywheel housing from the engine Clean the mounting surfaces of all foreign materi-
block al.
Rae 8-24181
2425-16
STEP 37 STEP
.
;
40
Remove the seal from the seal carrier. Install two guide bolts (M6 x 1.00 x 50 mm) .
STEP 38 STEP
'i!!! •
41
.
,
. --,
rh
Clean the seal su rface with loctite safety solvent. Insta~1 a new seal carrier gasket.
STEP 39
.,
..
Clean the seal surface on the crankshaft with loc- Install the seal carrier.
tite safety solvent.
IMPORTANT: The crankshaft sealing surface

must be free of all oil and grease to prevent dam-
age to the oil seal.
Rae 8-24181
2425-17
Install the seal carrie r bo lts and remove the guide Remove the seal installatio n tool.
bolts . Do not tighten the seal carrier bolts.
STEP 44
Install the seal and protective sleeve over the

Install the seal install ation tool into the seal carrier crankshaft until the outside diameter of the seal
with the small diameter toward the engine . This makes contact with the seal carri er.
will center the seal carrier to the crankshaft.
STEP 48
STEP 45
.
Tighten the seal carrier bolts to a torque of 71b ft (9
Nm)(O.9 kgm).
Remove the protective sleeve.
Rae 8-24181
2425-18
STEP 49 STEP 52
Install the seal installation tool with the small diam- Install the flywheel housing.
eter toward the seal.
STEP 50
Install the flywheel housing bolts and tighten the

Push the seal into the seal carrier until the outside bolts to a torque of 44 Ib ft (60 Nm)(6.0 kgm).
diameter of the seal installation tool makes contact
with the seal carrier.
4
Install the flywheel on the crankshaft.
Remove the seal installation tool.
Rae 8-241 8 1
2425-19
STEP 55 STEP 57
'M'·
,',.,-
'1-
~} ' .
;~,
1
Install the flywheel retaining bolts and tighten the Install the starter retaining bolts and tighten the
bolts to a torque of 101 Ib ft (137 Nm)(13.7 kgm) . bolts to a torque of 32 Ib ft (43 Nm)(4.3 kgm) .
STEP
,.
56 .
Install the starter into the flywheel housing. Install the engine oil pan . SI3e Section 2445 for oil
pan installation.
Ra e 8-24 181
2425-20
Front Oil Seal and Wear Sleeve Installation

Used when crankshaft flange is worn and standard seal does not stop oil flow .
STEP 59
1.
Lift the belt tensio ner and remove the fan belt. Remove the front cover bolts.
STEP 60
(.
Remove the tachometer drive. Remove the front cover.
STEP 61
Rem'o~the bolts from the crankshaft pulley and Clean the front cover mounting surfaces of all for-
remove th e crankshaft pu lley. eign material.
Rae 8-24181
2425-21
STEP 65
Remove the oil seal from the f ron t cover. Put the seal installation tool on the oil seal. The
small diameter of th e sea l installation tool must be
toward the seal.
STEP 66
STEP 69
Clean the seal surface with loctite safety solvent.
Push the seal into the cover unt il the outside diam-
STEP 67 eter of the installation to ol makes contact with the
cover.
Put locti te 277 on the outside diameter of the seal

surface and install the seal in the front cover.
Clean the crankshaft with loctite safety solvent.
NOTE: The seal surface must be free of al/ oil and

grease to preven t damage to the oil seal.
Rae 8-24181
2425-22
STEP 71 STEP 74
Install the wear sleeve on the crankshaft with the Install two guide bolts (MB x 12.5 x 75 mm).
flange toward the engine.
STEP 75.
'.: J$"&""
STEP 72 ;r$
Install a new front cover gasket.

Install the wear sleeve installation tool over the
wear sleeve. Push the wear sleeve on the crank-
shaft until the flange makes contact with the face STEP 76
of the crankshaft gear.
STEP 73
Carefully install the front cover.
Remove the wear sleeve installation tool.
Rae 8-241 81
2425-23
STEP 80
Install the front cover bolts and tighten the bolts to Install the tachometer drive.
a torque of 181b ft (24 Nm)(2.4 kgm).
STEP 81
Lift the belt tensioner and install the fan belt.

Install the crankshaft pulley .
STEP 79
Install the crankshaft pulley bolts and tighten the

bolts to a torque of 101 Ib ft (137 Nm)(13.7 kgm).
Rae 8-2418 1
2425-24
Rear Oil Seal and Wear Sleeve Installation

Used when the crankshaft flange is worn and standard seal does not stop oil flow.
STEP 85
Remove the engine oil pan . See Section 2445 in the Remove the bolts from the flywheel.
service manual for oil pan removal.
STEP 83
Remove the flywheel from the flywheel housing .

Remove the bolts that hold the starter to the fly-
wheel housing .
STEP 87
STEP 84
Remove the flywheel housing bolts .
Remove the starter from the flywheel housing .
Rae 8-24181
2425-25
STEP 88 STEP 91
Remove the flywheel housing. Remove the sea l from the sea l carrie r.
STEP 89 STEP 92
Remove the bolts f rom the sea l carr ier . Clean the seal surface with loctile safety so lvent.
STEP 90 STEP 93
Remove the seal carrier from the crankshaft. Install the seal in th e seal carrier.
Rae 8-24 181

2425-26
STEP 94 STEP 97
-,,,,-,
.,. :C",
,
Install the seal installation tool. Push the seal into Install the wear sleeve installation tool on the wear
the seal carrier until the outside diameter of the sleeve.
seal installation tool makes contact with the seal
•
carner.
.w,·
o ;;",.,
STEP 95
<
---~-
joY.'_ .
/
Push the wear sleeve on the crankshaft until the

flange of the wear sleeve is even with the rear seal
Clean the crankshaft sea l surface with loctite safe- surface on the crankshaft.
ty solvent.
IMPORTANT: The wear sleeve flange must be
even with the rear seal surface of the crankshaft.
STEP 96
'is!:'
:~'-'
STEP
. ••
,-",
Put the wear sleeve on the crankshaft with the

flange toward the engine .
Remove the wear sleeve installation tool.
Rae 8-24181
2425-27
STEP
l o.
. ,,..•
.
;,..;
"C>. . ,_:
.' .. ;
Clean the seal surface with loctite safety solvent. Carefully install the seal carrier.
IMPORTANT: The crankshaft seal surface must

be free of all oil and grease to prevent damage to
the sea/.
.,#.m ' ''' -
. ': .... -. .
Install the seal carrier bolts and tighten the bolts to
a torque of 7 Ib ft (9 Nm )(0.9 kgm).
STEP 105
Install two guide bolts (M6 x 1.00 x 50 mm).
I ,•
.." ~.
Install the flywheel housing .
In stall a new seal carrier gasket.
Rae 8-24 181

2425-28
STEP 109
."'"
Install the flywheel housing bolts and tighten the Install the starter in the flywheel ho using .
bolts to a torque of 44 Ib ft (60 Nm)(6.0 kgm).
STEP 110
STEP 107
Install the starter bolts and tig hten the bolts to a

Install the flywheel on the crankshaft. torque of 32 Ib ft (43 Nm )(4.3 kgm) .
STEP 108
Install the flywheel bolts and tighten to a torque of Install the engine oil pan . See Section 2445 in the
101 Ib ft (137 Nm)(13.7 kgm). service manual for oil pan installation .
Rae 8-2418 1
2425-29
Removal of Pistons and Rods

STEP 115
\.I-.---RIDGE--_
·,1
Remove the manifolds and cylinder head from the Remove the carbon from the top of the cylinder
engine. See Section 2415 of the service manual for walls. Check the cyl i nder walls for a ridge at the top
removal. of the ring movement zone. A ridge will cause dam-
age to the piston when the piston is removed . A
ridge will have to be removed with a ridge reamer.
STEP 113
STEP 116
, \
L "
Remove the engine oil pan and inlet tube. See
.
Section 2445 of the service manual for removal.
Install a ridge reamer into the cylinder.
STEP 114
.... ""
11 4
f'
...
tw
Check the side clearance of the piston connecting
rods . Replace the connecting rods ifthe side clear- Remove the ridge from the cylinder walls.
ance is more than 0.330 mm.
Rae 8-24 181

2425-30
STEP 118
Put a mark on each rod cap for cylinder identifica- Remove the rod cap.
tion .
'+ ,J
$' t Remove the pistons from the top of the engine
Put a identification mark on each piston for assem- block .
bly .
STEP 120
•
Remove the rod cap bolts .
Rae 8-24181
2425-31
Cylinder Wall Inspection
STEP 12:3 Scoring on Cylinder Walls

Inspect th e cylinder walls for the following condi-
tions.
Normal Wear
A smooth surface with some of the cross-hatch

pattern showing between the upper and lower lim-
its of the ring movement area shows normal wear.
There will always be a small amount of wear pre-
sent because of combustion pressure moving the
top ring against the cylinder wall.
Normal wear shows acceptable cylinder wall con-

ditions and the cylinder need not be machined.
Worn Cylinder Wall
Scoring on cylinder walls is caused by metal mov-

ing from one location to a diffl~rent location. This is
shown by heavy vertical lines. The vertical lines are
caused by metal coming in contact with the piston .
The scoring can be in one specific area or it can
occur the complete length of the piston movement.
If this condition is present , the cylinder must be
mach ined and the piston and rings replaced .
A smooth surface between the upper and lower

limits of the ring movement area shows a worn
cylinder wall because of normal wear and th e cyl-
inder must be machined.
Rae 8-24181
2425-32
STEP 124
Dusted Cylinder
Measure the cylinder wall bore for taper as follows :

1. Measure the bore parallel to the crankshaft at the
top end of the ring travel zone .
2. Measure the bore in the same position at the
bottom end of the ring travel zone.
3. Measure the bore at right angles to the crank-
shaft at the top end of the ring travel zone .
bottom end of the travel zone.
Compare the results of the measurements (1) and
Too much area in the piston ring movement area (3) with (2) and (4), to find out if the bore has taper.
shows a dusting failure. To measure use a inside micrometer, bore gauge
or taper gauge. If the taper is more than 0.076 mm ,
A dusting failure will cause the following : bore the cylinder.
1. Lower area of piston wall will show wear.
2. Too much piston ring groove wear.
3. Too much piston ring side clearance.
4. Washed away areas of the piston ring lands
where the aluminum will be gone.
S. Piston rings will have too much face contact and
wear which can be seen as a reduction in radial
width and increase in end gap.
6. Chrome piston rings will show wear through the
face . The chrome will be worn off the face and
base iron can be seen .
7. The cylinder heads can have smooth intake
parts and worn valve guides.
All of these conditions are caused by dirt which is

mixed with the intake air.
Rae 8-24181
2425-33
STEP 125 STEP 127 4-390 ENGINE
Removing g laze can be done by using a cylinder

hone with 250 to 300 grit stone.
Too much glaze (s mooth surface) on cylinder

walls of a new engine or an eng ine with an overhaul
is caused by run-in procedure that is not correct.
Measure the cyl in der wall bores for out-of-round Glaze does not permit the piston rings to seat cor-
as follows: rectly in the cylinder sleeves . This will cause
1. Measure the bore parallel to the cranks haft at the too much oil consumption.
top end of the ring travel .
2. Measure the bore in the same position at the Too much glaze on the cylinder walls can be pre-
bottom end of the ring travel. vented by giving you r custo mer in structi ons in the
3. Measure tile bore at right angles to the cran k- correct run- in procedu re. See Section 1024 in th e
shaft at the top end of the ring travel. se rvi ce manua l fo r th e correct run-in procedure .
bottom end of the ring travel.
Compare the measurements (1) and (3) to fi nd the

out-of-round wear at the top end of the bore .
Compare the measurements (2) and (4) to find the

out-of-round wear at the bottom of the bore.
If out-of-round is more than 0.038 mm , bore the

cylinders.
STEP 126 4-390 ENGINE

IMPORTANT: Before removing glaze, cover the
crankshaft iourna ls with a clean cloth to preve nt
abrasives and dirt caused by the cylinder hone
from falling on the crankshaft.
Rae 8-24181
2425-34
STEP 128 4-390 ENGINE STEP 129 4-390 ENGINE
Use a 3/ 8 inch or 1/ 2 inch drill to power the cyl i nder

hone. Use a lubricant/coolant with the hone to
keep the hone and the stones free of foreign mate- After removing the glaze, clean the cylinder walls
rial . with a clean cloth , warm water and a mild deter-
gent soap . After cleaning the cylinder walls, clean
Start the hone at the top of the cylinder bore and the cylinder walls again with clean engine oil.
actuate the hone up and down until the correct
cross-hatch pattern is reached. The correct cross- NOTE: Clean the cylinder walls until a clean white
hatch pattern is 40 to 60 degrees from horizontal. cloth keeps completely clean, one cleaning opera -
tion is not enough.
Use a 80 to 150 grit stone to reach the correct
cross-hatch pattern . IMPORTANT: Do not use gasoline, diesel fuel or
kerosene to clean cylinders because these materi-
Use a 250 to 300 grit stone to reach the correct als will not remove the abrasives from the sleeve
cylinder bore finish . surface.
Rae 8-24 181

2425-35
RECONDITIONING THE 4-390 ENGINE CYLINDER BLOCK

Reconditioning the Cylinder Block for Oversize Pistons
NOTE: Many of the photographs in this section show a cylinder block that has been cut in half for photo-
graphic purposes.
STEP 130 STEP 132
The cylinder block must be disassembled before Machine the cylinder bore to a diameter of 103.00
the cy linder can be machined for oversize pistons. to 103.04 mm for the 1.0 mm oversize pistons. See
Step 133 for the correct procedure to hone the
cylinder bore .
STEP 131
STEP 133
Machine the cylinder bore to a diameter of 102.50

to 102.59 fo r the 0.5 mm oversize pistons. See Step
133 for the correct procedure to hone the cylinder
bore .
Use a 3/8 or 1/ 2 inch drill to power the hone. Use a
lubricant/coolant with the hone to keep the hone
and the stones free from foreign material .
Start the hone at the top of the cylinder bore and

cross-hatch pattern is reached. The correct cross-
hatch pattern is 40 to 60 degrees from horizontal.

cross-hatch pattern.

cylinder bore finish .
Rae 8-2418 1
2425-36
Reconditioning the 4-390 Engine Cylinder Block for Sleeves

STEP 134 STEP 137
The cylinder block must be disassembled before Freeze the cylinder sleeves and push the cylinder
the cylinder block can be machined for sleeves. sleeves in the bore until the sleeve makes contact
with the ridge at the bottom of the cylinder bore.
STEP 135 NOTE: You must freeze the cylinder sleeves be-
fore installation.
A CAUTION:Always wear gloves to prevent

. . frostbite to your hands when handling
frozen parts.
STEP 138
Measure 6.35 mm up from the bottom of the cylin-

der bore. Put a mark on the cylinder at the 6.35 mm
'I. "
measu rement. .,,;..,..~
~~ ;c\.
, BLOCK SURFACE
STEP 136
~
c'
If the cylinder sleeve is not even with the cylinder

block surface, the sleeve must be machined.
NOTE: The cylinder sleeve must be even with the

cylinder block.
Machine th e cylinder bore to the measured depth

in Step 135 to a diameterof104.500to 104.515 mm.
IMPORTANT: Do not bore the cylinder beyond

the measured depth.
Rae 8-24181
2425-37
STEP 139 STEP 141
Measure the diameter of the piston sleeve with a

bore gauge.
STEP 140
Start the hone at the top of the cylinder bore and

cross-hatch pattern is reached . The correct cross-
hatch pattern is 40 to 60 degrees from horizontal.

cross-hatch pattern.

cylinder bore finish.
Measure the bore gauge with a micrometer. The

cylinder diameter must be machined to a diameter
of 102.00 to 102.04 mm .
Rae 8-241 81
2425-38
Piston and Connecting Rod Disassembly and Inspection

STEP 142
Put the piston assembly on a clean work surface. Remove the connecting rod.
STEP 143 STEP 146
Remove the piston pin retaining ring . Remove the fi rst and second compress ion rings.
STEP 144
Remove the piston pin from the piston . Remove the oil ring .
NOTE: The oil ring is a two piece ring.
Rae 8- 24181
2425-39
STEP 148 STEP 150
Measure the piston pin bore . If the piston pin bore

is more than 40 .025 mm the piston must be re-
placed .
STEP 151
'\
•
Measure the inside diameter of the connecting rod

for wear and out-of-round . If the inside diameter is
more than 40 .092 mm the connecting rod must be ~
replaced.
.~
Measure the diameter of the piston across the
STEP 149 thrust face 12 mm from the bottom of the piston, at
right angles to the piston pin holes. Replace the
piston if the diameter is less than 101 .823 mm .
STEP 152
Measure the diameter of the piston pin . If the diam-

eter is less than 39.990 mm the piston pin must be
replaced.
Break an old piston ring in half and use the broken

ring half to clean the piston ring grooves. Too
much deposit in the ring grooves can force the
rings out and will cause scoring .
Rae 8-241 8 1
2425-40
STEP 153 STEP 155

,.
Check the side clearance of the oil ring in the Clean the piston holes with a small drill or fine wire.
piston . Insert a feeler gauge between the upper
surface of a new ring and the piston lands to check
the clearance. Replace the piston if side clearance
is more than 0.13 mm.
STEP 154
Check the side clearance of the first and second

compression rings . Replace the piston if the side
clearance is more than 0.15 mm .
Rae 8-24181
2425-41
Piston Assembly
STEP 156 STEP 159
Put the piston rings in the cylinder and check end Install the first compression ring on the piston . The
gap. Replace the piston rings if the end gap is more piston ring must be installed with the side marked
than 0.806 mm. TOP toward the top of the piston to give good oil
control.
STEP 157
NOTE: The top piston ring on the 4 T-390 engine is
a key stone type ring.
STEP 160
SPECIAL LAP - - _ , f , V
Install the oil ring . I nstall the spring first and the oil
ring second.
NOTE: The spring must be between the oil ring The first compression ring, in a replacement set of
and the piston. rings , must have a special lap design on the sur-
face that contacts th e cylinder wall.
STEP 158
STEP 161
Install the second compression ring. The piston

ring must be installed with the side marked TOP
toward the top of the piston to give good oil con- Rotate the piston rings so that the ring ends are
trol. separated by 120 deg rees .
Rae 8-24181
2425-42
STEP 162 STEP 165
Install the connecting rod in the piston. The num- Apply lubrication to the pistons , piston rings and
ber on the connecting rod must be opposite of the cylinder walls , using clean engine oil.
number on the piston.
NOTE: Install the pistons in th e correc t bore.
STEP 163
STEP 166
Install the piston pin.

Install a ring compressor on the piston.
STEP 164
STEP 167
Install the piston pin retaining rings.

Carefully push the piston down into the cy linder.
IMPORTANT: Make sure that th e arrow on top of

the piston is toward the front of the engine.
Rae 8-24181
2425-43
STEP 168 STEP 170
&Ill'
, ~:f*~ ~ ~
Measure tIle connecting rod journals on the crank- Install the liners. The liner locks must be in align-
shaft. Measure the front and rear of each journal, ment.
checking for taper , If the taper is more than 0,013
mm, reconditioning of the journals must be done, NOTE: When installing the liners, make sure that
the liner locks are in alignment. Use a sliding type
movement when installing I'he liners. Never push
STEP 169 on the center of the liner locks.
The connecting rod journals must be checked

again , 90 degrees from the first measurements for
out-of-round . If out-of-round is more than 0.050
mm, reconditioning of the journals must be done. Clean the connecting rod journals and the rod
bearing liners. Put a piece of plastigage on the
bearing cap journal or the journal on the crank-
shaft.
Rae 8-241 81
2425-44
STEP 172 STEP 174
iil'!aiII......... '.J
Install the bearing caps. Remove the bearing caps and check the clearance
The clearance must be between 0.038 mm to 0.12!
NOTE: Make sure that the number on the bearing mm. If the clearance is more than 0.129 mm , under
cap is the same as the number on the connecting size bearing liners must be installed and recondi·
rod. tioning of the bearing journals must be done b)
grinding .
,.
STEP 173 NOTE: A clearance of 0.038 mm to 0.116 mm h
required when installing new bearing liners.
Lubricate the connecting rod bolts with clean en-

gine oil and torque the bolts. See below.
Torque Sequence:
Step 1 - Torque to 37 Ib ft (50 Nm)(5 .0 kgm) Apply lubrication to the bearing liners before in-
Step 2 - Torque to 74 Ib ft (100 Nm)(10.0 kgm) stallation, using clean engine oil.
Rae 8-24181
2425-45
STEP 176 STEP 178
Lubricate the connecting rod bolts with clean en- Use a dial indicator to check piston protrusion .
gine oil and torque the bolts. See below. The piston protrustion mu~;t not be more than
0.660 mm above the cylinde r block .
Torque Sequence:
Step 1 - Torque to 37 Ib ft (50 Nm)(5.0 kgm)
STEP 17i'
.... Ii
I i .:
Install the cylinder head and manifold. See Section
2415 of the service manual.
~
Install the engine oil inlet tube. See Section 2445 of
the service manual for the inlet tube and the oil pan
installation .
Ra e 8-24181
2425-46
REPLACEMENT OF THE MAIN BEARINGS

WITHOUT REMOVING THE CRANKSHAFT
Removal
STEP 182
Remove the engine oil pan and gasket. See Section Remove the bolts from the main bearing cap.
2445 of the service manual.
NOTE: Remove only one cap at a time to prevent
the crankshaft from moving.
STEP 181
STEP 183
&
Remove the bolts from the oil inlet tube. See Sec-
tion 2445 of the service manual for the oil inlet tube
removal. Remove the main bearing cap .
Rae 8-24181
2425-47
STEP 184
-,.
r
~
To remove the front main bearing liner, use a thin

piece of plastic to push the bearing liner out.
Installation
STEP 185
.-r. • • -
Put a new bearing liner in the, bearing cap.

.
Put a new bearing liner on the crankshaft. Use a NOTE: Make sure the bearing liner locks are al-
thin piece of plastic to push the bearing liner in igned when installing the linElrs. Slide the liner in
position. position. Never push on the center of the liners.
STEP 186
Install the bearing cap and torque the mounting

Put a piece of plastigage on the crankshaft journal. bolts. See below .
Torque Sequence:
Step 3 - Torque to 129 Ib ft ("175 Nm)(17.5 kgm)
Rae 8-241 81
2425-48
STEP 189
- ..
Remove the bearing cap and check the clearance .
Clearance must be 0.041 to 0.140 mm. New liners
- ~
lubrication to the cap bolts. Install the cap

bolts and torque. See below .
must be installed if the clearance is more t ha n
0.140 mm . Torque Sequence:
NOTE: The crankshaft must be machined if the Step 2 - Torque to 86 Ib ft (116 Nm)(11.6 kgm)
clearance is more than 0.11 9 mm with the new Step 3 - Torque to 129 Ib ft (175 Nm) (17 .5 kgm)
liners.
STEP 192
STEP 190
•
. ~
Install a new oil inlet tube gasket. See Section 2445

Add lubrication to the bearing liners and install the of the service manual for the installation of the oil
bearing cap . in let tube.
STEP 193
Install the oil pan . See Section 2445 of the service

manual.
Rae 8-24181
2425-49
CRANKSHAFT AND MAIN BEARINGS

Removal
STEP 197
, '",7"
Il ,;
Remove the cylinder head , See Section 2415 of the Remove the oil pan , See Section 2445 in the service
service manual for cylinder head removal. manual for oil pan removal.
STEP 195 STEP 198

~'1,-
Remove the crankshaft pulley bolts, Remove the oil inlet tube bolts, See Section 2445
for the oil inlet tube removal.
STEP 196
STEP 199
"~~,
("-
Remove the crankshaft pulley, Remove the tachometer drive assembly,
Rae 8-24181
2425-50
STEP 200 STEP 202
Remove the front cover bolts.
STEP 201
Turn the engine over with a engine turn over tool

and push the lock into the camshaft gear.
' f
Remove the front cover.

STEP 203 4-390 ENGINE
~
Loosen the injection pump lock bolt, move the slot

washer over the lock bolt, tighten the lock bolt to a
torque of 22 Ib ft (30 Nm)(3.0 kgm) .
NOTE: The slot washer will be loose after the lock

bolt is tightened.
Rae 8-24181
2425-51
Remove the injection pump and primer pump . See

Section 3412 in the service manual.
STEP 207
Loosen th e injection pump lock bolt and remove

the slotted tab was her.
STEP 205 4T -390 ENGINE Remove the lifter cover bolts .
STEP 208
.I -'
Tighten th e inj ec ti on pump lock bolt.
r
Remove the lifter cover.
Rae 8-24181
2425-52
STEP 209
Remove the breather cover. Remove the bolts that hold the camshaft thrust
plate.
STEP 210
STEP 213
Clean the lifter cover mounting surfaces of all for-

eign material. Remove the camshaft thrust plate .
STEP 211 STEP 214
PINS
Install pins to hold the lifters in place. Remove the camshaft.
Rae 8-24181
2425-53
STEP 215 STEP 218
Remove the front housing bolts . Remove the bolts that hold the starter to the fly-
wheel housing.
STEP 216
STEP 219
Remove the front housing.

Remove the starter.
STEP 217
STEP 220
I"
Clean all mounting surfaces of foreign material.

Remove the flywheel bolts.
Rae 8-~4181
2425-54
STEP 221 STEP 224
Remove the flywheel. Remove the bolts from the seal carrier.
STEP 222 STEP 225
Remove the flywheel housing bolts. Remove the seal carrier.
STEP 223 STEP 226
Remove the flywhee l housing . Clean the seal carrier mounting surfaces of all for-
eign material.
Rae 8-24181
2425-55
STEP 227 STEP 230
Remove the bolts from the connecting rod bearing Remove the bolts from the crankshaft main bear-
caps. ing caps .
STEP 228 STEP 231
Remove the connecting rod bearing caps. Each bearing cap has a number for assembly iden-
tification .
STEP 229 STEP 232
Remov e th e pistons and connecting rods. Remove the crankshaft main bearing caps .
Rae 8-24 181

2425-56
STEP 233 STEP 234
•
USED FAN BELTS
•
\ 1
I""
,
_ ......- - - - - -'
Remove the crankshaft from the engine , Remove the main bearing liners from the engine .
Crankshaft Gear Removal

STEP 235 STEP 236
~-
ji/I[ "t
-
•
Pull the gear off the crankshaft. Remove the pin from the crankshaft if the pin has
been damaged,
Rae 8-24181
2425-57
Crankshaft Inspection
STEP 237 STEP 239
Measure the main bearing journals to see if the

.... ""
Measure the connecting rod journals for taper.
journals are worn. Measure the front and rear of Measure the front and rear of each journal. Grind
each journal. If the diameter is less than 82.962 mm the journals if the taper is more than 0.013 mm .
grind the crankshaft journals.
NOTE: Grind the crankshaft journals undersize STEP 240

0.25 mm, 0.50 mm, 0.75 mm or 1.00 mm, if the
crankshaft journa ls are worn more than 0.025 mm.
STEP 238
Check the connecting rod journa ls again, 90 de-

grees from the first measurements (Step 239) for
out of round. Grind the journals if out of round is
more than 0.050 mm .
Measure the main bearing journals, again, 90 de-

grees from the first measurements (Step 237) for
out of round. If the out of round is more than 0.050
mm , grind the journals and use undersize liners.
Rae 8-24 181

2425-58
Crankshaft Gear Installation

STEP 241 STEP 243
Install the heated gear on the crankshaft.

Heat the crankshaft gear for a minimum of 25 min-
utes at· 250 0 F (121 0 C). Use a bearing heater oven .
Install the crankshaft gear pin.
Rae 8-24181
2425-59
Crankshaft Installation
STEP 244 STEP 247
USED FAN BELTS
/
Clean the oil spray nozzle with a small wire. If the Install the cran kshaft in the engine block .
nozzle is damaged it must be replaced.
-,
STEP 245
Install the liners in the bearing caps. Make sure the

Install the bearing liners. liner locks are aligned . Use a sliding type move-
ment when installing the liners. Never push on the
center of the liners.
STEP 246
STEP 249
Add lubrication to the bearing liners. Use clean

engine oil.
Clean the main bearing journals and put a piece of
plastigage on the journals to check main bearing
oil clearance.
Rae 8-24181
2425-60
STEP 250 STEP 253
Make sure the number on main bearing cap is in

the correct number sequence as shown above. Check the main bearing oil clearance. ClearancE
must be 0.041 to 0.140 mm . If the clearance is more
than 0.140 mm undersize bearing liners must be
installed. Install new undersize liners which will
STEP 251 give a clearance of 0.041 to 0.119 mm.
NOTE: If the clearance is more than 0.140 mm the
crankshaft must be machined.
STEP 254
Install the main bearing cap bolts and tighten to a

torque of 129 Ib ft (175 Nm)(17 .5 kgm).
STEP 252 Add lubrication to the liner. Use clean engine oil.
Remove the main bearing caps.
Add lubrication to the cap bolts. Install the cap

Torque Sequence:
Step 1 - Torque to 43 Ib ft (58 Nm)(5 .8 kgm)
Step 2 - Torque to 86 Ib ft (116 Nm) (11.6 kgm)
Rae 8-24181
2425-61
STEP 256 STEP 258
k~
Install the front housing.
STEP 259
·hY ""' ' ' '
Put a dial indicator on the crankshaft gear. Check

the crankshaft end clearance. The end clearance
must be 0.137 to 0.264 mm. If the clearance is more
than 0.332 mm, replace all the main bearing liners.
",
Install the front housing bolts and tighten to a
torque of 18 Ib ft (24 Nm)(2.4 kgm).
NOTE: To get an accurate reading, use a pry bar
between the crankshaft and the number two and
number four main bearing caps as shown above. STEP 260
Add lubrication to the camshaft bearing journals.

Use clean engine oil.
Install a new front housing gasket.
Rae 8-241 81
2425-62
STEP 261 STEP 264
Make sure the timing marks on the crankshaft and Put a dial indicator on the camshaft gear. Check
camshaft are aligned. the backlash between the camshaft gear and the
crankshaft gear. Backlash must be 0.08 to 0.33
mm . If backlash is more than 0.33 mm the gears
STEP 262 must be replaced .
NOTE: Too much backlash can also be caused by

a worn camshaft bushing.
STEP 265
- ~------
Install the camshaft thrust plate behind the cam-
shaft gear.
STEP 263
"\ ~
Remove the pins from the lifters .
Install the thrust plate bolts and tighten to a torque

of 18 Ib ft (24 Nm)(2.4 kgm) .
Rae 8-24181
2425-63
STEP 266
Install two guide bolts. Install the lifter cover .
STEP 267 STEP 270
• •
Install the breather cover. Install new seals on the lifter cover bolts.
STEP 268 STEP 271

.-.......,....,.........
...."...~
Install a new gasket on the lifter cover. Install the lifter cover bolts and tighten to a torque
of 9 Ib ft (12 Nm ) (1 .2 kgm) .
Rae 8-24181
2425-64
STEP 272
.. - .
.... - Clean the crankshaft seal surface of all oil and

Install the injection pump and the hand primer
pump . See Section 3412 in the service manual. grease using Loctite safety solvent. See seal instal-
lation in this section for the front crankshaft.
STEP 273
STEP 276
,
'.
.,
Install two guide bolts (M8 x 1.25 x 75 mm).
Install the tachomoter drive assembly.
STEP 274
STEP 277
2
Install a new front cover gasket. ,-

Clean the rear crankshaft seal of all foreign materi-
al, using loctite safety solvent. See seal installation
in this section for installing the rear crankshaft
seal.
Rae 8-24181
2425-65
STEP 278 STEP 280
••
Add lubrication to the cylinder walls and piston Carefully push the piston down into the block.
rings . Use clean engine oil.
IMPORTANT: Make sure that the word FRONT is
toward the front of the engim~. Make sure the cor-
STEP 279 rect connecting rod is in the correct cylinder.
-jt'
STEP 281
,
r,
,
Install a ring compressor on the piston.
NOTE: MakEl sure the piston rings are in the

grooves to the maximum before tightening the ring Install the bearing liners on the connecting rods
compressor. Tighten the ring compressor, a little and rod caps.
at a time, making sure the rings are free to be
pushed in. IMPORTANT: Make sure thE! liner locks are al-
igned when installing the liners. Use a sliding type
movement when installing thl~ liners. Never push
on the center of the liners.
Rae 8-24181
2425-66
STEP 282 STEP 285
"
Clean the connecting rod journals and the bearing Remove the bearing caps and check tile clearance.
liners. Put a piece of plastigage on the rod cap liner The clearance must be 0.023 to 0.089 mm. If the
or the rod journals . clearance is more than 0.114 mm , undersize bear-
ing liners must be installed and reconditioning of
the bearing journals must be done. Install new
STEP 283 bearing liners which will give a clearance of 0.023
to 0.089 mm.
STEP 286
I ~-
Install the bearing caps.
NOTE: Make sure the number on the bearing cap

is equal to the number on the connecting rod.
lubrication to the bearing liners. Use clean
engine oil.
Torque the connecting rods . See below.

Rae 8-24181
2425-67
STEP 287 STEP 290
~
Add lubricat ion to the rod bolts. Install the rod Install the flywheel housing .
Step 1 - Torque to 37 Ib ft (50 Nm)(5.0 kgm )

STEP 288
Install the flywheel housing bolts an

Install a new oil inlet tube gasket. See Section 2445

for oil inlet tube installation.
STEP 289
Install the flywheel and tighten the retaining bolts

to a torque of 101 Ib ft (137 Nm)(13.7 kgm).
Install the engine oil pan. See Section 2445 for oil
pan installation.
Rae 8-24 18 1
2425-68
STEP 293 STEP 294

\
Install the crankshaft pulley and tighten the retain- Install the cylinder head. See Section 2415 for in
ing bolts to a torque of 101 Ib ft (137 Nm)(13.7 stalling the cylinder head .
kgm) .
CAMSHAFT
Removal
STEP 297
Loosen th e fan pulley bolts. Remove the fan pulley bolts and the fan pulley .
STEP 296 STEP 298
"-
Disconnect the fuel lines and remove the injection
pump . See Section 3412 in the service manual.
Rae 8-24181
2425-69
STEP 299 STEP 302
Remove the bolts from the cylinder head covers. Remove the rocker arm assemblies .
STEP 300 STEP 303
Remove the cylinder head covers . Remove the push rods .
STEP 301 STEP 304
Remove the bolts from the rocker arm assemblies . Remove the gasket and clean the surface of all
foreign material.
Rae 8- 241 81
2425-70
STEP 305 STEP 308
•
Remove the bolts from the lifter cover. Raise the lifters and install retaining pins to hold
the lifters in place , when the camshaft is removed.
STEP 306
STEP 309
, ......
•
.f
Remove the lifter cover .
Remove the bolts from the camshaft thrust plate .
STEP 307
Remove the breather cover.
Rae 8-24181
2425-71
STEP 310 STEP 313

Q
',m
. ,,....., .
~
• t ,'I' ,
t'
Remove the camshaft thrust plate .
.• ,
Measure the camshaft bores. Use a bore gauge.
The bores must be measured in two positions .
Take a second measurement 90 degrees from the
STEP 311 first measurement.
•
NOTE: The crankshaft and pistons have been re-
moved for photographic purposes. These parts do
not have to be removed to service the camshaft.
STEP 314
,
......
Remove the camshaft from the engine block .
Camshaft Bore and

Bushing Inspection
STEP 312
If t he bushing diameter is more than 54 .146 mm,
the front camshaft bushing must be replaced .
Remove the engine oil pan. See Section 2445 in the

service manual.
Ra e 8-24181
2425-72
STEP 315 STEP 317
If the intermediate or the rear bores are more than Install the bushing on the puller. Align the oil
54.1 46 mm , disassemble the engine block and line holes. Pull the bushing into the cylinder block until
bore the bores. See Section 1024 in the service it is even with the housing.
manual for machining dimensions.
Valve Lifter Inspection
Camshaft Bushing Removal
STEP 318
and Installation
Remove the retaining pins from the lifters and re-

move the lifters.
NOTE: The crankshaft and pistons have been re-

Put a bushing puller in the engine block and pull moved for photographic purposes.
the bushing out of the cylinder block.
STEP 319
...
BORE GAUGE Y
Measurp. the lifter bores. Use an expandable bore

gauge.
Rae 8-24181
2425-73
STEP 320 STEP 323
If the diameter of the lifter bore is more than 16.055 Install the lifters in the block and fasten in position
mm the engine block must be replaced. with retaining pins .
STEP 321 Camshaft Disassembly

and Inspection
STEP 324
Measure the outside diam eter of the valve lifter

stem. Replace the valve lifters if the outside diame-
ter of the lifter stem is less than 15.936 mm.
Press the gear off the camshaft.

STEP 322
STEP 325
Put clean engine oil on the lifters before installa-

tion.
Remove the shaft key .
Rae 8-24181
2425-74
STEP 326 Camshaft Gear Installation
STEP 328
Measure the front and rear of each bea ring surface

on th e cams haft. Use a micrometer.
Install the shaft key .

STEP 327
STEP 329
Each bearing surface must be measured in four

positions . Measure the front and rear bearing sur-
faces again, 90 degrees from the first measure- Heat the camshaft gear a minimum of 45 minutes at
ment. a temperature of 250° F (121 ° C) . Use a bearing
heater oven.
NOTE: Replace the camshaft if the outside diame-
ter of any bearing surface is less than 53.962 mm. STEP 330
Install the camshaft gear on the camshaft with thE

lock pin hole down .
Rae 8-241 81
2425-75
Camshaft Installation
STEP 334
STEP 331
.... .....
Lubricate the camshaft bearing surface with clean Install the camshaft thrust plate bolts and tighten
engine oil. to a torque of 18 Ib ft (24 Nm)(2.4 kgm) .
STEP 332 STEP 335
i
Align the timing marks on the camshaft with the Check the camshaft end clearance with a dial indi-
timing mark on the crankshaft . cator. The end clearance must not be more than
0.130 to 0.470 mm . If the clearance is more than
0.470 mm the camshaft thrust plate must be re-
STEP 333 placed.
Install the camshaft thrust plate.
Rae 8-24181
2425-76
STEP 336 STEP 339
1' .
I
Put a dial indicator on the camshaft gear and check Install the oil breather cover.
the gear clearance between the camshaft gear and
the crankshaft gear. Gear clearance must be 0.076
to 0.330 mm. The gears must be replaced if the STEP 340
clearance is more than 0.450 mm.
NOTE: Too much gear clearance can also be

caused by worn camshaft bushings.
STEP 337
Install a new gasket on the lifter cover.
STEP 341
Remove the retaining pins from the lifters.
STEP 338
Install the lifter cover.
Install two guide bolts (M8 x 1.25 x 75 mm) .
Rae 8-24181
2425-77
STEP 342 STEP 345
.,-- ,.
,
'"
(
•
-
M ' .. 1111'1 I",
•
Install new seals on the lifter cover bolts.

-
Install the injection pump on the front
•
hou~ing.
See Section 3412 in the service manual for injec-
tion pump installation.
STEP 343
STEP 346
Install the lifter cover bolts and tighten to a torque

of 9 Ib ft (12 Nm) (1 .2 kgm) .
ty solvent. See front seal installation in this section.
STEP 344
STEP 347
• ~.t
..
-
,
.',
~\
Install a new injection pump housing gasket.
If the engine oil pan was removed, see Section

2445 in the service manual for installation.
Rae 8-24181
2425-78
STEP 348 STEP 351

\
Install the front crankshaft pulley and tighten the Install the rocker arm assemblies.
bolts to a torque of 101 Ib ft (137 Nm)(13.7 kgm) .
STEP 352
STEP 349
M~
..
,
)}.
.~!. "",~
-,~- ,
>
~.
1. ..
(. ,
Install the head bolts that hold the rocker arm as-
Install th e tachometer drive assembly. sembly and tighten the bolts to a torque of 93 Ib ft
(126 Nm)(12.6 kgm).
STEP 350
STEP 353
~
Install the push rods . \
Install the rocker arm bracket bolts . Tighten the
bracket bolts to a torque of 18 Ib ft (24 Nm)(2A
kgm) ,
Rae 8-24181
2425-79
Adjust the valve clearance. See Section 2415 for

adjusting the rocker arm to valve clearance. the fuel injectors.
..
See Section 3413 in the service manual to install
STEP 355 4-390 ENGINE STEP 358
See Section 3412 in the service manual to install Install the fan pulley and bolts. Tighten the bolts to
the injection pump fuel lines. a torque of 18 Ib ft (24 Nm)(2.4 kgm) .
See Section 3412 in the service manual to install Lift the belt tensioner and install the fan belt.
the injection pump fuel lines.
Ra e 8-24181
2425-80
STEP 360 STEP 362
, ~
",' -
_-~ .• iL'
Install new gaskets on the valve covers and install I nstall the valve cover bolts and tighten to a torque
the valve covers . of 18 Ib ft (24 Nm)(2.4 kgm) .
STEP 361
-' ;,
~:''*'' '
~: '
Install new seals on the valve cover bolts .
Rae 8-24181
2425-81
FLYWHEEL
Removal
STEP 363 STEP 366
Y'
•
•
Remove the bolts from the flywheel. Heat the new ring gear, 400° to 450° F (204° to
232° C) , in oil or in an oven. Do not use a torch to
heat the ring gear.
STEP 364
Install the ring gear on the flywheel.
STEP 367
,.C· .
o-
C) . . . . '"
,',
. '
Remove the flywheel from the engine.

t
...
~ ,
". ';'
Ring Gear Removal and Installation

Install the flywheel. Tighten the retaining bolts to a
STEP 365 torque of 101 Ib ft (137 Nm)(13.7 kgm) .
Remove the ring gear from the flywheel, using a

drift and hammer. Work around the circumference
of the ring gear.
Rae 8-24181
2425-82
TACHOMETER DRIVE
Removal and Disassembly
STEP 368 STEP 371
Remove the tachometer drive. Remove the bolts and washers from the cover.
STEP 369 STEP 372
Remove the tachometer drive assembly. Remove the tachometer drive from the cover.
STEP 370 STEP 373
Remove the cover seal. Remove the gasket from the tachometer drive cov-
er .
Rae 8-24181
2425-83
Assembly and Installation

STEP 374 STEP 377
. ~" -:.
-,-
5' ,7
'.
H,.
Install a new gasket on the tachometer drive. Install a new seal in the cover.
STEP 375 STEP 378
Install the tachometer drive in the cover. Install the tachometer drive assembly in the cover.
STEP 376 STEP 379
",,,, . '
57 5 7 •• ' .'
Install the washers and bolts in the cover. Tighten Install the tachometer drive assembly . Rotate the
the bolts a small amount. tachometer drive until the tachometer drive is at
the correct angle, Tighten the cover bolts .
Rae 8-24181
This Page is Blank

tion to install them on units previously sold .
•
LUBRICATION SYSTEM
Oil Pan, Oil Pump, Oil Cooler and Oil Filter Housing
Written In Clear
And
Simple
English
J I Case Rae 8-24191

A Tenneco Company
2445-2
TABLE OF CONTENTS
SPECIAL TOOLS ........ . ....... ... ..................... . .............. . .. .... .. .. ....... . ... ... . 2
SPECIFICATIONS . .... .. . .............. . .................. ................ . ........... . .......... 3
SPECIAL TORQUES .. ..... . ............ .. ...................................................... .. 3
SERVICING THE LUBRICATION SYSTEM

Oil Pump Removal . ..... ....................... . .. .... .............. . .......................... 4,5
Disassembly, I nspection and Assembly ............. . ... . ............................... . ......... 6
Oil Pump Installation ...................... ......... ...... ... .............. ...... . . . ........ . . . 7,8
OIL PRESSURE RELIEF VALVE

Re li ef Valve Disassembly ................................ . ... ....... ............ .. ..... . . . . . .... . 9
Relief Valve Assembly .. ................. . .................... . ........... . ........... . ......... 10
OIL FILTER HOUSING AND OIL COOLER

O il Filter Housing and Oil Cooler Removal . .. ............... . ... . ....................... . .. ...... 11
Oil Coo ler and Fil ter Housing Installation .. ..................... . ...... . .. .... . .. . ......... ... 12,13
OIL PAN AND OIL INLET TUBE

Oil Pan Removal ... ... .. . .... .. .. ... . ........ .. .. . ..... . .. ......... ...... . .... . .. .. . .......... . 13
Oil Inlet Tube Removal ......................................................................... 14
Oil Inlet Tube Installation . .. . ......................................... . ...................... 14,15
Oil Pan Installation ....................................................... .. . .. ..... .. . . . ... .... 15
SPECIAL TOOLS
CAS-1357 VALVE SPRING TESTER
TORQUE WRENCH LB FT
CAS-10066A DIAL INDICATOR
•
Rae 8-24190
2445-3
SPECIFICATIONS
Engi ne Oil Ca pacity:
Total Capacity Wi th Oil Filter . . .. .. . . ........ . ... . . .. .. . ... .. .. 11.0 qts 10.41 L
To tal Capacity Without Oil Filter .... ........ .... ... ..... . ..... 10.0 qts 9.56L
C hange Engine Oil and Oil Filters Every 250 Hours
Engine Oil Specifications:

20W-40 Above ........ . ....... . .. .. . .. . . .. . . . .. .. . ... . .. .. ...... 30° F
15W-40 Above .. .... .. .. . .................. .. ........... . . . ... . . 10° F
10W-30 Below .. ..... . .. ..... . . ... . ... ... . .. . .... . .. .. . ... . . ... . 90° F
O il Pump Idler Gear to Crankshaft . .. . ... . . . ..... . . .. . . . . .... . . . . ... ...... ... .. ............. 0.450 mm
O il Pump Rotor Clearance ..... ........ .. . .. ... ... . .. ... .. ...... .. .. . . ...... . ...... ... ... .. 0.178 mm
Oi l Pump Relief Valve Spring Specification :

Number of Coils ... ............ . ....... . .. .. . . . ... . .... ... . .. .. .. . . .. . .. ... . . ... ... .. .......... 17
Free Length .. ..... ... . ........... ... . . ... . . ......... . .. . ... . ..... .. .... . . .. .. . . . . . . . .. . . 55 .83 mm
Outside Diameter ..... . . ..... . ... . .. ... .. . . ........ . . . .. . . .. . .... . .... . .. ............... 14.02 mm
Wire Diameter . ...... . .. ... . . .... .. . ... .. . .. . . ....... ..... .... .. .. . . ..... . .. ... . .. ... . . . .. 2.03 mm
Assembled Height:
Compress to 44.98 mm ... ... .. .. ..... . . ..... .. .. . .... . .... .. . . ....... . ... . .... . .... .. . 63 to 79 N
Spring Load Height:
Compress to 39.98 mm . ..... .... ... .. .. .. .. . .. .. . .. ... ... .. . ...... . ... . . . .... ... . .... 95 to 113 N
SPECIAL TORQUES
Oil Pump Mounting Bolts .. . ... . ... ....... . . ... . ... .. ........ . .. . 18 Ib ft 24 Nm
(2.4 kgm)
Front Cover Bolts . ... .. . . . .. . . . .... .......... ... . . ... .... . ...... 18 Ib ft 24 Nm
(2.4 kgm)
C rankshaft Pull ey Bolts ...... . . .. . . ... .. . . . . . .. .. ... . ... . . . . .. .. 101 Ib ft 137 Nm

(13.7 kgm)
Fan Pulley Bracket Bolts ... .... .... ... . ....... . .. . ... . .. . ........ 181b ft 24 Nm
(2.4 kgm)
Fa n Pulley Bolts . . . ..... . . . ..... ... .... . .... .. . . . . .. .. . . ... . . .... 18 Ib ft 24 Nm

(2.4 kgm)
Filter Housing Bolts .... . . . . . . . . . .. . . ...... .. .. .. . . . .. .. . .. .... . . 18 Ib ft 24 Nm

(2.4 kgm)
Oil Inlet Tube Bolts .. . .... .... ..... . .... ..... . . ...... ..... .. . ... . 18 Ib ft 24 Nm
(2 .4 kgm)
Oil Pan Bolts . ..... . .. .. ... . . . . . ... . .. .. .. . . . .. .. . .. . ..... .... . . . 18 Ib ft 24 Nm

(2.4 kgm)
Oil Pan Drain Plug . ....... ........ . .. .. .... . ... . ... ... .... .. . .. . 55 Ib ft 75 Nm
(7.5 kgm)
Rae 8-24 191

2445-4
SERVICING THE LUBRICATION SYSTEM

Oil Pump Removal
STEP 1 STEP 3
Lift the belt tensioner pulley and remove the fan

belt.
STEP 4
Case 4-390 engine.

Case 4T -390 engine.
Remove the bolts and the fan belt pulley.
STEP 5
Loosen the fan pulley bolts.
Remove the pulley bracket bolts and the pulley

bracket.
Rae 8-24191
2445-5
STEP 6 STEP 9
..
Remove the tachometer drive assembly . Remove the front cover bolts .
STEP 7
Remove the bolts from the crankshaft pulley. Remove the front cover.
STEP 8
----$._ -.. . . ._""

Remove the crankshaft pulley .
,. ,
Remove the bolts that hold the oil pump .
Rae 8-24191
2445-6
Remove the oil pump.
Disassembly, Inspection and Assembly
STEP 13 STEP 15
Put the oil pump on a clean work surface. Measure the clearance between the lobe on the
gear and the lobe on the pump body. If the clear-
ance is more than 0.178 mm the pump must be
STEP 14 replaced .
STEP 16
Remove the back cover plate.
Install the back cover plate on the oil pump.
Rae 8-24191
2445-7
Oil Pump Installation

STEP 17
~I
Install the oil pump in the engine block. Clean the seal surface on the crankshaft with loc-
tite safety solvent. See Section 2425 in the service
STEP 18 manual for front cover installation.
~J
STEP 21
.{
Install the oil pump bolts and tighten to a torque of
18 Ib ft (24 Nm)(2.4 kgm). Follow the torque se-
quence above.
Install the crankshaft pulley.
NOTE: To prevent damage to the oil pump do not
tighten the bolts more than 18 Ib ft (24 Nm )(2.4
kg m).
STEP 22
STEP 19
Install the crankshaft pulley bolts and tighten to a

• .. $f:
to rque of 101 Ib ft (137 Nm)(13.7 kgm).
Check the backlash between the oil pump idler
gear and the crankshaft. Put a dial indicator on the
oil pump idler gear. If the backlash is more than
0.450 mm the oil pump must be replaced.
Rae 8-24191
2445-8
STEP 23 STEP 26
. ., ' -, ' ,
#J{J.
, ".
, , ·r ::;
"
(. ,
Instal l the tachometer drive assembly, Install the fan pu lley and the bolts,
STEP 24 STEP 27
, ,
" '
)
" . .
:"-.'; ' ...

-.\_ -
" t
In stall the fan pulley bracket. Lift the fan belt tensioner pulley and install the fan
belt.
STEP 25.. , "'-
STEP 28
In sta ll the bracket bolts and tighten to a torque of

18 Ib ft (24 Nm)(2,4 kgm) , Tighten the fan pulley bolts to a torque of 18 Ib ft
(24 Nm) (2,4 kgm) ,
Rae 8-24191
2445-9
OIL PRESSURE RELIEF VALVE

Disassembly
STEP 29 STEP 31
"1:.'.
•
/". ~.
. ~.
,
..l . I
. '
Remove the relief valve plug. Remove the relief valve.
STEP 30
•
>¥:w'
, .:it ('
e '~.
., '.
Remove the relief valve spring.
Rae 8-241 91
2445-10
Relief Valve Assembly
RELIEF
GASKET
STEP 32 STEP 34
"
. ,
•
•
•
• j
•
Install the relief valve, Install the relief valve spring.
STEP 33 STEP 35 .. .$ .
,&
, . -" ,
""'*'t..,
'
"t. ' fd'--

, . ' L . 2
Ihstall the relief valve plug and tighten,
Check the relief valve spring for the following

specifications:
Free Length ......................... 55.83 mm

Wire Diameter ......... . .. ............ 2.03 mm
Outside Diameter .. . .. . ............. 14.02 mm
Number of Coils ........................... 17
Assembled Height:
Compress to 44.98 mm ............ 63 to 79 N
Spring Load Height:
Compress to 39.98 mm ........... 95 to 113 N
Rae 8-24191
2445-11
OIL FILTER HOUSING AND OIL COOLER

Removal
STEP 36, STEP 39
Remove the oil filter. Remove the oil cooler.
STEP 37 STEP 40
Remove the filter housing bolts. Clean all surfaces of foreign material.
STEP 38 STEP 41
--....,...~."""'""~~~-
Remove the oil filter housing . Put the oil filter housing on a clean work surface
and remove the cold oil relief valve .
Rae 8-24 19 1
2445-12
Oil Cooler and Filter Housing Installation

STEP 42 STEP 45
Install the cold oil relief valve in the oil filter hous- Install the oil cooler.
ing.
STEP 46
STEP 43
.. In stall a new filter housing gasket.

Install two guide bolts 8M x 1.25 x 75 into the
engine block.
STEP 47
Install the oil filter housing.
Install a new oi l cooler gasket.
Rae 8-24191
2445-13
TEP 48
~ J
/
v
..
,--"'"
4. .t Y
Install the oil filter housing bolts and tighten to a

NOTE: See the operators manual for servicing the

oil filter.
OIL PAN AND OIL INLET TUBE

Oil Pan Removal
Remove the oil pan drain plug and remove the oil. Remove the oil pan.
STEP 50
Remove the oil pan bolts. Clean all surfaces of fo reign material.
Rae 8-24191
2445-14
Oil Inlet Tube Removal

STEP 53 STEP 55
l 4
Remove the oil inlet tube bolts. Clean all surfaces of foreign material.
STEP 54
Remove the oil inlet tube.
Oil Inlet Tube Installation

STEP 56 STEP 57
Install a new gasket. Install the oil inlet tube.
Rae 8-24191
2445-15
STEP 58
Install the oil inlet tube bolts and tighten to a tor-

que of 18 Ib ft (24 Nm)(2.4 kgm) .
Oil Pan Installation

STEP 59 STEP 61
Install a new oil pan gasket. Install the oil pan bolts and tighten to a torque of 18
Ib ft (24 Nm)(2.4 kgm) .
STEP 60
STEP 62
Install the oil pan .

Install the oil pan drain plug and tighten .

design or changes in specifications at any time without incurring any obliga.-
tion to instal l them on units previ ously sold .
Rae 8-24191
This Page is Blank
Section
2455
COOLING SYSTEM
Thermostat, Water Pump, Fan Pulley
and Belt Tensioner
Written I n Clear
And
Simple
English
J I Case
A Tenneco Company e Rae 8-2420 1
2455-2
TABLE OF CONTENTS
SAFETY RULES ... .. .. ....... . .... . .... . . .. ..... .. .................. . ...... . . . . ... . . . ... . . .. . 3
SPECIAL TORQUES . ......... . ...... ... ...... ......................... . .. ..... ...... . ...... . 4
SPECIAL TOOLS .. .... ..... .. . ....... . ........ . ...... ... .... . ...... . ... ....... .... .. ........ 4
SERV ICING THE COOLING SYSTEM

Water Pump Removal ...... . ... .... ... . . . .... .. . . . .. ... . .... ... . .. . ... .. .. ............. . ... . 5
Water Pump Disassembly . . . .. .. . . ....... . ........ . ..... . ...... . .. ............ . .. ......... .. 6
Water Pump Assembly .. .. .. ..... . ... .. .. .. . . .... .... .. ... ... .. ... . ... ... .... . . . . . .... . ..... 6
Water Pump Installation ............ . .... ... ...... . .... .. .... .. . . ..... .. ........ ............ 6
THERMOSTAT REPLACEMENT
The rmostat Removal . . ... ... .... . ... . ...... . ... ... ......... ........ . . . . . . . .... . . . . . .... .. ... 7
The rmostat Inspection ..... .. ... . . . ...... .. .. . . .. .. .. . . . . .. .. . . ... ........ .. ...... ...... ... . 9
The rmostat Installatio n ........ .. .. . .. . .. ...... . . . . .... . . ..... . . . ..... . . . ... . . .. . ........ . . . 9, 10
COOLING INLET SERVICING

Coolant Inl et Removal ... . ... . . ..... ...... . .. . .. . .. ..... . ..... .. . .... . . ...... . ..... . . . . ..... 11 ,12
Coolant Inlet Install ation . .. ... . ...... . .. .......... . .. .. . ... ..... ... . .. . . .. . . . . . . .. . . .. . ..... 12,13
FAN PUL LE Y SERVICING

Fan Pul ley Bracket Removal ........ . ......... ... ... . .. . . .. . . .. ............ .. . . . .... . . . . .... 14
Fan Pul ley and Pulley Bracket Installation . . .... . ............ .. ... . . . ..... .... . . ........... . . 15
BELT TENSIONER SERVICING

Belt Tensioner and Bracket Removal ... .. .... .... ... . . . .... ... . ...... . .. . . ... ... .... ...... . . 16,17
Belt Tension er and Bracket Installation ... .... .... . .. ..... ............... . ...... . ........... 17,18
Rae 8-24201
2455-3
THIS SAFETY ALERT SYMBOL INDICA TES IMPOR-
A TANT SAFETY MESSAGES IN THIS MANUAL. WHEN

YOU SEE THIS SYMBOL. CAREFULL Y READ THE
MESSAGE THA T FOLLOWS AND BE ALERT TO THE
POSSIBILITY OF PERSONAL INJURY OR DEATH.
SAFETY RULES
To remove the system pressure, slowly turn the
CAUTION Add coolant to the radia - radiator cap counterclockwise to the FIRST stop.
tor only when the engine is stopped or This will permit a gradual release of pressure with
slowly idling . To avoid being scalded little coolant loss.
when the pressure- type filler cap is
being removed, turn the cap slowly to Never put coolant in a hot engine. The engine
the first stop position to relieve pres- block or cylinder head can get cracks because of
sure before removing the cap. the difference in temperature between the metal
and coolant.
How to Clean the Cooling System

:Iean the cooling system a minimum of one time 3. Remove the radiator cleaner solution. Flush the
3ach year. In areas where the water has minerals, system with clean water. Fill the system with
:::Iean the system with more freque ncy. antifreeze and water for operation . Check the
hoses, radiator and water pump fo r leaks.
1. When the coolant is hot, open the radiator drain
valve, the engine block drain valve. Close the NOTE: After the cooling system is completely
valves after the system is empty. filled, run the engine for approximately 20 minutes
to remove all the air from the system. Check cool-
2. Add a radiator cleaner and fill the system with ant level and add coolant if needed.
clean water. Use a good type of radiator cleaner.
Follow the instructions given with the radiator
cleaner.
Rae 8-24201
2455-4
SPECIAL TORQUES
Water Pump Housing Bolts .. ............ . ....................... 18 Ib ft 24 Nm
(2.4 kgm)
Thermostat Housing Bolts ........... ...... ..... . ....... . . . ...... 18 Ib ft 24 Nm

(2.4 kgm)
Inlet Housi ng Bolts ......... ............ .. ..... . . .. .......... .... 32 Ib ft 43 Nm

(4.3 kgm )
Fan Pulley Bracket Bolts ............ ......... . .......... . ........ 18 Ib ft 24 Nm

(2.4 kgm)
Fan Pulley Bolts ................................................. 18 Ib ft 24 Nm

(2.4 kgm)
Tensioner Bracket Bolts . . ... ......... . . ... . .... .. ........... .... 18 Ib ft 24 Nm

(2.4 kgm)
Tensioner Bolt ..............................................•... 32 Ib ft 43 Nm

(4 .3 kgm)
SPECIAL TOOLS
TORQUE WRENCH LB FT
Rae 8-24201
2455-5
SERVICING THE COOLING SYSTEM

Water Pump Removal
STEP 1 STEP 4
Case 4-390 engine Remove the water pump.
STEP 2 STEP 5
Lift the belt tensioner pulley and remove the fan Clean the water pump mounting surfaces of ali
belt. foreign material.
STEP 3
Remove the water pump bolts.
Rae 8-24201
2455-6
Water Pump Disassembly

STEP 6
Install the water pum p bolts and tighten to a torqu

of 18 Ib ft (24 Nm)(2.4 kgm).
Remove the o-ring
STEP 10
Water Pump Assembly

STEP 7
•
... .,..,
"*'#fbi". -
•
J
Lift the belt tensioner pulley and install the fan bel
Install a new o-ring in the water pump housing.
Water Pump Installation

STEP 8
'" .'~ --'v? ..

~
Install the water pump into the engine block .
Rae 8-24201
2455-7
THERMOSTAT REPLACEMENT
Thermostat Removal
STEP 11 STEP 14 -~ ,
.«'
JL
\
i
L......- "'_'
Lift the belt tensioner pulley and remove the fan Remove the alternator bracket bolts.
belt.
STEP 12
Remove the alternator bracket.

Remove the bolts that hold the alternator to the
brackets .
STEP 16
1IIl!!'!"~
STEP 13
Remove the thermostat housing bolts .
Remove the alternator.
ac 8-24201
2455-8
STEP 17 STEP 20
\ _ _*..::1
Remove the thermostat housing assembly. Remove the seal from the thermostat housing .
STEP 18 STEP 21
Clean the thermostat housing mounting surface of Remove the thermostat from the thermostat hou!
all foreign material. ing.
STEP 19
Remove the engine lift bracket.
Rae 8-24201
2455-9
Thermostat Inspection
STEP 22
Check the thermostat for correct operation. Put

the thermostat in a container of hot water (approxi-
mately 175° F (79.4° C) water. The thermostat
shou Id be completely open at 203 0 F (95 0 C) . Re-
place the thermostat if it does not meet the above
specification .
Thermostat Installation
SEAL ~
THERM~AT \ ~~ ---LIFT BRACKET
THERMOSTAT HOUSING _~D.

~
/ ~ ~
~
//
'~'Cl
~
~ ',)
STEP 23
~ STEP 24
Install the thermostat in the thermostat housing. Install the seal in the thermostat hou8ing .
The thermostat must point out toward the radiator.
The pin in the thermostat must be at the top of the
thermostat housing .
2455-10
STEP 25 STEP 28
Install the lift bracket. Install the alternator and tighten the bolts .
STEP 26 STEP 29
Install the thermostat housing assembly. Tighten Lift the belt tensioner pulley and install the fan be
the bolts to a torque of 18 Ib ft (24 Nm)(2.4 kgm) .
STEP 27
Install the alternator bracket and tighten the bolts

to a to rque of 18 Ib ft (24 Nm)(2.4 kgm) .
Flac 8-24201
2455-11
Coolant Inlet Removal

STEP 30 STEP 33
"Ii!":
to'
!
jJ ."
J
Lift the belt tensioner pulley and remove the fan Remove the coolant inlet bolts.
belt.
STEP 34
Remove the coolant inlet.

Remove the bolts that hold the alternator.
STEP 35
STEP 32
Remove the o-ring.

Remove the alternator.
~ac 8-24201
2455-12
STEP 36
Clean the coolant inlet surface of all foreign mate-

rial.
Coolant Inlet Installation
~---O-RING
COOLANT INLET
STEP 37 STEP 38
Install a new o-ring for the coolant inlet. Install the coolant in let.
Rae 8-24201
2455-13
STEP 41
.STEP 39
"F
Install the coolant inlet bolts and tighten to a tor- Install the alternato r bolts and tighten .
que of 32 Ib ft (43 Nm)(4.3 kgm).
STEP 42
STEP 40
.
J
Lift the belt tensioner pulley and install the fan belt.
Install the alternator.
2455-14
Fan Pulley Bracket Removal

STEP 43 STEP 46
•
1<
\ 1-<1..
"
Loosen the fan pulley bolts. Remove the bracket bolts.
STEP 44 STEP 47
'F, ,
•
,
".':$
• .ft'
•
r«4>"
#
•
•
'\
tJ"
Lift the belt tensioner pulley and remove the fan Remove the bracket.
belt.
STEP 45
,
.,
'. f
%
,," .
\. . , ' , _."
,~
i>:<$
,,-,
,.y
. . .
t'".,
Remove the fan pulley bolts and the fan pulley.
Rae 1-24201
2455-15
Fan Pulley and Pulley Bracket Installation
STEP 48 STEP 51
•
a .. \ i
Install the pulley bracket. Lift the belt tensioner pulley and install the fan belt.
STEP49 STEP 52
I
Install the pulley bracket bolts and tighten to a Tighten the fan pulley bolts to a torque of 18 Ib ft
torque of 18 Ib ft (24 Nm) (2.4 kgm) . (24 Nm)(2.4 kgm) .
STEP 50
Install the fan pulley and bolts .

2455-16
BELT TENSIONER SERVICING
Belt Tensioner and Bracket Removal
STEP 53 STEP 55
Lift the belt tensioner pulley and remove the fan Remove the tensioner bolt and the belt tensior
belt.
STEP 56
STEP 54
Remove the bolts and the fan belt pulley .
STEP 57
18 LB FT (24 Nm)(2.4
---
-- - Remove the Allen head bolts from the belt tens
Use a precision type torque wrench to lift the belt
tensioner to a 45 degree angle. Lower the bel t bracket.
tensioner to a 35 degree angle . The spring tension
must not be less than 18 Ib ft (24 Nm)(2.4 kgm). If
the spring tension is less than 18 Ib ft (24 Nm)(2.4
kgm) the belt tensioner must be replaced .
NOTE: 00 not use a clik type torque wrench to

measure spring tension .
Rae 8-2420 1
2455-17
STEP 58
~
Remove the belt tensioner bracket.
Belt Tensioner and Bracket Installation

STEP 59~
STEP 61
t I
t
t,
Install the belt tensioner bracket. Install the fan belt pulley and bolts .
STEP 60 STEP 62
Install the Allen head bolts and tighten to a torque Install the belt tensioner.
of 18 Ib ft (24 Nm) (2.4 kgm).
2455-18
STEP 63 STEP 65
Install the belt tensioner bolt and tighten to a tor- Tighten the fan belt pulley bolts to a torque of 1E
que of 32 Ib ft (43 Nm)(4.3 kgm). ft (24 Nm)(2.4 kgm).
STEP 64
Lift the belt tensioner pulley and install the fan belt.

design or changes in specifications at any time without incurring an y obliga-
Section
2465
TURBOCHARGER
Written In Clear
And
Simple
English
IMPORTANT: This Turbocharger was made using the Metric Measuremen t

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

A Tenneco Company
2465-2
TABLE OF CONTENTS
SPECI FICATIONS • • •• • • •• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 2
SPECIAL TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3
SERVICING THE TURBOCHARGER

Removal • • • • • • • • • • • • • • • • • • • • • • • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 5 I
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
Disassembly • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• • •• •• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 7-13
Inspection After Disassembly . ...... ..... . . ..................................... .. ... . .. . .... 13-14
Assembly • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• • • • • • • • • • • • • • • • • • • • • • • • • • •• • • • • • • • • • • • • • • 15-22
Instaliati on • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 23,24
SPECIFICATIONS
Metric Value
Turbine Wheel Horizontal Movement ................................................. . 0.10 to 0.16 mm
Rae 8- 25550
2465-3
SPECIAL TORQUES
U.S. Va lue Metric Value
Turbine Housing Bolts . . .......... ..... .. .. .. ..... ... . . .. .. ... 96 Ib inc h 11 Nm
(1.1 kgm)
Center Housing to Back Plate Bolts . .......... .. .. .. . ... ....... 48 Ib inch 6 Nm

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

(0.6 kgm)
Compressor Lock Nut .. ..... ... .... . ........... . .... . ... .. .. 120 Ib inch 14 Nm
(1.4 kgm)
Thrust Bearing Screws (Torx Head) ............... .. . ... . . .. .. 36 Ib inch 5 Nm

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

(3 .2 kgm)
Drain Tube Bolts ......................... . ..... . .. . .. .. ... . ... .. 18 Ib ft 24 Nm

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

CAS-10033 LB FT TORQUE WRENCH
CAS-10066-1A DIAL INDICATOR
Rae 8-25550
2465-4
SERVICING THE TURBOCHARGER

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

Loosen the air intake hose clamps. tu rbocharger.
STEP 6
Remove the air intake hose. Disconnect the oil drain tube.
Rae 8-25550
2465-5
STEP 7
Remove the nuts that hold the turbocharger to the Clean the mounting surface on the turbocharger
exhaust manifold. and the exhaust manifold.
STEP 8 STEP 11
Remove the turbocharg er from the exhaust mani-

t"•
" '7
"1
Clean the mou nting surface on the turbocharger

fold . and the oil drain tube.
STEP 9
Remove the gasket.
Rae 8-25550
2465-6
Inspection
STEP 12 STEP 13
Put the tu rb ocharger on a cl ean work surfaca. Use a dial indicator to check the horizontal move-
ment of the turbine wheel assembly . The horizon-
tal movement must not be more than 0.10 to 0.16
mm . The turbocharger must be rebuilt if the move-
ment is more than 0.16 mm or less than 0.10 mm.
Rae 8-25550
2465-7
Disassembly
STEP 14 STEP 17
Put a identification mark on the compressor hous- Remove the compressor housing clamp plates .
ing and back plate. This identification is to make
su re the parts are in the correct position at assem-
bly. STEP 18
STEP 15
Lift the assembly off the compressor housing .
Put a identification mark on the turbine housing STEP 19

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

housing.
2465-8
STEP 20 STEP 23
Remove the retaining bolts from the lock plate. Put the turbine end of the center housing assembly
into the holding fixture.
STEP 21
Remove the lock plates and clamp plates from the

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

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

thread.
Rae 8-25550
2465-9
STEP 26 STEP 29
Remove the compressor wheel.
STEP 27
Remove the seal ring from the turbine shaft.
Lift the center housing from the turbine shaft. STEP 30
STEP 28
Turbocharger center housing.
Remove the heat shield .
Rae 8- 25550
2465-10
STEP 31 STEP 34
Make the tabs straight on the lock plate . Remove the center housing from the back plate.
STEP 32 STEP 35
Remove the retaining bolts from the center hous- Remove the oil baffle from the back plate.
ing.
STEP 33
Remove the seal from the back plate.

Remove the lock plates from the center hou sing .
Rae 8-2 5550

2465-11
STEP 37 STEP 40
Rem ove the oi l slinger from the back plate . Remove the torx head screws f rom the center
housing .
STEP 38
STEP 41
Remove the seal ring from the oil slinger.

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

Remove the thrust collar.
Rae 8-25550
2465-12
STEP 43 STEP 46
Remove the outer bearing retaining ring. Turn the center housing over and remove the outer
bearing retaining ring.
STEP 44
STEP 47
Use a wire hook and pull the bearing from the

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

Remove the inner bearing retaining ring.
Rae 8-25550
2465-13
STEP 49
Center housing disassembled .
Inspection After Disassembly

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

ing shows damage caused by wheel friction. Replace the turbocharger if the back plate has
wheel friction wear.
Rae 8-25550
2465-14
STEP 54 STEP 56
Inspect the compressor wheel for bent blades and Replace the turbocharger if the oil slinger shows
scratches. Replace the turbocharger if the wheel damage.
shows damage.
STEP 57
STEP 55
Inspect the center housing bearing surfaces for

Replace the turbocharger if the heat shield shows scoring or scratches. Replace the turbocharger if
damage. there is damage.
Rae 8- 25550
2465-15
Assembly
Is and the tur-

btnes
N
Lubricate
OTE:haft all be;~:~/;:fore
with clean en assembly.
Rae 8-25550
2465-16
STEP 58 STEP 61
Install a new inner bearing retaining ring. The Turn the center housing ove r and install a new
round edge of the retaining ring must be toward inner bearing retaining ring. The round edgeofthe
the top. retaining ring must be toward the top.
STEP 59 STEP 62
Install a new center housing bearing. Install a new bearing in the center housing .
STEP 60 STEP 63
Install a new outer bearing retaining ring with the Install a new outer bearing retaining ring with the
round edge down. round edge down.
Rae 8-25550
2465-17
STEP 64 STEP 67
Install the thrust collar with the large OD down. Tighten the thrust bearing screws to a torque of 36
Ib inch (5 Nm)(O.5 kgm ).
STEP 65
STEP 68
Install a new thrust bearing on the center housing.

Install the oil baffle on the center housing with the
cup side down.
STEP 66
STEP 69
Install new torx head screws in the center housing.
Install a new seal ring on the oil slinger.
Rae 8-25550
2465-18
STEP 70 STEP 73
Carefully install the oil slinger in the back plate. Install new lock plates and new mounting bolts.
STEP 71 STEP 74
Install a new seal in the back plate. Tighten the back plate mounting bolts to a torque
of 48 Ib inch (6 Nm)(O.6 kgm) .
STEP 72
Install the center housing on the back plate . Make

sure the mark on the back plate and the center Bend the tabs on the lock plate.
housing are aligned.
Rae 8-25550
2465-19
STEP 76 STEP 79
Install a new seal ring in the groove of the turbine Install the compressor wheel on the turbine shaft.
wheel.
STEP 80
STEP 77
Install a new compressor wheel lock nut.

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

careful not to damage the seal ring. Use a double universal joint socket to tighten the
lock nut on the compressor wheel. This procedure
will stop the turbine shaft from bending .
Rae 8-25550
2465-20
STEP 82 STEP 84
Tighten the lock nut to a torque of 120 Ib inch (14

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

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

ture. STEP 85
Install the clamp plates and the new lock plates.
Rae 8-25550
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2465-22
T UBINE SHAFT
Rae 8-25550
2465-23
Installation
STEP 92 STEP 95
Install a new gasket on the exhaust manifold . Install a new gasket on the oil drain tube.
STEP 93 STEP 96
Install the turbocharger on the exhaust manifold. Install the oil drain tube bolts.
STEP 94 STEP 97
Install the turbocharger mounting nuts and tighten Tighten the oil drain tube bolts to a torque of 181b
to a torque of 24 Ib ft (32 Nm)(3.2 kgm). ft (24 Nm)(2.4 kgm) .
2465-24
STEP 98
Install a tighten the bolt for the oil supply tube Install and tighten the air intake hose clamps.
clamp .
STEP 102
STEP 99
Turbocharger installed on engine.

Connect and tighten the oil supply tube to the
tu rbocharger.
STEP 100
Install the air intake hose.

Section
2565
TURBOCHARGER FAILURE ANALYSIS

A Tenneco Company
2565-2
CAUSES OF PREMATURE TURBOCHARGER FAILURE
Certain operating and maintenance conditions Push in the fuel shutoff control and press
can arise which could cause premature turbo- the start button. Run the engine (about 2 min.
charger failure. NOTE: The total solution to max. ) at 1000 RPM until normal engine oil
the problem is not in repairing the failure, but pressure shows on the engine oil pressure
in determining the cause. Replacing a damaged gauge assuring proper lubrication to the tur-
turbocharger without determining the cause will bocharger.
frequently result in a repeat failure. 4. If the engine fires and stops, wait for the star-
ting motor to stop spinning before attempting
Lack of Lubricating Oil another start.
5. Do not use the starting motor longer than 30
This type of failure can occur when the a- seconds without interruption . Wait at least
mount of oil being supplied to the turbocharger 3 minutes between crankings so batteries
is insufficient to lubricate or cool bearing can recuperate and the starting motor can
and journal surfaces. cool.
6. Should the engine kill when operating under
Operating temperatures affect the volume load, immediately restart the engine to
of oil required by the turbocharger. As turbo- prevent over-heating caused by stopping the
charger speed or engine load increases, the flow of oil for turbocharger, cooling and
need for lubricating oil increases. NOTE: In- lubrication.
sufficient oil for periods as short as five sec-
onds can cause failure. This is why it is nec- Foreign Material or Dirt in the
essary to prime the turbocharger as part of
the everyday operating procedure. IMPOR- Lubricating System.
TANT: It is very important that adequate Operating the engine with contaminated oil
lubrication reaches the turbocharger bear- will cause damage to the turbocharger bear-
ings and throughout the engine before opera- ings if the particles are of sufficient quantity.
ting the engine at rated speed. If the particles are large enough, they can
clog the internal oil passages and starve the
Priming The Turbocharger bearings. This is another reason why it is im-
portant to change the engine crankcase oil and
1. Place the transmission range shift lever in oil filters at regular specified intervals.
"N" Neutral position.
Foreign Material in Exhaust or
2. Set the throttle lever not more than 113 open Air I ntake Systems.
position (1000 RPM).
The rotating parts of the turbocharger can be
3. Push in the fuel shutoff control. Press starter damaged by particles introduced through the air
button until engine starts. IMPORTANT: Do intake, which makes proper maintenance of the
not increase throttle or apply load until nor- air cleaner system very importa nt.
mal oil pressure shows on the engine oil
pressure gauge, assuring proper lubrication High Exhaust Temperature
to the turbocharger.
Excessive temperature in the exhaust system
IMPORTANT: In very cold weather, at oil will cause lubricating oil to coke in the center
filter change or when the tractor has been housing drain annulus at the turbine end. Oil
idle for several weeks or more , proceed as leakage, carbon deposits and eventual damage
follows to prime the turbocharger. to the back of the turbine wheel will result.
High exhaust temperature can also erode the
Pull out the fuel shutoff control, press the turbine housing creating pitting a nd deposits
start button and hold . Allow the engine to on the turbine wheel.
crank until the engine oil pressure gauge High exhaust temperature can be caused by
pointer reaches the green zone. Do not the turbocharger itself. Carbon build up on the
exceed 30 seconds cranking time. turbine wheel, if severe, will slow the rotating
assembly, reducing the amount of inlet air.
2565-3
TURBOCHARGER FAILURE ANALYSIS
NOTE: Following are discussion and examples

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

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

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

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

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

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

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

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

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

in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold .
- 3-
FUEL
SYSTEMS
3001
ENGINE CONTROLS, FUEL LINES AND FUEL TANK
TABLE OF CONTENTS
Specifications .. . . . ...... . ..... . . .... .. . 3001-2 Removing Air From the Fuel System . ... . 3001-4
Throttle Linkage Adjustment .. .. .. .... .. 3001-2 Replacement of the Fuel Filters .. ... . . . .. 3001-5
Hand Throttle Adjustment .. ...... . ..... 3001-2 Removing Water From the Fuel System .. 3001-6
Illustration of Engine Controls .... . .. . .. 3001 -3 Illustration of Fuel Lines and Fuel Tank .. 3001-7
J I Case 8-67180
A Tenneco Compan y
3001 -2
SPECIFICATIONS
Engine speeds
Low idle .......... . ..... ... . ...... .... . . . .. . . .... . .. . .. . ... . .. . ............ . 850 to 900 rpm (r/ min)
Maximum no load speed ... .. . . . ... .... . ... .. .. . . ...... .. . ..... . . . .. . ...... 2330 to 2370 rpm (r/ min)
THROTTLE LINKAGE ADJUSTMENT

STEP 1 STEP 6
Disconnect the throttle rod at the fuel injection Push the throttle pedal down until the throttle ped-
pump. al is against the stop bolt.
STEP 2 STEP 7
Use a photo tachometer or other tachometer of
equa l accuracy and check the engine speeds. If the
engine speeds are not equal to the specifications
above , adjust the stop bolts on the fuel injection
pump as required.
NOTE: Adjustment of the maximum no load speed

must 'be done by an authorized Case service
person.
STEP 3
Connect the throttle rod to the arm on the fuel
injection pump .
627924
STEP 4 Adjust the length of the throttle rod at the f uel
Make sure that the hand throttle is in the low idle injection pump so that there is at least a 1/ 16 inch
position , (1 ,5 mm) space as shown ,
STEPS STEP 8
Release the throttle pedal.
STEP 9
Move the hand throttle to the maximum speed po-
sition , The throttle pedal should be against the stop
bolt before the hand throttle lever reaches the end
of the slot. Adjust the length of the throttle cable as
required ,
STEP 10
If the throttle cable was adjusted , repeat steps 5
through 9,
Check the position of the arm on the fuel injection

pump. Adjust the position of the cable at the hand
throttle until there is 1/ 16 inch (1,5 mm) of space as
shown above ,
HAND THROTTLE ADJUSTMENT

Move the hand throttle lever to the maximum smoothly or hold the setting after the throttle lever
speed position and then to the low idle position , has been released, the throttle lever must be ad-
The hand throttle lever must move smoothly and justed, Loosen the jam nut and turn the other nut
hold the throttle lever setting when the throttle on the bolt as required to either tighten or loosen
lever is released . If the throttle lever does not move the friction disc. Tighten the jam nut.
3001-3
A
A
861953
1. Throttle Rod 4. Nut 7. Throttle Pedal

2. Hand Throttle 5. Jam Nut B. Stop Bol t
3. Friction Disc 6. Throttle Cable 9. Arm on Injection Pump
Engine Controls
3001-4
REMOVING THE AIR FROM THE FUEL SYSTEM

STEP 1 STEP 7
If necessary, fill the fuel tank . Operate the hand prime r pump until fuel with no air
flows from around the vent screw. Tighten the vent
STEP 2 screw.
STEP 8
Push the hand primer pump lever up into the STOR-
AGE posit ion.
STEP9
Start the engine and ch eck for fuel leaks.
STEP 10
If the engine starts but does not run correctly, do
steps 11 through 13. If the engine does not start do
steps 14 through 16.
627902
STEP 11
Run the engine at low idle.
Loosen the vent screw on the filter head 1 to 2
t urns.
STEP 12
Loosen each fuel line at the fu el injector until fuel
STEP 3 with no air flows from around the fitting. Tighten
Operate the hand primer pump until fuel with no air
the fuel line.
f lows from around the vent screw .
NOTE: If there is no fuel when you operate the

STEP 13
Repeat steps 11 and 12 until there is no air in the
hand primer pump, rotate the engine crankshaft
fuel lines and the engine runs correctly .
approximately 1/3 turn.
STEP 4 STEP 14
If the engine did not start, run the engine with the
Tighten the vent screw .
starter.
STEPS
Turn the key switch to the ON position , but do not STEP 15
start t he engine. Have another person loosen each fuel line at the
fuel injectors until fuel with no ai r flows from
STEP 6 aro und the fitting. Tighten the f uel line.
STEP 16
Repeat steps 14 and 15 until the engine starts and
runs correctly.
Loosen the vent screw on the injection pump.

3001-5
REPLACEMENT OF THE FUEL FILTERS

Change the fuel filters every 500 hours of oper- STEP 7
ation or when engine power has decreased . Turn the filters count erclockwise and remove the
filters from the filter head .
STEP 1
Park the machine on a level surface. STEPS
Apply a thin layer of clean oil to the gasket of each
STEP 2 new filter.
Lower the loader bucket to the floor.
STEP 9
STEP 3 I nstall the filters . Use your hands to tighten the
Stop the engine and apply the parking brake . fi Iters 112 tu rn after the f ilters make contact with the
filter head. Do not use a strap wrench .
STEP 4
STEP 10
629816
Turn the fuel shutoff valve clockwise to stop the 866710
fuel. Replace the inline fuel fi lter.
STEPS STEP 11
627902
Clean the filter head and the outside of the fuel Turn the fuel shutoff valve coun tercloc kwise to
fi Iters. start the fuel.
STEP 6 STEP 12
Loosen the drain valve in the primary fuel filter. See Removing A ir From the Fuel System on page
3001-4, and remove the ai r from the fuel system.
STEP 13
Start the engine and check for fuel leaks at the fuel
filters.
3001-6
REMOVING WATER FROM THE FUEL SYSTEM

Check the primary filter for water and sedi- STEPS
ment after every 50 hours of operation, and the fuel Drain the primary filter until all water and sediment
tank every 50 hours of operation. has been removed .
STEP 1 STEP 6
Park the machine on a level surface. Tighten the drain valve in the primary filter.
STEP 2 STEP 7
Lower the loader bucket to the floor. If there was any water or sediment in the primary
filter do steps 8 through 10.
STEP 3
Stop the engine and apply the parking brake. STEP 8
STEP 4
:'\t'
6298 16
Loosen the drain plug in the bottom of the fuel tank .

627902
Loosen the drain valve in the primary filter. STEP 9

Drain all water and sediment from the fuel tank.
STEP 10
Install and tighten the drain plug .
3001-7
:..--1
86 1952
1. Fuel Tank 3. To Hand Pump 5. Fu el Level Sending Unit

2. Fro m Fuel Injec tors 4. Fuel Shutoff Valve
Fuel Lines and Fuel Tank

This Page is Blank
Section
3410
FUEL SYSTEMS AND FILTERS
Written In Clear
And
Simple
English

A Tenneco Company
3410-2
SPECIFICATIONS
Filter Replacement (First and Second Stage) ..... . . ..... . . ..... . . .... .. Every 500 hours or when loss of
•
engine power occurs
First Stage Filter .. . ... .. .................. . ........................... . .... . .. Ful l Fl ow, turn on type
Second Stage Filter ........... . ... , ................................ , ....... . .. Ful l Flow , turn on type
Fuel System Operating Pressure ... ........ ... ............. . ............................... 5 to 7 PSI
(34.475 to 48.265 kPa )
(3.448 to 4.827 Bar)
For Acceptable Number Two Diesel Fuel
A.P,I . Gravity (Min) ... ............ ...... ..... ......................... . . . .. . ... . .................. 30
Pour Point (Max) ... ... . .. . ........ , .. ,', ............ 10°F (5°C) below ambient operating temperature.
Distillation (90% Point) ..................... , .... " ..... " ................ 540 to 625° F (282 to 329° C)
Flash Point (Min) ............................................................... 125° F (52° C) or legal
Kinematic Viscosity Centistokes
At 100° F (38° C) ................... , ............................................ 2.0 to 4.3 Seconds*
Cetane Number (Min) .............................................. 40 (45 to 55 For Cold Temperature
or High Altitude Use).
Water and Sediment Volume (Max) ............ , ............ . ... ... ........... . ..... ........ .... 0.05%
Ash Weight (Max) .............. . . .......... . ................................. .. .... .. . ........ 0.010/0
Sulphur Weight (Max) ................................................................ . .. ... ... . 0.5 0/0
Carbon Residue or 10% Residuum (Max) ...... , ..... .. ...... ............... .•................. .. 0.2%
Corrosion, Copper Strip, 3 hours at 212%F (100°C) ..................... .. .... .... . .......... Number 3
(* 32 to 40 Saybolt Universal Seconds)
FUEL SYSTEM
Filter Removal and Installation
NOTE: At the first filter change and each filter NOTE: When the filte rs are too tight, you can
change after that, always install filter kit, Case Part cause damage to the gaskets and filters.
Number A77470.
5. Make sure there is fuel in the fuel tank.
1. Clean the filter head, elements and the engine
area next to the filters. 6. Loosen the air removal screw above the filter
head. Actuate the hand primer pump. Close the
2. Remove the drain plug from the first stage filter. air removal screw when clear fuel with no air
bubbles flows from the screw.
3. To remove the filters, use a clamp type filter
wrench . 7. The ignition switch must be turned to the ON
position to energize the fuel shutoff solenoid.
4. Put a small amount of clean oil or grease on the Do not turn the engine over until Step 8 is com-
seals of the new filters. Install the filters. Turn pleted .
the filters clockwise until the seal comes in con-
tact with the filter head. Use your hand to 8. Loosen the air removal screw on the fuel injec-
tighten the filter one half of a turn. To get the tion pump. Actuate the hand primer pump, close
correct seal, loosen the filters arwl again tighten the air removal screw when clear fuel with no air
one half to three fourths of a turn after the seal bubbles flows from the screw. Actuate the hand
comes in contact with the filter head. primer pump five more times to finish the air
removal.
Rae 8-24211
3410-3
Filter Replacement and Air Removal

STEP 1 STEP 3
Case 4-390 engine Lubricate the filter seal a small amount before in-
stallation .
Case 4T-390 engine.
STEP 2 Turn the filters clockwise until the filter seal makes
contact with the filters head . Use your hand to
tighten the filter one half of a turn. To get the
correct seal , loosen the filters and again tighten
the filters one half to three fourths of a turn after
the seal makes contact with the filter head. When
the filters are too tight, you can cause damage to
the seals and filters .
Use a clamp wrench to remove the fuel filters.
Rae 8-24211
3410-4
STEP 5 STEP 7
, 4T-390 ENGINE
t .";~ "'"T'""'·
Make sure there is fuel in the fuel tank. Loosen the

.- Turn the ignition switch to the ON position to ener-
air removal screw and actuate the hand primer gize the shutoff solenoid. Loosen the air removal
pump. Close the air removal screw when clear fuel screw on the fuel inlet line. Actuate the hand
with no air bubbles flows from the screw. primer pump. Close the air removal screw when
clear fuel with no ai r bubbles, flows from the screw.
NOTE: If the hand lever on the primer pump can

not be actuated, turn the engine until the pump can
be actuated.
Turn the ignition switch to the ON position to ener-

gize the shutoff solenoid. Loosen the air removal
screw on the fuel injection pump. Actuate the hand
primer pump. Close the air removal screw when
clear fuel with no air bubbles flows from the screw.
NOTE: " the hand lever on the primer pump can

not be actuated, turn the engine over until the
pump can be actuated.

Section
3412
INJECTION PUMP
Pump Drive Gear, Timing Pin, Fuel

Shutoff Solenoid, Primer Pump and Pump Timing
Written In Clear
And
Simple
English
NOTE: This engine was made using the metric measurement system. All
measurements and the checks must be made with metric tools to make sure of
an accurate reading when inspecting parts.

A Tenneco Company
3412-2
TABLE OF CONTENTS
SPECIAL TO OLS . . .. . .......... . . . ...•. . . ..... ... ... . ..... .. .......•. . . .... .. . ......... . .. . ... ... 2
SPECIAL TORQUES . . ... ...... . .... ... . . ..... . .... . ... . .... .. . . .... . ..... .. . .. . ... .. ... . . . . .... .. 3
GENERAL INFORMATION .... . .. . .. .. ... . .... . ............. .. ..... . . . ... ..... .. ..... .... .. . . ..... . 3
TROUBLESHOOTING GUIDE ....... .. .. .. ...... ....... .... ...... . .............. . ... . . . .. .. . .. . . .. 4
SERVICING THE FUEL SYSTEM

Injection Pump Removal ... .. ....... . ....... .... . . .. . . . .. .. . .. . . .......... . .. ......... . . ...... 5-10
Injection Pump Install ation ........... .. ..... . .. .... ...................... .. . ... ... . .. . . . . ... 10- 14
Injection Pump Gear Removal ... . . . .. ... ......... .. .... .. ..... .. ..... . ...... . . .. . .... .. . .... . 15-17
Injection Pump Gear Installation ... . .. . ..... . .... .. . .. ... . . ... .. ..... .. . . . . .. . .. . .. .. ... ... .. 18-20
TIMING LOCK PIN

Removal . ... . .. ..... .. ... ...... . ... ........ .. . . . .. .... .. .. . ... .. ....•. . ... .. .. . . ... . ........... 21
Installation . ..... . . .. .. . ..... ... .. .. .... . . . .... ... .. .. . ...... . .......... . . .. .. .. .. ........ .. ... 22
FUEL SHUTO FF SOLENOID

4T-390 Engine ........ ... .... ... . . . ....... .. ....... . ...... .. . .......... . . ...... . ..... . .. . . . .... 23
4-390 Engine ..... .. . . ... .... ..... .. ............... .. .... . ....... . ........ . .... . . .. . . . .. .. . . .. . . 24
PRIMER PUMP
Remova l .. . ..... . . .... . . . ... . . . . . . ..... .. ... . .. .......... .... .... .... .. . . . .... . .. . .. ... ..... 24,25
Install ation . .. . ... . . . . ... . ..... .. ...... .... . . . . .... .. . . ...... . .. .. . ...... .. . . . ... .. ....... .. . 25 ,26
INJECTION PUMP TIMING

4-390 Engine ................... .... . .. .. ..... . ...... . ... ... ... . . ... .... .. . .. . ..... . .. . .. . .. . 27-30
4T-390 Engine . .. ..... . .... .. .• .... . ... . ...... ... .. ..... ... . ..... . ..... .. .... .. .... . . . . .. . . . 31-38
SPECIAL TOOLS
CAS-1745
DIAL INDICATOR
TORQUE WRENCH LB FT
CAS-1690 ENGINE
TURN OVER TOOL
CAS-1691 GEAR PULLER
Rae 8-27080
3412-3
SPECIAL TORQUES
U .S. Value Metric Value
Injection Pump Mounting Bolts .. .. .............................. 18 Ib ft 24 Nm
(2.4 kgm)
Injection Pump Nut .......... ... ............. . ................... 48 Ib ft 65 Nm

(6 .5 kgm)
Fuel Line Inlet Bolt . . ............. . ...... ............ .... ...... . . 181b ft 24 Nm
(2.4 kgm)
Fuel Shutoff Solenoid (4T-390 Engine) ................ . .. . . ... ... 32 Ib ft 43 Nm

(4.3 kgm)
Fuel Shutoff Solenoid (4-390 Engine) ....................... .. .... 10 Ib ft 14 Nm

(1.4 kgm )
Leak Off Fitti ng . ... ... . .... . .... . ............................... 18 Ib ft 24 Nm

(2.4 kgm)
Crankshaft Pulley Bolts .. ..... . ............ . ................. . .. 101 Ib ft 137 Nm

13.7 kgm)
Inj ec tion Pump Lock Bolt .......................... . ...... . ...... 17 Ib ft 23 Nm

(2.3 kgm)
GENERAL INFORMATION
The f unction of th e injection pump is to supply the It is very important that you take extra care to
correct amount of fuel under pressure to the fuel prevent any dust or foreign material from entering
injec tors. The fuel must be pressurized with accu- the fu el system when service is done on the fuel
rate timing to the engine firing order. svstem .
Rae 8-27080
3412-4
Troubleshooting guide
for the diesel fuel injection system.
NOTE: It is assumed that the engine is in good

working order and properly tuned, and that the
electrical system has been checked and repaired
as necessary.
CAUSE t REMEDY
Improper fuel in the tank t Drain tank , flush system , fill with
proper fuel
Tank empty or tank vent blocked t Fill tank/ bleed system , check
ri
.......
' tank ve nt (See Section 3410)
Air in the fuel system t Bleed fu el system , eliminate air leaks (See
Section 3410)
Pump rear support bracket loose t Rep lace as necessary (See
Section 3412)
:::::::: Voltage supply malfunction/ stop solenoid defect ive t Correct
.:.:.:.:
.........
:.:.:.: electrical fau Its/ replace stop solenoid (See Section 3412)
Fuel filter blocked t Replace fuel filter (See Section 3410)

.:.:.:.: :.:.:.:.
:::::::: .:.:.:.: Fuel-supply lines bloc ked / restricted t Test all fuel supply lines -
.:.:.:.:.
:.:.:.: :.:.:.:.
..:.:.:.:
.... flush or replace
Loose connections, injection lines leak o r broken t Tighten th e
connection , eliminate the leak
Paraffin deposit in fuel filter t Replace filter, use Diesel Fuel no.
(See Operators Manual)
Pump-to-engine timing incorrect t Readj ust timing (See Section
3412)
Injection nozzle defective t Repair or rep lace (See Section 3413)
Engine air filter blocked t Replace air filter element
:.:.:.:. Injection sequence does not correspond to firing order t Install

.:.:.:.:
:.:.:.:. fuel injection lines in the correct order (See Section 3412)
.......
Overflow fitting interchanged with inlet fitting t Install fittings in
rm their proper positions (See Section 3412)
tf{{ Cold-start device malfunction (If equipped) t Check cold-start
;:;:;:;::;:;:;:; mechanism (If equipped)
Low or uneven engine compression t Repair as necessary (See
Section 2425)
Fuel injection pump defective or cannot be ad justed t Replace
(See Section 3412)
Rae 8-27080
34 12-5
SERVICING THE FUEL SYSTEM

Injection Pump Removal
STEP 1
~
Case 4-390 engine. Disconnect the fuel injector lines from the injec-
tor·s.
STEP 4
Case 4T-390 engine.
~.,.,
Disconnect the fuel injector lines from the injec-

tion pump .
Clean the engine before any service work is done

on the fuel system.
Remove the fuel injector line brackets .
Rae 8-27080
3412-6
STEP 6 4T-390 Engine
Disconnect the fuel inlet lin e from the injection

pump .
........ .
•
STEP 7
STEP 10 4T-390 Eng ine
j .,""~
COVER~
, 11
~I
"~
Install dust covers on the fuel injectors and the
injection pump . Remove the fuel inlet line and install dust covers in
the fu el inl et holes and on the fuel inlet line con-
nection .
STEP 8
STEP 11 4T -390 Engine
Remove the fuel inlet fitting and gaskets.
Remove the leak off fitting and gaskets. Install a

dust cover in the leak off hole in the injection
pump .
Rae 8-27080
3412-7
4-390 Engine STEP15

.JJt
\ \
t
Disconnect the fuel inlet line from the injection Remove the tachometer drive assembly .
pump.
STEP 16
STEP 13 4-390 Engine
Remove the nut and washer from the injection

Remove the fuel inlet line and install dust covers ill pUIllP shaft.
the fuel inlet holes and on the fuel inlet line con -
nection.
STEP 17
Remo ve the pl ug from the flywheel housing .
Disconnect the fuel leak off line.
Rae 8-27080
34 12-8
STEP 18 STEP 19
Install the engine turn over tool , push in on the lock Loosen the pump shaft lock bolt and remove the
pin and turn the engine over until the lock pin slotted tab .
engages in the camshaft gear.
Rae 8-27080
34 12-9
4T-390 Engine STEP 23
"!!' "'·t
Tighten the pump shaft lock bolt to a torque of 22 Loosen the nuts and bolt that hold the injection
Ib ft (30 Nm)(30 kgm). pump to the front housing .
STEP 21 4-390 Engine STEP 24
Loosen the pump shaft lock bolt and move the slot Install a gear puller and tighten the bolts until the
washer off the lock bolt shoulder. Tighten the lock gear is loose from the pump shaft.
bolt to a torque of 22 Ib ft (30 Nm)(3.0 kgm).
NOTE: The slot washer will be loose after the lock STEP 25
bolt has been tightened.
Remove the injection pump nuts and the injection

pump from the front housing .
IMPORTANT: If the key for the injection pump

Remove the injection pump bracket bolts and the shaft is not on the pump shaft when the pump is
injection pump bracket. removed, the front cover must be removed to re-
move the pump shaft key
Rae 8-27080
3412-10
STEP 26 STEP 27
Remove the gear puller f rom the inj ection pump Clea n the injection pump moun tin g surfaces of all
drive gear. foreign material.
Injection Pump Installation
STEP 28 STEP 30
j
Install a new gasket. In stall the wash er and nut o n t he injection pump
shaft.
STEP 29 STEP 31
In stal l t he in jection pump. Make sure th e slot in the Align the mark on t he injection pump f lange and
drive gear and the key in th e in jecti o n pump shaft the front housing. Install t he nutsa nd bolt that hold
are aligned . the injectio n pump to front housing .
NOTE: If the front cover was removed see Section NOTE : A new injection pump will have a mark on
2425 for instal/ation. the flange .
Rae 8- 27080
3412-11
STEP 32 4-390 Engine STEP 35 4T-390 Engine
Install the injection pump bracket and bolts . Loosen the pump shaft lock bolt.
STEP 33 STEP 36 4T-390 Engine
Tighten the injection pump nuts and bracket bolts

to a torque of 18 Ib ft (24 Nm )( 2A kgm).
LOCK
I
Install the slotted tab and tighten the lock bolt to a
torque of 22 Ib ft (30 Nm)(3 .0 kgm).
Loosen the lock bolt on the injection pump , move

the slot washer on the lock bolt. Tighten the lock
bolt to a torque of 22 Ib ft (30 Nm)(3.0 kgm).
NOTE: The slot washer will not move after the lock
Rae 8-27080
3412-12
STEP 37 STEP 40
Pull the lock pin out of the camshaft gear. Install the plug in the flywheel housing.
STEP 38
Tighten th e nut to a torqu e of 48 Ib ft (65 Nm)(6.5 Connect and tighten the fuel leak off line .
kgm).
STEP 39
Remove the dust covers and install the fuel inlet

Install th e tacho meter drive assembly. line.
NOTE: The nut on the injection pump and the

tachometer drive nut must be aligned.
Rae 8-27U80
3412-13
Connect and tighten the fuel inlet line to the injec- In stal l th e fue l inlet line.
tion pump .

Connect and tighten the fuel inlet line to the injec-

Remove the dust cover and install the leak off fit- tion pump.
ting and new gaskets. There must be a gasket on
each side of the leak off line.
STEP 48
Install the fuel inlet fitting and new gaskets. There

must be a gasket on eac h side of the fuel inlet line.
Tighten the leak off fitting to a torque of 18 Ib ft (24
Nm)(2A kgm) .
Rae 8-27080
34 12-14
STEP 49
~~
Tigh te n the fu el inl et fitting to a torque of 18 Ib ft

(2 4 Nm)( 2.4 kgm) .
STEP 53
,
J -
~... LT
To remove the air from the fuel system See Section
Remove the dust covers and install the injector 34 10 in the service manual.
lines .
I'
Co nn ect th e injector lin es to the fuel injectors and
the injection pump. Tighten the injector lines a
sm all amount.
Rae 8-27080
3412-15
Injection Pump Gear Removal
STEP 54 STEP 57
--
Lift the belt tensio ner and remove the fan belt. Remove the front cover bolts and the front cover.
STEP 55 STEP 58
:;
i ,
•
Mii!!'"Z -
Remove the crankshaft pulley bolts and the crank- Clean the front cover mounting surfaces of all for-
shaft pulle y. eign material.
STEP 56 STEP 59
Remove the tach omete r drive assem bly. Loosen the nut on the injection pump shaft.
Rae 8-27080
3412- 16
STEP 60
Remove the plug from the flywheel housing .
STEP 61
.~ ~;-
Loosen the lock bolt and remove the slotted tab .
Install th e eng in e turn over tool. Turn the engine Tighten the lock bolt to a torque of22 Ib ft (30
ove r until the lock pin en gages the camshaft gear. Nm)(3.0 kgm ).
Rae 8-27080
3412-17
STEP 64 4-390 Engine STEP 66

<,
Loosen the lock bolt and move the slot washer off Install the gear puller and tighten the bolts until the
the shou lder of the lock washer. Tighten the lock gear is loose on th e injection pump .
bolt to a torque of 22 Ib ft (30 Nm)(30 kgm).
NOTE: The slot washer will be loose after the lock STEP 67
bolt has been tightened. ~
STEP 65
Remove the drive gear from the injection pump

shaft.
Remove the nut and washer from the injection

pump shaft.
Rae 8-27080
3412-18
Injection Pump Drive Gear Installation
STEP 68
Loosen the pump shaft lock bolt, move the slot

LETTER A 4-390 washer on the lock bolt. Tighten the lock bolt to a
LETTER B = 4T-390 torque of 22 Ib ft (30 Nm)(3.0 kgm).
LETTER C 6T-590
and 6TA-590 NOTE: The slot washer will not move after the lock
LETTER D 6-590 bolt has been tightened.
STEP 71
Install the drive gear on the inject ion pump shaft .

Make sure the correct letter on the drive gea r and
the mark on the camshaft are in align.
NOTE: The slot in the drive gear and the key on

the pump shaft must be in align.
STEP 69 Loosen the lock bolt.
Install the washer and nut on the injection pump

sha ft.
Rae 8-27080
3412- 19
STEP 72 4T-390 Engine STEP 74
In stall the plug in the flywheel housing .
STEP 75
Install the slotted tab and tighten the lock bolt to a

Tighten the drive gear nut to a torque of 48 Ib ft (65

STEP 73 Nm)(6.5 kgm) .
I
Pull the lock pin out of the camshaft gear.
~
. ~(

ty solvent. See Section 2425 in the service manual
to install the front cover and the oi l seal.
Rae 8- 27080
3412-20
STEP 77 STEP 79
Install the crankshaft pulley and the crankshaft Lift the belt tensioner and insta ll the fan belt.
pul ley bolts. Tighten the crankshaft pulley bolts to
a torque of 101 Ib ft (137 Nm)(13.7 kgm).
STEP 78
Install the tachometer drive assembly.
NOTE: Make sure the drive gear nut and the ta -

chometer drive nut are in alignment.
Rae 8-27080
3412-21
TIMING LOCK PIN

Removal
STEP 80 STEP 82
Remove the retaining ring from the lock pin hous- Remove the a-ring from the lock pin .
ing .
STEP 81
Remove the lock pin from the housing .
Rae 8-27080
3412-22
Installation
RETAINING R I N G - - - -... ~
O-RING _ _ -_~~~~-._o_~
LOCK PIN -~
Install a new a-ring on the lock pin. Install the reta ining ring in the lock pin housing .
STEP 84
Install th e lock pin the housing .
Rae 8-27080
3412-23
FUEL SHUTOFF SOLENOID

4T -390 Engine
STEP 88
O-RING
\
~
\ SPRING
SOLENOID
Loosen the fuel shutoff solenoid . Disassemble the fuel shutoff solenoid Check the
plunger and solenoid for scoring.
STEP 87
____.»' 't-,.
STEP 89
.
,
!
Remove the fuel shutoff solenoid from the injec-
tion pump. Use a small wire to make sure the orifice in the
plunger is free of foreign material.
STEP 90 STEP 91
· SOLENOID ·
'\
PLUNGER
\
I
~...•
\SPRING
O-RING
i
Assemble the fuel shutoff solenoid . Install the fuel shutoff solenoid and tighten to a
Rae 8-27080
3412-2 4
4-390 Engine
STEP 92 STEP 93
/SOLENOID
AO-RING
o /SPRING
~ .:...- PLUNGER
Remove the fuel shutoff solenoid from the injec- Disassemble the fuel shutoff solenoid . Check the
tion pump . plunger and sol enoid for scoring .

STEP 94 STEP 95
i1
...
or'"~
/SOLENOID
.~
\., A.
t O-RING
/'PRONG
, .:::::r..... PLUNGER ,
~.,=- , -
Assemble the fuel shutoff solenoid . Install the fuel shutoff solenoid and tighten to a
torque of 10 Ib ft (14 Nm )(1.4 kgm).
PRIMER PUMP
Removal
STEP 96 STEP 97 (~
11! _~#t.
Disconnect the fuel inl et li ne fro m the primer Remove the fitting and gaskets from the fuel inlet
pump . line.
Rae 8-27080
3412-25
STEP 100
Remove the fuel inlet line. Remove the primer pump from the cylinder block.
STEP, 99
. STEP 101
Remove th e bolts that hold the primer pump to the Remove the gasket from the primer pump.
cylinder block .
Primer Pump Installation
STEP 102 STEP 103
Install the bolts in the primer pump and install a Install the primer pump in the cylinder block.
new gasket over the bolts.
Rae 8-27080
3412-26
STEP 104
Tighten the bolts that hold the primer pump to the Connect and tighten the fuel inlet line to the primer
cylinder block . pump.
STEP 105 STEP 108
Install the fuel inlet line. Tighten the inlet fitting to a torque of 24 Ib ft (32
Nm)(3 .2 kgm).
STEP 106
Instal l the new gaskets and fitting on the fuel inlet

line. There must be a gasket on each side of the
fuel inlet line.
Rae 8-27080
3412-27
INJECTION PUMP TIMING

4-390 Engine
STEP 109 STEP 111
Make sure the lock pin is engaged in the camshaft

gear.
STEP 112
Install the nuts that hold the injection pump to th e

front cover .
If the pump shaft is not in the locked position,

rotate the shaft clockwise until the key on the shaft
and the slot in the drive gear are aligned .
Rae 8-27080
34 12-28
STEP 113 STEP 116
Install th e injection pump bracket and bracket Loosen the lock bolt on the inj ection ump. Move
bolts . the slot washer on the lock bolt Tighten the lock
bolt to a torque of 22 Ib ft (30 Nm) (3.0 kgm) .
STEP 114 NOTE: The slot washer will not move after the lock
'"
STEP 117

shaft
STEP 115 Pull the lock pin out of the camshaft gear.
STEP 118
Tighten the drive gear nut a small amount

Nm) (6 .5 kgm ).
Rae 8-27080
3412-29
STEP 119 STEP 121
Remove the plug from the flywheel housing. Rotate the pump until the mark on the injection
pump flange and the mark on the front cover are in
align .
STEP 120
'"
STEP 122
Tighten the injection pump mounting nuts and

bracket bolts to a torque of 18 Ib ft (24 Nm)(2.4
kgm) .
Install the engine turn over too l, push in on the lock

pin and turn the engine over until the lock pin
engages in the camshaft gear.
LO CK PIN
Pull the lock pin o ut of the camshaft gear.
Rae 8-27080
3412-30
STEP 124 STEP 127
Connect and tighten the fuel leak off line. Tighten the fuel inlet fitting to a torque of 18 Ib It
(24 Nm)(2.4 kgm) .
STEP 125
STEP 128
\ 1'' '
L
~"";
.i
r''' J:'1-
I
Install the fuel inlet lin e, fitting and gaskets. There
must be a gasket on each side of the fuel inlet line. Connect and tighten th e fuel inlet line.
STEP 126 STEP 129

~~ ,
.......
Install th e fuel inlet line .

1- . Follow Step 160 through Step 168 to install the
injector lines and front cover.
Rae 8-27080
3412-31
4T -390 Engine
STEP 130
Make sure the lock pin is engaged in the camshaft Install the injection pump into the drive gear. Make
gear. sure the slot in the drive gear and the key on the
pump shaft are align ed .
STEP 131
STEP 133
Install the three nuts and th e bracket bolt . Tiqhten

the nuts and bracket bolt a sma ll amount.
STEP 134
,I
" I
If the pump shaft is not in the locked position,

rotate the shaft clockwise until the key in pump
shaft and the slot in the drive gear are aligned .

shaft.
Rae 8-27080
3412-32
STEP 135
Tight en the drive gear nut a small amount.
STEP 136
Loosen the pump shaft lock bolt.
STEP 138
\
Pull th e lock pin out of the camshaft gear.
Rae 8-27080
341 2-33
STEP 139 STEP 141

Nm )(6.5 kgm) .
STEP 140
Instal l the engine turn over tool , push in on the lock

pin and turn th e engine over until th e loc k pin
engages in th e camshaft gear.
Remove the plug from the fl yw hee l housing .

STEP 142
Remove the dust covers .
Rae 8-27080
341 2-34
STEP 143 STEP 146
Remo ve the plug from the rear of the injection

pump .
STEP 144
Install the engine tur·n over tool into the flywheel

housing . Turn the engine counterclockwise until
there is no movement in t he dial indicator.
Install a dial indicator in the injector pump.
STEP 147
1ft"O~~!""
STEP 145
Turn the dial indicator dial to zero.

Pull the lock pin out of the camshaft gear.
Rae 8-27080
3412 -35
STEP 148 STEP 150 _~_
Rotate the injection pump until the d ial indicator

reading is 2.0 mm.
NOTE: If 2.0 mm can not be reached go to Step 68

in this Section.
STEP 151
Install the engine turn over tool, push in on the lock

pin and turn the engine clockwise until the lock pin
engages in the camshaft gear. The dial indicator
must read 2.0 mm . If the reading is not correct
continue to Step 149. If the reading is correct go to
Step 151 .
Tighten the bracket bolt and the nuts that hold the
injection pump to the f ront cove r to a torque of 18
STEP 149 Ib ft (24 Nm)(2A kgm).
STEP 152
Loosen the bracket bolt and the nuts that hold the
injection pump to the front cover.
Remove the dial indicator from the injection pump.
Rae 8-27080
3412-36
STEP 153 STEP 156
Install the injection pump plug and tighten to a In stall th e fuel inlet lin e.
torqu e of 17 Ib ft (23 Nm)(2 .3 kgm).
STEP 157
STEP 154
r
J -L
Connect and tighten the fuel inlet line to the injec-
In sta ll the gaskets and th e leak off fitting . Th ere tion pump .
must be a gasket on each side of th e leak off line.
STEP 158
~ In stall the gaskets and inlet fitting . There must be a

Tighten the leak off fitting to a torque of 18 Ib ft (24 gasket on each side of the inlet line.
Nm )(24 kgm) .
Rae 8-27080
3412-37
.~ .
Tighten the inlet fitting to a torque 01 18 Ib It (24 Install and tighten the injector line brackets.
Nm)(24 kgm).
STEP 160
Connect and tighten the injector lines to the injec-

Install th e fuel injector lines. tion pump.
STEP 161 STEP 164
Connec t and tighten t he injector lines to the fuel Install th e tachometer drive asse mbl y.
injectors.
NOTE: The drive gear nut and the tachometer
drive nut must be in align.
Rae 8-27080
3412-38
STEP 165 STEP 166

.J,
i
Pull the lock pin out of the camshaft gear. In stall the plug in the fl ywheel housing.

Rac 8-27080
Section
3413
FUEL INJECTORS
Written In Clear
And
Simple
English
All measurements and checks must be made with metric tools to make sure of
an acc urate reading when inspecting parts.
J I Case Rae 8-2423 1

A Ter>n eco Company
3413-2
TABLE OF CONTENTS
SPECIF ICATIONS ..... ...... ...... ....... ...... ....... .................. . .. . ............ . ........ 3
SPECIAL TOOLS ........... . ... . ............. . . . .. .. .......... .. . . ........ . ....... . ........... ... 4
SPECIAL TORQUES . ... ... .... . . ............. ... ... . .. .... .................... ............... .... 4
GENERAL INFORMATION ...... .. .... . ... . . .. .. ...... ............................................. 5
OPERATI NG PROCEDURES .... . ....................... .... ....... .... . . ... ....... ............. ... 6
LOCATING BAD INJECTORS

Locating Bad Injectors at the Fuel pump ... ....... .... ....... .... ....... . .. . ......... . .... .. . . .... 7
Locating Bad Injectors at the Cylinder Head ............... . ... . ........................ .. .. .... .. 7
REMOVING INJECTORS .. . .. ..... .................... .... .. . . . . ..... . . .. . ....... .. ........ . .. .. 8,9
INSTALLING INJECTORS ................ .... ... ......... ................. .. .... .. .... ......... 9.10
FUEL INJECTOR TESTER ....... . ...... .. .... .. .. .... ... .. ........... .. .. . .... . ........... ..... .. 11
Nozzle Tester Preparatio n . . ..... . .. .. ................... .. . . ... .. .... . ..... .. . . . ............... 11
TESTING INJECTORS ....... .. ... . .. ...... ....... . .................. . ....................... . ... 12

Checking Opening pressure .. .. .. . .. ....... ... . ... .. .. ........... . .... . . .... ... . ... .... ... ... .. 12
Check ing Seat Leakage .. . ... .. ....... . ....... ..... ........ .... . . . .. ... ... . . . .... ... .... ....... . 13
Spray Pattern ... .......... .............. .................... . .. .. . ...... .............. . . . ...... 13
MAINTENANCE OF THE INJECTOR

Disassembly .... . ......... . . .. . ........ . . .... . ............ . ...... ... .. .. .. .. .. . . . ........... 14,15
Cleaning and Inspection ... . ... ..... . . . ......... ........... ....... ... .......... ........... . . .... 16
Assembly .. . ..... .... ... .... . ......... ... .................... . . .. .. .. . . . . . . ... ............. . 17-19
INJECTOR ADJUSTMENTS
Adjusting Opening Pressure . .. ...... . .. ... . . . .. . .... ... . . .. ... .. . ... .. ..• . . .... . .... . .... .. .... 20
Rae 8- 24231
3413-3
THIS SAFETY ALERT SYMBOL INDICATES IMPOR-
A TANT SAFETY MESSAGES IN THIS MANUAL. WHEN

YOU SEE THIS SYMBOL, CAREFULL Y READ THE
MESSAGE THAT FOLLOWS AND BE ALERT TO THE
POSSIBILITY OF PERSONAL INJURY OR DEA TH.
WARNING
When testing or adjusting fuel injectors, do not place your hands or arms in front of the
injector nozzle.
The fuel spray from an injector has sufficient pene-
A trating power to puncture the flesh and destroy tissue.

Should the fuel enter the blood stream, it may cause
blood poisoning.
In the event the skin is punctured from the discharge of an injector, apply the following first
aid immediately, then have the injury examined by a physician as quickly as possible.
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.
SPECIFICATIONS
Part Number Opening Pressure
Spray Number Spray

Robert Angle of Orifice
Bo sch Case Orif ices Size New Used
0430132001 J904197 155 4 0.28 mm 3475 to 3200 to

Degrees 3625 PS I 3625 PSI
(23 959 to (22 063 to
24 994 kPa) 24 994 kPa)
(240 to (220 to
250 Bar) 250 Bar)
Reset to 3475 to 3625 PSI

(23 959 to 24 994 kPa)
(220 to 250 Ba r)
When Opening Pressure
Falls Below 3200 PSI
(22 063 kPa)(220 Bar)

Valve Leakage Rate .. . . . . . . ...... . .... . ... . . ... . No Leakage Permissible
Slight MOistening of Nozzle Tip Permissible
Maximum Opening Pressure Variation

Between Each Cylinder . .. . . . . . . ... . . . .. . ...... .. .. . ......... . .. 150 PSI 1034 kPa
with Set of Injectors (10.34 Bar)
Ra e 8-24231
3413-4
SPECIAL TOOLS
TORQUE WRENCH LB FT
TORQUE WRENCH INCH POUND
CAS-10091 OR CAS-10249
DIESEL FUEL INJECTION
NOZZLE TESTER
MAGNIFYING GLASS
66-0135
CAS-1066A WRENCH
CAS 1694
INJECTOR BORE ORIFICE
CAS-13S7 CLEANING TOOL CLEANING WIRES
COMPRESSION SPRING TESTER 66-0036
SPECIAL TORQUES
US. Value Metric Valu e
Injector Retaining Nut .. ...... ... . .... . ... .. . ... .. ... . .. . ... .... . 44 Ib ft 60 Nm
(6.0 kgm)
Leak Off Bolt ..... . ... .. ..... .... .. ... . .. . . . .. .. ... . .. .. ...... . ... 6 Ib ft 8 Nm
(0.8 kgm )
Nozzle Cap Nut . .. ... . . . ........ . ... . .. . ..... . .. . ... . ... . .. .. ... 41 Ib ft 55 Nm
(55 kgm )
Rae 8-2 4231

3413-5
GENERAL INFORMATION
The fuel injectors are in the cylinder head . There is
INJECTOR VALVE - The valve controls the flow of
one injector for each cylinder. The fuel injector
the fuel from the injector.
sends a measured amount of fuel to the combus-
tion chamber from the injection pump . Each quan- VALVE TOP - The valve stop has two dowel pins
tity of fuel must be sent to the combustion cham- which hold the valve tip to the body. This will make
ber in the form of fine particles. This will make sure a spray pattern that is correct. Both faces of the
that there is complete combustion and efficient valve stop have a fine surface finish. The valve stop
engine performance. controls the distance that the valve will move.
IMPORTANT: The injector tip end and the injector
valve are a matched assembly. The two parts are OPENING PRESSURE CONTROL SPRING - The
made smooth to fit together with accuracy. The spring controls the fuel pressure that is necessary
injector tip or the injector valve can not be replaced to lift the valve f rom the seat.
separately for service. If it is necessary to replace
either the valve or tip, replace the complete tip SHIMS - The shims push down on the spring to
assembly. keep a given pressure on the valve.
IMPORTANT: Do not mix tip assemblies and bod- INJECTOR TIP - The valve and the valve seat are in
ies while the injectors are being disassembled. the injector tip. There are orifices in the injector tip
that atomize the fuel for better combustion and
INJECTOR BODY - the body holds the injector separate the fuel spray to mix the fuel spray with
parts in the correct position in the cylinder head . air.
The body has a high pressure channel and a leak
off channel. The lower face of the body has a fin- NOZZLE SEAL - The seal is under the cap nut and
ished surface and has two holes in the surface for stops engine compression leakage.
locating dowel pins .
OPENING PRESSURE CONTROL SPRING
INJECTOR BODY
I SPRAY ORIFICES
NOZZLE SEAL
LEAK OFF
LEAK OFF CHANNEL VALVE STOP
Rae 8-2423 1
3413-6
OPERATING PROCEDURES
The operation of the injector is easy and positive. When the fuel delivery stops , the pressure agains1
the valve is decreased and the control spring im-
A measured quantity of fuel under high pressure mediately returns the valve to the seat. This re-
moves from the injection pump to the high pres- moves the danger of leakage, after the measured
sure channel in the injector body. The fuel then amount of fuel has been released . The valve opens
moves through the valve stop channel and enters and closes very rapidly with a very clear noise.
the pressure chamber which is around the valve in
the injector tip. A small amount of fuel leaks, during injection ,
through the controlled clearance between the tip
When the pressure of the fuel against the valve is assembly and the injector body . This leakage adds
more than the set spring orifice, the valve is moved lubrication to all the moving parts in the injector.
from the seat. This permits the fuel under high This fuel then moves through the leak off channel ,
pressure to enter the injector tip . The fuel then leak off lines and returns to the fuel tank .
moves through the spray orifices and to the com-
bustion chamber. The fuel reaches the combus-
tion chamber in an atomized condition.
HIGH PRESSURE CHANNEL VALVE STOP CHANNEL
INJECTOR BODY
LEAK OFF TIP ASSEMBLY

LEAK OFF CHANNEL
OPENING PRESSURE CONTROL SPRING
Rae 8-24231
3413-7
LOCATING BAD INJECTORS

If there is a loss of power during engine operation , STEP 2
the injectors can be bad. Do the following proce-
dure to find the bad injectors.
Locating Bad Injectors

at the Fuel Pump
STEP 1
.~ ~
1. Loosen the tube nut on the fuel line. This will
release the fuel and the injector will not work. If
this injector is bad, there will not be any differ-
ence in the engine performance . Connect and
tighten the tube nut on the fuel line.
2. Do this procedure again for the remainder of the

injectors.
Case 4-390 engine.
Locating Bad Injectors

at the Cylinder Head
STEP 3
Case 4T-390 engine.
1. Loosen the tube nut on the fuel inlet line for the
injector at the cylinder head . If the injector is
bad , there will not be any diffe re nce in the en-
gine performance . Connect and tigh ten the tube
on the fuel inlet line.
2. Do this procedure again fo r the remainder of the

injectors.
Rae 8-24231
3413-8
REMOVING INJECTORS
STEP 4
I (
I ~
Clean the location around the fuel injectors. Disconnect the fuel line from the injector and in-
stall a dust cover over the inlet of the injector.
STEP 5
Remove the bolt and bracket half.

Remove the leak off bo lt.
STEP 9
Loosen the fuel line tube nut.

Remove the leak off line gasket.
Rae 8-24231
3413-9
STEP 10 STEP 11
~ 1
Remove the fuel injector from the engine .

IMPORTANT: Make sure that the injector sealing
gasket comes out with the injector. Use an accep-
table tool or wire to remove the sealing gasket from
the engine bore.
STEP 12
Install the special tool and a wrench on the flat

surface of the injector Loosen the injector.
Always replace the injector sealing gasket when a

fuel injector is removed . Remove the remainder of
the injectors using the same procedure .
INSTALLING INJECTORS
STEP 13 STEP 14
Install a injector bore cleaning tool. Turn the tool Install a new sealing gasket on the injector. Put a
clockwise . Use a ratchet wrench. Clean the bore small amount of white grease or light oil on the
with air under pressure or turn the engine over to gasket to keep the gasket in position.
remove the particles .
Rae 8-2423 1
3413-10
STEP 15 STEP 18
Install the injector in the cylinder head bore. The Tighten the leak off bolt to a torque of 6 Ib It (S
ball in the injector must align with the slot in the Nm)(O.S kgm).
cylinder head bore.
STEP 19
STEP 16 I
Remove the protective cover. Connect and tighten

Tighten the injector retaining nut to a torque of 44 the injection line to the injector and to the injection
Ib ft (60 Nm)(6.0 kgm). pump.
STEP 17 STEP 20
Install the gasket and the leak off screw.

-- ,
Install the injection line clamp and tighten the bolt.
NOTE: Make sure the top of the gasket does not

touch the leak off line.
Rae 8- 24231
3413-11
FUEL INJECTOR TESTER
Fuel injectors must be checked on the tester when

making the following service ope rations:
1. An injector that has been removed from the

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

A Diesel Fuel Injection Nozzle tester (CAS-10249) on the tester during an engine overhaul.
is needed for checking and adjusting the injectors.
The following instructions will work for all models 4. An injector must be removed and checked on the
of testers except for descriptions on adjustments tester before the injector is disassembled , if the
to the tester. Operating instructions are given with injector is the cause of engine performance that
the tester. is not acceptable.
The tester is used to make the following checks:
1. Check and adjust the injector opening pressure.
2. Check the injector assembly for fuel leakage.
3. Check the injector for accurate spring pattern.
Nozzle Tester Preparation

1. Fill the reservoir with clean fuel.
2. Connect the correct connectors to the connec-

tion tube .
3. Connect the injector to the tester.
4. To remove the air that is in the system , close the

pressure release valve and the gauge protection
valve , open the pump valve. Operate the pump
rapidly to remove the air from the system.
Rae 8-2423 1
3413-12
TESTING INJECTORS
The injector must be cleaned before testing the

injector. Wash the body, nozzle tip and the cap nut
in a so lve nt to remove external dirt, grease and
carbon deposits from the cap , body and outside
diameter of the tip .
IMPORTANT: Do not permit the wire brush to

contact the tip (spray hole area) of the nozzle.
Connect the injector to the nozzle tester. The noz-

zle tip must be down . Use adapter elbow (Part
Number Y900-3), straight adapter (Part Number
Y900-5) and adapter nut (Part Number Y900-6).
A WARNING When testing or adjusting

fuel injectors. do not place your hands
or arms in front of the injector nozzle.
Fuel from the spray orifices can enter clothing and

skin, causing serious damage. The tip must always
be put in a receptacle to hold the spray .
Checking Opening Pressure
Close the pressure release valve and the gauge If the injectors do not meet the given opening pres-
protection valve, operate the pump rapidly to flush sure:
the injector. Open the gauge protection valve and
raise the pressure slowly until the injector valve 1. New injectors can be a adjusted to the given
opens (the gauge reading will fall quickly at this opening pressures . See Page 20 .
point). Check the opening pressure against the
specifications: 2. Injectors in use must be disassembled and
cleaned. See Page 16.
NOTE: There must not be more than 150 PSI (1034
kPa)(10.34 bar) difference between any of the in- 3. Check for broken or weak opening pressure
jectors that have been removed from the engine. control springs.
Rae 8-24231
3413- 13
Checking Seat Leakage
Close the pressure re lease valve and the gauge 4. Open th e pressure release valve and remove th e
pro tect ion va lve . Open the pump valve and operate in jector.
th e pump rapi dly to flush the injector.
The follow ing procedure must be followed if drops
1. Dry the injector tip completely. Open the gauge of fuel are seen on the nozzle tip.
protection valve .
1. Disassemble and clean the inj ector, see Pages
14 through 16.
2. Lift the pressure at the injector to 100 PSI (690
kPa) (6 .9 ba r) under the opening pressure .
2. Injector assembly , see Pages 17 through 20 .
3. Close the pump valve for five seconds and check
th e nozzle tip (spray hole location) . The nozzle
leaks if drops of fuel are seen on the nozzle tip . A
small amount of mo isture on the nozzle tip is
permitted .
Spray Pattern
Close the pressure release valve and the gauge The injector will make a very clear noise when the
protection valve . Open t he pump valve and operate test stand is operated rap idly. Th is noise will not
the tester at 60 strokes a minute, check the spray necessarily occu r in the operation of the injector in
pattern . The nozzle must have a spray pattern that the engine . The noise is an indicat ion of good seat
will atomize the fuel. The nozzle must not have a width and interference angles. This noise can
solid spray pattern. change between nozzles. The noise in the nozzles
must not be compared for purpose of making
nozzles acceptable or not acceptable .
If this injector makes a solid type spray pattern , do

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

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

interference angles , bent valves and distortion
in the body . Replace the complete injector as-
SPRAY PATTERN THAT Will ATOMIZE FUEL sembly if there is distortion in the body . Under
other conditions , replace the tip assembly only .
SOLID TYPE SPRAY PATTERN

Rae 8-2423 1
3413-14
MAINTENANCE OF THE INJECTOR
Disassembly
STEP 21 STEP 23
This is a 17 millimeter injector. NOTE: Wet the nozzle and the holder assembly in
a cleaning solution that will remove carbon . Use
Gunk, Bende's Kleaner or a solution that is the
STEP 22 same as these. The cleaning solution will give as-
sistance to free the cap nut.
Use a small amount of force to turn th e ca p nut.

Check the nozzl e when there is a small amount of
movement. Look to see if th e nozzle turns with the
cap nut. If the nozzle turns with the cap nut, see
below .
IMPORTANT: The nozzle is being held in position

with the cap nut. If the nozzle turns with the cap
nut, carbon deposits between the two parts will
cause this . Do not loosen the cap nut. This will
cause damage to the dowel pins, valve stop and
holder body pressure face . Wet the nozzle and the
holder assembly in a cleaner solution that removes
carbon, until the nozzle is free in the cap nut. Re -
place the valve stop assembly if there is damage to
the dowel pins or valve stop.
Put the injector in a soft face vise with the two flat
surfaces toward the vise face. The tip of the injec-
tor must be up. Remove the sealing gasket.
Rae 8-2423 1
3413-15
STEP 24 STEP 27
'-..••",#,"'
r
Loosen and remove the nozzle cap nut Remove the pressure spring seat.
NOTE: The injector parts have tight tolerances.

Dirt will damage a smooth surface. Keep the work STEP 28
location and tools clean . Disassemble and assem-
pi'
ble all parts carefully to prevent damage.
STEP 25
(
Remove the pressure spring .
STEP 29
J.I
Remove the nozzle assembly.
STEP 26
oo
Remove the pressure adjusting shims.
Remove the valve stop assembly .
Rae 8-24231
3413-16
Cleaning and Inspection
1.AII parts must be put in a solvent to loosen the

carbon deposits.
2. A brass wire brush must be used to clean the

outside of the tip body. Use cleaning wires to
remove the carbon from the spray orifices . Use
cleaning wires that are 0.0005 inches to 0.001
inches (0.0127 to 0.0254 mm) smaller in diame-
ter than the spray hole. Put the cleaning wire in a
pin vise (66-0021). The end of the wire must
extend 1/32 inch (0.79 mm) pastthetipofthe pin
vise. A longer length of wire will hit the opposite
wall of the sac hole and will break .
4. Clean all channels with air under pressure . Di-
rect the air through both ends of the nozzle tip
assembly. Carbon deposits must be removed .
ORIFICE
CLEAN IN G WIRES
(66-0036)
SPRAY ORIFICE
5. Make sure that the nozzle valve slides freely in

the nozzle body .
6. Carefully clean the nozzle valve and the inside

3. Use a stone to remove sharp edges from the end diameter of the body to remove all dirt, varnish
of the wire. A small flat on one side of the wire and other foreign deposits.
will make it easier to cut the carbon from the
orifice. Put the cleaning wire in the spray orifice 7. The injector valve must be cleaned with a brush
and turn the wire until the wire is free. Wash the to remove deposits from the seat location . Var-
body with clean solvent and look at the tip . The nish must be removed with a solvent and a
nozzle t ip must be replaced if the orifice in the cleaning pad made of felt. Do not put the valve in
tip shows damage at the edges . Damage to the a motor driven lathe to clean the valve . This
orifice will change the spray pattern. method can remove too much material from the
valve which can change valve lift. Look at the
NOTE: Use a glass (66-0135) that makes objects valve for pitting or damage which can cause
look larger, to look at the tip. leakage.
8. Replace all parts that show damage.
Rae 8-24231
3413-17
Assembly
,-------,
I I
I VALVE STOP
~/
GASKET
lEAK OFF BOLT 1\

\ ~~
(?~ " / NOZZLE TIP ASSEMBLY
----@
NOZZLE HOLDER
SHIM AS NEEDED ·
PRESSURE SPR'NG
-----®I •
_________
~
SPRING SEAT _ ® ~ NOZZLE SEALING GASKET
I
I
I
\... -- _______ J ©
STEP 30
Install the pressure adjusting shims that are

needed to set the opening pressure .
Rae 8-24231
3413-18
STEP 31 STEP 33
#w -
Install the pressure spring in the nozzle holder. Install the valve stop assembly . Align the dowel
pins that are in the valve stop with the dowel pin
NOTE: Clean all parts in clean diesel fuel before holes that are in the nozzle holder.
,
assembly.
STEP 34
STEP 32
Put a small amount of clean fuel on the nozzle valve

Install the spring seat on the pressure spring . The and slide the nozzle valve up and down a number of
small diameter end of the spring seat must be to- times in the nozzle tip to make sure that there is
ward the pressure spring . free movement.
Rae 8-24231
3413-1 9
STEP 35 STEP 37
Align the dowel pin holes in the nozzle tip assem- Put the injector in a soft face vise with the tip of the
bly with the dowel pins in the stop valve assembly. injector up. The flat surface of the injector must be
Install the nozzle tip assembly on the valve stop toward the face of the vise. Tighten the cap nut to a
assembly. torque of 41 Ib ft (55 Nm)(5 .5 kgm).
STEP 36 STEP 38
Add lubrication to the nozzle shoulder. Do not put Check the fuel injector on the test stand .
grease on the holder or the threads of the cap nut.
Install the cap nut over the end of the nozzle tip
assembly and turn the cap nut clockwise two or
three times.
PRESSURE SPRING
SHIMS - AS NEEDED VALVE STOP
NOZZLE TIP
SPRING SEAT ASSEMBLY
CAP NUT
DOWEL PIN
Rae 8-24231
3413-20
INJECTOR ADJUSTMENTS
Adjusting the Opening Pressure

STEP 39 STEP 41
,,-
f j,
(
Remove the fuel injector from the nozzle tester. Put Assemble the fuel injector. See Pages 17 through
the injector in a soft face vise. The flats of the 19.
injector holder must be toward the face of the vise.
The injector tip must be up. Loosen the cap nut. To
disassemble the injector see Pages 14 and 15. STEP 42
STEP 40
JiJJ!..
Check again the opening pressure of the fuel injec-
tor on the nozzle tester. Repeat Steps 39 through
41 on this page , as necessary, until the needed
Add pressure adjusting shims to increase the opening is correct.
opening pressure. Remove pressure adjusting
shims to decrease opening pressure. Do this until
the correct pressure is reached.
IMPORTANT: The opening pressure is changed

by about 55 PSI (379 kPa)(3.79 bar) for each 0.001
inch (0.0254 mm) of shim thickness that is added
or removed.

Rac 8-24231
- 4-
ELECTRICAL
4000
REMOVAL AND INSTALLATION OF COMPONENTS
TABLE OF CONTENTS
C)tarter . . ... . . .... . . . . . .... .. . ...... . .. . 4000-2 Removal and Installation .. ..... .... . " 4000-7
Alternator .. . . .. .. .. .. . . . . ... . .. . . .. . .. . 4000-3 Replacing a Bulb . . . ... . . ... . .. .. . . .. . 4000-7
Drive Belt Replacement .. . . . . . .. .. ... . .. 4000-4 Gauge or Tachometer Removal

and Installat ion . . . . . ..... . ... ... . .. 4000-7
Instrument Cluster ..... .. . . .. . ... . . . . . . 4000-6
Circuit Board . .. . . . ........... . . .. . .. 4000-7
Illustration of the Instrument Cluster ... 4000-6
Turn Signal Switch Replacement .. . . . ... 4000-8
J I Case 8-67190
A Tenneco Compan y
4000-2
STARTER
Removal STEP 10
Open the hood.
STEP 1
Park the machine on a level surface and apply the STEP 11
parking brake. Disconnect the wires and the cable from the termi-
nals on the starter.
STEP 2
Lower the backhoe to the floor. STEP 12
Remove the two cap screws and lock washers that
STEP 3 fasten the starter to the f lywhee l housing .
Remove the pi n that fastens the support strut to the
loader frame . STEP 13
Remove the starter.
STEP 4
Raise the loader frame until the support strut is Installation
against the end of the lift cylinder.
STEP 1
STEPS Put the starter in place on the flywheel housing.
Stop the engine and install the pin in the support
strut. STEP 2
STEP 6 the starter to the f lywheel housing . Make sure the
Remove the cap screws and lock washers that ground cable is installed under the lower cap
fasten the battery cover to the right side of the screw.
machine.
STEP 3
STEP 7 Connect the wires and the cable to the termina ls on
Remove the battery cover. the starter.
STEP 8 STEP 4
If the machine has only one battery, disconnect the Close the hood.
negative battery cable from the battery.
STEPS
If the machine has only one battery , connect the
STEP9
negative battery cab le to the battery.
STEP 6
If the mach ine has two batteries, remove the termi-
nal nut from the terminal. Install the negative bat-
tery cable on the terminal. Make sure the jumper
cable is installed on the terminal. Install the termi-
nal nut on the terminal.
STEP 7
Install the battery cover.
STEP 8
Instal l the cap screws and lock washers that fasten
t he battery cover to t he machine.
If the machine has two batteries, rem ove the termi-
nal nut. Remove the negative battery cable from the
terminal and move the negative battery cable away
from the battery. Make sure the jumper cable is
installed on the terminal and start the terminal nut
onto the terminal.
4000-3
ALTERNATOR
Removal STEP 11
STEP 1
Park the machine on a level surface and apply the
parking brake.
STEP 2
Lower the backhoe to the floor.
STEP 3
Remove the pin that fastens the support strut to the
loader frame.
STEP 4
Raise the loader frame until the support strut is
against the end of the lift cylinder.
Install a 1/ 2 inch breaker bar in the bracket for the
tension pulley.
STEPS
Stop the engine and install the pin in the support
strut.
STEP 12
Use the breaker bar to move the tens ion pulley just
far enough to release the tension on the drive belt
STEPS
and remove the drive belt from the alternator.
Remove the cap screws and lock washers that fas-
ten the battery cover to the right side of the ma-
chine.
STEP 13
Remove the nut and lock washer from the 8+ termi-
nal of the alternator. Disconnect the wire from the
STEP 7 8+ terminal.
Remove the battery cover.
STEP 8 STEP 14
Disconnect th e two connectors from the alterna-
If the machine has only one battery, disconnect the
tor.
negative battery cable from the battery.
STEP 9 STEP1S
Remove the cap screw and lock washer that fasten
the link to the bottom of the alternator.
STEP 16
Hold the alternator and remove the cap screw and
lock washer at the top of the alternator.
STEP 17
Remove the alternator from the mounting bracket.
STEP 18
Fasten the pulley of the alternator in a vise that has
soft jaws.
866610 STEP 19
If the machine has two batteries, remove the termi- Remove the nut and lock washer from the shaft of
nal nut. Remove the negative battery cable from the the alternator.
terminal and move the negative battery cable away
from the battery. Make sure the jumper cable is STEP 20
installed on the terminal nut onto the terminal. Remove the al ternator from the vise .
STEP 10 STEP 21
Open the hood . Hit the face of the pulley with a soft hammer to
loosen the tapered bushing in the pulley .
4000-4
STEP 22 STEP 10
Remove th e tapered bushing and the pulley from Tighten both of the cap screws.
the shaft.
STEP 11
STEP 23 Install the wire on the 8+ terminal.
Remove the fan from the shaft.
STEP 12
Installation I nstall the nut and the lock washer on the 8 + termi-
nal.
STEP 1
Install the fan on the shaft. STEP 13
Install the connectors to the alternator.
STEP 2
Install the pulley on the shaft. STEP 14
Use the breaker bar to move the tensi on pulley just
STEP 3 far enough to install the drive belt. Install the drive
Install the tapered bushing on the shaft. belt on the alternator.
STEP 4 STEP1S
Start the lock washer and the nut onto the shaft. Remove the breaker bar.
STEPS STEP 16
Fasten the pulley in a vise that has soft jaws. Close the hood.
STEP 6 STEP 17
Tighten the nut to 50 pound-feet (68 N m, 6.9 If the machine has only a battery, connect the neg-
kg / m). ative battery cable to the battery.
STEP 7 STEP 18
Remove the alternator from the vise. If the machine has two batteries, remove the termi-
nal nut from the terminal. Install the negative bat-
STEP 8 tery cab le on the terminal. Make sure the jumper
Hold the alternator in alignment with the mounting cable is installed on the terminal. Install the termi-
bracket and install the cap screw and the f lat nal nut on the terminal.
washer at the top of the alternator. Do not tighten
the cap screw. STEP 19
I nstall the battery cover.
STEP 9
Install the cap screw and lock washer that fasten STEP 20
the link to the bottom of the alternator. Install the cap screws and lock washers that fasten
the battery cover to the machine.
DRIVE BELT REPLACEMENT

STEP 1 STEP 4
Park the machine on a level surface and apply the Raise the loader frame until the support strut is
parking brake. against the end of the lift cylinder.
STEP 2 STEPS
Lower the attachments to the floor. Stop the engine.
STEP 3 STEP 6
Remove the pin that fastens the support strut to the Install the pin in the support strut.
loader frame.
STEP 7
Open the hood .
4000-5
STEPS STEP 12
Remove the old drive belt.
STEP 13
I nstall the new d rive belt on the pu Iley on the water
pump and the pulley on the crankshaft.
STEP 14
Align the coupling with the pulley on the crank-
shaft.
STEP 15
Install the cap screws, flat washers , and lock wash-
ers that fasten the coupling to the pulley on the
crankshaft. Tighten the cap screws to 70 to 84
pound-feet (95 to 114 N m, 10 to 12 kg/ m).
I nstall a 1/2 inch breaker bar in the bracket for the
tension pulley.
STEP 16
Use the breake r bar to move the tension pulley just
STEP 9 far enough to install the drive belt. Install the drive
Use the breaker bar to move the tension pulley just
belt on the alternator.
far e.nough to release the tension on the drive belt.
Remove the drive belt from the alternator.
STEP 17
Remove the breaker bar.
STEP 10
Remove the four cap screws, flat washers , and lock
washers that fasten the coupling to the pulley on
STEP 18
Close the hood.
the crankshaft.
STEP 11
Move the coupling toward the hydraulic pump.
4000-6
INSTRUMENT CLUSTER
CLIP
OIL
TEMPERATURE
GAUGE
GASKET
A
VOLTMETER
TACHOMETER
COVER
4000-7
Removal Gauge or Tachometer Removal

and Installation
STEP 1
Remove the screws that fasten the instrument clus- STEP 1
ter to the instrument console. Remove the instrument cluster from the instru-
ment console.
STEP 2
Pull the instrument cluster out of the instrument STEP 2
console.
Remove the four screws that fasten the cover and
the retainer to the body.
STEP 3
Disconnect the connectors for the wiring harness STEP 3
from the instrument cluster. Remove the cover.
STEP 4 STEP 4
Remove the instrument cluster from the machine. Remove the retainer.
Installation STEPS
Remove the sc rews that fasten the gauge or the
STEP 1 tachometer to the body.
Connect the connectors for the wiring harness to
the instrument cluster. STEP 6
Remove the gauge or the tachometer from the
STEP 2 body. If you are removing a gauge, you must pull
I nstall the instrument cluster in the instrument the studs of the gauge from the clips in the body.
console.
STEP 7
STEP 3 Install the new gauge or the new tachometer in the
Install the screws that fasten the instrument cluster body. If you are installing a gauge, make sure the
to the instrument console. studs of the gauge are pushed into the clips in the
body.
Replacing a Bulb
STEPS
STEP 1 Install the screws that fasten the gauge or the ta-
Remove the instrument cluster from the instru- chometer to the body.
ment console.
STEP 9
STEP 2 I nstall the retai nero
Turn the socket counterclockwise and remove the
socket. STEP 10
Install the cover.
STEP 3
Pull the bulb from the socket and install the new STEP 11
bulb. I nstall the screws that fasten the cover and the
retainer to the body.
STEP 4
Install the socket and turn the socket clockwise to STEP 12
hold the socket in place. I nstall the instrument cluster in the instrument
console.
STEPS
Install the instrument cluster in the instrument Circuit Board
console .
The circuit board does not normally cause any
problems. Use an ohmmeter to check the continui-
ty of the strips. If there is no continuity in anyone of
the strips , the circuit board must be replaced .
4000-8
TURN SIGNAL SWITCH REPLACEMENT
ROD
\ LEVER KNO.
~"jr~./
~
~
@~
~~ TURN
SET SCREW-___ ~~~~:--- COLLAR SIGNAL SWITCH
~
I
•
ROLL PIN
I
COUPLER
870081
4000-9
STEP 1 STEP 14
Park the machine on a level surface and apply the Remove the Allen screws from the leverforthe turn
parking brake. signals . Remove the lever.
STEP 2 STEP 15
Lower the attachments to the floor. Use a screwdriver to loosen the bottom corners of
the cover for the steering column from the panel.
STEP 3 Remove the cover.
Stop the engine.
STEP 16
STEP 4 Move the rod for the turn signal switch so the turn
If the machine does not have a horn , remove the signal switch is in the center position .
cover from the center of the steering wheel. An 0-
ring holds the cover in position. STEP 17
Loosen the set screw in the collar on the rod for the
STEPS turn signal switch.
If the machine has a horn , do steps 6 through 10.
STEP 18
STEPS Pull the end of the rod off the turn signal switch.
Remove the cover from the center of the steering
wheel. STEP 19
Disconnect the connector from the turn signal
STEP 7 switch.
Push in and turn the horn button counterclockwise
approximately 1/ 4 turn . Remove the horn button . STEP 20
Hold the turn signal switch and remove the nut
STEPS from the turn signal switch .
Remove the top conductor, the spring and the bot-
tom conductor. STEP 21
Remove the turn signal switch from the mounting
STEP 9 plate .
Loosen and remove the three screws that fasten the
plate to the steering wheel. STEP 22
Put the shaft of the turn signal switch through the
STEP 10 hole in the mounting plate and start the nut onto
Move the horn wire over to the larger hol e of the the shaft.
slot and remove the plate.
STEP 23
STEP 11 Hold the turn signal switch and tighten the nut.
Remove the nut that fastens the steering wheel to
the steering shaft. STEP 24
Connect the con nector to the turn signal switch .
STEP 12
Use an acceptable puller and remove the steering STEP 25
wheel. I nstall the end of the rod on the shaft of the tu rn
signal switch. Make su re the end of the rod is seat-
STEP 13 ed on the shaft.
Remove the control lever for the power shuttle.
4000-10
STEP 26 STEP 33
Hold the end of the rod against the turn signal If the machine does not have a horn , install the
switch and slide the collar all the way up against the cover in the steering wheel.
mounting plate.
STEP 34
STEP 27 If the machine has a horn , do step 35 through step
Pull the collar away from the mounting plate a 39.
small amount and tighten the set screw in the col-
lar. STEP 35
I nstall the horn wi re through the plate and move the
STEP 28 horn wire to the smaller hole in the plate.
I nstall the cover on the steering column and en-
gage the bottom edges of the cover in the panel. STEP 36
I nstall the screws that fasten the plate to the steer-
STEP 29 ing wheel.
Put the lever for the turn signal in position on the
rod and install the two Allen screws . STEP 37
I nstall. the bottom conductor, the spring, and the
STEP 30 top conductor.
I nstall the control lever for the power shuttle.
STEP 38
STEP 31 Put the horn button in position on the steering
I nsta ll the steering wheel on the steering shaft. wheel. Push in and turn the horn button clockwise
approximately 1/4 turn.
STEP 32
Install the nut on the steering shaft. Tighten the nut STEP 39
to 32 to 37 pound-feet (43 to 50 Nm, 4.4 to 5.1 kgm). I nstall the cover.
4002
ELECTRICAL SPECIFICATIONS
AND TROUBLESHOOTING
TABLE OF CONTENTS
Specifications . . .. . . . ........ .. .. . ...... 4002-2 Checking Vol tage at the Alternator

Terminals . .... ..................... 4002-8
Using Booster Batteries to Start
the Engine ............ . ....... .. . .. .. 4002-4 Alternator and Voltage Regulator
Test . .. ................ . ........... 4002-9
Troubleshooting Charts . . .. .. . .... .... . 4002-5
Troubleshooting the Starting Circuit .... 4002-10
Battery .... .. .... . .. .. .. .... .. . . .. . .. 4002-5
General Inspection ..... . . .. ......... 4002-10
Alternator ... . ... .. ...... .. ....... .. .. 4002-6
Starter and Starter Solenoid Test ... . . 4002-10
Starter ... . .. .. .. ... . .. .. .. .. ..... .... 4002-7
Troubleshooting the Return-To-Dig
Troubleshooting the Charging Circuit . . . 4002-8 Control ... ..... . . . . ...... .. ........ . 4002-12
General Inspection ... . . ... . . . . . . . . ... 4002-8 Magnetic Detent Will Not Release the
Control Lever . . . ... . .. . .... .... ... 4002-12
Magnetic Detent Will Not Hold the

Control Lever . . . ... .. .. ... . .... . .. 4002-14
A T enneco Compa ny
4002-2
SPECIFICATIONS
Standard electrical system . .. . . ... ... . .......... ..... . . ... . .. .. .. . one 12 volt battery, negative ground
Optional electrical system ........ . ... . ..... . . two 12 volt batteries connected in parallel, negative ground
System voltage ... .... .. .. ........... . ....... .. .............. .. . ...... ......... approximately 12 volts
Battery , standard electrical system

J I Case part number, production battery ... ... . ....... . ....... .. ........... .. . A 176482 or BMF31 EW
J I Case part number, replacement battery ... ........ . .. ...... .. .. ... ... ....... . A 145205 or BMF31 E
Group size .. . .... ...... .. . ... . ... .. . . . ....... . .............. .. . . ... ... ... .... . .... ..... . ....... 31
Reserve capacity ................. .... ... . .. .... . . . . .... . . .. ..... . ....... . .. ... . . ... .. . 170 minutes
AtO° F(-17° C) .. .. .. .. .... ......... . . ....... . ... . .. .... . ............ . ............ .. .. 700amperes
At -20° F (-29° C) .. ... . ... ... . . .. .. ..... .... . ........ ..... . .. .. .. .. . ...... . . . ......... 520 amperes
Load for load (capacity) test . . ......... ........ . .. . ..... . ....... . ... . .. . .... . .. . . ... .... 350 amperes
Plates for cell . . . . ....... . ......................... .. . .... ... ..... . .. .. ...... . ... . ............ .. . 17
Approximate weight with electrolyte . ... ....... .. . ... .... .. . . .... . ... . . . ... . ... .. 60 pounds (25.8 kg)
Battery , optional electrical system

J I Case part number, production battery .... .... . .... . .. . .... ... .. .. ......... . 0128393 or BMF28SW
J I Case part number, replacement battery .... .. . . .. ... . ... ... .... .... . .. . ...... 0127414 or BMF28S
Group size ........ . .... . ............... .... .. .... .... . .. .. . . ....... • .. . . ... ... ...... . .. .... . ... 28
Reservecapacity ... . ....... .... ... .. . ......... .. . . . . ... .. ...... .. .. . . .... . ... ... . . . . .. 110minutes
At OaF (-17°C) . ... . .... .. .. ... ...... . ..... . ......... . . . . ... ..... . ............ ... .. ... 525 amperes
At -20° F (-29°C) . .... ... . . ... .. ..... . ... ................. ... .. .......... ... .... . . .... 390 amperes
Load for load (capacity) test . . . .... . . .. .... . .. . ... . ..... .. . . .. . ...... ..... . ..... . . ... ... 263 amperes
Plates per cell . . . . . .. . ...... . .. . .... .... . .. .. . .... ... .... .. . ........ . . ... .... .... ... . .. ... ...... 12
Appro ximate weight with electrolyte ... ... .. ... ... . .... . . ..... .. . . .... .... .. ..... 44 pounds (19.9 kg)
Alternator ........... . .. .. ........ .. .. .... ... ..... . . .. ..... . .. . ...... .... . ......... 12 volt, 65 ampere
Voltage regulator .. ........ ...... .. . .. . ....•... ..... ... ... . .. . .... . ......... solid state , not adjustable
Starter ... .. ............ .. ....... . . .... .. ... . .... ... .. ....... . . . . . .. ........ 12 volt , solenoid actuated
Fuses
Main fuse panel for machines with fuse block located on the engine
The main fuse panel is mounted on the ht side of the en ine. - _--.. ,. . .,
866844
1. Fuse for the starter magnetic switch and the key switch ... . . .. .. . ... .. .. . . . ..... . . ... 30 amperes
2. Fuse for the chassis magnetic switch ...... . . . . ... .. ........ .............. . ......... 30 amperes
3. Fuse for th e chassis magnetic switch ....... ... ... ... ......... .... . ... ...... . ....... 30 amperes
4. Not used
4002-3
Accessories fuse panel

The accessories fuse panel is mounted behind an access door at the bottom of the instrumen t console.
1. Fuse for the fuel shutoff sol enoid for machines with fuse block located on engine ,
tachometer, instrument cluster, and warning buzzer . ... .. . .. .... . ...... .. ........ 10 amperes
2. Fuse for the standard lamps . .. .... . . .. . . .. . . . ...... . ...... .. . ...... . .... . ....... . . 25 amperes
3. Fuse for the stop lamps, turn signal lamps, flasher, and horn .. . . ...... . ... ... .. . .. ... 10 amperes
4. Fuse fo r the beacon (if equipped) . .. .. . . . .. . . .. . . . .. .. .. ... .. ......... .. ........... 15 amperes
5. Fuse for th e flood lamps (if equipped) ... . ... ... . . ... .... .. .. .... ... . .. .. . ....... .. . 20 amperes
6. Fuse for the return-to-dig and the clutch cutout ... ..... ......... . ... . . . ..... .... . . . . 15 amperes
7. Fuse for the wipers (if equipped) .... ... . . .. .. . ... .... . .. .. .. . .... . . . . . ... .. .. .. .. .. 15 amperes
8. Fuse for th e blower (if equipped) ... . ... . . . . ... .. . ..... .. . ... .... . . . . . . ........ .. .. . 15 amperes
9. Fuse for the backup alarm (if equipped) ............ .. .... .. .. .. . . . . . ... . . . .. .. . . . .. . 5 amperes
10. Not used
11 . Fuse for th e dome lamps (i f equ ipped) . . . .... .. .. . . . ..... . . . . ........ . .. .... . .. . ... 10 amperes
Lamps Bulb Numbers

Rops Canopy
Head lamps . ..... . . . .. . . . .. ... ....... .. . . .... . ... .. . . ...... . ... .. .. J I Case part number 91946C1
Flood lamps .. . .. . .. . .. . . .. . . .. . . . . .. .. . . .. . . . . . . . . . . .. .. .... . . . .... J I Case part number 91947C1
Stop and tail lam ps . ... . . . .... . . . .. . . ... ... .. . . .... . ... . .. . ...... .. ... ..... .. . . ... ...... No. 1157
Flasher and turn signal lamps .. .... ... . ......... . .. . ...... . ... ... ............ . . . ..... . .. No. 1156
Rops Cab
Head lamps, sea led beam .. . ... .. . . .... . . . .. ..... ..... .. .. . . . .. . .... J I Case part numbe r 91946C1
Head lamps, replaceable bulb . ... ..... . . ... . .. . . .. ........ . .. .. . . . J I Case part number 1312210C1
Flood lamps, sealed beam . . .. . . . ... . .. . ... . ..... . ...... . . .. . . . . .. . . . J I Case part number 91947C1
Flood lamps, replaceable bulb .... . . . . . .. . . . . .. ........ . .... .. .. ... J I Case part number 131221 OC1
Rear turn signal lamps ... .. . ... .... . .. . . .. ... . ....... . ... ... . . ..... .... . .... . ....... . . . . No. 1156
Stop and tail lamps .. ... .. .. .. . .. . ..... . ...... .... ..... ..... .. . . ...... . . .... . ........ . .. No. 1157
Front warning lamps . ... . ... ... .. ... .. ... .. . ... . ....... .. ... .. .. . . .. . .. . .......... .. .... No. 1157
Dome lamps ... . ........ .. . . . . . . . .... . . . . . . .. . .. .. . ..... ... . . .. ..... ..... . .. . . . .... . . ... . No. 211
T urn indicator lamps .. . . . . .. . .. .. ... . . . . .... ... . . . .. . . . .. .. ..... . .. . ..... ... .. . . .... . . . . ... No. 168
I nstrument Panel
Warning lamps (upper) .. .. ....... . . . .. ..... ... . . . . ... . . . .... . . . . .... .. .... .. .. . . .. . . . . ... No. 168
Instrument lamps (lower) .. . .. . . . .. ... . .. ... ... . .. .... . ... . .. ... .... ..... .. . ..... . . . . ..... No. 194
Rotating beacon .... . ... . . . .. .... .. . . . .. .. . . . . .. . . ..... . .. . ... .. .. . .... .. . . ... . . . .. . . . . . .. No . 4416
4002-4
USING BOOSTER BATTERIES TO START THE ENGINE

/),. WARNING: Never use booster batteries
. . to start the engine If the electrolyte in the
battery on the machine IS frozen .
47-82-A
WARNING: Sparks or flame can cause

hydrogen gas in a battery to explode. To
prevent an explosion, do the following:
1. When you disconnect the battery
cables, always disconnect the negative (-)
battery first.
2. When you connect the battery cables,
always connect the negative (-) battery
cable last.
875048
3. Do not short circuit the battery posts
Have the other person connect the positive (+)
with metal items.
cable of the booster batteries to the battery termi-
4. Do not weld, grind, or smoke near a
nal of the starter solenoid .
ba ttery. 50·60A
STEP 6
The booster batteries must have a total output Have the other person connect the negative (-)
of 12 volts . If you are using another machine for cable of the booster batteries to a good ground
power , make sure the two machines do not touch. connection on the engine.
STEP 1 STEP 7
Two persons are required for this procedure. Turn the key switch to the START position and start
the engine.
STEP 2
After the engine is running, have the other person
STEP 3 disconnect the negative (-) cable of the booster
Lower the attachments to the floor. batteries and then the positive (+) cable of the
booster batteries.
STEP 4
Put all of the controls in the NEUTRAL position.
4002-5
TROUBLESHOOTING CHART
Battery(ies)
PROBLEM POSSIBLE CAUSE CORRECTION
Discharged Low electrolyte level in battery(ies) . See Electrolyte Level in Section 4005 .
battery(ies) .
Dirty battery top. See Mai ntenance in Section 4005.
Loose or dirty connections for Clean clamps on battery cables and

battery cables. clean battery posts .
Damaged battery cell or cells. Do Capacity (Load) Test in Section 4005 .
Low or no output from alternator. Do Trou bleshooting the Charging Circuit

in this section .
Battery(ies) needs Battery malfunction . .Do Battery Tests in Section 4005 .

water frequently .
Bad wire connections between Clean and tighten co nnections.
alternator and battery.
Bad voltage regulator. Do the Alternator and Voltage Regulator

Test in this section.
continued on next page

4002-6
Alternator
Noise coming from Damaged or worn drive belt. Install a new drive belt.
the alternator.
Damaged or loose pulley on the Remove the pulley and check for
alternator. damage to the rotor shaft and pulley .
Install new parts as necessary. Tighten
nut to specification in Section 4000.
Worn or damaged bearings in the Disassemble the alternator and replace

alternator. the bearings as necessary. See Section
4019.
Short circuit in the rectifier diodes. Disassemble the alternator and do the
diode tests in Section 4019 .
Short circuit in the stator. Look for burned insulation on the

stator coi ls. Also, do the stator tests
in Section 4019.
Voltmeter shows a Bad voltage regulator. Do the Alternator and Voltage Regulator
high charging rate Test in this section .
at all times .
Bad connection , wires, or other parts See the electrical schematic in the
in the charging circuit. pocket inside the rear cover of this
service manual.
Bad voltmeter. See Section 4004.
Voltmeter shows a Damaged drive belt. Rep lace the drive be lt.
low charging rate
or no charge. Bad regulator or alternator. Do the Alternator and Voltage Regulator
Test in this section .
Bad connections, wires or other See the electrical schematic in

parts in the charging circuit. Section 4003 and make repairs
as necessary.
Bad voltmeter. See Section 4004.

4002-7
Starter
Starter runs slowly. Discharged battery(ies). See Troubleshooting Chart for

Battery(ies).
Loose ground cable at starter or Clean and tighten connections .

frame .
Loose or dirty connections for Clean c lamp on battery cables and

battery cables. clean the battery posts .
Loose cap screws that hold starter Tighten cap screws .

to flywheel hOl:Jsing .
Using wrong engine oil for cold See Fluids and Lubricants Chart in
weather operation. Section 1002.
Worn or damaged starter. See Do the No Load Test for the starter .
Section 4006 .
Obstruction in exhaust system. Check exhaust system for obstruction .
Damaged hydraulic pump. See Sect ion 8005. Remove and inspect
hydraulic pump .
Starter does not run. Discharged battery(ies). See Troubleshooting Chart fo r

Battery(ies) .
Loose ground cable at starter or Clean and tighten connection.

frame.
Loose or dirty connections for Clean clamp on battery cables and

battery cables. clean the battery posts.
Bad connections, wires, or other See the electrical schematic in

parts in the starting circuit. Section 4003 and make repairs
as necessary.
Bad key switch . Install a new key switch .
Damaged starter solenoid. Do the Starter Solenoid Test in Section

4006.
Damaged starter. Do the No Load Test in Section 4006 .

4002-8
TROUBLESHOOTING THE CHARGING CIRCUIT

General Inspection STEP 2
STEP 1
Park the machine on a level surface and lower the
attachments to the floor.
STEP 2
Apply the parking brake and stop the engine.
STEP 3
Open the hood .
STEP 4
Make sure all of the controls are in the NEUTRAL
position .
STEP S
Check the condition of the battery(ies) according
to the instructions in Section 4005 .
STEP 6
Clean the battery posts and the connectors on the
battery cables . 851746
1. 0+ Terminal
STEP 7 2. 8 + Terminal
Make sure the connections in the charging circuit 3. W Terminal
are tig ht. See the electrical schematics in Section
4003.
Connect the positive voltmeter lead to the 8+ ter-
minal of the alternator. Connect the negative lead
STEPS
of the voltmeter to a good ground connection on
Make sure there is no oil or grease on the alternator
the engine .
drive belt and the alternator drive belt is tight.
STEP 9 STEP 3
If the voltmeter indicates system voltage, do step 8.
If the alternator still does not operate correctly , do
the following check.
STEP 4
If the voltmeter does not indicate system voltage,
Checking Voltage at the do step 5.
Alternator Terminals
STEPS
STEP 1 Connect the positive lead of the vol t meter to the
Do the General I nspection procedure above. battery terminal of the starter solenoid . Connect
the negative voltmeter lead to a good ground con -
nection on the engine .
STEP 6
If t he voltmeter indicates system voltage , repair or
replace the wire between the alternator and th e
starter solenoid .
STEP 7
If the voltmeter does not indicate system voltage ,
replace the positive battery cable and repeat step 1.
STEPS
Turn key switch to ON.
4002-9
STEP 9 Alternator And Voltage Regulator

Disconnect the connector from the 0+ terminal of Test
the alternator.
STEP 10
Connect the positive voltmeter lead to the terminal
in the connector. Connect the negative voltmeter
lead to a good ground connection on the engine.
STEP 11
If the voltmeter indicates system voltage , connect
the connector to the alternator and do the Alterna-
tor and Voltage Reg ulator Test in this section.
STEP 12
If the voltmeter does not indicate system voltage, 5 19617
remove the cover from the fuse panel on the bot- This test must be done using a tester for charg-
tom of the right console. ing systems. The following test is written for the
use of an OTC Charging System Analyzer, CAS-
STEP 13 10344. Other test equipment can be used. Connect
Remove the top fuse from the left fuse block. The the test equipment according to the instructions of
fuse will be a 10 ampere fuse . the manufacturer.
STEP 14 STEP 1
Use an ohmmeter to check the fuse . Do the Checking Voltage at the Alternator Termi-
nals procedure on page 4002-8 .
STEP1S
If the fuse is bad, replace the fuse and repeat step STEP 2
10. Connect the red lead of the tester to the 8+ termi-
nal of the alternator. Connect the black lead of the
STEP 16 tester to a good grou nd connection on the ma-
If the fuse is good, install the fuse in the fuse block chine.
and install the cover.
STEP 3
STEP 17 If lamp 2 of the tester is illuminated, the test con-
Remove the instrument cluster according to the nections and the battery are good. Do step 6.
instructions in Section 4000.
STEP 4
STEP 18 If lamp 2 and 4 of the tester are illuminated, the level
Remove the bulb for the alternator warning lamp of the charge in the battery is too low to complete
from the instrument cluster. the test. See Section 4005 and charge the battery.
STEP 19 STEPS
Use an ohmmeter to check the bulb. If none of the lamps in the tester illuminate, check
the connections for th e tester.
STEP 20
If the bulb is bad, replace the bulb, install the in- STEP 6
strument cluster, and repeat step 9. Have another person start the engine while you
look at the tester.
STEP 21
If the bulb is good, there is a problem in the circuit STEP 7
between the alternator and the IGN terminal of the If none of the lamps in the tester are illuminated,
key switch . See the electrical schematic in Section stop the engine . If one or more of the lamps is
4003 and use the voltmeter to check the circuit. ill uminated constantly, stop the engine. If any of
the lamps are illuminated intermittently, have the
other person slowly increase the engine speed (1/2
throttle maximum) until the lamps are illuminated
constantly or no longer illuminated . Have the other
person slowly decrease the engine speed to low
idle and stop the engine.
4002-10
STEP 8 NOTE: If a new voltage regulator is available, re-

If none of the lamps in the tester illuminated, the place the voltage regulator and repeat the test. If
alternator and voltage regulator are good . the alternator still does not work correctly, see Sec-
tion 4019, disassemble the alternator, and replace
STEP 9 the stator.
If lamp 1 of the tester illuminated, the rate of charge
is too high because of a short circuit in the voltage STEP 11
regulator. Replace the voltage regulator. If lamps 2 and 3 of the tester illuminated, there is a
short circuit in one of the negative diodes or the
STEP 10 stator is connected to ground. See Section 4019
If lamp 2 of the tester illuminated, the alternator is and inspect the diodes and the stator.
not charging because of an open circuit in the rotor
or the voltage regulator. See Section 4019 and in- STEP 12
spect the rotor. If there is not an open circuit in the If lamp 3 of the tester illuminated , there is an open
rotor, replace the voltage regulator. circuit or a short circuit in one of the diodes. See
Section 4019 and inspect the stator and the diodes.
TROUBLESHOOTING THE STARTING CIRCUIT

General Inspection STEP 8
Check for damaged insulation or broken wires in
STEP 1 the starting circuit. Repair or replace any damaged
Park the machine on a level surface and lower the or broken wires . See the electrical schematics in
attachments to the floor. Section 4003.
STEP 2 STEP 9
Apply the parking brake and stop the engine. If the starter still does not run correctly, do the
following test.
STEP 3
Make sure all of the controls are in the NEUTRAL Starter and Starter Solenoid
position. Test
STEP 4 Use a voltmeter for this test.
Open the hood.
STEP 1
STEPS Do the General Inspection procedure above.
Check the condition of the battery(ies) according
to the instructions in Section 4005. STEP 2
Make sure the key switch is in the OFF pos ition .
STEPS
Clean the battery posts and the connectors on the STEP 3
battery cables. Make sure all of the controls are in the NEUTRAL
position .
STEP 7
Check for loose connections and corrosion at the STEP 4
connec tions on the starter, starter solenoid, fuse Make sure the parking brake is applied .
block near the starter for machines with fuse block
on the engine , magnetic switch , and the key switch.
See the electrica l schematics in Section 4003.
4002-11
STEPS STEP 6
If the voltmeter did not indicate system voltage,
replace the positive battery cable and repeat the
test.
o STEP 7
If the voltmeter indicated system voltage, momen-
tarily connect a jumper wire between the battery
terminal and the switch terminal on the starter.
STEP 8
If the starter ran correctly , the starter and the star-
ter solenoid are good . Use the voltmeter to check
starting circuit. See the electri cal schematics in
Section 4003 .
STEP 9
If the starter did not run correctly, pull the boot
away from the motor terminal on the starter sole-
noid. Momentarily connect a jumper cable be-
851747 tween the motor terminal and the battery terminal
on the starter. During this test the starter drive will
1. Battery Terminal not engage the flywheel.
2. Switch Terminal
3. Motor Terminal STEP 10
If the starter motor ran , the starter solenoid is bad.
Connect the positive voltmeter lead to the battery Replace the starter so lenoid .
terminal on the starter soleno id . Connect the neg-
ative voltmeter lead to a good ground connection STEP 11
on the machine. Look at the voltmeter. If the starter motor did not run , the starter motor is
bad. Repair or replace the starter motor.
4002-12
TROUBLESHOOTING THE RETURN-TO-DIG CONTROL
15 AMPERES MAGNETIC
FUSE DETENT
SOLENOID
RED/ BLUE
RED/ BLUE
BLUE/ YELLOW
PURPLE/ RED
SIDE
CONSOLE
HARNESS
GROUND CONNECTION
AT INSTRUMENT RETURN-TO-DIG
CONSOLE HARNESS
MAGNETIC SWITCH
PROXIMITY PURPLE/RED
SWITCH RED/BLUE
RED/ BLUE
BLUE/YELLOW BLUE/ YELLOW
BROWN/PINK BROWN/ PINK
861950
The Magnetic Detent Will Not STEP 7

Release the Control Lever Move the loader control lever to the ROLLBACK po-
sition and release the loader contro l lever. If the
STEP 1 magnetic detent still does not release the loader
Park the machine on a level floor and apply the control lever, do the next step .
parking brake.
STEP 8
STEP 2 Turn the key switch to the OFF position .
Lower the bucket so the bottom of the bucket is flat
on the floor. STEP 9
If the magnetic detent released the loader control
STEP 3 lever, do the next step . If the magnetic detent did
Lower the other attachments to the floor. not release the loader control lever, the centering
spring in the loader con t rol valve is broken or the
STEP 4 spool cannot move freely in the loader control
Stop the engine. valve. See Section 8007 and repair the loader con-
trol valve as necessary.
STEPS
Adjust the return-to-dig according to the instruc- STEP 10
tions in Section 9010. Turn the key switch to the ON position.
STEP 6 STEP 11
Turn t he key switch to the ON position . Move the loader control lever to the ROLLBACK po-
sition and release the loader control lever.
4002-13
STEP 12 STEP 17
Remove the magnetic switch for the starting circuit
and insta ll the magnetic switch in the connector on
the harness for the return-to-dig circuit.
STEP 18
Move the loader control lever to the ROLLBACK po-
sition and release the loader control lever. If the
magnetic detent stil l does not release the loader
control lever, there is a short circuit in the wire
between the connector for the magnetic switch and
the inner fem ale terminal of the connector for the
proximity switch. If the magnetic detent released
the loader control lever, the magnetic switch is bad.
Install a new magnetic switch in the connector on
867036
the starting harness.
Disconnect the connector at the proximity switch .
STEP 13 STEP 19
If the magnetic detent did not release the loader
control lever, do the next step . If the magnetic de-
tent released the loader control valve, the prox-
im ity switch is bad and must be replaced .
STEP 14
Disconnect the return-to-dig harness from the

main harness. The connector is near the magnetic
switch.
STEP 20
867031
The magnetic switch for the return-to-dig circuit

and the magnetic switch for the starter are fas-
tened on the inside of the frame on the right side of
the machine. The two magnetic switches have the
same part number
NOTE: The magnetic switch for the starting cir-

cuit can be installed above the magnetic switch for
the return-to-dig circuit. Look at the wiring harnes-
ses in the photograph for correct identification of
the magnetic switches.
STEP 15 867033
Remove the magnetic switch for the return-to-dig If the magnetic switch did not release the loader
circuit. control lever, do the next step. If the magnetic de-
tent released the loader control lever, there is a
STEP 16 short circuit in the wire that connects the inner
If the magnetic detent released the loader control female terminal of the connector to the connector
lever, do the next step. If the magnetic detent did at the magnetic switc h. Repair or replace the wire.
not release the loader control lever, do step 19.
4002-14
STEP 21 STEPS
If the fuse is bad, replace the fuse and check the
operation of the return-to-dig circuit. If the return-
to-dig circuit still does not operate correctly , con -
tinue with the procedure . If the fuse is good, install
the fuse and continue wi t h the procedure.
STEP 6
Start the engine.
STEP 7
Raise the loader frame .
STEPS
Move the bucket control lever to the DUMP position
867035
and hold the bucket control lever until the bucket
Disconnect the two wires from the magnetic detent
stops moving .
on the loader control valve.
STEP 9
STEP 22
Lower the loader frame until the bucket is on the
Connect one lead of an ohmmeter to a good
floor.
ground connection. Connect the other lead to first
one terminal and then the other terminal on the
STEP 10
magnetic detent.
Lower the other attachm ents to the floor.
STEP 23
STEP 11
If the ohmmeter indicated continuity at either of the
Stop the engine.
terminals, there is a short circu it in the coil of the
magnetic detent. Replace th e coil assembly.
STEP 12
Make sure the parking brake is applied.
STEP 24
If the ohmmeter did not indicate continuity, there is
STEP 13
a short circuit in the purple/red wire that connects
Turn the key switch to the ON position .
t he magnetic detent to the connector on the main
harness. Repair or replace the wire.
STEP 14
Magnetic Detent Will Not Hold
the Control Lever
NOTE: See the electrical schematics on page
4002-12.
STEP 1
Park the machine on a level surface and lower the
attachments to the floor.
STEP 2
Apply the parking brake and stop the engine.
STEP 3
Remove the cover for the accessories fuse panel at Disconnect the connector at the proximity switch.
the bottom of the instrument console.
STEP 4
Check the fuse for the return-to-dig circuit. See
Specifications in this section for the location of the
fuse.
4002- 15
STEP 15 STEP 22
If the magnetic deten t did not hold the loader con-
trol lever, do the next step . If the magnetic detent
held the loader control lever, there is an open cir-
cuit in the ground circuit between th e inner female
terminal of the connector and the ground connec-
tion below the accessories fuse panel. See the elec-
trical schematics in Section 4003 and use an ohm-
meterto find the open circuit starting at the ground
connection.
STEP 23
Connect one lead of an ohmmeter to the inner
female termina l of the connector on the wiring har-
ness. Connect the other lead of the ohmmeter to a
867039
good ground connection .
Connect the positive lead of the voltmeter to the
outer female terminal of the connector on the wir-
STEP 24
ing harness . Do not make any connections to the
If the ohmmeter indicated continu ity, do the next
connector on the proximity switch. Connect the
step. If the ohmmeter did not indicate continuity,
negative lead of the voltmeter to a good ground
there is an open circuit in the ground circuit be-
connection.
tween the inne r female terminal of the connector
and the ground connection below the accessories
STEP 16 fuse panel. See the electrical schematic in Section
If the voltmeter indicates system voltage , do the
4003 and use an ohmmeter to find the open circuit
next step. If the voltmeter does not indicate system
starting at the ground connection . Repair the open
voltage , there is an open circuit in the circuit be-
circuit and con t inue with the procedure.
tween the outer female terminal of the connector
and the fuse . See the electrical schematics in Sec-
STEP 25
tion 4003 and use a voltmeter to find the open
Disconnect the jumper wire from the ground con-
circuit.
nection . Connect that end of the jumper wire to the
inner female terminal of the connector. Make sure
STEP 17 the other end of the jumper wire is connected to the
Connect a jumper wire between the inner female
male terminal of the connector.
terminal and the male terminal of the connector on
the wiring harness.
STEP 26
STEP 18
Move the loader control lever to the return-to-dig
position.
STEP 19
If t he magnetic detent did not hold the loader con-
trol lever, do the next step . If the magnetic detent
held the loader control lever, the proximity switch
is bad and must be replaced .
STEP 20
Disconnect the jumper wire from the inner female
terminal of the connector and connect that end of
the jumper wire to a good ground connection. The magnetic switch for the return-to-dig circuit
Make sure the other end of the jumper wire is still and the magnetic swi tch for the starter are fas-
connected to the outer male terminal of the con- tened on the inside of the frame on the right side of
nector. the machine. The two magnetic switches have the
same part number.
STEP 21
Move the loader control lever to the ROLLBACK po-
sition.
4002-16
STEP 27 STEP 35
Make an identification mark on the magnetic switch If the ohmmeter indicates con ti nuity, do the next
for the return-to-dig circuit and remove the mag- step . If the ohmmeter does not indicate continuity,
netic switch from the connector. there is an open circuit in the wire between the B
terminal and the connector for th e prox imity switch.
STEP 28 Repair or replace the wi re.
Remove the magnetic switch for the starter from
the connector and install the magnetic switch in STEP 36
the connector on the return-to-dig harness. Connect the positive lead of th e voltmeter to the C
terminal of the connector. Connect the negative
STEP 29 lead of the voltmeter to a good ground connection .
Move the loader control leve r to the ROLLBACK po-
sition . STEP 37
If the voltmeter indicates system voltage , do the
STEP 30 next step . If the voltmete r does not indicate system
If the magnet ic detent did not hold the loader con- voltage , there is an open c ircuit in the wire between
t rol lever, do the next step. If the magnetic detent the C terminal and the splice in the wiring harness.
held the loader control lever, the magnetic switch
with the identification mark is bad and must be STEP 38
disca rded . I nstall the good magneti c switch back in Install the magnetic switch in the connector on the
the connector on the harness for the starting cir- harness for the return-to-dig circuit.
cuit. I nstall a new magnetic switch in the connector
on the return-to-dig harness. STEP 39
STEP 31
Remove the magnetic switch from the connector
on the return-to-dig harness and install the mag-
netic switch in the connector on the harness for the
starti ng circui t.
STEP 32
c
Disconnect the return-to-dig harness from the

main harness. The connector is near the magnetic
switch .
STEP 40
Connect on e lead of the ohmmeter to a good

ground connection . Connect the other lead to the
A terminal of the connector on the return-to-dig
harness.
STEP 33
If the ohmmeter indicates continuity , do the next
step . If the ohmmeter does not indicate cont inuity,
there is an open circuit in the wire between the A
terminal in the connector and the splice in the wir-
ing harness. Repair or replace the wire. 867033
Connect the positive lead of the voltmeter to th e

STEP 34 inner female terminal in the con nector on the main
Oisconnect the ohmmeter lead from the A terminal
harness.
and co nnect the ohmmeter lead to the B te rm ina l.
4002-17
STEP 41 STEP 43
If the voltmeter does not indicate system voltage, One of the wires is red/ blue and the other wire is
do the next step. If the voltmeter indicates system purple/ red. Connect the positive lead of the volt-
voltage, there is a problem in the wire between the meter to the terminal on the red/ blue wire . Connect
middle terminal of the connector and the D termi- the negative lead of the voltmeter to a good ground
nal of the connector for the magnetic switch. connection .
STEP 42 STEP 44
If the voltmeter does not indicate voltage, there is
an open circuit in the wire between the terminal
and the splice in the main harness. If the voltmeter
indicates voltage, there is an open circuit in the
purple/ red wire that connects the loader control
valve to the connector on the main harness. Repair
or replace the wire.
867035
Disconnect the two wires from the loader control

valve .
This Page is Blank
4003
ELECTRICAL SCHEMATICS
TABLE OF CONTENTS
Electrical Symbols ....... . ........ . ... . 4003-2 Cab, Machine without Fuse Block Located
on the Engine . ......... .. .... ..... ... 4003-7
Cab, Machine with Fuse Block Located
on the Engine . .... . . ...... . .. . ..... .. 4003-3 Chassis, Rear, Machine without Fuse Block
Located on the Engine .... . ......... . . 4003-8
Chassis, Rear, Machine with Fuse Block
Located on the Engine .. . .... .... ... . . 4003-4 Chassis, Front, Machine without Fuse Block
Located on the Engine .. .. . .. ......... 4003-9
Chassis, Front, Machine with Fuse Block
Located on the Engine . ............ ... 4003-5 Canopy, Machine without Fuse Block Located
on the Engine ... .. .... . . .. .. ... .. . .. 4003-10
Canopy, Machine with Fuse Block
Located on the Engine . ... . ... . . . .. ... 4003-6
A Tenneco Compan y
4003-2
+
BATTERY, 12 VOLT
-illllllllll~ CIRCUIT BREAKER
STARTER SOLENOID
m FUSE
ALTERNATOR
0 DIODE
~
SENDER
~
MOTOR
®
SWITCH , NORMALLY
CLOSED (NC )
I· ~I HORN OR ALARM
OJ
SWITCH, NORMALLY LAMP
OPEN (NO)
MAGNETIC SWITCH,
GROUND CONNECTION
NORMALLY OPEN (NO)
KEY SWITCH
0 RES ISTOR
SOLENOID
~ VARIABLE RESISTOR
rtH
L __ :.J
CLUTCH 1__ ~z~ __ 1 870043
Electrical Symbols
4004
INSTRUMENT CLUSTER
TABLE OF CONTENTS
Removal and Installation . . . ... See Section 4000 Hydraulic Filter and A ir Cleaner ... .... 4004-2
Replacing a Bulb .. .. .. .. .. ... See Section 4000 Brake Failure ... . ... ....... . ... ... ... 4004-3
Gauge Removal and Installation . See Section 4000 Parking Brake ... ...... . ... .. ......... 4004-3
Circuit Board .......... . ..... See Section 4000 Checking a Gauge .. ... . .... .. . ... . . .. . 4004-4
Checking the Warning Lamps .. . . .. .. ... 4004-2 Water Temperature. Oil Temperature. or
Fuel Gauge .... .. ...... .... ........ 4004-4
Engine Oil Pressure .. ... . .... . . . .. . .. 4004-2
Voltmeter .............. .. . .. .... .. . . . 4004-4
Alternator .. ...... . . ...... .. .... ...... 4004-2
Checking the Tachometer . . ... . .. . ... .. 4004-5
J I Case 8-67230
A T enneco Company
4004-2
CHECKING THE WARNING LAMPS

Engine Oil Pressure Hydraulic Filter or Air Filter
STEP 1 Both of the warning lamps must illuminate
The warning lamp must illuminate when the key when the key switch is turned to START.
switch is in the ON position and the engine is not
running. If the warning lamp does not illuminate, STEP 1
the cause can be: If one of the warning lamps will not illuminate,
check for:
1. A bad bulb .
1. A bad bulb .
2. A bad connection at the connector in the
instrument cluster or at the pressure switch for 2. A bad connection at the instrument clus-
the engine oil pressure. ter.
3. An open circuit in the wires between the 3. An open circu it in the wire between the
instrument cluster and the pressure switch. instrument cluster and the diode.
STEP 2 4. An open circuit in the diode.

The warning lamp must not illuminate when the
engine is running. If the warning lamp illuminates, STEP 2
the cause can be: If neither of the warning lamps illuminate, check
for:
1. Low engine oil pressure.
1. An open circu it in the ground wire con-
2. A bad pressure switch for the engine oil nected to the housing of the key switch .
pressure.
2. A bad connection at either end of the
3. A short circuit in the wires between the ground wire.
instrument cluster and the pressure switch.
Neither of the warning lamps must illuminate when
Alternator the engine is running .
STEP 1 STEP 3
The warning lamp must illuminate when the key If either warning lamp illuminates when the engine
switch is in the ON position and the engine is not is running , the cause can be:
running . If the warning lamp does not illuminate,
the cause can be: 1. A dirty filter.
1. A bad bulb . 2. A bad pressu re switch for the warning

lamp.
2. A bad connection at the connector in the
instrument cluster or at the alternator. 3, A short circuit in the wires between the
pressure switch and the warning lamp.
3. An open circuit in the wires between the
alternator and the instrument panel. STEP 4
If both of the warning lamps illuminate when the
STEP 2 engine is running, the ca use can be:
engine is running . If the warning lamp illuminates, 1. A bad key switch.
the cause is probably the alternator or the voltage
regulator. See Section 4002 and check the alterna- 2. One of the warning lamps has illuminated
tor and voltage regulator. for one of the causes in Step 3 and the other
warning lamp has illuminated because of a bad
diode.
4004-3
Brake Failure Parking Brake

STEP 1 STEP 1
The warning lamp must illuminate when the key The warning lamp must illuminate when the key
switch is in the ON position and the plunger in the switch is in the ON position and the parking brake is
top of the master cylinder is pushed all the way applied. If the warning lamp does not illum inate,
down . If the warning lamp does not illuminate, the the cause can be :
cause can be:
1. A bad bu lb.
1. A bad bUlb.
2. Bad connections at the connector in the
2. Bad connections at the connector in the instrument c luster, the parking brake sw itch ,
instrument cluster, the master cylinder, or the or at the ground connection for the parking
ground connection for the master cylinder brake switch .
switch.
3. An open circuit in the wires between the
3. An open circuit in the wires between the instrument cluster and the parking brake
instrument cluster and the master cylinder. switch .
4. An open circuit in the wires between the 4. An open circuit in the wires between the
master cylinder and the ground connection. parking brake switch and the ground connec-
tion .
5. A bad switch in the master cylinder.
5. The parking brake switch is not adjusted
STEP2 correctly.
The warning lamp must not il luminate when the
key switch is in the ON position and the plunger is 6. A bad pa rking brake switch .
released . If the warning lamp illuminates, thecause
can be: STEP 2
1. The brake fluid in the master cyl inder is key switch is in the ON position and the parking
below the required level. brake is released . If the warning lamp illuminates,
the cause can be :
2. A bad switch in the master cylinder.
1. The parking brake switch is not adjusted
3. A short circuit in the wires between the correctly.
instrument cluster and the master cylinder.
2. A short circuit in the wires between the
instrument clus ter and the parking brake
switch.
3. A bad pa rking brake switch .

4004-4
CHECKING A GAUGE
Water Temperature, Oil STEP 2
Temperature, or Fuel Level if th e gauge only works part of the time, the cause
can be:
STEP 1
If the gauge does not work correctly: 1. A bad connecti o n at the sender.
1. Disconnect the wire from the sender. 2. A bad connection at the instrument clus-
ter.
2. Turn the key switch to ON.
3. Bad connection in the conn ectors in the
3. Hold the wire against the frame or the en- wiring harness.
gine to make a good grou nd connection.
4. A short circuit or an open circuit in the
4. Have another person look at the gauge. If wires between the instrument cluster and the
you are checking the water temperature gauge sender.
or the oil temperature gauge, the needle must
move all the way to the top of the gauge. If you 5. A bad sender.
are checking the fuel level gauge, the needle
must go all the way to the bottom of the gauge. 6. A bad gauge.
5. If the needle moved, the sender is bad and Voltmeter

must be replaced . If the needle did not move
the gauge is bad or there is an open circuit i~ STEP 1
the wires between the sender and the gauge. Connect the positive lead of a test voltmeter to the
positive post of the battery. Connect the negative
6. Install the wire on the sender. lead of the test voltmeter to the negative post of the
battery. If the machin e has two batteries, make sure
7. See Section 4000 and remove the instru- the leads are connected to the same battery.
ment cluster from the instrument console and
disconnect the wiring harness from the instru- STEP 2
ment cluster. Start the engine and run the engine at 1500 rpm
(r/ min).
8. See the wiring schematic in Section 4003
for the location of the terminal in the connec- STEP 3
tor on the wiring harness. Connect one lead of Read the test voltmeter.
an ohmmeter to the terminal in the connector.
Connect the other lead of the ohmmeter to a STEP 4
good ground connection. Read the voltmeter in the instrument cluster and
compare the readings . If the readings are within 1/ 2
9. If the ohmmeter did not indicate continui- volt, the voltmeter is good.
ty , there is a short circuit in the wires between
the connector and the sender. Repair or re-
place the wires. If the ohmmeter indicated con- U //) I EACH MARK
tinuity , the wires are good and the gauge must
~I IS 1/ 2 VOLT
be replaced .
0===> -lY
.:::::-. I
EEN
12 VOLTS
VOLTS
,~--+--. YELLOW
861936
4004-5
CHECKING THE TACHOMETER

STEP 1 STEP 12
Park the machine on a level surface and lower the Adjust the voltmeter to read volts DC (direct cur-
attachments to the floor. rent) .
STEP 2 STEP 13
Stop the engine and apply the parking brake. Connect the positive lead of the voltmeter to the
middle terminal (white wire with orange tracer) of
STEP 3 t he small connector on the wiring harness . Con -
Open the hood. nect the negative lead to a good ground connec-
tion .
STEP 4
Remove the connector from the W terminal of the 1. If the voltmeter indicates system voltage,
alternator. do the next step .
STEPS 2. If the voltmeter does not indicate system

Adjust a voltmeter to read volts AC (a lternating voltage, repair or rep lace the wire between the
cu rrent) . ·small connector and the key sw itch.
STEP 6 STEP 14
Connect one lead of the voltmeter to the W termi- Keep the positive lead connected to the middle
nal in the alternator. Connect the other lead to a termina l of the small connector. Connect the nega-
good ground connection on the engi ne. tive lead to the lower terminal (b lack wire with
orange tracer) of the small connector.
STEP 7
Have the other person start the engine while you 1. If the voltmeter indicates system voltage,
look at the volt meter. The voltmeter must ind icate a do the next step .
minimum of six volts AC.
2. If the voltmeter did not indicate system vol-
1. If the voltmeter indicated six volts or more , tage, repair or replace the wire between the
do the next step. sma ll connector and the ground connection.
2. If the voltmeter indicated less than six STEP1S

volts, see Section 4019 and replace the recti - Turn the key switch to the OFF pOSition.
fier bridge.
STEP 16
STEPS Connect one lead of an ohmmeter to the remaining
Remove the four screws that fasten the instrument terminal (yellow wire with red tracer) in the small
cluster to th e instrument conso le. connector on the wiring harn ess. Connect the
other lead to the terminal on the wire that was
STEP 9 connected to the W terminal of the alternator.
Remove the instrument cluster from the inst ru-
ment console . 1. If the ohmmeter indicates continuity, the
problem is in the tachometer and th e tacho-
STEP 10 meter must be rep laced.
Disconnect the wiring harness from the instrument
cluster. 2. If the ohmmeter does not indicate continu-
ity, there is an open circuit in the circuit be-
STEP 11 tween the connectors. Repair the open circuit.
Turn the key sw itch to the ON position.
This Page is Blank
4005
BATTERY(S)
TABLE OF CONTENTS
Specifications . . . ...... .. . .. .. See Section 4002 Battery Test . . ...... . .. .. . ..... . . . ... . .. 4005-5
Booster Batteries .. ... . .. . .. . . See Section 4002 Visual Checks .. . . .. . . .... . .. . ..... . .. 4005-5
Safety Rules . . . .. ...... . ...... . . . . . . ... 4005-2 Specific Gravity Check ....... . ...... . 4005-5
Maintenance ........... .. ..... ... .. .... 4005-3 Capacity (Load) Test . . .. . . ........... 4005-6
Electrolyte Level . . ... . ..... .... .. ... . 4005-3 Charging A Battery . ........ . ... . . ... . .. 4005-7
Inspecting and Clea ning the Battery ... 4005-3 Preparing a Dry Charged Battery
For Use .. . ......... . ... .. .. . .... ... . . 4005-8
Nonspill Caps ...... . .. . . .. . . . .. .. ... ... 4005-4
Written In Clear
And
Simple
English
J I Case 8-44360
A Tenneco Company
4005-2
SAFETY RULES
h WARNING: Never try to charge the bat- CAUTION: If the battery(s) in this
. . tery if the electrolyte In the battery IS fro- machine must have nonspill caps, do not
zen. 47-83 h operate t~e machine if the nonspill caps
. . do not work correctly or if the nonspill
caps are not in place. 48·99
CAUTION: Never cause sparks to occur
A or smoke near batteries that are charging or

have been recently charged. 13-8
CAUTION: Disconnect the ground

cable first when the battery cables are dis-
h connected from the battery.
. . Connect the ground cable last when the

battery cables are connected to the bat-
~~ 4~~
CAUTION: Some batteries have a venti-

lation tube. " there is battery acid in the
ventilation tube, this battery acid can be
released when the battery is turned upside
A down. If 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. 48·57·A
4005-3
MAINTENANCE
Electrolyte Level NOTE: Addwateronly. oONOT adde/ec tro-
Iyte.
If the battery is a maintenance free battery,
ch ec k the level of the electrolyte every 1000 hours Inspecting and Cleaning a Battery
of opera t ion or si x months, whichever occurs first. \
For all other batteries , check the level of the elec- If damage causeS' an electrol yte leak, replace
tro lyte every 250 hours of operation . the battery .
NOTE: A maintenance free battery will have If the batte ry in your mach ine has nonspill
the words Maintenance Free on the decal on the caps, see Nonsp ill Caps on page 4005-4 and check
top of the battery. If the center part of the decal has the condition of the nonspill caps. See Specifica-
been removed for access to the battery caps, it is tions in Section 4002 to find if th e battery in your
possible that the words Maintenance Free have machine must have nonspill caps.
been removed from the decal.
Inspect the battery at regular intervals for dirt,
Check the level of the electrolyte more often corrosion , and damage. Electrolyte and dirt on the
du r ing hot weather . The use of a large amount of top of the battery can cause the battery to dis-
water by the battery can be caused by high battery charge by making a passage for th e current to flow .
temperature or a voltage regulator setting that is
too high . Keep the electrolyte level above the top of If the battery must be cleaned , remove the
th e plates in the battery at all times to prevent battery from the battery carrier and clean the bat-
damage to the battery. tery, cable terminals, and the battery carrier. When
available , use Case Battery Saver and cleaner ac-
NOTE: On maintenance free batteries it is cording to the instructions on the container. Case
necessary to remove the center part of the decal for 6 "ttery Saver and Cleaner also helps prevent cor-
access to the battery caps. 00 not discard the cen - rosion . If Case Battery Saver and Cleaner is not
ter part of the decal. Install the center part of the available , use baking soda and water as a cleaner.
decal after the battery caps have been installed. DO NOT permit any type of cleaner to enter the
cells of the battery .
If the level of the electrolyte is low, add dis-
tilled water or other clean water until the electro- Install the battery in the machin e and make
lyte is ju st below the cell opening. Do not add more sure the fasteners are tight. Apply Case Battery
water than is needed. Too much water can cause Saver and Cleaner or Urethane Seal Coat to the
bad performance , a short serv ice life, and corro- cable terminals to prevent corrosion . See the Parts
sion around the battery. Counter Catalog . DO NOT apply grease.
4005-4
NONSPILL CAPS
See Specifications in Section 4002 to find if the The nonspill caps have a valve with a stem
battery(s) in your machine must have nonspill made of lead and rubber. When the nonspill cap is
caps. turned upside down, the weight of the lead holds
the rubber stem against the breather hole, prevent-
CAUTION: If the battery(s). in this
ing the loss of electrolyte.
machine must have nonspil/ caps, do not
A operate the machine if the nonspil/ caps

do not work correctly or if the nonspil/
caps are not in place. 48·99
If the breather hole and valve are closed by
foreign material , pressure in the battery can
become high enough to break the case of the bat-
Do not operate the machine if the nonspill tery. Always check the breather hole for foreign
caps do not work correctly of if the nonspill caps material when you check the electrolyte level. If
are not in place. Nonspill caps prevent electrolyte there is foreign material over the breather hole,
leakage which can cause personal injury and dam- turn the nonspill cap upside down and clean the
age to the machine if the machine turns over in an nonspill cap. Move the nonspill cap up and down
accident. rapidly. You must be able to hear the movement of
the valve. If you cannot hear the valve, wash the
nonspill cap and loosen the valve. Move the non-
spill 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 replace nonspill cap .
When you install a new battery, the new bat-

800305 tery MUST have nonspill caps . You can use the
nonspill caps from the old battery if the nonspill
caps are in good condition.
4005-5
BATTERY TEST
NOTE: To correctly test a battery, do each 2
part of the battery test until you know the condition
160 - - 1032
of the battery. 150-
- - -030
-+028
70 -
= - +,028
140_ _~ • .O26
60-
- - -.022
Visual Checks 130 -
120 -
- -.020
~ +.O '8 50 -
. = - -+02 1
- - i,0 14 = - - +.0 14
110 - - 10 12
100- _~!O'O 40 -
1. Make sure the cable connections are clean and _ + .004 + .006
= - - +.007
90 -
tight. Clean foreign material from the top of the 80 -
- - >.002 30 -
26 .7 --===:
- - -002
battery . 70 - - - .004
- - -.006
20 _
60 - - -008 ~ - .OO7
- - -.01 0
50 - - -.0 12
10 -
- - -.014
2. I nspect the battery case, battery posts , and 40 _ - - .0 16 = - - -.014
30 _ _~-.D1 e
cables for damage. - - - -022
0 -
20 - - -.024 = - - .021
- - -.026
10 - _ -.028 -10 -
_ _ _ -.030 = - -.028
3. Check the electrolyte level. See page 4005-3 . 0_ - -.032
-20-
4. If you added water to the battery, the battery

790863 A
must be charged for 15 minutes at 15 to 25 amperes 1. Temperature in of
to mix the water with the electrolyte. 2. Temperature in ° C
Specific Gravity Check Specific Gravity Chart
A hydrometer is used to check the specific

gravity (we ight) of the electrolyte. The specific 4. Make a record of the corrected specific gravity
gravity is an indication of the level of charge for reading for each cell.
each cell.
5. If the difference between the high reading and
Hydrometers are made to show the correct the low reading is .050 or more , charge the battery
spec ific gravity when the temperature of the elec- and check the specific gravity again. If after charg-
trolyte is BO° F (26 .7° C) . ing , the differen ce is still .050 or more, install a new
battery .
When you check the specific gravity, you must
know the temperatu re of the electrolyte. If your 6. The corrected specific gravity reading shows
hydrometer does not have a thermometer, get a the level of charge for the cell. The level of charge
thermometer to check the temperature of the elec- must be at least 75% in each of the cells . I n mainte-
trolyte. The thermome ter must indicate a high tem- nance free batteries the level of charge is at least
perature of at least 120° F (52 ° C) . 75% if the corrected specific gravity reading is
1.240 or higher. In all other batteries the level of
1. Remove enough electrolyte from a cell so that charge is at least 75% if the correc ted specific grav-
the float is free in th e tube . ity reading is 1.230 or higher.
NOTE: If the specific gravity cannot be checked 7. If the difference between the high reading and
without first adding water to the cell, the battery the low reading is less than .050 , and the level of
must be cha rged for 15 minutes at 15 to 25 amperes charge is at least 75% in all of the cel ls, do the
to mix the water with the electrolyte. Then check Capacity (Load) Test.
the specific gravity.
B. If the difference between the high reading and
2. Read the float. the low readi ng is less than .050, but the level of
charge is less than 75% in any of the cells , charge
3. Read the thermom eter. If the reading is above the battery and check the specific gravity again. If
BO ° F (26.7°C) add spec ific gravity points to the after charging:
reading for specific gravity. If the reading is be low
BO° F (26.7" C) subtract specific gravity points from a. The level of charge is less than 75% in any
the reading for specific gravity. See the following of the cells, discard the battery.
ill ustration and add or su btract specific gravity
points as needed . b. The level of charge is at least 75% in all of
the cells , do the Capacity (Load) Test.
4005-6
Capacity (Load) Test NOTE: Never apply a lo ad for longer tha n 15 sec-
onds. A fler each 15 seconds, turn the load control
This test can be done using a variable load knob to OFF for at least one minute.
tester such as the Sun Electric VAT -33 . Other test
equipment can be used . Connect the test equip- 4. Apply a 15 ampere load to the battery for 15
me nt according to the instructions of the manufac- seconds . Wait at least three minutes before contin-
ture r of th e equipment. uing with the test.
1. The level of charge of the battery must be at 5. Check and make a record of the temperature of
least 75%. Do the Specific Gravity Check in this the electrolyte.
section .
6. Find the correct load for thi s test in Specifica-
2. Prepare the tester (Sun ElectricVAT-33 shown) tions in Section 4002 .
fo r the test.
NOTE: The correct load is half of the cold crank-
a. Select the voltmete r range that will mea- ing amperes at 0° F ( -17° C).
sure 1 to 18 volts.
7. Turn the load control knob until the ammeter
b. Mi,lke sure the load control knob is in the indicates the specified load . Keep the load for 15
OFF position. seconds and read the voltmeter. Turn the load con-
trol knob to OFF .
c. Select th e ammeter range that will mea-
sure 0 to 1000 amperes. 8. Compare the test read ing and the temperature
of the electrolyte to the chart below .
d. Move the volt lead switch to the INT. posi-
tion . Temperature of Minimum Voltage
electrolyte
3. Connect the tester to th e batte ry as shown .
70° F(21 ° C) and above . . . .. . . .. ... . . .. ..... 9.6
60°F (16° C) ........ . .. .. ......... .. ....... 9.5
o 50° F (10°C) ..... . ... . . .. . . . .... .. .. . . . .... 9.4
40° F WC) ............ .. ...... .. ....... . .. 9.3
30°F (-1 ° C) ..... .. ...... .. ...... .. .. . .. ... 9.1
20°F (-7 ° C) ....... .... ... .. . .. ............ 8.9
10°F (-12°C) .. ..... ......... ..... ......... 8.7
OaF (-18 ° C) ... ...... ...... .......... . ..... 8.5
a. If the test result is equal to or more than the

voltage shown , the battery is in good condi-
tion .
b. If th e test result is less than the vol tage

shown , discard the batte!.y .
790499
1. LOAD CON TROL KNOB 2. AMMETER CLAMP
/
4005-7
CHARGING A BATTERY
WARNING: Never try to charge the bat- The charging rate must be decreased if:
A tery If the electrolyte In the battery is fro-

zen . 47-83 1. Too much gas causes the electro lyte to flow
from the cells .
Before you charge the battery, check the level
of the electrolyte . 2. The temperature of the electrolyte rises above
125 0 F (52 0 C).
It is difficult to give an exact charging rate
because of the following variable conditions: (1) NOTE: For the best charge, use the slow charg-
temperature of the electrolyte , (2) level of charge, ing rates.
and (3) condition of the battery . Use the charging
guide for the correct charging rate and time . The battery is fully charged when , over a three
hour period at a low charging rate. no cell is giving
See Specifications in Section 4002 for the res- too much gas, and the specific gravity does not
erve capacity of the battery in this machine. 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

'I nitia l rate for standard taper charger .

851285
NOTE: A maintenance free battery will have the removed to get access to the battery caps, it is
words Maintenace Free on the decal on the top of possible the words Maintenance Free will have
the battery. If the center part of the decal has been been removed from the decal.
Continued on next page

4005-8
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
Above 80 to 125 Minutes 15 Hou rs at 5 Amperes 3.7 5 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


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

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

1. Remove the caps from the battery. 4. Connect a battery charger to the battery.
2. Fill each cell to the top of the separators with 5. Charge the battery at 30 amperes until the spe-
electrolyte . This will permit the volume of electro- cific gravity is 1.250 or more and the temperature of
lyte to increase when heated by charging the bat- the electrolyte is at least 60° F (15.5 ° C) .
tery .
6. If necessary, fill each cell with electrolyte until
3. I nstall the caps on the battery. If the battery in the electrolyte is just below split ring at the bottom
your machine must have nonspill caps, install the of the cell opening .
nonspill caps. See Specifications in Section 4002
to find if th e battery in your machine must have
nonspill caps .
4006
STARTER AND STARTER SOLENOID
TABLE OF CONTENTS
Removal and Installation . ... . . See Section 4000 Brush Holder ..... . ....... .... . . ... . 4006-11
Specifications ....... . .. .... ..... ....... 4006-2 Armature . ....... . . ..... . ... . .... ... 4006-11
Lubrication . ... .. .. ........ ...... . .. ... 4006-2 Field Coil Test ......... .. . ... ... . ... 4006-12
No-Load Test . . ..... .. . ..... . ... ... ... . 4006-2 Assembly .. . ....... .. ... . ... . ... ... ... 4006-13
Disassembly ... . ....... . .............. . 4006-7 Illustration of Starter ..... . ... . .. .. .. .. 4006-19
Inspection ..... ...... .. ... . .... . . ... .. 4006-11 Starter Solenoid Test ..... . ....... .. . . . 4006-20
Brushes and Brush Springs .. . . .. . .. . 4006-11
J I Case 8-42910
A Tenneco Company
4006-2
SPECIFICATIONS
Case part number A170746
No-Load Test at 80° F (26JO C)

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

idler gear shaft and spring .
NO-LOAD TEST
General Information Test Equipment
1. The No-Load Test is done with the starter re- The No-Load Test can be done using a Sun
moved 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 armatu re shaft.
3. Check to see if the starter drive can be turned.
Pull the gear on the starte r drive out of the starter A remote starter button is needed to actuate
drive housing . Turn the gear to turn the starter the starter.
drive and the armature.
A fully charged 12 volt battery is needed to
4. If the starter drive cannot be turned, disassem- supply the electricity to turn the starter.
ble the starter and make repairs as needed . Then
do the No-Load Test.
4006-3
Test Procedure 3. Connect the positive battery cable to the bat-

tery terminal on the starter solenoid and the nega-
The illustrations in this procedure show the tive battery cab le to the mounting flange of the
use of the Sun Electric VAT-33 tester. Other test starter.
equipment can be used. Connect the test equip-
ment according to this procedure and the manu-
facturer's instructions.
1. If the VAT-33 tester is being used:

BBo
o 0
000000
a. Select the 0 to 100 ampere range.
+
b. Select the 18 to 40 volt range.
3
c. Move the volt lead switch to the EXT. posi-
tion .
d. Turn the load control to the OFF position.
831430
1. Positive Ba ttery Cable

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

post of the batte ry. Connect the negative load ca-
ble to the negative post.
795328
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.
831431
1. Positive Load Cab le
2. Negative Load Cable
4006-4
5. Connect the red voltmeter lead to the motor 7. Fasten the ammeter clamp around the positive
terminal on the starter solenoid. battery cable so that the tip of the arrow is toward
the starter.
B~o
000000 o 0
000000
+
I
o 0
831432
1. Red Voltmeter Lead
2. Motor Terminal
831434
1. Ammeter Clamp
6. Connect the black voltmeter lead the mount- 8. Connect the leads from the remote starter but-
ing flange on the starter. ton to the Battery and Switch terminals.
BBo
o 0
831433
1. Black Voltmeter Lead
3
831435
1. Remote Starter Button
2. Battery Terminal
3. Switch Terminal
4006-5
IMPORTANT: Steps g, 10, and 11 must be done 2. Low armature shaft speed and high current
rapidly. Do not load the battery for more than 15 draw 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
seconds. a. Tight, dirty, or worn bearings .
9. Actuate the remote starter button and turn the b. A bent armature shaft.
load control until the voltmeter indicates 11 volts.
c. Loose pole shoes (pole shoes make con-
tact with the armature).
141131 0
~~ 2 d. A short circuit in the armature coil. Disas-

o0 0 00 000000
semble the starter. Use an armature tester to
test the armature. Use the instructions in-
Li-~o~-¥O~-~+ cluded with the armature tester.
Lt-~--_A-'
e. Damaged field coil. Do the test on page

4006-12.
I 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

4006-12.
c. Damaged bearings.
5 4. If the armature does not rotate and the current
G) draw is zero, possible causes are:
a. An open field circuit. Disassemble the star-

1. Remote Starter Button ter and inspect the field coil connections.
2. Load Control
3. Voltmeter
4. Ammeter b. An open armature coil. Disassemble the
5. Hand Held Tachometer starter and check for burned commutator bars.
Use an armature tester to test the armature.
Use the instructions included with the arma-
ture tester.
10. Look at the ammeter and make a record of the
c. Brushes not making good contact with the
ammeter indication .
commutator bars. Check for high insulation
between the commutator bars, broken brush
11. Use the hand held tachometer and check the
springs, or worn brushes.
armature shaft speed. Make a record of armature
shaft speed .
5. Low armature shaft speed and low current
draw are indications of:
12. Release the remote starter button and turn the
load control to the OFF position .
a. Dirt or corrosion on connections.
Understanding No Load b. Damaged wiring.
Test Results
c. Dirty commutator bars.
1. If the current draw and the armature shaft
speed are within the ranges under Specifications, d. All causes in step 4.
the starter is good.
4006~
6. High armature shaft speed and high current Install a newfield coil. Dothe No Load Testagain to
draw are indications of a short circuit in the field check for improvement in the operation of the
coil . It is difficult to find a short circuit in a field coil . starter.
4006-7
DISASSEMBL Y
1. Pull back the boot on the motor terminal and 4. Remove the cover.
loosen and remove the nut and lock washer.
330735
330731
5. Hold the spring away from one of the brushes

2. Loosen and remove the screws that hold the connected to the field coil and remove the brush
cover. from the brush holder. Repeat this step for the
other brush connected to the field coil.
330732
330736
3. Loosen and remove the cap screws.

6. Remove the brush holder.
330733
33(J737
4006-8
7. Remove the field frame assembly. 10. Remove the starter drive housing from the star-
ter solenoid.
330741
8. Remove the armature.

11. Push down the starter drive housing as shown
to loosen and remove the starter drive.
330739
330743
9. Fasten the starter solenoid in a vise and loosen

and remove the screws that hold the starter drive
housing. 12. Remove the steel ball from the starter drive. If
necessary, use a magnet.
330740
4006-9
13. Remove the O-ring from the groove in the star- 16. Remove the bearing cage .
ter drive housing.
330704
330701
17. Remove the thrust washer.

14. Remove the spring .
330705
330702
18. Loosen and remove the screws that hold the

15. Remove the idler gear. cover.
330703 330706
4006-10
19. If necessary, use a hammer to loosen the cov- 21 . Remove the plunger.
er.
330709
330707
22. If necessary, remove the gasket from the cov-

20. Remove the cover. er.
330708 330710
4006-11
INSPECTION
All parts except the starter drive must be 3. If necessary, put the armature in a lathe and
cleaned using mineral spirits and a brush or cloth . remove enough material from the commutator to
Use a clean, dry cloth to clean the starter drive. make the run out less than .002 inch (0 .05 mm) .
Brushes and Brush Springs

1. If the length of a brush fastened to the brush
holder is less than 7/ 16 inch (11 mm), a new brush
holder assembly must be used when the starter is
assembled.
2. If the length of a brush fastened to the field coil

is less than 7/ 16 inch (11 mm), a new field frame
assembly must be used when the starter is assem-
bled.
3 . Use a spring scale to check the tension of the

brush springs. Pull the brush spring up until the 834918
brush spring is just above the brush holder. The

scale indication must be between 4 and 9 pounds
(1 .8 and 4 .1 kg). If a brush spring is not as speci- 4. Measure the diameter of the commutator. If the
fied, use a new brush spring when the starter is diameter is less than 1.38 inch (35 mm) , install a
assembled . new armature.
Brush Holder
1. Hold the leads of an ammeter against the frame
and the brush holders that have insulation be-
tween the brush holder and frame.
3 1314'
5. If the depth of the groove between the commu-

tator bars is less than .008 inch (0.2 mm) , cut the
insulation between the commutator bars to a depth
313142 of 1/ 64 to 1/ 32 inch (0 .5 toO .8 mm) . Use sandpaper
to remove the rough edges from the commutator
bars.
2. If there was an indication of a complete circuit,
install a new brush holder. 6. Check the bearings on the armature for free
rotation, rough balls, and damage to t he inner race
Armature or outer race . If a bearing is to be replaced , use a
press and acceptable tools to remove and install
1. Test the armature on an armature tester. Use the bearings.
the equipment manufacturer's instructions.
2. Put the armature on vee-blocks as shown and

check the runout of the armature with a dial indica-
tor. The runout must not be more than .002 inch
(0.05 mm ).
4006-12
Field Coli Test 3. Hold the leads of the ohmmeter against one of
the brushes and the end of the cable. The needle of
1. Hold the leads of an ohmmeter against one of the ohmmeter must move.
the brushes and the field frame. The needle of the
ohmmeter must not move.
3 13144
313143
4. If the needle of the ohmmeter did not move,

install a new field frame assembly.
2. If the needle of the ohmmeter moved, install a
new field frame assembly.
4006-13
ASSEMBLY
1. Install the plunger in the starter solenoid. 4. Install and tighten the screws.
330709 330712
2. If necessary, install a new gasket in the cover. 5. Install the bearings in the bearing cage.
330711 330714
3. I nstall the cover. 6. Lubricate the bearings and teeth of the idler
gear with the grease specified on page 4006-2
330705
330715
4006-14
7. Install the thrust washer. 10. Install the spring.
330834
8. Install the bearing cage as shown. 11. Install a new O-ring in the groove in the starter
drive housing. Lubricate the O-ring.
330835
330838
9. Install the idler gear.

12. Lubricate the open bearing on the starter drive
with the grease specified on page 4006-2.
330836
33084 1
4006-15
13. Start the starter drive into the starter drive 16. Assemble the starter drive housing and starter
housing . solenoid .
330802 33(}741
14. Push down the starter drive housing to push 17. Install a lock washer, flat washer, and O-ring
the starter drive all the way into the starter drive on the screws that hold the starter drive housing.
housing. Lubricate the O- rings.
330B03 330805
15. Put a small amount of grease in the hole in the 18. Install the screws in the starte r drive housing .
starter drive and install the steel ball in the hole.
330807
330aQ4
4006-16
19. Fasten the starter solenoid in the vise and 22. Use the springs to hold the brushes in the
tighten the screws that hold the starter drive hous- brush holder as shown.
ing .
330808
330740
23 . Install the brush holder.

20 . Install the armature.
330809
330739
24. Put the springs on to p of the brushes con-

21. Install the field frame assembly. nected to the brush holder.
330738
4006-17
25. Install the brushes that are connected to the 28. Install the cover and align the cover with the
field coil. brush holder.
330811
26. Use a cap screw to align the brush holder with 29. Install and tighten the screws that hold the
the field frame assembly. brush holder.
330812 330815
27 . Move the brush holder so that the brush holder 30. Install a lock washer, flat washer, and O-ring
is even with the end of the armature. on the cap screws . Lubricate the O-rings.
330813 330816
4006-18
31. Install and tighten the cap screws. 32. Install the cable, lock washer, and nut on the
motor terminal, and tighten the nut.
330731
33. Pull the boot over the motor terminal.

4006-19
2 14
~@
1. Cap Screw 7. Brush Holder 13. Plunger 18. Roller (6) 831437
2. Lock Washer 8. Bearing 14. Nut 19. Bearing Cage
3. Flat Washer 9. Armature 15. Starter Solenoid 20. Spring
4. O-Ring 10. Field Frame Assembly 21 . Steel Ball
5. Screw 11 . Cover 16. Thrust Washer 22. Starter Drive
6. Cover 12. Gasket 17. Idler Gear 23. Starter Drive Housing
4006-20
STARTER SOLENOID TEST

This test will check the condition of the pull-in 3. Connect a jumper wire to the battery term inal
winding and the hold-in winding in the starter sole- and the switch terminal in the starter solenoid
noid. housing. The jumper wire must be made from No.
10 or larger wire.
The jumper cable connected to the starter
mounting flange and the motor terminal must have 4. Connect the jumper cable with the common
a 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
1. Remove the rubber boot from the motor termi- of 5 seconds to prevent damage to the pull-in wind-
nal. Remove the nut and lock washer from the ing and the hold-in winding.
motor terminal. Then remove the wire from the
motor terminal. 5. Connect the jumper cable with the common
connection to the negative battery post. The pi-
2. Connect a jumper cable to the positive battery nion gear on the starter drive must come all the way
post of a fully charged 12 volt battery. Connect the out rapidly and with force.
other end of the jumper cable to the battery termi-
nal in the starter solenoid housing . 6. If the pinion gear did not come out rapidly and
with force, the pull-in winding is damaged . The
complete starter solenoid housing assembly must
be replaced.
o
o1 7. Disconnect the jumper cable from the motor
o terminal in the starter solenoid housing. The pi-
nion gear on the starter drive must not move to-
o + ward the starter drive housing.
1. 12 Volt Battery 831038 8. If the pinion gear started to move toward the
2. Starter starter drive housing, the hold-in winding is dam-
3. Battery Terminal aged. The complete starier solenoid housing as-
4. Switch Terminal
5. Motor Terminal
sembly must be replaced.
4019
ALTERNATOR
BOSCH
TABLE OF CONTENTS
Removal and Installation .. ... .. See Section 4000 Illustration of Alternator . . ... .. .... ... 4019-3
Specifications ..... .......... . .... . ... . . 4019-2 Inspection . .. . . . ... ......... .. ... .. .. .. 4'019-6
Disassembly .... . .. .. . ................. 4019-3 Assembly ..... . ...... . ...... .. .... .. ... 4019-8
J I Case
A Tenneco Company
e 8-42851
4019-2
SPECIFICATIONS
12 Volt Alternator
Manufacturer .. . ........ . ......... . . . .. .. . .. .. . ...... . .. ... .. . ... .... . . . .... . ... . ..... Robert Bosch
Robert Bosch part number ... . . ..... ... ... . . .. ......... .. ... .. . . .. . . . .. . . . ....... .. . .. 0120489475
Output ........ . .. .... . . ...... .. ....... .. . .. .. . .. .. . . ..... .. . ........ .. ....... 14 vo lts at 65 am peres
Resistance of rotor winding ... . . ...... . ........ . . . ... .. . . ....... . .. . ... ... . .. . . . . . . .. ..... 2.8 ohms
Resistance of stator winding . . ... . . . . .. ..... . .. . ...... .. •....... . . ..•. . ........ . . .. .... .. .. 0.1 ohms
Minimum brush length . . .... . . .. .... . ...... . . ... . ........ .. .. . ........... . . ... .... 0.55 inch (14 mm )
24 Volt Alternator
Manufacturer .. . ... . .... .. .. .. ... .. .. . . ... . .... . . . ..... . . . . . ... . . . .. .. .. ... . ... .. . .... Robert Bosch
Robert Bosch part numbe r . . .. .. . ...... ... . .... . .. .. . .. . .... ... . ...... . . .. .. . ......... 0120489481
Output .... . ....... . .... .. . . . .... . . ... .... . .... . . ... ... . ... . .. . . .......... . ... 28 volts at 45 amperes
Resistance of rotor winding ....... .. . . . . .. .. .... . . . ... . ........... . . .. ........ . .... ....... 9.0 ohms
Res istan ce of stator winding ... ... ............ . ............... . ..... .. .. ... ......... .•.... 0.22 ohms
Minimum brush length . . ... . .. ... .... . . . ..... . .. ... . .. ... . ... . .......... . ......... 0.55 inch (14 mm )
4019-3
DISASSEMBL Y
@4i
21 22
2~ 18
(j)
11
861 586
1. Cap Screw 7. Rotor 13. Insulator 1B. Flat Washer

2. Screw B. Rear Bearing 14. O-ring 19. Condenser
3. Cover 9. Stator 15. Housing 20. Fiber Washer
4. Spacer 10. Terminal 16. Voltage Regulator and 21. Nut
5. Front Bearing 11. Rectifier Bridge Brush Holder 22. Lock Washer
6. Bearing Retainer 12. Terminal Nut 17. Screw and Flat Washer
4019-4
NOTE: See Section 4000 for removal and in- 4. Remove the lead , flat washer, and fiber washer
sta llation of the pullev and fan. from the terminal.
1. Remove the screws and flat washers that fas-

ten the voltage regulator and brush holder to the
housing.
5. Remove the condenser from the housing .

519602
2. Remove the voltage regulator and brush hold-

er.
!j17728
6. Make alignment marks on the housing, the sta-

tor, and the cover.
3. Remove the nut that fastens the lead for the

condenser to the terminal.
519607
517724
4019-5
7. Remove the screws that fasten the housing, 10. Remove the rotor from the cover.
stator, and cover together.
517702
519609
11. Remove the O-ring from the housing.

8. Separate the cover and rotor fro m the stator
and housing .
519611
12. Remove the screws that fasten the rectifier

bridge to the housing.
9. Remove the screws that fasten the roto r to the
cover.
1. Screw 517H?5
4019-6
13. Remove the housing. 14. Remove the insulator from the terminal.
517822 5 17706
INSPECTION
1. Check th e stato r resistanc e. The resistan ce in 2. Check the stator for a short circu it. Make sure
each coil mu st be 0.1 ohm s for a 12 volt alternator the rectifier bridge does not touch th e stator. Con-
and 0.22 oh ms fo r a 24 vo lt altern ator. nect one lead of the ohmmeter to the housing of the
stator . Connect the othe r lead to each of the three
leads from the stator. If the pointer of the ohmmeter
moved , there is a short circuit in the stator. See step
5 and install a new stator.
517928
703630
4019-7
3. Check the positive diodes in the rectifier bridge. b. Reverse the ohmmeter leads. Read the
ohmmeter.
a. Connect the negative lead of the ohmme-
ter to the output (8+) terminal. Connect the c. There must be a high reading and a low
pos itive lead of the ohmmeter to one of the reading . If the readings are the sam e, replace
leads for the posit ive diodes. The positive di- the rect ifier bridge .
odes are the t hree diodes that are closest to the
output (8+) terminal. Read the ohmmeter. d. Repeat step 4 for the other two negative
diodes.
5. If any of the diodes are damaged , or if the stator

winding is bad, use a soldering iron to separate the
rectifier bridge from the stator. Use a heat setting of
at least 1000 watts and d isconnect the wires quick-
ly to prevent damage to the diod es. Connect the
rectifier bridge to the stator.
517936
b. Reverse the ohmmeter leads. Read the

ohmmeter.
c. There must be a high reading and a low

reading . If the readings are the same, replace
the rect ifier bridge.
d. Repeat step 3 for the other two positive

diodes. 6. I nspect the bearings on the rotor. If the bear-
ings are damaged , replace the bearings.
4. Check the negative diodes in the rectifier
bridge.
a. Connect the negative lead of the ohmme-

ter to the surface of the diode plate that is not
painted . Connect the positive lead of the
ohmmeter to one of the leads for the negative
diodes. Read the ohmmeter.
517944
703628
4019-8
7. Use the ohmmeter to check the resistance of 9. Check for continuity between the condenser
the rotor winding. The resistance must be 2.8 mounting tab and the lead. If there is continuity, the
ohms, for a 12 volt alternato r and 9.0 ohms for a 24 condenser is bad.
volt alternator.
517814
5 17902
10. Measure the length of each brush . The length

8. Hold one lead of the ohmmeter on the slip ring must be more than .55 inch (14 mm).
and the other lead on the housing. If the pointer
moved , there is a short circuit between the housing 11. Check for continuity between each brush and
and the rotor coil. the brush terminal. If there is no continuity, replace
the voltage regulator and brush holder.
517904
517914
ASSEMBLY
1. Install the insulator on the terminal. 2. Install the housing on the rectifier bridge and
stator.
517706
517822
401 9-9
3. I nstall the screws t hat fasten the rectifier bridge 6. I nsta ll the flat wash er and the nut on the termi-
to the housing . nal.
1. Screws 517825 517834
4. I nstall t he fi ber washer and then the flat washer 7. Install the condenser on the housing.
on the terminal.
517836
517830
8. Check for a short circuit between th e terminal

5. I nstall the lead for the condenser on the termi- and the housing . If there is continuity , the insulator
nal. is bad.
5 17832 517840
4019-10
12. Make sure the marks are in alignment and in-

stall the cover and roto r in the stator and housing.
1. O-ring 5 17828
5196 ' 1
10. Install the rotor in the cover.

13. Install the screws that fasten the housing, sta-
tor, and cover together. Tighten the screws evenly.
5 17702
519609
11. Install the screws that fasten the roto r to the

cover.
14. Install the vo ltage regulator and the brush
holder. Be careful not to damage the brushes.
4019-11
15. Install the screws and flat washers.
519602
This Page is Blank
- 5-
STEERING
5000
REMOVAL AND INSTALLATION OF STEERING
SYSTEM COMPONENTS
TABLE OF CONTENTS
Specifications . .. . . ...... ... .......... .. 5000-2 Removal .. . . ....... .. ... . .. . . . .. . .. .. 5000-5
Steering Control Valve .. . .... ..... .. ... . 5000-3 Installation .. . . ..... .. . ... ... ... . . . ... 5000-7
Illustration of Steering Control Valve Steering Cylinder, Two WheE!1 Drive

I nstaliation .... .. ........ . .. . ... .. .. 5000-3 Machines .... .. ... ....... .. ..... . . . . . 5000-8
Removal . ... ..... . . . ...... . ... ....... 5000-4 Removal ... . . .. ... .. .. .......... .. . .. 5000-8
Installation . . . .. .. .. . . . . .. . .. . ... ..... 5000-4 I nstaliatio n .. . .. .. ... .. . ....... . .. . . " 5000-8
Steering Column . .. .......... . ...... .. . 5000-5 Steering Cylinder, Fou r WhMI Drive
Machines . ... . ..... . . . . . . . . See Section 5022
J I Case 8-67240
A Ten neco Compan y

5000-2
SPECIFICATIONS
Special torques
Nut for the steering wheel ....... ...... ... . . .. .. . .. . 32 to 37 pound-feet (43 to 50 N m, 4.4 to 5.1 kg/ m)
Cap screws that fasten the steering cylinder to the axle ..... . .. . .. .. . . .. .. ...... 580 to 596 pound-feet
(786 to 944 N m, 80 to 96 kg / m)
Self-locking nuts that fasten the drive shaft to the drive yoke ..... ......... ..... ... 50 to 60 pound-feet
(67 to 81 N m, 6.9 to 8.3 kg/ m)
5000-3
STEERING CONTROL VALVE
. . . .- - - - - COVER
• • HORN BUTTON
~. TOP CONDUCTOR
SPRING----_.~
BOTTOM CONDUCTOR -
-~ ~
~_....~ _ _- PLATE
SCREW -.~
COVER---~
O-RING---~
NUT-
.I--STEERING CONTROL VALVE
TURN SIGNAL LEVER
~
~~- ~~/
"- /
~ / "-
"-'@~
~
870250
5000-4
Removal STEP 14
Use a screwdriver to loosen the bottom corners of
STEP 1 the cover around the steering column. Remove the
Park the machine on a level surface and apply the cover.
parking brake.
STEP1S
STEP 2 Open the access cover at the rear of the hood .
Lower the bucket to the floor and put the backhoe
in transport position . STEP 16
Clean the hose connections at the steering control
STEP 3 valve.
If the machine is not equipped with a horn, remove
the cover from the center of the steering wheel. The STEP 17
cover is held by the fit of an O-ring. Put identification tags on the hoses to the steering
control valve.
STEP 4
If the machine is equipped with a horn do steps 5 STEP 18
through 9. Disconnect the hoses from the steering control
valve. Install plugs in the hoses.
STEPS
Remove the cover from the center of the steering STEP 19
wheel. Loosen the two cap screws that hold the steering
control valve to the bracket for the steering column
STEP 6 and the steering column.
Push in the horn button and turn the horn button
counterclockwise approximately 1/ 4 turn . Remove STEP 20
the horn button. Hold the steering control valve and remove the cap
screws.
STEP 7
Remove the top conductor, spring, and bottom STEP 21
conductor. Remove the steering control valve.
STEP 8 Installation
Hold the steering control valve in alignment with
STEP 9 the steering column and the bracket for the steer-
Move the horn wire over to the larger hole of the ing column .
slot and remove the plate.
STEP 2
STEP 10 I nstall and tighten the cap screws.
Loosen and remove the nut that ho lds the steering
wheel in place. STEP 3
Remove the plugs from the hoses and connect the
STEP 11 hoses to the steering control valve.
Use an acceptable puller and remove the steering
wheel. STEP 4
Install the cover over the steering column and en-
STEP 12 gage the cover with the panel.
Loosen and remove the control lever for the power
shuttle. STEPS
Install the lever for the turn Signals. Install and
STEP 13 tighten the two Allen head screws that fasten the
Loosen and remove the two Allen head screws that lever.
fasten the lever for the turn signals. Remove the
lever for the turn signals . STEP 6
I nstall and tighten the control lever for t he power
shuttle .
5000-5
STEP 7 STEP 14
Install the steering wheel. Install the cover in the center of the steering wheel.
STEPS STEP1S
Install the nut that holds the steering wheel in If the machine is not equipped with a horn , insta ll
place. Tighten the nut to 32 to 37 pound-feet (43 to the cover in the center of the steering wheel.
50 N m, 4.4 to 5.1 kg / m) .
STEP 16
STEP 9 Start the engine and run the engine at low idle.
If the machine is equipped with a horn do steps 10
through 14. STEP 17
Turn the steering wheel all the way to the right and
STEP 10 left several times to remove any air from the steer-
Install the horn wire through the plate and move the ing system.
horn wire over to the smaller hole in the slot of the
plate. STEP1S
Check the level of the oil in the reservoir and add oil
STEP 11 as required.
Install and tighten the three screws that fasten the
Close the access cover.
STEP 12
Install the bottom conductor, spring, and top con-
ductor.
STEP 13
Install the horn button. Push in the horn button and
turn the horn button clockwise approximately 1/4
turn to fasten the horn button in place.
STEERING COLUMN
Removal STEP 7
Remove the top conductor, spring, and bottom
STEP 1 conductor.
parking brake. STEPS
STEP 2 plate to the steering wheel.
Lower the bucket to the floor and put the backhoe
in transport position. STEP 9
Move the horn wire over to the larger hole of the
STEP 3 slot and remove the plate.
If the machine is not equipped with a horn , remove
th e cover from the center of the steering wheel . The STEP 10
cover is held by th e fit of an O-ring. Loosen and remove the nut that holds the steering
wheel in place.
STEP 4
If the machine is equipped with a horn do steps 5 STEP 11
through 9. Use an acceptable puller and remove the steering
wheel.
STEPS
Remove the cover from the center of the steering STEP 12
wheel. Loosen and remove the control lever for the power
shuttle.
STEPS
Push in the horn button and turn the horn button STEP 13
counterclockwise approximately 1/ 4 turn. Remove Loosen and remove the two Allen head screws that
the horn button . fasten the lever for the turn signals. Remove the
lever for the turn signals .
5000-6
STEP 14 STEP 23
Use a screwdriver to loosen the bottom corners of Remove the roll pin f rom the power shuttle rod and
the cover around the steering column . Remove the sleeve.
cover.
STEP 24
STEP 15 Remove the sleeve from the power shuttle rod .
Loosen and remove the Ph illips head screws that
fasten the mounting plate for the lamp switches at STEP 25
the left side of the panel. Loosen and remove the cap screws and lock wash-
ers that fasten the mounting plate for the steering
STEP 16 column to the firewall . Early production machines
Loosen and remove the cap screws, lock washers, have nuts, lock washers, and bolts.
and flat washers that fasten the panel to the firewall.
STEP 26
STEP 17 Lift the mounting plate for the steering column and
Lift the panel a small amount and push the mount- pull the power shuttle rod through the self-aligning
ing plate for the lamp switches through the panel. bearing at the left side of the frame. Remove the
Lift the panel over the boots for the control levers at mounting plate and the power shuttle rod.
the right side of the panel and remove the panel.
STEP 27
STEP 18 Loosen t he nuts and lock washers on the bolts that
Disoonnect the wire harness from the right side of fasten the bracket for the turn signal lever to the
the bracket for the steering column . bracket for the steering column .
STEP 19 STEP 28
If the machine is equipped with a horn, disconnect If the machine is not equipped with a horn, remove
the horn wire. the steering column from the mounting plate.
STEP 20 STEP 29
Loosen and remove the two cap screws and lock If the machine is an early production machine and
washers that fasten the steering column to the is equipped with a horn, loosen and remove the
steering control valve . screws that fasten the plate for the horn wire to the
steering column and remove the plate. Remove the
STEP 21 steering column from the mounting plate .
Loosen and remove the nut and lock washer that
fasten the control rod for the power shuttle to the STEP 30
sleeve for the power shuttle rod . Move the control If the machine is a late production machi ne and is
rod out of the way. equipped with a horn, turn the steering column to
align the plate for the horn wire with the notch in
STEP 22 the mounting plate . Remove the steering column
Loosen the nut and bolt on the clamp that holds t he from the mounting plate.
roll pin in the sleeve. Remove the clamp .
5000-7
Installation STEP 13
Make sure the detent pin on the shuttle control
STEP 1 lever assembly is fully engaged in the neutral slot of
If the machine is a late production machine and is the detent plate. Tighten the Allen head screws in
equipped with a horn , turn the steering column to both lock colla rs to hold the shuttle control lever
align the plate for the horn wire with the notch in assembly in position.
the mounting plate. Install the steering column
through the mounting plate. STEP 14
Loosen the lock nut(s) and adjust one or both ball
STEP 2 joints on the control rod for the power shuttle so
If the machine is an early production machine and the control rod can be installed with the shuttle
is equipped with a horn, install the steering co lumn control lever assembly in neutral detent. Make sure
through the mounting plate . Install the plate and the thread engagement between the ball joints is
screws for the horn wire. equal and tighten the lock nuts.
STEP 3 STEP 15
If the machine is not equipped with a horn, install Connect the control rod for the power shuttle to the
the steering column through the mounting plate. sleeve on the power shuttle rod. Install the lock
washer and nut.
STEP 4
Tighten the nuts and lock washers on the bolts that STEP 16
fasten the bracket for the turn signal lever to the Install the two cap sc rews and lock washers that
bracket for the steering column. fasten the steering column to the steering control
valve.
STEPS
Install the mounting plate for the steering column STEP 17
and install the power shuttle rod through the self- If the machine is equipped With a horn , connect the
aligning bearing at the left side of the frame. horn wire .
STEP 6 STEP 18
Install the cap screws and lock washers that fasten Connect the wi re harness to the right side of the
the mounting plate for the steering column to the bracket for the steering column.
firewall. Early production machines have nuts,lock
washers, and bolts. STEP 19
Install the panel. Install the boots for the control
STEP 7 levers through the panel and pull the mounting
Install the sleeve on the end of the power shuttle plate for the lamp switches through the panel.
rod.
STEP 20
STEP 8 Install the cap screws, lock washers, and flat wash-
Align the hole in the sleeve with the hole in the ers that fasten the panel to tile firewa ll.
power shuttle rod and install the roll pin.
STEP 21
STEP 9 Install the Phillips head screws that fasten the
I nstall the clamp over the sleeve and tighten the mounting plate for the lamp switches.
clamp.
STEP 22
STEP 10 Install the cover around the steering column.
Connect the control rod forthe power shuttle to the
sleeve on the power shuttle rod. Install the lock STEP 23
washer and nut. Install the lever for the turn sign;lls. Install the two
Allen head screws that fasten the lever.
STEP 11
If adjustment of the power shuttle linkage is re- STEP 24
quired, do steps 12 th rough 15. Install the control lever for the power shuttle.
STEP 12 STEP 25
Loosen and remove the nut and lock washer that I nstall the steering wheel.
fasten the control rod for the power shuttle to the
sleeve for the power shuttle rod.
5000-8
STEP 26 STEP 30
Install the nut that holds the steering wheel in Install the bottom conductor, spring , and the top
place. Tighten the nuts t032 to 37 pound-feet (43 to conductor.
50 N m, 4.4 to 5.1 kg / m) .
STEP 31
STEP 27 Install the horn button . Push in the horn button and
If the machine is equipped with a horn do steps 28 turn the horn button clockwise approximately 1/4
through 32. turn.
STEP 28 STEP 32
Install the plate . Install the horn wire through the I nstall the cover in the center of the steeri ng wheel.
larger hole in the plate and move the horn wire over
to the smaller hole. STEP 33
If the machine is not equipped with a horn , install
STEP 29 the cover in the center of the steering wheel.
Install the three screws that fasten the plate to the
steering wheel.
STEERING CYLINDER, TWO WHEEL DRIVE MACHINES

Removal Installation
STEP 1 STEP 1
Clean the hose connections at the steering cylin- Install the steering cylinder on the axle and install
der. the cap screws and flat washers .
STEP 2 STEP 2
Put an identification tag on one of the hoses. Tighten the cap screws to 580 to 696 pound-feet
(786 to 944 N m, 80 to 96 kg / m) .
STEP 3
Disconnect the hoses from the steering cylinder. STEP 3
Align the steering links with the piston rod eyes and
STEP 4 install the pins.
Install a plug in each hose.
STEP 4
STEPS Install the bolts, lock washers, and nuts that fasten
Loosen and remove the nuts, lock washers, and the pins. Tighten the nuts.
bolts forthe pins that fasten the steering links to the
piston rod eyes of the steering cylinder. STEPS
Remove the plugs from the hoses and connect the
STEP 6 hoses to the steering cylinder.
Drive the pins out of the steering links and the
piston rod eyes. STEP 6
Lubricate the pins for the steering links with the
STEP 7 grease specified in Section 1002.
Loosen and remove the cap screws and flat wash-
ers that fasten the steering cylinder to the axle. STEP 7
There are access holes for the cap screws at each Check and adjust toe-in according to instructions
side of the front of the axle. in Section 5021.
STEP 8
Remove the steering cylinder.
5001
OPTIONAL TILT AND TELESCOPING STEERING COLUMN
TABLE OF CONTENTS
Special Tools ..... . . . . . . .. .. .. ......... 5001-2 Illustration of Tilt, Telescoping

Steering Column Installation . .. .. . . . 5001 -7
Steering Wheel .. . ........... .... .... .. . 5001-3
Tilt, Telescoping Steering Column ..... .. 5001-8
Removal . . . . .... . . . . . . .. .. ...... .. . . . 5001-3
Removal . ...... . . .... . .. . .. . . ........ 5001-8
Illustration of Steering Wheel
Installation .. . . .. ... .... .. . ... .... . . 5001-4 Installation .. . .. . .. . . ... ... ..... . .. .. 5001-14
Installation . .... . . . . . .. . .. . ... . . .. .. .. 5001-5
J I Case Bu r 8-72800
A Ten n eco C ompany

5001-2
SPECIAL TOOLS
877828 877829
CAS-10032, 0 to 200 pound-inch torque wrench CAS-10034, 100 to 750 pound-inch torque wren ch
5001-3
STEERING WHEEL
Removal STEP4
STEP 1
7269 13
Remove the locking knob from the steering column.

7?69;Jl
Push in the horn button and turn the button coun- STEPS
terclockwise approximately 1/ 4 turn. Remove the
horn button from the steering wheel assembly.
Disconnect the horn wire from the terminal on the
horn button .
STEP 2
12(;911
Remove the other internal tooth washer from the

steering column.
NOTE: 00 not remove the ring nut from the steer-

f26919 ing co lumn.
Loosen and remove the nut that fastens the locking
knob to the steering column. STEP 6
STEP 3
j26907
Loosen and remove the nut from the steering

f2691S
column.
Remove the internal tooth washer from the steering
column.
5001-4
STEP 7 1. Loosen and remove the allen head screws (1)

and external tooth washers (2) that fasten the top
plate (3) and the steering whe el (4 ) to th e bottom
plate (5 ) and outer column cover (6) .
2. Carefully push the horn wire (7) through the

hol es in the top plate (3) and the steering whee l (4).
3. Remove the top plate (3) and steering wheel (4)

from the machine.
726903
Remove th e locking ring from the steering column .
STEERING
WHEEL (4)
HORN
BUTTON !LNUT
INTERNAL
f!fjJW::ER
~ ~
/lOCKING
RING TOP PLATE
ALLEN HEAD
SCREWS (1) _ _ ,~,
I~~ /
~(~t;j
OUTER
COLUMN
COVER (8)
9872463
Illustration of Steering Whee l Installation

5001-5
1. Push the horn wire (7) through the hole in the
steering wheel (4) and the hole in the top plate (3).
2. Put the steering wheel (4) and top plate (3) in

position on the bottom plate (5) and outer column
cover (8 ).
3. I nstall the external tooth washers (2) and the

allen head screws (1) that fasten the steeri ng wheel
(4) to the bottom plate (5) .
STEP 8
726911
Install the internal tooth washer .
STEP 11
727903
In stall the locking ring on the steering column.
,
STEP9
7269 \3
Install the locking knob on th e steering column.
STEP 12
726905
Install the nut on the steering column . Use the

CAS-1 0034 torque wrench to tighten the nut to 384
to 444 pound-inch (43 to 50 Nm) .
726915
I nstall the other tooth was her.

5001-6
STEP 13 STEP 14
726917
I nstall the nut on the steering column. Do not Hold the locking knob in position against the stop
tighten the nut at this time. on the locking ring and use the CAS-1 0032 torque
wrench to tighten the nut on the steering column to
96 to 120 pound-inches (11 to 13.5 Nm).
STEP 15
Connect the horn wire to the terminal on the horn

button. Put the horn button in position on the lock-
LOCKING ing ring and push the horn button into place.
RING (4)
8872464
Turn the locking knob (1) clockwise until the

crossmember (2) in the locking knob (1) hits the
stop (3) on the locking ring (4).
5001 -7
_ _-::iit'HING
SHUTTLE CONTROL
LEVER
BOOT
BOTTOM
COVER
LOWER
/
SHUTTLE
ROD
,
",
,, ,
, ,
'- '
8872465
Illustration of T il t, Telescoping Steering Column Installation

5001-8
TILT, TELESCOPING STEERING COLUMN

The only servicable components for the tilt, STEP 18
telescoping steering column are the return springs.
If the return springs are damaged or worn:
1. Do steps 16 through 34 of removal.
2. Replace the return springs for the steering

column.
3. Do steps 65 through 83 of installation.
Removal
STEP 16
Remove the bottom cover from the steering co lumn .
STEP 19
Remove th e boot from the shuttle control lever.
STEP 17
776927
Loosen and remove the screws that fasten the top

cover to the steering cloumn.
STEP 20
726931
Loosen and remove the screws that fasten the bot-

tom cover to the steering column.
Remove the top cover from the steering column.
See page 5001-3, do steps 1 through 7 of steering

wheel removal.
5001-9
STEP 21 STEP 24
726901 72G828
Push the horn wire through the holes in the plates Remove the horn plate from the steering co lumn.
and the steering wheel. Use a rubber hammer and
hit the end of the shaft for the steering column, STEP 25
remove the steering wheel assembly from the steer-
ing column.
STEP 22
726733
Loosen and remove the nuts and lock washers that

fasten the turn signal mounting bracket and the
shuttle control lever mounting bracket to the steer-
726832
ing column .
Remove the spring from the steering column.
STEP 26
STEP 23
Remove the turn signal brac~et from the bolts and

Remove the inner column cover from the steering the steering column.
column.
5001 - 10
STEP 27 STEP 30
;26729 7261lb
Remove the spacers from the bolts . Loosen the Allen head set screw that fastens the
lower shuttle rod for the shuttle lever to the swivel
STEP 28 linkage .
STEP 31
i26727
Hold the mounting bracket for the shuttle control

lever in position on the steering column and re-
move the bolts . Pull the shuttle leve r straight out of the swivel
linkage.
STEP 29
STEP 32
726735
Loosen and remo ve the screws that fasten th e boot

to the bottom cover. Push the boot down for access Remove the key from the lower shuttl e rod .
to the swive l lin kage for th e shuttle control lever.
5001-11
STEP 33 STEP 36
726010
Move the turn signal linkage as required and re- Pull the swivel linkage straight off the lower shuttle
move the boot from the steering column. rod .
STEP 34 STEP 37
72601G 726017
Remove the bottom column cover from the dash Remove the key from the lower shuttle rod .
panel.
STEP 38
STEP 35
7?SOOS
Loosen the set screw that fastens the swivel linkage

Loosen the set screw that fastens the swivel linkage to the shaft on the turn sign al switch.
fo r th e shuttl e rod control lever to the lower shuttle
rod .
5001-12
STEP 39 STEP 42
7~'6003 726016
Loosen and remove the cap screw , lock washer, Disconnect the lights from the cover. Disconnect
and flat washer that fasten the bracket for the turn the plugs.
signal swivel linkage to the steering column. ne-
move the turn signal lever and linkage. Loosen and remove the cap screws and lock
washers that fasten the dash panel to the fire wall .
STEP 40 Remove the dash panel from the fire wa ll and the
control lever( s).
STEP 43
726012
Loosen and remove the screws that fasten t he

cover for the light switches to the dash panel.
726009
STEP 41 Remove the glove box from the dash panel by tilt-
ing the top of the box toward you and tt1en lifting up
and out with the box.
STEP 44
nemove the cover from the dash panel.
726614
Disconnect the plug from the turn signal switch .

5001-13
STEP 45 STEP 48
726612
Loosen and remove the cap screws that fasten the Loosen and remove the cap screws and lock
mounting bracket for the turn signal switch to th e washers that fasten the steering control valve to the
mounting plate for th e steering control valve . Re- mounting plate. Remove the mounting plate from
move the mounting bracket and turn signal switch th e steering column .
from the mounting plate for the steering control
valve. STEP 49
Hold the steering control valve in place . Loosen

Loosen and remove the bolts , lock washers, and and remove the cap sc rews and lock washers that
nuts that fasten th e bracket on the mounting plate fasten th e steering column to the steering control
for the steering control valve to the bracket on the valve . Remove the steering column from the steer-
tilt assembly. ing control valve.
STEP 47
Loosen and remove the bolt , lock washers , and

nuts that fasten the mounting plate for the steering
control va lve to th e firewall.
5001-14
STEP 50
noons
Install the bolts, lock washers, and nuts that fasten
the mou nting plate for the steering control valve to
Hold the steering control valve in place. Put the the fi rewal!.
steering column in place on the steering control
val ve. Install the cap screws and lock washers that STEP 53
fa sten the steering column to the steering control
valve.
STEP 51
726610
Install the bolts, lock washers , and nuts that fasten

the mounting plate for the steering control valve to
the bracket on the column.
726606
Put the mounting plate in position on the steering STEP 54

column . Install the cap screws and lock washers
that fasten the steering control valve to the mount-
ing plate .
726612
Put the mounting bracket for the turn signal switch

in place on the mounting plate for t he steering
control valve. Install the cap screws that fasten the
mounting bracket to the mounting plate .
5001 -15
STEP 55 STEP 58
726012
Connect the plug to the turn signal sw itch. In stal l th e screws that fasten the cover to the dash
panel.
Put the dash panel in position on the fire wall. Pu ll
th e rubb er boot(s) for the co ntrol levers through STEP 59
th e das h panel. Install the cap screws and lock
washers that fasten the dash pane l to th e firewall.
STEP 56
Install the g love box in the dash pane l.
Install the lights in the cover. Connect the plugs for

th e light swi tches.
STEP 57
720003
Put th e bracket for the turn signal swivel linkage in

pos iti on on the steering co lumn. Install the cap
screw and loc k washer th at fasten th e bracket to
th e st ee ring column .
72G013
Put the cover in place on the dash panel.

5001-16
STEP 61 STEP 64
72GOO~ 7/6021
Put the swivel linkage in position on the turn signal Tighten the set screw that fastens the swivel lin-
switch. Tighten the set screw that fastens the swiv- kage to the lower shuttle rod.
el linkage to the turn signal switch.
STEP 65
STEP 62
126Hlfi
72G017 Install the bottom column cover in th e dash panel.

Put the key in the slot in the lower shuttle rod.
STEP 66
STEP 63
726019 Move the turn signal lever and linkage as required

I nstall the swivel linkage for the shuttle control and install the boot on the steering column . Push
lever on th e lower shuttle rod. the boot down for access to the swivel linkage for
the shuttle control lever.
5001-17
STEP 67 STEP 70
72672 1 726727
Put the key in the slot in the lower shu ttle rod. Hold the shuttle contro l lever bracket in position on
th e steering co lumn and install the bolts.
STEP 68
STEP 71
Install the swivel linkage for the shut tle co ntro l 726729
lever on the lower shuttle rod. Install the spacers on the bolts.
STEP 69 STEP 72
726725 726731
Tighten the se t screw that fastens the sw ivel lin- Put th e turn si gn al bracket in place on the bolts and
kage to the lower shuttle rod . spacers.
5001 -1 8
STEP 73 STEP 76
12t)H:1O
Install the nuts and lock washers that fasten the Put the inner column cover on th e steering co lumn.
shuttle control mounting bracket and the turn sig-
nal mounting bracket to the steering column. STEP 77
STEP 74
726832
Put the spring on the steering column .

726735
Move the boot into position on the bottom column STEP 78

cover. I nstall the screws that fas ten the boot to the
bottom column cover .
STEP 75
Push the horn wire through the holes in the plates

and the steering wheel. Install the steering wheel
assembly on the steering column.
726828
Put the horn plate on the steering column as See page 5001-5 , do steps 8 th rough 15 of steeri ng
shown. wheel installation .
5001-19
STEP 79 STEP 82
726931
Put th e top cover in place. In stall th e screws th at fasten th e bottom cover to

th e steering co lu mn.
STEP 80
STEP 83
;26027
Install the sc re ws th at fasten the top cover to the 7269:ii:'
steerin g column. In sta ll the boot on the shuttle control lever.
STEP 81
726929
Put the bottom cover in place .

This Page is Blank
5002
STEERING SYSTEM TROUBLESHOOTING
AND PRESSURE CHECK
TABLE OF CONTENTS
Specifications . . . .... .. ... .. . . . . . .. .. .. . 5002-2 Pressure Setting Check . . . .. . .. . .. ... . 5002-4
Troubleshooting Chart ... . . ... ... . .. . . . 5002-3 Pressure Setting Adjustment . . .... . . . . 5002-4
Steering Relief Valve . .. . . . ..... .. . . . .. . 5002-4 Checking Steering Cylinder Packing .. ... 5002-5
J I Case 8-67250
A Tenn eco Company

5002-2
SPECIFICATIONS
NOTE: See the hydraulic schematic in the rear pocket of this Service Manual for the components and oil
flows in the steering circuit.
Steering relief valve . . . . . .... . ... . ...................... .. ..... . .... . .. . . 2050 to 2200 psi at full throttle
(14134 to 15 169 kPa, 144 to 154 kg/ cm 2)
Location .. ... . ... . . . .. . ...... . . ... .. . . .. . . ..... .. ... . . .... ... ... . .. ... .. . . . . In loader control valve
5002-3
Steering control valve Broken centering springs. Remove the steering control valve and
will not return to make repairs as necessary.
neutral
Dirt or rust in the steering control Remove the steering control valve and
valve or steering column. make repairs as necessary.
Machine does not turn Low oil level in the hydraulic reservoir. Check for oil leakage in the steering
when the steering circuit. Add oil as necessary.
wheel is turned
Hydraulic pump is damaged. Do the flowmeter test for the hydraulic
pump according to the instructions in
Section 8002.
Hoses connected to the wrong ports See the hydraulic schematic and
in the steering control valve. check the connections .
Steering relief valve open or damaged . Check the pressure setting of the steering
relief valve according to the instructions
on page 5002-4.
Worn or damaged parts in the steering Remove the steering control valve from
control valve . the machine. See Section 5007 and make
necessary repairs.
Steering wheel turns Low oil level in the hydraulic reservoir. Check for oil leakage in the steering
hard or the machine circuit. Add oil as necessary.
turns too slow
Worn piston packing in the steering See Checking Steering Cylinder Packing
cylinder. in this section .
Air pressure in the front tires is low. See Section 6229 and check the air
pressure in the front tires.
Steering relief valve pressure Check the pressure setting of the steering
setting too low. relief valve according to the instructions
in this section .
Damaged parts in the front axle. Check the parts of the front axle and
make repairs as necessary.
Hydraulic pump is worn. Do the flowmeter test for the hydraulic

pump according to the instructions in
Section 8002 .
Worn or damaged parts in the steering Remove the steering control valve. See
valve. Section 5007 and make the necessary
repairs.
Machine turns in the Hoses connected to the wrong ports See the hydraulic schematic and
wrong direction in the steering control valve. check the connections.
The rotor in the steering control valve Remove the steering con trol valve . See
installed wrong. Section 5007 and install rotor correctly.
5002-4
STEERING RELIEF VALVE

Pressure Setting Check STEP 11
Continue to run the engine at full throttle .
The steering relief valve is in the loader control
va lve. See Section 8007 . STEP 12
Turn the steering whee l all the way to the left or to
STEP 1 the right and look at the pressure gauge.
parking brake . STEP 13
The pressure must be 2050 to 2200 psi (14134 to 15
STEP 2 169 kPa , 144 to 54 kg/ cm 2).
Lower the loader bucket to the floor and put the
backhoe in the transport position . STEP 14
If the pressure is not correct, adju st the steering
STEP 3 relief valve .
Stop the engine.
Pressure Setting Adjustment
STEP 4
There is a quick disconnect fitting installed in the STEP 1
hydraulic line inside the front LH frame. Remove T he steering relief va lve is inside the bottom end
the dust cap from the qu ick disconnect fitting. section of the loader control valve. The loader con-
trol valve is fastened on the inside of the upper RH
STEPS frame toward the center of the machine.
Connect a 0 to 5000 psi (0 to 34 473 kPa, 351
kg/ cm 2) pressure gauge to the quick disco nnect STEP 2
fitting . The hose on the pressure gauge must be Use an Allen wrench to prevent the adjusting screw
long enough so that you can read the gauge from for the steering relief valve from turning and loosen
t he operators seat. the lock nut on the steering relief valve.
STEP 6 STEP 3
Heat the oil in the hydraulic system to operating Turn the adjusting screw clockwise to increase the
temperature by doing the following steps . pressure setting. Turn the adjustin!~ screw coun-
terclockwise to decrease the pressure setting .
STEP 7
Start the engine and run the engine at full throttle . STEP 4
Use the Allen wrench to prevent the adjusting
STEPS screw from turning and tighten the lock nut.
Hold the loader control lever in the ROLLBACK posi-
tion for 15 seconds. STEPS
Check the pressure setting again.
STEP 9
Retu rn the loader contro l lever to NEUTRAL for 15 STEP 6
seconds. If necessary, adjust the steering relief valve again .
STEP 10
Repeat steps 8 and 9 until the temperature of the
hydraulic oil is 125 0 F (51 0 C) . If a thermometer is
not available, feel the side of the hydrau lic reser-
voir. The side of the hydraulic reservoir must be
very warm .
5002-5
CHECKING STEERING CYLINDER PACKING

STEP 1 STEP 6
Park the machine on a level surface and apply the If the steering wheel is turned all the way to the left,
parking brake. disconnect the hose from the fitting from the RH
side of the steering cylinder.
STEP 2
Lower the bucket to the floor and put the backhoe STEP 7
in transport position . I nstall a plug in the hose that was disconnected .
STEP 3 STEP 8
Turn the steering wheel all the way to the right or to Start the engine and run the engine at high idle.
the left.
STEP 9
STEP 4 Continue to turn the steering wheel into the stop
Stop the engine. for 15 to 30 seconds while checking for leakage.
STEP 5 STEP 10
If the steering wheel is turned all the way to the Have another person check for leakage at the steer-
right, disconnect the hose from the fitting at the LH ing cylinder.
side of the steering cylinder.
STEP 11
If there is constant leakage from the steering cylin-
der, the packing in the steering cylinder is dam-
aged and repairs must be made.
This Page is Blank
5007
STEERING CONTROL VALVE - EATON
TABLE OF CONTENTS
Specifications . ................. .. ... . .. 5007-2 Inspection . . ............. . . ... .. ...... . 5007-8
Special Tools ...... .. ....... . . ...... .. . 5007-2 Assembly ......... .... . ....... ... . ... . 5007-12
Disassembly ...... ... ... ........ . . . .... 5007-3
A Tenneco Company
5007-2
SPECIFICATIONS
Rotor and stator clearance 005 inch (0.13 mm )
Special Torques
Allen head plug ... .. .. . .. . . . . .... . . . . . . . . . . ... . .. . ..... .. .. . .. . .. . 100 pound-inches (11 Nm, 1 kg .m)
Ferry head screws for fas tening end plate ....... 225 to 275 pound-inches (25 to 31 Nm, 2.5 to 3.1 kg/ m)
SPECIAL TOOL
The tool is used to install the centering springs
in the steering control valve. The part number of
the tool is CAS-1239. See Section 1001 for infor-
mation about ordering the tool.
785606
5007-3
DISASSEMBL Y
STEP 1 STEP 4
523511
Put the steering control valve in the vise so the end Remove the end plate,
plate is up, Use a punch and hammer and hit the
Ferry head screws to make th e Ferry head screws STEPS
easier to remove ,
STEP 2
523532
Lift th e metering gear set . space r. drive shaft. and

spacer plate as an assembly from the body of the
523 514 steering control va lve.
Loosen the Ferry head screws.
STEP 6
STEP 3
523536
523521 Sepa rate the metering gear set , spacer, drive shaft,
Remove th e Ferry head sc rews . and spacer plate.
5007-4
STEP 7 STEP 10
523915
Push the rotor out of the stator. Remove and discard the a-ring from the body.
STEP 8 STEP 11
523906 877704
Remove and the a-ring from the stator. Find the anticavitation valves in the body. Put iden-
tification marks on the body for use (juring assem-
STEP9 bly.
STEP 12
523908
Remove and discard the a-ring from the end plate.

877698
Remove the springs, pins, and balls f rom the ports

in the body.
5007-5
STEP 13 STEP15
S23917 523921
Remove the body of the steering control valve from Remove the washer.
the vise. Push the spool and sleeve part of the way
out of the bottom of the body . Turn the sleeve and STEP 16
spool in both directions and pull the sleeve and
spool out of the body . Do not use force to push the
sleeve and spool out of the body . The pin inside of
the sleeve and spool can keep the sleeve and spool
from coming out of the body . If the sleeve and
spool cannot be pushed out of the body easily, use
a magnet to move the pin inside the spool one way
or the other.
STEP 14
523923
Remove the bearing .
STEP 17
52391 9
Remove the spacer from the spool and discard the

spacer.
523925
Remove the other washer.

5007-6
STEP 113 STEP 21
523927 523933
Use a punch to push the pin out of the sleeve and The gland in the body if the steering control valve is
spool. difficult to remove . If there was no leakag e around
the gland , do not remove the gland . (If the gland
STEP 1!~ must be removed, see step 28). Remove the seal
from the gland and discard the seal.
STEP 22
523929
Pull the spool straight out of the sleeve. Turn the

spool in both di rections as the spool is pulled out of
tile sleeve. 523935
Remove the O-ring and backup ring from the bot-
STEP 20 tom of the gland and discard the O-ring and back-
up ring.
STEP 23
Push the ce ntering springs out of the spool. There

are fou r centeri ng spri ngs and two spacers. Do not
lose any of the centering springs or spacers.
Remove the All en head plug from th e body of the
steering control valve .
5007-7
STEP 24 STEP 27
523813 523820
Install a No. 8-32 screw in the seat for the check

valve .
STEP 25
523822
Remove and discard the O-rings on the seat.
523815 STEP 28
Use pliers to pull the seat out of the body of the
stee ring control valve .
STEP 26
52382.4
If there was leakage around t he gland in the steer-

ing control valve , the gland must be removed from
the body. Put the body in a vise with the gland up.
523817 Use a punch and screwdriver and move the end of
Remove the body of the steering control valve from the retaining ring out of thEl groove in the body .
the vise. Turn the body up and let the steel ball and Remove the retaining ring.
retainer fallout of the body.
5007-8
STEP 29 STEP 30
Remove and discard the O-ring from the bore for
the gland .
Remove the body of the steering control valve from

the vise. Put the body in a press with the gland
down. Put blocks under the body to hold th e body
off the press table . Press the g land out of the body .
INSPECTION
Clean all parts in cleaning solvent. Put the STEP 31
parts on paper towels until the parts are dry. Do not
use cloths to wipe the parts dry.
Check all machined surfaces for wear or dam-

age. If there are rough places on the ends of the
stator and rotor, or on the machined surfaces on
the body, !~nd plate, or spacer plate , make the sur-
faces smooth by using 600 grit emery cloth. Put the
emery cloth on a surface that is flat. The surface
must be as flat as a piece of glass. If the emery cloth
is new, move a piece of steel across the emery cloth
six times to remove the sha rp 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 this method
until all rough places have been removed. Make
sure that the part is kept flat on the emery cloth as
the part is moved across the emery cloth. Clean the 8871974
parts in cleaning solvent to remove any grit on the

parts. If the spool (3), sleeve (2), or the bore in the body
(1) of the steering control valve is damaged or
worn, use a complete new steering control valve.
The spool (3), sleeve (2), or body of the steering
control valve are not available separately .
5007-9
STEP 32 STEP 35
877703
I nspect the check valve in the inlet port of the body. Inspect the springs (1) , pins (2), and ba ll s (3) for
Push the check valve in to see if the spring works damage or wear. Use new parts as needed .
co rrectly. If the check valve is worn or damaged,
use a complete new steering control valve. STEP 36
STEP 33
87 1975
Check th e steel ball (1) and retainer (2) for damage

or wear. Use a new steel ball (1) or retainer (2) as
needed.
STEP 34
Use a feeler gauge to measure the clearance be-
tween the rotor and stator. If clearance is more than
/ 2 0.005 inch (0.13 mm) , a new metering gear set must
be used.
871976
Check the washers (1) and bearing (2) for damage

or wear. Use new parts as needed .
!3007-10
~
FERRY HEAD
SCREW
O-RING
/ SPACER PLATE
WASHER
BEARING
B
. . .a / ~ SPACER
,,;rJ00d~~~
BACKUP RING
°r R ' 7 'NG RING
WAS"'R ;'
O-RING }~VO_SEAL
GLAND
6671959
5007 -11
r----II~ A
- ....- C
SECTION A-A
STEERING CHECK
ANTICAVITATION
VALVE
VALVE
~ SECTION 8-8
~
SECTION C-C 8811 967
5007-12
ASSEMBLY
SlrEP 37 STEP 40
523830 523620
If the gland was removed from the body, install a Remove the body from the vise. Put the body in a
new a - ring in the bore for the gland. Lubricate the press. Install the seal in the gland with the lip for the
a- ring with petroleum jelly. seal toward the outside of the body. Push the seal
into the gland until the seal stops moving.
STEP 38
STEP 41
523828
Push the gland into the body of the steering con- 1. Large Diameter O-ring 523841
tro l valve until the gland stops moving . Install new a-rings on the seat for the check valve .
Lubricate the a-rings with petroleum jelly. The
ST'EP 39 large diameter a-rings must be installed on the end
of the seat that has threads.
STEP 42
523824
Put the body of the steering control valve in a vise

with the gland up. Use a screwdriver and punch to
start the end of the retaining ring into the groove in 523622
the body . Push the retaining ring into the groove in Install the retainer in the bore for the check valve .
the body. Make sure the retainer is flat in the bottom of the
5007-13
STEP 43 STEP 46
523624 523809
Install the steel ball in the bore for the check valve . Install and tighten the Allen head plug to 100
pound-inches (11 Nm . 1 kg/ m) .
STEP 44
STEP 47
523626
I nstall th e seat for the check valve in the bore. The

end of the seat with threads must be up. Install the backup ring in the bottom of the gland.
Use petroleum jelly to hold the backup ring in
STEP 45 place.
STEP 48
523629
Applya small amount of 242 (blue) Loctite on the

threads of the Allen head plug. 523839
Install the O-ring on the backup ring in the bottom

of the gland. Use petroleum jelly to hold the O-ring
in place .
5007 -14
STEP 49 STEP 52
523637
Apply petroleum jelly on the O-ring for the body of Install the spool in the sleeve. The spool must be
the steering control valve . Install the O-ring in the installed straight into the sleeve . Turn the spool in
groove in the body. both directions as the spoo l is pushed into the
sleeve .
SlrEP 50
STEP 53
523633
Put clean oil on the in side of the sleeve. 523639
Put the spool and sleeve in a vise with soft jaws.

STEP 51 Tighten the vise just enough to hold th e spool and
sleeve in position. Turn the sleeve and move the
sleeve on the spool unti I the slots in the sleeve and
spool for the centering springs are in alignment.
STEP 54
Pu t clean oil on the outside of the spool.
52364 1
Install the tool shown on page 5007-2 through the

slot for th e centering spring.
5007 -15
STEP 55 STEP 58
Assemble the centering springs and spacers in sets Install the washer, and the bearing, and the other
of three. Put the two sets of centering springs and washer on the spool.
spacers in the end of the tool with the notched
corners toward the sleeve. Use you thumb and fin- STEP 59
ger to compress the centering springs.
STEP 56
523726
Install a new spacer on the spool.
52371 7 STEP 60
Push the centering springs into the spool. Move the
tool as necessary to put the centering springs in
position .
STEP 57
523728
Put clean oil on the outside of the sleeve and spool.
523721
Install the pin in the sleeve through the spool.

~i007-16
STEP 61 STEP 64
-...,....~"'~~~
523731 877702
Put clean oil on the bore in the body of the stee ring Install the balls in the ports in the body that are
control valve . marked with the identification mar-ks.
STEP 62 STEP 65
523733 877701
The sleeve and spool must be installed straight into Install the pins in the ports.
ttle body of the steering control valve.
STEP 66
STEP 6~1
677700
524 106 Install the springs in the pins .

The pin can move out of the sleeve and spool. If the
pin moves out of the sleeve and spool, the pin can
keep the sleeve and spool from being pushed into
the body. Hold the sleeve and spool in position in
the body. Put the end of the sleeve and spool on the
bench . Lower the body onto the sleeve and spool
as shown .
5007-17
STEP 67 STEP 70
523737 524117
Put petro leu m jelly on the O-ring for the stator. Check the pos ition of the slot in the d rive shaft
Install the O- ring in the groove in the stator. again and make sure the slot is in the correct posi-
tion.
STEP 68
STEP 71
-~--
5241 10
Align the rotor and stator and push the rotor into 524122
the stator. Instal l the spacer plate on the stator. Turn the spa-
cer plate to align the holes with the holes in the
NOTE: The drive shaft must be in the rotor in the stator.
correct position.
STEP 69
524112
Engage the teeth on the drive shaft and the teet h in

the rotor so the slot in the end of the drive shaft is
between the two teeth on the rotor .
5007-18
STEP 72 STEP 74
523704
P t the body of the steering control valve in the Put clean oil on the metering gea r set, spacer plate ,
vise. Hold the meteri ng gear set, spacer plate , and and drive shaft assembly.
d nve shafts as an assembly in position over the
body of the steering control valve. Turn the meter- STEP 75
inn gear set , spacer plate, and drive shaft assembly
to put the slot in the end of the drive shaft in align-
mElnt with the pin inside the spool.
Lower the metering gear set , spacer plate , and

drive shaft assembly into position on the body.
Turn the metering gear set , spacer plate, and drive
shaft assembly a small amount in one direction or
the other until the slot in the drive shaft is engaged
with the pin inside of the spool. Turn the spacer
plate and stator to align the holes with the holes in
the body.
SlrEP 73 523735
Put petrolem jelly on the O-ring for the end plate.

Install the O-ring in the groove in the end plate.
STEP 76
524128
Install the spacer in the rotor on top of the drive

shaft.
533623
Install the end plate on the metering gear set. Align

the holes in the end plate with the holes in the
stator.
5007-19
STEP 77 STEP 79
523517
Install the Ferry head screws . T ighten the Ferry head screws to 225 to 275
pound- inches (25 to 31 kg / m) in the sequence
STEP 78 shown in the Step 78 .
Tighten the Ferry head screws to 100 to 150

pound-inches (11 to 17 Nm , 1.2 to 1.7 kg/m) in the
sequence shown.
This Page is Blank
5008
STEERING CONTROL VALVE - DANFOSS
TABLE OF CONTENTS
Specifications .. . ..... .. . . . . . . . . .. .. . ... 5008-2 Inspection ...... . ... . .... . ............. 5008-7
Special Tool .... .. .. . . . ... . . . . . .... . ... 5008-2 Assembly ...... . . . ....... . .... . . . . . ... 5008-10
Disassembly .......................... . 5008-3
A Tenneco Compa ny
5008-2
SPECIFICATIONS
Rotor and stator clearance .. . ...... .. ........... .. .. .. ......... ... .. ............ .. ...... .. ... ........... ... .. .. ... .... " ....... 0.005 inch (0 .13 mm)
Special torques
Cap screws for fastening end plate .... " ... .. . ... .. .... ... ... ... 212 to 319 pound-inches (24 to 36 Nm)
SPECIAL TOOL
785606
The tool is used to install the centering springs in the
steering control valve . The part number of the tool is
CAS-1239. See Section 1001 for information about
ordering the tool.
5008-3
DISASSEMBLY
STEP 1 STEP 4
709810 709622
Put the steering control valve in the vise so the end plate Remove and discard the O-ring from the stator.
is up. Loosen the cap screws.
STEP 5
STEP 2
709626
709612 Remove the metering gear set and spacer from the
Remove the cap screws and flat washers . One cap body.
screw has a guide pin .
STEP 6
STEP 3
709620 Remove the drive shaft

Remove the end plate.
5008-4
STEP "' STEP 10
Remove the spacer plate . Remove and discard the O-ring from the body.
STEP 8 STEP 11
710010 709836
Separate the metering gear set and spacer. Loosen the plug in the body.
STEP 9 STEP 12
710016
Fiemove and discard the other O-ring from the stator. Remove the plug .
5008-5
STEP 13 STEP 15
709912 709918
Remove the body of the steering control valve from the Remove the washer .
vise . Turn the body up and let the steel balls , plungers,
and springs fall out of the body. STEP 16
STEP 14
709920
Remove the bearing.

7099 16
Push the spool and sleeve part of the way out of the
bottom of the body. Turn the sleeve and spool in both
directions and pull the sleeve and spool out of the body.
The pin inside the spool can move out of the sleeve and
spool and keep the sleeve and spool from coming out
of the body. If the sleeve and spool cannot be pushed
out of the body easily, use a magnet to move the pin
inside the spool one way or the other.
710116
Remove the other washer.

5008-6
STEP 18 STEP 21
709926 709932
Remove the retaining ring . Push the centering springs out of the spool. There are
four centering springs . Do not lose any of the centering
STEP 19 spri ngs.
STEP 22
-
l
'.
"-
709928
Use a punch to push the pin out of the sleeve and spool.
709936
STEP 20 Use an acceptable tool through the bore of the body

and remove the inner seal . Discard the inner seal.
STEP 23
,
709930
Pull the spool straight out of the sleeve . Turn the spool
in both directions as the spool is pulled out of the
sleeve. 710004
Remove the outer seal from the bore. Discard the outer
seal.
5008-7
INSPECTION
Clean all parts in cleaning solvent. Put the parts on STEP 25
paper towels until the parts arc dry. Do not use cloths to
wipe the parts dry.
Check all machined surfaces for wear or damage. If

there are rough places on the ends of the stator and
rotor, or on the machined surfaces on the body, end
plate, or spacer plate, make the surfaces smooth by
using 600 grit emery cloth. Put the emery cloth on a
surface that is flat. The surface must be as flat as a
piece of glass. If the emery cloth is new, move a piece of
steel across the emery cloth six times to remove the
sharp pieces of grit. Move the rotor , stator, body, end
plate, or spacer across the emery cloth six times. Then
check to see if the rough places have been removed . 710008
Use this method until all rough places have been Inspect the check valve in the inlet port of the body.
removed. Make sure that the part is kept flat on the Push the check valve in to see if the spring works
emery cloth as the part is moved across the emery correctly. If the check valve is worn or damaged , use a
cloth. Clean the parts in cleaning solvent to remove any complete new steering control valve .
grit on the parts .
STEP 26
STEP 24
/ 2
87 1976
Check the washers (1) and bearing (2) for damage or

wear. Use new parts as needed.
STEP 27
8871979
If the spool (2) , sleeve (3) , or bore in the body (1) of the
steering control valve is damaged or worn, use a
complete new steering control valve. The spool (2) ,
sleeve (3), or body of the steering control valve are not
available separately.
7099 12A
Inspect the springs (1), plungers (2) , and balls (3) for
damage or wear. Use new parts as needed .
5008-8
STEP 28
523912
Use a feeler gauge to measure the clearance between

the rotor and stator. If clearance is more than 0.005 inch
(0.13 mm) , a new metering gear set must be used.
5008-9
SEA L
'yO
~ ___ PlN
SLEEVE
687 1956
5008-10
ASSEMBLY
STEP 29 STEP 32
710018 710030
Lubricate the inner seal with clean oil. Use an acceptable driver and hammer and drive the
outer seal against the seat in the bore.
STEP 30
STEP 33
INNER SEAL
:'~
710024
ThE' inner seal is not difficult to install. Install the inner 710034
seal through the opposite end of the bore shown in the Put clean oi l on the inside of the sleeve .
photograph . Use you r fingers to seat the inner seal
aga.inst the body. Make sure the lips of the inner seal STEP 34
are toward the inside of the body.
. '",--
710036
Put clean oil on the outside of the spool.
710028
Install the outer seal in the body with the lips of the outer
seal toward the outside of the body.
5008-11
STEP 35 STEP 38
FLAT SPRING--- -+- FLAT SPRING
CURVED SPR IN GS
8871957
710102
Install the centering springs as shown in the illustration .
Install the spool in the sleeve. The spool must be
installed straight into the sleeve. Turn the spool in both STEP 39
directions as the spool is pushed into the sleeve.
STEP 36
Put the two flat springs in the slot of the tool with the two
curved springs between the flat spring s.
Put the spool and sleeve in a vise with soft jaws. Tighten STEP 40
the vise just enough to hold the spool and sleeve in
position . Turn the sleeve and move the sleeve on the
spool until the slots in the sleeve and spool for th e
centering springs are in alignment.
STEP 37
71011 4
Use your thumb and finger to compress the centering

spri ngs. Push the centering springs into the spool.
Move the tool as necessary to put the centering springs
in position .
Install the tool shown on page 5008-2 through the slot

for the centering springs.
S008-12
STEP 41 STEP 44
7 10118 710122
Install the retaining ring. The retaining ring must be able Put clean oil on the outside of the sleeve and spool.
to rotate free of the centering springs.
STEP 45
STEP 42
P
710120 Install the pin in the sleeve through the spool.

Install the washer, and the bearing, and the other
washer on the spool. STEP 46
STEP 43,
WASHER----.~======~m
BEARING -a:au:"===='0'*
WASHER _1'ZZl5~~~==~
'--NOTE
SPOOL-..........~I
710124
Put clean oil in the bore in the body of the steering

control valve .
6871958
NOTE: The chamfer on the washer must be towards

the sleeve.
The washer withlhe chamfer must be installed nearest

the sleeve as shown in the illustration.
5008-13
STEP 47 STEP 50
710128 709836
The sleeve and spool must be instal led straight into the Tighten the plug .
body of the steering control valve. The pin can move out
of the sleeve and spool. If the pin moves out of the STEP 51
sleeve and spool , the pin can keep tho sleeve and
spool from being pushed into the body. Hold tho sleeve
and spool in position in the body . Put the end of tho
sleeve and spool on the bench and lower the body onto
tho sloeve and spool.
STEP 48
710130
Install the steel ball in the port shown .
STEP 52
709906
Put the body of the steering control valve in the vise .
Install the steel ball.
STEP 49
710132
Install the other steel ball in the port shown.
709904
Install the plug .

5008-1 4
STEP 53 STEP 56
710134 710218
Install the spring and plunger . Apply petroleum jelly on each O-ring for the stator.
Install an O-ring in the groove in each side of the stator.
STEP 54
71013G
Install the other sprin g and plunger. 710220
Align the rotor and stator and install the rotor in the
STEP 55 stator .
STEP 58
710202
Install the O-ring in th e groove in the body.
71022'
The drive shaft must be instal led in the rotor in the
correct position. Engage the teeth on the drive shaft
and the teeth in the rotor so the slot in the end of the
drive shaft is between the two teeth on the rotor.
5008-1 5
STEP 59 STEP 61
710228 710232
Install the spacer plate on the stator. Turn the spacer Put clean oi l on the metering gear set, spacer plate , and
plate to align the holes with the holes in the stator. drive shaft assembly.
STEP 60 STEP 62
7102 12 710234
Hold the metering gear set. spacer plate , and drive Install the spacer in the rotor on top of the drive shaft.
shaft as an assembly in position over the body of the
steering control valve. Turn the metering gear set, STEP 63
spacer plate, and drive shaft assembly to put the slot in
the end of the drive shaft in alignment with the pin inside
the spool. Lower the metering gear set, spacer plate,
and drive shaft assembly into position on the body.
Turn the metering gear set, spacer plate , and drive
shaft assembly a small amount in one direction or the
other until the slot in the drive shaft is engaged with
the pin inside of the spool. Turn the spacer plate and
stator to align the holes with the holes in the body.
709820
Install the end plate. Align the holes in the end plate with
the holes in the stator.
5008-1 6
STEP 64 STEP 66
709816
Install the cap screw with the guide pin in the hole Tighten the cap screws to 100 to 150 pound-inches (11
shown . to 17 Nm) in the sequence shown.
STEP 6S STEP 67
709812
Install the remaining cap screws and flat washers . Tighten the cap screws to 212 to 319 pound-inches (24
to 36 Nm) in the sequence shown in step 66 .
5010
STEERING CYLINDER
TABLE OF CONTENTS
Steering Cylinder, Two Wheel Drive Machines ... .. ... ... . .. . . . ........ . .. . . .. .. ........ ... .... . 5010-2
Disassembly . ... . .. .. . .. .... . ... . . .. . .... . . .... ... . ...... . . ...... .. .......... . . ...... . .. ... 5010-2
Illustration of Stee ring Cylinder ... . . . .. . ........... ... .. ... .. . . . ... . . . .. . .... ... . . . . • ....... . 5010-3
Inspection . . .... . ..... .. ... ... .. . .......... . .. . . . . . ........ .. .... . . .. . ......... . .. . . ...... . 5010-4
Assembly .. ... .. ... .. . ... . .... ... ..... ..... ........ .... .... .. .. .. ..... . .... . .. . . . . . . . . .. .. . 5010-4
Steering Cylinder, Four Wheel Drive Machines . . . .. . . . . .... ... . ..... .. . . .......... .. . . See Section 5022
J I Case
A Tenneco Company
5010-2
STEERING CYLINDER, TWO WHEEL DRIVE MACHINES

Disassembly STEP 6
Pull one end of the piston rod straight out of the
STEP 1 tube until the piston contacts the gland.
Clean the outside of the cylinder.
STEP 7
STEP 2 Use a soft hamme r to drive the gland out of the tube
Fasten ttle cylinder in a vise or other holding and pull the piston rod stra ight out of the tube to
equipment . Be careful to prevent damage to the prevent damage to the tube.
tube .
STEP 8
STEP 3 Remove the gland from the piston rod.
One end of the piston rod has two flat areas to
prevent the piston rod from turning when the lock STEP 9
nuts for the rod eyes are loosened . The rod eye at Use a soft hammer to drive the gland out of the
the end of the piston rod that has two flat areas has other end of the tube. Remove the gland.
LH threads . Prevent the piston rod from turning ,
loosen the lock nut, and turn the rod eye out of the NOTE: The piston cannot be removed from the
piston rod. piston rod. If the piston or the piston rod is dam-
aged, the piston rod assembly must be replaced.
STEP 4
The rod eye in the other end of the piston rod has STEP 10
RH threads . Prevent the piston rod from turning, Remove the wear ring from the piston. Remove the
loosen the lock nut, and turn the rod eye out of the seal and the backup ring from the piston.
piston rod .
STEP 11
STEPS Remove the a-ring and backup ring from the out-
Loose n and remove a nut from each tie rod and side of each gland. Remove the wiper and seal from
remove the tie rods that hold the cylinder together. the bore of each gland.
5010-3
ROD EYE
~ LOCKNUT
@
NUTS
~
BACKUP
RING
00 O-RING
TIE RODS
;,/}\) WIPER
PISTON ROD
~ @SEAl
GLAND
'~ ;/)~RING
O-RING V V SEAL
BACKUP ~
RING ~
BACKUP
RING
GLAND
@ WIPER
SEAL
@(fp
NUTS
LOCK NUT
@ ~RODEYE.'rn
5010-4
Inspection Assembly
STEP 1
Discard the parts removed from the piston and the
glands.
STEP 2
Clean all parts in cleaning solvent.
~b~::;to/ GLAND
STEP 3
Illum inate the inside of the tube. Inspect the inside
of the tube for deep grooves and other damage. If
there is damage to the tube, a new tube must be
used.
STEP 4
Check to be sure that the piston rod is straight. If ...-,..----....,..., 1---------
the piston rod is not straight , install a new piston I
1---------
rod assembly.
861554
STEPS
I nspect t~le piston for damage and wear. If the pis-
STEP 1
ton is damaged , or worn , a new piston rod as-
Install a new seal into the bore of each gland . The
sembly must be used .
lips of the seal must be toward the inside of the
cylinder. The seal can be difficult to install. Do not
STEPS
damage the seal.
Remove small scratches on the piston rod and
inside the tube with emery cloth of medium grit.
STEP 2
Use the emery cloth with a rotary motion.
I nsta ll a new wiper into the bore of each gland. The
lip of the wiper must be toward the outside end of
STEP 7
the gland.
Inspect both ends of the tube for sharp edges that
will cut tile gland a-rings and remove the sharp
edges as necessary.
STEP 3
I nstall a new backup ring in the groove in the gland.
STEP 8
Inspect both glands for rust. Clean and remove rust
STEP 4
as necessary. Install a new a-ring in the groove in the gland. The
a-ring must be between the backup ring and the
small end of t he gland.
861555
5010-5
STEPS STEP 14
Install a new wear ring in the wide groove in the Push the other gland onto the piston rod assembly.
piston .
STEP 15
STEP 6 Push the piston rod assembly straight into the tube,
Install a new backup ring in the narrow groove in and through the gland in the end of the tube.
the piston.
STEP 16
STEP 7 Carefully start the other gland into the tube.
Install a new seal on top of the backup ring .
STEP 17
STEP 8 Make sure the ports in both glands are installed
Fasten the tube in the vise or other holding equip- correctly and drive the gland into the tube.
ment. Be careful to prevent damage to the tube.
STEP 18
STEP 9 Install the tie rods and nuts. Tighten the nuts to 27
Lubricate the bore of the tube with clean oil. to 42 pound -feet (203 to 271 Nm) .
STEP 10 STEP 19
Lubricate the O-ring on both glands and the bore of The rod eye for the end of the piston rod that has
both glands with clean oil. two flat areas has LH threads. Prevent the piston
rod from turning, and turn the rod eye into the
STEP 11 piston rod.
Remove any marks and sharp edges on the cham-
fers at the ends of the piston rod assembly. Make STEP 20
sure that the piston rod is clean. The rod eye for the other end of the piston rod has
RH threads. Prevent the piston rod from turning ,
STEP 12 and turn the rod eye into the piston rod.
Lubricate the piston with clean oil.
STEP 21
STEP 13 Do not tighten the lock nuts for the rod eyes until
Install one of the glands in the tube. after installation of the steering cyl in der.
This Page is Blank
5021
FRON,. AXLE, 2WD MACHINES
TABLE OF CONTENTS
Specifications . ......... . . . ....... . . . ... 5021-2 Kingpin Bearings and Thrust Bearing .. . 5021-19
Illustration of Front Wheel Bearings .. .. . 502 1-2 Removal . . .......... . .. . . .... . ..... . 5021-19
Illustration of Front Axle . ..... .......... 5021-3 Installation .... .. ... ........... . . . .. . 5021-21
Front Wheel Bearings . .. ... ... .. . .. . ... . 5021-4 Toe-In . .... . .......... ... . ... . ..... ... 5021-27
Removal , Inspection and Installation ... 5021-4 Measuring Toe-In .... . ... .......... . 5021-27
Wheel Bearing Adjustment ... ..... .. .. 5021-9 Adjustment ....•.... .... .. . . .. ...... 5021 -27
Spindle .... . ..................... .. ... 5021-10
Removal ..... . ... . .... .. ... ...... ... 5021-10
Installation . . .... . ............... . .. . 5021-13
A Tenneco Company
5021-2
SPECIFICATIONS
Service
Toe-In . . ... .. . .. ..... . . . . . ......... . ...... .. . .. ... ........ .. . ... .. . ... ... .. 0 to 3/ 16 inch (0 to 5 mm)
Clean and lubricate front wheel bearings .. .. ... ... .. .... . .. ... .. .. . .. After every 500 hours of operation
Wheel bearing grease .. .. .. ......... .. ... .. . .. .. . . ..... .... ... .. . ..... Number 2 wheel bearing grease
Special Torques
Wheel bearing nut ... . ...... . ...... ... . .. ..... . ..... 75 to 85 pound-feet (101 to 115 N m, 11 to 12 kg / m)
with wheel turning . Then loosen a maximum of 1/ 6 turn
Front wheel bolts .... .. . .. .. . . .. . ... ... ... . ....... 115 to 130 pound-feet (156 to 176 N m, 16 to 18 kg/ m)
SPINDLE
1 SPINDLE SEAL
K~-:a. / HUB SEAL
~
..- , IJfril~
I
BEARING CUP
~rfl) , / WHEEL BEARING
/ . ~ , q" FLAT WASHER

WHEEL BEARING /
@fB' NUT
HUB / {J@~
BEARING CUP , // 0
I 1
COTTER PIN
SPINDLE SEAL
861480
5021-3
FLATWA~ / SNAP RING
P'VOT\ .~:~;~
KING PIN
THRUST
BET NG
~
!
BOLT
SEAL • 0
BEARING-----:~
O-RING r:'\
SPAGER
SNAPR'NG-
~
i
.. '-Jo'
GREASE
861481
FITTING
5021-4
FRONT WHEEL BEARINGS

Removal, Inspection STEP 5
and Installation
STEP 1
f
Remove the cotter pin.
633543
STEP 6
Raise the front wheel and put an acceptable sup-
port un der the front axle.
STEP 2
Loosen and remove the wheel bolts .
STEP 3
Removal the wheel.
STEP 4
633505
Remove the nut.
STEP 7
Remove the cap.
Pull the hub toward you to remove the outer wheel

bearing from the spindle. It can be necessary to hit
the hub with a soft hammer.
5021-5
STEP 8 STEP 11
Remove the flat washer and wheel bearing. Use two prybars and remove the spindle seal.
STEP 9 STEP 12
633511 63351 7
Remove the hub. Remove the dirt and grease from the spindle.
STEP 10 STEP 13
633513 021321
Use a chisel to move the spindle seal away from the Put an acceptable driver on top of the wheel bear-
sp indle. ing.
5021-6
STEP 14 STEP 17
Clean the wheel bearings in cleaning solvent to
remove all indications of grease from the wheel
bearings.
STEP 18
Check the bearing cups for scoring , flat areas and
pitting.
STEP 19
Inspect the rollers in the wheel bearings for flat
areas, scoring and other damage. Also check the
inner race for wear and damage .
STEP 20
021322
Press the hub seal and wheel bearing out of the

hub.
STEP 15
021329
Fill each wheel bearing with the grease specified

on page 5021-2.
STEP 21
021325
Use a hammer and punch and remove the outer

bearing cup from the hub only if inspection indi-
cates the need for a new bearing cup or wheel.
STEP 16
021332
Start the outer bearing cup into the hUb.
021326
Use a hammer and punch and remove the inner

bearing cup from the hub only if inspection indi-
cates the need for a new bea ring cup or wheel
bearing.
5021-7
STEP 22 STEP 25
021336 02 1420
Use an acceptable driver and press the bearing cup Put the other wheel bearing in the hub.
all the way into the hub.
STEP 26
-
STEP 23
02 1423
021340 Put the hub seal on an acceptable driver. The lip of

Start the inner bearing cup into the hub. the hub seal must be toward the driver.
STEP 24 STEP 27
0214 18
Use an acceptable driver and press the bearing cup Press the hub seal into the hub until the hub seal
all the way into the hub. stops moving. Be careful not to damage the hub
seal by using too much pressure.
5021-8
STEP 28 STEP 31
Drive the new spindle seal all the way onto the I nstall the outer wheel bearing.
sp indle. Be careful not to damage the spindle seal.
STEP 32
STEP 29
1)33925 Install the flat washer and nut.

Fill the groove in the hub seal with wheel bearing
grease . STEP 33
STEP 30
Tighten the nut to 75 to 85 pound-feet (1 01 to 115 N

!;33927 m, 11 to 12 kg / m) and turn the hub at the same time.
I nstall the hub onto the spindle. Then loosen the nut to the next cotter pin hole.
5021-9
STEP 34 STEP 37
l·.·"'"
'f'
633936 633543
Install a new cotter pin. Remove the support from under the front axle and
lower the wheel to the floor.
STEP 35
--- STEP 38
634104
I nstall the cap. 634108
Tig hten the wheel bolts to 115 to 130 pou nd-feet

STEP 36 (156 to 176 Nm , 16 to 18 kg / m).
Wheel Bearing Adjustment

Turn the wheel or hub and tighten the nut to 75
to 85 pound-feet (101 to 115 N m, 11 to 12 kg / m).
Then loosen the nut to the first cotter pin hole and
install a new cotter pin.
6341 07
I nstall the wheel and wheel bolts. Do not use an

impact wrench to install the wheel bolts.
5021-10
SPINDLE
Removal STEPS
STEP 1

633543
Raise the front wheel off the floor and put an ac- STEP 6
ceptable support under the front axle .
STEP 2
STEP 3
Remove the wheel.
STEP 4
633505
Remove the nut.
STEP 7
6 ~13501
Remove the cap.
633507
Pull the hub toward you then remove the outer

wheel bearing from the sp indl e. It can be neces-
sary to hit the hub with a soft hammer.
5021-11
STEP 8 STEP11
Remove th e flat washer and wheel bearing. Remove the nut and lock washer.
STEP 9 STEP 12
633528
Remove the hub. Drive the lock pin out of the spindle .
STEP 10 STEP 13
633640
Loosen the nut on the lock pin. Loosen the nuts on the bolts that hold the pivot pin
for the steering link .
5021-12
STEP 14 STEP 17
6:13642 633604
Drive the pivot pin out of the steering link. Remove the O-ring .
STEP 15 STEP 18
633606
Remove the snap ring. The O-ring used betwE,en Remove the snap ri ng at the bottom of the king pin.
the spacer and bearing will cause the snap ring to
be difficu lt to remove. STEP 19
STEP 16
633608
Remove the spacer.

633602
Remove the spacer.

5021-13
STEP 20 STEP 23
633610 633616
Remove the O-ring. Remove the thrust washer.
STEP 21 Installation
STEP 1
6 3361 2
Drive the king pin toward th e top to prevent dam-

age to the seal. 634103
Put the thrust washer on the bottom boss.
STEP 22
STEP 2
633614
Remove the spindle and thrust bearing. 634016
I nstall the spindle.

5021 -14
STEP 3 STEP 7
6:\40 18 634024
Get the thrust bearing . The case of the thrust bear- Hold the spindle and pus h the kingpin into place.
ing must be on top when the t hrust bearing is
installed. STEPS
STEP 4
634026
Install the lock pin.

6:14020
Install th e thrust bearing . Remember, the case STEP 9
must be on top .
STEPS
Align the spindle , thrust bearing and thrust washer
with the front axle.
STEP 6
Install the lock washer and nut but do not tighten

the nut now.
Install the kingpin so that the notch fo r the lock is

toward the outside .
5021-15
STEP 10 STEP 13
Hit the spacer and snap ring to make sure that the
snap ring is in the groove. See Step 17.
STEP 14
63390?
I nstall a new O-ring in the bottom boss. Use grease
to hold the O-ring.
STEP 11
Install a new O- ri ng in the top boss.
STEP 15
Apply a small amount of grease to a spacer and

install the spacer so that the grease f itting is to-
ward the center of the machine.
Install the spacer so that the grease fitting is to-
STEP 12 ward the center of the machine.
STEP 16
Install the snap ring.

63391 3

5021-16
STEP 17 STEP 20
63:3915 633921
Hit th e spacer and snap rin g to make sure that the Drive the pivot pin into the steering link.
snap ring is in the groove.
STEP 21
STEP 18
633923
633917 Tighten the nuts on the bolts that hold the pivot pin.
Tighten the nut that holds the lock pin.
STEP 22
STEP 19
6335 19
Drive the spindle seal all the way onto the spindle.
Align the steering link with the spindle and start the Be careful not to damage the spindle seal.
pivot pin into the steering link .
5021 -17
STEP 23 STEP 26
6.13931
Fill the groove in the hub seal with the wheel bear- I nstall the flat washer and nut.
ing grease specified on page 5021-2 .
STEP 27
STEP 24
633933
Tighten the nut to 75 to 85 pound-feet (101 to 115 N

In stall the hub onto the spindle . m. 11 to 12 kg / m) and turn the hub at the same time.
Then loose the nut a maximum of 1/ 6 turn .
STEP 25
STEP 28
633929
Install the outer wheel bearing. 633936
Install a new cotter pin .

5021-18
STEP 29 STEP 31
63·1104 633543
Install the cap. Remove the support from under the front axle and
lower the wheel to the floor.
STEP 30
STEP 32
634107
I nstall th e wheel and wheel bolts . Do not use an

impact wrench to install the wheel bolts. Tighten the wheel bolts to 115 to 130 pound-feet
(156 to 176 N m, 16 to 18 kg/ m) .
STEP 33
Lubricate the bearings for the kingpin . Lubricate
the tie rod ends.
5021-19
KINGPIN BEARINGS AND THRUST BEARINGS

Removal STEPS
STEP 1
Drive the lock pin out of the spind le.
Raise the front wheel and put an acceptable sup- STEP 6

port under the fron t axle.
STEP 2
STEP 3
Remove the wheel.
STEP 4
633732
Remove the snap ring . The O- rin g used between

the spacer and bearing will cause the snap ring to
be difficult to remove .
STEP 7
Loosen and remove the nut and lock washe r from

th e lock pin .
633734
Remove the spacer.

5021-20
STEP 8 STEP 11
Remove t he O-ring. Remove the O-ring .
STEP 9 STEP 12
6~{3804
Remove the snap ring at the bottom of the king p in. Drive the kingpin out of the spindle.
STEP 10 STEP 13
633812
Remove the spacer. Remove the spindle and thrust bearing and put the
spindle out of the way.
5021-21
STEP 14 STEP 17
633706 633712
Remove the thrust washer. Drive the bottom bearing out of the boss.
STEP 1
633708
Use an acceptable driver and drive the top bearing

out of the boss.
Clean the bores for the bear ings.
STEP 16
STEP 2
Remove the seal.

Put a bearing on a driver that has a pilot end. The
number on one end of the bearing must be toward
the driver. The tape on the driver is 1/ 4 inch from
the bearing to help install the bearing to the correct
depth.
502 1-22
STEP 3 STEP 6
63.3719 633725
Drive the bearing into the bottom boss until the Put the bearing on the driver so that the end of the
tape is even with the top of the boss. bearing with the number is toward the driver.
STEP 4 STEP 7
623721 633727
I nstall the seal on acceptab le driver so that the lip is Drive the bearing into the boss until the bearing is
toward th e driver. The driver must have a lar~l er even with the bottom of the boss.
diameter than the seal.
STEP 8
STEP 5
633723 Clean the bore in the spindle.

Drive the seal into the boss until the driver touches
the boss.
5021-23
STEP9 STEP 12
633816 633822
Install the thrust washer. I nstall the thrust bearing so that the case is on top.
STEP 10 STEP 13
Align the spindle, thrust washer and thrust bearing
with the front axle.
STEP 14
Install the spindle .
STEP 11
Start the kingpin into the spindle so that the notch

for the lock pin is toward the outside .
STEP 15
033820
Get the th rust bearing . The case of the thrust bear-

ing must be on top when the thrust bearing is
installed.
633826
Use a soft hammer and drive the kingpin into the

spindle.
~;021-24
STEP 15 STEP 18
633836
Install the lock pin. Apply a small amount of grease to a spacer and
install the spacer so that the grease fitting is to-
STEP 16 ward the center of the machine.
STEP 19
Install the lock washer and nut but do not tighten

the nut now.
STEP 1"/
STEP 20
Install a new O-ring in the bottom boss. Use grease

to hold the O-ring. Hit the spacer and snap ring to make sure that the
snap ring is in the groove.
5021-25
STEP 21 STEP 24
634005 6340"
Install a new O-ring in the top boss . H it the spacer and sna p ring to make sure that the
snap ring is in the groove .
STEP 22
STEP 25
634007
Install the spacer so that the grease f itting is to-

(
633832
wa rd the center of th e machine . Tighten the nut on the lock pin .
STEP 23 STEP 26
634009
I nstall the snap ri ng. I nstall the wheel and wheel bolts . Do not use a
impact wrench to install the wheel bo lts.
5021-26
STEP 27 STEP 28
634108
Remove t he support from under the front axle and Tighten the wheel nuts to 115 to 130 pound-feet
lower the wheel to the floo r. (156 to 176 N m, 16 to 18 kg / m).
STEP 29
Lubricate the bearings for the kingpins.
5021-27
TOE-IN
Measuring Toe-In STEP 7
The measurement at the rear of the tires must to 0
STEP 1 to 3/ 16 inch (0 to 5 mm) more than the measure-
Raise the front of the machine until the front wheels ment at the front of the ti res.
are free of the floor.
Adjustment
STEP 2
Hold a tool that has a sharp pOint against the cen- STEP 1
ter of the tire tread . Loosen the lock nut at each end of the piston rod
for the steering cylinder.
STEP 3
Hold the tool in one place and rotate the wheel to STEP 2
make a fine line around the tire. Repeat this proce- Turn the piston rod as needed to increase or de-
dure for the other front wheel. crease the toe-in .
STEP 4 STEP 3
Lower the front wheels to the floor. When the toe-in is correct , tighten the lock nut
nearest the flat on the piston rod first to 27 to 42
STEPS pound-feet (203 to 271 Nm) . Then tighten the other
Tu rn the steering wheel as needed to put the front lock nut to 27 to 42 pound -feet (203 to 271 Nm) .
wheels in the straight position.
STEP 6
Measure the distance between the marks at the
front and rear of the tires.
.-------------------------------8------------------------------.j
....,....................... ,......... "..... ,....,. •• • ·• ............. , ....... . .............. " .... ,,/1 . .... • ..
I-------------------------------A,-------------------------------.:
861482
1. Mark Around Center of Tire Measurement B Must Be Equal To Or Up To

2. Steering Cylinder 3/ 16 Inch (5 mm ) Less Than Measurement A
3. Loosen Lock Nuts And Turn
Piston Rod As Required
This Page is Blank
5022
FRONT A.XLE - FOUR WHEEL DRIVE
TABLE OF CONTENTS
Specifications ... . .. .. ... .. ... ..... . . . . . 5022-2 Planetary .. .. . .... .... .. .. ... .... . .... 5022-18
Special Tools ..................... . .... 5022-3 Disassembly . .... . . .. . . ... . ... .. .. .. 5022-18
Toe-In . . .. .. .... . ..... . ... . .... .. . .. ... 5022-4 Assembly .. . ..... .. .. . ..... . .. .. .... 5022-23
Measuring Toe-In ............... . .. ...5022-4 Swivel Housing and Axle Shaft . ... . .... 5022-31
Adjustment ........ .. ... .. .. .... . ... . 5022-4 Removal and Disassembly ........ . .. 5022-31
Front Axle . .... .. .............. . .. . . ... 5022-5 Replacing a Universal Joint ... .... ... 5022-34
Removal .......... . . .... .. ...... . .... 5022-5 Assembly and Installation . . .... ..... . 5022-36
Installation .. . ..... . . .. .. ... . . . .. . .... 5022-7 Differential Carrier ............ ... .... . 5022-42
Inspection .......... .. .. .. .. . . .. .. .. .. 5022-11 Removal .. . .. ... . ... .. .... . ...... ... 5022-42
Exploded Views Installation .... .. . . .. ... .. ... .. ... .. . 5022-43
Planetary ... ......... .. .... ... .. .. .. 5022-12 Disassembly of Differential Carrier . .. 5022-45
Swivel Housing ...... . ..... ..... . ... 5022-13 Disassembly of Differential . .. ... . .. .. 5022-49
Axle Housing and Axle Shaft . . .. . . . .. 5022-14 Assembly of Differential . ... .. .. . .... 5022-51
Differential Carrier . .. ........... . .. . 5022-15 Assembly of Differential Carrier . ... .. 5022-55
Pinion Gear Installation .. ....... . . .. . 5022-16
Differential . .. ........ ...... .. . ... .. . 5022-17
A Tenneco Company
5022-2
SPECIFICATIONS
Bac klash for ring gear ... .. ............. ... .... .. ... ... .......... . 0.008 to 0.010 inch (0 .20 to 0.25 mm)
Rotating torque pinion shaft without seal . .. ..... ... . .. ............ 15 to 20 pound-inches (1.7 to 22 Nm)
Gear lu bricant . ...... .. . .. . .... . ... ....... ..... . .. ... ... ... .... . . . . . . .... CaselH Gear Lube (85W-140)
Capacities
Center bowl ... ........... ... . ... ... ...... ........ ... ....... . ... ......... ... 7.4 U.S. quarts (7 litres)
Planetary (each) .. . ..... ... . . ...... . ..... ....... ... .. ... ....... .. .. . ... .... .. . 1.1 U.S. quart (1 litre)
Special torques
Studs for wheel . . . .... . .. . . .... .. . .... ... .. .... ..... . . . . . .. .. .... . . 52 pound-feet (70 N m, 7.2 kg / m)
Wheel nuts . .......... .. ... ..................... 200 to 240 pound-feet (270 to 325 Nm, 28 to 83 kg / m)
Allen screws for cover for planetary

with 242 Loctite . ............... . .. .. .. ... .. .. ..... . ... . .. . .. 300 pound-inches (34 N m, 3.4 kg / m)
All en screws for carrier ........... . .. ....... . .. .. ..... .. .. . ... .. . .... 59 pound-feet (80 N m, 8 kg / m)
Nut for ball jOint .............. . .. ............... 125 to 133 pound-feet (169 to 180 Nm , 17 to 18 kg/ m)
Cap sc rews for king pin . .. . .... . ......... .. .... ............ .. .. ... 101 pound-feet (137 N m, 14 kg / m)
Nut for bolts that hold flange . .. . .. .... ...... ... . . .... .... . .. .. . 528 pound -inches (60 N m, 6.1 kg / m)
Cap sc rews that hold cove r .......... . .. . ... ... . ... ....... . . .. . . . 84 pound-inches (9.5 N m, 1.0 kg / m)
Nuts that hold differential carrier ................................. 74 pound-feet (100 N m, 10.2 kg / m)
Cap screw for lock for adjusting ring ..... .. . .. ....... .. . ... ..... . 84 pound-inches (9.5 N m, 1.0 kg / m)
Nuts for bearing caps . .. ....... ..................... ... . . .. ....... 115 pound-feet (156 N m, 16 kg / m)
Studs for bearing caps .. ... . ... ...... .. .. ...... . .. ...... .. . ........ 52 pound-feet (70 N m, 7.2 kg / m)
Cap screws for ring gear with 271 Loctite .... . . . .... . .. . ......... . ... 52 pound-feet (70 N m, 7.2 kg / m)
Self-locking nuts for bolts that hold

the drive shaft . ................ . ...... ... ... .... . . .. 50 to 60 pound-feet (68 to 81 N m, 7 to 8 kg / m)
5022-3
SPECIAL TOOLS
The tools shown on this page are required to
disassemble and assemble the planetaries and the
differential.
The tools are available f rom Service Tools in

the U.S. and from Jobborn Manufacturing Co . in
Canada. See Section 1001 for the correct address .
613844
The tool shown above is used to turn the ad-

justing rings for the differential. The part number is
CAS-1840.
STUD
FEELER
GAUGE HANDLE
875432
The tools shown above are used to find the

correct shim to install on the pinion shaft so that
pinion shaft is installed in the correct position. The
tools are part of tool set CAS-1839.
613822
The tool shown above is used to remove and

install two wheel studs that help hold the carrier for
the planetary. The part number is CAS-1842.
2107 12
The tool shown above is used to remove and

tighten the pinion nut. The part number is CAS-
1885.
5022-4
TOE-IN
Measuring Toe-In STEP 7
Measure the distance between the marks at the
STEP 1 front and rear of the tires.
Raise th e front wheels off the floor.
STEPS
STEP 2 The measurement at the front of the tires must be
Ho ld a tool that has a sharp pOint against the cen- equal to or up to 3/ 16 inch (5 mm) less than the
ter of th e tire tread. measurement at the rear of the tires.
STEP 3 Adjustment
Hold th e tool in one place and rotate the wheel to
make a fi ne line around the tire. STEP 1
Loosen the clamp at each end of the piston rod for
STEP 4 the steering cyl inder.
Repeat steps 2 and 3 for the other wheel.
STEP 2
STEP 5 Turn the piston rod as required to increase or de-
Lower the front wheels to the floor. crease the toe-in.
STEP 6 STEP 3
Tu rn the steering wheel as needed to put the fro nt When the toe-in is correct, tighten both cl amps.
wheels in t he straight position .
• 8-------------------------------.1
I~--------------------------A---------------------------.I
8701 71
1. Ma rk Around Center Of Tire Measurement B Must Be Equal To Or Up To
2. Steerin g Cylinder 3/ 16 Inch (5 mm) Less Than Measurement A
3. Loosen Clamps and Turn
Pis ton Rod A s Required
5022-5
FRONT AXLE
Removal STEP 4
Carefully tilt the guard as required to remove th e
STEP 1 guard from under the drive shaft.
STEPS
632508
Loosen and remove the self-locking nuts from the

bo lts that hold the guard for the front drive shaft. 632516
Do not remove the bolts now. Loosen and rem ove the self-locking nuts from the
bolts that hold the drive shaft. Do not remove the
STEP 2 bolts now.
STEP 6
Remove the bolts and remove the drive shaft.
STEP 7
632510
Use floor jack to hold and lower the guard. The

gu ard is balanced with the floor jack in the position
shown.
STEP 3
Raise the front wheels above t he floor and use
acceptable stands to hold th e machi ne in place.
6.12512
Careful ly lower the guard.

5022-6
STEPS STEP 11
Install a plug in each hose and a cap on each fitting.
STEP 12
075592
Install blocks between th e axle stops and frame to

prevent the ax le from tilting .
875586
STEP 9 Remove the snap ring fro m the rear of the pivot
shaft.
STEP 13
E\75430
Loosen and remove the nuts, hardened washers

and wheels.
875585
STEP 10 Remove the flat washers .
STEP 14
E;75587
Disconnect the hoses from the steering cylinder.

Fasten an identification tag to one hose for correct 875584
installation. Loosen and remove the grease fitting .

5022-7
STEP 15 NOTE: If the machine has a front counterweight,

the flat washers are larger than the hole in the
counterweight and must be removed.
STEP 19
Loosen and remove the cap screws that hold the

guard and remove the guard .
STEP 16 875583
Use the floor jack to hold and lower the front axle. Flat washers are used between the front axle and
frame . Carefully lower the f ront axle and remove
STEP 17 the flat washers . Be careful to prevent the front axle
Drive the pivot pin out of the frame . from rolling to the front or rear.
STEP 18 STEP 20
Mv; e the front axle from under the machine.
Installation
STEP 1
875582
If necessary, use a slide hammer to remove the

pivot pin .
875472
Carefully raise the front axle into alignment with

the frame.
5022-8
STEP 2 STEPS
875433
Instal l th e th ick flat washer, and thin flat washer Install the thin flat washer(s) between the frame
between the f rame and the front axle . and front axle . Use as required to remove all clear-
ance between the frame and the front axle.
STEP 3
STEP 6
Start the pivot pin into the fram e and front ax le and
loosen and re move the grease fitt ing .
Drive the pivot pin through the rear pivot and
STEP 4 frame.
STEP 7
8;'5431
Drive the pivot pin into the rear pivot of the front
a)( le but not throug h the rear pivot.
Install the flat washers on the pivot pin.
5022-9
STEP 8 STEP 13
875586 875587
Install the snap ring. Connect the hoses to the steering cylinder.
STEP 9 STEP 14
Hit the pivot pin to move the pivot pin toward the
fro nt of the machine as far as possible .
STEP 10
Check the clearance between the frame and snap
ring on the pin at the front of the machine. Use
washers as required to remove as much clearance
as possible.
STEP 11
I nstall the guard and cap screws and tighten the

cap screws.
STEP 15
I nsta ll and tighten both grease fittings.
STEP 12
Loosen and remove the plugs from the hoses and
t he caps from the fittings.
875572
Install the whee ls , hardened washers and nuts. Do

not use an impact wrench to install the nuts.
5022-10
STEP 16 STEP 21
875575 632512
Tighten the nuts to 199 to 240 pound-feet (2"70 to Carefully move the guard under the drive shaft.
325 Nm , 28 to 33 kg/ m).
STEP 22
STEP 17
Rem ove the supports and lower the wheels to the
floor.
STEP 18
Lubricate the pivot pin for the front axle.
STEP 19
I nstall the drive shaft and bolts .
STEP 20
632510
Raise the guard into al ignment with the brackets

and install the bolts .
STEP 23
I nstall and tighten the self-lock ing nuts to 50 to 60

pound-feet (68 to 81 N m, "7 to 8 kg/ m) .
Remove the floor jack and install and tighten the

self-locking nuts on th e bolts.
STEP 24
Make sure that the center bowl and planetaries are
filled with th e correct gear lu brica nt and amount.
See page 5022-2.
5022-11
INSPECTION
STEP 1 STEP 6
Remove and discard all seals and O-rings . Inspect the bushing in the swivel housing . If the
bushing is worn or damaged , install a new bush-
STEP 2 ing.
I nspect the housings for cracks and other damage.
Replace the housings as necessary. STEP 7
Inspect the ring gear and gear on the pinion shaft.
STEP 3 The ring gear and pinion shaft are a matched set. If
I nspect the bearings and bearing cups . If a bearing the ring gear or the gear on the pinion shaft are
or bearing cup is worn or damaged, install a new damaged, install a new matched set.
bearing assembly . Do not use a new bearing with
an old bearing cup. STEP 8
Inspect the pinion gears an d sun gear for the plan-
STEP 4 etary. If any of the gears are worn or damaged , it is
I nspect the bushings inside the axle housing. If the recommended that you install all new gears.
bushings are damaged or worn , install new bush-
ings. STEP9
I nspect the pinion gears and side gears for the
STEPS differential. If any of the gears are worn or dam-
I nspect the bushings on the end of the swivel pins aged, it is recommended that you install all new
and the bushings in the end of the axle housing . gears.
These bushings are a matched set. If the bushing
on the end of the swivel pin must be replaced ; also
replace the bushing in the axle housing .
5022-12
DOWEL PIN
~ oX ~/
\ "" DOWEL PIN
BEARING CUP STUD BUSHING

1
BEARING WASHER \ HUB
SUN GEAR \ ~~
\
~ ii3 q§)\~ \ CAP SCREW RING GEAR
\
SNAP RING
SPACER
870351
Planetary
5022-13
GREASE FITTING - - - -
- - - T O P KING PIN
STOP SCREW
TWO PIECE BUSHING ----...~9

SEAL----.~~
SHIMS---'~
~e
LOCK WASHER----..
~---
~ .
, ..
..
BOTTOM KING PIN
GREASE FITTING
CAP SCREW ----~.! 870352
Swivel Housing
5022-16
Pinion G ear Installation

5022-17
~\
RING GEAR
CAPSCREW~ _
THRUST WASHER
\
CASE HALF
~ BEARING
THRUST WASHER
PINION GEAR:--~
S'DEGEAR_~ PINION GEAR
THRUST WASHER
PINION SHAFT/
870356
Differential
5022-18
PLANETARY
Disassembly STEP 4
STEP 1
875345
Two studs with shoulde rs hold the ca.rrier. Use tool

CAS-1842, shown on page 5022-3 , to remove the
Raise the whee l(s) above the floor and use an ac- wheel studs .
ceptabl e stand(s ) to hold the machine in place .
STEPS
STEP 2
.f~
875346
Install tool CAS-1842 on a stud and tighten the nut

Loosen and remove the nuts and hardened wash- to hold the tool on the stud .
ers that hold the wheel(s).
STEP 6
STEP 3
Re move th e whee l(s).
Loosen and remove the stud.

5022-19
STEP 7 STEP 11
Repeat steps 5 and 6 for the other stud.
STEP 8
875352
Remove the gasket materi al from the housing and

carrier.
875348
Loosen and remove the two Allen head screws that STEP 12
help hold the carrier.
STEP 9
875351
Remove the snap ring that holds the sun gear.
875349 STEP 13
Put a drain pan below the planetary and use two
pry bars to loosen the carrier.
STEP 10
8;5353
Remo ve the sun gear.
Remove the carrier.

5022-20
STEP 14 STEP 17
875358
Remove t he spacer. Install four of the cap sc rews just removed in the
threaded holes in the hub.
STEP1S
STEP 18
Remove the thrust washer.

Tighten the cap screws evenly to free the ring gear
STEP 1(i from the swivel housing.
STEP 19

hub for the ring gear. 875360
Remove the ring gear.

5022-21
STEP 20 STEP 23
875364
Use two prybars as shown to remove the outer Use prybars as shown to remove the wheel bearing
wheel bearing from the swivel housing . from the outer bearing surface.
STEP 21 STEP 24
1175:165
Remove the planetary housing and wheel bearing. If inspection indicates the need for a new wear ring,
use a chisel to cut the wear ring. Be careful not to
STEP 22 cut the swivel housing. Remove the wear ring.
STEP 25
875:16 3
Slide the inner wheel bearing off the inner bearing

surface. 612232
Remove the retaining ring from the ring gear.

5022-22
STEP 26 STEP 29
612234 612238
Remove the hub. Drive the roll pins out of the pinion shafts.
STEP 27' STEP 30
612304
Press the bushings from the hub only if new bush- Press the pinion shafts out of the carrier.
ing(s) are needed or a new hub is being instal led .
STEP 31
STEP 28
612436
875367 Remove the pinion gears and th rust washers being

Loosen and remove the A llen head screws and careful not to lose the needles.
remove the cover.
5022-23
STEP 32 STEP 2
Remove the bearing cups only if inspection indi- Press a new sea l into the planetary housing.
cates the need for a new bearing cup or bearing.
STEP 3
STEP 33
612402
" , 232R Install a new O-ring on each pinion shaft.

Remove and discard the seal.
STEP 4
STEP 34
I nspect the parts according to instructions on page
5022-11.
J~ssembly
STEP 1
87!:i3GG
Install the thrust washer with the larger I.D. in the

recess in the pinion gear. Use petroleum jelly to
hold the thrust washer in place.
6 12410
Press new bearing cups intothe planetary housing

as required.
5022-24
STEPS STEP 8
612440 875368
Install 30 needles in each pinion gear using petro- Install the pinion shaft to align the thrust washers
leum jelly to hold the needles in place. and pinion gear with the carrier.
STEP 6 STEP 9
612442
Put the other thrust washer on the pinion gear. Make a mark on the end of the pinion shaft aligned
with the center of the hole for the roll pin. Then
STEP 7' extend the mark across the end of the pinion shaft.
STEP 10
Install the pinion gear in the carrier so that the

875371
thrust washer with the larger J.D. is toward the
cove r. Install the pinion shaft so that the mark is aligned
with the hole for the roll pin in the carrier.
5022-25
STEP 11 STEP 14
875374
Lubricate the O-ring with oil. Apply 242 Loctite to the t hreads in the pinion
shafts.
STEP 12
STEP 15
875373
Press the pinion shaft all the way into the carrier. 875375
I nstall the cover and Allen head screws and tighten

STEP 13 the Allen head screws to 84 pound-inches (9.5 N m,
1 kg/ m) .
STEP 16
1S/~311
Drive the roll pin into the carrier.
Press bushings into the hu b for the ring gear as

required .
5022-26
STEP 1'7 STEP 20
875366A
Make sure a retaining ring has been installed in the Install the wear ring on the swivel ho using,
inner groove in the ring gear and install the hub,
STEP 21
STEP1B
875409
612236 Install the bearing on the swivel housing,

Instal l th e other retaining ring ,
STEP 22
STEP 19
786356 Lubricate the bearing with gear lubri can t.

If th e wear ring was removed from the swivel hous-
ing, heat a new wear ring in an oven to 120° F
(49 0 C),
iNARNING: Use insulated gloves or
A I mens when working with hot parts,

47-41A
5022-27
STEP 23 STEP 26
875416
Install the planetary housing. Hold the planetary housing and use a soft hammer
to drive the bearing onto the swivel housing .
STEP 24
STEP 27
Lubricate the other bearing with gear lubricant. 875417
Align the large diameter bushing with the large

STEP 25 hole in the swivel housing and install the ring gear.
STEP 28
875413
Start the bearing onto the swivel housing.

875418
Install a cap screw in every ot her bushing.

5022-28
STEP 29 STEP 32
875423 875354
Tighten th e cap screws evenly to pull the ring gear Install the spacer.
against the swivel housing.
STEP 33
STEP 30
Install the sun gear.

Install the remainder of the cap screws and tighten
the cap screws to 184 pou nd-feet (249 N m, 25 STEP 34
kg / m) .
STEP 31
875351
875355
Install the thrust washer.
5022-29
STEP 35 STEP 38
0754?5
Apply form-in-place gasket material to the plane- Install the studs.

tary housing.
STEP 39
STEP 36
875427 Install tool CAS-1842 on a st ud so that the tool is

Install the carrier. close to but not touch ing the carrier. Tighten the
nut to hold the tool in place.
STEP 37
STEP 40
875578
nstall and tighten the Allen screws to 59 pound- 875576
feet (80 N m, 8 kg/ m) . Tighten the stud to 52 pound -feet (70 N m, 7 kg/ m) .
5022-30
STEP 41 STEP 43
Repeat steps 39 and 40 for the other stud .
STEP 42
Fill the planetary(ies) with 1.1 U.S. quart (1 litre) of
gear lubricant.
875572
Install the wheel(s) , hardened washers and nuts.

Do not use an impact wrench to install the nuts.
STEP 44
Tighten the nuts to 200 to 240 pound- eet (270 to

325 Nm, 28 to 33 kg / m) .
5022-31
SWIVEL HOUSING AND AXLE SHAFT

I~emoval and Disassembly STEP 4
STEP 1
Do the necessary steps under Planetary Disassem-
bly beginning on page 5022-18 for access to the
sw ivel housing .
STEP 2
STEP 5
Remove the bearing only if th e bearing is to be

replaced or used on a new swivel hou sing.
STEP 3
Loosen and remove the nut.
STEP 6
I nstall the nut so that the notciles are up and the nut
is even with the end of the stud.
STEP 7
Remove the wear ring only if the wear ring is worn
and the swivel housing is to be used again.
875381
Use a hydrauli c ram as shown to app ly pressure

against the stud and hit the ann on the swivel hou s-
ing with a heavy brass hamm l'!r to loosen th e stud .
5022-32
STEP 8 STEP 11
875385
Remove the nut and remove the ball joint from the Remove the shims and keep for use during assem-
swivel hOLising. bly. Fasten an identification tag to the shims .
STEP 9 STEP 12
Repeat steps 9 through 11 for the bottom king pin.
STEP 13

top king pin .
STEP 10 Remove the swivel housing.
STEP 14
Remove the king pin.
Remove the axle shaft.

5022-33
STEP 15 STEP 18
875388
Remove the sea l for each king pin . Remove the seal from the axle housing .
STEP 16 STEP 19
875390 875394
Use an acceptable puller and remove the top bush- Remove the bushing only if inspection indi cates
ing only if inspection indicates the need for a new the need for a new bushing.
bushing.
STEP 20
STEP 17
612338
87""92 Remove the seal from the swivel housing .

The bottom bushing is difficult to remove . The bot-
tom bushing can' be removed using tools and
bloc ks as shown .
5022-34
STEP 21 STEP 24
612414A 875405
If inspection indicates the need for a new bushing Put the king pin in a press as shown and press the
in the swivel housing , support the swivel housing king pin out of the bushing.
on a sleeve and press the bushing out of the swivel
housing. Replacing a Universal Joint
STEP 22 STEP 1
The bushing on the bottom king pin and early top It is recommended that both universal joints be
king pin can be difficult to remove. replaced at the same time.
STEP 23 STEP 2
875400
Fasten the king pin in a vise and use a hammer and Remove the snap rings.
chisel that has a long taper to start the bushing off
the king pin.
5022-35
STEP 3 STEP 10
875401 146730
Support the coupling as shown and use an accep- Suppo rt the yoke as shown and press the other
table driver and press the bearing cap out of the bearing cap out of the yoke .
coupling until the cross stops moving .
STEP 11
STEP 4 Remove the cross from the yoke.
Fasten the bearing cap in a vise and remove the
coupling from the bearing cap. STEP 12
Use an acceptable driver and press the bearing cap
STEPS out of the yoke.
Suppo rt the coupling as shown in step 3 and press
the other bearing cap out of the coupling. STEP 13
Press a bearing cap into the yoke on the axle shaft
STEP 6 until the bearing cap is even with the inside of th e
Remove the cross from the coupling. yoke .
STEP 7 STEP 14
Use an acceptable driver and press the bearing cap Install the cross in the yoke and carefully install the
out of the yoke . cross in the bearing cap .
STEP 8 STEP 15
Press the other bearing cap into the yoke until the
bearing cap is j ust above the end of the cross.
STEP 16
Carefully raise th e cross into the top bearing cap
and press the bearing caps into the yoke .
STEP 17
Use an acceptable driver and press a bearing cap
into the yoke until the groove for the snap ring can
be seen.
STEP 18
Support the axle shaft as shown and press a bear-
ing cap out of the yoke until the cross stops mov-
STEP 19
Repeat steps 17 and 18 for the other bearing cap.
ing.
STEP 20
STEP 9 Press a bearing cap into the yoke until the bearing
Fasten the bearing cap in the vise and remove the
cap is even with the inside of the coupling.
yoke from the bearing cap.
5022-36
STEP 21 STEP 4
Install the cross in the coupling and carefully in-
stall the cross in the bearing cap.
STEP 22
Press t he other bearing cap into the coupling until
th e bearing cap is just above the end of the cross .
STEP 23
Carefully raise the cross into the top bearing cap
and press the bearing caps into the coupling .
STEP 24
Use an acceptable driver and press a bearing cap
into the yoke until the groove for the snap ring can
875396
be seen.
Drive the bushing into the bore until thE! bushing is
5/ 16 inch (8 mm) beyond the end of the bore.
STEP 25
Install the snap ring .
STEPS
STEP 26
Repeat steps 24 and 25 for the other bearing cap .

STEP 1
If the bushing was removed from the swivel hous-
ing , press a new bushing into the swivel housing
until the bushing is even with the outside end of the
bore.
STEP 2
Press a new seal into the swivel housing until th e
sea l stops moving . 875397
I nstall a new seal on an acceptable driver.

STEP 3
STEP 6
875395
If the bushing was removed from the axle housing,

install a new bushing on a driver that has a pilot so Drive the seal into the housing until the seal stops
that the spl it in the bushing is toward the front or moving .
rear.
5022-37
STEP 7 STEP 10
875389 875403
If the bushings for the king pins were removed from Use an acceptable driver and drive the seal all the
t he axle housing , install the new bushings on a way into the bore.
driver that has a pilot.
STEP 11
STEP 8 Repeat steps 9 and 10 for the bottom seal.
STEP 12
875391
Drive the bushing all the way into the bore.

875404
IMPORTANT: If the top bushing was a two piece Install the axle shaft. You will have to hold the long
bushing, these parts must be replaced with a single axle shaft with one hand to align and engage the
bushing and a new king pin. long axle shaft with the side gear in the differential.
STEP 9 STEP 13
Install the swivel housing .
STEP 14
If the old swive l housing is being installed and no
new bearings were installed in the axle housing , do
steps 15 through 18.
Start a new seal into the top bore .

5022-38
STEP 15 STEP 18
Repeat steps 15 through 17 for the bottom king pin .
STEP 19
If a new swivel housing or new bearings have been
insta lled for the king pins , do steps 20 ·:hrou gh 34 .
STEP 20
Install the top king pin and shims.
STEP 16
875419
Install the top king pin without shims .
STEP 21
875408
I nstall the cap screws and lock washers .
STEP 17
875421
Install shims equal to approximately 0.040 inch (1

mm) on the bottom king pin .
STEP 22
785420
Tighten the cap screws to 101 pound -feet (137 N m,

14 kg/ m).
875428
Install the bottom king pin.

5022-39
STEP 23 STEP 26
Subtract 0.004 inch (0.10 mm) from the measure-
ment in step 25 . Example: 0.020 inch (0 .50 mm)
minus 0.004 inch (0.10 mm) '3q uals 0.16 inch (0.40
mm).
STEP 27
Subtract the answer found in step 26 from the
thickness of shims installed in step 21. Example: If
0.040 inch (1 mm) shims we re installed in step 21 ,
subtract 0.016 inch (0.40 mrn) which equals 0.024
inch (0 .60 mm) . Divide this answer by two. The
answer is the thickness of shims to be installed on
each king pin. If the shims cannot be divided equal -
ly, install the th ickest set of shims on the top king
pin .
Install the cap screws and lock washers that hold
the bottom king pin and tighten the cap screws to STEP 28
101 pound-feet (134 N m, 14 kg/ m).
STEP 24
875414

top and bottom king pins.
I nstall and tighten the cap screws that hold the top STEP 29
king pin .
STEP 25
875422
Remove the bottom king pin and install the correct

thickness of shims.
875426
Use a dial indicator and check the free travel of the

swi vel housing and make a record of the measure-
ment. If you do not have free trave l, remove t he top
an d bottom king pins. Begin again at Step 21 but
add additional shims on the bottom king pin .
5022-40
STEP 30 STEP 33
Install the ottom king pin and cap screws. Install the cap screws and lock washers .
STEP 31 STEP 34
875429 87542U
Tighten the cap screws to 101 pound-feet (134 N m, Tighten the cap screws to 101 pound-feet (134 N m,
14 kg/ m). 14kg/ m).
STEP 32 STEP 35
875-107 875382
Install t he correct thickness of shims on the top Install the ball joint in the arm on the swivel hous-
king pin and install the top king pin. ing.
5022-41
STEP 36 STEP 38
Lubricate the king pins .
STEP 39
Assemble the planetary according to instructions
under Planetary Assembly beginning on page
5022-26.
875415
I nstall and tighten the nut to 170 pound-feet (230 N

m , 23 kg/ m).
STEP 37
875379
Install a new cotter pin. If a notch in the nut is not

aligned with the stud , tighten the nut to align the
nearest notch with the hole.
5022-42
DIFFERENTIAL CARRIER
Removal STEP 7
Keep the shims and king pins together for use dur-
STEP 1 ing installation.
Remove the front axle according to instructions in
this section. STEP 8
STEP 2
Put the front axle on an acceptable stand .
STEP3
Loosen an d remove the filler and drain plugs forthe
ce nter bowl and drain the gear lubricant.
STEP 4
Fasten acceptable lifting equipment to the swivel
housing and planetary.
STEPS
Remove the planetary, swivel housing and axle

shaft as an assembly.
STEP 9
Repeat steps 4 through 8 at th e other side of the
axle .
STEP 10
Loosen an d remove the cap screws that hold the

ki ng pins in place .
STEPS
Loosen and remove the self-locking nuts.
Remove th e king pins .

5022-43
STEP 11 STEP 2
875439
875518
Install an M10 x 1.5 x 35 mm cap screw in the
threaded holes in the differential carrier. Tighten Lower the differential carrier onto the axle hous-
the cap screws evenly to remove the differntial car- ing .
rier from the dowel pins.
STEP 3
STEP 12
875530
I nstall a self-locking nut on the stud on each side of
Rem ove the differential ca rrier . the dowel pins and tighten the four self-locking
nuts evenly.
STEP 13
Remove the gasket material from the axle housing STEP 4
and clean the inside of the center bowl.
Installation
STEP 1
875515
Install the remainder of the self-locking nuts and

tighten the self-locking nuts to 74 pound-feet (100
N m, 10 kg/ m) .
875519
Apply form-in-place gasket material to the axle

housing.
5022-44
STEPS STEP 8
8755 16
Fasten lifting equipment to the swivel housing and Install the top king pin and shim s, and the cap
plan etary as shown . screws and loc k washers .
STEP 6 STEP 9
Start the ax le shaft into the axle housing . Tighten the cap screws to 101 pound-feet (1 34 N m,
14kg/ m).
STEP 7
STEP 10
It Repeat steps 8 and 9 for the bottom king pin .
STEP 11
8754 78
The axle shaft can be difficult to engage with the

side gear in the differential. With one hand , align
th e ax le shaft with the side gear and with the other
hand pustl the assembly into the axle housing . If
necessary, have another person turn the pinion Install the ball jOint.
shatto
5022-45
STEP 12 Disassembly of Differential

Carrier
STEP 1
875474
I nstall and tighten the nut to 170 pound-feet (230 N

m, 23 kg / m) .
STEP 13 Fasten the differential carrier in a repair stand.
STEP 2
I nstall a new cotter pin. If the nut is not aligned with

the hole in the stud , tighten the nut until the cotter 875527
pin can be installed. Prevent the pinion shaft from turning and measure
the backlash of the ring gear. Make a record of the
STEP 14 measu rement.
Repeat steps 5 through 13 at the other side of the
front axle. STEP 3
STEP 15
Lubricate the king pins.
STEP 16
Fill the center bowl with 7.4 U.S. quarts (7Iitres) of
gear lubricant.
STEP 17
Install the front axle according to instructions in
this section.
Loosen and remove the nuts and bolts that hold the
flange .
5022-46
STEP 4 STEP 7
875525 875522
Remove the flange. Make sure that at least one bearing cap and the
differential carrier have an identification mark. If
STEPS necessary, make an identification mark.
STEP 8

cover. 875521
Loosen and remove the cap screw and !ock nut that
STEP 6 hold each adjusting ring.
STEP 9
875523
Remove ttle cover.
Loosen and remove the self-locking nuts that hold

each bearing cap.
5022-47
STEP 10 STEP 13
875446 875443
Loosen both adjusting rings . Remove the bearing cups and fasten an identi fi ca-
tion tag to the bearin g cups for correct installati on
STEP 11 if the bearing cups are to be used again .
STEP 14
Remove both bearing caps.
STEP 12 Use a narrow chisel to push the nut out of the slot in
the pinion shaft.
STEP 15
875444
Remove the adjusting ring , bearing cups and dif-

ferential.
Prevent the pin ion shaft from turning and use tool
CAS-1885 shown on page 5022-3 to loosen and
remove the pinion nut.
5022-48
STEP 16 STEP 19
875471
Remove the thrust washer by raising the plain side Press the seal from the cover.
on top of the shoulder and then removing the tab
from the slot. STEP 20
STEP 17
87549 1
Remove the spacer.
Use a soft Ilammer and drive the pinion shaft out of STEP 21
t he outer bea ring .
STEP 18
613138
Press the pinion shaft from the inner bearing.
875469
Remove th e outer bearing .

5022-49
STEP 22 STEP 3
875545
Remove the bearing c ups only if inspection indi - Look for an alignment on each case half. If there is
cates the need for new parts. A spacer is used no alignment mark , make an alignment mark.
between the differential carrier and th e inner bear-
ing cup. Do not lose the spacer. STEP 4
Disassembly of Differential
STEP 1
Separate the case halves .
STEPS
875442
Loosen and remove the cap screws that ho ld the

ring gear.
STEP 2
87554:
Remove the side gear.
875546
Re move the ring gear.

5022-50
STEP 6 STEP 9
875539
Remove the thrust washer. Use a soft hammer and drive the pinion shaft out of
the case half and remove the pinion shaft.
STEP 7
STEP 10
Lift one end of the top pinion shaft out of the case
ha lf. Slide the other pinion shaft out of the case half until
the notch is in the bore fo r the pinion ",haft.
STEP 8
STEP 11
Remove the thrust washer and pinion gear.

Remove the pi nion gear and thrust washer and
pinion shaft assembly.
5022-51
STEP12 STEP 15
Inspect the parts according to instructions on page
5022-11 .
Assembly of Differential
STEP 1
07 5537
Remove the side gear.
STEP13
875533
Press a new bearing onto the case halves as re-

quired .
STEP 2
875536
Remove the thrust washer.
STEP14
875536
Install a thrust washer in the case half without

threaded holes.
STEP 3
875534
If a bearing is to be removed from either case half,

remove the bearing as shown.
875569
Lubricate a side gear with gear lubrican t. I nstall the

side gear.
5022-52
STEP 4 STEP 7
875568 875564
Install a t hrust washer on a pinion shaft. Lubricate the thrust surface of a pinion gear with
the gear lubricant.
STEPS
STEP 8
875567
Lubricate the thrust surface of a pinion gear with 875562
gear lubricant. Slide the pinion shaft out of the case half and install
the pinion gear and a thrust washer on the pinion
STEP 6 shaft.
STEP 9
87 5565
Install the pinion gear on the pin shaft and insta ll

the pi n ion shaft. 875561
Push the pinion shaft into case half.

5022-53
STEP 13
875560 875556
In stall a thrust washer on the other pinion shaft. Lubricate the thrust surface of th e remaining pi-
nion gear with gear lubricant.
STEP 11
STEP 14
875559
Lubricate the thrust surface of a pinion gear with 875554
gear lubricant. I nstall the pinion gear and remaining thrust washer
on the pinion shaft.
STEP 12
STEP 15
875557
In stall the pin ion gear on the pinion shaft and in- 875553
stall the pinion shaft in the case half. Hit the pinion shaft w ith a ~; oft hammer to make
sure that the parts are seated .
5022-54
STEP 16 STEP 19
875552
I nstall th e other side gear. Apply 271 Loctite to the threads in the case half.
STEP 1"' STEP 20
675532 875550
Make sure that the threads in the other case half Assemble the case halves and make sure that the
and the t hreads on the cap screws are free of alignment marks are aligned .
lubricant.
STEP 21
STEP 13
875551 Make sure the mounting surfaces for the ring gear
Lubricate both sides of the other th rust washer with are clean and install the ring gear.
gear lubr icant and install the thrust washer in the
case half.
5022-55
STEP 22 STEP2
Install the cap screws that hold the ring gear. Use an acceptable driver and press the seal 1/ 8
inch (3 mm) below the top of the cover .
STEP 23
STEP 3
875449
Fasten the ring gear in a vise that has soft jaws and 875489
t ighten the cap screws to 52 pound-feet (70 N m, 7 If new bearing cups are being installed the differ-
kg/ m). ential carrier , make sure that the spacer is installed
in the bore for the inner bea l'ing cup .
Assembly of Differential Carrier
STEP 4
STEP 1
875497
Use an acceptable driver and drive the bearing cup

Start a new seal into the cover. into the differential carrier.
5022-56
STEPS STEPS
875453 875495
Install the bearing caps making sure the numbers Check to see that each cup moves freely. If a bear-
are matched . ing cup does not move freely use em '9ry cloth to
clean the bearing cap and leg so that the bearing
STEP 6 cup will move freely.
STEP 9
Loosen and remove the self-locking nuts, bearing
caps and bearing cups .
STEP 10
875452
Install the bearing cups.
STEP 7
Install the inner bearing.
STEP 11
I nstall and tighten the self-locking nuts to 115

pound-feet (156 N m, 16 kg / m).
Assemble the gauge bloc k, adapter and stud from

kit CAS-1839 shown on page 5022-3.
5022-57
STEP 12 STEP 15
875492 875510
Install the gauge b lock assembly in the inner bear- I nstall the bearing caps with numbers matched,
ing. and the self-locking nuts. Ti~lhten the self-locking
nuts to 115 pound- feet (156 t~ m, 16 kg/ m).
STEP 13
STEP 16
875486
Install the outer bearing and handle. Tighten the

handle until the bearings become difficult to turn. Use the metric feeler gauge from the kit and mea-
sure the space between the gauge tube and gauge
STEP 14 block. Write the measurement on line b in step 18.
STEP 17
875487
Install the gauge tube.

6'~U24
Write the numbers on the end of the pinion on line d

in step 18.
5022-58
STEP 18 STEP 22
The number on line a does not change . Add line a
and line b and write the answer on line c . Subtract
line d from line c. Line e is the thickness of the shim
to be installed on the pinion shaft .
Example
a. 108 .499 mm a. 108.499 mm
b. + mm b. + 1.650 mm
c. III III c. 110.149 mm
d. - mm d. 107.450 mm
e. mm e. 2.699 mm
use 2.70 mm
thick shim
STEP 19 875466
Loosen and remove the self-locking nuts, bearing Install a new spacer on the pinion shaft. This spa-
caps, gauge tube, gauge block assembly and bear- cer must be new.
ings.
STEP 23
STEP 20
875464
613108 Lubricate the bearing with gear lubricant.

Insall the shim with the thickness specified in step
18. The chamfer on the I D must be towards the STEP 24
pinion gear.
STEP 2'1
875463
Lubricate the other bearing with gear lubricant.
613142
Use an acceptab le driver and press the inn er bear-

ing again st the shim.
5022-59
STEP 25 STEP 28
875465
Install the pinion shaft and outer bearing . Install a block between the pinion gear and carrier
housing to prevent the pinion shaft from turning .
STEP 26
STEP 29
875484
I nstall the washer. Engage the tab in the slot before 87546'
installing the washer on the threaded part of the Use tool CAS-1885 and tighten the pinion nut to 50
pinion shaft. pound-feet (68 Nm, 7 kg / m) .
STEP 27 STEP 30
Use a pound-inch (Nm, kg/ m) torque wrench and

check the rotating torque of the pin ion shaft. Use a
Install a new pinion nut.
1-15/16 inch 12 point socket and a 118 inch (3 mm)
cotter pin as a shaft adapter. The rotating torque
must be 15 to 20 pound- i nche~; (1.7 to 2.2 Nm).lf the
rotating torque is less than specified , tighten the
pinion nut a small amount and check the rotating
torque again . If you tighten the nut too much , you
must remove the pinion shaft and install a new
spacer as shown in Step 22.
5022-60
STEP ~11 STEP 34
875480 875509
When the rotating torque is as specified, use a Tighten the cap screws to 84 pound-inches (9 N m,
hammer and punch and drive part of the pinio n nut 1 kg/ m).
into the slot in the pinion shaft.
STEP 35
STEP 32
875512
Install the flange and bolts and self-locking nuts.

Apply form-in-place gasket material to the differ-
ential carrier. STEP 36
STEP 33
Tighten the self-locking nuts to 528 pound-inches

(60 N m, 6 kg/ m) .
I nstall th e cover and cap screws.
5022-61
STEP 40
Install the differential in the differential carrier and Install these self-locking nuts and tighten the self-
lubricate the bearings with gear lubricant. locking nuts to pull the bea. ring caps against the
differential carrier.
STEP 38
STEP 41
I nstall the beari ng cu ps. 875500
Install the adjusting rings .

STEP 39
STEP 42
875502
Install the bearing caps making su re that the num- 875507
bers are matched. Tighten both adjusting rin9s while making sure
that there is clearance between the ri ng gear and
pinion gear (backlash).
5022-62
STEP 413 STEP 46

If the original ring and pinion gears are being used,
the backlash must be equal to the measurement
made during disassembly.
STEP 47
If new ring and pin ion gears are being used, the
backlash must be 0.008 to 0.010 inch (0.20 to 0.25
mm).
STEP 48
875506
Use a dial indicator and check for end play. If there

is end play, tighten the adjusting ring fart hest from
the rin g gear . T hen tighten each adjusting ring one
notch .
STEP 44
If there is not enough backlash, loosen the adjust-

i ng ri ng nearest the ri ng gear one notch and tig hten
the opposite adjusting ring one notch. Check the
backlash aga in . Continue with this step until the
backlash is correct.
STEP 49
87550a
Tighten th e self-locking nuts to 115 pound-feet

(156 N m, 16 kg / m).
STEP 45
If there is too much backlash, loosen the adjusting

ring farthest from the ring gear one notch and
tighten the opposite adjusting ring one notch.
Check the backlash again. Continue with this step
until the backlash is correct.
875504
Use the di al indicator and check the back lash of the

ring gear. Check the backlash at 90 degree inter-
vals . If the readings are not equal, adjust the back-
lash at th e position that had the smallest reading.
5022-63
STEP 50 STEP 51
When the backlash is correct, install the lock and Tighten both cap screws to 84 pound-inches (9 N
cap screw that hold each adjusting ring . m, 1 kg/ m) .
This Page is Blank
6200
REMOVAL AND INSTALLATION OF
POWER TRAIN COMPONENTS
TABLE OF CONTENTS
Torque Specifications . . . . . .. . .... .. . . . . 6200-2 Replacing the Flex Plate . . .. ...... ... 6200-12
Special Tools .. . ... . ..... . . .. . . . .... ... 6200-2 Installation .. . ... ... . . .. . . . .. ... ..... 6200-1 3
Power Shuttle ...... .. ........ . .. ..... .. 6200-3 Transaxle ..... ..... .... .. . .. . . .. ...... 6200-14
Removal ..... .. ..... ... . ... .. .... .. .. 6200-3 Removal . .. .. . . ... ...... . . .. . ....... 6200-14
Installation .. . .. . ...... . ...... .. .. . ... 6200-6 Installation ... .. . ..... .......... ... .. 6200-16
Torque Converter .... . .... .. . . .. ... ... 6200-11 Replacing a Universal Joint .. . .. .. ..... 6200-19
Removal . ..... . .. . .. ......... . ... . .. 6200-11
A Tenneco Co mpan y
6200-2
Cap screws that hold power shuttle . .................. 54 to 64 pound-feet (73 to 87 N m, 7.4 to 8.8 kg / m)
Cap screws for rear drive shaft ... .. .. ... . . ..... . 156 to 216 pound-inches (17 to 24 N m, 1.8 to 2.5 kg / m)
Self-locking nuts for front drive shaft . . ....... .. . .... . . 70 to 84 pound-feet (95 to 114 N m, 10 to 11 kg / m)
Cap screws, flex plate to torque converter . . . .. ... 456 to 504 pound-inches (53 to 56 N m, 5 . ;~ to 5.8 kg / m)
Cap screws, flex plate to flywheel ..... .. ........ . 156 to 180 pound-inches (1 8 to 20 N m, 1.13 to 2.0 kg/ m)
Self-locking nuts for transaxle mounting bolts .. 810 to 990 pound-feet (1099 to 1342 N m, 112 to 136 kg/ m)
Wheel bolts and nuts ... ... ...... . ....... .. . .. . . ........... ..... . .. . . ...... .. . . .. . ... See Section 6229
SPECIAL TOOLS
The tools shown below are available for Ser-
vice Tools in the U.S . and from Jobborn Manufac-
turing Co . in Canada .
757062
The tool is used to correctly install the flex

plate on the torque converter . The part number is
CAS-1153A.
430842
The tool shown above is used to turn the fly-

wheel when draining the torque converter. The part
number is CAS-1690 .
6200-3
POWER SHUTTLE
IRemoval STEPS
STEP 1
If the machine has four wheel drive, pul l up the
contro l lever for the transfer case and move the
machine forward a small amount to engage the
transfer case. Then stop the engine.
STEP 2
App ly the parking brake.
STEP 3
If the machine has four wheel drive do steps 4
t h rough 10.
632512
STEP 4
Carefully lower the guard. It can be necessary to
use a pry bar to remove the 9uard from the brack-
ets.
STEP 7
Carefully tilt the guard as required to remove the
guard from under the drive shaft.
STEP 8
Remove the guard for th e control linkage from the
transaxle .
STEP9
632508

bolts that hold the guard for the front drive shaft.
Do not remove the bolts now.
STEPS
Loosen and remove th e self··locking nuts from the

bolts that hold the front drivEl shaft. Do not remove
the bolts now.
STEP 10
Remove the bolts and remo ve the drive shaft.
Use a floor jack to hold and lower the guard. The

guard is ba lanced with the floor jack in the position
shown.
6200-4
STEP 11 STEP 16
632523
Loosen and remove the cap screws and clamps Use tool CAS-1690 and turn the flywheel until the
that hold the d rive shaft. drain plug in the torque converter can be seen
through the hole in the bottom of the f lywheel
STEP 12 housing.
Remove the drive shaft.
STEP 17
STEP 13
Loosen the plug on the end of the dipstick and
remove the dipstick.
STEP 14
632529
Loosen and remove the drain plug from the torque

converter.
STEP 18
632521
Loosen the clamp that holds the filler tube and

remove the clamp.
STEP 15
Have available a container that holds 3 U.S. gal-
lons (11 litres).
Loosen and remove the drain plug from the power

shuttle.
6200-5
STEP 19 STEP 23
632705
Loosen the nut that holds the wire on the tempera- If equipped with a backup alarm , disconnect the
ture sender and remove the wire . wiring from the backup alarm switch.
STEP 20 STEP 24
fi32S34 632706
Loosen completely the nut at the bottom of the Disconnect the wiring to the clutch cutout sole-
filler tube. noid.
STEP 21 STEP 25
Remove the filler tube from the power shuttle.
STEP 22
632709
Disconnect the wire for the sender for the fuel

gauge.
632537
Disco nnect the wiring from the neutral start switch.

6200-6
STEP 26 STEP 34
Carefully lower the power shuttle.
STEP 35
Remove the power shuttle from under the ma-
chine. Raise the machine as required for the nec-
essary clearance.
Installation
STEP 1
Fasten the power shuttle to the transmission jack.
STEP 2
Install a 7/ 16-NC x 4 inch (102 mm) stud in the
6327 14
middle hole on each side of the torque converter
Loosen and remove the nut that fastens the linkage
housing.
to the control arm.
STEP 3
STEP 27
Move the power shuttle under the machine.
STEP 4
Align the power shuttle with the studs and start the
power shuttle onto the studs.
STEPS
Move the power shuttle forward.
IMPORTANT: DO NOT use extra force to push

the power shuttle into place. If the power shuttle
does not easily slide into contact with the torque
conve rte r housing, parts are not correctly aligned.
632717 STEP 6
Put identification tags on the hoses. Disconnect Turn the flywheel as required and p sh the power
the hoses from the power shuttle. shuttle forward until the power shuttle touches the
torque converter housing .
STEP 28
I nstall a plug in each hose and a cap on each fitting. STEP 7
I nstall the two top cap screws and lock washers to
STEP 29 hold the power shuttle.
Loosen and remove the two top and bottom cap
screws that ho ld the power shuttle. STEP 8
Remove the transmission jack.
STEP 30
Loosen but do not remove the midd le cap screws . STEP 9
Remove the studs and install the remainder of the
STEP 31 cap screws and lock washers .
Fasten a transmission jack to the power shuttle.
STEP 10
STEP 32 Tighten the cap screws to 54 to 64 pound-feet (73
Remove the middle cap screws that hold the power to 87 N m, 7.4 to 8.8 kg / m) .
shuttle .
STEP 33
Carefully move the power shutt le to the rear to
cl ea r the torque converte r.
6200-7
STEP 11 STEP 16
I_ oose n and remo ve the plug from the top hose and
t he ca p from the top fitting .
STEP 12
632709
Connect the wire for the sender for the fuel gauge.
STEP 17
632717
Co nnect the to p hose to the top f itting .
STEP 13
I_oosen and remove the plug from the other hose
and the ca p from the other fitting.
STEP 14
Conn ect the wiring for the clutch cutou t so lenoid.
STEP 18
632721
Connect the hose to the fitt ing .
6:32705
If equipped with a backup alarm , connect the wir-

ing to th e backup ring alarm switch.
6327 14
Engage the linkag e with the contro l arm and install

the lock washe r and nut. Tighten th e nut.
6200-8
STEP 19 STEP 23
632529
Install and tighten the drain plug for the torque

Connect the wiring to the neutral start sw itch.
converter.
STEP 20
STEP 24
Install the filler tube for the power shuttle.
Make sure that the drain plug for th e power shuttle
has been installed.
STEP 21
STEP 25
Install the drive shaft.
STEP 26
Align the filler tube with the bracket and tighten the
nut at the bottom of the filler tube.
STEP 22 632802
Install the clamps and cap screws that hold the

drive shaft.
STEP 27
63253 1
Install the wire on the temperature sender and

tighten 'he nut.
Tighten the cap screws to 156 to 216 pound-inches

(17 to 24 N m, 1.8 to 2.5 kg/ m) .
6200-9
STEP 28 STEP 33
If the machine has four wheel drive. do steps 29
through 34 .
STEP 29
Install the front drive shaft.
STEP 30
Raise the guard i nto alignmen t with the brackets

and install the bolts.
STEP 34
~ ?'
632806
Install the bolts and the self-locking nuts that hold

the front drive shaft and tighten these self-locking
nuts to 70 to 84 pound-feet (95 to 114 N m, 10 to 11
k9 / m) .
STEP 31
Install the guard for the control linkage on the
transaxle.
STEP 32
632508
Remove the floor jack and install self-locking nuts

on the bolts that hold the guard. Tighten the self-
locking nuts to 100 to 150 pound-feet (136 to 203
Nm, 14 to 21 kg / m).
STEP 35
6325 12
Carefully move the guard under the front drive

shaft.
Install and tighten the clamp that holds the filler

tube.
6200-10
STEP 36 STEP 39
Have available 8 U.S. quarts (7.5 litres) of Case Start the engine and run the engine at low idle.
TCH fluid.
STEP 40
STEP 37 I mmediately add the 4 U.S. quarts (4 litres) of oil to
Fill the power shuttle with 3 U.S. quarts (3Iitres) of the power shuttle .
Case TCH Fluid .
STEP 41
STEP 38 Check the level of the oil in the power shuttle and
Have another 4 U .S. quarts (4 litres) of Case TCH add oil as required until the oil is at th e FULL mark
Fluid ready to add to the power shuttle. on the dipstick.
STEP 42
Stop the engine and checks for leaks.
6200-11
TORQUE CONVERTER
The torque converter cannot be repaired. If the STEP 4
torque converter is damaged or does not work cor-
rectly, a new torque converter must be insta lled.
Removal
NOTE: The photographs show the engine
removed from the machine. The procedure is the
same when the engine is in the machine.
STEP 1
Flemove the power shuttle according to the in-
structions in this section.
329022
STEP 2 If necessary, hit the torque converter housin g with
a soft hammer to loosen the torque co nverter hous-
ing. Do not let the torque converter housing fall.
STEPS
Remo ve the torque co nve rter housing.
STEP 6
J290Hl
Loosen and remove all but two of the cap screws

that hold the torque converter housing.
STEP 3
329J11"A
Loosen the cap screws that 110Id the torque con-

verter.
329020
Loosen and remove the rema inder of the cap

screws.
329 103
Hold the torque converter in place and remove th e

cap screws and lock washers.
STEPS
Remo ve the torque converte l' .
6200-12
Replacing the Flex Plate STEP 4
STEP 1
329109
Install the reinforcement ring.

321905
Loosen and remove the cap screws that hold the STEPS
flex plate .
STEP 2
Install the tool CAS-1153A to align the parts with

the torque converter.
329107
Remove t he flex plate and reinforcement ring . STEPS
STEP 3
I nstall and t ighten the four cap screws to 456 to 504

pound-inches (53 to 56 N m, 5.2 to 5.8 kg/ m).
Install th e flex plate.
6200-13
STEP 7 STEP 2
Remove the tool and install and tighten the remain- Tighten the cap screws to 156 to 180 pound-inches
der of the cap screws to the same torque value . (18 to 20 N m, 1.8 to 2.0 kg / m).
Installation STEP 3
STEP 1
1. Boss Must Be On Top

3 291 03
Hold the torque converter in alignment with the

flywheel and install the cap screws and lock wash- Install the torque converter housing as shown and
ers. the cap screws and lock washers.
STEP 4
Tig hten the cap screws.
STEPS
Install the power shuttle according to instructions
in this section.
6200-14
TRANSAXLE
Removal STEPS
STEP 1
If the machine has four wheel drive, pull up the
control lever for the transfer case and move the
machine forward a small amount to engage the
transfer ca se . Then stop the engine .
STEP 2
Appl y th e parking brake.
STEP 3
If the machine has four wheel drive do steps 4
th rough '12.
STEP 4 Carefully lower the guard. It can be necessary to

use a pry bar to remove the guard from the brack-
ets .
STEP 7
Carefully tilt the guard as required to remove the
guard from under the front drive shaft.
STEPS
Remove the guard for the control linkage from the
transa xle .
STEP 9
632508

bolts that hold the guard for the front drive shaft .
Do not remove the bolts now.
STEPS
632516
Loosen and remove the self-locking uts from the

bolts that hold the front drive shaft. Do not remove
the bolts now.
STEP 10
Remove the bolts and the front drive shaft.
Use a floor jack to hold and lower the guard . The
guard is balanced with the floor jack in the position
shown.
6200-15
STEP11
Remove the cotter pin from the top and bottom Release the parking brake and remove the cotter
c levis pins that hold th e control rod for the transfer pin and clevis pins that hold t he clevis of the park-
case . ing brake cab le.
STEP 12 STEP 15
632729
Loosen and remove the self-locking nut, flat washer
Remove the top and bottom clevis pins and the
and bolt that holds the clamp for the parking brake
contro l rod.
cable.
SiTEP13
STEP 16
Loosen the other self-locking nut and disengage
the parking brake cable from the cla mp .
STEP 17
Loosen and remove the cap screws and straps that

fasten the drive shaft to the power shuttle. Remove
the d rive shaft.
632623
Remove the cotter pin and clevis pin that holds the
spring in the differential lock linkage.
6200-16
STEP 18 STEP 30
Remove the transaxle from under the machine.
Installation
STEP 1
Fasten the transaxle to the transmission jack.
STEP 2
Move the transaxle under the machine .
STEP 3
Carefully raise the transax le into position .
STEP 4
632624
Align the transaxle and install the bolts and hard-
Use a screwdrive r in the inner notch to remove the ened washers, clamps, and hardened washers and
front clip from the pin that fastens the shift linkage nuts.
to the shift lever in the transmission.
STEPS
STEP 19 Tighten the self-locking nuts to 810 to 990 pound-
Remove the pin and use wire to hold the shift lin- feet (1099 to 1342 N m, 112 to 139 kg / m).
kage out of the way.
IMPORTANT: After 50 hours of opl~ration, the
STEP 20 self-locking nuts must again be tightened to the
Remove any dirt from the connection of the brake same torque value.
hose at each brake cylinder.
STEP 6
STEP 21 Remove the transmission jack.
Disconnect the brake hose f rom each brake cylin-
der and in stall a cap on each brake hose. STEP 7
I nstall the wheels .
STEP 22
If equipped with a backup alarm, loosen and re- STEP 8
move the two cap screws that fasten the mounting Install and tighten the wheel bolts. See Section
plate to the transaxle. 6229.
STEP 23 STEP 9
Use wire to hold the backup alarm out of the way. Lower the wheels to the floor.
STEP 24 STEP 10
Raise the rear wheels off the floor and use accepta- If equipped , align the mounting bracket for the
ble supports to hold the machine in place. backup alarm with the transaxle and install the cap
scre ws and ground wire that hold the mounting
STEP 25 bracket.
Loosen and remove the wheel bolts.
STEP 11
STEP 26 Tighten the cap screws .
Remove the wheels.
STEP 12
STEP 27 Align the shift linkage wi t h the sh ift lever and in-
Fasten a transmission jack to the transax le. stal l the pin.
STEP 28
Loosen and remove the nuts, hardened washers,
bolts and clamps that hold the transaxle .
STEP 29
Carefully lower the transaxle.
6200-17
STEP 13 STEP 17
632635
632624
Install the bolt , flat washer, and self-locking nut.
Install the clip that holds the pin.
STEP 14 STEP 18
Loosen and remove the cap from each brake hose
and connect each brake hose to the brake cy li nder.
STEP 15
632637
Tighten the self-lock ing nuts.
STEP 20
632620
Install the clevis pin and cotter pin that holds the
spring in the d ifferential lock linkage.
STEP 16
Install the clevis pin and co tt er pin that hold the

clevis for the parking brake cable.
632630
Engage the parking brake w ith the c lamp .

6200-18
STEP 21 STEP 25
Install the drive shaft on the transaxle.
STEP 22
63272!)
Engage the control rod for the transfer case with

the control lever and install the botlom and top
632602 clevis pins .
I nstal l the clamps and cap screws that fasten the
drive shaft to the power shuttle . STEP 26
STEP 23
632642
Install a cotter pin in the bottom and top clevis pins .

632803 STEP 27
Tighten the cap screws to 156 to 216 pound-inches Install the front drive shaft.
(17 to 24 N m, 1.8 to 2.5 kg/m).
STEP 28
STEP 24
If the machine has four wh ee l drive, do steps 25
through 32.
632806
Install the bolts and self-locking nuts that hold the

front drive shaft and tighten the se lf-locking nuts to
70 to 84 pound-feet (95 to 114 N m, 10 to 11 kg / m).
STEP 29
Install the guard for the control linkage on the
transa xle .
6200-19
STEP 30 STEP 32
Carefully move the guard under th e front drive Remo ve the floor jack and install the self-locking
shaft. nuts on the guard. Tighten the se lf-locking nuts to
100 to 150 poun d-feet (136 to 203 Nm, 14 to 21
STEP 31 kg/ m).
STEP 33
Make sure that the transaxle has been filled with
gear lub ricant.
STEP 34
See Section 7106 . Remove the air from the brake
system.
632510
Raise the guard into alignment with the brackets

and install the bolts .
REPLACING A UNIVERSAL JOINT

NOTE: This procedure shows the removal of STEP 1
the rear universal joint of the drive shaft for the
transaxle. Use this procedure for removing the
other universal joint and universal joints of the
drive shaft for the front drive axle.
330918
Remove the snap rings that hold the bearing caps .

6200-20
STEP 2 STEPS
Repeat steps 2, 3, and 4 to remove t '1 e cross from
the yoke.
STEP 6
Clean the bores in the yoke and shaft.
STEP 7
Use an acceptable support and driver and press the

bearing caps out of the shaft. Make sure that the
grease fitt ing is up as shown.
STEP 3
330927
Start the bearing cap into the yoke. Do not press

the bearing cap all the way in .
STEP 8
330921
Remove the bearing cap. If necessary, use pliers to

remove th e bearing cap .
STEP 4
330928
Install the cross in the yoke.
330922
Remove the cross from the shaft.

6200-21
STEP 9 STEP 12
Install the cross in the bearing cap. Be careful not Install a snap ring in the groove.
to move the needles.
STEP 13
STEP 10
330931 Press the other bearing cap all the way into the
Press the other bearing cap a short distance into yoke.
tile yoke. Carefully raise the cross into the top
bearing cap and press the bearing cap into the STEP 14
yoke.
STEP 11
Install a snap ring .
Use the driver and press the bearing cap into the
yoke until the groove for the snap ring can be seen.
6200-22
STEP 15 STEP 18
330936 330941
Start a bea ring cap into the shaft. Do not press the Press the other bearing cap a short distance into
bearing cap all the way in. the shaft. Carefully raise the cross into the top
bearing cap and press the bea ring cap into the
STEP 16 yoke.
STEP 19
I nstall the cross in the shaft.

3309'3
STEP 17 Use the driver and press the bearing cap into the
shaft until the groove for the snap ring can be seen .
STEP 20
330938
Install th H cross in the bearing cap being carefu l

not to move the needles.
Install a snap ring.
STEP 21
Repeat steps 19 and 20 for the other bearing cap.
6201
MAINTENANCE
TABLE OF CONTENTS
Specifications ... .... ...... . . . . .. ... . ... 6201-2 Gear Lubricant Change .. .......... .. . 6201-4
Special Tool . .. .. . . . . ....... . . . .. ...... 6201-2 Front Drive Axle .. .. . . .. . . . ... ... . .... .. 6201-5
Power Shuttle . . ... . .... . .... .... .. ... . . 6201-3 Gear Lubricant Level .. . .............. 6201-5
Oil Level Check .... .. . .. . .... . ..... .. 6201 -3 Gear Lubri cant Change . . ..... . ....... 6201-5
Oi l Change .. .... . .. ...... . . ... . . . ... 6201 -3 Transfer Case .. .... . . .... .. . . ... .. . .... 6201-6
T ransaxle .. .. .. . ...... .... .. . . . .. . . .. . . 6201-4 Gear Lu bricant Level ...... . . . . .. . . . . . 6201-6
Gear Lubricant Leve l . .. .. . ....... . . . . 6201 -4 Gear Lubricant Change . . . .. . . . . . ... .. 6201-6
A Tenneco Com pan y

6201 -2
SPECIFICATIONS
Power Shuttle
Type of oil .... . . . . . . ...... . . .. . . ..... .. ..... ............ .. .... .. ... ... ..... .. ....... Case TCH Flui d
Altern ate ... . .... .. . . .. . ... . .. . .. . ... .. . ... .. ... .. ....... . . .. . .. .... . .. . . . . .. .. . Type C3 flu id (10W)
Oil ca pa city (ap proximate )

Power shutt le .. .. ... . .. . .. . ...... ...... . . . ... ..... . ... .. ..... .... . . . ... 2-1 / 2 U.S . qua rts (2.4 litres)
Torque converter ..... . . . . .. ... . .. ........ . . ... ..... . ..... . .. .. . .. . . . .. . S-1 / 2 U.S. qua rts (S .2 lit res)
Total system .. . .. . .. .. .. . .. . ....... . . . ... . . .. ... ... . ... . . .. . .. . ... ... ... . .. 8 U.S. quarts (7 .6 litres)
Front Drive Axle

Type of lubricant .... . . . . ... . ........ . . .. . .... .... .... .. . . . . . . .. . .... . ... Case IH 13S-H EP Gear Lube
Alternate lubricant ...... ... ... .... . . . ...... . ..... ... . . .. . ..... . . ............ . API-G L-S (SAE 8SW-140)
Capacity of planetary .. . ..... . ........ .. ... . .. . . .... . . . .. . ...... .. . .. ........ .. .. 2.1 U.S. pints (1 litre)
Capacity of center bowl .... ... ... . ... .. . . . ..... .. . . . . ... . ... .. ... . ..... . ..... . 14.8 U.S . pin ts (7 litres)
Trans ~er Case

Type of lubricant .. .... . . ..... ... . .... . .... . . ... .. .. .. . ... . . ............. Case IH 13S-H EP Gea r Lube
Alternate lubricant ........ . . .. .. .. . . . . ... .. ... ... . . . .. . . . . ..................... .. API-GL-S (8S W-140 )
Capaci ty . . . . .. .. . .. ..... .. . .. ... .. . . . ... . . . . ... ... . ... . .. . .. .. . ..... ... ....... . .. 1 U.S. pint (O .S litre)
Transaxle
Type of lubricant . . ... .. . . . . . .. .............. . . .... . . ........ . . . . . .. .. Case Transa xle Fluid (MS-1317)
Alternate lubricant . .. . .. . ... .. . . ... . . .. . . ...... ... . . . ....... . ........ ... .. .... . ... .... ... . . . .. . Non e
Capac ity - ref ill .. ... .............. . ........ .. . .. ..... .... ................. 20 .S U.S. quarts (19.4 lit res)
Total ... ... . ..... . . ..... ..... .. ... . . ..... . .... . . ... . ...... . . . . . . . 22 US . quarts (20 .8 litres)
SPECIAL TOOL
430842
Tool CAS-1690 is used to turn the flywheel

when servicing the power shuttle . See Section 1001
for orde ring information for the tool.
6201-3
POWER SHUTTLE
Oil Level Check Oil Change
Check the level of the oil in the power shuttle Change the oil in the power shuttle and clean
after every 50 hours of operat io n. Th e oi l must be the suction screen every 1000 hours of operation.
warm (needle in Oil Temp gauge in centerof green
zone). If the oil is co ld , do steps 4 through 9 to heat STEP 1
th e oil. Do steps 1 throu gh 9 under Oil Level Check.
STEP 1 STEP 2
Park the machine on a level surface Stop the engine .
STEP 2 STEP 3
Apply the parking brake. Th e oil must be drained from the torque converter
and from the oil pan on the power shuttle.
S'rEP 3
Move the transmission control leve r to fourth gear. STEP 4
The torque converter and power shuttle hold ap-
STEP4 proximately 8 U.S . quarts (7.6 Jitres) of oil.
Move the power shuttle control lever to the FOR-
WARD posit ion, STEPS
Put a drain pan under the drain plug in the power
STEP 5 shuttle .
Slowly increase the engine speed to full throttle. If
th e machine moves , see Sect ion 7106 and adjust STEP 6
the parking brake. Loosen the drain plug and drain the oil from the
power shuttle.
STEP 6
Run the engine at fu ll throttle for 40 seconds. The n STEP 7
move the power shuttle control lever to NEUTRAL. Put a drain pan under the flywtleel housing.
STEP 7 STEPS
Continue to run the engine at ful l throttle for 10 Have another person use tool CAS-1690 to turn the
seconds. flywheel as yo u look fo r the plug in the torque
converter through the hole in the bottom of the
STEP S flywheel housing.
Decrease the engine speed to low idle.
STEP 9
STEP 9 Loosen and remove the drain plug from the torque
Repeat steps 4 through 8 unti l the needle in the converter and drain the oil from the torque conver-
gauge for Oil Temp is in the center of the green ter.
zone on the gauge.
STEP 10
STEP 10 Loosen and remove the cap screws that hold the oil
Run the engine at low idle with the power shuttl e pan and remove the oil pan.
control lever in NEUTRAL for approximate ly 10 sec-
onds. STEP 11
Remove the suction screen. Remove and discard
STEP 11 the a-ring from th e tube on the suction screen.
With the engine running at low idle, loosen the plug
on t he dipstick and check the level of the oil. STEP 12
C lean the suction screen in cleaning solvent and
STEP 12 dry with compressed air.
The level of the oil in the power shuttle must be
between the Add and the Full marks on the dipst- STEP 13
ick. Remove all gasket material from the oil pan and the
bottom of the power shuttle.
STEP 13
Add oil as necessary.
6201-4
STEP 14 STEP 20
Apply for m-in-p lace gasket material to the flan ge Install 3 U.S. quarts (2 .8 litres) of oil in the power
of the oil pa n. shuttle.
STEP 15 STEP 21
Install a new O-ring on the tube on the suction Start the engine and run the engin e at low idl e.
screen. Immediately insta ll the remain der of t he oil in the
power shuttle .
STEP Hi
Install th e suction screen in the power shutt le. STEP 22
Make sure that the transmissio n control lever is in
STEP 17 NEUTRAL.
Install the oil pan and cap screws . Tighten the cap
screws . STEP 23
Move the power shuttle control lever to the FOR-
STEP 18 WARD and REVERSE positions several times to fill the
Install th e drain plugs in the torque converter and passages in the power shuttle .
in the oil pan.
STEP 24
STEP 19 Check the level of the oi l in the power shuttle ac-
Have 8 U .S. quarts (7 .6Iitres) of the oil specif ied on cording to instructions in this section .
page 6201-2 ready to be installed in the power
shuttle.
TRANSAXLE
Gear Lubricant Level Gear Lubrlcant Change
Chec k the level of the gear lubricant after ev- Change the gear lubricant afte r every 1000
ery 100 hou rs of operation. Check the level of the hours of operation .
gear lubricant before the machine is moved .
STEP 1
STEP 1 Remove the cover and the dipst ick for th e trans-
Park the machine on a leve l surface. axle .
STEP 2 STEP 2
Remove t he cover. Use a container that will hold six U .S. gallons (22
litres) and loosen and remove the drain plug .
STEP 3
Remove the dipstick. The gear lubricant must be STEP 3
between the Full and Add marks. After the gear lubricant has drained as completely
as possible, install and tighten the drain plug .
STEP4
If the gear lubricant is at or below the Add mark, STEP 4
add gear lubricant until the gear lubricant is at the Fil l the transa xle with 20.5 U.S . quarts (19.4 litres)
Full mark . of Case Transaxle Fluid .
STEPS
Wait a few moments and check the level of the gear
lubricant. Add gear lubricant as required.
6201-5
FRONT DRIVE AXLE

(Gear Lubricant Level STEP 6
Add th e gear lubricant specified on page 6201-2 as
Check the level of the gear lubricant in the required and install and tigh ten the filler plug .
center bowl and each planetary end after every 250
hours of operation . Gear Lubricant Change
STEP 1 The gear lubricant in each planetary and the
Park the machine on a level surface. center bowl must be chan ned after every 1000
hours of operation .
STEP 2
STEP 1
Turn the wheels as required so that the filler plug
for each planetary is at the bottom .
STEP 2
Loosen and remove the filler plugs and drain the
gear lubricant.
STEP 3
The fill plug for each planetary must be in the posi-

tion shown in the illustration above. Move the ma-
chine as required .
STEP 3
Loosen and remove the filler plug from each plane-
tary . The gear lubricant must be even with the bot-
tom of the hole. The center bowl holds 14.8 .S . pints (7 litres) of
gear lubricant. Loosen and remove the filler and
STEP 4 drain plugs and drain the gear lubricant.
Add gear lubricant specified on page 6201-2 as
required and install and tighten the filler plug . STEP4
Install the drain plug in the center bow l and fill the
STEPS center bowl with 14.8 U.S. pints (7Iitres) of the gear
lubricant speci fied on page 6201-2 . Install and
tighten the filler plu g.
STEPS
I nstall the drain plug in each planetary and turn the
wheels so that the fill hole is at the top .
STEP 6
Fill each planetary with 2.1 U.S pints (1 litres) of
gear lubricant specified on page 6201-2. Install and
tighten the fill plugs.
Loosen and remove the filler plug for the center

bowl. The gear lubricant must be even with the
bottom of the hole.
6201-6
TRANSFER CASE
Gear Lubricant Level STEP 4
Add gear lubricant as requ ired and install and
Check the leve l of the gear lubricant after ev- tighten the filler plug.
ery 100 hours of operation .
Gear Lubricant Change
STEP 1
Park the mach ine on a level surface . The gear lub ricant must be changed after
every 1000 hours of operation.
STEP 2
Loosen and remove the fille r plug . STEP 1
The tran sfer case holds one pint (0.5 litre) of gear
STEP 3 lubricant. Loosen and remove the fill er and drain
plugs.
STEP 2
Install and tig hten the drain plu g.
STEP 3
Fill the transfer case with one pint (0.5 li tre) of the
gear lubrica nt specified on page 6201-2 .
STEP 4
Install and tighten the fill er plug .
The gear lubricant must be even with the bottom of

the hole.
6202
POWER SHUTTLE
OPERATION AND TROUBLESHOOTING
TABLE OF CONTENTS
Specifications ...... .. ......... . ...... . . 6202-2 Troubleshooting the Power Shuttle ..... 6202-10
Operation . ... .... ...... .. ..... . ........ 6202-2 Checks To Do Before Testing . . . . . ... 6202-10
General Information ............. . .... 6202-2 Testing the Power Shuttle With a
Pressure Gauge .... ........ .. .... . 6202-10
Oil Flow in Neutral .. .. .. ........... . . 6202-4
General Information ............... 6202-10
Forward Clutch Actuated ............. 6202-5
Test No.1 - Clutch Circuits . ... .. . . 6202-11
Reverse Clutch Actuated .............. 6202-6
Test NO.2 - Cooling Circuit .. ... ... 6202-11
Clutch Cutout Actuated ........ . .... . . 6202-7
Understanding Results of Tests .. .. 6202-13
Troubleshooting Chart . .. .. .... .. . . .... 6202-8
Decimal Measure Check Sheet . .. .. .... 6202-15
Metric Measure Sheet ............... .. 6202-16
J I Case 8-67320
A Tenneco Company
6202-2
SPECIFICATIONS
Oil temperature for the tests .. .... . .. .. ... . ... . ...... .... . . ... Needle in the gauge for Oil Temp must be
in the center of the green zone on the gauge
Charging pump pressure
Engine at low idle .......... . ....... .. .. . . . . ..... . . ... 65 psi (448 kPa , 4.6 kg / cm 2) minim m in neutral
Engine at 2000 rpm (r/ min) . ..... . . ... ..... .......... 130 psi (896 kPa , 9.1 kg/ cm 2) minim um in neutral
Foward and reverse clutch pressure

Engine speed at low idle ...... . . ....... .... .. ...... .. ...... ... 65 psi (448 kPa, 4.6 kg / crn 2) minimum
Engine speed at full throttle .... . .. ... .. .. . .... . .. .. ..... . ..... 125 psi (862 kPa, 8.8 kg/ crn 2) minimum
Cooling system pressure

Engine at 2000 rpm (r/ min) . ... . .. .. . ........ . . ... .... .. ... .. . . .... 25 psi (172 kPa, 1.8 kg /c m2) or less
OPERATION
General Information Oil from the charging pump flows through in-
ternal passages to the control valve. The oil flows
The power sh uttle lets t he operator change the through holes in the control valve spool and pushes
direction of machine movement without complete- the pressure regulator piston . As the pressure in
ly stopping the machine. Before you make a shift, the charging circuit increases, the pressure regula-
decrease the engine speed to less than 1500 rpm tor piston moves to open a hole in the control valve
(r/ min) to prevent damage to the power shuttle. spool. The pressure regulator piston continues to
open or close the hole as necessary to keep the
The power shuttle receives power from the en- correct pressure in the charging circuit. The oil not
gine thro ugh the torque converter. The power shut- needed to lubricate the parts of the power shuttle
tle uses multiple disc forward or reverse clutches or to engage a clutch flows from the hole in the
and a pinion cage and output shaft assembly to control valve spool to the relief valve . The relief
send the power to the drive shaft. valve releases oil as necessary to keep the correct
amount of pressure on the oil flowing to the torque
The forward and reverse clutches are operated converter. The oil which is released through the
by the oil flow from the charging pump in the power relief valve returns to the oil pan of the power shut-
shuttle. The oil flow from the charging pump is tle . The oil which is returning from thE! torque con-
control led by a control valve and a pressure regula- verter flows through the front bearing on the input
tor pisto n. The pressure regulator piston , which is shaft to the oil cooler behind the radiator of the
in the control valve spool, keeps the correct amount machine. From the oil cooler, the oil flows to the oil
of pressure in the charging circuit. pan of the power shuttle.
6202-3
,6
.1
11 2
lilll 3
1m4 800373
1. PUMP FLOW 5. FROM CHARGING PUMP 9. RELIEF VALVE

2. TO TORQUE CONVERTER 6. TO OIL COOLER 10. TO CHARGING PUMP
3. FROM TORQUE CONVERTER 7. FROM OIL COOLER 11. CHARGING PUMP
4. SUCTION OIL 8. PRESSURE REGULATOR PISTON
Oil Flow To and From Torque Converter

6202-4
Oil Flow in Neutral

When the control valve is in neutral, oil cannot
flow to the forward or reverse clutches. Oil contin-
ues to flow to the torque converter and through
lubrication passages as shown on page 6202-3.
.1
.2
[;13
rn4
800374
1. PUMP FLOW 5. TO CHARGING PUMP 8. FORWARD CLUTCH

2. LUBRICATION OIL 6. FROM CHARGING PUMP 9. TO TORQUE CONVERTER
3. STATIC OIL 7. REVERSE CLUTCH
4. SUCTION OIL
6202-5
Forward Clutch Actuated the input shaft. As pressure increases behind the
piston for the forward clutch, the piston moves to
When the control valve is in the forward posi- hold the metal and friction discs tightly between
tion , passages in the control valve spool are al- the piston and the pressure plate. With the forward
igned with passages in the housing. Oil from the clutch engaged, the input shaft , the ring gear, and
charging pump flows to the forward clutch through the pinion cage and output shaft assembly rotate
the passages in the housing, the output shaft, and as one piece.
.1
.2
ell 3
rnJ4
800375
1. PUMP FLOW 5. TO CHARGING PUMP 7. FORWARD CLUTCH

2. LUBRICATION OIL 6. FROM CHARGING PUMP 8. TO TORQUE CONVERTER
3. STATIC OIL
4. SUCTION OIL
6202-6
Reverse Clutch Actuated moves to hold th e metal and friction discs tightly
between the pressure plate and the front of the
When the control valve is in the reverse posi- housing for the power shuttle. With the reverse
tion , passages in the control valve spool are al- clutch engaged , the ring gear cannot rotate . The
igned with passages in the housing . Oil from the input shaft rotates inside the pinion cage and out-
charging pump flows to the reverse clutch through put shaft assembly. This rotation causes the pinion
the passages in the housing. Oil from the charging gears to rotate. The outer pinion gears rotate
pump flows to the reverse clutch through the pas- against the inside of the ring gear, causing the
sages in the housing. As the pressure increases pinion cage and output shaft assembly to rotate in
behind the piston in the reverse clutch , the piston a direction opposite the rotation of the input shaft.
.1
.2
tm3
04
800376
1. PUM P FLOW 5. TO CHAR G ING PUMP 7. REVERSE CLUTCH

2. LU BR ICAT ION OIL 6. FROM CHARGIN G PUMP 8. TO TORQUE CO NVERTER
3. STATI C O IL
4. SUCTI ON O IL
6202-7
Clutch Cutout Actuated 1. Pushing the clutch cutout button on the tran-
saxle shift lever.
The clutch cutout function is used to disen-
gage the clutches without moving the direction
2. Pushing the clutch cutout button on the loader
control lever to NEUTR A L.
control lever.
The clutch cutout solenoid is fastened to the
control valve. The clutch cutout solenoid is spring When the clutch cutout solenoid is actuated ,
loaded to hold the plunger and spool in position for the spring on the plunger moves the plunger away
normal operation of the power shuttle. from the spool so that the spring for the spool can
move the spool to stop the flow of oil to the clutch.
The clutch cutout solenoid is electrically actu- At the same time, the spool connects the passage
ated to actuate the clutch cutout function . for the clutch to a return passage in the control
valve to immediately relieve the pressure in the
The clutch cutout solenoid can be actuated by: clutch .
'11
801344
1. PUMP FLOW 6. TO CHARGING PUMP 10. SPOOL

2. LUBRICATION OIL 7. FROM CHARGING PUMP 11 . PLUNGER (9) AND
3. STATIC OIL 8. CLUTCH CUTOUT SPOOL (10) MOVED
4. RETURN OIL SOLENOID IN THIS DIRECTION
5. SUCTION OIL 9. PLUNGER 12. TO TORQUE CONVERTER
6202-8
External oil leakage Cap screws that fasten the adapter Remove the power shuttle. Remove
to the shuttle housing are loose. the adapter and check the gasket.
Install a new gasket if necessary.
Install the adapter and tighten the cap
screws.
Oil line connections loose. Tighten the connections .
O-ring on control valve spool is Remove the control valve spool. Replace
damaged. the O-ring.
Cap screws that fasten the cover Remove the cover plate. Replace the
plate for the control valve are loose. gasket and install the cover plate again .
Rear seal is damaged . Replace the rear seal.
Cap screws on the rear bearing Remove the rear bearing retainer. Re-
retainer are loose. place the gasket. Install the rear
bearing retainer.
Control lever does Detent spring is broken. Replace the spring.

not stay in the
correct position Detent ball will not move freely. Clean and lubricant the detent ball
and bore in the valve cover.
Oil temperature in Low oil level. Check the oil level and add oil as
the torque conver- necessary.
ter is too hot
Operating the machine in the wrong See the Operators Manual.
gear.
Oil cooler filled with dirt. Clean the dirt from the fins in t he oil
cooler and the radiator. Do Test No.2
on page 6202- 11 to learn if t he inside
of the oil cooler is filled with dirt.
Machine will not Damaged torque converter. Replace the torque converter.
move in either
forward or reverse Damaged pressure regulator piston Remove control valve spool and check
reverse in the control valve spool. pressure regulator piston.
Broken spring for pressure Remove control valve spool and check
reg ulator piston . the spring .
Low oil level. Check the o il level and add oil as

necessary.
Worn charging pump. Remove shuttle and replace the

charg ing pump assembly.
6202-9
High oil pressure Damaged pressure regulator Remove the control valve spool and
piston . check the pressure regulator piston .
Damaged relief valve. Remove the relief valve from the tubes
on the power shuttle. Check the relief
valve.
Stall speed too high Torque converter is damaged . Check the power shuttle to see if the
pressures are correct. If the pressures are
correct, replace the torque converter.
6202-10
TROUBLESHOOTING THE POWER SHUTTLE

Checks to Do Before Testing Testing the Power Shuttle With
a Pressure Gauge
1. Change the oil in the power shuttle and torque
converter and clean the suction screen in the General Information
power shuttle according to instructions in Section
6201. There is a check sheet on page 6202-15 or
6202-16. Make a copy of the check sheet. Use the
2. Check the level of the oil in the power shuttle check sheet to write the readings of the pressure
according to the instructions in Section 6201 . gauge tests.
3. Do the stall checks according to the instruc- See the following illustration for location of
tions in Section 2002. test ports.
4. Check the adjustment of the linkage for the

power shuttle control lever. Make sure that the con-
trol arm on the control valve spoo l can move into
the detent position s. If adjustment is necessary,
see Section 6211.
1. Test Port For Test No. 1

2. Test Port For Test No.2
3. From Oil Cooler
4. To Oil Cooler
Test Port Locations
6202-11
Test No.1 - Clutch Circuits 8. Decrease the engine speed to low idle.
1. Remove the Allen head pi ug from th e test port 9. Move the direction control lever to FORWARD .
for test No. 1. See location of test port on page Read the pressure gauge and write the reading on
6202-10 . line 3 on the check sheet.
2. Connect a pressure gauge to the test port. The 10. With the direction control lever in FORWARD,
pressure gauge must be accurate in the range of 0 increase the engine speed to full throttle . Read the
to 300 psi (0 to 2068 kPa, 0 to 2.1 kg/ m2). pressure gauge and write the reading on line 4 on
the check sheet.
3. Start the engine. Run the engine at low idle.
11. Decrease the engine speed to low idle.
4. Read the gaugeforOil Temp . The pointer in the
gauge must be in the center of the green zone of the 12. Move the direction control lever to REVERSE .
gauge. Read the pressure gauge and write the reading on
line 5 on the check sheet.
5. If the temperature is not correct
13. With the direction control lever in REVERSE, in-
a. Make sure that the parking brake is ap- crease the engine speed to full throttle . Read the
plied . pressure gauge and write the reading on line 6 on
the check sheet.
b. Move the transmission control lever to
fourth gear. 14. Decrease the engine speed to low idle and stop
the engine .
c. Move the direction control lever to FOR-
WARD . 15. Disconnect the pressure gauge and install and
tighten the plug for the test port.
d. Slowly increase the engine speed to full
throttle . If the machine moves, decrease en- Test No.2 - Cooling Circuit
gine speed and stop the engine . See Section
7106 and adjust the parking brake. 1. Remove the Allen head plug from the test port
for test No.2. See location of test port on page
e. Run the engine at full throttle for 40 sec- 6202-10.
onds. Then put the direction control lever in
NEUTRAL. 2. Connect a pressure gauge to the test port. The
pressure gauge must be accurate in the range of 0
f. Continue to run the engine at full throttle to 150 psi (0 to 1034 kPa, 0 to 10.5 kg/ cm 2).
with the direction control lever in NEUTRAL for
10 seconds. 3. Start the engine . Run the engine at low idle.
g. Decrease the engine speed to low idle. 4. Look at the gauge for Oil Temp . The pointer in
the gauge must be in the center of the green zone of
h. Repeat steps 6c through 6g until the nee- the gauge .
dle in the gauge for Oil Temp is in the center of
the green zone on the gauge. 5. If the temperature of the oil is not correct, heat
the oil according to the instructions in step 5 under
i. Decrease the engine speed to low idle. test NO. 1.
Move the direction control lever to NEUTRAL.
Move the transm iss ion control lever to NEU- 6. Make sure that the transmission control lever
T RAL . and the direction control lever are in NEUTRAL.
6. Read the pressure gauge and write the reading 7. Increase the engine speed to full throttle .
on line 1 on the check sheet.
8. Read the pressure gauge. Write the reading on
7. Increase the engine speed to full throttle. Read line 7 on the check sheet.
the pressure gauge and write the reading on line 2
on the check sheet. 9. Decrease the engine speed to low idle.
6202-12
10. Move the direction control lever to FORWARD. 13. Move the power shuttle control lever to RE-
Increase the engine speed to full throttle . Increase the engine speed to full throttle.
VERSE .
11 . Read the pressure gauge and write the reading 14. Read the pressure gauge and write the reading
on line 8 of the check sheet. on line 9 on the check sheet.
12. Decrease the engine speed to low idle. 15. Decrease the engine speed to low idle and stop
the engine.
6202-1 3
Understanding Results of Tests
PRESSURE IN DICATION POSSIBLE CAUSE AND CORRECTION
Pressure on line 1 is less than Problem in the pressure regulator valve . Remove the control
65 psi (448 kPa , 4.6 kg / cm 2) valve from the power shuttle . Remove the piston from the
control valve. Check for a broken spring. Also check to make
sure that the piston moves freely .
Charging pump worn or damaged . If the pressure indications

in the FORWARD pOSition and the REVERSE posit ion are also low,
remove the power shuttle and replace the charging pump . See
Section 6210 .
Pressure on line 2 is more than PrOblem in the pressure regulator valve. Remove the control
140 psi (965 kPa, 9.8 kg /cm2) valve from the power shuttle . Remove the piston from the
control valve. Check to make sure that the piston moves freely.
Pressure on line 3 is more than Leakage in the forward clutch circuit. See Section 6210 and
5 psi (34 kPa , 0.4 kg/ cm 2) less disassemble the power shuttle and check the following parts :
than the pressure on line 1 sealing rings on the input and output shafts, supply tube
inside the input shaft, and the O-rings on the piston .
Pressure on line 4 is more than
5 psi (34 kPa, 0.4 kg/ cm 2) less
than the pressure on line 2.
Pressure on line 5 is more than Leakage in the reverse clutch circuit. See Sect ion 6210 and
5 psi (34 kPa , 0.4 kg/ cm 2) less disassemble the power shuttle and check O-rings on the
than the pressure on line 1. piston.
Pressure on line 6 is more than

5 psi (34 kPa, 0.4 kg/ cm 2) less
than the pressure on line 2.
Pressures on lines 1 through 6 Charging pump worn or damaged . Remove the power shuttle
are too low. and replace the charging pump. See Section 6210.
Pressures on lines 1 through 6 Problem in the relief valve. Remove the relief valve from the
are too high . tubes on the power shuttle. Disassemble the relief valve and
check to make sure that the ball in the relief valve moves
freely .
Pressure regulator valve does not operate correctly. Remove

the control valve spool from the power shuttle. Remove the
piston and check to make sure that the piston moves freely .
Pressures on lines 1 and 2 are Clutch cutout solenoid does not work correctly or cutout
according to specifications . spool does not move freely in control valve . Check the clutch
Pressures on lines 3 through 6 cutout solenoid first. If the clutch cutout solenoid is not
are below speCifications the problem, remove the control valve , disassemble, and check
for the cause of the problem.
Another possible cause is a defect in one of the clutch cutout

switches.
Pressures on lines 7, 8, and Oil cooler filled with dirt. Remove the oil cooler and the
9 are more than 25 psi connecting lines. Clean the oil cooler and the connecting
(172 kPa, 1.8 kg / cm 2) lines.
6202-14
PRESSURE INDICATION POSSIBLE CAUSE AND CORRECTION
Pressure on line 7 is much Damaged torque converter. If the pressure in line 1 was more
less than 25 psi (172 kPa, than 65 psi (448 kPa, 4.6 kg / cm 2), remove the power shuttle
1.8 kg/ cm 2) and replace the torque converter.
Pressures on lines 8 and 9 Leakage in the clutch circuits. If the pressures on lines 3, 4, 5, and
are much less than 25 psi 6 were low, disassemble the power shuttle and find the cause
(172 kPa , 1.8 kg/ cm 2). of the leakage. See Section 6210 .
Pressure on line 7 is correct.
6202-15
DECIMAL MEASURE CHECK SHEET

Owner __________________________________________________________ Date _ __ _
Prod uct I dentificati on N umber _______________________________________ Hours _ _ _ _
Low idle ______________________________-<.>850 to 900 rpm

Full throttle (no load) 2330 to 2370 rpm
Torque converter stall speed 2100 rpm minimum
Hydraulic stall speed 2260 rpm minimum
Test No.1 - Power Shuttle Clutch Circuits

Direction control lever in NEUTRAL
1. ___________ psi at low idle 65 psi minimum

2. __________ psi at full throttle 130 psi minimum
Direction control lever in the F position
3. _______ psi at low idle 60 psi minimum

4. _ _ __ _ psi at full throttle 120 psi minimum
Direction control leve r in the R position
5. ________ Ipsi at low idle 60 psi minimum

6. _________ psi at full throttle 125 psi minimum
Test No.2 - Cooling Circuit

Direction control in NEUTRAL
7. _ _ __ _ psi at full throttle 25 psi minimum
8. _________ psi at full throttle 25 psi maximum
Direction control lever in the R position
9. _________ psi at full throttle 25 psi maximum

6202-16
METRIC MEASURE CHECK SHEET

Owner __________________________________________________________ Date ___ __
Prod uct Identification Number _______________________________________ Hours _ _ __
Low idle ___________________________ 850 to 900 r/ min

Full throttle (no load) 2330 to 2370 r/ min
Torque converter stall speed 2100 r/min minimum
Hydraulic stall speed 2260 r/min minimum
Test No.1 - Power Shuttle Clutch Circuits

Direction control lever in NEUTRAL
1. _____ kPa, kg/cm2 at low idle 448 kPa , 4.6 kg/ cm 2 minimum
2. ______ kPa, kg/ cm2 at full throttle 896 kPa , 9.1 kg/ cm 2 minimum
3. _ _ _ _ kPa, kg/cm2 at low idle 414 kPa, 4.2 kg/ cm 2 minimum

4. _______ kPa, kg/cm2 at full throttle 862 kPa, 8.8 kg/cm2 minimum
5. _ _ _ _ kPa, kg/cm2 at low idle 414 kPa, 4.2 kg/ cm 2 minimum

6. _ _ _ _ kPa, kg/cm2 at full throttle 862 kPa, 8.8 kg/cm2 minimum
Test No.2 - Cooling Circuit

Direction control in NEUTRAL
7. ________ kPa, kg/cm 2 at full throttle 172 kPa, 1.8 kg / cm 2 minimum
8. _______ kPa, kg/ cm 2 at full throttle 172 kPa, 1.8 kg /c m2 maximum
9. ______ kPa, kg/cm 2 at full throttle 172 kPa, 1.8 kg/ cm 2 maximum
6210
POWER SHUTTLE
TABLE OF CONTENTS
Removal/Installation . . .. . . .. . ... .. Section 6000 Disassembly of Pinion Cage
and Output Shaft . . ... . ... . . . . ... .. 6210-19
Specifications . . .. ... . ........ . . . . .. .. .. 6210-2
Assembly of Control Valve ... . .. .. . .... 6210-21
Inspection ... . . . ... .. .... . .. . ... .. .. . . . 6210-3
Assembly of Charging Pump .. .. ... . . .. 6210-23
Exploded View of Power Shuttle . .... . .. . 6210-5
Assembly of Adapter . ... . . . ...... .. ... 6210-24
Disassembly . .. ...... . . ...... . ......... 6210-6
Assembly of Forward Clutch . ... .. . .... 6210-25
Disassembly of Control Valve . .. ... . . 6210-11
Assembly of Pinion Cage and
Disassembly of Charging Pump . ... . . 6210-13 Output Shaft ... . ............. ... . ... 6210-30
Disassembly of Adapter Assembly of Power Shuttle . .. . . . ....... 6210-32

(Reverse Clutch) .. .. . .. . ...... . ... 6210-14
Disassembly of Forward Clutch .. ... . 6210-15
J I Case 8-44810
A Tenneco Company
6210-2
SPECIFICATIONS
Approximate weight . .. ..... .. . . . . .. .. . . . .. ... ..... ......... . .................. . .. 100 pounds (45 kg)
Springs Compressed length
Spring for piston . .... .... . .................. 2.073 inches at 74 to 82 pounds (52 .7 mm at 34 to 37 kg)
Spring for reverse clutch . . . ... . . .. . . .. .. ... .... ... 1 inch at 13.5 to 16.5 pounds (25.4 mm at 6 to 7 kg)
Special torques
Cap screws for retainer .. .. .. . . . ... . ... . ....... ... . . .. 40 to 50 pound-feet (54 to 68 N m, 6 to 7 kg / m)
Ferry head screws for adapter ....... . ............ 324 to 444 pound-inches (37 to 50 N m, 4 to 5 kg / m)
Cap screws for charging pump .. .. . . . ... . . . ... 204 to 264 pound-inches (23 to 30 N m, 2.3 to 3.0 kg / m)
Self-locking nut for yoke ... . ..... .. .... . ... .... .. . 75 to 85 pound-feet (102 to 115 N m, 11 to 12 kg / m)
6210-3
INSPECTION
Clean all parts of the power shuttle in cleaning 2. Inspect the piston for wear and damage.
solvent. Discard all O-rings, seals , sealing rings,
and gaskets. 3. Check the smooth sides of the front and rear
pressure plates for pitting and scoring . Check the
Charging Pump teeth on the pressure plates for damage.
1. The seal in the charging pump is the only part 4. Inspect the friction discs and the metal discs
that is available separately for repairs . If any of the for wear and damage . Check the friction discs and
other parts of the charging pump must be re- the metal discs for warpage. All friction discs must
placed , you must use a new charging pump . be replaced at the same time. All metal discs must
be replaced at the same time .
2. Inspect the gears for wear and damage.
5. Check the clutch spring for damage. Replace
3. Inspect the bushings in the drive gear and in the clutch spring after 1000 hours of use.
the converter support for pitting, scoring , or wear.
6. Check the clutch hub for damage. Also check
4. Inspect the body and converter support for pit- the Woodruff key and the keyway in the input shaft.
ting, scoring , cracks , or wear.
7. Inspect the ring gear fo r wear and damage.
5. There is not much clearance between the parts
of the charging pump . It is possible for the parts of 8. Inspect the input shaft for wear and damage at
the charging pump to look good but still be worn the bearing area. Also check the drive gear for wear
enough so that the charging pump must be re- and damage. Make sure that the oil passages in the
placed. If troubleshooting shows that there is not input shaft are free of dirt and other foreign
enough flow from the charging pump, it is recom- material.
mended that a new charging pump be used.
Pinion Cage and Output
Adapter Shaft Assembly
1. Inspect the adapter for wear and for cracks, NOTE: See step 4 on page 6210-19 for more
pitting, and scoring in the piston area . information.
2. Make sure that all the passages in the adapter 1. Check the pinion gears to make sure that the
are free of dirt and other foreign material. pinion gears rotate freely. Also inspect the teeth for
wear and damage.
3. Check the bushing for wear, pitting, and scor-
ing . 2. Check to make sure that there is not too much
end play of the pinion gears.
Reverse Clutch
3. Check the needle bearing in the pinion cage for
1. Inspect the piston for wear and damage. damage and worn needles.
2. Inspect the smooth side of the pressure plate Other Components

for pitting and scoring.
1. Check the thrust washer for wear and damage.
3. Inspect the springs for distortion . Check to
make sure that the spring pressure is according to 2. Inspect the housing for cracks or other dam -
the specification on page 6102-2. age. Make sure that all oil passages are free of dirt
and other foreign material.
4. Check the dowel pins for wear and damage.
3. Check the needle bearing in the housing for
5. Check the friction discs and the metal discs for damage and worn needles.
wear and damage. The friction discs and the metal
discs must be flat. 4. Check to make sure that the spring for the
piston is equal to the specifications on page 6210-
Forward Clutch 2.
1. Inspect the cylinder for wear and damage.

Check for pitting in the piston area .
6210-4
1. Cap Screw 38. Pinion Cage and Output Shaft

2. Seal 39. Needle Bearing
3. Body 40. Collector Ring
4. Drive Gear 41. Long Pin
5. Driven Gear 42. Short Pin
6. Stator Support 43. Inner Shaft
7. Gasket 44. Outer Shaft (No. 2 on end)
8. Screw 45. Spacer
9. Ferry Head Screw 46. Needle (48 Each Pinion Gear)
10. Adapter 47. Inner Pinion Gear
11. Bush ing 48. Outer Pinion Gear
12. O-ring 49. Baffle
13. Reverse Clutch 50. Housing
14. Piston 51. Breather
15. Quad Ring 52. Clutch Cutout Solenoid
16. Pressure Plate 53. Control Arm
17. Dowel Pin 54. Control Valve
18. Spring 55. Roll Pin
19. Friction Disc 56. Groove Pin
20. Metal Disc 57. Seal
21 . Forward Clutch 58. Plunger
22. Snap Ring 59. Spool
23. Bearing 60. Expansion Plug
24. Thrust Washer 61. Piston
25. Cylinder 62. Spring Seat
26. Bearing Ring 63. Detent Plate
27. Clutch Spring 64 . Steel Ball
28. Rear Pressure Plate 65. Cover
29. Front Pressure Plate 66. Lock Washer
30. Hub 67. Neutral Start Switch
31. Ring Gear 68. Self-Locking Nut
32. Sealing Ring 69. Hardened Washer
33. Input Shaft 70. Yoke
34. Woodruff Key 71. Retainer
35. Oil Supply Tube 72 . Ball Bearing
36. Cup Plug 73.Suction Screen
37. Pinion Cage and Output Shaft Assembly 74 . Oil Pan
75. Plug
76. Charging Pump
6210-5
851060
6210-6
DISASSEMBLY
1. Remove the clutch cutout solenoid from the 5. Remove the cover, steel ball , and spring .
power shuttle by rotating the clutch cutout sole-
noid counterclockwise .
2. Remove the control arm from the control valve.
004844
6. Remove the detent plate.

1. Control Arm 004706 ~
3. Remove the snap ring from the control valve .
004802
7. Remove the control valve from the housing.

1. Snap Ring 003604
4. Loosen and remove the cap screws and lock

washers that hold the cover .
004707
6210-7
8. Loosen and remove the cap screws and lock 11 . Put the power shuttle on the bench as shown .
--
washers that hold the oil pan .
00361'
003608
12. Loosen and remove the cap screws that hold

9. Remove the oil pan. the charging pump .
003609 00361 2
10. Remove the suction screen . 13. Remove the charging pump.
003610
6210-8
14 . Remove the gasket. 18 . Remove the adapter.
003619
15. Use a dial indicator to check the end play of the 19 . Remove the gasket.
input shaft.
003620
003615
20 . Remove the pressure plate .

16. If the end play is more than .086 inch (2 .18
mm) , check the thrust washer (item 24, page 6210-
4) in the forward clutch assembly for wear.
17. Loosen and remove the Ferry head screws that

hold the adapter.
003621
003618
6210-9
21 . Remove the springs. 24. Remove the remainder of the friction discs and
the metal disc. There is a total of three friction discs
and two metal discs in the reverse clutch.
25. Remove the three dowel pins.
22. Remove the friction disc.
1. Friction Disc 003623
23. Remove the metal disc.

003627
27. Remove the forward clutch assembly .
003628
6210-10
28. Prevent the yoke from turning and use an im- 33. Hit the retainer with a soft hamme r to remove
pact wrench to loosen and remove the self-locking the retainer from the housing .
nut.
29 . Remove the hardened washer and yoke.
30. Use a soft hammer and drive the pinion cage

and output shaft assembly out of the bearing.
003844
003840
31. Remo ve the pinion cage and output shaft as-

sembly.
1. Baffle 003801
35 . If necessary, remove the baffle.
32. Loosen and remove the cap screws and lock

washers that hold the retainer.
003803
6210-11
36. Use an acceptable tool to remove the needle 3. Remove the seal from the plunger.
bearing.
004807
003807
4. Drive the groove pin out of the control valve .

Disassembly of The groove pin is installed even with or just below
Control Valve the 00 of the control valve . Drive the groove pin
out of the control valve from the opposite end.
1. Use a hammer and a punch to drive the roll pin
out the control valve as shown.
004805
5. Remove the spool and spring from the control

valve.
2. Remove the plunger and spring from the con-
trol valve.
1. Spool 004806
2. Spring
1. Plunger 004804
2. Spring
6210-12
6. Put the control valve in a press and use an 9. Remove the spring seat.
acceptable driver to compress the spring for the
piston until the snap ring can be removed.
004600
10. Rem ove the spring .
7. Remove the snap rin
1. Valve Spring 004607
1. Snap Ring 004603
11. Remove the piston .
8. Slowly release the tension of the spring and

remove the driver and snap ring .
1. Piston 004608
004604
6210-1 3
12. Remove the O-ring(s) from the control valve. 3. Mark a mark on the drive gear. the driven gear,
and the body .
004609
1. Mark 003822
Disassembly of Charging Pump

4. Remove the drive gear.
1. Loosen the screw that holds the stator support.
003823
1. Screw 003820
5. Remove the driven gear.

2. Remove the screw and let the body and gears
fall onto the bench. Remove the converter support.
003824
0038 21
6210-14
6. Put the body in a vise with soft jaws. Use an 3. Remove the O-ring from the adapter.
acceptable puller to remove the seal from the body.
4. Remove the quad ring from the piston.

Disassembly of Adapter
1. Apply compressed air to the hole shown to
push the piston from the adapter. Hold the piston
as shown.
003939
5. If the bushing in the adapter is worn or dam-

aged , use an acceptable driver and press the bush-
ing out of the adapter.
.,.
2. Remove the piston from the adapter .
004030
003936
6210-15
Disassembly of Forward Clutch 4. Remove the snap ring that hol ds the cyli nd er.
1. Snap Ring 004041
5. Use an acceptabl e dri ver and press the cylin-

der out of the ring gear.
2. Remove the snap ring from the groove in the
input shaft.
6. Remove the snap ring that ho lds the front pres-

sure plate.
3. Press the input shaft out of the forward c lutc h.
Do not let the input shaft fall.
004040
6210-16
7. Remove the rear pressure plate. 10. Remove the remainder of the frict ion discs and
metal discs. There is a total of seven fr iction discs
and six metal discs.
11. Remove the front pressure plate.
8. Remove a friction disc.
9. Remove a metal disc.

1. Snap Ring 004006
1. Sealing Rings 004008

6210- 17
14. Rem ove the sealing rings from the input shaft . 17 . Remove the Woodruff ke y from the input shaft .
1. Woodruff Key 0040 13
15 . If the clutch hub must be removed from the 18. Remo ve the sealin g rings from the end of t he
input shaft, remove the snap ring from the groove shaft.
in the i ut shaft.
1. Snap Ring 004010
19. Remove the clutch spring.

16. Press the input shaft out of the clutch hub.
1. Clutch Spring 004721

6210-18
20. Remo ve the snap ring that holds the bearing in 23 . Remove the piston from the cylinder.
the cylind er.
1. Piston 004723
24. Remove the O-ring f rom the cylinder.

21. Use an acceptable driver and press the bearing
out of the cylinder.
004724
004630
25. Remove the quad ring from the piston .
22. There are three holes in the inner bore of the

cylinder. Close two of these holes with your fingers
and apply air pressu re into the other hole to push
the piston out of the cylinder.
004727
004722
6210-19
26. Remove the bearing ring. 3. If the needle bearing that is installed in the
pinion cage and output shaft must be replaced , use
an acceptable lIer to remove the needle beari
004726
003819
Disassembly of Pinion Cage

and Output Shaft
4. If the pinion gears or th e needle bearings in the
1. Disengage the ends of the sealing rings on the pinion cage are damaged , the pinion cage can be
ou tput shaft. disassembled. There is a collector ring which is
rolled around the pinion cage by a lathe operation .
Before the collector ring is removed, check with
your local machine shop to make sure that a new
collector ring can be correctly installed on the pi-
nion cage. If the collector ring cannot be correctly
installed , it is recommended that a new pinion cage
and output shaft assembly be used . If the pinion
cage is to be disassembled , use the following
procedure:
1. Sealing Rings 0038 11
2. Remove th e sealing rings.
1. Col/ector Ring 003815
a. Remove the collector ring from the pinion

cage .
b. Use a punch and hammer to remove the

retaining pins which fasten th e pinion shafts in
position.
003812
6210-20
c. Press the pinIOn shafts from the pinion Disassembly of Retainer

cage. There are 48 needle bearings and three
bearing spacers for each pinion gear. 1. Fasten the retainer in the vise with soft jaws.
Use an acceptable puller to remove the seal from
d. Remove the pinion gears, needle bearings, the retai nero
and bearings spacers from the pinion cage.
Keep the pinion gears and bearing spacers
together so that if the parts are used again , the
bearing spacers can be installed in the correct
pinion gear.
003943
2. Use an acceptable driver and press the bearing

from the retainer.
003910
6210-21
ASSEMBLY OF CONTROL VALVE

1. Install a new O-ring(s) in the groove(s) in the 4. I nstall the spri ng seat.
control valve .
1. Spring Seat 004606
5. Put the snap ring and driver on top of the spring

2. Lubricate the piston and bore for the piston seat.
with clean oil and install the piston , closed end first,
in the control valve.
1. Snap Ring 004604
1. Piston 004608
6. Compress the spring until the snap ring can be
installed in the groove in the contro l valve . Then
3. Install the spring. install the snap ring in the groove.
1. Spring 004607 004603

6210-22
7. Release the tension on the spring slowly. 10. Install the spring and plunger in the control
valve .
NOTE: Before installing the plunger, install tool

075492 in the end of the control val ve. This tool
prevents the lip of the seal from rolling to the out-
side when the plunger is installed.
'ii7;'L.
iii
8 . Install the spring in the end of the spool and
install the spool in the control valve , spring end 1. Spring Plunger 004804
fi rst.
11. Start the small diameter end of the groove pin

into the hole in the large 00 of the control valve .
Push the plunger all the way into the control valve.
Hold the plunger in place and drive th e groove pin
into the control valve . The end of the groove pin
must be even with or just below the 00 of the
control valve .
1. Clutch Cutout Spring Spool 004806
9. Install a new seal on the plunger.

---....",....
004809
12. Push in and hold the plunger and drive the roll
pin into the control valve. The end of the roll pin
must be even with or just below the 00 of the
control valve .
004808
0048 10
6210-23
ASSEMBLY OF CHARGING PUMP

1. Sta rt a new seal into the body. 4. I nstall the d rive gear into the driven gear. Make
sure that the marks made du ring disassembly are in
alignment.
1. Marks 003822
2. Press the sea l into the body until the seal stops
moving.
5. Assemble the converter support and body so
that the holes for the screw are aligned .
003821
3. Install the driven gear into the body. Make sure

that the marks made during disassembly are in
alignment. 6. I nstall and tighten the screw to fasten the parts
of the charging pump together.
1. Marks 003824
1. Screw 003820
62 10-24
ASSEMBLY OF ADAPTER
1. If the bushing was removed from the adapter, 3. Press the bushing into the adapter until the
the bushing must be installed so that the new bush- bushing is even with the cover. Then measure the
ing is in the position shown . diameter of the bushing. The diameter must be
1.375 to 1.376 inches (34.92 to 34 .95 mm) . Ream the
bushing as required.
4. Install a new quad ring in the g roove in the

piston.
800389
1. SPLIT IN THE BUSHING
2. Put the adapter in the press and install the new

bushing so that the split is in the correct position.
003940
5. Install a new O-ring in the groove in the adap-

ter.
004031
003938
6210-25
6. Lubricate the quad ring, a-ring and the bore in

the adapter and piston with clean oil. Push the
piston into the adapte r.
004617
ASSEMBLY OF FORWARD CLUTCH

1. Install a new quad ring in the groove in the 3. Install a new a-ring in the cyl inder.
piston.
JIIII""'"'"'"
004725
4. Lubricate the quad ring , a-ring , and the bore in

2. Install the bearing ring in the groove in the the piston cylinder with clean oil . Push the piston
piston . into the cylinder.
1. Bearing Ring 004 729 004730

6210-26
5. Put petroleum jelly on the clutch spring . Install 8. Install the input shaft in the clutch hub so that
the clutch spring in the cylinder on top of the pis- the Woodruff key is in alignment with the keyway in
ton as shown . The petroleum jelly will keep the the clutch hUb.
clutch spring in place when the cylinder and piston
assembly is installed in the ring gear.
004121
1. Clutch Spring 004731
9. Press the input shaft all the way into the cl utch
hub.
6. Install the Woodruff key in the input shaft.
004122
1. Woodruff Key 0040 13
7. Put the clutch hub in the press as shown.
1. Snap Ring 004010
004120
6210-27
11. Install the sealing rings in the grooves in the 14. Put clean oil on the friction discs and the metal
input shaft. discs. Install a f riction disc in the ring gear.
()()4008 004003
12 . Engage the ends of the sealing rings. 15. Install a meta l disc in th e ring gear.
13. Put the ring gear in the press and install the 16. Install the remainder of the friction discs and
front pressure plate. the metal discs. Th ere is a total of seven friction
discs and six metal discs.
17. Install the rear pressure plate .
004 125
004 126
6210-28
18. The snap ring that holds the rear pressure plate 21. The snap ring that holds the cylinder must be
must be .090 to .093 inch (2.29 to 2.36 mm) thick . .074 to .078 inch (1.88 to 1.98 mm) thi c k. Measure
Measure the snap ring to make sure that the snap the snap ring to make sure that the snap ring is the
ring is the correct thickness. Install the snap ring correct thickness .
on the rear pressure plate.
004127
22. Install the snap ring.

19. Start the cylinder and piston assembly into the
ring gear. Make sure that the clutch spring is in
position in the cylinder.
004633
004631 23. Push the front pressure plate down to remove

all the space from between the clutc h discs and
measure the distance between the front pressure
20. Carefully press the cylinder into the ring gear. plate and the lip in the ring gear.
If the clutch spring comes off the piston while you
are pressing the cylinder into the ring gear, the
piston or cylinder can be damaged .
004632
6210-29
24 . Select the correct thickness of snap ring to get 26. Put the input shaft in the press as shown .
a clearance of .011 to .046 inch (0 .28 to 1.17 mm)
between the front pressure plate and the snap ring.
Snap rings are available in thickness as follows:
.050 to 0.54 inch (1 .27 to 1.37 mm)

.062 to .066 inch (1 .575 to 1.676 mm)
.074 to .078 inch (1 .88 to 1.98 mm)
.084 to .088 inch (2 .134 to 2.235 mm)
0.96 to .100 inch (2.44 to 2.54 mm)
NOTE: The snap ring must not completely fill the

groove. End play between the front pressure plate
and the lip of the ring gear is necessary for correct
forward clutch operation.
004639
27 . Install the ring gear and foward clutch assem-

bly on the input shaft. Turn the input shaft as nec-
essary to align the splines in the c lutch hub with the
splines in the friction discs. Wh en all the friction
discs are engaged and th e input shaft is in the
correct position , the bottom of the ring gear will be
even with the bottom of the drive gear on the input
shaft.
25. Install the correct snap ring.
28. Press the bearing into the cylinder until the

groove for the snap ring can be seen.
6210-30
29 . Install the snap rin in the cylinder. 32 . Install new sealing rings in the grooves in the
input shaft.
1. Snap Ring 004643
1. Sealing Rings 004615
30. Install the snap ring in the groove in the input

shaft. 33 . Apply petroleum jelly to the thrust washer and
install the thrust washer on the input shaft. The
petroleum jelly will hold the thrust washer in place
when the forward clutch is installed .
1. Thrust Washer 004616
ASSEMBLY OF PINION CAGE AND OUTPUT SHAFT

1. If the pinion cage was disassembled: d. There are three pinion gears that have
notches in the teeth. Install these pinion gears
a. Apply peteroleum jelly on the inside of the between the thrust plates so that the pinion
pinion gears. Install the spacer in the center of gears are in alignment with holes fo r the outer
the pinion gears. pinion shafts.
b. Install 24 needle bearings in each end of e. Get the pinion shafts that have a number 2
each pinion gear. Install spacers in each end of on the end of the pinion shaft. Align th e holes
the pinion gears. for the retaining pin in the pinion shaft and in
the pinion cage and press the pinion shafts into
c. Apply petroleum jelly on the smooth side the outer holes through the pinion gears.
of the thrust plates. Install the thrust plates in Install the pins that hold the pinion shafts .
the pinion cage so that the smooth side of the
thrust plates are against the pinion cage . f. Use the same method to install the remain-
der of the pinion gears and pinion shafts.
6210-31
g. Take the pinion cage and output shaft as- 2. If the needle bearing was removed from the
sembly to your local machine shop . Have the pinion cage and output shaft assembly , press a
machine shop install the collector ring on the new needle bearing into the pinion cage and out-
back of the pinion cage. The collector ring put shaft assembly to the dimension shown . Press
must be rolled into postion and must be oil the needle bearing from the side that has numbers
tight. or other marks.
003815
1 INNER PINION GEAR 5. PINION SHAFT

(PLAIN TEETH ) 6. PINION SHAFT RETAINING PIN
2. OUTER PINI ON GEAR 7. THRUST WASHER (2 PER
(NOTCHED TEETH ) PAIR OF PINION GEARS
3. PINION SH AFT S STAM PED WITH 8. NEEDLE BEARINGS
NUMBER 2 MUST BE INSTALLED (48 PER PINION GEAR)
IN OUTER PINION GEARS 9. OIL COLLECTOR RING
4. NEEDLE BEARING SPA CER 10 . 5/ 16 INCH (7.9 mm )
(3 PER PINION GEAR ) 751637
621 0-32
3. Install new sealing rings on the output shaft. 4. Engage the end of the seal in g rings.
ASSEMBLY OF POWER SHUTTLE

1. Press a new seal into the retainer.
003917
2. If the needle bearing was removed from the 4. Put the pinion cage and output shaft assembly
housing, press a new needle bearing into the bore in the press on a hollow suppo rt that is approxi-
unt il the needle bearing is 1/ 8 inch to 1/ 32 inch (3 .2 mately 3 inches (75 mm) high.
to 0.8 mm) below the end of the bore .
003807
6210-33
5. Install the housing on the pinion cage and out- 8. I nstall the retainer, cap screws, and lock wash-
put shaft assembly. ers.
004739
6. Press the bearing onto the shaft. 9. Tighten the cap screws to 40 to 50 pound-feet
(54 to 68 N m, 6 to 7 kg / m) .
7. Install a new gasket on the housing . 10. Install the yoke, hardened washer and self-
locking nut. Tighten the self-locking nut to 75 to 85
pound-feet (102 to 115 N m, 11 to 12 kg/ m) .
11 . Make sure that the thrust washer is installed on

the input shaft. I nstall the forward clutch assembly
into the pinion cage and output shaft assembly .
Turn the input shaft as necessary to align the drive
r with the pinion gears.
1. Gasket 004736
003628
6210-34
12 . In stall the thrust washer on the forward clutch. 15. Install a metal disc . The groove in one lug is not
in the centerofthe lug. Install the metal disc so that
this lug is in the location shown.
13. Install the three dowel pins in the slots in the

housing. 16. Install the remainder of the f riction discs and
the metal disc . There is a total of three frictio n discs
and two metal discs in the reverse clutch . Make
sure that the metal discs are installed according to
the instructions in step 14.
17. Install the 11 springs .
14. Lubricate the metal discs and friction discs

with clean oil and install a friction disc.
18. Install the pressure plate . There is a V-notch in

the 00 of the pressure plate . Install the press ure
plate so that the V-notch is aligned with th e large
hole at the top of the housing .
003625
1. V-Notch 003621
6210-35
19. Install a new gasket. 22 . I nstall the gasket for the charging pump .
1. 003620
20 . Install the adapter . 23. Install the charging pump .
21 . Install the Ferry head screws that hold the 24 . I nstall and t ighten the cap screws to 204 to 264
adapter. Tigh ten the Ferry head screws to 324 to pound-inches (23 to 30 N m, 2.3 to 3.0 kg/ m) .
444 pound-inches (37 to 50 N m, 4 to 5 kg/m).
6210-36
.,
25 . Install the suction screen. 28 . Lubricate the control valve and bore for the
control valve with clean oil. Install the control valve
so that the notch is in the position shown.
26. Apply form-in-place gasket material to the

housing .
29 . Install the detent plate so that the tab engages
the notch in the contro l valve . If necessary, use
petroleum je lly to hold the detent plate in place .
004742
27 . Install the oil pan and cap screws. Tighten the

cap screws.
30. If necessary, install a new gasket on th e cover.

Use petroleum jelly to hold the gasket. Also install
the spring in the cover.
003608
6210-37
31 . Install the steel ball in the center recess in the 33. Install the snap ring on the control valve.
detent plate using petroleum jelly to hold the steel
ball in place. Then install the cover engaging the
spring with the steel ball.
34. Install the control arm on the control valve .
32. Install the cap screws and lock washers and

tighten the cap screws .
35 . Install the c lutch cutout solenoid on the con-

trol valve.
This Page is Blank
6211
CONTROLS
TABLE OF CONTENTS
Power Shuttle Control Linkage Illustration of Shift Linkage for

Adjustment ... . ...... ... ..... . .. . .... 6211-2 Transmission ................... . . . . . 62 11 -5
Illustration of Control Linkage for Differential Lock Pedal Adjustmen t .... .. 6211-6
Power Shuttle . .. . . . ....... . . .. ... . ... 6211-3
Illustration of Linkage for Differential
Illustration of Electrical Components for Lock . . . .. .... ... ............... .. . . . 6211 -6
Power Shuttle .... . .... . . .. . . ..... . ... 6211-4
Illustration of Shift Lin kage for
Transfer Case ...... ... . . .. . . .... . . ... 62 11 -7
A Tenneco Company
6211 -2
POWER SHUTTLE CONTROL LINKAGE ADJUSTMENT

1. Make sure that the pin in the shuttle control control rod (3) until the ball joint (5)can be con-
lever (1) is in the NEUTRAL position between the nected to the control lever (6) on the power shuttle
tabs on the detent plate (2) . (7) with the control lever (6) in the NEUTRAL posi-
tion.
2. Adjust the length of the control rod (3) evenly
between the ball joints (4 and 5) on the ends of the
6211-3
Shuttle Cho~~~; control lever(lt~~

I Lever (1) A d·ustment:
I the
tabs on
Put the S Ton between .th the
NEUTRAL POSI I Lock In place WI 10).
the detenl plate (2)~n the control rod (
locking collars (9)
.....> ./
/'
8872010
. k ag e for P0 wer Shuttle

Control Lin
6211-4
CLUTCH CUTOUT
SOLENOID \
870358A
Electrical Components for Power Shuttle

6211 -5
\
\
\
\
\
O_KNOB
\
\
\
\
\ ._BOOT
\
\
\
\
\
\ CLIP
\
\
\
PIN !
'- \
~~
PIN~\
CLIP
~ t:\ r;- 'HIFe LEVER
/'
CLIP
,, ~ 4JJ
~\.yr~- CAPSCREW
@~~; PIVOT
/
CAPSCRE
44 TO 52 p~. TIGHTEN TO
I
(60 TO 70 N UNO-FEET LOCK WASHER
m, 6 TO 7 kg/ m)
870359
Shift Linkage for T ransmission

6211-6
DIFFERENTIAL LOCK PEDAL ADJUSTMENT

1. Make sure that the stop (1) on the pedal (2) is 3. Turn the yoke (3) one addi t ional turn (c lock-
aga inst the bottom of the floor plate. wise).
2. Adjust the yoke (3) on th e contro l rod (4) until

all free travel is removed from the pedal (2) .
B87201'
62 11-7
LOCK NUT !
LEVER
GREASE FITTING /
COTTER PIN
\
HANDLE-""""'€ii-
.. =.@~ ~/ c. I
~~/.'~
•
~ SPACER~~) \
CLEVIS PIN
BOOT- ~ _-
RETAINE;O~ - - CONTROL ROD
PIVOT BRACKET- V
COTTER PIN - f COTTER PIN

r-~ /
TRANSFER CASE
I BELLCRANK
~
~~/-l CLEVIS PIN
"\ ,
\
\
\ WASHER
\
\
\
\/~~--BOLT
\
....... _-./
1
I
WASHER
I
/~~'BOLT
"
I
I
LOCK WASHER-e SHIFT LINKAGE GUARD
~-NUT
887191 2
Shift Linkag e for Tran sfer Case

This Page is Blank
Section
6216
TRANSFER GEAR BOX
4 WHEEL DRIVE
Written In Clear
And
Simple
English
II Case Rae 8-23451

Tenneco Company
6216-2
TABLE OF CONTENTS
SPECIAL TORQUES . ...... .... . .. . ..... ... ... . . ........ . .. ..... . .. .. ....... .. ..... .. . ... . .. . ... . .. 2
SPECIAL TOOLS . . .. ..... ............. .... ....... . . .. .. .. . . .. .... . . .. ... . .. . .. . . . ... . . . . .. . ..... .. 3
DISASSEMBLY OF TRANSFER GEAR BOX . .. . ... . . . .... ... . . . .. . . ..... .. . ....... . ... . .......... 4-12
TRANSFER GEAR BOX ASSEMBLY (Prior to Transmission Serial No. 16270319) ......... .•... .... 13-26
TRANSFER GEAR BOX ASSEMBLY (Transmission Serial No . 16270319 and After) ...... . .. .... ... . 14-26
SPECIAL TORQUES
Adjustable Cover Bolts .... .... ..... .. . .......... ...... . .. . . 35 to 42 Ib ft 48 to 57 Nm
(4 .8 to 5.7 kgm)
Front Cover Bolts ............... . .......•.. ... ..... ..... ... 35 to 42 Ib ft 48 to 57 Nm

(4.8 to 5.7 kgm )
Rear Cover Bolts ... ........... ... .... .. . . .. .. .... ....... .. . 80 to 90 Ib ft 109 to 122 Nm
(10.9 to 12.2 kgm)
Rae 8- 23451
6216-3
SPECIAL TOOLS
TELESCOPING GAUGE SET CAS-l0087
OUTSIDE MICROMETER 1 TO 2 INCH CAS-l00S8
TORQUE WRENCH LB FT
DEPTH MICROMETER CAS-l0064-l
OUTSIDE MICROMETER 0 TO 1 INCH CAS-l0057
TORQUE WRENCH LB FT
TORQUE WRENCH LB INCH
Rae 8- 23451
6216-4
DISASSEMBLY OF TRANSFER GEAR BOX

IMPORTANT: All of the Serial Numbers in this section are Transm ission Serial Numbers.
STEP 1 STEP 4
Remove the mainshaft oil seal. Remove the shims .
STEP 2 STEP 5
")
Remove the bolts from the mainshaft adjustable Remove the nuts and bolts from the front cover.
cover.
STEP 6
STEP 3
Remove the adjustable cover.

NOTE: On Transmission Serial Numbers 162703 19
and After the shift rail yoke is on the rear housing.
Rae 8-23451
6216-5
STEP 7 STEP 10
Remove the front cover. Remove the rear cover from the transaxle.
STEP 8 STEP 11
I
Remove the two ferry head bolts. Remove the gasket from th e transaxle.
STEP 9
Remove t he bolts from the rear cover.
Ra e 8-23451
6216-6
STEP 12 STEP 14 Press Fit Housing
Clean all foreign material from the transaxle hous-

•
Remove the retaining ring from the input gear
bearing.
ing.
STEP 13 Slip Fit Housing STEP 15 Press Fit Housing
-
the rear housing .
~
Remove the retaining ring and the input gear from Press the input gear and roller bearing out of the
rear housing .
Rae 8-23451
6216-7
STEP 16
Remove the input gear seal. Remove the snap ring from the input shaft.
STEP 17
Remove the bearing retaining ring.
NOTE: On Transmission Serial Numbers 16270319

STEP 18 Serial No. 16270319 and Aller and After press the front and rear roller bearing off
the input gear.
INPUT GEAR
Remove the snap ring , shaft and the o-ring from

the input gear .
Rae 8- 23451
62 16-8
STEP 21 PRIOR TO SERIAL NO. 16270319
Use a mild steel rod and push the cup plug out of Remove the th rust was hers and bearing off t he
the input gear. idler gear.
Pull the output shaft needle bearing out of the rear Remove the idl er gear f ro m the front housing .
housing .
STEP 23
Remove th e thrust was hers and bearing off th e

Pull the idler gear needle bearing out of the rear idler gear.
housing.
Rae 8-23451
6216-9
STEP 27 STEP 30
Cut and remove the locking wire . Rem ove the sh ift fork from the sh ift collar.
STEP 28
Remove the set screw from the shift fork. Rem ove the output shaft seal.
STEP 29
Remove the shift rail from the shift fork . Remove the output shaft snap ring.
Rae 8-23451
6216-10
STEP 33
Press the output shaft out of the roller bearing. Press the roller bearing out of the front housing.
STEP 37
Rem ove the front retaining ring. Use a mild steel rod and push the needle bearing
out of the front housing .
Remove the rear reta ining ring.

Pull the input shaft needle bearing out of the front
housing .
Rae 8-23451
6216-11
STEP 39 PRIOR TO SERIAL NO . 16270319 STEP 41

~f ~"""".~
J
Remove the shift rail seal. Remov e the spacer from the output shaft.
STEP 40 SERIAL NO. 16270319 AND AFTER STEP 43
7HOUSING
Remove the shift rail seal from the rea r housing . Rem ove the output gear from the output shaft.
STEP 42
Remove the breather from the front cover.
Rae 8-23451
6216-12
STEP 44
Remove the shift collar, detent balls and springs .
Rae 8-23451
6216-13
TRANSFER GEAR BOX ASSEMBLY
Prior to Transmission Serial No. 16270319
REAR HOUSING
/4'~ /", SH\' ADJUSTABLE COVER
"'li> @ __RHA'"'"G ,,"G

00 i
DRAIN
PLUG
/) I
SEAL /
0 ()tbrl /
'"PUT GEAR
SNAP RING / Ljfl~ CUP PLUG
" / FRONT HOUSING
\.... ROLLER BEARING ~@ /.
..., THRUST WASHERS @ (j BREATHER
NEEDLEBEARING~~ / \ / 0 ~/
~@ ( t. ,
;fJ@w@~1
NEEDLE BEARING :: A
THRUST WASHERS ~~ ' \

~ ....~ ~
~\ELBOW
/?
(~r1
~!~':;I BEARING
/
l'
'()~
/~@I]w ~,/)
,1/' , ,:.
,. -t "'-
)
I ~';~~<':/Ol IDLER GEAR @
J ~ ~ r 1.n \ ~ ( SEAL
. ,>C~ I 1/" ,// 1\
~.......
r , I Je" '<:.:1'//:, (. . (.\I
1") :'/', '- I \
'I". ' "( /!~: .' )\
DETENT BALLS
1 BEARING
,
NEEDLE BEAR ING
\""'/ \J!§II
r~
I ,! ~. ~'/. ! C' 0/ SPRINGS
\~:~
/
/ <(jl~~I-"'I> OUTPUT SHAFT
/ SHIFT COLLAR SHIFT RAIL /
J t1Ju(O:::::~"G,
NEEDLE BEARING SHIFT YOKE
' . SPACER
LOCK'"G WORE )~ /I _iI(§J f1 R07

RETAINING SCREW ~ f / ,r.;:t .
t. JI
OUTPUT GEAR \ lY.@ilil>'I/
, )J .J! ( t\ ,
/ , ' /, \
SHIFT FORK
RETAINING RING
/ (f:'::'
I,
-I
,/I/ ' .'-
'i". ." f '~
,
'I , ~,
\
I k:..:::: ~ l:. ·~ " ,\ 1)

M>-J.1~)&~:'
~i.l,'v..:..::> : /
Ra e 8-23451
6216-14
TRANSFER GEAR BOX ASSEMBLY

Transmission Serial No. 16270319 and After
SHIMS
ADJUSTABLE COVER
/ SEAL
d
....
.... ....
,
' ... ~ BEARING
NEEDLE BEARING - - - - - - ~@ ~
[!@fljJ
SNAP RING
'"'"S; WM""/~~D@
V
I
1
IDLER GEAR
THRUST WASHERS
YOKE
Ie$,
I I (c{~)
FRONT HOUSING
11'1\ // 11"
'~(( L/ fief'.. .
~
J I ' ://
' ,I/ ~' , '
A'I
' <. , 'OJ' 1.'1 ,
~ Ii!;
~
I 1
SEAL /
'iI!I
:~-~
1 ;~\~\
, rl " l ') ;11 I,
DETE/NT BALLS
("
OUTPUT GEAR
~ ,~- '" \ SELECT SPACER
. . . ,. . ... \' ~ 1
' p..,,....-:; .... I"~ 0 ' ROLLER BEAR ING
SHIFT RAIL \,( ,~ : , ~~}::~~~~ .~ \ ',.... ~ / SNAP RING
~ ~ : // ®tf1
\iO
• I.Jf!!J SPRINGS' ....... .... / . r
/ . . ", ~J/(Q) /0'~1

((I., _ ' . ,", (j) /~:;~ ,~;i i
/
NEEDLE B E A R I N G /
OUTPUT~SHAFT ~Q(Y
~ \ . . . . . . ,. . \
I
', ,: .- .
'I:;~I ' I~~ l
i,( " V'/ .'&1
,)
LOCKING WIRE
RETAINING SCREW
I \
SHIFT COLLAR
SHIFT FORK
.... , _,-' RETAINI NG RING """':'S.;:"J ~~
SEAL
t
Rae 8-23451
6216-1 5
STEP 45 PRIOR TO SERIAL NO. 16270319 STEP 47
Install th e bearin g retaining ring and press in the

roll er bearing.
Press th e input gear needle bearing into the fro nt

housing until it is even with the housing surface.
STEP 46
Install the front retaining ring .
STEP 49
Press the id le r gear needle bearing into the front

housing to a depth of 0.38 inch ± 0.10 inch (9 .65
mm ± 2.54 mm) .
Install the three sp rings and deten t balls. Use a

hose clamp and three pieces of 1/ 2 x 1/ 4 inch (12.7
x 6.35 mm) mil d steel rod . Install the shift colla r on
th e shaft sp li nes.
Rae 8-23451
6216-16
STEP 50 STEP 52
Instal l the snap ring in the groove on the output

shaft.
STEP 53
Use a soft face hammer to push the shift collar over

the detent balls .
Use a telescoping gauge to check t he distance

STEP 51 between the gear and snap ring.
STEP 54
Install the output gear on the output shaft.
Use a micrometer to measure the distance. Make a

record of the reading.
Rae 8-23451
6216-17
STEP 55 STEP 58
Use a micrometer to measure the thickness of the Press the outpu t shaft into the roller bearing.
roller bearing . Make a record of this reading .
NOTE: Support the inner race of the bearing while
pressing in the output shaft.
STEP 56
Remove the snap ring from the output shaft.
Install the snap ring into the groove on the output

STEP 57 shaft .
Use the reading in Step 53 and install the thickest

spacer .
Rae 8-23451
6216-1 8
STEP 60 STEP 63
Install the shift fork on the shift collar. Install the locking wire .
STEP 61 STEP 64
Install the shift rail into the shift fork . Install the shift rail seal.
NOTE: On Transmission Series Number 16270319

and After the threaded end of the shift rail must go STEP 65 PRIOR TO SERIAL NO. 16270319
toward the rear housing.
STEP 62
• ~ '\
Install the transfer gear box breather .
Install the retaining bolt and tighten.
Rae 8-23451
6216-19
STEP 66
Install th e idler gear into the front housing .
Push the o utput shaft sea l into the front housing to

a depth of 0.28 inch (7 .11 mm) .
Install the thrust washers and bearing .

STEP 67
Install the thrust washers and bearing on th e idler

gear.
Rae 8-23451
6216-20
STEP 70
Apply no. 2 pe rmatex to the bore of the idler gear.
STEP 73
Press the needle bearing into the rear housing until

it is even with the housing surface .
STEP 71
Push the cup plug into the gear bo re.
'"
Press the idler gear needl e bearing into the rear
housing to a depth of 0.20 inch (5 .08 mm).
Press the roller bearin g on th e input gear.
NOTE: On Transmission Serial Number 16270319

and After press a ro ller bearing on each side of the
gear.
NOTE: Press on the inner race only.
Rae 8-23451
6216-21
STEP 75
!!t¥1YF*
In sta ll th e snap ring in the groove Install the rear bearing retaining ring.
STEP 76 Press Fit Housing STEP 79 Slip Fit Housing
Install the bearing retain ing ring in the top groove. Install the retaining ring in the bottom groove.
STEP 77 Press Fit Housing
Press the input shaft assembly into the rear hous-

ing until the bearin g makes co ntact with the retain-
ing ring .
NOTE: Press on the outer race only.
Rae 8-23451
6216-22
STEP 80 Slip Fit Housing
.. ~.
Install th e input gear and the retaining ring . Install a new gasket on the transaxle housing .
Install the input shaft seal to a depth of 1.12 inch Install the rear housing on the transaxle housing .
(28.45 mm).
Rae 8-23451
62 16-23
STEP 84 STEP 87
Put no. 2 permatex on the threads of the two top Install the bolts and nu ts . Tighten the bolts and
cover bo lts. nuts to a torque of 35 to 421b ft (48 to 57 Nm)(4.8 to
5. 7 kgm)
STEP 85 STEP 88 SERIAL NO. 16270319 AND AFTER

~
SEAL
Tighten the rear cover bolts to a torque of 80 to 90

Ib ft (109 to 122 Nm)(10.9 to 12.2 kgm).
Install the shift rail seal.
STEP 86 STEP 89 SERIAL NO. 16270319 AND AFTER
Appl ya 1/ 8 inch stripofRTV 108 (Case No. 345-61)

adhesive the front cover.
Install the lock nut and yoke on th e shift rail.
Rae 8-2345 1
6216-24
STEP 90 STEP 92 SERIAL NO . 16270319 AND AFTER
O- RING
SHAFT----"
Immec
Install the yoke on the shift rail.
STEP 91
Install the a-ring and shaft in the input gear. Instal l

the snap ring on the shaft.
STEP 93 SERIAL NO 16270319 AND AFTER
In sta ll the input gear seal into the front housing.

Install the mainshaft shims .
Rae 8-23451
6216-25
STEP 94
Apply RTV 108 (Case No. 345-61) adhesive to the ""

Install the cover bolts and tighten to a torque of 35
adjustable cover . to 42 Ib It (48 to 57 Nm)(4.8 to 5.7 kgm) .
STEP 95 STEP 97
Install the adjustable cover. Install a new mainshaft seal.
NOTE: For mainshaft adjustment see Section 6214

for naturally aspirated engines, See Section 6215
for turbocharged engines in this service manal.
Fi ll the transfer gear box with 1 pt of new Case FDL

fluid.
NOTE: For Hand Brake Installation see Section

7123 in the service manual.
Rae 8-23451
6216-26
PRIOR TO TRANSMISSION SERIAL NO. 16270319 TRANSMSSION SERIAL NO. 16270319 AND AFTER

tion to install them on units previously so ld .
Rac 8-23451
6217
TRANSAXLE AND DIFFERENTIAL LOCK
WET BRAKES
TRANSMISSION SERIAL NUMBER 16276842 AND AFTER
TABLE OF CONTENTS
General Information .. .... .. .... .. .. .. .. 6217-2 Countershaft Removal .. . ... ... .. . . .. 6217-16
Special Tools .. . . .. . ..... . ...... . . . .... 6217-3 Countershaft Installation .... . ..... ... 6217-20
Specifications for Tools That Must Mainshaft Installation . .. .. .... . .. .. .. 6217-26

Be Made . .. . .. .. . .. .... . . ... ..... . .. . 6217-4
Shifter Assembly ....... . ......... ... 6217-36
Special Torques . . .. . ...... .. . . . ... ..... 6217-5
Disassembly of Centerwh ee l ......... 6217-43
Specifications ..... .. ..... .. . ... ..... . .. 6217-5
Assembling Differential Centerwheel and
Servicing the Transaxle Assembly . .. .. .. 6217-6 Side Gears ... . ... . ... . . . ... . .. .. .. 6217-44
Final Drive Gear and Axle Housing Setting Differential Pinion to Side Gear
Removal .... ...... ... ....... .. . .... 6217-6 Backlash .. . . ... . ...... .. .... .. . .. 6217-48
Axle Housing Removal ............ . ... 6217-7 Differential Centerwheel Installation .. 6217-50
Axle Shaft Removal .. . . . .. . . . . .. . ..... 6217-8 Adjusting Ring Gear to Pinion Gear
Backlash .. ...... . .... ........... . 6217-53
Differential Side Gear and Center
Wheel Removal . . ..... . .... . . . . . ... 6217-9 Axle Shaft and Housing Installation . .. 6217-59
Mainshaft Removal .................. 6217-12 Servicing the Differential Lock

Assembly . . .... . ... .... . . ... . .... . 6217-65
J I Case 8-67550
A Tenneco Company
6217-2
GENERAL INFORMATION
THIS SAFETY ALERT SYMBOL INDICATES IMPOR -
A TANT SAFETY MESSAGES IN THIS MANUAL WHEN

YOU SEE THIS SYMBOL CAREFULL Y READ THE
MESSAGE THA T FOLLOWS AND BE ALERT TO THE
POSSIBILITY OF PERSONAL INJURY OR DEATH.
CLEANING - Before any service work is done, BEARINGS - Check bearings for easy action . If
steam clean the complete outside surface of the bearings have a loose fit or rough action , replace
axles and transmission . Clean all metal parts ex- the bearings. If necessary, wash bearings with good
cept bearings, in mineral spirits or by steam clean- solvent or kerosene and permit to air dry. DO NOT
ing. Do not use Caustic soda for steam cleaning. DRY WITH COMPRESSED AIR .
After cleaning, dry and lubricate all parts. Clean oil
passages with compressed air. Clean bearing if Bearings can be heated for assembly. Do not heat
necessary in kerosene, dry the bearings com- the bearing beyond a temperature of 250° F
pletely and lubricate the bearings with oil. (120°C). Heating will temporarily increase the
clearance of the inner bearing race so that a hy-
INSPECTION - Check all parts when the parts are draulic press is not needed when installing bear-
disassembled. Replace all parts that have wear or ings over shafts.
damage. Small scoring or grooves can be removed
with a hone or crocus cloth. Complete visual in-
spection for indications of wear, stress, pitting and
the replacement of parts as necessary, will prevent
h CAUTION A/ways wear heat protective
. . gloves to prevent burning your hands
early differential and transmission failures.
when handling heated parts.
GEARS - Check all gears for wear and damage.
Replace gears that have wear or damage.
NOTE: If it is necessary to rep/ace either the ring

gear or the pinion gear, rep/ace both parts.
OIL SEALS, O-RINGS AND GASKETS - Always

install new oil seals, a-rings and gaskets. Put oil or
petroleum jelly on seals and o-rings.
6217-3
SPECIAL TOOLS
CAS 1625 BEARING DRIVER

SPRING COMPRESSION TESTER
DIAL INDICATOR
o TO 1 INCH (0 TO 25.4 mm) DEPTH MICROMETER
CAS 1624 SEAL AND

BUSHING DRIVER
CAS 1465-4 OIL SEAL DRIVE (2)
o TO 1 INCH (0 TO 25.4 mm) MICROMETER
CAS 1194 PROTECTIVE SLEEVE
TORQUE WRENCH LB FT
CAS 1465-2 OIL SEAL DRIVE

6217-5
SPECIAL TORQUES
U.S. Value Metric Valve
Front Cover Bolts .. .. ...... ... . .. . .. . .... . .. . ..... . ..... ... 80 to 90 Ib ft 109 to 130 Nm
(10.9 to 13.0 kgm )
Front Cover Nuts ... . .. .. ...•. . .. . . . . .. . . . . . " . .. .. .... . . .. 35 to 42 Ib ft 48 to 57 Nm
(4.8 to 5.7 kgm)
Mainshaft Rolling Torque .. . .. . .... . . , ....... . .. . . . . . . .. . . .. .. . 5 Ib inch 0.57 Nm
(0 .06 kgm)
Countershaft Rolling Torque . . . .. .. ... . . . . .. " . .. . . ....... 4 to 12 Ib inch 0.45 to 1.4 Nm
(0.05 to 0.14 kgm)
Ring Gear Bolts . . . . . .. .. . . . . . . .. . .. . . .. . . . . . . .... . ..• . ... .. 50 to 55 Ib ft 68 to 75 Nm
(6.8 to 7. 5 kgm)
Brake Housing Bolts . .. , . .. .. .. .. . .. .. .. . ...... . . . .. . ... ... 80 to 96 Ib ft 109 to 130 Nm
(10.9 to 13.0 kgm )
Side Gear Rolling Torque ... . . . . " . . .. . .. .. . , . .. , . ... . . . . . . . . . 4 to 8 Ib ft 5t011 Nm
(0.5 to 1.1 kgm)
Axle Housing Bolts . ... ... . . ...... . .. , .. ... . . ...... . . . ... 220 to 264 Ib ft 298 to 358 Nm
(29.8 to 35 .8 kgm)
Rear Cover Bolts .. . . . .. ... . . .. . .. . . ..... . .. . . .. • . . . ... . . ... 35 to 42 Ib ft 48 to 57 Nm
(4.8 to 5.7 kgm)
Top Cover Bolts . .. . .. . .. ... ... . . . . ... . . . . . . .. . ... . . ... , .. . 35 to 42 Ib ft 48 to 57 Nm
(4.8 to 5.7 kgm)
Differentia l Lock Bolts . ... . .. . . . . . . . . .. . .. .. . .. , ... . ... . . .. . 17 to 21 Ib ft 23 to 29 Nm
(2 .3 to 2. 9 kgm)
T ra nsmission Cover Bo lts . . . . .. .. . . . . ... .. .. . . . .. ..... . .... 35 to 42 Ib ft 48 to 57 Nm
(4. 8 to 5.7 kgm )
SPECIFICATIONS
Cou ntershaft Gear Clearance .. . .. .. .. . .. .. ..... . . .. . . 0.001 to 0.006 inch 0.025 to 0.152 mm
Mai nshaft End Travel . . . ...... . .... . . . . .. . ... . ... . . .. . .. ... . . . 0.001 inch 0.025 mm
Pinion Gea r Back lash . .. .. . .. . . .. . . ...... . . . , ., . . ..... . . . . . . . 0.005 inch 0.127 mm
Ring Gear Backlash . .... . ... . . ... . . . ... .. . . . ,. , . . . . . . 0.006 to 0.011 inch 0.152 to 0.279 mm
Shift Rail Detent Spring
Free Length . .. . . . .... . .. . . . . . . . . . ... .. . . .. . . ..... ... .. .. . . . . Optional Optional
OD .... ... . . .. . ... . ... ... .. . .. ...... .. .. . . ..... . ... . . ... . .. 0.390 inch 9.906 mm
Compress to 0.812 inch (20.6 mm) .. ... .. . . . . . . ... .. .. . . , .. . 28 to 45 Ib 124.6 to 200 .2 N
Outer Lever Sp ring
Length . .. . ... .. . . . ... . . . . . ...... .. .. . . . . , . . ...... . . . . . . . . . . 2.06 inch 52 .32 mm
ID . . . .... . ... .. .. .. .. .... . . , . . . . .. . . . .. , . .... . . . . . ... . . . .. . 0.651 inch 16.54 mm
Wire Diameter , ... . . . . .. ... .. . . . . , ... . . .. ...... . . . ..... , . . . 0.192 inch 4.88 mm
No. of Coil s . .. .... ... . ..... . . . .. . ........ . . . . . . . . .. ..... .... .. . . ... 5 5
Inner Lever Spring
Leng th . . .. .. . ..... . . .. .. . .... . . . . .... ..... . . .. .. . . . .. .. . . . . 1.81 inch 45 .97 mm
ID . . . . . .. . ... . . . .. .. .. . .... . , . . . . . . . . .. .. .. . . . . . .. ..... . .. . 0.708 inch 17.98 mm
Wire Diameter . . . .. . . . . . . .. . .. . , . . .. . . . . ........ .. . .... , . .. 0.135 inch 3.43 mm
6217-6
SERVICING THE TRANSAXLE ASSEMBLY

Final Drive Gear and STEP 4
Axle Housing Removal ..
STEP 1
Remove the gasket.
STEPS
Clean the complete transaxle assembly before you
do any service work .
STEP 2
631208
Remove the bolts from transaxle cover.
STEP 3
Remove the transaxle cover.

6217-7
Axle Housing Removal STEP 9
STEP 7
631334
Install two guide pins in transaxl e housing .
Before the final drive gear can be removed from the STEP 10
transaxle housing , the axle must be moved away
from the transaxle housing. Support the axle hous-
ing with a chain hoist.
IMPORTANT: Final drive gear removal. There are

two methods by which the final drive gears can be
removed from the transaxle housing.
1. Complete removal of the axle housing, fol-

lowing Steps 8 through 13.
2. Removal of the axle shafts from the axle

housing , follow Steps 15 through 18.
STEP 8
Remove the remaining axle housing bol ts and pul l
the axle housing from the t ransaxle housing.
STEP 11
Remove two axle hous ing bolts.
631340
Axle housing removed f rom t he transaxle housing .

6217-8
STEP 12 STEP 16
631340 Push the axle out of the housing until the inner
Remove the guide pins. bearing cone is loose.
STEP 13 STEP 17
Remove the final drive gear.
STEP 14
Support the other axle housing and remove the
axle housing and final drive gear. Follow step 2
through 13.
Axle Shaft Removal

STEP 15
Mark the axle housing , bearing cup and the bearing

cone before removal for correct side ident ification
of parts as assembly.
NOTE: If either the bearing cup or the bearing

cone is replaced, you must replace both bearing
cup and bearing cone.
Push the axle shaft out of the housing.
6217-9
STEP 19 STEP 22
Remove the other fin al drive gear and axle by fol- 631310
lowing Steps 6 through 18. Remove the gasket material f rom the brake hou s-
ing .
Differential Side Gear
and Centerwheel Removal STEP 23
STEP 20
631312
Remove the brake disc .

631344
Remove the brake cover bolts. STEP 24
STEP 21
631316
Remove the steel plate.

631304
Remove the brake cover.

6217-1 0
STEP 25 STEP 28
631318
Remove the other brake disc. Loosen the cap screws that fasten the actuator
assembly to the brake housing.
STEP 26
STEP 29
631428
Remove the dust cover from the actuator assem- 631434
bly. Remove the cap screws, flat washers and plates.
STEP 30
Loosen the lock nut. Remove the lock nut and ad- Remove the actuator assembly .
justing nut.
6217-11
STEP 31 STEP 34
Repeat steps 32 and 33 to remove the other tw o
brake discs and steel plates .
STEP 35
Remove the actuating disc.
STEP 32
631406
Remove the two ferry head bolts .
STEP 36
Remove the brake disc.
STEP 33
631414
Remove the brake housing and shims from the

transaxle housing .
Remove the steel plate .

6217-12
STEP 37 STEP 41
63 15 12
Mark the shims for assembly. Remove the ring gear assembly.
NOTE: The shims must be kept together for as- Mainshaft Removal
sembly.
STEP 42
STEP 38
Shift the transmission to NEUTRAL. Remove the

Remove the differential side gear assembly. bolts that hold the top front cover.
STEP 39 STEP 43
631 5 16
Remove the side gear shims. Remove the top front cover and shifter assembly.
STEP 40
Repeat steps 20 through 39 for re moval of the LH
brake housing and side gear.
6217-13
STEP 44 STEP 47
631524
Remove the gasket. Remove the brake disc.
STEP 45 STEP 48
Loosen the cap screws that fasten the parking Loosen and remove t he front cover, flat washers ,
brake to the front of the transaxle . and cap screws .
STEP 46 STEP 49
631522
Remove the parking brake assembly. Remove the front cover.

6217-1 4
STEP 50 STEP 53
Remove the gasket from the transaxle. Remove the rear cover.
STEP 51
6316 18 Before the mainshaft and gears can be removed ,

Remove the shims. the front bearing cup and cone must be moved .
Moving the beari ng wi II give you access to the snap
IMPORTANT: The shims must be kept together ring . You must lift the snap ring from the groove
for installation. before the mainshaft and gears can be removed .
STEP 52 STEP 55
two C-clamps on 4th gear. Pull the gear

Remove the bolts from the rear cover. evenly until the gear makes contact with the trans-
mission housing.
NOTE: As the gear is pulled against the housing,

the mainshaft will also move.
6217-15
STEP 56
.
With a soft hammer, push the mainshaft into the Remove the "e" clamps . Place the spacer tool be-
housing. tween the snap ring and the groove washer.
STEP 57 STEP 60
Move the groove washer against 3rd gear to make Place two large screwdrivers or prybars between
the snap ring visable . 4th gear and housing. This will take up the move-
ment in the gear cluster.
STEP 58
Lift the snap ring out of the groove. Move the snap
ring along the shaft until the snap ring makes con- Put a large rod through the rear opening in the
tact with 1st and 2nd sliding gear. housing . Push t he mainshaft out of the rear bear-
ing cone.
NOTE: Be careful when you push the mainshaft

to prevent damage to the rear bearing cone.
6217-16
STEP 62 STEP 65
Mainshaft and gears removed from the housing.

e mainshaft 2 to 3 inches (50.8 to 76.2 mm)
out of the housing . Countershaft Removal
STEP 66
Before you disassemble the countershaft assem-

Remove the spacer tool and prybars. bly, the clearance between 2nd and 3rd gear hubs
must be measured. Record the clearance for use
when the countershaft is assembled.
NOTE: Any new part/s that are installed must

have the hub thickness measured and compared
against the hub thickness of replaced part/so This
will help find the spacer thickness required to keep
the correct amount of clearance between gears
during assembly.
STEP 67
Pull the mainshaft from the housing and remove

the gears.
To measure the clearance, do not tilt the gears on

the shaft splines , use two screwdrivers to separate
the gears. Check the clearance with a feeler gauge.
6217-17
STEP 68 STEP 71
Put a prybar between the gear teeth and housi ng to Remove the front bearing .
stop rotation of shaft. Loosen the countershaft ad-
justing nut. STEP 72
STEP 69
Remove the spacer.
With a soft face hammer, push the countershaft

into the housing.
STEP 70
Pull the countershaft into the re ar housing and

remove the gears.
Remove the countershaft nut.

6217-18
STEP 74 STEP 77
Countershaft and gears removed from the hous- Remove the oil retainer.
ing.
STEP 78
STEP 75
Remove the bearing cup. Use a hammer and a 'mild

steel rod.
STEP 79
Remove th e snap ring.

Remove the snap ring.
NOTE: If the front bearing cup in Step 75 has a

flange on the outer surface there will not be a snap
ring.
6217-19
Remove the bottom countershaft rear bearing cup .

6217-20
" n
Counters h a ft Installa t 10
'-..
'-
"-
'\
/' ./
/' /"
/'
/'
/'
/'
(~(I~ 7"
/'
/'
/'
/'
'-.. /'
'--
0" SUNG"
/ ~~~~@~ /
2ND GEAR /
'-...(J.
/
til
~~@
'"
ONTBEARINGCONE
....____AOUST'NGNUT
3RDGEAR
<THG'"
/
I
SELECT SPACER T BEARING CUP
FRON
621 7-21
STEP 81 STEP 84
FLANGE
(@
/
ell
Install the snap ring for the mainshaft rear bearing
cup. ing cup.
NOTE: If the countershaft front bearing cup has a

flange on the outer surface 00 Not install the snap
ring.
STEP 85
FLANGE
I
r;
Install the rear countershaft bearing cup until the
outer ring makes contact with the housing.
IMPORTANT: The rear countershaft bearing must

be cooled before the bearing cup is installed. Install the countershaft fron t bearing cup.
NOTE: A new countershaft front bearing cup will

have a flange on the outer cup surface.
Install the mainshaft rear bearing cup .
IMPORTANT: The mainshaft rear bearing cup

must be installed before you install the counter- Install the countershaft through the rear opening in
shaft and gears. the housing.
6217 -22
STEP 87 STEP 90
Install the 1st gear on the countershaft with the hub I nstali the 3rd gear on the countershaft.
forward.
STEP 88
I nstall the gear spacer on the countershaft.

I nstal l the oil slinger gear on the 2nd gear hub. The
side of the slinger gear with oil grooves must go
toward 2nd gear.
Install 4th gear with hub forward.
I nstal l the 2nd gear on the countershaft with the oil

slinger gear toward 1st gear.
6217-23
STEP 93
Measure the shim spacer thickness and select the Heat the bearing in a bearing oven. Install the heat-
correct spacer which will give you 0.001 to 0.006 ed bearing on the countershaft.
inch (0 .0254 to 0.1624 mm) clearance between
gears, see Steps 66 and 67. NOTE: Do not heat the bearing beyond a temper-
ature of 250 0 F (120 0 C).
Remember:
A. When the thickness of new parts is more A CAUTION Always wear heat protectille
than the thickness of the parts you replace, . . glOll6s to . prellent burning your hands
subtract the difference in thickness from clear- when handling heated parts.
ance in Step 67. If there is less than 0.001 inch
(0 .025 mm), a thinner spacer must be used.
STEP 96
b. When the thickness of new parts is less
than the thickness of the parts you replace, add
the difference in the thickness to the clear-
ance in Step 67. If the amount of the two is
more than 0.006 inch (0.152 mm) a thicker
spacer must be used .
Install the countershaft adjusting nut. Tighten the

nut until bearing end travel is removed.
STEP 97
After the co rrect spacer has been selected, install

the spacer on the countershaft.
,.
Tighten the countershaft bearings to a rolling tor-
que of 4 to 12 Ib inch (0.45 to 1.4 Nm) (0.05 to 0.14
kgm).
6217-24
STEP 98
Use a s face hammer and tap both ends of the Use a hammer and punc h to push th e thin section
countershaft , this will help seat bearings , repeat of the adjusting nut into the slots on the coun ter-
Step 97 for rolling torque . shaft.
STEP 99
Check the clearance between 2nd and 3rd gear

hubs. Separate the two gears with two large screw-
drivers and check with a feeler gauge. The clear-
ance must be 0.001 to 0.006 inch (0.025 to 0.152
mm) . If the clearance is not correct, a different size
spacer must be used . Remove the bearing cone
and spacer. Repeat Step 95 through 98 until t he
clearance is correct.
6217-25
COUNTERSHAFT
62 17-26
Mainshaft Installation
OIL RETAINER
SNAP RING
/ / REAR BEARING CUP
@Ot?'l//"" ""'NG CON'
!JiJ~ MAINSHAFT
1ST AND 2ND SLIDING GEAR
3RD SLIDING GEAR
./'--"...... / PIN
./ ;H:UST WASHE: ....... ...... ....... ......

. / I ~ /0
I
SNAP RING
4TH GEAR BUSHING ...... ...... ...... / " '\
....... THRUST WASHER /
4TH SLIDING GEAR " .... ./ /
.... 3RD GEAR BUSHING /
~ / FRONT BEARING CUP - --

(lV ~ /
Va //
PIN SEAL
r(()!?Xl GASKET
3RD AND 4TH GEAR SYNCHRONIZER ~
/«0
SHIMS 0.005 , 0.007 AND 0.035 INCH
(0 .127, 0.179 AND 0.889 mm)
SEAL
~
HUB AND SLEEVE
Synchronizer Assembly
NOTE: On some models the 3rd gear bushing and the 4th gear bushing can
have internal splines instead of the bushing and pin.
6217 -27
STEP 101
Yo,.
Press the bearing off the mainshaft. Put Loctite 601 in the groove of the 4th gear bush-
ing . Install the pin in the groove. Start the main-
shaft into the front housing. Carefully install the
bushing and pin assembly on the mainshaft.
NOTE: Some models can have bushings with in -

ternal splines instead of the pin .
Measure a distance of 2.125 inches (54 mm) from

the front of the shaft and mark the shaft with a piece
of tape.
Install 4th gear on the mainshaft, with

grooves toward the front of the housing.
Put the front bearing cone on mainshaft until it

makes contact with the tape.
~ CAUTION Always wear heat protective

. . gloves to prevent burning your hands i' :.
Install the thrust washer on the mainshaft.
6217-28
Put the synchronizer sleeve inside of the hub. Put one blocker ring on the 4th gear hub .
STEP 108 STEP 111
nstall the three shifter plates in the synchronizer Measure the synchronizer sleeve hu b length, the
sleeve grooves. short side of the hub must go forward.
STEP 109 STEP 112
Install a spring on each side of the synchronizer to I nstall the synchronizer on the mainshaft.
hold the shifter plate in place.
IMPORTANT: The SHORT HUB on the synchro-
nizer sleeve MUST FACE FORWARD, as shown in
the drawing. (The outer hub can be installed in
either direction).
6217-29
STEP 113 STEP 116
. .."..
Install the thrust washer on the mainshaft. Install the 3rd gear with the blocker ring into the
synchronizer assembly.
STEP 117
~ \ . - '
Put Loctite 601 in the groove of the 3rd gear bush-

ing. Install the pin in the groove. Carefully in sta ll Install the groove washer with the flat side toward
the 3rd gear bushing and pin assemb ly on the 3rd gear.
mainshaft.
STEP 118
NOTE: Some models can have bushings with in-
ternal splines instead of the pin. \
STEP 115
Install snap r ng on the mainshaft. Do not put

the snap ring in the mainshaft groove.
.... .
Place the blocker ring on the third gear.
6217 -30
Install the 1st and 2nd sliding gear on the main- Use a soft face hammer to push t he mainshaft into
shaft. The small gear end must go to the rear. the rear bearing cone.
Install the rear bearing cone in the bearing cup. Move the gear cluster forward and install the snap
ring in the mainshaft groove.
STEP 121
Align and start the mainshaft into the rear bearing

cone.
6217-31
STEP 125 STEP 128
I/' _
With a soft face hammer carefully push the bearing

cup into housing until the cup makes contact with Install the front cover and tighten the 1/ 2 inch bolts
the bearing cone. to a torque of 80 to 96 1b ft (109 to 130 Nm ) (10.9 to
13.0 kgm).
Tighten the 3/8 inch front cover nuts to a torque of

35 to 42 Ib ft (48 to 57 Nm) (4.8 to 5.7 kgm).
STEP 129
Use a scraper and clean the front housing of all

foreign material.
STEP 127
631906
Use bearing driver (CAS 1625) on the mainshaft

and remove all movement between the gears.
STEP 130
Put a new front cover gasket on the housing.
Remove the front cover.

62 17-32
STEP 131
Tap the rear of the mainshaft with a soft face ham-

631626
mer and turn the shaft at the same time at least
Subtract three shims from the sh ims that you re- three turn s. Place a dial indicator on the face of the
moved in Step 51. Install the remaining shims in the rear bearing cone as shown. While checking lateral
front cover. movement , read the dia l indicator which will tell
you the amount of shims that must be added for the
STEP 132 correct end travel of 0.001 inch (0.025 mm) or as
close as possibl e.
I nstall front cover and tighten the 1/ 2 inch bolts to a

torque of 80 to 96 Ib ft (109 to 130 Nm) (10.9 to 13.0 Remove the front cover and add the correct amount
kgm) and the 3/ 8 inch nuts to a torque of 35 to 42 Ib of shims to get 0.000 to 0.001 inch (0 .000 to 0.025
ft (48 to 57 Nm) (4.8 to 5.7 kgm). mm) end travel. Shims are available in 0.005 , 0.007
and 0.035 inch (0.127,0.178 and 0.889 mm) sizes.
STEP 135
Install the front cover. Install the alignment tool

(CAS 1791) over the countershaft and into the front
cover. See Special Tools pag e fo r th e ali gn ment
tool.
6217-33
STEP 136 STEP 139
6310 10 Apply #2 permate x to the 0.0. of the bearing oil

Tighten the 1/2 inch bolts to a torque of 80 to 961b ft retainer.
(109 to 130 Nm) (10 .9 to 13.0 kgm) and the 3/8 inch
nuts to a torque of 35 to 421b ft (48 to 57 Nm) (4.8 to
5.7 kgm) and remove the alignment tool.
STEP 137
TAP REAR
Tap the rear of the mainshaft with a soft face ham-

mer and rotate the shaft several turns while tapp-
ing the shaft.
STEP 138
A lign the oil retainer slots with the oil holes in the
housing. Press cup into housing until it is flu sh with
the housing.
IMPORTANT: The slots in the retainer must align

with the housing oil holes for the bearing to receive
Check the shaft end travel again with a dial indica- the correct amount of oil.
tor as shown in Step 133. End travel must be 0.000
to 0.001 inch (0.000 to 0.025 mm). If not, add o r
subtract shims, see Step 134 through Step 138 to
get the correct end travel.
6217-34
STEP 141 STEP 142
Install the brake disc.
STEP 143
631522
Install the parking brake.
STEP 144
Apply Number 2 permatex of the new mainshaft

seal and the countershaft seal. Install the seals (lip
inward) see inset, in the front cover. Apply an inch
pound torque wrench to the nut on the yoke to
check the rolling torque. The rolling torque must
not be more than 5 inch pound (0 .57 Nm) (0.6 kgm)
for correct bearing preload , including seal drag . If
more than 5 inch pound (0.57 Nm) (0.6 kgm) a shim
may have to be removed, see Step 134 through
Step 138.
NOTE: An adapter can be made from a used Tighten the cap screws to fasten the parking brake
yoke, see inset, by brazing a nut to a used yoke. to the front of the transax le.
6217-35
6217-36
Shifter Assembly
KNOB
----a DUST COVER
SNAP RING . /
~ lEVER SEAT
~/
HAND LEVER
~~
JAM NUT
RETAONING SCREW \
~t?~
GASKET
/
INTERLOCK PLUG DETENT BAll
!/
SPRING _ _ _ _ _ _
.. ~
1
o 6)
~ ~
~
3RD AND 4TH SHIFTER RAil
___ SPIRal PIN
~~ 0 IJ ~ 'RD AND OTH SHIFTER FORK
1ST AND 2ND SHIFTER RAil - ~ ./ /
1ST AND 2ND SHIFTER FORK - - - -

621 7-37
STEP 145
Put the shifter assembly on a suitable work sur- Turn the shifter cover over.
fac e.
STEP 146
Remove the roll pins that hold the forks to the

Remove the dust cover and the seat retaining snap shifter rails .
ring.
STEP~1~
5~O ______~~
Push the rail through 1st and 2nd fork and remove
Remove the gear shift hand lever. the fo rk .
6217-38
STEP 151 STEP 154
Cover the opening in the shift cover when remov- Inspect the detent springs. Springs must have the
ing the rails to prevent injury from the moving de- following specifications .
tent balls. Remove the detent ball and detent
spring. Free length ..... ... .................. Optional
0 .0 ......... Work in 0.390 inch (9.906 mm) bore
Compress to 0.812" (20.625 mm) ..... 28 to 45 Ib
Wire Diameter ........ .. .. 0.072 inch (1.829 mm)
STEP 155
Remove the shift rail interlock lock plug .
STEP 153
Install the detent spring in the 1st and 2nd housing .
bore.
STEP 156
Repeat Step 150 through Step 153 to remove the

3rd and 4th shifter for k and rail.
I nstall the steel detent ball in the cover on top of the

spring.
6217-39
STEP 160
Install a pilot sleeve to compress the detent spring Install the fork retaining spi rol pi n.
and ball. See page 4 for sleeve specifications.
STEP 161
Install the shift rail interlock lock plug .

Install the 1st and 2nd shift rail part way into the
cover.
STEP 159
Install the detent spring and detent ball for the 3rd
and 4th shift rai I.
Install the 1st and 2nd shift fork (small fork) on the
shift rail.
621 7 -40
STEP 163 1ST AND 2ND SHIFTER FORK
1
3RD AND 4TH SHIFTER FORK
Shift rails and forks installed in shifter.
Using the pilot sleeve , install the 3rd and 4th shift
rail and fo rk.
INTERLOCK PLUG
STEP 164 .-,

Install the shift lever into the cover. Make sure the
lever engages in the shift forks.
Install the fork retaining spirol pin .
STEP 165
I nstall the gear sh ift lever seat.

62 17-41
STEP 168
Install the lever seat retaining ring . Install a new shift cover gas ket.
STEP 172
Install the shift lever dust cover. Install the shift cover assembly. make sure the
forks engage into the sliding gear and the syn -
chronizer assemb ly.
I . -"
Clean the cover area of all foreign material.
~
I nstall the cover bolts and tighten to a torque of 35

to 42 Ib ft (48 to 57 Nm) (4.8 to 5.7 kgm) .
6217-42
6217-43
Disassembly of Centerwheel STEP 177

STEP 174
Remove the bolts from the ring gear.
Remove the pinion gear groove pins . STEP 178
Lift the ring gear off the centerwheel.
Remove i ion ns and the gears. Replace the

gears if worn or damaged.
Clean the threaded holes of the ring gears (3/ 8"

NF) .
Press the cross shaft out of the centerwheel. NOTE: You must replace all the ring gear bolts
with new bolts if the old bolts were removed.
IMPORTANT: Pinion pins and gears must be re-
moved from centerwheel before you press cross
shaft from the centerwheel.
6217-44
Assembling Differential Centerwheel and Side Gears
BEARING CONE
CROSS SHAFT
~
, ... ... - ......
... ...
....
....
..
.... ,
\,
,"
. ... .. , ' BOLT 3/8 X 7/8 INCH
,
I
/ADE8
\.
.... .... ~~
..... . - . ". ,
".
~ HARDENED WASHER
~'») '..........
@ CENTERWHEEL
~ ........... PINION GEAR
\ ~GROOVEPIN
~ ~ - - GEAR PIN
~ RING GEAR
~ \ RH "DE GEAR
r BUSHING
BEARING CONE
6217-45
STEP 182
Apply Loetite 271 to the ring gear threaded holes. Install the ring gear on the eenterwheel.
STEP 183
I nstall new bolts and new hardened washers.

gear.
6217 -46
STEP 184
Press the cross shaft into the centerwheel until the

smooth area between the splines is visable in the
pinion gear mounting holes.
STEP 186
Install the pinion gears and pins.
NOTE: Make sure hole in the pin aligns with the

For maximum Loctite strength the following tor-
centerwheel hole.
que sequence must be followed .
1. Tighten bolts 1 and 2 by hand. Then

tighten bolts 1 and 2, 1/ 2 turn at a time until a
torque of 30 Ib ft (41 Nm) (4.1 kgm) is reached.
2. Tighten each bolt (3 through 20) to a tor-

que of 40 Ib ft (41 Nm) (5.4 kgm) in the shown
sequence .
3. Tighten the bolts 1 through 20 to a torque

of 40 Ib ft (54 Nm) (5.4 kgm) in the shown
sequence.
4. Then loosen each bolt 1/ 4 turn (one at

time) in the sequence shown . Tighten to a
torque of 50 to 55 Ib ft (68 to 75 Nm) (6.8 to 7.5 Install the pinion retaining groove pins to a depth of
kgm). 0.12 inch (3 .05 mm) below the c enterwheel sur-
face.
NOTE: Each bolt must be loosened and torqued
before loosening the next bolt.
6217-47
STEP 188
Use a hammer and center punch to secure the Using CAS 1624 Bushing Driver, pre ss the bushing
groove pins. This will prevent the groove pins from in until the outer edge of the bushing driver makes
moving. contact with the surface of the side gear.
STEP 192
NOTE: Some of the Loader/ Backhoe side gears Heat the bearing and install on the RH side gear
have an identification mark cut in the spur gear. until bearing makes contact with the spur gear.
Replacement parts may not have an identification Repeat this step for the LH side gear.
mark cut in the side gear.
NOTE: Do not heat the bearing beyond a temper-
STEP 190 ature of 250 0 F (120 0 C).
h CAUTION Always wear heat protective

Place a new bushing in RH side gear.

6217-48
Remove the bearing cup from the brake housing. Place the side gear on the centerwheel assembly .
NOTE: Never replace just one part of a bearing. If

one of the parts is bad, replace both the bearing
cup and the bearing cone.
NOTE: Install a thicker thrust washer if no back-

Install the bearing cup into the brake housing until lash is present.
the bearing cup makes contact with the bottom of
the bore. Use a soft face hammer.
Setting Differential Pinion

to Side Gear Backlash
Put dial indicator on one of the pinion gear teeth.

Hold the side gear in place and rotate the pinion
gear in each direction checking back lash. Check
the backlash in several sections of side gear.
IMPORTANT: The backlash must be 0.005 inch

(0.127 mm) minimum at the tightest pinion gear
Turn the LH side gear over and place a thrust
and no more than 0.015 inch (0.381 mm ) at the
washer 'I n side gear.
loosest pinion gear.
6217-49
STEP 199 STEP 202
Install the RH side gear and check the pinion gear

A 0.005 inch (0.127 mm) change in thrust washer to make sure there is backlash present.
thickness will change backlash approximately
0.0035 inch (0.089 mm).
NOTE: Thrust washers are available in sizes from

0.079 to 0.109 inch (1.767 to 2.769 mm).
Put a dial indicator on one of the pinion gear teeth.

Hold the side gear in place and rotate the pinion
gear in both directions checking back lash . Check
the backlash in several sections of the side gear.
IMPORTANT: Backlash must be 0.005 inch (0.127

Remove the LH side gear and thrust washers . mm) minimum at the tightest pinion gear and no
more than 0.015 inch (0.381 mm) at the loosest
NOTE: The thrust washers must be kept with the pinion gear.
LH side gear for installation.
A 0.005 inch (0.127 mm) change in thrust washer

thickness will change backlash approximately 0.035
Place a thrust washer on cross shaft . inch (0.089 mm) .
NOTE: The thrust washers must be kept with the

RH side gear for installation.
6217-50
Differential Centerwheel Installation
./
."/
./
/'
./
./
/'
RING GEAR AND LH SIDE G EA R

CENTERWHEEL ASSEMBLY
"-.... THRUST WASHERS
THRUST WASHERS
'" "D' a'A' ~(Ql
(
,
'- ./
./
./
'G ~~)
"" SHIMS
O-RING
BRAKE HOUSING
6217-51
STEP 208
Install the centerwheel assembly in the transaxle

housing . Install the guide pins.
STEP 209
Install the RH thrust washer.

Remove the seals from the brake housing.
STEP 210
631514
Install the RH side gear on the cross shaft.
Remove the O-ring .

6217-52
STEP 211 STEP 214
Install the other Ferry head bolt and long bolt with
Install t he original shims that were removed in step washers . Tighten the bolts to 80 to 96 pound-feet
37. (109 to 130 Nm , 10.9 to 13 kg m).
STEP 212 STEP 215

Repeat steps 208 through 214 to install the other
brake housing and shims.
STEP 216
631726
Install the brake housing without the O-ring and

seals .
Install the brake disc tool shown on page 4.
STEP 217
631730
Instal l one Ferry head bolt and one long bolt. Use 631a 14
approximately one inch (25 mm) of washers under Use a torque w re nch on the brake disc tool and
the head of long bolt. Remove the guide pins. measure t he rolling torque required to turn one
differential side gear with the pinion gear locked
against rotation. The rolling torque must be 4 to 8
pound-feet (5t011 Nm , O.5t01.1 kg / m) .
6217-53
STEP 218 STEP 221
Add or subtract shims as necessary between the Moving some bearing carrier shims from the right
brake housing and transaxle housing to get the side to the left side will increase backlash and from
correct rolling torque. the left side to the right side will decrease back-
lash .
Adjusting Ring Gear to
Pinion Gear Backlash NOTE: You must not change the total number of
shims.
STEP 219
STEP 222
RING GEAR ALIGN MARKS
Align the identification mark on the pinion gear

tooth to the identification marks on the ring gear
teeth. These three teeth have identification marks
to indicate the position of minimum backlash.
These teeth must mesh together when setting
backlash.
Remove the brake housing .
STEP 220
STEP 223
Put a dial indicator on the ring gear teeth. With the

pinion gear locked against rotat ion check the gear
backlash. The backlash must be 0.006 to 0.011 inch Install a new O-ring on the brake housing.
(0.52 to 0.279 mm).
6217-54
STEP 224
Install new seals in the brake housing . Install a steel plate. Align the notch in the steel
plate with the groove in the brake housing.
STEP 225
STEP 228
Install the brake housing.

Install a brake disc.
STEP 226
STEP 229
Repeat steps 227 and 228 unt il three steel plates
and three brake discs are installed.
STEP 230
Install the ferry head bolts. Tighten the ferry head

bolts to 80 to 96 pound-feet (109 to 130 Nm, 10.9 to
13 kgm).
Install the actuating disc.

6217-55
STEP 231
Apply RTV 106 gasket material on the actuator Install the adjusting nut and lock nut. Do not
assembly . tighten at this time.
STEP 232 STEP 235
Install the actuator assembly. I nstall a brake disc.
STEP 233
63 1316
Install the plates, flat washers , and cap screws to Install a steel plate make sure that the notch in the
fasten the actuator assembly. steel plate is aligned with the groove in the hous-
ing.
6217-56
STEP 240
••
Install the last brake disc. Remove the differential lock housing .
STEP 238 STEP 241
Remove the pin from the brake cover. Clean the old gasket material from the brake cover.
STEP 239 STEP 242
631642
~
631818
Replace the O-rings on both ends of the pin . Apply RTV 106 gasket material to the brake
housing .
6217-57
STEP 243 STEP 246
631828 Apply RTV 106 gasket masterial on the brake cover.

Install the pin . Make sure the steel plates are in
alignment and the pin is pushed all the way into the STEP 247
hole in the brake housing.
STEP 244
631840
Align the collar in the differential lock housing with

the shaft. Install the differential lock cover.
STEP 248
Install the brake cover.
STEP 245
631842
Install and tighten the cap screws to 17 to 21

pound-feet (23 to 29 Nm , 2.3 to 2.9 kgm) .
STEP 249
Install and tighten the cap screws to 80 to 96 Install the othe r brake housing, brake discs, and
pound-feet (109 to 130 Nm , 10.9 to 13 kgm). brake cover.
STEP 250
See Section 7125 to adjust the brakes .
6217-58
861738
6217-59
Axle Shaft and H ouslng

. Installation
7""
W"H\
~~ ~~\
SHAFT NUT
INNER BEARING CONE
INNER BEARING CUP
INNER OIL SEA L
HOU""G O-","G \ ~
/ ~ ,
/ " / ,
......
'" , ,, ______ / / / /
" ~
A ~
AXLE HOUSING ()}/./
AXLE SHAFT
6217-60
STEP 251 STEP 254
Stand the axle shaft on end and put the protective

sleeve CAS 1194 on the axle shaft.
seal.
STEP 252
STEP 255
Press a new seal (lip up) over sleeve and on the axle
shaft.
Use rubber bands to hold the seal drivers in posi-
NOTE: Apply #2 lithium grease to seal lip. tion.
STEP 253
Remove the protective sleeve. Put the heated bear-

ing on the axle shaft, the bearing must make con- Install the axle housing inner bearing cup until it is
tact with the shaft shoulder. seated against the housing shoulder .
NOTE: Do not heat bearing beyond a tempera-

ture of 250 0 F (120 0 C).
h CAUTION Always wear heat protective

6217-61
STEP 260
Put the inner oil seal in the axle housing . Insta the axle housing outer bearing cup u
bearing is seated against the housing shoulder.
STEP 258
Push the oil seal into position using CAS 1465-2

Axle housing ready for installation on the transaxle
STEP 259 housing .
STEP 262
' Install a new O-ring in the ~xle housing groove.

Lubricate the O-ring with Case FDL oil.
Install a guide stud in the transaxle housing.

621 7-62
STEP 263
Put the axle housing on the guide stud and slide

into place being careful not to damage the O-ring. NOTE: After you complete Step 269, remove the
seal drivers. If the seal is not flush with the axle
STEP 264 housing, use a screwdriver to work the seal the rest
of the way into the axle housing until it is flush .
I nstall the axle mount ing bolts and tighten the bolts
to a torque of 220 to 264 Ib ft (298 to 358 Nm) (29.8
to 35.8 kgm) .
Install the final drive gear in the transaxle housing. Put the final drive gear on axle shaft and in stall flat
Final drive gear must be installed with the correct washer and nut.
side toward the nut. See th e marks on the final drive
gear.
6217-63
Tighten the nut to seat the bearing cups and bear- I nstall the rear cover and bolts. Tighten the bolts to
ing cones. Rotate the axle shaft several turns, then a torque of 35 to 42 Ib ft (48 to 57 Nm) (4.8 to 5.7
tighten the nut again until it is seated. After the nut kgm).
is seated, tighten one more notch (1 / 16 turn) and
install the cotter pin. STEP 274
STEP 270
Repeat Steps 251 through 269 to install the other
axle housing and shaft.
Install a new top cover gasket.
STEP 275
..
.Clean the rear of transaxle housing and the cover
of all foreign material.
I nstall the top cover and bolts to a torq ue of 35 to 42

Ib ft (48 to 57 Nm (4.8 to 5.7 kgm).
STEP 276
Fill the transaxle housing with the correct oil. See
Maintenance and Lubrication in this service man-
Apply RTV 108 adhesive to the housing. ual.
6217-64
861737
6217-65
Servicing the Differential STEP 280

Lock Assembly
STEP 277
Remove the roll pin that holds the actuating lever to

the shaft.
Remove the bolts.
STEP 278
•
Remove the shaft from the differential cover.
STEP 282
Remove the differential lock assembly from the

SEAL
brake housing .
Remove the seal from the differential cover.
Remove the engaging collar and the lever fingers.

6217-66
6217-67
STEP
Put a new bushing in the cover. Start the shaft into cover. Install the spring on the
shaft.
Inner lever spring specifications:

Length ........ . ..... . . 1.81 inch (45.97 mm)
ID . ........ . ........ . 0.708 inch (17.98 mm)
Wire Diameter . . ..... . 0.135 inch (3.43 inch)
Number of Coils . ........ ..... . ... . ... 5-1 / 2
STEP 287
--~--~~------------------~
Press the bushing into the cover:
STEP 285
,
OIL SEAL
Install the actuating lever on the shaft. Hold the
lever in place with a new roll pin.
STEP 288_ .......",---,--=-
Install a new seal in the cover.
Install the lever fingers in the actuating lever.

6217-68
STEP 289 STEP 291
I nstall the collar in differential cover. The collar

must engage with the lever fingers. Install th e differential lock on the RH brake hous-
ing. Engage th e act uating collar splines with the
STEP 290 differential cross shaft spl ines.
STEP 292
Apply RTV 106 gasket material on the orake cover.
Install th e cover bolts . Tighten the bo lts to a torque

of 17 to 21 Ib ft (23 to 29 Nm ) (2.3 to 2.9 kgm).
6229
WHEELS AND TIRES
TABLE OF CONTENTS
Wheel Bolts and Nuts ................ ... 6229-2 Tire Pressure .. . . .... ... ... ... .. . . ... .. 6229-2
Torque Specification . ..... .. .. ... . ... 6229-2 Front Tires . .... ... .... .. ...... .. .... 6229-2
Genera l Informat ion ......... . ... .. ... 6229-2 Rear Tires . .... ......... . .... ........ 6229-2
J I Case
A Tenneco Company
s Bur 8-67341
6229-2
WHEEL BOLTS AND NUTS

Torque Specification
Front wheel , two wheel drive ... ... .. ..... . ... ... .. . ......... . ... 115 to 130 pound-feet (156 to 178 Nm
Front whee l, four wheel drive .... . .. . ........ . .. ....... . ..... . .. 200 to 240 pound-feet (270 to 325 Nm
Rear wheel
All early production wheels - grade 8 bolts with a head size of 1 inch ... . . . . . .... 150 to 170 pound-feE
(203 to 230 Nm
All early production whee ls and the new 0140062 wheels - grade 5 bolts with
a head size of 7/ 8 inch . .. .... . . ...... . ..... . .. . ... . .. . .... .. 150 to 170 pound-feet (203 to 230 Nm
0140062 whee ls - grade 8 bolts with a head size of 1 inch .. . . ... . .. . .. . ... . . ... . 220 to 240 pound-feE
(298 to 325 Nm
GRA~E 5 I GRADE 8 I
BOL~ BOLT--±....
( i 2 7181NCH ~1INCH
~
t I
General Information
Tighten the wheel bolts on a new machine or whenever a wheel has been rem oved and installed after ever:
two hours of operation until the wheel bolts stay tight.
TIRE PRESSURE
Front Tires
11L x 16, 10 PR, F3 48 psi (33 1 kPa
12 x 16.5, 6 PR , Lug 45 psi (310 kPa
12 x 16.5, 8 PR , Lug 60 psi (41 4 kPa
Rear Tires
16.9 x 24 , 10 PR , R4 28 psi (193 kPa
17.5L x 24, 8 PR, R4 22 psi (152 kPa
17.5L x 24, 10 PR, R4 . . . . . .. ... .. .... , .. . ......... . . ............. . .............. . ... . 28 psi (193 kPa
7106
BRAKES, BRAKE PEDALS TO TRANSAXLE
TABLE OF CONTENTS
Specifications . .. ..... .. ..... . .......... 7106-2 Parking Brake Adjustment .... .. . . . . .... 7106-6
Brakes . . . ... . .......... ... .. ... ... .. ... 7106-2 Illustration of Parking Brake Cable
Instal lation .. .. .. .. . ... ....... . ..... 7106-7
Master Cylinder Fluid Level .... .... . .. 7106- 2
Illustration of Parking Brake .... . . .... 7106-8
Check the Warning Lamp for the
Master Cylinder ... .............. . .. 7106-2 Removing Air From the Brake System ... 7106-9
Brake Pedal Adjustment . .. . .... ...... . . 7106-3 Illustration of the Brake Hydraulic
I nstaliation .. .. ... .. ... . . . . .. . .. .. ... 7106-10
Checking Brake Pedal Height . . . ...... 7106-3
Master Cylinder .. .. . . . . .. .. . .... . .... . 7106-11
Brake Pedal Height Adjustment .... . .. 7106-3
Removal ......... .. . . .. . . . .. ... . .. .. 7106-11
Illustration of Brake Pedal Installation . . 7106-4
Installation .. . . ...... .. . .. ... . . . ..... 7106-13
Brake Adjustment ... . .. . . .. . .. . .... . .. . 7106-5
Illustration of Master Cylinder . . . . .. .. 7106-15
General Information .... .... ......... . 7106-5
Disassembly ...... . .... . ... . . . . .. .. . 7106-16
Checking the Brake Adjustment ... . .. . 7106-5
Inspection ... . . .... . .. .. ...... .... . . 7106-16
Adjustment Procedure .... .. .. . ..... .. 7106-5
Assembly ... .. .... .. ... ... . . ..... ... 7106-16
A Tenneco Company
7106-2
SPECIFICATIONS
Type of oil Case T CH Fluid
Capacity
Reservoir .. . ..... . . . • . . .. .. ... . . . ........... . . ... . . .. . . . .... . . .. .. ...... . ... 16 f lu id ounces (41 ml)
System . ....... . . . .... . .... . .. ... ...... . .. ..... . .. .. . ........ • ..... . . .. .. ... 32 fl ui d ou nces (83 ml)
Master Cylinder
Girling part number . . . . ... . . .... . .... ..... ........... . . ... . ... . .. . ... . . .. . . . . ... . ... . . .. A73067171
Case part number 0136837
Brake pedal travel
Releas ed pos iti on ... .. . . . . . . . . ... . .. . .... . .. . .. . .......... . .. . . .. .. ..... .. .... . 7-1 / 4 inc h (185 mm)
Applied position ... . .... . ... . . ... .... . .. . . . .. . .. . .. .. .... . . . .... . . . ... . . . . . .. ... . 3-3/ 4 inch (95 mm )
BRAKES
Master Cylinder Reservoir Checking the Warning Lamp for
Fluid Level the Master Cylinder Reservoir
Check the fluid level of the master cy li nder With th e eng ine stopped and the key switch in
reservo ir every 250 hours of operat ion. In addition th e ON pos iti on, ope n th e access cover and push
to the 250 hour c heck, there is a warning lamp fo r dow n th e plu nge r on th e cap on the mas ter cylin-
low fluid leve l in th e master cy lin derreservoir. If t he der reservoir. If t he wa rn ing lamp does not ill umi-
warning lamp illuminates , add Case TC H fluid to nate, rep lace the warnin g lamp bulb .
raise the fluid leve l to the fu ll mark.
7106-3
BRAKE PEDAL ADJUSTMENT

Checking Brake Pedal Height
I
I
I
I
I
,,
I
UPPER STOP
,, \----ADJUSTING
BOLT
, BRAKE PEDAL
I IN RELEASED
I POSITION
\ BRAKE PEDAL!
\,"'-
______ L_O_C~ _
__!_
BRAKE PEDAL
IN APPLIED
POSITION
7-1/4
(185 mm)
LHES
3-3/4 INCHES
(95 mm)
METAL FLOOR PLATE

870232
STEP 1 Brake Pedal Height Adjustment

Remove the rubber pads from the brake pedals .
STEP 1
STEP 2 Loosen the lock nuts on the upper stop adjusting
Release the brake pedal lock. bolt.
STEP 3 STEP 2
Remove the rubber mat from the floor plate under Turn the upper stop adjusting bo lt clockwise or
the brake pedals. counterclockwi se as required until the pedal is 7-
1/ 4 inches (185 mm ) above the metal floor plate.
STEP 4
Measure the distance from the brake pedals to the STEP 3
floor plate. The brake pedals must be 7-1/4 inches Tighten the lock nuts on the upper stop adjusting
(185 mm) from the floor plate. bolt.
STEP 4
Repeat steps 1 through 3 for the other brake pedal.
7106-4
UPPER
STOP BOLT
LH
BRAKE
PEDAL
RH
BRAKE
PEDAL 870119
Brake Pedal Installation

7106-5
BRAKE ADJUSTMENT
Remove the cover from the brak e cylinder on the
The brakes can be adjusted at any time for the transaxle.
comfort of the operator. The brakes MUST be ad-
justed when the top of either brake pedal, pushed STEPS
down , is 3-3/ 4 (95 mm) or less from the metal floor Loosen the lock nut on th e brak e cylind er.
plate.
Check the Brake Adjustment

STEP 1
Remove the rubber pads from the brake pedals.
STEP 2
Release the brake lock .
STEP 3
Remove the rubber mat from the floor plate under
the brake pedals.
STEP 4
Using a brake force of, 75 pounds (34 kg) push
down the right brake pedal. Measure the distance
from the brake pedal to the metal floor plate. See
the illustration on page 7106-3. The brake pedal STEP9
must stop moving 3-3/ 4 inch (95 mm) from the met- Turn the right rear wheel in a forward direction and
al floor plate . If the measurement is less than 3-3/ 4 tighten the adjusting nut until th e wheel becomes
inch (95 mm) the brake must be adjusted . See Ad- difficult to turn .
justment Procedure below.
STEP 10
STEP S After step 9 has been compl eted , loosen the ad-
Repeat step 4 for the left brake pedal. justing nut two complete turns counterclockwise .
Adjustment Procedure STEP 11

Prevent the adjusting nut from turning and tighten
STEP 1 the lock nut.
It is recommended that the brakes be adjusted
when the brakes are cold. STEP 12
Install the cover on the brake cy linder.
STEP 2
Park the machine on a level surface and lower the STEP 13
loader bucket to the floor. Repeat steps 7 through 12 for the other wheel.
STEP 3 STEP 14
Make sure the backhoe is in the transport position. Remove the supports from the rear of the machine.
STEP 4 STEP1S
Move the transmission control lever to the NEUTRAL Engage the bra ke pedal lock.
position.
STEP 16
STEPS Test the brakes. The machine must stop in a
Raise the rear of the machine so the rear tires can straight line when the brakes are applied . If the
be rotated. Install acceptable supports to hold the machine does not stop in a straight line wh en the
machine in place . brakes are applied , see Section 7125 and repair the
brakes as requi red.
STEP 6
Clean both brake actuators and the area around STEP 17
the brake actuato rs. Install the rubber pads on the brake pedals and
install the floormat.
7106-6
PARKING BRAKE ADJUSTMENT

Th e parking brake must prevent the machine STEP 3
from moving forward with the transmission in third Check the adjustment by trying to move the ma-
gear and the engine running at 1500 rpm (r/ min) . chine with the parking brake applied .
To adjust the parking brake do the following : STEP 4

Repeat steps 2 and 3 until the parking brake is
STEP 1 adjusted correctly.
Release the parking brake.
STEPS
STEP 2 If the parking brake will not prevent the machine
Turn the knob on the parking brake lever several from moving, the problem can be in the cable or
turns to sho rten the cable. parking brake mechanism . Repair the cable or the
parking brake mechanism as required .
7106-7
/--
,
' \
f "
"
~
<!>
I
\
\
\
\
I \
I \
I \
I \
\
I
I \
I \
I \
I \
I \
\
I \
I \
I
\
\
"
\.
"
"- "-
"-
"-
"-
" \.
"\ \
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I
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I
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~ //~
~~
68720 12
Parking Brak e C able Installation

7106-8
1 Transfer Case 5 Ferry Head Screw 9 Housing 12. Hair Pin

2: Transaxle 6: Brake Shoe 10· Bracket . 13. Mount
3. Disc 7 Spring 11: Clevis Pin 14. Actuator
4. Spacer 8: Cap Screw
Parking Brake
7106-9
REMOVING AIR FROM THE BRAKE SYSTEM

If a brake line was disconnected for any rea- STEP 4
son , it is necessary to remove any air that entered When the brake pedal touches the floor plate, hold
the brake system. the brake pedal in place and have the other person
tighten the air removal screw.
STEP 1
Two persons are required, one to actuate the mas- STEPS
ter cylinder and the other to open and close the air Repeat steps 2, 3, and 4 until the re are no bubbles
removal screw in the brake cylinder. in the fluid com ing from the brake cylinder.
STEP 2 STEP 6
Move the brake pedal down and up several times to Fill th e master cylinder reservoir with Case TCH
increase pressure in the brake system . Fluid .
STEP 3
When the brake pedal feels "hard" , continue to
push against the pedal and have the other person
open the air removal screw at the brake cylinder.
7106-11
MASTER CYLINDER
Removal STEP 7
STEP 1
STEP 2
Apply the parking brake .
STEP 3
629620
Disconnect the tube for the ether injection system

from the intake manifold.
STEP 8
866552
Rem ove the p in that hold s the strut in place and
lower the strut onto the lift cy linder.
STEP 4
Raise the loader frame until the strut is against th e
STEPS
629624
Disconnect the wire connecto r for the ether injec-

tion system from the eng i ne tem peratu re sw itch on
the intak e manifold .
STEP 9
Find the wire connector for the eth er injection sys-
tem to the wiring harness. Disconnect the wire
connector for the eth er inject ion from the wiring
harn ess .
In sta ll the pin in th e strut.
STEP 6
Stop the eng ine.
7106-12
STEP 10 STEP 13
629636
Fo r machines without turbocharger, disconnect Loosen and remove the bolts, flat washers , lock
the air cleaner hose from the intake manifold . Put a washers, and nuts that fasten the air cleaner
cover over the opening in the in take manifold. mounting bracket to the frame .
STEP 11 STEP 14
For machines with a turbocharger, disconnect the Remove the air cleaner and mounting bracket from
air cleaner hose from the turbocharger. Put a cover the machine.
over the opening in the turbocharger .
STEP 15
STEP 12 Remove any dirt from the master cylinder and the
area around the master cylinder.
STEP 16
Remove the cotter pin and clevis pin that fasten the
push rod to the brake pedal.
STEP 17
Disconnect the tube for the master cylinder reser-
voir from the master cylinder.
STEP 18
Drain the f luid from the master cyl inder reservoir.
STEP 19
Disconnect the tubes from the master cylinder.
If the machine is equipped with an air condit ioner,
loosen and remove the bolt, lock washer, clamp on STEP 20
the air conditioner hose, and nut that fasten the air Loosen and remove the nuts, lock washers , and
cleaner mounting bracket to the frame. bolts that fasten the master cylinder to the frame.
STEP 21
Remove the master cy li nder from the frame .
STEP 22
Install caps on the tubes for the master cylinder.
7106-1 3
Installation
STEP 1
If a new master cylinder is being installed, fill the
master cylinder with clean Case TCH fluid.
STEP 2
Hold the master cylinder in alignment with the
holes in the frame and install the bolts, lock wash-
ers, and nuts that fasten the master cylinder to the
frame .
STEP 3
Connect the tubes to the master cylinder.
STEP 4 629636
Install the cotter pin and clevis pin that fastens the I nstall the bolts, lock washers, flat washers , and
yoke on the master cylinder to the brake pedal. See nuts that fasten the air cleaner mo unt ing bracket to
step 20 on page 7106-17 to adj ust the master cylin- the frame .
der.
STEP 11
STEP 5
Fill the reservoir with Case TCH fluid until the fluid
level is at the full mark.
STEP 6
See page 7106-9 and remove the air from the brake
syste m.
STEP 7
Check for leakage at the master cylinder.
STEP 8
tion on the machine. 629622
Connect the air cleaner hose to the intake manifold

STEP9 or turbocharger.
STEP 12
tem to the wiring harness. Connect the wire con-
nector for the ether injection system to the wiring
harness.

install the bolt, lock washer, clamp on the air con-
ditioner hose, and the nut that fastens the air
cleaner mounting bracket to the frame .
7106-14
STEP 13 STEP 14
629624 629620
Connect the wire connector for the ether injection Connect the tube for the ether injection system to
system to the engine temperature switch on the the intake manifold.
intake manifold .
STEP 15
Lower the hood.
7106-15
@)_. FLOW VALVE ADAPTER

~.
0+--'- GASKET
~I_' FLOW VALVE
~-.--
BALL
BODY
PISTON
SEAL
PUSH
ROD
SNAP WASHER
RING
BOOT
870122
Master Cylinder
7106-16
Disassembly STEP 18
Remove the spring from the spring seat.
STEP 1
Clean the outside of the master cylinder. STEP 19
Remove the check valve seat from the check valve
STEP 2 piston .
Fasten the body of the master cylinder in the vise.
STEP 20
STEP 3 Remove the wave spring from the check valve pis-
Remove the flow valve adapter from the master ton .
cylinder.
STEP 21
STEP 4 Remove the check va lve seal from the check valve
Remove the flow valve from the master cylinder. piston .
STEPS Inspection
Remove the ball from the master cylinder.
STEP 1
STEP 6 Inspect the bores in the body for scoring , pitting , or
Remove the gasket from the flow valve adapter. other damage. If the bores in the body are dam-
aged a new master cylinder must be used.
STEP 7
Remove the flow valve seal from the flow valve. STEP 2
Check the tab in the spring seat. Push the tab down
STEP 8 a small amount so that the tab will engage the end
Loosen the lock nut. Remove the clevis and lock of the piston to hold the check valve assembly in
nut from the push rod. place. If the tab is broken , use a new master cylin-
der.
STEP 9
Remove the boot from the master cylinder. STEP 3
Inspect the flow va lve, ball, check valve piston,
STEP 10 piston, and the push rod for scoring, pitting, or
Remove the snap ring from the body. other damage. If the flow valve , ball, check valve
piston , piston, or the push rod are damaged a new
STEP 11 master cylinder must be used.
Remove the push rod and washer from the body.
Assembly
STEP 12
Hit the open end of the master cylinder against a STEP 1
piece of wood to move the piston assembly to the I nstall the check valve seat.
end of the master cylinder.
STEP 2
STEP 13 Install the spring on the spring seat.
Pull the piston assembly from the master cylinder.
STEP 3
STEP 14 Install the check valve assembly in the spring. En-
There is a small tab in the spring seat that holds the gage the stem of the check valve piston in the
spring seat on the piston . Use a screwdriver to lift spring seat.
up the tab.
STEP 4
STEP1S I nstall the check assembly on the piston. Push the
Remove the check valve assembly from the piston . check va lve assembly onto the piston until the tab
in the spring seat engages the end of the piston .
STEP 16
Remove the sea l from the piston . STEPS
Install the seal on the piston .
STEP 17
Disconnect the check valve piston from the spring
seat.
7106-17
STEP6 STEP 17
Lubricate the bore of the body with clean hydraulic Repeat step 16 until the flow valve adapter can be
flu id. turned completely into the master cylinder by
hand .
STEP 7
Install the piston assembly into the bore of the STEP 18
body. Tighten the flow valve adapter to 30 to 34 pound-
feet 941 to 47 N m, 4 to 5 kg / mi·
STEP8
Push the piston assembly into the bore until the STEP 19
push rod and washer can be installed . See page 71 06-13 and install the master cylinder on
the machine.
STEP9
I nstall the push rod and washer. STEP 20
Depress the brake pedal to stroke the piston in the
STEP10 master cylinder. Release the brake pedal and allow
Install the snap ring . the piston to return . Adjust the push rod to piston
clearance to .025 to .050 inch (0.6 to 1.3 mm). Turn
STEP 11 the clevis clockwise to shorten or counterclock-
Install the boot. wise to lengtl:len. Tighten the lock nut against the
clevis. See the illustration below.
STEP12
I nstall the lock nut and clevis on the push rod. Do
not tighten the lock nut on the push rod at this time .
0.025 to 0.05 INCH
STEP13 -- - (0.6 to 1.3 mm)
Install the ball in the body.
STEP14
Lubricate the flow valve seal and the flow valve with
clean hydraulic oil. I nstall the flow valve in the bore
in the master cylinder. The flow valve must be cen-
tered in the bore of the master cylinder.
STEP15
Install a new gasket on the flow valve adapter.
870123
STEP16
Carefully start the flow valve adapter into the bore
in the master cylinder by hand. If the flow valve
adapter cannot be turned into the master cylinder
completely by hand remove the flow valve adapter
from the master cylinder and make sure that the
flow valve is in the center of the bore in the master
cylinder.
This Page is Blank
7125
DIFFERENTIAL BRAKES
WET BRAKES
TRANSMISSION SERIAL NUMBER 16276842 AND AFTER
TABLE OF CONTENTS
Special Torques . . . ... . . .. ... . . . ... . . ... 7125-2 Disassembly of Brake

Actuator Assembl y .... . ... .. . . .. . .. 7125-9
Special Tools .. .. ....... . ...... . . . . .. .. 7125-2
Assembly of Brake
Specifications .... .. . .. ..... . .... .. ..... 7125-2 ActuatorAssembl y . . ... . .. ... . .. .. 7125-11
Removing the Brake Assembly .. . .. . .. .. 7125-3 Installing the Brake Assembly . .. .. .. . . . 71 25- 15
Disassembly of Actuating Disc .. ..... . 7125-5 Brake Adjustment .. .. ....... . . ... .. ... 7125- 18
Assembly of Actuating Disc .. ... .... . . 7125-7 H. ',d Brake 2 Wheel Drive . . . ... . .. .... 7125- 19
Assembly and Installation . . . .. . . .. ... 7125-19
Hand Brake 4 Wheel Drive . .. .... ...... 7125-21
J I Case 8-67560
A Tenneco Company
7125-2
SPECIAL TORQUES
u.s. Value Metri c Value
Brake Cover Bolts ....... . ... . .. . . . .. ..... . .. ... ... . . . . . .... 80 to 96 Ib It 109 to 130 Nm
(10 .9 to 13.0 kgm)
Ferry Head Bolts (Hand Brake) .... ....... .. .......... .. .. 110 to 132 Ib ft 149 to 179 Nm
(14 .9 to 17.9 kgm)
Retaining Bolts (Hand Brake) . ... . .. ....... .. ............ . . . 70 to 84 Ib ft 95 to 114 Nm
(9 .5 to 11.4 kgm)
Air Removal Screw ..... . . .... . . ....... . ...... • ......... . 10 to 50 Ib inch 1 to 6 Nm
(0 1 to 0.6 kgm)
SPECIAL TOOLS

TORQUE WRENCH LB FT
SPECIFICATIONS
u.S. Value Metri c Value
Han d Brake Compression Spring
Free Length ..... . ...... . ............ ..... .. . ............. .. .. 2.50 inch 63 .5 mm
OD .. .. ........ . .. . . .. .... . .. . .... ....... .. .. .. .... . ....... . .. 0.94 inch 23 .87 mm
ID .. . .. . . . .. . ..... . . .. ...... . .. .. ..... . ... . ........ ....... . ... 0.65 inch 16.51 mm
Wire Diameter .. . ... .... .... . .. ... ... .. . ... .. . .. ... .. .. ... . .. 0.072 inch 1.83 mm
No. of Coils . . ... . . ... . . . . . . . ... . .. .. .. ...... . . .. . . .. ... . . . ........... 8 8
Compress to 1.50 inch (38 .1 mm) at ... ... .. . . .. . . . . ..... . .. ... 11 to 13 Ib 49 to 58 N
Hand Bra ke Return Spring

Free Length ...... . ..... . .. .. ....... . .... .. ... . .. .. .. ... . . .. ... .. . . 2.70 68.58 mm
OD .... .. ........... .. ....... . . .. .......... . .. ......... ..... ...... 0.65 16.51 mm
Wire Diameter . . . ..... . ...... . . . .... . .. ..... . ..... . .. ... .. ... . .... 0.072 1.83 mm
No. of Coils .. .......... . .. ..... .... .... ... . . ... .. ......... . .. .. .. 19.25 19.25 mm
External to 3.45 inch (87 .63 mm) at .. .. ............ .... . . . . 11 .8 to 13.81b 53 .3 to 61 .4 N
Actuator Compression Spring

Free Length .......... .. ..... . . ... .. . .. ..... . .. ...... .. ...... . 3.05 inch 77.47 mm
ID . . .. . .. . ...... . .. . . . ...... .. .. .... ......... . ... . .... .. ...... 1.54 inch 39 .12 mm
Wire Diameter ..... .. ... . ........ .. .. . ... . .. . . . . .. . .. . .... ... 0.120 inch 3.05 mm
No . of Coils .. ..... . ...... .... . .. . . ... ..... .... .. .... . ..... ..... .. .. 4.2 4.2
Compress to J .55 inch (39 .37 mm) at . .. . . . . .. . .. ... .. .... . ... . 27 to 33 Ib 120 to 147 N
7125-3
REMOVING THE BRAKE ASSEMBLY

STEP 1 STEP 4
.~
Loosen and remove the cap screws and flat wash- Remove the brake cover.
ers from the differential lock assembly .
STEPS
STEP 2 ,-
Remove the dust cover from the actu ator assem-

Remove the differential lock assembly. bly .
STEP 3 STEP 6
632018
Loosen and remove the cap screws that fasten the Loosen the lock nut. Remove the lock nut and ad-
brake cover to the brake housing . justing nut.
7125-4
STEP 7 STEP 10
632022
Loosen the cap screws that fasten the actuator Remove the two brake discs and one steel plate
assembly to the brake housing. from the brake housing .
STEPS STEP 11
632024
Remove the cap screws , flat washers , and plates Remove the actuating disc.
from the actuator assembly.
STEP 12
STEP9
632032
632026 Remove the brake disc.

Remove the actuator assembly.
7125-5
STEP 13 STEP 17
632036 Remove th e bra ke rod .

Remove the steel plate .
STEP 14
Repeat steps 12 and 13 to remove the other two
brake discs and steel plates .
Disassembly of Actuating Disc

STEP 15
STEP 19
Remove the cotter pin .
STEP 16
Remove th e link and th e shoulde r bo lt.
Remove the pin from the brake rod.

7125-6
Remove the three return springs. Check the steel balls for rust and pitting. Replace
the steel balls as needed.
STEP 21
Lift one half of the actuating disc off the steel balls.
Check the ball seat and ramp for damage. The
actuating disc must be replaced if damaged.
NOTE: There are six steel balls and six ramps.

7125-7
Assembly of Actuating Disc

ACTUATOR ROD
PIN
b
ACTUATING DISC
/
~OTTER PIN
~\ STEEL BALL
RETURN SPRING
STEP 24 STEP 25
Put the other half of the actuating disc on the steel

disc. balls.
7125-8
STEP 26 STEP 29
Install t he three return springs. Install the actuating rod on the li nks.
spring with three coils must be toward the discs.
STEP 30
Install the pin through the actuating r

Install the link and the shoulder bolt. links.
STEP 28 STEP 31
Install and tighten the nut. Use a punch and Install the cotter pin.
hammer to stake the nuts in position.
7125-9
Disassembly of Brake STEP 35

Actuator Assembly
STEP 32
STEP 36
Remove the retaining ring from the actuator hous-
ing.
STEP 33
Remove the backup ring and O-ring from the actu-

ator housing.
STEP 37
Remove the washer from the actuator housing.
Remove the air removal screw from the actuator

housing .
7125-10
STEP 38 STEP 39
Clean the actuator housing with compressed air.

Check the bore for pitting and scoring. Use a cylin-
der hone to make the bore smooth if necessary.
7125- 11
Assembly of Brake Actuator Assembly

RETAINING RING- 0 WASHER
COMPRESSION SPRING - @/
~~ "STO'
O-RING
~
~U'''NG
©
~
ACTUATOR HOUSING
O-RING t
~ BACKUP RING
0/
©/
STEP40 __________________ --~
STEP 41
Install the air removal screw. Tighten the air removal screw to a torque of 10 to 50
Ib inch (1 to 6 Nm ) 0.1 to 0.6 kgm).
7125-12
STEP 42
Install a new O-ring on the piston . Install a new backup ring in the actuator housing.
STEP 43
Install a new backup ring on the piston. Lubricate the piston, O-rings and th e cylinder bore
with clean mineral oil or TCH fluid. Install the pis-
STEP 44 ton into the actuator hou sing .
IMPORTANT: Never use brake fluid as a lubri-

cant on this machine.
ST P47
Install a new O-ring in the actuator housing.
Install the compression spring in the actuator

housing.
7125-13
STEP 48
I nstall the washer on the compression spring . Install the retaining ring in the lowe r groove in the
cy linder bore.
NOTE: The flat side of the reta ining ring must be

up.
7125-14
A.-------,
Q
"'Q
BOLT
@) .4 _lOCK NUT
OUST COVER
PlATE---~
[j _ lJ
e
~WASHER
~-
I .. - - ADJUSTING NUT
, @/
BOLT
",'"
""
","
,,/'"
'"
.".~- ....
\
:
I
I
I
/ i ~..?-LATE //
ACTUATOR ASSEMBLY :
" '" ",'" "" '"
"," '" STEEL PLATE
, '"
BRAKrlSC t
",'
, _ _ _ BRAKE HOUSING
...
\
'" '" ..... ... ...
" .....
.....
/ '" / ...
I\ // " .
,
I
"
... ..... ",'" "" '" "
..... ..... '"
..... " .... ","
'" "
'"
B RAKE COVER" -- '
\)~~'.ING
\ OVER PIN
O·RING
7125-15
INSTALLING THE BRAKE ASSEMBLY

STEP 50 STEP 54
Install a steel plate in the brake housing. Make sure Apply RTV 106 gasket material on the actuator
the notch in the steel plate is in alignment with the assembly .
groove in the brake housing.
STEP 55
STEP 51
.4
632026
632038 Install the actuator assembly .

Install a brake disc.
STEP 56
STEP 52
Repeat steps 50 and 51 until a total of three steel
plates and three brake discs are installed.
STEP 53
632024
Install the plates, flat washers, and cap screws to

fasten the actuator assembly to the brake housing .
632030
Install the actuating di sc.
7125-16
STEP 57 STEP 60
632020 631642
Install the adjusting nut. Replace the O-rings on the pin.
STEP 58 STEP 61
632016 632 142
Install the brake disc in the brake housing . Install Al ign the steel plates and actuating disc with the
the steel plate and other brake disc. hole in the brake housing . Install the pin . Push the
pin all the way into the hole in the brake housing.
STEP 59
~ STEP 62
631638
Remove the pin from the brake cover. 632144
Apply RTV 106 gasket material to the brake

housing .
7125-17
STEP 63 STEP 66
632230
Install the brake cover. Align the collar in the differentia l lock assembly
with the splines of the shaft. Install the differential
STEP 64 lock assembly .
STEP 67
632226
Tighten the cap screws to 80 to 96 Ib feet (109 to

130 Nm) (10.9 to 13 kgm). 632220
Tighten the cap screws to 17 to 21 Ib feet (23 to 29

STEP 65 Nm) (2.3 to 2.9 kgm).
STEP 68
632102
Apply RTV 106 gasket material to the brake cover.

632106
Tighten the adjusting nut on the actuator assembly

to 50 Ib inches (6 Nm)(0 .06 kgm). Then loosen the
adjusting nut 4-3/ 4 turns.
7125-18
STEP 69 STEP 70
632108
Install the lock nut. Prevent the adjusting nut from Install the dust cover.
turning and tighten the lock nut.
BRAKE ADJUSTMENT
STEP 1 STEP 6
Park the machine on a level surface. Loosen the adjusting nut two complete turns .
Tighten the lock nut.
STEP 2
Raise the rear wheels above the floor. Use blocks or STEP 7
support stands to support the rear of the machine. Repeat steps 5 and 6 for the other side .
STEP 3 STEPS
Remove the dust cover and loosen the lock nut. Tighten the lock nuts and install the dust covers.
STEP 4
Release the parking brake.
STEP 5
Rotate one of the rear wheels manually in the for-
ward direct ion. Tighten the adjusting nut until you
feel resistance as you rotate the whee l.
7125-19
HAND BRAKE 2 WHEEL DRIVE
DISC
) , B7
1
/ DISC PAD '- ,,
MOUNTING PLATE /1 \ SPACER '
(). '--, ~
~""61') ~ ~-
t:'~ (/ " ~_ - - - D I S C PAD
....
FERRY HEAD BOLTS , t:', "'" @ ()"'~
'~ ~
' ~ /~ " ,
___ , I
BRAKE HOUSING - - - ,,_/
£7" )/" ~ .. ~ -.----RETAINING BOLT
MOUNTING BRACKET~ ~ (~::K~ liN
" \p
...,:~'" ACTUATING LEVER
PIVOT PLATE-~------:-~ ~
~~
,---- - SPRING
Assembly and Installation 2. Install the brake disc on the countershaft.
1. Install the mounting plate on the transmission 3. Assemble the brake housing and install the
housing and tighten the Ferry head bolts to a tor- housing on the mounting plate.
que of 110 to 1321b feet (149 to 179 Nm) (14 .9 to
17.9 kgm) . 4. Tighten the retaining bolts to a torque of 70 to
841b feet (95 to 114 Nm) (9 .5 to 11.4 kgm) .
7125-20
9
7125-21
HAND BRAKE 4 WHEEL DRIVE
Assembly and Installation 2. Assemble the brake housing and install the
housing assembly on the transfer gear box.
1. I nstall the brake disc on the upper transfer gear
box shaft. 3. T ighten the retaining bolts to a torque of 70 to
84 Ib feel (95 to 14 Nm) (9.5 to 11 .4 kgm).
7125-22
8000
REMOVAL AND INSTALLATION OF
HYDRAULIC COMPONENTS
TABLE OF CONTENTS
Oil Cooler ........ .... . . ..... . . .. .. .. . . 8000-2 Cylinders . ........... . ......... . .. ... . 8000-26
Removal . ... .. . . ... . . . ............... 8000-2 Loader Lift Cylinder ... . . .. . ... . ..... 8000-26
Installation ........... .... ..... . .... . . 8000-6 Loader Bucket Cylinder .......... .... 8000-29
Illustration of Oil Cooler Loader Bucket Clam Cylinder . ... . ... 8000-31
Installation .. .. ....... ... .. .. . ..... 8000-10
Boom Cylinder .... . .... ... . ... . . . .. . 8000-33
Hydraulic Pump ... . . .. .. . ......... . . . . 8000- 11
Dipper Cylind er . .... .. ... ... . ....... 8000-35
Removal . . .. . .. ... ......... . .... . .. . 8000-11
Extendable Dipper Cylind er . ... .. . ... 8000-37
Installation ..... .... . . . . .. .... .. . .... 8000-14
Backhoe Buc ket Cylinder .. .......... 8000-39
Illustration of Hydraulic Pump
Installation . . ...... . . ... ... ....... . 8000-18 Illustration of Backhoe Bu cket Cylinder
Installation without Extendable
Loader Control Valve .. . ..... .... .. .. . . 8000-19 Dipper .... .. .. . ................... 8000-40
Removal .. .. . .... . ...... . . .......... 8000-19 Illustration of Backhoe Bucket Cylinder

I nstaliation wi th Exte ndabl e Dipper .. . 8000-41
Installation ......... . ... . ... .. .... . .. 8000-20
Swing Cy lind er .. ......... . . . .... .. .. 8000-42
Backhoe Control Valve .. .. ........ .. .. 8000-22
Illustration of Swing Cylinder
Removal ... .. ....... ...... . ...... . .. 8000-22 Installation .... .... .... . ... ...... .. 8000-43
Installation ... .. . ................. ... 8000-22 Stabilizer Cylinder .. . .. .. ...... . . .... 8000-44
Swing Sequence Valve . . .... . .... .. .. . . 8000-24 Illustration of Stabilizer Cylinder . .... 8000-45
Removal .. . . ..... . .. .. ...... . ...... . 8000-24 Lift Cylinder (Three-Poi nt Hitch ) . .... 8000-46
Installation . . ... . . .. . . . ........ . ..... 8000-24 Tilt Cylinder .... . . . .. ... . .... . .. . . . . 8000-47
Three-Point Hitch Control Valve . . . . .... 8000-25 Pitch Cylinder . . . ... ....... .. .. . .... . 8000-48
Remova l ....... .... ...... . ... . . .. ... 8000-25 Illustration of Cylinders for Three-Poin t
Hitch ........ ... ...... . ...... . . . .. 8000-49
Installation ... . .... . .... . .. . .... .. . .. 8000-25
Swing Sequence Valve Adjustment ..... 8000-50

A Tenneco Company
8000-2
OIL COOLER
Removal STEPS
Raise the hood.
STEP 1
Park the machine on a level surface. STEP 7
Have another person hold the hood in position .
STEP 2
Apply the parking brake. STEPS
STEP 3
630140
Loosen and remove the bolts, spacers, flat wash -

866552 ers, and nuts that fasten the hold down straps to the
Remove the pin that holds the strut in place and shroud.
STEP 9
STEP 4
STEPS
630136
Loosen and remove the bolts , flat wash ers , lock

washers , and nuts that fasten the hood mounting
bracket to the frame.
866550 STEP 10
Install the pin in the strut. Stop the engine Have the other person he lp yo u remove the hood .
8000-3
STEP 11 STEP 14
627928 628040
Loosen and remove the cap screws , flat washers, Loosen and remove the cap screw and lock washer
and lock washers that fasten the top cover to the that fasten the radiator retaining bracket to the
bottom cover. shroud .
STEP 12 STEP 15
627930 628004
Remove the top cover from the machine. Remove the radiator retaining bracket from the
radiator.
STEP 13
STEP 16
628038
Loosen and remove the bolts, flat washers, and &30128
self-locking nuts that fasten the oil cooler and radi- Put a block under the radiator to hold the radiator
ator assembly to the shroud. in place when the shroud is removed from the
machine.
8000-4
STEP 17 STEP 20
628001 628122
Loosen and remove the bolts, washers , and nuts Loosen and remove the cap screw and lock washer
that fasten the shroud to the frame. that fasten the clamp on the hose for the co nden-
ser to the radiator.
STEP 18
STEP 21
628008
Remove the shroud from the machine. 628126
Loosen and remove the bolts , lock washers, and

STEP 19 nuts that fasten the mounting brackets to the oil
If the machine is not equipped with an air condi- cooler and condenser. Remove the mounting
tioner go to step 25. If the machine is equipped with brackets.
an air conditio ner do steps 20 through 24 .
STEP 22
NOTE: The following photos show a machine
with the bumper and bottom cover removed. It is
not necessary to remove the bumper or the bottom
cover from the machine.
628206
Loosen and remove the cap sc rews, lock washers ,

and flat washers that fasten the air cond itioning
condenser to th e oil coo ler and radiato r.
8000-5
STEP 23 STEP 27
628210 626312
Pull the air conditioning condenser away from the Loosen and remove the cap screws, lock washers ,
oil cooler. and flat washers that fasten the oil cooler to the
radiator.
STEP 24
STEP 28
6283 14
Fasten the air conditioning condenser out of the

way. 628024
Hold the oil cooler in position and disconnect the

STEP 25 tubes from the fittings on the oil cooler.
Connect a vacuum pump to the hydraulic reservoir.
Start the vacuum pump. STEP 29
STEP 26
628020
628012 Remove the oi l cooler from the machine. Install

Loosen the tubes on the fittings on the oil cooler. caps on the fittings and plugs in the tubes. Stop the
Do not remove the tubes from the fittings at this vacuum pump.
time.
NOTE: Also use another wrench on the fittings
that are welded to the bottom of the oil cooler.
8000-6
Installation STEP 4
STEP 1
628014
I nstall the cap screws, lock washers , and f lat wash-

628020 ers that fasten the oil coole r to the radiator.
Start the vacu um pump. Remove the plugs from the
tubes and the caps from the fittings. Put the oil STEP 5
cooler in position on the tubes.
STEP 2
6280 12
Tighten the tubes on th e fittings on the oil cooler.

Disconnect the vacuum pump from the hydraulic
628024 reservoir.
Connect the tubes to the fittings on the oil cooler.
Do not tighten the tubes on the fittings at this time. NOTE: Use another wrench on the fittings that
are welded to the bottom of the oil cooler.
STEP 3
STEP 6
If the machine is not equipped with an air condi-
tioner go to step 11 . If the machine is equipped wi th
an air conditione r do steps 7 through 10.
If equipped put the space r in position between the

oil coo le r and the radiator.
8000-7
STEP 7 STEP 10
628210 628 122
Put the condenser in position on the oil cooler. Install the cap screw and lock washer that fasten
the clamp on the hose for t he condenser to the
STEP 8 radiator.
STEP 11
628206
Install the cap screws , lock washers, and flat wash-

ers that fasten the condenser to the oil cooler and 628008
radiator assemb ly . Put the shroud in pos ition on the machine. Make
sure that the mounting brackets on the oil cooler
STEP 9 are on top of the tabs o n the shroud . Make sure that
the rubber insulators are in positi on on the mount-
ing brackets .
STEP 12
628126
Put the mounting brackets in position on th e oil

cooler. I nstall the bolts, lock washers, and nuts that
fasten the mounting brackets to the condenser and
the oil cooler. 6:m128
Remove the block from th e radi ator.

8000-8
STEP 13 STEP 16
628001 628001
Install the bolts , flat washers , and nuts that fasten Move the top of shroud as far as possible toward
the shroud to the frame. Do not tighten the nuts on the rear of the machin e. Hold the shroud and
the bolts at this time. tighten the bolts to 270 to 324 pound-feet (366 to
439 N m, 37 to 45 kg/m).
STEP 14
STEP 17
628004
Put the radiator retaining bracket in position on the 628038
radiator and shroud. I nstall the bolts , flat washers , and se lf- loc king nuts
that fasten the oil cooler and radiator assembly to
STEP 15 the sh roud.
STEP 18
Start and run the en gin e at low idle for ap pro xi-
mately 1 minute. Stop th e engine.
STEP 19
Check for oil leakage at the oil cooler.
STEP 20
Check the oil level in the hydraulic reservoir. Add
oil as required. See Section 8001.
628040
I nstall the cap screw and lock washe r that fasten

the radiator reta inin g bracket to the shroud.
8000-9
STEP 21 STEP 24
627930 630136
Put the top cover in position on the machine. I nstall the bolts, flat washers, and lock washers that
fasten the hinges to the frame . Do not tighten the
STEP 22 bolts at this time .
STEP 25
STEP 26
h80d for access to the hinge mounting bolts.
STEP 27
Push the hood toward the rear of the machine as far
as possible. Tighten the hinge mounting bolts.
STEP 28
627 928
I nstall the cap sc rews , flat washers, and lock wash-

STEP 23
Have another person help you put the hood in posi-
with the holes in the frame.
I nstall the bolts , spacers , flat washers, and nuts to

fasten the holddown straps to the shroud.
8000-10
870336 A
Oil Cooler Installation

8000-11
HYDRAULIC PUMP
Removal STEP 7
Have another person hold the hood in position .
STEP 1
Park the machine on a level surface . STEPS
STEP 2
STEP 3
630140
Loosen and remove the bolts , spacers, flat wash-

ers, and nuts that fasten the holddown straps to the
shroud .
STEP 9
lower the strut onto the lift cyli'hder.
STEP 4
Raise the loader f rame until the strut is against the
STEPS
630136
Loosen and remove the bolts, flat washers, lock

washers, and nuts that fasten the hood mounting
bracket to the frame.
866550
Install the pin in the strut. Stop the engine.
STEP 6
Raise the hood.
8000-12
STEP 10 STEP 17
Have th e oth er person help you remove the hood .
STEP 11
If the machine is equipped with a bumper go to step
17. If the machine is equipped with a counter-
weight do steps 12 through 16.
STEP 12
628224
Loosen the cap screws that fasten th e bumper to

the frame. Do not remove the cap screws at this
time.
STEP 18
62793U
Loosen and remove the cap screws , flat washers,

bottom cover.
STEP 13
Remove th e top cover from the machine.
STEP 14
Loosen and remove the cap screws , flat washers,
and lock washers that fasten the bottom cover to
the frame.
628226
STEP 15 Hold the bumper in position and remove the cap

Remove the bottom cover from the machine. screws and lock washers that fasten the bumper to
the frame.
STEP 16
Go to step 24 . STEP 19
Remove the bumper from the frame .

8000-13
STEP 20 STEP 23
628232 628306
Loosen and remove the cap screws that fasten the Remove the bottom cover from the machine.
top cover to the bottom cover.
STEP 24
STEP 21 If the machine is equipped with a counterweight
and an air conditioner the counterweight must be
removed before the hydraulic pump can be re-
moved. See Section 9010 and remove the counter-
weight from the machi ne.
NOTE: The fol/owing photographs show a ma-

chine without an air conditioner and with a coun-
terweight. Use a similar procedure to remove the
.- hydraulic pump from aI/ machines.
--' STEP 25
See Section 8001. Drain the oil from the hydraulic
reservoir .
628234
STEP 26
Remove the top cover from the machine.
STEP 22
, ,...,
630124

628302
fittings on the outlet hoses to the hydraulic pump .
Loosen and remove the cap screws, lock washers,
and flat washers that fasten the bottom cover to the
frame.
8000-14
STEP 27 STEP 30
630032
Loosen the clamp that fastens the inlet hose to the Pull the hydraulic pump towa rd the front of the
flange fitting on the hydraulic pump . Move the machine.
clamp out of the way.
STEP 31
STEP 28
630020
630030 Rotate the hydraul ic pump as required and remove

Loosen and remove the cap screws, lock washers , the hydraulic pump from the machine. I nstall plugs
and flange mounting brackets that fasten the flange in the hydraulic lines.
fitting on the inlet hose to the hydraulic pump .
NOTE: When the hydraulic pump is removed, it is
STEP 29 recommended that you remove, clean, and install
the suction screen.
Installation
STEP 1
Apply Molykote Type G to the splined shaft on the
hydraulic pump.
630024
Loosen and remove the cap screws, flat washers,

and lock washers that fasten the hydraulic pump to
the engine mounting bracket.
8000-15
STEP 2 STEPS
630020 630030
Remove plugs from the lines. Rotate the pump as Make sure that the flange fitting on the inlet hose is
required to put the pump in position on the main position on the hydraulic pump . Install the flange
chine. Be careful not to damage the O-ring on the mounting brackets , cap screws , and lock washers
flange fitting on the inlet hose. that fasten the flange fittings on the inlet hose to
the hydraulic pump.
STEP 3
STEP 6
Install the splined shaft on the hydraulic pump in 630032
the coupling on the engine. Put the clamp in position on the inl et hose. Tighten
the clamp .
STEP 4
630024

the top of the hydraulic pump to the engine mount-
ing bracket. Install the cap screws , lock washers,
and flat washers that fasten the bottom of the hy-
draulic pump to the engin e mounting bracket.
8000-16
STEP 7 STEP 14
. ....
11:.,
630121\ 628302
Make sure that the O-rings are in position in the I nstali the cap screws, lock washers , and flat wash-
flange fitti ngs on the outlet hoses. Put the outlet ers that fasten the bottom cover to the frame.
hoses in posi tion on the hydraulic pump . Install the
flan ge mounting brackets, cap screws, and lock STEP 15
washers that fasten the flange fitti ngs on the outlet
hoses to the hydraulic pump.
STEP 8
See Section 8001. Fill the hydraulic reservoir.
STEP 9
Start and run the engine at low idle for approxi-
mately 2 minutes. Stop the engine.
••
STEP 10
Check for oil leakage at the hydraulic pump.
STEP11 626234
Put the top cover in pos ition on the bottom cover.
oil as required. See Section 8001 .
STEP 12 STEP 16
If the machine is equipped with a counterweight
and an air condi ti oner, see Section 9010 and install
the counterweight on the machine.
STEP 13
I nstall the cap screws, loc k washers , and flat wash-

628306
Put the bottom cover in position on the frame.
8000-17
STEP 17 STEP 21
If the machine is equipped with a counterweight go
to step 20 . If the machine is equipped with a
bumper do steps 18 and 19.
STEP 18
I nstall the bolts , flat washers , and lock washers that

fasten the hinges to the frame. Do not tighten the
bolts at this time .
628228 STEP 22
Put the bumper in position on the frame. Lower the hood so that the rubber bumpers are on
the air cleane r bracket .
STEP 19
STEP 23
hood for access to the hinge mounting bolts .
STEP 24
Push the hood toward the rear of the machine as far
as possible . Tighten the hinge mounting bolts.
STEP 25
Hold the bumper in position and install the cap

screws and lock washers that fasten the bumper to
the frame . Tighten the cap screws.
STEP 20
Have another person hel p you put the hood in posi-
with the holes in the frame.
630140
I nstall the bolts, spacers , flat washers, and nuts to

fasten the hold down straps to the shroud.
8000-19
LOADER CONTROL VALVE

Removal STEP 9
STEP 1 tem to the wiring harness. Disconnect the wire
Park the machine on a level surface. connector for the ether injection syste m from the
wiring harness.
STEP 2
STEP 3
STEP 4
Stop the engine.
STEPS
Move the loader control levers in all directions to
release pressure from the hydraulic circuits .
STEP 6
Raise the hood.
STEP 7
For machines without turbocharger, disconnect
the air cleaner hose from the intake manifold. Put a
cover over the opening in the intake manifold.
STEP 11
For machines with a turbocharger, disconnect the
air cleaner hose from the turbocharger. Put a cover
over the opening in the turbocharger.
STEP 12
629620
Disconnect the tube for the ether injection system
STEP 8
632411

loosen and remove the bolt , lock washer, clamp on
the air conditioner hose, and nut that fasten the air
cleaner mounting bracket to the frame.
STEP 13
Loosen and remove the bolts, flat washers , lock
washers , and nuts that faste n t he air cleaner
629624 mounting bracket to the frame.
tion system from the engine temperature switch on
the intake manifold.
8000-20
Remove the air cleaner and mounting bracket from
the machine. STEP 1
Use lifting equipment to put the loader control
STEP1S valve in position on the machine.
Find the wires for the return-to-dig switch on the
loader control valve . Disconnect the wires from the STEP 2
return-to-dig switch. Install the cap screws and lock wash ers that fasten
the loader control valve to the mounting plate.
STEP 16
Fasten identification tags to the loader linkage at STEP 3
the loader control valve. Remove the lifting eq uipment from the loader con-
trol valve .
STEP 17
Remove the access cover from the inside of the STEP 4
operators compartment to get access to the fittings. Connect the tubes and hoses to the fitting s on the
loader control valve.
STEP 18
Disconnect the linkage from the loader control STEPS
valve . Connect the linkage to the loader control valve.
STEP 19 STEP 6
Clean the loader control valve and the area around Connect the wires to the return-to-dig switch on
the loader control valve. Fasten identification tags the loader control valve.
to the tubes and hoses at the loader control valve.
STEP 7
NOTE: Close all openings with caps and plugs to Remove any covers from the turbocharger or in-
keep dirt out of the hydraulic system. take manifold. Start and run the engine at low idle.
STEP 20 STEP 8
Disconnect the tubes and hoses from the fittings in Move the loader control to raise the loader com-
the loader control valve. pletely . Continue to hold the loader control in the
RAISE position for 30 seconds.
STEP 21
Connect lifting equipment to the loader control STEP 9
valve. The weight of the loader control valve is Lower the loader bucket to the floor. Stop the
approximately 72 pounds (33 kg) . engine.
STEP 22 STEP 10
Loosen and remove the cap screws and lock wash- Check for oil leakage at the loader control valve.
ers that fasten the loader control valve to the
mounting plate . STEP 11
Check th e oil level in the hydraulic reservoir. Add
STEP 23 oil as required. See Section 8001 for specifica-
Remove the loader control valve from the machine. tions .
STEP 12
8000-21
STEP 13 STEP 17
629624
If the machine is equipped with an air cond itioner, Connect the wire connector for th e ether injection
install the bolt, lock washer, clamp on the air con- system to the engine temperature switch on the
ditioner hose, and the nut that fastens the air intake manifold.
STEP 18
STEP 14
Install the bolts , lock washers , flat washers , and
nuts that fasten the air cleaner mounting bracket to
the frame .
STEP 15
629620
Connect the tube for the eth er injection system to

the intake manifold .
STEP 19
Lower the hood.
629622
Connect the air cleaner hose to the intake mani- STEP 20

fold or to the turbocharger. I nstall the access cover inside the operators
compartment.
STEP 16
tem to the wiring harness. Connect the wire con-
nector for the ether injection system to the wiring
harness.
8000-22
BACKHOE CONTROL VALVE

Removal STEP 14
Disconnect the linkage from the spools in the
STEP 1 backhoe control valve.
Clean the backhoe control valve and the area
around the backhoe control valve. STEP1S
The weight of the backhoe control valve is approxi-
STEP 2 mately 120 pounds (54 kg). Have another person
Park the machine on a level surface. help with the following steps.
STEP 3 STEP 16
Lower the loader bucket to the floor. Hold the backhoe control valve in place and re-
move the bolts, lock washers, and nuts that fasten
STEP 4 the left side of the backhoe control valve to the
If the machine is equipped with an extendable dip- mounting bracket.
per, install the extendahoe lock pin.
STEP 17
STEPS Remove the cap screw, lock washer, and spacers
If the backhoe is not in the transport position, put that fasten right side of the backhoe control va lve
the backhoe in the transport position. to the mounting bracket.
STEP 6 STEP1S
Lower the stabilizers until the stabilizers just touch Remove the backhoe control valve from the ma-
the floor. chine.
STEP 7 Installation
Stop the engine and apply the parking brake .
STEP 1
STEPS If the fittings were removed from the backhoe con-.
Install the swing lock pin. trol valve , or a new backhoe control va lve is being
used , or the dipper or boom section of the backhoe
STEP9 control valve has been replaced :
Move each backhoe control lever in both direc-
tions until all hydraulic pressure has been removed a. Make sure that a restrictor is installed in
from the backhoe hydraulic circuits. the A port of the dipper section , and the Sport
of the boom section of the bac kh oe control
STEP 10 valve . The restrictor must be installed with the
Fasten identification tags to the hoses and tubes large end of the restrictor toward the inside of
for the backhoe control valve. the backhoe control valve .
NOTE: Close each opening with a cap or plug as b. Install new O-rings on the fittings .
the hose or tube is removed from the backhoe
contro l valve. c . Lubricate the O-rings with clean hydraulic
oil.
STEP11
Disconnect the hoses and tubes from the backhoe d. Install the fittings in the backhoe control
control valve . valve.
STEP 12 STEP 2
Disconnect the tube for the "S" port of the swing Put the backhoe control valve in position on thlil
section from the fitting in the swing sequence mounting bracket. Make sure tha t the rubber
valve. mount is in position in the mounting bracket.
STEP 13 STEP 3
Fasten identification tags to the linkage for the Install the cap screw , lock washer, and spacers
backhoe control valve. that fasten the backhoe control valve to the mount-
ing bracket. Make sure that the spacers are in posi-
tion between the backhoe control val ve and the
mounting bracket.
8000-23
STEP 4 STEP 8
Connect the linkage to the spools in the backhoe Slowly and completely extend and retract each
control valve. cylinder several times to remove any air from the
backhoe hydraulic circuits .
STEPS
Connect the tube to the fitting in the swing se- STEP9
quence valve and to the "8" port in the swing sec- Stop the engine.
tion of the backhoe control valve.
STEP 10
STEP 6 Check for oil leakage at the backhoe control valve.
Connect the remaining tubes and the hoses to the
fittings in the backhoe control valve. STEP 11
STEP 7 oil as required. See Section 8001 fo r specifica-
Start and run the engine at low idle. tions.
8000-24
SWING SEQUENCE VALVE
Removal STEP1S
Remove the swing sequence valve from the ma-
STEP 1 chine.
Clean the swing sequence valve and the area
around the swing sequence valve . Installation
STEP 2 STEP 1
Park the machine on a level surface. Hold the swing sequence valve in position on the
mounting bracket. Install the cap sc rews that fas-
STEP 3 ten the swing sequence valve to th e mounting
Lower the loader bucket to the floor. bracket.
STEP 4 STEP 2
If the backhoe is not in the transport position, put Turn the spool so that the hole is vert ical. Put the
the backhoe in the transport position. yoke in position on the spool. Install the cl evis pin
and cotter pin that fasten the yoke to the spool.
STEP S
Connect the tube to the " B" port in th e swing sec-
STEP 6 tion of the backhoe control valve and to th e fitting
Install the swing locking pin. in the bottom of the swing sequence valve .
STEP 7 STEP4
Move the swing control pedals or levers in both Connect the remaining tubes and the hoses to the
directions to remove any pressure in the swing fittings in the swing sequence valve.
hydraulic circuit.
STEPS
STEP 8 Remove the swing locking pin .
Fasten identification tags to the hoses and tubes
for the swing sequence valve. STEP 6
Start and run the engine at low idle.
STEP 9
Disconnect the tube from the "B" port in the swing STEP 7
section of the backhoe control valve and from the Slowly and compl etely swing the backho e to the
fitting in the bottom of the swing sequence valve. left and then to the right several t imes to re move
any air from the swing hydrauli c circu it.
STEP 10
Install caps on the fitting in the backhoe control STEP 8
valve and the swing sequence valve . Stop the engine.
STEP 11 STEP 9
Disconnect the remaining tubes and the hoses Check for oil leakage at the swing sequence valve.
from the swing sequence valve.
STEP 10
STEP 12 Check the oil level in the hydraulic rese rv oir. Ad d
Close all openings with caps or plugs to keep dirt oil as required . See Section 8001 for spec ifica-
out of the hydraulic system . tions .
STEP 13 STEP 11
Remove the cotter pin and clevis pin that fastens See Swing Sequence Va lve Adjustm ent on page
the yoke on the linkage to the spool in the swing 8000-50. Adjust the swing sequence valve as re-
sequence valve. quired .
STEP 14
Hold the swing sequence valve in position on the
mounting bracket. The weight of the swing se-
quence valve is approximately 20 pounds (9 kg).
Loosen and remove the cap screws that fasten the
swinQ sequence valve to the mountina bracket.
8000-25
THREE-POINT HITCH CONTROL VALVE

STEP 1 STEP 1
Park the machine on a level surface. If the fittings were removed from the th ree-paint
hitch control valve , or a new three-point hitch con-
STEP 2 trol valve is being used. Insta ll new O-rings on the
Lower the loader bucket to the floor. fittings, lubricate the O-rings with clean hydraulic
oil. Install the fittings in the three-paint hitch con-
STEP 3 trol valve.
Lower any rear attachments to the floor.
STEP 2
STEP 4 Put the three-point hitch control valve in place on
Stop the engine, and apply the parking brake . the mounting bracket. Install the bolts, lock wash-
ers , and nuts that fasten the three-point hitch con-
STEPS trol valve to the mounting bracket.
Move all control levers for the three-point hitch in
one direction and then in the other to remove any STEP 3
pressure in the hydraulic circuit. Connect the linkage to the spool eyes in the three-
point hitch control valve.
STEPS
Clean the three-point hitch control valve and the STEP 4
area around the three-point hitch control valve. Connect the hoses to the fittings in the three-paint
hitch con t rol valve.
STEP 7
Fasten identification tags to the hoses at the three- STEPS
paint hitch control valve. Start and run the engine at low idle .
STEPS STEPS
Disconnect the hoses from the fittings at the three- Move all control levers for the three-paint hitch
point hitch control valve . slowly in both direction s to remove any ai r from the
hydraulic circuits.
STEP 9
Close all openings to keep dirt out of the hydraulic STEP 7
system. Lower any rear attachment to the floor. Stop the
engine.
STEP 10
Disconnect the linkage from the spool eyes at the STEPS
three-point hitch control valve . Check for oil leakage at the three-point hitch con-
trol valve .
STEP 11
Hold the three-paint hitch control valve in place STEP 9
and remove the bolts, lock washes, and nuts that Check the level in the hydraulic reservoir. Add oil
fasten the three-paint hitch control valve to the as required. See Section 8001 for specifications.
mounting bracket.
STEP 12
Remove the three-paint hitch control valve from
the machine.
8000-26
CYLINDERS
Loader Lift Cylinder STEP 14
Loosen and remove the clamp and rubber insula-
Removal tor that fastens the tube for the rod end of the
cylinder to the cylinder tube.
STEP 1
Remove the dirt and grease from the hose and tube STEP1S
connections at the loader lift cylinder to be re- Disconnect the tube from the fitting at the rod end
moved . of the cylinder. Install a cap on the fitting and a plug
in the tube . Move the tube out of the way .
STEP 2
Park the machine on a level surface. STEP 16
Disconnect the hose from the fitting at the closed
STEP 3 end of the cyli nde r. I nstall a cap on the f itting and a
Raise the loader frame until the pivot pin for the plug in the hose.
piston rod eye of the cylinder is above the hood.
STEP 17
STEP 4 Remove the driver from the piston rod eye and
Use an acceptable support (chain hoist or stand) to lower the cylinder onto the front axle.
hold the loader frame in place.
STEP 18
STEP S Remove the snap ring , spacer, and washer from the
Stop the engine and apply the parking brake. closed end of the cylinder.
STEP 6 STEP 19
Remove the snap ring and washer from the outer Remove the cylinder from the pivot pin. The we ight
end of the pivot pin at the rod end of the cylinder. of the cylinder is approximately 60 pounds (27 kg).
STEP 7 Installation
If you are removing the left lift cylinder, drive the
pivot pin out of the strut, loader frame, and the STEP 1
cylinder rod eye. Do not remove the driver now. Make sure that the washer is in position on the pivot
pin . Put the cylinder in position on the pivot pin .
STEP 8
If you are removing the right lift cylinder, drive the STEP 2
pivot pin out of the loader frame and the cylinder Install the washers and snap rin g that fastens the
rod eye. Do not remove the driver now. closed end of the loader lift cy linder to th e ma-
chine.
STEP 9
Start and run the engine at low idle. STEP 3
Connect the hose to the fi tting at the closed end of
STEP 10 the cylinder.
Remove the support and lower the bucket to the
floor. STEP 4
Connect the tube to the fitting at the rod end of the
STEP 11 cylinder. Do not tighten the tube on the fitt ing at
Stop the engine. this time.
STEP 12 STEPS
Move the loader control in all directions to remove Put the rubber insulator in position between the
any pressure from the loader circuits . cylinder tube and the tube for the ro d end of the
cylinder. Install the clamp that fastens the tube and
STEP 13 rubber insulator to the cylinder tube.
Loosen the self-locking nut on the clamp that fas-
tens the hoses together at the closed end of the STEP 6
cylinder. Remove the clamp from the hoses. I nstall the clam p that fastens the hoses tog ether at
the closed end of th e cylinder.
8000-27
STEP7 STEP 16
Tighten the tube on the fitting at the rod end of the Hold the piston rod in alignment with the loader
cylinder. frame and drive the pivot pin into the piston rod
eye, loader frame, and the strut.
STEP8
Start and run the engine at low idle. STEP 17
Install the washer and the snap ring that holds the
STEP9 pivot pin in place.
Slowly extend or retract the piston rod as required
to align the piston rod eye with the loader frame . STEP 18
Lubricate the pivot pins for the loader lift cylinder.
STEP10
Stop the engine. Move the loader control lever to STEP 19
the FLOAT position . Start and run the engine at low idle.
STEP 11 STEP 20
If the left loader lift cylinder is being installed go to With the engine running at low idle, slowly and
step 15. If the right loader lift cylinder is being completely extend and retract the loader lift cylin-
installed do steps 12 through 14. der four times to remove air om the loader lift cy-
linder hydraulic circuit.
STEP12
Hold the piston rod eye in alignment with the STEP 21
loader frame and start the tapered end of the pivot Stop the engine.
pin into the loader frame and the piston rod eye.
STEP 22
STEP13 Check for oil leakage at the cylinder.
Drive the pivot pin into place.
STEP 23
STEP14 Check the oil level in the hydraulic reservoir. Add
Install the washer and snap ring that holds the pivot oil as required. See Section 8001 for specifica-
pin in place . tions.
STEP15
Hold the strut in place on the loader frame. Start the
tapered end of the pivot pin into the strut and the
loader frame.
8000-28
Loader Lift Cylinder Installation

8000-29
Loader Bucket Cylinder Installation

Removal STEP 1
Put the cylinder in position in the cylinder links.
STEP 1
Remove the dirt and grease from the hose and tube STEP 2
connections at the loader lift cylind er to be re- T ighten the nut on t he bolt that fastens the cylinder
moved. links to the loader lift arm. Tighten the nut on the
bolt that fastens the cylin der links to th e bucket
STEP 2 link.
Pa rk the machine on a level surface.
STE P 3
STEP 3 Connect the hose to the fitting at the rod end of the
Lower the loader bucket until the bucket is flat on cylinder.
the floor.
STEP 4
STEP 4 Connect the hose to the tube for the closed end of
Stop the engine and apply the parking brake . th e cylinder.
STEPS STEPS
Move the loader control in all directions to remove Sta rt and run the engine at low idle.
any pressure in the loader circuits .
STEP 6
STEP 6 Slowl y exte nd or re tract the piston rod as required
Disconnect the hose from the tube for the closed to align the piston ro d eye with the hole in the
end of the cylinder. loader frame .
STEP 7 STEP 7
Install a cap on the hose and a plug in the tube. Stop the engine.
STEPS STEP S
Disconnect the hose from the fitting at the rod end In stall t he pivot pin t hat fastens t he cyli nder to the
of the cylinder. load er li ft arm .
STEP9 STEP9
Install a cap on the fitting and a plug in the hose. Install the snap ri ng on the pivot pin.
STEP 10 STEP 10
Loosen the nut on the bolt that fastens the cylinder Lubri cate th e pivot pins for th e loader bucket cyl in-
links to the bucket link . Loosen the nut on the bolt de r.
that fa stens the cy linder links to the loader lift arm
until the cylinder can be removed from the cylinder STEP 11
links. Start and run th e engine at low id le.
STEP 11 STEP 12
Remove the cylinder from the links and lower the Wi th th e engin e run ni ng at low idle, slowly and
cyl inder to the loader lift arm. completely extend and retract th e loader lift cylin-
de r four t imes to remove ai r fro m the loader bucket
STEP 12 cylinder hydraulic circu it.
Remove a snap ring from the pivot pin that fastens
the cylinder to the loader lift arm . STEP 13
Stop the eng ine.
STEP 13
Hold the cylinder in position and remove the pivot STEP 14
pin th at fastens the cy linder to the loader lift arm . Ch eck for oil leakage at the cylinder.
STEP 14 STEP 15
The weight of the cyl inde r is approximately 40 Ch eck the oil level in the hydraulic reservoi r. Add
pounds (1 9 kg). Rem ove th e cylinder from the ma- oi l as required. See Section 8001 for specifica-
chine. tio ns.
8000-30
/ ""...,., \
RIGHT LOADER
\"CKET CYLINDER
870339
Loader Buck et c yllnder

. Installation
8000-31
Loader Bucket Clam Cylinder Installation
Removal STEP 1
Put th e closed end of the clam cy linder in position
STEP 1 on the bucket.
Remove the dirt and grease from the hose and tube
connections at the clam cylinder to be removed. STEP 2
Install the pivot pin that fastens the closed end of
STEP 2 the cylinder to the bucket.
Park the machine on a level surface .
STEP 3
STEP 3 Connect the hoses to the fittings on the cylinder.
Lower the loader bucket until the loader bucket is
flat on the floor. STEP 4
STEP 4
Stop the engi ne and apply the parking brake. STEPS
Slowly exte nd or retract the piston rod as required
STEPS to align the piston rod eye with the holes in the
Move the clam control lever in all directions to bucket.
remove any pressure in the clam hydraulic circuits.
STEP 6
STEP 6 Stop the engine.
Fasten identification tags to the hoses for the clam
cylinder. STEP 7
Install the pivot pin that fastens the piston rod eye
STEP 7 to the bucket.
Disconnect the hoses from th e fittings in the clam
cylinder. STEPS
I nstall the bolts and self-locking nuts that fasten
STEPS the pivot pin to the bucket.
Install caps on the fittings and plugs in the hoses.
STEP 9
STEP 10 Lubricate the pivot pi ns for the loader bucket clam
Loosen and remove the nuts and bolts that fasten cylinder.
the pivot pins for the clam cylinder to the bucket.
STEP 10
STEP 11 Start and run the engine at low idle.
Remove the pivot pin that fastens the closed end of
the clam cylinder to the bucket. Do not remove the STEP 11
driver now. With the engine running at low idle, slowly and
completely extend and retract the loader bucket
STEP 12 clam cylinder four times to remove air from the
Remove the pivot pin that fastens the rod end of the clam cylinder hydraulic circuit.
clam cylinder to the bucket.
STEP 12
The weight of the cylinder is approximately 33
pounds (15 kg) . Hold the clam cylinder in position STEP 13
and remove the driver from the closed end of the Check for oil leakage at the cylinder.
cylinder.
STEP 14
STEP 14 Check the oil level in the hydraulic reservoir. Add
Remove the c lam cylinder from the bucket. oil as required . See Section 8001 for specifica-
tions.
8000-32
RIGHT .......-;
CLAM
CYLINDER
/ /
/ I
/ /
/ /
/ /
/ I
/ II
/ /
\ I / /
/ /
---- --:::.. /~~

\ \ ./ /
"-\ ":;-
870340
Clam Cylinder Installation

8000-33
Boom Cylinder STEP 14

Install caps on the hoses and plugs in the tubes.
Removal
STEP1S
STEP 1 Remove the cotter pin and pin that hold the pivot
Remove the dirt and grease from the hose and tube pin in the closed end of the boom cylin der.
connections at the boom cylinder.
STEP 16
STEP2 Remove the pivot pin from the swing tower frame
Park the machine on a level surface . and the closed end of the boom cylinder.
STEP3 STEP 17
Lower the loader bucket to the floor . Remove the boom cylinder from th e machine.
STEP4 Installation
Lower the stabilizers to the floor.
STEP 1
STEPS Put the new seals and the closed end of the boom
Completely extend the bucket cylinder. Com- cylinder in position in the swing tower frame .
pletely retract the dipper cylinder. Lower the boom
until the backhoe bucket is on the floor. STEP 2
Lubricate the pivot pin . Al ign th e hole in the pivot
STEP6 pin with the hole in the closed end of the boom
Stop the engine and apply the parking brake. cylinder. Install the pivot pin in the swing tower
frame and the closed end of the boom cylinder.
STEP7
Move the backhoe control levers in both di rect ions STEP 3
to remove any pressure in the backhoe hydraulic Install the pin and cotte r pin to hold the pivot pin in
circuits. the swing tower frame and th e closed end of the
boom cylinder.
STEPS
Put supports under the boom to keep the boom in STEP 4
position when the boom cylinder is removed. Connect the hoses to the tubes on the boom cylin -
der.
STEP9
Fasten lifting equipment to the boom cylinder. Use STEPS
the lifting equipment to hold the weight of the Start and run the engine at low idle .
boom cylinder during removal of the pivot pins.
The weight of the boom cylinder is approximately STEP 6
170 pounds (77 kg). Slowly extend or retract the piston rod as required
to align the piston rod eye with the holes in the
STEP10 boom.
Loosen and remove the cap screw and retainer that
hold the pivot pin in the boom and the rod end of STEP 7
the boom cylinder. Stop the engine .
STEP 11 STEPS
Remove the pivot pin and retaining pin from the Install new seals at the rod end of the boom cylin-
boom and the rod end of the boom cylinder. der. Lubricate the pivot pin . Start the pivot pin into
the boom and the piston rod eye. Align the retain-
STEP12 ing pin in the pivot pin with the slots in the boom.
Start and run the engine at low idle. Completely Install the pivot pin .
retract the boom cylinder. Stop the engine.
STEP 9
STEP13 Install the cap screw and retainer that holds the
Disconnect the hoses from the tubes on the boom pivot pin in the boom and the rod end of the boom
cylinder. cylinder. Tighten the cap screw to 270 to 324
8000-34
STEP 10 STEP 14
Remove the lifting equipment from the boom cylin- Stop the engine.
der.
STEP 15
STEP 11 Check for oil leakage at the boom cylinder.
Lubricate the pivot points on the boom cylinder.
See Section 1212. STEP 16
STEP 12 oil as required. See Section 8001 for specifica-
Start and run the engine at low idle. tions.
STEP 13
With the engine running at low idle, slowly and
completely extend and retract the boom cylinder
four times to remove air from the boom cylinder
hydraulic circuit.
BOOM
CYLINDER
/
870341A
Boom Cylinder Installation

8000-35
Dipper Cylinder STEP 14

Remove the dipper cylinder from the machine.
Removal
Installation
STEP 1
connections at the dipper cylinder. Replace the seals at the closed end of the dipper
cylinder. Put the closed end of the dipper cylinder
STEP 2 in position on the boom .
STEP 2
STEP 3 Lubricate the pivot pin . Start the pivot pin into the
Extend the boom and dipper completely. Lower the boom and the closed end of the dipper cylinder.
bucket to the floor. Align the retaining pin in the pivot pin with the slots
in the boom. In stall the pivot pin .
STEP 4
Put supports under the boom to keep the dipper in STEP 3
position when the hoses are disconnected from the Install the cap screw and retainer that holds the
dipper cylinder. pivot pin in the boom and the close d end of the
dipper cylinder. Tighten the cap sc rew to 270 to 324
STEPS pound-feet (366 to 439 N m, 37 to 45 kg/ m) .
Stop the engine and apply the parking brake.
STEP 4
STEP 6 Connect the hoses to the tubes on the dipper cylin-
Move the dipper control lever in both directions to der. I nstall new seals at the rod end of the dipper
remove the pressure in the dipper hydraulic cir- cylinder.
cuit.
STEPS
STEP 7 Start and run th e engine at low idl e.
Disconnect the hoses from the tubes for the dipper
cylinder. STEP 6
Slowly extend or retract the piston rod as required
STEP S to align the pisto n rod eye with the holes in the
Install caps on the hoses and plugs in the tubes. dipper.
STEP 9 STEP 7
Fasten lifting equipment to the dipper cylinder. Use Stop the engine .
the lifting equipment to hold the weight of the
dipper cylinder during removal of the pivot pins. STEPS
The weight of the dipper cylinder is approximately Lubricate the pivot pin . Start the pivot pin into the
155 pounds (70 kg). dipper and the piston rod eye . Ali gn the retaining
pin in the pivot pin with the slots in the boom . Install
STEP 10 the pivot pin .
Loosen and remove the cap screw and retainer that
hold the pivot pin in the boom and the closed end of STEP 9
the dipper cylinder. Install the cap screw and retain er that hold the
pivot pin in the dip per and the rod end of the boom
STEP 11 cylinder. Tighten the cap screw to 270 to 324
Remove the pivot pin and retaining pin from the pound-feet (366 to 439 N m, 37 to 45 kg/ m).
boom and the closed end of the dipper cylinder.
STEP 10
STEP 12 Remove the lifting equipment from the dipper cyl-
Loosen and remove the cap screw and retainer that inder.
hold the pivot pin in the dipper and the rod end of
the dipper cylinder. STEP 11
Lubricate the pivot points fo r the dipper cylinder.
STEP 13 See Section 1212.
Remove the pivot pin and retaining pin from the
dipper and the rod end of the dipper cylinder. STEP 12
8000-36
STEP 13 STEP 15
With the engine runn ing at low idle, slowly and Check for oil leakage at the dipper cylinder.
completely extend and retract the dipper cylinder
four times to remove air from the dipper cylinder STEP 16
hydraulic circuit. Check the oil level in the hydraulic reservoir. Add
oil as required . See Section 8001 for specifica-
STEP 14 tions .
Stop the engine.
\DIPPER
CYLINDER
810342 A
Dipper Cylinder Installation

8000-37
Extendable Dipper Cylinder Installation
Removal STEP 1
Put the closed end of th e extendable dipper cylin-
STEP 1 der in position in the dipper.
STEP 2
STEP 2 Install the pivot pin .
See Section 9100 and remove the dipper exten-
sion. STEP 3
STEP 3
Connect the hoses for the extendable dipper cylin-
STEP 4 der to the tubes on the boom .
Move the control lever for the extendable dipper
cylinder in both directions to remove the pressure STEPS
in the extendable dipper cylinder hydraulic circuit. Start and run the engine at low idle.
STEPS STEPS
Remove ali dirt and grease from the hoses, tubes, Operate the control lever for the extendable dipper
and fittings at the extendable dipper cylinder. cylinder to extend and then retract the piston rod .
This must be done slowly to prevent damage
STEPS caused by air in the extendable dipper cylinder. Be
Disconnect the hoses for the extendable dipper careful not to damage the rod end of the extenda-
cylinder at the tubes on the boom . Put identifica- ble dipper cylinder.
tion tags on the hoses and tubes.
STEP 7
STEP 7 Move the piston rod completely in and out of the
Install caps on the hoses and plugs in the tubes . extendable dipper cylinder four times to remove all
the air from the extendable di pper cylinder.
STEP 8
Remove one of the snap rings from the pivot pin at STEP 8
the closed end of the extendable dipper cylinder. Stop the engine.
STEP9 STEP 9
Remove the pivot pin. Check for oil leakage at the extendable dipper cyl-
inder.
STEP 10
Carefully move the extendable cylinder out of the STEP 10
dipper. Check the oil level in the hydraulic reservoir. Add
oil as required . See Section 8001 for specifica-
tions.
STEP 11
See Section 9100. Install the dipper extension .
8000-38
~I B
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\
EXTENDABLE
DIPPER
CYLINDER
870343 A
Extendable D'Ipper C YI'mder Installation

8000-39
Backhoe Bucket Cylinder STEP 14

Remove the pivot pin from one bucket guide link,
Removal one side of the bucket dump link, and the piston
rod eye . Do not remove the pivot pin from the other
STEP 1 bucket guide link , and the other side of the bucket
Remove the dirt and grease from the hose and tube dump link .
connections at the bucket cylinder.
STEP 15
STEP 2 Remove the bucket cylinder from the machine.
Installation
STEP 3
Extend the boom and dipper with the bucket in the STEP 1
DUMP position . Put the closed end of the bucket cylinder in posi-
tion on the dipper.
STEP 4
Put supports under the dipper to keep the dipper STEP 2
and bucket in position after the hoses are discon- Start the pivot pin into the dipper and the closed
nected from the bucket cylinder. end of the bucket cylinder. A lign the retaining pin
in the pivot pin with the slots in the dipper. Install
STEP 5 the pivot pin.
Stop the engine and apply the parking brake .
STEP 3
STEP 6 Install the cap screw and retainer that hold the
Move the bucket control lever in both directions to pivot pin in the dipper and the closed end of the
remove pressure in the bucket hydrauliC circuit. bucket cylin der. Tighten the cap scre w to 270 to
324 pound-feet (366 to 439 N m, 37 to 45 kg/ m).
STEP 7
Fasten an identification tag to a hose for the bucket STEP 4
cylinder. Connect the hoses for the bucket cylinder to the
tubes on the boom .
STEPS
Disconnect the hoses for the bucket cylinder at the STEP 5
tubes on the boom . Sta rt and run the engine at low idle.
STEP 9 STEP 6
Install caps on the hoses and plugs in the tubes. Slowly extend or retract the piston rod as required
to align the piston rod eye with the holes in the
STEP 10 bucket dump link and the holes in the bucket guide
Fasten lifting equipment to the bucket cylinder. links.
Use the lifting equipment to hold the weight of the
bucket cylinder during removal of the pivot pins . STEP 7
The weight of the bucket is approximately 98 Stop the eng ine.
pounds (45 kg) .
STEPS
STEP 11 Make sure that the seal is in place between the
Loosen and remove the cap screw and retainer that bucket dump link and the bucket guide link . Install
hold the pivot pin in the dipper and the closed end the pivot pin in the piston rod eye, bucket dump
of the bucket cylinder. link, and the bucket guide link .
STEP 12 STEP 9
Remove the pivot pin and retaining pin from the Install the washer and snap ring that holds the pivot
dipper and the closed end of the bucket cylinder. pin in the bucket links and the rod end of the bucket
cylinder.
STEP 13
Remove the snap ring and washer from one end of STEP 10
the pivot pin at the rod end of the bucket cylinder. Remove the lifting equipment from the bucket cyl-
inder.
8000-40
STEP 11 STEP 14
Lubricate the pivot points for the bucket cylinder. Stop the engine .
See Section 1212.
STEP 15
STEP 12 Check for oil leakage at the bucket cylinde r.
STEP 16
With the engine running at low idle, slowly and oil as required . See Section 8001 for specifica-
completely extend and retract the bucket cylinder tions.
four times to remove air from the bucket cylinder
hydraulic circuit.
BACKHOE
I---CONTROL
VALVE
870344 A
Backhoe Bucket Cylinder Installation Wi thou t Extendable Dipper

8000-41
,
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BACKH~ '"'il)
CONTROL ",.,.~
VALVE ~
870345 A
With Extend~~~der 1nstallation

Backhoe Bucket C I"
e Dipper
8000-42
Swing Cylinder STEP 16

The weight of the swing cylinder is approxi mately
Removal 70 pounds (32 kg) . Remove the swing cylind er from
the machine.
S'TEP 1
Remove the dirt and grease from the hose and tube Installation
connections at the swing cylinder.
STEP 1
STEP 2 Replace the seals in both ends of the swing cy lind-
Park the machine on a level surface. ers. Put the closed end of the swing cyl in der in
position on the frame.
S'TEP 3
Install the swing lock pin for the backhoe. STEP 2
Lubricate the pivot pin. Install the pivot pin that
STEP 4 fastens the closed end of the swing cylind er to the
Stop the engine and apply the parking brake. frame .
STEP 5 STEP 3
Move both of the swing control pedals to remove Install the cap screw, and lock washer t hat hold the
any pressure from the swing hydraulic circuit. pivot pin at the closed end of the swing cy linder.
STEP 6 STEP 4
Remove the cap screw, lock washer, and flat Connect the hoses to the f ittings in the swin g cylin -
washer that hold the pivot pin in position at the rod der.
end of the swing cylinder.
STEP 5
STEP 7 Start and run the engine at low idle.
Remove the pivot pin that fastens the rod end of the
swing cylinder to the swing tower frame. STEP 6
Slowly extend or retract the piston rod eye as re-
STEP S quired to align the piston rod eye with the holes in
Start and run the engine at low idle. the swing tower.
STEP 9 STEP 7
Carefully move the swing control pedal to move the Stop the engine .
rod eye out of the swing tower.
STEPS
STEP 10 Lubricate the pivot pin . Install the pivot pi n that
Stop the engine . fastens the rod end of t he swi ng cylinder to the
swing tower.
STEP 11
Move one swi ng control pedal and then the other to STEP 9
remove pressure in the swing cylinder hydraulic Install the cap screw, loc k washer, and flat washe r
circuit. that hold the pivot pin in the swing towe r and the
rod end of the swing cylinder.
STEP 12
Disconnect the hoses from the fittings in the swing STEP 10
cylinder. Lubricate the pivot pins for the swing cyli nder.
STEP 13 STEP 11
Install caps on the fittings and plugs in the hoses. Remove th e swing lock pin for the bac khoe.
STEP 14 STEP 12
Remove the cap screw and lock washer that hold Start and run the engine at low idle.
the pivot pin at the closed end of the swing cylinder
to the frame. STEP 13
With the engine running at low idle, slowly swing
STEP 15 left and then right compl etely four times to remove
Remove the pivot pin that fastens the closed end of the air from the swing cyl inder hydraulic circuit.
the swing cylinder to the f-rame .
8000-43
STEP14 STEP 16
Stop the engine. Check the oil level in the hydraulic reservoir. Add
as required . See Section 8001 for specifications.
STEP15
Check for oil leakage at the swing cylinder.
SWING
SEQUENCE
VALVE
870346 A
Swing Cylinder Installation

8000-44
Stabilizer Cylinder STEP 14

Remove the stabilizer cylinder f rom th e machine.
Removal
Installation
STEP 1
connections at the stabilizer cylinder to be re- Put the closed end of the stabilizer cylinder in posi-
moved . tion on the frame. Install the pivot pin .
STEP 2 STEP 2
Park the machine on a level surface. Install the snap ring that fastens the pivot pin in the
frame .
STEP 3
Lower the loader bucket to the floor. STEP 3
Connect the hoses to the tubes for th e stabilizer
STEP 4 cylinder.
Lower the stabilizer until the stabilizer pad just
comes into contact with the floor. STEP 4
STEPS
Stop the engine and apply the parking brake. STEPS
Slowly extend or retract as required the piston rod
STEP 6 to align the piston rod eye with the hol e in the
Move the stabilizer control lever in both directions stabilizer.
to remove the pressure from the stabilizer hydrau-
lic circuit. STEP 6
Stop the engine.
STEP 7
Fasten identification tags to the hoses for the sta- STEP7
bilizer cylinder. Install the pivot pin that fastens the rod end of the
stabilizer cylinder to the stabilizer.
STEP 8
Disconnect the hoses from the tubes on the stabil- STEP 8
izer cylinder. Install the snap ring on the pivot pin .
STEP 9 STEP9
I nstall caps on the hoses and plugs in the tubes. Start and run the engine at low idle, slow ly and
completely extend and retract the stabilizer cylin -
STEP 10 der four times to remove air from the stabilizer
Remove one of the snap rings from the pivot pin at cylinder hydraulic circuit .
the rod end of the stabilizer cylinder.
STEP 10
Remove the pivot pin that fastens the rod end of the
cy lind er to the stabilizer. STEP 11
Check for oil leakage at the cylinder.
STEP 12
Remove one of the snap rings from the pivot pin at STEP 12
the closed end of the stabilizer cylinder. Check the oil level in the hydraulic reservoir. Add
oil as required . See Section 8001 for specif ica-
STEP 13 tions.
The weight of the stabi lizer cylinder is approxi-
mately 99 pounds (45 kg). Hold the stabilizer in
position and remove the pivot pin that fastens the
stabi lizer cylinder to the frame .
8000-45
BACKHOE
CONTROL
LVE
----_ /
870347
Stabilizer Cyllnder
. Installation
eOOO-46
LIFT CYLINDER (THREE-POINT HITCH)

Bemoval STEP 2
Install the pivot pin . Make sure that the ho le in the
STEP 1 pivot pin is in alignment with the hole in the mount-
Park the machine on a level surface. ing bracket.
STEP 2 STEP3
Put blocks under the draft arms of the three-point Install the bolt, lock washer, and nut that ho ld th e
itch . pivot pin in position .
STEP 3 STEP 4
Lower the draft arms onto the blocks. Connect the hoses to the fittings on the lift cylin-
der.
STEP 4
Stop the engine and apply the parking brake. STEPS
Start and run the engine at low idle .
STEPS
Move all control levers for the three-point hitch in STEP 6
one direction and then in the other to remove any Slowly move the control lever for the lift cyli nder to
pressure in the hydraulic circuit. put the rod end of the li ft cylinder in position for
installation of th e pivot pin.
STEP 6
Ftemove all dirt and grease from the lift cylinder STEP 7
and the area around the lift cylinder. Stop the engine .
STEP 7 STEPS
Disconnect the hydraulic hoses from the fittings Install the pivot pin.
on the lift cylinder. Install caps on the fittings and
plugs in the hoses. STEP9
STEPS
Ftemove the snap ring from the pivot pin at the rod STEP 10
end of the lift cylinder. Lubricate the pivot pins for the lift cylind er. See
Section 1212 for lubricant specifications.
STEP9
Flemove the pivot pin . Do not let the lift cylinder STEP 11
fall. Start and run the engine at low idle.
STEP 10 STEP 12
Ftemove the nut, lock washer, and bolt from the Operate the control lever for the lift c ylinder.
pivot pin at the closed end of the lift cylinder. Slowly extend and retract the lift cylind er to re-
move the air from the lift cylinder.
STEP11
The weight of the lift cylinder is approximately 29 STEP 13
pounds (13 kg). Hold the lift cylinder and remove Stop the engine.
tile pivot pin.
STEP 14
STEP 12 Check for oil leakage at the lift cylinder .
Flemove the lift cylinder from the machine.
STEP1S
Installation Check the oil level in the hydraulic reservo ir. Add
oil as required . See Section 8001.
STEP 1
Put the closed end of the lift cylinder in position on
tile three-point hitch .
8000-47
TILT CYLINDER
STEP 1 STEP 1
Park the machine on a level surface . Pu t the closed end of the tilt cylinder in position on
the three-point hitch .
STEP 2
Put blocks under the draft arms of the three-point STEP2
hitch Install the pivot pin .
STEP 3 STEP3
Lower the draft arms onto the blocks . Install the wa sher and snap ri ng .
STEP 4 STEP 4
Stop the engine and apply the parking brake . Connect the hoses to the fittings on the tilt cylin-
der.
STEPS
Move all control levers for the three-point hitch in STEPS
one direction and then in the other to remove any Start and run the engine at low idle.
pressure in the hydraulic circuit.
STEPS
STEPS Slowly move the control lever for th e tilt cylinder to
Remove the dirt and grease from the tilt cylinder put the rod end of the cylinder in position for instal-
and the area around the tilt cylinder. lation of the pivot pin.
STEP 7 STEP 7
Disconnect the hydraulic hoses from the fittings Stop the engine .
on the tilt cylinder. Install caps on the fittings and
plugs in the hoses. STEPS
In stal l the pivot pin.
STEPS
Remove the snap ring and washer from the closed STEP 9
end of the tilt cylinder. Install the snap ring .
STEP 9 STEP 10
Remove the pivot pin from the closed end of the tilt Lubricate the pivot pins for the tilt cylinder. See
cylinder. Section 1212 for the lubricant specifi cations.
STEP 10 STEP 11
Remove the snap ring from the pivot pin at the rod Start and run the engine at low idl e.
end of the tilt cylinder.
STEP 12
STEP 11 Operate the control lever fo r the ti lt cylinder.
The weight of th e tilt cylinder is approximately 23 Slowly exten d and retract the til t cy lind er to re-
pounds (10 kg) . Hold the tilt cylinder in place and move the air from the tilt cylinder.
remove the pivot pin.
STEP 13
STEP 12 Stop the engine .
Remove the tilt cylinder from the machine.
STEP 14
Check for oil leakage at the tilt cylinder.
STEP1S
oil as required. See Sectio n 8001 .
BOOO-48
PITCH CYLINDER
lRemoval STEP 2
Install the pivot pin .
STEP 1
Park the machine on a level surface . STEP 3
STEP2
Put blocks under the draft arms of the three-point STEP 4
hitch. Connect the hoses to the fitting s on the pitch cylin-
der.
STEP 3
Lower the draft arms onto the blocks. STEPS
Start and run the engine at low id le.
STEP 4
Stop the engine and apply the parking brake . STEP 6
Slowly move the control lever for th e pitch cylinder
STEPS to put the rod end of the cylinder in pOSition for
Move all control levers for the three-point hitch in installation of the pivot pin.
one direction and then in the other to remove any
pressure in the hydraulic circuit. STEP 7
Stop the engine.
STEP 6
Hemove all dirt and grease from the pitch cylinder STEP 8
and the area around the pitch cylinder. Install the pivot pin .
STEP 7 STEP 9
Disconnect the hydraulic hoses from the fittings Install the Klik pin.
on the pitch cylinder. Install caps on the fittings
and plugs in the hoses. STEP 10
Lubricate the pivot pins for the pitch cylinder. See
STEP 8 Section 1212 for the lubricant specifications.
Hemove the snap ring from the pivot pin at the
closed end of the pitch cylinder. STEP 11
STEP 9
Hemove the pivot pin. Do not let the pitch cylinder STEP 12
fall. Operate the control lever for the pitch cy lind er.
Slowly extend and retract the pitch cylinder to
STEP 10 remove the air from the pitch cylinder.
f~emove the Klik pin from the pivot pin at the rod
Elnd of the pitch cylinder. STEP 13
Stop the engine .
STEP 11
he weight of the pitch cylinder is approximately STEP 14
30 pounds (14 kg). Hold the pitch cylinder and Check for oil leakage at the pi tc h cylinder.
remove the pivot pin.
STEP1S
f~emove the pitch cylinder from the machine. oil as required . See Section 8001 .
Installation
STEP 1
Put the closed end of the pitch cylinder in position
on the three-point hitch.
8000-49
/
/
/
/
~ _/
8 872127
I ch C y rmder Install atio n

Three-Point - H't
8000-50
SWING SEQUENCE VALVE ADJUSTMENT

STEPS
Make sure that the clevis pin that fastens the yok e
on the control rod to the spool eye in th e swing
sequence valve is in a vertical position . If th e clevis
pin is not vertical after the jam nuts are tig htened
on the control rod, the control rod or the spoo l can
be damaged .
STEP 6
Tighten the jam nut at the yoke and at the ball jOint
on the control rod .
STEP 7
Start and run the engine at approximately 1/ 4 throt-
tle.
STEPS
Swing the backhoe completely to the left and then
BALL I to the right. See the illustration below for the cor-
I
JOINT~ I
I rect swing cushion adjustment. Sho rten or leng-
I
then the control rod as required .
,~\
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/ 'JAM
NUT
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ROD Gil CORRECT AMOUNT OF CUSHION
~ 870348
NOTE: The following adjustment instructions are

given viewing the machine from the rear.
STEP 1
Swing the swing tower completely to the left.
STEP 2
Loosen the jam nut at the yoke and at the ball joint
on the control rod.
LENGTHEN CONTROL ROD TO INCREASE
THE RIGHT CUSHION. (TURN COUNTERCLOCKWISE)
STEP 3
Turn the control rod clockwise or counterclock-
wise until the cam follower will turn freely. The cam
follower must still touch the cam or be within 0.02
inch (0.5 mm) from the cam.
STEP 4
After step 3 has been completed , turn the control
rod clockwise 1/4 to 1/ 2 turn to shorten the control
rod .
t==--=-=-=- /
SHORTEN CONTROL ROD TO INCREASE
THE LEFT CUSHION. (TURN CLOCKWISE ) 870349
8001
MAINTENANCE
TABLE OF CONTENTS
Specifications ..... .. . . ... ... . ........ .. 8001-2 Procedure to Check the Condition of
the Hydraulic Filter . . .... . ... . . . .... 8001-2
Maintenance . . . .. .. .. . .. ... .. . . ... . ... . 8001-2
Procedure to Replace the Hydraulic
Oil Level Check .. . . ... ..... .. . . ..... . 8001-2 Filter . . .. ... ....... . ............. .. 8001-3
Hydraulic Filter .... .. . . . .......... . .. 8001-2 Oil Change ...... . ....... . ... . . . .. .. . 8001-4
J I Case 8-67370
A Tenneco Company
8001-2
SPECIFICATIONS
Hydraulic oil Case TCH Fluid
Alternate oil .. .. . .. ..... ..... . ........ . . . .. ...... ...... . .. . .. . ..... Eng in e oil , SAE 10W-30, API CC
Capacity of reservoir . .. . . . . ... .. . , ........ . . .... ..... , . . .. .. .... .... .. . .. . . 21 U.S . gallons (79 .5 litres)
Interval for oil change . . . . . .. . .. . .. ...... . , .. .. .. ... . ..... . . .. . . .. . . after every 1000 hours of operation
Interval for filter change . . . . .. .. ... . . . .. .. ... . .. , . . ..... . ... after every 1000 hours of operation or when
the warning lamp for the filter stays illuminated .
MAINTENANCE
Check the level of the oil every 50 hours of Hydraulic Filter
operation . Change the hydraulic oil and oil filter
every 1000 hours of operation. The hydraulic filter is installed on the right side
of the machine. If the machine is new, replace the
Oil Level Check filter after the first 20 hours of operat ion. Th en ,
replace the filter after every 1000 hours of opera-
STEP 1 tion or if the warning lamp for the hydrauli c filter is
Park the machine on a level su rface . illuminated .
STEP 2
Lower the loader bucket to the floor and put the
backhoe in the transport position .
STEP 3
Stop the engine.
k "~
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WATER ,~
L~~
Oil ~
STEP 4 TEMP. ' TEMP.
cr-\
C3 'y
VOLT S •.'
HOURS
[eXeXeXeO
861757
Procedure to Check the

Condition of the Hydraulic
Filter
STEP 1
Start the engine and raise the temperature of the
T he oil level sight gauge is on the upper RH frame. hydraulic oil to operating temperatu re (sid e of the
Oil must be in the center of the sight gauge. DO hydraul ic reservoir feels very warm ). To in crease
NOT overfill the hydraulic reservoir. the temperature of the hydraulic oil, do the follow-
ing :
STEPS
See Section 1002 for the correct oil. Add oil as a. Roll back the loader bucket and hold th e
necessary. control lever in this pos iti on for 15 seconds .
b. After 15 seconds , move the contro l lever to

th e NEUTRAL position .
c. Do this procedure until the si de of the hy-

draulic reservoir feels very warm .
8001 -3
STEP 2 STEP 7
Increase the engine speed to full throttle. If the
warning la mp for the hydraulic filter illuminates,
replace the filter.
Procedure to Replace the

Hydraulic Filter
STEP 1
Raise the loader to full height and install the lift arm
support strut to support the lift arms.
STEP 2
Stop the engine.
STEP 3
Open the access cover and open the hood. Disconnect the air cleaner hose from the intake
manifold.
STEP 4
If equipped , disconnect the ether injection tube

loosen and remove th e bolt and clamp on the air
conditioner hose.
STEPS

tion system from the engine temperature switch on
Remove the four mounting bolts that fasten the air
the intake manifold.
STEP 6
STEP 10
Disconnect the wire connec tor for the ether injec-
Remove the air cleaner and mounting bracket from
tion system from the wiring harness.
the machine. Clean the hydraulic filter and filter
head.
8001-4
STEP 11 STEP 21
Start the engine and check for leaks at the hydrau-
Iic fi Iter.
Oil Change
Change the hydraulic oil every 1000 hours of
operation.
STEP 1
Make sure the hydraulic oil is at operating temper-
ature.
STEP 2
Lower the loader bucket to the ground and put the
866744
backhoe in the transport position.
Use a strap wrench and remov e the old filter from
the machine.
STEP 3
Stop the engine and put a Do Not Operate tag on
STEP 12 the key switch.
Lubricate the gasket on the new filter with clean
Case TCH Fluid.
STEP 4
STEP 13
Install the new filter and turn clockwise until the
gasket contacts the head of the filter assembly.
Continue to tighten the filter for 1/3 turn.
IMPORTANT: 00 not use a filter strap wrench to

install the filter. A fluid leak can occur if the filter is
dented by the filter strap wrench.
STEP 14
STEP1S
If the machine is equipped with an air conditioner, Put a container under the drain plug that will hold
install th e clamp and hose. 22 U.S. gallons (83 litres).
STEP 16 STEPS
Instal l the air cleaner mounting bracket to the Push the button in the fill cap to remove the air
frame. pressure in the reservoir. Remove the fill cap.
STEP 17 STEP 6
Connect the air cleaner hose to the intake mani- After the oil is drained from the reservoir, install the
fold . Make sure the hose connections are tight. drain plug.
STEP 18 STEP 7
Connect the wire connector for the ether injection Replace the hydraulic filter.
system to the wiring harness.
STEP 8
STEP 19 Fill the reservoir with oil.
Connect the wire connector for the ether injection
system to the engine temperature switch on the STEP 9
inta ke manifold . Start the engine and operate the loader an d back-
hoe controls for three to four minutes. Stop the
STEP 20 engine and check for leaks. Check the flu id level.
Connect the ether injection tube to the intake man-
ifold.
8002
HYDRAULIC SCHEMATICS, SPECIFICATIONS,
AND TROUBLESHOOTING
TABLE OF CONTENTS
Specifications . ...... ...... ... ... ....... 8002-2 Loader and Backhoe Cont rol Valves . . 8002-14
Special Tools ... . ... . . . . ... . . . . . ... .... 8002-3 Three Point Hitch Control Valve . .. ... 8002-15
Backhoe Hydraulic Schematic ... ... . ... 8002-4 Boom Cylinder Relief Valve
Three Point Hitch Hydraulic Schematic . . 8002-5 Pressure Check .. ..... . .. .. ... ... ... 8002-16
Bad Performance in All Circuits .. .. . .... 8002-6 Cylinder Packing . . . .... . ... . . .. . . . .... 8002-17
Bad Performance in a Single Circuit .. . . . 8002-7 Loader Lift Cylinders . .... .. .. .... .. . 8002-17
Any Single Ci rcuit .... . . .. ..... .. ... .. 8002-7 Loader Bucket Cylinders . ..... . ..... . 8002-17
Swing Circuit . ... .... .. . ...... ... ... . 8002-8 Loader Clam Cylinders .. . . . . . ... . .. . 8002-17
Stabilizer Circuit .. ... . ..... . .. . ..... . 8002-8 Boom Cylinder . . . ... ..... . . . . . ... .. . 8002-18
Bad Performance in All Backhoe Circuits; Dipper Cylinder . . .. ... ........ . . .. .. 8002-18
Other Circuits Work Correctly .. . .... .. 8002-8 Backhoe Bucket Cylinder . . ..... .. .. . 8002-18
Hydraulic Oil Becomes Too Hot .. .. . . ... 8002-9 Swing Cylinders ... . .. . . .. ... ... .. .. . 8002-19
Bad Performance of Components .... . .. 8002-9 Stabilizer Cylinders .... . ... . ......... 8002-19
Hydraulic Pump .......... .. ... .. .. . . . 8002-9 Extension Cylinder ..... .. . . . .. . . .... 8002-19
Control Valves . .. . . . ... . . ... . .. . . .. . 8002-10 Flowmeter Test . ......... .. . ...... . ... 8002-21
Cylinders ...... . . . .. . .... . . .. .. . . .. . 8002-10 General Information .... . . .. . ... ..... 8002-21
Hoses and Fittings ..... .. .. ... . . . .. . 8002-11 Test No.1 - Output of the Rear Section
Checks and Pressure Settings .. .. . .... . 8002-12 of the Hydraulic Pump . .. .... . ..... 8002-21
Heating the Hydraulic Oil .... . . . . .. . . 8002-12 Understanding the Results of the Test .. 8002-22
Main Relief Valve .. .... . . ... .. .. . . .. . 8002-12 Test No. 2 - Output of the Front Section
Swing Sequence Valve .... .. ..... .... 8002-13 of the Hydraulic Pump . ..... . ... . .. 8002-23
Three Po int Hitch Relief Valve . .. . .. . . 8002-14 Understanding the Results of the Test .. 8002-25
Circuit Relief Valve . ....... . ......... 8002-14 Flowmeter Check Sheets . . ... . . ....... 8002-26
J I Case Bu r 8-67381
A Tenneco Company
8002-2
SPECIFICATIONS
Hydraulic pump output
Rear section . .............. . . ... ... .. . .. .. . ....... . ...... . .. ..... 26 U.S. gpm at 2200 rpm at 2550 psi
(98 L/ min at 2200 r/ min at 17 582 kPa , 182 kg/ cm 2)
Front section ... . ........ .. ...... ......... ... . . .... .. ... . ...... ... 7 U.S. gpm at 2200 rpm at 2550 psi
(26 L/ min at 2200 r/ min at 17 582 kPa , 180 kg/ cm 2
Relief valves
Main relief valve 2500 to 2600 psi (17 237 to 17 927 kPa, 176 to 183 kg/cm 2 )
Steering relief valve ........ . ...... . .... ..... 2050 to 2200 psi (14135 to 15169 kPa, 144 to 155 kg/ cm 2)
Swing Sequence Valve Hand Pump

High pressure relief valves . .. . . .. . . ..... . . 3150 to 3350 psi (21719 to 23 098 kPa, 221 to 235 kg/ cm 2)
Low pressure relief valve .... . .. . .. . . ... . . . . . . .. 1150 to 1300 psi (7929 to 8963 kPa, 81 to 91 kg / cm 2)
Boom cylinder relief valve (In piston) . .. ... . 4500 to 5000 psi (31 028 to 34 475 kPa, 316 to 352 kg/ cm2)
Three point hitch relief valve ...... ....... . . 2488 to 2588 psi (17 155 to 17 844 kPa. 175 to 182 kg/cm2)
Circuit relief valves Hand Pump

Backhoe boom, A port ... . .. . ........... .. .. 1575 to 1725 psi (10860 to 11894 kPa, 111 to 121 kg / cm 2)
Backhoe boom, B port ....... . . . .... .... .... 4000 to 4200 psi (27 580 to 28 959 kPa, 281 to 295 kg/cm 2 )
Backhoe dipper, A and B ports .... . ......... 2950 to 3150 psi (20340 to 21 719 kPa, 207 to 221 kg/ cm 2)
Backhoe bucket, A and B ports .... . ......... 2950 to 3150 psi (20340 to 21 719 kPa, 207 to 221 kg/ cm 2)
Backhoe swing, A and B ports .... .. . ... ... . . 2050 to 2250 psi (14135 to 15 514 kPa, 144 to 158 kg / cm 2)
Loader bucket, A and B ports . ..... . . .. ..... . 2500 to 2700 psi (17 237 to 18616 kPa, 176 to 190 kg / cm 2)
Three Point Hitch Lift, B port ........... ..... 2650 to 2750 psi (18271 to 18961 kPa, 186 to 193 kg/cm2)
Hydraulic oil, capacities, and service intervals .. .. ... . .. . .. ...... .................... . See Section 8001
8002-3
SPECIAL TOOLS
See Section 1001 for information about order-
ing special tools.
CAS-10090 Hand Pump 877895
CAS-10280 Flowmeter 785789
009638
CAS-1804 Pressure Test Fitting Kit
797157
CAS-1808 Flowmeter Fitting Kit
CAS-1913 Hand Pump 877808
CAS-1205 Test Block 220423

8002-6
BAD PERFORMANCE IN ALL CIRCUITS

CHECK INSTRUCTIONS
1. Maintenance 1. Check the service records for the machine. Make sure that the
machine has had the necessary lubrication , maintenance and
service . See Section 1212 for correct lubricants and service
intervals.
2. Attachments 2. Check field installed attachments that can be causing bad

performance in the hydraulic system .
3. Oil level 3. Check the level of the oil in the reservoir. See Section 8001 .
4. Hydraulic oil filter 4. Replace the hydraulic oil filter.
5. Setting of main relief valve 5. See page 8002-12 . Check and adjust the main relief valve.
6. Engine stall speed 6. See Section 2002 for instructions.
7. Contamination in the hydraulic 7 . See Section 8003 .

system
8. Check the output of the 8. See the instructions beginning on page 8002-21 .
hyd rauli c pump with a flowmeter
8002-7
BAD PERFORMANCE IN A SINGLE CIRCUIT

Any Single Circuit
CHECK INSTRUCTIONS
1. Mechan ical problems 1. Check the cylinder rods to make sure the cylinder rods are
not bent. Check the pivot pins for damage. Make sure the pivot
pins have the correct amount of lubrication .
2. Damaged hoses and tubes 2. Visually check the hoses and tubes in the bad circuit.
3. Spools in the control valves 3. Measure the movement of the control valve spool that
controls the bad circuit. See the correct section for the specifi-
cations.
4. Circuit relief valve 4. See the instructions beginning on page 8002-14. Check and
adjust the pressure setting of the circuit reli ef va lve in the bad
circuit.
5. Cylinder packing 5. See page 8002-17 . Check the cylinder packing in the cylinders
of the bad circuit.
6. If the load falls slightly when you 6. See Section 8007 for the loader control va lve, Section 8107
move the control lever into a for the backhoe control valve, or Section 8207 for the three
power posit ion , check the load point hitch control valve. I nspect and clean the check valves.
check valve Replace parts as necessary.
7. If the problem is in a backhoe 7. See Section 8107 . Remove the plug for the load check valve.
circuit, check the O-ring on the Inspect the O-ring on the plug .
plug for the load check valve
8. Control valve 8. See Section 8007 for the loader control valve , 8107 for
the backhoe control valve, or Section 8009 for the three point
hitch control valve . Disassemble and inspect the spools and
spool bores for wear and damage.
8002-8
Swing Circuit
PROBLEM INSTRUCTIONS
1. Backhoe swings correctly but 1. See page 8002-14 . Check and adjust the pressure setting
does not stop when swing control of the circuit relief valves in the swing sect ion . See Section
is returned to NEUTRAL 8107 and check the anticavitation valves in the swing section .
2. Backhoe stops too rapidly when 2. See page 8002-14. Check and adjust the pressure
the swing control is returned to settings of the circuit relief valves in the swing section.
NEUTR AL
3. Erratic swinging movement 3. Make sure that the linkage between the cam and the swing
sequence valve moves freely and that the roller stays against
the cam . See page 8002-13 . Check the pressure settings of the
relief valves in the swing sequence valve .
4. Backhoe does not come to a 4. Make sure that the linkage between the cam and the swing
gradual stop when the backhoe sequence valve moves free ly and that the roller stays against
is swung all the way to th e the cam . See page 8002-13. Check the pressu re settin gs of
right or left relief valves in the swing sequence valve .
5. Swing sequence valve linkage 5. See Section 8000. Adjust linkag e.
6. Swing sequence valve 6. See Section 8108. Disassemb le and inspect the parts of the
swing sequence valve.
Stabilizer Circuit
PROBLEM INSTRUCTIONS
1. Stabilizers will not hold the 1. See page 8002-19. Check the cyl inde r packing. If the
machine in position cylinder packing is good, remove the check valves from the A
ports of the stabilizer sections of the backhoe control valve .
See Section 8107 . Disassemble and ins pect the parts of the
check valves.
BAD PERFORMANCE IN ALL BACKHOE CIRCUITS;

OTHER CIRCUITS WORK CORRECTLY
CHECK INSTRUCTIONS
1. Check valve in the inlet of the 1. Remove the regeneration check valve from the inlet of the
backhoe control valve backhoe control valve. See Section 8107 . Inspect the parts of
the check valve.
2. Regeneration spool in the out- 2. Remove the regeneration spool from the outlet of the backhoe
let of the back hoe control valve control va lve . See Section 8107. Inspect the regeneration
spool.
3. Check the output of the 3. See page 8002-21. Check the output of the hydrau lic pump .
hydraulic pump
8002-9
HYDRAULIC OIL BECOMES TOO HOT

CHECK INSTRUCTIONS
1. Oil cooler filled with dirt 1. Clean the oil cooler.
2. Oil cooler bypass valve 2. Check the oil cooler bypass valve in the hydraulic filter.
3. Operator does not move the 3. Move the control levers into full power positions.
control levers all the way into a
power position
4. Pressure setting of main relief 4. See page 8002-12 for instructions.

valve
5. Pressu re setting of steering 5. See Section 5002 . Check and adjust the steering relief valve.
relief valve
6. Pressure setting of a circuit 6. See page 8002-14. Check and adjust the circuit relief valves.
relief valve
7. Contaminated oil 7. See Section 8003.
BAD PERFORMANCE ·OF COMPONENTS

Hydraulic Pump
Too much noise. Loose mounting hardware. Tighten hardware.
Loose nuts on studs that hold the Tighten nuts.

hydraulic pump together.
Air is entering the suction line. Repai r as necessary.
Oil level in reservoir too low. Fill the reservoir. See Section
8001 .
External oil leakage Loose nuts on studs that hold the Tighten nuts.
hydraulic pump together.
Damaged seal or shaft. See Section 8005. Disassemble

hydraulic pump and replace the
seal.
8002-10
Control Valves
Spool does not return Centering spring is broken. Install a new centering spring.
to neutra l
Spring housing is not centered. Loosen mounting hardware and
position spring housing correctly.
Spool is bent. Replace the valve section or

complete valve.
Damaged spool bore . Replace the valve section or

complete valve.
Shims between va lve sections are Install shims as necessary.

missing or not instal led correctly.
Cap screws that hold control valve Tighten cap screws to correct
together are too tight. torque.
Oil leakage around Damaged seals. Replace seals.

spools
Detents do not work Damaged detent parts. Disassemble and replace parts
correctly as necessary.
Cylinders
No movement Piston cap screw is loose or See Section 8090 . Repair as

broken. necessary.
Hoses are not connected correctly. See the hydraulic schematics in

this section.
Cylinder packing Dirty oil. See Sect ion 8003 .

wears rapidly
Pressure setting of main relief See page 8002-12. Adjust ma in

valve too high . relief valve.
Piston rod is bent Pressure setting of main relief See page 8002-12. Adjust main
valve too high. relief va lve .
Pivot pins did not get the correct See Section 1212.
lubrication .
8002-11
Hoses and Fittings

Hose cover is split Hose is twisted. Connect the hose at the swivel
fitting last. Make sure that the
hose does not twist as the fitting
is tightened .
Fitting pulled from Pressure setting of main relief See page 8002-12 . Check and
hose or hole in hose valve set too high . adjust the main relief valve.
8002-12
CHECKS AND PRESSURE SETTINGS

Heating the Hydraulic Oil STEP4
STEP 1
Park the machine on a level surface. Lower the
loader bucket to the floor.
STEP 2
STEP 3
Run the engine at full throttle.
STEP 4
Hold the bucket control lever in the ROLLBACK posi-
tion for 30 seconds . Then release the bucket con-
6330'1
trol lever.
Connect a pressure gauge (3000 psi , 20 685 kPa ,
211 kg / cm 2) to the quick disconnect fitting . Use
STEP S
fittings from fitting kit CAS-1804 to connect the
Keep the engine running at full throttle and keep
pressure gauge.
the bucket control lever in NEUTRAL for 15 seconds .
STEP 6 STEPS
Start and run the engin e at full throttle. Hold th e
Repeat steps 4 and 5 until the hydraulic oil is at
loader control lever in ROLLBAC K posit ion .
operating temperature. The hydraulic oil must be
at least 130°F (54° C).
STEP 6
When the bucket stops moving , read the pressure
Main Relief Valve gauge.
The main relief valve in the loader control valve
STEP 7
gives protection to the loader circuits and the
Make a record of the pressure . Compare the pres-
backhoe or three point hitch circuits.
sure to the specifications on page 8002-2.
STEP 1
STEPS
See the instructions on this page to heat the hy-
draulic oil.
STEP 2
Stop the engine .
STEP 3
632944
If the pressure is not correct , loosen the lock nut on

the adjusting screw of th e main re lief valve.
STEP 9
Turn the adjusting screw clockwise to inc rease the
pressure setting or counterclockwise to decrease
633014
the pressure setting .
There is a quick disconnect coupling below the left
front of the machine.
8002-13
STEP 10 STEP 3
Repeat steps 5 through 9 until the pressure is cor- The oil in the hand pump must be 70 to 80 0 F (21 to
rect. 2rC) . Be sure that the hand pump is full of Case
TCH Flu id.
STEP 11
Prevent the adjusting screw from turning and STEP 4
tighten the lock nut. Operate the handle of the hand pump to fill the
hose and test block with oil.
Swing Sequence Valve
STEPS
There are two high pressure relief valves at the Tighten the connections at the test block.
front of the swing sequence valve . The low pres-
sure relief valve is at the rear of the swing sequence STEP 6
valve . Before you install a new relief valve, you
must check and adjust the pressure setting.
STEP 1
220431
Operate the handle of the hand pump and read the

pressure gauge. Make a record of the highest pres-
sure. Make several checks to be sure of the pres-
sure reading.
Remove the relief valve from the swing sequence
valve. Check the condition of the a-rings and STEP 7
backup rings. Install new a-rings and backup rings Compare the pressure with t he specifications on
as necessary. page 8002-2 .
STEP 2 STEP 8
If the pressure is not co rrect, loosen the lock nut on
the adjusting screw .
STEP 9
Turn the adjusting screw clockwise to increase the
the pressure setting.
STEP 10
Repeat steps 6 throug h 9 unt il the pressure setting
is correct.
STEP 11
Prevent the adjusting screw from turning and
220423
tighten the lock nut.
Install the relief valve in the CAS-1205 test block .
Connect the hand pum p to the test block . Do not
tighten the connection of the hand pump at this
time.
8002-1 4
Three Point Hitch Relief Valve Circuit Relief Valves

STEP 1 Loader and Backhoe Control Valves
See the instructions on page 8002-12 to heat the
hydraulic oil. Before you install a new circuit relief valve, you
must check and adjust the pressure setting .
STEP 2
Lower the three point hitch or attachment to the STEP 1
floor. Remove the circuit relief valve from the control
valve.
STEP 3
Stop the engine. STEP 2
Check the condition of the a-rings on the circ uit
STEP 4 relief valve . Replace the a-rings as necessary.
Find a 3/ 4-16 UNF straight thread tee fitting in the
CAS-1808 flowmeter fitting kit. STEP 3
STEPS
Use fittings from CAS-1804 pressure test fitting kit
to connect a pressure gauge (3000 psi, 20685 kPa,
211 kg / cm 2) to the tee fitting from the flowmeter
fitting kit.
STEP 6
Disconnect the hose from the fitting in the inlet port
in the three point hitch control valve. Remove the
fitting from the inlet port in the three point hitch
control valve . Install the tee fitting in the inlet port.
Connect the hose for the inlet port to the other end
of the tee fitting . 220423
Install the circuit relief valve in th e CAS-1205 test

STEP 7 block .
Start and run the engine at full throttle. Hold the
t hree point hitch lift control lever in the LIFT posi-
tion. STEP 4
Connect the hand pump to the bottom port in the
STEP 8 test block. Do not tighten the connection at this
When the three point hitch stops moving , read the time .
pressure gauge.
STEP S
STEP 9 The oil in the hand pump must be 70 to 80° F (21 to
Make a record of the pressure . Compare the pres- 27 ° C) . Be sure that the hand pump is filled with
sure to the specifications on page 8002-2. Case TCH Fluid.
STEP 10 STEP 6
If the pressure is not correct, loosen the nut on the Operate the handl e of the han d pump to fill the
adjusting screw of the three point hitch relief valve. hose and test block with oil.
STEP 11 STEP 7
Turn the adjusting screw clockwise to increase the Tighten the connecti o ns at the test block .
the pressure setting .
STEP 12
Repeat steps 7 through 11 until the pressure is
correct.
STEP 13
8002-15
STEPS Three Point Hitch Control Valve
STEP 1
Disconnect t he hose f rom the B port in the lift
sect ion of the three point hitch control valve .
STEP 2
Connect the CAS-10090 ha nd pump to the B port in
th e lift section of the three point hitch control valve .
Use fittings from the fitting kit CAS-1804 to con-
nect the hand pump. Do not tighten the connection
on the hand pu mp at this time .
STEP 3
The oil in th e ha nd pump must be 70 to 80° F (21 to
220431
2JO C ). Be sure t hat the hand pump is fu ll of Case
Operate the handle of the hand pump and read the
TCH Fluid .
pressure gauge. Make a record of the highest pres-
sure.
STEP 4
Operate the ha ndle of the hand pump to fill the
STEP 9 hose with oil.
Make several checks to make sure of the pressure
indication.
STEP S
Tig hten the connections.
STEP 10
Compare the pressure with the specifications on
page 8002-2 .
STEP 6
Operate the ha ndle of the hand pump and read the
pre ss ure gaug e. Make a record of the highest pres-
STEP 11 sure. Make seve ral checks to be sure of the pres-
If the pressure is not correct, loosen the lock nut on
sure readin g.
the adjusting screw.
STEP 12 STEP 7
Co mpare the pressure with the specifications on
Turn the adjusting screw clockwise to increase the
page 8002-2.
the pressure setting.
STEP S
If t he pressure is not correct, loosen the lock nut on
STEP 13 th e adj ustin g scre w.
Repeat steps 8 through 12 until the pressure set-
ting is correct.
STEP 9
Tu rn t he adjust ing screw clockwise to increase the
STEP 14 pressure setti ng or counterclockwise to decrease
th e pressure setting.
STEP 10
Re peat steps 6 through 9 until the pressure setting
is correct.
STEP 11
Prevent the adj usting screw from turning and
tig hten the loc k nut.
8002-16
Boom Cylinder Relief Valve STEP 12

Pressure Check Connect the CAS-1913 hand pump and a 6000 psi
(41 3170 kPa , 422 kg/ cm 2) gauge from the CAS-
STEP 1 1804 Pressure Test Fitting Kit to the fitting at the
Park the machine on a level surface . rod end of the cylinder. Do not tighten the connec-
tions at this time.
STEP 2
Lower the boom until the bucket is flat on the floor. STEP 13
Set the hand pump to the HI position .
STEP 3
Stop the engine. STEP 14
The oil in the hand pump must be 70 to 80° F (21 to
STEP 4 2YO C). Make sure the hand pump is filled with Case
Connect acceptable lifting equipment to the boom TCH Fluid.
that will hold the boom in place when the rod end of
the boom cy linder is disconnected from the boom . STEP 15
Operate the handle of the hand pump until the air is
STEP 5 removed from the hose and fittings and the oil that
Connect acceptable lifting equipment to the boom flows from around the fitting at the cylinder is free
cylinder that will hold the boom cy linder in place. of air.
STEP 6 STEP 16
Remove the pivot pin that fastens the rod end of the Tighten the connections at the cylinder.
cylinder to the boom .
STEP 17
STEP 7 Operate the handle of the hand pump and read the
Start and run the engine at low idle. pressure gauge. Make a record of the highest
pressure .
STEP 8
Completely retract the boom cylinder. STEP 18
Make several checks to make sure of the pressure
STEP 9 indication .
Stop the engine.
STEP 19
STEP 10 Compare the pressure with th e specifications on
Disconnect the hose from the fitting at the rod end page 8002-2 .
of the cylinder.
STEP 20
STEP 11 The relief valve in the piston cannot be adjusted. If
I nstall a plug in the hose. the pressure setting is not correct the piston must
be replaced .
8002-17
Cylinder Packing STEP 2
Loader Lift Cylinders
STEP 1
STEP 2
Hold the loader control lever in RAISE until the load-
er f rame is all the way up.
STEP 3
Hold the bucket con t rol leve r in the ROLLBAC K posi-

tion until the bucket stops moving . Lowe r the load-
er frame until the bucket is on the f loor. Put blocks
under the bucket to keep the bucket in position .
STEP 3
Stop the engine . Disconnect the hose from the rod
end of each bucket cylinder.
STEP 4
Connect lifting equipment to the loader frame to
support the loader frame. STEPS
Start and run the engine at full throttle.
STEP 4
Stop the engine. Disconnect the hose from the tube STEP 6
that is connected to the rod end of each lift Hold the loader cont rol lever in ROLLBACK and have
cylinder. another person check for constant leakage from
the fitting at the rod end of each bucket cylinder.
STEPS
Install a cap on each hose. STEP 7
If there is constant leakage, t he packing is dam-
STEP 6 aged and repairs must be made.
Loader Clam Cylinders
STEP 7
Hold the loader control lever in RAISE and have STEP 1
another person check for constant leakage from Park the machine on a level surface.
the tube connected to the fitting at the rod end of
each lift cylinder. STEP 2
Hold the control lever in position to close the
STEP 8 bucket.
If there is constant leakage, the packing is dam-
aged and repairs must be made. STEP 3
Lower the bucket to the floor and stop the engine.
Loader Bucket Cylinders
STEP 4
STEP 1 Disconnect the hose from the f itting at the rod end
Park the machine on a level surface . of each clam cylinder.
8002-18
STEP S Dipper Cylinder

STEP 1
STEP 6
Start and run the engine at full throttle . Hold the
control lever in position to close the bucket.
STEP 7
Have anoth er person check for constant leakage
from the fitting at the rod end of each clam cylin-
der.
STEPS
If there is constant leakage, the packing is dam-
Boom Cylinder
866596
Put the backhoe in the transport position . Make

sure that the boom latch is engaged to hold the
backhoe in the transport position.
STEP 2
Hold the dipper control lever in the IN position unti l
the dipper stops moving.
STEP 3
Stop the engine.
STEP 4
Disconnect the hose from the t ube that is con-
nected to the rod end of the dipper cylinder.
866596 STEPS
Put the backhoe in the transport position. Make I nstall a cap on the hose.
sure that the boom latch is engaged to hold the
backhoe in the transport position . STEP 6
Start and run the engine at full throttle .
STEP 2
Disconnect the hose from the tube that is con- STEP 7
nected to the rod end of th e boom cylinder. Hold the dipper control lever in the IN position and
have another person check for leakage from the
STEP 3 tube that is connected to the rod end of the dipper
Install a cap on the hose. cylinder.
STEP 4 STEPS
Start and run the engine at full throttle. If there is constant leakage, the packing is dam-
STEP S
Hold the boom control lever in the LOWER position Backhoe Bucket Cylinder
and have another person check for leakage from
the tube. STEP 1
Put the backhoe in position for easy access to the
STEP 6 bucket cylinder.
If there is constant leakage from the tube , the pack-
ing is damaged and repairs must be made. STEP 2
Hold the bucket contro l lever in the LOAD position
until the bucket stops moving. Lowe r the boom
until the bucket is on the floo r.
8002-19
STEP 3 STEP 7
Stop the engine. Start and run the engine at full throttle.
STEP 4 STEP 8
Disconnect the hose from the tube that is con- Hold the swing control in the LEFT position . Have
nected to the rod end of the bucket cylinder. another person check for leakage from the fitting at
the closed end of the left swing cylinder and from
STEPS the fitting at the rod end of the right swing cylinder.
I nstall a cap on the hose.
STEP 9
STEP 6 If there is constant leakage f rom the fitting at the
Start and run the engine at full throttle. closed end of the left swing cylinde r, the packing in
the left swing cylinder is damaged and repairs must
STEP 7 be made. If there is constant leakage from the fit-
Hold the bucket control lever in the LOAD position ting at the rod end of the right swing cylinder, the
and have another person check for leakage from packing in the right swing cylinder is damaged and
the tube that is connected to the rod end of the repairs must be made.
bucket cylinder.
Stabilizer Cylinders
STEP 8
If there is constant leakage, the packing is dam- STEP 1
aged and repairs must be made. Put the backhoe in the transport position .
Swing Cylinders STEP 2

Run the engine at full throttle .
STEP 1
STEP 3
Hold both stabi lize r control levers in position to
raise the rear of the machine until the machine
stops moving.
STEP 4
Stop the engine .
STEPS
Move the right stabilizer control lever into the
LOWER position . If the machine moves, immedi-
ately release the right stabilizer control lever. Re-
peat this step for the left stabilizer.
866666
STEP 6
Put the backhoe in the transport position and in- If the machine moved , the packing in that stabilizer
stall the swing lock pin . cylinder is damaged and repairs must be made.
STEP 2 Extension Cylinder
Stop the engine.
STEP 1
STEP 3 Completely extend the dipper and lower the bucket
Disconnect the hose from the closed end of the left
to the floor.
swing cylinder.
STEP 2
STEP 4 Stop the engine .
Install a plug in the hose.
STEP 3
STEPS Disconnect the hose from the A port of the dipper
Di scon nect the hose from the rod end of the right extension section in the backhoe control valve.
swing cylinder.
STEP 4
STEP 6 Install a cap on the fitting .
Install a plug in the hose.
8002-20
STEP 5 STEP 7
Start and run the engine at full throttle. If there is constant leakage. the packing is dam-
STEP 6
Hold the extension control lever in the OUT posi-
tion and have another person check for leakage
from the hose.
8002-21
FLOWMETER TEST
General Information
The flowmeter measures the volume, pres-
sure , and temperature of the hydraulic oil as the
hydraulic oil flows through the flowmeter.
This test will indicate whether there are prob-

lems in the lines between the reservoir and the
hydraulic pump, and whether the hydraulic pump
is working within acceptable standards of efficien-
cy.
A check sheet is at the end of this section.

Make a copy of the check sheet and write the re-
sults of the test in the correct space.
632934
Connect a vacuum pump to the reservoir to keep

Test No.1 - Output of the the oil in the reservoir while flowmeter hoses are
Rear Section of the Hydraulic connected into the circuit.
Pump
STEP 1
STEP2
STEP 3
Stop the engine and apply the parking brake.
STEP 4
633014
Start the vacuum pump . There is a quick discon-

nect fitting below the left f ront of the machine.
Remove the quick disconnect fitting .
Open the top cover.
632923
Connect the inlet hose of th e flowm eter to the tee

fitting .
8002-22
STEP, 8 STEP 11
Start and run the engi ne at full throttle.
STEP 12
Hold the temperature switch in the TEMPERATURE
position . The temperature must be at least 130°F
(54° C).
STEP 13
If the temperature is not correct, close the pressure
valve until the pressure is 1000 psi (6894 kPa, 70
kg /cm 2).
632925
STEP 14
Continue to run the engine at full throttle until the
Disconnect the inlet tube for the loader control
temperature of the oil is 130°F (54°C).
valve from the tee fitting . Install a cap on the tee
fitting and a plug in the tube . Stop the vacuum
pump. STEP 15
Open the pressure valve completely .
STEP 16
Run the engine at 2000 rpm (r/min).
STEP 17
Read the flow gauge. Wri te the flow on line 2 of the
check sheet.
STEP 18
Slowly close the pressure valve until the pressure is
2000 psi (13789 kPa, 141 kg / c m2). Adjust the en-
gine speed to 2000 rpm (r/min).
632938
STEP 19
Disconnect the vacuum pump from the hydraulic Read the flow gauge. Write the flow on line 3 of the
reservoir. Install the outlet hose of the flowmeter check sheet.
into the hydraulic reservoir below oil level. Use a
piece of wi re to fasten the outlet hose in the hy- STEP 20
draulic reservoir. Open the pressure valve.
STEP 10 STEP 21
Decrease the engine speed to low idle and stop the
engine.
Understanding the Results

of the Test
If the output of the hydraul ic pump on line 2 of
the check sheet is less than 25 U.S. gpm (95 L/ min) :
There is an air leak or a restriction betwee n the

hydraulic pump and the reservoir.
126630
The hydraulic pump is badly worn or dam-
Prepa re th e flowmeter for the test by doing the aged.
following steps: Open the pressure valve com-
pletely. Move the range switch to the HI position . The tachometer is not accurate .
Make sure the flow switch is in the FLOW position .
Pull the ollfoH switch to the ON position. Make sure The flowmeter you are using is not accurate .
all con nections are tight.
8002-23
If the output on line 2 of the check sheet is STEP 3

more than 26 U.S. gpm (98 L/ min). there are no
problems between the hydraulic pump and the res-
ervoir.
Loss of output at higher pressures shows that

the hydraulic pump is worn or damaged. Use the
efficiency of the hydraulic pump to make a judg-
mentwhen the hydraulic pump must be repaired or
replaced.
The efficiency of the hydraulic pump is found

by dividing the output on line 3 of the check sheet
by the output on line 2 of the check sheet.
Example: Line 2 = 25 U.S. gpm (95 Llmin)

Line 3 = 22 U.S. gpm (83 L/ min) Connect a vacuum pump to the reservoir to keep
the oil in the reservoir while flowmeter hoses are
.88 .87 connected into the circuit.
25/22.00 95/ 83.00
STEP 4
.88 = 88% efficient
If the efficiency is below 75%, it is recom-

mended that repairs be made to the hydraulic
pump or a new hydraulic pump be installed .
If the efficiency is above 75%, the hydraulic

pump is good .
Test No.2 - Output of the

Front Section of the Hydraulic
Pump
STEP 1
Start the vacuum pump . Disconnect the inlet hose
Do Test No. 1 on page 8002-21 .
of the flowmeter from the tee fitting .
STEP 2
632938
633014
Remove the outlet hose of the flowmeter from the
Install the quick disconnect fitting on the tee fit-
hydraulic reservoir.
ting. Connect the inlet tube of the loader control
valve to the tee fitting .
8002-24
STEP 6 STEP 9
632928 126630
Disconnect the inlet tube for the backhoe control Prepare the flowmeter for the test by doing the
valve from the hose. Connect the inlet hose of the following steps: Open the pressure valve com-
flowmeter to the hose. Install a plug in the tube. pletely. Move the range switch to the La position.
Make sure the flow switch is in the FLOW position .
STEP 7 Pull the on/off switch to the ON position . Make sure
Stop the vacuum pump. all connections are tight.
STEPS STEP 10
STEP 11
Hold the temperature switch in the TEMPERATURE
position. The temperature must be at least 130° F
(54° C) .
STEP 12
If the temperature is not correct, close the pressure
valve until the pressure is 1000 psi (6894 kPa, 70
kg / cm 2) .
STEP 13
Continue to run the engine at full throttle until the
632938
temperature of the oil is 130°F (54°C).
Disconnect the vacuum pump from the hydraulic
reservoir. Install the outlet hose of the flowmeter
into the hydraulic reservoir below oil level. Use a
STEP 14
Open the pressure valve completely.
piece of wire to fasten the outlet hose in the hy-
draulic reservoir. STEP 15
Run the engine at 2000 rpm (r/ min) .
STEP 16
Read the flow gauge. Write the flow on line 4 of the
check sheet.
STEP 17
Slowly close the pressure valve until the pressure is
2000 psi (13789 kPa , 141 kg/ cm 2). Adjust the en-
gine speed to 2000 rpm (r/min).
8002-25
STEP 18 Loss of output at higher pressures shows that

Read the flow gauge. Write the flow on line 5 of the the hydraulic pump is worn or damaged . Use the
check sheet. efficiency of the hydraulic pump to make a judg-
ment when the hydraul ic pump must be repaired or
STEP 19 replaced.
Open the pressure valve .
The efficiency of the hydraulic pump is found
STEP 20 by dividing the output on line 5 of the check sheet
Decrease the engine speed to low idle and stop the by the output on line 4 of the check sheet.
engine.
Example: Line 4 = 7 U.S. gpm (26 Llmin)
Understanding the Results of Line 5 = 6 U.S. gpm (23 L/ min)
the Test
.85 .88
If the output of the hydraulic pump on line 4 of 7 ) 6.00 26) 23 .00
the check sheet is less than 7 U.S. gpm (26 L/ min) :
.85 = 85% efficient
There is an air leak or a restriction between the
If the hydraulic pump efficiency is below 75%,
hydraulic pump and the reservoir.
it is recommended that repairs be made to the hy-
draulic pump or a new hydraulic pump be in-
The hydraul ic pump is badly worn or dam-
stalled .
aged.
If the hydraulic pump efficiency is above 75%,
The tachometer is not accutate.
the hydraulic pump is good.
The flowmeter you are using is not accurate.
If the output on line 4 of the check sheet is

more than 7 U.S. gpm (26 L/min), there are no
problems between the hydraulic pump and the res-
ervoir.
8002-26
DECIMAL MEASURE FLOWMETER CHECK SHEET

Owner _________________________________________ Date _______ Hours _______
Model _______________________________ P.I.N . _____________________________
Test No. 1 - Output of the Rea r Section of the Hydraulic Pump
1. Temperature of the oil of
2. gpm at 0 psi at 2000 rpm
Test No. 2 - Output of the Front Section of the Hydraulic Pump
METRIC MEASURE FLOWMETER CHECK SHEET

Owner _________________________________________ Date _______ Hours _______
Model _______________________________ P.I.N. __________________________
Test No. 1 - Output of the Rear Section of the Hydraulic Pump
1. Temperature of the oi l _________________ ° C
2. L/ min at 0 kPa, kg/ cm 2 at 2000 r/ min
3. L/ min at 13 789 kPa, 141 kg/ cm 2 at 2000 r/ min
Test No. 2 - Output of the Front Section of the Hydraulic Pump
4. L/min at 0 kPa, kg/ cm2 at 2000 r/ min
5. L/ min at 13 789 kPa, 141 kg/ cm 2 at 2000 r/ min

8003
CLEANING THE HYDRAULIC SYSTEM
TABLE OF CONTENTS
Portable Filter . . . . . . . ... .. . . .... ... . .... 8003-2 Cleaning the Hydraulic System ... ... . . .. 8003-4
General Information . . ... . .. . ... .. ...... 8003-3 Flushing Water From

the Hydraulic System .. .. . ... . . .... ... 8003-6
Types of Contamination .. . .. . . ... .. . ... 8003-3
J I Case 8-67390
A T e n neco COIllPitny
8003-2
PORTABLE FILTER
The Portable Filter and Fitti ng Kit are avai lable
from Service Tools in the United States or from
Jobborn Manfaucturing Co . in Canada. See Spe-
cial Tools in Section 1001 for correct address.
The part number of the Portable Filter is CAS-

10162A and for the Fitting Kit the part number is
CAS-10508.
Fitting Kit
806127
Portable Fi iter
8003-3
GENERAL INFORMATION
Contamination in the hydraulic system is a 1. Cylinder rod seals leak.
major cause of the malfunction of hydraulic com-
ponents. Contamination is any foreign material in 2. Control valve spools do not return to NEUTRAL.
the hydraulic oil. Contamination can enter the hy-
draulic system in several ways. 3. Movement of control valve spools is difficult.
1. When you drain the oil or disconnect any line. 4. Hydraulic oil becomes too hot.
2. When you disassemble a component. 5. Pump gears, housing , and other parts wear
rapid ly .
3. From normal wear of the hydraulic compo-
nents. 6. Relief valves or check val ves held open by dirt.
4. From damaged or worn seals. 7. Quick failure of compo nents tha t have been
repaired.
5. From a damaged component in the hydraulic
system. 8. Cycle times are slow; machine does not have
enough power.
All hydraulic systems operate with some con-
tamination. The design of the components in this If your machine has any of these problems ,
hydraulic system permits efficient operation with a check the hydraulic oil for contamination. See
small amount of contamination. An increase in this Types of Contamination below. If you find contam-
amount of contamination will cause problems in ination , use the Portable Filter to clean th e hydrau -
the hydraulic system. The fol lowing list includes li c system .
some of these problems .
TYPES OF CONTAMINATION
There are two types of contamination , micro- 2. Visible contamination is foreign material that
scopic and visible. can be found by sight , touch , or odor . Visible con-
tamination can cause a sudden failure of a compo-
1. Microscopic contamination occurs when very nent. Examples of visible contamination .
fine particles of foreign material are in suspension
in the hyd raulic oil. These particles are too small to a. Particles of metal or dirt in the oil.
see or feel. Mic roscopic contamination can be
found by identification of the following problems b. Air in the oil.
or by testing in a laboratory. Examples of the prob-
lems: c. The oil is dark and th ick .
a. Cylinder rod seals leak . d. The oil has the odor of burned oi l.
b. Control valve spools do not return to NEU- e. Water in the oil. See page 8003-6 .
TRAL.
c . The hydraulic system has a high operating

temperature.
8003-4
CLEANING THE HYDRAULIC SYSTEM

1. Prepare the portable filter shown on page 8. Loosen and remove the drain plug from the
8003-2 by doing th e following steps: reservoir.
a. Remove all the hydraulic oil from the inlet 9. See the fitting kit shown on page 8003-2 . Install
and outlet hoses for the portable filter. the valve in the hole for the drain plug . Make sure
that the valve is closed.
b. Remove the filter element from the porta-
ble filter. 10. Stop the vacuum pump.
c. Remove all hydraulic oil from the portable 11 . Connect the inlet hose for the portable filter to
filte r. the valve that is installed in the hole for the drain
plug.
d. Clean the inside of th e housing for th e filter
element. 12. Disconnect the vacuum pump fro m the filler
cap opening on the hydraulic reservoir.
e. Install a new filter element.
13. Install the outlet hose for t he portable filter in
2. You must know whether th e con tamination is the hydraulic reservo ir.
microscop ic or visi b le. See Types of Contamina-
tion on page 8003-3 . 14. Open the valve that is installed in the hole for
the drain plug .
3. If the co ntamination is microscopic:
15. Move the switch for the portable filter to the ON
a. Check the maintenance schedule for the pos ition. Start and ru n the engine at 1500 rpm
mach ine to learn if the hydraulic oil must be (r/ min).
changed . If needed , change the hydraulic oil.
See Section 8001. Change the hydraulic filter. 16. Run the portable filter for 10 minutes.
b. Do steps 6 through 38. 17. Continue to run the portable filter.
4. If the co ntamination is visible : 18. Increase the engine speed to full throttle. Heat
the oil to operating temperature by doing the fol -
a. Change the hydraulic oil and hydraulic fil- lowing steps:
ter. See Section 8001 . Remove and clean the
hy drau lic pump suction screen . a. Hold the bucket control lever in the ROLL-
BACK position for 15 seconds .
b. Do steps 5 through 38 .
b. Return the bucket con t rol lever to NEUTRAL
5. Check the amount of contamination in the hy- for 30 seconds .
draulic system by doi ng the follow ing steps .
c. Repeat steps 18a and 18b until the oi l in the
a. Disassemble one cylinder in two different hydra uli c system is at operating temperature .
circuits . Check for damage to seals , scoring of
the cylinder wall, etc. Repair the cyl ind ers as 19. Continue to run the engine at full throttle. Con-
necessary. tinue to run the portable filter.
b. If, in your judgment, th e damage to the 20. Operate each hydraulic circuit to complete ly
cy lin ders was caused by severe co ntamination extend and retract the cyl in ders. Continue to oper-
and is not th e result of normal wea r, it is neces- ate each hydraulic circuit two times, one after the
sary to remove , clean and repair valves, pump , other, forA5 minutes.
lines, cy linders, hydraulic reservoir, etc . in the
hydra ulic system. 21. Decrease the engine speed to low idle.
6. Loosen and remove the filler cap from the
reservoir.
7. Connectavacuum pumpto thefillercapopen-

ing. Start the vacuum pump .
8003-5
22 . Continue to run the portable filter for 10 min- 31. Install the drain pl ug .
utes.
32. Stop the vacuum pump. Disconnect the vacu-
23. Stop the portable filter. um pump from the hydrau li c reservoir.
24. Stop the engine . 33. Install the filler cap.
25. Remove the hose from the hydraulic reservoir. 34. Remove the hydraulic filter element from the
machine.
26. Close the valve that is installed in the hole for
the drain plug . 35 . Install a new hydraulic fi lte r element on the
machine.
27. Disconnect the inlet hose for the portable filter
from the valve . 36 . Check the oil level in the hydraulic reservoir.
Add oil as required . See Section 8001 .
28. Connect a vacuum pump to the fill cap open-
ing of the hydraulic reservoir. 37. Start the engine. Check ·f o r oil leakage around
the new hydraulic filter.
29. Start the vacuum pump .
38. Stop the engine .
30 . Remove the valve from the hole for the drain
plug.
8003-6
FLUSHING WATER FROM THE HYDRAULIC SYSTEM

1. Start and run the engine at 1500 rpm (r/ min). 11. Disconnect the line from the rod end and
closed end of each cy linde r.
2. Completely retract the cylinders of all attach-
ments on the machine. 12. Be sure all con trol levers are in the NEUTR AL
- - position .
WARNING: If retracting the cylinder rods
h causes the attachment to be raised, block 13. Start the engine and run th e eng ine at low idl e.
. . the attachment in place before proceeding
to the next step. 39·4 IMPORTANT: Check the oil level in the hydraulic ,
reservoir frequently while doing step 14.
3. Any attachment or part of an attachment that is
raised must be supported to prevent the attach- 14. Move each control lever in both directions un-
ment from falling. til oil begins to flow fro m th e open line . Ho ld the
control lever in place unti l clean oil flows from the
4. Loosen and remove the filler cap from the open line .
reservoir.
15. Stop th e engine .
5. Drain the hydraulic oil from the reservoir.
16. Connect the line to the CLOS ED end of each
a. The reservoir holds approximately 21 U.S. cylinder.
gallons (79.5 litres) of hydraulic oil.
17. Start th e engine and run the engine at low idle.
b. Have available acceptable equipment to
drain the hydraulic oil. 18. Completely exte nd all cyli nders. As the piston
rod comes out of the cylinder, oil will be pushed out
c. Remove the drain plug from the bottom of of the rod end of t he cy linder.
the reservoir.
19. Support the loader frame so that the loader
6. Remove the hydraulic oil filter from the ma- frame will stay in the RA ISED pOSition .
ch ine.
20 . Stop th e engine.
7. Install a new hydraulic oil filter on the machine.
21. Connect the lines to the rod end of the cy li n-
8. Install the drain pi ug in the bottom of the reser- ders.
voir.
22. Fill the reservoir to th e correct level.
9. Fill the hydraulic reservoir with 21 U.S. gallons
(79.5 litres) of Case TCH Fluid. 23 . Install the filler cap for the reservoir.
10. Move each control lever in both directions to

release pressure in the circuits .
8005
HYDRAULIC PUMP - SECTIONS FASTENED
TOGETHER WITH STUDS
TABLE OF CONTENTS
Specifications . ..... ..... . .. . .. ... .. .. .. 8005-2 Inspection ........... ..... . . . . . .... . ... 8005-8
Disassembly .... . ...... . ........ ... . ... 8005-3 Assembly .. . ..... . .. . .... . . ... . .... . . .. 8005-9
Exploded View . ..... . .... . ....... . ... . . 8005-7 Cross Section .. . ..... . .. . ........ . .. . . 8005-12
A Tenne co Company
8005-2
SPECIFICATIONS
Manufacturer . . ... . .......... ..... . . . ...... . .. .... .. .. . . ............. . . . ..... ... Commercial Shearing
Rotation ..... . . . .. ....... . . ... .. . .................... . .. . ... Counterclockwi se as seen from shaft end
Wear Specifications . . . . . ....... .. .. . . . ........... .. ... ..... . .. .. .. .... .. . ... ... .. .. ... See Inspection
Special Torques
Nuts that hold the sections together ............. . . ........... . . .. . 200 pound-feet (271 N m, 28 kg/ m)
Weight . . . . ...... ...... .. .... . .... . .. ...... ... ..... . . .. . . . ... . .... ..... ...... ... ... 80 pounds (36 kg)
8005-3
OISASSEMBL Y
STEP 1 STEP 4
700038 700005
Clean the outside of the hydraulic pump. Fasten Remove the quad ring .
the hydraulic pump in a vise with soft jaws. Make
alignment marks on each section of the hydraulic STEPS
pump.
STEP 2
Remove the thrust plate.
700042 STEP 6
Loosen and remove the nuts and flat washers .
STEP 3
Remove the driven gear.
70001\1j
Remove the end cover.

8005-4
STEP 7 STEP 10
70001 1 7000 19
Remove the drive gear. Remove the carrier.
STEP 8 STEP 11
700013 700023
Remove the other thrust plate. Remove th e quad ring .
STEP 9 STEP 12
700015
Remove the gear housing . Remove the thrust plate.

8005-5
STEP 13 STEP 16
Remove the driven gear. Remove the other thrust plate.
STEP 14 STEP 17
Remove the coupling. Remove the gear housing .
STEP 15 STEP 18
700 120
Remove the drive gear. Remove th e stud s.

8005-6
STEP 19 STEP 20
700124 700209
Remove the oil seal from the drive end cover. Remove the seal from the thrust plates .
8005-7
VER FLAT
'N°T WAr~
c::>~~/
THRUSTSlL
PLATE 1 'I
STUD
NUT
QUAD
THRUST
PlT
T
/~ 1
SEAL
870019
8005-8
INSPECTION
STEP 1 STEP 7
Discard all seals and quad rings.
STEP 2
Clean all parts in cleaning solvent.
STEP 3
Do not remove the plugs from the drive end cover
and end cover.
STEP 4
Check all machined surfaces for damage.
STEPS
525018
Measure the thickness of the thrust plates. If the

thickness of a thrust plate is less than 0.247 inch
(6.27 mm), install a new thrust plate.
STEP 8
525026
Measure the amount of wear caused by the gear

teeth in the gear housings. If the wear is more than
0.005 inch (0.13 mm). use a new gear housing .
STEP 6
Inspect the bushings in the drive end cover, ca r-

rier, and end cover. If the bushings are worn or
damaged, use a new hydra ulic pump.
700206
I nspect the gears for wear and damage. If the gears

must be replaced , use a hydraulic pump.
8005-9
ASSEMBLY
STEP 1 STEP 4
700201 700209
Install new quad rings in the grooves in the gear Install new seals in each thrust plate .
housing. Use petroleum jelly to hold the quad rings
in place . STEPS
STEP 2
700 122
Fasten the drive end cover in the vise with soft jaws.
700 126
Install a new oil seal in the drive end cover. STEPS
STEP 3
I nstall the studs.
Press the oil seal into the drive end cover.

8005-10
STEP 7 STEP 10
Install the gear housing . Install the coupling .
STEPS STEP 11
700114
Install the thrust plate with the seal down and the I nstall the driven gear.
grooves as shown above.
STEP 12
STEP 9
700111 Install the thrust plate wi t h the seal up as show n

Install the drive gear. above .
8005-11
STEP13 STEP 16
700011
Install the carrier. Install the drive gear.
STEP14 STEP 17
7000 17
Install the gear housing. Install the driven gear.
STEP15 STEP 18
700013
I nstall the th rust plate with the seal down as shown Install the thrust plate with the seal up as shown.
above.
8005-12
STEP 19 STEP 20
Install the end cover. Install the nuts and flat washers . Tighten the nuts
evenly to 200 pound-feet (271 N m, 28 kg/ m).
THRUST
QUAD RING PLATE
BUSHING
DRIVE END DOWEL

COVER PIN GEAR END COVER
DOWEL PIN CARRIER
HOUSING 870020
8006
HYDRAULIC PUMP - SECTIONS
FASTENED TOGETHER WITH CAP SCREWS
TABLE OF CONTENTS
Specifications . . ... .. . .... . .. .. . . . . ... .. 8006-2 Inspection ... . .... .. . ... . . . ... .. ....... 8006-7
Disassembly . ........ .... .. ..... . ... . . . 8006-3 Assembly . .. .. ......... .. ... ...... . .. . 8006-10
A T enneco Company
8006-2
SPECIFICATIONS
Manufacturer .. . . ...... . ..... ........................ . . . ...... .. . .... . ..... ... . Commercial Shearing
Rotation ....... . ...... . .. .... . . ... . . ... . .. . ................. Counterclockwise as seen from shaft end
Wear Specifications . .... ..... ..... . . .... .. .... .. ... .... .. . ........... .... .... ........ See Inspection
Special Torques
Cap screws that hold the sections together .. . .... ...... .... . ...... 200 pound-feet (271 Nm, 28 kg/ m)
Weight ......... .. .. .. .. .. .... . ... . ...... . ... . . . ....... . . . . ....... ......... . . . .. . . 80 pounds (36 kg)
8006-3
DISASSEMBLY
STEP 1 STEP 4
877711 877708
Clean the outside of the hydraulic pump. Fasten Remove the quad rin g.
the hydraulic pump in a vise with soft jaws. Make
al ignment marks on each section of the hydraulic STEPS
pump .
STEP 2
Remove the th rust plate.
877710 STEP 6
Loosen and remove the cap screws and flat wash-
ers.
STEP 3
Remove the dri ve n gea r.
877709
Remove the end cover.

8006-4
STEP 7 STEP 11
877705 877686
Remove the drive gear. Remove the carrier.
STEP 8 STEP 12
877696
Remove the other thrust plate . Remove the quad ring .
STEP 9 STEP 13
877688 877695
Remove the gear housing . Rem ove the thrust plate.
STEP 10
Remove the quad ring from bottom of the gear
housing.
8006-5
STEP 14 STEP 17
87769'1 877691
Remove the driven gear. Re move th e other thrust plate .
STEP 15 STEP 18
877693 877690
Remove the coup ling . Remove the gear housing.
STEP 16 STEP 19
Remove the quad ring f rom the bottom of the gear
housin g .
877692
Remove the drive gear.

8006-6
STEP 20 STEP 21
700124 700209
Remove the oil seal from the drive end cover. Remove the seal from the thrust plates .
8006-7
INSPECTION
Discard all seals and quad rings . Clean all STEP 24
parts in cleaning solvent. Check all machined sur-
faces for damage or wear.
STEP 22
525018
Measure the thickness of the thrust plates. If the

thickness of a thrust plate is less than 0.247 inch
(6.27 mm), instal l a new thrust plate.
525026
Measure the amount of wear caused by the gear

teeth in the gear housing . If the wear is more than
0.005 inch (0.13 mm), use a new gear housing.
STEP 23
Inspect the bushings (1) in the drive end cover,

carrier, and end cover. If the bushings are worn or
damaged , use a new hydraulic pump .
700206
I nspect the gears for wear and damage. If the gears

must be replaced, use a new hydraulic pump.
8006-8
FLAT ~
]~~-
~ CAP SCREW
DOWEL
PIN
\
SEAL
8 87 1979
8006-9
BUSHING
DRIVE END
COVER
GEAR HOUSING DOWEL PIN f
CARRIER GEAR
HOUSING
8871980
Hydraulic Pump Cross Section

8006-10
ASSEMBLY
STEP 26 STEP 29
70020 1 700209
Install new quad rings in the grooves in the gear Install new seals in each thrust plate .
housings Use petroleum jelly to hold the q uad
rings in place. STEP 30
STEP 27
877683
Fasten the drive end cover in the vise wi th soft

700126 jaws.
Install a new oi l seal in the drive end cover.
STEP 31
STEP 28
877682
7U01 28 Install the gear housing.

Press the oi l seal into the drive end cover.
8006-11
STEP 32 STEP 35
877691
Install the thrust plate with the seal down and the Install the driven gear.
STEP 36
STEP 33
877692 Install the thrust plate with th e sea l up as shown

Install the drive gear. above.
STEP 34 STEP 37
877693 877685A
Install the coupling . Install the carrie r.

8006-12
STEP 38 STEP 41
877685
Install the gear housing . Install the driven gear.
STEP 39 STEP 42
877689 877707
Install the thrust plate with the seal down and the Install the thrust plate with the seal up as shown.
STEP 43
STEP 40
t
877687
" 77705 Install the end cover.

Install the drive gear.
8006-13
STEP 44
877684
I nstall the cap sc rews and flat washers. Tighten the

cap screws evenly to 200 pound-feet (271 Nm, 28
kg / m) .
This Page is Blank
8007
LOADER CONTROL VALVE
TABLE OF CONTENTS
Specifications . ... . ..... .. .. . ...... .. ... 8007-2 Assembly ....... . .. . .... . .. . . . . ..... 8007-20
Special Tools .... ...... . . ... .. . .. .. . ... 8007-3 Cross Section . . . .. ....... .. ..... . .. . 8007-25
Separating the Valve Sections . . . .. ..... . 8007-4 Lift Section .. . .. ..... .. . . ... ... . ...... 8007-26
Assembling the Valve Sections . . ..... . .. 8007-5 Disassembly ... . .. ....... ... ..... ... 8007-26
Outlet Section ... .. .... ... .. .. . . . . .. . .. 8007-6 Explod ed View . . .. .... . ....... .. .... 8007-29
Disassembly ....... . .. ....... ... . .... 8007-6 Inspection ... .... ........ . ..... . .. . . 8007-30
Exploded View . . . .......... .. ... .... . 8007-7 Assembly ... ........... . . .. .... . .... 8007-30
Assembly ... .. .... .. ........ ... ...... 8007-8 Cross Section . . ........ . ... ... . ..... 8007-34
Cross Section .. . .. . .. ..... ... ... . . .. . 8007-9 Clam Section . . . . . . . . ... ..... . . . .. . ... 8007-35
Inlet Section .. . . . ........ . .... .. ... ... 8007-10 Disassembly .. .. .. .... . . .. . . ..... . .. 8007-35
Disassembly .. . .. . .. . . .. .. ..... . .. . . 8007- 10 Exploded View . . ....... .... .. . ...... 8007-37
Inspection .... . . . .. ... . ... .. .... .... 8007-11 Inspection ............... .. ......... 8007-38
Exploded View .. .. . .. .... ....... . ... 8007-12 Assembly .. . ... . . . . ...... ... . ... . . .. 8007-38
Assembly . . . .. . . ... .. ... .. .. ... ... . . 8007-13 Cross Section ... . . . ......... . . .. .. .. 8007-41
Cross Section .. .. .. .... . ... ...... . .. 8007-14 Circuit Relief Valve . . . ......... . ....... 8007-42
Bucket Section ....... ....... ... ... .. .. 8007-15 Disassembly . .. .. . . ... . .... . .... . ... 8007-42
Disasse mbly . .. . . . . . ... . ... .. ... .. .. 8007-15 Inspection ........ . . . . .. . .. . .... .. .. 8007-43
Exploded View .. .. . .... . .. ... .. ... .. 8007-19 Assembly ... .... . .. .... . .... . . . . . ... 8007-43
Inspection .... .. . .... . . .. ...... . .. .. 8007-20
J I Case 8-67410
A Tenneco Compan y
8007-2
SPECIFICATIONS
Manufacturer . . . . . . . ... .... .. . ... .. . ..... . . . ..... . .... . . . . . . ... . . . . ... . ... . . .... . . . .. . .. . . .. . J I Case
Pressure Settings .. . .. . . . ...... .. . . . .. .. . ... . . . . . . .. .. ... ... .. .. ... ... .. ... . ... .. ... See Section 8002
Ports and Spools

Spool travel , neutral to pressure . .. . .... . . . ..... . .. . . . . . ........ . ..... .. .. . . . .. .. 0.390 inch (9.9 mm)
Spool travel , neut ral to float . . .... . .. ... .... . ........ . .. . . . .. .. . . . . . . .. .. . . . ... . 0.680 inch (17.2 mm)
Spool moved into the body ... .. . . ....... .. . . .. . ... . .. . . . . .... . . . ....... . .. . . .. ... . pressure at A port
Spool moved out of the body .... . . . ...... . . .. .......... . ....... . ..... . . . .. . . . .. ... pressure at B port
Inlet, outlet, and power beyond ports ... .. . .......... . . . . . . . . . ... . ... . . . ... . . .. . . . . . . • . . . spl it flange
Threads in steering pilot port . ..... . . . .... .. .. . . . .... . .. ... .. .. .. . .... . . .. . .. 1/ 2 - 18, straig ht thread
Threads in steering outlet port . ....... . .. .. .. ...... . .... . . ... . . . . .... .. . . ... . 3/ 4 - 16, straig ht thread
Threads in A and B ports .. ..... . ......... .. ... . . . .... . .. . .. . .. . . . . . .... . . . .. 718 - 14, straig ht thread
Special torques
Nuts that fasten the valve sections together . .. . . .. . . ... . 20 to 30 pound-feet (27 to 41 N m, 3 to 4 kg / m)
Main relief valve . . .. . .. .. . . . . . . . . . .. .. . . ... ....... ... . 35 to 40 pound-feet (47 to 54 N m, 5 to 6 kg / m)
Circuit relief valves or plugs for load check valves . . . . . 65 to 85 pound-feet (88 to 155 N m, 9 to 12 kg / m)
Spool cap or detent housing . . .... .. ... . .. . . . . ... . .. . . . 20 to 30 pound-feet (27 to 41 N m, 3 to 4 kg / m )
Allen head screws for bucket spool .... .. .. . ... .. . .. . . Tighten screws evenly to 15 to 30 pound-inches
(2 to 3 N m, 0.2 to 0.3 kg / m). Then tighten the Allen head screws
evenly to 50 to 60 pound-inches (6 to 7 N m, 0.6 to 0.7 kg / m).
Circuit relief valve body ....... ... ... ... . . . . .. .. . . .. . .. 8 to 12 pound-feet (11 to 16 N m, 1 to 1.5 kg / m)
Weight . . .... . . . . . .. ... . . .. . . . . ... . .. . . . . .. ... .. . . ........... . . . .... . approximately 70 pounds (32 kg)
8007-3
SPECIAL TOOLS
_4 _1 2
1 '
0 ,
u~
786802
861843
The spring compressing plate is used to com -
press the centering springs fo'r removal and instal- 1. 3/8-16 NC x 3 Inches (76 mm)
lation. The part number of the tool is CAS-1147-2. 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.
8007-4
SEPARATING THE VALVE SECTIONS

STEP 1 STEP 4
628430 628438
Clean the outside of the loader control valve . Write Remove the shims .
a number on each sect ion of the loader control
valve. STEPS
STEP 2
628440
Remove the remainder of the sections and shims.

628434
Loosen and remove the nuts that fasten the sec- STEPS
tions together.
STEP 3
628444
Remove the studs from the outlet sectio n.
628436
Remove the inlet section.

8007-5
ASSEMBLING THE VALVE SECTIONS

STEP 1 STEP 4
I nspect the a-rings in the valve sections. Replace
a-rings as necessary. Use petroleum jelly to hold
the a-rings in place as the valve sections are as-
sembled.
STEP 2
628404
Install the valve sections according to the se-

quence of the numbers yo u wrote on the valve
sections. I nstall the shims between each section as
shown in step 3.
628444 STEPS
Install the studs in the outlet section.
STEP 3
628432
Install the nuts on the studs. Make sure the valve is

on a flat surface. Tighten the nuts to 20 to 30
628402 pound-feet (27 to 41 N m, 3 to 4 kg/ m) .
Install the shims .
8007-6
OUTLET SECTION
Disassembly STEP 4
STEP 1
628820
Remove the spring .

6284 10
Fasten the outlet section in the vise with soft jaws. STEPS
Loosen and remove the main relief valve.
STEP 2
628824
Remove the poppet.
6280115 STEPS
Loosen the plug in the other end of the outlet Do not disassemb le th e main relief va lve. None of
section. the internal parts of the main relief valve are avail-
able for service.
STEP 3
628818
Remove the plug.

8007-7
ij. . --PLUG
O ....·--O-RING
I. . ·--SPRING
~••--POPPET
... 1
--BODY
MAIN
Vll'---- RELIEF
VALVE
870012
Outlet Section
8007-8
Assembly STEP 3
STEP 1
628818
I nstall a new O-ring on the plug. Lubricate the 0-

628824 ring with clean hydraulic oil. Install the plug .
Install the poppet.
STEP 4
STEP 2
628408
628820 Install new O-rings and a new backup ri ng on the

Install the spring. main relief valve. Lubricate the O-rings and bac-
kup ring with clean hydraulic oil. Install the main
relief valve. Tighten the main relief valve to 35 to 40
8007-9
MAIN .ElF VALVE
861799
Outlet Section
8007-10
INLET SECTION
Disassembly STEP 4
STEP 1
628712
Loosen and remove the plug from the other end of

628744 the inlet section.
Fasten the inlet section in the vise with soft jaws.
Loosen th e steering relief valve. STEPS
STEP 2
Remove the spool.
Remove the steering relief valve . STEP 6

STEP 3
Fasten the steering relief valve in the vise with soft

jaws. Prevent the adjusting screw from turn ing and
Remove the spring. loosen t he lock nut. Make a count of the number of
turns needed to remove the adjusting screw from
the body.
8007-11
STEP 7 Inspection
STEP 1
628924
Remove the steering relief valve from the vise and
separate the parts. 628928
I nspect the seat in the end of the body. If the seat is

damaged , use a press to replace the seat. Replace
the O- rings and back up ring on the body and ad-
justing screw.
STEP 2
I nspect the orifice in the orifice plug . Make sure the
orifice is clean.
STEP 3
Inspect the spool and spring . Use new parts as
necessary.
8007-12
@--PLUG
O-RING--.Q
--.....'\
O-RING-6
/
I / '"
/'
"-
" S P R I N G - ._ _
""
I
-
O-BACKUP RING "" /
O-RING-O " /
~-SEAT "" /
~ "-_/
~_BODY
POPPET-t
I_SPRING
O-RING-O
; ••--ADJUSTING SCREW
LOCKNUT-~ 870013
I nlet Section
8007-13
Assembly STEP 4
STEP 1
Install a new O-ring on the plug. Lubricate the 0-

628924 ring with clean hydraulic oil. Install the plug in the
Lubricate the new O-ring on the adjusting screw. inlet section.
Assemble the parts of the steering relief valve.
STEPS
STEP 2
628706
Install the spring in the other end of the inlet sec-

Fasten the body in the vise with soft jaws. Tighten tion.
the adjusting screw the same number of turns as in
step 6 under Disassembly . Tighten the lock nut. STEPS
STEP 3
Lubricate the new O-rings and backup ring on the

628920 steering relief valve. Install the steering relief valve .
I nstall the spool.
8007-14
STEP 7
Tighten the steering relief valve to 65 to 85 pound-

feet (88 to 155 N m, 9 to 12 kg/ m).
SPRING
STEERING
RELIEF
VAL\
861798
Inlet Section
8007-15
BUCKET SECTION
Disassembly STEP 4
STEP 1
41 5 114
Remove th e cap and gasket.

415107
Remove the O-rings from the bucket section. STEPS
STEP 2
415 117
Remove th e snap ring .

41 5111
Fasten the bucket section in the vise with soft jaws. STEP 6
Loosen the Allen head screws .
STEP 3
Remove the washer.
415113
Hold the cap in place and remove the Allen head

screws .
8007-16
STEP 7 STEP 10
415 11 9
Remove th e spring. Pull the spool from the body .
STEPS STEP 11
415120 415235
Remove the detent washer. Remove the O-ring , retainer, spring washe rs, and
other O-ring from the spool.
STEP 9
STEP 12
4 15 12 1
Remove the coi l and terminal. 415237
Remove the detent housing .

8007-17
STEP 13 STEP 16
415238 628632
See Special Tools in this section . Install the spring Loosen and remove the circuit relief valve from the
compressing plates to compress the centering body.
spring.
STEP 17
STEP 14
628642
415240 See Special Tools in this section. Use the tool to

Loosen and remove the stud. pull the load ch eck plug, spring , and poppet from
the body.
STEP 15
STEP 18
Repeat steps 16 and 17 to remove the other circuit
relief valve.
STEP 19
415242
Release the spring tension and separate the cen-

tering spring and spring seats .
629304
Use a prybar to remove the wiper.

8007 -18
STEP 20
629306
Remove the O-ring from the spool bore.
STEP 21
See page 8007-42 for disassembly, inspection, and
assembly of the circuit relief valves.
8007-19
CIRCUIT
A RELIEF - -
VALVE
s---
©>_---SPRING WASHERS
O. O-RING
O-RING--.
WIPER--·:
---GASKET
~-SPRING SEAT
1-. -SPRING
BODy--·.. 1
O-SPRING SEAT
---STUD
~~
---COIL
TER.'~ 0-DETENTWASHER
O-RING ~ ~ _ _ _ SPRING
. . . . . 'Q ®---WASHER BACKUP RING--_
"0°-- SNAP RING

LOAD CHECK PLUG-~
/~ I CIRCUIT
RELIEF - - -
RUBBER PLUG
I+-ALLEN SCREW A VALVE
970014
Bucket Section
8007-20
Inspection STEP 4
STEP 1 O-RING
BACKUP RINGS
628530
Replace the a-ring and backup rings on t he load

415232 check plug .
Remove and discard the a-ring from the terminal.
STEPS
STEP 2 Inspect the spool and spool bore for wear and
damage. If either part is worn or damaged, use a
complete new bucket section .
STEP 6
Use an ohmmeter to check the coil and termina l fo r
cont inuity and for a short circu it. If the terminal is
damaged, use a soldering iron to replace the termi-
nal. If the coil is damaged, remove the terminal
from the old co il and install the terminal on the new
coil.
STEP 7
Discard the a-rings and gasket.
415231
I nspect the rubber plug in the cap. Replace the

Assembly
rubber plug as necessary.
STEP 1
See page 8007-42 for disassembly, inspection , and
STEP 3
assembly of the circuit re li ef valves .
STEP 2
628526
I nspect the poppet, spring , and load check plug .

Use new parts as necessary.
629308
Install a new a-ring in the groove of the spoo l bore .

8007-21
STEP 3 STEP 6
628642 415242
Use the tool to install the load check plug, spring, Assemble the spring and spring seats. Use the
and poppet The groove in the load check plug spring compressing plates to compress the spring.
must be toward the spool bore.
STEP 7
STEP 4
415243
628634 I nstall the spring and spring seats on the spool.

Lubricate the O-rings and backup ring on the cir-
cuit relief valve. Install the circuit relief valve. STEPS
STEPS
415201
Apply 242 Loctite to the threa ds of the stud. Install

628630 the stud in the spool.
Tighten the circuit reli ef valve to 65 to 85 pound-
feet (88 to 155 N m, 9 to 12 kg/ m).
8007-22
STEP 9 STEP 12
415238 4'~202
Remove the spring comp ressing plates. Push the parts against the detent housing .
STEP 10 STEP 13
415237 415124
Instal l the detent housing. Lubricate the spool , spool bore, and the O-rings
with clean hydraulic oil. Install the spool into the
STEP 11 bore .
STEP 14
415235
I nstall the O- rings, spring washers , and retainer.

41512 1
Install the coil and terminal on the stud.

8007-23
STEP 15 STEP 18
415120 41511 7
Install the detent washer. Hold the washer in place and install the snap ring.
STEP 16 STEP 19
41 5114
I nstall the spring. Install a new O-ring on the term ina l. Install the
gasket. Put the terminal in the cap.
STEP 17
STEP 20
415118
I nstall the washer. 415 113
Align the gasket and cap with the detent housing.

Install the Allen head screws and lock washers.
8007-24
STEP 21 STEP 23
415110 628742
T ighten the Allen head screws evenly to 15 to 30 Use a hollow sleeve and a hammer to push the
pound- inch es (2 to 3 N m, 0.2 to 0.3 kg/ m). Then wiper into the body.
tighten the Allen head screws to 50 to 60 pound-
inches (6 to 7 N m, 0.6 to 0.7 kg/ m) . STEP 24
STEP 22
415108
Install new O-rings in the bucket section .

628738
Lubricate the wiper with clean hydraulic oil. Install

the wiper with the lip up.
8007-25
CIRCUIT
RELIEF
/VALVE
BODY ___
DETE NT HOUSING
GASKET
861800
Bucket Section
8007-26
LIFT SECTION
Disassembly STEP 4
STEP 1
415324
Remove the ball retainer.
Remove and discard the O-rings from the body.
STEP 2
415107
.
STEP 5
Remove the eight steel balls.

1\ 15322
Fasten the lift section in the vise with soft jaws. STEP 6
Loosen and remove the plug .
STEP 3
415328
Remove the spacer.
415323
Remove the detent spring.

8007-27
STEP 7 STEP 10
415409 41 5424
Loosen and remove the detent housing. See page 8007 -2 for the spri ng compressing plates .
Fasten the spring compressing plates to compress
STEP8 the centering spring .
STEP 11
-~----
Pull the spool from the body .

415426
STEP9 Loosen and remove the stud.
STEP 12
415422
Remove the O-ring and retainer from the spool.

415428
Remove the cen tering spri ng and spri ng seats from

the spool.
8007-28
STEP 13 STEP 16
41 5430 4 154 15
Release the tension on the centering spring and Remove the wiper from the spool bore.
separate the centering spring and spring seats.
STEP 17
STEP 14
415417
41541 3 Remove the O-ring from the spool bore .

Loosen and remove the plug from the body.
STEP 18
STEP 15 Repeat steps 14 and 15 to remove the other plug ,
load check plug , spring, and poppet.
Use the tool shown on page 8007-2 to pull the load

check plug from the body.
8007-29
~----
"- \
\
\
\
\
\
!-, --PLUG
\ O---0-RING
\
\
e0"'---
' BACKUP RING
O-RING
SPOOL---+-,.,n:; \
\
LOAD CHECK PLUG--~' ~
\ _--BACKUP RING
\ - - - O-RING
\ 1_-- BACKUP RING
\
I \ WIPER---+- I_---SPRING
SPRING _ _ _" ~ \
SEAT O-RING---_ ----POPPET
\
\
\
~:;..!-4--- SPRING
\
\
\ I---BODY
@I
. ...._ _ _ SPRING \
W SEAT
\
\
~_'--STUD \
\
\
\
\
O-RING --';-----+-" 1""1.... I
' - ' C)I••---POPPET
DETENT RETAINER \ , ~ l!J
~--- HOUSING
\ I ~I .'--- SPRING
"- '-..../ / ~
~ • BACKUP RING
Q. O-RING
e· BACKUP RING
~.'---SPACER
© ...--- STEEL BALLS LOAD CHECK PLUG - - - , ~
®- BALL RETAINER
O'··---O-RING
o· BACKUP RING
O. O-RING
11-4.--- SPRING
; .......- - P L U G
~I-+'----PLUG
(),-4.----
I
RUBBER PLUG 870015
Lift Section
8007-30
Inspection STEPS
Inspect the stud , spacer, steel balls, and ball re-
STEP 1 tainer fo r damage and wear. Install new parts as
necessary.
Assembly
STEP 1
628526
I nspect the load check poppet, spring, and load

check plug . If any of the parts are damaged, re-
place the parts as necessary.
4 15419
STEP 2 Install a new a-ring in the spool bore.
O-RING STEP 2
BACKUP RING
628530
Replace the a-ring and backup rings on the load

check plug .
Use the tool shown on page 8007-2 to install the
STEP 3 load check plug, spring, and load check poppet.
I nspect the spool and spool bore for wear and The groove in the load check plug must be aligned
damage. If either part is worn or damaged, use a with the work port.
complete new lift section.
STEP 3
STEP 4
BACKUP RING
O-RING 415411
415420 Install the plug . Tighten the plug to 65 to 85 pound-

Replace the a-rings and backup ring on the plug . feet (88 to 155 N m, 9 to 12 kg / m).
8007-31
STEP 4 STEP 7
415430 415424
Assemble the centering spring and spring seats. Remove the spring com pressin g plates.
Use the spring compressing plates shown on page
8007-2 to compress the centering spring. STEPS
STEPS
41 5422
Install the retainer and a new O-ri ng on the spool.

4 15428
I nstall the centeri ng spri ng and spri ng seats on the STEP 9

spool.
STEP 6
41 5410
Lubricate the spool , spool bore, and the O-rings

with clean hydraulic oi l. Install the spool into the
41 5429 spool bore.
Apply 242 Loctite (blue) to the threads of the stud.
Install the stud in the spool.
8007-32
STEP 10 STEP 13
415433 415436
Install the detent housing . I nstall the eight steel balls. Put the steel balls even-
ly around the spacer.
STEP 11
STEP 14
415434
Apply No. 2 molydisulfide grease to the groove in 415437
the spacer. Apply No. 2 molydisulfide grease to the flat si de of

the ball retainer.
STEP 12
STEP 15
415435
Install the spacer so that the groove in the spacer is 415438
up. Install the ball retainer with the flat side down .
8007-33
STEP16 STEP 19
Install the detent spring . Use a hollow sleeve and a hammer to push the
wiper into the body.
STEP17
STEP 20
Install the plug.

Install new O-rings in the body.
STEP18
Lubricate the new wiper with clean hydraulic oil.

Install the wiper with the lip of the wiper up.
8007-34
\.------PLUG
WIPER -----;:::=..v
O-RING -----~~("
APORT
~T-~~--- SPRING
POPPET
BODy _ _ _ _ ....
~
O-RING _ _ _ _ _~~"::j
RETAINER _ _ _ _ _ _~.Ja:\
SPRING ---------ll!Jy
SPRING
SEAT --....!<:lJ,
SPACER---------~~
DETENT
HOUSING
'-----PLUG 861801
Lift Section
8007-35
CLAM SECTION
Disassembly STEP 4
STEP 1
628532
Remove the O-ring and retaine r from the spoo l.

415107
Remove the O- rings from the clam section. STEPS

STEP 2
628534
Use the spring compressing plates shown in Spe-

628842 cial Tools to compress the sp ring .
Fasten the clam section in the vise with soft jaws.
Loosen and remove the spool cap . STEP 6
STEP 3
628538
Loosen and remove th e cap screw .

628804
Pull the spool from the body.

8007-36
STEP 7 STEP 10
628624 628520
Remove the spring and spring seats from the spool. Use a prybar to remove the wiper from the other
Release the spring tension and separate the spring, end of the spool bore.
spring seats, and washer.
STEP 11
STEP 8
628522
628508 Remove the O-ring from the spool bore.

Loosen and remove the plug .
STEP 12
STEP 9 Do steps 8 and 9 to remove the other plug, load
check plug, spring, and poppet.
Use the tool shown in Special Tools to pull the load

check plug, spring, and poppet from the body.
8007-37
- -- PLUG
a-RING
BACKUP RING
a-RING
r-..... LOAD CHECK PLUG
I "- \ BACKUP RING

I \ a-RING
\
BACKUP RING
\
\
SPOOL \ WIPER SPRING
\ a-RING
\ POPPET
\
\
\
\
\
\
\
\
\
\ BODY
\
\
a-RING ·0 \
\
RETAINER .~ \
\
SPRING
SEAT I~ \
\ I
WASHER .@ \.
, ....... I
~. POPPET
SPRING I
~ ~.
e,
SPRING
BACKUP RING
SPRING
SEAT ·e 0'
C'
a-RING
BACKUP RING
I~
~
CAP SCREW
LOAD CHECK PLUG •
.~
O· a-RING
SPOOL CAP
eJ· BACKUP RING
C). a-RING
~.--PLUG
870016
Clam Spool
8007-38
Inspection Assembly
STEP 1 STEP 1
628526 628524
Inspect th e load check poppet, spring , and lock I nstall a new a-ring in the groove of the spool bore.
check plug . Use new parts as necessary.
STEP 2
STEP 2
O-R NG
BACKUP RINGS
628510
628530 Lubricate the a-ring and backup rings on the load

Replace the a-ring and backup rings on the load check plug. Use the too l to install the load check
check plug . plug, spring , and poppet. The groove in the load
check plug must be toward the spool bore.
STEP 3
STEP 3
4 15420
Rep lace the a-rings and backup ring on the plugs .

628506
STEP 4 Lubricate the a-rings and backup ring on the plug .

Inspect the spool and spool bore for wear and I nstall the plug . Tighten the plug to 65 to 85 pound-
damag e. If the spool or spool bore are damaged , feet (88 to 155 N m, 9 to 12 kg/ m) .
use a complet e new clam secti on.
8007-39
STEP 4 STEP 7
628624 628536
Assemble the spring, spring seats, and washer. Use Tighten the cap screw.
the spring compressing plates shown in Special
Tools to compress the spring . STEP 8
STEPS
628534
Release the tension of the spring and remove the

628539 spring compressing plates.
Apply 242 Loctite to the threads of the cap screw.
STEP9
STEP 6
628532
628622 Install the retainer and a new O-ring on the spool.

Install the cap screw to fasten the spring to the
spool.
8007-40
STEP 10 STEP 13
628804 628625
Lubricate the spool , spool bore, and O-rings. In- Lubricate a new wiper. Install the wipe r with the lips
stall the spool in the bore. up.
STEP 11 STEP 14
628802 628628
I nstall the spool cap. Use a hollow sleeve and a hammer to push the
wiper into the bore.
STEP 12
628844
Tighten the spool cap to 20 to 30 pound-feet (27 to

41 N m, 3 to 4 kg / m) .
8007-41
PLUG
WIPER _ _ _ _ -=:;rJl
O-RING _------"~-'IIIr /
lOADC HECK PLUG
APORT
SPRING
POPPET
BPORT
SPRING _ _ _ _.-11
861802
Clam Spool
8007-42
CIRCUIT RELIEF VALVE

Disassembly STEP 2
STEP 1
628604
Move the circuit relief valve in the vise. Fasten the

628644 poppet seat in the vise . Loosen the body from the
Fasten the circuit relief valve in the vise with soft poppet seat.
jaws. Loosen the lock nut. Loosen and remove the
adjusting screw and lock nut. STEP 3
NOTE: If you disassemble more than one relief

valve, keep the parts for each relief valve together.
This procedure will prevent mixing the parts dur-
ing assembly.
628606
Remove the relief valve from the vise. Separate the

parts of the relief valve.
8007-43
~
LOCKNUT--_.
ADJUSTING _ _ _....
SCREW
1 ~"
/ \
/ ~
BODY---.- // I-·___ SPRING
/ 0 ....- - - O-RING
/
/
/
~ ....- - - POPPET
O-RING~O
SPRING _ __ -+. ~
SEAT
C)
/
/
/
/
/
/
t=. _--
I &.
POPPET SEAT
(~ ....- - - BACKUP RING

SPRING---·I // 0 . . --- O-RING
\ /
\ J 870017
Circuit Relief Valve
Inspection Assembly
STEP 1 STEP 1
I nspect the parts of the rei ief valve. All of the repai r
parts in the relief valve are available in a kit. If any of
the parts are damaged , replace all the parts in the
kit.
STEP 2
628606
Lubricate the O-rings on the parts of the relief

valve. Assemble the parts into the body.
628734
Replace the O-rings and backup ring on the parts

of the relief valve .
8007-44
STEP 2 STEP 4
See the procedure in Section 8002 . Check and ad-
just the pressure setting of the relief valve in a test
block before the relief valve is installed in the
bucket section .
ADJUSTING SCREW~
BODY--·Y
628602
SPRING
Fasten the poppet seat in the vise with soft jaws. OR
Tighten the body to 8 to 12 pound-feet (11 to 16 N PIN
m, 1 to 1.5 kg/ m).
STEP 3
SPRING ---~-+:--
POPPET
SEAT ---~*~ "~~--O-RING
~JOp.""~
861803
628644
I nstall the ad just ing screw and lock nut in the body.
8009
THREE-POINT HITCH CONTROL VALVE
TABLE OF CONTENTS
Specifications . .. . . . . . . ..... . .. .. ..... . . 8009-2 Exp loded View ... . . . . . . . .. .. .. . . ... . 8009-18
Special Tools ... .. . ... .... . ... .. .. . . . . . 8009-2 Assembl y .. .. ... .. . ....... .. ........ 8009-19
Separating the Valve Sections . ......... . 8009-3 Inlet/Outlet and Auxiliary Section .... . . 8009-22
Assembling the Valve Sections . . . . . .. . .. 8009-5 Disassembly . .. . .. .. .. . . . . . . . . .. . ... 8009-22
Lift Section . .. . . . ..... . .... . . . . . . . ... . . 8009-6 Exploded View . . . ........ . . .. .... .. . 8009-26
Disassembly .. .. . .. .. . . . ... ....... . . . 8009-6 Assembly ... . ... . . . ......... . ....... 8009-27
Exploded View . .... . .. . ....... ... ... 8009-10 Inspection . .. . . . ... . . . . .......... ... . . 8009-30
Assembly . ... ... .... .. . .... .. .... . .. 8009-11 Relief Valves . . . . . . .. . .. .. .. .. .. . .. . ... 8009-31
Tilt and Pitch Sections .. . . . . . . ... .. .... 8009-15 Disassembly . . ... . ... . . .. . ... . .. .. .. 8009-31
Disassembly .............. . .... . . . .. 8009-15 Inspection . . . . ....... . .. .. .. .. . .. ... 8009-32
Assembly ... .. . .. . . . . . .. ... .. . . . .. . . 8009-32
A Tenneco Compan y
8009-2
SPECIFICATIONS
Manufacturer .... ... ............. . . .. . . ... . . . .. .. ..... ... , .... . .... .... . ... ....... ... . . . ..... Rexroth
Weight ..... ... ....... .. .................. .. . ...... . . . ... .. . .. . .. ...... .. ........ .... 20 pounds (9 kg)
Spec ial Torques

Detent stud ................. ... .. . ..... .. . ........ .. . 17 to 21 pound -feet (23 to 28 N m, 2 to 3 kg/ m)
Self-locking nuts on suds that

hold sections together .... . .. . .. . .. .. .. .. . . .. .. .. . . . 17 to 21 pound-feet (23 to 28 N m, 2 to 3 kg/ m)
Plugs and relief valves ........ . . ..... ..... .. ...•. . .. .. 50 to 60 pound-feet (60 to 80 N m, 7 to 8 kg/ m)
Allen screws for spool caps

and retainers .... ..... . .. .. ... .. . .. . ............. 60 to 80 pound-inches (7 to 9 N m, 0.7 to 0.9 kg/ m)
SPECIAL TOOLS
786802
The spring compressing plates are used to

compress the cen tering springs for removal and
installation . The part number of the too l is CAS-
1147-2. See Section 1001 for information abo ut
ordering the spec ial tool.
8009-3

STEP 1 STEPS
Clean the outside of the three-point control valve.
STEP 2
Remove the lift section.
721802 STEP 6
Write numbers on each section.
STEP 3
7218 10
Remove the pitch section.
72 1804 STEP7
Loosen the studs that fasten the va lve sectio ns
together.
STEP 4
721812
Remove the tilt section .
721806
Remove the studs and self-locking nuts.

8009-4
INLET/ OUTLET /
AND AUXILIARY
SECTION
LIFT SECTION
887 1897
Three Pain
. t Hitch Control Valve
8009-5

STEP 8 STEP 11
72181 4 721820
Replace the O-rings in each section of the control Install the pitch section .
valve.
STEP 12
STEP 9
721822
7218 16 Install the lift section.

Remove the sel f-locking nuts from the studs. In-
stall the studs in the in let/outlet and auxili ary sec- STEP 13
tion.
STEP 10
721824
Make sure that the control valve is on a flat surface.

Install the self- locking nuts. Tighten the self-lock-
72 18 18 ing nuts to 17 to 21 pound-feet (23 to 28 N m, 2 to 3
Install the tilt section. kg/m) .
8009-6
LIFT SECTION
Disassembly STEP 17
STEP 14 ,
721832
Remove the large steel bal l.

721826
Fasten the lift section in the vise with soft jaws. STEP 18
Loosen the Al len head screws.
STEP 15
, .
>'::
' ";-'
,
Remove the three small steel balls.
721828 STEP 19
Remove the Al len head screws and spool cap.
STEP 16
721836
Remove th e spring.
721830
There is a spring and detent balls inside the detent

sleeve. Use a punch to compress the spring and
remove the detent sleeve.
8009-7
STEP 20 STEP 23
721902
Remove the retai nero Remove the plug .
STEP 21 STEP 24
7:>1910
Pull the spool and detent housing from the body . Loosen the Allen head screws in the retainer.
STEP 22 STEP 25
721906 72 191 2
Loosen the plug in the body. Remove the All en head screws, retainer , and wiper .
8009-8
STEP 26 STEP 29
72 1914 72 1928
Remove the O-ring. Loosen the plug for the load check valve . It can be
necessary to loosen the fitting to get access to the
STEP 27 plug .
STEP 30
72 1924
Loosen the circuit relief valve from the body.

721930
STEP 28 Remove the plug .
STEP 31
721926
Remove the circuit relief valve.

721934
Remove the spring .

8009-9
STEP 32 STEP 35
721936 700802
Remove the poppet. Loosen and remove the detent stud from the spool .
STEP 33 STEP 36
700840 7OU838
Remove the sleeve , O-ring, and detent housing Release the spring tension and separate the spring
from the spool. seats from the spri ng.
STEP 34
700844
I nstall the spring compressing plates shown on

page 8009-2 .
8009-10
"\
CAP-+-B [9---SLEEVE
LOC K N UT --+ ® O..--O-RING
ADJUSTING SCREW- i e-SPOOLEYE
SPRING _ _ I
POPPET --+-~
BODY_~
O-RING-~
-SPOOL
Q-BACKUP RING
O-RING--+O
~""-SPRING
PLUNGER- ~
PISTO N _ t : j J 9..--SPRING
SEAT
HOUSING_~
,. !~ALLENSCREW
I-SPRING
~ __ SPRING
a- RING - 0 r(;'\ - + - RETAINER

V SEAT
BACKUPRING-O ~ ~""'RETAINER
o ~-WIPER
O-RIN G - - I
I
I
Ih.-J;
I. ~ ::--
I
q > - O-RING
(-
II
I /'\
11 I -- STUD
DETENT
~ '0 I STEEL _ 0
BALLS EI
..
~-SPRING
POPPET ~ ~( -. O-RING
0 - - STEEL BALL
O- RI \ ~ ~ ~ " I o~....-DETENT SLEEVE
~(J~'NG ~ ~ ~ ' ()~ I

O-O-RING
! / 2i \
a -R ING
;V I '\ '- '- PLUG
__ DETENT
HOUSING
PLU G 0 '" '- "-

/~BACKUP RING '- "- ~_SPOOl
a -RING '- .. ~ CAP
......
~il
>- . -PLUG ...... "-
......
" ALLEN __
SCREW B871898
Lift Secti on
8009-1 1
Assembly STEP 41
STEP 37
See page 8009-30. I nspect the parts of the lift sec-
tion .
STEP 38
700804
Install the detent housing on the spool. Lub ricate

the O-ring with clean oil. Carefull y install the 0-
ring into the detent ho using .
STEP 42
700838
Assemble the spring seats and spring. Use the tool

shown on page 8009-2 to compress the spring.
STEP 39
700806
Install the sleeve into the detent housing.
STEP 43
700802
Install the sprin g seats and spring on the spool.

Tighten the detent stud to 17 to 21 pound-feet (23
to 28 N m, 2 to 3 kg/ m).
STEP 40
721936
Install the poppet in the body .
700844
Remove the tool from the spool.

8009- 12
STEP 44 STEP 47
721934 721926
In stall the spring in the poppet. Lub ri ca te the O-rings and backup ring on the cir-
c uit relief valve. Install the circuit relief valve .
STEP 45
STEP 48
721930
Lubricate the O-ring w ith c lean oil. Install the plug .

Lubricate the O-rings and backup ring on the plug .
STEP 46 I nstall th e pi ug.
STEP 49
721928
Tighten th e plug.
722004
Ti ghte n t he plug to 50 to 60 pound -feet (68 to 80

Nm,7 to 8 kg/ m) .
8009-13
STEP 50 STEP 53
72 1904 122008
Lubricate the spool and O-ring on the detent hous- I nstall the th ree steel balls in the holes in the detent
ing with clean oil. Install the spool and detent hous- stud . Apply petroleum jelly to the steel balls to hold
ing in the body. the steel balls in position.
STEP 51 STEP 54
721 902 721832
Install the retainer. Install the large steel ball in the end of the detent
stud.
STEP 52
STEP 55
,'
72 1836
Install the spring. 721830
Use a punch to push in the steel ball and install the

detent sleeve. Make sure the large steel ball is
pushed past the small steel balls .
8009-14
STEP 56 STEP 59
721828 722016
Install the spoo l cap . Install the wiper on the spool.
STEP 57 STEP 60
722010 722018
Tighten the Allen head screws to 60 to 80 pound- Install the retainer. Tighten the Allen head screws
inches (7 to 9 N m, 0.7 to 0.9 kg/ m) . to 60 to 80 pound-inches (7 to 9 Nm, 0.7 to 0.9
kg/ m).
STEP 58
722014
Lubricate the O-ring with clean oil. Install the 0-

ring on the spool.
8009-15
TILT AND PITCH SECTIONS

Disassembly STEP 64
STEP 61
722028
Loosen the plug from the body .

722022
Fasten the section in the vise with soft jaws. Loos- STEP 65
en the Allen head screws in the spool cap.
STEP 62
722030
Remove the plug .
7220~4 STEP 66
Remove the Allen head screws and spool cap.
STEP 63
722032
Loosen the Allen head screws from the retainer .
722026
Pull the spool, O-ring , and wiper from the body.

8009-16
STEP 67 STEP 70
722034 722106
Remove the Allen head screws , retainer , and wiper. Loosen th e plug for the load check valve.
STEP 68 STEP 71
722036 722108
Remove the O-ring . Remove the plug .
STEP 69 STEP 72
722037 722110
Loosen and remove the plug . Remove the spring from the body.
8009-17
STEP 73 STEP 76
722114 700834
Remove the poppet. Loosen and remove the Allen head screw f rom the
spool.
STEP 74
STEP 77
700828
Remove the O-ring , wiper, and reta iner from th e 700838
spool. Release the spring tension and separate the spring

seats and spring.
STEP 75
700832
Use the tool shown on page 8009-2 to com press the

spring.
8009-18
(
I
" "- "-
"-
I "'
I
I
~_SPOOL
~ EYE
I
RETAINER ~
_SPOOL
a-O-RING
@--WIPER
~-RETAINER
POPPET
@ __ SPRING
SEAT
O-RING
til-SPRING
A SPRING
~-SEAT
PLUG
" 5+-ALLEN
S
......... SCREW
"-
"-,,- ........ '-- )I ~ 0_ ALLEN
~ SCREW
SPOOL -
CAP
8871899
Tilt and Pitch Sections

8009-19
Assembly STEP 81
See page 8009-30. Inspect the parts of the tilt

or pitch section .
STEP 78
700828
Lubricate the a - ring and spool with c lean oil. In-

stall th e retainer. Carefully install the wiper and 0-
ring . Push the retainer , wiper, and a-ring aga inst
the spri ng seat.
700838
Assemble the spring seats and spring. Use the too l STEP 82
to compress the spring.
STEP 79
722114
Install the poppet in the body .
700834 STEP 83
Install the spring and spring seats on the spool.
STEP 80
722110
Install the spring.
700032

8009-20
STEP 84 STEP 87
722108 722030
Lubricate the a-ring with clean oil. Install the plug . Lubricate the a -rings and backup ring on the plug.
Install the plug in the body. Tighten the plug to 50
STEP 85 to 60 pound-feet (68 to 80 N m, 7 to 8 kg / m) .
STEP 88
722106
Tighten the plug .

72::'116
STEP 86 Lubricate the spool and a-ring with c lean oil. In-
stall the spool in the body.
STEP 89
722037
Lubricate the a-rings and backup ring on the plug.

Install the plug in the body. Tighten the plug to 50
to 60 pound-feet (68 to 80 N m, 7 to 8 kg/ m). 722118
Install the spool cap.

8009-21
STEP 90 STEP 93
722120 722126
Tighten the Allen head screws to 60 to 80 pound- I nstall the retainer.

inches (7 to 9 N m, 0.7 to 0.9 kg/ m) .
STEP 94
STEP 91
722128
722 122 Tighten the Allen head screws to 60 to 80 pound-

Lubricate the a-ring with clean oil. Install the 0- inches (7 to 9 N m, 0.7 to 0.9 kg/ m) .
ring on the spool.
STEP 92
722 124
Install the wiper on the spool.

8009-22
INLET/OUTLET AND AUXILIARY SECTION

Disassembly STEP 98
STEP 95
722302
Loosen the plug from the body .

722130
Fasten the section in the vise with soft jaws. Loos- STEP 99
en th e Allen head screws in the spool cap .
STEP 96
722306
Remove the plug .
722134 STEP 100

Remove the Allen head screws and spool cap.
STEP 97
Loosen the relief valve.
722 136
Pull the spool , O-ring , and wiper from the body .

8009-23
STEP 101 STEP 104
722310 7223 16
Remove the relief va lve. Remove the O-ring .
STEP 102 STEP 105
722312 7223 18
Loosen the Allen head screw from the retainer. Loosen the plug .
STEP 103 STEP 106
7223 14 722322
Remove the Allen head screws , retainer, and wiper. Rem ove the plug.
8009-24
STEP 107 STEP 110
722324 722330
Loosen the plug for the load check va lve. Remove the poppet.
STEP 108 STEP 111
722326 700828
Remove the plug. Remove the O-ring, w iper, and reta iner from th e
spool.
STEP 109
STEP 112
722328
Remove the spring from the body. 700832
Use the tool shown on page 8009-2 to compress the

spring.
8009-25
STEP 113 STEP 114
700834 700838
Loosen and remove the Allen head screw from the Release the spring ten sion and separate the spring
spool. seats and spring.
8009-26
~ 1 - - ALLEN SCREW
I
(-- "-
I "-,,-
I \
I I
I ~ -EYE
SPOOL
I
I
I
-SPOOL
a-O-RING
@-WIPER
~-RETAINER
cQ SPRING
~-SEAT
PLUG
I_SPRING
~+-SPRING SEAT
~ _ALLEN SCREW
SPOOLCAP~~\ ALLEN
SCREW
POPPET-~
SPRING- I
ADJUSTING __ ~
SCREW ~
LOCKNUT-@
8--CAP
8871900
Inlet/Outlet and Au x iliary Sections

8009-27
Assembly STEP 118
See page 8009-30. Inspect the parts of the inlet!

outlet and auxiliary section .
STEP 115
700828
Lubricate the O- ring and spool wi t h clean oil. In-

stall the reta iner. Carefully install the wiper and 0-
ring. Push the retainer, wiper, and O-ring against
the spri ng seat.
700838
Assemb le the spring seats and spring . Use the tool STEP 119
to compress the spring.
STEP 116
722330
Install the poppet in the body.
700834 STEP 120

In stall the spring and spring seats on the spool.
STEP 117
722328
Install the spring .
700832

8009-28
STEP 121 STEP 124
722326 7223]0
Lubricate the a-ring wi th clean oil. I nstall the plug. Lubricate the a-rings and backup rin9 on the relief
valve. Install the relief valve in the body. Tighten the
STEP 122 relief valve to 50 to 60 pound-feet (68 to 80 N m, 7 to
8 kg/m).
STEP 125
722324
Tighten the plug.
STEP 123 722304
Lubricate the a-rings and backup ring on the plug .

Install the plug in the body . Tighten the plug to 50
to 60 pound-feet (68 to 80 N m, 7 to 8 kg/ m).
STEP 126
722320
Lubricate the a-rings and backup ring on the plug.

I nstall the plug in the body. Tighten the plug to 50
to 60 pound-feet (68 to 80 N m, 7 to 8 kg/ m) .
722136
Lubricate the spool and a-ring with clean oil. In-

stall the spool in the body.
8009-29
STEP 127 STEP 130

-
722134
Install the spool cap . Install the wiper on the spool.
STEP 128
722132 722204
Tighten the Allen head screws to 60 to 80 pound- Install the retainer and Allen head screws . Tighten
inches (7 to 9 N m, 0.7 to 0.9 kg/ m) . the All en head screws to 60 to 80 pound-inches (7
to 9 N m, 0.7 to 0.9 kg/ m).
STEP 129
722332
Lubricate th e O-ring with clean oil. Install the 0-

ring on the spool.
8009-30
INSPECTION
Disca rd all a-rings , backup rings , and wipers. STEP 133
Clean all parts in cleaning solvent. Inspect the
spools and spool bores forwearand damage. Use a BACKUP RING
new valve section if the spools or spool bores are
damaged .
STEP 132
O-RINGS
700824
Install new a-rings and backup ring on the plugs.
STEP 134
700842
I nstall a new a-ring in the detent housing for the lift

spool.
700826
Install a new a-ring on the plug for the load check

va lves .
8009-31
RELIEF VALVES
Disassembly STEP 138
STEP 135
701518
Loosen the body from the housing .

700506
Fasten the relief valve in the vise with soft jaws. STEP 139
Remove the cover.
STEP 136
701520
Remove the body.
700510 STEP 140

Loosen the lock nut.
STEP 137
701616
Separate the parts of the relief valve.
700512
Remove the adjusting screw and lock nut. Make a

count of the number of turns needed to remove the
ad justing screw. Record this count.
8009-32
Inspection STEP 143
Remove and discard the O-rings and backup

rings. Inspect the seal on the bottom of the adjust-
ing nut. Replace the adjusting nut if the seat is
damaged.
STEP 141
POPPET
\1 SPRING
O-RINGS
701614
Install new O-rings and backup ring on the body .
BODY Assembly
PLUNGER STEP 144
701616
I nspect the parts of the rei ief valve. Th e spri ngs, 0-

rings , and backup rings are ava ilable for service. If
any of the other parts are damaged, use a new relief
valve.
STEP 142
BACKUP RING
701520
Install the piston, plunger, spring , and body in the

housing .
STEP 145
O-RINGS
7016 10
Install new O-ring s and backup ring on the hous-

ing .
7(} 1518
T ig hten the body .

8009-33
STEP 146 STEP 148
700512 700506
Install the poppet , spring, adjusting screw, and Tighten the lock nut and install th e cover.
lock nut in the body.
After the three point hitch control valve is as-
STEP 147 sembled and installed , see Section 8002 and check
the pressure setti ng of the relief valves.
700S10
Turn the adjusting screw into the body the same

number of turns needed to remove the adjusting
screw.
This Page is Blank
8090
CYLINDERS
TABLE OF CONTENTS
Specifications . . .. . . .. ........ . . .. ... ... 8090-2 Disassembly . ..... . . .. .. .. ... .. . . . . . 8090-14
Special Tools . ..... .. .... .... . ..... . .. . 8090-4 Inspection .. . .......... . . .. . ... . .... 8090-14
Loader Bucket and Lift, Backhoe Extension, Assembly ... . .. . .... . ..... ... ... . .. . 8090-14
Bucket, Swing, Stabilizer, and Dipper
Cylinders .. . ..... . ........... . . . ..... 8090-6 Tilt Cylinder for the Three Point
Hitch . .. . . .. . .... . ... .. .. . .. . ....... 8090-18
Disassembly .... .. ....... .. .. . ....... 8090-6
Disassembly . ... . . . . . .. .. .. ...... . .. 8090-18
Inspection . ..... .. .. .. ... .. ....... .. . 8090-6
Inspection .. .. ..... .. ....... ... ..... 8090- 18
Assembly ... .. .. .. . .. . . . ... . .... ..... 8090-6
Assembly ........ .. . ... . . . . . .. .. .... 8090-18
Boom Cylinder .. . . . .... .. . .. . . .... . . . . 8090-10
Pitch Cylinder for the Three Point
Relief Valve Pressure Check .. . .. . . .. 8090-10 Hitch .. . . ........ . ...... . ... .. . . .... 8090-22
Disassembly . . .. . .. ... . . . .. . ... . . . .. 8090-10 Disassembly . . . . . .. .. . . .... . . .. ... .. 8090-22
Inspection .. . . ... ..... . . .. . .. . .. .. . . 8090-10 Inspection . ...... . .... ... .. .. .. . . ... 8090-22
Assembly .. ... . . . . . ... . .. .. .. . . .. . .. 8090-12 Assembly ... . . ..... . ... .... . ... .. . .. 8090-22
Lift Cylinder for the Three Point

Hitch and Clam Cylinder .. . ... . .... .. 8090-14
A Tenneco Company
8090-2
SPECIFICATIONS
Torque Specifications for Piston Cap Screw with 242 Loctite on the Threads
Loader Cylinders
Bucket cylinder .... .. ...... ....... . .. ......... . . . ...... ... ... ... ... .. .. . . . .. . . 269 to 3~!9 pound-feet
(365 to 460 Nm , 37 to 47 kg/ m)
Lift cyl inder . ... . .. . . . .... . ........... . . . ... . . ...... .. . ... .. . . .. . .. .. .. ... ... . 269 to 3 ~! 9 pound-feet
(365 to 460 Nm , 37 to 47 kg/ m)
Clam cylinder . .. .. . . ... ... . .. . ... .. . .. .... . ........... . .. . .... . . ........ . .... 475 to 5~~ 5 pound-feet
(644 to 711 Nm , 66 to 73 kg/ m)
Three Point Hitch Cylinders

Lift cylinder, 3 Inches (76.2 mm) 10 ..... . ...... . .. . . ... .. .. . . . .. ...... ... .. ... . 475 to 5 ~'5 pound-feet
(644 to 711 Nm, 66 to 73 kg/ m)
Ti lt cylinder, 2-1 / 2 Inches (63.5 mm ) 10 .. .. . .. .. .. ............ . . ... . .. . . . . .. ... 200 to 2~'0 pound-feet
(271 to 298 Nm , 28 to 30 kg / m)
Pitch cylinder, 2-1 / 2 Inches (63.5 mm) 10 .. . ... . ..... . . ............. . ........... 203 to 240 pound -feet
(275 to 325 Nm , 28 to 33 kg/ m)
Backhoe Cylinders
Extensio n cylinder . ..... . . ..... . ........ . .. . . . ...... . . . .. . .. .. . .. .. ... . ....... 269 to 3:39 pound-feet
(365 to 460 Nm , 37 to 47 kg/ m)
Bucket cy linder . . ..... . .. ... . ...... . .. . . .. . ... . . . .. . .. .... . . .... ... . ..... . ... . 661 to 819 pound-feet
(895 to 11 10 Nm, 91 to 113 kg / m)
Swing cylinder ... . .. ......... . ... .. . . .. . . .. . . .. .. .. . . . . .... ... . . .. . . ... . ... .. 269 to 3::19 pound-feet
(365 to 460 Nm , 37 to 47 kg/ m)
Stabilizer cylinder .. ......... . .. . . .. ..... ...... . . .. ...... ..... .. .. ..... ... .. .. 661 to 819 pound-feet
(895 tolll0Nm , 91 tol 13kg/m)
Boom cy linder . ..... . . .... ... .. .. .. . • .... ... .... .. .. .. .. ... ... . ...... . .... . . 1446 to 1697 pound-feet
(1960 to 2300 Nm , 200 to 235 kg/ m)
Dipper cylinder ...... ......... .... ......... . . .. .... .... . .. . .... . .... ..... . .. 2443 to 2841 pound-feet
(3310 to 3850 Nm , 338 to 393 kg/ m)
Torque for all glands . .. .. .. . . ... . . .. ....... .... .. .. . . .. . .... . . .. .. .... .... '" 100 to 400 pound-feet
(135 to 542 Nm , 14 to 55 kg/ m)
8090-3
Cylinder weights (approximate)
Loader Cylinders
Bucket cylinder .. ........ . . ... .. . .. . ...... ........ . . . .. . .... . .......... . ......... 40 pounds (19 kg)
Lift cylinder .. ..... .. .. ... . .... .... . ..... .... ... .. .. . . ....... . . ..... . .. . ... . ... . . 60 pounds (27 kg)
Clam cylinder ... . ............ . . ..... .. . .. .. ..... . ....... . .... . ........ .. .. . .. ... 33 pounds (15 kg)
Three Point Hitch Cylinders

Lift cylinder . .. . .. .. . ..... .. .. . .. ........ .. ... ..... .. ... . .......... .. .... .. ... . .. 29 pounds (13 kg)
Tilt cylinder ....... . ...... . . ............... ..... ......... . .......... ... ..... ... . 23 pounds (10.4 kg)
Pitch cylinder . .. ............. .................................................. 30 pounds (13.6 kg)
Backhoe Cylinders
Extension cylinder .... ... .... .. ... . . . .. .. ............. . .... .. . ... .... . ... .. ..... . 82 pounds (37 kg)
Bucket cylinder .. .. . .. . ...... .. ... ...... . .. ..... . . ... . . . ... .. . .. . . .. ......... . ... 98 pounds (45 kg)
Swin g cylinder . .... . . ... .... . . .... . . . .. ...... . ............. . . . . . .... . .. . .... .. .. 70 pounds (32 kg)
Stabilizer cylinder ... . .. . . .. .. .. ... .... . . .. ..... ... . .... . .. . . . ... .. .............. 99 pounds (45 kg)
Boom cylinder .... '.. . . . ..... . .. .. . . .. .. .... ... . . . .. .. ......... .... . ... . .... . .... 170 pounds (77 kg)
Dipper cylinde r .......... . ... . .......... . .... . .................. . . . . .. . . .... .... 155 pounds (70 kg)
Hand Pump
Boom Cylinder Relief Valve ... . .... . .. . . ... . .. .. . . . ....... . . .. .... . ..... . .... . .... . .. 4500 to 5000 psi
(31028 to 34 475 kPa , 316 to 352 bar)
8090-4
SPECIAL TOOLS
The tools shown are available from Service
Tools in the United States and from Jobborn Manu-
facturing Co . in Canada. See Special Tools in Sec-
tion 1001 for the correct address.
795329
The torque multiplier is used to loosen and

tighten the piston cap screw. Use the torque multi-
plier according to the instructons of the manufac-
turer. The part number of the torquE! multiplier is
786441 CAS-1039
This tool is used to remove and install the
gland on Case cylinders. The part number on the
gland wrench is CAS-1456 .
Pressure Test Kit 009638
505802
1. CAS-1659 For One Inch (25 mm) Rods

2. CAS-1660 For 1-1 / 4 and 1-1 /2 Inch (32
and 38 mm) Rods
3. CAS-1758 For 2 Inch (50 mm) Rods
The tool shown is used to install the seal in the

glands of the cylinders.
Pressure Tes t Kit CAS-1804 877558
An adapter and pressure gauge from either of

the Pressure Test kits is used with the Hydraulic
Hand Pump Test kit to test the relief valve in the
boom cylinder.
8090-5
877808
The hand pump shown is used to check the

pressure setting of the relief valve in the boom
cy linder. The part number of the hand pump is
CAS-1913.
8090-6
LOADER BUCKET AND LIFT, BACKHOE EXTENSION, BUCKET, SWING,

STABILIZER, AND DIPPER CYLINDERS
Disassembly 4. Check to be sure that the pistoll rod (6) is
straight. If th e piston rod (6) is not straight , instal l a
Clean the outside of the cylinder. If the hoses new piston rod (6) .
were removed with the cylinder, remove the hoses
from the cylinder. 5. Remove small scratches on the piston rod (6)
or inside the tube (1) with emery c iottI of medium
1. Fasten the tube (1) in a vise or other holding grit. Use the emery c loth with a rotary motion.
equipment. Be careful to prevent damage to the
tube(1). 6. Inspect the bushing (18) and ~;eal (19), if
equipped, in the position rod eye (5) and the closed
2. Loosen and remove th e lock screw (2) from the end of the tube (1) , replace as required.
gland (3) and tube (1)
7. Inspect the gland (3) for rust and clean and
3. Use the gland wrench shown on page 8090-4 to remove rust as required.
loosen and remove the gland (3) from the tube (1) .
8. Inspect the gland end of th e tube (1) for sharp
4. Pull the piston rod (4) straight out of the tube edges that will cut the gland O-ring (12), remove as
(1) to prevent damage to the tube (1). required.
5. Fasten the piston rod eye (5) ina vise and put a 9. Inspect the piston (4) for damage and wear. If
support below the piston rod (6) near the piston (4). the piston (4) is damaged or worn, a new piston (4)
Use a shop cloth between the support and the pis- must be used .
ton rod (6) to prevent damage to the piston rod (6).
Assembly
6. Loosen and remove the cap screw (7) and har-
dened washer (8) that holds the piston (4) . Use the NOTE: If a new gland (3) is being installed,
torque multiplier shown on page 8090-4 for cap put the part number of the cylinder on the new
screws that have a high torque value. gland (3).
7. Remove the piston (4) from the piston rod (6). 1. Install the bushing (17) in the gla d (3) .
8. Remove the gland (3) from the piston rod (6). 2. I nstall the wide seal (15) in the gland . The wide
seal (15) is to be installed so that the lips of the wide
9. Remove the seal (9) , backup ring (10), and seal (15) are toward the small end of HIe gland (3) .
wear ring (11) from the piston (4). The wide seal (15) can be difficult to install. Use the
tool shown on page 8090-4 .
10. Remove the O-ring (12), backup ring (13) ,
wiper (14) , wide seal (15 ), narrow seal (16), and 3. Install a new wiper (14) in the gland (3) . The lips
bushing (17) from the gland (3). of the wiper (14) must be toward the large end of
the gland (3)
Inspection
4. Install the narrow sea l (16) in the gland (3). The
1. Clean the piston (4), gland (3), piston rod (6), sid e of the narrow sea l (16) with the groove must be
tube (1) , hardened washer (8), and cap screw (7) in toward the small end of the gland (3).
cleaning solvent.
5. Install a new backup ring (13) in the groove on
2. Discard the parts that were removed from the the outside of the gland (3). If both sides of the
piston (4) and the gland (3). backu p ri ng (13) are not f lat , the side that is not flat
must be toward the sma ll end of the gland (3).
3. Illumi nate the inside of the tube (1). I nspect the
inside of the tube (1) for deep grooves and other 6. Install the O-ring (12) next to the backup ring
damage. If there is damage to the tube (1) , a new (13) in the groove on the outside of the gland (3).
tube (1) must be used. The O- ri ng (12) must be toward the small end of the
gland (3)
7. Fasten the piston rod eye (5) in the vise .

8090-7
B872038
8090-8
8. Remove any marks and sharp edges on the 18. Install a new seal (9) on top of th e backup ring
chamfer at the end of the piston rod (6) . (10) on the outside of the piston (4).
9. Lubricate the bore of th §l gland (3) with clean 19 . Fasten the tube (1) in a vise or other holding
oil. equipmen t. Be careful to prevent damage to the
tube (1) .
10. Push the gland (3) onto the piston rod (6). If
necessary, use a soft hammer to drive the gland (3) 20. Lubricate the inside of the tube (1) and the
onto the piston rod (6). piston (4) with clean oil.
11. Put a support below and near the end of the 21. Push the piston (4) straight into the tube (1).
piston rod (6). Use a shop cloth between the sup-
port and the piston rod (6) to prevent damage to the 22. When the piston (4) is in the smooth part of the
piston (4). tube (1) , start the gland (3) into the tube (1).
12 . Put the piston (4) on the end of the piston rod 23. Lubri cate the a-ring (12) on the g land (3) with
(6) . clean oil.
13 . Put the hardened washer (8) on the cap screw 24 . Tighten the gland (3) to 100 to 400 pound-feet
(7) . (135 to 542 Nm). If the lock screw (2) 110Ies become
aligned in this torque range , install the lock screw
14 . Make sure there is no oil on the threads at the (2) . Tighten the lock screw (2) to 20 pound-inches
end of the piston rod (6) or on the threads of the cap (2.3 Nm). If the lock screw (2) holes are not al-
screw (7) . Appl y 242 Loctite to the first six threads igned, do steps 25 through 27.
on the cap screw (7).
25 . Tighten the gland (3) to 100 to 400 pound-feet
15 . In stall the cap screw (7) . Tighten the cap screw (135 to 542 Nm).
(7) to the torque value on page 8090-2 for the
cylinder that is being repaired. A torque multiplier 26. Use a No. 26 drill and dri ll a hole half in the
can be used to help tighten the cap screw. gland (3) and hal f in the tube (1). Drill to a depth of
7/ 16 inch (11 mm) . Do not drill in line with a hole in
16 . Install a new wear ring (11) in the end groove the gland (3) for the gland wrench .
on the outside of the piston (4).
27. Install the lock screw (2) . Tighten the lock
17 . Install a new backup ring (10) in the center screw (2) to 20 pound-inches (2 .3 Nrn).
groove on the outside of the piston (4) .
If the hoses were removed with the cyli nder,
install new a-rings , if equipped , on the hose fit-
tings. Lubricate the a-rings with clean oil. Install
the hoses.
8090-9
8872038
8090-10
BOOM CYLINDER
NOTE: Check the pressure setting of the re- 1. Fasten the tube (1) in a vise or other ho lding
lief valve in the boom cylinder before disassem- equipment. Be careful to prevent damage to the
bling the boom cylinder. tube (1) .
Relief Valve Pressure Check 2. Loosen and remove t he lock screw (2) from the
gland (3) and tube (1).
1. Fasten the cylinder in a vise or other holding
equipment. Be careful to prevent damage to the 3. Use the gland wrench shown on page 8090-4 to
cylinder. loosen and remove the gland (3) from the tube (1).
2. Make sure that the piston rod is completely 4. Pull the piston rod (4) straight out of the tube
retracted into the cylinder. Fasten the piston rod so (1) to prevent damage to the tub e (1) .
that the piston rod cannot move in the cylinder.
5. Fasten the piston rod eye (5) in a vise and put a
3. Putadrain pan under the portattheclosedend support below the piston rod (6) near tile piston (4) .
of the cylinder. Use a shop cloth between the support and the pis-
ton rod (6) to prevent damage to the p iston rod (6) .
4. Connect the hand pump and a 6000 psi (41 370
kPa , 422 bar) gauge to the port at the rod end of the 6. Loosen and remove the cap screw (7) and har-
cylinder. Do not tighten the connection at this time. dened washer (8) that holds the piston (4). Use the
See pages 8090-4 and 8090-5 for the hand pump torque multiplier shown on page 8090-4 for cap
and pressure test kit. screws that have a high torque value.
5. Set the hand pump to the HI position. 7. Remove the piston (4) from the piston rod (6).
6. The oil in the hand pump must be 70 to 80° F (21 8. Remove the gland (3) from the piston rod (6).
to 27° C) . Make sure that the hand pump is filled
with Case TCH Fluid. NOTE: 00 not remove the plug for the relief valve
(10) from the piston.
7. Operate the handle of the hand pump until the
ai r is removed from the hose and fittings and the oil 9. Remove the seal (9) and wear rings (11) from
that flows from around the fitting at the cylinder is the piston (4).
free of air.
10. Remove the O-ring (12). backup ring (13) ,
8. Tighten the connections at the cylinder. wiper (14) wide seal (15) , narrow seal (16), and
bushing (17) from the gland (3) .
9. Operate the handle of the hand pump and read
the pressure gauge. Make a record of the highest Inspection
pressure.
1. Clean the piston (4), gland (3), piston rod (6),
10. Make several checks to make sure of the pres- tube (1) hardened washer (8) , and cap screw (7) in
sure indication. cleaning solvent.
11. The pressure must be between 4500 and 5000 2. Discard the parts that were removed from the
psi (31 028 and 34 475 kPa, 316 to 352 bar) . piston (4) and the gland (3).
12. The relief valve in the piston cannot be ad- 3. Illuminate the inside of the tube (1). Inspect the
justed . If the pressure setting is not correct the inside of the tube (1) for deep grooves and other
piston must be replaced. damage. If there is damage to the tube (1) , a new
tube (1) must be used.
Disassembly
4. Check to be sure that the piston rod (6) is
Clean the outside of the cylinder . If the hoses straight. If the piston rod (6) is not straight, install a
were removed with the cylinder, remove the hoses new piston rod (6).
from the cylinder.
5. Remove smal l scratches on the piston rod (6)
or inside the tube (1) with emery cloth of medium
grit. Use the emery cloth with a rotar~1 motion .
8090-11
Backhoe B oom Cylinder

8090-12
6. Inspect the bush i ng (18) and seal (19), if 11 . Put a support below and near the end of the
equipped , in the piston rod eye (5) and the closed piston rod (6) . Use a shop cloth between the sup-
end of the tube (1), replace as required. port and the piston rod (6) to prevent damage to the
piston (4).
7. Inspect the gland (3) for rust and clean and
remove rust as required. 12. Put the piston (4) on the end of the piston rod
(6)
8. Inspect the gland end of the tube (1) for sharp
edges that wi II cut the gland O-ri ng (12) , remove as 13. Put the hardened washer (8) on the cap screw
required. (7) .
9. Inspect the piston (4) for damage and wear. If 14. Make sure th ere is no oil on the threads at the
the piston (4) is damaged or worn , a new piston (4) end of the piston rod (6) or on the threads of the cap
must be used. screw (7) . Apply 242 Loc tite to the first six threads
on the cap screw (7).
Assembly
15. Install the cap screw (7). Tighten the cap screw
NOTE: If a new gland (3) is being installed, (7) to the torque val ue on page 8090-2 for the
put the part number of the cylinder on the new cylinder that is being repaired. A Torque multiplier
gland (3). can be used to help tighten the cap screw.
1. Install the bushing (17) in the gland (3). 16. Install a new wear ring (11) in each groove on
t he outside ends of the piston (4) .
2. I nstall the wide seal (13) in the gland. The wide
seal (15) is to be installed so that the lips of the wide 17. In stall a seal (9) in the center groove on the
seal (15) are toward the small end of the gland (3) . outside of the piston (4) .
The wide seal (15) can be difficult to install. Use the
tool shown on page 8090-4. 18. Fasten the tube (1) in a vise or other ho lding
equ ipment. Be careful to prevent damage to the
3. Install a new wiper (14) in the gland (3) . The lips tube (1).
of the wiper (14) must be toward the large end of
the gland (3) . 19. Lubricate the inside of the tube (1) and the
piston (4) with clean oil.
4. Install the narrow seal (16) in th e gland (3) . The
side of the narrow seal (16) with the groove must be 20 . Push the piston (4) straight into tile tube (1) .
toward the small end of the gland (3).
21. When the piston (4) is in the smooth part of the
5. Install a new backup ring (13) in the groove on tube (1), start the gland (3) into the tube (1) .
the outside of the gland (3) . If both sides of the
backup ring (13) are not flat , the side that is not flat 22 . Lubricate the O-ring (12) on the gland (3) with
must be toward the small end of th e gland (3). clean oil.
6. Install the O-ring (12 ) next to the backup ring 23 . Tighten the gland (3 ) to 100 to 400 pound-feet
(13) in the groove on the outside of the gland (3). (135 to 542 Nm). If the lock screw (2) holes become
The O-ring (12) must be toward the small end of the aligned in this torque range , install the lock screw
gland (3) . (2) . Tighten the lock screw (2) to 20 pound-inches
(2.3 Nm) . If the lock screw (2) holes are not al-
7. Fasten the piston rod eye (5) in the vise . igned , do steps 25 through 27 .
8. Remove any marks and sha rp edges on the 24. Tighten the gland (3) to 100 to 400 pound-feet
chamfer at the end of the piston rod (6). (135 to 542 Nm).
9. Lubricate the bore of the gland (3) and the 25. Use a No. 26 drill and drill a ho le half in the
piston rod (6) with clean oil. gland (3) and half in the tube (1) . Drill to a depth of
7/ 16 inch (11 mm). Do not drill in line with a hole in
10. Push the gland (3) onto the piston rod (6). If the gland (3) for the gland wrench .
necessary , use a soft hammer to drive the gland (3)
onto the piston rod (6) .
8090-13
26. I nstall th e lock screw (2). Tighten the lock If the hoses were removed with the cylinder ,
screw (2) to 20 pound-inches (2.3 Nm). install new O-rings , if equipped, on the hose fit-
tings. Lubricate the O-rings with clean oil. Install
the hoses.
14
15 ~
3 ~~ 4
~\\
17
"" ~~ 1\ /
7)?
8872039
Backhoe Boom Cylinder

8090-14
LIFT CYLINDER FOR THREE POINT HITCH AND CLAM CYLlNIDER

Disassembly 5. Remove small scratches on the piston rod (6)
or inside the tube (1) with emery cloth of med ium
Clean the outside of the cylinder. If the hoses grit. Use the emery cloth with a rotary motion .
from the cylinder. 6. Inspect the bushing (18) and seal (19), if
equipped, in the piston rod eye (5) and the c losed
1. Fasten the tube (1) in a vise or other holding end of the tub e (1) , replace as requi red.
tube(1). 7. Inspect the gland (3) for rust and cl ea n and
remove rust as required.
2. Loosen and remove the lock screw (2) from the
gland (3) and tube (1) . 8. Inspect the gland end of the tube (1) for sharp
edges that will cut the gland O-ri ng (12) , remove as
3. Use the gland wrench shown on page 8090-4 to required .
loosen and remove the gland (3) from the tube (1).
9. Inspect the piston (4) for damage and wear. If
4. Pull the piston rod (4) straight out of the tube the piston (4) is damaged or worn , a nHW piston (4)
(1) to prevent damage to the tube (1). must be used .
5. Fasten the piston rod eye (5) in a vise and put a Assembly
support below the piston rod (6) near the piston (4).
Use a shop cloth between the support and the pis- NOTE: If a new gland (3) is being installed,
ton rod (6) to prevent damage to the piston rod (6). put the part number of the cylinder on the new
gland (3).
dened washer (8) that hold s the piston (4). Use the 1. Install the bushing (17) in the gland (3) .
torque multiplier shown on page 8090-4 for cap
screws that have a high torque value . 2. I nstall the wide seal (15) in t he gland. The wide
seal (15) is to be installed so that the lips of the wide
7. Remove the piston (4) from the piston rod (6). seal (15) are toward the small end of the gla nd (3).
The wide seal (15) can be difficu lt to install . Use the
8. Remove the gland (3) from the piston rod (6). tool shown on page 8090-4.
9. Remove the seal (9), backup ring (10), and 3. Install a new wiper (1 4) in th e glancl (3). The lips
wear rings (11) from the piston (4). of the wiper (14) must be toward th e larg e end of
the gland (3).
10. Remove the O-ring (12), backup ring (13),
wiper (14) , wide seal (15), narrow seal (16), and 4. Install the narrow seal (16) in the gland (3) . The
bushing (17) from the gland (3) . side of the narrow seal (16) with the groove must be
toward the small end of the gland (3).
Inspection
1. Clean the piston (4) , gland (3), piston rod (6), the outside of the gland (3). If both sides of the
tube (1) , hardened washer (8) , and cap screw (7) in backup ring (13) are not flat, the side that is not flat
cleaning solvent. must be toward the small end of the gland (3).
2. Discard the parts that were removed from the 6. Install the O-ring (12) next to the backup ring
piston (4) and the gland (3) . (13) in the groove on the outside of tile gl an d (3) .
The O-ring (12) must be toward the small end of the
3. Illuminate the inside of the tube (1). Inspect the gland (3) .
inside of the tube (1) for deep grooves and other
damage. If there is damage to the tube (1), a new 7. Fasten the piston rod eye (5) in the vise.
tube (1) must be used.
8. Remove any marks and sharp edges on the
4. Check to be sure that th e piston rod (6) is chamfer at the end of the pisto n rod (6).
straight. If the piston rod (6) is not straight, install a
new piston rod (6) . 9. Lubricate the bore of the g land (3) and the
piston rod (6) with clean oil.
8090-16
10 . Push the gland (3) onto the piston rod (6). If 20 . Lubricate the inside of the tube (1) and the
necessary. use a soft hammer to drive the gland (3) piston (4) with clean oil.
onto the piston rod (6).
21 . Push the piston (4) straight into th e tube (1).
11 . Put a support below and near the end of the
piston rod (6) . Use a shop cloth between the sup- 22. When the piston (4) is in the smooth part of the
port and the piston rod (6) to prevent damage to the tube (1). start the gland (3) into the tube (1 ).
piston (4) .
23. Lubricate the O-ring (12) on the gland (3) w ith
12. Put the piston (4) on the end of the piston rod c lean oil.
(6) .
24. Tighten the gland (3) to 100 to 400 pound-feet
13. Put the hardened washer (8) on the cap screw (135 to 542 Nm) . If the lock screw (2) holes become
(7) . aligned in this torque range . install the lock screw
(2) . Ti ghten the lock screw (2) to 20 pound-i nches
14. Make sure there is no oil on the threads at the (2.3 Nm). If the lock screw (2) hol es are not al-
end of the piston rod (6) or on the th reads of the cap igned. do steps 25 through 27 .
screw (7) . Apply 242 Loctite to the first six threads
on the cap screw (7) . 25. Tighten the gland (3) to 100 to 400 pound-feet
(135 to 542 Nm) .
15. Install the cap screw (7) . Tighten the cap screw
(7) to the torque va lue on page 8090-2 for the 26. Use a No . 26 drill and drill a hole half in the
cylinder that is being repai red. A torque multiplier gland (3) and half in the tube (1) . Drill to a depth of
can be used to help tighten the cap screw. 7/ 16 inch (11 mm) . Do not drill in line w ith a hole in
the gland (3) for the gland wrench .
16. Install a new wear ring (11) in each groove on
the outside ends of the piston (4). 27 . Install the lock screw (2) . Tighten the lock
screw (2) to 20 pound-inches (2.3 Nm) .
17. Install a new seal (9) in the center groove on the
outside of the piston (4). If the hoses were removed with the cy linder,
install new O-rings , if equipped , on the hose fit-
18. Install a new backup ring (10) on top of the seal tings. Lubri cate the O-rings with clean oil. Install
(9) on the outside of the piston (4) . the hoses.
19. Fasten the tube (1) in a vise or other holding

tube (1) .
6 7 18 8872040
8090-18
TILT CYLINDER FOR THE THREE POINT HITCH

Clean the outside of the cylinder. If the hoses grit. Use the emery cloth with a rotary motion .
from the cylinder. 6. Inspect the bushings (17) and snap ring (18) , if
equipped, in the piston rod eye (5) and the closed
1. Fasten the tube (1) in a vise or other holding end of the tube (1), rep lace as required.
tube (1) . 7. Inspect the gland (3) for rust and clean and
gland (3) and tube (1). 8. Inspect the gland end of the tube (1) for sharp
edges that will cut the gland a-ring (12) , remove as
3. Use the gland wrench shown on page 8090-4 to required.
loosen and remove the gland (3) from the tube (1).
9. Inspect the piston (6) for damage and wear . If
4. Pull the piston rod (4) straight out of the tube the piston (6) is damaged or worn , a new piston (6)
(1) to prevent damage to the tube (1). must be used.
5. Fasten the piston rod eye (5) in a vise and puta Assembly
Use a shop cloth between the support and the pis- NOTE: If a new gland (3) is being installed,
gland (3).
dened washer (8) that holds the piston (6). Use the 1. Install the wide seal (15) in the gla nd . The wide
torque multiplier shown on page 8090-4 for cap seal (15) is to be installed so that the lips of the w ide
screws that have a high to rque value. seal (15) are toward the small end of the gla nd (3 ).
The wide seal (15) can be difficult to in s.tall . Use th e
7. Remove the piston (6) from the piston rod (4). tool shown on page 8090-4.
8. Remove the gland (3) from the piston rod (4). 2. Install a new wiper (14) in the gland (3). The lips
of the wiper (14) must be toward the larg e end of
9. Remove the sea l (9), backup ring (10), and the gland (3) .
wear rings (11) from the piston (6).
3. Install the narrow seal (16) in th e gl and (3 ). The
10. Remove the a-ring (12), backup ring (13), side of the narrow seal (16) with the groove must be
wiper (14), wide seal (15), and narrow seal (16) toward the small end of the gland (3 ).
from the gland (3) .
4. Install a new backup ring (13) in th e groove on
Inspection the outside of the gland (3) . If both sides of the
backup ring (13) are not flat, the side that is not flat
1. Clean the piston (6), gland (3) , piston rod (4) , must be toward th e small end of th e gland (3) .
tube (1) , hardened washer (8) , and cap scre w (7) in
cleaning solvent. 5. In stall the a-ring (12) next to the IJackup ring
(13) in the groove on the outside of th e gland (3 ).
2. Discard the parts that were removed from th e The a-ring (12) must be toward the small end of the
piston (6) and the gland (3). gland (3) .
3. III um i nate the inside of the tube (1 ). I nspect the 6. Fasten the piston rod eye (5 ) in th e vis e.
inside of the tube (1) for deep grooves and other
damage. If there is damage to the tube (1), a new 7. Remove any marks and sharp edges on the
tube (1) must be used. chamfer at the end of the piston rod (4).
4. Check to be sure that the piston rod (4) is 8. Lubricate the bore of the gland (3 ) with clean
straight. If the piston rod (4) is not straig ht, install a oil.
new piston rod (4).
8090-19
17 8872077
Tilt Cylinder for the Three Point Hitch

8090-20
9. Push the gland (3) onto the piston rod (4) . If 18 . Fasten the tube (1) in a vise or other holding
necessary, use a soft hammer to drive the gland (3) equipment. Be careful to prevent damage to the
onto the piston rod (4). tube (1) .
10. Put a support below and near the end of the 19. Lubricate the piston (6) and th e inside of the
pisto n rod (4) . Use a shop cloth between the sup- tube (1) with clean oil.
port and the piston rod (4) to prevent damage to the
piston (6). 20 . Push the piston (6) straight into the tube (1).
11 . Put th e piston (6) on the end of the piston rod 21. Wh en th e piston (6) is in th e smooth part of the
(4) . tube (1), start the gland (3) into the tu be (1) .
12 . Put th e hardened washer (8) on the cap screw 22 . Lubricate the a-ring (12) on the gland (3) with
(7) . clean oil.
13. Make sure there is no oil on the threads in the 23 . Tig hten the gland (3) to 100 to 400 pound-feet
end of the piston rod (4) or on the threads of the cap (135 to 542 Nm) . If t he loc k screw (2) holes become
screw (7). App ly 242 Loctite to the first six threads aligned in th is torque range , install th e lock screw
on the cap screw (7). 92 ). Ti g hte n the lock screw (2) to 20 pound- inches
(2.3 Nm). If the lock screw (2) holes are not al-
14. Install the cap screw (7). Tighten th e cap screw igned , do steps 24 through 26.
(7) to the torque value on page 8090-2 for the
cy linder that is being repaired . A torque multiplier 24 . Tighten the gland (3) to 100 to 400 pound-feet
can be used to help tighten the cap screw. When a (135 to 542 Nm ).
torque multiplier is used , a chain must be used to
hold the piston rod (4) in position. Use a shop cl oth 25. Use a No. 26 drill and drill a hole half in the
and a metal protector between the piston rod (4) gland (3) and ha lf in the tube (1) . Drill to a depth of
and the chain. 7/ 16 inch (11 mm ). Do not drill in line wi th a hole in
the gland (3) for the gland wrench.
15 . In sta ll a new wea r ring (11 ) in the end grooves
on the outs ide of the piston (6). 26. Install the lock screw (2). Tigh ten the lock
screw (2) to 20 pound-inches (2.3 Nm) .
16. Install a new sea l (9) in th e center groove on the
outside of the piston (6). If the hoses were removed with the cyl inder,
install new a-rings , if equipped , on the hose fit-
17. Install a new backup ring (10) on top of the seal tings . Lubricate the a-rings with clean oil. Instal l
(9) on the ou tsid e of the piston (6). the hoses .
8090-21
___ 2
8090-22
PITCH CYLINDER FOR THE THREE POINT HITCH

Clean the outside of the cylinder. If the hoses grit. Use the emery cloth with a rotary motion.
were removed with the cylinder, remove t he hoses
from the cylinder. 6. Inspect the bushings (15) and snap rings (16)
in the piston rod eye (5) and the close d end of the
1. Fasten the tube (1) in a vise or other ho ldi ng tube (1), replace as required.
tube (1). 7. Inspect the gland (3) for rust and clean and
gland (3) and tube (1). 8. Inspect the gland end of the tube (1) fo r sh arp
edges that will cut the gland a-ring (10) , remove as
3. Use the gland wrench shown on page 8090-4 to required.
loosen and remove the gland (3) from the tube (1) .
9. Inspect the piston (6) for damage wear. If the
4. Pull the piston rod (4) straight out of the t ube piston (6) is damaged or worn, a new piston (6)
(1) to prevent damage to the tube (1). must be used .
5. Fasten the piston rod eye (5) in a vise and put a Assembly
Use a shop cloth between the support and t he pis- NOTE: If a new gland (3) is being installed,
gland (3).
6. Loosen and remove the cap screw (7) that
holds the piston (6) . Use the torque mu ltiplier 1. Install the wide seal (13) in the gland . The wide
shown on page 8090-4 for cap screws that have a seal (13) is to be installed so that the lips of th e wide
high torque value. seal (13) are toward the small end of the gland (3).
The wide seal (13) can be difficult to install. Use the
7. Remove the piston (6) from the piston rod (4). tool shown on page 8090-4 .
8. Remove the gland (3) from the piston rod (4) . 2. Install a new wiper (12) in the gland (3). The lips
of the wiper (12) must be toward the large end of
9. Remove the seal (8) and backup ring (9) from the gland (3).
the piston (6).
3. Install the narrow seal (14) in the gland (3). The
10. Remove the a-ring (10). backup ring (11). side of the narrow seal (14) with the groove must be
wiper (12), wide seal (13), and narrow seal (14) toward the small end of the gland (3) .
from the gland (3).
Inspection the outside of the gland (3). If both sides of the
backup ring (11) are not flat , the side that is not f lat
1. Cl ea n the piston (6) , g land (3), piston rod (4), must be toward the small end of the gland (3).
tube (1). and cap screw (7) in cleaning solvent.
5. Install the a-ring (10) next to the backup ring
2. Discard the parts that were removed from the (11) in the groove on the outside of the gland (3).
piston (6) and the gland (3) . The a-ring (10) must be toward the small end of the
gland (3).
3. Illuminate the inside of the tube (1). Inspect t he
inside of the tube (1) for deep grooves and other 6. Fasten the piston rod eye (5) in th e vise .
damage. If there is damage to the tube (1). a new
tube (1) must be used. 7. Remove any marks and sharp edges on the
chamfer at the end of the piston rod.
4. Check to be sure that the piston rod (4) is
straight. If the piston rod (4) is not straight, install a 8. Lubricate th e bore of the gland (3 ) with clean
new piston rod (4). oil.
8090-23
16
/ 15
If?)) /
~v0"
8872078
Pitch Cylinder for the Three Point Hitch

8090-24
9. Push the gland (3) onto the piston rod (4). If 17. Lubricate the piston (6) and the inside of the
necessary, use a soft hammer to drive the gland (3) tube (1) with clean oil.
onto the piston rod (4).
18. Push the piston (6) straight into tile tube (1).
10. Put a support below and near the end of th e
piston rod (4). Use a shop cloth between the sup- 19. When the piston (6) is in the smooth part of the
port and the piston rod (4) to prevent damage to th e tube (1) , start th e gland (3) into the tube (1).
piston (6) .
20. Lubricate the a-ring (10) on the gland (3) with
11 . Put the piston (6) on the end of the piston rod clean oil.
(4 ) .
21. Tighten the gland (3) to 100 to 400 pound-feet
12. Make sure there is no oil on the threads in th e (135 to 542 Nm) . If the loc k screw (2) holes become
end of the piston rod (4) or on the threads of the cap aligned in this torque range , install the lock screw
screw (7) . Apply 242 Loctite to the first six threads (2). Tighten the lock screw (2) to 20 pound-inches
on the cap screw (7). (2.3 Nm). If the lock screw (2 ) holes are not al-
igned , do steps 22 through 24.
13. Install the cap screw (7). Tighten the cap screw
(7) to the torque value on page 8090-2 fo r the 22. Tighten the gland (3 ) to 100 to 400 pound-feet
cylinder that is being repaired . A torque multiplier (135 to 542 Nm).
can be used to help tighten the cap screw .
23. Use a No. 26 drill and drill a hole half in the
14. Install a new seal (8) in the center groove on the gland (3) and half in the tube (1 ). Drill to a depth of
outside of the piston (6). 7/16 inch (11 mm) . Do not drill in lin e with a hole in
the gland (3) for the gland wrench .
15. Install a new backup ring (9) on top of the seal
on the outside of the piston (6) . 24. Install the lock screw (2) . Tighten the loc k
screw (2) to 20 pound -inches (2.3 Nm) .
16. Fasten the tube (1) in a vise or other holding
equipment. Be careful to prevent damage to the If the hoses were removed with the cylinder,
tube(1) . install new a-rings , if equ ipped, on the hose fit-
tings. Lubricate the a-rings with clean oil. Install
the hoses.
8090-25
6
,~ 2
16
/ 15
R)) /
~@~"
8872078
This Page is Blank
8107
BACKHOE CONTROL VALVE
TABLE OF CONTENTS
Specifications ..... ........ . ............ 8107-2 Assembly .......... .. . ... .... .. ..... 8107-21
Special Tools ...................... .. .. 8107-3 Stabilizer Section ..................... 8107-27
Exploded View of Backhoe Control Valve . . 8107-4 Disassembly .. .................. . ... 8107-27
Separating the Valve Sections ........... 8107-5 Assembly ... . . .. .. . . ........... . .... 8107-31
Assembling the Valve Sections .. ...... . . 8107-6 Bucket, Dipper, and Extendable
Dipper Sections . .... ............ .... 8107-36
Inlet Section . ...... .. .... .... .......... 8107-7
Disassembly ...... .. . .... ... . ... . ... 8107-36
Disassembly .... ... ... . . ...... ....... 8107-7
Assembly ...... .. ... . ... .. ... .. ..... 8107-40
Assembly .................. .. .... .... 8107-9
Circuit Relief Valve ............ .. ... ... 8107-45
Outlet Section ..... .. . ........ . ..... .. 8107-11
Disassembly ......... ........ .. ..... 8107-45
Disassembly ..... ........... . ..... .. 8107-11
Inspection .... . .... . ... . .. ....... .. . 8107-46
Assembly ........ .. .... . . ... ........ 8107-13
Assembly ... . ....... .......... . ..... 8107-47
Swing and Boom Section ...... . . .. .. .. 8107-15
Inspection . ... . .. . ......... . .......... 8107-48
Disassembly ....... .... ... . .. ....... 8107-15
A Tenneco Company
8107-2
SPECIFICATIONS
Manufacturer . . . .... ...... . .. . . . ................ . . ... . . . ... .. ... .. .... ........ ... .. .. .. . .. .. . J I Case
Pressure settings ... ........ . . . ... .. . . . ... .... .. . .. .......... .. ... . . .. . . ..... .... .. . See Section 8002
Ports and Spools
Spool travel , neutral to pressure .. .. .. ....... .. . ..... .... .. .. .. .. .... . . ......... 0.45 inch (11.5 mm)
Spool moved into the body .. ........ ..... .. ......... . .... . .. .. .... .. .. .. .... ... . . . pressure at A port
Spool moved out of the body .. . ....... . ........ . .. . . .... .... ... . . .. . .. . . .. ........ pressure at B port
Threads in inlet and outlet ports . . ......... . . .. . . .. .... .... ..... ... . .. . . . . 1-5/ 16 -12 , ~; traight thread
Threads in inlet of swing section port 718 - 14, ~;traight thread
Threads in A and B ports of stabilizer 3/4 -16, straight thread
Threads in A and B ports of other sections .... . ..... .... .. ... . ..... .... .. . 1-1/16 - 12, straight thread
Special torques
Nuts that fasten the valve sections together ...... . .. ..... . ........... .. ... ........ 20 to 30 pound-feet
(27 to 41 N m, 3 to 4 kg / m)
Circuit relief valves or plugs for load check valves ...... . .. .. .. . .. ...... . .... .... . . 65 to 85 pound-feet
(88 to 155 N m, 9 to 12 kg / m)
Spool cap ... . ... . .. . .. .. .. . .. .. ... . . .. . ......... .... . 20 to 30 pound-feet (27 to 41 N m, 3 to 4 kg/ m)
Weight ...... . . .. . . . ... . . . .. ..... ... .. ... . ..... . . . . . . .... . .. .. . . .... approximately 1.20 pounds (55 kg)
8107-3
SPECIAL TOOLS
786802
861843
The spring compressing plates are used to
compress the centering springs for removal and 1. 3/8-16 NC x 3 Inches (76 mm)
installation. The part number of the tool is CAS- Or Longer Hex Bolt
2. Grind Two Sides Evenly
1147-2.
To 15/32 Inch (1"/.9 mm)
3. Grind To 1/8 Inch
(3.2 mm)
4. 5/8 Inch (10.1 mm)
The tool is used to remove and instal l the load
check plugs.
8107-4
INLET SECTION
SHIM
O-RING 870187 A
Explode d View 0 f Backhoe Co ntrol Valve

8107-5

STEP 1 STEP 4
630342 630306
Clean the backhoe control valve and put the valve Remove the shims .
on a clean bench. Write numbers on each section
of the valve . STEPS
STEP 2
630308
Remove the remainder of the sections and shims.

630302
Loosen and remove the nuts from the studs . STEP 6
STEP 3
630312
Remove the studs from the outlet section .

630304
Remove the inlet section.

8107-6

STEP 1 STEP 4
630314 630308
Install new O-rings in each section . Use the numbers on each valve section as a guide
and install the valve sections and shims.
STEP 2
STEPS
6303 12
Install the studs in the outlet section. 630344
Install the nuts. Tighten the nuts to 20 to 30 pound-

STEP 3 feet (27 to 41 N m, 3 to 4 kg / m).
630310
Install the shims on the studs.

8107-7
INLET SECTION
Disassembly STEP 3
STEP 1
630406
Remove the spring.
630318
Fasten the inlet section in a vise with soft jaws. STEP 4

Loosen the plug.
STEP 2
630408
Remove the poppet.
630320 STEPS
Remove the plug. See Inspection on page 8107-46 and inspect the
parts of the inlet section.
8107-8
POPPET 870188
I nlet Section
8107-9
Assembly STEP 3
STEP 1
630320
Install a new a-ring on the plug. Lubricate the 0-

630408 ring with clean hydraulic oil. Install the plug.
I nstall the poppet.
STEP 2
6~ro406
Install the spring.

8107-10
I nlet Section
8107-11
OUTLET SECTION
Disassembly STEPS
STEP 1
Fasten the outlet section in the vise with soft jaws.
Loosen and remove the plug.
STEP 2
Remove the O-ring from the bore for the spool.

630416
Remove the spring. STEP 6

See page 8107-46 and inspect the parts of the out-
STEP3 let section.
630420
Remove the spool.
STEP 4
630422
Remove the piston .

8107-12
r~......... 7 SECTION
O-RING
PLUG 870189
Outlet Section
8107-13
Assembly STEP 4
STEP 1
See the illustration on page 8107-12 and install a
new a-ring in th e bore for the spool.
STEP 2
630416
Install the spring.
STEPS
630422
Install the piston.
STEP 3
630414
Install a new a-r ing on the plug . Lubricate the 0-

ring with clean hydraulic oil. Install the plug.
630420
Lubricate the spool with clean hydraulic oil. Install

the spool.
8107-14
PISTON--I~~~~~j%
- O-R ING
Pl.UG
SPRING 86 1846
Outlet Section
8107-15
SWING AND BOOM SECTION

Disassembly STEP 4
STEP 1
629342

630428 8107-3 to compress the spring .
Fasten the section in the vise with soft jaws. Loos-
en and remove th e cap. STEPS
STEP 2
629344
Remove the snap ring from t he spool.

630540
Pull the spool , retainer, and O-ring from the body. STEPS
STEP 3
629302
Release the spring tension and separate the spring

629340 seats and spring.
8107-16
STEP 7 STEP 10
Repeat steps 7, 8, and 9 to remove the, ci rcu it rei ief
valve from the A port.
STEP 11
630544
Loosen the circuit relief valve.
STEP 8 630730
Remove the wiper from the A port end of th e spool

bore.
STEP 12
Remove the circuit relief valve.
630732
Remove the O-ring from the bore.
NOTE: Steps 13 through 16 are for the swing sec-

tion only. The boom section does not have this
check valve assembly.
\
\ STEP 13
630506
Use the tool shown on page 8107-3 to remove the

load check plug, spring, and poppet.
Loosen the check valve body in the swing section.

8107-17
STEP 14 STEP 17
630518 630510
Remove the check valve body. Loosen the plug.
STEP 15 STEP 18
630520 630512
Remove the spring. Remove the plug .
STEP 16 STEP 19
630522 630514
Remove the plunger. Remove the spring and poppet.

8107-18
STEP 20 STEP 22
Repeat steps 17, 18, and 19 to remove the other See page 8107-46 and inspect the parts of the
plug , spring, and poppet. swing section.
STEP 21
See page 8107-45 for the disassembly and assem-
bly of the circuit relief valves .
8107-19
LOCK NUT .~
ADJUSTING
SCREW
·1
BODY--
.~
O-RING~-------"'-O
SPRING
SEAT -~
0
CIRCUIT
.ll:------ SPOOL
·1
RELIEF
SPRING VALVE
PIN ~
POPPET 'U
O-RING--- e
•• 0
Ii
/
~~:~ET _____.
/
/
BACKUP----O /
~O /
O-RING~
RING
: ,_/ / /
CIRCUIT
SPRING RELIEF C _ , _ _ -SN AP RING
VALVE
CAP
LOAD CHECK PLUG
BODY
ADJUSTING
--~~
SCREW
870190
LOCK NUT
.~
Swing Section
8107-20
ADJUSTING
.
LOCK NUT _ _ _ _..
~
• ~
SCREW - ~
BODY _ _ _ _ .~
O-RING-- ~
~O
SPOO L
SPRING 0
SEAT • ~
- .I
CIRCUIT
RELIEF
SPRING VALVE
P I N - - - - - -__
• ~
POPPET-----... le
O-RING -----~o
~~:~ET----...... S
~
BACKUP
RING - -0
O-RING-------- : ,
/-
/
/
O-RING_ I
BACKUP -0
RING ·0
- - - -...
~~:~ET----_,
_----~O
it
O-RING
POPPET-----+· e
SPRING----~·I
_ - - - - SPRING
SPRING
SPRING
_.I CIRCUIT
RELIEF
SEAT -----.@ VALVE
O-RING ---:-0 _----CAP
BODy_.
A
ADJUST'NG
SCREW
fjJ ~
LOCK NUT--__ ,"1:1 870191
Boom Section
8107-21
Assembly STEP4
STEP 1
630522
Install the plunger in the body.

630514
Install the poppet and spring in the body. STEPS
STEP 2
630520
Install the spring.

630512
Install a new a-ring on the plug . Lubricate the 0- STEP 6

ring with clean hydraulic oil. Install the plug.
STEP 3
Repeat steps 1 and 2 to install the other poppet,
spring, and plug.
NOTE: Steps 4 through 7 are for the swing sec-

tion only. The boom section does not have this
check valve assembly.
629338
Install a new a-ring and backup ring on the check

valve body .
8107-22
STEP 7 STEP 10
630518 628526
Lubricate the a-ring and backup ring with clean Install the spring and poppet on the load check
oil. Install the check valve body. plug.
STEPS STEP 11
630734 630506
Install a new a-ring in the A port end of the spool Lubricate the a-ring and backup rings on the load
bore. check plug. Install the poppet, spring, and load
check plug. Make sure that the groove in the load
STEP 9 check plug is toward the spool bore.
STEP 12
BACKUP RING
O-RING
628530
Install a new a-ring and new backup rings on the

load check plug. 630502
Lubricate the a-rings and backup rinDs on the cir-

cu it relief valve. Install the circuit relief valve.
8107-23
STEP 13 STEP 17
630542 629342
Tighten the circuit relief valve to 65 to 85 pound- Release the spring tension and remove the spring
feet (88 to 155 N m, 9 to 12 kg / m). com pressi ng plates.
STEP14 STEP 18
Repeat steps 9 through 13 to install the other load
check valve and circuit relief valve .
STEP15
629340
Lubricate the a-ring with ch3an oil. Carefully in-

stall the retainer and a-ring. Do not cut the a-r ing
on the spool.
629302
Assemble the spring seats and spring. Use the STEP 19

spring compressing plates to compress the spring.
STEP16
630540
Lubricate the spool and spool bore with clean oil.

I nstall the spool.
629344
Install the spring and spring seats on the spool.

I nstall the snap ring.
8107-24
STEP 20 STEP 22
630429 629310
Install the cap . Move the body in the vise so that the spool eye is
up. Lubricate the wiper with clean oil. Install the
STEP 21 wiper with the lip up.
STEP 23
630426
Tighten the cap to 20 to 30 pound-feet (27 to 41 N m,

3 to 4 kg / m). 629312
Use a hollow sleeve and a hammer to push the

8107-25
SPOOL~
PLUNGER
·---O-RING
O-RING--_ _ _-l,-.~••
RETAINER-----.p"t/f'i~
SPRING------*
CAP-------·V
SPRING SEAT
SNAP RING 861 847
Swing Section
8107-26
________ CIRCUIT RELIEF VALVE

SPOOL _ _ _ _ _ _ _ _
r - - LOAD CHECK PLUG
BODY--_ _ _ _~I
SPRING--------tt.
'" PLUG
CAP------
-"T"'r-..,..:p.---'~RELIEF VALVE
SPRING SEAT SNAP RING 861848
Boom Section
8107-27
STABILIZER SECTION
Disassembly STEP 4
STEP 1
629342

630944 8107-3 to compress the spring.
Fasten the section in the vise with soft jaws. Loos-
en and remove the cap . STEPS
STEP 2
629344
Remove the snap ring from the spool.

630904
Pull the spool , retainer, and O-ring from the body. STEP 6
STEP 3
629302

629340 seats and spring .
8107-28
STEP 7 STEP 10
630908 630918
Loosen the plug. Remove the check valve.
STEP 8 STEP 11
630910 630920
Remove the plug . Remove the spool from the body .
STEP9 STEP 12
630912 631010
Loosen the check valve in th e other end of the Remove the wiper from the spool bore.
body.
8107-29
STEP 13 STEP 15
631014 63 1002
Remove the O-ring from the bore . Remove the spring .
STEP 14 STEP 16
630926 631004
Fasten the check valve in the vise with soft jaws. Remove the plunger.
Loosen and remove the plug.
STEP 17
See page 8107-48 and inspect the parts of the sta-
bilizer section.
8107-30
~~
PLUG
O-RING -0
SPRING
·1 SPOOL
PLUNGER
.@
BODY--------~l~
O-RING ===------..~ Q~"'''_--- WIPER
BACKUP RING ------:.g 0-

- - - - - O-RING
O-RING -0
I-----BODY
SPOOL----_I
O-RING - - - -...
I _ _ _ _ O-RING
./
0o ..---- RETAI NER
O-RING_~O
I
;' '" Q,. .---- SPRING SEAT
BACKUP RING
o
"0 I·,----SPRING
O-RING .0
~_... - - - - SPRING SEA'r
PLUG-----Jl;! e . . -------SNAP RING
Stabi Iizer Section

B-' -CAP
870 19 ~
8107-31
Assembly STEP 4
STEP 1
631042
Lubricate the a - ring on the p lug . Install th e plug in

631008 the body.
Install new a-rings (1 ) and backup rings (2) on the
body of the check valve. I nstall a new a-ring on the STEPS
plug .
STEP 2
63 1018
Install a new a-ring in the A port end of the spool

bore.
631004
Fasten the body of the check valve in the vise with STEP 6
soft jaws. I nstall the plunger.
STEP 3
630920
Lubricate the spool with clean oil. Install the spool

in the body.
Install the spring.

8107-32
STEP 7 STEP 10
6309 18 630910
Lubricate the a-rings and backup rings on the Lubricate the a-rings and backup ring on the plug.
check valve. I nstall the check valve . Install the plug.
STEP 8 STEP 11
630916 630906
Tighten the check valve to 65 to 85 pound-feet (88 Tighten the plug to 65 t085 pound-feet (88 to 155 N m,
to 155 N m, 9 to 12 kg/ m). 9 to 12 kg/ m) .
STEP9 STEP 12
415420 629302
Install new a-rings and a backup ring on the plug . Assemb le the spring seats and spring. Use the
8107-33
STEP 13 STEP 16
639344 630904
Install the spring and spring seats on the spool. Lubricate the spool and spool bore with clean oil.
Install the snap ring. I nstall the spool.
STEP 14 STEP 17
629342 630902
Release the spring tension and remove the spring I nstall the cap.
compressing plates.
STEP 18
STEP 15
630942
639340 Tighten the cap to 20 to 30 pound-feet (27 to 41 n m,

Lubricate the a-ring with clean oil. Carefully in- 3 to 4 kg / m).
stall the retainer and a-ring . Do not cut the a-ring
on the spool.
8107-34
STEP 19
SPRING--~.;.!
631020
Move the body in the vise so that the spool eye is

wiper with the lip up.
STEP 20
861849
Check Valve
631022

8107-35
SPOOL____________..
WIPER--_ _ _~=::;n_
O-RING-----+~",....r/
BODY _ _ _ _
SPRING --------'01
CAP-----.I
861850
SPRING SEAT
Stabilizer Section
8107-36
BUCKET, DIPPER, AND EXTENDABLE DIPPER SECTIONS

Disassembly STEP 4
NOTE: The bucke t and dipper sections have

circuit relief valves at the A port and B port. The
extendable dipper section has plugs in place of the
circuit relief valves. The following photographs
show the dipper section.
STEP 1
629342

8107-3 to compress the spring .
STEPS
630840
Fasten t he section in the vise with soft jaws. Loos-

en and remove the cap .
STEP 2
629344
Rem ove the snap ring from the spool.
STEP 6
630844
Pull the spool, retainer, and O-ring from the body.
STEP 3
629302

seats and spring.
1
629340

8107-37
STEP 7 STEP 11
630804 630822
Loosen the circuit relief valve. Remove the wiper from the A port end of the spool
bore.
STEP 8
STEP 12
630806
Remove the circuit relief valve. 630824
Remove the O-ring from the bore .

STEP 9
STEP 13
See page 8107-45 for the disassembly and assem-
bly of the circuit relief va lves.
STEP 14
See page 8107-46 and inspect the parts of the sec-
tion .
630808
Use the tool shown on page 8107-3 to remove the

load check plug , spring , and poppet.
STEP 10
Repeat steps 7,8, and 9 to remove the circuit relief
valve , load check plug, spring, and poppet from the
A port.
8107-38
LOCK NUT .~
ADJUSTING
SCREW ·1
•
~
BODY
LOAD CHECK
PLUG
O-RING- -0
"'0 SPOOL
SPRING SEAT .~
CIRCUIT
-I RELIEF
VALVE
-I
POPPET
~e
O-RING .0
POPPET
SEAT
BACKUP RING
'S
'0 /
O-RING
'0
I /
\ /
.... ./
/-
/ \
( \
O-RING-
_ _ _-....
..
BACKUP .~ 6 \
RING ~
POPPET _ _ _ _ _ •~
SEAT ~
e
O-RING - - - - -..... 0
POPPET - - - - -..... '-----SPRING SEAT
SPRING ... 1 _----SPRING
--I
SPRING SEAT - - - -......... @
CIRCUIT
RELIEF
VALVE
\ ,_----SPRING SEAT
C '..· - - - - - S N A P RING
_---~O
O-RING- ~O
BACKUP RING' "I ~."----CAP
LOAD CHECK
PLUG
g
BODY-_.@
ADJUSTING ~
SCREW -------.~
870'193
LOCK NUT • @il
Bucket and Dipper Section

8107-39
PLUG_--.!
SPOOL
O-RING--_ _ _~_O
BACKUP _ _ _ _ _ _... ~ /_\

RING ~ /
__ -----..-0 / ~I
O-RING
LOAD CHECK PLUG

\
-/ .... .
"-8
0-----
BACKUP RING
----:::=:~
O-RING WIPER
~
BACKUP RING _ ____~
SPRING & 0" O-RING
POPPET~~
~~
"r f 'c ____ BODY
/~
WO~
~~'q
Ir::r__________
c,
O-RING
POPPET-----... '.?@
10
. . _____ RETAINER
~ @. .
SPRING - - - - -...
BACKUP RING
O-RING
•
•
~a ------SPRINGSEAT
811J'··----- SPRING
BACKUP R I N G - - - - A.
LOAD CHECK ~~ @ ...-----SPRINGSEAT
PLUG - I V
B
I " ..... ' ~ / c .·------
. SNAP RING
O-RING---_ _ _• CD
BACKUP RING 0I
• _ . . ._____ CAP
O-RING '0
PLUG_-S
870194
Extendable Dipper Section

8107-40
Assembly STEP4
STEP 1
630808
Lubricate the O-ring and backup rings on t he load

630936 check plug. Install the poppet, spring, and load
Install a new O-ring in the A port end of the spool check plug . Make sure that the groove in the load
bore. check plug is toward the spool bore.
STEP 2 STEPS
O-RING
628530 630806
Install a new O-ring and new backup rings on the Lubricate the O-rings and back up rings on the cir-
load check plug. cuit relief valve. Install the circu it relief valve.
STEP 3 STEP 6
628526 630802
Install the spring and poppet on the load check Tighten the circuit relief valve to 65 to 85 pound-
plug . feet (88 to 155 N m, 9 to 12 kg/ m).
8107-41
STEP7 STEP 11
Repeat steps 2 through 6 to install the other load
check valve and circuit relief valve.
STEP8
629340
Lubricate the O-ring with clean oil. Carefully in-

stall the retainer and O-ring . Do not cut the O-ring
on the spool.
629302
Assemble the spring seats and spring. Use the STEP 12

STEP9
630844
Lubricate the spool an d spool bore wi th clean oil.

Install the spool.
639344
Install the spring and spring seats on the spool. STEP 13

STEP10
630842
Install the cap.
629342
Release the spring tension and remove the spring

compressing plates .
8107-42
STEP 14 STEP 16
630838 6309d0
Tighten the cap to 20 to 30 pound-feet (27 to 41 Nm , Use a hollow sleeve and a hamme r to push the
3 to 4 kg / m). wiper into the body.
STEP 15
630938
Move th e body in the vise so that the spool eye is

wiper with the lip up.
8107-43
_ _ _ CIRCUIT RELIE F VALVE
WIPER -----;:=::!;:.i
O-RING--_ _+~ ••
BACKUP RING
~1'~",1*~~s::~::i::=-- O-RING
__--SPRING
=~~~r-
r+.,.--..:...--+---- POPPET
BODY-
____ ~I
O-RINGj-_~~1t
RETAINER-
SPRING---~
1..........-_ _ CIRCUIT RELIEF VALVE
CAP ---_I!...'-
861851
SNAP RING
Bucket and Dipper Section

8107-44
_ _ _ _ _-==!ii1
WIPER--
O-RING - - -_ _-+~~~
J....>;.,---:.,,:+--_ POPPET
SPRING----""H:'
CAP'-----_~~~~~
86 1852
SPRING SEAT
Extendable Dipper Section

8107-45

Disassembly STEP 3
STEP 1
628606
628644
Fasten the circuit relief valve in the vise with soft

jaws. Loosen the lock nut. Loosen and remove the
adjusting screw and lock nut.
NOTE: If you disassemble more than one circuit

relief valve, keep the parts for each relief valve
togeth er. This procedure will prevent mixing the
parts during assembly.
STEP 2
628730
Remove the circuit relief valve from the vise. Sepa-

rate the parts of the circuit relief valve. Some cir-
cuit relief valves have a spri ng and pin and some
circuit relief valves have two springs.
628604
Move the circuit relief valve in the vise. Fasten the

poppet seat in the vise . Loosen the body from the
poppet seat.
8107-46
LoCKNUT-----------+.~
ADJUSTING
SCREW -----------+.
I I
"'-\
I
/
/
/ ~:,.(....- - - - - - - - - SPRING
/
BODY --------+- /
/
/ O ..·---------O-RING
/
/
/
~ ••-----POPPET
O-RING~g / (i. ---- POPPET SEAT

SPRING ~ /
SEAT • -.- /
0 ..---- BACKUP I~ING
~~R~~NG--_'~_' //
0 ..---- O-RING
870195
\.... /
Inspection STEP 2
STEP 1
I ns pect th e parts of the circuit relief valve . All of the
repair parts are available in a kit. If any of the parts
are damaged , replace all the parts in the kit.
628734

of the circuit relief valve .
8107-47
Assembly STEP 3
STEP 1
628644
I nstall the adjusting screw and lock nut in the body.

628606
STEP 4
See the procedure in Section 8002 . Check and ad-
just the pressure setting of the circuit relief valve
before the relief valve is installed in the section.
ADJUSTING SCREW~
BODY--+Y'
SPRING
628730
OR
Lubricate the O-rings on the parts of the relief PIN
valve . Assemble the parts into the body.
STEP 2
SPRING --~~+,.
POPPET
SEAT - - - - - f...1\.
861803
628602
Fasten the poppet seat in the vise with soft jaws.

Tighten the body to 8 to 12 pound-feet (11 to 16 N
m, 1 to 1.5 kg/ m).
81 07-48
INSPECTION
STEP 1 STEP 4
Discard all O- rings, backup rings, and wipers. Inspect the spools and spool bores. Use a new
section if the spool or bore is damaged.
STEP 2
Clean all parts in cleaning solvent. STEPS
Inspect the poppets. Use new parts as necessary.
STEP 3
STEP 6
Inspect all machined surfaces .
Inspect the seat inside the inlet section. If the seat

is damaged , use a 21 / 32 inch (17 mm) diameter drill
and drill the seat to a depth of 11 / 32 inch (8 .7 mm).
A thin shell of the seat will stay in the inlet section .
Remove this thin shell. Remove all metal chips from
the inlet section .
8108
SWING SEQUENCE VALVE
TABLE OF CONTENTS
Specifications .. ... . . . .. .. . .... . . . ... . .. 8108-2 Assembly . . . . . . .. .. .. .. .. . . . . ..... ... . . 8108-9
Disassembly .. .. ..... . .. . ... .. .. .. .. . .. 8108-3 Cross Section View of Relief Valve . . ... . 8108-13
Exploded View of Swing Sequence Cross Section View of Swing

Valve ........ .. .. .. .. ... .. ...... ... .. 8108-7 Sequence Valve ... . ... .. . . . . . . .. .. . . 8108-14
Inspection . ..... . . . .. . . . . .. . . .. . .. . .... 8108-8
J I Case 8-67450
A Ten neco Company

8108-2
SPECIFICATIONS
Manufacturer .. . . .. ....... . .............. .. . .. .. ... .. ... ..... . ........... . .. . ..... . . ... ... . . J . I. Case
Pressure settings . .. . .... ................... ...... . ... . ...... .. ... . ......... . .... . .. See Section 8002
Ports ....... . ....... ..... .... ... .. . ......... . .. ... .... . .... . ................. 7/8 - 14, straight thread
Special Torques
Relief valves .. ... .... . ......... .. ... ... .... . .. ...... 65 to 85 pound-feet (88 to 155 N m, 9 to 12 kg/ m)
Spool cap .. ... . ..... . ........... ........ ....... .... .. 20 to 30 pound-feet (27 to 41 N tn , 3 to 4 kg/ m)
Relief valve body .............. ... ... .. .......... . .... 8 to 12 pound-feet (11 to 16 N tn , 1 to 1.5 kg/ m)
Weight . .. .. . .... .. .. . ... .. ... .. ... . .......... .. . ............. . . . . ... . approximately 20 pounds (9 kg)
8108-3
OISASSEMBL Y
STEP 1 STEPS
Clean the outside of the swing sequence valve.
Fasten the swing sequence valve in the vise with
soft jaws.
STEP 2
629030
Loosen one of the high pressure relief valves.
STEP 6
629022
Loosen the spool cap. The springs will push against
the spool cap as the spool cap is loosened.
STEP 3
Remove the high pressure relief valve.
STEP 7
Remove the spool cap.
STEP 4
629130
Fasten an identi fi cation tag to the high pressure

relief valve.
Pull the spool from the body.

8108-4
STEPS STEP 11
629036 629044
Loosen and remove the other high pressure relief Remove the O-ring from the body.
valve .
STEP 12
STEP 9
629008
629130 Loosen the lo.w pressure relief valve.

Fasten an identification tag to the high pressure
relief valve. STEP 13
STEP 10
Remove the low pressure relief valve.

629040
Remove the wiper from the other end of the body.

8108-5
STEP 14 STEP 17
629128 629120
Fasten an identification tag to the low pressure Remove the plunger from th e op posite end of the
relief valve. body.
STEP15 STEP 18
629116 629122
Loosen the plug inside the bore for the relief valve. Remove the spri ng.
STEP16 STEP 19
629"8 629142
Remove the plug. Remove the O-ring an d retainer from the spool.
8108-6
STEP 20 NOTE: If you disassemble more than one relief

valve, keep the parts for each relief valve together.
This procedure will prevent mixing the parts dur-
ing assembly.
STEP 23
629144
Remove the springs from the spool.
STEP 21
628604
Loosen the vise. Fasten the poppet seat in the vise.

Loosen the body from the poppet seat.
STEP 24
HIGH PRESSURE
RELIEF VALVE
629101
Loosen and remove the Allen head screw and

spring seat from the spool.
STEP 22
628606
LOW PRESSURE
RELIEF VALVE
628644
Fasten the relief valve in the vise with soft jaws.

Loosen the lock nut from the adjusting screw . Re-
move the adjusting screw and lock nut. 628730
Remove the relief valve from the vise. Separate the

parts of the relief valve.
8108-7
POPPET
SEAT BACKUP
RING
O-RING LOCK NUT
POPPET ADJUSTING
SPRING SPRING B
f"\ f:J~ D-RING ~ ~

IV BACKUP Of!'
\ D-RING , ~~ ~ ~
" - . .~ BODY
.'
...---.. POPPET
~U
\ O-RING
SPRING i POPPET
PLUNGER \: SEAT
I
I
I
II ~~.
~, ..... " )~" ' _ _ _ _ _ _ SPOOL
~ WIPER
B/ "
""
O-RING
SPRING
CAP S~f ~~ '-"'.IN<
~~
\
ALLEN HEAD SC REW
Swing Sequence Valve

870313
8108-8
INSPECTION
STEP 1 STEP 4
Inspect the springs . If the springs are damaged,
install new springs.
STEPS
I nspect the spool and spool bore. If the parts are
damaged or worn, use a new swing sequence valve .
STEP 6
Inspect the plunger. If the plunger is damaged or
worn, install a new plunger.
629140
Rep lace the O-ring on the plug.
STEP 2
Inspect the parts of the relief valves. All of the repair
parts in the relief valves are available in a kit. If any
of the parts are damaged , replace all the parts in the
kit.
STEP 3
628734

of the relief valves.
8108-9
ASSEMBLY
STEP 1 STEP 3
LOW PRESSURE
RELIEF VALVE
628644
628730 I nstall the adjusting screw and lock nut in the body.
STEP 4
HIGH PRESSURE See the procedure in Section 8002. Check and ad-
RELIEF VALVE just the pressure setting of each relief valve in a test
block before the relief valve is installed in the swing
sequence valve.
STEPS
628606
Lubricate th e O-rings on the parts of the relief

valve . Assemble the parts in the body .
STEP 2
62912'3
Fasten the body in the vise with soft jaws. Install the
spring and plunger into the body.
ST EP 6
628602
Fasten the poppet seat in the vise with soft jaws.

T ighten the body to 8 to 12 pound-feet (11 to 16 N
m, 1 to 1.5 kg/ m.).
Lubricate the O-ring on the plug with clean hy-

draulic oil. Install the plug in the bore for the low
pressure relief valve .
8108-10
STEP 7 STEP 10
629116 629004
Tighten the plug . Install a new a-ring in the spool bore.
STEPS STEP 11
62911 4 629036
Lubricate the a-rings and backup ring on the low Lubricate the a-rings and backup ring on one of
pressure relief valve with clean hydraulic oil. Install the high pressure relief valves with clean hydraulic
the low pressure relief valve. oil. Install the high pressure relief valve.
STEP 9 STEP 12
629006 629038
Tighten the low pressure relief valve to 65 to 85 Tighten the high pressure relief valve to 65 to 85
pound-feet (88 to 155 N m, 9 to 12 kg/m). pound-feet (88 to 155 N m, 9 to 12 kg/ m) .
8108-11
STEP 13 STEP 16
629032 629103
Lubricate the O-rings and backup ring on the other Lubricate the spool with clean hydraulic oil. Install
high pressure relief valve with clean hydraulic oil. the spool into the body.
Install the high pressure relief valve.
STEP 17
STEP 14
629238
629028 Move the body in the vise so that a rod can be

Tighten the high pressure relief valve to 65 to 85 installed through the hole in the end of the spool.
pound-feet (88 to 155 N m, 9 to 12 kg / m) . Fasten the body in the vise with the end of the spool
in contact with the vise.
STEP 15
STEP 18
629230
Fasten the body in the vise with soft jaws as shown 629232
above. Install a new O-ring on the spool.

8108-12
STEP 19 STEP 22
629234 629206
Install the retainer. Make sure the shoulder on the Install the spool cap. Do not tighten the spool cap
retainer is down . at this time.
STEP 20 STEP 23
629212
Install the three springs on the spool. Move the swing sequence valve in the vise so that
the spool is not in contact with the vise . Remove the
STEP 21 rod from the end of the spool.
STEP 24
629242
Install the spring seat on the springs . Push down on

the spring seat to compress the springs. I nstall the
Tighten the spool cap. The spool cap must be
Allen head screw.
tightened to a torque of 20 to 30 pou nd-feet (27 to
41 N m. 3 to 4 kg/ m) .
8108-13
STEP 25 ADJUSTING -SCREW~
BODY---....
SPRING
OR
PIN
630232 SPRING -----!~-;;.

I nstall a new wiper on the spool. The lips of the
wiper must be up.
POPPET
STEP 26 SEAT ---"";":l\.
861803
Cross Section of Relief Valve
630234

wiper into the body until the top of the wiper is even
with the surface of the housing .
8108-14
LOW PRESSURE
r---RELlEFVALVE
O-RING---~~~1'
ORIFICE PLUG
RETAI"IER-_ _-!~
BODY
ALLEN HEAD SCREW
SPRING SEAT----~~~tzj~~
HIGH PRESSURE
SPOOLCAP-------J RELIEF VALVE (2) 861804
Cross Section of Swing Sequence Valve

9002
AIR CONDITIONING TROUBLESHOOTING
AND SYSTEM CHECKS
TABLE OF CONTENTS
Safety Rules .. .. . ...................... 9002-2 Troubleshooting . .. . ......... .. ........ 9002-5
Special Tools .. .......... . ... . . . ....... 9002-2 System Checks .. .. .... . .. . . . ........ .. 9002-7
Illustration .. ... ......... . .............. 9002-3 Pressure Testing . .. . .... .. .. ... . . ..... 9002-13
Operation ..... . .... . ....... . .... ... . ... 9002-4
J I Case 8-67460
A Tenneco Company
9002-2
SAFETY RULES
This Symbol Shows Important Information About Safety In This Manual.
A When You See This Symbol, Carefully Read The Information That
Follows and Understand The Possible Causes of Injury Or Death. l·l-A
I\.CAUTION: Never touch liquid refrigerant

. . since even a drop on your skin will cause
severe and painful frostbite. 46-87
DANGER: When refrigerant comes in
A contact with an open flame, it forms phos-

gene gas, never breathe these urnes. 46-90
SPECIAL TOOLS
The tools shown on this page are needed for The tools shown below are used to service the
the troubleshooting and system checks for the air air conditioning system. The tools are available
conditioning system. The tools are available from separately or in a kit. The part number of the kit is
Service Tools in the U.S. and from Jobborn Manu- CAS-10023 .
facturing Co. in Canada. See Special Tools in Sec-
tion 1001 for the correct address.
The tool shown below is used to check for

leaks in the air conditioning system. The part num-
ber is CAS-10028.
1. CAS-10023-1 Manifold Gauge Set 131233
2. CAS-tO023-2 Goggles
3. CAS-tO023-3 Wrench
4. CAS-10023-4 Thermometer
5. CAS-10023-5 Control Valve
6. CAS-10023-6 Adapter
131238 7. CAS-10023-7 Check Valve
9002-3
.r", . 5
.M
(
)
861485
.:':':':':':': Low Pressure Gas 1. Typical Expansion Valve 4. Compressor
~"''1 High Pressure Gas 2. Temperature Sensor 5. Condenser
- - Low Pressure Liquid 3. Evaporator 6. Receiver-Drier
- High Pressure Liquid
9002-4
OPERATION
The air co nditioning system includes five major corrosion of internal components of the air condi-
components: condenser, evaporator, compressor, tioning system . The receiver-drier is also a refriger-
expansion valve , and receiver-drier. These compo- ant reservoir for the air conditioning system.
nents are connected by tubes and hoses to operate
as a closed system. The air conditioning system is The refrigerant, still in a liquid from, flows to the
charged with R12 refrigerant. expansion valve. The expansion valve causes a re-
striction in the f low of refrigerant to the evaporator.
The compressor receives the refrigerant in gas Because of this restriction, the refrigerant flowing
fo rm. The compressor then compresses the refriger- out of the expansion valve is under less pressure
ant and sends the refrigerant, still in gas form, to the than the refrigerant flowing in. As refrigeran t flows
condenser. The condenser uses air flow from the through the evaporator, the refrigerant takes heat
rad iator fan to remove heat from the refrigerant. As from the air around the evaporator. The combination
heat is removed , the refrigerant changes into a liq- of increased heat and decreased pressure causes
uid. evaporation of the refrigerant. The evaporation
causes the air flowing over the evaporation coil to
The liquid refrigerant flows from the condenser become very cool. The cooled air is then used to
to the receiver-drier. The receiver-drier is a con- keep the operators cab cool.
tainer filled with a drying material which removes
mo isture that has entered the air cond itioning sys- The refrige rant, in a gas form again, flows back
tem . Moisture must be removed in order to prevent to the compressor, and the cycle is repeated.
9002-5
TROUBLESHOOTING
Problem
No Cooling
I
I J
I COMPRESSOR RUNS I lCOMPRESSOR DOES NOT RUNJ
MECHANICAL
See mechanical Compressor Check , page 9002-
7.
ELECTRIC J~L
See Blower and Compressor Clutch Check , page
9002-8.
I
I I
l REFRIGERATION. 1
See Visual and Leak Check, page 9002-11.
'~ INTERNAL SYSTEM PROBLEM

See Pressure Testing page, 9002-13 .
J
9002-6
Problem Problem
Not Enough Cooling Erratic Cooling
MECHANICAL MECHANICAL
See Mechanical Compressor Check , page 9002- See Mechanical Compressor Check , page 9002-
7. See Evaporator and Plenum Check, page 9002- 7.
12.
ELECTRICAL
ELECTRICAL See Blower and Compressor Clutch Check -
See Blower and Compressor Clutch Check on Blower Motor Check , Blower Switch Check , and
page 9002-8 Compressor Clutch Check , page 9002-8 .
REFRIGERATION INTERNAL SYSTEM PROBLEM

See Cab Temperature Check , page 9002-10 . See See Pressure Testing, page 9002-13.
Visual and Leak Check, page 9002-11 .
INTERNAL SYSTEM PROBLEM Problem

See Pressu re Testing page, 9002-13. Noise in System
MECHANICAL a
See Mechanical Compressor check, page 9002-7.
See Blower Motor Check , page 9002-8 .
ELECTRICAL ;;]
See Compressor Clutch Check, page 9002-8.
INTERNAL SYSTEM PROBLEM

See Pressure Testing, page 9002-13.
9002-7
SYSTEM CHECKS
I Mechanical Compressor Checks I
IDrive Belt 1. Loose or broken drive belt. Adjust to 100 -120

• pounds (45 - 54 kg) tension with a belt ten-
sion gauge.
2. Too much belt wear, Replace belt to prevent

too much slippage.
IMounting Brackets 1. Loose mounting bolts. Tighten to the correct

torque.
2. Bracket broken or has cracks . Replace

bracket.
Pulley and Belt I 1. Compressor pulley and drive pulley must be

I Alignment J aligned. See Alignment of Compressor Pul-
ley and Drive Pulley in Section 9003.
lCompressor Clutch 1. See Section 9003. Remove compressor

I clutch. Inspect clutch plate and pulley fric-
tion surfaces. Use a cloth to clean: dirty fric-
tion surfaces will perm it clutch slippage.
2. If compressor is frozen , pulley will slide on

belt. Remove compressor for service or re-
placement, see Section 9003 .
9002-8
lBlower and Compressor Clutch Check
Blower Fuse ~ 1.
(20 Ampere)
I
Check for damaged blower fuse .
I
1. Check switch operation . Switch must give

Blower Switch I three different blower speeds : Low, Medium ,
and High .
2. Check for loose connections or broken wires. I

Repair or replace as necessa ry .
Blower Motor L 1. Check wiring to blower motor. Repa ir or re-

place as necessary.
2. Check motor ground wire. Make sure motor

ground wire is making good contact with
mounting bracket.
1. Turn switch to maximum cold. Compressor

clutch must engage.
Temperature
Control Switch NOTE: Blower must be operating , since
electrical power to temperature control
switch is received from blower switch .
2. Turn the blower off. Disconnect the wires

from the temperature control. Using an
ohmmeter, check continuity between switch
terminals. If continuity is not present when
switch is on maximum cold, replace switch.
(Conti nued on next page)

9002-9
Blower and Compressor Clutch Check (Continued)
1. Actuate blower and put temperature control

in maximum cold position . Disconnect wire
l Compressor Clutch J to comp ressor clutch ; compressor clutch
must disengage.
2. Check current draw. Current draw must be

4.6 amperes at 12 volts. Resistance must be
2.6 ohms. See Section 9003.
9002-10
I Cab Temperature Check I

I Air Louvers L
- 1. Make sure ports are fully open for most effi-

cient air conditioning operation .
2. Check blower; blower must be operating .
I Air Conditioning I
... 1. Feel the air conditioning hoses. The high
pressure hose (small line) must be warmer
than the low pressure hose (large line).
2. If no temperature difference, the system is

low on refrigerant, there is a restriction in
system, or compressor is not operating cor-
rectly.
1. Put a thermometer in the air duct and run

I Duct Temperature ~ compressor for five minutes to make temper-
ature stable.
2. Duct temperature must be below 50° F (10° C)

if system is operating at maximum efficiency .
NOTE: Ambient temperature must be 70 -

gO°F (21 - 32°C).
3. If temperature is above 50° F (10° C), system

is low on refrigerant , there is restriction in
system, or compressor has malfunction .
9002-11
Visual and Leak Check
Sight Glass 1. Check sight glass after compressor has been

operating for five to ten minutes .
o 2. Slow moving bubbles; needs a small amount

of refrigerant.
3. Fast moving bubbles ; very low on refriger-

ant.
4. Foam ; very low on refrigerant.
5. Oil streaks; complete loss of refrigerant.
o
6. Clear; a clear sight glass can indicate a normal
charge or one of the following problems:
a. Too much charge.

770418 b. Complete loss of refri~lerant charge.
See page 9002-13 and do the pressure test.
rcc;o~m;;;p~re~s~s~o;r;Hko~s~e~s")-----..{ 1. Make sure all hose connections are tight.
2. Inspect hoses for sharp turn or cracks . Re-

place all damaged hoses.
(Continued on next page)

9002-12
Visual and Leak Check (Continued)
I Leak Check
I
1. Stop engine.
2. See page 9002-2 for Special tools. Do calibra-

tion of leak finding tool and check system for
leaks. Use instructions from the manufac-
turer of the leak finding tool.
3. Repair all leaks and add refrigerant to the

system, see Section 9003.
Evaporator and Plenum Check
Evaporator 1. Remove cab trim panels and headliners, see

. ._~ Section 9003, Evaporator Removal and In-
stallation .
2. Inspect evaporator f ins. Repair all bent or

damaged fins.
3. I nspect evaporator for restrictions. Clean

with a brush and vacuum. If the evaporator is
filled with mud, it wi ll be necessary to flush
carefully with water (Do Not Use Steam).
CAUTION: Do not steam clean any air

conditioning system parts while the system
is charged. The heat will cause the refrigerant
to rise to a pressure that could cause the
system to explode. 46-88
1. Correct plenum sealing will pull ai r only

Plenum Sealing I---------~ through the evaporator and not around the
evaporator.
9002-13
PRESSURE TESTING
Manifold Gauge Set indicate both psi (kPa) pressure and inches of mer-
cury.
The manifold gauge set is the most important
tool used to service the air conditioning system. The
manifold gauge set is used to learn the high and low During normal operation the low pressure
pressures of the system, the correct refrigerant gauge must always indicate from 7 to 30 psi (48 to
charge, system diagnosis, and operating efficiency. 207 kPa) after the system has run 10 to 15 minutes.
The manifold gauge set can read both the high (dis-
charge) and low (suction) sides at the same time, HIGH PRESSURE GAUGE - The high side
since pressures must be compared in order to make gauge is a pressure gauge used to indicate pres-
a diagnosis of system operation . sures in the high side of the system. The gauge must
indicate from 0 - 400 psi (0 - :~758 kPa) minimum.
LOW PRESSURE GAUGE - The low pressure
gauge is a compound gauge. All air conditioning During normal operatio n, the high pressure
systems can, under some conditions, change from a gauge will normally indicate from 120 to 270 psi (827
pressure into a vacuum on the low side. For this to 1861 kPa), including correction for ambient air
reason, it is necessary that a gauge be used that will temperatures, see pressure - temperature chart.
Pressure - Temperature Chart

Pressu re-T em peratu re Chart
Normal High Pressure Reading Ambient Temperature
150 - 170 psi 80° F (26 .7° C)

(1034 - 1172 kPa)
175 - 185 psi I 90° F (32.2° C)

(1206 - 1275 kPa)
195 - 205 psi 95° F (35° C)

(1344 - 1413 kPa)
210 - 230 psi 100°F (37 .8°C)

(1447 - 1585 kPa)
230 - 250 psi 105°F (40.rC)

(1585 - 1723 kPa)
250 - 270 psi 110°F (43°C)

(1723 - 1861 kPa)
NOTE: Ambient temperature is the tempera-

ture of the air around the machine. Connect the
manifold gauge set according to the instructions in
Section 9003, page 9003-7 to do the following pres-
sure tests .
9002-14
Problem - No Cooling
1. LOW PRESSURE GAUGE READING IN A VACUUM

2. HIGH PRESSURE GAUGE READING BELOW PRESSURE-
TEMPERATURE CHART
I --
Indications of Low Refrigerant Charge
1. Test system for leaks, see page 9002-12. It
a. Sight glass clear - no bubbles can be necessary to add some mfrigerant
~
charge, see Section 9003.
b. Discharge air from evaporator warm .
2. Discharge system of refrigerant , see Section I

9003.
3. Repair system leaks as necessary . See Air

and Moisture Removal in Section 9003.
4. Check compressor oil leve l, see Section I

9003.
5. Remove air and moisture from the system ,

see Section 9003.
I
6. Charge system with new refrigerant. see Sec-

tion 9003.
I
9002-15
Problem - No Cooling
1. LOW PRESSURE GAUGE READING ABOVE 30 PSI (207 kPa)

2. HIGH PRESSURE GAUGE READING ABOVE PRESSURE-
TEMPERATURE CHART
I
Indications of Air in System
a.
b.
Bubbles in sight glass.
Discharge air from evaporator warm. - 1. Discharge refrigerant from system, See Sec-
tion 9003.
2. Replace receiver-drier if drying material is

full of moisture and removal procedure can-
not remove moisture from receiver-drier.

see Section 9003.
4. Charge system with new refrigerant, see Sec-

tion 9003.
Indications of a Problem
in Condenser Operation
,. 1. Inspect for loose or worn compressor belt
.
a. Bubbles in sight glass at intervals. and fan belts .
b. Line between condenser and evaporator

inlet very hot.
2. Inspect condenser and radiator for restric-
c. Discharge air from evaporator warm . tions in air passages.
I
9002-16
Indications of a Problem in Condenser Operation (Continued)
3.
I
Check system for too much refrigeran t.
a. Discharge refrigerant until bubbles can

be seen in sight glass and gauge pres-
sure is below normal.
b. Add refrigerant until bubbles cannot be

seen in sight glass and gauges indicate
normal pressures , see Section 9003.
4. Remove and inspect condenser for restric-

tion caused by oil.
a. Use compressed air to remove oil from

condenser.
b. Replace receiver-drier.
c. Remove air and moisture and charge sys-

tem, see Section 9003.
in Expansion Valve Operation
1. Remove cab trim panels and headliners, see
a. Discharge air from evaporator warm . Section 9003 . Inspect temperature sensing
b. Much condensation on suction hose at

compressor.
I contact to evaporato r outlet for looseness or
corrosion .
c. Much condensation on evaporator out-

let. 2. Clean contact surface between temperature
sensing bulb and evaporator outl et, see Sec-
tion 9003.
3. Fasten temperature sensing bulb to evapora-

tor outlet and tighten .
4. Fill the area between temperature sensing

bulb and evaporator outlet with lithium base
grease to make a better conductor.

9002-17
Indications of a Problem in
Expansion Valve Operation (Continued)
I
5. Install the insulation putty in the original po-
sition .
6. Discharge the system and remove expansion

valve, see Section 9003 .
7. Test expans ion valve and replace or adjust as

necessary, see Section 9003.
8. Replace expansion valve, remove air and

moisture, and charge system , see Section
9003.
9002-18
Problem - Not Enough Cooling
1. LOW PRESSURE GAUGE READING NORMAL,

7 TO 30 PS I (48 TO 207 kPa)
2. HIGH PRESSURE GAUGE REA DING NORMAL,
ACCORDING TO PRESSURE-TEMPERATURE CHART
Indications of Air In System
-
a. Sight glass free of bubbles or bubbles 1. Test system for leaks, see page 9002-12.
can be seen only at intervals. Possible leak has let air enter; check com-
pressor seal carefully, see Section 9003.
b. Suction line warm to your hand .
c. Evaporator discharge air only a little

cool. 2. Discharge system of refrigerant. See Section
9003 .
3. Repair system leaks as necessary, see Dis-

charging the System in Section 9003 .
4. Replace receiver-drier if drying material is

full of moisture and removal procedure can-
not remove moisture from receiver-drier.
5. Check compressor oil level , see Section

9003 .

9002-19
Ind ications of Air in System (Continued)
1
6. Remove air and moistu re from the system ,
see Section 9003.
7.
I
Charge system with new refrigerant, see Sec-
tion 9003.
1. LOW PRESSURE GAUGE READING BELOW 7 PSI (48 kPa)

TEMPERATURE CHART
J
I
Indications of Low Refrigerant Charge 1. Test system for leaks. System has a loss of
refrigerant.
a. Bubbles in sight glass.
b. Discharge air from evaporator on ly a lit-

tie cool. rt NOTE: Normally , the system will have a
loss of 1/ 2 to 1 ounce (14.7 - 29.5 ml) of
refrigerant between seasons.
a. If leak is found , do Step 2.
b. If no leak is found, do Step 6.
I
2. Discharge system of refrigerant. See Section
9003 .
I
9002-20
Indications of Low Refrigerant Charge (Continued)
I
3. Repair system leaks as necessary. See Dis-
charging the System in Section 9003.
4. Check compressor oil level. See Section

9003 .

see Section 9003.

tion 9003 .
Indications of High Pressure Restriction 1. Discharge the system.

I
a. Discharge air from evaporator only a little
cool.
~ 2. Remove and replace part which has restric-
b. Condensation or frost on receiver-drier. tion.
c. Liquid line to receiver-drier cool , with

frost or condensation .
3. Remove air and moisture from t he system,
see Section 9003.
4. Charge system with new refrigeral1t, see Sec- I

tion 9003.
Indications of a Problem 1. Expansion valve inlet whic h has condensa-

in Expansion Valve Operation tion or frost is an ind ication of a restriction in
the expansion valve .
a. Discharge air from evaporator only a little
cool. a. Discharge the system. See Section 9003 .
~
b. Condensation or frost on expansion b. Remove expansion valve and clean or re-
valve inlet. place. See Section 9003 .
c. Inlet end of expansion valve is warm . c. Remove air and moisture and charge sys-
tem. See Section 9003.
I
9002-21
in Expans ion Valve Operation (Continued)
2.
J
Inlet end of expansion valve is warm, indicat-
ing expansion valve is not completely open .
a. Discharge system. Test expansion valve

and adjust or replace. See Section 9003.
b. Install expansion valve, remove air and

moisture, and charge system, see Sec-
tion 9003.
c . Clean contact surface between tempera-

ture sensing and evaporator outlet. See
Section 9003 .
d. Fill the area between temperature sens-

ing bulb and evaporator outlet with lith-
ium base grease to make a better con-
ductor.
e. Install the insulation putty in the original

position.
9002-22

TEMPERATURE CHART
J
Indications of a Problem 1. Separate the compressor f rom the system .
in Compressor Operation See Section 9003.
a. System is fully charged; no bubbles in

sight glass.
• 2. Internal leak in compresso r is indicated . Re-
b. Evaporator discharge air only a little move compressor from machine. Possible
cool. causes are :
a. Leakl'lge at valves .
b. Leakage at head gasket
c. Pistons, rings, or cylinders have wear

or scoring .
3. Check and make a record of com pressor oil

level before doing service work . See Section
9003.
4. Repair or replace compressor as necessary.

See Section 9003.
I
9002-23
in Compressor Operation (Continued)
5. Replace receiver-drier if:
a. The system has been opened for repairs

two times.
b. Receiver-drier operated two or more sea-

sons.
c. Disassembly of comp ressor showed fine

particles of drying material (normally
yellow or brown particles).
6. Fill compressor with new refrigeration oil ac-

cording to instructions in Section 9003. In-
stall compressor in machine.
7. Remove air and moisture from the system,

see Section 9003. Charge system.
8. Operate system and check refrigerant

charge. See Section 9003 .
9002-24

TEMPERATURE CHART
I
J
in Condenser Operation
III 1. Inspect for loose or worn fan and compressor
belts.
a. Bubbles in sight glass at intervals.
b. Liquid line very hot.

•
2. Inspect condenser and rad iator for restric-
c. Discharge air from evaporator warm . tions in air passages .
3. Check system for too much refrigerant.
a. Remove refrigerant until there are

bubbles in sight glass and gauge 'pres-
sure is below normal.
b. Add refrigerant until there are no bubbles

in sight glass and gauge pressures are
normal. See Section 9003.
c. If there is stili a problem , do step 4.

9002-25
in Condenser Operation (Continued)
•
4. Remove and inspect condenser for restric-
tions caused by oil.
a. Discharge system , see Section 9003.
b. Use compressed air to remove oil from

condenser.
c. Replace the receiver-drier.
d. Remove air and moisture from the sys-

tem and charge system, see Section
9003.
Indications of Air in System

1. Discharge refrigerant from system , see Sec-
a. Bubbles in sight glass. - tion 9003.
b. Discharge air from evaporator warm .
2. Replace receiver-drier if drying material is full of

moisture and removal procedure cannot re-
move moisture from receiver-drier.

see Section 9003.
4. Charge system with new refrigerant. See

Section 9003 .
9002-26
Problem - Erratic Cooling
1. LOW PRESSURE GAUGE READING NORMAL,

7 TO 30 PSI (48 TO 207 kPa)
2. HIGH PRESSURE GAUGE READING NORMAL,
.ACCORDING TO PRESSURE-TEMPERATURE CHART
J
I
Moisture in the System
1. Discharge system of refrigerant. If too much
a. Cooling is acceptable during cool part of moisture enters the orifice of the expansion
day, but not acceptable during hot part of ~ valve, the freezing of this moisture can stop
day. refrigerant flow. See Section 9003 .
2. Replace receiver-drier. Drying material is full

of moisture.
3. Remove air and moisture from the system .

See Section 9003.
.
NOTE: Vacuum pump must run for at least
2 to 3 hours to remove a large amount of
moisture.

tion 9003 .
9002-27
Problem - Erratic Cooling
1. LOW PRESSURE GAUGE READING BELOW 7 PSI (48 kPa)

TEMPERATURE CHART
•
in Expansion Valve Operation 1. Expansion valve inlet which has condensa-
tion or frost is an indication of a restriction in
a. Discharge air from evaporator only a little the expansion valve.
cool.
b. Condensation or frost on expansion 1. a. Discharge the system. See Section 9003.
valve inlet. b. Remove expansion valve and clean or re-

place . See Section 9003.
c. Inlet end of expansion valve is warm.
c. Remove air and moisture and charge sys-
tem. See Section 9003 .
2. Inlet end of expans ion valve is warm , indicat-

ing expansion valve is not completely .open .
a. Discharge system. Test expansion valve

and adjust or replace. See Section 9003.
b. Install expansion valve, remove air and

moisture, and charge system . See Sec-
tion 9003 .
c. Clean contact surfacE! between tempera-

ture sensing bulb and evaporator outlet.
See Section 9003.

9002-28
Indications of a Problem in
Expansion Valve Operation (Continued)
I
d. Continue performance test for possible
other problems.
e. Fasten temperature sensing bulb to eva-

porator outlet and tighten securely.
f. Fill the area between temperature sensing

bulb and evaporator outlet with lith ium
base grease to make a better conductor.
g. Install the insulat ion putty in the original

position .
Problem - Noise in System
1. LOW PRESSURE GAUGE READING NORMAL, 7 TO 30 PSI

(48 TO 207 kPa)
TEMPERATURE CHART
•
I
Indications of Too Much
Refrigerant in System
a.
b.
c.
Sight glass clear.
Discharge air from evaporator cool.
Compressor makes noise.

- 1. Remove refrigerant from the system until
bubbles show in the sight glass and gauge
readings are below normal.
2. Add new refrigerant until bubbles do not

show and gauge readings are normal. See
Section 9003.
9003
AIR CONDITIONING SYSTEM
TABLE OF CONTENTS
Specifications ....... . . . . ... ... .. .. . . .. . 9003-2 Compressor .. .. .. ... . .... . . . ......... 9003-12
Special Tools .. .. ... .. . ..... . ...... . ... 9003-3 Removal . ... . .. .. ... . ... . . . .. .. ..... 9003-13
Adjustment of Drive Belt . . . .. .... .. . .. .. 9003-4 Replacing the Coil or Clutch Assembly . 9003-13
Lubrication of Compressor . . ..... . ... . . . 9003-5 Replacing the Seal ... . .. . ......... . . 9003-18
General Information .... . .. ... . ... .. . . 9003-5 Replacing the Valve Plate or Gaskets . . 9003-23
Lub rican t . .. ...... .. .. . .. ... .. . ... ... 9003-5 Replacing the Air Conditioning Control . . 9003-27
Oil Level Check . . .. . . .. . .. . .... . . .... 9003-5 Expansion Valve ... .. . ..... .. ....... . . 9003-27
Oil Level fo r a New Comp ressor .... . .. . . 9003-6 Removal . ..... ...................... 9003-27
Discharging the Air Conditiong System .. 9003-7 Installation .. . .. .. . ..... . ... ... . . . .. . 9003-28
Removing Air and Moisture from the Inspection .... . .. . . . . ... . . . ......... 9003-29
Air Conditioning System . .. . . .. .. . .. . . 9003-8
Testing and Adjustin g . . .. . .. ... . . . .. 9003-30
Charging the Air Conditioning System . .. 9003-9
Replacing the Evaporator . . . .. .. ... . . .. 9003-32
General Informatio n . .. .. . . . .. .. ... ... 9003-9
Condensor . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9003-35
Charging Procdure ..... . . . .... . .... .. 9003-9
Removal . .. . . . ... . .. .. . . .. . .. . . ..... 9003-36
Installation . . . .. . ... . . .. . . . .... . . .... 9003-36
J I Case 8-67470
A T enneco Compan y
9003-2
SPECIFICATIONS
Compressor Manufacturer Sanyo-Sanden Corporation
Lubricant .. . .. .. .... . . .. .. .... ....... . . .. .......... . . .. . . ......... . ........ Suniso-5GS or equivalent
Coil
Resistance ..... . ........... . ... .. ..... . . . . .. . .... .... . .. . . . . . ... ... . . 2.8 to 3.3 ohms at 80 0 F (27 0 C)
Current draw . .. .. . . . .... . .. .. ... .. . .. ..... . ........... . .. . .. . .... . . . .. 3.6 to 4.2 amperes at 12 volts
Torque
Cap screws for end cover .. . . ................. 264 to 300 pound-inches (30 to 34 N m, 3.0 to 3.4 kg/ m)
Nut for clutch plate ........................... 300 to 360 pound-inches (34 to 40 N m, 3.4 to 4.2 kg/ m)
Refrigerant ... . . ... .. ........ . ................. . . ... . .... . ... . ....... . . . ..... .. .. . ... R-12 refrigerant
System capacity .. . ........ . . ... .. ... . .. . . .. . ... .. ..... .. .. . ............... 80 U.S. ounces (2.26 kg)
9003-3
SPECIAL TOOLS
The tools shown in the first three illustrations
are required to service the air conditioning system
(finding leaks, charging the air conditioning sys-
tem, checking the charge of the air conditioning
system, and repairing the compressor).
The tools shown in the next three illustrations

are required during the disassembly and assembly
of the compressor.
The tools are available from Service Tools in

the U.S. and from Jobborn Manufacturing Co . in
Canada. See Special Tools in Section 1001 for the
correct address.
1. CAS-10023-1 Gauge Manifold 131233
and Hoses
2. CAS-10023-2 Goggles
3. CAS-10023-3 Wrench
4. CAS-10023-4 Thermometer
5. CAS-10023-5 Control Valve
6. CAS-10023-6 Adapter
7. CAS-10023-7 Check Valve
The tools shown below are used to charge and
check the charge of the air conditioning system .
The tools are available as a kit or separately . The
part number of the kit is CAS-10023.
131 238
The leak detector shown is used to find

leaks in the air conditioning system. The part num-
ber of the leak detector is CAS-10028.
414636
The tool kit shown below is needed to replace

the seal, coil, or complete clutch assembly. Not all
tools in the kit are required for the compressor
used on this machine. The part number of the kit is
CAS-10747 .
131243
The tool shown is a vacuum pump that is

used to remove air and moisture from theaircondi-
tioning system. The part number of the vacuum
pump is CAS-10027.
9003-4
The reducers and connector shown below are

The two hoses shown below are required when used when testing the expansion val ve. The redu-
testing the expansion valve. The hoses are the cers are refrigeration grade fitti ngs and are avail-
same type that are used with the gauge manifold . ab le from Grould Inc., Valve and Fittings Division .
The part number of the hoses is Imperial-Eastman The part numbers are 661-FA-06x04 (UR3-64) and
336FTY or equivalent. 661-FA-08x04 (UR3-84).
The connector is available from Service Parts

Supply. The part number of the connector is 218-
732 .
821029
1. Use A No. 71 Drill And Drill

Hole In One Side Of Tee.
The tee shown below is required when testing

the expansion valve . The Case part number is 222-
735 with the modification shown .
ADJUSTMENT OF DRIVE BELT

Check the tension of the drive belt after every STEP 1
250 hours of operation. If a new drive belt is in- Loosen slightly, the nuts on the bolts that hold the
stalled , check the tension of the drive belt after the compressor.
first 20 hours of operation.
STEP 2
The correct tension for a new drive belt is 95 to Use a prybar near the front of the compressor to
115 pounds (43 to 52 kg) measured with a belt tighten the drive belt and tighten the nuts.
tension gauge.
STEP 3
The correct tension for a drive belt used more Use a belt tension gauge and check the tension of
than 20 hours is 90 to 110 pounds (40 to 50 kg) the drive belt.
measured with a belt tension gauge.
STEP 4
To adjust the tension of the drive belt: Repeat steps 1, 2, and 3 as required .
9003-5
LUBRICATION OF COMPRESSOR
Connect the hose from the low pressure gauge to
Because the air conditioning system is a the low pressure port.
closed system, the compressor will not need regu-
lar oil level checks or oil changes . STEP 4
Start the engine and run the engine at low idle with
An oil change is necessary only when the air the air conditioning control set for maximum cool-
conditioning system has contamination from a leak ing and the blower at high speed . Run the engine
or a component failure. for 10 minutes.
Lubricant STEPS
Stop the engine.
The compressor uses refrigeration oil. Refrig-
eration oil is a special oil that has most of the
moisture removed. Use Suniso-5GS, Texaco No. DANGER: When refrigerant comes in
768, Capella WF1 00, or an equivalent refrigeration
oil when you add or change oil. A contact with an open flame, it forms phos-
gene gas, never breathe these fumes. 46-90
Oil Level Check

WARNING: The refrigerant discharged
The level of the oil must be checked whenever from the air conditioning system does not
a new receiver-drier, condenser, or evaporator has h. have the oxygen you need to breathe .
been installed . . . Make sure that the repair area has good
ventilation. Breathinf; a large amount of
STEP 1 refrigerant can cause personal injury.
The gauge manifold must be connected to the high 46-89A
and low pressure ports in the compressor. Make
sure that both valves in the gauge manifold are WARNING: Always wear safety goggles
closed. when working with refrigerant. Liquid refri-
gerant in your eyes can cause blindness.
If you get any near your eyes, rinse them
immediately with mineral oil to absorb the
refrigerant. Follow by flooding your eyes
with a weak solution of boric acid and con-
tact a doctor immediately. 46-86
STEP 6
Discharge the air conditioning system slowly to
prevent removing too much oil with the refrigerant.
a. Open the high pressure valve a small

amount.
b. Open the low pressure valve a small

amount.
1. Low Pressure Gauge

2. High Pressure Gauge
3. Charge-Discharge Hose
4. Low Pressure Port
5. High Pressure Port
STEP 2
Connect the hose from the high pressure gauge to
the high pressure port.
9003-6
STEP 7 STEP 10
840536
1. Point Must Be Toward Left

Side Of Machine. Stop On
Dipstick Must Touch
The Compressor
Put the angle gauge from the tool kit shown on Install the dipstick so that the pa int on the stop near
page 9003-2 on the front or rear mounting flange. the handle is toward the left. The stop must touch
Adjust the level on the angle gauge until the bubble the compressor as shown.
is between the marks. Tighten the wing nut.
STEP 11
STEPS Read the degrees on the angle gauge and the
Loosen and remove the filler plug. notches in the dipstick .
STEP9 STEP 12
Compare the readings with the chart and add oil as
required. Add oil in amounts less tha n 1 U.S. fluid
ounce (30 mL) and check the level again . The oil
must be that which is specified on page 9003-2 .
Angle Gauge Oil Level

Reading Notches
840535
o .. ... .... ... .... ..... ............... .. .... 2-4
10 . . . .... ..... . ........ . ... .. . . .. ..... . . ... 4-5
1. Piston Rod 20 .. ......... . .............. . ..... . . ....... 5-6
2. Plate
Look into the fill hole and check to see if a piston

STEP 13
Charge the air conditioning system according to
rod and the plate are in the position shown below . If
instructions in this section.
the parts are not in the correct position, use a
socket wrench and turn the shaft to put the parts in
Oil Level for a New Compressor
the position shown. This is important to correctly
install the dipstick.
STEP 1
Drain the oil from the old compressor into a mea-
suring container.
STEP 2
Drain the oil from the new compressor into a
CLEAN measuring container.
STEP 3
Fill the new compressor with the new oil equal to
the amount drained from the old compressor plus 1
U.S. fluid ounce (30 mL) of new oil.
STEP 4
Install and tighten the filler plug .
STEPS
No oil level check will be needed after the com-
pressor has been installed .
9003-7
DISCHARGING THE AIR CONDITIONING SYSTEM

The air conditioning system must be dis- STEP 4
charged before beginning the removal of any com- Loosen and remove the cap from the low pressure
ponent of the air conditioning system . port.
STEPS
DANGER: When refngerant comes in Connect the hose from the low pressure gauge to
A contact with an open flame, it forms phos-

gene gas, never breathe these fumes . 46-90
the low pressu re port.
STEP 6
Hold the charge-discharge hose from the gauge
WARNING: The refrigerant discharged manifold so that the refrige ant will be discharged
from the air conditioning system does not away from you.
h have the oxygen you need to breathe .
. . Make sure that the repair area has good IMPORTANT: The refrigerant must be released
ventilation. Breathing a large amount of slowly to prevent removing the oil in the compres-
refrigerant can cause personal injury. sor with the refrigerant.
46-89A
STEP 7
Open the valve for the low pressure gauge a small
WARNING: Always wear safety goggles
amount to slowly release the refrigerant.
when working with refrigerant. Liquid refri-
gerant in your eyes can cause blindness.
STEPS
Open the valve for the high pressure gauge a small
amount to release the refri gerant.
tact a doctor immediately. 46-86 STEP 9
When the low pressure gauge and high pressure
gauge indicate zero , the air conditioning system is
STEP 1
discharged.
Make sure each valve in the gauge manifold is

closed.
STEP 2
Loosen and remove the cap from the high pressure
port.
1. Low Pressure Gauge
2. High Pressure Gauge
STEP 3 4. Low Pressure Port
Connect the hose from the high pressure gauge to 5. High Pressure Port
the high pressure port.
9003-8
REMOVING AIR AND MOISTURE FROM THE AIR CONDITIONING SYSTEM

When the air conditioning system has been STEP 2
discharged and opened for service, air enters the
air conditioning system before the openings can be
closed. The air carries moisture which can cause
damage to the air conditioning system . It is neces-
sary to remove the air and moisture before the air
conditioning system is charged with new re-
frigerant.
Replace the receiver-drier before removing

the air and moisture if:
a. The air conditioning system has been

opened before.
b. The receiver-drier has been used for more

Make sure that the valves in the gauge manifold are
than two seasons.
open.
c. The reason for service is too much air and
moisture in the air conditioning system.
STEP 3
Connect the charge-discharge hose from the
gauge manifold to the vacuum pump .
d . Disassembly of the compressor shows
particles of the drying material inside the com-
pressor.
STEP 4
Run the vacuum pump for a minimum of 30 min-
utes. The low pressure gauge must indicate a vac-
STEP 1
uum of 28 to 29 inches of mercury (95 to 100 kPa)
If the hoses from the gauge manifold have been
within five minutes. If the vacuum is not as speci-
disconnected from the compressor:
fied, there is a leak in the air conditioning system or
the vacuum pump is not working correctly.
NOTE: The vacuum indication will be one inch of

mercury (3.3 kPa) less for every 1000 feet (305
meters) above sea level.
STEPS
To check for a leak in the air conditioning system:
a. Close the valve for the low pressure and

high pressure gauges.
b. Stop the vacuum pump.
c. If the reading of the low pressure gauge

increases more than one inch of mercury (3.3
kPa) in four minutes, there is a leak in the air
conditioning system.
1. Low Pressure Gauge d. Check all connections in the air cond ition-
2. High Pressure Gauge ing system.
4. Low Pressure Port STEP 6
5. High Pressure Port Before disconnecting the vacuum pump , make
a. Connect the hose from the high pressure sure that the valves for the low pressure and high
gauge to the high pressure port. pressure gauges have been closed.
b. Connect the hose from the low pressure

gauge to the low pressure port.
9003-9
CHARGING
, THE AIR CONDITIONING SYSTEM
General Information
Charge the air conditioning system only when
there is no indication of leaks.
If the air conditioning system has been dis-

charged, air and moisture must be removed from
the air conditioning system according to instruc-
tions in this section before the air conditioning
system can be charged .
If refrigerant is being added to a charged air

conditioning system, removal of air and moisture is
not necessary.
The correct amount of R12 refrigerant for the

air conditioning system is 42 ounces (1.2 kg). Us-
ing more refrigerant than required will damage the
compressor.
Use the procedure that follows to correctly b. Loosen and remove the cap from the high
charge the air conditioning system . pressure port.
Charging Procedure c. Connect the hose from the high pressure

gauge to the high pressure port.
STEP 1
If the air conditioning system is to rece ive a com- d. Loosen and remove the cap from the low
plete charge of refrigerant , remove air and mo is- pressure port.
ture from the air conditioning system according to
instructions in this section. Then continue the pro- e. Connect the hose from the low pressure
cedure at step 3. gauge to the low pressure port.
STEP 2
131008
If you are only adding refrigerant:
a. Make sure the valves in the gauge manifold

are closed .
9003-10
WARNING: Always wear safety goggles STEP 7

when working with refrigerant. Liquid refri- Open the control valve on the container several
gerant in your eyes can cause blindness. turns .
immediately with mineral 011 to absorb the STEP 8
refrigerant. Follow by flooding your eyes Slowly open the valve for the low pressure gauge to
with a weak solution of boric acid and con- prevent the pressure from going above 40 psi (276
tact a doctor immediately. 46-86 kPa, 2.8 kg / cm 2). At a higher pressure the refriger-
antwill become liquid and damage the compressor.
CAUTION: Never touch liquid refrigerant
A since even a drop on your skin will cause
severe and painful frostbite. 46-87
STEP 9
Start the engi ne and run the engine at 1500 rpm
(r/min).
STEP 3 STEP 10
Turn the air conditioning control to the COLD posi-
tion.
STEP 11
Turn the knob for the blower to the HI posit ion.
STEP 12
Continue to charge the air conditioning system
until 80 ounces (2.26 kg) of refrigerant is in the air
conditioning system or until there are no air bub-
bles in the sight glass on the top of the re-
ceiver-drier.
STEP 13
131229
When changing containers of refrigerant:
Install the control valve on the container of refrig-
erant. a. Close the valve for the low pressure gauge.
STEP 4 b. Close the control valve on the container.
c. Remove the control valve from the empty

container.
d. Install the control valve on the new con-

tainer.
STEP 14
Open the valve for the low pressure gauge and the
control valve on the container of refrigerant.
STEP 15
Read the low pressure gauge and the high pres-
131023
sure gauge. The air conditioning system is cor-
Connect the charge-discharge hose from the rectly charged when :
gauge manifold to the control valve.
a. The indication of the low pressure gauge is
7 to 30 psi (48 to 207 kPa, 0.5 to 2.1 kg /c m2).
STEP 5
Loosen the connection of the charge-discharge
hose and the gauge manifold.
STEPS
Open the control valve a small amount to remove
the air from the charge-discharge hose. Then
tighten the connection at the gauge manifold.
9003-11
STEP 16
Ambient Temperature" High Pressure Indication If the high pressure reading is too high:
80°F (26 .7°C) 150 to 170 psi a. Close the cont rol valve for the refrigerant
(1034 to 1172 kPa, container.
10.5 to 11.9 kg/cm2)
b. Disconnect the charge-discharge hose
90° F (32.2° C) 175 to 185 psi from the control valve .
(1206 to 1275 kPa,
12.2 to 13 kg/cm2) c. Slowly open the valve for the high pressure
gauge to decrease the high pressure to the
95° F (35°C) 195 to 205 psi correct value.
(1344 to 1413 kPa,
13.6 to 14.3 kg/cm2) d. Close the valve for the high pressure gauge
when the reading is correct.
100° F (37 .8° C) 210 to 230 psi
(1447 to 1585 kPa, STEP 17
14.7 to 16 kg/cm2) After the air conditioning system has the correct
charge, stop the engine.
105°F (40 .7°C) 230 to 250 psi
(1585 to 1723 kPa,
16 to 17.5 kg/cm2) WARNING: Always wear safety goggles
when working with refrigerant. Liquid refri-
110°F (43°C) 250 to 270 psi gerant in your eyes can cause blindness.
(1723 to 1861 kPa,
17.5 to 19 kg/cm2) A If you get any near your eyes, rinse them
"The temperature of the air around the machine.
tact a doctor immediately. 46-86
830057
STEP 18
b. The indication of the high pressure gauge Disconnect the hoses from the low and high pres-
is the same as in the temperature-pressure sure ports.
chart that follows .
STEP 19
Install the cap on the low and high pressure ports.
9003-12
COMPRESSOR
9003-13
Removal STEP 6
Adjust the drive belt according to instructions in
STEP 1 this section.
Discharge the air conditioning system according
to instructions in this section . STEP 7
Loosen and remove the plugs from the hoses.
STEP 2
Disconnect the hoses from the compressor. STEPS
Connect the hoses to the co mpressor.
STEP 3
Install a plug in each hose. STEP 9
Install and tighten the cap screw that holds the
STEP 4 clamp for the wire.
Disconnect the wire from the wiring harness.
STEP 10
STEP S Connect the wire to the wirin g harness.
Loosen and remove the cap screw that holds the
clamp for the wire . STEP 11
Charge the air conditio ning system according to
STEP 6 instructions in this section .
Loosen and remove the nut and lock washer from
the bolt at the top of the adjustment strap. Replacing the Coil or
Clutch Assembly
STEP 7
Remove the bolt and flat washer. NOTE: Special tools are from kit CAS-10747
shown on page 9003-3.
STEPS
Loosen and remove the nut, lock washer and flat STEP 1
washer from the bolt that holds the compressor.
STEP 9
Hold the compressor and remove the bolt and re-
move the compressor from the machine.
Installation
STEP 1
Align the compressor with the mounting bracket
and install the bolt and flat washer.
STEP 2
Install the flat washer, lock washer and nut on the
bolt.
Fasten the compressor in a vise. Loosen and re-
STEP 3 move the three cap screws ancl lock washers from
Install the drive belt on the pulley . the cover on the clutch . Remove the cover. Loosen
and remove the nut that holds the clutch plate.
STEP 4 ~
Align the adjusting strap with the compressor and
install the bolt and flat washer.
STEPS
Install the lock washer and nut on the bolt.
9003-14
STEP 2 STEPS
414308
Install the puller for the clutch plate. Remove the large snap ring.
STEP 3 STEP 6
414309 414315
Remove the clutch plate. Remove the small snap ring.
STEP 4 STEP 7
414439
Remove the shield from the bore of the pulley . Install the jaws of the puller for the pulley.
9003-15
STEP 8 STEP 11
Install the separator. Remove the separator.
STEP 9 STEP 12
414441
Install the handle. Loosen the screw that holds the c lamp for the wire .
STEP 10 STEP 13
414403
Remove the pulley . Remove the snap ring that holds the coil.
9003-16
STEP 14 STEP 17
Remove the coil. Install the snap ring that holds the coil.
STEP 15 STEP 18
414405
When you install the coil , ma ke sure that the boss Install the wire behind the clamp and tighten the
on the bottom of the coil engages the hole in the screw.
front of the compressor.
STEP 19
STEP 16
414404 Install the pulley.

Install the coil.
9003-17
STEP 20 STEP 23
414314
Assemble the two parts of the driver as shown . Install the large snap ring.
STEP 21 STEP 24
414530
Drive the pulley all the way onto the compressor. Start the shield into the pulley.
STEP 22 STEP 25
414315
Install the snap ring that holds the pulley. Drive the shield into the pulley .
9003-18
STEP 26 STEP 29
Drive the clutch plate all the way onto the shaft. If the gap is more than .032 inch (0 .81 mm) or less
than .016 inch (0.41 mm), remove the clutch plate
STEP 27 and add or remove shims as required to get the
correct gap.
STEP 30
Install the cover on the clutch.
Replacing the Seal

STEP 1
Install and tighten the nut to 300 to 360 pound-

inches (34 to 40 N m, 3.4 to 4.2 kg / m) .
STEP 28
Fasten the compressor in a vise. Remove the cover

from the clutch. Loosen and remove the nut that
holds the clutch plate.
414634
If a new clutch assemb ly has been installed check

the gap between the clutch plate and pulley.
9003-19
STEP 2 STEPS
Install the puller for the clutch plate. Use a pair of wire cutters to remove the Woodruff
key .
STEP 3
STEP 6
Remove the clutch plate .

Remove the shims for the clutch plate.
STEP 4
STEP 7
414310
Drive the bottom of the Woodruff key into the key-

way. Use a pair of snap ring pliers and remove the felt
seal.
9003-20
STEP 8 STEP 11
414539
Remove the snap ring that holds the seal seat. Install the seal tool and engage the notc hes in the
seal tool with the tabs on the seal.
STEP 9
STEP 12
414537
Remove the the seal seat. 414540
Remove the seal.

STEP 10
STEP 13
Remove the O-ring from the groove. Be careful not 414541
to make a scratch in the groove. I nstall the protector on the shaft.

9003-21
STEP 14 STEP 17
41 4501
Carefully remove the seal from the container. Install the new O-ring in the bottom groove in the
bore for the seal.
NOTE: DO NOT touch the sealing surface of the
carbon ring. Body salts and acids will damage the STEP 18
sealing surface.
STEP 15
Carefully remove the seal seat from the container.
NOTE: DO NO T touch the sealing surface of the

Install the seal on the seal tool. seal seat. Body salts and acids will damage the
sealing surface.
STEP 16
STEP 19
Lubricate the protector with refrigeration oil and 41 4504
install the seal. Lubricate the sealing surface of the seal seat with
refrigeration oil and install the seal seat.
9003-22
STEP 20 STEP 23
Install the snap ring so that the chamfer on the 10 Remove the protector.
will be on top.
STEP 24
STEP 21
1\14510
Install the Woodruff key. If pliers are used as

Install the new felt seal. shown, use a piece of metal as a protector between
the pliers and shaft to prevent damage to the shaft.
STEP 22
STEP 25
Drive the felt seal into the bore until the metal is
even with the top of the bore. Install the same shims that were removed .
9003-23
STEP 26 STEP 2
414642 414331
Drive the clutch plate all the way onto the shaft. Fasten the compresso r in a vise and loosen and
remove the cap screws that hold the end cap.
STEP 27
STEP 3
Install and tighten the nut to 300 to 360 pound-

inc hes (34 to 40 N m, 3.4 to 4.2 kg/ m). Hit the end cap to loosen the end cap.
STEP 30 STEP 4
Install the cover on the clutch .
Replacing the Valve Plate

or Gaskets
STEP 1
Remove the dirt and grease from the compressor.
Remove the end cap .

9003-24
STEP 5 STEPS
414339
Remove the gasket from the end plate. If the gaskets are being replaced , remove the other
gasket from the valve plate. Be careful not to dam-
STEP 6 age the valves.
STEP 9
Loosen the valve plate.

414343
STEP 7 Install the new gaskets on the valve plate. The

gaskets will only fit one way .
STEP 10
Remove the valve plate.
Install the valve plate.

9003-25
STEP 11 STEP 13
Fill the compressor with the same amount of NEW
refrigeration oi I.
STEP 14
Install and tighten the f iller plug.
Install and tighten every other cap screw to 264 to

300 pound-inches (30 to 34 N m, 3.0 to 3.4 kg/ m)
until all cap screws have been tightened.
STEP 12
Loosen and remove the filler plug and drain the oil
into a measuring container.
9003-26
18
840537 A
1. Nut 6. Coil 10. O-Ring 14. Gasket

2. Clutch Plate 7. Shims 11 . Seal 15. Valve Plate
3. Shield 8. Felt Seal 12. Woodruff Key 16. End Cap
4. Snap Ring 9. Seal Seat 13. Cylinder Assembly 17. Cap Screw
5. Pulley 18. Cover
9003-27
REPLACING THE AIR CONDITIONING CONTROL

STEP 1 STEPS
Remove the evaporator according to instructions Route the tube for the new air conditioning control
in this section. the same way as the original.
STEP 2 STEP 7
Loosen and remove the nut that holds the air con- Connect the w iring to the air conditioning control.
ditioning control.
STEPS
STEP 3 Install the air conditioning control in the mounting
Remove the air conditioning control from the plate.
mounting plate .
STEP 9
STEP 4 Install and tighten the nut Ulat holds the air condi-
Disconnect the wiring from the air conditioning tioning control.
control.
STEP 10
STEPS Install the evaporator according to instructions in
Completely remove the air conditioning control. this section.
EXPANSION VALVE
Removal STEPS
Disengage the vertica l cover from the frame beg i n-
STEP 1 ning at the top and remove the vertical cover.
Discharge the air conditioning system according
to instructions in this section . STEP 9
Disengage the left vertical cover beginning at the
STEP 2 top and remove the vertical cover.
Turn the temperature control to HOT.
NOTE: The front headliner MUST be removed
STEP 3 first.
Drain one U.S. gallon (4 litres) of coolant from the
radiator. STEP 10
Hold the front headliner in place and loosen and
STEP 4 remove the screws at the front of the front head-
Remove the knobs from the switches, air condi- liner and the screws on each side including the
tioning control and temperature control. screw at the junction of the front and rear headlin-
ers .
STEPS
Loosen and remove the screws that hold the con- STEP 11
trol panel. Lower the front headliner onto the control console.
STEPS STEP 12
Disengage the control panel from the vertical cov- Loosen the clamp on the front drain hoses.
er and disconnect the wiring from the cab lamp
switch. STEP 13
Remove the hoses from the drain pan .
STEP 7
Loosen and remove the screws that hold the bot-
tom of the vertical cover.
9003-28
STEP 14 STEP 3
Loosen and remove the screw from the left and Install the clamp that holds the temperature sen-
right rear sides of the rear headliner. sor.
STEP 15 STEP 4
Hold the rear headliner in place and loosen and Connect the equalizer tube to the evaporator.
remove the screws from the left and right sides of
the rear headliner. STEP 5
Connect the tube to the expansion valve .
STEP 16
Carefully lower the rear headliner behind the seat. STEP 6
Install new insulation tape around the temperature
STEP 17 sensor and outlet tube, and the expansion valve
Remove the insulation from the expansion valve, and the equalizer tube.
the connection of the equalizer tube at the outlet
tube. STEP 7
Carefully raise the rear headliner and engage the
rear headliner with the slot at the rear of the roof.
STEP 8
Hold the rear headliner in place and install a screw
in the center hole on the right and left sides of the
rear headliner.
STEP 9
Install and tighten the screw at the left and right
rear sides of the rear headliner.
STEP 10
Connect the front drain hoses to the drain pan.
STEP 11
Tighten the clamp on each hose.
STEP 12
870368
Carefully raise the front headliner and engage the
front headliner with the rear headliner.
STEP 18 STEP 13
Disconnect the tube from the equalizer valve. Install and tighten the screws at the front of the
front headliner.
STEP 19
Disconnect the equalizer tube. STEP 14
Install and tighten the screws on the right sides of
STEP 20 the front and rear headliners.
Disconnect the expansion valve from the evapora-
tor. STEP 15
I nstall the left vertical cover.
STEP 21
Remove the expansion valve. STEP 16
I nstall the right vertical cover.
Installation
STEP 17
STEP 1 Install and tighten the screws at the bottom of the
Connect the expansion valve to the evaporator. right vertical cover.
STEP 2
Apply a small amount of grease between the tem-
perature sensor and the outlet tube.
9003-29
STEP 18 STEP 1
Connect the wires to the cab lamp switch in the Use an Allen wrench and remove the adjusting
control panel and engage the control panel with screw. Make a record of the amount of turns
the right vertical cover. needed to remove the adjusting screw.
STEP 19 STEP 2
Install and tighten the screws that hold the control Remove the spring .
panel.
STEP 3
STEP 20 Remove the valve.
Install the knobs for the switches and the air condi-
tioning and temperature controls. STEP 4
Remove the three pins from the body.
STEP 21
Charge the air conditioning system according to STEPS
instructions in this section . Use a sharp tool and carefully remove the screen
from the inlet port.
Inspection
STEP 6
Clean all parts in clea n mineral spirits and dry the
parts with compressed air.
STEP 7
Inspect the parts for wear and damage.
STEP 8
Install the pins in the bores in the body .
STEP 9
Install the valve.
STEP 10
I nstall the spring so that the large end is against the
adjusting screw.
STEP 11
Install the adjusting screw the same amount of
turns required for removal.
STEP 12
Install the screen in the inlet port.
1. Body 4. Valve
2. Screen 5. Spring STEP 13
3. Pin 6. Adjusting Screw Check the operation of the expansion valve ac-
The expansion valve can be disassembled for cording to the instructions that follow.
inspection. The parts of the expansion valve are not
serviced separately. If any part is damaged , a new
expansion valve must be installed.
9003-30
Testing and Adjusting STEP 2

Connect the refrigerant container to the gauge
VYA""""'U; During the testing proce-
manifold.
dure, refrigerant is released from the hole
which is drilled in the tee . Wear safety
STEP 3
A goggles and do not let the refrigerant
come into contact with your skin or with
an open flame . Make sure that the work
Connect the gauge manifold to the expansion .
area has enough ventilation. STEP 4

48-39 Put the temperature sensor in the hot water.
Test No.1 - Checking High STEP 5

Pressure Setting Hold the refrigerant conta iner so that the valve is
down . The refrigerant MUST be sent to the expan-
sion valve as a liquid.
STEPS
Open the valve on the the refrigerant container.
STEP 7
2 Slowly open the valve for the high pressure gauge
until the pressure is 70 psi (483 kPa, 4.9 kg / cm 2).
2 STEPS
Read the low pressure gauge. The pressu re must
I be 43 to 55 psi (296 to 379 kPa, 3.0 to 3.8 kg/ cm2) .
STEP 9
2 If the pressure is not as specified , adjust the pres-
4T-~ sure setting according to the instructions under
~-~ Adjustment.
-- ~-
821032 STEP 10
1. R-12 Refrigerant Close the valve on the refrigerant container before
2. See Special Toors In This Section disconnecting the expansion valve.
3. Expansion Valve
4. Water At 125° F (52°C)
STEP 1
Close the valves in the gauge manifold .
9003-31
Test No.2 - Checking Low Pressure STEP 4

Setting Put the temperature sensor in water that has been
cooled to approximately 32° F (0° C) .
STEPS
Hold the refrigerant container so that the valve is
down. The refrigerant MUST be sent to the expan-
sion valve as a liquid.
STEPS
Open the valve on the refrigerant container.
STEP 7
2 Slowly open the valve for the high pressure gauge
until the pressure is 70 psi (483 kPa, 4.9 kg/ cm 2).
I
STEP 8
Read the low pressure gauge. The pressure must
be 19.5 to 22.5 psi (134 to 155 kPa , 1.4 to 1.6
kg/ cm 2).
STEP 9
If the pressure is not as specified, adjust the pres-
821033
1. R-12 Refrigerant sure setting according to the instructions under
2. See Special Tools In This Section Adjustment.
3. Expansion Valve
4. Water At32°F (0° C) STEP 10
Close the valve on the refrigerant container before
STEP 1 disconnecting the expansion valve .
Close the valves on the gauge manifold .
Adjustment
STEP 2
Connect the refrigerant container to the gauge STEP 1
manifold . Turn the adjusting screw in the outlet port into the
body to increase the low pressure indication.
STEP 3
Connect the gauge manifold to the expansion valve STEP 2
as shown . Turn the adjusting screw into t he outlet port out of
the body to decrease the low pressure indication.
STEP 3
Do Test No.1 and Test No. 2 again .
9003-33
STEP 1 STEP 14
Discharge the air conditioning system according Loosen and remove the screw f rom the left and
to instructions in this section . right rear sides of the rear headliner.
STEP 2 STEP1S
Turn the temperature contro l to HOT. Hold the rear headliner in place and loosen and
remove the screws from the left and right sides of
STEP 3 the rear headliner.
Drain one U.S. gallon (4 litres) of coolant from the
radiator. STEP 16
Carefully lower the rear headliner behind the seat.
STEP 4
Remove the knobs from the switches, air condi- STEP 17
tioning control and temperature control. Loosen both clamps on the hoses connected to the
heater.
STEPS
trol panel. Slide the hoses to the rear.
STEP 6 STEP 19
Disengage the control panel from the right vertical Remove the insu lation from the connections to the
cover. expansion valve and evaporator.
STEP 7 STEP 20
Loosen and remove the screws that hold the bot- Disconnect the tubes from the expansion valve and
tom of the right vertical cover. evaporator.
STEP 8 STEP 21
Disengage the vertical cover from the frame begin- Loosen the cap screws that hold the evaporator.
ning at the top and remove the vertical cover.
STEP 22
STEP 9
Disengage the left vertical cover beginning at the 1-_ _ 4 INCHES
(100 mm) - - - -..1
top and remove the vertical cover.
IMPORTANT: The front headliner must be re-

moved first.
STEP 10
remove the screws at the front of the headliner and
the screws on each side including the screw at the
junction of the front and rear headliners.
2 INCHES
STEP 11 I1"".>-----.-.I -- (50 mm) 861647
Lower the front head Iiner onto the control console .

Carefully remove the evaporator and remove the
temperature sensor and tube for the air condition-
STEP 12 ing control from the evaporator.
Loosen the clamp on the front drain hoses.
STEP 23
STEP 13 Remove any remaining insulation from the expan-
Remove the front drain hoses from the drain pan.
sion valve and the connections to the evaporator.
9003-34
STEP 24 STEP 35
Remove the clamp that holds the temperature sen- Apply new insulation tape to the connections .
sor.
STEP 36
STEP 25 Slide the hoses onto the tubes from the heater.
Disconnect the expansion valve and equalizer tube
from the evaporator. STEP 37
Tighten the clamps for both hoses.
STEP 26
Connect the expansion valve to the new evapora- STEP 38
tor. Carefu lly raise the rear headliner and engage the
rear headliner with the slot at the rear of the roof.
STEP 27
Connect the equalizer tube to the outlet tube of the STEP 39
evaporator. Hold the rear headliner in place and install a screw
in the center hole on the right and left sides of the
STEP 28 rear headliner.
Apply a small amount of grease between the tem-
perature sensor and the outlet tube. STEP 40
Install and tighten the screw at the left and right
STEP 29 rear sides of the rear headliner.
Install the clamp the holds the temperature sensor.
STEP 41
STEP 30 Connect the front drain hoses to the drain pan.
Apply new insulation tapes to the tubes at each end
of the evaporator, the inlet and outlet tubes, and the STEP 42
expansion valve and the equalizer tube. Tighten the clamp on each hose.
STEP 31 STEP 43
1-_ _ 4INCHES _ _ _ _1 Carefully raise the front headliner into position and
(100 mm) engage the front headliner with the rear headliner.
STEP 44
I nstall and tighten the screws at the front of the
front headliner.
STEP 45
Install and tighten the screws on the right and left
sides of the front and rear headliners.
STEP 46
~
• _ _"",.1.__ 2 INCHES
.- I (50 mm)
861647
I nstall the left vertical cover .
Install the temperature sensor and tube in the eva-
STEP 47
porator as shown above.
Install the right vertical cover.
STEP 32
STEP 48
I nstall the evaporator.
Install and tighten the screws at the bottom of the
right vertical cover.
STEP 33
Install and tighten the cap screws that hold the
STEP 49
evaporator.
Connect the wires to the cab lamp switch and en-
gage the control panel with the right vertical cover.
STEP 34
Connect the tubes to the expansion valve and eva-
porator.
9003-35
STEP 50 STEP 52
Install and tighten the screws that hold the control Fill the radiator to the correct level.
panel.
STEP 53
STEP 51 Charge the air conditionin g system according to
Install the knobs for the switches and the air condi- instructions in this section.
tioning and temperature controls.
CONDENSOR
COMPRESSOR
e~
~ COPPER
~~ GASKET
COPPER
GASKET
~j
"
870369
9003-36
Removal STEP 13
Remove the guard .
STEP 1
Discharge the air conditioning system according STEP 14
to instructions in this section. Disconnect the hoses from the condensor.
STEP 2 STEP1S
Have another person hold the hood in position. Install and tigten a plug in each hose.
STEP 3 STEP 16
Make an align ment mark at the top and rear of each Loosen and remove the nuts and lock washers from
pivot bracket for the hood. the bolts that hold the mounti ng brackets.
STEP 4 STEP 17
Loosen and remove the nut, lock washer, spacer, Remove the mounting brackets and the bolts .
flat washer and bolt that fasten each cable to the
radiator shroud. STEP 18
Loosen and remove all but the top cap screws that
STEPS hold the condensor.
Loosen and remove the front and rear cap screws
that hold each pivot bracket. STEP 19
Hold the condensor in place and remove the top
STEP 6 cap screws and remove the condensor.
Remove the hood from the machine.
Installation
STEP 7
Put blocks between the radiator and pump to hold STEP 1
the radiator in place with the radiator shroud or Hold the condensor in place and install the flat
mounting brackets removed. washers, lock washers and cap screws.
STEP 8 STEP 2
Loosen and remove the self-locking nut, bolt and Tighten the cap screws.
flat washer from each oil cooler mount.
STEP 3
STEP 9 Install the mounting brackets and bolts and the
Loosen and remove the cap screw and bracket at lock washers and nuts.
the top of the radiator.
STEP 4
STEP 10 Tighten the nuts.
Loosen and remove the nuts and bolts that hold the
radiator shroud. STEPS
Loosen and remove the plug from each hose.
STEP 11
Remove the radiator shroud . STEP 6
Connect the hoses to th e condensor.
STEP 12
Loosen and remove the cap screws that hold the STEP 7
guard at the bottom of the condensor. Install the guard and cap screws.
9003-37
STEP 8 STEP 19
Tighten the cap screws. Install the hood .
STEP 9 STEP 20
Install the radiator shroud . Install the cap screws that hold the pivot brackets.
STEP 10 STEP 21
Install the bolts and flat washers, and nuts that hold Align each pivot bracket with the alignment marks
the radiator shroud. and tighten the cap screws.
STEP 11 STEP 22
I nstall the bracket and cap screw at the top of the Close the hood. The top rear of the hood must be
radiator. even with the frame .
STEP 12 STEP 23
Tighten the cap screw. If the top of the hood is too high , check to see if the
sides of the hood are touch ing the frame . To cor-
STEP 13 rect this problem, move the pivot brackets forward.
Have another person push and hold the top of the
radiator shroud all the way to the rear. STEP 24
If the top of the hood is too high and the sound of
STEP 14 metal hitting metal is heard at the front of the hood,
Tighten the nuts. the radiator sh roud is not in the correct position . To
correct this problem , t he top of the radiator shroud
STEP 15 must be moved farther to the rear.
I nstall a bolt and flat washer and self-locking nut in
each oil cooler mount. STEP 25
When the hood can be closed and is in the correct
STEP 16 position, tighten the nuts on the bolts that hold the
Tighten the self-locking nuts. radiator shroud to 270 to 324 pound-feet (366 to
439 N m, 37 to 44 kg/ m).
STEP 17
Remove the blocks from below the radiator. STEP 26
Charge the air conditioning system according to
STEP 18 instructions in this section.
Make sure that the pivot brackets are all the way on
the pivots for the hood .
This Page is Blank
9010
LOADER
TABLE OF CONTENTS
Standard Bucket . . ... . . .............. .. 9010-2 Adjustment for Return-To-Dig . . .... ... . 9010-11
Replacement of Cutting Edge ....... . . 9010-2 Adjustment of Antirollback ... . . .... . . . . 9010-12
Clam Bucket . ....... .. . ..... . .......... 9010-4 Illustration of Loader Controls

Installation .. .. .. ... ... ... .. ...... . . . 9010-14
Replacement of Cutting Edge for
Clam .. . . . .. . .. . .. .. . . . . . . ......... 9010-4 Illustration of Lift Cylinder Hydraulic
Installation . .... . .. . .. .. ..... .. . .. ... 9010-15
Replacement of Cutting Edge for
Blade .... .. .. ....... .... .. ....... . . 9010-5 Illustration of Bucket Cylinder Hydraulic
Installation . . . . . . ... .. .. . .. . . .. . . .... 9010-16
Bucket Teeth . ....... . .. . ... . . . ........ 9010-6
Illustration of Front Counterweight ... .. 9010-17
Replacement of Tooth Shank ........ . 9010-6
Illustration of Rear Counterweight and
Replacement of Tooth Point . ... ... ... 9010-6 Drawbar ..... .. .. . .............. . .. . 9010-18
Loader Frame .... . .. . . .. . . ..... . .. . .... 9010-7 Illustration of Loader Clam Cylinder
Hydraulic Circuit .. . . .. . . .... .. ..... . 9010-19
Removal ..... .. . .... . . .. ...... . .... . . 9010-7
Illustration of Loader Clam Cylinder
Illustration of Loader Frame .... . ...... 9010-9 Hydraulic Circuit ... .. . . . . ... . . . . ... . 9010-20
Installation ............ . ......... . ... 9010-10
J I Case 8-67480
A Tenneco Company
9010-2
STANDARD BUCKET
Replacement of Cutting Edge STEP 6
Cut through each corne r of the bucket in the area
STEP 1 shown .
If the bucket is not removed, put the bucket at an
acceptable height and put supports under the
bucket to hold the bucket in place.
STEP 2
If the bucket is not removed, disconnect the wiring
from the alternator.
STEP 3
If there are bucket teeth on the cutting edge, use
carbon arc rod to remove the bucket teeth.
STEP 4
Use carbon arc rod or an acetylene cutting torch to
remove the cutting edge. Keep distortion to a mini-
mum amount when removing the cutting edge.
STEP 7
STEPS Use a grinder to remove any welds or extra metal
on the bucket that will prevent the new cutting edge
When removing the weld at the rear of the cutting
from fitting correctly.
edge, cut off the cutting edge according to the
dimension below.
STEP 8
Put the new cutting edge in place and use C-
clamps to hold the cutting edge in place. See illus-
tration for the correct dimension to the rear of the
cutting edge.
STEP 9
See photos on next page for welding specifica-
tions. Use E-7018 welding rod .
STEP 10
When welding the top of the bucket floor to the rear
of the cutting edge:
a. Start at one end of the bucket and weld

toward the center until one welding rod is
used .
b. Start at the center of the bucket and weld in

both directions from center until one welding
861652
rod is used .
1. 27 Inches (687 mm).
c. Start at the end of the bucket and weld
used .
d. Continue to weld the cutting edge to the

bucket using this method until the cutting edge
is completely welded .
9010-3
STEP 11 STEP 12
If bucket teet h were removed from the old cutting Connect the wiring to the alternator.
edge, install the bucket teeth on the new cutting
edge . See instructions in this section.
1. 3/ 16 Inch (5 mm) Groove 633129 1. 1/4 Inch (6 mm) Fillet 633125
2. Fill Each Corner

3. 1/ 8 Inch (3 mm) Groove
1. 3/ 16 Inch (5 mm) Fillet 633122
2. 3/4 Inch (20 mm) Groove

1. 1/4 Inch (6 mm) Fillet 633132
Weld Specifications
9010-4
CLAM BUCKET
Replacement of Cutting Edge STEP 6
for Clam Use grin der to remove any welds or extra metal on
the clam that will prevent the new cutting edge
STEP 1 from fitting correctly.
If the clam bucket is not removed, put the clam
bucket at an acceptable height and use an accep- STEP 7
table support to hold the clam bucket in place. Put the new cutting edge in place and use C-
clamps to hold the cutting edge in place.
STEP 2
If the clam bucket is not removed , disconnect the STEP 8
See page 901 0-5 for welding specifications. Use E-
wiring from the alternator.
7018 welding rod.
STEP 3
If there are bucket teeth on the cutting edge, use STEP 9
carbon arc to remove the welds that hold the When welding the top of the clam floor to the rear of
bucket teeth in place. the cutting edge:
STEP 4 a. Start at one end of the clam and weld to-

Use carbon arc rod or an acetylene torch to re- ward the center until one welding rod is used.
move the welds that hold the cutting edge in place.
Keep distortion to a minumum amount when re- b. Start at the center of the clam and weld in
moving the welds. both directions from center until one welding
rod is used.
STEP 5
Cut through each corner in the area shown. c. Start at the other end of the clam and weld
used .
d . Continue to weld the cutting edge to the

clam using this method until the cutting edge is
completely welded.
STEP 10
If bucket teeth were removed from the cutting
edge, install the bucket teeth on the new cutting
edge. See instructions in this section .
STEP 11
Connect the wiring to the alternator.
1. Cut through Each Corner Here 815491
9010-5
1. 1/4 Inch (6 mm) Fillet 815491 1. 1/4 Inch (6 mm) Fillet 815490
2. Fill Each Corner
1. 1/4 Inch (6 mm) Fillet 815488
1. 1/4 Inch (6 mm) Butt 815489 2. 1/4 Inch (6 mm) Butf

2. 1/4 Inch (6 mm) Fillet
Weld Specifications
Replacement of Cutting Edge STEPS

for Blade Use a grinder to remove any welds or extra metal
on the blade that will prevent the new cutting edge
STEP 1 from fitting correctly.
If the clam bucket is not removed , put the clam
bucket at an acceptable height and put supports STEP 6
under the crossmember in the loader frame. Put the new cutt ing edge in place on the blade and
use C-clamps to hold t he cutting edge in place .
STEP 2
If the clam bucket is not removed , disconnect the STEP 7
wiring from the alternator. Use E-7018 welding rod to weld the cutting edge to
the blade.
STEP 3
Open the clam and put a support under the clam to a. Make a 1/ 4 inch (6 mm) fillet weld at the top
hold the clam in place . of the cutting edge and blade .
STEP4 b. Make a 3/ 16 inch (5 mm) fillet weld at the

Use carbon arc rod or an acetylene cutting torch to bottom of the blade and cutting edge .
remove the welds t hat hold the cutting edge in
place. Keep distortion to a minimum amount when STEP 8
removing the cutting edge. Connect the wiring to the alternator.
9010-6
BUCKET TEETH
Replacement to Tooth Shank STEP 4
See the following illustration for weld specifica-
STEP 1 tions and instructions.
Use carbon arc rod or an acteylene cutting torch to
remove the welds that hold the tooth shank in
place.
STEP 2
Use grinder to remove any welds or extra material
that will prevent the tooth shank from fitting cor-
rectly .
STEP 3
See the following illustration for the correct loca-
tion of the tooth shank on the cutting edge .
1.-----l-----.·I~'~---2~
1. 3/8 INCH (10 mm) FILLET. WELD AROUND EACH

CORNER 3/ 8 IN CH (10 mm). WELD TWO TIMES
2. 2-1 / 2 INCHES (63 mm)
3. 3/ 8 INCH (10 mm) FILLET. WELD BOTH SIDES AND
REAR OF TOOTH SHANK . WELD TWO TIMES
4. BENT AREA OF TOOTH POINT
Replacement of Tooth Point

861656
1. 9.1 Inches (231 mm)

2. 8.9 Inches (226 mm)
STEP 1
3. Put the Tooth Shank As Close to the Corner Heat the part of the tooth point that has been
As Possible and Keep the Corner of the pressed into the hole on each side of the tooth
Tooth Point Even With the Outer Surface of shank.
the Cutting Edge
STEP 2
NOTE: These dimensions are for the 82 Inch
(2083 mm) Bucket and 4-ln-1 Bucket. Bend the tooth point out of the hole on each side of
the tooth shank .
STEP 3
Use a pair of pliers to remove the tooth point from
the tooth shank.
STEP 4
Install a new tooth point on the tooth shank .
STEPS
Heat the part of the tooth pOint that will be pressed
into the hole on each side of the tooth shank .
STEP 6
Have another person push the tooth point against
the tooth shank .
STEP 7
Use an acceptable tool and press the heated part of
the tooth pOint into the hole on each side of the
tooth shank .
9010-7
LOADER FRAME
Removal STEP 12
Hold the left lift cylinder, remove the driver and
STEP 1 lower the lift cylinder onto the front axle. Two flat
Start the engine and raise the loader frame so that washers are used between the strut and loader
pivot pins for the piston rod eyes are above the top frame; do not lose the flat washers . It is not neces-
of the hood . Stop the engine. sary to remove the strut.
STEP 2 STEP 13
Connect a lifting sling to the crossmember in the Hold the right lift cylinder, remove the driver and
loader frame and connect a chain hoist to the lift- lower the lift cylinder onto the front axle.
ing sling.
STEP 14
STEP 3 Loosen and remove the nut and flat washer that
Tighten the chain hoist to hold the loader frame in fasten the switch for return-to-dig to the mounting
place when a pivot pin is removed. slot in the loader frame. Remove the switch from
the mounting slot.
STEP 4
Move the loader control lever in both directions to STEP1S
be sure that the chain hoist is holding the loader Loosen and remove the cap screw, flat washer, and
frame. clamp that fasten the wire harness for the switch to
the loader frame .
STEPS
Remove the snap ring from the outer end of the STEP 16
pivot pin for the piston rod of the left lift cylinder. Remove the tie straps that fasten the wire harness
to the tubes and hoses.
STEP 6
Use a hammer and a driver that has a smaller di- STEP 17
ameter than the pivot pin for the piston rod eye and Put the switch and wire harness out of th e way .
drive the pivot pin out of the loader frame. Do not
remove the driver at this time. Be careful not to STEP 18
damage the seals in the piston rod eye. Move the loader control lever in both directions to
release any pressure in the bucket circuits.
STEP 7
Remove the snap ring from the outer end of the STEP 19
pivot pin for the piston rod of the right lift cylinder. Disconnect the hoses to the bucket cylinders from
the tubes forward of the pivot shaft at the left side of
STEP 8 the machine. Install a plug in each tube and a cap
Use a hammer and a driver that has a smaller diam- on each hose. Fasten an identification tag to one of
eter than the pivot pin for the piston rod eye and the hoses.
drive the pivot pin out of the loader frame. Do not
remove the driver at this time. STEP 20
Remove the cotter pin and clevis pin that fasten the
STEP 9 antirollback actuator to the rollback arm .
Disconnect the chain hoist from the lifting sling
and lower the loader frame to the floor. STEP 21
Remove the anti rollbac k actuato r from the rod on
STEP 10 the loader frame.
If equipped with a clam bucket, move the clam
control lever in both directions to release any pres- STEP 22
sure in the clam circuits. Remove the snap ring and flat washer from the
right end of the pivot shaft.
STEP 11
If equipped with a clam bucket, disconnect the STEP 23
hoses to the clam cylinders from the tubes forward Connect a lifting sling to both sides of the loader
of the pivot shaft on the right side of the machine. frame and connect a chain hoist to the lifting sling .
Install a plug in each tube and a cap on each hose.
Fasten an identification tag to one of the hoses.
9010-8
STEP 24 STEP 25
Use an acceptable driver and a hammer and drive Raise the loader frame until the loader frame is free
the pivot shaft out of the loader frame. A cone of the machine.
shaped washer is used between the frame and the
loader frame on each side of the machine. Do not STEP 26
lose the cone shaped washers . Have another per- Carefully move the machine out of the loader
son hold the pivot shaft on the other side of the frame.
machine.
9010-9
861828
Loader Fram e I nstaliation

9010-10
I nstall the clamp, cap screw, and flat washer that
STEP 1 fasten the wire harness to the loader frame.
Carefully move the machine into the loader frame.
STEP 14
STEP 2 Install new tie straps to fasten the wire harness to
Lower the loader frame into alignment with the the hoses and tubes.
bosses on the frame.
STEP 15
STEP 3 Put the loader control lever in the FLOAT position
Use a prybar and the chain hoist and align the and align the piston rod eye of the right lift cylinder
loader frame with the frame. with the loader frame.
STEP 4 STEP 16
Apply grease to the pivot shaft. Start the pivot shaft I nstall a snap ri ng on the large end of the pivot pi n.
into the loader frame. I nstall a cone shaped washer Lubricate the pivot pin with grease. Start the pivot
between the loader frame and the frame. Make sure pin into the loader frame. Hold the right lift cylinder
the large side of the cone shaped washer is against in alignment with the loader frame and push the
the frame , and drive the pivot shaft through the pivot pin all the way into the loader frame.
frame to the other side of the frame.
STEP 17
STEPS Align the piston rod eye of the left lift cylinder with
Install the other cone shaped washer on the other the loader frame.
side of the machine between the loader frame and
the frame. Make sure the large side of the cone STEP 18
shaped washer is against the frame and drive the Install a snap ring on the la rge end of the pivot pin .
pivot shaft all the way into the loader frame . Hold a flat washer between the strut and the out-
side of the loader frame and start the pivot pin into
STEP 6 the strut and loader frame.
Install the flat washer and snap ring on the end of
the pivot shaft. STEP 19
Hold the lift cylinder in alignment with the loader
STEP 7 frame and push the pivot pin into the boss on the
Disconnect the lifting sling and chain hoist. inside of the loader frame. Install a flat washer
between the strut and the inside of the loader
STEP 8 frame.
I nstall the anti roll back actuator on the rod on the
loader frame. STEP 20
Push the pivot pin all the way into the loader frame.
STEP 9
Install the clevis pin and a new cotter pin that fasten STEP 21
the anti rollback actuator to the rollback arm . Install a snap ring on the inside end of each pivot
pin for the lift cylinders.
STEP 10
Remove the plugs from the tubes to the bucket STEP 22
cylinders and the caps from the hoses and connect Lubricate the pivot shaft for the loader frame at
the hoses to the tubes. each end.
STEP 11 STEP 23
If equipped with a clam bucket, remove the plugs Lubricate the piston rod eye for each lift cylinder.
from the tubes to the clam cylinders and the caps
from the hoses and connect the hoses to the tubes. STEP 24
Operate the bucket cylinders, and clam cylinders if
STEP 12 equipped, through several complete cycles with
Install the switch for return-to-dig in the mounting the engine running at low idle to remove any air
slot in the loader frame. I nstall the flat washer and from the circuits.
nut. Do not tighten the nut at this time.
STEP 25
See Adjustment For Return-To-Dig in this section
and adjust the return-to-d ig.
9010-11
ADJUSTMENT FOR RETURN-TO-DIG

STEP 1 STEP 9
parking brake.
STEP2
Lower the loader frame and put the bucket flat on
the floor or in the correct digging position.
STEP 3
Stop the engine.
STEP 4
Clean the switch so the LED at the wire end of the
switch can be seen.
STEPS
Slowly move the switch rearward unti l the LED is
Move the inner LH bucket link all the way to the left.
no longer illuminated.
STEP 6 STEP 10
Hold the switch in position and tigh ten the nuts for
the switch .
STEP 11
Start the engine. Raise the loader frame all the way
and dump the bucket completely.
STEP 12
Increase the engine speed to full throttle.
STEP 13
Put the loader control lever in the RETURN -TO- DIG
position. The loader frame will lower to the floor
866685 and the bucket will roll back .
There must be 0.012 to 0.027 inches (0.3 to 0.7 mm)
clearance between the switch and the inner bucket STEP 14
link. Check the position of the bucket on the floor.
STEP 7 STEP1S
Turn the key switch to the ON position. If the bucket is not in the correct position , do steps
16 through 19.
STEP 8
Loosen the nuts for the switch, and move the STEP 16
switch all the way forward in the mounting slot. Loosen the nuts for the switch.
STEP 17
Move the switch rearward if the bucket did not roll
back far enoug h.
STEP 18
Move the switch forward if the bucket rolled back
too far.
STEP 19
Repeat steps 11 through 18 until the bucket returns
to the correct position .
9010-12
ADJUSTMENT OF ANTI ROLLBACK
CONNECTED TO RH
INNER BUCKET LINK
r/
5-5/ 8 INCHES
(143 mm)
~~ ....... ~
OFFSET YOKE - - -
- - - - ROLLBACK ARM
861909
9010-13
STEP 1 STEPS
Check to see that the offset yoke and rollback rod Raise the loader frame all the way.
are adjusted to a length of 5-5/8 inches (143 mm)
from the center of the bent end of the rollback rod STEP 6
to the center of the clevis pin in the offset yoke. Look at a side cutting edge of the bucket.
STEP 2 STEP 7
Raise the loader fram e until the pivot pin for the The side cutting edge must be approximately level.
bucket is 32-1 / 2 to 33-1 / 2 inches (825 to 850 mm)
from the floor. STEP 8
If the side cutting edge is not in the specified posi-
STEP 3 tion, shorten the length between the offset yoke
Roll the bucket all the way back . and rollback rod to increase the amount of roll-
back. I ncrease the length between the yoke and the
STEP 4 rollback rod to decrease the amount of rollback.
Check to see that the rollback rod, rollback arm,
and block are engaged complete ly without any free
travel in the pivot joints. Adjust the length of the
offset yoke and roll back rod as required.
9010-14
CLAM SPOOL
BUCKET
SPOOL
870102
Loader Contro Is I nstaliation

9010-17
NOTE: The weight of the front counterweight is approximately 900 pounds

(409 kg). Use acceptable lifting equipment to remove and install the front
counterweight.
Front Counterweight
9010-18
861864
NOTE: The weight of each counterweight is 1425 pounds (646 kg). Use
acceptable lifting equipment to remove and install the counterweights.
Rear Counterweight and Drawbar

9010- 19
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
\
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\
870241
\
Loader Clam cylinder Hydraulic Ci rcuit

9010-20
870248
.
Loader Clam Cyllnde · cui!
r Hydraulic C Ir
9033
THREE POINT HITCH
TABLE OF CONTENTS
Removal .. . . . . .. . ..... .. ... .... ........ 9033-2 Three Point Hitch Hydraulic
Installation . . ...... ..... .... . ......... 9033-5
Installation . . . ... .... . . . . .. . . . .. . .. .... . 9033-2
Three Point Hitch Closure
Illustration of Three Point Hitch Installation . ....... .. .. . ... .. .. ... . . . . 9033-6
Installation . . ... ........ . . ...... ..... . 9033-4
Three Point Hitch Controls . ... . ... . .. .. . 9033-7
J I Case Bur 8-£7491
A T enneco Company
9033-2
Removal STEP 15
Loosen and remove the nuts, lock washers, flai
STEP 1 washers, and bolts that fasten the cover to bot I'
Park the machine on a level surface and apply the fenders and the floor plate .
parking brake.
STEP 16
STEP 2 Loosen and remove the nuts , flat washers, and
Lower the loader bucket to the floor and stop the bolts that fasten the three point hitch to the frame.
engine.
STEP 17
STEP 3 Remove the three point hitch from the machine.
Move the control levers for the three pOint hitch
control valve. in bOlh directions, to relieve any NOTE: Machine must be equipped with three
pressure in the circuits. point hitch, backhoe, or rear counterweight before
the machine is operated.
STEP 4
Loosen and remove the nuts , lock wash ers. flat Installation
washers, and bolts that fasten the rear Gover for the
three point hitch cont rol valve. STEP 1
Use acceptable lifting equ ipment to install the
STEPS three point hitch against the rear of the frame, and
Remove the cover. align the holes in the three point hitch with the
holes in the frame.
STEP 6
Disconnect the inlet hose from the three point hitch STEP2
control valve. Install the bolts. flat washers, and nuts that fasten
the three point hitch to the frame. Tighten the nuts.
STEP 7
Install a plug in the hose and a cap on the fitting . STEP3
Install the bolts , flat washers, lock washers, and
STEP 8 nuts that fasten the cover to both fenders and the
Disconnect the outlet hose from the three point floor plate. Tighten the nuts.
hitch control valve.
STEP 4
STEP 9 Install the rear wheels on the machine . Install and
Install a plug in the hose and a cap on the fitting. lighten the wheel bolts.
STEP 10 STEPS
Connect acceptable lifting equipment to the top Rai se the rear of the machine .
crossmember of the three point hitch frame.
STEP 6
STEP 11 Remove the support stands from under the rear
Use an acceptable jack to raise the rear of the axle and from under each side of the frame.
machine until the rear wheels are approximately
two inches (50 mm) above the floor. STEP 7
Lower the rear of the machine until the rear ti res are
STEP 12 on the floor.
Put support stands under the rea r axle and under
each side of the frame to support the machine. STEP8
Disconnect the lifting equipment from the three
STEP 13 point hitch.
Loosen and remove the bolts that hold the rear
wheels In place . STEP9
Remove the plug from the hose and the cap from
STEP 14 the fitting, and connect the outlet hose to the three
Remove the rear wheels from the machine. point hitch control valve .
9033-3
STEP 10 STEP 14
Remove the plug from the hose and the cap from Check the level of the reservoir and add o il as
the fitting , and connect the inlet hose to the three required .
point hitch control valve .
STEP 15
STEP 11 Instalilhe rear cover for the three point hitch con-
Start the engine and run the engine at low idle. Irol valve.
STEP 12 STEP 16
Slowly operate each cylinde r th rough several cy- Install the bolts, flal washe rs, lock washers, and
cles to remove any air from the circuits. nuts. Tighten the nuts.
STEP 13
Stop the engine and check for oil leaks.
9033-4
A'
PITCH CY!.IN[)ER
,,
,,,
I
,,
TILT
CYLINDER
..,""
Three Point Hitch Insta llation

9033-5
Three Point Hitch H ydraul ic Installation

9033-6
CLOSURE INSTALLATION FOR

CAB MACHINE WITH THREE
POINT HITCH --
1
.....
...
... .... •
.•,
""'/ ,,
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- -
CLOSUR E INSTALL.ATlON FOR
ROPS MACHINE WITH THREE
POINT HITCH
Three Poi nt Hitc h Closure Insta llatio n

9033-7
Three Point H itch Controls

This Page is Blank
9061
ROPS CAB AND ROPS CANOPY
TABLE OF CONTENTS
Torque Specifications . . .......... ........... 9061-2 RQPS Canopy .. .. 9061-9
Possible Damage 10 RQPS Cab or Removal _ ................... ••• ..... 9061-9

ROPS Canopy .... .......... . .... ... .... . . 9061-2
Installation . . . ................ .. .. . ........ 9061 -10
M aintenance and Inspection of ROPS
Cab or ROPS Canopy .... . .. . 9061 -2 Replacing the Heater . .... ..... .. .... 9061 -11
Illustration of POD Installation . ......... . 9061-3 Replacing the Temperature Control ...... 9061-13
RQPS Cab with Backhoe .......... . . .. ... .. 9061-5
Removal ..... .................. 9061-5
Ins tallation ........ ... ... .... . .. ... ......... 90e1-7
A Tenneco Compa ny
9061-2
Nut for front support of ROPS cab and canopy ............................ . ........ 50 to 55 pound·feet
(68 to 74 N m, 7.0 to 7.6 kg/ m)
Cap screws for rear support of ROPS cab and canopy........... .. . ............. 600 to 720 pound-feet
(813 to 976 N m, 83 to 99 kgl m)
Nut for steering wheel .... . . . . .•........•. • ... , • . . .•. • .......... • ............ .. ... 32 to 37 pound-feet
(43 to 50 N m, 4.4 to 5.0 kg/ m)
Bolt for rear POD mount .... , . . , ...... . .•. • ..... .. .•. •.. . .... . •. .. ............ . 220 to 264 pound-feet
(298 to 358 N m, 31 to 36 kg /m )
Bolt for front center POD mount ................................... . .......... . . ... 50 to 55 pound-feet
(68 to 74 N m, 7.0 to 7.6 kg / m)
POSSIBLE DAMAGE TO THE ROPS CAB OR ROPS CANOPY

If the machine has rolled over or the ROPS cab seat belt, and all accessories, wiring etc ., in th e
or ROPS canopy has been in some type of accident ROPS cab or ROPS canopy. Before operating the
(such as hitt ing an overhead object during trans- machine again , all damaged parts must be re-
port), you must replace the ROPS cab or ROPS placed .
canopy to get as much protection as you had origi-
nally. Do not weld or try to straighten a ROPS cab or
ROPS canopy.
After an accident, check for damage to the
ROPS cab or ROPS canopy, the operators seat, the
MAINTENANCE AND INSPECTION OF THE ROPS CAB

OR ROPS CANOPY
After every 500 ho urs of operation or every six Do not install attachments that will make
months, whichever comes first, do the following: the total weight 01 the machine more than
h.the weight shown in the maximum gross
STEP 1 . . vehicle weight section of the ROPS serial
See il lustration on page 9061-3. Check the torque number plate. 41)~
on the ROPS cab or ROPS canopy mounting bolts.
If necessary, tighten the cap sc rews and nuts to the
correct torque. Do not change the ROPS in any way.
Changes made to the RQPS which are not
STEP 2 authorized, such 8S welding, drilling, or
See illustration on page 9061-4. Check the opera- h.cutting will make the ROPS weaker and
tors seat and the mounting parts for the seat belt. . . decrease your protection. Replace the
Make sure that all nuts and c ap screws are tight. RQPS if it becomes damaged in any way.
Replace parts that are worn or damaged . DO NOT TRY TO MAKE REPAIRS TO THE
RQPS. 4! 2~
Grade 8 hardware is used to mount and

h
anchor the ROPS Parts used for replace-
~ ment must be those shown In parts ca -
ta/og. 4 ' N~
9061. 3
TIGHTEN TO 600 TO 7'20 POUND-fEEl

(81.3 TO 976 Nn'I, 83 TO 99 ",g/m)
~
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liGHTEN 10 SO 10 s5 POUND-fEET
\ ~68TO 14 N"" 7 .0 'TO 7 ,4 kg'''')
\
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liGHTEN TO 50,.0 55 POUND-fEET
(68 TO 74 Nm, 7 .0 'TO 7 ," ",glm)
liGHTEN TO 120 TO 264 POUND-fEEl - - . . :

(29 358 Nm, 30 TO 36 ",gI"')
610 T orque specificatiOns tor ROPS , Cab , ROPS CanopY and FlOor
ROPS Canopy ShOwn , Mounting tor ROPS Cab is Ihe Same
9061-4
, : /3
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i -2
<;>
. . - ". !'.
. 1103&3
1. Tighten /080 to 96 Pound-Feet 3. Tighten to 54 to 64 Pound-Feet

( 109 to 130 Nm, 11 to 13 kg/ my (73 to 87 Nm, 8 to 9 kg/ m)
2. Tighten to 204 10357 Pound-Inches
(23 to 28 Nm, 2.5 to 3.0 kg l m)
Seat and Seat Belt Installation

9061-5
ROPS CAB WITH BACKHOE

Removal STEP 15
Rotate the turn signal lever to disengage the turn
STEP 1 signal lever and remove the turn signal lever.
If the machine has an air conditioner, discharge the
air conditioning system according to instructions STEP 16
in Section 9003. Use a screwdriver at the bottom corners of the
cover for the steering column and disengage the
STEP 2 cover from the control console.
Turn the temperature control to HOT.
STEP 17
STEP 3 Remove the cover.
Drain two U.S. gallons (8Iitres) of coo lant from the
radiator. STEP 18
Loosen and remove the six cap screws that hold the
STEP 4 control console.
If the machine does not have a horn, use a screwd-
river and carefully remove the cover from the cen- STEP 19
ter of the steering wheel. Move the control console out of the way and loos-
en and remove the cap screws that fasten the front
STEPS of the RaPS cab to the frame.
If the machine has a horn, do steps 6 through 10.
.STEP 20
STEP 6 ·Loosen and remove the cap screws that hold the
Remove the rubber cover at the center of t he steer- seat support. Do not let the seat fall.
ing wheel.
STEP 21
STEP7 Remove the seat from the RaPS cab.
Push down and turn the horn button counter-
clockwise approximately 1/4 turn and remove the STEP 22
horn button. Loosen and remove the self-locking nut and shoul-
der bolt that fastens the cable to the top of the left
STEP8 door.
Remove the top and bottom conductors and spring.
STEP 23
STEP9 Loosen and remove the self-locking nut that fas-
Loosen and remove the screws that hold the plate. tens the door cylinder to the door.
STEP 10 STEP 24
Disengage the wire from the plate and remove the Open the door all the way.
plate .
STEP 25
STEP 11 Disengage the left vertical cover from the frame
Loosen and remove the nut that holds the steering beginning at the top and remove the cover.
wheel.
STEP 26
STEP 12 Loosen and remove the screws that hold the bot-
Use a steering wheel puller to remove the steering tom cover.
wheel and be careful not to cut the wire if equipped
with a horn. STEP 27
Remove the bottom cover.
STEP 13
Loosen and remove the direction control lever. STEP 28
Loosen and remove the screws that hold the in-
STEP14 strument cluster.
Loosen the Allen head screws that hold the turn
signal lever. STEP 29
Disconnect the wiring harness from the instrument
cluster.
9061-6
STEP 30 STEP 44
Loosen and remove the nut that holds the key Loosen and remove the five cap screws that hold
switch and remove the key switch from the switch the support for the instrument console. Do not lose
panel. the ground wire installed with the top cap screw.
STEP 31 STEP 45
Disconnect the wiring from the cold start switch, if Move the support out of the way.
equipped .
STEP 46
STEP 32 Loosen the clamp on each heater hose.
Loosen and remove the screws that hold the rear
switch panel in the instrument console. STEP 47
Remove the hose from each tube.
STEP 33
Disconnect the wiring from the switches one at a STEP 48
time and fasten an identification to each wire for If equipped with air conditioning , disconnect the
correct connections during installation . hoses from the tubes to the evaporator.
STEP 34 STEP 49
Loosen and remove the screws that hold the bot- Install a plug in each hose and a cap on each tube.
tom vertical cover.
STEP 50
STEP 35 Loosen and remove the nut, lock washer and bolt
Remove the bottom vertical cover. that holds the clamp for the heater hoses.
STEP 36 STEP 51
Loosen and remove the nuts, lock washers and flat If equipped with a warning buzzer, loosen and re-
washers from the bolts that hold the instrument move the cap screws that hold the mounting plate
console. for the warning buzzer.
STEP 37 STEP 52
Remove the bolts that hold the instrument console. Disconnect the ROPS cab wiring harness from the
main wiring harness.
STEP 38
Use a soft hammer and drive the knob off the throt- STEP 53
tle lever. Remove the floor mat.
STEP 39 STEP 54
Apply the parking brake and move the throttle lever Loosen and remove the cap screw that fasten the
all the way forward. ROPS cab to the floor.
STEP 40 STEP 55
Carefully remove the instrument console . Loosen and remove the cap screws at the outside
rear bottom of the ROPS cab.
STEP 41
Loosen and remove the nut, lock washer, flat STEP 56
washer and spacer from the bolt that holds the Remove the rubber plugs from the top of the roof.
throttle cable.
STEP 57
STEP 42 Loosen and remove the cap screws and retainers .
Remove the bolt and flat washer from the throttle
lever. STEP 58
Install a lifting eye in the hole for cap screws.
STEP 43
Loosen and remove the nuts, lock washers, clamps STEP 59
and bolts that hold the tube for the throttle cable. Fasten acceptable lifting equipment to the lifting
eyes.
9061-7
STEP 60 STEP 12
Loosen and remove the nuts, hardened washers Install the retainers and cap screws that hold the
and bolts that hold the front supports for the ROPS roof and tighten the cap screws.
cab.
STEP 13
STEP 61 I nstali the rubber plugs.
Loosen and remove the cap screws and hardened
washers that hold the side supports for the ROPS STEP 14
cab . If equipped with a warning buzzer, install and
tighten the cap screws that hold the mounting plate
STEP 62 for the warning buzzer.
Carefully raise the ROPS cab and remove the
ROPS cab from the Machine. STEP 15
Install the bolt , lock washer and nut that holds the
Installation clamp for the heater hoses and tighten the nut.
STEP 1 STEP 16
Fasten the lifting equipment to the ROPS cab us- If equipped with air conditioning, loosen and re-
ing the same method as for removal. move the cap from each tube and the plug from
each hose.
STEP 2
Carefully lower the ROPS cab onto the machine. STEP 17
Connect the hoses to the tubes .
STEP 3
Align the mounting holes in the ROPS cab with the STEP 18
floor and the frame . I nstall the heater hoses onto the tubes and tighten
the clamps.
STEP 4
Install the cap screws lock washers and flat wash- STEP 19
ers that fasten the ROPS cab to the floor and the Put the support for the instrument console in place
frame including cap screws at the outer rear. and install and tighten the cap screws that hold the
support. When installing the top cap screw make
STEPS sure that the ground wire for the key switch is
Install the bolts, and hardened washers and nuts installed with the cap screw.
that hold the front support for the ROPS cab.
STEP 20
STEP 6 I nstall the clamps , bolts, lock washers and nuts that
Install the cap screws and hardened washers that hold the tube for the throttle cable. T ighten the
hold the side supports for the ROPS cab. nuts.
STEP 7 STEP 21
Tighten the cap screws that fasten the ROPS cab to I nstall the bolt and flat washer for the throttle cable
the floor and frame. in the th rottle lever.
STEP 8 STEP 22
Tighten the nuts at the front supports to 50 to 55 Install the spacer, throttle cable , flat wash er, lock
pound-feet (68 to 74 N m, 7.0 to 7.6 kg/m). washer and nut on the bolt and tighten the nut.
STEP 9 STEP 23
Tighten the cap screws that hold the side supports Apply the parking brake and move the throttle lever
to 600 to 720 pound-feet (813 to 976 N m, 83 to 99 forward for installation of the control console.
kg / m) .
STEP 24
STEP 10 Carefully install the control console.
Remove the lifting equipment from the lifting eyes .
STEP 25
STEP 11 Use the soft hammer and drive the knob onto the
Loosen and remove the lifting eyes. throttle lever.
9061-8
STEP 26 STEP 42
I nstall the bolts that hold the control console. Install and tighten the self-locking nut that holds
the piston rod.
STEP 27
Install the flat washers, lock washers and nuts on STEP 43
the bolts and tighten the nuts. I nstall the shoulder bolt and cable, and the self-
locking nut at the top of the door.
STEP 28
I nstall the bottom vertical cover. STEP 44
Tighten the self-locking nut.
STEP 29
I nstall and tighten the screws that hold the bottom STEP 45
vertical cover. I nstall the floor mat.
STEP 30 STEP 46
Connect the wiring to the switches in the rear I nstall the seat.
switch panel.
STEP 47
STEP 31 Install the cap screws and lock washers that ho ld
Install the rear switch panel. the seat and tighten the cap screws .
STEP 32 STEP 48
Install and tighten the screws that hold the rear Align the control console with the frame and install
switch panel. and tighten the six cap screws that hold the control
console .
STEP 33
Connect the wiring to the cold start switch, if STEP 49
equipped . Install the cover for the steering column and en-
gage the cover with the control console.
STEP 34
Install the ground wire on the key switch. STEP 50
Engage the turn signal lever with the Allen head
STEP 35 screws and tighten the Allen head screws .
Install the key switch in the switch panel and install
and tighten the nut that holds the key switch. STEP 51
Install and tighten the direction control lever.
STEP 36
Connect the wiring harness to the instrument clus- STEP 52
ter. Install the steering wheel with a spoke at the bot-
tom.
STEP 37
I nstall the instrument cluster in the control console STEP 53
and install and tighten the screws that hold the Install the nut that holds the steering wheel and
instrument cluster. tighten the nut to 32 to 37 pound-feet (43 to 50 N m,
4.4 to 5.0 kg/m) .
STEP 38
Engage the bottom cover with the support for the STEP 54
door cylinder and install the bottom cover. If the machine has a horn , do steps 55 through 59 .
STEP 39 STEP 55
Install and tighten the screws that hold the bottom Engage the horn wire with the plate.
cover.
STEP 56
STEP 40 Align the plate with the steering wheel and install
Engage the piston rod of the door cylinder with the and tighten the screws that hold the plate.
suppo rt.
STEP 57
STEP 41 I nstall the bottom conductor, spring and top con-
Engine the piston rod of the door cylinder with the ductor.
support.
9061-9
STEP 58 STEP 60
To install the horn button , push down and turn the If the machine has air conditioning , charge the air
horn button clockwise to engage the horn button conditioning system according to instructions in
with the plate . Section 9003.
STEP 59
Install the rubber cover.
ROPS CANOPY
Removal STEP 12
Use a soft hammer and drive the knob off the throt-
STEP 1 tle lever.
seat support. Do not let the seal fall. STEP 13
Apply the parking brake and move the throttle lever
STEP 2 all the way forward.
Remove the seat.
STEP 14
STEP 3 Carefully remove the instrument console.
Loosen and remove the nuts, lock washers, bolts
and bracket that holds the left fender. STEP 15
Loosen and remove the nut, lock washer, flat
STEP 4 washer and spacer from the bolt that holds the
Loosen and remove the screws that hold the in- throttle cable.
strument cluster.
STEP 16
STEP 5 Remove the bolt and flat washer from the throttle
Discon nect the wi ri ng harness from the instrument lever.
cluster.
STEP 17
STEP 6 Loosen and remove the nuts, lock washers, clamps
Loosen and remove the nut that holds the key and bolts that the tube for the throttle cable.
switch and remove the key switch from the switch
panel. STEP 18
Loosen and remove the five cap screws that hold
STEP 7 the support for the instrument console. Do not lose
Disconnect the wiring from the cold start switch, if the ground wire installed with the top cap screw.
equipped.
STEP 19
STEP 8 Move the support out of the way.
Loosen and remove the screws that hold the rear
switch panel in the instrument console. STEP 20
If equipped with a warning buzzer, disconnect the
STEP 9 wiring from the main wiring harness. Fasten an
Disconnect the wiring from the switches one at a identification to the wiring for correct connections
time and fasten an identification tag to each wire during installation .
for correct connections during installation.
STEP 21
STEP 10 Disconnect the wiring harness for the ROPS cano-
Loosen and remove the nuts, lock washers and flat py from the main wiring harness.
washer from the bolts that hold the instrument
console . STEP 22
Loosen and remove the nuts, lock washers, bolts
STEP 11 and bracket that holds the right fender.
Remove the bolts that hold the instrument conso le.
9061-10
STEP 23 STEP 11
Fasten acceptable lifting equipment to the RapS If equipped with a warning buzzer, connect the
canopy. wiring to the main wiring harness.
STEP 24 STEP 12
Loosen and remove the nuts, hardened washers Put the support for the instrument console in place.
and bolts that hold the front supports forthe RapS
canopy. STEP 13
Install the cap screws that hold the support making
STEP 25 sure that the ground wire for the key switch is
Loosen and remove the cap screws and hardened installed with the top cap screw. Tighten the cap
washers that hold the side supports for the RapS screws.
canopy .
STEP 14
STEP 26 Install the clamps, bolts , lock washers and nuts that
Carefully raise the RapS canopy and remove the hold the tube for throttle cable. Tighten the nuts.
RapS canopy from the machine.
STEP 15
Installation I nstall the bolt and flat washer in the throttle lever.
STEP 1 STEP 16
Fasten the lifting equipment to the RapS canopy. Install the spacer, throttle cable, flat washer, lock
washer and nut on the bolt and tighten the nut.
STEP 2
Carefully lower the RapS canopy onto the ma- STEP 17
chine. Apply the parking brake and move the throttle lever
forward for installation of the control console .
STEP 3
Align the holes in the supports with the floor. STEP 18
Carefully install the control console.
STEP 4
Install the bolts, and hardened washers and nuts STEP 19
that hold the front supports. Use the soft hammer and drive the knob onto the
throttle lever.
STEPS
Install the cap screws and hardened washers that STEP 20
hold the side supports. Install the bolts that hold the instrument console.
STEP 6 STEP 21
Tighten the nuts at the front supports to 50 to 55 Connect the wiring to the switches in the rear
pound-feet (68 to 74 N m, 7.0 to 7.6 kg/m). switch panel.
STEP 7 STEP 22
Tighten the cap screws that hold the side supports Connect the wiring to the switches in the rear
to 600 to 720 pound-feet (813 to 976 N m, 83 to 99 switch panel.
kg/m).
STEP 23
STEP 8 Install the rear switch panel.
Remove the lifting equipment.
STEP 24
STEP 9 Install and tighten the screws that hold the rear
Install the bracket, bolts, lock washers and nuts switch panel.
that hold the right fender and tighten the nuts.
STEP 25
STEP 10 Connect the wiring to the cold start button, if
Connect the wiring harness for the RapS canopy equipped.
to the main wiring harness.
STEP 26
Install the ground wire on the key switch .
9061-11
STEP 27 STEP 30
Install the key switch in the switch panel and install Install the bracket , bolts , lock washers and nuts
and tighten the nut that holds the key switch . that hold the left fender and tighten the nuts.
STEP 28 STEP 31
Connect thewiring harness to the Instrument clus- Install the seat.
ter.
STEP 32
STEP 29 Install and tighten the cap screws thaI hold the
Install the instrument cluster In the instrument seat.
console and install and tighten the screws that hold
the instrument cluster.
REPLACING THE HEATER

STEP 1 STEP 10
Turn the temperature control to HOT. Lower the front headliner onto the control console.
STEP2 STEP 11
Drain one U.S. gallon (4 litres) of coolant from the Loosen the clamp on each front drain hose.
radiator.
STEP 12
STEP3 " equipped with air conditioning , remove the drain
Remove the knobs from the switches, ai r condi- hoses from the drain pan .
t ioning control and temperature control.
STEP 13
STEP 4 Loosen and remove the screw from the left and
Loosen and remove the screws that hold the con- right rear sides of the rear headliner.
trol panel.
STEP 14
STEP 5 Hold the headliner in place and loosen and remove
Disengage the control panel from the vertica l cov- the screws from the left and right sides of the rear
er and disconnect the wires from the cab lamp headliner.
switch .
STEP 15
STEP6 Carefully lower the rear headliner behind the seat.
Loosen and remove the screws that hol d the bot-
tom of the cover. STEP 16
Disconnect the yellow wire from the wiring harness.
STEP 7
Disengage the vertical cover from the frame begin- STEP 17
ning at the top and remove the cover. Loosen the five cap screws that fasten the blower
mount to the frame.
STEP 8
Disengage the vertical left cover from the frame STEP 18
beginning at the top and remove the cover. Hold the blower assembly in place and remove the
cap screws.
IMPORTANT: The front headliner MUST be re-
moved first. STEP 19
Remove the blower assembly.
STEP 9
remove the screws at the front and on each side
including the screws at the junction of the front and
rear head liners.
9061 -12
BAFFLE
....
.",
- '- ,,
,- ,
-,
,
Heater Installation
9061-13
ST EP 20 STEP 10
Loosen both clamps on the hoses connected to the Install and tighten the screw at the left and right
heater. rear sides of the rear head liner.
STEP 21 STEP 11
Slide the hoses to the rear. Connect the f ront drain hoses to the drain pan.
STEP 22 STEP 12
Hold the heater and loosen and remove the cap Tighte n the clamp on each hose.
screws that hold the heater.
STEP 13
STEP 23 Ca refully raise the front headliner into position and
Remove the heater. engage the f ront headliner with the rear head-liner.
Install and t ighten the screws at the front of the
STEP 1 front headliner.
Hold the heater in place and install the cap screws
that hold the heater. STEP 15
Insta ll and tig hten the screws on the lett and right
STEP 2 sides of the front and rear headliners.
Tighten the cap screws.
STEP 16
STEP 3 Install the left vertical cover.
Slide the hoses onto the tubes from the heater.
STEP 17
STEP 4 I nstall the right vertical cover.
T ighten the clamps for both hoses.
STEP 18
STEP 5 Install and tighten the screws at the bottom of the
Hold the blower assembly and install the cap rig ht vertical cover.
screws that hold the blower mount.
STEP 19
STEP 6 Connect the wires to the cab lamp switch and en -
Tighten the cap screws. gage the control panel with the right cover.
STEP7 STEP 20
Connect the yellow wire to the wiring harness. Install and tighten the screws that hold the control
panel.
STEP 8
Carefu lly raise the rear headliner and engage the STEP 21
rear headl ine r with the slot at the rear of the roof. Install the knobs for the switches, air conditioning
control and tem perature cont rol.
STEP 9
Hold the rear head li ner in place and install a sc rew STEP 22
into the center hole on the right and left sides of the Fill the radiator to the correct level.
rear headliner.
9061-14
REPLACING THE TEMPERATURE CONTROL
_ CONTRO L PANEL
SWITCH MOUNT
,.
\,;.- %- HEAT ER HOS E
:':::>}-<::"i CLAMP
TEMPERATURECO'NTROL--~~~-2~;~~~~!>:l~
HEATER H05E ---\-';
.;
"0lliS
STEP 1 STEP 6
Turn the temperature control to HOT. Loosen and remove the screws at th e bottom of the
vertical cover.
STEP 2
Drain one U.S. gallon (4Iitres) of coolant from the STEP 7
radiator. Disengage the vertical cover from the frame begin-
ning at the top and remove the vertical cover.
STEP 3
Remove the knobs from the switches and the air STEPS
conditioning and temperature controls . Loosen and remove the screws that hold the mount
for the switches and put the mount out of the way.
STEP 4
trol panel. Loosen both clamps on the top hose.
STEPS STEP 10
Disengage the control panel from the vertical cov- Slide the hose upward until free of the temperature
er and disconnect the wires from the cab lamp control.
switch .
STEP 11
Loosen the top clamp on the bottom hose.
9061 -15
STEP 12 STEP 18
Remove the temperature control from the bottom Engage the vertical cover with the notches in the
hose. frame.
STEP 13 STEP 19
Push the temperature control into the bottom hose Install and tighten the screws al the bottom of the
and check to make sure that the temperature con - vertical cover.
trol is aligned with the mount for the switches.
STEP 20
STEP 14 Connect the wires to the cab lamp switch and en-
Tighten the top clamp on the bottom hose. gage the cont rol panel with the vertical cover.
STEP 15 STEP 21
Slide the top hose onto the temperature control. Install and tighten the screws that hold the control
panel.
STEP 16
T ighten both clamps on the top hose. STEP 22
Insta ll the knobs.
STEP 17
Al ign the mount forlhe switches with the fra me and STEP 23
install and tighten the screws. Fi ll the rad iator 10 the correct level.
This Page is Blank
9064
SEAT AND SEAT BELT S
TABLE OF CONTENT S
illustration of Standard Seat and Seat Belt Install ation ...... .. . ........•.•........ • .•.......... 9064-2
Illustration of Seal Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . •.• . . . . . . . . . . . . . . . . . .. . . .. .. 9064-3
Illustration of Standard Seat Assembly ............. . . . . ......... • ....... . ... . . . ..... .. ..• ...... 9064-4
http://www.ioffer.com/sellingluserfriendlycds
J I Case 8·675 10
A Tenneco Company
9064-2
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1. Tighten 10 80 to 96 Pound-Feet (10910130 N m. 111013 kg/ m)

2. Tighten to 5410 64 Pound-Feet (73 to 87 N m, 7.5 10 9.0 kg/ m)
3. Tighten to 17 to 21 Pound-Feel (23 10 28 N 01, 2.5 to 3.0 kg/ my
Standard Seal and Seat Belt Insta llation

9064-3
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'- I ~ ~
SEAT SLID e
~
~, ~
SLIDE TUBES
<"
, ~..!-,-:
~~
~ l _-- -¥ SLIDE "ELEASE HANDLE
~Ch __ SWIVEL LEVER
AWARNING
\~
HEIGHT ADJUSTER HANDLE
RISER
/~
CLAMP
\
SLIDE TUBE BELLOWS
I -SHAFT
/j0C2./-
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-
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Seat Support
9064-4
RETAINER
CLIP / '
~ ~~
SEAT
BACKREST
SEAT CU!;HIC)N
SEAT SHELL
Standard Seat Assembly

9065
SUSPENSION SEAT
TABLE OF CONTENTS
Suspension Seat ... . .... 9065-2 Illustration ......• _.•.•.. . ....•.... . . 9065-11
Disassembly ..... . • • . . • .•. . . ........ 9065-2 Illust ration ......... . . • .•.. . .... . .... 9065-12
Illustration .............•. • . • ......... 9065-6 Il lustration ..... . ....• • . • .• . . . ...... . 9065-13
Assembly . ... .. .... ... . . . . . . .. .. . . .. . 9065-7
http://www.ioffer.comlselling/userfriendlycds
http://stores.ebay.comlUserFriendlyC Os
J I Case 8-67520
A 1ermeco Comni1ny
9065-2
SUSPENSION SEAT
Disassembly STEP 4
STEP 1
/
Remove the fasteners that fasten the boot to the
Use a prybar and rem ove the cover.
STEP 5
881006
seat slide.
STEP 2
Raise the boot and rem ove the retainer rings for the
shaft that fastens the seat to the arm .
M'~
Use a hammer and punch and drive the pin out of STEP 6
the knob and the adjuster rod .
STEP 3
Remove the shaft.
Remove the knob.

9065-3
STEP 7 STEP 10
Loosen and remove the cap screws thai fasten the Remove the retainer ring and mounting pin that
seat to the housing. fasten the shoc k absorber to the housing . Remove
the shock abso rber.
STEP 8
STEP 11
Remove the seat.

Loosen and remove the self-locking nut from the
STEP 9 bottom of the adjuster rod .
~
- STEP 12
~-
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Remove the retainer ring and mounting pin that
fasten the piston rod eye o f the shock absorber to .....,
the arm . Remove the adjuster springs from the housing and
sp ring bracket.
9065-4
STEP 13 STEP 17
The adjuster rod is threaded into the bottom of the Remove the adjuster assembly.
spring bracket. Install the punch th rough the hole
in the adjuster rod and turn the adjuster rod out of STEP 18
the spring bracket.
STEP 14
Remove the spri ng bracket .
STEP 15
Loosen and remove the cap screws that laslen the

seat base to the seal support assembly .
_.
Disconnect the springs for the seat tilt handle from
STEP 19
the adjuster assembly .
STEP 16
Remove the cotter pins from the pivot pins that
fasten the adjuster assembly to the seat base. Re-
move the pivot pins.
Remove the seat base .
STEP 20
If it is necessary to disassemble the seal support
assembly , have another person help you with steps
21 through 26.
9065-5
WARNING . The spring in th e seal col- STEP 24

h umn Is compressed. The release 01 thIs
. . compression. using the wrong method,
will cause personal injury. '>ll J\
STEP 21
Put the seat support assembly on the floor.
STEP 22
Have the other person push downward on the seat
slide with both hands. Release the height adjuster
handle and put the suspension riser one notch
below the highest position. Make sure the height
ad juster handle is latched in this position.
STEP 23
-"
Loosen and remove the two Allen head screws that
Have the other person hold onto the seal slide with fasten the swivel latch to the seat column support .
both hands.
STEP 25
With the other person holding onto the seat slide
with both hands, release the height adjuster han-
die and the spring will release compression. Do not
lose the two pins for the swivel latch .
STEP 26
Remove the suspension riser from the seat column
support.
9065-6
A
SHOCK ABSOABER
UPPER 5P,,,NO, _
LOWER SPB"NO
_ _ ',OJ'US1rER SPRING
ARM
ADJUSTER ROD
KNOB /
~/STER ASS\MBLV ~ n
,\ PIN ~ / A
, I / .. MOUNTING PIN
PIVOT PIN
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COVER
f--conER PIN
SEAT BASE
Suspension Seat Adjuster Assembly

9065·7
Assembly STEP 9
STEP 1
If it was necessary to disassemble the seat support
assembly, have another person help you with steps
2 through 8. If the seat support assembly was not
disassembled , go to step 9.
STEP 2
Apply 242 Loetite to the threads in the seat column
support.
STEP 3
Install the swivel latch in posi tion in the sus pen·
sian riser.
Install the seat base .
STEP 4
Hold the suspension riser over the seat colum n
support and install the shaft in the center hole in
STEP 10
the seat column support.
STEP 5
Lower the suspension riser onto the shaft and seat
column support. Make sure the shaft is through t he
center hole in the swivel latch.
STEP 6
Have the other person push downward on the seat
slide with both hands. and engage the height ad·
jusler handle.
STEP7
Install and tighten the cap screws for the seat base.
STEP 11
Install the two pins in the swivellalch and the seat

column support .
STEP 8
Install and lighten the two Allen head screws. Install the adjuster assembly.
STEP 12
Install the pivot pins that fasten the adjuster as-
sembly to the seat base. Install the cotler pins.
9065-8
STEP 13 STEP 17
adjuster assembly.
~~
Connect the springs for the seat tilt handle to the

-,
Install and tighten the self-locking nut on the bot-
tom of the adjuster rod.
STEP 14 STEP 18
Install the spring bracket .
STEP 15
Insta ll the shock absorber. Install the mounting pin

and retainer ring that fasten the shock absorber to
~-
the housing.
The adjuster rod is threaded into the bottom of the
spring bracket. Install a punch through the hole in STEP 19
the ad juster rod and turn the adjuster rod into the
spring bracket.
STEP 16
-~
Install the mounting pin and retainer ring that fas-
len the piston rod eye of the shock absorber to the
Install the adjuster springs in the housing and

spring bracket.
- arm.
9065-9
STEP 20 STEP 23
Install the seat. Install the retainer rings on the shafl.
STEP 21 STEP 24
667001
I nstall and tighten the cap screws that faslen the Install the cover.
seat to the housing.
STEP 25
STEP 22
Align the hole in the knob with the hole in the

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Raise the boot and install the shaft that fastens the adjuster rod and install the pin. Drive the pin all the
seal to the arm . way into the knob and adjuster rod .
9065-10
STEP 26
/
Install new fasteners to fasten the boot to the seal
slide.
9065-11
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1. Tighten to 80 to 96 Pound-Feel (109 to 130 N m, 11 to 13 kg/ mj

2. Tighten to 54 to 64 Pound·Feet (73 to 87 N m , 7.5 to 9.0 kg l m )
3. Tighten to 17 to 2 1 Pound-Feet (23 to 28 N m, 2.5 to 3.0 kgl m )
Suspension Seat and Seat Belt Installation

9065-12
SEAT SLIDE
SLIDE TUBES
LEVER
AWARNIN
~
HEIGHT ADJUSTER HANOLE
RISER
BELLOWS
CLAMP
170237
Seal Suppo rt
9()65-13
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sUSpension Seat ASsembly
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This Page is Blank
9100
BACKHOE
TABLE OF CONTENTS
Swing Tower ...... . . . . .. •. . . . . . .. 9100-2 Stabili zer Cylinder Hydraul ic

Installation.. .. ....... . ..... .... . 9100-1 9
Removal ... . ..... . ..• . • . ...... . . . 9100-2
Swin9 Tower and Swing Cylinder
Installation ..... . . . . . •.• . ....• • . . ... 9100-3 Installation . . ............ ....... .. . 9100-20
Boom ........... . . .• .•. • .. . ... . .• . . . .. 9100-5 Sequence Valve Linkage 9100-21
Removal ....... . . . •. • . . . . . ... . .•..... 9100-5 Swing Cylinder Hydraulic Installation ·9100-22
Installation .. . ...• . • .• . . . ..• . . . . • ... .. 9100-6 800m Latch Installation . . ........... 9100-23
Dippe r ....... . .. . .... • . . • .•.... . 9100-8 800m and Dipper Installation .. 9100-24
Removal .... . . . .... • .. • ••... . . 9100-8 Boom Cylinder Hydraulic Installation .9100-25
Installation . .... . ..•..•••....... 9100-8 Dipper Cylinder Hydraulic

Installat ion . ... ... ........ . 9100-26
Dipper Extension ... . ... _•.•• . , ....... . 9100- '0
Quic k Cou p ler and Bucket
Removal ............ , . • .. • •• ........ 9100·'0 Installation .............. ...... 9100-27
Installation .......................... 9100· 10 Bucket Cylinder Installation Without

Extendable Dipper 9100-28
Replacing Wear Pl ates for the Dippe r . 9100-' 1
Extendable Dipper .. ... 9100-29
Cutting Edges ..... . ........ ..... ..... . 9100- 12
Extension Cylinder Hydraulic
Heavy Duly Buckets .... . .• _.... . . . .. 9100-'2 Installatio n . ..... . ........... . 9100-30
Bucket Teeth ...... .. ................. 9100-1 4 Bucket Cylinder Hydraulic Installation

With Extendable Dipper ..... . . . ... . 9100-31
Replacing a Tooth Shank .......... . . 9100-14
Backhoe Controls With Foot Sw ing 9100-32
Replacing a Tooth Point ..... . ....... 9100-16
Optional Backhoe co ntrols WIth
Explo ded Views ..... . .... . . .. .. ..... 9100- 17 Foot Swi ng .. . ........ . ........... 9100-33
Supply and Return Lines ... ... 9100-17 Backhoe Contro ls with Hand Swing .. 9100-34
Stabilizer Installation. A ll Backhoes ... 91 00-18 Swing Section Valve

Adj ustment .. .... .. .. .... See Section 8000
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Bur 8-67531
9100-2
SWING TOWER
Removal STEP 14
Loosen and remove the nuts , lock washers, flat
STEP 1 washers, bolts and clamp at the open ing in the
Remove all dirt from the hose connections at the swing towe r.
backhoe control valve.
STEP 15
STEP 2 Write a number on each clamp ring so that the
Start the engine and run the engine at 1000 rpm hoses will be installed in the correct position dur-
(r/ min). ing installation .
STEP 3 STEP 16
Hold the bucket control lever in the HOLD position Loosen and remove the self-locking nut and bolt
until the bucket stops moving. that holds the pivot pin for the boom cylinder.
STEP 4 STEP 17
Extend the dipper and boom as far as possible in Fasten acceptable lifting equipment to the boom
the space that is available. The bucket must touch cyli nder to hold the boom cylinder while the pivot
the floor. pin is being removed.
STEP 5 STEP 18
Fasten a lifting sling and a chain hoist to the boom Drive the pivot pin out of the swing tower and re-
and dipper pivot area to prevent the boom and move the driver.
dipper from falling when the boom is free of the
swing tower. STEP 19
Lower the boom cylinder until the boom cylinder
STEP6 touches that boom. Remove the lifting equipment.
Move the control levers for the backhoe in both
directions to release any pressure in the circuits. STEP 20
Loosen and remove the cap screw , hardened
STEP7 washer and spacer that holds each pivot pin for the
Disconnect the hoses from the backhoe control boom.
valve one at a time and fasten an identification tag
to each hose. STEP 21
Use another chain hoist or other acceptable lifting
STEP 8 equ ipment to hold the boom when the pivot pins
Install a cap on each fi tt ing and a pl ug in each hose. are removed.
STEP 9 STEP 22
Loosen and remove the nut, lock washer and bolt Remove both pivot pins.
that fastens one of the clamps to the swing tower.
STEP 23
STEP 10 Ca refully move the machine away from the swing
Loosen and remove the other nut, lock washer, bolt tower. Flat washers can be used between the boom
and the clamps. and swing tower; do not lose the flat washers.
STEP 11 STEP 24
Write a number on each clamp ring so t hat the Loosen and remove the cap sc rews , lock washers
hoses will be installed in the correct position dur- and hardened washers that hold the retainer for the
ing installation. pivot pins fo r the piston rod eyes of the swing
cylinders.
STEP 12
Repeat steps 9 through 11 for the other clamp and STEP 25
hoses fastened to the swing tower. Remove the retainer.
STEP 13 STEP 26
Loosen and remove the nuts, lock washers, bolts, Remove the snap ring and flat washer from each
support and clamps th at are fastened to the frame. pivot pin.
9100-3
STEP 27 STEP 2
Use a hammer or hydraulic ram and an acceptable Move the swing tower into alignment with the
driver to remove the pivots pins from the swing frame.
tower.
STEP 3
STEP 28 Insta ll the thrust washer for the bottom pivot of the
Loosen and remove the cap screw, lock washer and swing lower.
hardened washer that fastens the cable to the
boom latch. STEP 4
Install the bottom pivot pin so thaI the pin will
STEP 29 engage the notches in the bushing.
Remove a snap ring and ftat washers from one end
of the boom latch . STEP 5
Install the shim(sj , flat washer and snap ring on the
STEP 30 bottom of the pivot pin . If shims were not used and
Drive the pivot pin oul of the swing tower. there is space between the fl at washer and swing
tower, install shims to decrease the space to the
STEP 31 minimum .
Remove the driver and the boom latCh ,
STEP 6
STEP 32 Install the top pivot pin.
Loosen and remove the self- locki ng nut and flat
washer from the bolt that holds the cam on the top STEP 7
pivot pin for the swing tower. Inslall the flat washer and snap rin g that holds the
top pivot pin.
STEP 33
Remove the bolt and flat washers used as spacers. STEP 8
Make a record of the amount of flat washers for use Insta ll the bolt and the same amount of flat wash -
duri ng installation. ers used between the cam and the swing tower.
STEP 34 STEP 9
Remove the snap ring and flat washer from the Install a flat washer and the self-locking nut on the
bottom of the bottom pivot pin for the swing tower. bolt and tighten the self-locking nut.
STEP 35 STEP 10
Fasten acceptable lifting equ ipment to the swing Insta ll the pivot pins for the piston rod eyes of the
tower. swing cyl inders from the top of the swing tower.
STEP 36 STEP 11
Use a hammer or hydraulic ram and an acceptable Push the pivot pins into the swing tower far enough
driver f rom the bottom of the bottom pivot pin and so that the flat washers and snap ring can be in-
remove the bottom pivot pin. stalled.
STEP 37 STEP 12
Drive the top pivot pin out of the swing tower. Install a flat washer and snap ring on the bottom of
each pivot pin.
STEP 38
Remove the swing tower from the frame. STEP 13
Turn the pivot pins as required so that the boss on
Installation each pivot pin is aligned with the retainer.
NOTE: Lubricate all pivot pins with grease before STEP 14

installation. Install the retainer.
STEP 1 STEP 15
Fasten the lifting equipment to the swing tower so Insta ll the ha rdened washers, lock washers and
thallhe swing lower is level. cap screws that hold the retainer.
9100-4
STEP 16 STEP 32
Tighten th e cap screws. Install the top boll, lock washers and nut and
tighten the nut.
STEP 17
Install the bumper using the same amount of shims STEP 33
that were removed. Tighten the bolt. Engage the top of the clamp with the boss on the
bottom of the swing tower and install the bottom
STEP 18 bolt.
Carefully move the machine into alignment with
boom . Install new seals in the bottom of the boom. STEP 34
Install the lock washers and nut on the bolt and
STEP 19 tighten nut.
Use a prybar and the lifting equipment to align the
boom with the swing tower. STEP 35
Repeat steps 31 th rou gh 34 to instal l the hoses and
STEP 20 clam ps on the ot her side of the swing tower.
Start a pivot pin for the boom into the swing tower.
STEP 36
STEP 21 Put t he hoses in a pair of cl amps that are fastened
If flat washers were used between the boom and to the frame.
swing tower. be sure to install the flat washers . See
the illustration on page 9100-24. STEP 37
A lign the clamps with the mounting bracket on the
STEP 22 frame and install the bolt, lock washer and nUl.
Start the pivot pin into the boom being careful not
to damage the seal and push the pivot pin all the STEP 38
way into the swing tower. Tighten the nut
STEP 23 STEP 39
Install the spacer, hardened washer and cap screw In stall the bottom boll , support, lock washer and
that holds the pivot pin. nut.
STEP 24 STEP 40
Tighten the cap screw. T ighten the nut.
STEP 25 STEP 41
Repeat steps 20 through 24 for the other pivot pin Repeat steps 36 th rough 40 to install the hoses and
for the boom . clamps on the other side of the frame.
STEP 26 STEP 42
Remove the lifting equipment from the boom. Loosen an d remove the plugs and caps from one
hose and one fitting at a time.
STEP 27
Put the hoses in the clamp area in the opening STEP 43
according to the numbers on the clamp rings. Connect the hose to the fitting.
STEP 28 STEP 44
Install the clamp. flat washers and bolts. Start the pivot pi n for the boom latch into the swing
tower.
STEP 29
Install the flat washers, lock washers and nuts on STEP 45
the bolts. Align the boom latch with the swing tower and
push the pivot pin inlo Ihe swing tower.
STEP 30
Tighten the nuts. STEP 46
Install the flat washers and snap ring on the pivot
STEP 31 pin.
Put the hoses in a pair of clamps that are fastened
to tile swing tower according to the numbers on the
clamp rings.
9100-5
STEP 47 STEP 52
Install the hardened washer, lock washer and cap Install the bolt and self- locking nut that holds the
screw that fastens the cable to the boom latch and pivot pin and tighten the self-locking nut.
tighten the cap screw.
STEP 53
STEP 48 Lubricate each pivot pin that was removed and
Install new seals in the ears for t he pivot pin for the installed.
boom cylinder. Each seal must be installed so that
the lip is to the outside of the bushing. STEP 54
Start the engine and run the engine at 1000 rpm
STEP 49 (r/ min).
Use the lifting equipment to hold the boom cylin-
der in alignment with the swing tower. STEP 55
Slowly operate the bucket cylinder, dipper c ylin-
STEP 50 der, extension cylinder if equipped , and boom cyl -
Start the pivot pin into one of the ears and align the inder through four complete cycles to remove any
hole in the pivot pin wit h the hole in the boom air from the circuits.
cylinder.
STEP 51
Push the pivot pin all the way into the swing tower.
BOOM
Removal STEP 9
Fasten an identification tag to on e of the hoses.
STEP 1
With the engine runn ing at low idle, hold the bucket STEP 10
cont rol lever in the LOAD position un til the bucket I nstall and tighten a plug in each tube and a cap on
stops moving. each hose.
STEP 2 STEP 11
Put the boom and dipper in an acceptable position If equipped with an extendable dipper , disconnect
for removal of these parts . The bucket must touch the hoses from the extension cylinder from the
the floor. tubes inside the boom .
STEP 3 STEP 12
With the engine stopped, move the backhoe con- Fasten an identification tag to one of the hoses.
trol levers in both directions to release any p res~
sure in the circuits. STEP 13
I nstall and t ighten a plug in each tube and a cap on
STEP 4 each hose.
Fasten acceptable lifting equipment to the dipper
cylinder to hold the dipper cylinder. STEP 14
Fasten other acceptable lifting equipment to the
STEP 5 dipper.
Loosen and remove t he cap screw and hardened
washer that holds the pivot pin for t he piston rod STEP 15
eye of the di pper cylinder. Loosen and remove the self-locking nut and hard-
ened washer that holds the pivot pin for the dipper.
STEP 6
Drive the pivot pin out of the dipper. STEP 16
Drive the pivot pin out of the dipper.
STEP 7
Raise the dipper cylinder for access to the hoses STEP 17
inside the boom. Move the dipper out of the way.
STEP 8 STEP 18
Disconnect the hoses from the bucket cylinder at Use the lifting equipment that he ld the d ipper to
the tubes inside the boom . hold the boom .
9100-6
Loosen and remove the cap screw and hardened
washer that holds the pivot pin for the piston rod NOTE: Lubricate all pivot pins with grease before
eye of Ihe boom cylinder. installation. Replace al/ seals.
STEP 20 STEP 1
Drive the pivot pin out of the boom . Move the boom into alignment with the swing
tower.
STEP 21
Move the boom cylinder toward the mach ine and STEP 2
use a chain to move the boom cylinder out of the Install the pivot pins for the boom.
way.
STEP 3
STEP 22 Inslall the spacer, hardened washer and cap screw
Raise the dipper cylinder and disconnect the hoses thaI holds each pivot pin.
from the tube on the dipper cylinder.
STEP 4
STEP 23 Tighten the cap screws.
Install and tighten a plug in each tube and acap on
each hose. STEP 5
Put the tubes in the boom in th is sequence; tubes to
STEP 24 the extension cylinder in the bottom notch, tubes
Lower the dipper cylinder and fasten the lifti ng to the bucket cylinder in the middle notch, and
equipment for removal of the dipper cylinder. tubes to the dipper cylinder in the top notch.
STEP 25 STEP 6
Loosen the remove the cap screw and hardened Install the clamps, lock washers and nuts and
washer that holds the pivot pin for the dippe r cy lin- tighten the nuts.
der.
STEP 7
STEP 26 Raise the boom to an acceptable position for In·
Drive the pivot pin out of the boom . stallation of the dipper cylinder.
STEP 27 STEP 8
Remove the dipper cyl inder. Lower the dipper cylinder inlo the boom and align
Ihe dipper cylinder wit h the boom .
STEP 28
Lower the boom to the floor and use th e liftin g STEP 9
equipment to hold the boom when the pivot pins for Start the pivot pin fo r the dipper cylinder into the
the boom are removed . boom and dipper cylinder and push the pivot pin all
the way into the boom .
STEP 29
Loosen the nuts, lock washers and clam ps that STEP 10
hold the lubes in the boom . Install the hardened washer and cap screw that
holds the pivot pin and tighten the cap screw.
STEP 30
Move the tubes out of the way. STEP 11
Raise the dipper cylinder as required to connect
STEP 31 the hoses to the tube.
Loosen and remove the cap sc rew , hardened
washer and spacer that holds each pivot pi n for the STEP 12
boom . Loosen and remove the plugs from the tubes and
Ihe caps from the hoses and connect the hoses to
STEP 32 the tubes.
Remove the pivot pins for the boom .
STEP 13
STEP 33 Lower the dipper cylinder onto the boom .
Remove the boom .
9100-7
STEP 14 STEP 22
Carefully lower the boom cylinder onto the boom . If equipped with an extendable dipper. loosen and
remove the plugs from the tubes and the caps from
STEP 15 the hoses and connect the hoses to the tubes.
Raise or lower the boom as required to align the
piston rod eye of the boom cyl inder with the boom . STEP 23
Loosen and remove the plugs from the tubes and
STEP 16 the caps from the hoses for the bucket cyl inder and
Start the pivot for the piston rod eye into the boom connect the hoses to the tubes.
and piston rod eye and push the pivot pin all the
way into the boom. STEP 24
Use the lifting equipment to al ign the piston rod
STEP 17 eye of the dipper cylinder with the dipper.
Install the cap screw and hardened washer that
holds the pivot pin and tighten the cap screw. STEP 25
Start the pivot pin for the piston rod eye of the
STEP 18 dipper cylinder into the dipper and piston rod eye
Use the other lifting equ ipment and move the dip- and push the pivot pin all the way into the dipper.
per into alignment with the boom.
STEP 26
STEP 19 Insta ll the hardened washer and ca p screw that
Start the pivot pin for the dipper into the boom and holds the pivot pin and tighten the cap screw.
dipper and push the pivot pin all the way into t he
boom . STEP 27
Lubricate each pivot pin that was removed and
STEP 20 insta lled .
Install the hardened washer and self-locking nut.
The ears of th e boom must be pulled together 1/ 16 STEP 28
to 1/8 inch (1 to 3 mm ). Measure the distance be- Start the engine and run the engine at 1000 rp m
tween the ears before and after the self- lock ing nut (r/ min).
is tightened. Add or remove hardened washers as
required . STEP 29
Slowly operate the bucket cylinder, dipper cyl in-
STEP 21 der. and extension cylinder if equipped, through
Tighten th e self-locking nut to 500 to 550 pound- four complete cycles to remove any air from the
feet (678 to 746 N m. 69 to 76 kg/ m). circuits.
9100-8
DIPPER
Removal STEP 14
Fasten an identification tag to one of the hoses.
STEP 1
With the engine running at 1000 rpm (r/ min) use STEP 15
the backhoe controls as required so that the bucket Install and tighten a plug in each tube and a cap on
teeth are just off the floor and side cutting edges each hose.
are at a slight angle toward the machine.
STEP 16
STEP 2 If equipped with an extendable dipper, disconnect
Remove the Klik pin from the pivot pin for the the hoses from the extension cylinder at the tubes
bucket. inside the boom .
STEP 3 STEP 17
Remove the pivot pin for t he bucket. Fasten an identification tag to one of the hoses.
STEP 4 STEP 18
Use the boom, dipper and bucket controls as re- Install and tighten a plug in each tube and a cap on
quired to disengage the coupler from the bucket. each hose.
STEP 5 STEP 19
Move the bucket out of the way. Loosen and remove the self- locking nut and hard-
ened washer from the pivot pin for the dipper.
STEP 6
Retract the bucket cyl inder and put the boom and STEP 20
dipper in an acceptable position for removal of the Drive the pivot pin out of the dipper.
dipper.
STEP 21
STEP 7 Remove the dipper.
With the engine stopped, move the bucket control
lever and the extension control lever if equipped , in Installation
both directions to release any pressure in the cir-
cuits. NOTE: Lubricate each pivot pin with grease be-
fore installation. Replace all seals.
STEP8
Fasten acceptable lifting equipment to the dipper STEP 1
to hold and remove the dipper. Install seals in the bores for the pivot pin for th e
dipper. Each seal must be in stalled so that the lip is
STEP 9 to the outside of the bushing.
Fasten acceptable liftinQ equipment to the dipper
cylinder. STEP 2
Move the dipper into alignment with the boom .
STEP 10
Loosen and remove the cap screw and hardened STEP 3
washer that holds the pivot pin for the piston rod Start the pivot pin for the dipper into the boom and
eye of the dipper cylinder. push the pivot pin all the way into the boom.
STEP 11 STEP 4
Drive the pivot pin out of the dipper. Install the hardened washer and self-locking nut.
Th e ea rs of the boom must be pulled together 1/16
STEP 12 to 1/8 inch (1 to 3 mm). Measure the distance be-
Raise the dipper cyl inder for access to the hose tween the ears before and after the self-locking nut
connections in the boom. is tightened. Add or remove hardened washers as
requi red.
STEP 13
Disconnect the hoses from the bucket cylinder at STEP 5
the tubes inside the boom . Tighten the self- locking nut to 500 to 550 pound-
feet (678 to 746 N m, 69 to 76 kg/m) .
9100-9
STEP 6 STEP 11
If equipped with an extendable dipper. loosen and U se the boom , dipper and bucket controls as re-
remove the plugs from the tubes and the ca ps from quired and engage the coupler with the bucket .
the hoses and connect the hoses to the tu bes .
STEP 12
ST EP 7 Raise the boom to align the holes for the pivot pin.
Loosen and remove the plugs f rom the lu bes and
the caps from the hoses for the buc ket cy linder and STEP 13
con nect the hoses to the lubes. Install the pivot pin and the Ktik pin that holds the
pivot pin .
STEP 8
Loosen the dipper cylinder and align the piston rod STEP 14
eye wilh the dipper. Lub ricate each pivot pin that was removed and
installed .
STEP 9
Start the pivot pin for the piston rod eye into t he STEP 15
dipper and piston rod eye and push t he pivot pin all Start the engine and run the engine at 1000 rpm
the way into the dipper. (r/ min).
STEP 10 STEP 16
Install the hardened washer and cap screw that Slowly operate the bucket cylinder and the exten-
holds the pivot pin and tig hten the cap sc rew. sion cylinder if equ ipped , through four complete
cycles to remove any air from the circuits.
9100-10
DIPPER EXTENSION
Removal STEP 15
Drive the pivot pin out of the dipper extension.
STEP 1
With the engine running at 1000 rpm (r/ minl use STEP 16
the backhoe controls as required so that the bucket Remove the transport pin from the dipper exten -
teeth are just off the floor and the side cutting sion.
edges are al a slight angle toward the machine .
NOTE: The weight of the dipper extension with
STEP2 the end cap and coupler is approximately 395
Remove the Klik pin thaI holds the pivot pin for the pounds (179 kg). The length of the tube part of the
bucket. dipper extension is approximately 5-112 feet (1.7
mi·
STEP 3
Remove the pivot pin for the bucket. STEP 17
Install a bar in the hole in the end cap and fasten
STEP 4 acceptable lifting equipment to the bar.
Use the boom , dipper and bucket controls as re-
quired to disengage the coupler from the bucket. STEP 18
Loosen the chain hoist a small amount and pull the
STEP 5 dipper extension off the dipper. Repeat this step
Move the bucket out of the way. until the dipper extension has been moved off the
dipper approximately 2-1 /2 feet (0.8 m).
STEP6
Make sure thaI the transport lock pin is removed STEP 19
from the dipper. Remove the lifting equipment from the dipper ex-
tension and install a strap type lifting sling around
STEP 7 the dipper extension approx imately 2 feet (0. 6 m)
Completely extend the dipper and raise or lower from the end of the end cap and connect the lifting
the boom so that the end of the dipper is about 3 sling to the chain hoist.
feet (1 m) above the floor.
STEP 20
STEP 8 Loosen the chain hoist a small amount and pull the
Completely retract the bucket cyl inder and stop dipper extension off the dipper.
the engine .
STEP 21
STEP 9 Repeat this step unt il the dipper extension is free of
Put a block under the bucket cylinder to hold the the dipper. The dipper extension probably will not
bucket cylinde r when the pivot pin for the piston be balanced on the lifting sling .
rod eye is removed.
Installation
STEP 10
Remove the snap ring and ffat washe r from one end STEP 1
of the pivot pin for the piston rod eye. Fasten the lifting sling and lifting equ ipment to the
dipper extension so that the dipper extension will
STEP 11 be balanced .
Drive the pivot pin out of the bucket links.
STEP 2
STEP 12 Start the dipper extension onto the dipper.
Slowly remove the driver and lower a bucket link
and then the coupler and the other bucket link. STEP 3
Loosen the chain hoist and push the dipper exten-
STEP 13 sion onto the dipper.
If a new dipper extension is to be installed , loosen
the cap screws that hold the end cap. STEP 4
Repeat this step until the lifting Sling touches the
STEP 14 dipper.
Remove a snap ring and a flat washer from one end
of the pivot pin at the end cap end of the dipper
extension.
9100-11
STEP 5 STEP 16
Remove the lifting sling from the dipper extension. Raise the boom to align the holes for the pivot pin.
Install the bar through the hole in the end cap and
fasten the lifting sling to the bar. STEP 17
Install the pivot pin and the Klik pin that holds the
STEP 6 pivot pin.
Loosen the chain hoist and push the dipper exten-
sion onto the dipper. Repeat this step until the STEP 18
dipper extension is all the way into the dipper. It is Lubricate each pivot pin that was removed and
possible that you will have to align the piston rod installed.
eye of the extension cylinder with the end cap to
push the dipper extension onto the dipper. Replacing Wear Plates for
the Dipper
STEP7
Install the transport pin through the dipper exten- STEP 1
sion . Remove the dipper extension according to instruc-
tions in this section.
STEP8
Hold the piston rod eye of the extension cyl inder in STEP 2
alignment with the dipper extension and start the Remove the screws that hold the wear plates.
pivot pin into the dipper extension and piston rod
eye. STEP 3
Install the bottom wear plate and shims so thai the
STEP9 wear plale is even with the bottom slide rail.
In sta ll the flat washer and snap ring on the pivot
pin . STEP 4
In stall and tighten the screws to 24 to 48 pound-
STEP 10 inches (2 .7 to 5.4 N m, 0.27 to 0.54 kg/m) to hold the
If a new dipper extension is being installed , tighten wear plate in place.
the cap screws that hold the end cap to 340 to 420
pound-Ieet (461 to 569 N m , 47 to 58 kg / m) . STEP 5
Install sh ims and the top wear plate so that the
STEP 11 outside dimension of the wear plates is 9.19to 9.25
Put the block under the bucket cylinder to hold the inches (233.5 to 235.0 mm).
piston rod eye in alignment with the bucket links.
STEP 6
STEP 12 Inslall and tighten the screws to 24 to 48 pound -
Align a bucket lin k with the piston rod eye and start inches (2 .7 to 4.8 N m, 0.27 to 0.54 kg/m).
the pivot pin into the bucket link and piston rod eye.
STEP 7
STEP 13 Install the side wear plates and shims so that the
Hold the other bucket link in al ignment with the wear plates are even with the side slide rail.
piston rod eye and push the pivot pin into the other
bucket link. STEP 8
Install and tighten the screws to 24 to 48 pound-
STEP 14 inches (2.7 to 5.4 N m, 0.27 to 0.54 kg/ m) to hold the
Install the flat washer and snap ring on the pivot wear plate in place.
pin .
STEP 9
STEP 15 DO NOT lubricate the dipper extension. If the
Use the boom, dipper and bucket controls as re- dipper extension has been lUbricated, you must
quired and engage the coupler with the bucket. remove all lubricant from the dipper extension and
the inside of the dipper.
9100-12
CUTTING EDGES
Heavy Duty Buckets STEP 7
Bottom Cutting Edge Removal

and Installation
STEP 1
Remove the bucket from the dipper.
STEP 2
Remove the bucket teeth. Use carbon arc rod or an
acetylene cutting torch to remove the welds.
IMPORTANT: When removing the bottom weld at

the rear of the bottom cutting edge, DO NOT cut
through the bottom of the bucket.
STEP3
Use carbon arc rod or an acetylene cutti ng torch to
remove the welds that hold the bottom cutting
edge. tG HSO
STEP 4 1. 1/2 Inch (1 4 mm )

Use a grinder and remove any welds still on the 2. 7/8 Inch (20 mm) No Weld
bucket and any extra metal so that the new bottom 3. No Weld, Top Only
cutting edge wi ll fi t the bucket. 4. First Weld. 7/1 6 Inch (10 mm ) Flare
Bevel Weld.
Second Weld. 7/1 6 Inch (10 mm )
STEP 5 Fillet Weld.
Hold the new bottom cutting edge in place and 5. Bottom All Around 5/1 6 Inch (8 mm )
make several tack welds to hold the bottom cutting Fillet. Weld Two Times
edge. 6. 5/16 Inch (8 mm) Fillet. Weld
Two Times
STEP 6
See the above ill ustration and install the corner
bucket teeth and weld the bucket teeth in place.
Use E7018 welding rod.
STEPS
Weld the remaining bucket teeth to the bottom
cutt ing according to instructions in this section.
Side Cutting Edge Removal

and Installation
8611' 9
1. 6 Inches (151 mm)

STEP 1
2. 1-7/8 Inch (48 mm ) If the bucket is not removed from the backhoe,
3. 1/4 Inch (6 mm) Fillet Top and Bottom discon nect the wiring from the alternator.
4. Fill Groove Betwe en Wear Plates and
Bottom Cu tting Edge STEP2
5. 1/ 4 Inch (6 mm) Fillet All Around Use c arbon arc rod or an acetylene cutting torch to
6. 311 6 to 0 Inch (5 to 0 mm) Fillet remove the welds that hold the side cutti ng edge.
See the above illustration for the weld locations
Continued on next page
and specifications. 00 NOT make any welds on the
inside of the bucket except the bottom of the
bucket to the bottom cutting edge. Use E7018 weld-
ing rod and weld the bottom cutting edge in place.
9100-13
STEP 3 STEP 8
Use a grinder and remove an welds still on the
bucket and any extra metal so that the new side
cutting edge will fit the bucket.
STEP 4
Use E7018 welding rod and weld the side cutting to
the bucket with a 1/ 4 inch (6 mm) tillet all around
the side cutting edge.
24 Inch (610 mm)

High Capacity Bucket
Bottom Cutting Edge 2
Removal and Inslallalion
STEP 1 2 - I 1- 1
If the bucket is not removed from the backhoe. 1. 1·7/8 Inch (48 mm )
"17'1
disconnect the wiring from the alternator. 2. 1/4 Inch (6 mm ) Filler
3. 1-7/ 16 Inch (36.5 mm )
STEP 2 4. 5/1 6 Inch (8 mm ) Groove We ld.
Remove the bucket teeth. Use carbon arc rod or an Weld Twa Times
acetylene cutting torch to remove the welds.
See the above illustration for weld locations and
STEP3 specifications. Use E7018 welding rod and weld the
Remove all welds that hold the bottom cutti ng edge bottom cutting edge to the bucket.
in place . Use carbon arc rod or an acetylene cutti ng
torch to remove t he welds . STEP 9
Fill the corners cut through during removal.
STEP 4
Cut through each corner of the bottom cutting Side Culling Edge Removal
edge and bucket.
and Inslallalion
STEP S
Remove the cutting edge from the bucket.
STEP 1
If the bucket is not removed from the backhoe,
STEP 6 disconnect the wiring from the alternator.
Use a grinder to remove any welds still on the
bucket any extra metal so that the new cutt ing edge
STEP 2
Remove all welds that hold the side cutting edge in
will fit the bucket.
place. Use carbon arc rod or an acety lene cutting
torch to remove the welds.
STEP 7
Put the new bottom cutting edge in place and use
C·clamps to hold the bottom cutting edge in place.
STEP 3
Remove the side cutting edge from the bucket.
STEP 4
Use a grinder to remove any welds still on the
bucket and any extra meta l so that the new side
cutting edge wi ll fit the bucket.
STEPS
Put the side cutting edge in place and use a C-
clamp to hold the side cutting edge in place .
9100-14
STEP 6 See the illustration for weld locations and

speci fications. Use E701S welding rod and weld the
side cutting edge to the bu cket.
M17S1
1. 1-7/8 Inch (48 mm)
2. 1/ 4 Inch (6 mm) Fillet
3. 1-7/1 6 Inch (36.5 mm)
4. 5/16 Inch (8 mm) Groove Weld.
Weld Two Times
BUCKET TEETH
Replacing a Tooth Shank that will prevent the new tooth shank from fitting
correctly .
STEP 1
Use carbon arc rod or an acetylene cutt ing torch to STEP 3
remove the welds that hold the tooth shank . If a new cutting edge has been installed. see th e
illustrations for the co rrect location of the bucket
STEP 2 teeth.
Use a grinder to remove any welds or extra metal
9100-1 5
Standard Duty Trenching Bucket
1. Centerline of Bucker • 4 •
2. 0.50 Inch ( 14 mm )
3. Center Tooth
4. 12 Inch (305 mm) Bucket -
6.12 Inches (155 mm) - 6- - 5
18 Inch (457 mm) Bucket-
9.625 Inches (244 mm)
24 Inch (610 mm ) Bucket-
~
- ,
6
12.625 Inches (32 1 mm )
(~
5. 0.75 Inch (19 mm)
6. 24 Inch (610 mm) Bucket - IJ
3.9 Inches (99 mm)
'""
Ii
.,
- ....1" - -
.... ,
~
"
~ -3
-I -2 1
Banos.
Heavy Duty Buckets

7 •
6 •
, 5, •
, 4
- 3-
~ I--
h,
--- --- -- -- -- t--
= = = =
1~2 '- '-

,
- '- '-
1
1. Cente r Too th 5. 16 Inch (406 mm) Bucket- 6. 36 Inch (914 mm ) Bucket-
2. 0.50 Inch (14 mm ) 7.0 Inches ( 177.9 mm) 22.44 Inches (570 mm)
3. 24 Inch (610 mm) Bucker- 18 Inch (457 mm) Bucket- 7. 24 Inch (610 mm ) Bucket -
7.13 Inches (1 81 mm) 8.0 Inches (203.3 mm ) 16.34 Inches (415 mm )
30 Inch (762 mm) Bucket - 24 Inch (610 mm) Bucket- 30 Inch (762 mm) Bucket-
8.86 Inches (225.1 mm) 10.98 Inches (279 mm) 20.65 Inches (524.4 mm )
36 Inch (9 14 mm) Bucket - 30 Inch (762 mm) Bucket - 36 Inch (9 14 mm ) Bucket-
7.64 Inches (194 mm) 14.0 Inches (355.7 mm ) 27.83 Inches (707 mm )
4. 36 Inch (914 mm) Bucket- 36 Inch (914 mm) Bucket-
11 .57 Inches (294 mm) 17.0 Inches (432 mm)
9100-16
STEP4 Replacing a Tooth Point

STEP 1
3 Use a hammer and punch to remove the flex pin
,/ trom the tooth point.
STEP 2
Install the new tooth point and drive a new flex pin
2 into the tooth point.
1- 3
1. 718 Inch (20 mm) No Weld
2. No Weld
3. 5/ 16 Inch (8 mm) Fillet Both Sides.
Weld Two Times
See the above ill ustration for the weld specifica-

tions for the middle bucket teeth. Use E7018 weld-
in g rod and weld the tooth shanks in place.
STEP 5
3
f-I
ro-
4 6
po
4 I ;7
/5
--".
_6
4 I
1
1
2
I I
1- I-
1. 1/2 Inch (1 4 mm)
2. 7/8 Inch (20 mm) No Weld
3. No Weld, Top Only
4. First Weld. 7/16 Inch (10 mm) Flare
Bevel We/d.
Second Weld. 7/16 Inch (10 mm)
Fillet Weld.
S. Bottom All Around 5/16 Inch (8 mm)
Fillet. Weld Two Times
6. 5/ 16 Inch (8 mm) Fillet. Weld
Two Times
See the above illustration for the weld specifica-

tions for the corner bucket teeth. Use E701 B weld-
ing rod and weld the tooth shanks in place.
9100-17
1. To Qi/Filter 4. End Inle/ Port Of Backhoe Control Valve

2. From Front Sec lion of Pump 5. Inlet Port In Swing Section
3. From Powor Beyond Port 6. Outlet Port In Backhoe Control Valve
Of Loader Control Valve 7. Hose Used Instead of Tube When
Equipped With Removable Backhoe.
Supply and Return Lines

9100-18
..
Stabilizer Installation
. , All Backhoes
9100-19
(
(
(
I
I
I
I
I
\
\
\
\
I
I
"'- I
- /
I~\
- - - -'/
/
~
~
~
b~ g
Stabil ize r Cy linde r H yd rau lic Installation
o · ~-
1e
~
~kd I '
•I •
.:!. . ~
-
~~
<>
Gl
I
~
1. Use Flat Wash

In,en (1.5 to 4 5 m ers As Required F
Pm And The.9 m) Clearance B or .059 To. 177
In The Down ;on: La/ch. The Boetween The Upper
OSItion, om Latch Must 8e
Swing T ower and SWtOg

. C YI"tnder Installation
9100-21
Sequence Valve Linkage

9100-22
I
I
I
I
I
I
I I
I
I I
\ I
I \ I
/ \
I \ I
I
o~
I
C
I
I
I
I
I
I
C
I
Swing C y tinder Hydraulic Installation

9100-23
Shim (1) •• r.qulred to compress the

bum~r (2) 0.39 to 0.59 Inch (10 to 15 mm)
with Ihe boom In the kicked polltlon, To
/ prevent poulble demege to the boom, do
=-- ( not ,him too much.
--. ' \
Boom Latch Installation

9100-24
:c. I,c
SEAL
Shim, use .s required to d.cr• •••• pece

betw"" boom end ,wing tower to. min-
imum and keep boom centered in swing
tower.
Boom and Dipper Installation

9100-25
Boom Cylinder Hydraul ic Installation

9100-26
Dipper Cylinder Hydraulic Installation

9100-27
870381
Quick Coupler and Bucket Installation

9100-28
.),
15.."
"-
.~.." / A B
r -' ,
y 1 '9" " ..
'-:;;-~-.JL: "/ ) ..-, e
,'~- ..·l- /;I>rr~~- -

,,
,
,,
...
-
, ,,
,
-.-
.70312 1.
Bucket Cylinder H yd raulic Installation Without Extendable Dipper

9100-29
DIPPER eXTENSION
DIPPER
TlCINTENTO 340 TO 420 POUND·FEET

(461 TO 570 Nm)
TIGHTEN TO
500 TO 550
POUND-FEET
(678 TO 746 Nm)
TIGHTEN TO 24 TO
48 POUND-INCHES (2.7
TO 5.4 Nm)
TIGHTEN TO 24 TO 48 POUND· INCHES

(2,7 TO 5.4 Nm)
.~
Extendable Dipper Installation

9100-30
ff
~; ;:'---,AJ
I,
~ ~
'"
1_
\ ..... - .....
" ....... _------"
"',
...
p
\ \-r
I I
I I
I I
I \ ~/
l.t
$~~~
,, ,,
AS
. n
allatlO
·e Ins\
. nCy I'oder
I \-IydrauII
E~tenSIO
9100-31
,, ,
I ,
,
... I I
...-~'~
~~(~
, ,,
I
,- I
I
,, \ a,,. ~
-...,
\
\
i
c!:>
\
\
,
, , I
Bucket Cylinder Hydraulic Installation With Extendable Dipper

9100-32
RIGHT
, STABIUZER
I
J
DIPPER
. - - - - EXTENSION
IF USED
SW ING
BELLCRANK
DIPPER
/.,..tAt
EXTENSION
",..
IF USED U
RIGHT SWING . 103MA
. Foot Swi ng
Backhoe Controls With
9100-33
RIGHT
LEFT ...... STABILIZER
STABILIZER
I
TILT CONTROL
LEVER
DIP PER EXTENSION

/IFUSED
~. ,-
't1~ DIPPER
............ EXTENSION
e o IF USED
'C ~ ~
'RIGHT
SWING
. F00 t Swing
Optional Bac khoe Controls with
9 100-34
• BOOM AND
SWING
• BUCKET AND
SWI NG -- - . / DIPPER
~"'''''- 41/
DIPPER
~e
J R BU CKET
~
e
LEFT
~~ RIGHT
STABILIZER
"'-
"" V I
D WITHDUT
USE R EXTENSION
DIPPE
~'tJ, ~~
I ~ ...~~ e
-
RIGHT
STABILIZER
I'"<=I_/~I~'''''
:>
'l ~ " ,e ~'"
y . ~
lEFT R
STABILIZE
DIPPER
EXTENSION
Back hoe Controls With Han d Swing

Case 580k SM

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Case 580 K

Backhoe • Loader • Tractor

SERIES/SECTION SECTION NO. FORM NO.

ThIS symbol means A TrENT/ONI BECOME ALERT! YOUR SAFETY

IMPORTANT: To prevent injury on the job, A WARNING: Read operator's manual to

DANGER: Engine exhaust fumes can

WARNING: Whenever the bucket must

1. Lift Cylinder Support Strut 866554

WARNING: When dOing checks and

WARNING: When putting the hydraulic

A mittens when working with hot parts.

WARNING: DO NOT, for any reason, CAUTION: Some components of this

SERVICE MANUAL INTRODUCTION

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

oil. Not applicable if special graphites, moly-disul- Pound- Newton Kilogram

7/8 In 400-480 542-651 55.3-66.4

1.0 In 580-696 787-944 80.2-96.2

1-1/8 In 800-880 1085-11$3 111-122

1-1/4 In 1120-1240 1519-1681 155-171

1-3/8 In 1460-1680 1980-2278 202-232

1-1/2 In 1940-2200 2631-2983 268-304

TORQUE SPECIFICATIONS - METRIC HARDWARE

These values apply to fasteners with coarse

M4 2-3 3-4 0.3-0.4 . M8 27-32 37-43 3.7-4.4

M5 5-6 6.5-8 0.7-0.8 M10 54-64 73-87 7.5-8.8

M6 8-9 10.5-12 1.1-1 .2 M12 93-112 125-150 12.9-15.5

M8 19-23 26-31 2.6-3.2 M14 149-179 200-245 20.6-24.7

M1 0 38-45 52-61 5.3-6.2 M16 230-280 310-380 31 .8-38.7

M1 2 66-79 90-107 9.1-10.9 M20 450-540 610-730 62 .2-74.7

M14 106-127 144-172 14.7-17.6 M24 780-940 1050-1275 108-130

M1 6 160-200 217-271 22.1-27.7 M30 1470-1770 2000-2400 203-245

M20 320-380 434-515 44.2-52.5 M36 2580-3090 3500-4200 357-427

M24 500-600 675-815 69.1-83.0

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fittings Straight Threads with O-ring

Split Flange Mounting Bolts

5/16-18 15-20 20-27 2.1-2 .8

3/8-16 20-25 26-33 2.8-3.5

7/16-14 35-45 47-61 4.7-6.2

1/2-13 55-65 74-88 7.6-9.0

5/8-11 140-150 190-203 19.4-20.7

GENERAL ENGINE SPECIFICATIONIS

J 1Case Rae 8-28800

Piston and Connecting Rods

Engine Lubricating System

NOTE: The J I Case Company reserves the right to make improvements in

J I Case Rae 8- 24161

ENGINE SPECIFICATION DETAILS

Piston .. .. . . .. . .. . . .... .. .... . . . ... . ... .. ... . .. . . .... . . ......... . . ... .. . . . . . . . . .. . . . . . . . . . .. . . . . 4

Pi sto n Pin .. . . . . . . . .. . . .. . .. . .. ...... . . .. . . . .. . . . . .. . . . .. .. ... ... . ... . . .. .... . . . . . .. . . ... . . . . ... 4

Cy lind er Head .. . . .... . . .... . . .. .. .. . . . ... . .. . . .. .. . .. . .. . . . . .. ... . ... . .. . . . . . . ... . . . . .•. . .. . . .. 5

Tappets .. . .... . . .. . ....... .... .. . . .. . . . . . . ... . .. . .. . . .... . .. .. . . . . . . . . ... . .. . .. .. ... .. . . . .. . .. . 5

Cranksh aft ... .. ...... . . . . . . . . . . . . . ... ... . .. . .. ... . . . . . . . . . . . . . .. . . . .. . . . .. . .. .. . ... . .. . . . .. . . . . . 6

Gea r Train . . .... . . . .. ... . .. .. . .. . . ... . . . .. .. .. .. . . . .. ..... . . . . . .. . . . . . . . .. . .... . . ... . . . ...... . . . 7

Rocker Arm Assemb ly ... . .. . . . . . . .. . .. . . .. . . . . . . . . . .. ... . .. ...... . . . . . . . . . . ... .. . . .... . . . . . . ... . 7

Turboc harger . .. . . .. . . . . . .. . .. . . . .. . .. .. . . .. . . . . .. . .. . . . . . . .... . .... . .... . . . . ... . .. . ... . .. . . . . . . 7

Valve Springs . . .. . . . . . . . . ... .. . . . . . .. .... . . . . ... .. . . . . .. . . . .. . . . ... .. . ...... . . . . . . ... . . . . . .... . . 8

Run-In Procedure For Rebuilt Engine

Run-In Procedure For Rebuilt Engines (With A Dynamometer)

STEP TIME ENGINE SPEED DYNAMOMETER SCALE LOAD

Run-In Procedure for Rebuilt Engines (Without A Dynamomelter)

Run-In Procedure (Agriculture Tractors)

Run-In Procedure (Construction Equipment)

ModeINumber ~5~8~0~K~ SI N _________

r-8~___A_ir_C_I_e_a_ne_r_' _' ____________________~:~~:~:~~:+-~-+_2_00_1~ ~