Case 580CK Model B

Backhoe • Loader • Tractor

Service Manual
v 8.0

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 TABLE OF CONTENTS

SERIES/ SECTION SECTION NO.

10 SERIES - GENERAL
General Specifications, 580B Tractors 11
Detailed Specifications, 580B Tractors 12
Lubrication, Shuttle Tractors 13
Lubrication, Hydrostatic Tractors 13
Lubrication, Loader & Backhoe 13

20 SERIES - ENGINE
Cylinder Head & Valves, Diesel 22
Cylinder Head & Valves, Spark Ignition 22
Engine Block Assemblies 23
Air Cleaner System 24

30 SERIES - FUEL SYSTEM

Fuel System & Filters 31
Roosa Master Model DB Fuel Injection Pump 32
Roosa Master Fuel Injectors 33
Model 267 Carburetor 35

40 SERIES - HYDRAULICS
Hydraulic Diagrams, Trouble Shooting, Testing, & Service 42
Hydraulic System & Power Steering Oil Filters 42
Torque Converter - Power Shuttle Hydraulic Pump 43
Equipment Pump 43
Three-Point Hitch Cylinders 44
Loader Control Valve 44a
Backhoe Control Valve 44b
Stabilizer Control Valve 44c
Three-Point Hitch Control Valve 44d
Cylinder Removal/Installation 45
Loader Cylinders 45
Backhoe Cylinder 46
Auxiliary Cylinder 47
Hydra-Guide Hydraulics Guidance System 47
Boom Lockout System 49

50 SERIES - STEERING
Power Steering Pump & Hand Pump 52
Steering Control Valve 53
Steering Cylinders & Adjustment 54
Steering Axle & Wheel Bearings 55

60 SERIES - POWER TRAIN

Torque Converter, Power Shuttle Countershaft, Control Valves, & Adjustment 61
Power Shuttle Clutch Pack, Rockford Clutch 62
Power Shuttle Clutch Pack, Twin Disc 63
Hydrostatic Drive, Gear Train, Control Linkage 64
Four-Speed Transmission & Final Drive 65
Mechanical Shuttle 66
Duel Range Assembly 67
11-Inch Traction Clutch 68
Independent Power Take-Off 69

NOTE: The following sections also relate to the Power Train:

Torque Converter-Power Shuttle Hydraulic Pump 43
70 SERIES - BRAKES

Differential Brakes, Differential Lock, and Parking Brakes. 74

80 SERIES - ELECTRICAL
Wiring Diagram, Tractor 81
Wiring Diagram Fork Lift Tractor 81

90 SERIES - MOUNTED EQUIPMENT

Miscellaneous Equipment (Includes Rear Attachment Support Arms,
Counterweights, Moldboard, Logging & Pallet Forks, & Rollbar) 91
Loader 92
Backhoe 93
Three-Point Hitch 97

100 SERIES - HOW IT WORKS - TROUBLE SHOOTING

Hydraulic Testing - Torque Converter - Power Shuttle 101
How It Works - Hydrostatic Power Steering. 151
How It Works - Torque Converter with Rockford Power Shuttle. 162
How It Works - Torque Converter with Twin Disc Power Shuttle 163
How It Works - Hydrostatic Transmission. 164

NOTE: Also refer to sections in the 40 Series, Hydraulics, for troubleshooting and how it works
information relating to the equipment hydraulics system.
 Figure 1 Figure 2
DIESEL ENGINES

Type ..................."Case" Open Chamber Combustion 4 Cylinder, 4 Stroke Cycle, VaIve-in-Head.

Firing Order ......................................................................................................................1-3-4-2
H i m .......................................................................................................3+13(16I ~ I c ~ (96.81~m)
~ s
Stroke .............,......................................,,.,.................................,............
4-1; Inches ( lO4.Smm)
Piston Displacement ....................................................................... 188 Cubic Inches (3
Compression Ratio ....................................................,....,................,............................. 17.5 to 1
Cylinder Sleeves .......................................................................................... Removable Wet Type
No Load Govern d (Mechanical Shuttle) ............................................................2060 R P M
No Load Gave d (Power Shuttle) ã..ã..ã,.......,ã.,,., ......................................
2250 R P M
Rated Engine echanical Shuttle) ...............................,......,,....,.........,............. 1900 RPM
-..
Rated Engine Speed (Power Shuttle) ......*............................. .................................. 2100 RPM
Engine Idling Speed ................................................................................................ 600-650 RPM
'Valve Tappet Clearance (Exhaust) ...*.. ................ã.+....... (Hot and Cold) ,014 Inch (0.356mm)
(Intake) ........................................(Hot and Cold) .014 Inch (O.356rnm)
'Hot Settings Are Made? After t h e Engine Has Operated At Thermostat Controlled Temperature
For At Least Fifteen Minutes.

Bac. Form 9-80721

Piston and Connecting Rods
Rings per Piston .....................................................................,.................,...,.,.......................
3
Number of Compression Ring's ....................................................................................................
2
Number of Oil Rings ....................... ............+..........+....................ã...................+......................
... 1
.-....... Full Floating Type
Type Pins ..............................................................................................
Type Bearing ................................Replaceable Precision, Steel Back, Copper-Lead Alloy Liners,

Number of Bearings ...............................,......................................................................-.-.......-...

5
Type Bearings .........
+ ...................
Replaceable Precision, Steel Back, Copper-Lead Alloy Liners.

Engine Lubricating System

Oil Pressure ................... 50 to 70 Pounds (3.5 to 4.9 kgicrn2)with Engine Warm and Operating
at Rated Engine Speed.
Type System ,...............................................................................Pressure and Spray Circulation
..... Gear T y p e
Oil Pump ..............................................................................................................
Oil Filter ........................,.... ............,..............................................,.,......
Full Flow Spin OH Type

Fuel System
fuel Injection Pump ................................................................................................
Roosa-Master
*...........,...,. 8 Degrees Before Top Dead Center
Pump Timing ..,...,................................................
Fuel Injectors .............................................................................................................
Type
Pencil
(Opening Pressure 2800 PSI).
Fuel Transfer Pump .,................................ ......,...................,. Vane Type, Integral Part of
,, ,.,..ã.
Injection Pump.
Governor .......,-, ....................................
Mechanical, Fly-Weight, Integral Part of Injection Pump.
1st Stage Fuel Filter ......................................................................................... Replaceable Type
2nd Stage Fuel Filter .....,,.,,,,Ã.......,......,......,-.--..,.....,....................................... Replaceable Type
Fuel Tank Water Trap and Drain ...........................................,..... Located in Base of Fuel Tank
Fuel Tank Capacity .......................................................................... 22 U.S. Gallons (83,31liters)
Fuel Level Gauge .....................ãã.................................Electric, Located on Instrument Panel,

General
Type .............................................................................
4 Cylinder, 4 Stroke Cycle, Valve-in-Head
Firing Order ...,..,... -, .............................. .... .. .....
......,...... .. .. ... ............................................. 1-3 4-2
Bore (188G) ..,................................... ..--,............................. ..,.,...............3-13/16 Inches (96Amtn)
(159G)ã,,,.,.. ...-.,-............,,- ....................................,.........................
3-1j2 Inches (SS.Pmmj
Stroke .......................................................................-.........,......................
4-1/8 Inches (104,Smrn)
Compression Ratio (188G) ................................................................,................................ 7,5 to 1
(159G) ..................................... .........-,.............,......,..........................
7,42 to 1
Piston Displacement ........................................................................................... 377 Cubic Inches
No Load Governed Speed ( l W G I ............................................................,.......,............. 2250 RPM
(159G) ................................ ,,.,...,.,,ã..,...,ãã .......,.ã....,,..ã.2250 RPM
RatM Engine Speed (188G1 .............. .+..... .................................................................
2100 R P M
( 159G 1 ...........................................................................................
1900 R P M
Engine Idling Speed .............................................,...,..................................,....... . ......... 600 RPM
Â¥ValvTappet Clearance (Intake) ..................................... (Hot and Cold) ,014 Inches (0,356mm)
(Exhaust) ..................,..... .....,.
...,.......+.......,.(Cold) ,020 Inches (Oh50Smrn)
(Hot) ,014 Inches (0.356mrn)
Exhaust Valve Rotators ...........................................................................................Positive Type
Â¥HoSettings Arc Made After The Engine Has Operated At Thermostat Controlic-d Temperature
For At Least Fifteen Minutes.
Piston and Connecting Rods
Rings per Piston ......................................................................................................................... 4
Number of Compression Rings .................................................................................................... 3
Number of Oil Rings ..................................................................................................................
3
Type P'm ..............................................................................,,.....................,...
Full Floating Tyw
Type Bearings ,.......................,.....Replaceable, Precision Steel Back, Copper Lead Alloy Liners.

Main Bearings
Number of Bearings .........................,................,.............-........................................................~..
3
Type Bearings ..............................
Replaceable, Precision Steel Back, Copper Lead Alloy Liners.
Engine Lubricating System
Oil Pressure ......................
24 to 32 Pounds (1.7 to 2.3 kg/cm2) with Engine Warm and Operating
at Rated Engine Speed
Type System .........................................................,............................. Pressure Spray Circulation
Oil Pump .....,......................,................,.................................................,.................,..,.
Gear Type
Oil Filter ................................................................................................
Full Flow, Spin on Type

Fuel System
Fuel Tank Capacity ..............................................................,...,. 22 U.S. Gallons (83.3 liters)
..,£Ã

Carburetor ...............,....................Zenith (wfsolenoid shu t-off) 1-1/4 Inch SAK Flange (31,7rnm)
Fuel Strainer ...............................................,...............,........In Sediment Bowl Under Fuel Tank
.. ..-
Fuel Filter ......................... ...................,....I....................... .. Mounted on Fuel Strainer Head

Distributor Ignition
Contact Point Gap ...........................................................................................................-020Inch
Dwell Angle .................................. ,..,,. ..................................................................................... 700
Spark Plugs .....................................,.....................,,............................................... Prestolite 18 8
Plug Gap .....................................,..................................,.....................,.,..................... .025 Inch
Thread ...............,..........................................................................................................,.....
18 M M
Shank Length ................................................................................................................... 3/2 Inch
Engine Timing
Static Timing UWG) ...... .........................................................................................,.......
..x.... TDC
...
(159G) .................-..,,.............................................................................. 3QATDC
Running Timing (18SG) ........................................................................ 34" BTDC at Rated Speed
(mG) -, ......,.. ...........................,-,......,............,...........
;JOifBTDCat Rated Speed

GENERAL SPECIFICATIONS
Cooling System
Capacity (188D & 188G) ................................................................16-1' 2 U.S. Quarts (15.6 liters)
(159G) ....................................................... ...-.. ..... 14 U,S. Quarts (13.3 liters)
Type of System ..................................ã. ..,.............--...............Pressurized Thcrmosia t Con trolled
Impeller Type Pump,
Radiator .,........,,,,....,.,.................................. ,..,,..Ã..,.................. Heavy Duty Fin &Ed Tube Type
Thermostat .....................................Starts to Open at Approximately 1779F.Fully Open a t 202".
Pressure Cap Required ..........................,.,...,.........................,.............................................
4 PSI
WtieJi using a proper operating pressure cap, the engine temperature can safely rise to 2,30T'.
Electrical System
Type of System - Diesel and Spark Ignition ..,-...................................., 12 Volt Negative Ground
Batteries ....................................................................
(2) 12 Volt Batteries Connected in Parallel
Parking Brake
Type ....................... Cable Actuated by Orchlin Type Handle . Adjustable from Operator's Seat.
Hydraulic Brakes
Type ..................................................................Heavy Duty, Disc and Band Differential Brakes
Brake Pedals ............Can Be Locked Together for Safe Road Travel or Operated Independently
for Steering Assistance

Clutch Type .............................................................. Foot Opera fed, Spring Loaded, Single Disc.
Disc Size ......................,........................
.....,.,-,,ã..È,,..,ã--......,,--,..r.......,..,ã,., 11 Inch {279,4mrn)
Throwout Bearing ............................................................................. Ball Thrust wfgrease fitting
Transmission ............................................................................................................
8 Speed Gear
Dual Range Shuttle ................................................................Mechanical Actuated Forward and
Reverse Clutch
,,...................+.ã.,...,..,
P.T.O. .............................................. ......~.,..............,.....,......,...
Independent

Power Shuttle
Torque Converter ....................................................................................................... Single Stage
Power Shuttle .......................................... Hydraulically Actuated Forward and Reverse Clutches
Transmission ............................................................................................................4 Speed Gear
P,TdO....................................,..,,.,.,,.ã.,.,.,..,,,,.,.-. ...............................
b , , à ,,,ã,.......... Independent
Hydrostatic Power Steering
Relief Valve Pressure ................. ã,.............,.,ã..................................................1500 to 1700 PSI
Pump Capacity at No Load Engine RPM ...................................................... 6.7 GPM (25.41mm)
Capacity of Reservoir ....................................................................................... 1 Quart (-95 liter)
Capacity of System ã..,,ã .......................................................,..............,...
2.5 Quarts (236 liters)
.. ...
Type of Oil ................................................................. ......................,...................Case TCH
Hand Pump Type .......................................................................... Gerotor Bi-Directional Driven
By the Steering Wheel.
Actuating Cylinders .......................................,.... ...................,....-...
2 Way Cylinders Are Integral
Part of Steering System.

Power Take-Off
Type ...........................................................................................................................
Independent
Rotation .............................................................................................................-...........
Clockwise
Spline Size .........................................
,540 RPM at 1750 RPM ...................., 1-318" Dia. (34.9mm)

Method of Engagement ...................................................................................

PTO Control Lever
Pulley Diameter ..............................................................................-.........
10.25 Inches (260.4mrn)
Pulley Face Width ...,......,-.+ ....................... .,......................................... 6.5 Inches (165.1mm)
Ratio Engine R P M to Belt Pulley RPM .......................................................................... 1.53 to 1
1 RPM o f Belt Pulley ................
..+...,.....ã, ...............
2.68 Feet (Q.S72m) Per Minute Belt Travel
 . 79 Inches (2 007mm)
122.5 Inches (3 112mm)
. 1/4 Inch (6.35rnm)
57 Inches (1 448rnrn)
.................................................................... 54 Inches (1 372mm)
62 Inches (1 575rnmj
(W15-24 Integral Rim) ........,.,..+... ....*.....-..,.+ ....................62 Inches (1 575rnrn)
(W12-24 Integral Rim, 1.81 offset) ...................... L...4.a..,. .................. Dished Out
Only - 66 Inches (1 676mm)
Rear Wheel Tread (W12-24 Demountable Rim) Wheel dished in and lugs inside - 60 Inches (1524mm),
-
Wheel dished out and lugs outside 64 Inches (1 626mrn), 68 Inches (1727mm), 72 Inches (1829mrn),
76 Inches (1 930rnrn),
Rear Wheel Tread (W15L-24and WEL-28 Demountable Rim) Wheel dished out only and lugs inside -
64 Inches (1626mrn),68 Inches (1 727mm),72 Inches (1 829mrn1, 76 Inches (1 930mm).
 ATE TRAVEL SPEEDS
WITH 14.8-24 TIRES

LOW

1 DIRECT

NOTE: Listed above are the approximate speeds obtained under full load conditions. Normal
transport speeds are approximately 10% higher than those listed above.
11-8

FUEL SPECIFICATIONS

CAUTION "EVEl, FILL THE ["U EL TANK WHEN THE ENGINE IS IWN NI:\G on WHE"
:\E.\fl ,\A- OPE" ["L'-\~[E. DO :\OT SMOKE WHEN WORKll'W NEAR ["LAMlvI ABLE ["UELS.

GASOLINE
Case G,,~oline Engines are ciesigned to operate on R e gular Grade gaso lin e having a m inimum
reseal'ch method ra.ling of 90.7 Octane . This will give full power and economy toge ther with
long engine life and low n1uinlenance cos t.

The a verage Oct~ne :-lumber I\atings for Ile gular Grade g aso line are:

:\[otOI' Ile sen rch ,86.2 Octane Number

Hescarch :'I'Jelliod 94.2 Octane Number

Thesc two Octane flatings are used to d e fine the anti-knock quality of gasoline. It h as
become COmmo n pract ice in the Petrol eu m Industry to r e fe r to only the Res ear ch ~'1 ethod R ati ng.

Wh en on ly one Octa ne nating is give n for gasoline and the rating method is not s pec ified, it
can be assumed to be the Hesea rch Method r ating.
 11-9

D IESEL
Case di e sel e ngines are designed to ope rate most e ffi c i e ntl y when us ing a !\umber 2 Di e se l
F ue l. Most well known re fin e rs and distributors marke t a good gTad e of Dies e l Fue l and there
s hould be no di ffi c ulty i n obtaining it.

Do not confus e number 2 Diesel Fuel with Number 2 Furnace Oil, as thi s does not always
m eet the fu e l s pe c ific a ti ons fo r diesel e ngines .

Specifications fo r a Su itable
Number 2 Diesel Fuel
A. P.1. Gravity (iVlinimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 30
P o ur Po int (iVlaximum) ..... . . . . . . . . 100F ahrenhe it be low ambie nt ope r a ting' te mperature.

DL'lTILLATION

90~6 Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 0- 625 Fnhrenhe it

0

End Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5 0 Fahr enhe it

FLASH POINT (iVIi nimum) . . . . . . . . . . . . . . . •. . . . . 125 0 F ahr e nhe i t o r le gal

Kine mati c Viscos ity , c ent is tokes @ 100 0 Fahr e nhe it. . . . . . . . . . . . .. 2.0-4 .3 Seoond s*

Cetane No. (Minimum) . . . . . . . . . . . 40 (45 -55 fOl' win te r or hi gh a lti t ude use)
Wa ter a nd Sed ime nt Vo l. (Maximum) .. .05%
As h, wt . (i'Vl aximum) . . . . . . . . . . . . . .01%
Sulphur wt. (Maximum) . . . . . . . .5 %
Carbo n Res idue on 10% (M aximum) . . .2%
Co r r osion, Copper Strip,
3 hrs . @ 212 0 F ahre nhe it . . . 1\0 . :3

(* 32-40 Sayb olt Universal Seoond s )

NOTt The use of ,,"umbe r 1 Diese l F uel, which is a lighte r fuel, m ay r e s ult in a lo s s of
e ngine po we r and a ls o incr eased fu e l c o ns umptio n be cause it h as l e ss heat conte nt and a lo\\'e r
viscos ity than Numbe r 2 Dies e l Fue l.

The life of the inj ection pump may a lso be affe cted beca us e of the l ack of lubr i c ant in the
lighte r 1\ umbe r 1 Die s e l Fuel.
11-10

FUEL CONDITIONER

Cnse Diesel Fuel COl1c1ition flJ~ is reco mn1ended for use in all Case Diesel e ngine fu e l systenl.
Cnse Lullr ~ - Gas Conditioner is reconlln e nded for use in all Case Gasolin e e ngine fu e l
:-ivs te nls.
, These fu e l condit ionl' ],"; shoul d be used us dil'ected on the contain e r,

lubra -Gas
Diesel Condition er
Fuel M20426
Conditioner

UserFriendlyCDs

~
:~:~~~~~"
..-".
----'''-'"-
.. _-.--
---- ._ ---

CASE DIESEl FUEL CONDIT IONER CA SE LU 8RA-GAS CONDIT I ONER

Prevents gLlmmy deposits fr om fOl'ming Improved lubri cation. to uppe ,' int.ern al
in t he fuel sy stem, parts of the engine,
Improved lub ri c ation to th e Up)l8 1' intema l Reduces cylinder and ring we ar , im-
p;l l' ts of the engine, proved compress ion, reduced cor r oSion of
Elimin ates fo uling of injector no zz les , the internal. engine parts,
v alves and nW.nifolcls. Reduces crankcase 0!1 dilution_
He lps keep co nden satio n suspe nded in the H elps keep condensation suspend ed i n the
fuel, all owing it to be bUl'ned with the fu e l. fu el, allowing it to be burned with. the fuel.
l\Iaintnins a hi ghe r degree of fuel com- Maintai ns a higher engin e performance
bustion and engine pel'formaIl CE' frorn fu e l fl'OM {!.leI the engine bu rn s .
t h e engi ne UU l'llS.
 Section
12
DETAILED SPECIFICATIONS

TABLE OF CONTENTS
ENGINE BLOCK .............................. ........................ ........................... . .... ... ....... ............ ......... 2
CYLINDER HEAD AKO VALVES ............ .. . .......... .............. ....... ....... .... ........... .. . .... . ........ .. 7
COOL ING SYSTEM ....... ..................... .. .................................... .. ...... .. ........... .. ....................... 10
ENGINE OIL FILTER ....... .. ......... ..... ...... .. ........... .......................... ..... . . . ........... .. ....... 11
AIR CLEANE R ............... ............. .. ......................................................... ...... .. .. ... .. ....... .. ...... 11
F UE L SYSTEM ........... .............. ..... ... ................................................. .. ... .... ............. . ............ 12
BRAKE S ............................ .. ...................... ................................. ......... ..... ........................... 11
POWER TRAli': ...................... .. ..... .. ....... .... .................... .......................... ........ ......... 15
STEE R ING ............... .... ... ..... ...... ......... ........... .......... .......... .. .. ..... . ..... .............. 16
GENE RAL TORQUE TABLE ..... ......... ........ .. .......... ....... ...... ...... .... .... .. . .............. .. .... 17
SPECIAL TORQUES ........................................... ..... .......... ........... ... .. .. ..... .. ..... ... ........... ....... ... 17

R,Jc. Fonll 9-80731

12·2

Engine Block
~OTE: All dimensions are given in inches. Specifications apply to all engine's un te'ss not ed.
Maximum Limit
Including Wear
CYLI:\DER SLEE VE S
LD . of sleeve (109G) .3..5013 to 3.5028 .005
(1 88D) 3.8115 to 3.8125 .005
(188G ) ....... ..... ............. ........ ..... 3.8130 to 3.8145 .000
(148G) ..... ...... ................. ..... ..... .. .. .... 3.2745 to 3.3765 .005
Sleeve out·ai·round .... ......................................... ...... ....................... ....... .. .. ........... ..... ....... .. .004
Clearance to bottom of pisto n skirt (1880) ................. 00.35 to .0055
(188G) .................................................. 0025 to .0035
(159G) .0015 to .0045
(148G ) .0030 to .0035
Tape)" .001
PISTON
Type ........... ... ... .. ...... ................................ ........ ......... Cam Ground
:Vlaterial ................................................................ Aluminum Alloy
0.0 . at bottom of skirt : 90" to piston pin (l88G) .... 3.8090 to 3.8105
(1880) ...................................... 3.8070 to 3.8080
(159G ) ............ ..... ............. ..... ... 3.4983 to 3.4998
(148(; ) ................... ....... .. ...... ... ......... 3.3735 to 3.3750
1.0. of pis ton p in bore (188 0) ............. .. .... ........ ..... 1.2500 to 1.2503 .001
(l8RG, 159G ) .......... ....... .... . ... ............ 9992 to .9994 .001
(148G) ............................. ...... ............... 8592 to .8594 .001

Width of 1st ring groove i188D ) ........ ...... .............. . . Keystone Type
(188G. 159G. 148G) ... ................... ..... ..... 0965 to .0975
\\'idlh of 2nd ring g roove (18SD ) ......... ....... ..... .... ........... 097 to .098
(148G . logG . 188C;) ..................... .. ...... ... 0955 to .0965
Wid t h of 3rd ri ng groove (188D) .1 895 to .1885
(188G, 159G, 148(; ) .0955 to .0965
Wid t h 01 4th ring groove (l&QG, 159G . 148B) ....... ........... 250 to .251
PISTO:\ RI:\GS
:-';0. 1 Compres sion (1880) .. . ......... Chrome Grooved Keystone
(J88G, 159. 148(; ) .. ............................. Tapered Face
Widlll (1880) .................................. Not measurea ble
(188G, 159G. 148(;\ ........... .... ................. 0930 to .0935
 12-3

Engine Block (Continued)

:Vla ximum Limit
PI STON RINGS (Continued) Including Wear

End gap in 3.812 I.O . sle eve (1880) ..... ...... ..... .. ... .. •.. ... . .015 to .025
3.375 I.D. sleeve (1 48G ) .. .. ' .... . " .. ' , .. .... . , .. .010 to .020
.
3 ..500 l.0. sl eeve (159G) . .. ..... .... .. ..... ... . . . .010 to .020
3.812 I.O . s leeve (188G) ...... ..... ...... .. ... .. .. .010 to .020
Side cleara nce (1880 ) ........... ... .. .... .. .... ....... .... ... _. Not measureable
(188G, 1;;9G, 148G) ._ .............................. 0030 to .0045
No.2 Compress ion (l88G. 159G, 148G) ........ .... ...... ... Tapered Face
(188D ) ................... .. .... . .. . ...... .. ....... .. _... . Grooved
Width (188G. 159G. 148G ) .0930 to .0935
(1880) ...... _............ .... ............ _........... . . 0925 to .093')
End Gap in 3.812 sleeve (188 0 ) ..................... ... ...... .. ...... 015 to .02')
,1.375 sleeve (148G) .010 to .020
3. 500 sleeve (159G) .010 to .020
3, 81 2 s leeve> (188(; ) .010 to .020
No.2 Compression
Side clea rance (1880) .0035 to ,0055
(l88G,159(;.148G ) .............. ..... .......... ..... .0020 to .0035
':\0 . 3 Compress ion (188(; ,159(; ,148G) .. .... ........ ...... .... Tapered Face
Wid th .... ...... ...... .... ........ .. ........ .... ................... .. .... .. .. . 0930 to .0935
Ene! g ap in :1 .812 sleeve (188G ) .... ............ .. ..... .. ...... .... 010 to .020
3.375 sleeve (148G) ...... .... ....... .... .... ........ ...... ..... .... ..... .010 to .020
3. 500 sleeve (159G) .... .. ..... .... .... .. .. .. .. ....... .. ...... .......... . .010 to .020
Side c lea ran ce ........................ ...... ............. ....... ....... .0020 to .0035
OIL Rl :\GS
Width (1880 ) .182;') to .1 888
(188G.159G.148G) ...... .... ...... ........ .... .... ... 248.5 to .2490
Side c lea rance (1880) ...... .... ...... .... ........ .. ...... ........ .. ....... 000 to .007
(188G. 1;J9G.148G) ................................... 0010 to .0015
End ga p in 3.812 1. 0 . s leeve (188G) .... ..................... .. ... .010 to .018
.3.375 1. 0. sleeve (148(;) .................. ...... .... .... ............... 010 to .018
3.500 I.O . sleeve (159(; ) .010 to .018
Rail end gap in 3.812 I.O. sleeve (1 88 0) .... .... ..... ........... 015 to .050
12· ·)

Engine Block (Continued)

ilila x imum Ll mi I
Includi ng Wear

1-' ISTO" 1-']~:

Typt> ... ..... ...... . Pu ll F loa ting

0.0. of pin 11811 01 ... . ... .... . 1.2497 to 1.2498
i188G . 1:;9(; ) .9991 to .Q992
IH8G ) .8592 to .8593
F it in pi ston ( ISSD) .0002 to .0006
OSSC, 159(;) .0000 to .(J003
( 1·)8(;) .............. .. .0000 to .0002
F'i t in r od bushi ng (I88D ) ....... .. ......... ...... .... .. .......... . . 0002 to .0006
(188G ,lJ9C.1 4HC ) .000.3 to .0006
CO, ' J IXTl J ' C ROD
Bu shing ............ Repl acea bl e Bronze
Bushing LD. installed (rca rn t'd 10 size' )
(188G ,159G) ...... ........ .......... .... .. 9995 to .9997 .001
1188D ) 1.2502 to 1.2504 .001
t1~8G ) .. .... ...... .... ...... .... ... 8590 to .8598 .001
Hushing oul ·or· round .... ..... 0015
Rearing Liners .. .. Repla cea ble
Hearin g li ner wid th 1.1 20 to 1.130
Rod width at c r a nk c nel .... 1.303.5 to 1.3055
,Journa l LO. withoUI bearing liners ...... 2,1870 to 2.1875
Bearing oil clearance ... . " .0010 to .0035 ....... ... ............ .......... 006
Cnd ers ize be ari ngs ror ,crvice .002,.010 ,. 020, .030
Side clearance ..... .005 to .fil l
Ca p baits ............... .... .. .... Self locking type
CRA l"KSHAFT
Typc o
... .. .... .. ...... ..... Balanced
:Vl ai n bea rin g li ners R ep lacea ble
EIle] play , center m a in beari ng cap .0111 to .006
Thrus t s pace r s td. t hic kness .092 to .098
Conn ect in g roel j ournal st d . a.D. 2.0605 to 2'(J613
G rind to .010" 0.0. u nd ers ize 2.D:105 to 2.051:;
.020 " O.D. unde rs ize 2.0405 to 2.0415
.O;lll" U.D. unc! Ns ize 2.030') to 2.0315
Co nlH.'0 ling rod journa i maxi rnu rn tapC'!' .... . .. .... .. . _...... , .......... ... ..... .... .. , . .. ....... . ... .. . ..' .002
 Engine Block (Conti nued)
Maxim um Limit
In c luding \\"car

CR.-\:\KSHAF T (Contin ued)

.J ournals out ·of·round . .O()]

Mai'l bearing line r widt h 1st, (1880, ISSG ) 1.276 to l.286

Main bearing liner widt h 1s t, (159G, U8G) 1.870 10 1.8S0
Main bear ing liner width 3rd (1880) .... ..... ................ 1.371 to 1.37:l
:l1alll bearing line r wi dth 2nd (lSSG) ................ .. 1.371 to U 7.J
Main bearing Iin c'!' wid th 2nd a nd 4th (188D) .... . .950 to 1.000
:Vlain bc'aring liner widt h 5th (188 0), (l88G 3rd.) 1.557 to 1.567
l;nders izc' main bearing line r s for service ............ 002 ,. 010 ,.020,.0:,0
Main beari ng oi l c learance ....... ...... ....... ... . .. .0012 to .0042
;Vla in bea ring jou rnal std. 0 .0. (lSSG, 188D) 2.8730 to 2.8/40
(159G.14 8C ) .............. ...... ................. . 2.6230 10 2.6240
G rin d to:
.010" 0. 0. undersize , (188(;, 188D) ., ..... ....... . .. ... ... 2. 8630 to 2.8610
.020" 0.0. unders ize , (188(;. 1880) ... . ....... ...... . ..... 2.8530 to 2.8.'>40
.0:)0" 0.0. u ndefSiz('. (I88G , 1880 ) .... ... ..... ....... .... 2.8430 to 2.8440
.010" 0.0 . undersiz(>, (10';9(;, 148GI ....... ' " .. - . , , " ..... 2.6130 to 2.6140
.020" O .D. undersize, (lo9G, 148(; ) . .. .., ... ... ..... . .... 2.6030 to 2.6040
.0.30" 0.0. und ersize. (159G, 148G ) .... . ......... .... ." . 2.3930 to 2.59'10
Ma in journ a l bore LD. w l o li ners (1880, 188G ) :3. 066 to 3.067
(l59G,USG) .... .................. . ................ .. 2.816 to 2.817
ivlai n journJl w id th be iween c heek":
2nd (];,j9(;. U8C) .. ... 1.499 to 1..')(12
2nd and 4t h (1880) 1.183 to 1.189
2nd (188G) Ll770 to 1.3740
3rd (188D ) L J740 to 1.3770
3rd tl.S9G ,148G ) 1. 74 1 to 1.7')1
5t h (1&30) .... ................. ..... .................................... . 1. 745 to 1.751
Connec tin g r od journal width be twee n cheeks .... ....... 1..3105 to 1.3145
CA :vrSHAFT
Ty pp '.,_, ,," .... .. ..... .... ............. .. .. ..... ................... .... .. Pa rabolic
Bushings (188D) __ ............ .... .................. ..... .... 5, R ep la cea ble
Bllshings (l8RG) ........... ...... ........ __ ....................... 4. Rep lacea bl('
Bu s hings (159G , 148(; I 3, Replaeea bl e
Oil CiC'a rance ............................................ .. ............... 002 to .00"
12-6

Engin e Block IContinued)

Maximum Limit
Including Weal'

CAMSHAFT (Continued)

Bushing lubrica tion:

Fro nt bushing ____________ ... ... ... . __ .. _... ........ . _..... . Pressure lubr ica ted
born oil pump.
Int er mediate bushing Gravity [low lubrica ted
Rear bushing (1880 Only) Pressure lubricated with
rear oi l metering.
Oil clearance ......................................... .................. ..... . 002 to .005 ........ .... ... .... .... ......... 007
l.D. of bushing installed ......... .......... ... .......... ....... ...... 1.752 to .1753
Bushing width:
1s t (front) (l59G.148G) 1.307 to l. 317
1st (front) (1880. 188G ) 1.213 to 1.223
2nd (159G,l.j8G) ........ . .713 to .723
2nd. 3rel & 4th (1880) ..j90 to .500
2nel. & 3rd. (lfSSG) .............................................. ... ..... .490 to .500
3rd (rear) (148G. 159G) ...... . . ................... ... , ..... .. ..... l.l77 to l.l97
4th (rear) (188(; ) ., ......... ,', . ..... .... ...... .. .. . ... . . .. ........... 1.213 to 1.223
.
5th ( rea r) (1880 ) , . . . . . . . . . . . ... . .. . ., , ., .., , .. . ., . . . . ... .... .... . .. . 1.213 to 1.223
O.D. of each bearing s urface (159G. 1880) 1. 749 to l. 750 .004
0.0. of each hearing s ur face (148(;,188G) 1.749 to 1.750 .004
Thrust plate' thick ness .............................................. _. _149 to .147
Camshaft e nd play ............... .... ........... Taken up hy thrust plate
Camsh a ft e nd c leara nce ........... .............. .................... 003 to .0(17
V.-\LVE PCSH ROD LIFTERS
Type ..... . ................... .............. , .................... Mushroom
Body 0.0. std. .5615 to .5620
1.0. of hloc k bor e. , td . .5625 to .5633 .0015
GI::AR TRAI:\
Backlash:
Crankshaft gear to camsha ft gear ................ ..... ....... _... 0002 to .000
Camshaft gear to ieller gear I Diesel) ............... ............ 0004 to .006
[ellpr gear to fuel pump gear [Diesel) ......................... ,0005 to .007
Crankshaft gear to oi l pump gear ..... " .......................... 002 to .008
Crankshaft gear 10 fuel pump gear (D iesel) ........... !';Iaximum .019
 12-7

Engine Block (Continued)

Maximum Limit
Including Wear
IDLER G EAR
0_0. of idler gear journal (Diesel) .. __ . __ .... __ ......... _.. 1.3740 to 1.3705 .0005
l.D. of idler gear w / bu shi ng (Diese l) ._ ........ _._... _.... __ .. 1.376 to 1.377
Thrust washer shims (Diesel) _...... _.......... _.... _. ___ .... 005,.006,.007,.009
Idler gear end play (Diesel) ... _......... __ .... _... __ .. _......... _... _.... __ .. _._._ ............ __ ................ ....... _... 003
OIL PUMP FRONT MOCNTED
Positive displacement pump . ___ ....... _.... __ .... _.... _..... _._ ...... Gear Type'
Pump gears to oil pump cover clearance .... _.............. 0015 to .0055
Pump gears radial clearance .... _...... _....... __ ..... _.... __ ...... _ .002 to .005
Drive gear to body clearance (I88G,159G,148G) ..... _... _... 003 to .006
Drive gear to body clearance (1880) ._ ... __ .... ___ ... _...... _ J)035 to .0065
Relief valve spring:
Wire thickness (1880) ........ __ ... __ ........ __ .... _.... _........ ___ ._ ...... _... _.. 0625
Maximum 0.0. (l88G,109G,148G) ....... _.... _.......... _.... _...... _.......... .469
Maximum O.D. (l88D ) ............ .. _........ ..... _.. .. ........................... .4844
Free lengt h (188G, 159G ,148G) .......... _............................. _.. _........... 2
Free length (188D) .............. _...... _...................... _............ _........ 2-1 /8
Load a t 1.38 inches (I88G,159G,148G) .... .. ...... ...... 6-3/ 4 to 7-1 / 4 lbs.
Load a t 1.44 inches (188 0) ........................... _...... ........ 18 to 19 lbs.
Oil press ure (lS8G, l59G, H 8G) .... _..................... _.... _..... 24 to 32 PSI
Oil pressure (1880) _........ _............ _.............. _.... _.......... 50 to 75 PSI
Bac klash , crankshaft drive gear and oil pump gear .. _.. _.. _002 to .008

Cylinder Head and Valves

Diesel Engines

CYLIND ER HEAD
Warpage ................................. _......................... _....... .. ............ _.................. ............. _........ . _006"

EX HAUST VALVE S
Tappet Clearance (Hot a nd Cold) .......... _.. .... _................ _................................ 0l4"
Face Ang le ....... .................. ......... _................ ...... ..... ... .. ....... _............................ -14"
Face Run-Out ............ ............ _.......................... _... _.... ....... ... .. .. ........... ..... ...... ....... .............. .002"
0.0. of Head ................................... _............. _........ _..................... 1:l9W' to H08"
0.0. of Stem ................................ _............ _......... _......................... :l:J99" to .3409" ..... .OW "
Length ......................... .. ............. _...... _.. _........................................ 6.:139" to 6. 364 "
Insert Seat Angle ................ -........ _.. _....... .. .. _........... .................... ..... ......... ........ 45('
Sea t Face Width ........ -................................................ _................................ 0415"
Seat Run -Out .......... .. .. ....................... _.. _............................... _........ ... .. ........... ................ ..... 002"
12·8

Cylinder Head a nd Valves (Continued)

Maximum Li mit
Including Wear
EXH.\ L:ST VALVES (Con tinued I
Insert Height ................... .. . . . .... ..................... ..................... ..... .247;) " to .2525"
0.0. o f Insf'rt ... ... ... . .. ... ........... ...... ..................... ............ 1.44;JO" to 1.4505"
LD. of In se:·t .... .... . ....... . . . ............ ....... ..... ... .... ..... ... .... ......... 1.245" to 1.255"

INTAKE VALVES
Tappet Clea rance (Hot and Cold I ................................ .. .............. ...... ... .......... 014"
Fa ce Angle . .. ..... ... .... ...................... .. ............. ...... ..................... ................ 44'
F a ce Run·Out ... ...... ............. ......................................... ....... .................. ........ ................. 002"
0.0. of Hea d ..... .. .... ............. ........... ........ .......... ........... ..... ... ... 1.599 " to 1.609"
0 .0. of Stem .............. .... ....... ............. ........... .......... .. ................... 3409" to .3419" .... . ..... 002"
Length ............ ..... ...... ...... .. ... .... ...... ............................................... 6.339" to 6.364"
Sea tAngle .. ...... .. ............. ..... ........... ... .... .... .......... ........ ................ .......... ......... -15'
Sea t Run·Out ............ ... .... ...................... .. ........................................................... .. ... .. .... 002"
Seat Width ..................... ... ...................................... .. .......... ....... ... 082" to .09.J"

EXH AUST VALVE G UiDES

Leng th ............. ... ................................. .. ............. ......................... ... .............. 3.125"
0.0 ...... ......... ................. ........ . ... .. ..... ......... .. ............ .... . ... .. ............ 6565" to .6575"
1.0. (I nstalled and Reamed) ........... .. .................................. ... ........ 3429" to .3439" ..... . .... 001"
11
V al ve SteIn Clearance in GuidE' . ......... " ... . ............................. ....... , ... ,002/1 to .004
Pro trusi on Above Cylind er Head ........................... ........... .. ... ........ ................ 875 "

INTAKE VALV!': GU IDES

Length ....................................................... ............... ... ... ... ................. .. .. .. .. 3.250"
0. 0. . ... .. .......... ....... ......... ..... . ..... ... .............................. .. .............. .6565" to .6575"
LD. ( Installed and Reamed) ............... .. ................... ......... .... ......... 34 29" to .:3439" ........... 001"
Valve Ste m Clcdra nee in Guide ......................... .. .................... ......... 001 " to .003"
Pro trusion Above Cylinder Head ..... .......... ... ..... ... ... .. ............. .... .. .... .............. 875"

VALVE SPRI1\C
Free Length ................. ....................... ... ...... ........ ...... .. ......... ..... ..... ...... .. .. 2. 375"
Tota l Coils .......................................... .. ........ ........ ..................................... .. .. 8.25
Wire Diameter ...... .. ... ..... ........................ .... .................................................. 102"
LD . .............. ......... . . . . . . . . . . .. ........... ........ ... .... .. .................... ... 958" to .978"
ComprE'ssed to 1.521 " (Va lve Open) ......... ........... .... ................... ..... 110 to 118 lbs .
Compressed to 1.875" (Va lvE' Closed) ............... .... ......... .....................53 to 59 lbs .

ROCKER ARM ASSEMBL Y

0.0. of Shaft ... ... . .622" to .623"
1.0 . of Arm Bore ........ ....... ... . .......... ..... .............. ........ .................. . .02'1" to .625"
Shaft Sp ri ng
Free Lengt h .... . .......... , .... ..... -- .... ................. ... ........... -.... -... ..... .. ...... .... 2.5 /'
Wire Diameter . ... ... . .... .... .... ............ ................. ......... ..................... 072 "
Compres sed to 1.70" ......... ......... ..... ................................. 7.5 to 8.5 lbs .
Lubri ca lion ..... ......... .. .. .................... Engine oil, camshaft m etE-ring
Shaft Oil Holes .... .. ......... . .. ... .................. ......... ...... Toward valve s ide of e ngine ,
shaft cannot be rotated.
 12-9

Cylinder Head and Valves (Continued)

Spark Ignition Engines
:'vlaximum Limit
Including \Vear
CYLINDER HEAD
Warpage ..... _........................................ . ......... _.. ..... .. ..... ......... ....... ....... .. . ......... 006"

SPARK PLUG
Gap Se tting (18mm) ........ _..... .. ............... _................................................. ...... 025"

EXHAUST VALVE
Tappet Cleara nce (COLD) ................... . .. .......•... ...... . _.... .... .... _........ _... •.......... . 020"
(HOT) ................................................................... ................ 014"
Face Angle ............... ....... .................. .... ... .... ..... .... ............... .. .......................... 44"
Face Run-out .. . ...... ... _....... ........... ........ .. .............. _.... _.............. ................ ... ........ _............. . .002"
Length (188 and 201) .......................•...... ....... ............. ... .. ..... ......... 5.824" to 5.844"
Length (148 and 159) .... _.......................................... . ..... .......... . ..... 5.309" to 5.3-34"
0.0 . of Head (188 and 201) ...... . ................................. ............ . .. ... . 1.398" to 10408"
0.0. of Head (148 and 159) ........................... . ............................... 1.265" to 1.275"
0.0. of Stem .... _......... .................................... ......... .... .... _.............. 3382" to .3390" .............. 002"
Inse rt Sea tAngle ............................................ .................................................. 45 0
Seat Contact Width (188 and 201) ..................... . ...... . ......................... 072" to .085"
Seat Contact Width (148 and 159) ... ... ............. ....... _.... ..........• . ........... 090 " to .100"
Seat Run·Out ........... ......... ................. . _.............. ...... •. ........... .................... _.................. ....... 002"
Insert Height (188 and 201) ........ ... ............................ ................ ..... 247.5" to .25£5"
Insert Height (148 and 159) ._ ....... .............. . .... ..... .... .. ......... .............. _198" to .203"
0.0. of Insert (188 and 201) ........ ........... ..................... .... .. ......... 1.4495" to 1. 4.10.5"
0.0. of Insert (148 and }.';9) ... _.................................. . ........ _.... ... 1..176.';" to 1.3775 "
I.D. of Insert (188 a nd 201) ......... . ...... ....... ....... ... .•............. ........... 1.245" to 1.255"
I.D . of Insert (148 and 159) ...... ....... ...... ..................... . .. ................ 1.074" to 1.084"

INTAKE VALVE
Tappet Clearance (HOT AND COLD) ............ ... .................... . ......................... 014"
Face Angle .............. _.............................. . .... ................. ... __ ................. ... . _......... 29"
Face Run-Out .. _...................................... ....... . ........ .... .. ................... .. ... ...................... .. .. . _... 002 "
Length (188 and 201) .. .. _....... ....... .... . ......... ........ .. .. .............. .......... 5.796" to :'.81G"
Length (148 and 159) ...... .............. ... ............. .... .......... ............... .. .. 5.275 " to 5.300"
0.0. of Stem .................................................................................. 3406" to .3414"
0.0. of Hea d (188 and 201) ........................................................... 1.51-1" to Li24"
0.0. of Head (148 and 1.19 ) ........................................................ _.. 1.410" to 1.420"
Sea tAngle .... ... ........... ............................................•............... . ....... ............ ...... 30:1
Seat Run-out ....................................................................................................................... 002"
Seat Contact Width (188 and 201) ...................................................... 055" to .070"
Sea t Contac t Width (148 and 159) ...................................................... 04.5 " to .060"

EXHAUST VALVE GUID E

LE'ngth (188 a nd 201) .......... .. ........................................................................ 2. 8.}j"
Length (148 a nd 159) .... ............. ...... ..... ................................. _................ .... .. 2.438"
0.0 ................................................................................................. 6565" to .6575"
1.0. ( Insta lled and Reamed) .............. .................................... ... ..... 3422" to .3432" ............ .. oor
Protrusio n Abo ve Cyli nd e r Head (188 & 201) ............................................ 1.000"
Protrusion Above Cylind e r Head (148 & 159) ...................... .. _.. ...................... 844"
 12-10

Cylinder Head and Valves (Continued)

:lIaximum Limi t
[ncluding Wear
I:\TAK£ VALVE GUWr::
Length (188 ancl 2(1) ......... ............ ..... .. ...... . ........ ...... .... .... .. .............. ... ........ 3.1 25"
Leng th (14 8 and 1.)9) ......... ...... ...... .. ......... ........ ................ ......... ................. 2. 688"
0.0 ........... ..... ..................... .... ........ .... .. .. ... ........ ........... .... ....... .. ..... 6565" to .6575"
LD. (I nstalled and Ream ed) .......... .... ............. .. ... ... ..... .................. 3422 " to .34:12" .... .. .. ..... 002"
Protr usion ."\bove Cylinder Head ........ .... .. .. .. ....... ... ....... ...... .. ....................... 1.000"

VALVE: SP RI:\ C (E:xhaus t Valve )

Free Leng th .. ..... ........ .................. ...... ...... ..... .......... .. ... .. ............. ........ ....... 2-:3 / 16"
To tal Coils ..... .......... .. .. .. .. .......... .... .. ....... .. ...... ..... ... ... ..... ..... ........ ..... ............ 7·3 / 4
Wire Diameter ... , .................. .. .......... ........ ... ..... ...................... . , ............. ... , ... , .162"
LD .. , ...... , ................... .... .............. , ...... .... .... .. ................. .... ............... .970" to .990"
Compressed to 1.3:12" (Va lve Open ) ..... ... .... .. ....... ... ..... .. .. .. ... .. ........ 110 to 118 lbs.
Compressed to 1.686" (Valve Closed) ... .............................................. 53 to .19 Ib s .

VALVE SPR ING (Intake Valve )

F ree Length ., ...................... , .... , ... ...... ......... ...... ..... , .... .. .... .. .. ....... ............... 2-3/8"
Tota l Coils ., .... .................. , ... .. ... ..... .. ....... ....... ....... .. ... ................................. , 8-114
Wire Diamete r , ............ ..... .................. .. .................. ... ..................................... 162"
1.0 .... .... .......................................... .. ............... ...... ................ .. .... ..... . 958" to .978 "
Compressed to 1.521" (Valve Ope n) ...... ... ............. .. ...... ..... ............. 110 to 118 Ibs.
Compressed to 1.87.'5" ( Valve Closed) .... .. .. ... ........... ..... ..... ..... ............ 53 to 59 lbs.

ROC KER AR;VI ASSE ;VIB L Y

0.0. of shaft .... ..................... ...... .................. .......... ......... .... ..... .. ...... 622" to .623"
LD . of Rocker Arm ......................... .......... ....... .... .... .. ...................... 624" to .62,)"
(Insta lled and Rea med on 148 and 159)
Shaft Spring (188 and 201):
F ree Length ................ ........ .. ................ ...... ... , .......................................... 2-1/ 2"
LD ....... ...... ......... " ...... ........ .. , ............. , ..... .. ... .... ... .. .. .. , ...... " ..... " ... , ... ,', .. ,. 11116"
Wire Diameter .... .. " .. ................... .... .... ' .. .. .... ............................................... 072"
Co mpressed to 1-3 / 4" .......... ...... .. .. .. ............... ... .. .. ............ ........... . 7.5 to 8.5 lbs ,
Shaft Spring (148 and 159):
Free Length .............. ....... ................ .. .. ... ..... .... ............ .... ............ ...... .... . 1·3116"
Total Coils ..... ................. ... ...... ...... ,., ........... .. .... . , .. ' .......... ... .......... ..... .............. 7
LD .. ....... ... ... , ............... , .. " ............................................ ,........................... ll ilG"
Wire Diameter .. ..... ,." ..... ..... .... .......... ' ....... .... ................... .... ........ ............ ... 072"
Com pressed to 11116" ....... .. .. .... .. .... .... .... .. ................ ... ............. .... . 7.5 to 8.5 Ibs.
Lubrication ................ .. ................. .. .................. ..... E ngine oil, ca mshaCt m e te ring .
Sha ft Oil Holes .... .. .................... .............................. Toward valve side of eng ine .
Shaft cannot be rotated .

Cooling System
Type ........... ....... ............. .. .. .. ... . .... Pressurized thermos tat controlled by-pass fOfced ci rculation

Pump Type , .............. ...... . Impeller Type - Sea led Pre-Lubricated Bearings.

Fan .... ............ , .. , ... .. , ........ .. .... . , .. , ................. , ....... " .................. ..... .. ................ , ..... .. Suction Type

Fan belt adjus tment ................... 60 to 75 P ou nd tension w /belt tension gauge or 112" deflection
 12-11

Cooling System (Continued)

Cooling System Capacity (l88D a nd 188G) ....... _.... ..... _............ ... ...... . ][i-112 C.S. Qts.
(148G a nd 159G ) .......... .... ....... ....... .... ... ....... ........... . .. 14 C.S. Qts.
Radia tor c ap ... .. ....... ................... ... ........ ..... ............ ... .... ... . . ..... ...... ...... 4 P SI

Thermostat ... ......... ..... .............. ... ..... ... ...... ........ .. ........... .... Start to open at ap pro xi mately 177"F.
Fully Open at 202"F .

Cold weather coolant ......... ... .... ..... ........ Re putable top brand "High Bo ilding Point" Anti- Fre<'ze

Radiato r .. ....... .... .............................. .. ..... ........ ... ........................ Hea vy Du ty Vin and Tu be Type

Engine Oil Filter

Type ............ ......... ..... .. ...... ...... .... .......................... ...... ........ ............ .. . Full Flow s pin on tYPE"

Capaci ty ... ........................... ...... ... .. .. .. ... ...... .... .. .. ... .... ......... ............. ... .. .. ... ...... 1 C.S. Quart

Filter rep lacement ......... . .. ...... ... .......... .. ... ....... .. ........ .. ..... ... ....... ... ............... Every 240 hou rs

Air Cleaner
Dry type ................................. .. ............................................................... Re placc'3 ble Elemen t

Cha nge Interval .................... .. .............................. Every six washings or more oft('n if required.

Ele m ent service inte rval ...... ........... When the re d sig nal a ppears in the clea r plastic window of
t he restric ti on ind ica tor.

Dust cup c heck ........... .. ..... .. ......................................... .... ....... . ... Whc'nevN eleme nt is serviced.

PRE·SCREEN ER

Se rvice Interval . . " . .......... ... .. .... .. ........... .... .. .. , ............ ... ... . ........ \Vh eneverclcm0nt is serviced.

RESTRICTION INDrCATO R

Replacement ...................... ..... .. .............. ......... .. .. ....... When the red sig nal do('s not d isappear
a fter severa l r esets or dOt'S not m eet the
speci fi cation given below.

CAS E DONALDSON INCHES OF I THES OF

:--:0. NO . WATER ME RCCRY

A59568 RBXOO·2 254 27.7" to 32.3" 2,(14" to 2.37"

12·12

Fuel System
FUEL FILTERS (Spa rk Ignition IOngine)

Fuel strainer serv ici ng ................. ....... ... .... ...... ........ ...... .. .... ................. Every 240 Hours

Fuel filter replacement ......... .... .. ........... ... ......................... ........... Every 1000 Hours or e a r li er
when loss of e ngine horsepower is indicated .

FUEL FILTERS (Diesel E ngine)

Filter replacement (Final and Primary) Every 600 hours Or e arlier when loss of engine
horsepowcr is indic ated.

Final stage filter ....... ......... .... .. ................................................................ :lO :vTicron F il tration

Primary stage filter .................. ... ........ ... .. ................. ... ............. .. ....... 2 to .~ ;,Tieron F iltra tion

Fuel fil ter element s pr ing:

No. of coi ls (active) ................ .... .................. .. .................... .................... .. .. . ................. 5·1 / 2

F r ee le ngth ................... ....... .. .. ....... .. .. ... .. ............... ......... ........... ..... .......... ................... 1.120"

Wire diame te r ............................................................................................ ... ........... ........ 060"

l. D. of spring ,6.15" to .665"

FUEL TANK

Capacity ........ ........... ........ ....... ......... ............ .... ........... ............ .. ... ............. .... .. . . 22 U.S. Ga ll ons

Water trap ........................... ... .. ......... .... ........... ... ........ ......... ... ... .. .............. .. ......... . Drain daily

FUEL 1NJECTIOi\ PUMP

Type ...... ....... .................... ..... ......................................... ..... .. .. .......... Roose iVIaster, Model DB

Rotation ...... ... ... ............. .... ... ... ................... ... ... ..... ........... .................... ....... ... Counter· clockwi se

N!o un ting ..... .... ...... ...... ........... .. .. ....... ........... .......... .. .......... .. ............... . Left hand side of engine

Drive ........................ .. ...... .. ........ .......... .. ....... .... ......... ............. Gear driven at 1/2 cngine speed

Lubrication ........................... .... ............................................................... Self lubrica teci by fu e l

Governor ........ ........ .. ..... ...... Cen trifuga l type, variable speed, fl ywe ight, integra l part of pump

TIMI NG

Timing marks ................. Located on cranksha ft pulley (0 0 to 35" BTDC) and (0'1 to 1.111 ATDC)
tim ing pointer loca ted on timing gear cover.
1750 RPM Rated Engine Speed .......... ........... ................ ......... ............... .......... ............. 4" BTDC

1850·1900 RPM Rated F: nginc Speed 8° BTDC

2000·2100 RPi\ll Rated Engine Speed 8' BTDC

 12-13

Fuel System (Continued)

TLvlI0:G (Continued )

22(J0-22'50 RPM Rated e ngi ne Speed .... ............... .......... ............... .. ...... .. ...... .......... .. .... . 8" BTOC

FUE L [:\.JECTOR

Ty pe ...... ... ...... .... _.... _........... ........... ......... .. ................... ..... ........ Roosa Master-Pencil

Opening pressu re (nev.) 2750 to 2850 PSI

(servic ed) ........ ...... .............................................................. .. .............. 2550 to 2650 PSI

Ma ximum opening prt'ss ure differt'nce betlVee n cylinders ............................................. 100 PSI

Valve lift .................................. .. ........ .. ........................... .. ....... 1/2 turn off valve seat or .009"

Spray orifice size ......... ........ .......... .. ................................................ ............. ........... .. ...... .. .011"

Sac hole size .012"

:\umber of orifices ...................................................... _.......................... _................ .. ............... 4

Orific o spray angle ............... ............ ...... ................ ............ ......... ................. ........ ........... 160"

Leakoff rate .................. .......... .. .......................... 3 to 10 drops in 30 seconds a t 1500 PSI after
first drop appears (se rviced injector).

Opening pressure control spring:

Free length .536"

0<0. of coils ........ .... ................................................ ........................ .. .............. ....... ................. 7

Wire diameter .. .056"

0.0. of spring .272"

Compressed to .4:l5" - ,457" ....................................................... ..................... 27 Ibs. pressure

CARB URETOR (188(; and 159G)

Type .................. ............ .......... .......................... .. .............. ... ...... Zen ith Updraft, Si ngle venturi
with magnetic shut·o~f sOlenoid.
Magnetic fue l shut -oli sole noid ................................ ....................................... " ........ ....... 12 Volt
Idle Speed adjustment ...................... ...... ...................... ... ......... _......... ................. 600 to 650 RPM
Idle mixture adjustme nt ............................................................... Appmximately 1 (urn open
Load adjustment ........................................ ,............. .. ................ Approximately 2 turllS opens
Floa t ad justment ............ ........ ................ ......... .... ........................... ........ .. 1.156", without gaske t
Venturi (at narrow point) (l88G) ........................ .... , ............................................................ 78"
Venturi (at nan'ow point) (l59G) ............................ , ....... ..................................................... 74"
Main je t (l88G i ......... ........... .......... , ........ ............................. ..................... ....... , ..... ............. 049"
Main jet (159G) ..................................................................................... .. ............................ 037"
Main discharge jet .................. ......................................... ............. ... ......... .......................... 118"
Well vent jet (l88G I .................... .. .................................................................... .... .............. 039"
Wetl vent jet (159G) ......................................... , ............. , .............. .............................. , ...... .051 "
Idling j et (l88G) . ......... ..... .. ............................ _.. .................................... . .................. .. ......... 025 "
 12·14

Fuel System (Continued)

C\RBCRr-:TOR (Continued )

Idling jet ( 159G ) ...... ............ .... .... ...... ....... ........... ... . .. .......... ....... ..... ...... .. ...... ..... .. ............... 020"
Float val VI' sea t (l88G) ...................... .... .. .... .............. ...... .... .. .......... .. ..... .. .. .. ".".... .. .......... .069"
F loa t va lve sea t ( 1~9G) ... .. ................... .. ......... .................. ............ .. .. . " .. .. .. .. .... .. .. . ............. .078"
Idle air bleed ( l 8SG) ........ ..... .. .. .. . .. . ...... ...... ". " ................................................................... 055"
Idle air bleed ( 159G) ............................................................................................... 059"

Choke Lever spring: Idle adjusting need le spring:

Number of coils ............... ..... .......... .... 18 Number of coils ............................... 4·1/2
Wire diameter ................ ........ .......... .031" Wire diameter ................................... 040"
Free le ngth ..................................... . 1.000" Free length .......... .. ...... ...... .......... .... .469"

CARBURETOR (148G)

Type .............................. .. ............. ... ................. Marvel·Schebler Updraft, Single Ven turi
with shut ·off sole noid.
ylagnetic fuel shu t·off solenoid ......... .. .. .. ............ .... ....................................... .. ................ 12 Volt
Idle Speed adjustmen t ..... .................... ... ... ....... ... ..................... .. .................... 600 to 650 RPM
Idle mixture adjustment "''''''''''''''' '''''' '''' '''''''' ''''''' '''''''' '''' ' ''''''''''' Approximately 1 t urn open
Load ad justm ent ......... .... ...... .......... .. .............. ..... ........ ................... Approximately 2 turns open
Float <ldj ustment ..................... .. .. ........ ..... .......... ........... ... ............................. 114" from gasket
Venturi (at narrowest point) .. .. ..... .... ........ .. ........... ..... ............. ...................... ...... .. .......... .782"
Power jet ................................ ... ........................................................................................ 0635"
iYlain nozzle .............................................. ,... ............... ..................................................... .115/1
Upper Vent hole ............ ...... .. .................. ....... ............ ...................................................... .046.5"
Id ling jet ........... .................. ....................... .... ... ...... .. .. ................. ... .................... ............. .033"
F loa t valve sea t ...................... ......... .. .. ........ .. ... . .. ...... ..... .... ......... ............ .. ...................... .070"
Idl e feed hole ....................................... ...................... ...................................................... .0. 0"

Choke Lever Spring: Idle Adjusting Needle Spring:

Number of co ils .................................... 5 Number of co ils " ...................... ...... .. 5
Wire diameter .................. .... .0317" 1.0. ... .. .. ........... .. .... ........... ... .. . . .203"
1. O. . ...... .. .. ..... .. ............ .. .. ...... ....... .281" Free length " ....... "" .. " .. .. " ........ ..... . .531 "

Choke Valve Spring: Throttle Lever Spring

Numbe r of coil s ....... .. .. ............. 26 to 27 Number of coils ............. ..... ..... 4·112 to 5
Wire diameter ........... ".................... .029" 1. D. . .. " .... "" " ...... ",, .. ".................... .165"
Free le ngth " ...... .. .... .. .. .... .. .. " ."" ... 1.062" Free le ngth .......... ........................... .281"

Brakes
Type flui d ......... ..... .............. ..... .................................... .......... .... .. .............. ... .. .......... Case TCH
Free pedal ........................... .... .......... .. ...... ...... ..................... 1·1/4" to 1·3/4"
Brake Pedal Return Spri ng:
Free Length .................................................................................................. " .. ... .... ....... 4.625"
Wire Diameter .............. ....... ........................................................................ ........................ 135"
:\0. of Coils ... .. ................ .. .................................... ....... .............. .. ........ .. .. ...... .. ........... 22·1/ 4
 12 -1:;

Brakes (Continued)
Disc Spring:
Free Length ................... _............ . ...... _...... ................ ........ .. ......... ............ ... ......... 1.27"
Wire Diamete r ... _... . ......... ... ................................................................................. .. ....... .. .0857"
No. of Coils ............... ..... ..... .. _.............. . _................ ... .. ... .. .. 10·114
Expand to 1.37" 22-1 /2 to 27-1/2 lbs.
Retractor Spring:
Free Length ............ _............ ..... .. . _..... ............. .... . ... .......... .............. _............... .. .. ............... .. 66"
Wire Diameter ... _................ ................. ... .. .... _.. ..... ............. .. ..................... _... ... .. .. ...... ....... _ .060"
No. of Coils ..... ......... .. .. ........ ... .. ............ _...... .. .......... ....... .. .................. ............... .......... .... .. 5-3/ 4
Expand to .74" ........ ........ ........ .. ...... -........ .. .... .......... ....... .. ........ ...... ......... . ............. . 9 to 11 lbs.

Power Train
S HUTILE TRACTORS
Reverse id ler gear bu s hing 1.0. (burnished) .. ................. ........ .............. ............. .. .. .862" 10 .863"
Co untershaft bea ring pre-load .... ........ .................... .. ....... 4 10 12 in. Ibs. required [0 rOiale sh afl.
Differential end play ......... _.............. _........ ........... ............ ....... _.... ........ _................. .. 1'0 e nd play
Diffe re nlial gea r 10 count er-shaft pinion backlash ............. .. __ ...... ...... .............. ........... 005" 10 .009"
Axle sha ft end play ................ _...... ................ .. .... .... .... _.... ... .. _.. ..... ......... ................ .0001" 10 .001"
Countershafl e nd play (between 2nd and 3rd speed gear ) ... .. _............. ...... ...... _00 1" 10 .006"
Gear shift fo rk r a il interloc k plug .............................. _._.... ........ .. ...... ....... ...... 0.0 .. 373" to .375"
Longth .566" to ..074"
:Vla in d r ive shaft end play ............ ....... __ .... ... _....... .............. .......... .... .... .. .............. .. ... 002" to .005"
Differentia l cenler wheel to side wheel bac kl as h (pinion gear) .... ................ .. .. _._ .... 005" to .015"
Shifter Lever S upport Spring:
Free Length ........ ........... ............... ,..................... ...... . , .... .... .................. ... .... ............ ......... , .. .. 211
Wire Diameter ....... ... .................... ..... .... .. ... _....... ... .. .. .... ........ _....... ...... . .. ................. . _.... .. .. 1416"
No. of Co ils .. _....... ...... _....... ........ ..... . .. ....... .... .. .. .... .. ................. ...................... ........... .... Optiona l
Com press to 1-5116" ............. ... .. . ............. ...... .. ........ ........ .......... .. .. .................. ........ 35 to 50 Ibs.
Range Detent Spr ing:
Free Leng th ................. .. ...... .. .................................... . ........................... .................. ..... Optio nal
Wi re Dia meter ...... .... .. ........ .... .. .... ..... .. ..... .... .. ..... .... ... .... .. .. .............. ... ... ...... . ..... ............... .. 072"
No. of Coils .......... ........ ... .... ....... .. ...... .. .............. ....... ................. ..... ........ .. .... .. ............. Opti ona l
Compress t.o 13116" .................... .. .................. .. ...................... .. .. ..... ............. ... ........ 35 to 38 Ibs.
Neutral St.art Spring:
Free Lengt.h ..................... .. ................ ..... ..................... ..... . .. .... ......... ............... ........ ........ 1·911 6"
Wire Diameter ...... ................ ...... .. ... ............. .......... .... .. . .. .. ................ .. ... . ........ ...... .............. 056"
No. of Coil s ................. ..... ............. ............ ....... .......... .......... ....... ................... ... .. .. . ..... ........... 11
Compress to 1.2;;0" .............................................. .... ...................... .. . ..... ........ ..... ..... ... 19-112 Ibs.
12·16

Power Train (Continued)

HYDROSTAT1 C TRACTORS

Forward· Reverse peda ls free travel ..... .... ........ ... ...... .. " ... . " ..... .................................. 1/4" to 112"
P ini()n shaft bea r ing preload " ."""""." " ... " ." .. """.".",, ..... ,,"" 4 to 12 in . lbs. rolling torque
Dump valve pad to lever clearance """" ..... . " .. "" .... . " ..... .. ................... "" ............... .. " .. ,, .... . 045"

Steering
STEERING HAND PUMP

Steering sh a ft 10 body clearance .006" Max.

Rotor to stator clearance .................. ....................... .. " ... .......... ..... " .... . " .. " ....... " .. " .. 005" Max.

STEERING CONTROL VALVE

Centering Spring:
No. of Coils .... " ................. .... ........................ " .. " ... ................ " .......................... " .................. 6
Free Length ............. " ...... .. .... ... .. .......................... " ................................... ... .. ........ ..........860"
Wire Diameter .................... ....... ................... ... .......... ...................... ................................. 080"
1.0. of Spring ......................... ......................... ................ ........ ........... " ............. ................ 625"
Compressed to .824" ................................................ " .. ............................................ 1.5·2.5 lbs.

STEERING AXLE

Front wheel toe·in ........... ...... ....... ....................... ............ ...... ............. .............. ... .. .............. 1/ 4"

Front pivot pin bushing, insta lled and removed 1.0 ........................................... 1.744" to 1.746"

Rear pivot pin bushing, installed and remove d 1.0 ...... .. ................................. " ..... 863" to .864"
 12-17

GENERAL TORQUE SPECIFICATION TABLE ( Rev i sed 6 - 67)

USE THE FOlLOWING TORQ UES WHEN SPECIA L TORQ UES ARE NOT GI VEN
NOTE: These val ues apply to fastene rs as r e ce ived fr om s upplier, d ry , or Id len
lub r icitte d with 1100'm a l engine oil. T he y do 11 0t " pply i f s pcc i;!1 g- r" l'il ite ct
or moly- di sulphi (le gre3ses or other extre me press ure luh r ic.mts" re
used. Thi s " ppl ies to both UK F anel U:\C t hreads.
SAE Grade No . 5 8 ..
Bolt head identification
ma rks as per grade
Note: Manufacturing
Ma rks Will Vary
0 0
Torque Foot Pounds
@ 0 ®
To rque Fo ot Po unds
I \ @
Bolt Size Min. Max . Min. M ax.
1 .' 4" 9 11 12 15
5 ' 16 17 20.5 24 29
3B 35 42 45 54
7 16 54 64 70 84
1·2 80 96 110 132
916 110 132 160 192
5. 8 150 180 220 264
3 4 270 324 380 456
7 8 400 480 600 720
1" 580 696 900 1080
1-1 8 800 880 1280 1440
1-1 4 11 20 1240 1820 2000
1-3 8 1460 1680 2 380 2720
1-12 1940 2200 316 0 35 6 0
* Thick nuts mus t be used wi th Grade 8 b olts

Special Torques
ENGINE BLOCK

Camshaft nut .... .... ................................. .... .......................... .................... . __ ...... ... 80 to 90 Ft. Ibs.
Connecting rod nuts ........... .. ... ... ............ ..... ....... ........................ ................ ..... .. ... 45 to 55 Ft. lbs.
Cra nkshaft nut .............. ............. ......................................................... .... .......... 125 to 135 F t. Ibs .
Flywheel to crankshaft bolt ......... ....... ........................................... .. .... ...... .......... 65 to 70 Ft. lbs.
Main bearing cap bolts .......... ... ...... .. .. ..................... .. ......... ... ... .... .. ....... ............. 90 to 100 Ft. lbs.
Oil pan capscrews (Stamped s teel) ...... .. ......................................... .......... ..... ...... 10 to 12 Ft. lbs.
Oil pan capscrews (Cast iron ) ........... _... .. _.. .......... ...... ... .. .... .. .. ...................... ...... 24 to 28 Ft. lbs.
Oil pan to sea l r etainer ............ .... ............ ... .. _..................................................... 15 to 20 Ft. lbs.
Oil pan drain plug .................... ....................... .... ................................... ... .. .. .... .. 18 to 20 Ft. Ibs.
Oil pump cover capscrews ................................ ...... ............................................... . 6 to 8 Ft. Ibs.
Oil sea l reta Iner bolts (Grade 8 bolts) ............................................... ..... ... _........ . 12 to 15 Ft. lb5.
Fuel pump drive gear nut (Diesel) ........... .. ... .. .. .............. .. _.. ....... ...... .................. :35 to 40 Ft. Ibs.
12-18

Special Torques (Co ntinued)

CYLI0iDER HEAD AND VALVES
Cylinder head flanged nuts ........ ... ......................... .. ......................................... .. 90 to 100 ft. Ibs.
Cylinde r head st ud nut s w/ hard e ned wash e rs ........................ .................. ........... 95 to 105 ft. Ibs.
Cylinder head grade 8 bolt s ........ ......................... ..... .... ..................... .............. 110 to 115 ft. Ibs.
Intakc and exha us t manifold stud nuts ............. ..................... ....... .. .............. .... .... 25 to .30 ft. Ibs.
Roc ker arm bracket stud nut s a nd bolts ........................ .. ....................... ............. 25 to 30 It. Ibs.
Valve cover s tud nuts .. ............. .............. ............... .................................................. 5 to 8 It. Ibs.
Water pump st ud nuts ................. .. .............. .. ... .. .. .................. .... ..... ...................... 20 to 25 ft. Ibs.
Spark plugs .................................................................................... ....................... 32 to 35 ft. Ibs.

FUEL SYSTE1v1
Fue l injector pressure adj us ting sc rew locknu t ...... .. ............................. .... ... ........ 70 to 75 in. Ibs.
Fuel injector clamp capscrews ...................................................................................... 20 ft. Ibs.
High pressure fue l li ne banjo connec tion screws ............. .. ............................................ 35 ft. Ibs.
Fuel inle t filter a ssemb ly (Diesel) ... .............. ............................................... .... ........ ..... 20 ft. Ibs.
STEERING
Con t rol Valve e nd cap retaining bolts ............ ... ............................................ .... .... 14 to 17 ft. Ibs.
Hand pump body bolts ........ ........ .................. .. ........... .......................... .. ............... 18 to 22 It. Ibs.
Power s tee ring pump cove l' bolts ................................................. ................. ......... 9 to 11 ft. Ibs.
Relief val ve locknut ................ .. ....................... .. ............................. ...................... 18 to 20 ft. Ibs.
Relief valve ca rtridge ................................. .. .................................. ...................... 10 to 12 ft. Ibs.
Cylinder end plate re tai ning scrcws ...................... ................. ............... .... ......... .. .... ;) to 7 ft. Ibs.
Piston rod locknu t ............. .. ......................... .. ......................... ... ..... ...................... 30 to 35 ft. Ibs.

POWER TRAI;\ (Shuttle Trac tors)

Front cover or dual range hou sing nuts .......... .... ............................................. .... 35 to 40 ft. Ibs.
Axle housing bolt s ........ ................... .................... .................. .... ............. ..... ....... 150 to 180 ft. Ibs.
Differentia l brake housing bolts ........ .. .................................................................. 70 to 90 ft. Ibs.
Countershaft locking bolts ............ .. ........................ ................. ......... ............... ...... 35 to 40 ft. Ibs.
Transmission case to torque tube bolls ........................... ......... ................... ...... .. 80 to 132 ft. Ibs.
Transmission case to torque tu be s tud nuts ............. ..................... .. ................... 110 to 132 ft. Ibs.
Reve rse idler ge ar stud nuts .... .......... .................... ............... ................... .......... 130 to 145 ft. Ibs.

POWER TRAIN (Hydrostatic Tractors)

Banjo fitting bo lt on hydrostatic pump ......... .............................. ...... .. .................. 14 to 16 ft. Ibs.
Servo mounting bolts ......... ........ ....................... .. ................................................... 18 to 21 ft. Ibs.
Hydrosta tic pump brac ke t to hou sing bolts ........................................................... 35 to 42 ft. Ibs.
Hydros ta tic pump mounting bolts .. ............................. .... .......... .. ...... .. ...... ............ 30 to 90 ft. Ibs .
Hydrostatic motor mounting bolts ........ .................... ............. .................. ......... ..... 80 to 96 ft. Ibs.
 Section
13
LUBRICATION

580 SERIES B HYDROSTATIC TRACTORS

Rae . Form 9·80761

Rat. Form 9-80741
 SECTION
13

MAINTE ANCE
AND
LUBRICATION
FOR
LOADER AND BACKHOE

Burl. Form 9·720815 KHCa O Printed i n U .S .A.

 L UBRICAT ION

Lub r l c anls
Lubricants Backhoe L ubr l callo n I"olnls

G rt?ase
rease Fitti ng s
F ittirigs The backhoe pivot points Shoul
should d 00 lu bricate d every
be luhrifatticl V& l'y
lJO \' e 32' fI-.. (0' C.)
Above
A C. ) . . ... . i\Jultipu
Multipurpose o r No,
rpo se or :-.io. 2 10 hou l's. If the backhoe is
1 0 hours. is u sed
s e d In
in se abnormal
ve r e o rr abnor
severe mal
IH h\.u m - ~ oa p
l U h S u m - s o ~ pbase grease
grease wo r king conditions
working conditions,. reduce the
the ti me lnte
time r vtLl hyonchfitf.
interv;il by One ha lf.
32' F.
Below :32' F. (0'
(0"C.) . . .... Multipurpose or
~ l1Jl t ; pu l' pose No.11
o r NO.
ba s e ggrease
lith iu m -soap buse
lithium-fcoap r e ase 1. St abi lizer c y l iinde
Stabilizer ..........
n d err . oni-. e;Jch
one ear'ti r;~i.(}ej e
Dipper
Pippt.'). ex
u ~tension
t e f l  ¥ : 'we
l ie~aar
N strip?
t - st r ips (Extencliihi~<?)
( Ex te tldohoe) 2. Swing l l n r t ttrunnion
S w i n g c~ yylinder ~runn
r ion ....... tho eac
1\\'0 e a c h sside
t.de
STP 011
Oil Treatment 3. Swing cyli nder rrod
Sftlngcyllnder oc! eye ........ ne each
one 8-ide
e-ich side
.; . Swing to\w>r
Swing towe r pi vot s . . . . . . . . . top
pivots to',?and bo ttom
Load er L
Loader ubricallon I"olnts
Lubrication O. Boom pi vots .. . . . . . . . . . . . . . .o
pivots ne each
one ei~~ side
S I~ Lh~
6. Boom c yyli n d e r . . . . . . . . . . . . . t\\'o
l i nder two eeach
a c h si
s i de
de
The oade rr pivots
The lloads shank?
p ivots shou ld be llubricate
u l ~ i - i c ' a tde de ve
v e ry
r y 10
10 7. Dipper cy li nde r. . . . . . . . . . . . . o ne
Dipper cylinder n e each sirl
hirle e
hou If the
h o u r ss,. If loade r is
the' 1oadt;r is us en in severe
u$erl severe o rr abnorm a b n o r ma l O. Dippe pivot.. . . . . . . . . . . . . . . . ...
Dipperl' pivot . . . . . .one
\\'orking conlHtion5,. w
~i-orkir'igconflitions i n c e the Orne
r educe t i w Inter
interval v al by one 9. Bucket c y l i n d e r . . . . . . . . . . . . .. otle
Bucke t cylinder. .oni: eJ.(!h
e w h endenri
half.
Â¥Half 10. Bucket pivot pil'ot . . . . . . . . . . . . . . . . . . ... . . .one
I I. Swing pedalpe rl al . . . . . . . . . . . . . . . one each sside ide
I. .oaner frame
I.oatle-r pivott .. .. .... . . . . . . one
fr ame phro One each side
2. H:-r'dra - Le,~ el1ng cyli
cylindpr.
nder . ...... one eeaoh en
h d
~ c end
3. . . . . . . . .
Li ft cylinde r ... , ... two e aacc h si de
aide
4, T!lt cylinder.
Tilt ..............
cyli nde r .. , , , .. one each
e ac h side
s id e
5, T ilt cylinder
Tilt tru nnI on . . . . . . . . two each side
c yli nder trunnion sIde
6, bucket
BLlc ket link
li nk ............... tivo
l\vo each
e ach side
j , u i h e t pivot
Bucket
B . . . . . . . . . . . . . . . one each side
pi vot .. sl de
R, Cla m cc!~lirider.
('Urn .............
yli nde r . two each
e a.ch sirle
sirte
9. Clam
C l ~ mpivot ... ................ one
o n e eeach
ach sside
ide

f' igu re 2 - Backhoe Lu"bricaUon Point5

Backhoe Control
Backhoe C o n t r o l Lever
Levers
71()QBS Each control lever
leve r pivot is i~ pprovirie4
rov ided 5% gre~sc
lh ll.:igr~tlSe
wiith
fitting.
filting. The pivots aare r e in itiall y luiiru-atesl
initidlly lubricated at ai the fac to r y.
thefiictory.
F lg-ure I . Lo ade r Lu1)),lcatinn Pojnts The
T l1e pivots hou ld r('aare
p tvots sshould y require
r e lly lul'incation kbecause
l'equ! 1'e lui)1'iciltion c a u s e of
the protection provi ded by the contr
protec tion provided controlol tower. Lu Lubricate
bdc a te
T h ree-Point H itc h L ubrication Points leverr pivots
the leve e very ssix
pi\'ots every m onth soorr ever)
ix months every 1000
1000 hou hours.
rs.

rhe j3-point
The ~poin t h itc h pivot
hileh pi vot pint¡
po int s- shoul he lubricated
shouldci 'be To guln access
gain acc ess to grew=
t o the greEl htt~ l1 gs , rremove
s fittings, emo ve the
. " ~ ~ e r v10
every hour';. . If the hitc
10 hours hitch i s used
h is used in s e ve
ii-i se v e re
r e or abah-- upper
upp er front con
control t ro l tower c(J ve r . If
covt-r, It" the
thv bbJ).c
~ ckh.o
k h oec -is
no w o r k iing
r ma l work
nnrm.jl t:onriitlon$,
n g cond rt:rince
itlon s . redu the time inte
ce the interval
n Ta l by equipped with boom
b oom lockout,
l ock out, d isconnect the IILOL'S
diftconncct ines from
from
half. Ilemove
13ne ha.lf. d i rt gie.i'so flfittings
f r o m grea,5e
r t [roro he lockout ccontr
tthe arid rreliefva-lvc-"..
o n t r ooll and I t is
eli ef val v es . lt t5 [wt ncc'essa-ry
nut oecessal'y
One Hemo\'e di tt lngs before
sppl? greasii gu
3ppl ~r ing grease gunn. to remove
remov e tthe valves
he val ve s frfrom
o m the front
fr on t cco+,'er.
a ...·er .

1.
,!. 1 ift
Li ft cyli ncte r ... . . . . . . . . . . . . . onE:
cylinder. one each
e ach end Dipper Extension
E x t e n s i o n Wear
W e a r Strips
Strips
2. Li
Lift 4 ~ t i.
ft arm ... .. .. . . . . . . . . . . . . . . . . . . . . one
3.
:j Tilt cylimler rod eye .. . . . . . . . . ., ,. .. ,. . ..
T11tc:~linrlerrodeye , oone
ne Lubricate the we
Lubrie fl te the wear
a r strips once a month with
s t. ri ps .onCe w ith
Treatment,
STP Oil T r e a tm e nt.

Exce ss i\'e lubrication

Excessive lu brication of the M
\Veal' u~i i l
f r t r ~ p :will
@ i I r strips
e s u l t iinn rapid
r esult r apid weal' tr; ps bec~mse the liiln'scxnt
wear of the sstripsbecniise ltlb~'i c anl
also act actss aa.ss a colle c t o r of dirt
c o l l ectot' +in'%grit.
d i r t and grit.

T
Too lubricate thewear
lu br icate the we Dr sstrips,
tr Ips , fful
u l ly
l y ex tend the dipper
?iienll
x ten5i on and apply a light cotit
eextension coa t of a!. llutrrtcant : to tach
u l ~ r i itint EH"I ch
strip.
s t r lp. Ret r a c t the dipper extensson
R e tract e xtenSiD r1 311dan11 remove
r e Q'lQve excess
lubricant.
lubri ca nt.

2
 Section
22
CYLI N DER HEAD AND VALV ES
188 DIESEL ENGINES

SPEC IFICATIONS
Maximum Limit
CY LINDER HEAD Including Wear
Warpage .......... ....... ...... ........ ...... ...... .. ............ ....... .. .... .... ........ .... ... ... ......... ............... .. ........ 006"

EXHAUST VALVES
Tappe t Cleara nce (Hot and Cold ) .... ................ ....... ....... .. ................... .. .......... 0)4"
Face Angle ..... ............... ............ ........... ... ........ .... .... .. .... .... ..... .......................... 44"
Face Run·Out ........ ................... ........ ....... ....... .. .............. .................................................... 002"
0.0. of Head .. ......................................... .......... .. .. .............. ... ....... 1.398" to 1.408"
0.0. of Stem .. ... ..................... .... .. ................. ........................ ......... 3399" to .3409" ....... .... . .002"
Le ngth ........................................................................................... 6.339 " to 6.364"
Insert Seat Angle ........ .. ..... .................. ................ ..... ...... ... .. .. ............... ............ 45"
Sea t Face Width ......... ................. ........ ...... ............... ........................... ........ .0415 "
Seat Run·Out ......................................... ....... ..................... .. .......... .... ..................... ............. 002"
Insert Height ........... .... ......... ........... ... .......................................... .2475" to .2525"
O.D. of Insert ............................................................................. 1,4450" to 1.4505 "
1.0. or Insert ................................................................................ 1.245" to 1.255"

INTAKE VALVES
Tappet Clearance (Hot and Cold ) ................................................................... 014"
F ace Angle .... ....... ........... ............ ............. ........ ................. .. ..................... ........ 4411
Face Run-Out .......................................... ........................................................................... 002 "
O.D . of Head ...... ........... ......... .............................................. ......... 1.599" to 1.609"
O.D. of Stem .................................................................................. :3409" 10 .3419" ............. 002"
Length ........................................................................................... 6.339" to 6.364"
Sea tAngle ........................................................................................................ 45"
Seat Run-Out ............................................................................... ... ............... ....... .. ...... ....... 002"
Seat Width .......... .. .. ........ .... ... .. ... ............................... .......... ...... ...... .082" to .094 "

Rae. Form 9-80471

 22·2

SPECIFICATIONS (Continued)
Maximum
Max imum Limit
EXHAUST VALVE GeIDES GLIDES Includ
IncJuding ing Wear
Wea r
Length .........................................................................................................
LC'ngth ........ ........ ......... . ...................................................................... 3.125"
0.0. ..........................................................................................
O.D. .......... ......... .. . . . . ...... ............................... .. ...............6565" 6565" to .6575"
.toto
,,
1 Â¥ FÃ

l.ll
1.1).. (Insta lle d aand
( Installed nd R o a m e d ) .........................................................
Hpamecl) ........ ........ ... ... .... ...........................,3429" .·3439" ...............
3429" to -3439" . .001"
.OUI1'
V k e Stc~m
Vaa!vt> Stpm Cle a ranc(' in GlI
Cl~.:nanrc .......................................................
iCle ............................
CÈuirU- 002" to .
.............................,002" .004"
%I"
Protrusion Above Cy Cylinder ...................................................................
lincler Head ............ ...... ............... ...... ....... .. ....................,875"
875"

I:,\T.\KE
INTAKE V A L V E Ger
VALVF: GLID DES
ES
LLeng .........................................................................................................
c n ~thl h....................................................................................................... 3.25fl"
3.250 "
0O.D. ...............................................................................................
.0 ........... ......... ................ .................... .. .......................... .. ............6565"
6565" to .6575"
lI.D
,D.. ( tnhtatled
Insta lled and Rea m e d ) .......................................................
R o a med) . .................. .. .... ... .... .......... .. ..... .. .....3J29"
3429" to .3439" .............
.3439" .... .... ....,001"
001"
Valv!? Stem
Valve S t ~ mClearance
CleLir.-inre in Gu ........................................................
ide ..........
Ciuirif1 001" to .003"
........ ......... ....... ........................001" ,OO':V'
Protrusion Abo\'c Above Cylinder Head ...................................................................
....................................................................,873"
875 "

VALVE SPRINGSPRII\C
F r ee Length ..............................................................................................
Free 2,375"
... .. ...... .. ... ....................... .. .................... .. .......... .......... 2.3 75 "
Tota ......................................................................................................
I olall Coils ......... .. ....... .... .... .. ....... ......................................... ..................... .. 8.25 F.25
Wire D Diiaam me tN ...........................................................................................
t e r ... .... ... .. ............. .. .........................................................-162"
lfi2 "
l.D. .
I.D. . ....................................................................................................
......... .. ............................................. .. .............. .. ........958" 958" to .978"
.978"
Compressed to 1.52]" (Valve Open)
1.521'' (Valve ................................................
Open) ........ no to 118
.. ................... ... ................ 110 118 tbs.
lbs.
Compressed to l.875" 1.875" (Va ( V alvel v e Closed)
Closed) ...... ................................................. ')3 to "in
.. ............... ... ........................53 59 Ibs.
Ibs.
ROCKER ARM ASSI-;&IDLY
ASSEMBLY
,
....................................................................................
O.D. of Shaft ........................ ..... ........................................ .. ............b22
622" to ,623"
.623" .d !f

1.0. Boro ..............................................................................

1.11, of Arm Bore ................................................ ................. .. ..........,624"
624" to .625"
Sh af t Spring
Shaft Sprinp
Free Length .................................................................................................
Leng th .... .. ... .. ... ...... ........................................................................ 2.0"
2.7''
K i r o Diameter
Wire .............................................,..............................................
Diarnisater ... .... ............................ ........................................................,072'' 072 "
Compressed
Compre ssed to 1.7:," ....................................................................
1 i?" .............. ...... ................................................. 7.5 to 8." 8.5 lbs.
Ibs .
Lubrication .........................................................
Lu bricat ion .................................. c a m s h a f t rmetering
.. ............. .. ......... Engine oil, camshaft nwring
Sha
Shaft ........................................................
ft Oil Holes ............ .. .... .. ................................... Towa
Toward rd valve
va lve sside of engine.
i d e of e ngine ,
shaft canno
cannott bbee rotated.
r ota ted.

SPECIAL TORQUES
Cylinder Hea d Studs w/Flange
Head w/ Flan ge NuNuts .................................................................... 90 to 100
ts .................................................................... 100 fit.
t. Ibs-
Ibs .
Inta ke <lnd
IhTal,-Q 'ind Exhaust :Vlanifo ld Stud :'\UIS
"Manifold ............................................................... 25 to ,'\0
S u t s ............................................................ 30 fft.t . lbs.
Ibs.
Coverr Stud Nuts ........
inderr Head Valve Cove
Cy linde ...................................................................
.... .............................. .............. ............ 5 to 8 fft.t . Ibs.
Ibs.
Rocker Arm Rraiiket R o l k ....................................................................................
Roc ke r AIm Bracket Boll s ..................................................... ft-
..... .. ....................... 25 to 30 ft. Ibs.
ibs.

CHECKING COMPRESSION PRESSURE

1. Clea
1. Cleann the eengiinc thoroughly,
ng ine thoroug hly, preferably
pre ferab ly by aand
n d tthe
h e engine l'un ning method.
running method, NOTE: ThE'
NOTE: The
steam cleaning.
cleani ng. engine must be at operaf
a t ope ing temperature
r ating tempe rat ure
c i t h e r method used.
for either
2. Be fore cranking
2.Ec'foro cranking the eengine
ngine make sure s u r e all
a ll
ope controls
rating con
operating trols arc neutral, brakes
a r c in neutral, ATCRANKING METHOD -. Close the needle
A.CRANKING
a r e set aand
are t h e wheels a rree secu
nd the securely
re ly blocked.
bloc ked. valve at the t h e ffuel tank.. Disconnec
u e l tank Disconnectt aall ll high

3.Thero
3. a r c Iwo
The re are
preshion
mc·t hods of checking
two methods
pressure
pression pressu re
com-
chec king com·
t h e cranking method
the
- p r e s s u r e fu
pressure fuelel lines
lincs and
weenn injectors. Remove all of tt. he
wee
tors. R e f e r to the chart
Refer
leak-off lines
a n d leak·off lines bet-

c h a r t on Page
bet·
injec-
h e injec'
P age 3.
 22-3

CHECKING COMPRESSION PRESSURE (Continued)

ELRUNNING METHOD - Disconnect tlle
B.RUNNING the lIigll
high a small amount (a (a teaspoon)
teaspoon) of tlle
of oil into the
pressure fuel line and a n d leak-off line from from cylinder and reclleck the compression. If
recheck tlle If
nnumber
umbe r one injector. Using an a n appropriate the pressure rises to near normal, com-
tlle com-
lengtll
length of tubing or
o r 1I0se,
hose, route the tlle fuel from pression loss is past the tlle rings.
r ings. Very little
tllese lines back to the
these fuel tank oorr a clean
tlle fuC'1 cllange in compression indicates leakage
change
container. Refer to chartc h a r t below. tlle valves.
past the valves. A low pressure reading
will ccause
a u s e difficulty in starting particu-
4. Clean the
4, tlle injector bores of loose carbon and and larly at
a t low temperatures.
residue.
residue. Replace thetlle compression seal in the tlle
injector bore of the cylinder to be cllecked checked NOTE :: Take several compression reading
and install a Bacllarach 70-314 (0-558).
Bacharach 70-314 (D-558). Com-Com- on eeacll
a c h cylinder. TlIis
This is done by pressing the
pression Gauge Adapter, Figure 1. 1. Secure vent valve button, Figure 2, to relieve gauge
witll
with ana n original injector cclamp
l a m p assembly pressure. WlIen
When tlle
the button is released the
tlle
and spacer,
spacer. Figure 1, 1, Inset A. Tigllten bolt
A. Tighten gauge will again indicate compression
compre ssion pres-
to 20 ift. t . lbs.
Ibs. Connect Case No. CD-504 CD-504 sure,
sure.
Compression Gauge to the aadapter,
d a p t e r , Figure 2.
COMPRESSION ADAPTER
COMPRESSION ORIGINAL CLAMP
70-314
70-314 (0658)
(D558) ASSEMBLY A ND
AND
IMPORTANT:: It is very important tllat that SPACER
all cylinder pressure bbee approximately
approxfmately alike.
alike.
For
F o r tlle
the allowable compression pressure VENT
variation refer to chart
c h a r t below.

IN SET A

1(' 1
CLAMP I..~
........'" :------~~~A
ASSEMBLY

u--- SPACER
~'
Figure 2
CD504
C D 5 0 4 COMPRESSION

IMPORTANT : Replace tlle compression seal

GAUGE

on all injectors at the time

1e of installation,
Figure 3.
COMPRESSION ADAPTER
70-314 (0558)

Figure 1
CARBON s l : : : C T O \
5. If
5. If tlle
the compression is ggreater
r e a t e r than the figure CARBO

~~_----COMPRESSION
mentioned, carbon deposits are a r e indicated.
If the reading is below these
If tlle tllese figures,
figures, leaking
valves oorr excessive ring clearance is in- in- COMPRESSION SEAL
dicatccl. NOT"E:: To make a simple clleck check
wllen a compression leak is indicated, squirt
when
Figure 3

NORMAL ALLOWABLE
ENGINE COMPRESSION VARIATION
SPEED
SPEED BETWEEN
PRESSURE CYLINDERS
1 1 Approxfmately
CRANKING 200
Approximately200 RPM
R PM 1 400 PSI"
PSI' 1 25 PSI 1
RUNNING
-
RU NNING I 800 R PM
RPM I PSI*
480 PSI" 1 20 PSI
PSI 1
NOTE:: -A
NOTE 4% reduction in PSI m
• A 4% u s t be allowed for every
must e v e r y 100D
1000 ft.
ft. above sea
s e a level.
 CYLIND ER HEAD AND COMPONENTS
(Refer to Figure 4)
Disassembly
isconnect the exhaust
Re move the muffle r and hood from vehicle . Disconnect e xha us t system and aairir cleaner
ing bolt and remove the fan belt
from the m anifolds. Loos e n the a lternator ad justing belt.. Remove
Remove the
water pum p and all s tud nut s sec uring water manifold
nifold to cylinder Steam
clyIinder head. Stea m clean entire
clea n the en tire
area where service work is to be performed.
1. Drain the cooling system . (..\UTION: [[ 5. R emove the intake manifold (4 ) and discard
thE' enginE' is hot , do not remove the r adi- the gaske ts (5).
ator ca p until the coolan t ha s had s ufficie nt 6. Remove the e xhaust stack (6) a nd gasket (7) .
ti me to cool. Loosen the cap to the first 7. Re move the exhaus t m anlfold (8) and d is·
sto p carefully to relie ve a ny excess pres· card the g aske ts (9).
sure before removing it completely. Re· 8. Re move the va lve cover (10) and cover
move the upper rad iatOl' and wa ter pump g asket (11 ) . Discard gasket.
hoses. 9. Remove the bol ls and washers (12), and
2.0isconn<"c t the hig h pressu re fuel li nes the r ocker arm a ssembly (1.3) . Remove the
from the in jector s a nd th e lea k-off tu bes. push rods (11 ) and tag them fo r proper re-
Ca p t hem \0 preve nt a ny forei g n pa rticles ass embly .
from enter ing . Remove the injectors as 10. Remove the fl a nged nu ts (15 ). Remove the
d escribed in Sec lion 33 of the Sel'vlce cylinde r head assE'mbly (16), fire rings (17)
Ma nua l. and head g asket (18). Discar d the fire rings
3. Remove the breather tube (1). and head ga sket.
4. Re move the intake elbow (2) and g asket (3), NOTE : Refer to Ins pection ancl Servicing on
and d isca rd the gasket. Page 6 and 7 prior to a ssembly .

Assembly
1.Place ne
1. new nder head gasket
cylinder
W cyli (18) on the
f i d ~ k e t(IS) 8. Ins
8. Install
ta ll the intake (4
t h e Intake ) and ee.xhau.51
('1) xhaust (8) (81 m an i·
mani-
engine block block.. NOTE!
NOTE : BeBP sure sure the two fol ds using new gaskets fi
folds (5 & Torque the
9 ) . Torque
& 9).
dowel ri ngs aare
rings installed
re ins talled in theil'their proper
prope r stud nuts and bolts 25-30 fft. Ibs..
t . Ibs
locati on, Inset
location, Inse t A. 9. Install
lnstall the intake el bow (2)
elbow ( 2 ) using
usin g new gasket
Ins ta ll the new fire
2. Install fire rings (1 7) with either
(IT) e ithe r (2). Install the exha exhaust ust stack (6) ( 6 ) using
using new
side
side up. NOTE NOTE;: The fire fire rings
rillgs must be gaske
gaskett (7).
In sta lled dl'Y.
Installed dry. 10. Reinstall
10. Reins tall the air a il' cleanei
cleaner sy stem and e x·
3. Install
Ins tall new gaskel gasket (19)
(19) between timIng timing- system.
haust system . Refill system.
cooling system.
the cooling
cover and cyli cylinder
nder head, c ~ ~ i t i nitg with
head , coating Reconnect the high pressure fuel fuel lines to
a ssealer.
ea le r . the Injectors
inj ectors and the leak-riff leak-off tubes.
4. Ins tall the cy li nde r head (1~ ) a nd fl anged 11.Apply
11. Apply clean englne engine Oil oil to the rocker arm arm
nuts (151. Lubricate thread s with clean en- assembly
assem bly and start the eengine. ngine . ChecCheckk that
gin e oil pr ior to torq uing . Torque the fla nge the rocker arms aare r e receiving
receivIn g lubricating
lubricatin g
nu ts to 60 (t. Ibs . and then to 90-100 ft. lbs. oil. Operate the engine for aapproximately
oil. pprOxima te ly
usi ng the torqui ng seq uen ce shown in Inse t 8 . one hour,
hour , (under load if possible) possible) to thor- thor·
5. Ins tall the water pump and a new gas ke t, oughly warm up the engine englne seat the hea headd
co ating t.he g asket with a sE'aler . Torque the gaskets..
gaskets
wa ter pump st ud nuts 20-25 ft. Ibs. Ins tali 12.Shut
12. Sh ut tthe engine
h e engl ne off. Bac Backk off each cylindercyllnder
the fa n be lt and adjust . head fla nged nut individually
flanged indi vidually 114 I 4 aand re-
n d reo
6. Co a t the p ush rod s (14 ) with clean e ng ine torque to 100 100 ft.ft . Ibs. NOTE: DO NOT NOT
oil and insta ll the m in their original lo- RACK
BACK OF OFF F ALL THE THE FFLANCEDL A N G E D NUTSNGTS
cation. AT THE SAME SAME TIME. TIME .
7. Install the roc ker arm a ssembly (13) . NOTE: n. Ins ta ll new valve cover gas
li3.1nstall gasketket (II ) aand
(11) nd
The l' ar mount ing bolt is d ri lled for oil valve cover (10) (10).. Torclue
Torque the valve va lve cover
passage to the ['Ocker arm shafts . Torque the sstud
tud nuts 5-8 5-8 ft. Ibs.
lbs . IInstall
nst<lU breather tube
bolts (12) to 25·30 ft . Ibs. Adjust the valve (1
(1) .
+

tappet cl earance, refer to P age 16.

 22-5

®--- -
, .'
@I-- -

\-

~
, e.,
•
I
I

o --®
INSET A

TIGH TEN IN G SEOU ENC E

22·6
22-6

H
CYLINDER HEAD (Continue
NTS (Continued)
AND COMPONENTS
Inspection
Inspection
Replace all gaskets,
gaskets, seals aand
nd worn or defective parts.

1. Clean the top surface

1,Clean surface of the block and (A40682)
(A40682) and plate (OTC 970·7),
970-7), cla mp the
clamp
sleeve flange ca refully . All traces of car·
flange carefully, car- cylinder sleeve in place, Figure 7. NOTE: NOTE :
bon and other deposits must be removed. The plate OTC 970-7
970·7 is available through
cleaning, the use of a rag dampened
During cleaning, loca l Owatonna
local Owa tonna Tool dealers or the Owatonna
Owa tonna
in solvent is recommended. Tool Co., Owatonna, Minnesot a. Torque the
Owatonna, Minnesota.
hold down capscrews to 50 (t. t t . lbs.
2. Using extreme care not to scratch surfaces.
Remove any small burrs in the areas
areas to be 4. Clean and inspect the cylinder head thor-
4.Clean thor·
measured so acc urate readings can be ob·
accurate ob- oughly. If
If evidence of fretting
fretting or erosion
tained. exists in the area of fire· ring contact or
fire-ring
tha n .006"
if the head is warped more than .006",, the
3. Sleeve protrusion must be checked to deter· deter- head must be resurfaced or replaced.
o r replaced,
mine which fire ring is used, Figure 5. 5. Make
sure the correct
cor rect fire ring is used. NOTE:
used. NOTE: 5. Inspect push rods for straightness,
straightness, cracked
standard size fire ring is
Only the stanclard Is included or worn ends. Replace if necessary.
in the valve grind gaske
gaskett kit. However, a
thicker fire
fire ring is available if the pro· pro- 6.CClean
6 l e a n all bolt and stud thrcad s.
threads.
trusion chart indicates a need for it. The
thicker fire
fire ring can be identified
identified by a 7. Clean the rocker arm
7.Clean a r m cover and discard
black marking stripe.
stripe. Either a magnetic the old gasket.
base dial indica tor or a depth micrometer
indicator
can be used to determine the cy linder sleeve
cylinder 8. Replace all hoses if cracks and deterior-
8,Replace deterior·
protrusion as
a s indicated in Figure 6. Measure ation Is
is found.
found. Replace hose clamps to assure
cylinder sleeve protrusion at points A,B,C A,B,C a tight connection.
and D.
D. Using ball (A283121,
(A28312), clamping bar

USE USE OVERSIZE

INOER SLEEVE PROTR
CYLINDER TRUSI
USION STANDARD (THICKNESS)
FIRE RINGS FIRE RINGS

1 MORE THAN .003""

MORE .003"*

.001" .. 003""

LESS THAN .001 ""

F igure 5

"If sleeve protrusion varies more than .003" around circumference, change that sleeve and
check again. If sleeve shows severe erosion, replace the sleeve. N
again. If NOTE:: Cylinder head war-
war·
page should not exceed .006"
,006" (maximum)
(maximum) measuring from
from end to end.
end.
 22 -7

DIA
D I A L IND CATOR
INDICATOR
\

CYLINDER SLEEVE
1
CYLINDER SLEEVE
PROTRUSION
R BLOCK
CYLINDER

Figure 6

A40682 BAR
A4 0 682 CLAMPING B",
A",
R_.?!

aTe 9 70 · 7 PLATE

A . 0. C AND 0.'"
AT POINTS A. J

7
ure 7
Figure
22-8

ROCKER ARM ASSEMBLY

(Refer to Figure 8)

Disassembly
1.
1.Remove the rocker arm shaft bracket bolts assembling.
when assembling.
(1&
(1 & 9). NOTE:: The rear bracket bolt is
9 ) . NOTE
drilled for oil passage to the rocker arm 3. Remove the shaft springs (6) ( 6 ) and tag the
shafts.
shafts. front and rear shafts (8
( 8).) ,

2. Remove and tag each rocker arm (4 & 7)

(4 & 7 ) and 4. Remove each tappet adjusting screw (5)
4. (5) from
bracket (3,
(3, 10,
10, 11 & 12)
11 & 1 2 ) for proper location each rocker arm,
arm, refer to Inset A.

Inspection
Check the shaft springs for damage and shaft and rocker arm is .010".
,010". Replace the
tension.
proper tension, shaft and rocker arms when wear is beyond
this point
point..
SPRING SPECIFlCATIOO'lS
SPRlO'lC SPECIFICATIONS
Clean the oil passage in the rocker arms to
Free Length .......................................
......................... ... ....... '" 2.5"
2.5" insure free oil flow.
flow. Inspect the valve stem
..................................
Wire Diameter .... .. _............................,072"
072" contact area on the rocker arm for wear. Re-
Re-
............ 7.5 to 8.5 Ibs,
Compressed to 1.75" ............ Ibs. place if worn.

Flush the shafts to remove any residual Clean and check the oil passages in the tap
tap--
material.
material. Inspect the shalts
shafts for excessive pet adjusting
adjusting"screws and (he
the rear bracket bolt.
wear or
o r worn spots on the bottom side of the
shafts. Inspect the push rods for straightness,
straightness ,
con-
if these con-
cracked or worn ends, replace if
Inspec
Inspectt the rocker arm shaft passages for ditions exist.
exist.
wear. The maximum clearance between the

Assembly
With all component parts cleaned thoroughly and worn parts replaced, coat them with clean
engine oil.

1.
1. Insta ll the intermediate brackets (10)
Install (10) on the (6)
(6) on the rocker arm shafts (8 ).
(8).
(8), starting with the front shaft.
shafts (8), shaft. The
front shaft is installed with the short end of 5. Install the center bracket (11)
5.Install (11) to the long
the shaft (from
(from the cut-out)
cut-out) toward the front end (from cut-out) of the shafts (8).
(from the cut-out) In-
(8). In-
of the
thE' engine,
engine, see Inset B.
B. The rear shaft is (12) and rear
stall the front (12) ( 3 ) brackets to
rea r (3)
install E'd with the short end of the shaft (from
installed (from the shafts
shafts (8).
(8).
the cut-out)
cut-out) toward the rear of the engine.
engine.
6. Before installing the rocker
roc ker arm assembly
2 , Insert the bracket bolt (9)
2. (9) into the inter-
inter- on the cylinder head, crank the engine (fuel (fuel
mediate
m (10) -- it must line up with
ediate bracket (10) removed) with the starting
injectors removed) starting- motor
cut-out in the shaft.
the cut-out shaft. (approximately 11 to 3 minutes)
minutes ) until oil
appears at the rear oil passage in th head,
thee head,
3. Install the tappet adjusting screws (5) (5) into see Inset C. Install the rocker arm
a r m assembly
the rocker arms (4 & 77),
(4 & ) , make sure the screws to the cylinder with bracket bolts (1 (1 && 9),
9),
are turned into the rocker arms as far as making sure the rear bracket drill ed bolt (1)
drilled (1)
possible.
possible. is installed the cylinder head oil passage hole.

4. Install the rocker arms (4

4.Install & 7)
(4 & 7 ) and springs 7. Adjust the tappets, refer to Page 16.
7.Adjust 16.
 229

INS ET A
INSET INSET C
OI
OILL PASSAGE
PAtSAGE

OIL PASSAGE--\ \

OIL HOLE PLU(,GEI)"""'- ~~~

TAPPET SCREW

/OIL HOLES ~ INSET B

I==::===:-_J : =-:=--=---::--1 r:-: -- - (1 ;-~=-: j FAN.

-SHORT
I-SHORT END-
END-I CUT OUT CUT OUT/ -SHORT
I-SHORT END
ENO-l

Figure 8
22-10

HEAD ASSEMBLY
CYLINDER HEAD
(Refer to Figure 9)

Disassembly
L Using a valve spring comp
1.Using ressor, com-
compressor, 3.
3. Drive the intake valve gu exhaustt
ide (8) and exhaus
guide
press the spring (1) (1) enough to rremove emove the (9) down through
valve guide (9) throu h the head using
re tainer locks
valve retainer loc ks (2).
( 2 ) . Release the sspring
pring an arbor.
arbor.
compressor and remove re move the valve spring
retainer (3)
( 3 ).. Remove the valve va lve sspring
pring (l),
(I), 4. The exha
4.The ust valve sca
exhaust ts (10
seats (10)) can be re-
re-
valve stem oil seals seals (4 ( 4 ) and valve spring moved w with a special
ial seat removing tool,
seats (5). Re move any carbon
( 5 ) . Remove car bon from the ever aattempt
Inset B. NOTE : Never ttempt to remove
valve stems before they are r emoved from
a r e removed a valve seat with a center punch, cold chisel
the cylinder head. or pry bar.

2. Remove the intake valves (6)

2.Remove ( 6 ) and the ex-
e x- 5. T
Too remove the cup plugs (11 ) or expansion
(11) expa nsion
haust valves (7)
(7) from the cylinder head (13)
(13) plug (12)
(t2) they must be drilled and
a nd pryed out.
rac k or holder. NOTE:
and set them in a rack NO'IE:
Mark them on removal so they may be in- -
NOTE : Refer to Inspection
Inspect ion and Servi ci ng
Servicing
stalled in their original location. on P ages
es 12,13,14
12,13,14 and 15
I.->prior to assembly.
assembly.

Assembly
1. If the valve guides have been replaced,
1. If rep laced, install the m in their original locations
them locations..
the new gguides
uides (8
(8 & 9) using-
using an arbor. Press
the guides into the head from the top of the 4.
4. Install the valve va lve sspring
pring seats (5) va lve
( Z ) ,, valve
cylinder head.
head . The guides must protrude above springs (1), the valve
( I ) , the valve retainers
reta iners (3).
( 3 ) . Com-
the cylinder head (intake
(intake and exhaust)
exhaust) .875",
.873", press the valve springs so so tthe
h e valve stem stern
Inset A. (4) can be installed in the lowe
seals (4) lowerr grooves
of the valve stems. Insta ll the valve retainer
stems. Install re tainer
2. To install new exhaust valve seats (10)
(30) cclean
lea n ( 2)) . Remove the spring compressor
locks (2
the recess in the cylinder hhead.
e a d Place the ccarefully.
arefully.
valve seats in dry Ice shrink
ice to shrin k them. In-
sert the valve seats in the head and press 5. Install new plugs (11
5. (11& 2 ) if they were
& 112) re-·
we re re
them in place, using a suitable press. press, moved. NOTE:: The
Theccup
up plug (11) must
(11)lip m ust be
flush with the top of the cylinder head.
head . The
3.Lubricate
3. Lubricate the intake valves (6) ( 6 ) and exhaust
a nd exh a ust eexpansion
xpansi on plug (12)
(12) must be firmly seated
fiIm ly sea ted
valves (7)
( 7 ) with
wi th clean eengine
ngine oil and install cyli nder head.
against the ridge in the cylinder he<l d_
 22-11

A
INSET A

.875"

EXH AUS T SEAT REMOVI NG TOOL

® .~,
I

EXHAUST VALVE INTAKE VALVE

ASSEMBLY ASS EM BLY
1',
I '
I "

Figure 9
22·12

I NS PECTION OF VA LVES, GUIDES, HEAD AND SPRINGS

Clean the cylinder head complete ly. Re-
completely. Re - Clea
Cleann the valves with a power
powe r driven fine
fine
move
mov e all traces
tra ces of carbon
ca rbon a nndd other deposits. wire bru sh, being very careful not to scratch
brush,
Check for cracks aand nd any evidence
e .-idence of fret·
fret- the valve stE'ms. Refer to Figure
stems. RE'fer F igure "H
II for valve
va lve
ti ng or erosion existing
ting exis ting in the areaa rea of fire
fi re nomencla ture.
nomenclature.
ring contact. Check the head [or for evidence of of FACE STEM
RETA INER GROOVE
warpage. If warpago
warpage. exists w6
warpage exists and is more tha thann
_006", the cylinder
.006" cyl!nder head mu st be resurfaced
h('ad must
or replaced
replaced..
Va lve springs should be cchocked
Valve hecked [orfor flat
squa red eends.
nds, broken coils coil s aandnd correc TIP
squared correctt Figure
MARGIN
spring pressure.
press ure. Use a Val ve Spring Tester
Valve
r eferring to the spring s&pecitir'ations
pecl fica tions below.
below: va lve s for
Inspect the valves fo r excess ive wear
excessive wea r or
referring
ne<;ked stem
necked s, Figure 12.
steins, cann be caused
12. This ca
Free Le ngth -- ----- --- .------- ...... ------.... --- -- 2.375" by lack ofof lubricat ion, plugged water pas-
lubrication, pas-
To ta l Coils .... -- .... -.. ---- -- ----- -- --- --... -- ---- --- 8.25" sages
sages or opera ting the eengine
operating ngine under contin
contin-o
Wi re Diameter --- ----- -- -----.-- --.----- ----- ------ .1 62" uous overload aatt excess ive engi
excessive ne RPM.
engine RP1Vl. Re-
Re-
place valves if this condition exi s ts.
exists-
Valve ICompressed
~ o m ~ r e s s e dSpring
[ 1 Replace if
Pos ition
Position Hei
Heightht 1 ~ r e s s u r [eLess than
Pressure

ill'~~~=rnn=mo
Valve Open 1 1.521" 1.521" I 114
134 Ibs.Ibs . I llO 110 Its.
lbs.
Valve ~ i o s e d ) 1.875"
Va lve Closed 1 56 Ibs.ibs. 1 53 Ibs,
33 Ibs.
Remove all a ll carbon from the bore of tho the NECKED VALVE STE M
va lve guides with a fine
valve fin e wire brush br ush and blow -
cclean
lean witwithh compressed air. Valve Val ve guides ca cann Fig ure 12
Figure 1
be checked (or for wea wearr by usingusi ng a bore gauge
and micrometer,
micrometer, refer re fer to Figure
Fi gure 10, 10, Inset A. Inspect the valves for deep grooves in the
Th
The valveva lve guides should be chec ked aatt the
be checked fac e, Figure 1.3
face. 1.3.. This can caused
ca n be cau sed by abra-
midd le and bottom of the guide bore for
top , middle
top, ssives
ives entering the engine through t\'le the intake
weal',
wear, Figure 10. 10. If the dia diametw
meter is grea greaterter system or not servicing the air a ir cleaner ro-
cleane r re-
tthh an .3440 " at
a n .34411" a t aanyny point aalong long the [lie bore, the gula rly. If
gularly. If grinding the valve face f<lce will
wi ll not
guide must replaced.. Use aan
mus t be replaced n aarbor
rbor equal correct this condition, replace
repl ace the valve.
to the ins inside diameter
ide diam eter of of the valve va lve gguide uide to
keep the gguide uide from colla psing when pressed
collapsing IN VALVE FACE
GROOVE IN FACE
into
info place. P Press
re ss in from the trip top of the head
until
unti l the guide
guIde (Intake
(Intake and ExhausExhaust) t) protrudes
a dis ta nce of ,875"
distance .875" above the head head,, rrefer efer to
Figure 9, 9, Inset A, Page 11. 11. Replacement guides
must
m rE'amed after installation
ust be reamed ins ta llati on . Ream the Figure 13
gguide
uide .3429"
.3429" to .3439".3439" diameter.

EXPANDABLE
EXP BORE
A ND A BLE BOR E GAUGE- ,.411
GAUGE'~~
fnspect
Inspect the valve
va lve face a nnd
or pitting, Figure U. 1 4 Rust
usually be removed by gr indlng
d stem for rust
s t or pltUng
pitting ca
inding the
can
val ve
t h e valve
CHECK WE A R face. If rustrus t or pitti ng on the valve stem stem
OF GUIDE AT
IN S ET A TH REE POI NTS exis ts , replace
exists, repla ce the vvalve. These conditions
ca n be caused by using
can usi ng poor qua engine
lity eng
quality ine
oil or fu fuel tha t does not meet the specifIc'
el that specific-
aation
tion given in Section 11 11 and by improper
storing of of the engine.
engine.
GU IDE
R EB ORE

~.
A RE A RUST OR PiniNG
PITTING

MI C ROM ETER
" ' " "
, \ . ", , . ·111 1 :1

Figure 1 0 Figure 14
 22-13

INSPECTION OF VALVES. GUIDES. HEAD AND SPRINGS (Cont'd)

Hea vy carbon oorr varnish
Heavy varni sh deposits
deposits on the CHECK DIAMETER
DIAMETER OF STEM AT
A T 1tiflEE
THRE E pOIr.lTS
POINTS
valves, Figure 15, should bf-
be removed before
befo re .3409
valves are ground.
ground. This condition is usually
caused by worn piston rings and sleeves
usua lly *B' .3419 INTAKE V A L V E
,3419 [NTAH VALVE

which allow
a llow too much oil to reach the com- com-
bustion chamber.
cham ber. Th.is conditions
This c'otiititions could also
be caused by worn valve guides or bad sea ls
seals -.* *_-,;3
.3;.-:3:-:::9,,9_
3 3 3 EXHA U ST VA
EXHAUST LVE
VALVE
.3340
4 0 99
on the valves. Low oper a ting temperature
operating templ?rature is
sti ll aanother
still cause.
nothl?f ca use.
HEAVY CARBO
C A R B ON
N AND VARNISH
V ARN ISH OEP0SlTS
DEPOSITS

Figure 15

Inspec t the vaivcj

Inspect va lve head Kir
tor dishing and
and the Figure 18
valve
va face for deep burned spots, Figure 16.
lve face 16-
These conditions cannot be corrected by The check ing of the
gri nding tthe
grinding ves . The vdlves
valves.
h e val re-
"a lves must be re- valve fa ce runou ! should
placed. These conditlon a rp usually
conditionbs are usua lly caused be do ne after th e valves
by running t he engine under
runnin g the undcr excessive
excessive loads have been ground. A Vee
at ng ine temperatures,
a t high eengine tempera tures, block type holder wi th a
dia l Indicator , Figure 19
can be used to c heck the OI A L I r.lO ICATOR
va lve face and stem run-
out. The valve face run-
au t should not exceed
more tha n .002". The
valve stem r unout should
lIot exceed _002". If the
DEEP BU
DEEP BURNED
RNED valve face and i or val ve
VALVE PACE
VALV E FACE DI SHED VALVE HEAD stem runout is greater,
Figure 16 the valve m ust be reo
placed. figure 19
lves with worn keeper grooves or if the
Vahes
Va
stern titipp is worn
stem the ccham-
\\'orn oorr dished beyond thl? ham- I OTE : Sma ll amounts Of ' -ery line pitting,

fer, replace tthe h e valves, Figu

Figure
[-e 17.
17. Figure 20, may b found on the s urfaces of
the va lves faces a nd seats afler Ille va lves
WORN s TEM TIP a re cleaned . These are normal a nd wil l not
affect engine perrOt·ma nce. This fine pitting
Is c aused by a norma l oxid ation process and
can happen on any engine eluring the r un- in
\ peri od. It Is not necessa ry to grind val 'es
WORM RETAINER
WORN R" GROOVE
TA INER GRO OVE
or seats if Lhis fin e pitting is found a s thE'
Figure 17 pitting will generally reoccur after the en·
The checki of the va
ng of
checking lve stem diameter
valve gine is run for a few hours.
can be best be done with a good,
ca n be good, accurate
acc urate
micrometer , Figure 18. The valve stem
micrometer, s tem FINE PI TTING
being straight, should be measured
meas ured at three
stem,, F
points along the stem igure 18.
Figure 18, Wear limit
must a t aall
.002" at
mu st not exceed -002" ll points
poin ts of mea-
surement.
surem ent. If greater,, repla
If the wear is greater replacece
the valve. Figure 20
22-14

REFACING INTAKE AND EXHAUST VALVES

Before refacing the valves, they should be
Before refacing the valves. t hey should be Correct refacing of intake and exhaust
Correct refacing of i ntake and ex haus t
wire brushed, cleaned and inspected. A 440
wire br ush ed, cleaned and inspected. A 44"
valves and valve s e a t s will provide a lhin-
val ves and va lve sea ts will provide a 10 In-
angle is the correct valve face grinding angle.
angle is the correc t valve face grinding angle .
terference angle. This angle is important
terference angle. Thi s angle is importan t
Set the refacing machine protractor a t this
Set t he refacing machine pro trac tor at this
since it aids in cutting carbon and helps seat
since it aids in cutting carbon and helps seat
angle. Be s u r e the chuck of the machine is
a ngl e. Be sure the chuck of the m achine is
the valves.
the valves.
clean before installing the valve. Dress the
c lean before installing the va lve. Dress the
grinding wheel before starting to reface the
grinding wheel before starting to reface the
valves. Take only
val ves . Take only lig light cuts as
ht cuts a s tthe valve
he val is
ve' is
refaced. The last cut must be very
r efa ced . The l ast cu t must be very fine so
fine so
the valve face will have a polished finish,
the va lve face w ill have a polished fini sh.
IMPORTANT: Replace any valve that has

~
IMPORTANT: Rep lace any va lve that has
a thin edge o r margin, Figure 21. If the
a th i n edge or m argin , Figu r e 21. If the
margin on the ground valve is less than half
margin on th e ground va lve is l ess than half
the margin on a new valve, replace the valve.
th e margin on a new valve, replace the valve.

I1
l ' INTERFERENCE ANGLE /
VALVE F
VALVE
GRINDIN FACE ' "
GR IND IN G ANGL'0- ~~;§§5~" ===c= //)
11
INTAKE VALVE AND VALVE SEAT
INTAKE VALVE AND VALVE SEAT
MARGIN
MARGIN

T EXHAUST VALVE AND VALVE SEAT

EXHAUST VALVE AND VALVE SEAT

CHAMFER /
CHAMFER --------- -
1 Figure 22

When the top edge of the contact a r e a is

Figure 21 When the top edge of the con tact area is
too high o r low on the valve face, the s e a t
too hig h or Iowan the valve face, the seat
The tip end of the valve should be checked contact area must be moved. This is done
The tip end of the valve shou ld be checked contact area must be moved. This is done
for roughness o r wear. Usually this c a n be
fo r roughness or wear. usua lly t his can be
by using the narrowing stones. Refer to
by using the narrow ing stones. Refer to
removed with some very light cuts against P a g e 15, The contact area width should
rem oved with some very lig ht c ut s against Page 15. The contact area width sho uld
the side of the grinding wheel and will square never exceed the specified dimension of
the side of the g rinding wheel and will square never exceed the speci fied dimension of
up the end. Never grind off the valve s t e m .0608" to .0962" (exhaust valve) and -704"
up the end . Never grind off the valve stem .0608" to .0962" (exhaust valve) and _7(14 "
end beyond the chamfer. to ,1057" (intake valve).
end beyond the chamfer . to .1057" (intake va l ve).
 22·13

GRINDING INTAK E AND EXHAUST V ALVE SEATS

Alwa
Alwaysy s use
USE' a precision seat grinder.
grinder. Take The valve
va lve sea ontac t area width
seatt ccontact Io-
wi dth and 10·
ve ry light ccuts
very uts with the ggrinding
r inding stones so cation ccan
a n be cha usi ng the :30"
nged by using
changed .30' and
just eenough
just noug h metal is removed
rem oved to end up with 60')
60') na rrowing stones,
narrowing stones, Figure
Fi g ure 25.
2:;.
a good ssmooth
mooth sca
scatt finish.
finish.
The proper angle of grind is 45"
haust valve and intake valveva lve seats,
ex·
450 for ex-
Fig ure 23.
seats, Figure t<::::/ 30'
30" NARROWING STONE
seatt grinding ang
The sea angle of the
le of tho stone
s tone sshould
hould be \
dressed frequenctly on a stone dresse
drE!ssed dresscrr to
maintain a clean aaccurate surface..
ccurate surface
.0608 TO .0962

~Offl
VALVE SEAT GRINDING
G R I N D I N G AREA

60 ' NARROWING STONE

60D STON E C3
EXHAUST VALVE SEAT
EXHAUST

EXHAUST VALVE SEAT

~~:g1'
1057
IDTH

INTAKE
INTAK E VALVE SEAT
F igure 25
Figure 2

INTAKE VALVE SEAT

INTAKE No'rE: E: If If the valve-
valvE' hea a s receded
headd hhas recE'ded more
morc
than .010
,010"" (exhaust intake valve)
(e xhaus t valve and intak@ valve) be-
be·
Figure 23 low tho
the cylinder he ad ssurface,
c ylinder head urface , F Figure
igure 26, the
valve or o r val
valve insert. or both sshould
vE' ins(>rt reo
be re-
hould bE'
ll\lPORT.4.NT:: The wive
va lve seat runout
runou t pi ac ('d to keep the compression ratio
placed ra1io equa
equall
sshould
hould be checked after finish grinding with between
be twe en cylinders tor an
cy linde rs for ffficiontt running
a n efficien r unning
aa ddial
ial indicator aand seatl ggrinding
nd SE?a rind ing pilot, Fig-
Fig· eengine.
ngine.
2-4. The
ure 24. runout
The run out of the valve
va lvE' seat must
m ust
xceed .002"
not eexceed ,002" .,

DIAL INDICATOR r
.010"

EXHAUST VALVE

.01 0"

INTAKE VALVE
/Â -
26
ure 26
Figure
Figure 24
22 16

LOCATING TOP DEAD CENTER AND TAPPET ADJUSTMENTS

FJRI);G ORDER -------.--.-.-.-----.----
F)RIN(; ORDER ----- - 1-.,-42
-- ----------- ---- -- --- ---------- l-:j-4.2 TIMING
T I M I N G POINTER
ThE'
The Top Dead Center Center position of number 11
and -1~ cyli nders iiss indicated
cylinders indica ted by the TD C m
OIP TDC ark
mark
on Ih
On the~ ilywhocl. R ~ f e rto Fig
fl yw heel. Refer Figui ur e 27
Th", tappet adjustments can b('
The do ne in two
be done
steps aass desc ribed in
described i n the foliiwing
th e foll owi ng manner. o
COLD SETIING c
STEP 1 - Rem ove the val ve ('O\-er -pr,. Crank the
eengine unHI the tJm
ngi ne until timinging pointer is i s aaligned
ligned with w i th
rhe TDC
the TOC ti ming mark on the fl)whee
timing fhwheel, l, Figure
27_
7 . Checkh w k the t h p push rrods ods on ,-0 S o .. 11 cylcylinder
inder
looseness.
torr loose
fo ness _ If the push rod rodss arE'a r e loose,
loose,
No. 1
1\0. 1 cyli nder is a
cylinder att TD DCC on tth~d
he compression
co mpress ion FLYWHEEL HOU S ING OPENING
stroke. If th
s t r o b . If t h e push rods arc tight,
d s are tight, crank the Figure 27
engin(> one comp
engine complete
lete rrevolution
evolu tion and align the
pnmtt'r and the TDC
pointer TO C mark m ar k on tthe he n flywheel,
ywheel , inder No.
inder No, 4 should be at TDC T OC on tho com--
t h e COIll
Figure
F igu r e 27. pression stroke. Check th thee push
pu sh rods roel s on
Ch eck and adjust the followin
Chock followsngg valve
va lve clear- ' 0. 44 ccylinder
No.
1\ looseness..
yl inder for looseness
ances ; int akC' valve at .014" 14" Clearance
clearance on Checkk aand
Chec nd adjust the ffollowing
ollowing valve clear- clear-
cylinders
cyl i nders 11 and·a n d 2,
'I. and tthe exhaust
h e exh aus t valvcs
valves on inta k e valves a t .01-1"
ances; intake _014" clearance
cl ea r ance on cyl-cyl-
cylinders 1 1 and 3 at .01'1" clearance,
,011" cleara nce, Figure inders 3 and 4, and the t h e exha
exhaustuot xalves
\'alves on
28.
S 8. cylinders 2 a and
nd 4 .014" cclearance,
4 aatt .014" learance, FigureF igu r e
STEP 2 -- Cra Crank h e engine one com
nk tthe complete
plete re- re- 28.
28.
olutio n and align the timing pointer and tthe
vvolution he G
HOT SETTING
SE
TDC mar
TDe fl y wheel. Figure
m a r k on the fivwheel. Fig ure 27. 27 . Cyl-
Cyl- Follow steps 11 and 2 wh while
ile tthe engine
h e engi ne is
hot. The tappet cclearances
hoI. o r hot settings
lear ances ffor set ti ngs
a r e .014"
are .014" for the in
intake ,020" for
take valves and .020" f or
\
\
the eexhaust valves.
xha ust va lves.

• FAN
FEELER E

INTAKE INTAKE INTAKE INTAKE

Figure 28
PORTANT: Tho
JMPORTANT: Th e valve tappet c
clearance is
lea r a nce Is a critical
criti adju stment.

The enentire
tire combustion system of tthe h e engine will be seri
seriously affected
ously affect ed by adjusting the valve
tappet other
t'lppe t clearance to any o ther ssetti
~ t tng
i n .g .

Excessive
E ;, cessive cclearance changee the
lea ran ce will chang th e valve
va lve timing and could result in overh ealJng , power loss
overheating,
and possibl
dnd possiblee valve
va l ve breakage.
breakage.

Insufficientt cleara
Insufficien clearbance
nce would all
allow
ow the valve
valvess to rremain
emain open and be burned by the hot exhaust
exhau st
gases.
ga ses.
 ion

22
CYLINDER HEAD AND VALVES

148. 159. 188 AND 201

SPARK IGNITION ENGINES

UserFr~endlyCDs

TABLE OF CONTENTS
.. ...... " ................. .................... ...... ..... .. _.. _.. . _ , .. .. .. .
S pec l ftc at io n~ .. , .. .. .. ..... ... ., "'~,-'

Specl31 Torq \l(, s .... .... __ ...... .. . _.... .. .. ..... .... .. ....... . ... ..... .... . ", ...... ...... " ..... _. ..... . .. .... , ..... ... .... .. .. ,', ..... , 3
Checking: Compn'ssion Prl'ssu ro:> " ", .................. .. ", .. .............. ......... ,............. _.. ................... __ t,;
Cylinder Hf.>ad and Com;xm e nl'<;
(148 a!'ld L:;9) .. , .. ... _.... ,. , ....... " ........... "" ....... ..... _.. .... .... , ...... ..... , ... ... . _.... ____ , ... , ..... ....... . _, n·~J
( ISS ~!Jd 201) ," ... _..... " ., .... _..... .. . ...... .. ... ........ ,... ...... ....... ... ........ ," ._.... "', ... ... _........ .. ,.... 10-13
Rock .. r Ar m A~S{'mbly
(1 48 and \.39 ) ......... ...... , .. ............... .... ...... .. .... ... ... ....... . ....... ... .. ....... .. " " , ...... , " ', .. ...... ..... 11.15
( I SS a nd Wl~ . , ........... ,' ... .... " .... ........ ..... ", ..... .. . ". , ....... ,., .. .. .... .. " .... ...... ... . ,.... ,." .. . ... Hi, 17
Cyllnd(>r Head As sl'rnbly
(US and l ag ; .................... .... ..... ..... ............................................................ .. ................ 18,19
(1 88 a nd 201 ., ....... .... ,.,' ................. , ........... . ........ ...... ..... . ,." ..... ........ . . " ............... , . ,... :10.21
In.speclion of Va l" .. ~ , Guid es. Head and Springs ... .. .. . .. ............ , .. ... ,..... . .... .. ,.......... " .. ... 22,23
Refacing Intake and (';xh<!.ust V;;llves ............................................................ ....... ............... 24
Grindi ng l ntake and F..:xhaust V"I\'(> & at s ... .. ..... , .................... ,." ........ .. ,', . . " .. " ... .. .. .... " ... ...... . ~
l .ocaUng T op Dead Cente r a ll(1 T a ppe t A di l! ~ hnents __ .. .. .......... .. .. .... ", ...... .. .... " ..... .. .... , .... . 26

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22-2

SPECIFICATIONS
iVIaximum Limit
Including Wear
CYLINDER HE AD
Warpage .. _... _....... ............................................................................................................. 006"

SPARK PLUG
Gap Setting (18mm) .................... _.................................................................. 025"

EXHAUST VALVE
Tappet Cleara nce (COL D) .. .. .. .. .... .... ...... ....... .. .. __ ...... ... .. .... ........ _... .. ..... _.. ...... 020 "
(HOT ) ....................................... _......... ....... ........ .. ....... .... ..... .014"
Face Angle ............. _......... .... ... .. .......... ... ....... ...... .. .. ....... .... .. ........ .... ....... ......... 440
Face Run-out ...... ....... _... .... .. .. ... .. .... ... ............. .................. ... .. .... ......... ... ... ....... .......... .. .. ...... 002"
Lengt h (188 a nd 201) ................... .. .... ........ ........ .. .......................... 5.824" to 5.844"
Le ngth (148 and 159) ........ .......... ..... ............. .. ............. .. .. .... ..... ..... 5.309" to 5.334"
0.0. of Head (188 and 201) .... ......... ... .. .. .... ........ ... .. ........ ............. . 1.398" to 1.408"
0.0. of Head (148 and 159) ........................................................... 1.265" to 1.275"
0. 0. of Stem .................................................................................. 3382" to .3390" .............. 002"
Insert Sea tAngle .............................................................................................. 45'
Seat Contact Width (188 a nd 201) ...... ................ .... ... .. .. .. ... .. ............. . 072" to .085"
Sea t Contac t Width (148 and 139 ) ...................................................... 090" to .100"
Seat Run-Out ... ....... ............. _............................................................................... _............... 002"
Inse rt Height (188 a nd 201) .......... ............. ........ ......... .......... .. ........ 2475" to .2525"
Insert Height (148 and 159) .... .... ... ............. .... .. .. .. .... ......................... 198" to .203"
0.0. of Insert (188 a nd 201) ......... .. .. .. ... ... ......... .......... .......... ..... 1.4495" to 1.4505"
0.0 . of Insert (148 and 159) _.... .. ......... ...... .......... ..... .. ... ...... ....... 1.3765" to 1.3775"
I.O. of Insert (188 and 201) .... ............ ..... .. .................................... 1.245" to 1.255"
I.O . of Insert (148 and 159) ....................... _.... ... .... ..... .............. .... . 1.074" to 1.084"

INTAKE VAL VE
Tappet Cleara nce (HOT AND CO LD ) ....... .. .................................................... 014"
Fac e Angle ..... ...... ......... .. _......... ....... .......... ....... ... .... .......... ........ ........ ............ .. 29"
Face Run-Out ..... .............. ............ ............ .... ..... ..... .. ............ ....... ............ .. .... ...... ............. ... 002"
Length (188 a nd 201) ........................................ .. ........................... 5.796" to 5.816"
Length (148 a nd 159) ..................................................................... 5.275" to 5.300"
0.0 . of Stem ..................... _...................................... _.................... . 3406" to .3414"
0. 0. of Head (188 and 201) ...... ... .. .. ....... ........ ........... ...... ...... .. ...... 1.514" to 1.524"
0.0. of Head (148 a nd 159) ............ ... ........ ........ ........ ....... ............. 1.410" to 1.420"
Seat Angle ..... ... .. .............. ..... ........ ........... ...................................... ...... ........... . 30"
Seat Run-out .............. ..................... ........ .............. ..... .. ...... .. .......... ........... .......... .... ............. 002"
Seat Contact Width (188 a nd 201) ........ ............. .......... ............ .. .. ...... .055" to .070"
Seat Contact Width (148 a nd 159) ...................................................... 045" to .060"

EXHAUST VALVE GUIDE

Length (188 and 201) .................................................................................... 2.834 "
Length (148 and 1.59) .... ........... .. .............. ....... ........ .......... .... .... ............. ....... 2.438"
0.0 ......................................... _....................................................... 6565" to .6575"
I.O. (Installed a nd Reamed) .......................................................... 3422" to .3432" .......... .... 002"
Protrusion Above Cylinder Head (188 & 201) ............................................... 1.000"
Protrusion Above Cylinder Head (148 & 159) ................................................. 844"
 22-3

SPECIFICATIONS (Continued)
Maxim um Limit
Incl uding Wear
INTAKE VAL E GUIDE
Length (1 88 and 201 ) _.. ....... ... .... ............................. .... ................. _............. 3. 125"
Length (148 and 159) .. ..... ................... .................. ..... ......... ..... ... ...... .... .. ...... 2. 688"
0.0 .... ...... .. .............. ........................... ................... _...•... _.. .. ............ 6565" to .6575"
1.0 . (In sta lle d and Reamed) ................. ........... ........ ..... .. ....... .... '" .3422" to .3432" .............. 002"
Protrusion Above Cylinde r Head ..... ... ............ .... ....... .......... ......................... 1.000"

VALVE SPRI NG (Exhau st Valve )

Free Length .............................. .. ................................... ....... ........... ........ _. 2·.3/16"
Tota l Coils .......... . .... _._.... .......... ..... ..... _............ _.............................. _..... _.. ...... 7-3/4
WIre Dlameter .. .. .. .............. ....... ....... .. _............... ........ .. .... .. ..... ....... ...... _....... .162"
J.D .... _................. ..... .... .... ... .......... ..... ... ...... ....... ..... ... ...... ......... ... ..... 970" to .990"'
Compressed to 1.332" (Valve Open ) .. _................. .... ... .. ...... .... .. _..... 110 to 118 lbs.
Com pressed to 1.686" (Va lve Closed) ........ . _..... ...... . .. ......... ....... ......... 53 to 59 Ibs.

VALVE SPRIN G ( Intake Valve)

Free Length ..... ..... ..... .. ................ ...... _.................................. .... ... ... _.... ........ 2·3/8"
Tota l Coils .. .............. ..._........... ........ .... _...... _....... _.... _..................... _............... 8-1/4
Wire Diameter ............. .... _.. ......................... ... ....... ......................................... 162"
J. D . ... ............. .. .. .............. ................ ....... ..... ................. ..... ..... .......... 958 " to .978"
Compressed to 1.521" (Valve Open) ............ . _......... .... .. ..... ........ _..... 110 to 118 Ibs.
Compressed to 1.875" (Valve Closed) ... ......... ..... ..... .......... ....... ....... ... 53 to 59 Ibs.

ROCKER ARM ASSEr.mLY

0.0. of shaft .... _.. , ..... _.. , __............. ,... .......... . , ..... ...... .............. ... " .. ...... 622" to .623"
l. D . of Rocker Arm .... _... ............... _................................ .............. .624" to .625"'
(Installed and ReamE'd on 148 and 159)
Shaft Spri ng (188 and 201):
Free Len gth .......... _................... .... ........ ......................... ........ .. ......... .. .... _ 2-112"
1.0 ........................................................ __ ..... _._ ........... _........ _......... .......... _ 11/16"
Wire Diameter ........ __........ __..... __ ...... __ .... _.. ..... _..... . _..... . _.. _........ .. .................. 072"
Compressed to 1-3/4" ................... _... .. ............... ..... ............... ........ 7.5 to 8.5 Ibs .
Shaft Spring (148 and 1. .09):
Free Length ..... ... .... .. ... ................... _...... ....... _... ............................. .... . ...... 1-3/ 16"'
Total Coils ..... .... ... _...... . _.. ... .. ........... ....... ......... _...... ................. .... ............. .. ... .. . 7
r.D .... ... ..... . ... ......... ............................ ...... ... ........ ..... ............ .. ........ _.......... 11 , 16"
Wire Diameter .... ............ _....... _.. .................................................................. 072"
Compressed to 11116" ..... ......... .. •...•...... ............................... .. __ ...... 7.5 (0 8.5 lbs.
Lubrication .............. .. ..................... _........ ..... .. ....... Engine oil, camshaft metering .
Shaft Oil Holes ..... ..... .. _...... ........... .... ...... _............... Toward valve side of engin.e .
Shaft c annot be r otated .

SPECIAL TORQUES
Cylinder Head Flanged Nuts (188 and 201) ................... ...................... .. ...... ..... .... 9lJ to 100 it. Ibs.
Cylinder Head S tud Nuts (148 and 159) ............ .......... _...... ........ .... ...... ... ... ......... 9,1 10 105 ft. Ibs.
fn take a nd Exhaust Manifold Stud Nuts .................. ............................ ..... ... ....... 2.5 to 30 ft. Ibs.
Rocker Arm Bracket Stud Nuts and Bolts ........................... .......... ... ................ . .. 25 to 30 ft. Ibs .
Valve Cover Stud Nuts " ......................................................... _.. ... ................. . ... ..... 5 to 8 fUbs_
Water P ump Stud Nuts .. _.................. .. ............ .... .. _..... . ........ ..... . __ ... ........... _... . .... 20 to 25 ft. Ibs.
Spark P lugs ............... ........................................... .. ....... _... .......... ... ... .... .......... ..... . 32 to 35 ft. Ibs.
22-4

CHECKING COMPRESSION PRESSURE

1. Clean the engine thoroughly , preferably by A. Wh e n using the remote control type of
steam cleaning. compression tester, F igure I, make sure
the wires are correc tly a ttached to the
2. Before cranking the e ng ine for compres- s tarter termina ls . Incorrec t attac hing of
s ion checking , make sure all operating wires will ca use damage to the testing
controls are in neutra l, brakes are set and equipme nt , Figure 1.
the wheels are securely blocked.
B. When using the ignition switch operation
3. Only the cranking method is advised to be type of compression tes ter , Figu r e 2, be
used when c hecking compress io n pressure. sure the carbure tor thro ttle plate (bu tter-
NOTE : The e ngine must be at ope rating fly) val ve is he ld in the wide open position.
tempera t ure at the time of compression Drain the ca rburetor to prevent fue l fr om
checking. e ntering the cylinders.

4. With the engine at opera ti ng tempera ture, COMPRES'510N

shut the eng ine off. Close the fuel needle
va lve at the fu el rank. This will prevent
e xcessive fu el from e nte r ing the cylinder
a nd wa s hing of the cylinder walls. Dis -
connect a ll high tension spark plug wires .
Remove all spark plugs to provide mini-
mum loa d on the starting m otor and battery.

5. Check the compression pressure, using a

reliable gauge and suitable a dapter to fit in
a 18 mm t hread plug hole. Refer to chart on
COMPRESSION AnAPlrFR (18mm~
Page 5.

6. Two common ty pes of compression gauge Figure 2

equipment used are the remote control and
the ignition switch ope ration type.
7. It is very important that all cylinder pres-
COMPRESSION TESTER - _ _ __ sures be approximately alike. For the allow-
able compression pressure variation, refer
to the chart on Page 5.
SWITCH -----~
8. If the compression reading is below these
fi g ures, leaking val ves or excessive ring
clea rance is indicated. NOTE: To make
a simple c heck when a compr eSSion leak Is
SOLENOID indicated, squirt a small amount (a te aspoon )
of oil into the cylinder and recheck the com-
pression. If the p ress ure ri ses to near no r-
mal, compression loss is p ast the rings. Very
little c hange in compression indicates le akage
past the valves. A low pressure r eading will
ca use difficulty in starting particula rly at low
temperatures .

NOTE: Always ta ke a second set of readings

for an accurate c hec k. This will also ind icate
how much the loss of cra nking speed, due to
ba ttery disc harge , is affecting the compress ion
pressure reading.
Figure 1
 22-5

CHECKING COMPRESSION PRESSURE (Continued)

9_ Be fore ins ta lling the spark plugs , clea n them 118mml SPARK PLUG

~~
thoroughly and check them for burned elec-
trodes or cracke d ins ul a tion. Replace them
if necessa ry. Regap all p lugs to .025" setting,
Figure 3.

~GASKET
10. Replace a ll spark plug g askets, Figure 3, be-
fore installing for proper sea ting and sealing.
Install the spa rk plugs finge r tight. Using the
exact size s pa rk plug w('ench 01' a thin wall
deep socket , torque the s park plugs 32 to 35
[t o Ibs .
ROUND GAUGE WILL GIVE
A MORE ACCURATE READIN G

Figure 3

NORMAL
ENGINE SPEED ALLOWABLE VARIATION
COMPRESSION
A PPROXIMATELY BETWEEN CYLINDERS
PRESSURE
(1 48) 150 RPM 140 PSI' 20 PSI
(159) 150 RPM 125 PS I" 20 PSI
CRANKING
(1 8 8) 150 RPM 125 PSI' 20 PSI
(20111 5 0 RPM 150 PSI' 20 PSI

aA 4 % reduction in PSI must be allowed for every 1000 ft . above sea leve l.
22-6

CYLI N DE R HEAD AND COMPONENT S

148 AND 159
(Refer to Figure 4)

D isassembly
Remove the muffle r a nd hood fro m the vehicle. St eam clea n the entire engine area whe re se rvice
works is to be performed. Disconnec t a nd remove the a ir cleaner system.

L Dra in the cooling sy s te m. CAUTJON: If 4. Remove the bolts that c on nect the inta ke
the e ngine is hot, do not r emove the radi a tor manifold (7) 10 the exhaust manifo ld (8) . Re-
cap until th e coolant ha s had suffi cient time move the inla ke m a nifold (7) a nd e xha ust
to cool. Loosen th e cap to the first stop m a nifold (8)_ Remove m anifold gaske t ( 9 )
carefully to relieve any exc ess pressu.r e and discard_
before r emoving it complete ly.
5. Remove th e valve cover ( 10 ) , gaske t (11) and
2. Remove the hose from the the the rm ostat breather tube (12). Disc a rd the gasket.
housin g (I). Remove the therm osta t housing
(1 ) a nd gaske l (2). Di sc a rd the g ask et. NOTE ; 6. Remove the roc ke r arm brac ke t bolts (13 )
If the thermostat is to be serviced, refer and th e stud nu t, ( 14) . RemQve th e roc ker
to Sec tion 23. arm assembly (19 ) . See Page 14 and 15 for
servicing of the rocker arm assemb ly .

3. Disconnect the lin kage and fue l lines from 7. Remove the push rods (15) and tag them so
the c arbure tor (3). Remove t h e carbure tor they c a n be installe d in their proper loca tion
assembly (3 ) and gasket (4 ) . DI scard the whe n r ea ssem bllng .
g asket. Di sconnect the hi gh tension wires
from th e spark plugs and r emove the spark 8. Remove the c ylin der head stud nuts (1 6) a nd
plugs (5) and g askets ( 0 ) . the c yl inde r head ( 17 ) . Remove the c ylinde r
head gaske t (18) a nd discard the gasket.

Inspection
1. Replace all gaskets and worn or defective 4. Cle an and ins pect the cyli nde r hea ds thor-
parts. oughly . If evidence of fretting or e r os ion
exists or if the head is wa rped more tha n
2. Clea n the top surface of the cylinder block _006" , the head must be r esurfaced or r e -
a nd sleeve flange ca refully. Tlw top of the placed.
pistons may be c leaned with a powe r driven
wire brush. NOTE : The pistons must be a t 5. In spe ct the push r ods [or straightness ,
top dea d ce nter whe n be ing cleaned_ All c ra cked or worn end s . Repla ce if necessa ry .
traces of c arbon and ot her de posits must be
r emoved. During cleaning , th e use of a clean 6. Clean the valve cover a nd fl usll au! the
lint fr ee c loth dampe ned In solvent is r e - brea the r tube.
commende d.
7. Clea n and check the s park pl ugs . If replace-
3. Clea n all bolt a nd slud threads. m ent is required, r cga p the spark plugs to .025
se tting.
 22-7

Figure 4
22-8

CYLINDER HEAD AND COMPONENTS (Continued)

148 AND 159
(Refer to Figure 5)
Assembly
1. Install new cylind er hea d gasket (18) with the 11. Install the carbure tor (3) with a new gas ket
TOP mark up. (4) to the intake manifold (7)_ Torque the
mounting baits 35 - 42 ft. Ibs. Recon nect the
2. Install the cylinder head (17) and stud nuts linkage and fuel line to the carburetor.
(16), tighten the stud nut s (16) finger tight.
12. Reconnect the hose to the thermostat housing
3. Install new intak e and ex haust manifold gas- (1) and clamp securely_ Make sure the drain
ket (9). Install th e e xhaust manifold (8) and valves are closed and refill the cooling sys-
intake manifold (7), leaving the stud nuts tem. Reinstall the air cleaner system making
finger tight- sure all connections are tight. Install the
spark plugs (5) with new gaskets (6) and torque
4_ Install the thermosta t housing (1) and new 32 - 35 ft. Ibs. Reco nnect all of the hig h tension
gasket ( 2), leaving stud nut s finger tight. wires to the spark plugs.

5_ Torque the cy linder head stud nuts to 60 13. Apply clean e ngine oil to the rocker arm
ft. Ibs. and then to 95 - 105 ft. Ibs. NOTE : assembly and start the engine. Check that the
Lubricate threads with clean engine oil rocker arms are receiving lub r icating oil.
prior to torquing and use the tightening Opera te the engine for approximately one hour,
sequence shown in Inset A. (under load if possible) to thoroughly warm
up the e ngine and seat the heacl gaskets.
6. Torque the e xhaust manifold and intake mani-
fold stud nuts 25 - 30 ft. Ibs. Torque the 14. Shut the e ngine off. Back off each s tud nut
thermostat housing stud nuts 20 - 25 ft. Ibs. individually 1/ 4 turn and retorque to 95 .
105 ft. Ibs. in the proper sequence, Inset A.
7. Coat the push rods (15) with c lean engine oil NOTE : DO NOT BACK OF F ALL THE
and install them in their original location. STUD NUTS AT THE SAM E TIME . Recheck
the torque to make sure all stud nuts have
8. Insta ll the rocker arm assembly (19). Make retained their proper torque. Recheck the
sure all of the push rods (15) are engaged with rocker arm stud nuts and mounting bolts to
the a djus ting screws on the rocker arms. Tor- make sure they have retained the 25 -30 ft.
que the mounting bolts ( 13) and stud nuts (14) Ibs. torque.
25 - 30 ft. Ibs .
15. Install a new valve cover gasket (11 ) and
9. Adjust the valve tappet clearance, refer to valve cover (10). Torque the cover nuts 5 to
Page 26. 8 ft. Ibs_ Do not over torque the cover nut s .
Install the breather tube (12).
10. Install the e xhaust stack (21) and new gasket
(20), if it was removed. Torque the mounting
bolts 3'1 to 42 ft. Ibs.
 lN"imA-- - - - - - - 22-9

i INSET A

1'0 11 OS 10

<oj~
I 7
I

Figure 5
 22·10

CYLINDER HEAD AND COMPONENTS (Continued)

188 AND 201
(Refer to Figure 6)
Disassembly

Remove the muffler a nd hood from the vehicle. Steam clea n the enti re engine area where
ser vice wOl'k is to be pe rform ed. Disconnect and remove the a ir cleaner system .

L Drain the cooli ng system. CAUTION: If 4. Remove the bolts tha t connect the in take
the engine is hot. do not remove the radiat or manifold (7) to the exhaust manifold ( 8). Re ·
cap until th e coo lan t has had s ulficient time move the in ta ke manifold (7) and exhaust
to cool. Loo se n the cap to the first stop manifold (8) . Remove m anjfold gasket (9)
carefully to r e li('v(' a ny excess pre ssure and discard.
before removing it completely.
5. Remove the valve cover (10), gasket (11 ) and
2. Re move the hose from the the the rmos tat b reather tu be (12). Disca rd the g as ket.
hous ing (I). Remove the thermostat housing
( 1 ) and gaske t (2). Disca rd the g asket. NOTE; 6. Remove the rocker arm bracket bolts (13 ) .
If the thermostat is to be s erviced, refer Remove th e roc ker arm assembly ( 19) . See
to Section 20. P a ge 16 a nd 17 for servicing of the rocker
a rm assembly.

3. Disconnect the linkage a nd fuel lines from 7. Remove the push rods (l,)) and tag them so
the carburetor (3). Remove the carburetor they can be installed in th eir prope l' locat ion
assembly (3) and gasket (4 ). Di sca rd the when reassembling.
gasket. Disconnect the hig h tension wires
from the spa r k plugs a nd remove the s pa rk 8. Remo ve the cylinder head s tud nuts (16) and
plugs (5) and gasket" (6) . the cylinde r head (17). Remo ve the cylinder
head gasket (18) a nd discard the gasket.

Inspection
1. Re place all gaskets a nd worn or defec ti ve 4. Clean and ins pect the cyl inder heads thor·
part s. oughly. If evidence o f fre tti ng or erosion
e xists or if the hea d is warped more tha n
2. Clea n the lop surface of the cy linder block .006", the head must be resurfClc pd or reo
a nd sleeve flange care full y . The top of the placed.
pistons may be clean ed with a power driven
wire brush. l\'OTE: The pistons must be at 5. Inspect the pu sh rods for stra ig htnes s,
top dead center when being ('leaned. All c racked or worn e nd s. Replace if necessary .
traces of ('a r bon and other de posits mu s t be
r e moved . Duri ng cleaning. the use of a clean 6. Clean the valve cover and flush out the
lint free clo th dam pened in solvent is 1'1" breather tube.
comm e nded.
7. Clean and check the spark plugs. If repla ce·
3. Clean a ll bolt and stud threa ds. m ent is required, r egap the spa rk plugs to .02 5
se tting.
 22-11

Figure 6
 CYLINDER H EAD AND COMPONENTS (Continued)
188 AND 201
(Refer to Figure 7)
Assemoly
L Tnstall new cyli nd(> r head gaske t (18) wIth the 11. Ins ta ll the c ar buretor (3) with a new gasket
TOP mark up. (4) to the in ta ke manifold (7 ) . Torque the
mount ing bolts 35 - 42 ft. Ills. Reconnect the
2. Install the cylinder hear! (17) and stud nuts linka ge and fuel line to the c a rburetor .
(15), tight e n the stud nuts (16) finger tight.
12. Reconnect the hose to the thermostat housing
,1. Ins tall new intake and exhaust manifold gas- (1) and clamp securely. Mcke sure the drain
ket (9) . In s tall t.he exhaust man ifold ( 8) and valves are close d and refill the c ooling sys-
inta ke manifold (7). leaving t ile stud nuts tem . Reinstall the air cleaner s y ste m m a king
finger tight. su re all connections are tigh t. In s tall the
spark plugs (5) wi th new gasket s (6 ) and torq ue
4. Insta ll the the rmostat housing Il ) and new 32 - 35 ft. Ibs. Reconnect all of t he high tens ion
gasket (2 ). leav ing st ud nuts finger tight. wires to the spark plugs.

J. Torq uE' th(~ cylinder head fl anged nuts to 13. Apply clean engine oil to the rocker arm
60 ft. )bs. a nd then to 90-100 ft . los. 'O'J'E : assembly and start the engine. Check tha t the
Lubrica te t hreads with c lean eng ine oil roc ke r a rms are recei ving lubricating oil.
prior to torq uing a nd usc the tightening se- Opera te the engine for approxlma te ly one hour,
quence s hown in Inset A. (under load if possible ) to thorough ly warm
up the e ngine and seat the head gaskets.
6. Torqu e th e exhaust manifold a nd Inta ke mani-
fold s tud nuts 25 - 30 ft. Ibs. Torque the 14. Shut the e ngine off. Back of[ each cylinder
thermo sta t housi ng stud nuts 20 . 25 ft . lbs. head fla nged nu t individually 1/4 turn a nd
retorque to 90-100 ft. Ibs . in the proper
7. Coat the pu s h rods (1;;) with clean engine oil sequence, Inset A. NOTE : DO NOT BACK
and insta ll the m in the ir ori gina l location. OFF ALL TH E FLA NGE D NUTS AT THE
SAME TIME. Recheck the torque to make
8. Ins tall the r oc ke r arm assem b ly (19). Make sure a ll flanged nu ts have ret;Jined their
sure all u t the push r ods (15 ) are engaged proper torque. Rechec k the rocker arm
wi th th f' ac!j us ting scr('ws o n the rocker arms. bolts to make su re they have reta ined the
Torque t he m ounting boits (U) 25-30 ft. Ibs. 25-30 ft. Ibs. torque .

9. Adj ust the va lve tappet <.:iC'Jrance, refer to 15. Install a new valve cove r gasket (11) and
P age 26. valve cover (10) . Torque the cover nuts 5 to
8 ft. lbs. 00 not over torque the cover nuts.
10. Install the e xha us t s tac k (21) and new gasket In s tall the brea the r tube ( 12).
(20), if it was remo ved. Torque the mo unti ng
bolts ;15 to 42 ft. Jbs.
 22-13

13 . INSET A

Fi gure 7
22-14

ROCKER ARM ASSEMBLY

148 AND 159
( Refer to Figure 8)

Disassembly
I. Hem ove the rocker arm s haft bracket (5) be fore the e nd brackets can be removed.
bolts (I) an d studs (9). !l;OTE : The ce nter 3. R em ove the shaft sprin gs (8) and s pacers
bracket is drilled for oil passge to the (11) from the sha fts (5). T ag the fro nt and
rocker arm sha fts . rear shafts (.5) for proper locat ion when
2. RemovE' and tag ea ch rocker arm bra c ket assemblin g .
(2 & l UI for proper location \\"h('n assem - 4. Remove the tappet a dju s ting screws (12) fro m
bling. ~OTE: The e nd brackr·ts will ha ve the roc ke r a rm s_ Remove the pu s h rods a nd
to bEe' moved uU lwanl sl igh tl,' in order to tag them for proper locat ion.
re m ovE' the' retainer pins ( 4) from the s hafts
Inspection
Check the s haH s prings for da mage and The roc ker arm mus t be ft'ee on the shaH
pro pel' tensio n. without a ny s ide wob ble. !f any is noted, r e o
SPHI:\ C SP E CJF!C.\TlO:'<S place t he rocker a rm bushing, Clea n the oil
Free Le ngt h .. .. ........... .. ... ...... ... ].;l/16 passage in the roc ker arms. Inset A , to insure
Wire Diame ter . .... ................... ..... ... . 072" free oil flow. Inspect t hE' valve stem contact
l. D. ................. .......... .. ........... 11116" area on the rocker arm for wea I'. Replace if
Compressed to 11 116" 1_5 to 8.5 Ibs. worn.
Clea n and check the o il passage in the tappet
Flu sh the s haft s to r emove any residual adjusti ng screws ,
m ater ial. Inspect the s halts for e xcessive Ins pect the push ['ods for straightness,
wear or worn spells on thE' bo ttom side of the cracke d or worn ends, r e place if these condi-
s haft. Replace the sh aft if any of these condi- tions exis t.
tion s exists. Clean and c heck the oil passage in the cen ter
In spec t the rocker a rms by in st alling each rocke r arm bracket, Inset B.
r ocker ann on the shafts in its proper loca tion.
Assembly
Wit h all component parts c lea ned thoroughly and worn parts replacE'd. coat them with c lean
engine oi l.
I. Insta ll t hE' pl ugs (3) in to the ou te r ends of (6), inte rmedia te bracket (2) . spacer (11), red I'
the s halts (5), if they were r emoveel , to a rocker arm ( 7), spri ng (8 ) a nd front rocker
point w hich will allow the re tai ner pins (4) arm (6).
to be installed and not block any oil holes. 5. Starling wit h the rear sha tt insta ll a fro nt
NOTE : If the pl ugs (3) are installed too rocker a rm (6) , spring (8) , r ea r roc ker arm
far they will block the flow at oil to one or (7 ). interm edi a te bracke t (2) . spacer' ( 11 ),
more roc ker a rms . front rocker arm (6), spring (8) a nd rear
2. Inst a ll t he e nd bracket s (2 ) part wayan the rocker arm (7).
shafts (5) so the retaining pins (4) ca n be in- 6. Ins tall these two rocker ~rm shaft assem·
stalled in s haft. Tap the end brackets further blies into the center bracke t ( 10) a nd wire
on the shafts so the pi n engages the s lot in the c omplete assem bly together.
the bracket and the oil holes in the sha ft are 7. Install the ta ppet a dj us ting sc rews (12) into
toward the valve side of the bracket. the rocker a rm s (6 & 7) as far as possible.
.3. Install new roc ker arm bu shi ng ( 13) in to 8. Install t he push rods in thei r proper location .
the roc ke r a rm s ( 6 & 7) if they are be.ing Ins tall the r oc ker arm as sembly to the cyl ·
replaced, :-.'OTE : The bushing (13) must ind er head with th e bracket bol ts (1 ) and
be pressed into the r ocker arm and reamed stud s (9). Torque the bracket boIlS a nd stud
to ,624" -.625", In set A. nuts 25· 30 t t. Ibs .
4. Starting with the front s haft install a r ear 9. Adjust the tappets, re fer to Page 26.
r ocker arm (7) , spri ng (8), fron t rocker arm
TAPPET SCREW INSET A
OIL HOLE . INSET B
r;rV' L.C
CROCKER A RM
. •'

REAM .624 " . . 625 "

OIL PASSA GE

l.-----------------------------Fi9ure 8
22-16

ROCKE R ARM ASSEMBLY (Continued)

188 AND 20 1
(Refer to Figure 9)

Disassembly
1. Remove the rocker arm shaft bracket when asse mb ling .
bolts (l & 91. I'o- OTE : The c e nter bracke t
bolt is d r ill ed for oil passage to the rocker 3. Remove the shaft sp rin gs (6) a nd tag the
arm shaHs. front and rcar shall s (8).

2. Rc'mo\-e and lag !?aeh roc ker ann (-1 & 7) and 4. Remove cac h tappet adj usting screw (~ ) from
brac ket (:l . 10. 11 & 12 1 fo r proper local ion ea ch r ocker orm , r !? fer to Ins E't 1\.

Inspection
Cheek Ihe sl1a ft spr ings for damage and rocker a rm on the shafts in its proper loca -
proper te nsion. tion . The rocker arm must be frce on the
shaft without any side wol;Jblc. If any is noted,
SPRI~G SPEC (FICATIO~ S replace the rocker a 1'111_ Clean the oil passage
Free Length . ............... . ...... .... . 2. 5" in the rocke r arms to illsure fr e e oil flow .
Wire Diam e ler .................. 072" Inspect the valve ste m contact area on the
Compressed to 1.70," ............ 7. :; to 8,,) Ibs. rocker arm for wear. Replace if worn.

Flush Ihe s haft s to remove a ny residual Clean a nd check the oil passage in the
mat e rial. InspC'c l Ihe shafts [or e xcess ive tappet adjusting screws, Inse t A, and the
wea r or worn spots on Ihe boltom sid e of the center ,I )rack.et retaining bolt (1).
s ha ft . Replace the shaft if any of these con-
ditions exist.s. Inspect the push rods for st raightness.
cracked or worn e nds, replace if th e~e con-
Inspect th C' r oc ke r arms by installing each ditions exist.

Assembly
With all compone nt pa rts cleaned thoroughly a nd worn parts r eplaced, coat them with clean
engine oil.
1. In s ta ll the inte rm edia te bracke ts (10) on the 5. Insta ll the center bra c ket (11) to Ihe long
shafts (8 ). s tarting wi Ih the fro nl s haft. The end (from the cut-out) of the shafts (8). In ·
front s ha ft is installed wi t h t he s hort end of s tall the front (12 ) a nd r ea l' (.3) brackets to
the Sha ft (from the cut-out) toward the fronl Ihe s hafts (8).
of the engine. see Inset B. The rea r shaft is
installed wilh the shar i end o f the sha ft (from 6. Before installing the rocker ann asse mbly
the cut ·out) loward the r ea r of the e ng ine . on the cylinder head, crank the en g ine (fuel
inj ec tors removed) with the starting motor
2. Inse rt Ihe brac kel bolt (9 ) inlo the inter- (approximately 1 to 3 minutes) until oil ap-
mediate bracket (10) it musl line up with pears at the center oil passage in t he head,
Ihe cut -oul in Ihe s haft. see Inset C. Install the rocker arm as sem-
bly to the cy linder head with bracket bolts
3. Ins tall the tap pet adjusling scrt' WS <,5) into (1 & 9), m a king sure the cen ter bracket
the roc ker arms (4 & 7). make sUrE' the screw s drillcd bolt (1) is installed in the cylinder
are turned into the rocker arms as far as head oil passage hole . T orque the
possible. bracket bolts 25-30 fl. Ibs.

4. Install the rocker arms (4 & 7) a nd springs 7. Adjust the tappets, re fer to Page 26.
(6) on the rocker arm shafts (8 ) .
 22-17

INSET A INSET C
OIL PASSAG E

OI L PASSAGE

OIL HOLE PLUGGED /

TAPPET SCREW

~OILHOLES~

t:'l;::::(: : ~ -: --::--1
I-sHORT END-I ~CUT OUT
Figure 9
2:1·18

CYLINDER HEAD ASSEMBLY

148 AND 159
(Refer to Figure 10)

Disassembly
1. U sing a valve spring com p ressor, com · down through the cy linder head (9 ) using
press the v alve spring (1) enough to remove an arbor.
the va lve ret ain er loc ks (2i. R elease the 4. Remove the exhau st va lve seats (8) fr om
spring compressor and r emo\"(' the intake the cy linder head (9) using a special seat
va l\'(' seals i3 ), in take val "" retain ers (4) removing tool, Inset B. NOTE: Nevt'r Jt·
a ncl the exlla ust valvE' rotators (5). Remove tempt to remove a valve st'at with a center
the spring s (J). punc h, cold chisel or pry bar.
2. H emov!? any carbon from the valve s tems 5. Remove the push rod tubes (12 ) from the
bC'fon? they ue r emoved f rom the cylinder cylinder head (9) by driv i ng them down
head. He'move the inl a ke valves (6) and ex· throug h the h ead, Rem ove tile puSh rod tube
hau st \'alves 171 from the cyli nder head (9) "0" ri ngs (13) and discard them .
and "Pt t hem in a rack or hold er. N OT E: 6. To remove t he expansion pl ug (14 ) f r om the
:Vlark the valv es on remova l SO they can cylinder head (9) it must be elrUled anel
bo installed in their original loca tion. pryed out,
:l. Hemove t he int a ke valve g uides (10) and the NOTE : Refer to Inspec tion and Servicing
c xhoust v<l l ve g uide s ( 11 ) by driving them on Pages 22,23, 24 a nd 25 prior to Assembly.

Assembly
1. If the va lve guid e'S are be ing r eplac ed, in- valve seals (3) can be i nsta lled in t.he lower
sta ll new guid es (10 & 11) in the cylinder groove on tht' valve st.ems . I nsta ll the
head using a n arbor. Press the guides into valve retai ner locks (2 ) and r em ove the
the head [rom t hl' top of the cylinder head. spring compressor c ar eful ly.
The guides must protrude above the cylinder 6. Ins ta ll the valve springs (1) and t.he ex·
head (intake · 1.1'100" and ex ha ust · ,844"), haus t valve rotators (5) on the exhaust
I nse t A. After the gu ides have been pressed valves (7), Compress the valve spr ings so
in to place, the'), must be ream ed to .3422" that the valve r eta iner locks (2) ca n be in ·
. . 3132", lns('\ A. s talled , Remove the spring compressor
:2. To ins tall new exhaust valve se ats (8), care f ully.
clean the r('cI'Ss in tlle cylincl er heael (9), 7. [n sta ll new expansion plug (14 ) i f it. was
Plac(l the valve scat s in dry ice to shrink r emoved. The plug must be pressed in place
them . Insert thE' valve seat s in the head and firmly seated aga inst the retaining ridge
and pr ess them in pla ce , usi ng a suitable In the cylinder ht'ad.
pl"(~SS .
1. Install new pu sh rod tube " 0" rings (13) NOTE: When engine assem bly is complete,
in the eylincicr head r ecesses , Lubric at e a check of the opera tion of Ihe r otators
the push rod tubes (12) with clean engine mu st be made. It is impossi ble to d etermine
oil anel install t hem into the cylinder head, whether or no t the r ota tor i s turning without
:\,OTE: Th e tubes m us t be i nstalled from an identifying rnark .
the top with the tapered end dQ>.vn. Be sure P la ce a dab of white paint on ea ch oJ the 1'0'
t hey DO 1\'OT protrude below the cylinder tators and note it's position , Sta rt the eng ine
head, Sec In set C and observ e whether or not the rotator is
'1. Lubrica te the intake valves ( 6) and exhau st turning. DO "OT a ttempt r ep ai rs on rota tors .
val ves ( 7) with clean engi ne oil and in sta ll There i s not a set speed a t whic h the rot ators
them in their ori g ina l location. should turn. Some ro tators will turn faster
,j . [nsta ll thE' valve spri ngs (1) a nd valve re~ than others. As long as the rotator is t urning
ta int'rs (4) on t he intake va lves (6). Com· the valve, it is functi oning proper ly.
press the val v e springs so that the intake
 22-19

INS ET A R EAM/ .3422 " . . 34 32" INSET B

\ I
.844"
-'-
""

INSET C

.0312 "

INTAKE VALVE EXH AU

AS SSE™ VALVE
A SSE MBLY SLY

,
22·20

CYLINDER HEAD ASSEMBLY (Continued)

188 AND 201
(Refer to Figure 11 )

Disassembly
1. Usi ng a valve spri ng compressor, compress exhaust va lve g uides (11) by driving them
tIl!' s pring (1 1 enoug h to remove the valve d own through t he cylinde r hea d (9 ) using an
reta ine r locks (21. Release (he s pring com· a rbor .
pr('sso r a nd ,r emov(' t he intak e va lve seal (.3)
inta ke va lve rNainers ( 4) and the e xhau s t 4 . Remove the e xhaust va lve sea l, (12) Iro m
valvE' r Olators (5). Remove the s prings (1) the cylinder head (9) using a specia l seat
a nd va lve' s pri ng sea ts (6) . r emovIng tool, In set B. NOTE: Never at ·
tempt to remove a va lve s ea t with a cent er
2. Remove any carbo n from t he va lve s tem s punch, cold c hisel or pry bar.
belorc they are r ('moved from the cylin der
head. Remove the in take valves (8) and the 5. To r e m ove Ihe expansio n plug (13 ) from the
e xhaust valves (7) fro m the cyli nder head cylinder head (9) it must be drilled a nd p ryed
(9 ) a nd se t them in a r ac k o r holder. NOTE: out.
Mark t he va lves on r emova l so t hey ca n be
ins ta ll ed in t heir origina l location . NOTE : Refe r to [nspeclton a nd Servic ing on
Pages 22,2:3, 24 a nd 25 prior to a ssembly .
.3. Remove the int ake valve guides (10) a nd th e

Assembly
1. If the va lve g uides a re being r eplaced , insta ll 5. Install theval"" spring sea ts (6). valve s prings
new valve g uid('s (10 & 11) into the cylinde r (1) and the exhaust valve rotators (5) o n the
head us ing a n arbor . P ress the g uides into exhaust valves (7 ) . Compress .the valve springs
the head from the to p of t he cy linder head. so that the va lve re ta iner loc ks (2) ca n be in·
The guides must protrude a bove the cylinder stalled. Re m ove the spring compressor care·
head I intake a nd e xhaust) 1.000", Inset A. fully.
After the g uide s have been pressed into place,
t hey mus t be reamed to ..1422"·. 34.32", Inset A. 6. [nstall new expans ion plug (13) If it was re o
m oved . The plug mus t be pressed in place
2. To ins ta ll new ex ha ust va lve seats 02), c lea n a nd firml y seat,ed aga in s t the r eta iner ridge
the r ecess in the cy linde r head ~S) . Place the in the cylinder head.
valve s ea lS in dry ice to shri nk the m. Insert
the valve seats in the hea d and press them in NOTE : When engine as sembly is complete ,
pla ce . using a s ui table press. a check of the opera ti on a t the ro ta tors
mus t be made. It is imposs ib le to de te rmine
3. Lubrica te th e intake va lves (8 ) 'l nd e xha us t whether or not the ro tator is ttl nting w Ithout
valves (7) with c lea n e ng ine oi l and instal l a n ide ntifying mark.
them in thE'll' original location.
Place a dab of whUe pa in t o n each of the roo
~. Install the valve spring sea ts (6), valve springs tators and note it 's position . Start the e ng in e
(1) a nd the va lve reta ine rs (4) on the int ake a nd observe whethe r or no t the rota tor Is
valvE'S (8) . Compress the valvc spring so the turnIng. DO NOT attempt repairs on ro taiors.
int akl' valvE' seals (3 ) t hey c an be insta lled In
the lower g roove on t he valve s tems. Install The re is not a set s peed a t w hic h the rotators
the va lve re ta iner loc ks (2) ancl r e m ove the shOuld turn. Some rOtators wi ll turn fas ter
spring compressor c are fully. than olhers . As long as the rotator is turning
the valve, it is functionin g pro pe rly.
 22 ·21

INS ET B INS ET A
- -I -1-
1 .0 00"

~~:-'-,.-
l _I

'-
EXHAUST S EAT RE M O VI N G TOOL

io

, I
J ~ '"
e I N

I: ~I ~
!
I
§ 1 t.:: 11 ~
~ I "L...

INTAKE VALVE CD ". ~---<D EX HAU ST VALVE

ASSEMBLY
Figure 11 ~ ASSEM BLY
1-_ _ _ _ _ _....
22-22

INSPECTION OF VALVES, GUIDES, HEAD AND SPRINGS

Clean the cylinder head completely. Re- exhaust valves a nd 1.00(J " on a ll intake
m ove all traces of carbon and other deposits. valves, above the hea d. Repl a cement guides
Check for cracks and any evidence of fret- must be reamed after insta llation. Ream
ting or erosion existing in the area of fire new guides .3422" to .3432" diameter.
ring contact. Check the head for evidence of
warpage. If warpage exists and is more than Clean the valves with a power driven fin e
.006", the cylinder head mus t be resurfaced wire brush, being very careful no t t o scratch
or replaced_ thE' valve stems. Refer to Figure 13 for valve
Val\'(, springs should be chccked for flat nomenclature.
squared ends, broken coils and correct HEAD FACE STEM
spring pn'ssure_ Cse a Valve Sp ring Tester RETAINER

fE·felTing to the spring specifica tions be low: \

EXH,\UST VALVE SPRIKGS
Va l\"(' Comprps sed Spri ng Replace if
SEA L GROOVE
Position Height PressurE- Lcs s than TIP
Valye Open U~l2" 114 Ibs . 110 Ibs. MARGIN Figure 13
\'al\'e Closed 1.686" 56 Ibs. 50 Ibs. Inspec t the valves for e xcessive wear or
L\TA]{E VAL VI-: SPRl:'\GS necked stems, Figure 14. This ca n be caused
\'al"c Compressed Spri ng Replace if by lack of lubrication, plugged water pas-
Posillo n Hei.ght Press ure Less than sages or operating the engine under contin-
Vain' Open U21" 114 Ibs. 110 Ibs. uous overload at excessive engine RPM. Re-
Valve Closed 1.87:;" 56 Ibs. 50 Ibs. place valves if this condition e xists.
Remove a ll carbon from the bore of th e
\'a lve guides with a fine wi re brush and blow NECKED VALVE STEM
clean with compressed a ir. Valve guides can
be checked for wea r by using a bore gauge
and micromet er, refer to Figure 12, Inset A.
The valve guides should be c hecked at the top, Figure 14
middle and bottom of the g uide bore for wear, Inspect the valves for deep grooves in thE'
Figure 12. If the diameter is grea te r than face, FIgure 15. ThIs can be caused by abra-
.3.52" at any point al ong the horC', the guide sives entering the engine through the intake
mu st be (('placed. Cse an arbor equal to th e system or not servicing the air cleaner r e-
insid e diameter o t the valve guide 1.0 keep the gularly. If grinding the valve face will not
guide from collapsi ng when pressed into correct this condition, repla ce the valve.
place. Press in fl'Om the top ot the head until
GROOVE IN VALVE FACE
the g uid e protrudes a distance of ,84," on
148 & 1';9 exhaust valves, 1.000" on 188 & 201

EXPANDABLE BDRE GAUGE~ Figure 15

Inspect the valve fac e and ste m for rust
CHECK WEAR
OF GUIDE AT or pitting, Figure 16. Rust or pitting can
tNSET A THREE POINTS usually be removed by grinding the va lve
face. If rust or pitting on the valve stem

I
exists, replace th e valve. These conditions
can be caused by using poor quality engine
oil or fuel that does no! meet th e speci fic -
GUIDE
REBORE ation given i.n Section 11 a nd by improper
AREA storing of the engine.
RUST OR PITTING

, . .' ,'
"

Fi gure 12 Figure 16
 22-23

INSPECTION OF VALV ES, GUIDES, HEAD AND SPRINGS (Cont'd)

Hea vy car bon or va r nish de posi ts on the CHECK DIAMErER Of STEM A T THREE PO I NTS
valves, F ig ure 17, should be removed twfote
va lves arC ground . Th is condition is usually .
~:06
14
INTAKE VALV E
ca used by worn piston ri ngs and s leeves
wh ich allow too muc h oil 10 reach the com-
bustion chamber. This c ondit ions could also
be caused by wo m va lve gUides or bad sea ls _ _ ;.::
.3c: 3..:
8.;:.2_ EXHA UST VALVE
.3390
on the valves . Low operating temperature is
sill! another cause.
H EAVY CARBON AN D V AIlNI S H D EPOS ITS

CRID M ETER
Figure 17

In spec t the valve hea d [or dishing and the Figure 20

va lve fa ce for deep bu r ned s pot s, Figure 16.
These condi tions cannot be corrected by The checking of the
grindi ng the valves , T he va lves mus t be reo valve face runout should
placed . These conditions are usually cau sed be done a fte r the valves
by runn ing t he engi ne under excessive loads have been ground. A Vee
at hig h engine temperatu res . block type h older with a
dial indicator , Figure 21
ca n be used to check the
/
D IAL INO IC A TOR
valve face and s tem r un-
out. The valve face 1'110-
out should no t exceed
more th an .002". The
valve stem runo ut s hould
not exceed .002". J( t e
DEeP BURNED va lve face and lor val ve
VALVE FAC E stem runout is greater,
OI SHED VALVE HEAD

Figure 18 the valve must be e-

placed _ Figure 21
Valves with worn keeper grooves Or if the
s tem tip is worn or d is hed beyond the cham- NOTE : Small amounts of very f ine pi tti ng,
fe r, r ep lace the valves , Figure 19, Figure 22, may be found on the surfaces of
the val ves faces and seats after the val ves
are clea ned. T hese are normal and wil l not
affect engine pe rformance. Th is fine pitting
is caused by a norma t oxid atio n process and
can hap pen on any engi ne during the run-in
period. It is not necessary to grind va l ves
WORN RETAI NER GR OOVE
or seats if this fi ne pitting is found as the
Figure 19 pitting will genera lly reoCCur a fte the e n-
The checking of th e val ve stem diameter gine is run for a few hours .
<;an be hes t be done wi th a good , accur ate
micrometer, Flgure 20 . T he valve s tem FINE PITTIN G
being straight , s h ould b measured at three
points a long the stem , FIg'llre 20. Wear limit
must not exceed .002" at all points of mea-
su rement. If the wea r is grea ter, replace
the val ve. Figure 22
22·2i

REFACING INTAKE A ND EXHAUST VALVES

Before r efacing the v alves, t hey sh ould be Correct r efac ing of intak e a nd ex haust v alves
wire brushed , cleaned and in ~pected . 44" and al ve seats wi ll provide a 1" in terference
angle on xhaust valves and 29" angJe on a ngle. This angle i s im portant ,ince it aids i n
intake va lves i s t he correct va[\' face g r i nd- cutti ng carbon and Mips seat the valves.
Ing angle. SN t he r IO' acing machine p r otractor
at this a ngle. Be sur e the c huck of the m achine
is clE'a n befor e Insta lling the val ve. Dress
th e grinding whee l before sta rting to r eface
t he vah'" . Ta ke only li ghl cu ts as the v alve
i ~ r efaced. The last cu t mu st bE> very fi ne so
he valve fa ce wil l h av a poli h d fin ish.
IMPORTA T : Repl ace any valve tha t has
a Ihi n dge or mar gi n, F igure 23. If the
m argin on the ground va l ve Is l ess t han half
the m argin on a new valve, r eplace the va lve.

~~EM~
G AI NOING~A~
N~G:.I:.LE~ ~~=~~=~=
I IN TAKE VA LV E AN D VALV E SEAT"

1
MA RGIN

/
/

CHAMFER-------
T F igure 2 4

Figure 23 Wh en the top edge of the contact area i s lOa

high or lOw On the valve face. I he seat contac t
T he ti p end of the val ve should be checked area must be m oved. Th is is do ne by using the
fo r rou ghness or wear . Usually t his can be n3l'l'Owjng stones . Refer to Page 25. The con-
r em oved wlth so m e very ligh t cuts aga inst tac t area w idth should n("vcr pxceed the speci -
the side of the g r ind in g w heel a nd will square fi ed dimensi ons.
up the pnd . Neve,- gri nd off the valve stem
end beyo nd the ch 'l m f er .
 22 .25

GRINDING INTAKE AND EXHAUST VALVE SEATS

Always use a precl sion seat grinder. Take The valve sea t contact area w idth a nd 10 '
very li gh t cuts with the grinding s tones so cation can be c hanged by using 15", ;1/]" and
jus t enough metal is r emoved to e nd up with 60" narrow ing st ones, Figure 27 .
a good s m ooth seat fin ish
i~ 30 ' NARROWING STO NE
The prope r a ng le of g r ind is 45 0 for exha ust
valve seats and 30" for intake va lve sea ts ,
"'=7
FIgure 25 . The seat grinding angle of the
stone s hould be d ressed frequen tly on a stone
dressN to m aintai n a c lean accurate surface . (1 488. '69 1
60' NARRO W ING
STONE .090 TO .100
VALVE SEAT GRINDIN G AR EA \ \ ... SEAT W IDTH

45 '
LJ (~~~ ~D2~~5/\(
SEA T W IDTH

EX HA U ST VALV E SEAT

"'Z:7
.~
15' NARROWING STONE

EXHA US T V A LVE SEAT

60· NARROW ING /148 8. ' 59)

StON E ~ ./ .0 4 6 TO .0 60
~( SEAl' W IDTH
(1 88 & 2 01)
.0 5 5 T O .0 70
SEA T WIDTH

INtAKE VALVE SEAT INTAKE VALVE SEAT

Fi gure 2 7
Figure 25
If the va lve he ad ha s receded more than
IJI.IPORTANT: The valve seat runout the " A " and " B" dimensions be low the
s hou ld be c hecked after fin ish grinding with cylinder head surfa cE', the valve , va lve insert
a d ia l ind icatDr and seat grinding pilot, F ig- (exhaust ) or cylind er hea d must be rep laced .
NOTE: Meas ure rcom the '.'alve head edge
ure 26 . The runou! of the valve sea t must
no t. exceed .002" . to the cylinde r head face using a dept h m ic·
rometer.

EXHAUST VALVE INTAKE VALVE

Figure 28
Engi ne A B
148 & 1~9 .940" . ~{) "

188 & 201 1.060" l. OOO"

IMPORTANT : Do not attempt to sah'age a

cylinder head by install ing inserts for Intake
Figure 2 6 valves.
22-26

LOCATING TOP DEAD CENTER AND TAPPET ADJUSTMENTS

FIRrNG ORDER .............. .... ............. . 1·3+2 TIMING POINTER
T he Top Dea d Center position of number 1
and 4 cylinders is Indicated by the TOC m ark
on the flyw heel. Refer to F igurf> 29
T he tappet ad j ustments c an be done in two
steps a s described in the following manner. D
COLD SETTING c
STEP J . Remo\'e the v a tve CO\H·. Crank the
engine un til the t imin g pai nter is aligned with
the TDC timi ng mark On the flywheel, Fig ure
29. Check the push rods on No . 1 cylinder
fo r looseness . If the push l"ods are loose ,
No.1 cyUnde r is at TDC on the compress ion flYWHEEL HOUSING OPENING
stroke . If the push rods are tight, cra nk the Figure 29
engine one complete r evolution ;md a lign the
pointer a nd the TOC m ark on the flywhee l. illder No. 4 should be at T OC on the com·
Figure 29. pression stroke . Clleck the push rods on
Chec k and adjUst t he followin g valve c lear· No.4 cylinder for looseness.
ances ; in ta e valve at .014" clearance on Check and adju st the foll ow ing valve clear·
c ylinders 1 and 2, a nd the e xhaust valves on ances; intake valves at .014 " c learance on c yl·
cylinders 1 and 3 at .014" clpara nc€', FigurE' inders 3 and 4, and the exhaust valves on
30. cylinders 2 and 4 at .014" cl ea rance. Figure
STE P 2 . Crank thc engi ne o n,,' complete reo 30.
voluti on and align the lim ing pointe r a nd the HOT SETTING
TOe m ark on the n y\vhe"l . Fi g ure 29. Cyl· Follow steps 1 a nd 2 while the engine is
hot. The tappe t clea r ances for hot settings
are .014" for the inta ke valves and .020 " fo r
the e x haust valves.

Figure 30
ThIPORTANT : The valve ta ppet c learance Is a crit ical ad justment.

The en tire combus ti on system of the e ngine will be seriously affected by adjusting the va lve
tappe t clearance to an y o ther setting.

Excessive c leara nce will change the valve timing and cou ld result in overheating, power loss
a nd possible valve breakage.

Insufficient cleara nce would allow the valves to remain open and be burned by the hot exhaust
gases.
 ion

23
ENGINE BLOCK ASSEMBLIES

1880 DIESE L AND

188G. 159G. 148G SPARK IGNITION ENGINES

U serFriflendlyCDs
TABLE OF CONTENTS
Sp ('C i l kalion~ . .. ... . ", ...... ...... .... ........ ...... .. " ....... ...... .. ....... .... ..... _............... ... ......... ... 23·2 10 23-7
Spcda l Torqlle~ .. , .. ... ......... _.. __ . " .' ........ .... _... ... , ... .... .. .. ..... , ...... ..... .............. . _......... ,_ .. ............ 23·i
Engi ne Lu br lc.:lt ion .. . .. .......... ... ..... " ....... ...... .... ..... . .. , ..... _.. " ... _." .... .......... . __ " ,., ... ... " ... " .. . 23·&, 23·9
Flyw~l, Oil Pa n. seal R ('ta~ ne r and Oil F'ille r .... __..... .. ........ __." , .. .. " .... . ..... "" ... ... 2~ - HI to 23- 13
Dil':lcl Tim Ing Gear COH'r , Gears and Wa ter Pump ........... ............ . ... ... ..... ............. 23- 1-1 10 23·}7
Spa r k Igni tio n T iming r. ell!" Cover, GM r ana W." c r Pump ... ..... ..... ................ ... .... 23·,81023-2 1
C;un s ha fl , Bus hings and Li fre rs ........ ... _.. ........... .............. ........ .... ........ ........ _ ... , .... . , 23·22 10 23·25
P isTons . Rings, Sk'cl-'es a nd ConnecTing Rods - Dis a sseml)ly . inspeCT ion ____ .... .... .... ... ~ 3·2.(j , :13-27
Cy li nde r Sleev('s . Inspco:.'t lon . .. ...... ... ... _. ..... .. ...... ... ............ .. ... .. .. .. .. ..... ....... .... .. ..... ..... .. ... _, .. 2.1·28
Cylln<!(!r Slec\"{>s . Dt'gla zi ng . .. ____ .. , ... .. . , .. __ _.... __ ... , __ .. ... ... ..... .. .... .. ... .. ... ... __ .. ............ _______ .. .. 23-29
Cyll ndcr Sleeves· Hon inv. .. ..... ... .... ... .. . .... ............. .... ....... ..... .. ....................... _ ... ... ..... ....... _ 23-.1(1
Pi s tons a nd Cy lin der Sleev(,s . Inspc<:llon ...... .............. .......... .. ................... .. .......... __ , .... ..... . 2,l·31
P IsTons. Ri ngs, Sleeves and Co nn ecl!n g Rods · AsS("m bly .... __ . .. ...... .. ..... __ .. .. ..... ...... 23 · ,1~ to 23·35
Cra nkshaft , Bear ings, Linc n and Oil f'wn p .. " ... ....... .. .. " .... " ..... " ... ... ... .... ..... ..... .. :!3-3G to 23·39
0 11 Pum p ... ....... ..... .. ...... ..... ......... " " ', .......... . ..... ... .. ,_.... ..... ... .. .. .. .. .... ........ . .. ......... _... 23· ~O. 23·4;
Thermos ta t and F .ltl Bell , .................. .... ..... " ... .. ... .. .. .... .......... ___ .. ............ _ . .. . _... __ ... 23- 12.2J·1:I
Loea llng: Top o.~a d CenTe r ..... .. ... ..... .. .. .... .......... ... ..... ......... .... ..... ... ....... " ........... .... ... . _. , ..... .. 23-4-1

R:>e f a.m 9_8043 1

23·2

SPECIFICATIONS
:\OTE: All dimensions are given in inches. Specifications apply to all engines unless noted.
Maximu m Limit
Including W,,'ar
CY U:\OER SLEEVES
LO. of sleeve (159G) ............................................. 3 ..5013 to 3.5028
(1880 ) .............................................. 3.8113 to 3.8125 .00;)
(188G ) ....... . .......................... 3.8130 to 3.8145 .OO~

(148G ) .............................................. 3.3745 to 3.3765 .OOS

Sleeve out· of·round ............................................................................................................ . .004
Clearance to bottom of piston skirt (l 88D) ................. 0035 to .0055
(188G) ................. .............. ........ ......... 0025 to .0035
(159G) .0015 to .0043
(148G) .0030 to .0035
Taper .001
PISTO:\
Type ................................................. .. ....................... Cam Ground
7vlateria l ........... ............ ............ ........ ................ ..... Aluminum Alloy
0.0. a t bottom of skirt: 90" [0 p iston pin (188G) .... 3.8090 to 3.8105
(1 880) .......................... .......... ......... .. 3.8070 to 3.8080
(159G! ............................................... 3.498:3 to 3.4998
(148G) ...... ................... ..... ................ 3.3735 to 3.3750
l.0. of piston pin bore (1880 ) ................................ 1.2500 to 1.2503 .[J01
(188G, 1',9G ) ........................................ 9992 to .9994 .001
(148(;! ............................. .. ............... .. .8592 to .8594 .001

Width of 1st ring groove (188DI ......... ............... ...... Keystone Type
(188G. 1')9(;, 148C ) ................................ 0965 to .0975
Width of 2nd ring groove (18SDI .................................... 097 to .098
(148G , 159G, 188(; 1 ............................... 0955 to .0965
Width of 3rd ring groove (l88D) .......... .. ............ ......... 1895 to .1885
(188G, 159G, 14RG 1 ........... .................... .0955 to .096.1
Width of 4th ring groove (188G. 159G. 148B) .................. 250 to .251
PI STON RINGS
:\0. 1 Compression (1880) ...... ........ ....... Chrome Grooved Keystone
(188G, 159. 148G) ......... .......... ............. Tapered Face
Width (1880 ) ........................... Not m easureable
(188G, 159G. 148G I ................................ 0930 to .0935
 23-3

SPECIFICATIONS (Cont'd)

Maximum Limit
PISTON RINGS (Continued ) Including Wear

E nd gap in 3.812 1.0 . sleeve (1880 ) ............................... 015 to .025

3.375 J.D. sleeve (148G) ....... .............. ..... .010 to .020
3.500 J.O. s leeve (159G ) .... ...... .... .. .... ....... 010 to .020
:l.812 1.0. sleeve (l88G) ................. .......... 010 to .020
Side clearance (1880) .......... ............ ........ .. , ...... .... No t measureable
(l88G, 159G , 148G) ................................ 0030 to .0045
No.2 Compre ssi on (188G, 159G. 148G ) ........ .......... ... Tapered Face
(1880) . . .... .......... .. ... ...... ...................... .... .... Grooved
Width (lS8G, 159G, 148G) ...... .. .......... _........ .. ... .. ........ . . 0930 to .0935
(1880 ) ................................................... 0925 to .0935
End Gap in 3.812 s leeve (1880) ........ .. ... .. .............. ......... 015 to .025
3.375 slee ve (148G) ................................... 010 to .020
3.500 sleeve (159G) .010 to .020
3.812 sleeve (l88G ) .010 to .020
No.2 Compression
Side cleara nce (1880 ) ...... ........................... .......... .. .... .Om5 to .0055
(l88G,159G.148G) .............. .. .. ........ .... ..... 0020 to .0035
No.3 Compression (188G,159G,14SG) ...... ................ .. Tapered Face
Wid th ................................................ .. ...................... 0930 to .0935
E nd gap in 3.S12 sleeve (l88G ) .. .................... .. ........... 010 to .020
3.375 s leeve (148G) ...... ................................................ 010 to .020
3.500 sleeve ( lo9G) ................ ...... ............ ...... ...... ........ 010 to .020
Side c lea rance .0020 to .0035
OIL R ING S
Width (1880 ) ...... .............. .......... ..... .... .... ............. ....... 1825 to .1888
(l88G ,159G, 148G) .... .............. .... ............ .2485 to .2490
Side clearance (1880 ) .... .................... _........... ... ........ .. .. .. 000 to .007
(l88G, 159G, 148G ) .................................. .(l01O to .0015
End gap in 3.812 J.O. sleeve (lS8G ) .......... .......... ........... 010 to .018
3.375 J.O . s leeve (148G) .. .. ...... ..................... ........ ........ 010 to .01S
3.500 J.O. sleeve (159G ) .... ........ .... .... ...... ...... .. ....... ..... .010 to .018
Ra il end gap in 3.812 J.D. sleeve (1880) ........................ 015 to .055
23·4

SPECIFICATIONS (Cont'd)
:Vlaximum Limit
lncluding Wea r

PlSTON PIj\'
Type ............ .... .......................................................... Full Floating
0.0. of pin (1880 ) .............................. .. ................... 1.2497 to 1.2198
(188G. 159G) ........................ .................. 9991 to .9992
(148G) .................. ................ ............. 8592 to .8593
Fit in piston (1880) ................................ ..... ............. 0002 to .0006
(188G, 159G) .................. , ...................... 0000 to .0003
(148G ) .......... .... ... .............................. 0000 to .0002
Fit in rod bushing (1880 ) ...................... ..................... 0002 to .0006
(188G .159G ,148G ) ............ ... ..... .. ........... .. 0003 to .0006
C01\NECTl:\G ROD
Bushing ..................... " _" ............. _... , ............. .. Replaceable Bronze
Bushing 1.0. insta lled (reamed to size)
(188G,159G) ........................... .... ............ 9995 to .9997 .001
(1880) ...................... .. ................ .. ..... 1.2502 to 1.2504 .001
(148GI ............... ................. .. ................ 8596 to .8598 .001
Bushing out·of·round .0015
Bearing Lin<>rs ............................................... ... .... ...... Replaceable
Bearing liner width ..... ....................... ....................... 1.120 to 1.130
Rod width at crank e nd ............................. .. ........... 1..3035 to 1.3005
Journal 1.0. without bea ring liners ......................... 2.1870 to 2.1875
Bearing oil clearance ................................................. 0010 to .0035 ..... .......... .................. 006
Undersize bearings for service ............................... 002,.010 •. 020,.030
Side clearance ........................................ .. ...................... 005 to .Oll
Cap bolts ................................ .. ........................... Self locking type
CRA:\'KSHAFT
Type ........................ ... ..... .... ..... . .... .... ..... ........ .... ............. Ba la nced
Main bearing liners .......................... ..... ............ ..... .... Re placeable
End play , center main bearing cap ............................... 001 to .006
Thrust spacer std. thickness ........................................... 092 to .098
Connecting rod journa l std . 0.0 .............................. 2.0605 to 2.0615
Grind to .010" 0.0. undersize ............... .................. 2.0505 to 2.051.5
.020" 0.0. undersize .......................... 2.0405 to 2.0415
.030" O. O. unders ize .......................... 2.0305 to 2.0315
Connecting rod journal maximum taper ............................. ... ...................................... .... .... 002
 23-5

SPECIFICATIONS (Cont' d)
Maximwn Limit
Including Wear

CRANKSHAFT (Continued )
Journa ls out-of-round .. .......... _... ........ .. .. __ .. ... ....... ... .. ..... ..... _..... .. 001
Main bearing liner width 1st , (ISS0, I SSG) _... .. ........ .. 1.276 to 1.286
Ma in bearing liner wid 1h 1st, (159G , 148G) ................ 1.870 to I.SS0
Ma in bearing liner width 3rd (ISS0) .......................... 1.371 10 1.373
Main bearing liner wid th 2nd (I SSG) ................ .. ....... 1.371 to 1.373
Main bearing liner width 2nd and 4th (188D) .. ....... ..... .950 to 1.000
Mai n bearing line r width 5th (1SSD) , (ISSG 3rd.) ...... 1.557 to 1.567
Unders ize main bea ring liners for service ............. 002,.010,.020,.030
Main bearing oi l cleara nce .. ........ ...... ... .... ....... .. ......... .0012 to .0042
Main bearing journa l sid. O.D. (18SG , ISSD) ..... _.. .. 2.8730 to 2.8740
(l59G,148G) ....................................... 2.6230 to 2.6240
Grind to:
.010" 0. 0 . unders ize. (ISSG, 1880) 2.8630 to 2.8640
.020" O.D. underS ize , (l88G, 188D ) 2.8530 to 2.8540
.030" O. D. unders ize. (ISSG, 1880) .... .... ............... 2.8430 to 2.8440
.010" 0.0. und ers ize. (159G, 14SG ) ....................... 2.6130 to 2.6140
.020" O. D. undersize. (159G, 14SG) .. .... ................. 2.6030 to 2.6040
.030" 0.0. und ers ize, (159G, 148G) .. .... .... ........ .. ... 2.5930 to 2.5940
Mai n Journal bo re I.O. w l o liners (ISSD, 188G) ...... .. . 3.066 to 3.067
(159G,l48G) ...... ................ ...... ...... .. ...... 2.816 to 2.817
Main journal width be tween cheeks :
2nd (159G, 148G) ...... .... .... ................ .... ........ .... ...... 1.499 to 1.502
2nd a nd 4th (1880) ............................................... _.. 1.185 to 1.189
2nd (I SSG) ................................................. -.. .... ... 1.3770 to U740
:lrd (1SS0 ) ........ .. ......... .. ...... ... .............. ....... ......... 1.3740 to L1770
3rd (159G, 148G) ............... ... .... ...... .. ............... .... ...... 1.741 to 1.75 1
5th (ISSD ) ._....................... _.................................... 1.745 to 1.755
Connecting rod journal width betwee n cheeks .. ..... .... 1.3105 to 1.3145
CAMSHAFT
Type ....................................................... .. ................. .... .. Parabolic
Bu sh ings (188D ) ......... _........ .. .. .. ..... ...... .. .. ........... .... . 5, Replac eable
Bushings (ISSG) ................. ..... .... ....... ..... ... , ... .. .. ..... 4, Replaceab le
Bushings (159G, 148G) ... ....... _... ..... .. ................... ..... 3, Replacea ble
Oil Clearance ... _............................................................. 002 to .00:,
23·6

SPECIFICATIONS (Cont'd)
Maximum Limit
Including Wear

CAMSHAFT (Continued)

Bushing lubrication:
Front bushing .. ,...... , .. "' ... , .. ,',., ... " .... ', .... ,..... Pressure lubricated
from oil pump,
Intermediate bushing ................................. Gravity flow lubricated
Rear bushing (1880 On ly ) ....................... Pressure lubricate d with
rear oil meterIng.
Oil clearance ................................................................. ,002 to ,005 ............................... ,007
1.0, of bushing installed ........ ... .. ................................ 1.752 to ,1753
Bushing width:
1st (front) (lS9G.H8G) .......... .................................. 1.307 to 1.317
1st (front) (188D.I88G) ........................................... , 1.213 to 1.223
2nd (lS9G.H8G) ...... , ............ ..... , .. ........ , .............. .......... 713 to ,723
2nd. 3rd & 4th (1880) ........................................ ......... .490 to .500
2nd. & 3rd, (l88G) ...................................................... .490 to ,500
3rd (rear) (148G, 1S9G) ........................................... 1.177 to 1.197
4th (rear) (I88G) .................................................... , 1.213 to 1.223
5th (rear) (l 88D) ..................................................... 1.213 to 1.223
0,0, of each bearing surface (159G. 188D ) ............... 1.749 to 1.750 .004
0,0, of each bearing surface (l48G,l88G) ............... 1.749 to 1.750 ,004
Thrust plate thickness ................ " ............................... 149 to .147
Camshaft end play ....................... ... ..... Taken up by thrust pIa te
Camshaft end clearance ............................................ , .003 to ,007
VALVE PUSH ROD LIFTERS
Type ,., "",.".,,', .. ,,', "" ,.. ,"',.,.," "' ..... "' .. ' .. ,' .... ', ...... ", .... ,' Mushroom
Body 0.0, std, ...................... ............. ........................ , .5615 to ,5620
J.D, of block bore, std, , .............................................. ,5625 to .5635 .............................. , ,0015
GEAR TRAlj\;
Ba('klash:
Crankshaft gear to camshaft gear .......... .......... .. .......... 0002 to .006
Camshaft gear to idler gear (Diesei) ......... , ...... , ......... ,0004 to .006
Idler gear to fuel pump gear (Diesel ) ............ ............. ,0005 to ,007
Crankshaft gear to oil pump gear ................................. ,002 to ,008
Crankshaft gear to fuel pump gear (Diesel) ........... Maximum ,019
 23·7

SPECIFICATIONS (Cont'd)
Maximum Limit
Including Wear

IDLER GEAR
0,0, of idler gear journal (Diesel) "'"''''''''' '' ''''''''' 1.3740 to 1.3755 """,,"""",,",, ,"""" ,0005
J.D, at idler ge ar w/ bushing (DiesE'l) "'"",,.""" "" "'" 1.376 to 1.377
Thrust washer s hims (Diesel) """, .. " " ""."", ... "". ,005,,006,,007,,009
Idler gea r end play (Di esel) ",. """ """ " """" """"" """""."".""" ""." ". "'''''''"."''''''',,'',, ,003
OIL PUMP FRONT MOUNTE D
Positive displaceme nt pump """."""."""""" .. ""." ."." , Gear Type
Pump gears to oil pump cover c leara nce "" .. """ .. "" ,0015 to ,0055
Pump gears radial cl eara nce ""."""",,,,,,,,,,,,,,,, ... ,,,,,,,, ,002 to .005
Drive gear to body c lea ra nce (l88G,159G,148G) ,,"'''''''' ,003 to ,006
Drive gear to body c lea rance (1880) .""".""".,, " ,,.,,. ,0035 to ,0065
Relief valve spring:
Wi re thickne ss (I88D ) "" """ """"""""" .""" ". """." "." """ ", ,0625
Maximum 0,0 , (188G, 159G, 148G) """.""." ... ". " """.".". " .""." , .469
Maxim urn 0 ,0, (1880 ) " . "." """"" ". "." """""" """,,.,," ". ,,"" .4844
Free length (188G ,159G, 148G) ".""" ."""".""" " .. """" " .. """"""" 2
Free length (1880) '''",,'' "",," "'"'' """. "" "" """ """" """,",," 2·118
Load at 1.:38 inches (188G,159G,148G) " ",," ,, """ " 6·3/ 4 to 7·1 / 4 lbs.
Load at 1.44 inc hes (188D ) ""'''''''''''''''''''''''''''''''''''''' 18 to 19 Ibs,
Oil pressure (188G,159G,148G ) .".""""."""" .. " .. " "." ". 24 to 32 P SI
Oil pressure (1880) """"""""'"'''''''''''''''''''''''''''''''''' 50 to 75 PSI
Backlash , crankshaft d rive gear and oil pump gear "'''''' ,002 to ,008

SPECIAL TORQUES
Camshaft nut """""""" .. """ ""."."""." "" """ """ """" " """"".".". " .. """""."" 80 to 90 Ft. Ibs,
ConnE'cting rod nuts '"'' '' .. ''." .... "" .... " .. " .. "."''" .. " .. '' .. " .. "'' ... ,,'''',, .,,,,''''''''' '',,''' 45 to 55 Ft. Ibs.
Cra nksha ft nu t "" "" ""' ''". "'''''' .. ''''''"' .. .. "'''' .. ''"." .. ,,.,,.,,'',,'''''''''''.'',,''.'',,.,,'' 125 to 135 Ft. lbs,
Flywheel to crankshaft bolt """.""""""" .. . " ." ""." " .. """ .. "." ."" "". " ."""."""" 65 to 70 Ft. lbs ,
Main bea ring cap bolts "" "" """ "" """,,,,,.,,,,,, ,,,,,, ,,,,,, ,, ,, ,,.,,. ,, ,,.,, .. ,,,,,,,,.,,,,,,,,,,, 90 to 100 Ft. lbs ,
Oil pan capscrews (Sta mped steel ) """ "" ""."" " .. " .. "."." ." "". " .. """""""".""" 10 to 12 F t, lbs.
Oil pan capscrews (Cast iron ) """""""" "" "'"''' ''''' ''' ' ''''''''' '''''' ''''''''' '''''' '''' '''' '' 24 to 28 Ft. lbs,
Oil pa n to seal retainer """ """ .. " " ."" """" " ."."".", .. """ "" ".""" ... "" .. "." .. "" . 15 to 20 Ft. lbs.
Oi l pa n drain plug " .... """"""" ." """" "". " .. """ .. " .. ",, ...... ,,""" .. ",," ,, .,,,, .. "",," 18 to 20 Ft. lbs.
Oil pump cover capscrews "".""''', .. "''''" .... ".".""." .. ''". ,,'' ,'''',,.,, ,, '',,'''''''''' ... ,,'''' 6 to 8 Ft. lbs,
Oil seal r etai ner bolts (Grade 8 bolts) "" ..... " .. "" "" .. . " .. "" .. "" " .. " .. ".""" ..... " ... 12 to 15 Ft. lbs.
Fuel pump drive gear nut (Diesel) .""" " .. "". " .... ".""" .... .. " .... "" " .. ,," ,,.,," ",,. ,,, 35 to 40 Ft. lbs.
23-8

ENGINE LUBRICATION INSET A

o FULL PRESSURE
Engine 61 k I dl o, G e a r
o METERED FEED
DIESEL ENGINE o DRI P FEED

-.. ROCKER ARM SHAFT

o SUCTION FEED

In jccl i eon
Pl..I m p O r i yt-
I dler Geer
Ti m i ng Gear Cover

PUM P DRIVE IDl ER GEAR

LU BR I CAT I ON

I N5ET B
CR~KSHAFT
BEARING
~/"'"----
Com

FlOATING
INTAKE
SCREEN

SPARK IGNITION ENGINE Camshaft/

- - ROCKER ARM SHA FT

I
Thrust Plate

Cam shaft G(!ar

t CAMSHAfT GEAR
LU BRI CATION

CAMSHAFT _ OIL GALLERY I NSET C

BUS H I N\ClJG ~r:::':::::::::'~lf::::!:~===:::::::::::::~S~EI

_ INSET A
E
Crankshafl Ma i n Be ari n g
SEE
INSET B
\

CR~KSHAFT
BEARING
f! /";;---___

FLOATI NG
Connoct ing lied Journal
/
INTAKE
SCREEN CO NNEC TI NG RO D
LU BRICA TI ON
Figure 1
 23-9

ENGINE LUBRICATION

INSET D INSET E

Cyli nder Wall

ting Rod

Connl!'cling Rod Journal

ROCKER ARM AND

CYLINDER WALL LUB RI CATIO N PUSH ROD LU BRI CATI ON

Figure 2

OIL FILTER

o FILTERED OIL UNFILTE RED OIL

~ r
... ")
- .
- ,..
o 0 0 a 0 0
Q
0-00 0
0 .s..
O~ 0 0
0
Q 0 O~
0 w::~=rl ~ 0
000-0
0 0 Q
o~
""O~:;:;:=l[::~:
\

1
-
\'---- ----...1: PRESSU RE Rel i Ef VAL VE
( Set 710 9Ib s. )

CLEAN OIL FILTER PLUGGED Oil FILTER

Figure 3
23·10

FLYWHEEL, OllPAN, SEAL RETAINER AND Oil FilTER

(Refer to Figure 4}
Disassembly
1. Remove the oil pan drain plug (1) lVith output hub (29) (Hydrostatic Tractor Only).
gasket (2) to drain the engine and r em ove If the ring gear (17 or 20) is worn or dam·
the engine oil filter (6) and di sca rd. aged, it must be dri ven or broken off the
flywhee I to be removed .
2. Remove t he oil pan bolts (1.3) and gasket
(14). Remove all the gasket material from 6. For dry clutch tractor flywh eel. Inse t A.
block a nd oi l p an. r emove oil seal (21), snap ring (2.3) and "0"
ring (22). Press bearing (24 ) out of flywh eel.
3. Remo \'e the dipstick (3). extension tube (2) .
"0" rin g and clamp (4) if equipped, and the 7. Remove the rear oil seal retainer (26) and
dipstick socket (5 ) if it need s replacing. gasket (27) . Press seal (28) from retainer
(26) .
4. Remove ada pter (8) and plug (7) if adapter
requires r epl acem enl. 8. Rem ove any cup plugs from block that need
replacing by drilling a hole i n them and
NOTE : On engines equipped with the pulling them oul.
timing marks on the flywh ee l it is advisable
to rotate the flywheel until the TD C mark i s 9. To remove the Diesel tac hometer drive
lined up with liming painter. Then seribe a (30). a puller can be made f rom an old
mark on the front crankshaft pulley and timing tachometer drive cab le. Cu t off the end
cover. that screws into the drive and weld a stud
to it. With this tool, pull tile tachometer
5. Remove the flywheel mounting bolls (15) or drive.
(18) and flywheel assembly (16 or 19) and

Inspection
Replace a ll damaged or worn part s, oi l seals, gaske ts. "0" rings and oil filt er.
 23-11

DRY CLU1'CH ONLY

13

STAMPED STEEL PAN

Figure 4
 FLYWHEEL, OILPAN, SEALRETAINER AND OILFILTER
(Refer to Figure 5)
Assembly
1. To inst all new cup plugS,. coa t th e bore 9. Install the flywheel 3ssembty (19 or 16 ) to
with Gusolia or equivale nt and install the the crankshaft with output hub (29 ) (Hyd ros -
cup plugs un til the oUiE'r edge is even with talic Tractor onl y ). IMPORTAJ"I T : Prior
thE' inner edge of th e' c ha mfe r in th e bore. to installing output hub ( :19). lubricate th e
Install the tac hom e ter driv<' 130) (Diesel spline hole and fa ce of hub libprall y w it h
onl:-,' ) into the block, engaging the gear on ;2 Mol y Di sulfid e Greas e . Torque the r e -
th e ca mshaft . taining bolts 6'; to 70 ft. lbs.

2. Press in new rear oil seal (lXt into the re- 0) into the block to
10. Ins tall di psti c k socket
tain er 1261 (st'<lI lip in tow ard block) flush the depth s hown in In set l".
with rea r of rc tain('r, In set A. A ssemble
gaske t (27 ) to retai ner and lay a bead of 11. Prpss the filler adapter ( H) into the block
Perma tex :\0. 2 on bot h sides at t he gasket. flan ge unt it seated. Press pl ug (7) in until
seat ed a gainst the adapte r. App ly a thill
3. C'sing a Ca se :\0. (;1;)028 Sleeve. [nset C, coat of new oil or grease to the ga s ket of
s lide the oil sea l (28) a nd re ta iner (26) onto new oil filt er (6) a nd insta ll turning clock-
the cra nk shaft. wise until gasket c ontact is made. Hand
tighten 112 of a turn and loose n fi lter. Re-
4. Remove th e 51",-'\'e and in s tall a Case :\0. tighten until gasket contact is m ade and
G1.3.')06 Aligning Tool. Inset D with the too l hand tighten 112 to 3/ 4 of a turn to obtain
pins in the aligning pin holes in the flange, the proper sC'a ling without da magi ng the
refer to InSPt G, below. T he tool must be filter.
installed over th(' fl ange on th e crankshaft.
12. Install a new oi l pan gaske t (H ) a nd oil
O. In stall !he t\\'O bo ttom and Ilw top bolts (25). pa n (13) to block with t he long bolts to the
T ig hten the bolt s s ligh tly the n remove the rear. Torqu e the bolts 24 to 28 ft. lbs. ior
aligning tool. cast iron pan, 10 to 12 ft. Ibs. for sta m ped
s teel oil pan. Torque the rear bolts 15 to
6. Insta U the remaining bolts and lockwa s hers 20 ft. Ibs.
(2.'> ). then torque 12 to 15 f1. Ill, .
13. Install the oil pan drain plug (9 ) with new
7. Preheut the npw flywheel ring gear (17 or ga sket (10). Torque 18 to 20 ft. Ibs . Refill
20) <100 to t50nF .. e it hpr in oil or a n oven. the C'ngin e crankcase wi th the prope r a-
Do not us€' a torch. In stall th e rin g gear mount of oil.
with the large ('J1amfcr toward the flywh eel,
Ins0 t E. INSET G

8.0 n dry clutch tractor fl ywheel ( 19), Inset B, G13506 ALIGNING TOOL
in s tall snap ring U.3 ) in groove of flywheel.
Pr" ,s bearing (2'J ) in until sea ted against
the snap rin g from the gear side of flywh eel.
Ins tall ncw oil seal (21) from r ea r side with
lip Inward unhl seate d agai nst the snap ring.
Ins ta ll new "0" ring (22 ). Lubricate the oil
seal a nd "0 " ring with dri vc·way oil.

REAR VIEW OF ENGINE BLOC K

 z:n:l

LIP

BLO C K .

LAR GE CHA M FER

DRY C LUTCH ON LY

CAST IRON PAN

STAMPED STEEL PAN

Figure 5
 DIESEL T I MING GEAR COVER , GEARSANDWATER PUMP

(Refer to Figure 6)

Disassembly
1. EC'm o\'(' tan bla de Ill. pu l ley ( 2 ), w dter (18) a nd fl exible coupler (i f equipped) . E e·
pum p I:n and g ask C't I~ ) . m ove p ulley r etainer nut (21l ), a nd pull the
crankshaft p ulley (21) w ith key (22) .
2. ~' C'm o \'(' thC'p um pdrivPco\'('l" (~I , g as kc'l (6).
plu nger ( 7) u nd spri ng (8). Remove nu t a nd 5. R emovc t he timing gear cover (23 ) and gas·
loc kw 3S hC'r ('II unci pump d r i \'e gC'ar (10 ). k et (24 ) a nd (30). Press the seal (2;)) from the
timi ng gea r cover.
3. Rem ove lock platc' poinl e'r ( 11 ), thru st
pla te (12), shim s ( 13 ), id ler gea r (14 ) a nd 6. Remo vethe nut (26) and loc kwdsher (27 ) . Pull
journal (1.1) . the ca msh att gear (28) w ith key (29).

• . Rem ove bolt a nd washer (16). 117 ) , bushing

Inspection
Clea n a ll parts thoroug hl y belore i nspect ing R ethread sli ghtly da m aged t hreads : iJu rrs a nd
nicks m ay be removed w ith a hone or c ro cus
Inspec t th e gears for ch ipped teet h, burrs. or clot h.
excessi ve wea r. Light burrs and ni cks ca n be
r emoved with a hone or "roc us clot h. Replace Inspect the oil passage in the (' ng ine hlock
if da rn aged or worn. which ma tes wi th pump dri ve i dl er gear .i our·
na l oil g ro ove . Th is passage m ust be free of
LTsing a n inside micrometer or a bo n? ga uge dirt or other fo rei gn pa rticl es.
and mi C' r omet er , check t he inside diame te r of
the pum p d r i ve idler geur hus hing. T he ma xi· Inspec t the th r ust spr ing f or t he follow ing
mum allowable in side d i am eter i s 1.378" . Re· specifications:
place the entire idler gear if the hush i ng ex·
ceeds this d i m en si on or is o therwi se da m aged. F ree l ength ..... ... .. .. .... .. .. ...... .... .. ... .... 1.22"
0.0 ... .... .. .. .. .. .. .... . ......... ..... .... ........ 255"
In spec t t he idle r gear i ourn al for a plugged T ota l coil s .. ....... .. .. .. .... ....... ...... ..... .... .... 15
oi l hol e. Blowou t w ith compres scd a ir. Wire d i am eter .. .... .. ...... .......... .. .. .0.18"
Compressed 10 .950" ... ..... ...... . 6 Ibs. 4 oz.
Check the end of the th r ust pl unger f or ex·
cess ive wea r. yIak(' S Ur(' the plu ngor is fre0 in Inspect the wa ter pump for leaks or worn
the bore of the inj ec tio n p um p dr i \'e shaft. Re· bea rings . If th ese condition s ex ist, r eplace the
place i f necessary . pum p assemhly.

Inspect th e i dle r gear j ourna l w ith a micro · Chec k the fa n p ullcy for woa r and the fan
meter . as show n in In se l A. The m ini mu m ou t· blad e fo r d amago. R epl ace them i f these can·
si de dim ension is 1..374". Rep la ce t he j ourna l diti ons exist.
i f this d im ension i s l ess.

Inspec t thf' pump dr ivE' shal t for strippeci or

dama ,ged threads , bur rs . ni cks or oth 0r da m age.
 ~,1 - 1:)

INSET A

Figure 6
:!3-1I;

DIESE L TIM ING G EAR COVER, G EARS AN D WATER PU MP

(Refer to Figure 7)
Assembly
1. Coa l Ihe oUl side dim e l"r 01 a new oil s('al I nsta ll lockwa s hpr a ncl nut (9 ) a nd to rque .15
(2~) wilil " Pe rrn<.lI ex" or eQui \-a l('nt , and to 40 ft. Ibs.
inSlali rhe seal inlO t h(' ti ming gear ('ov('r
12:)1 with thE' lip tu rnro tow ard~ th(' block to 8. Install key (22) a nd press on th cra nkshaft
a d ep lh oi _::;6" irom the o utc'r edge . In se l A. pulley (21). In s tall the ret ai ning nut (20) a nd
torque 12" (0 J:l5 It. Ibs. Ins all the fle xible
2. In s la ll kC'y (2~1J and pre'ss t he gear ( 28) 10 Ihe coupler (191, bushing (18) wa s her (1 71 and re-
cams ha lt. Insl all Ihe lockwash<;r 127 ) a nd nu t lain wit h bolts and IDckw a~her, torquf'd 54 to
126). :-':OTE: :VIaKe sure the gea r is in s la ll- 64ft. Ibs. , ( If equippe d) .
C'd Ivith th c' timing marks outward . Torq ue Ih C'
nut 80 to 90 ft. Ibs. 9. Check lor timing gea r tra in backl as h. Loca te
a e1ial indicator on the in jection pump d r ive
.J. Apply " PC'I-n1;;Iex" or equivJlcnt to both gear. Inset D_ Rotate the pu mp dr h 'e gear
s ides of th e timing gea r cover gaske t (24 ) and (10) to the right as fa r as possible witho u l
(l lii and in s tall with the cover 12.11 _ A specia l m oving the crankshaft gear. SC'l tt1 0 di a l in -
zinc -platC'd capscre\\' is used in th e water dicator to zero.
pump ca \·iI O' . Torque th e cover c apscrews 35
to 42 ft. Ibs. NC'xt, r otate the pump drive gear to the le ft
as fa r as possi ble witholl t moving t he crank-
4 Coa t the inside of the oi l sca l w ith ciC'3n oiL s ha ft gea r. The dial ind icator will Indica te
CAUTIO]\; : Do no t a llow gas kC't se<1 l('r to the a m ou nt of bac klas h in the gear tra in .
plug oil hole in pipe plug in oil g a llN:\'. T ht' bac klash mus t not excee d .006" for
cam s haf t gear to crankshaft gea r , .006" fo r
:J. Insta ll the p llm p dril'e idle r gear journal ( 1'; ) cam s /la fl gear to idler gear a nd _007" lor
in th0 lim ing g0ar ('OVPf. Align The oil groove idl e r gear to pump dri ve gea r.
as s hown in lnsC' t O.
If th e backlash is greater than as specified.
".InSla ll tile iel ler gear ~ !4 ! with ir s large hub r epl ace the timing gea rs r equi r ed . Exces-
s iele toward the ('ng ine block. In s tall the s iv e backlas h will cause e rratic pu mp act ion.
icll c'r gear s him s (13 1, thr us t pl at i' (12) anel
lock pl ate with t im in g point er to the idl e r Excess iv e bac klash be twee n Lhe gears can
gear jou rn a l (I ;' ). Wh en instal ling tile thru s t a lso be ca used by worn camshaft bushings.
plat e the rE' must b e .003" c lea r anc e between
the face 01 the gear and Ih thrust plate , Inset 10. Insta ll thC' t hrust spring (8) and thrust
C. Adcl or clelete the shi m s until the pr oper plunge r (17) into t he drive sh alt. Install th e
clearancC' is obtained . T be pointers should drive gear covC'r (5) a nd g asket ( 6 ) . Torque
poin t tOwa rd the cen ters of the cam s haft <lnd the bolts and nut s ;15 to 42 It. Ibs .
in jection pump drive gea r. Torque the cap·
seres 35 to i2 It. Ibs. Bend Ihe e a rs 01 the 11. Apply "Permatex " or equival en t to t he
loe k pl ate over 10 prevent t he capscrews fro m wa te r pump g asket ( 4 ) and inst all the water
loosening. pump (3). Torque the bolts 35 to 42 ft Ibs.

7. }{otate the camsilaf t ge a r ( 281 unli 115 single 12. In s ta ll the Ia n pulley (2 ) a nd fa n (1 1 to the
ti mi ng mark is aligne d with Ihe poi nter. In · water pump and torque ttle bolts :35 to 42
stall the pump drive gea r (10 1 so that its ft. Ibs.
timing mark is a ligne d lVil h thE' pOint0r (11).
 INSET 0

OIAl IIliD ICATDR

INSET A

.560 "

FA N .

Figure 7
23-18

SPARK IGN ITION TIM I N G GEAR COVER, GEAR AN 0 WATER PU MP

(Refer to Figure 8)
Disassembly
1. Remove the fan (1) and fan pulley (2) . Re- 5. Punch out the roll pin (12) from the govE-r-
move the wat er pump assembly (3 ) with nor le ver, Inset A. Rem ove thrus t spacer
gasket (4). (16), governor leve r (13) , fe lt was her (l4J
and thrus t ball (19). Using a s ui ta ble puller,
2. Remove washer (5) and cou pling assembly remove needle bearings (15) and OS).
(7) with bushings (6) (if eq ui pped) .
6. Rem ove the gove rn or shaft (20) from cam-
3. Remove nut (8) and pull the crankshaft s haft gear. Remove nut (21 ), lip washer (22)
pulley (9) a nd remove key (2'». and pull the camshaft gea r (23) from the
camshaft with key (24 ).
4. Remove the timing cover ( !O) with gasket
(11). Remove pipe plug (27). Pre'ss out oil
seal (26).

Inspection
l. Thoroughly clean a ll parts beton' inspec- 5.lnspect the needle bearings fo r pi ts , wear
tion. Re place a ll worn or damaged parts, or other damage .
ga skets and oil seals.
6. Check (he lever and s haft a ssembly for
2. Check the governor s haft assembly for damage or wear. Check the leve r for a p it-
run-out, Inset B. A[so , be su re the assem- ted rna ting surface with (he governor shaft
bly opera tes smooth ly in the c 'lms ha ft bore. assembly.

,3. Inspect the go vernor weights on the cam- 7. Check the water pump for lea ks or worn
shaft gear. The weights mus t swing freely bearings. Replace lhe pump if these ca n·
on the hinge pi ns. The pin s houlder must be d itions e xist.
tight against the gear. A[so , ch eck the
weights for excessive wear in the grooves 8. Ch eck tbe belt pulley and fa n for wear or
where they m a te with the go,'ernor shaft damage. Replace them if these condit ions
assembly. exist.

4. Inspec t the thrust ball for excessive wear.

 23-19

INSET A

'\
I
I
I
J
I
I
I
I

INSET B

-RUN-OUT NOT
TO EXCEED .010 "

FACE MUST
....---BE SMOOTH

7
Figure 8
23-20

SPARK IGNITION TIMING GEAR COVER, GEAR AND WATER PUMP

(Refer to Figure 9)
Assembly
l. Install key (24) to camshaft and press on (27). Lubricate the LD. of oil seal (26)with
camshaft gear (23). Install the lip washer Lubriplate or equivalent.
(22) and nut (21). Torque the nut 80 to 90
ft. Ibs. Using a dial indicator, check the 6. Apply Permatex or equiva len t to b ot h s ide s
backlash between the camsh a ft gear a nd of g aske t (11). Install the a ssemb led timing
crankshaft gear. If the backlash is more gear cover (10) with new ga s ket (11 ) to en gin e
than .006", the gear may have to be re- blockwlthlocatingringdowels (28) and bolts.
placed. Excessive backlash betwee n gears Torque the retaining bolts 35 to 42 ft. Ibs.
can also be caused by worn c a m s ha ft bush-
ings. 7. Install key (25) to the cran ks ha ft and pres s
on crankshaft pulley (9). Ins tall nut (8) a nd
2. Install the governor shaft (20) to the gover- torque 125 to 135 ft. lbs.
nor weights on the camshaft gear (23).
8. Install flexible coupling (7) with bushings (6)
3. Press a new oil seal (26) into the timing and hea\'ywasher (5) (if equipped) and torque
gear cover to the depth s'LMn in, Inset A. bolts 54 to 64 ft. lbs.

4. Press needle bearings (18) and (15) into the 9. Apply Permatex or equivalent to both sides
timing gear cover (P r essing on numbered of gasket (4). Install water pump (3) with
side of bearing only) as shown in, Inset B. gasket (4) and torque retainlng bolts and
nuts 35 to 42 ft. lbs.
5. Install the dust seal (14). Coat the LD. of
the seal with Lubriplate or equivalent. In- 10. Install fan pulley (2) and fan (1) to water
stall the thrust ball (19), governor lever pump and torque retaining bolts 35 to 42
(17), thrust spacer (16) governor lever (13). ft. lbs.
Align the holes in the levers (17) and (13)
and insta ll pin (12). Install the pipe plug
 23-21

INSET B

INSET A

.560"

®-:PZZZl
FAN .
Figure 9
23·22

CAMSHAFT, BUSHING S AND LIFTERS

(Refer to Figure 1 0 )
D isassembly
1. Remove the camsh a ft thrust pla te (3). e rcise care when rem oving the camsha ft
so as not to damage the bus hings .
NOTE : The pu sh rod lifte rs (.1 ) will have
to be held in a rais ed p ositi on [or r emoval 4.Remove the valve lifte rs (5 ) one at a tlmc
of the c amsha ft. and mark them so they can be insta lled in
their original locations.
2. Raise the push rod lifters (5) using eight
long, round stick s slightly large r in dia· 5. Check the camshaft bus hIngs (6,7, and 8)
meter tha n the push rods. Taper the end for wea r . If the c leara nce Is .005" or
of each stick a nd force the ta pered end more between the O.D. of the ca m s ha ft
into th e inne r bore of each pus h r od lifte r. bearing surfaces and the I. D. of the bush ·
Lift up th e lifte r s as fa r a s possible with ings, th e bushings must be r eplaced. Cse
the s ticks ; lock the sticks in place with an a rbor puller similar to that shown in
c loths pins or other suita ble de vices . Inset A, Case P a rt ;:-;0. A41103. T his puller
should be used to preven t damage to the
3. Remove the camshaft (4 ). CAUTION : Ex· engine block.

Inspection
Clean the c a msha ft thoroughly a nd blowout Clean the Jifters a nd c heck the body outside
the oil hol es with compr ess ed air. Check the diameter for exce ssive wea r which should not
camshaft for r oughne ss, scoring, scratches, be less tha n .5600".
grooves or wea r. If any of the se conditions
e xist , the camshaft shou ld be r e pla ced , Check Check the lifte r bore in the bloc k for ex·
the bea ring surfa ces of the cams ha ft with a cessive wear or ou t o f round ness wh ich s ho uld
micromete r. If any diam e te r is le ss than not exceed .5650" diam e ter at a ny paint.
2.242" , replace the c a msh aft. Check the Check the lifter bore in tht' block for scoring
thic,kness of the tHrust pl a te. If exce ss ive or g rooves.
wea r is seen, It sholltcl be repla ced .
 23-23

Jl"cD 1 88
DIESEL ENG INE

REAR
BUSHING

~@
1-7/ 32"

INTERMED IAT E
B USHINGS
~'@ @
'" 6
1/ 2"

(fil~
( ~~~

'0G@@
CASE PART NO . A41 103

REAR
BUSH ING
1 · 3 / 16 "

INTER MED IATE

BUSHING
23 1 32"

0,' ~ 188 S PA R K IGNITION

EN GINE
FRO NT BUS>iING
1 · 5 / 1S "

~0 ~? ~~~
::::,~, ~ -0
' ·7 / 32 ~ ~
@"..
INTERMEDIATE V~
B US HINGS "-V
1 / 2" FRONT BUSHING
' ·7 / 3 2 "

Figure 10
23-24

CAMSHAFT, BUSHINGS AND LIFTERS

(Refer to Figura 11)
Assembly
1. The camshaft bushing kits inc lude a 1-7 / 32" Ignition Engines the intermediates and
inch wide rear camshaft bushi ng . The holes center bushing oil holes m ust line up with
in the 1-7/32 inch wide rea r bushing are the oil holes in the block when ins ta lled,
offset toward the chamfe red edge of the Inset D.
bushing.
7. On the 188 Diesel, 188, 159 and 148 Spa rk
2. The 1-7/32 inch wide r ea l' bushing is used Ignition engines the front bu shin gs a.re
in the 188 Diesel Engines and also in the pressed 1/ 32 inch below the front face of
188 Spark Ignition Engines. The 1-7/ 32 block, Inse t E.
inch wide rear bushing must be ins talled
with the chamfered edge in to the block to a 8. Press new c amshaft bushing s into the cam-
specified dep th . shaft bore with a press ing tool similar to
that shown in Inset F .
3. On 188 Diesel Engines, the two oil holes
in the rear bushing must line up with the 9. Line ream the bushings 1.752 to 1. 75.3 inches
two oil holes in the block when the bushing diameter.
is installed to a depth of 5116 inch, Inset A.
10. Install the push rod lifters in their origi na l
4. On the 188 Spark Ignition Engine, only one location using the eight long, round sticks
of the rear bushing oil holes must line up slightly la rge r in dia meter than the push
with the oil hole in the block when the bush- rods used in removal. Force the tapered
ing is ins talled to a depth of 191:J2 inches, end into the inner bore of eac h push rod
Inset B. The other rear bushing oil hole lifter. Lift up the lifters a s fa r as possible
will not line up as it is not required for with the sticks; lock the sticks in place
engine lubrication. with cloths pins or other sui ta ble devices.

NOTE: On the Spark Ignition Engin es, 11. Lubricate the bushings and camshaft with
the 1-7/32 inch wide rear bushing will new engine oil a nd carefully install the cam-
protrude inside the block approximately shaft (4) into place being careful as not to
1 / 4 inch when installed. THIS I S NORMAL. damage the bushings.

5. On the 148 and 159 Spark Igni[ion e ngines 12. Install the thrust plate 0 ). Rota te the ca m-
it is only required to line up the all holes shaft to insure that it does not b ind On the
in rear bushing, with the oil holes in the thrust plate. If it does, loosen the thrust
block when the bushings are installed, plate bolts and l'e·center the pla te. Tor-
Inset C. que the bolts 17 to 20 ft. lbs .

6. On th e 188 Diesel, 188, 159 and 148 Spark

 23-2.';

DIESEL ENGINE
J!'\D '48 AND 159 SPARK
IGNITION ENG INE

~
0
? Cf, :~~~~~' ~ REAR cP T
/':\0
@fJ ~?~~~m'"
REAR •
i

0. t! JJ!
BUSHING

~@
1-7 / 32"

l
~ O~ SUR ~FA:-:C:::E:---::IN"'S::-:E::T=-=C-' '@
REAR SURFACE
OF BLOC K
INTE RMEDI A TE
BUSHI NG S
1 /2 "

I NSET A
~
~6
\.V
REAR
OF BLOCK'~~~~q~
'
~
I FRON T BUSHING
1 -5 / 16 "

'///7 :>I FRONT BUSHING

\ J:~~L HOLES
1-7/ 32 "
ALIGN OIL HOLE

WILL LI NE UP
g
I
(~j PRE SS flUSH WITH BLOCK
5 / 16" -
- -
INSET E
188D,188G,159G
INSET 0
188 D,188G _159G
AND 148G ENGINES AND 148G ENGINES
CD\--- ' 88 SPARK IGNITION ~ l ".
ENG INE I ALIGN

~ / I ALIGN
OIL HOLE
OIL HOLE

,
0 0 , ~~CD~,
- ---- -
1 / 32"~

REAR
&-0
B1U_'7S/ H312N"G @o olpRESS INTERMEDIATE
-v PRESS FRONT BUSHING
WITHIN 1/32" OF FRO NT
BU SH iNGS flUSH WITH
FORWA RD FACE OF
FACE OF BLOCK BLO CK
INTERMEDIATE ' ,~~~~~~~~~~~~~~~~~~~~~
BUSHINGS ~ INSET F
1 / 2" ~
INSET B FRONT BUSHING
REA R SUR FA CE " 1 -7 /3 2"
OF BLOC K
\
\ ONLY ONE Oil
HOLE WILL
-

LINE UP

19 / 32 "

THIS D IMEN SI O N - i
WILL VARY r-
I

Figure 11
23-26

PISTONS, RINGS, SLEEVES AND CONNECTING RODS

(Refer to Figure 12)

Disassembly
:'I;OTE: When the pistons and rods are to piston rings (1), with a ring expand er,
be removed. check for a rid ge formed in Inse t C.
the piston s leeve a t the lop of the rin g
travel, Inse t .-\. If a ridge is present, use 6. Remove the roc! cap (6 ) an d bearing linprs
a ridge reamer to remo vE' the ridge or (12) from th e connec ting rod 15) .
dam a ge to the piston rings anc! la nds will
resuit. 7. The pis lon pin bushing (9) m ust be replaced
when th e inside c!ia mete r exce ed s Ihe maxi ·
l. Check to be sure that the roc! s and ca ps mum wear limit , refer to inspectio n below,
are numbered as to their location in th e when checked at a numbe r of poi nts. Press
block. If not , they mus t be num bered for the piston pin bushing (9 ) from the rods (5)
r e installation in their sanw location. us ing the proper size a rbor, Inset O.

2. Using a feele r ga uge, check each connect- 8.11' the cylinder sleE'ves (10) are to be re-
ing rod for excess ive s ide c leara nce. In se t m oved, mark th em with pai nt in r elation
D, Page 34. If it exceed s .oJ 1", the rods to Ihe block. (;se a s leeve pull er and a-
must be repla ced. dapter as illustrated in In set B. to r emove
sleeves .
3. Remove the c onnec ti ng rod bea ring cap (6)
and push the connecting roc! and pi ston a - CAUTION : To prevent sedimen t from the
ssem bly up and out through the top of the block from damag ing Ihe cra.nkshaft and
bl ock. Reinst a ll rod c ap (6) to a void mixing main bearings, cover them with cl ~a n clo th s
of the caps. befo rp the sleeves are removed.

4. Remove Ihe two pis ton pin r eta iner rings 9_ Re m ove and c!isca rd the slc'eve "0" rings
(.'l i from each pi s ton (2 ) and r emove the pin (11). NOTE : ','e ver a ttempt to re-use
(4) from the rod 15) a nd piston (2) . them .

.'i. To avoic! damagE' 10 th e pbtons. re mow the

Inspection
Thoroughly clean and ins pect a ll parts for the polished surfaces are d ull , r oug h or
nicks, burrs, sera tches, gTOOVC'S and exces- c heck0d by acid corrosion. If thE' pin bore
sive wear. All paris that arc worn or dam- in th e pis tons e"ceeds 1.25013" (l 88D j, 1.0004"
a ged must be replacec!. (I8SG, 159G) •. 8604" (14RG) , re place pIs to ns.
If the Il llshing in Ihe rod e xceed s 1.25 l~" (1880),
Check the connecting rods and cal's for or l.0007 " (I8SG, 159G) replace> the bushings.
crac ks and cWY noticea ble twi st , bOI,\'ed or
bent condition. Re placE' if anyone or more Cle an the oil holes in the cran kshaft and
of these cond it ions e xist. block. Pipe plugs at the en d of each oil g al-
lery in the bl ock will have to be r emoved .
Remove all c arbon d e pos its fr om the Coat the threa ds of the pipe plugs with Per-
piston . Be care full not 10 sc ratch the piston mat ex ~2 before ins ta llat ion.
s ki r t. Remove all the Carbon fr om the ring
grooves \\,.Iith a ring groove cleaning tool.

Inspect Ihe piston pins for cracks, score

marks or pitting . Discard the pi s ton pins if
 23-27

SPAR K IGNITION r'N~S~ET~A~--------

DIESEL

INS ET C

~ ~;f
RING EXPANDER

INSET B IN SET D

®-{S SLEEVE PULLER

Figure 12
2.3-28

CYLINDER SLEEVES
Inspection
NORMAL WEAR

Fig ure 13, illu s tra tes normal wear of the inder sleeve, Figure 13 indicates satisfactory
cylind('r slcevE' identified by a smooth s hiny sleeve condition s and the s leeve need not be
surfac(' be tween the upper and lower limits repla ced ,
of the ring tra vel. There is a lways a sligh t Figure 14, illustra tes a worn out cylinder
wear presC'nt due to combustion pressures sleeve due to normal wea r and should be re-
forcing the top ring outward agaillst th e cyl- placed.

Figure 13 Figure 14
SCUFFED CYLINDER WALLS
A scuffed cylinder wall, FigurC' 15, call be Figure 16, illustrates complete s coring
iden tified by heavy vertical linE'S f r inged by a failure with its hea t discoloration and m etal
discolored band caused by m etal transferring transfer. If you have cyli nder sleeves tha t
from one spot to another, The ver tical scuff compare with either' Figures 15 or 16, the
marks arc ca used by the m etal coming in sleeves must be replaced.
contact with the pis ton_ The scuffing may be NOTE: It is not necessary to r eplace all
In one particular a rea or it may occur the the sleeves in an e ngine. Replace only those
e ntire length of the piston tra vel. sleeves that have been damaged as descri bed
above.

Figure 15 Figure 16
 23-29

CYLINDER SLEEVES (Cont'd)

Deglazing
Figure 17 illus trates a se U-ce ntering pow - Power t he brush with a 31 " or 112" drill
e r brush deglazer that can be used to r E'move with a 300 to :350 RPM s pee and uS ing a good
thC' g laze form('d on th e Inner surface of the gradC' of oil as a lubr icant. The heav ier the
cyllndl'r slervC's. lubrican t, the fin er the finish.

T hl:! g laze must be rCll10vcd so thaI the The brush must be rotating b fOto entcr-
piston rings ca n properly sea t themselves ing the cyl inder sl0eve rod ,,'hen re moved to
within a reasonable period o f run-in-time. prevent scratches and to insure an even
finish. This will also brin the cross hatel,-
The necessary degl azi ng can be done by Ing up and au t On r e moval.
usIng 180 grit silicone carbide double spiral
brush. 'l'he necessary size brush can be pur- Actuating the brush up and down at a r a te
cha d from the J r Ca e Co. Service Pans of 30 to 40 times per minut , a fast (>ven and
Suppl y , Racine ,Wise , perfect cross hatch finish Is obta ined in 20 to
30 second s , Figure 17 .
Part :\0. Bore Range
A-12451 3.00" thru 3..50" IMPORTANT : Use the following proced-
.0.42452 :3_50" thru ·1.00" ure to protect the engine [ rom abrasives .

1. BEFORE BRUsli DEGL Zll'-:G:

Cover th e c rankshaft journa ls with c lea n
rags to prevent abrasives and dirt, reSUlt-
ing from the brUS hi ng opera tion , from
dropping onto the c ra nksha. ft.

2. AFTER SRUSH DE GLAZlt-\G:

Wipe as muc h Of the abra lI'es from the
cylinder s leeves as pOSSible, the n s wab
each sleE've wi th a clean cloth dampened
in warm watE'r and a mild detergent soa p.
AftE'!' swabbing the sleev es with the da mp
cloth, wipe t he ro out with SAE lOW e ngine
oil.
IMPORTANT: SWAB AND WIPE OUT T HE
CYLINDE R SLEEVE S UNTIL A, CLEA N
WHITE CLOTH WILL REMA n, AS OLUTF.·
LY CLEAN WHEN IT IS RUBBE D 0:\ THE
SLEEVE. ONE SWABBING· WIPING OpER·
ATIO . IS NOt Ei\OUGH !

CAUTION : DO j\;OT USF. GASOLI LIE,

DIESEL FUEL on KEROSENE TO (LEAL
THE SLEEVES _ THIS WILL ;--:01' RE -
POWER BRUSH
MOVE THE AB RAS rV}:;S FRO:V! THE SUR-
FA CE OF TH}': SLEEVES.
CROSS HATCHED SLEEVE

Figure 17
23-30

CYLINDER SLEEVES (Cont'd)

Honing
Excessive glaze (sm oo th shiny surface) for· is perf aiming hitch and drawbar work ,
med on cylinder sleeve walls 01 a new or shift to a lower ge ar to prevent lugging ,
overhauled engine is due to imprope r Run·ln·
Procedure. Excessive oil con Sllm ption results These two factors will permit the slig ht wear
from the glaze build up not allow ing the rings necessary for seating of rings to the cylinder
to seat properly in the cylinder sleeves. Ex· sleeves ,
cessively glazed cylinder sleeves Can be a·
voided by properly in structing your customer Use a power hone as illu strated in FIgure 18,
in the correct Run·ln·Procedure in the Op· to r emove the glaze formed on the Inner sur·
erator's Instruction Manual. The two mos t face of cylinder sleeves.
important lac tors are:
The necessary deglazing can be done by
L Maintain the correct Operating Temperature. using 180 . 220 grit honing stones and honing
oil.
2, Maintain a "'ormal Load on The Engine for
the firs t 8 hours. Do not " baby" the engine, The glaze must be removed so that the piston
but do not "lug" it. Engine must not be rings can properly seat themselves withIn a
"lu gged" down below its Itated Engine reasonable period of run·in time ,
RPiVI, to avoid prolonged hydraulic stall.
(Do not exceed 10 seconds of stall). If the r~IPORTANT: Use the following procedu1'(';
tractor has a mechanic al transmission and to protect the e ngine from a brasives.

1. BEFORE HONING :
1 ' 7 INCH Cover the crankshaft journa ls with clean rags
DRill to preve nt abrasives and dI rt , r es ultin g from
the honing operation, from elr'opping onto the
crankshaft,

2,AFTER HONING:
Wipe as much of the abrasives from the cy l·
inder sleeves as possible, then swab each
180-220 GRIT STONE POWER CYLINDER HONE
slee ve with a clean cloth dampened In warm
water and a mild deterge nt soap , Afte r swab·
bing the sleeves with the da m p cloth, wipe
them out with SAE lOW engine oi l.

IMPORTANT: SWAB A1'10 WIPE OUT THE

CYLINDER SLEEVES UNTIL A CLEAN
WHITE CLOTH WILL RE MA IN ABSO LUTE ·
L Y CLEAN WHEN IT IS R UBBE D ON THE
SLEEVE. ONE SWABBI , G· WIPI NG OPER·
ATION IS NOT ENOUGH!

CAUTION : DO NOT USE GASOLINE,

DIESEL FUEL OR KERO SENE TO CLEAN
THE SLEEVES AS THIS WlLL lOT RE·
Figure 1 8 MOVE THE ABRASIVES FRO M THE SUR-
FACE OF THE SLEEVES.
 23-31

PISTONS AND CYLINDER SLEEVES

Inspection
1. Csing a micrometer, measure the diame te r
at the pist on across the thrus t faces a t the
bottom of the pistons, perpe ndic ular to the
pi ston pin hole, Figure 19. If this m ea sure -
me nt is less than 3.8090" (18SG) . 3.8070"
(1880). :l.4983" (lo9G ) or 3.3735" ( H 8G),
re place the pistons_

Figure 21

Check the cylind er sleeves for wea r. It the

sleeve 1.0. Is greater then 3. 5078" {159G),
3.8175" (188D), 3.8195" (l 8SG)' or .3 .3815"
(B8G), when c hecked a t any point in the sleeve,
it must be r eplaced.

Figure 19 3. Using an ins ide m icrometer , cy li nder bore

gauge or a taper ga uge, Figure 22, check the
IMPOR'fANT: When c hecking the m ea sure- sleeve dia m e ter just below the top ring lo-
ments of the pistons a nd sleeves, the parts cation at its upper most travel a nd a t sev-
s hould be at or close to 70" Fahre nheit. eral poin ts down the length of the sleeve.

Figure 2 0 c
2. Using an inside mic ro m e te r or a cylinder
bore gauge Figure 20. c heck the sleeve bore
for out of r oundness. Chec k crosswise and Figure 22
le ngthwise to the engine block jus t be low the
top r ing loca tion a t its uppe r m ost trave l. Subtracting the smalies t reading from th e
If th e out of roundnes e xceeds .005", the largest r eading wili g ive the a mount of taper.
s lee ves should be r<:'placed. If the tape r is more than _001", replace s leeve.
 23· 32

PISTONS, RINGS, SLEEVE S AND CONNECTING RODS

(Refer to Figure 23)
Ass embly
1. Cl~an the ins ide surface of the pis ton pin of the cylinde r bloc k and t he "0" ri ngs with
bus hi ng hole in th e conne cting rod before c lean drive -away oil.
ins ta lling new bushi ng.
10. Carefu lly install t he sleeves ( 10 ) into block
2. In s ta ll the new bushing (9 ) into the r od (8) and pre ss into p lace by hand. Do no r ro ta te
while aligning t he oil holes in t he bus hing s leeves wh ile they are be ing in stalle d , they
a nd rod, In set A. Press in the bus hing using mu s t be ins ta lled in the same position and
the n rbor used tor removal, In set H. location they WE're in before r e mova l.

;1, Carefu lly ream the bushing 1. 2502" to 1.2504" NOTE : Prim' to in stalli ng the pis ton c om-
for the ( ] 880 ), .9995" to .9997" fo r the (I 88G pression top ring (1 ) , s!?concl c om press Ion
and 159G) and .8596" to _8598" the (148G) if rin g (2) and t hir d compre ss ion r ing (3) I Sp a r k
new pis ton pins are to be inswlled . If piston Ignition) and oil ri ngs 141 to pis ton (5) , th e
pins (6) are to be reused, re am t he bus hi ngs r ing e nd gap must b ch(>c ked I ns ta ll each
for th e (1880 ) .0004" to .0007", (I83G , 159G, ring i nto the cyli nde r slee ve a pprox ima tely
148G) ,0003" to .0006" la rger tha n pis ton I " from the bo ttom of t he sle ev€ a nd c heck
pin diame te r. Chec k the bus hin g (9) a fter end g a p with a f!?e le r gauge . The pnd g a ps
r eaming for a cle a n s m ooth surfa ce. NOTE : must mect spec ifica tion s as listed on P a ge 3.
This is a full floati ng type pis ton pin a nd a 11. Each r ing e xcept the (1880 ) top r ing must be
press fit mus t not be used. checked for s ide c lea rance , Ins",t B , befor e
ins tallation. Wh en the sic!e cleara nce e ,'(ceed s
4. Che ck the pis ton pin bore in the p iston ( 5). the m axi mum s pecifi ed c lea ra nce, lis ted on
It shou ld not e xceed .0002" to .0006 " for the Page 3, of any one rin g , t e p iston mus t be
(1 88 D) .0000" to .OOOJ" for the (l88G and replaced.
l 59G) and .000 1" to .0002 " fo r the (148G )
la rger than the pi ston pin dia m eter . 12. There are two types of oil r in gs use d. Inset
G m us t have the e xpander In s ta ll ed in the
.J. Insta ll one pi ston pin r(' ta in e r r ing (7) and grooves firs!.. Do not o,-e rl a p, h um p or cut
warm the pisto ns to 50"F . wa rm e r than t he of[ t he e nd o f e xpa nd e r. Install t he upper a nd
pis ton pin te mperature. lower stee l rails with e nd ga ps sta gge red
120".
ti. Lub rica te the piston pin (6) a nel bus hing (9) ,
with clea n a nti-scuff lub rican t. Assemble 13. The second type of oil r ing Inset Y , insta ll
the piston (5) to th(' rod wit h the a rrow in the the oil ri ng int o the bottom groove of thi"
pi ston top (Oi e s!?l ) toward s tam ped numbered piston. The oil ring can be insta ll ed wi th
side of the r od . Use ha nd pr ess ure only to th e s pring e ither up Or down .
ins ta ll the pis ton pin a nd r e ta in in plac(' with
reta ine!" ri ng (7). 14. There a re two ty pes of 2nd and 3rd com -
preSSion rin.gs used, In set C and inset S .
I. Th oroughly clean the inn!"r su rfa ces of the Install the rings with the "1' '' or " TOP"
cy lind ~ r bloc k t ha t contacts t he s leeves anel mark towa rd the top of the pi s ton. The ta per
the ou te r s ur fa ce s of the cyli nder sle" ves Inse t E or t he groove Inset C m u ~t. a Iso be
(10), including the "0" ring grooves . toward t he lop of the piston.

R. In s ta l! ea ch s)('eV(: into t he block without 15. The re a re two types of top com pre ssion
"0" rings to ch('c k for the free m oveme nt. rings used. Ins tall t. he firs t type of top com -
pression ri ng , Inset 0 with th e groove side
9. Remove the sle rv('s fr om the bloc k a nd care- up. Insta ll the sec ond type of top c om pression
ful ly install new "0" r ing s (11) int o the groove ri ng , Inset E, wi th the "1''' or " TOP " and
On ('a eh sleeve. Lubricate the Inside s ur fa ces taper towa rd top of pis ton.
 23-33

INSET A INSET B
DIESEL SPAR K IGNITION
OI L HOLE MUST BE
ALIGNED IN ROD

O -w-o AND BUSHING

0 --0--,.0
o 0---.--..0
0 4 .
INSET 0 KEYSTONE
TYP E

~~---0
,""WJ~~ . 'r~
J'C ft~ ~~ ,0 cb 6

~ --@~101~N-SE=T-:-H;-----:~-:--. 1
INSET E

Q)
STAMP ED
Ii (]) (j) ._ _ TAPER
FAce
NU MBER

ARBOR

INSET C

INSET G

F igure 23
 PISTONS, RINGS, SLEEVES AND CONNECTING RODS (Cont'd)
(Refer to Figure 24)
Assembly
16. Lubricate the cylinder sl eevi's and the 21. Ins tall the rod w/ liner. keeping the same
piston asse mblies with new engine oil. numbered cap with the same num bered rod.
IMPORTANT: Hotate the piston rings Install the re taining bolts (4) and nuts (5) and
so tha t the ring end gaps are staggered torque 45 to 55 ft. Ibs .
as illustrated in Inse t A. NOTE : If three
piece oil ring is used. place t he expander Check the connecting rod side clearance
in the oil ring groov e . Install one rail 90 0 which must be within .005" to .011". Inse t D.
to the le ft of the expander ga p and the other If the side clearance exceeds .011" t he rod
rail 9()1l to th e righ t of th e expa nder gap. ma y have to be rep lace d.
CAUTION : Check to assure that the ex-
pander ends are not overlapped. CHECKI 0iG BEAHI0iG CLCAHA:\CE:

17. P lace a ring compressor over the piston. A plasti gauge materia l manufactured ('am -
[nset B. :VI:lke sure the piston r ings are ful- mercially ca n b e used for c hecking connecting
ly in the groov<'s before tigh t... ning the ring rod clearance.
compres sor. Tighten the ring compresso r a
little at a tim .... making sure the r ings ar... 1. Remove the connecting rod cap a nd wipe the
free to compress. oil from the bearing s hell a nd cra nkshaft
journa l.
18. :Vlake s ure the cra nks haft rod journals are
c lean . Install the bearing lin ers (.3) into the 2. Place a piece of plasti ga uge full width on
connecting rod :l nd cap (2). Inset C. making the bearing liner. Inse t E.
sure that the bearing liner lock lines up with
the groove in the rod and cap. l:se a sliding 3. Torque the connecting rod cap baits and nu ts
moveme nt when installing the bearing liners. 45 to 55 ft. Ibs.
NOTE : Never press on the center of the
liner when installing. 4. Re move the rod cap. Th(' fl attened p lasti
gauge will be found eithe r on the rod cap or
19. The connecting rods and caps are s tamped crankshaft .
consecutively 1 th r u 4 on the bea ri ng end of
the rods and caps. ""umber 1 connecting rod 5. Compare the flatte ned ga uge m ateria l at its
and cap must go in I\umber 1 cyl inder (front). widest point with the sca le that is furniShed,
The number must bedown and tow a rd the cam- Inset F.
sha ft side of the e ngine. The arrow stamped
on top of the diesel e ngine piston must point 6. The number within th e g raduation indicate s
toward the fan. the c learance in thousand ths of an inch. The
r od bearings clearance should be .0010" to
20. Ins tall the piston rod assembly into its .0035".
righ t location and posilion in the block. With
a bloc k of wood and hammer. ge ntly tap the
pisto n down into the sleeve. Ma ke sure the
connecting rod lines up with the cr3nkshaft
.jour nal.
 23-35

INSET B

PISTO N

2ND
COMP
OIL RING +-+--of H-+R ING

OIL RING

, 2 0"~-I-__
90· RING COMPRES S ~~
•
3RD CO M PR ESSI ON RING

DIESEL SPARK IGNITION

STAMPED ~ INS H F
NUMBER ~

\S~
"--cD

INSET D PLASTI G AU GE

INSET C

Figure 24
2.3·36

CRANKSHAFT, BEARINGS, LINERS AND OIL PUMP

(Refer to Figure 25)

Disassembly
1. Wi t h the oil s linger (1) removed, use a 3, Rem ove the cap bolt s ( 11 ), oil p ump as sem·
gear type pulle r and remo ve the crank · bly (12 ) , sh im (13), ca ps (14 ) a nd lower
s haft gear (2) . Remove the th l' ust spa cer bearing lines (16 ), Refer to Page 40 for
( 3), thrust shirn ( .J ) (S park igniti on e ngines ) servi cing of the oil pump ,
and k ey (5) ,
4, Re move t he c rank sh aft (lil with the upper
2, Remove cotler pin (7) and oil screen (81, liners (17),
Loosen lock nu t (10) and remove with oi l
pipe ( 9) fro m pump,

I nspection
Clean the cran ks haft thoroughly in c lea n The crankshaft j ournal s mus t be g round with
diesel fuel and blowout all oi l holes with preciSion equ ipmen t a nd checked w ith a mic-
com pressed a iI', rometer frequently during the g rind ing opera ·
tion.
Check each main bearing journa l with a
microm e te r for out of rou ndness Or ex· The c ra nksha ft must be Clea ned tho rough ly
cessive wear. If t he out of round ness e x · after g rinding and chec ke d for runou! with
ceeds ,00l" or the main journal diamete rs a dial indicator. If the crankshaft r unout is
are s ma ller tha n 2,8725" (1880, 188G) more than ,002", th'" cra nk s haft must be
2, ii225" 1l59G , 148G)' it is possible the re placed,
cra nksh aft is worn only ,002", The ,002"
underSize bearing liners can be installed Check the crankshaft g ear for worn teeth
providing t he oil clearance is m ainta ined a nd r eplace if nec e'3sary,
at ,0012" to ,0012 ",
Clean the oil flo a t screen in clean diese l
When the c r anks haft journals are worn fuel and blowou t with com pressed air. Re·
more than ,002", the cra nksha ft wi ll ha ve to place if th'" scree n is d am aged,
be g rou nd undersize ,010", .020" or .030".
figure 25
23 -38

CRANKSHAFT, BEARINGS, LINERS AND OIL PUMP

(Refer to Figure 26)
Assembly
CAUTION: TH E BORE IN THE BLOCK bea ring (15) a nd c ran kshaft fl3nge with a
AN D THE BEA R I:\ G CAP S MUST BE AB- feeler g auge, In set C or dial indicator .
SOLUT E LY CLE AN A ' 0 FR EE OF DIRT
OR GR E ASE . ANY DIRT LE F T BEl-ll~D 6. Normal cra nksh aft end play is .001" to
THE LIN ER S WILL INTE RFER E WITH .005" . If excessive e nd p la y canno t be
T HE COOLI NG OF THE L1l':E RS AND WILL ta ken up the crankshaft must be replaced .
R ESULT IN ' ·HOT· SPOTS" A:,oo PRE·
:VIATURE FAIL URE . 7. Check the bea ring oil c learance as follow s:
A plasti ga uge materia l m a nufactured com·
1. Insta ll the key (5). thru st sh im (4) (Spark mercially may be used for checkIn g bearing
I g niti on Engine) thru st spa cer C-j) and press clearances as follows:
the cranksha ft gear (~) on cra nkshaft (6),
with the timing m a r ks to the outside. NOTE : WHEN CHE CKING BEARING CLE AR·
ANCE DO NOT HAVE THE WE IG HT OF THE
~. Ins tall the main beari ng liner uppe r ha lves CRANK SHAFT ON THE BEA R ING CAPS.
(17) in the block wit h the lock enga ging the
loc k groove, Inset A, (liner half wi th oil 8. Remove only one of the bearing caps at a
groove in center) . Lubricate the liners a nd time and wipe the oil from the bearing
crankshaft journals wi th d r ive ·away oil. s hell a nd cra nk shaft jo urnal.

3. Carefully set th e c r ankshaft (61 in pla ce in

9. Place a pi ece of plasti gauge full width on
the block a nd insta ll the bea r Ing caps (H
the bea ring liner , as show n In Inset D .
and 15) with new Uners (16) e ngaging the
lock grooves, Inset B. The number ed side
10. Tighte n the bearing ca p 80 to 100 ft. Ib s.
or arrowed sid~ of the main bea ring ca ps
Torque.
must be toward (he ci.lmshaft . Lubricate
the liners with drive·away oil.
11. R emove the bea ring cap. The fl a ttened
pla sti gauge will be found ei ther on the
CAUTION : THE MA IN BEARlJ';GS AR E
bearing shell or crankshaft.
NUMBERED FROM 1 1'HR U 5 DIeSEL
AN D 1 THRlJ 3 SPAf(K IGNI TION START·
12. Compa re the flattened gauge material a t
I:.I G WITH THY. P[JLL E Y E ND OF THE
its widest point with the scale that is fur·
CRA KSHAFT. MAKE SUR E THE NUM·
nish~d as sbown in Inset D.
BERED SIDE OR ARROW OF TH E MAI N
BEA R l.NG CAPS ARE INSTALLED ON
13.Tbe number within the gra du a tion indica tes
TH E CAMSHAFT S lOE AND IN THE RIGHT
clearance in thou sandths of an inc h. Oil
LOCA TIO;'; 1:,\ THE BLOCK.
bearing clearance shou ld be .0012" to .004~".
4. The ma in bea ring capscrews mus t be tor·
q ued e venly 90 to 100 ft. Ibs. NOTE: UNDERS IZE LI NEB. S ARE AVAIL·
ABLE. IF' IT IS NECE SSARY TO GRiND
5. Chec k the c ranksha ft end play as follows: DOWN ONE OR MORE JO URNA LS IT IS AD
T he cran kshaft e nd thrus t is taken up by VISA BLE TO GRI:\,D ALL THE JOURl':ALS
the cen[('r bearing liner flange.
14. Check the pump drive gear lor cor rec t
To obta in an accura te r eadi ng use a pry backlash a s shown in Inset E. usi ng a dial
bar between Ihe crank throw a nd number 4 indicator. Cor rec t bac kla sh may be ob·
m ai n bearing cap (Diesel Engi np) and num· tained by adding or removing shi m s Ioea ted
bel' J main bearIng ca p (Spark Ignition En · between the oil pu m p body and the front
gi ne), Takp up a ll end play with the pry bar. main cap. Inse t E. Correct backlash is .002"
Che ck the clearance between the cente r to .008" .
 23- 39

INSET D INSET C
, \ BEARING CAP 188 DIESEL
PLAS TI ~AUGE SCALE .. V

PLASTi GAUGE FEELER GAUGE

INSET A

IGNITIO~8
188, 159 AND 1
SPARK

INSET E

INSET B

10

- __ ~______~L~O~CK~GR~O~O~VE~..J
F Igure 26
23-10

OIL PUMP
(Refer to Figure 27)

Disassembly
1, Re move the pum p cover (3) from the pump val ve (10), RemoVE' "0 " r ing (6 ) a nd dis-
bod", I"), ca rd,

2, If se rvicing of the relie f valve is necessary, NOTE : The m a jor interna l parts of the
r emove co ller pin (7 ) , the cup plug (8 ) by pump are not se rviced , If the r equi reme nt s
drilling a hole? thru it and pull ing the cup during ins pec tion are not sat isfac to ry the
plug out. Remove the >pring ( 9 ) and r elief pump assemb ly must be r e placed,

Inspection
Check the reli ef valve sp rin g to m ee t the cover (3) on the body (5) a nd to rque the cover
following spec-ifica tions: bolts 6 to 8 ft. Ills. Re mo ve the cover and
c heck the gear to cove r clearance Inset g , If
Wire Th ickness ,_". " "."" " .", .. .0625 " m ore? than ,0055 " c lea r a nce , 11 new pu mp
Maximum 0,0, .,, '" " "" " "" .. "" """ .469" assembl y is req uired ,
Free Le ngth ( Diesel ) """,,,,,.,, .. ,,_ .. ,,, 2,06" Chec k the te(> th on the pump drivE' gear a nd
Spark Ig nition .... "" ...... ," " " """"'"'''' 2" the pump body , If exce?ssive wear is no ticed
Compress to 1,44" ( Di esel ) '" 18 to 19 lbs, o n the gear or the c lea ra nce is not ,0065" to
Compressed to 1.38 " (Spark Ign ,) '" 6, 75 to ,0035" DIE SEL and ,003" to .006" ( PAR K
7,25 Ibs, IGNTION), replace m e nt a t th e pum p is re-
quired , Inse t C,
Check the radial clea rance as shown in
Inse t ,;, ~'Iore than ,00:)" c leara nce requ ires
a new pump asse mbl y ,

Pl ace a strip a t pla s ti g a uge o n the top of

e ither g ear a s shown in Ins et B. P os ition the

Assembly
1 Assembl e the pump cover (3 ) with new 2, Insta ll relief valve (10) , s pring (9) an d in-
gasket (4) to th(> pump body (5 1 and torque sta ll the cup plug (8) to a de pth ,iu st be-
capscrews 6 to 8 ft. lbs, NOTE : While yond co tter pin hole Inset 0, Retain in pla ce
tig htening bol ts and sc rews, position the with co tte r pin (7), Ins tall a new " 0 " ring
co ve? r to p rov ide free rota lion of s ha lt (6) .
a nd gea r"
 23-41

INSET A INSET B

,
PLASTI GAUGE

SCALE

.002" TO .005" ClEA RANCE .0015" TO .00 5 5" ClEA RANC E

~SP@ ~c
fIJ
c
Oc ~
0
c 0 C-

l" O

INSET C
(DIESEL) .0035" TO .0065 .. -....J1--
INSET D
I SPARK IGNITION ) - - ---11--
.003" TO .006 "

Figure 27
23·42

SAFETY PRECAUTION
CAU'fIOJli : Cilre s hould bo exercised whe n servicing components of the pressurized coo ling
syste m or d rain ing the syst em. There is a da nger of being sprayed by hot coola nt when opening
drains or removing the r a diator cap. Relieve the pressure by turning the radiator cap counter·
clockw ise to the FIRST s top. a llowing a gradual reduction in pressure and minim izing coolant
loss . Jl.'E VER pour c old coo la n t into a hot e ngine . The engine block or cylinder head m ay crack
by th e sudden co ntrac tion caused by th e difference in temperature be tween t he metal and the
coolant.
CLEANING THE COOLING SYSTEM
It is recomm ended that the cooling system be clea ned at lea s t once a year. In areas where
water con taining sca le form ing mineral s is a ll that is a vailable, c lean the syste m m ore often .
Add any nationally know n commerc ial brand clea ner marke ted by a reputable manufacturere r.
rOLLOW T HE DIRECTIONS PROVIDED WITH TH E CLEANER. If water is used in the cooling
system during the summ er m onth s, always add a reputable brand rust (or corrosion ) inhibitor.
THERMOSTAT AND FAN BELT
(Refer to Figure 28)
Disassembly
1. Dra in tho cooling system . C.~lITION ; Re· gasket (4) and thermos ta t (5) on the diesel
m ov(' the radiator cap carefully as des· engine. Discard gas ket.
cribed above . 4. Remove hose c lamp (6) a nd s upport (7)
2. Remove the upper radiator hose (2) , hos e from hose (2) on the spark ignition engine.
cl a mps (1) and th ermost at (~ ) on the spark 5. L oosen the a lterna tor adjusting bolt and
ignition engine. remove the fan belt.
:J. Remove the t he rmos t" t housing (~l) wi t h
Inspection
NOTE : Remove a ll remai ning gasket m a terial from the mounting surfaces. Replace all gas ·
kets. Clean a ll t hreads on bo lts.
THERMOSTATS . The thermos ta ts should conditions exis t.
be checked for prope r operat ion. Thi s can HOSES· Check the radiator hoses for cracks
be d one by submerging the th ermosta t with and deteriora tion. Replace if npcessa ry.
a the rmometer in a containe r of hot wa ter RADIATOR CAP - Inspect radiator ca p for
at a tempe rature of 1750 to 18311 F. The any d e fec ts or d amage w hich might impair
thermosta ts should Ile comple te ly open at its sea ling powe r. Tes t the cap for leaks.
202"F. Re plac e the thermos tat if it is not If the radiator cap is defective, replace
rea sonably c lose to t he a bove s pecifications. it. IMPORTANT: The replacement ca p
FA); BE LT· Ch eck th(' fa n belt for wear, must have the same PS I r ati ng a s t he ori·
c racks or fray ing. Repla ce if a ny of these ginal c ap.
Assembly
1. On the spa rk igni tion engi ne. install the method of chec king the be lt tension is using
the rmost a t housing (.3 ) wit h bolts and new a Belt Te nsion Gauge , Ins('t C. The proper
ga ske t (4). Torque thE' bolt s 20 to 25 foot be lt adjustment will give 1/ 2" de(lec tion or
pounds. 60 pou nds te nsion on the ga uge be tween the
2. Ins ta ll the thermos tat (~i. ;'viake certain alte rnator and cra nksha ft pulley. IMPOR-
they arc properly ins tall e d as indicated TANT: U th e tension is too great, the al·
in In se ts i\ a nd B. terna tor, wa ter pump bearings and fa n bell
3. On the diesel e ngine in s tall t he housing (3) will wear excessive ly . It the belt is loose,
wi th new gasket (4). Torque retaining bolts excessive belt wear ar:d slippage will res-
35 to 42 ft. Ibs. Install t he hose (2) wi th new s uIt. CAUTION : When us ing a pry bar to
clamps (1 ) a nd secure . put tension on the fan be lt, apply only to the
4. On the spark ignition engine. install the fr ont cast housing a rea, Inset C.
s upport (7) into hose (2) il nd install with 6. Close a ll drain va lves ancl fill the sys tem
clamps (1) and (6). ~'lak e sure th e clam p with c lean coola nt. Stan the engine a nd run
(6) is centered ove r the su pport (7) and se· appro ximately 10 to 15 minutes a nd check
c ure the clamp s. for lea ks. Shut e ngine olf dnd c heck the
:i. Install the fan belt. Adj us t the fan belt for c ool ant level. Add c oolant it necessa ry.
proper deflectio n as show n a nd desc ribed
in Inset C. NOTE : Th e mo st a ccura te
 INSET A

DIESEL ENGINE

INSET C

60 POUND S
TENSION OR 1 /2 "
BELT DEFLE CTION

ALTERNATOR
11
...------....
BELT TE N SI ON GAUG E
CRAN KS HAFT PULLEY

"--./

INSET B

SPARK IGN ITION ENGINE

Figure 28
23-44

LOCATING TO P DEA D CENTER

It is required that the fl ywhee l be se t on FLYWHEEL
the TOC mark with the pointer in the flywheel
housing, Figure 30. The n scribe a mark on
the [rant cra nk s ha ft pulley a nd timing cover.
Thi s will be an a id when the flywhee l has to
be removed a nd install ed . Wh e n the flywheel
is in s talled, line up th e TOC marks and the D
poin ter. Then proceed as follows to check the c
timing pointe r in the flywheel housing.

LCra nk th e engine until t he 20'" 8TO C mark

TOC MARK 0 '
on the flyw he el is al igned with the timing TIMING POINTER
pointe r.

2_R emove the va lve cover.

Figure 30

8.Crank the e ngine counter-c lockw ise (3 or

4 degrees) pa st the ze ro mark of the dial
indicator, until a reading o[ .010 " shows
on th e indicator. Again scribe a mark on
the flywhe el in line with the timing pointer.

9.Half the dis tance between these two m a rks

on the flyw heel will be the TOP Oead Center
Mark.

NO . 1 CYLINOER 10. The timing pointer, Figure 30, used with

the timing m a rks on the flywhee l s hould then
be adjusted so it line s up with the TO C mark.
Figure 29

:1.Compre ss the e xhau s t valve s pring on

the :\0. 1 cylinde r and remove the keepers,
valve r e ta iner or va lve r otator , spring and
retain er . Thi s will allow the va lve to foll ow
the movement o[ the Ko. 1 piston.

4.ln s tall a dia l indicator so the indicator

fin ger is under slight press ure on the top
e nd of t he e xha ust valve st em of No. 1
cy li nde r, Figure 29.

5.Cra nk the eng ine slowly cloc kwise until

the dia l indicator hand s tops moving. Re -
set the dial indica tor to zero .

6.Crank the engi ne c lockwise (3 or 4 degrees)

until a rea ding o f .010" shows on the dial
indica tor.

7. Scribe a m a rk on the flywhee l. Figure 30,

in line \vith the timing pointer.
 ion
24
AIR CLEANER . RESTRICTION INDICATOR
AND PRE-SCREENER

188D DIESEL AND

188G. 159G. 148G SPARK IGNITION ENGINES

SPECIFICATIONS

DI;l typf' .. ........ ... ...... .... .. , ... .... .. ... . .. ... ......... .. ...... .... _.. , .......................... .. . H..placeable element

Ch~ l\gc in te rva l ... . ........ .. ....... ... .. , .... ... ..... ...................... " ........ " .. . ,.... A rWr eve ry .six washings,
or 1)('!ore If rcqu Jr~.

Eh'nl c nt sl'r vice in terva l .. ... . .. ... ... .. .... . . , .. ... .. ...... ...... ...... ' ... , ... ,, _' " Whe n Ill(' red s ig nal apP€'8rs
in the dear plastic wi nd ow of t he res tricUon Indicate r .

P.EST R1CrlO:-; ! "DICATOR

R('plu('em(-nt .... ... . ..... ..... . . ......................... .. _._... ...... When the red slg nfll d oes no t disappear
a ft er 50:('ral rC:::Cl s o r does not meet Ihl'
slX'Cifl cm lon.s ,::ivcn on Page 4.

S('n-i('(' intern, l ...... ... .. .. .. ..... ................. . ................... .. .. .. . .... ...... ................ ......... .\ s Heq uircd

fl. •• r."m ~ · 8 05J'

 242

AIR CLEANER AND PRE-SCREENER

(Refer to Figure 1)
The a ir cleaner sys tem is composed of parts which r equire serv icing at different intervals.
T he importance of servicing t he air c lea ner a nd pre- sc r ee ner c a nnot be over emphasized. Thi s
mainte nance is important and will help insure maximum tractor performa nce an d prolong the
life o f the engi ne.
IMPORTAN'l': Th e a ir clean C'r should be serviced when the red s ig nal is s ta tionary in the
r estrict io n indicator window. T he indicat or (13) is located in the in s trument pa nel. To reset the
indicator after air c leaner servicing, s tart the e ngine and press the reset button in, and relea se.
If the clear signa l a ppears, the indicator is fun c tioning properly . If the r ed s igna l r em ai ns, press
the reset button several tim es. If the red signal still does not disa ppear, check th e indicator as
descri bed on P age 4.
Disassembly
CAUTIO ' : NEVER SERVICE THE AIR CLE A:'-JER WHIL E THE EN G l:\E
IS RU; -ll',G'

l. Rem ove the hood and pre-screener (1). 3. Re move wi ng nut (6 ) a nd washer gasket (7).
2. Loosen th e th umb sc rew (2 ! on the du s t Remove the filter e le ment (8) from the ai r
cup c lam p as sembly (3). Rem ove the dust cleane r body (9).
c up (4 ) with clamp assembly (3) from the 4. Remove the rubbe r baffle (5) fr om the dust
cleaner body (9). cup (4 ) _
Inspection
Clean the dust cup, ba ffl e and air clea ner (bot h sides) with clean wate r until the drain
body with a clea n c lo th. water shows no evide nce of dirt. Use a hose
There are two m ethods in whi ch the elemen t without a nozzle a nd flush from the inside of
m ay be cleaned.By c om pressed air or washing. the elem en t to th e outside, P ressu re s hould
CO MPRESSE D AIR METHOD - If conta m ina- not e xceed 40 PSI. Let the elem en t a ir d ry
tion Is chie fly du st , di r ec t a jet of dry c lean complete ly before installing . I 'O'fE : Re place
a ir fr om the in side of the fil ter to the outside the filter e le m e nt afte r every s ix clea n Ings .
using a curved exte nsion. Keep the a ir nozzle Inspect th e filter e lement after clea ning by
a r easona ble dis tance from the element and using a d rop cord, Inset C, and rota tlng \0
m ove t he nozzle up and down wh ile r ota ting check for damage or holes. Visuall y chec k
the e leme n t. ll\-lPORT..\.t'llT : :\02z1e press ure the rubbe r gas ket for d amage a nd any dents
must not exc eed )00 P SI. in the m etal. Re place the ele ment if a ny of
WA SH iN G METHOD - If the el ment a ppears these cond itions exist.
oily or sooty, the wash ing methOd should be Once a year, remove the e ntire air clea ner
used. Wash the filter element using Case (10) and tubes (12). Submerge them in Case
!'"i1 ter Elem en t Cleaner Par t No. A40910, Filter Element Clea ner P art No . M0910, In -
Inset A, which is ava ilabl e tllrough yo ur set 1'1._ Wh en insta ll ing the a ir cleaner ( 10).
Authorized Case Dealer. sing a s ui ta ble tubes (12) and hoses (11 ). ma ke s ure all con-
con taine r, Inset B, mix two ounc es of clea n- nections are tight. Air cleane r efficiency is
er to one gallon of wa ter a t a tem pe ra ture direc tly depend nt upo n air- tigh t con nec tions_
of ap prox imately IOO"F . Soak the e lement Che ck the pre -screene r for punc tures in the
for 4 hours and then a gitate in the so lution screening. Clean with com pressed a ir.
for approximately 2 m inutes. Rinse filte r

Assembly
1. Install the filt er element ( 8) in the body .3. Pl ace the dust cup On the body and secure
(9) and secure with wing nu l ( 6 ) and wa sh- with the clamp asse mbly (3). Make s urE'
er ga sket (7 ). the dust c up (4) is ail the wayan with the
2. Place th e ba ffle (~) in the du s t c up (4) arrows pointing up.
with the le ttering up. 4. Replace the hood and pre-screener (1).
 24·3

I
I
I
-'

,/
,/

SPAR K IGNITION

INSET 8 IN SET A

I N SET C

.-;:::

Figure 1
24-4

RESTRICTION INDICATOR CHECK

(Refer to Figure 2)
The r estriction indica tor can be c hecked on a Dis tributor Tester that is equipped with a
manometer.

1. Remove the restriction indicator a nd 3. Replace the indicator if it does not meet
filter fitting and attach the manometer hose. s pecifica tion s. There are no adj ustme nts .

2. Turn the tester vac uu m rcgula tor switch 4. If the restriction ind icator is faulty. a lso
on a nd s lowly inc rease thc vacuum until the replace the filt er fitting, Inset E, Diesel
red signal appears and remains in the c lea r or In se t A, Spark Ig nition. This fitting con-
window of the indicator. L's ing the part tains a fine s intered aUoy filter tha t is
number marked on the restriction ind icator readily fouied if contaminated a ir is a ilowed
body. refer to the chart for the proper to pass through it.
speci fi cations, F igure 2.
MOD EL NUMBER
RESET BU
TTON~

1/
INSET A

r
I / 1

VACUUM TUBE
~®/~ MODEL NO . 'RBXOO

FILTER FITTING
CLEAR OR
RED SIGNAL

IN S ET B ~~~_ _ _- VAC UUM TUBE

o
FI LTE R FITTING - -~
AIR TUBE _ _
RESTRICTION

INDICATOR" ,
/

-d!..
~. VACUUM TUBE

DO NALDSON INCHES OF INCHES OF

CASE NO.
NO . WATER ME RCURY

27 .7 TO 2 .04 TO
A59568 RBXOO-2254
32 .3 INCHES 2 .37 INCHES

Figure 2
 Seclion

31
FUE L SYSTEM AND FILTERS

188D DIESEL AND

188G . 159G. 148G SPARK IGNITION ENGINES

SPECIFICATIONS

FlIrl' l" rcplacf'm pnr {~-I ua l i1 fld Pr lm ilr'Y) ..... ... .. ...... .... Every 600 hours or NIl'llcr when l oss ot
€ ng ine hors<?polI'c r is ind icated.

f'in ill ."td ~(' fillrr ,. " , .. " .. ,'" .. , .. ... ........... . " .. " , .. ,', ... .......... .... ..... " ...... ........ :l() :>'I Ic:ron F iltr aTion

l~ r i/ll , .ry s(;Jgc> ! llter ... ... ...... .. ... ........................... . _.. .. " ....... ... .......... .... :.l to :) MiCron F'il t ral iolL

:-"um bPr 01 coils .. ... .. ... ... ... _..... ............ " .... _.. ,. ........ ........ ... ,' ... .... _.. ...... .. .... ... ... ....... .... ... .. . 5·1 ·2

F' re<> lC' ng l h .. .. , .. .. • " ... .... ,. _.. , .. .. .. .... .. ...... . ... .... ... ... .. , ..... ... ... .. .... ... .. " .. . ", . .. .......... ........ _..... 1.120"

II··If!? d 1<l!ll('
' tC'1 ,. , •.•• •• .•. •• •. . ...... . .. . .. . .... " .•. .. ..... .. ... .. .•• •..• . • ... ••.•.• ••.• •.•. • •. ••• •.• _. ••• ••.. ..• ..• •• ... ..... . - . 060"

1.0.01 s pri ng ......... .. ... ........... ..... ............... ...... ................ .... ... ............ . _._... ... __ , .... ' .6~5" to .665"

.. ..... .. " .. . " .... . " ........... .... , ... . " .. .. , .... , .. . " .. " ... ,', ... " ....... .. F. v(' r)' l <l{l hou r~

, .... .. ..... .... .. .......... ........ .-. - .. .. Every 1000 hours or ea l11t'f wht>r. loss of
"

e ngI ne horsl?;JO'o'· ..... l!i In d i(" I! e<i.

Flo C ~ o · .., !i- 6 0~ ~ 1

 PRIMARY AND FINAL FILTERS
'88 D Diesel Engines
(Refer to Figure 1)
IMPORl'A1'il' : Clea n the filt ers and the (14) and in sta l l with now ga skel (13 ) with
eng ine area adjacent to til e' f ilters. r eta iner llut (12 ) and nell' gasket 113 ) . Close
I 'OTE : Service both the primary and the dra in va lve ( 11) .
fina l filter a t the same time.
8. Install the drain valve (9) with nell' "0" ring
1. Close the fu el tank shut·oft valve and re- (10) .
move th(' bleed va l\'e (2) w ith gasket (:l)
and drain plug (9 ) with "0 " ring (10 ) fro m 9. Check the element spring (8) for the
final filte r (l). Open the dra in valve (11 ) follow ing specifica tion s:
on th e primary filt er.
No. of coil s .............. . ...................... . 0-112
2. Unscrew th e filter c ap (1) until the element Free length ...... ....... . 1.120"
(4) , and gasket ('1) c an be r emoved with the Wire did . .............. .. .......... . .(16U "
fil ter cap. 1.0. of spring ....... . 6:;')" to . {j6J"

:J. Remove the rubber sea l (6 ), "'asher ( 7) and 10. Insta ll spring (8) , wa shel' (7) and new
spring ( 8) . seal (6) .

4. Remove the retainer nut (12) with gas ket 11. Ins tall a new final fil ter ( oj ) and lower gas -
(1.1) and remove the primary filter shell ket (5) to the filter hea d (17) stand pipe with
(14) with t he filt er elem",nt (16) and gasket the four holes and notc hes up. I nstall new
(15) from filt er head (17 1_ :'IIOTE: Replace upper gasket (5) and cover (1 ) and tighten .
all gaske ts, seals and "0 " rings when re- CAUTIO. ': Do not over tighten or the (> 1('-
placing W ter etement s. ment m ay be cr ushed and become inoper<l-
tive. Ins ta ll bleed v alve 12) with new gas ket
'i. If filter head ports and pa ssages appt'3r (3).
d i rty . disconnect f uel lin es fro m the filter
h ead (17 ) and remove f rom blo ck. Flush 12. Fill the fuel tank and open the fue l tank
the head thorough ty in clean diesel fuel and shut-off valve. Wa i t a few minutes to make
b low pa ssages and ports ou t clear with sure the filters are f ull 01 fue l.
compre ssed ai r. Install the hea d to the
block a nd connect fuel lines. 13. Open th'" bleed va lve (2) on t he f inal filler
and allow fu e l to fl ow until it flow s f ree 01
G. Flush the primary f ilter shell tl4) in clean bubbles, then C105(> the bIped va l\'E'. Wipe
diesel fu el and wipe with clean lint free the filt er fre e of diesel fuel.
cloth.
14. Start the engine and op('rate for several
7. Install J new clement (16) in to the shell minutes and check for lea ks .
 FUEL FLOW

RETURN LINE

~~i--~~~\--~--~~
J ~'- --
tIl FUr:
FUEL TANK

IN J EC TO RS
t t l
!t t
WATER TRAP

--
Itirl:. ~~l'~~~?~~~lj
,-I>'f) I '
VALVE . ....
rf ':- ~ _-@
~ .15

\t
DRAIN

_ t '-r'(r t ~
m
FINAL FILTER

TRANSFER PUMP ~.~~7 I

t
DRAIN

---0
I

_ ,___J
PR IMARY FILTER

DRAIN
=
_
U NFILTERED
FI LTERED
rzzzzz:zzJ A ETU A N
= HIGH PRESSURE

Figure 1
31--.

FUEL STRAINE R AN D FILTER

(Refer to Figure 2)
188G. 159G and 148G Spark Ignition Eng ines
IMPORTA ~T: Clea n the area of the fu e l hose (9). Check hose for cracks or d e te rior-
s tra iner a nd filt e r before servicing . a tion, replacE' if these co nditions E' xi s t.

1. Close the fu e l s hut-off valve (1) on the 6_Remove fuel filte r (10) fro m fu el s trainer.
fue l s tra iner (2 ). Check fuel line (11). If the line is c rimped
or pinched to res tric t fue l fl ow, replace it.
2. e nscrell' the ja m n ut (3) a nd sw ing the ba il
(4) up and ou t of the wa y . 7. Install new filt er (10) to fue l s tra in er (2).
Ins ta ll hose clamps (8) to hose (9) and s e-
3. R.' m ove the fuel bowl (5) with a gentle down- c ure cla mps.
wa rd pu ll. Clea n the fu e l bowl a nd rinse in
c lea n fu el. 8. Ins ta ll sc re en (7) with new gaskC't (6) to
s tra iner head (12).
4 . Remove the cork gaske t (6) and fu e l screen
(7 ). Fl ush the> screen in clean f ue l. It sc r E'en 9. F ill th e fuel bowl (5) with clean fue l a nd
re m a in s plugged or is punct ured , rep lace c arefully install to s tra in er head. Swi ng the
th e screen. bail (4) down inpla cea nd reta in by tight e ning
the jam nut (3). Ope n th e fue l s hu t- off valve
J. Loose n the hose cla mps (8) and r e m ove with (1) .

- .... \
)
/
/
/
/
/
/

Fi gure 2
 n

32
ROOSA MASTER

MODEL DB FUE L INJECTION PUMPS

188 SERIES DIESEL ENGINES

TABLE OF CONTENTS
Descri ption ..... .... .... .... ........ .... .... ........... ..... ..... ,' ...... , ......... .. , ..... . , ...... ...... ,... ..... ", ... ..... .. ... .1:2.-2
Remov ing the Fuel [ni CClio n Pump .. . " , .. ........... ... ...... .... ... ....... ', .. ... .... ... ,.,_. _._. ,. __ ___ ___ .. _.... 32·3
I n ~tall(ng the Fue l Injt'CtiOfl P l!mp .. .. ,", ......... ........... .... ........... , ....... ... ... ..... .. ...... ' ..... .. ....... .... :32 - ~
'nmlng the Fllel I nj(,('tion Pump to EngIne ..... ........... ... ..... ..... ... ... _...... .. ... ..... ...... ,..... .... .. .... . n·B
E ngi ne Spt>ed ... .. ... .. ... . ..... .... .... ....... .. " . ....... , ... " ........ .......... .... . , .......... ..... ... ... ... .. "', .. ... ..... ..... 32·7
Check ing Engine S(X.'(.'{l . ..... ...... .... .... ........... ....... ......... ...... ............ ...... ...... . . __._._ , ____ ___ ...... __._ 32·7
No Lo;J(] Governed E ng ine Speed . .. .... ...... ........ " ..... " ................ .. ......... ... ...... ...... . ... . , .. 32 -8
Low Idle Speed A dj ustm en t .. ... .... .. .. ," .. ... •...... . , ......... .......• , ....... ..... ...... .. .. _. . .. __ , ______ _____ .. ___ . 32·9

Special Torques
H igh pressllre fuel lin e ('onn ec tion screws ... "" , ...... ...• .... .. ", ..•.. . " ........... .. ____ ... ....... ... .. J.' fl. Ib'iO.
FlU,,1 inlet f ilter assemlJlv ... ........ ................... , ...... .. ............. , ... ......................... ....... _...... 10 fl Ibs.

R"". F~ ' m 9 _8 0421

32-2

DESCRIPTION

So me Case Diesel E ngi nes a re equipped The function of the fuel i njeCtion pump is
with a Roosa M aster :VI ode l DB Fuel inj ec tion to deliver accurately m etered quantities of
P ump , Figure 1. This i s an ex tremely com- fu el und er high pres sure to the fu el inj ectors.
pact and precision unit wh ic h incorporates a This must be done with accur ate t iming in
high press ure inj ec tion pump, a mech an ical r ela tion to the engi ne firing ord er and for a
variable speed cE'ntrifugal type governor . ver y definite period of tim e i n rela tion to
vane ty pE' fuel transiE'r pump and is self load and E'ngine speed requirem ents .
lubricated by the f uel.

CAS E PART NO

'\

Figure1

T o m eet th ese rigid requirement s, the It is therefore doubly impor tan t that yo u
M odel DB Injection Pump is of necess ity, ta k e extra precautions to prevent th e entry
man ufactured to unusually close to lerances. of dust or simil ar abrasi ves w hen yo u per-
Wh i le the pum p ca nnot be considerab le deli- form service work tha t invol ves t he fu el in -
c ate , the preCis ion wi t h which it i s m anu- jection pump or other components of the fu el
fac tured can be compared to that of a fine system.
watc h.
 32 -:3

Removing the Fuel Injection Pump

NOTE: : Ste a m clea n the €'ng ine tho roughl y Use every possible precaut ion to ob ta in a b -
in the a r ea of the fu el inject ion pump and solute clean liness , to preve nt en ll-y of fOl'(' ign
lines prior to pe rformi ng any service work. maller into fu e l sys tem a nd injecl ion pump.

I
I

Figure 2
1. B efore ren10ving pump, set engine a t COf- th e sa me pump is goi ng to be r eins talled,
rect pump timing on '1 cylinder, refer to and then line up sc r ibe m arks on insta lla-
Page 32-6. tion of pump,

2. Close the fu e l tank shu t- off valve. 6, Remove the three nut s and washers from
pump flange stu ds .
3. Remove hig h press ure (uel lines, fue l in-
let line a t pump a nd leak-off lin E', Figure 2. 7. Cal'~ fully pull pump rear'ward off of the
pump drive sh a [1.
4. Di sconnec t the throttle r od from the gover-
nOr control le ver and the fue l s hut-off cable 8. l{emove the tlming gea r cove r if the re is
from the s hu t·of[ lever. an occaSion to remove the pump d rive
sha ft. Re fer to Sec ti on 23 o f this servic('
'j. It is advisabl€' to put a sma ll scribe mark m a nu aL
on pump [lang€' a nd t im in g gear housing if
 Installing the Fuel Injection Pump
(Refer to Figure 3)
1. Any time the inject ion pump is removed timing gear housing and tighten nu ts on
from the engine fOl' a ny l'eason, the two flange .
d r ive shaft seals and the pi lot tu be "0"
ring seal m ust bl? r eplacE'd. 8. Recheck timing and adjust if nec essa ry.
Wa sh re moved fuel li nes, in c lean d iesc'l
2. Lubricate the seals fre<- Iy an d Install on th<- fuel. Blow them c le an with flltered com-
CO.322 slee ve tool wit h the lips of the sea ls pressed air. Reinstall lines in same orde r
ou tw ard , lSL'a ls back to back) ,In se L". as removal.

3. Slide C0322 slee \'(' tool over pump drive IJI,IPORTANT: Before installing fuel line
sh aft a nd ins tall seals in thei r respec tive connector scrcws into high pressu r e lines
grooves, Inset A and B. at pump, be sure tha t two ne w copper was h-
ers are used on eac h connec tion . Also make
U IPORl'A T: Thorough ly lubricat E' the SU1'e both washers are in p la ce befo re tigh t-
two sea ls on pu m p drive shaft with "I ullfi- en ing up co noc'c tol' scrcws. Torq ue connec ·
pla te" to a void damage a nd fac il it a te ease tion sc rews 35 1'1. Ibs.
or in s tallation, InsetC.
Do not tighten connec tor screws wi thout
•. Be su re to exam ine pil ot tube "0" ring washers in place :IS p ump seizure c ould re-
sea l on f tOllt of pump for damage or nicks. s ult. This is due to connector screw going
Replace if ne cessa ry . too deep into pump body.

IMPORTANT: J[ front s ide of flang-e on in - 9. To remove the cap a nd filter assembly.

jec tion pump as well as ma ting s urfa ce on disconnect fue l s upply lin e at pump inlet
timI ng gear hou sing has any bllrrs or nicks and re move nut on top of pum p. This screen
where the 1'.1'0 su rfaces m ake contact, be assembly is an assem bled unit . If "0"
sure they are r e moved . A burr or nic k ring or screen on c ap a nd e lem ent Is dam ,
could resu lt in mi s-a lignment o f the pum p, aged in an y wa y, replace the damaged par ts.
in turn ca using seizure. Tighten to 20 ft. Ibs when insta lling .

~. Re ar e nd of s ha ft is equippe d w!th drive Do not attempt to be nd either of the levers

tang whic h has a hole in one side. Thi s hole on pump pivot s haft [o r any r aSOn as this
mus t lilH? up with hole loca ted interna lly in could result in leakage at-Ound the pivot s haft
pump o n th e rotor toward rear end of pump seals due to s ha ft be ing spru ng w hen bending-
hous ing. Wi th a cl iJ n Screw driver turn levers.
pum p rolor to approximately the position
as ta ng on e nd of d ri ve shaft so tha t both NO'I'E : When re placing an in jec tion pu mp
holes '.vill correspond with eac h other whe n be sure replacem ent pump is for- t he COIT(>Ct
assem bl ed. If holes a re not aligned, pump [ull load RP:VI of e ngine.
wou ld I)E' 180" out o[ tim e, Inset B.
The full RPM is stamped on serial pla te of
6. Using specia l tool 1'0. CD331, compress pump. It would be possible to insta ll a n in-
sea ls on drive sha ft ,Inset D, Slide pump correct pump. th(>l'efol'E' always refe r to the
onto sh a ft be ing careful not to damage seals part s cata log when ordering a replacement
du ring a ssemb ly. If sea l is rolled over on pump.
shaft in asse mbly, remove pump and re -
place r ear seal eve n though no vis ua l dama ge If pump is be ing returned to an aul horized
is appa rent. DO NOT FORCE afte r pu m p is Roosa-Master service stat ion, be su re it is
moved forwa rd. It may be nec essa ry to ro- complete with drive shalt. He placemen t pumps
tate p ump Sligh tly 10 permit tang on shaft are complete with drive shaft and necessa ry
to engage slot In pump . pump m ou nting part s.

7. Jf sa m e pump is ins ta lled wh lch was re -

mo ved, line up scri be marks On fla nge and .
 .t2·.)

IN SET B

I
I
t

,
i

DRI VE
I
I I / ----~
DRIVE TANG LINE UP HOLE NO LOAD GO V ERNED , __THROTIlE LEVER

SPEED ADJUSTING SCR EW

C;,
FUEL LINE
C ONNECTOR
CAP AND
FILTER
[@ ~
SCREEN
/ASSEMBLY

SCREW~ ASSEMBLY ai /" "O"~' NG .~ '-....

SCREW

~ LO CK NUT

COPPER ____ @ @ . \
WASHERS~ D
THROTILE STOP PL,nE

SHUT-OFF ADJUSTING
SCREW~'

LOCKNUT- ~ ~
~- ~ ~
~-~ ~
;., \ J
() ..... '" !Q,'b

~ ~~

t? \
SHUT OFF LEVER
SHUT-OFF LEVER RETAINING SCRE W

IN SET 0

IN SET C

LUBRI CATE THIS AREA OF SH AFT WITH

\
SEA L CO MPRESSION
TO OL CD 331
LUBRIPLATE BEIFO flE INSTALLI NG PUMP

( Y
Figure 3
.1'2-()

Timing the Fuel Injection Pump to Engine

T o dCI('rm ine top () ('~d Center o n '.:0. 1 .'3. Remove the ti ming hole plug on the plug
cyl i nder: f1 ywh ee i housing and turn eng ine i n d irec tion
1. SimI off f uel. A sh ut,off i s loca led o n bottom of rotation until fl y whee l is alig ned with
ot Ihe fuel l ank. Ru n engi ne un lil il SlOpS. Ihe COlTecl o:iegrre mad" F' igu re oj, for your
specifled fu el pump rim i ng .
2. T o set 1"'0. 1) Cylinder on top of campr(',·
sion stroke, cr ank eng ine um il pu sh rod s Rated Spe",d T iming
ar C' loose on 1'.:0. 1) cylind er [ top of com· 1750 .... , ..................... ........ ......... . BTDC
oj "
press ion stroke ) and the rocker a rms on 1850, 1900 .... . ......... .. .... ... ......... .. . . 8" BTDC
th e opposing cylin der ('.:0. 4\ ca n be rock· 2000. 2100 .......... ......... .. 80 BTDC
('d op<:n Or closf'd I"i th a sligh t back and 2200 , 22~0 ............... . 8" BTD C
forth m ovem ent of Ihe crankshaft.

MARK IN
INJ ECTI ON PUMP
WI NDOW M U ST
BE IN ALI GNM ENT

/
FLYWHEEL HOUSING TIMING HOLE

Figure 4 Figure 5

.1. PemO\' e the cover from in '",c lion pump To advan ce timin g, move top of pum p aW'ay
windO\\', F ig ure 4 . If pump is co r r ectly from the cy li nder b lock, Figure 5.
timed, the timing m arks in t he window will
be in alignment. To re tard pump limin g m ove top of pu m p
tow ard the cylind er bloc k . T ig h tE'n nuls on
5. In t he event t iming marks are not in align· flange after ro tating pump to th e speci fi ed
ment , it m ay be necessary to adju st pump tim ing.
tim i ng . To do thi s put a scr ibe l i ne on
timi ng g<:ar housing a nd pump mounting 6. Turn engine over at l east two turn s a nd
flan ge to use as a refer e>nce mark . Next recheck timing. R eadjus t if necessa r y . It
l oosen the th ree nut s on pu mp fl ange and m ay be> necessary to r epeat this procedu re
r ota te pump until timing ma rks are in sever al times befor e cor rec t timing i s ob ·
alignment in the window on the pump, ta ined.
F igu r e 'l. NOTE : You wi ll not ice there
are 0·12" m arks on top siele o f the pump CAUTION : '.:ever attem p t to a dj ust timing
flan ge. Disrega rd tht'sf:' m arks as t hey with the eng ine runnin g . This could re su lt
are calibr at ion m arks for Service Sta tion in serious injury to I he mechan ic or d amage
use only. to i nj ec tion pump.
 32-7

ENGINE SPEED
The Authorized E ngine Speed Adjustments tempting. to ta ke an accura te engine speed
desc ribed In the follow ing paragraphs of this reading.
manual are for the informa tion a nd use of
Authorized Case Dealers only. 5. Fuel does no t meet the re quir ed specifi-
Unaut horized changes in the governed e n- cations for Number 2 Diesel Fuel.
gi ne speed of the Ca se Diese l Engine will
au tom a tica lly void a nd waive any Warra nty 6. Plugged a ir c lea ner.
whatsoever by the J. I. Ca se Compa. ny.
Before m aking a ny cha nges in the no load 7. Fuel ta nk breather partl y plugged.
governed e ngine speed, c he ck that the e ngine
s peed is no t a ffected by one or more of the 8. Fuel filt e r bleed by -p ass va ive not closed
followin g conditions: completely.

1. Check to be sure the engine is equipped 9. Lack of fuel to the Inj ectors due to plugged
wi th rhe correct injection pump. The pump fuel filt ers, air or water in the fuel system.
can be identified by the number sta mped
on rh(' governor housing, refer to P age 10. Fuel injection pump not timed as describecl
32-2. in this seetlon.

2. E ng ine mus t be carefu lly "Run-In" (Whe n 11. Va lve tappet cleara nce not adjus ted a n d
ne w or overha uled). set correc tly. Refer to Cylinder Hea d
Se ction.
3. Eng ine lub r icati ng oil v iscosity not accord-
in g to recomm e nd a tions. 12. One or more faulty injE' c tors.

4. Incorrect oil viscosity In the tran smi ssion, 13. Loss of compress ion in one or mo re
Or the hydraulic sys tem. NOTE : The trans- cylinders.
ml s ~ ion and hydraul ic oil must be warmed
up to the proper tem peratu re before a t- 14. Fue l s hu t off ou t of a d justme nt.
Checking Engine Speed
CAUTION: MAKE SliR E THE POWE R gainst the tachometer d rl \'(' shaf t.
TRAI l 1 IS [1\ ~EUTRA L. 2. Hold the tachometer in position until the
Checking engine s peeds is c ritical and ca n ha nd stops moving. Ta ke th'" reading and
onl y be m ade with a lachometer that is know n double it to arrivC' il t the no load gover-
to be accurate. nevolution counters of a ny ned e ngi ne speed .
t yp~ or tachome te rs tha t ha ve been in use for
a long tIme withoul being checked for accur-
acy MUST NOT be used .
Allow the engine to run until tem pera ture
gau ge reads normal operating temperature.
Check the coo la nt temperature wit h a ther-
mome ter.
Ra ted Speed No Load Governed Speed
1750 1890 to 1925
1850 2000 to 2030 -------~~~~-- ---
1900 2050 to 2090
2000 2160 to 2220 RUBBER CONICAL TIP
2100 2270 to 2310
~200 2380 to 2420
2250 2440 to 2480
Figura 6
1. Take the s peed readi ng from the tac hom e te r 3. To eliminate the pos sibility of e rror, check
drive shaft , which run s at one ha lf the e n- the engine s peed with t.he tachometer at
g ine speed. Hold the conical rubber tip a - least three times.
32-8

N o Load Governed Engine

CAUTION: Before changing or adjusting If the "'"A Load Governed speed adjusting
the !'-' o Load Governed speed adjusting screw screw is not against the pump boss, adjust
on the pu mp , m ake sure the i? ngine is opera- until it holds the control lever aga inst the
ting w ith the correc t injec tion pump. The pump boss.
pump can be identified by the number stamped
On the Serial "'umber plate located on side of If the No Load Governed speed screw is
pump hou si ng. against the pump boss bu t the No L oa d Gover-
ned speed is still low, the speed c an be i n-
Set t he engine throttle in the "'0 Load Gover- creased a limited al1lount by m eans of the 1\'0
ned Speed Position_ Check the position of the Load Governed spE'€d adjusting screw ,
governor co ni rol levcr. Th e 0 Load Gover-
ned speed sere'" shou ld be ag~ins t the pump
boss. RC'fcr to Figure 7.

NO LOAD GOVERNED SP EED

ADJUSTING SCREW

COUNTERCLOCKWISE
~
TO REDUC E NO LOAD
~_.,p,\:'!j GOVERNED SPEED
~
CLOCKWISE TD INCR EASE
......~Iil"--1. NO LOAD GOVER NED SPEE D

Figure 7
TO r;\ CR EASE t he e nginE' 1\0 Load Governed the correc t ","0 L oa d Governed engine speed
speed by means of the ;\0 Load Governed speed is obtai ned, Figure 7. Check the Ko Load Gov-
adjusting screw , loos en the lock nut and turn the erned engine speed after eac h 1/2 turn.
:"\0 L oa d Governed speed adju sling screw out
(counter-clockwise) 112 tu rn a t a time and IMPORTANT: The No Load Governed speed
tigh ten lock nut , Figure 7. Check Ihe No Load adjusting screws are sealed with a wire and
Governed engine speed aft er ea ch 1/ 2 turn. lead sea l. You musl have the necessa ry equip-
m ent to resea l the adjusting screw when th e
TO DECREASE the engine No Load Governed adjust.ment is complete_ Alw ays m ake a re-
Speed_ Set the e ngine thro ttle lever in the :-;0 cord of the datE' you broke the seal, the serial
Load Governed Speed position. Loosen the lock number 01 the machine or engi ne and t he rea -
nut on the :\0 Lo ad Governed spc'C'd adjusting son why you broke the seal.
screw a nd turn the screw in (c lockwi se) un t il'
 Low Idl e Speed Adjustment
Set the engine throttle in the Low I d le spcC'd low speed stop.
position. Check the po~ i tio n of t he governo r
C'on trollever . T he Low Idl.~ speed sc r e'w Sll ould If til(' Low Idle speed serf'\\' is aga i nst th e'
be aga I nst the pump bos;:, Figure 8. pump boss I) " t he engine speed ;s sti ll low,
ill(' C'ngine speed can be i ncrea sed a lim it ed
l! t il(' L ow Idle speed screw i s not aga in st amou nt by means (l[ The Loc,' I d le speed ad-
tile pump boss, ad ju!i t. the t hrottle linkage rod ju sting ser eI\'.
un til It holds til<' co ntrol lever agai nst the

FigureS

TO DECREASE the engine speed by m ea ns of the After the correc t engi ne specll is set t igh ten
Low Idl e speed a dju sting screw, loos en the lock- the lock nut s whilE' holdi ng Tb0 ad.iusT ing scr (''.'/.
nut and turn the screw ou t (counter-clockwise)
until the corr ect engi ne spe0d Is obta ined, Fig- IMPORTAN T: The Low lClle speed adjust-
ure 8, check !'ngin!' speed after eac h 1/ 2 turn. ing screw is seajpC\ with a w ire a nd leac\
seal. You must ha\-e the necessary eq u ip-
TO INCREASE the !'nginp speeci by means of ment to reseal ttle adju stIng screw when the
the Low Id le speed adjusting screw, l oosen the adjustment is com plete. Alwa y s m ake a re -
lock nut and t urn the adj usti ng screw in (Clock- cord of t he d ate you broke the eaI , the
wise ) 112 turn at a tim e, Figu r C' 8. Cheek en- seria l number of the engine and t he r eason
gine speed after each 1 12 t urn. why you broke the sea l.
 ion
3
ROOSA MASTER FUE L INJECTORS

'88 DIESEL ENGINES

SPECIFICATIONS
fT l : L INJF.CTOH
........... -...-.- ... - .....- ...... ....... .... .............. , .. ,', ................................. , ...... , .. , .... Roos a lI J<l st er
Opt'll ing p ressuf(' \new } . ....... ... ... ............ .... ........ .. .. .. ........ .......... .. ..... .. .. ........... 275010 :.IS50 PS I
15ervk:cd l .. ........ ..... .. _. _._. ___ .... _.. .. ...... ............. ... ............. .. . ....... ... .. ..... .. ....... . :l.WJ lo 2fi5() P S I
M(lxtn lum o!X'nl ng prl.'SS llr e dlUe r(' nl'C bClwC'€!l c,\'linders .... ..... .... ..... _.... .. .... .. ........ ..... 100 PSI
VJlv(> ]((1 . .. ... ,,_. ___ ... _..... ...................................... .. ... __ . _.. _...... 1/ 2 tu r n olr val\'(' seal or .OO~ W

Sp ray orifice $ize ...... ... ... ,. ," .... .. ......... .... ............ .... .................... ... .. .... . .Olr
SIIC" hole sIze> ... . . ... .. .. .... .. " .... . .... . .... ...................... ... .. , .... .. .. .. ..... ...... , ... ' ......... .. . .
,'\vmOE>r of Ol'ifi C l'S .. . .. .. . . ..... ..... ... .. ...... ......... . ........ " .. . . , ... . .. .. . . .... ... . ... .. ... ... .......... ... . . ... .. .... I
Olific e spr ay 11llgJl' .. ........... ... ... ... ..... ..... .. ... .. .. ........ ..... .. ...... .. ....... .... ... ......... ... .. .... ....... . ..... 1Ij(Y'
~(j koff rat E' .. .... ... ..... ... ... .. .. ..... ...... .... .... ... .. .. ..... . , .......1 to 10 drops I n 30 seconOs.al 1500 PSI
il fter iiI's! <1"0]1 ilppears (servlcC<l in jector)

Opening pr('ss ur(' ('O:llrol sprmg:

E'"ref! L.('n2 1h ... ...•. _. __ ._. _._, . .................... ................ . _.. .. _................. .... ' ..... _..... ___ _ .... .. ... _ .., ..
.....-",
);0 of N ils ............ . ,.. .. ................. ...... . ........... .. ..... ..... ....... . .......... ..... _.. .. ................. 7
Wlr!' d iameter ....... ... ... ... .. ..... ....... .. .. ... .. ...... ............. ... ............. .. ......... .. ... ............ ........ .U.}6··
0.1). of s pring .. -- ..... ., .. , ........ .... -.. . .............. .. ..... .... ............ .................... ..... .. .. .. .... .. .. . • -I ' ''''
~ 1<.

Comp r('~sed to .4 1~" . Xlj" .,.... ..... .. .. " ... ..... .. ........ ... .. .. .......... ,'" ... ,... .. .. '. __ .. "2., Ibs. pressur('

Special Torques

E'"u ('1 injector pn.'»sur(' adjllstinz ~Cf{'W locknu t ............... ......... .... ............... . TO 10 75 Inch Ibs.
Fu el injeNo ~ c la m p c,lpscrcws ............... _...... _.... .... ............. " .............. .. ... ___ .. _.. _.. . .... . to It. l bs ,

Roo _ F""" 9 604 11

 A WAkNINfJ
W/I.II , •• Hllf 0' .'ju.fillf 'UIII ;IIju'o,,_ '0 "0'
,1.0. gou' /I.llt1. 0' I"m, ill "011' 0/,/1. ;IIj,o'o, 11011111,.

T/I, lu.1 "'.y I,om ." illj,o'o, /I.,

,u"io;'II'
,'11.".fillf 'OW" '0
,UIIO'U'. ,It,
n,,/I .11' '.",oy
nuu•. I/loul, ,,,. 1".1 '"'" ,,,. 6100' ""lIm_ if mllg
0."" 6100' ,oi.oll;nf.

III ,,,, • V.II' ,,,. ,k;II ;, ,UIIO'U'.' I,om fit, 'i•.

O".'f. 0/.11 ;IIju'o ,_ ."Ig ,A. 'ollowinf Ii", IIi'
;mmet/i."'g_ ' '.11 "IIV. ,/I. illju,y 'It.mlll.' 6g • ' '!i'
tiei." lit fuioklg •• ,oui61•.

W.d ,,,. i"ju,.' ,." wifA 60,'e 1101' ,olu#olf_

'u,'o" ,/I. ;"ju,,' lillf.' 0' A.If' wif" • ,,/ill'
.If'
.Iilff.0 ,/I. illj,,'" ,." will ,.mllill 116'0 I,,'./y ., ,,,,
UII 'illI ,"g.ioi." 0." .It.mill. if.
 33-:3

D e scription
Th e fue l inj e ctor is a cl osed end (injector efficient e ngin e pe rform ance .
va l ve doe s not proj e c t t hr ough an opening in
the in jec tor tip) diffe r e ntI a l pressure, hyd- IMfI()llTANTThe inj ecto t' body a nd valve is
r a ulically ope r a ted hole type injector. a m ated assembly, accur ately lapped to a
ve ry c los e fit fo r pre cise mete ring of fuel
The fue l injectors are located in the cyl- to e'ac h cyli nd e r , The bod y or va lve cannot
ind e r head - ol1e for eac h cylinder. It is the be install ed individ ually for servic e. If it is
fu nc tion of the fue l in jecto r to di rect a meter- necessar y to replac e e ithe r the valve or
e d quantity of fu e l r eceived from the injec- body , repl ace the comple te as s embly,
tion pump to the c ombus tio n chamber. Eac h
c h a r ge of fuel must b e d elivered into the CAIITlDN Do not mix val ve s and bodies
combustion c hamber with a definite spray while disas s e mbling the injector.
pa ttern to insure complete combustion and
PRE SS URE ADJUSTING SCREW
INJECTOR BODY

TIP\~
VALV~ ~/

LOCKNUT
I
SP~AY O~IFIC~S
\
CARBON SEAL LIFT ADJUSTING SC~EW

COMPHSSION S~AL

INLET FITTING---..

Figur e 1
L\;JECTOR BODY - Hou ses the injector parts presses the opening pressure control spring
in their co rrec t position in the cylinde r he ad. to maintain a predete rmined s pring pressure
The part of the inj ector body whi c h proje cts on the val ve,
into the c ylinde r head is Teflon coateel to
prevent sticking. LIFT ADJUSTI NG SCREW - Controls the
val ve travel elistance .
INJECTOfl VALVE - Contro ls the fl ow of
tuel fr o m the i njec tor. [i\;JECTOR TIP - Contain s the va lve se a t
anel four spray orifi ce s whi c h direc t the fuel
VALVE GUm E - Supports a nd guide s the spray in the combustion c h a mber.
moveme nt of the va lve in the b oel y .
CARBor; SEAL - Pre ve nts carbon ac c um-
OPE:--:ING PRE SS liHE CO I\TRO L SPRING- ulation in the cylind e r head openings.
Controls fu e l pre s s ure nece ss a ry to lift the
valve fr om its seat. COMPRESSIor; SEAL - i\ nylon s e al under
the inlet fitting that pre ve nts e ngine COm-
PRESSURE ADJlI ST[i\; G SCREW - Com- pression leakage,
 Operatin g Princ iples
The ope ration of the injector is sllllp le ilt the in s tan t the pressure of the fuel
and posit i ve . agains t the valve exceeds the p r edete rmined
spring fo r ce. the valve is for ced from its
A m e te l'ed quant ity of fLkl und e r high seat allowin g fu e l und e r high pressure to
pressure from the i nje c tion pum p flows no\\' th rough the four spr ay orifices to the
through the i nl e t line of the inj ec t or ar ound co mbustion c ha mber .
the inj ecto r va lve.

LIFT ADJUSTING SCREW

INJECTOI BODY
PRE SSU RE
CO N TR O L
VALVE SPR ING
TIP

\
\
SPR AY ORi f ICES
\
CAliON SEA L

CO MPO!SS ION HA L P AE SSU IlE ADJUSTING SCREW

INLET FITT I NG

Figure 2

The instan t t he fuel deli very ce ases , the During inj ec ti on, a small amount of fue l
pr essu r e against the valve i s reduced a nd leaks through th e c lose ly contro ll ed cle a r -
the c ontrol s p ri ng sn a ps the valve to its ance at th e guid e, lu bric ating all the mo vi ng
s eat . T hi s eli minates any poss ibility of part.s in th e inj eo to I'. Th is fuel U, e!) flows off
drippi ng aIte r the m ete r ed amount of fuel through le"leaff lines at th e top o f the i n-
h as been deli ve red. In actual operation, the jector anel r eturns to the fuel tank .
val ve ope ns and closes ve ry rapid ly with a
distinct c l\"tter .
 :1:1- 5

Special Tools
Til" fo llowin g Spe c ial Tool s Ca n be pu r chased thl' Ollgh
th e Ser vice Part s Supply, J.l. Case Co , R acine , Wise .

SEA L TO O L
CASE PA RT
NO. A4244 9

OR IFICE INJECT O R
CLEANING W I RES HOLDING TOO L
66- 0 0 36 66 - 0147

SA C HOLE M A G N fFV ING G LASS

o /Il L LI TIP S EA T
66 ·0135
l ET OF I , SCRA Pf R
.010 " 66 -0 14 9 TO RO UE
66 ·0 151 WRE N CH
AO APTEi
66-0146

ENGINE
COMPREISION
VA LV E ADAPTH
RE H PA C TOIiI LA P P I N G TEIT PU MP AO A PT ER
70.314 ( 0 .558)
66- 0 148 CO M P 0 UN 0 65·1 7 8 i N H)
66.0 H '

Fi gure 3
inj ector Tool Kit. Ca!>e Part No . M20 520, Bach m'ach P arl :-io. 6U-00 1O.
T h is Kit i s used in con junc tio n w ith the Case Diese l T ool K its
Cnse P art No . M20 24 7 (CD- SOO) a nd C",e Part No. M202-l6 (CD-350) .

BOR E C U'ANI NG TOOL

TEST STA N D CAS E PA RT N O. A43277
CASE: PA RT N O. M 2 0322
BA CH ARACH PA RT N O. 65 ·93 4D NOZZLE PULLING TOOL
CASE PART NO . A4327 8

Figure 4
33 - 6

Isolating Faully In,ectors

If the engine is mi s fir ing and One 0 1' more Loosen the fuel i nle t tube nut (1) in turn on
of th e injec tors is suspec ted, th e following each in jecto r. This will allow fue l to es cape
procedure can be uti! ized to iso late the and r ende r the inje c tor i no perative. The in-
fa ulty inj ec tors. jector le as t affecting engine perfo rmance
i s the faulty one.
The engine s hou ld be run at a speed
wh ere the mi sfiring is m os t a pp ar ent.

--
"\
I

I
I

Figure 5
 33-7

Removing InJectors
Clean the cylinde r head area around the Re move the in jector (8) from the cylinder
inj e.c tors. Disconnect thc le ak-off line nuts head by pulling upward and turning . If the
from the tee . Remove the li nes (6) and tee inj ecto r cannot be easily r emoved by hand,
(7) from the inj ector , Figure 7. use nozzle puller Case No. 43278.CAUTlfJN
Never attempt to remove an injector by
prying with a sc r ew driver or similar tool
as this will r esult in distortion of the in-
jector body.

Remove and disc,wd the compress ion seat

and the carbon seal, Figure 8.

CARBON DAM SEAL

LO OSENING INLET fiTTING

Fi gure 6

Disconnect the injector inlet fitting (1),

Figure 7, using the one-hand and two-wrench
method, Figure 6. This method minimizes
damagc to the inlet fitting.

~ COMPRESSION
~ --seAl

Figure 7 Figure 8

Loosen ~nd remove the clamp assembly These two seal s mus t al ways be replaced
(2 and 3) and spacer (4). The locating plate whenever the inj e ctor is re moved and in-
(5) r e mains with the inj ector , Figure 7. s tall ed in the cylinder head. In stall pro-
tecti ve caps on the injector.
 Installing Injectors
Clean the inj ector bo r e i n t111' cyline!er he ad cla mp caps c r e\\' 20 ft. Ibs , [nsta ll tec and
a nd Ilia\\' ou t \\'ith co mprps~ ed ai l' .NO TI Use leak- off line s , Cr ank th e engine with the
bore c leaning too l C" H' ~: o, ,.14 3277 a nd st arter until the fue l fla Il'S fl' om U,e loose n-
g radu:1l 1y turn it by h and in t<) the bo r e . Al- ed inj ec to r inl e t fltting .
ways turn the tool i n a cloc kw is e d ir ectio n,
Turnin g in counte r - c loc kw ise wi ll du ll th e
tool. Cl ean ami ins pe c t the cyli nde r head, in-
jAc to r in let fi ttings and se a l sur faces. Dirt
o r bur rs on th e se Li ling SUrfi1Cl~ :j can caus e
in jec to r (1\s\o 1'\ion whe n c lamping inj ector
in place , resulting in a sti Cki ng val ve.

H." l rOOl

TIGHTENI NG INlET f i TTING

Figure 11

Then tighte n the inlet fittin g' us ing the one-

hand two-wrench squee ze method , figu re 11 .
Fi g ure 9 Start the e ngi ne and ch eck [o1' l"'''ks .

l1 e mol'e protec tive C eL l'S fr o m the inj ec -

tors . Ins ta ll a ne w compre s s ion s ea l (6) and
new ~~ !' bon s€~d (7) !ls i ""the carbo n seal tool ,
Case 1'0 . .'\42H9 , FIgures 9 10. "n"
In stall the in jf'cto r in to the c ylinrle l' head
bore uSing a t\\'is ti ng motion . Db :\ 01' lubri-
('ate. [n sta ll s pace r (4) the cl am p ass e mbly
(2) nnel (3) en gaging the locating plate (5). •
F!gu r e 10. Connec t and hane! lighte n inlet f:i~ ""
connection (1) t.o, the ,~ ~Ub~ Torq ue injector '...--(D ~ .~
/~" ':'Of~~.~ Ol., ,\\,
, ;1 ' J~._ ,,»:iJ2:.'S.., ----cD .~ ,
: : : -.,: . --.-- ?? '-" -~-------==---------- ,
,
~ 'I .-._- ->~. j#r--
?~~ . >t --:c - jii) ":.>::::.
~~. C£. ; __~d --. J
~, 0, ~ ~
I I

~~ ir~'~ '" Figure 10

 I nlector Test Stand
Fuel injectors must be checked on the
test stand whe n pe r forming the following
se rvi ce operations:

1. Whenel'er an inj ector has been r e mo ved

f rom the engine fo r cleaning, t he injector
must be checked on the tes t stand prior
to in stall ing it on the engine .

2. When a new injecto r assembly is to be in -

stalled , it mu st be checked on the test
stand prior to in stalling it on th e engine.

3. When a com plete engine ovel'haul is pe r-

formed , the injectors should be remo ved
and checked on the test stand .
Figure 12
4. Whe n an injecto r is suspected to be the
An " Approved" Injector Test Stand, Case c ause of unsatisfactory engine pel'fo rm -
Part No. 1\<120322 (Bachar ach No. 65-9340 ), mance , it shoul d he r emoved from the
is r equired fo r testi ng and arl justing the in- cylinder head and checked on the test
jectors and c all be pur ch as ed through the stand prior to dL as:oemhling it.
Se rvice Par ts Supp ly, J.l. CaseCo .,Racine,
,Visc o Exc ept for descripti ons r eferr inges- IItIPOIlTANT ALWAYS CHECK T HE PER -
pec ially to adjus tme nts on the test stand it- fORMANC E Of A~ Ii"JEC TOH ON THE
self , all of the following instructions will T EST ST AN D BE fOR E DISASSEMB LING
apply to a ll makes. Operating instructions IT . IF IT CH ECKS OUT S ATISfACTOH -
are also furnished with the test stand. ILY, TH En E IS NO :-IEE D TO DI ' ASSElI-l -
BL E on ADJe ST IT.
An injector tool kit, Case P art No. M2 0520
(Bacha r ach No. 60-00 10) , is required to ser- Preparing Test Stand
vice the i njecto .'s . A new compression ga uge
adapte r, Bac harach 1\0. "70-314(D-558) i s 1. After filling the test stand fuel r e servoir ,
also included in t.he tool kit . This kit is used loosen the bl eeder scr ew .
in con junction with the Case Diesel Tool Kits
Case Part No . M20247 (CD- 800) <Uld Case 2. When the fue l flowlng fr om the bleeder
Part No. M20246 (CD- 350) . screw ope ning is free of air bubb les ,
tighten the s crew .
The test stand is used to perform the fol-
low ing' checks : 3. Wash the COnIlector tube and adapte r in
clean diese l fu e l. Blow clean with filte r ed
1. Check and adj us t the injec tor opening compressed air and cO!lI1ect securely to
pressure . T his is aduplicate of the fac tory the test stand, Figure 12 .
procedure .
4. Operate the hand lever slowly unt il cl ean
2. Check the in jector asse mhly fo r f ue l fuel flows from the adapter,
leakage.
5. The te st st and is now ready for use.
3 . Check and acl just the i nje ctor leak- off. NOTt Complete m aintenance in structions
are furnis hed with the test stand . FOllow
4. Accurate ly (,heck the in jector sp r ay pat- the instr uct ions carefull y .
te rn.
 TESTING IN.JECTORS
Phor 10 l e stling an inj ector, r~m o ve the enclo sed in a rece ptacl e , pr e ferab ly t r a ns-
loose carhOn from the tip \\'i th the inj e ctor p a rent, to conta in the spray.
c l e aning b rush, Figure l3. C lean the carbon Checking Opening Pressure
seal groove a nd body be lo w the groove in
t he sam e manne r. CAtlTlOII Do not s c rape Cl os e the pre ssure gauge val ve and flush
or brus h the Te flon co a ting above the carbon the injec tor by o pera ting the te st pump r a -
seal g-roove. pidl y. Open the g auge a nd r aise the pre ssure
Slowly until the injecto r va l ve ope ns . (The
BRASS WIRE BRUSH
gaug~ reading will drop sh a rply at this poi nt).
Check o pening pre ssure against th ~ spec i-
SEAL GROOV fications.

NOTE When t e sting' m o re than one i n-

jecto r out of the e ngine , the re must not be
m o r e than 100 PSI d iffere nce b etween a ny of
the inj e ctors in that e ngin e .

If the injectors do not me e t the spe Cified

I
opening pre ssure :
/
I 1. Ne w injectors can be adjusted to the s peci-
fied o pening pressure . Se e P a ge 15.

Figure 13 2. Used injecto rs should be di sassembl ed

and clea ned. See P age 12.
Using the test pump adapte r P a rt No.
6.5- 8 78 , c onn e ct the injec to r with the tip 3. Va lve lift screw may beoutofad justment.
fac ing downward, Figllre 14. See Page 15.

TEST PUMP ADAPTER 4. Check for broken or weak ope n ing' pres -
s ure control spring, s ee spe cifi catio ns.
Checking Seat Leakage
Point the inj e ctor tip do wn and ope rate
the test pump r a pidly to firml y seat the
valve. Dry th e inj e ctor tip thoroughl y . Raise
the pressure at the injectOl' 20 0-3 00 P SI
under the specified ope ning pressure i\
drop should now form on the tip within 10
seconds. Slight dampne s s, howeve r, is per-
miss able with a used in jector.

If drops fo rm on t he injecto r tip, the

fo llowi ng should be done:
Figure 14
1. Di s ass e mble and cl ean i nj e ct o r, P age 12 .
Do not atte mpt to conne c t the inj e ctor
inlet fitting d i r e ct ly to a s tand a rd Erme to 2. Valve is not free in guide. L ap va lve to
or 60· s\\'age d type line a s damage to the guide. See Page 14.
tubing c a n r e s ul t.
3. Inspect for pitted or c racke d valvE' tip.
CAtlTlfJ1I THE DfJECTO fl TIP SHOULD eroded va lve seat or pit ted a nd dis tort ed
ALWAYS B E DIR ECTED AW i\Y FflONITH E body . These conditions r equi re replace·
OPEfl ,\TOfl. F ue l fro m the sp n y orifi ces m e nt of the compl e te in jector assembly .
can pe ne tr ate clothi ng and s kin c ausing
seriou s infec tion. The tip s hould al ways be
 33 -11

T ESTING INJECTORS (Cont)

Spray Pattern
Close the p r essure gauge . Ope r ate the 2. Dis a ssemble and c lean inj ector , See Page
teste r at 60 strokes pe r minute and obs erve 12.
the s pray pattern. Fue l should be fine ly
a tomi zed , Fi gure 15 and not a so lid ilTeg- 3. Lap the valve to guide a '·ea . Pag·e 14.
u ar spray patte rn , Fi gure 16 .
4. Check for pitted or '_roeled valve or seat,
valve interfer ence a ngle worn, bent ,'alve
and distorted body . Th ese conditions
would r equire r ep I ace ment of the complete
injector as s e mbly .

Injector Leakofl
Lo osen connector nuts and r epos itio n in-
jecto r tip s lightly above a hori zontal plane ,
Figure 17 . Tigh ten connector nuts nnd r aise
pres s ure t o 1500 PSI. Obs erve leakage from
the r eturn end of the injector. Afte r one drop
fall s , le akoff should be 3 to 10 d r ops in 30
s e conds with 1\'0 . 2 diesel fu e l at r oo m t em-
Figure 15 per ature (65' -7 5' F. )
Fi ne Alomi z .. d Sprll.\ Pattern

F igure 1 6
So li d Type Ir r egul ar Sp ray Pattern figure 17

The injector will ch atter when th e teste r If the leakoff does not m eet this spec ifi-
i s o perated r apidly. Although thi s chatter cation proceed as follows :
m ay not occur in oper ati on of the injec tor
in th e engine , it is an indic ation of val ve 1. If exce ssive le akoff is noted , injector
fr eedom and wi 11 i mprove atomi zation. mus t be rep Iaced .
Chatter is gen er all y an ind ication of good
s e at width and inter fe rence angl e cond itions . 2. If low le akoff is noted elis as s e mb le and
c lean injec tor. Se e Pages 12 thru 14.
If the in jector produce s a solid type irreg-
ular s pr ay patte rn proceed as fo ll ows : 3. Lap the val ve t.o gu ide area to inc r ease
th e nozzl e le ak off. See Page 14.
l. Check lor e r ooed , clogged o r chipped
or ific e s. See Page 13.
~3-12

SERVICING IN..JECTORS
2. Holding the inj ector in on hand , invert
Disassembly it and back out the pressure adjusti ng
screw allowin g the spring, sp r ing s eats
It is impor t ant to r emember that the in- and ball washer to fall into your hand ,
jector contaI ns c losely fitted parts which Fi gure 20. The valve may sl ide out ofthe
are precision grou nd and finished . Dirt is body at this time and should be handled
it s g r eatest enemy. Exe rci se ut most Gare careful ly by its stem .
in keeping the wo rk area and tool s clea.n. PH<suae
Hand le all par ts car efully to avoid d a mage . ADJUST ING
LI FT A D J USTING SC.EW SCREW
LOCAT I NG PLAH """' -.........,
I, PI£5IUIE

~ / II
' ADJUST I N G
'Q "~CIfW"

/
/ ~,
~

/
/
/
\!l
II
----.All
LOCKNUT

WASH ER Figure 20
. , UPPU 3. If the valve doe s not. slide f r ee ly fro m the
/
INHCTOI/
IODY I
~ " " HAT body, a val ve r etractor , No . 56 - 01 48, Fig-
ure 21 may b e used . To prevent bendi ng
SPIING
I the valve, bottom it in the body with the
/ l OWEI SlAT retractor. Pus h down on the retrac tor
/ body to m ount the collet. Turn the knurled
nut counter-clockwi seta secure the coll et
~ /
and withdraw the valve .
~ \ /

I CO MPRESSION/
HAl
VAL VE RETRAnoR

r. AUON HAL
f
{
I VAlV E

\
Figure 18

1 . Place t he i njector in the holding tool No .

66-0147 and secure the tool in a ' i8e.
Loosen t.he pressure adj u sting s cre w lock-
nut, F igu re 19 .
Figure 21
4. All parts s hould be placed in a solven t to
loosen carbon deposi ts .
Cleaning and Inspection
1. A brass wire brush should be use d to clea n
the tip and body exterior . To cl ean carbon
IN HC TO' from spray orifices. use clean ing wirE'S
HOLDING TOOL
.008", .009" and .010" di a . S€cure the wire
in the pin vise wi th the end protrudi ng 1 /3 2".
A longer lengt h of wire will bott om on the
opposite wall of the sa c 1101(' a nd le nds to
break easi ly . Figur(' 22.
Figure 19
 33- 13
SERVICING INJECTORS (coni)
jector to proper operating condition , use
t he methods o utlined below;
ORIFI CE 1. SEAT L EAKAGE : If l ack of freedom of
the valve movement has been ruled out as
the cause of seat leakage, the valve may
be cleaned up by lapping it to the tip seat .
Use lapping compound No. 66- 0145, for
this purpo~ e . The purpose of l appingis to
poli sh the seats of both val ve and tip to
obtai n a tight seal . Excessive lappingw:ill
destroy the int rference angle between
Figure 22 the seat and valve, causing alossofchat-
Use a stone to r move cutting burrs from ter with poor atom i.zation
the end of the wire. If a small flat is stoned
On on e siele of the wire it will facil itate
cutting carbon from the orifice. Insert the
clecu1i ng wi re and rotate it until it is free .
Flus h the body llnd inspect t he tip. (f any
ori fices are chipped at the edges or eroded
to an exten t that s pr ay patte rn is affected,
the injecto r shou ld be r eplaced .
2. The seat area i n the tip c an be cleaned
USi ng the tip seat s craper t ool No .66-0149,
Figure 23 . VALVE
3 . Insert sac hole drill No . 66-0151 into the
sac: hO le , rotate it to clean deposits from TIP
t he sac hole; repeat or i fice c l eaning.
SAL HOL E D RIll TIP H AT
Figure 24
Pl ace a sma ll amount ofl apping compound
No . 66 - 0 145 on the valve seat and insert
,'al ve into the body , Grip the topofthe valve
with th e retractor, No . 66-01 48 , F igure 25.
VALVE RETRAC TOR

/--------
lJ PSEA T
AHA
SAC HOLE

Figura 23
4 . Th e in jector valve may be cleaned with a
brush to remove deposits from the s eat Figure 5
,u'ea . Varnish should be remQved with a Hotate the val ve by hand, first c lockwise
solvent and fe lt cle aningpad . Do not chuck then counte r - clockwise for a to tsl of 3 - 5
the vaj l'e in a motor d ri ven lapping l athe r evolutions. tAlITlOIi Never attempt to use
fo r clean ing, as this technique will bend motor d r iven chucks of any kind for th is
the valve . Inspect the valve for pitting or purpose . Flush the body· thoroughly. Wash
erosio n which cou ld c a use leakage. the valve and reassemble injector .
5 . Inspect the adjusting s crews fo r th read The injector may be then retested. IT t he
damage and replace if neceasary . valve and seat is worn, the seat may be
tight, but chatter may be lo stin the l apping
Reconditioning Injectors process . In such a case, the injector must
U 5i Ol[JI e c leaning does not l'e store a in- be replac ed .
33 - 14

SERVICING IN.JEC TORS (cont)

2. VALVE GUIDE SERVICl:-\G: Low r e turn seat, s pri og, aod lowe r seat to the lift and
.l e ak-off is an indication o f varn is h accu- pressure adjus ting screw assembly . THt
m ul ation bet ween the guide and \'al ve . In - the injector body and with the lower s eat
suffici ent clearance ean c ause s ti cki ng and Lown Sf AT
lo ss of chatte r. If r etu rn leak -off is found
to be be low s pecifi ed quan tities , the va lve
guide c len r ance may be inc reased by lap-
ping.
VALVE GUIDE AtEA
\
\
VALVE I

Figure 28
in contact with the top of valve, Figu re 28,
pu sh the va lve a nd spring components ini o
Place a s ma ll a mount of lapping compound the body. Exe rcise care not to dislodge' the
So. 66 -014 5 on the guide are a of the valve, lower spring scat du r ing this assembly.
Figure 26. Botto m th e valve ill the body and Thread the pressure a d justing screw by
g ras p with th e r etractor a s previously des- ha nd un til the spring is compressed with
c ribcd. n ot ate the valve ten revolutions e nough forc(' to hold a ll parts in place
whi le rai s ing' and lowering it very slightly. (8-10 fu ll t urns).
Flus h and was h compowld fro m both com- 2. Install inj ec tor as sembly on t e st st and.
ponent s . i~ sse mbl e and r eche ck r e turn leak- Test and adjus t open ing pressur e , va lve
off. li le akoff is s till low, la p th e guide until lift and leak-o ff, r efer to P age 15 .
correct le ak age is obtained . Always flush 3. Tighten locknut 70 t o 75 inch Its . and in-
th e inj ector thor oughl y rLfte r lapping. s t all ne w seals . Figure 29 .
tAUT/Oil The r equired amourl t of m ate ri al LIFT ADJUSTI N G SCREW-
I
r e moved is us uall y onl y a few milli onth s of LOCATING PLATE PRES SURE
an inch . i\:e ver use moto riz ed chucks for this \~
/~" ~D J USI I NG SC I-!...W
ope r ation .
~ ",L OC~NUT - ,
Assembly
Wash and flush all parts tho roughly be for e
;' ~
I
assemb ly. Asse mb le with hand s and all parts
wet with c lea n fuel. / B All
1. Handl e the valve by its sh ank as s hown in ! WA5HfI
INL ET !
Figure 27. Shde it pa rtiall y into th e body. FITTI NG /
UPPEI
lns ta lJ the loc ating plate to the body be fo r e
asse mbl y of the pre ssure ad justing sc r e w /
and loc knut to the body. /
/
/
/
/ VA LV E
~ /
~\ /

Figure 2 7
I COMPtESSION/
SEA l

CARBON SEAL (,

2. ,>' sse m ble the ba ll WitS he r , uppe r s pri ng "Figure 29

 33-15

IN.JECTOR AD.JUSTMENTS
bottom the valve with excess ive force as
Adjusting Opening Pressure
bending of the valve c,m r es ult.
1. Hemm'e the inj ec tor from te st stand and
secure in holding tool in a vise, Fig'ure
30. Loos e n th e adju sti ng screw locknut
anr! r econnect the inj ector , with tip facing
downward.

INJECTOR
HOLDING TOOl

Figure 30
2. Carefu lly turn the lift adjusting screw in
until it bottoms, Hecol'd the fraction of a Figure 32
tUI'll required and compare to specifica- 3. Turn the lift ad justing screw coun ter-
tions. Back out the li ft adjusting screw clockwise 1/2 of a turn to obtain the speCi -
far enough to prevent bottoming when the fied lift. After setting the valve lift, hold
prestiure adjusting screw is turned. the pressure adjus ti ng screw and s ecure
the locknut.
PRESSURE 4. Recheck the opening press ure. Note that
ADJUSTING SCREW the lift is set before checki ng spray pat-
tern fmd chatter as the a mount of lift will
affect these characteristics .
Tightening Locknut
Remove the in jector from the tester and
place in holding' tool, No. 66 - 0147. Secure
the tool in a vise , Figure :33. Tighten the
pressure adjusting s crew locknut 70 to 75
inch Ibs. torque, us ing to rque wrench adap-
ter, No. 66-0146. The press ure adjusting
screw must be held while securingtbe lock-
nut. Recheck opening pressure on the test
F igure 31 stand.
3. Turn pressure adjusting screw clo ckwi se
to increase, or counter-clockwis e to de-
crease opening' pressure. Do not tighten
locknut at this time.
Setting Valve Lilt
l. While pumping fuel through injector, hold
the pressure adjusting sc r ew and slowly
turn lift adjusting s crew clockwise until
valve ceases to open, Figure 32.
2. Check for bottoming of the va lve by
r aisi ng the pressure 200 -500 PSI over INHCTOR
injector opening pressure . Al though so me HOLDING TOOL
fue l may collect on the t ip, a rapid dribble
should not be app,lrent. Do not manu ally
Figure 33
 ion
35
MODE L 267 SERIES CARBUR ETOR

188G AND 159G SPARK IGNITION ENGINES

SPECIFICATIONS
CAnB U I{ETOI(
T )' II<' ................. ............ ................................ ............................... ZenI t h t.;pdm fl. Si ngl e u' !1 (url
wI th maj!,netlc slil.l t-ort sol('nold
l\'Jag:n('llc fur l :;hOJI ·ofl sol(' no[d .............................. .. ...... _..... .. ..... " .... , .............. ......... ...... . U Vol!
Id!!? S~adJusrm e nf ............................... ... ..... ....... ...................... ... ..... ... _....... "e:l1 10 661} H P;q
Id le m ixture a Ojustm cnt .... ...... ................... .... ... .......................... Al'pro x im:u~ly I ItI r n OiK'fl
t..oau adjus tm eni .... ........................................ .... ............. .. ......... AllprQ xim<l lt>ly" tu r n.. o p~> rl"
Floot a("ljuslmcnl .... ................. .......... ............ .............. ....................... 1.1:'06". without j!;ask('t
Vcn l url tat naITO\\.' palnlj (IS8G J ............... ... .. ........... ..................... , ...... ,., ..... .. , ............ ,., .. .;Ij ~
Venlu rl ( (It narrow ;3Oinl ) n59G 1 ........ ' ........... .. ..... ....................... .... .. ... .... .. . ......... ............ .7r
;'vlai n Jet (18-1(» ....... ... .. .. ................ ......... ... .......... ........ ... ....... .
. .. .. . ................................ . .019"
"'l oll n JC1 (159(;) ... .. ...... .. .. ..... ........... ........ . , .... ................................. .......... ...... _ .. ... .......... .. . " ,.
;\'la in dischargc Jet ..... .............. ..................... .......... .. ... ....................... . ................ . · ..... .
Wel l vt'n1 Jl't (188G ) ••... _............................... ....... ... ... ... ...... .... .. .. .................... .. _.....•.. _.. ... .. .0"-
. 1I8~ "
W ('II venl Jl't ( 159(; ) ............... .. . ................... ..... ................... .... ........... , ...... ... .................. . •001 "
Idling j('l ( 188G) ..................... .... ........ ............. . .... .................................... ... ....... ......... .. . .(1"25"
Id ling jet ( 1!i9G) ....................... ..... .... ............ .... ................ .. .. ............... .... .. ............. .. .0'1CI"
Float " al vt' SE'a t {ISSG, ............... ...................... ....................... ... .............. ....... . ......... .
F1o." valve s('at ( ~;!lG) ..................................... ..... ........................ _.. ,....... _...... .. -. ..DiS"
............ """
Id le air btL'<'d {188G J .................... ....... ... ........ _............ ... . ,........................ .. . . ...... .. ...... .
{dIp a ll' b l~ ( l~ ) .. _.... . ......... .. ....... ......... .... ............................................. . ... . ... '

Choke u\"('r ~pr ing: Idle 3djus :ing nt¥'dlc 'prin.£:

:-;"umbpr or <:ol!s ....................... .... .... .. 18 Number of ('olls .......... .. ... . ......... Hl!
Wi re dianlNE'r ........ ..... .... ... .... ...... ... . .OJ)", Wln' d imn(! l('r . . .. ..... ·.. .O~ O"
F"rC(' length ... ... ......... ... ..... .. ,...... , .. .. 1.000" Free l en gl h ... . .................... ·... .16!)"
 INTRODUCTION
(Refer to Figure 1)
Tho? Zen it h I\'lodel 267 Seri es C'arburcto!', Figure 1, used on the Case 188G and J59" GasoHne
('; ng in es Is an updraft of single ,'cnt ur i design. The f uel bowl i s l oc ated near the centN line of
the carbur lor and tog ether w ith the twin floa t, makes it possib le to main tain proper metering
of air and fuel to the engine wi lho ut flood ing when operated at extreme ang les. The ca r buretor is
sea led and balanced i n tha t ali ai r fo r the fuel bowl m etering, well ven ting and for idling, must
come through the a i r clea ner ,

HOW IT WORKS
(Refer to Figure 2)
High Speed System
I'lle hlgh ' pcc'd ,y.'tf'm cx p.rlS 1ts i ntl uence Ihroug hout the governed range of rhe en gi ne .

Th" sy sr f>m consists of a ,'poturi ; c ontrolling the max imum vo lume of a i r admitted inlO l he
<'ngine : thc m,. i n j et , " 'h ich "" g ul"te, t hc fl ow of f uel from the fl oat cham ber to Ihe d ischarge
jet; I h(' """II ,' en!, whi ch m~ln[,lins a uni form mi xt ure ratio under changing c arburetor suc l ion
and engine speed s and a disChij"ge j et, which delivers the fue l into the air stream. The main jet
deteJ'mines I he rn aximum amOtlrrt of ruel w hich m ay be ob ta ined by reduc ing the amount wh en the
,ld j ust me nl needle is tur ned to\\'"rd i ts seat (c lock w ise) or by i nc rea si ng the amou nt of fuel whe n
the "djustm",nt necdle i s t urn (I away from its seal (counter·c loc kwise ) . The fl ow of fuel f ro m
t he mai n jet is c oot r ol lE'd by th" si ze of [he weil v en t a nd the size of t he diSC ha rge j et.
, 'OTE: Tilt· ma i n jet on thcs~ ca rburetor s are equipped with a magnetiC' solenoid that is
electricall y energized wile n Ihe ignition key switch is turned " on", ho ldi ng the main jet off of
its sea t at a dL ta nc ", predetCl'mined by the m ai n jet adjusT.ing screw . Wilen Ihe ignition ke "
~'.\' i tc h is turned "o ff" , t he m agne t releases the main j et a'l ld the spl'ing pressu r e holds the j et
n eed le finnly aga inst i ts sea t preven ting any fu el from entering Ihe venturi.
TIlE' purpose of tile m~gnet ic solenoid on th e m ain jet is to pl'Ov idc a t! l mmedia t an d positive
fuc- I shut -off ,,·ithin rhe carbu),pror, w he n the ig ni tion key sw itch i s turned off.

Idle System
T he idling system consists of the id ling j et , idling needle and passages . T he id llng j N r eceives
th .. fupl from Ihe main j et throug h passage (A) . Th e fuel i s metered through t he id ling jet an d is
mixed wilh air \\'h ich i s admitted f r om beh ind the venturi rhroug h passage ( 8) . The id l e adju sting
needle c o no-ol~ t he am oun ! o f f u .. ] a nd ai r whic h i s adm itted to I he system a nd (unctions only at
iriling and low engine speecls. A t these speed s the t hrott le pl ate i s almos t c losed and causes a v ery
stro ng suc lion past th e edge of 1h£' !hrortle plate. This suct ion draws the mixture of (ue l and air
from the id ling j et whi ch i s d i scha rg ed in to thl? air s tream through the pl-imary passage .

Choke System
The choke' SYS!f'ffi cUI"iSI' of a valve and plate m ounted on a shaft located in the air entrance
und operated llIl'ch Jnicall)' by " le ver mounted ex ternally on thE' shaft with a choke c able. The
chokr \'~ke is 01 n <'~Oll · aur O nlJli c t"pe, having OJ. poppet \o'Ol l v(>, wh ich is cont roll ed by a spr ing.
The> popppt "al ,-o ope>ns automalica lly when the engine sta r ts a. nd imm ediately aci miTs enough a i r
10 avoid ove r choking a nd fl ooding of t he engine.
 :35-3

PART NO . STAMPED HERE

Figure 1

THROTTLE PLAT E

FLOAT VALVE ASSEMBLY

CHOKE ASSEMBLY

MAGNETIC SHUT-OFF SOLENOID

LOAD ADJUSTMENTSCREW

Figure 2
35 4

CARBURETOR
(Refer to Figure 3)
Removal and Disassembly
NOTE : Make sure the area where the carburetor is to be disassembled , is clea n and well
lig hted .

1. Disconnect th(' air c leanE'r tu be a nd fu e l (14) and (13) fro m the throttle body .
from the carburetor.
14. Using a suitable size and length of rod
2. Disconnect the choke cabl e and the gov- inserted through the throttle shaft hole,
e rnor linkage (rom the carburetor. punch out the plug (19).

3. Remo ve the two carburetor ret ai ning bolts 15. If bushings (20) are to be re moved. use
and remove the c arburetor assembly from a suitable size tap and lap the bushi ng ro
the intake manitold. a pproxima tely four (hreads. Ins ta !! a bolt
or s tud and pull the bu sh ings (20) from the
'J. Remove and d iscard carburetor m o unting throttle body.
gaske t (1).
16. Remove the magnetic fuel shut-off sole-
5. Remove the fou r screws and lockwashers noid assembly (21) from the fue l bowl (3)
which retain the throttle body (2) to the Refer to Page 14 and 1.5 for servic ing.
fue l bowl 0 ) .
17. Remove the discharge j e t (22) and fiber
6. With the throttle body and fu e l bowl sepa - washer (23). Discard the fiber washer (22).
rated . remove the gasket (4) a nd discard.
18. Remove the m a in jet (24) a nd fi ber wash-
7. P ress a screw driver agains t fl oat axle er (25) . Disc a rd the fib er wa sher (25) .
('l) at slotted side of fl oat hinge bra c ket
and force through the hinge brac ket. Re- 19. R emove the weI! vent (26) a ncl drai n plug
move the floa t a xle (5) fr om opposite side (27 ).
and remo ve t he float (6).
20. If the drain disc (28) is to be replaced.
8. Remove t he float valve (39), soat (7 ) and punch a hole through il a nd r emove.
th e fiber sea t wash('r (8) . Discard the
washer (8). 21. Remove the choke plate (29). NOTE:
Scribe or mark the choke bracke t, lever
9. Remove the venturi (9) and idle jet (10) and t.he adjacent s haft boss 3S an aid to
from the throttle body (2) . proper reassembly.

10. Remove the idle adj usting needle (11), 22. Remove the choke level' spring (30). Re-
spring (12 ) a nd plugs (13 ) . move the ch oke shaft (31) w ith lev" ,.· assem-
bly (32 ) a nd swi vel snew, wa s her a nd nul.
NOTE : Scribe or m ark the throttle body (33).
(2) and levers to aCI as a g uide for proper
reassembly of the fo!!owing parts. 23. Remove the c hoke bracket (34) assembled
with clip, sc rew a nd nut ( 35 ).
n. Unscrew the throttle stop sc r ew (13 ) oul
until the th rea ded e nd is fl ush with the 24. R e move the packing r('tain er (36) and
lever (H) . pac king (37) .

12. Remove Ihe two thrOl\le plate screws 25. Using a suita ble size and leng th of r od
a nd the thro ttl e pla te (15 ). punc h out plug (38) .

13. RemoVE' the throttle shaft aS 5('mbly (16).

 35-5

Figure 3
35-6

CARBURETOR (Cont'd)
(Refer to Figure 4)
Inspection
With the carburetor com pletely disasse mbled, inspec t a ll metal compone nts for wear, cracks,
score ma rks and burrs_ Clean all metal components with a carb uretor cleaning solution and rinse
in a recomme nder] salven!. CAUTION: Never use a drill to c lea n out jets.
1. F UE L BOWL (3 ) - Blowout all passages must be smooth and free o f ridges. Check
in the fuel bowl. Reverse the flow of com- the spring for a ny cracked or bro ken coils
pressed air in all passages to insure all a nd for specific a tions listed below. Re-
dirt h3 s been removed. Check drain disc place if necessary.
(28)_ If dam aged or if it remains clogged 6. THROTTLE PLATE (15 ) - Inspect the plate
after bowl c lea ning, replace. for burrs, damaged e dges a nd flatness.
2. THROTTLE BODY (2) - Blow ou t all pas- Never clea n the plale with a buffing wheel
sages in the throttle body with compressed or sharp ins trume nt.
a ir_ Reverse the flow of com pressed air 7. THROTTLE SHAFT (l6) - Repiace the
in all passages to insure that all di r t has throttle shaft if there is evidence of wear
been r em oved . Check the bushings (20) for on bearing surfaces . Check the s ha ft for
any wear. Replace if wear is detected. straightness .
3.FLOAT ASSEMBLY (5) (0) - Check float 8. CHOKE PLATE ASSE MBLY (29) - Insp ec t
(6) for leakage ca used by pin holes or the plate for burrs or da m aged edges .
other damage. Chec k the top side of the Make sure tha t the plate is nat. Insu re
floa t leve r where it conta c ts the fuel that poppe t va lve works freely and does not
needle valve for wear. Replace fl oat If stick.
any of these conditions exist. Check the 9. CHOKE SHAFT (31) - Check the sha ft
float shaft (5 ) bearing surface for wear. bearing surfaces for wea r and that the
Replace if necessa ry. shaft is straight.
4.FUEL VALVE SEAT AND VALVE (7)(.39)- 10. SOLENOID ASSEMBLY (21) - For chec k·
Chec k the seat a nd needle for wear. If re- ing and servicing of the sole noid , refer to
placement is necessary for either part, Pages 14 and 15. NOTE: Replace the fiber
replace both at the sa m e time. washers (8), (25), (23), (41) packing (37), sea l
5. IDLE ADJUSTING NEE DLE (11) AND (18) , plugs (19), (38) a nd ga skets (1) a nd (4).
SPRING (12) - Inspect the needle point. It

Refer to the specifications listed below to verify correctness of the following parts.
DESCRIPTION AND STAMPED INSIDE NE AREST
REFERENCE NUMBE R NUMBER DIAMETER DR ILL SIZE
Venturi (9) (at narrow point ) (159G) ....... #19 ....................... 74 Inch
Venturi (9) (at narrow poin t) (18SG) ..... #18 .. ................ ...... 78 Inch
Main jet (24) (188G) ...... ............... .......... ~24 .. .. ................... 049 Inch .............................. 3/ 64
;".!ain j et (24) (159G) ............ ........ ...... ..... ~28 ............ .... ....... 037 Inc h ................................ #63
Main discharge jet (22) ................... .. ..... #60 ........... .... ........ 118 Inch ........ .............. ..... ..... ii32
Well vent jet (26) (188G) ........................ #20 .......... .. ........... 0:39 Inc h .......... ... .... ...... ... ...... #62
Well vent je t (26) (159G) ..... ....... ...... ...... #26 ............ ........ .. .051 Inch .......... .... .......... _....... #55
Idling jet (10) (188G) ........ ...... ..... .......... #13 ....................... 025 Inch ........... ... . _................ #72
Idling jet (10) (159G) .......... .... .. ............. #10 .. .. .... ............... 020 Inch .......... ........ .. .. _.. ....... #76
Float valve seat (7) (l88G) .. , .. ........ ....... #35 ....................... 069 Inch .... .............. ..... .. ...... _ #50
Float valve seat (7) (159G) ......... .... ... .... #40 .......... .. .. .. ....... 078 Inc h ............................ _... #47
Idle a ir bleed (I88G) .......... .... .......... ...... #28 .............. ...... ... 055 Inc h .... _........................... #55
Idle air bleed (l59G ) ........ ................. ..... #30 ....................... 059 Inch .................. .... ........ .. ii54

Choke lever spri ng (30) ........ .. Specifications Idle adj. need le spring (12) .... Specifica tions
:\umber of coil s ................. ....... ............ 18 Number of co ils ............ .......... ............ . 4·112
Wire diam('ter .................................... 031" Wire diameter .............. _.. _.. .................. . 040"
Free le ngth ........... .... .. .. _, .............. ... 1.000" Free iength .......................................... .469"
 :1';·7

Figure 4
35·8

CARBURETOR (Cont'd)
(Refer to Figure 5)
Assembly and Installation
1.1nstall a new plug (38 ) a nd a new choke 10. Press in a new stop pin (40) if rep la ce·
shaft packing (37) into the fue l bowl (3) m e nt wa s required, Figure 5, Inset A.
a nd the packing retain e r (36).
11. install idling jet (10) and float va ive seat
2. Referring to scribe m arks tor correct (7) with a new fiber washer (8) int o th e
posi ti on. install cho ke bracket (34) assem· throttie body (2) .
bled with clip. screw a nd nu t (35) to the
fuel bowl and r e ta in with mounting screws. 12. Inst a ll a ne w throttle shaft sea l (18) with
the sea l lip to the outside a nd washe r (17).
3. Insert the choke pla te assembly (29) with
the poppet valve fi rs t a nd the stem down 13. Referring to scribe marks for correct
into the air int ake. Holding the choke plate positioning, install throttle shaft (16) as·
up, insert the c hoke s haft (31 ) assembled sembled with lever (14). Back out the stop
with the lever (32 ), swivel screw, nut and screw (13) far enough to pe rmit com plete
washer (33 ) into place with the shaft cut· c losing of the throttle plate.
ou t section fac ing up. Rot ati ng the shaft to
the closed posit ion , place the choke plate 14. Rotate the throttle shaft to the open posi·
(29) in the c ut·out a nd inst a ll screws to tion a nd insert the throttle pla te (15 ) in the
retain. NOTE : Be s ure the choke plate c ut·out section of the shaft.
is properly centered before tigh tening the
scre\Vs. IMPORTANT: The throttle plate (15) is
made with two opposite edges beveled to
4. Install the c hoke lever spring (30) to r eo fit the throttle body bore whe n the plate
turn the c hoke to the wide open position. is in the closed position. Whe n properly
Installed, the side of the throttle plate (15)
5. Install plug (27) a nd drain disc (28) if reo farthest away from the m ountin g flange wiiI
place m ent was required. be aligned with the idle port a nd beveled
edge is facing the moun ting fl a nge when the
6. In sta ll the m ai n je t (24) with a ne w fiber plate is closed, Inse t B.
washer (25 ). Ins tall the well vent je t (26 )
a nd the je t (22) with a new fiber washer (23). 15. Install the throttle plate sc rews, being sure
that the throttle plate is properly centered
7. Install the venturi (9) In the fuel bowl (3) in the throttie bore. A s light pressure on the
wi th the small opening down. ]'I;OTE : The plate must be maintained with fingers until
notched side of the venturi (9) must be the screws are tightened.
pla ced toward the well vent jet (26).
16. Install the idle adjusting nee die (11) with
8. fn sta ll new throttle shaft bushIngs (20), if spring (12) into the throttle body (2). Seat
r eplacem e nt was required. lightly and bac k·out one full turn as a pre·
liminary adjustme nt.
9. Inst a ll th e e nd plug (19) and plugs (1 3).
 35-9

INSET B

INSET A
_.26"

Figure 5
35-10

CARBURETOR (Cont'd)
(Refer to Figure 6)
Assembly and Installation (Continued)
17. Invert the throttle body (2) and install the tlon and turn the throttle s top sc rew (l:J)
fuel valve ( 39) into the seat ( 7). In until it just contacts the stop pin (40),
then turn the stop screw (13 ) in an addi-
18. Install the fuel float (6) wIth the axle (5) tional 1-112 turns as a preliminary ad just-
to the body. Viewed from the free end of ment.
float, the flo a t (6) must be centered and
at right angles to the machined surface. 21. Install the shut-off solenoid (21) with a
The float setting Is m easured from the new fiber washer (41) to the carburetor.
machined surface (w /o gasket ) of the body Turn the adjusting screw all the way in,
to the top of the float at the highest point, then turn out one full turn for a prelimin-
Inset A . To increase or decrease the ary ad justme nt.
distance, use long nosed plie r s and bend
the lever close to the float body, Figure 22. With a new mounting gasket (I), insta ll
6, Inset A. Replace the float if position the carburetor to the intake manifold with
is off m ore than 1/16". two bolts and lockwas hers. Torque the bolts
35 to 42 ft. lbs. Connect the solenoid wire.
19. Place a new fuel bowl gasket (4) on the
machined surface of the fu el bowl (3). 23. Connect the governor linkage to the car -
Assemble the throttle body (2 ) to the fuel buretor a nd the choke cable to the choke
bowl (3) and retain with screws and lock- le vel' of the ca rbureto r. Connec t the fuel
washers. Tighten th e screws evenly and line and air cleaner tube to the ca rbu retor .
firmly. Ma ke s ure the connections are tight.

20. Hold the throttle lever in a closed posi-

 35-11

INSET A

S E PO INTS
BEND AT THEG ADJUSTMENTS
WH EN MAKIN

Figure 6
 35-12

IDLING SPEED AND MIXTURE ADJUSTMENTS

(Refer to Figure 7)
NOTE: Adjustments for idling speed and idling mixture can bes t be made toge ther whe n the
engine is running and a t the proper e ngine operating temperature.

Idle Speed Adjustment

Idling Speed Adjustment is m ade at the idle speed screw which determines how fa r the car-
bure tor throttle valve will close wh en the engine is idling. The idling speed adjustment should
be set so the engine operates at a s peed of 600 to 650 RPM.

Idle Mixture Adjustment

Jdling Speed :Vlixture Adjustment is dete rmined by turning the idle mixture adjustme nt sc rew
out until the engine operates roughly , then turn the screw in until the engine idles smoothly.
The correc t adjustm ent is ap proxima te ly I turn ope n.

Load Adjustment
To obtain a starting point , ope rate the engine a t no load governed engine speed of 2060 RPM (159G )
and 2250 RPM (188G). Be sure the engine is up to the correct engine operating temperature . Turn
the load adjustment screw in (clockwise) until th e e ngine misfires and power falls off; then turn it
out (counter-clockwise ) until thc engine runs smoothly. Turning the adjustment out produces a
richer mixture , while turnIng it in produces a leaner mixture. The correct setting is approximately
2 turns open .

After the preliminary load a dj ustment has been made however, it may b e necessary to Slightly
readjus t the carbu retor load sett ing when the engine is under load.

Run the engine under load a nd ca refully observe how it reacts. If the re is ba c kfiring through
the carbure tor, loss of power, or if the engine tends to stall when the load is applied, it indicates
the setting is too lean. Turn the load ad jus tment screw out (counter-clockw ise) not more than
118 of a turn and again try the e ngine under load. Continue to do this until the e ngine pulls
smoot hly when the load is applied.

ThIPORTANT : Avoid the use of lean mixtures . Opera ting the engine with too lean a carburetor
load mixture ca uses loss of power and hIgh valve tempera tures.

Al though it is not necessary or advisable to constantly read just the carburetor set tings, they
can be reset when the load condit ions or the fuel quality is ch a nged radica lly. Operating a n en-
gine unde r light loads with an overly rich carbu retor setting not only wastes fuel, but may cause
undue wear and damage from engine oil dilution. Opera ting under heavy loads wit h too lean a
carbure tor setting will cause ge neral engine overheating, loss of power and will burn the valves.
 35·13

..JW~_-tDLE SPEED ADJUSTMEN T

IDLE MIXTURE ADJUSTMENT

LOAD ADJUSTMENT~

Figure 7
35 -14

MAGNETIC FUEL SHUT-OFF SOLENOID

(Refer to Figure 8)

Checking Operation
To check th e operat ion of the solenoid for main jet in the shut-otf assemb ly must be
the Main J et Asse mbly: drawn and held against the m ai n jet ad-
justing screw with a decided "snap" or
l. D isconnect th E' soleno id lead wire from the ('click",
wire on the i gni t ion switch side of ballast
r es istor. 5. When ignition k ey i s turned to "OFF" the
main j et in the shut-all assembly must be
2. Remove t he assembly from thc· carb uretor. released and forced by spring pr essure a -
gai nst its seat in th e assembly with a decided
3. Connect the lead wire to the i gni t ion switch "snap" or Hclick". If action is sluggish in
and ground the solenoid assemb ly . Nos. 4 and 5 - remov e a nd c lean parts as
described below and r e-check - if still
4. Wh en the ig nition key is tu r ned "ON " the sluggish, replace comple te assembly.

Disassembly and Cleaning

l. Remove the main jet adjusting screw (1) , assembly by carefully submerging the body
spring (3) a nd main j et (4 ) f rom the sole- partially «(10 not let wire or plastic insu-
noid body (5) . Remove "0" ri ng (2) from l ation contact solvent) into a so lvent such as
adjusting screw. B endix Speed Clene - The body need only be
su bmerged enough to fl ush out the inner bor e
2. Clean the main j et adjusting screw a nd jet and seats.
by submerging in a solvent such as Bendix
Speed Clene. After clea ning parts - blow dry with com-
pressed air.
CAUTION : Clean the solenoid body of the

Inspection and Assembly

1. Inspect seat on both ends of jl?t - if nicked 3. R eplace "0" rin g (2) on adjusting screw (1)
or scored - replace jet. Install jet (4 ) in and install screw in solenoid body.
solenoid body (5).
4. Install main j et assembly in carburetor and
2. Install spring (3) in solenoid booy (5) . re-adjust as described on Page 12.
 35-15

SOLENOID SEAT

LOA O ADJUSTING SCREW ~

~o

Figure 8
 Section

42
HYDRAULIC SYSTEM AND POWER STEERING

OIL FILTERS

Rae . Form 9 -80691

42-2

HYDRAULIC SYSTEM FILTER - POWER SHUTTLE

E le ment Change Inte r va l .... . _................ .... .... _..... .. __ .. ................ _.. ........ After the first 20 hours of
operation and every 240 hours the reafter.
Type ............................................................................................................. 10 Micron Filtration

Regular int erva l replacement of the e le ment hyd r au lic system. The filter is eas ily acces -
is ve ry important to the service life of the sIble and is located forward of the radiator.

,'
,c ",
c

CD '0
CD ,~

Figure 1 Figure 2 Figure 3

1. Rl'move the radia tor g rille. Thor oughly Wire Diameter ........ .... ..... .. ....... .. ...... .092"
clean the filt er hou sing beCOTe attempting I. D. Diameter .................................... 813 "
to change the filter e lement. Free LengUl .................... , ........ ... ... ... 2.00"
2. Remove the draIn p lug (5) wit h "0" ri ng (6). Compressed to 1.125" .. _..... _.. _... 27·33 Ibs .
Disca rd the "0 " ring (6) .
3. Remove the fo ur hex. bolts (1 ) from the fil ter 7. Install the s pring (10), relainer (9 ) and hex .
CdP (2). bol t (8 ) to the filter cap 12).
4. Rem ove the filter cap (2 ), "0" r ing (3 ) and 8. Install the drain p lug (5) with a n w "0"
the filter el"ment (4). Discard the " 0 " r ing ri ng (6). Instal! new element (4 ), new "0"
(3 ) . r ing (2) a nd filter cap (21.
3. Cl ean out the filte r body (7) with a clea n lint 9_P ress the ca p dow n into p lace by hand and
free c loth . secure with the four hex . bolls \ 1).
6. Remove the hex. bolt (8). retainer (9) and lO.Start a nd rUn the engine at idle speed for
spring (10) _Check the spring for damage a nd approx!mate ly 5 minutes and check the fllter
proper tension. assem bly for oil leakage. Check the trans -
rrUss ion oil level immedia tel y after sh utting
Spring Specifications: the e ngi ne down .
Total Coil s ...... ...... . . ......... .. .... ...... . 6·112
 42·3

HYDRAULIC SYSTEM FILTER - HYDROSTATIC

Element Change Interval ",,,,,,,,,,,,,,,.,,,,,,,,,,,,, .. . ,,,, .. ,,,, .. ,,,,,,,,, .. , ... ,,, ..... After the first 20 hours of
operation a nd every 240 hours thereafter
Type " .. ,'" .. "" .... ,"", .... ", .......... ", .. "" ..................... , .... " ... " ...... " .. , .. , .. " .... , .... 10 :"licron Fi lt ra lion

Regular interval replacement of the e lement raulic system, The fi lter is easily acce ssib le
is very important to the service life of the hyd· and is located forward or the radiator.

, CD
0-..... j :-0
Q --<D
O -<D
G --<D
O -(f)
I

l
0--0
10

@ -o
~
Figure 4 F igure 5 Figure 6
1, Rem ove the radia tor g ri lle , Thoroughly 7, Install the drai n p lug Ill ) with a new "0"
clea n the fil te r housing before attem pti ng rI ng (12), Install new lower " 0" ring (9),
to c hange t he filter eleme nt. elem e nt (8), ne ',v gdsket (7), retaille r (6 1 and
2, Loosen the loc k nut ( 1 ) a nd back out the s lot· up pe r "0 " ri ng (51 .
ted hf'ad s c rew (2 ) four or fiv e t urns , 8, Install the HI le r cap (4 ) witt1 the fou r he x.
:1. Remove the four hex . bolts (3 ) from t he filter bol ts (3) ,
c a p (4 ). 9, TIghten t he slotted head screw (2 ; s nugly ,
4. Remove the f!itercap (4), upper "0 " ring (5), Tighten the lock nul (1). locking the screw
retainer (6 ), gasket (7) , filter element (8) a nd (2) in pl ace,
lower "0 " ring (9) . Disca rd the "0" rings 10, Start and run the engine at idle speed for
( 5 & 9) and gasket ( 7). a p proximate ly 5 minutes and c heck tile filter
'), Remove the d rai n plug (11) w ith "0" ring aSsembly for oil leakage, Check Ihe trans·
(12) . Discat'd the " 0" r ing (12) , mi ssion oil level immediately afte r shutting
,i. Clean o ut the fil ter body (10) with a clean the engine down.
lint free c loth ,
42-4

POWER STEERING FILTER

Elemen t Change Interval ............... .. ........ .. .......... .. ...................................... .... .... .. ...... 1000 Hours
Capac ity (Rese rvoir On ly) .. .. ..... .... .......................... ....... _.. ... .. ........................ .......... 1 U. S. Quart
Type Flu id ..................... .. .......... .. .. ........... _...... .. ...... ......... .. .... ..... ............. .................... Case TCH
Type Filter .......... .. .... .. ................................................................. ......... ... ... .. 25 Micron F iltration

Regular inte rval replacement of the e le- pump reservoir shell. The reservoir shell
men t is very importa nt to the service liie of is located on the R.H. side of the engine .iust
the steering system . The re placeable fllter be low the a lternator.
clement is located inside the powE'r steering MP BODY

~-- . . . .
(0 2009 iI:5erh-'~'iS'
INSET A

_4_15 / 16 ,,_1
Fi gure 7
1. Clean the rese rvoir shell and the imm ediate 5.1nstall new e lemen t (8), reta ine r (7) , spring
area before atte mp ting to service the ele- (6) and jam nut (5) . Tighten the ja m nu t until
m e nt. a m easurem ent of 4-15/1 6 inch is obtai ned
1l\IPORTANT: Before removing the re- m easuring from the outside of the jam nut
servoir shell. mark both the she ll and pump to the she ll fla nge on the pum p. Refer to
body to insure proper relocat ion whe n as- Inset A.
s",mb ling. This will insure a good seal and 6. Install a new "0 " ring ( i ) , reservoir she ll
correc t oil level r eading on dips tick. (3), copper sealing washer 12) a nd acorn nut
2. Remove the acorn nut (I) and copper seal ing (1 ) . Torque the acorn nut 20-25 ft. lbs.
wa sher (2) . Dra in the reservoir shell (3 )_
3. Remove the reservoir shell (3), "0" ri ng
(4), jam nut (5), spring (6), r e tainer (7 ) and BLEEDING PROC EDURE
e lement (8) .
1. Remove the rese rvoir cap and di ps tick. Fill
NOTE : On gasolinp tractors it require s re- the r eservoir with Case TeB and start the
moval of the distributor. engine.
2. Operate the e ngine at aprox lm ately 600 RPM
4. Check the re taining spring for damage and a nd turn the steering whee l throug h several
proper te nsion. t urns . NOTE : The fir st few tim es y ou turn
the steering wheel, DO NOT m a ke ful! turns.
Spring Spec ifi ca tio ns: 3. Shut the e ngine oft and refi ll the reser voir
Ac tiveCoils ............... .. ..... . ..... .. .............. 8 to the "1-'" ma r k On the dipsti c k.
Wire Diameter .............. _.. .. ..... ........ .. . 041" 4. Repeat the above procedure un til the fluid
Free Length .................................... 2.383" leve l ceases to drop after turning the steer-
Compressed to 1.375" .. .... .. .. .... .. 2.2-2.8 Ibs. ing wheel.
 ECTION
42
HYDRAULIC DIAGRAMS
TROU L SHOOTING
T ING AND S IC

Burl. Fonn 9·720815 KHCBO P,inl.d in U . S .A.

 TABLE OF CONTENTS

HYDRAULIC D1AGRANIS . . 3

Loader With 4 - In-l Bucket 3

Standard Backhoe . . . . 4

Backhoe With Extendable Dipper. 5

HYDRAULIC SPECIFICA TIONS. 6

HYDRAULIC SYSTENI SERVICE. 6

HYDRA-LEV ELING CIRCUT . . 9

HYDRAULIC SYSTEM TROUBLE SHOOTING 10

Poor Or No Operation Of One C ircuit 10

Poor Or No Operation Of All Circuits 11

Sluggish Backhoe Circuits, Loader OK . 11

Equipment Hydraulics-Engine Sta ll Test 11

NOTW: For Hydra-Guide Trouble Shooting, see Section 47.

TROllBLE SHOOTING CHART . . . . . . . . . . . . . . . 13

TESTING THE HYDRAULIC SYSTEM WITH A FLOWMETER. 19

Flowmeter Check Sheet . . . . . . . . . . . . . . . . 25

TESTING AND ADJUSTING HELIE!" VALVE PRESSURE SETTL'lGS 26

Specifications. . . 26

Main Relief Valves 27

Low Pressure Secondary Relief Valves. 28

Tilt Spool Relief Valves . 29

Boom Lockout Relief Valve 30

Testing Secondary Helief Valves With a Hand Pump 31

Adjusting Relief Valves . . . . . . . . . . . . . 34

2
 L.H. CLAM R.H. CLAM
CYLINDER CYLI N DER

DUMP
OIL FROM PUMP TO
LOADER CONTROL VA LV E

SUCTION AND RET URN OIL

- OIL FROM "A" PORTS TO

CYLINDER
L.H. TILT
CYLINDER
R.H. TILT
CYLINDER

- OIL FROM" B" PORTS TO

CYLINDERS

NO....HYDRAULICS FOR STANDARD

NOT~ PUMP I NLET
MID OUT LET POR TS
REVERSED ON HYDRA-
STATIC MODELS
LOADER ARE THE SAME EXCEPT CLAM
HYDRAULICS ARE REMOVED.

L.H. LIFT
CYLINDER

HYDRA-LEVELING
CYLINDER
701308

Figure 1 - Loader With 4-ln-l Bucket

3
'FU!1 ~ .o UTP\JT
2'3 GP.'1. AT 1900 R'PX :'.r l OOO PS I
H,;,HJ REL IEF I,ft.LV E SETiu,C
flOMER VA L.V£ )
2200 + 75 PS I AT f Ull THROTTL E
SECONDA~ "'-'R El lE F '/AlVr:: 5ETT 1NGS
SEE FI GuRE 13 .
1. SWJI,C CUSHIOu REL.IEF VALVE'
39 0 0 + 20Q P~I ':'.T 5 GPIt
2 . R£STRI CTOR / CHECK V~ l VE PUMP SUPPLY AND RE TU RN OIL
}. P.(GE .... ER.:..TIO·, CHECK V':" L.VE
HGEI/ER,.. rI O ~l sP Ol OIL FROM lO'.lER ( " 8") PORT S
{I . D IP PER
5. P ER BE "'01,0 flTTI 'lG CY L iW ER OF CONTRO L VA LVE S
Oil f ROM UPPER (HA il ) PORTS
BUCKET OF CO':TROL VALVES
CY LI NDER
BOOM CYlI NDERS

SI,.,IIN{;
CYL INDER S

THES E LI lIE S A~ R~E~R~E~V~ER~S~E~o~§~~i1

AT VALV E SECT I Or: 0" UNITS
~lTH OUAL CONTRO L LEUER S

P"""'-tC

STABILIZ ER CYLI NO ER STABILIZER CY Li llOER

71 (,997

TO RE SERVOIR

Figure 2 - Hydra ulic Diagram of Standard B ackhoe

4
- PUMP SUPPLY ANO RETUR N 0 I L PUMP OUTPUT
_ 0 1L FR OM UPPER (A) PORT S OF CON TROL VALVES 23 GPM @ 1900 RPM 2000 PS I
- 0 1L FRCM LG;J ER (B) PORTS OF CONTROL VALVES NAill RELIEF VA LVE SETT WG ( LOAOER V;:'.LIJE)
2200 j: 75 PS I @ FULL THRO TTLE
SECONDARY RELI EF VALVE SElf l NG S
SEE FIGURE 13.
I. S\.J!fJG CUSHION RELI EF VALVE
3900 .:t 200 PS I @ 5 GP~,
2. RESTRICTOR/CHECK VALVE
3. REGE NERA TI ON CHECK VALVE
BUCKET
4 . REGENE RA TIOIl SPOOL
CYLI~WER
5. PO\.JER BEYOt:D f I TT I r~G

8001'\ CYLI ;WERS

DIPPER
EXTEj~SIOij CYLI NOER
CYLINDER

NOT£ CON~IECT lOllS AT S'.II i,G

SECTION ARE REVERSED IF
EQU I PPED ',J! TH DUA L
CONTROL LEVERS,

BACKHO E

STABILIZER STAB IL IZ ER
CYLiNOER CYLJ rmER

STAB I LI ZER
CO NTROL VA LVE

TO RE SER VOIR
..I
FRO,'1 PUM P 710991

Figure 3 - Hydraulic Diagram of Backhoe Wit h Extendable Dipper

5
 HYDRAULIC SPECIFICATIONS

Descripti on of pump, valves, etc . . . . . . . . . . Refer to sect ions 43 through 49.

~l ain relief valve setting (loader / backhoe) 22 00± 75 psi at full thr ottle
(155 ± 5,2 kg/ cm')
Main relief valve setting (hitc h) 1800 ± 75 psi a t full throttle
(127 ± 5,2 kg/ cm2 )
Secondary reli ef valve settings . . . . . . . . . . . . See page 26.
Hydraulic oil requirements
nesel'voir oil refill, lo ade r-backhoe ... 11 C.S. ga llons (42 li ters)
Heservoir oil refill, 3-point hitch only . 5-1 / 2 C. S. gallons (21 liters)
Total oil in system, lo ader backhoe .. 24 C.S. gallons (91 liters)
Total oil in s ys tem, loader only or lo ader- hitch 16 U. S. gallon s (60 liter s )
Total oil in sys te m, 3-point hitch only. .7 C. S. ga ll ons (26 lite r s )
Recommended oil . . . . . . Ca se T CH Fluid
Alternate oil. . . . . . . . . . . . . . . . . . . . Engine oil m eeting API des ignation
of SD or CA (MS or DG). If coldes t
expec ted temperatu re is above
32° F., use SAE lOW oil ; below
32° F., use SAE 5\V oil.
Oil change period . . . . . . . . . . . . . . . . . . . . Every 500 hours.
Oil filt er change period . . . . . . Every oil c hange or when filter
condition gauge pointer is in r ed zone.

U.S. AND METRIC TORQUE SPECIFICATIONS

Hydrauli c Fill ings (Sleel)

37 ' Fl are Straight Thread

F em:1l (:: S\vivel U -Hlll g
Da sh Tube Thread T Ol'que To rque
Size 0.0. Size ft. I bs . m - kg ft.l b5 . m-kg
4 1 / 4" 7/ 16" - 20 6-I Z 0,8-1,7 12 -1 9 1. 7-2 ,6
:; 5/ 16" I / Z" - 20 8 -1 6 1,1-2 .2 16 - 25 2 . 2-3 ,3
6 3/8" 9 / 16" - 18 10- 25 1,4-3.5 23-40 3. 5- 5 . 5
8 1 /2 " 3 / 4" - 16 1 3- 42 2. 1-5 .8 42-67 5,8- 9.2
10 5/8" 7 / S" - 14 2 5 - 58 3 ,5-8,0 58- 92 8.0-1 2,i
IZ 3/4" 1-1 / 16" - 1 2 -l 0- 80 5.5-11.0 80-1 28 I! -I S
14 7/S " 1- 3/ 16" - 12 60 -1 00 8 . 3-14 , 0 100 - 160 14- 22
16 I" 1-:5/ 16" - 12 75-1 17 1 0-1 6 117 - 18 7 15-26
20 1-1 / 4" 1-5/0 " - 12 125-1 65 1 7- 23 165- 26 4 23 - 36
24 1-1 / 2" 1-7 /8"-1 2 2 10 - 250 29 - 35 250-400 35 - 55
7011].!.

HYDRAULIC SYSTEM SERVICE

Reservoirs transport position and the loader bucket

rolled back at ground l evel.
T he loader subfr ames also serve as
hydraulic reservoirs. Each subframe has a NOTE: The hydrauli c oil should be at or
r efill capacity of 5-1 / 2 U.S. gallons. near operating temperatur e when check-
ing the oil level.

Check ing Reservoir Oil Level 3. Remove the oil level plug. The oil s hould
be level with the plug opening . If additional
1. Have the trac tor standing on a l evel spot. oil is required, r emove br eat her and re-
duc er from re s ervoir and add oil through
this opening until the proper oil level is
2. Have the backhoe (if so equipped) in the obtained.

6
 Filling Rese rvoirs

1. Remove the r e servoir br eather and vent

plug from the right or left hand reservoir.
Figure 4.

2. Fill the reservoirs tlu'ough the breather

opening until oil appears at the vent
plug hole; then reinstall vent plug.

3. Remove the oil level plug and continu e

filling until oil is level with the plug
opening.

NOTE: Each reservoir has a capacity

of 5-1/2 U.S. gallons.

4. Re install breather assembly and oil level

Figure 4 plug~
Reservoir Oil Level and Vent Plugs
5. Start engine and operate the loader and
Draining Reservoirs backhoe through several complete cycles
to bleed air from the hydraulio system.
NOTE: The hydrauliO oil should be at or
near operating temper ature before draining. 6. Check oil level and add as required.

1. Have the tractor standing on a level Hydraulic System Filter

surface.

." ' -~
- HOUSING
-: ~ :--~.'~. RESERVOIR

.. ~, /
0 - O- ~ I ,'JG
P I[
~
'9
10 FillER

/1 . ~
.- I ' . '
If
/' / .' _ E LEMEN T

J)' ./

.:-

·l _ _ O-:\ING

.,
/:/'

'l -/"
.-
,:.-. ' \ PLl:G
CRlI'N
/i ~ _HEAD
~ ~ 'NASHE!~
"
:; /
CRAIN PLUG
.,,:;. . &<I ..... ,~O() PLAIN
\ "" -
.. _LOCKIVA SHER
Figure 5 - Reservoir Drain Plugs BYPASS
RELI EF
A- CAPSCREW

2. Have the backhoe (if so equipped) in the

transport position and the loader bucket Figure 6 - Hydraulic System Filter
rolled back at ground level.
The filter element must be changed at
3. Remove drain plugs from elbow at bot- every oil change or when filter condition
tom of reservoirs. Approximately 5-1/2 gauge moves into the red (change) zone.
U.S. gallons will drain from each reser-
voir. The filter is located in the hydraulic

7
return line, just forward of the loader con- 2. R eplace hydraulic system filter eleme nt.
trol valve.
3. Reinstall drain plug(s) and fill res erVOll'S
To chang'e the elem ent: with flushing oil. Use Case TCH Fluid
and di esel fuel mixed half and half for
1. Unscrew the filter housing from filter flushing oil.
head.

2. Remove the elem e nt and discard. Then 4. Operate the loader and backhoe through
r e move o-ring from filt e r housing and several (3 or 4) complete cycl es. This
discard. will allow most of the Hushing oil to
pass through the filter.
3. Position element on filter head.
5. Drain the hydraulic reservoirs. Then
4. Install o-ring' on filter housing and lubri- drain the remainder of the hydraulic
cate o-ring and housing thr eads. Screw system as completely as poss il)le.
housing into filte r head and tighten se-
cur e ly. Do not exc e ed 90 foot-pounds 6. Depend ing on the amowlt of contamina-
torque. tion, it may be necessary to r e move,
disassembl e , and clean each valve, cylin-
Cleani ng Hydraulic S y stem der, hose e tc. in the s y s t e m . Whether
this should be done is a matter of
If one component in the hydraulic system judgme nt by the mecrumic.
fails and is replaced, it is oft en necessary
to clean the entire hydraulic system. This is
especially true if it is evide nt that contami- 7. When replacing filter element, clean
nation of the hydraulic oil caused the failure filter head and housing befor e installing
or entered the system as a result of the new element.
failur e .
8. Fill r e servoirs with new CaseTCH Fluid.
P roper cleaning of the hydraulic system
requires considerable time--whethe r to un- 9. Bleed air from the syste m by cycling'
dertake the task is a matter of good judgment each cylinder until it runs smoothly.
on the part of the mechanic. Considerable oil will be transferred from
the reservoir to the valves, c ylinders,
Cleaning Procedure etc. during this proc e ss. Keep adding
oil. When all the air has been r emoved,
1. Drain the hydraulic reservoir(s). Then recheck the oil level and add if r equired.
drain the remainder of the hydraul ic
system as completely as possible. 10. Reinstall breather on reservoir.

8
 HYDRA-LEVELING CIRCUIT

The Hydra-Leveling circuit keeps the the tilt cylinders. This displacement causes
bucket level as the load is lifted from the the bucket to roll forward as the arms are
ground to dump height \Vithout attention from rais ed.
the operator.
As the lift arms are lowered, the rod
is pushed back into the Hydra- Leveling cy-
This is accomplished by mechanically linder. This forc es oil from the bottom of
causing oil to be transferred between the the Hydra-Leveling cylinder into the rear
Hydra-Leveling cylinder and the two tilt of the tilt cylinde rs. This displacement causes
cylinders. the bucket to roll back gradually as the arms
are lowered.
As the lift arms are raised, the piston
rod is pulled out of the Hydra -Leveling Hydra- Level ing act ion may be overridden
cy lind er. This force s oil from the top of the at any time by actuating the tilt cyl inder spool
Hydra -Leveling' cylinder into the front of of the loader control val ve.

OIL DISPLAcm 8Y HYDRA-

ltvELING CYU hiDER

OIL DISPL ACED BY

TILT CYU ND.fRS

HDnI COLO RS kEVERSED

WHEN LOWERI NG 8UCKET.

701309

Figure 7 - Hydra-Leveling' Circuit

9
 HYDRAULIC SY STE M TROUBLE SHOOTING

Problem: Poor Or No Operallon e. If the Cil'CUit contains two cylinder s ,

01 One Circuli Only repeat the test for the other cylinder.

If only a single circuit is performing CAUTION: P erform this check ca re-

poorly, the problem is in that circuit--worn fully. Move control l ever so that the
cylinder packing, faulty secondary relief open line is al ways on the RETU RN
val ves or worn val ve spool. side. Build engine speed gradually;
a badly worn cylinder wil l allow a
1. Check cylinder packing: consider a ble amowlt of oil to leak
past a t maximum system pres s ure.
a. Run the cylind e r to the end of its
stroke. Shut off the engine. Provide 2, If cylinder leak age was found, remove
support for the equipment if raised. and rebuild the cylinder, Then, if pos -
sible, operate the circuit under working
b. Disconnect the hos e 01' tube on the conditions to see if the problem has
RETURN' side at the cylinder. been solved. If the c ircuit still is not
sa ti s factory, there is additional l eakage
in the control valve.

NOTE: If there are no s econdary r elief

valves in the circ uit, proc eed to step 6.

3. Check the setting of the seconda ry relief

valves in the circuit, Refer to page 26,

4. Adjust relief valves to specificat ions. If

any r el ief valve cannot be adjus ted, re-
move it from the control val ve. Clean and
inspect thoroughiY--l'epa ir or replace if
required. Check and adjust pressure
setting USing a test fixtur e . if available.
Reinstall the relief valve in the control
valve. Adjust pressure setting if l'e-
quired. Operate the circuit to see if the
problem has been solved.

Figllre 8 - Cylinde r Packing Check

WA"NINO: If a reli ef valve is removed.

c. Start the engine and run at hal f the attachinent must be r es ting on the
speed. Continue control lever move- ground or supported.
ment in sam e di rection to force
oil over the main relief \'al ve and 5, One final c heck is advi sable before
build system pressure to maximum. removing the control val ve. rremove any
secondary reli ef valve in the circ uit
d. Increase eng ine speed gradually which was not removed previou s ly. Check
while holding control leve l' in pow er the external o-ring a t the poppet end of
position. Check for leakage through the cartridge--replac e if damaged . Rein-
the open I ine ; there s hould be no stall the relief valve a nd op erate the
leakage. Any leakage indicates worn mac hine.
cylinder packing. Slight leakage is
pe rmis s ible . 6. If thi s did not solve the problem. ex-

10
 cessive spool leakage is almost certain. 8. Make a field check for oil contamination.
Remove the control valve and replace the RW1 engine, then draw oil sample from
spool, valve, 01' valve section as required. the top of the r ese rvoir . Compa re the
drained oil with new oil-look for the
Problem: Poor Or No following Signs:
Operation Of ~ Circuits
a. Feel the oil with your fingers. If
If all the cil'cuits are performing W1sat- the oil is gritty 01' contains particles
isfactorily, a worn pump is the most prob- large enough to be felt, the oil must
able cause. However, the pump never should be replaced. Probably the pump or
be removed for repairs or replacement W1til a valve or cylinder has been severely
obvious system faults have been corrected damaged. In addition, the foreign
and a flowmeter test has been rW1. Make the matter m ay have damaged other
following checks: parts in the system. The system
shoul d be tested with a flowmeter
1. Check hydr aulic oil level. Fill to proper after changing the oil to determin e
level with Case TCH Fluid. the l ocation and extent ofthe damage.

2. Check filter gauge and service the filter b. Milky color, a sign of water in the oil.
element if required.
c. Foam, a Sign tha t a ir is entering
3. Clean the reservoir bl'eather(s). the system.

4. Check the suction line to the pump for a d. Scorched smell or da rkening or
loose or damaged connection that could thickening, signs of s ever e over-
cause a ir leakage. Tighten or rep a ir. heating.

Q. Install a pressul'e gauge in the loader

control valve, page 27. Check the setting 9. If any of the above signs are found in
of the main relief valve. Adjust if r e- the oil, drain, flu s h, and clean the system
quir ed. a s outlined on page 8. Reflll with new
Case TCH Fluid. Replace the filter
6. If corrections made to this point did not el ement.
solve the problem, pe rform the Equip-
ment Hydraulics-Engine Stall Test out- 10. If the problem still has not been cor-
lined on page 11. Titis test will determine rected, check the pump and other system
if a ll or part of the problem is in the components as required with a flowmeter.
engine. A faulty engine will lug down Hook up the flowmet e r as shown in Figure
excessively when equipment is operated 11. Start by t esting pump output and
near the rei ief val ve setting and cause a continue W1til the trouble is fOW1d.
corresponding loss of oil volume from the
pump. If the engine is fOW1d to be at Problem: Sluggish Operation
fault, refer to the engine and fuel systems In All Backhoe Circuits;
sections (Series 20 and 30) of this manual Loader Clre .... i'S Ok
as required.
Check the condition of the internal o-ring
7. Determine, if possible, the number of On the power beyond fitting at the loade r
operating hours since the last hydraulic and stabilizer control valves outlet.
oil change. Also de termine, if possible,
whether the proper oil wa s installed
(non-foaming type of correct viscosity Equipment Hydraulics -
such as Case TCH Fluid or approved Engine Stall Test
substitute, page 6). If the oil bas not been
changed within 500 hours or if an in- 1. In this test, rpm lmder load s hould be:
correct oil was installed, drain and refill
the reservoir with Case TCH Fluid. a. 1900 rpm - Dry clutch model.

11
 b. 2100 rpm - Torque converter or If engine speed is below s pecified rpm, it
hydrostatic model. indicates either engine wear or excessive
pressure in the hydraulic system. Check the
2. Place bucket on ground. Run the engine main relief valve pressu,'e setting. If faulty,
at full throttle. repair or adjust. Repeat the stal l test des-
cribed above. If engine speed 1.s s till low,
3. Tilt the bucket back and hold lever in the engine is likely at fault.
power position to open the main ,'eli ef
valve.
If engine speed is above specified rpm,
Test Summary the equipment hydra ulic system is ineffic ient,
indicating leakage, pump wear, or a low
Engine speed when the oil is going ove,' m a in relief valve pressure setting. Con-
the main relief valve should be approxi- tinue t esting the hydraulic sy st em with a
m at ely the specified rpm. flowmete r.

MOST HYDRAULIC PROB LEMS AR E CA USED BY

CONTAMINATED OIL!

Keep The Oil Cle an

1. Cle a n the filler cap a r ea before checking oil level.

2. Use a clean fLUmel and conta iner when adding Oil.

3. Cle an ex terio l' of components, li nes, and fittings before removal.

Clo se op en ings w ith clean caplugs.

4. Make repair s on a clean work bench. Use cl ean tools.

5. Change oil and service the filter(s) when making repairs.

NOTE: If drai ned oil is reused, it should be filtered befor e

reinstalling in the reservo ir.

6. If parts ins pection indicates that metal chips, shredded packing,

etc. have ente red the hydraulic system, the system should be
flushed , filt er (s) serviced, and new oil installed.
701167

12
 1'RO UBLE SHOOTING C HART

Problem: Poor f"er'orrnance

SY"'IPTOM POSSIDLE CAUSE REMEDY

Poor or ,,"0 Operation 1. Worn pump is probable but 1. Refe r to pag"e 11 and check
of ALL Circuits other possible causes include out the hydraul ic syste m us
low oil level, use of impro- outlined. Correc t any defect
per oil, loose fitting in suc- before prooeeding with
tion line to pump, and o hecks. Conclude with a flow-
contaminated oil. meter te st if checks and
correction do not sol ve the
problem.

Poor no No Operation 1. Worn cylinder packing, 1. Refer to page 10 and check th e

of ONE Circuit Only worn valve spool, or low circuit a s described. Clean,
secondary relief valve set- repair, or r eplac e the item
ting (if in circuit) can cause found to be defective.
this problem.

Poor or No Operation 1. Defective O-ring on power 1. Disconnect the hose fr om the

of ALL Backhoe or beyond fitting in loader or power beyond fitting. Remove
Hitch Circuits; stabilizer control valve fitting and r e pluce o-ring, if
Loade r OK outlet. damaged .
2. De fective qui ck disconnect 2. Uncouple and in spect both
f itting. quiok d isconnects . Repair or
replace if r equired.
3. Dirty or defective part in 3. Remove buckhoe valve. Dis-
regeneration mechanism in assemble inlet and outlet
backhoe valve. sections . Cl ean and replace
pa r ts as r equired. Check
spring te nsion.
4. Inl e t section in backhoe or 4. Inspec t inlet s ection for
hitch val ve cracked. cracks. Replac e if a crack is
found.
5. Hitch valve only: Dirty or 5. Remove valve. Disassemble
worn parts in inlet section. the inl et section. Inspect com
pensating s pool and spool bor e
for wear and dam ~ ge. Check
spring tenSion. Replace pa rts
as r equired. Clean bor es and
p a ssuges.
6. Hitch valve only: Orifice 6. Di s assemble the val ve s ec-
plate or orifice pa ssage tions 'Uld clean thoroughly.
through val ve sections closed
by dirt.

Control Moved To 1. Hoses cr ossed. 1. Refer to hyd raul ic diagl'um in

Power Position-- this man.lal , Disc onnect hoses
Cylinder Moves In and reconnect as shown,
Wrong Direction

13
 SY MPTO"I POSSIBLE CAUSE REMEDY

Control Lever 1. Chec k poppet in control l. Refer to control vnl ve s ec tion

F ea ther ed- - Cyl inde r va l ve worn or held off of this ma nual and d ete rmine
Move s Sl ightly In sea t by dirt . location of p oppet. Lowe r
Opposite Dire ction attachme nt to ground. Remove
popp e t a ss e mbl y from val ve.
R epl ac e thc poppet. Wipe the
sea t dean.

Cylinder Creeps l. Faul t in spool cap prevents l. Lower a ttac hment to growld.
With Control Lever spo ol f1'onl returning to true Re move spool cap. Inspect
In Nelltrnl, Engin e ne lltrnl. cente ring sp ring; a nd parts for
Running cor r ec t as se mbly. If r e qll ir ed
remove spool and c ap for
repa irs .
2. Spool binds . 2. See Spool Binds , page 17.

Cylinder Drifts, l. Worn piston packing. 1. Check c yl i nde r pack ing as

Cont rol Lever outlined ill step 2, Problem:
In Neutral, Engine Poor Opera tion of One Ci r-
Off cuit Onl y, p age 10. Rebuild
cylinder if d efective.
2. Spool o r relief valve 2. Continue w it h circui t c hecks
l eakag'e. outlined tmde r Problem: POOl'
Op e ration of One Circuit Only.

Boom Swings l. Crossover (low pressure) 1. Test and adjus t settin g of

Normally--Stops r elief val ve(s) in swing crossover rel ie f val ves . Se e
With Jarring Impact sect ion s et too high. pa ge 28. If t he rel ief val ve
oarmot be ad justed, r emove
and clea n o r repl ace parts .
2. Re strictor(s) at closed end 2. Disconnect hose at c l osed end
of s wing cylinders missing" of swing cylind e r. Inspect
o r improperly installed. restricto r- - smal l e nd goes
into cylinde r fi rst .
3. Defec tive swing cushion 3. Remove reli ef va lve from
r elief valv e , spring , o r swing cylinde r being retracted
r estr ictor pin in swing when jarring impact occuned .
cylinder. Add shims and clea n the relie f
valve . If this does not solve
proi)l e m. r e nlove and disa s-
semble cy l inder. Check
res tricto r pin for prope r
assembly--tapered e nd should
be outs ide of piston. Clean
parts and r eass emble.

Boom Raises l. Hes t r ictor pin or s pring 1. Remove cyllnder a nd disas-

Normally To Full in \lOom cy linde r piston is semble . Install restrictor pin
Heig"ht--Stops With missing or damaged. if missing or repl a c 0 with new
Jar r ing Impact part if dama g"ed.

14
SYi\IPTOM POSSIBLE CAUSE RENIEDY

Boom Drop s 1. Restrictor in lower port of lo Lower bucket to ground . Dis-

Too Fast boom section in control connect hose at lower port of
val ve is missing or impro- boom section . Install rest r ic-
perly installed. tor correctly - -the big end
goes in the val ve port first.

Boom S\vings 1. Crossover (low pl'essuI'e) l. T est and adjust setting of

Normal l y--Coasts relief valve in swing section crossover rel ief valves . See
When Controls Are of control valve set too low page 28, If the relief valve
Re turned To or held open by dirt. cannot be adjusted , remove
Ke utral a nd clean 01' r epair .
2, Spool not returning to 2, See Cylinder Creeps With
neutl'al. Control L ever In Ke utral,
Engin e Hunning on page 14.

Control Lever lo Linkage or control lever lo L ubricate as r equir ed. Back-

Hard To Operate r equires lubrication. ho e levers ha ve grease fittings
2 Spool binds. 2, See Spool Binds , pag'e 17 .

Loader Control Lever 1. \VOl'll 01' missing parts in 1. Remove detent housing for
Moved To Float, Will detent housing in lift spool inspection. Replace WOI'Il or
Kot Stay In portion of loadet' control missing parts.
De te nt val ve.

Boom Lockout 1. Hoses connected to wrong lo Refer to hydraul ic diagram in

Does Not Operate ports. this manua.!, Sw itc h hoses.
Properly 2, Poppet in lockout val ve 2. Remove lockout va.! ve for
worn or held off seat inspection. Dis assembl e valve
by dirt. --cl ean or r eplace parts as
required.
3, Relief va.! ve in lockout 3. Remove r e li ef val ve. Check
circuit is set too low or setting with luUlcl pun'lp , pag·e
or held off sea t by dirt. 26. Adjust to speCificati ons .
The valve also may be disas-
sembled for cleaning.

Hydra-Guide Does See Section 47.

Not Operate Properly

Hydra ulic Extendable

Dipper Does Not
Operate Properly
l. Slow l a o Diverter val ve linkage lao Check linkage--make sure
out of adjustment. spool can be pOSitioned pro-
perly. Adj us t linkage as
required ,
l b , Wear or damage to di verter lb. Remove diverter valve. Clean,
val ve hous ing or spool. repair , or replace parts as
requ ired,
l c . Worn cylinder. l c. Remove and rebuild cylinder,
2. Dippel' Does 2 See possible caus es Ib and
Not Maintain lc under "Slow" (above).
POSition
3. Binding :3. lI'1 ec hanical bind. 3. In spect dipper for bind.

15
SYMPTOM POSSIBLE CAUSE REMEDY
Problem: Failure Or Poor Operation 01 Major Co mponent

Pump is Noisy 1. Loose mounting bolts . 1. Tighten.

2. Loose [lump ti e bolts. 2. Check bolts wit h 11 torque
wr e nc h. Tig"hte n to spec ifica -
tion s .
3. \Vorn or durrluged bearings 3. Remove and rebui l d pump.
or gea rs.

Flowmeter Tes t 1. Wo r n or damaged pump. I. Remove pump fr om tractor .

Shows That Pump (Al s o see Pump Damag'e Replace or d isassemble and
Output Is Low below.) re build. Dr ain r es ervoi r and
refill with Case TCH Flu id.
Al so flu sh s yste m if oil is
co ntam ina ted . Servic e fi lter .
2. Us e of improper oil. 2 Use Case TCH Fluid.

External Oil 1. Worn se,ll or pump sha.ft . 1. Re move [lump and r epl ac e
Leak age seal. Check s haft at sealing
s urface for damage.
2. Drai n passage t o suc tion 2. Disas semble pump and c lean
side of pump plugged. the pa ssage .
3. P ump tie bolt s loose. 3. Check bolts with a to r que
wrench. Tighten to specifica-
tions .
4. Pump hou sing seal s 4. Dis asse mbl e pump and repl ace
damaged. s eal s.

Pump Dam age:

1. We ar Plates 1. Contaminated Oi l. 1. Rebuild pump . D rain, flus h,
Sco red and refill sys te m with Case
TCH Fluid. Se r vice t he filter.
2. Heavy Wear 2. Contamin a t ed oil. 2. Same as 1.
Or Scoring
At Inlet
3. Gea rs, Sha fts 3. Contaminated or improper 3. Same as 1.
And Bea rings oil .
Corrod ed,
Pitted, Etc.
4. Drive Shaft 4. Da m aged or mi s aligned 4. Rebuild p ump. Rep lac e coup-
B r oken coup ling. ling.
5. Gear (s) 5. Contaminated oil, misal - 5. Replace both g ears. CheCk
Damaged igned coupling, high ma in bea rings . F ill syste m with
r e I lei va l ve setting, d a maged Case TCH Fluid. Check and
shaft bea r ing. adjust relief val ve setting.
6. Disc olored 6. Ve ry low oil leve l or 6. Bring oil up to prop e r level
Shaft At contaminated or or drain, flush and r efill
B earing improper oil. sy stem with Case TCH Fluid.
Sul'face 01' Se r vice the filter .
Sides of
Ge ars
7. Gear Housing 7. High m ain r eI ief val ve 7. Rep lac e housing or pump .
Cracked pr es sure setting. Chec k and adj us t main reI ief
valve.

16
SYMPTOM Pa:;SIBLE CAU SE REMEDY

Valve Spool l. Tie nxl torque too high 1. Check tie rods with torque
Binds--Lever (sectional valves). WI' enc h.Tighten to
Hard To specifications.
Operate 2. Valve distorted . 2. Shim between val ve and
nlolUlting plate .
;J . Cap full of oU. 3. Replace spool seal at cap end.
4. Sludge in val ve. 4. Remove valve and clean
thoroughly.
5. BWT on spool. 5. Remove burr with crocus
cloth.
6. Scored spool bore. 6. Replace val ve (loader val vel
or val ve section (sectional
valves).
7. Bent spool. 7. Replac e spool (loader val vel
or val ve section (sectional
type valves).

Excessive 1. Failure to lubricate fittings l. Lubr icate fittings daily or

Cyl inder as specified. more often if operating in
Bushing Wear severe conditions.
2. Excessive relief valve 2. Check a nd adjust main relief
pressure settings. val ve and secondary relief
val ve(s) if in circuit.

Excessive 1. Contaminated oil. l. Drain, flush, and refill system

Cylinder with Case TCH Fluid. Service
Packing Wear the filter.
2. Excessive relief val ve 2. Check and adjust main reli ef
pres sure settings. val ve and secondary relief
val ve (s) if in circuit.

Bent Piston l. Failure to lubricate l. Lubricate fittings daUy or

Rod cylinder pivot pins. mOY'e ofte n if operating in
severe conditions .
2. Bent dipper arm or other 2. Make inspection for misalign-
misal ignment in loader or ment. Replace parts as
backhoe . requi red.
3. Excessive relief valve 3. Check and adjust main relief
pressure settings. val ve and secondary relief
valve(s) if in circuit.

Outer Hose l. Hose twisted. l. Install hose properly--the

Cover Separated hose must not be hvisted whe n
From Wire fittings are tightened. TUTn
Braid swivel fitting only.

Fitting Pulled l. Hose hvisted. 1. Same as Remedy 1 above.

From End Of 2. Torque applied to hose 2. Turn sw i vel fitting onl y.
Hose 01' Burst instead of fitting.
Hose 3. Loader dropped at fast 3. Follow correct operating
r ate, then suddenly stopped procedures.
by returning control
lever to neutral.

17
SYMPTOM POSSIB LE CAU SE REMEDY
Fitting Pulled 4. F a ulty secondary relief 4. Check and 8,djust relief valves
From End Of valve . to specifications.
Hose Or Bur s t
Hose (Cont.)

Da maged Thr eads 1. Ove r torqued. 1. Torque to specifica t ions

On Hose Or Tube See page 6.
Fitting'

MOST HYDR A ULIC PROBLEMS ARE CAUSED BY

C ONTAMINATED OIL!

Keep The O il Clean

1. Cl ean the fil ler cap area be fore checking oil l eve!.

2. Use a clean [Wille l and con t ainer when adding oil.

3. Cl ean 8o" te1'io1' of com ponents . line s, and fittings before remo" ,,!.
Clo se ope nings with cl ean caplugs .

4. Make l'epail's on a clean work bench. Use cl ean tools.

o. Change o il and s ervice the Iilte r(s) whe n making repalrs.

NOTa: If drained oil is reu sed. it should be filte red be for e

r e installing il1 the r eser vo ir.

6. If parts ins pe ction indic ates that m etal chips, shredded packing ,
etc . ha y enter ed the hydraulic syste m, the sys te m should be
flushed. fiIte r( s ) serviced. and new oil installed.
70116 ;

18
 TESTING THE HYDRAULIC SYSTEM WITH A FLOWMETER

Hydraulic troubles in this and other

Case machines can be qUickly and positively
diagl10sed with the aid of a flowmeter. This
prevents trial-and-errol' replacement of
parts,

The flowm e ter is portable and can be

used in the shop or eas ily transported to
the field for on-the-spot troubl e shooting.

Three Flowrneters Available

Three 110wmeters are offered through the

Case Service Tool Program. Refer to the Case
Service Tools Catalog.

30 GPM F lowmeter Figure 10 - 100 glJm Flowmeter

Suitable for wheel t ractors and small Description o' Tests

crawlers. 0-250° tempera ture gauge; 0-3000 .
psi pressure gauge, No. M20271, Figure 9. The fl ow meter s imulat es the load con -
ditions identical to those met during operation
60 GPM Flowmeter of the tractor and meaSll r cs the temperature,
volume, and preS SU1'e of the oil passing
Handles ail but the largest Case ma- through the flow meter.
chines, 0-250° temperature gauge; 0-3000
psi pressure gauge. No. M20270, Fig'Ure 9. By interpreting these measurem ents as
described on the following' pages, hydraulic
faults can be iden tified.

Each test consists of:

1. First, learning how much oil the pump

delivers to the system at no load.

2. Then, by applying a fixed, normal opera-

ting pressure on all the components,
finding out how much oil is Lmavailabl e for
work because it is:

a. Not being delivered by the pump, due

to internal slippage caused by wear ,
or because of a leak or restriction in
Figure 9 - 30 gpm and 60 gllm Flowmeter t he sUe!ion line.

100 GPM Flowmeter b. Not being delivered to the cylinders

because it is leak ing back to the
Capable of testing ali Case machines. reservoil' by passageways that are
0-250° temperature ga uge ; 0-3000 psi pres- supposedly closed, namely, valve
sure gauge. No. M20512. Figure 10. leakage.

19
 c. Not being' used by the c yl inde r be- CAUTION : In this hookup. there is no
ca use it is leaking past the cylinder r elief valve in the circuit. Ther efore ,
piston packing and returning' to the make certa in the flowmeter load val ve is
reservoir. open before sta rtinp; the test. When t e st-
ing, close the flowm eter load valve
Hooking Up T he Flo_meier gradually . Limit the test tim e a thigh
pressur e s to 30 seconds . Do not exceed
Befor e installing the flowmeter, perform the tractor's main reli ef valve setting
the suggested checks described under P 1'0- (2200 psi) WIder any circumstanc e .
bl em: Poor Or No C1Je ration Of All Circuits,
page 11.
Interp r eting Test Results
Refer to Figure 11.
1. In the ft'e e flow test, the readings wer e
1. Lower the lo ader and rear H.ttachment tak en with the lo ael val VC' opeo --t\o re-
to the ground. striction was applied to the oil. Even a
baclly worn pump will usually ha.ve near
2. Disconnect the high pressu re 1ine on the capacity output at fr e e flow. How e ver,
right hand side of the trac tor. Connect if the fr ee flow reading is I ess than
the flowmeter hose to the tube as shown. 90% of specifications, a restric tion or
a il' leak caused by a loos e fitti ng in the
NOT.., Have a contamer under the suction l in e is fl strong poss ibility.
disconnected line to catch oil .
2. The a mount of gllm dropoff at incr eas-
3. Connect the flowmeter r eturn hos e at ingly higher pressur es i ndic ates · the
the r eservo ir as shown. amount of pwnp weal'. Although pump
r epai r or repl ac ement is a m atter of
NOT.., If the return hose is inserted judgment, a gllm reading of about 80%
into the rese r voil' op ening , it must be of the pump's rated capac ity indic ates
t ied securely or held down during the the pump is still efficient enough to use.
tests.
T esl No. 2 - Main Relie' Valve
4. Turn the flowmetel' load val ve to com-
pletely OPE N. Set the volume control to Refe r to Figur e 12.
handle 30 gllm.
1. Shut off engine . Re move plug from tee.
5. St a rt the engine and heat the oil by Connect tee a s shown. Thi s hookup will
closing the load valve un til the pr e ssure be used for all remaining tests .
is a bout 1000 psi. Rllll the engin e under
this load until the flow m etel' te mper ature 2. Make sure tire load valve is fully open .
gauge r ecords 120" I'. Open the load va l ve.
3. Run engine at specified rpm.
Tesl No. 1 - Pump OulpUI
4. Completely roll back the bucket and
1. With the engine running at 1900 rpm, gradually close the flowmeter load val ve
take the gllm r e ading with the load val ve with the control level' held in power
wide open. pOSition. Watch the flowmeter flow gauge .
When the g(lllonage start s to drop, the
2. \V i th the engine running; at the specifiecl "cracking point" for the main r elief
sp eed, graduall y apply a loa d with the val ve has been reached. Record this
flo\\~neter lo ad valve. Take readings at reading. Continue to c lose the loael valve .
850. 1000, a nd 1600 psi. Eng ine speed may When gallonage drop s to 7.ero. read the
drop at high test pressures. Make correc- pressur e gauge again. Thi s is the setting
tions as required to m ai nta in the spec ified of the m a in reli ef valv e . Record thi s
speeds. r eading on the check sheet.

20
 TEST NO. 1 - FfTTINGS AND HOSES REQUftED

FLOWM ETER NO.

HE!". CASE NO. KIT NO . DESCRIPTION REQ ' D.

1. A21574 3/4" I. D. (-12) bulk hose 2

2. 220-226 3/4" - 14 male pipe fitting 2*
3. T42 1-5/16" - 12 J.I.C. swivel tee 1
4. 218-779 T63 1-5/ 16" - 12 J. I. C. plug 1
5. D39149 1-5/ 16" - 12 J.I.C. swil'el tee 1
6. 220-206 1-1 / 16" - 12 J. I. C. swivel fitting 1
7. 221-1604 T74 1" to 3/4" pipe re duce r bush ing 1*

'One additional fi tting required if flowmeter kit Is used.

PRESSURE Ll NE

\
0 1SCOW,ECT
TH IS HOSE
FRO M TUH£

710913

Figu re 11 - Hookup for Test No.1 - Pump output

21
 '('I;;:5TS 2 THRU !5 - FIT'TWIIGS AND HOSES REQUIRED

FLOWMETER NO .
REF. CASE NO. KIT NO . DESC RIPTION REQ 'D .

l. A21 574 3/4" I.D. (-12) bulk hose 2

2. 220-226 3/ 4" - 14 male pipe fitting 3'
3. T42 1-5/ 16" - 12 J.I.C. swivel tee 1
4. D39149 1-5/16" - 12 J. I.e. swivel tee 1
5. 220-206 1-1/16 " - 12 J.I.C. swive l fitting 1
6. 221-1604 T74 1" to 3/ 4" pipe reducer bushing 1*

' One a dd itional fitting r equired if flowmete r kit is used.

NOTE : HO SE COtINECT I DI, S AT

Fl OI/H ETER CAN BE VA" I ED To
SUIT OPERATOR . QU I CK DIS -
CONNE CTS AR E DES I RABLE 'F
TE STER I S USED fRE QUfNTL Y .

PRESSliRE li NE

7 109 14

Figure 12 - Hookup for Tests 2 Thru 5 (Tee or System Test)

22
Interpreting Test Results 2. Fully extend and retract individually the
boom, crowd, bucket and stabilizer cyl-
1. The "cracking point" of a relief valve inders. Record the gpm re ad ing at the
in satisfactory condition will be within end of their strokes,
10% of its setting at full flow. Make any
adjustments necessary before continu ing NOTE: Check the boom down circuit
the tests. under 850 psi system pressure .

2. If the relief valve is adjusted, repeat 3. Partially close the flowmeter load valve
T est No.2. to develop 1600 psi system pressur e and
swing the boom against the stops in both
Test No. a - Loader C irculis directions. Record the gp m readings .

1. Test the tilt circuit. Interpreting Test Results

a. With engine running a t specified 1. The gpm readings for e ach cylinde r
speed, close load valve until 1600 should compare closely with the pump
psi is reached on flowmeter pressure output dete rmined in Test No. 1.
gauge. Dump the bucket and hold
l e ver in pow er pos ition--take gpm 2. If ALL cylinder circuit readings al'e
reading. below the pr e viously recorded gpm, it
indic ates that oil is leaking at som e
b. Completely roll back the bucket and point in the system before it r eac hes
take the gpm reading at 1600 ps i. the backhoe control valve . The most
I ikely spot is the pow e r beyond fitting.
2. Test the lift and cla m circuits in the
same manner. a. Check the in ternal o-ri ng on the
power beyond Ii tting in the loader and
Interpreting Test Results stabilizer cont rol valve outlet,

1. The recorded S'j"lm rcadings for each b, Check the main reli ef valve pa rts
cylinder tested at 1600 psi should com- and seals for damage or dirt.
pare closely with the pr e viously recorded
pump gpm at 1600 psi. 3. If the g'j"lm r eadings for ONE pair of
cylinde rs ar e below pump g'j"lm readings
2. If the gpm readings for ONE pair of in both the extended and r etrac ted posi-
cylinders ar e below pump gpm r eadings tions, packing leakage is p r obabl e in
in both the extended and retracted po- either or both the cylind e rs. If the S'j"lm
sitions, it indicates leakage past the reading is low in just on e position, spool
cylinder packing in e ither or both of l eakage is the probabl e cause.
the cylinde rs. If the S'j"lm r eading is low
in just one pOSition , spool leakage is NOTE: If the S'j"lm r eadings for the swing
probable. cylinders a re low, check and adjust the
crossover relief valves crest No.5) to the
3. If ALL cylinder gpm readings ar e low, high end of the range. Repeat Test No.
it indi cates tha t oil is leaking before 4 for swing cylinders. If readings are
it r eac hes the cylinders. Check the m ain still low, cylinder l eakage is indicated.
r el ief valve seals and parts for damage .
Also check the o-ring neares t the check
popp et on check val ve cartridges. Test No. 5 - Lo_ Pressure
Backhoe Relle' Valves
Test No.4 - Backhoe Clrculis

1. With engine running at specified speed, Swing Crossover Relief Valve

close the load valve until 1600 pSi is
reached on the flowm eter pressure gauge. 1. With the engine running at 800 rpm

23
 swing boom to right or left until it Boom Down Relief Valve
stops.
1. This relief valve is located in the top
2. Hold swing pedal down with the tester ("A") port of the boom section of the
load valve closed. Read the gauge. It control valve. Extend bucket, clipper,
should read 1600 to 1900 pSi. Sw inging ancl boom to gl'ouncl level.
boom to right tests the relief valve at
port "8" (nearest spool cap). 2. With the e ngine running at 800 rpm
move the control leve r to lower the
boom. With the teste r load va lve closed ,
3. To test the opposite secondary reli ef re acl the gauge. It s hould read 900 -1250
val ve, sw ing boom in opposite direction. psi.

24
 Flo_meter Check Sheet
OWNER _ _ _ _ _ _ _ _ _ _ _ _ _ __ DATE ________________________

MOD E L _______________________ SE RIAL NO. _____________ HOURS _____________

SPECIFICA TIONS Pump Output

D48950 (Cessna) . . . . . . . . • 23 gpm at 1900 rpm at 1600 psi
D49241 (TRW) . . . . . . . . . . 23 gpm at 1900 rpm at 1600 psi
D522 71 (Webster) . . . . . . . . 11.5 gpm at 1900 rpm at 1600 psi
Loader main relief valve . . . . . . . . . . 2200 ± 75 psi at full throttle
Swing crossover reliefs. . . . . . . . . . .. 1750 ± 150 psi a t 800 rpm
Boom down relief . . . . . . . . . . . . . 1000 + 250,-100 psi at 800 rpm
TEST NO. 1 _ _ _ _ _ _ _ _ _ _ _ _ gpm at _ _ _ _ _ _ _ _0"-_ _ _ _ _ _ _ psi

____________________ gpm at _______8:..5:..0:.....::a:.:

nd:::....o:1-"0-"0:..0___________ psi

_____________________ gpm at ____________~1"_'6'_'0'-"0'-----_________ psi

TES T NO. 2 Cr ack point _ _ _ _ _ _ _ _ _ _ _ psi at. ____fu=l....

l-"th"'r..,o""t"'tl!Se'-,_ _ __

Pressure setting _ _ _ _ _ _ _ _ _ psi at _ _ _-"f"'u..,l1~t""h"'r_"o"tt"'I"'e_ _ __

TEST NO. 3 TEST PSI GPM EXTENDED GPiVI RETRACTED

Tilt 1600

Lift 1600

Clam 1600

TEST NO. 4 TEST PSI GPlVI EXTENDED GPM RETRACTED

Bucket 1600

Dipper 1600

Dipper Ext. 1600

Boom raise 1600

Boom down 850

Swing 1600

R.H. Stablltzer 1600

L. H. Stablltzer 1600

TEST NO. 5 Swing right at ________ psi Swing left at _ _ _ _ _ _ _ psi

Boom down ______________ psl

25
 TESTING AND ADJUSTING RELIEF VALVE PRESSURE SETTINGS

Specifications

The Hand Pump column shows the approx- actuated. The Full Flow column shows the
imate r ange within whic h eac h reI ief va lve pressure range within which the reI ief val ve
should crack or bypass with the hand pump should bypass during' normal operation.
BACKHOE VALVE

PUMP "_LIEF
j:.=~==~L-L~ 1\:'J " VALVE:
~ElIH

BOOM
LOCKOUT
VALVE

71()990

Fig'ure 13 - Location of Relief Valves

REF. HAND PUMP FULL FLOW TEST PROCEDURE

1. 750 to 1050 psi 1000 + 250,-100 psi @ 10 gpm Page 28

2. 2100 to 2500 psi 2750 -'- 250,-100 psi @ 10 gpm Page 33
3. 1400 to 1700 psi 1750 ± 150 psi @ 10 gpm P age 28 or 33
4. 1550 to 1750 psi 2050 ± 100 psi @ 10 gpm P age 29 or 33
5. 2000 to 2400 psi 2500±100 psi @10 gpm P age 29 or 33
6. 2200 ± 75 psi @ full throttle Page 27
7. 2200 ± 100 psi @ full throttle Page 28
8. 1800 to 2000 psi Page 33
9. 1800 ± 75 psi @ full th.rottle Page 27
10. 2900 to 3300 psi 2900 to 3300 psi @ 1. 5 gpm Pa<>e 30
'?

NO'" Settings with warm oil, approx. 120· F.

26
 Checking A nd A dJu.llng The Main Relief Valve

L oader And Backhoe T hree Point Hitch

The main relief val ve is set at 2200 ± 75 The main relief valve is set at 1800 ± 75
psi at full throttle with the oil warm (about psi at full throttl e with the oil warm (about
120' F.). The valve is located at the inlet 120· F.). The valve is located in the inlet
to the loader control valve . section of the three point hitch control valve.

1. Install a 0-3000 psi pre ssure gauge .

a If the unit is equipp ed with a loader,

remove the 1/4" pipe plug from the
loader control valve and install pres-
sure gauge as shown in Figure 14.

b. If the unit is a drawbar mod el, r e-

move the plug at the pump relief
vah'e, Figure 16. Install pressul'e
gauge in the plug opening.

Fi,,'ur e 14 - Pr essur e Gauge Installed

1. Remove 1/ 4" pip e plug from control valve

and install a 0-3000 psi pressure gauge
as shown in Figure 14.

2. If oil is cold, oper ate a cylinder over

relief lUltil the oil is at 120 0 F. (pump
supply line is warm touch).

3. Run engiue at full throttle. Raise loader

about thl'ee feet off gr ound. Dump bucket Figure 15 - Relief Valve Loc ation
completely.
2. With the engine rlUtning at full throttle,
4. Hold lever in the dump position. The pres- hold the pitch control lever in the pitch
sure gauge should read 2200 ± 75 psi. forward pos iti on and r ead p ressure
gauge.

5. If adjustment is required, remove acorn NOTE: If oil is cold, operate a cylinder

nut on relief valve and loosen jam nut. over relief until the oil is at 1200 F.
(re servoir warm to touch).
a To Increase pr essure, turn tile ad-
justing screw clockwise. 3. If tile setting is not as specified, adjust
the main relief valve.
b. To decrease pressure, turn the ad-
justing" screw cOlU\terclockwise. a. Remove the acorn nut and loosen the
jam nut .
6. Wilen tile pressure gauge indicates tile
specified pressure, tigllten jam nut and b. Turn the adjustulg screw clockwise
r e install the acorn nut. to raise the pressure setting or

27
 ~
counterclockwise to lower the pres-
su re setting.
,?
c. When the relief valve is properly i
SI,i
adjusted, tighten jam nut.
l"<:)
"/l

Pump Relief Valve TO FIL TER_&l

,I
(Non-Loader Models Only) f

The relief valve is set at 2200 ± 100

0
psi at full throttle with oil of 120 F.
QUICK
1. Remove the 1/8" NPT plug from the
r eli ef valve, Figure 16. Install a 0-3000
psi pressur e gauge.

2. Uncouple the quick disconnect coupling

at the rear of the tractor.
a. Remove acorn nut and loosen the
3. Start engine. If the oil is cold, allow jam nut.
the engine to operate until the oil is
0
warmed to 120 F. (pump supply line b. Turn the adjusting scr ew into the
warm to touch). val ve to raise the setting; turn the
adjusting scre,,, out of the valve to
4. With engine at full thr ottle read the lower the setting.
pressure gauge.
c. Recheck pressure. When correct,
5. If the setting is not as specified, adjust tighten the jam nut and reinstall
the relief valve: acorn nut.

Testing Lo_ f"ressure Secondary Valves

Secondary relief valves with a setting 3. Lower stabilizers to normal diggingposi-

LOWER than the main relief valve can be tion.
tested with a pressure gauge installed in the
inlet to the loader conll'ol valve. The valves 4. Fully extend the bucket and dipper arm .
which can be tested in this manner include: Lower the boom until the bucket touches
ground directly behind the tractor at
a. Backhoe boom (at port "A"), maximum reach.

b. Backhoe swing crossover (both 5, Run the engine at 800 rpm and apply
ports). down pressure to the boom. The gauge
should read as specified on page 26.
Boom Down Relief Valve

This relie f valve is identified as item I,

Figure 13. Loader main relief should be Swing Crossover Relief Valves
properly adjusted .
These two relief valves a re identified as
1. fnstall a pressur e gauge as shown in item 3, Figure 13.
Figure 14.
1. install a 3000 psi gauge as shown in
2. Lower the loader bucket to gTound level. Figur e 14.

28
2. Swing crossover valves are tested in b. To test the valve at the lower ("B")
the port OPPOSITE the side on which port, swing the boom all the way to
the valve Is located. Run the engine at the right.
800 rpm when testing.
3. Hold the foot pedal down until a steady
a. To test the valve at the top ("A") gauge reading is obtained. The pressure
port, swing the boom all the way should read 1600 to 1900 psi. Adjust the
to the left. val ve(s) if necess ary, see page 34.

Tesllng Loader Tilt Spool Relle' Valve.

1. To check the secondary relief valve 2. To check the secondary relief valve
nearest the spool cap (at port "B"): nearest the eye of the spool (at port
itA"):
a. Install service tee 026337 in the
line from the tilt cylinders to port a. Install service tee 026337 in the
"B" in the control valve. See Figure line from the tilt cylinders to port
17. "A" in the control valve. See Figure
18,
b. Install a 3000 psi pressure gauge in
the tee.

c. With the bucket empty, start the

engine and raise the loader to 1/2
of full height and roll the bucket all
the way back.

Figure 18 - Checking Dump Relief Valve

b. Install a 3000 psi pressure gauge

in the tee.

c. Start the tractor, lower the bucket

to the ground and fully dump the
Figure 17 - Checking Rollback Relief Valve bucket.

d. With the engine running at 800 rpm d. With the engine running at 800 rpm
under hydraulic load, lower the load- under hydraulic load, raise the load-
er and read the gauge as it descends. er and read the gauge as it ascends.
If the reading is not between 1950 If the reading is not between 2400
and 2150 pSi, the secondary relief and 2600 pS i , the secondary relief
valve should be adjusted. val ve should be adjusted.

29
 Testi ng And AdJusting B oom L ockout Relle' Valve

Refer to Figure 19. a. Loosen the locking screw.

1. If the oil is cold, start the engine and b. Turn the adjusting scr ew into the
hold a control 1ever In full power pos- valve to increas e pressure; turn
ition until the oil is 120' F. (reservoir the adjusting screw out of the valve
warm to touch). to decr eas e pressur e .

2. Lower the backhoe bucket to the ground. c. Recheck setting. If c or rect, tighten
With the engine shut off, move the boom the locking screw.
control lever in both directions to
equalize pr e ssur e . 7. Re install relie f val ve.

3. Disconnect tube from the upper port of

the relief' val \'e. Remove connector. Using
an adapt er. Figure 21, conn ect the hand
pump to the upper port. Move lockout
valve handle to Lock pOS ition.

4. Operate the hand pump. The pl'essure

gauge should record between 2900 and
3300 psi.

NOTE; See Hand Pump Test Procedures,

page 33.

5. If the pressure reading is not within

specific ations, remove the r eli ef valve.

6. Remove expansion plug fr om bottom of Figure 19 - Boom L ockout Relief Valve

r e lief valve and adjust as follows:

30
 Te.tlng Secondary Relle' Valve. Wllh A Hand Pump

Description Of Hand Pump The items listed below, when assembled

as Illustrate d, make a ver satile , portable
The pressure settings of all relief valves te s ting unit. The hose and fittings- are avail-
excepting main reJlef valves can be checked a ble through the Case Reu sable Fittings and
with the hand pump outfit shown in Figure 20 Flexible Hose Line s Program. Refer to Parts
and the adapt e rs in Figures 21 and 22. Catalog Bl 044.

710912

Figure 20 - Hand Pump Assembly

Hand Pump A ssembly - F ittings And Hoses

REF. CASE NO. DESCRIPTION REQ'D.

I. ];120276 Hand pump assembly . . . . . . . . . . . . . . . . . . . . . 1

2. 220-204 7/ 8" - 14 JIC s wivel fitting . . . . . . . . . . . . . . . . 1
3. A21572 1/2 " ill bulk hose, cut to length . . . . . . 2
4. 220-224 1 / 2" - 14 male pipe fitting. . . . . . . . . . 2
5. D23911 1/2" - 14 female pipe tee . . . . . . . . ,.. .. 1
6. 221-88 1/2" to 1/ 4" pipe reducer bu shing , . . . . . . . ... , 1
7. 221-130 1 / 4" pipe nipple . . . . . . . .. . . . .. . . . . . . . . . . . . . . 1
8. Mounting bo ar d , make localJy . . . . . . . . . . . . . . . . . . .. 1
9. 220-203 3 / 4" - 16 JIC swivel fitting . . . . . . . . . . . . . . . , , . . 1
10. Dl2806 Kit for off-machine te s ting of Commerlcal- Shearlng
seconda ry relief valves ... , .. ... . . . . , . , . . 1
II. A22789 Pressure gauge, 0 to 3000 psi ., . . . . " ... , .. ," 1
331-55 Case TCH Fluid . . . . . . . . . . . . , . . . . , . . , . . . . . .. 1 gal.

31
 Adapters Re qu ired To Connect Hand Pum p· To Control Valve Ports

'JORK
PORT

HM. O PUMP HOSE AOA PTER

71 0923
Figure 21

HA ND P Ui\'IP HOSE ADAPTER REQUIRED CONTROL VALV E PORT

JIC Thread , 37" Flare Cas e Part No. Straight Th r ead With O-ring

3/ 4" - 16 .JIC 218-5059 3/ 4" - 14

3/4" - 16 JIC 21 8-5060 7/8" - 14
3/ 4" - 16 .JIe 21 8-5070 1-1 / 16" - 12
3/4" - 16 JIC 218-5071 1-5/ 16" - 12
7/ 8" - 14 JIC 218-5066 314 " - 16
7/ 8" - 14 JIC 218-5062 7 /8" - 14
7/ 8" - 14 .JIC 218-5063 1-1 / 16" - 12
7/8" - 14 JI C 218- 5078 1-5/16" - 12

Adapters Required T o Connect Hand Pump· To Hoses And Tubes

HAN D PUM P HOS E ADAPTER CYl J Pl DER HOSE OR TU8 E

710924

Figure 22

HAND PUMP HOSE ADAPT E R REQUIRED CYLINDER HOSE O R TUBE

J IC Thread, 37" Flare Ca se Part No. JIC Thread , 37" Flare

3/ 4" - 16 JIC 218 -43 0 7/ 8" - 14 JIC

7/ 8" - 14 JIC 218- 430 3/4" - 16 JI C
7/ 8" - 14 JIC 218-736 7/ 8" - 14 .JIC

*Hand pllmp eqllipped as shown in Flgllr e 20 .

32
Hand Pump Test Procedures under Checking Pressure Settings
With The Control Valve Removed
Refer to Figures 20, 21, and 22 to deter- From The Tractor.
mine the hoses and fittings needed and make
these available before starting the tests. 5. Actuate the lever on the hand pump back
and forth. If oil is lost from line when
installing hand pump, itwill be necessary
to replace this oil by actuating the hand
pump lever--the hand pump must be
operated against a solid colwnn of oil.
Build up pressure against the relief valve
until it bypasses. ;>,lake several checks
as air in lines, etc. may give a false
initial reading.

6. Compare the readings with Spec ific ations

on page 26. Instructions for adjusting
val ves are on page 34.

CHECKING PRESSURE SETTINGS WITH

THE CONTROL VALVE REiVIOVEO
FROM TRACTOR

When the control valve has been re-

moved for servicing, the hand pump can
be easily joined directly to the control
Figure 23 - Hand Pump valve ports, Figure 21.

CHECKING PRESSURE SETTING WITH 1. Join the hand pump to the port ad-
THE CONTROL VALVE ON THE TRACTOR jacent to the valve being tested.

1. Warm up the hydraulic oil to normal

operating temperature of approximately 2. To test swing cross over relief valves:
125 F.
0

a. Join the hand pump to the port

2. Have the buckets resting on the ground. OPPOSITE the side of the relief
valve being tested. Test the top valve
3. Move the control lever back and forth from the bottom port, and vice versa.
for each circuit to be tested. This will
equalize hydraulic pressure within the b. Leave the opposite port open to
circuits. provide an outlet for the hand pump
oil.
4. Connect the hand pump to the circuit
at either of two locations:
3. To test swing hlghpressure relief valves:
a. The port next to the relief valve
being tested. a. Join the hand pump to the port on
the same s ide as the relief valve
b. Any convenient swivel fitting in the being test ed .
line leading from the port next to
the relief valve being tested. b. Install a plug (Case No. 218-5157)
in the OPPOSITE port.
NOTE: To test a relief valve in
the swing' section, see steps 2 and 3 4. Actuate the lever on the hand pump,

33
-
building' up pressure until the valve 5. Compare the r e ading with specifications
"cracks" open or bypasses. Make several on page 26, Adjust the val ve as r equ i red,
checks, See topic below.

Adlustln g Relle ' Valve.

Loader M ain Re lief Valve Ba ckhoe Second ary Relief Valves

1. Remove the acorn nut On the main r elief 1. Loosen jam nut.
val ve and loo s en the j am nut, To de-
c r ea se pressu re, turn the adjusting 2. Turn adjusting scr ew clockwise to in-
s crew cOlUlter clockwis e (out), To in- cr ease pr e ssure; counterclockwise to
crease pre ssure, turn the adj usting s c re w decrea.se pressure .
clockwise (in),
3. Again check pressure, then s ecure pr es-
sure setting with jam nut (without dis-
2, When the correct pressure has been turbing setting).
obtained , secure the setting with the
jam nut (without disturbing the setting). Backho e Swing Crossover Valves
Replace the acorn cap.
1. Loosen jam nut.

2. Turn adj usting screw clockwise to in-

Loader Secondary Relief Valve crease pressure; counterclockwise to
decrea se pressure.
These secondary relief valves are ad-
justed by adding or removing shims. 3. Again check pr e ssure, then secur e set-
ting with jam nut being c a reful not to
change the setting.
1. Use an Allen wrench and r emove the
plug from the end of the valve. Shims Pump Relie f Valve
are loc at ed ben eath this plug.
Used on non-loader models only. See
2. To increase pressure--add shims. To page 28.
decrease pressure--remove sllims.
Boo m Lockout Relie f V alv e
3. Install plug, tighten sec urely, and re-
check the setting. See page 30.

34
 4
TORQUE CONVERTER - POWER SHUTTLE

HYDRAULIC PUMP

A_ Fo ,m !I·8 oo0 1
 TORQUE CONVERTER HYDRAULIC PUMP
(Refer to Figure 1)
Disassembly
1. R emove tile adapter plate (2-1 I from th e through 22 ).
torque tube (28)
6. Remove roll pin (18 ), washer (22) if equip-
2. Remove hex. bolls (231 and remove the ed, roll p in (21 ). spring (20) , ball 119 1 from
all pump (11) from the adapter plate . relief valve body (17 ) .

3. Remove the Allen head seli-locking scre w 7. Remove hex . bolts (1), lockwashers 12 1 and
<15) from the end of shaft no!. then remove carefully Jift cover assembly 13) off of
snap ring jl-l) and '."asher <131 . p ump body assembly Ill) .

4. With a 5ultabl puller. remo'.'e the oil 8. Pull out drive shaft (10) and d rl ve gea r
pwnp drive gear (12). The gPJr is keyed (6), i dler shaft (8) and driven gear ( S) .
to the s haft (lO! with ke:! 19 ; .
9.lf necessary , press Shafts (10 and 8) from
5. Remove relief va!\'e assembl} (items 17 gears 16 and 5).

Inspection
Thoroughly cJea n a 11 parts bpfore inspec- Free Length .. ... . . . .. .. ...... . i 90 "
tio n. Replace all damaged or worn parts . Tota l CoJls .. ... .... . .. .... .. .... .... ... ....... 22
Working Coils .. . . . ... .... 20
Inspect all metal parts for scoring, nicks, Wire D ameter ... . . .. .. 052"
burrs or other damage . SUght burrs and Compressed to1 .27" .... . .. IT .5·21'i lbs .
nicks can be removed wi th a hone Of crocus
clo th . Check gears (S and 6) for wear. Width of
new gears is .7490" to .7500" . Outside dla·
Chec k cover assembly (3) and oj) pump metel' of new gears is 1.707" to 1. 709" . Ex-
body assembly ( ll) for excess II-ea r and out- cesslvely \Vorn gears Should be replac ed .
of- round ness.
Check shafts (8 and J(J) for wear. Shaft
Check re lief valve spring 12(J) for: di ameter is .4912" to .4915"' when new.

Assembly
l.Press shait (10) into gear (6' .594" from and r oll pin (18) 118" x 3 '4 " into body 1171,
outside of gear t o end of shall lend opposite Inset C. Assemble the relief valve assembly
snap ring groove I. Inset A. Th e gear is keyed to tbe oil pump body. Torque :30 to 40 ft. lbs .
127) to tlle shaft.
5. Assemble key (9) and the Dll pump drive
2. Press shaft (8) Into gear ,.'i ) .594" f r om gear ( l2) tosha!t (10) . the assemble washer
eithe r end of the shaft, Inset 8. The gear (13) , snap ring [14) and the Allen head screw
is keyed ( 7) to t h shaf l. (1 5) .

:l . Place shafts (8 and 10) into ady assembly 6. Place new gaskets (25) in oil pump body Ill).
(11 ) and replace cover assembly (3). Tor- then assemble the oil pump 10 the adapter
que hex . bolts (11 to 9-11 ft . lbs. plate (24) . Torque hex. bolts to 3';-42 ft.lb • .

'L Assemble the relief valve assem bly by in- 7. R eplac the adapter plate \ 2-11 on the Il'act r .
stalling t he baJl (19) , sprlng 120\ . roll pln Tor que the adapter plate mounting hex. bolts
(2 1) 3/ J6" x 1", washer (22\ i f equIpped (26 ) to 35,42 ft. Ibs.
 43-3

INSET A
HVORAUlIC PUMp

('0--- ~
® Ii)
INSET C

INSET B

®-~~
Figure 1 R ELI EF VA LVE
43-4

RELIEF VALVE TESTING

1. Remove hose lines and ins tall A22791 Pres- 4. If Pressure is Low - check for a plugged
sure Gauge in filter housing , Fig ure 2. filt er, r estricted lines, worn pump , low oil
leve l 0 1' worn spring in relief va lve. If the
press ure is still low, a washe r , Fig ure 3
m a y be added. One washer r a ises the pres-
s ure a pproximately 25 PSI.

5. If Pressure is High check for incorrect

oil viscosity, faulty pressure g auge or in -
c orrec t s pring in relief va lve . If the press ur e
is s till hig h, removing a wa sher will lower
the pressure approximately 25 P SI.

IN SET A
RELIEF VALVE

ADD OR REMOVE WASHERS HERE

Figure 2

2. Set the parking bra ke and make sure all

controls a r c in ne utral.

3. With the c lutc h engaged. hydraulic oil

walm and th e e ngine running , the press ure
gauge s hould rea d:

Idle Speed (600 Engi ne RPM ) - 275-325 PSI

Figure 3
High Idle (2250 Eng ine RPM ) -musl not exceed
550 PSI
 SECTION
43

EQUIPMENT PUMP
Includes Ihe Follovving Pumps:
048950 (Cessna)
049241 (TRW)
052271 (Websler)

Burt. " 0 " " 8-720BI5 K H CBO Pri nt .. d in U .S .A .

 TABLE OF CONTENTS

HYDRAULIC PUMP D4 8950 (CESSNA) All Models Except Dr awbar Tractors With Hitch .. 3

Specifications. . .3

Remova l .. .. . . . . . . . . . . .. 5

Disassembly. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 5

Assembly . . . . . . . . . .. . .. .. .. 7

Testing a nd Installlng Pump ...... 8

HYDRAULIC PUMP D49241 (TRW) All Model s Exc ept Dl'awbal' Tr actor s With Hitch 10

Specific a lions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

HYDTIAU LIC PUIYIP D52271 (WE BSTE R) Dr awbar T r actor With Three -Point Hitch. 14

Specifications . 14

Removal . . . . 14

Disassembly 14

Assembly .. 16

2
 HYDRAULIC PUMP 048950 (CESSNA)

Used on all mod els exc ept drawbar Operation

tractor with three-point hitch. Ca n be inte r-
changed with hydraul ic pump D49241. page 10. A bronze faced steel plate called a
diaphragm reduces gear end clearance by
Gener al applying hydraulic pressure from the outlet
side of the pump. The area behind the
The two gears revol ve in a close fitting diaphr agm is divided into pr e ssure com-
housing a nd tr ap oil between the gear teeth partments fOI"med by grooves in the fac e
as the teeth move out of mesh. The oil is of the front cover. A rubber "V" seal and
carried around the edge of the housing two gask ets are Ins talled in the groove in
and discharged at the outlet side. Refer the front cover.
to Figur e 1.
Pressul'ized oil from the outlet side of
VIE '0\' FROM REAR Of PUMP the pump is directed to the "V" seal through
a drilled passage in the gear plate. The
pressurized oil mO\1es the "V" seal rmd two
gaskets aga inst the diaphragm. Thed iaphragm
in turn presses against the gea r faces reducing'
gear end clearance and oil leakage. S ix
small holes drilled in the diaphragm equalize
pre ssure on both sides of the diaphragm.

A tln'ust pl ate is located at the opposite

side of the gear s to absorh wea r from the
gear faces . The six hole s in the t hru s t plate
maintain equal pressure on both s ides of
the thrust plate.

Two ball type rei ief val ves loc ated in

the frout cover pr event shalt seal blowout.
One r eli e ves into the suction sid e and the
other into the outlet side . When the gear
_ HIGH PRESS URE OUTLET OIL
shaft luhrication pressur e exc e eds either
_ L OW PRESSURE INLET OI L. U.UU'8 the suction pressure or the outl et pres sure ,
One of the steel balls will be forced from
Figure 1 - Pump Operation its seal and oil w ill flow past it.

Specifications

Output •• • . . . • . 24-25 gpm @ 2000 rp m @ 2000 psi

(91-95 l/mn @ 2000 tr/mn @ 141 kg/em' )
Tie bolt torque. · . . . . • . • . • • 40 foot-pounds (5, 5 m-kg)
Mounting bolt torque . • . . . . . . 80-8 5 foot-pound s (11-12 m-kg)
Rotation . . . . . . . • Count e rcl ockwise viewed fro m shaft end.
Wear allowances ... . . . . . . . . . . . . . . . .. Se e pages 6 and 7.

3
 DIAPHRAGM
MEAR PL ATE)

.I
~
~I .

\
3/8" - 16 x 3-1/2" (4)
FERRY HEAD
_ 3/ 8" - 16 x 3-1/4" (4)
f ERRY HEAD
701368

Figur e 2 - Expl oded View of D4 8950 Pmnp

4
Removal

1. Dra in hydraulic r eser voirs.

2 Remove radiator grille . Then remove dirt

and grease from pwnp and surrounding
area.

3. Disconnect suc tion line a t pump and plug

with clean caplug.

4. Disconnect tube at eillow on outlet side

of pwnp a nd plug with clean caplug.
htt,:lIstores.eba~comi UserfriendlyCDs 701356

5. Remove the two capscr ews that mount

the pump to the trac tor. Pull the pump Figu re 4 - Front Cover Removed
straight out to disengage it from the
crankshaft coupling. 4. To s ep arate r ear- cover fro m gear pl ate,
tap end of drive s ha ft with soft ham mer.
Disassembly Do not allow gear plate to cock on dowel
pins. Figure 5.
1. Scribe a line across the three sections
of the pump so that the front cover,
rear cover , and gear plate can be re-
assembled in the same pOSition.

Figure 5 - Gea r P late and Rea r Cover

Figure 3 - Disassembling Pump Sec tion

2 Use a standard 7/ 16", 12 point socket

to ,'emove the eight capsc r ews that hold
the pump together.

:3 . Use u soft metal ham m er , tap the front

cove r fr om the gear plate. DO NOT try
tu p r y sections apart, as the maehined
surfaces will lJe damaged. Fig"ur e 4.

Figure 6 - Removing Di aph ragm (W ear Plate)

5
5. Slip a sharp instrument under the dia-
phr'agm on the fronl co ve r and gently REPLACE GEAR IF
DIMENSION " A" IS
pry the diaphragm loo se . Figure 6. Re- LESS TH AN 873"
move the springs and bal ls, nylatron gas-
ket, protector gaske t, and V-seal. Dis-
card the gas kets and s eals. Figure 7.

7Dl 361

Figure 9 - Idler Gear and Shaft

• •~- " \/'" SEAL

2. Inspect the idler gear and shaft, F igur e

9. If the bearing area of the Shaft mea-
~NYLATRON sures less tha n .873", the s haft and gea r
l;g;;r GASKET
assemblies should be replaced. Check
the gear ends for scoring, biuing due to
701359 he at, and excessive wear. Check gear
width, if less than 1.297", r e pl ace gear.
Figure 7 - Removing Seals Make sure the snap rings are in plaCE:.
If the gear teeth have sharP edges,
6. Remove and discard the shaft seal from break corner with emery cloth.•
the front cover.

NOTE: Shafts and gears are serviced as

SHAfT SEAL
an as sembly only, and a l'e not ava ilabl e
separately.

701360

Figure 8 - Front Cover and Shaft Seal

Inspection 701362

Clean all parts and inspe ct for nicks Figure 10 - Checking the Wea r Plate
and burrs. Remove all imperfections On
machined surfaces with fine e mery cioth.
3. Inspect the wear pl a tes. Check for score
1. Inspect the driveshaft. Check the spline s marks and e rosion pits. If noticeably
fa r small cracks, wea r a t shaft seal eroded in c e nte r, deeply scored or
contact area, and rough spots. burned, replac e .

6
4 Insp ec t the bushings in lJoth the front 1. Place a new V-s ea l on the front co ve l'
and back covers. Figure 11. If the the V down. Use a dull ins t rument
bearing inside diameter is more than and install the s ea l into the co ver.
. 879 ". lJoth the front and rear covel'S In stall new pro tector gas ket on the V-
mu st be repl ac8d as an assem llly with seal. Ins tall new Nyl at ron ga s ket.
the bushings. Bushings are not supplied
sep ara tely. Bushings in t1,e front cover
are flus h with the edge of the cover.

REPUCE COy~R IF I
OIMENS~'lI. IS MORE
THAN .8 79 INCHE5

"V"S EAl
PROTECTOR

"~.~
~. NYLATRCN
~ GAS KET

701359

701363 Figure 13 - Ins tall ing Seals in Fl·ont Cove r

Figure 11 - Checking the Bushings 2. Pl ace one ball in eueh hole in the front
cover. Plac e a spr ing on top of eac h
5. Inspect the gear plate . Figure 12. Check ball.
inside of plate for excessive wear o r
scor e mark s . If inside diame ter of gear
pocket measure s over 2.107". replace.

REPLACE IF
DIMENS ION ''A"
IS MORE THAN
2.107 INCHES

701"" Figure 14 - Installing Balls and Springs

Figl.ll' e 12 - Checking the Gea r Plate 3. Install new cliaphragm (wear plate) with
the bronze s ide up. It must fit inside of
Assembly the rim on the V- seul. Mak e sure co il s
of the sp rings a r e not wedged be tween
A service kit is ava ilable for replacing diap hragrn and front cover. Figul'e 15 .
a ll the pump seal s and gaskets . Tlti s kit
contains a new thru st pl ate. diaphragm. 4. On the r ear co ver . install the thrust
gaske ts , shaft seal, diaphragm seal, and two plate (wea l' pla te ) with Ill'onze siele to-
steel balls and s prings . Refe r to the Case wa rd the gea rs. Sicle with cutaway nlust
Parts Catalog. be on the suction sick: of the pump (side

7
 with large s t portholes). This plate fits
inside the gear plate when gear plate
is s eated on r ear cove r. Figure 16.

Figure 17 - Installing Gears

8. Install seal protec tor (sleeve. tape. e tc .)

o n pump s ha ft. Carefully install s e al
Figure 15 - Front Cover a nd Diaphragm over the shaft. Use a 1-5/16" 0 .0. s ea l
driver and hammer. tap the seal until
". Lubl'ic a te the ge ar s in hydraulic oil it is seated In the counterbore of front
a nd In s tall assemb l ie s in rear cover. cove l'.
Figure 17.

TIGHTEN TO 40 FT. LBS. TORQUE

70llto7

Figure 18 - Assembling Pump

Figure 16 9. Us e a wr ench o r simila r tool and ro-

Re a r Cov er. Ge ar Pl a te . and We ar Plate tate the pump shaft 10 r e volutions. Pwnp
shoul d be almost fr e e enough to rota te
6. Appl y a thin coat of he avy grease to s haft by hand. If not. disas sem ble pump
mac hined surface s of gear plate and to find the c ause of the bind.
install ove r gea rs. Do not allow the
plate to cock on the gea r s. Half moon
ports On the gear plate faoe the rear Testing And Installing Pump
cover. Notice the s mall ho l e drilled in
one of the half moon cavitie s . This 1. Pour hydraulic oil in the la rger (suction)
must be on the high pr ess ure port side. port of the pump. Rotate the pump a few
r evolutions.
7. Slip rear cove l' In place . ins tall bolts.
and tighten evenly to 40 ft. pounds torque. 2. If shop test stand is available the fol-

8
lowing procedure for testing a rebuilt 3. If a shop tes t stand is not available the
pump is recommended: following procedure for testing rebuil t
pumps is recomm ended .
a. MOlmt pump on test stand making
sure the proper level of clean oil a. Install the pump on the tractor with
is availabl e in the rese rvoir. two capscrews and lockwashers.
Torque the capscrews 80- 85 ft.-lb s .
Reconnect the hydraulic lines and
b. Start pump and run for three min- fill oil reservoir.
utes at zero pressure.
b. Start the engine and run the pump
c. Interm ittently load pump to 500 psi at zero pressure (all control levers
for three minutes. in neutral) for three minutes. Have
the engine set at half speed.
d. Int e rmittently load pump to 1000
psi for three minutes. c. With the engine still at half spe ed ,
operate the control levers inter-
e. Intermittently load pump to 2000 mittently for thr ee minutes .
psi for thre e minutes.
d. Increase engine speed to full throttle
f. Remove the pump from the test and operate the control levers inter-
stand. Check the pump for leaks. mittently for three minutes.
Check the driveshaft for freed om of
movement (it should move by hand e. Idle the e ngine and check the pump
pressure). and hydraulic connections for leaks.

9
 HYDRAULIC PUMP 049241 (TRW )

U sed on all models except drawbar the oil groove in the end cove r, Oil fr om the
t!'actm' with thre e-point hitch, Can be inter- discharge sid e of the pump is dir ected to the
changed with hydraulic pump D48950, page 3, oil groove cast into the end cover by the two
slots and groove in the pressure plate. As
General discharge pressur e incr eases hyd raulic pres-
sure forces the seal package again s t the
The two gears r evolving in aclosefitting gears and pre vents leakage from the pr e s-
housing trap oil between the gear teeth as SU1'e side to the suction s ide of pump,
the teeth move out of mesh, The oil is carried
around the edge of the housing and discharged Holes in the pressure plate permit pump
at the outl et side. Refer to Figur e 1. oil to fill the pressur e "compartments "
formed by the seal pack. With pressure on
Operation both s ides of the gear plate thus equal i zed,
the pr essure plate maintains conta ct with the
A bronze faced plate call ed a pressure gear sides through all pres sure ranges.
plate reduc es gear end clearance by applying
hydr aulic pressure from the discharge side A positive pressure on the shaft seal is
of the pump, A seal package consisting of maintained by the oil passed through the end
a rubber web seal, two paper backing webs cover shaft bushings and a check valve in
and a phenolic backing web is pr essed into the driven gear shaft.

Oil UNDF.R rHE

SEAL PACKAGE FORCfS
ftRt:5SUAE' PLA Te AG AINST G'EA..IlS

SU\.L PACKAGE

Figure 19 - Gear Loading

Specifications

-Output. . • . . . 24.5 gpm @ 2000 rpm @ 2000 psi

(93 l i mn @ 2000 tr/ mn @ 141 kg/ cm<)
Tie bolt torque. · •. 25-35 foot-pounds (3.5-4.8 m-kg-)
Mounting bolt torque • . •. 80-85 foot-pounds (11-12 m-kg)
Rotation ., . . '. Counterclockwise viewed from s haft end.
Wear allowances . . . • . • . . • • . . . . • • • • . • . . See page 12.

10
 ~ DOWEL
END COVER
\
:\j
<.\j~ \
PRESSURE PLATE

3/8" - 16 x 1 -J/4~"~~~~~
FERR Y HEAD '

" ~::::3/8" -16 x 3/4"

FERRY HEAD
;

Fig"ure 20 - Exploded View of 049241 Pump

Removal 2. Remo ve the eight end cover mounting
bolts (four long and four short).
1. Drain hydraulic reservoirs.
3. Using a soft hammer, strike the mounting
ears alternately to separate the end
2. Remove radiator grille, Then remove cover from the body.
dirt and grease from pump and sur-
roundIng area.

3. Di sco nnect suction line at pump and

plug with clean caplug.

4. Disconnect tube at elbow on outlet side

of pump and plug with clean caplug.

5. Hemove the two capscrews and lock-

washers that mount the pump to the
tractor. Pull the plllnp straight out to
disengage it from the crankshaft
coupling.

Disassembly

1. Scribe a mark on the end cover and body

to assure proper reassembly. Figure 21 - Seal Package

11
4. Remove the pressure plate and a-ring 5 Using an inside n1icron1etcr, measure the
from the end cover. diameter of the gear bushlngs. If either
bushing exceeds 0.8777" in diameter the
CAUTION: DO NOT attempt to remove body must be replaced.
the seal package from the end cover.
These parts are serviceable only as Gears
part of a new end cover assembly.
1. Measure the diameter of both gears. If
5. Remove the drive and driven gears from either gear has a dimneter less than
the pump body. Do not remove the spring 2.1203" the gears must be replaced.
or check valve from the driven gear.
2. Measure the diameter of the gear
Inspection journals. If the dimnete r o f a journal is
less than 0.8737" the gears must be
Body replaced.

1. Check the sealing surface for nicks and 3. Measure the thickness of both gears . If
burrs. Ifnlcks or burrs are noted, remove one gear measures less than 1.5110"
with a piece of crocus cloth or flat India the gears must be replaced.
stone.
NOT.: The thlckness of the gears must
2. Clean the body in cleanlng solvent and mea sure the same within 0.0005".
make sure all passages are free of
foreig1l matter. 4. Check gear faces and journals for
scoring. Replace the gear set if heavy
:3. U sing an inside micrometer, measure the scoring is evident. The gear teeth should
gear bores. If either bo re dlameter have sharp corners and not rounded.
exceed s 2.1253", the lJody must be re-
placed. End Cover

CAUTION: DO NUT remo ve the seal

package from the end cover. These parts
are not serviceable ite m s.

1. Use a lint free cloth moistened with

cleaning sol vent and clean end cover.
Do not SUbmerge in cleaning sol vent
or dry with compressed all'.

2. Check the sealing surfRee fbI' nicks and

burrs. If nicks or burrs dre noted,
remove with a piece of crocus cloth
or flat India stone.

3. Using an inside micrometer, measur e the

bushlng diameter. If either bushing ex-
ceeds 0.8777" in dlmneter the end cover
704l1''7 must be replaced.

Figure 22 4. Inspect the shaft seal for cracks, de-

terioration and other defects.
4. Using a depth micrometer, measure the
depth of the gear bores. If either bore 5. If the pump has been disassembled be-
depth exceeds 1.5155" the body must be cause of low output and the pump tXldy
replaced. and gears are found to be serviceable,

12
 it can be assumed tha t the s eal package a soft hammer until thE' body is seated
is pmbablydefective , r equ iring end cover against the end co ver .
r e placement.

6. Inspec t the pressure pl ate for scoring.

pitting' and exc essive wear.

Assen'lbly

1. Position gears in body as shown in

Figure 23. The check valve spring in
the driven gear must be up.

Figure 24 - P r essure Plate Ins talled

5. Secure the end cov.:: r to the body with

the eight fe rry head bo lts (four long and
fo ul' short). Torque the bolts evenly to
25-35 foot powlds . Tor que bolts in se-
quence as shown in Figure 25.

Figure 23 - Installing Gear s

2. If the shaft seai wa s r emoved . press in a

new se:t!' The seal must be squa r e to the
bus hing within .002" and pr essed in . 010" -
. 020" be low the eCig'e of the s eal bore .

.3 . Coat the smooth side of the press ure

pl ate with a light. clean grease and
position on e nd cove r as shown in Figure
2 4. The n coat the a -ring with grease
a nd position in groove formed by the
pre ssllre plate a nd end cover.

4. Set body on work bench w ith gears up Figure 25 - Torque Sequence

and instal l end cover over gears being
ca r eful no t to damage the shaft seal. In stallation
When end cover starts On dowel pins
invert the pump and s et the pump on See Testing a nd Ins t alling Pum p on
open jaws of vise. Strike the body wi th page 8.

13
 HYDRAULIC PUMP 052271 (WEBSTER)

Used on drawbar tractors with three-point hitch only.

Specifications

Output . . . . . . . • . . . 12 gpm @ 2000 rpm @ 2000 psi (45 1/mn @ 2000 tr/ mn @ 2000 kg/em')
T Ie bolt torque . . . . · ..•• 25-35 foot-pounds (3.5-4,8 m-kg)
Mounting bolt torque · . . • . . 80-85 fo ot-pound s (11-12 m-kg)
Rotation . . . . . . Counterclockwise viewed from s haft end.
Wear allowances · . . • • . . • . . . • . • . . . . . See page 16.

General Di s assembly

The two gears revol ving in a close fitting 1. Scribe a m ark across the thr e e sections
hous ing tra p oll between the gear teeth as of the pllmp to assure proper r eas sembly.
the teeth move out of mesh. The oU is carr ied
al'ound the edge of the housing and discharged 2. Remove the eight tie bolts (six hex.
at the outlet side. Move m ent of au thr ough head ruld two socket head).
the pump is the same as s hown in Figure 1.
3. Secure the pump U1 a vise. USU1g a soft
hammer, strike the mounting ears alter-
Operation nately to sepera te the body fro m the
gear plate.
Two br onze faced pressure plates reduce
gear end clearance and internal leakage by 4. Remove the pressure pl ate , pressure
applying hydr aulic pressure fr om the dis- plate seal , backup ring and sealu1g rU1g
charge side of the pump. Oil from the dis- fr om the body. Do not remove the shaft
charge side of the pump is directed to the seal unless it is to be replaced.
pock et for med by the sealing ring a nd its
backup ring under each pressure plate. As 5. Remove the drive and driven gear s from
discharge pressure increases, hydraulic the end cover. Then rem ove the gear
pressure forc es the press ure pl ates more plate fr om the end cover. T ap the gear
firmly against the gears. pl ate with a soft hammer to aid removal.

Drill ed passages from the suc tion side 6. Rem ove the pressure plate, pressure
of the pump provide bearing lubrication. plate seal, backup ring and sealU1g ring
from the end cover.

Removal 7, DO NOT remove the bearings from the

body or end cover unless ins pection
1. Dra in hydr a ulic reservoir. indicates need for replacement.

2. Remove r adiator grille. Then remove Inspection

dirt and grease from pump and su r-
rounding' area. Body
3. Disconnect suction line a t pump and plug 1. Check the sealing sur face for nicks
with clean caplug. anci hurl'S that m ay result in leakage
when the pump is reassembled. Use a
4. Disc onnec t tuhe at elhow on outlet side flat India stone to re move defects .
of pump and plug with clean caplug.
2. Inspect the gear shaft beurings for flat
5. Remove the tw o capscrcws with lock- spots, pitting and othe r d efec ts . If the
washers that mount the pump to the bearings are to be removed, use a suit-
tractor. Pull the pump straight out to abl e bearing jlull er being' careful not to
disengage it fro m the crankshaft coupling. damag'e the bearing uore.

14
 PRESSURE PLATE
SEAL RING
\

DRIVEN GEAR

\
PRESSURE PLA TE
SEAL RING

'\
BODY

701369

Figure 26 - Exploded View of 3 Point Hitch Pump

15
3. Clean the body in cleaning solvent and NOTE: Whenever the gears are replaced,
dry with compressed air. Make surc all the four shaft bearings must be re-
passag'es are open. placed.

4. Inspect the shaft seal for wear, deter- Sealing Rings And Pressure Plates
ioration and other defects.
1. Discard the pressure plate seal rings and
Gear Plate the two sealing rings.

1. Check the sealing' surfaces for nicks 2. Inspect the two backup rings for signs
a nd burrs that may result in leakage of cracks and other defects.
when the pump is reassembled. Use a
flat India stone to r e move defects. 3. Check the pressure plates for excessive
wear. Place a straightedge on the pres-
2. Measure the diameter of the gear bores. sure plate; if wear exceeds .005" where
If either bore measures over 2.181" the gears contact the pressure plate the
the gear plate must be replaced. plate must be replaced.

3. Clean the gear plate in cleaning solvent

and dry with compressed air. NOTE: Scoring, pitting, CJtc. are sig11s
of possible oil contamination. Check the
End Cover hydraulic oil for contamination (water,
metal particles. etc.).
1. Check the sealing surface for nicks and
burrs that may result in leakage when As sembly
the pump is reassembled. Use a flat
India stone to remove defects. 1. If the shaft seal was removed press in
a new seal. Press the seal in until it is
seated On shoulder in seal bore.
2. Inspect the gea r shaft bearings for flat
spots, pitting and other defects. If the 2. If the gear shaft bCJarings were re moved
bearings are to be removed, use a suitabl e install new bearings. Press the drive
bearing puller being careful not to damage shaft bearing into the bo<ly until it is
the bearing bore. approximately 3/32" below the edge of
the bearing bore, Figure 27. Press the
remaining body bearing and the end
3. Clean the end cover in cleaning sol vent cover bearings in until the bear ing is
and dry with ccmpressed air. Make sure seated On the shoulder in the bearing
all passages are open. bore.
PRESS BEARING IN APPROXII/,ATELY
Gears 3/3 " BELOW THIS EDGE

1. Inspect the gears for excessive wear,

scoring, grooves and pitting. A dull
finish on the gear faces, bearing jour-
nals and teeth indi cate abrasive ma-
te rial in the hydraul ic all.

2. If the gears measure less than 2.173" 701370

in diameter or .6995" in width the gears

must be replaced. Figure 27 - Driveshaft Bearing Install a tion

3. If wear in the shaft seal area is easily 3. Secure the end cover in a vise with the
detectable with a fingernail, the gears ports down. Install a sealing ring followed
should be replaced. by a backup ring in groove in end cover.

16
4. Lightly coat the pr essure pl ate seal ring face up) with seal ring On body. Make
with grease and place pressure plate sure the r owlcl port hol e is on the
(with aU grooves ) in seal ring with pre ss ure side of the oody.
bronze face up. Place the pressure
pla te (bron ze face up) with seal ring on 9. Lubricate s haft seal with bear ing gr ease
end cover making sur e hol es in plate and position body on gea r plate . Use
co rr e spond to po rt openings in end cover. care not to damage the s e al lip.

5. Pl ace ge a r plate on end cover aligning 10. Ins tall the e ight tie bolts a nd tighten
mark madc during disassembly. eve nly. Torque the oolts to 25 -35 foot
pounds.
6. In stall the d rive and driven gears in
their respectiv e bo res. 11. After the tie bolts have been torqued,
rotate the dri veshaft to check fr eedom
7. Ins tall the renlaullng sealing ring of movement. If movem ent Is jerky o r
followed by the backup ring in groove in turning effort is gre ater than 3 inch
the body. pounds, the pump should be di sa ssem-
bled to deter min e cause cf bind.

8. Lightly coat the pres sure plate seal Installation

ring w ith grease and pl ace press ure
pl ate in s eal ring with bronze face See Testing a nd Ins talling Pump on
up. Place the pre s s ure plate (bronze page 8.

17
 Section

4
3 POINT HITCH CYLI NDERS

TABLE OF CQNTENTS
Til t Cylinder ..... ........... .. ..... ........... ..... .................. ......... ..... ... ... ............. ... .... .... .. .... ............. ...... 2

Lift Cylinder ............... .... ... ......... .. ... .... ... ... ......... ..... ......... .. ... .... .... .... .. ........ .. ......... ... ... .............. . 4

Pitch Cylinde r ... .... ........ ,...... ...... ... .. .... ............ , ..... .. ... ....... .. .... ..... , ........ ... .. . ,...... ,..... .. ........... ... ,.. 6

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Rae. Form 9-80821

 44-2

TILT CYLINDER
(Refer to Figure 1)
L Pis ton r od "C" c up sea l. Ins tall into g land (6) with sea l lip toward pi ston end of rod.

2. Pi s ton rod wiper (outer ). Press into g land (6 ) with wiper lip toward piston rod eye.

3. Gland "0" ring. Inse t A.

4. Gland back-up ri ng . Inst a ll wit h c urved face to ward " 0" ring (3), Inset A.

5. Piston rod wiper (inner). Ins tall in to g land (6) with tapered lip toward piston end of rod , Inset A.

6. Sea l g land . Lubricate the bore' of the sea l gland a nd slide the seal gland assem bly over piston
rod.

7. Pi s ton rod (1.25 " diameter ) .

8. Piston ha lf, rod end (1- 114" ci ia meter recess). Se e o. 10 be low a nd Inset B.

9. Piston hal f. bolt end (1 -.) / 8" diame ter rece ss ). See 1\0. 10 be low and Inse t B.

10. Pi ston "Vee Sea l" packing . In stall ha rd outer packing ring on each piston half. In stall t hree
c hevron r ings on each pis ton half with the "Y" of the c hevron ring toward s the cente r of the
pi s ton . See Inse t B.

11. P iston seal bearing ri ng . Ins ta ll between the "Vee Seal" packing. See Inset B.

12. Pi sto n retaining was her.

13. Piston retai ning bolt (gl'ade S, 3/ 4" diame te r). T orque 200-220 ft. Ibs. Clamp r od eye e nd
of piston rod in a vise and s upport the piston rod when to rquing the bo lt.

14. Seal g land retaining scr!'w (=8-32 x 1/4" se lf·tapping ) . Lub ricate the pisto n seals and install
pi s ton rod with gland into th e cylind er be ing careful not to cut the "0" ring or back·up ring.
Torque th e gland 100-200 ft. Ibs. using Case spanner wrench 044111, [nset C.

15. Rod pivo t bu s hing (self a ligning) .

16. Bushing re ta in ing sna p rings_

17. TU\le pivot bus hings. Press in to place.

18. Cylinder tube.

19. Grease fi tt ing.

 .J4-4

LIFT CYLI NDE R

(Refer to Figure 2)
1. Piston rod "U" c up seal. Install into gland (6) with sE'al lip toward piston e nd of rod.

2. Piston rod wi pe r (outer). PrE's s into gl a nd (6) with wipE'r lip towa rd piston rod eye.

3. Gland "0" r ing, InsE' t A.

4. Gland ba ck-up ring. Insta ll wit h curved face toward "0" ring (:l) , Inse t A_

,5. Pisto n rod wi per (i nne r). Install into gla nd (6) with tape red lip towa rd pis ton end of rod, Inset A.

6. SE'a l gland. Lubricate the bore of the sea l g land and s lide the seal g land assem bly over piston
rod.

7. Piston rod (LiO" dia me te r).

8. Pi s ton half, rod end (1- 112" d ia m e te r recess). See No. 10 be low a nd Inset B.

9. P iston ha lf, bolt e nd (1-5/8" di am eter recess) . See No. 10 below and Inset B.

10. Piston "Vee SE'a l " pac king . Ins ta ll hard oute r packing ring on ea ch piston half. Install threE'
c he vron ri ngs on each piston half wit h the "V" of the chevron ring towa rds the cente r of the
pis ton. See Inset B.

11. Piston sea l bearing r ing. Install between the " Vee Seal" packing. See Inset B.

12. Piston r eta ining washer .

13. Pi s ton re ta ining bolt (grade 8, :Ji4" diameter). Torque 200-220 ft. lbs. Clamp rod eye e nd of
piston rod in a visc :il1d s upport the piston rod whe n torq uing the bolt.

14. Sea l g land re taining screw (08-32 x 1/ 4" self-ta pping ) . Lubricate the piston seal s and inst all
pisto n r od with gland in to the cylinder being careful not to c ut the "0" ring or back-up ring.
To rque the gland 100-200 ft. lb s. Us ing Ca se spanne r wrench D44112, Inset C.

15. R od pi vot bushings. Pre ss into plac e.

16. T ube pivot bushings. Press into place.

17. Cylinder tube .

18. Grease fi ttings.

 44·5

INSET A INSET B PACKING RING

NYLON RING
NYLON RING RENE RING
NEOP

INSET C
 44- 6

PITCH CYLINDER
(Refer to Figure 3)
L Pis ton rod " U" c up ,ca L Ins tall in to g la nd (6) with seal lip to wa rd piston ('nd of rod.

2. Piston rod wi p('r (outer )_ P res, into g land (6) with wiper lip towa r d pi s ton rod eye.

:3. Gland "0 " ring, Inset 1\.

4. Gland bac k-up r ing _ In sta ll with c ur ved [a ce towa rd "0 " r ing (3), In se t A.

'i_ Pi ston r od wipe r (inne r). Insta ll int o g land ( 6 ) with tapered lip to ward piston end o[ rod, Inset A.

6_Seal g la nd_ Lubricat e thre bore of the seal g la nd a nd slide the sea l gland a ssembly 0\-'(' 1' piston
rod .

7. Pis ton rod (1.25" diametel·) .

8. Cylinder p is ton.

9. Piston "0 " r ing , 1Ils('t B.

10. P is ton sea l rIng. Install onto p i$ton coveri ng "0 " ring, Inse t B.

11. Pis ton wea r ring . Inset B.

12_ Pi s ton r eta ining bolt (grade 8, 3/4" diameter) . Torque 200-220 it. lhs. Oamp rod eye end of
pi ston rod in a VIse and SU P POrl the p iston rod when torquing the bolt.

13. Seai g ia nd retaining screw ("8-32 x 1/4" self-tapping) . Lubl"icate the piston seals and install
pisto n rod with g la nd in to the cyli nder being careful not to e u the s eal rIng or wear ring.
Torque the gia nd 100-200 ft. Jbs. using Case s pa nner wrench 044111, Inset C

H. Piston rod pi vot bushing (self aligning)_

15. Bushing retainin g snap r ing:;.;,

16. Cylinder tube.

17. Tube pivot bushing (scJ[ aligning)_

18. Bushing r et aining snap rings .

 44-7

INSET B

,
I
......

I
I
I
,

17

INSET C

044111

figure 3
 SECTION
44a

LOADER
CONTROL
VALVE

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Burl . For", 9-72085 K H CBO Print e d in U .S . A .

 TABLE OF CONTENTS

SPECIFICATIONS. . ........•.....•....•••..••..••....•.. , 3

SPECIAL TOOLS . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL . . . 5

OP ERATION .. . .. 6-8

i\Ia!n Relief Valve . 6

on Flow - Lift Spool Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

on Flow - Lift Spool In Float.. 8

Float Detent .. . . . . . . . . . . . 8

SERVICING WADER CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14

Removal . . . . . . . . . . . . . . . 9

Disassembly . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 9

Lift Spool .. . .. . . . . . . . . . . . . . . . . . . . . . . . 9

Tilt and Clam Spool . . . . . . . . . . . . . . . . . . . . . . . . • . . . .. . . . 9

Main Relief Valve . . . . • • . . • . . . . . . . . . . . . . . . • • . . . 10

Secondary Rellef Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 10

Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11

Assembly . . . . . . • . . . • . . . . . . . • . • • • . • . • . . . . . . . . . . . . . . . • . . .. 11

Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12

Sec ondary ReItef Valves . . . . . . . . . .. 12

Main Relfef Valve . . . . . . . . . . . . . . . 12

Tilt and Clam Spool . . . . . . . . . . . . . .. 13

Lift Spool . . . . . . . . . . . . . . . . 13

InstaHation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .. 14

2
 SPECIFICATIONS

Case part no.

2 spool val ve . .. D45040
3 spool valve . . . D52 0 42
Description . . . . . . See page 5.
Relief val've p ressur e setting
Ma in relief val ve . . . .. 2200 ± 75 psi @ full throttl e
(155± 5,2 kg/ cm'@full throttle
Secondary reI ief val ve
Clam B port .. 2500 ± 100 ps i @ 10 gpm
(176 ± 7 kg / cm z @ 38 l i mn)
Tilt A port. , 2500 ± 100 psi @10 gVm
(176 ± 7 kg/e m' @38 1/mn)
Tilt B port, , 205 0 ± 100 psi @ 10 gpm
(144 ,_ 7 kg/ c m"@ 38 1/mn)
Oil t emperature when c hecking pressure settings . . . . . . 120" F. (49 " C.)
Spools and ports
Spool travel, neutral to pressure 3/8" (10 mm) in an d out
Sp ool in . . . . . . . . A port pr e s s uri zecj
Spool out .. , .. . . B port pressuriz ed
Spool travel, neutral to float . 11/16" (17 mm)
Port threads
All work ports . 7/8 "-14 st r a ight
Inlet port .. .. 1-1/16"-12 str a ight
Outlet port, power beyond .. 1-5/ 16"-12 straight
Power beyond fitting, internal. 1-1/ 16"-12 straight
Outlet port, return oil 1-1 / 16"-12 s traight
Weight (approx.)
2 spo ol valve . .. 28 Ills. (12,7 kg)
3 spool valve .. .. 36 Ibs. (16, 3 kg)
Spring specifications . . Compre s sed length
Ma in r'elief plunger. . . . 13 / 16" @ 4-6 Ibs .
11 / 16" @ 25.5-28.5 Ibs .
Ma in relief poppet . . 21/32" @ 4 .5-5.5 Ibs.
Secondary rel ief 27/ 32" @145.5-178.5 Ibs.
Check valve. . . . .. 3/8" @ 3/4 lb.
5/8" @ 1/ 4 lb.
Detent 1-3/8 " @ 153-187 Ibs .

U.S . AND METRIC TORQUE SPECIFICATIONS

Hydraulic Fillings (Sleel)
0
37 Flare St r aight Threa d
F em ale Swive l O- Rmg
D <.J sh T ube Th re ad Torque Torque
Size U .D. Slze ft. illS . m-kg; flo los . Ill - kg
4 1 / 4" 7 /16" - 20 6- 12 0.8 -1,7 12-19 1,7-2, 6
.) :) / 16" 1 /2 " - 20 8-16 1,1-2 ,2 16-25 2, 2- 3,5
6 3 / 8" 9 / 16" - 18 10- 25 1 ,4 - 3 ,5 25- 40 3 ,5- 5 , 5
b 1/2 " 3 / 4" - 16 1 5- 42 2 ,1-5, 8 42- 67 5 , 8- 9 ,2
10 5/6" 7 /8 " - 14 25- 58 3, 5- 8 ,0 58-92 0 ,0-12,7
12 :J / 4 " 1 -1 / 16 " - 12 4 0 - 80 5,5-11,0 50-12 8 11-1 8
H 7 / 8" 1-3/ 1 6" - 12 60-1 00 8 ,3-1 4,0 10 0- 16 0 14. - 22
16 1" 1-5/ 16 " - 12 75 -117 10-16 117-1 8 7 16 - 26
20 1-1 /4 " 1- 5/8" - 12 125-1 65 17-23 165- 264 23-:J 6
24 1-1 / 2" 1- 7/8 " - 12 210-250 29 - 35 250-400 36- 55
70117':

3
 SPECIA L T OOLS
The tools (kit part no. D45700) ill- Service Parts Supply to aid In servicing
ustrated in Figure 1 are available from the loader control valve.

690 154
.6901 55

Figure 1 - Special Service Tools

MOST HYDRAULIC PROBLEMS ARE C AUSED BY

CONTAMINA TED OIL!

Keep The 011 Clean

1. Cle an the filler c ap area before checkIng oil level.

2. Us e a clean funnel and containe r when adding oll.

3. Clea n exterior of components, li nes, and fittings before removal.

Close openings with cl ean c aplugs.

4. Make r epa irs on a cle a n wOl'k bench. Use clean tools.

5. Change oil and s ervice the filter(s) when making repairs.

NOT.: If drained oil is reused, It should be filtered before

r e installing in the rese rvoi r .

6. If pa rts inspec t ion indicates tha t metal chips, shredded packing,

etc. have entcred the hydraulic system, the system should be
flushed, filte r(s) serviced, and new oil ins talled.
70 1167

4
 GENERAL
The loader contro l valve Is a two spool ce nter outlet which contains a power beyond
(three spool with 4-in-1 bucket), open center, fitting.
parallel circuit (passage) valve . The parallel
passage is connected to the Inlet port and The power beyond fitting permit s the in-
dead ends at the lift s pool, supplying oil to the stallation of rear mounted hydraulic s without
work ports. Check valves between the work additional valves to control oil flow. It also
port s and the parallel passage prevent rever se permits the use of the main relief valve to
oil flow between the cylinders and the control protect the backhoe hydraulic system from
valve as a spool is moved into a power po- excessive pre ssu re. However, o nly one sys -
s ition. An adjustable maIn relief valve at the tem can be operated at one time -actuating
cont rol val ve inl et prevents excessive pres- a loader 80ntrol valve s poo l blocks 011 flow
sur e in the hyd raulic sys tem. Seconda r y r elief to the rear mounte d hydraulic system.
valve s are connected to the A and B ports of
the tilt s pool, and the Bpo rtofthe c lam spoo l
to protect the individu al c i r cuit s when a cyl- With the loader control v alve spool s In
inder is forced to m ove with the spool in neutral, oil flow s stra ight through the open
neutral. The valve contains two outlet ports, center passage and the power beyond fitting
one connectln~ the wo rk port return passage s to the rear mounted hydraulic s control
to the r eservoir retur n line and the open valve( s ) to the re servoir.

CHECK VA LVE
•
•
HIGH PRE
STATIC
- OIL

LIFT SPOOL PORTS A A~H} s . !t~=:=~'11

CLAM SPOOL paRT ~. POVIER .n'~ ''' '
",...7.."...,~
FITTING

'POPPET

PARA ll EL
CIRC UIT

SEC m mAR Y R£UE F

TILT SPOOL PORTS A Atl D fs ,
CLAM SPOOL PORT 8 ,
BM66 11 ~3

Figure 2 - all Flow - Spools In Neutral

5
 OPERATION

Main Relle. Valve m ai n relief valve opens to protec t the hy-

draulic system from damage. When the relief
The main reltef valve is located at the I'alve is open, oil is diverted to the r e servoir.
inlet of the control valve. The valve poppet
protrudes into the open ce nter pa ssage a s 1. When pressure in the open ce nter passage
illustrated in FIgure 2. reaches the pres s ure se tting of the relief
valve, the pilot plwlger is fo rc ed off its
The main r e ltef valve is pilot operated. seat.
This me ans a spear shaped pilot plunger
controls the pressure at which the valve 2. Oil flows through the plunger seat fas ter
opens and permits a gradual opening of the than it can be s upplied, creating a
r e llef valve. Note that a small hole is drilled pressure differential (lower pressure )
through the poppet. This permits the same between the poppet and plunge r.
pressure to be maintained on both s ides of
the poppet during normal operation and helps 3. The pressure in the open cente r passage
control the gradual opening of the l'eliefvalve then unseats the poppet and oil is diverted
when pressure r e ac hes the spec ified set ting. through the seat sleeve to the r eservoIr.

When a cylinder reaches the end of its 4. The relief valve will remain open until
travel or is held for any reason with the con- the cylinder move s a r the control valve
trol va lve spool in ;) power positIon , the spoo I Is returned to neutral.

CD ®
PRESSURE BELOW snTl N G PRE SStJIIE ABOVE SHfi NG
OF MA.1N REliEf VALVE Of MA I N RELIEF V. . . LVE

ST" CD
FiO".... S BACK
TO 1lf:.5E R\>011

STE P CD
11 ~U S!;U. E
ON POPPEr
CAUSES POPPEt
TO UNStAT

"""""'''-1~§~~
:::;! srEP CD
OIL UNA8lE TO SlEED
T.l"f: U PINHOLE
FAST ENOUGH to
R£FlAC£ Oil !lED
PAST PILOT PlUNGfR

STEPC!)
P ~ ES SJJR E
CAUSES
PILO T PLUNGEr.
TO UNSEAT

• STATIC Oil • HI GH PRE SSURE Oi l

Ou. aHOw AREA Of PRES SURE

IAA I N RE LIEF J>l FFERfNTIAl
SUTI NG Qll BElOW NAIN
REU EF SE rTt NG

Figure 3 - ?vlain Relief Valve Operation

6
Oil Flow - the r od end of the lift cylinders
Lilt Spool Actuated c ausing the loader fram e to lower.

In Figure 4 the lift spool Is moved Into c. Simultaneously, the [J port is opened
the valve body which: to the return pass age, allowing oil
displaced from the clo sed end of the
11ft cylinders to retu r n to the r e s er -
a. Blocks the open center passage. With voir.
open center blocked, all 011 from the
pump flows through the parallel When the spool Is returned to neutral, 011
pas sage. Is locked be tween the control valve a.nd lift
cylinde rs, preventing further movement of the
loade r frame.
b. As pressure in the para llel passage
increases, the check poppets open, To r a ise the loader frame, the spool Is
permitting oil to flow to the A port. moved out of the valve body and 011 flow i s
From the A port, 011 is directed to reversed .
• HIG H PRESSURE OIL
• STATIC OIL

LOW PRESSURE 01 L

OPEN

TO CYLINDER

SPCOL ACT UATED

INTO VALVE BODY 711 0jS

Figure 4 - 011 Flow - Llft Spool Actuated

7
 lOW eKt,> ",,<t
all Flo_ -
Lift Spool In Float . STATIC

When the 11ft spool is in the float po-

sition, oil from the pump flow s through the
open center passage to the outlet. The two
work ports are dil'ectly connected through
the hollow center of the spool. Openings
next to the narrow, outer lands permits oil
to entel' the hollow center of the spool. 011
in the 11ft cylinders is then free to flow
through the spool in either direction, Another
opening which Is po sitioned in the r eturn
passage allows a small portion of oil to be
diverted to the reservoir. The loader frame
11'111 lower because of its weight if raised ,
or follow the contour of the ground as in
dozing.

6M5 6 11 :'2

SPOOL IN N EUT RAL

Figure 5 - 011 Flow - Lift Spool ill Float

Float Detenl The amount of pressure required to

engage or disengage the detent is dete rmined
The float detent hold s the 11ft spool in by the pOSition of the adjus tment plug in the
the float position mechanically. Refer to detent housing.
Figure 6. As the spool is pushed into the valve
DO Eti T SPR I r<G OE TEI C ~. f"1 SPOOL
body, the detent stud forces the s teel balls
outwal'd, a llowing the spool to be positioned
in float , When the r idge On the detent s tud
p asses the balls, the detent spring and the
tapered surface of the de tent cam hold the
balls in the groove on the stud, preventing
the spool from re turning to neutral when
the c.ontrol lever is released. A light tug on
BALL S (6) "em,
the control lever will allow the spool to r eturn
to neutral. Figure 6 - Float Dete nt (Spool In Neut ral )

8
 SERVICING LOADER CONTROL VALVE

Removal

Figure 7 - Control Valve Location

1. Remove accumu lated dirt and gre ase

from contro l valve and surrounding area.

2. Rest the loader and backhoe buckets on

the noor. Figure 8 - Lift Spool

3. With the engine shut off, opera te the 4. Grasp the spool centering spring and
control lever In all directions to equalize pull spool from valve body. Then remove
elr cu it pres sures. the two a-ring retaine rs a nd a-rings
from the spool.
4. Disconnect the hoses and tubes from the
control valve. Plug the hoses and tubes 5. Remove the spool gland a nd sleeve from
with c lean caplugs. the control valve. Then remove the wiper
reta iner, wiper and a-rings from the
5. Disconnect the (;ontrollever linkage from spool gland.
the spools.
6. Do not remove cente ring spring from
6. Remove the control va lve from the mount- spool unless orange Loctite is avatlable
ing plate by removing the four bolts with for use during asse mbly. To remove
nuts and lockwasher s. the spring, secure spool in a SaFT
jawed vise ane! install spring compressor
illustrated in Figure 1. Compress spring
DI.a • • embl~ and unscrew the de te nt stud. Remove
spring compl'e s sor from spring.
Lift Spool
Tilt Sp ool And Clam Spool
1. Remove the detent adjusting plug and
spring from the dete nt housing, Figure 8. 1. Unscrew the spool cap from the valve
body.
2. Re move the detent cam, stee l ba Us(8) and
detent washer from the detent housing. 2. Grasp the spool centering spring and
pull from valve body. Then remove
3. Unscrew detent housing from oontrol a -ring and O- ring ret a iner from the
valve. spool.

9
 SPOOlCA~ from the cartridge. Do not remove
Sf'.lJo,P -R ING \. the pilot plunger seat unlesa it is to
SPRI G SEA 1 "
5PAC Ert ......
(C'.
" -.
'(,II
be replaoed.

PLUC ............. ~0
@--c.-C EN f ER:ING S'i'R 1I.... jG
'"" . \S)~O-AING
~s:PRJ NG $~A r A ..rtV-- O!:!AIN SLEEVE
~-O-Rn..JC RETAINER . / / ' C -" ~- '5EA T 5lE·eVf
J ./
,J _
-"- O -R IN G ~, _ SAC KUP I? ING

? . >::1~ ~. Yl -'O -R ING A

~) J ~C""TRlOG'
&'1
#,1'--
k\~'; V
(92
PIlO T PLUNG ER

. ..J ""'''''''''''-' POPPEl' /: '- ?LU NCER SPRING

/] k O -RING
-
_ POP PEl
SEA T
_
//
w- - A DJUSTlNG $CREw
~ -c R..l '-
(,f'. A ~"'- POPPET ; : I.,..I _ - WA.SHfR

1I!!I\©-
W -
O - O -<lN G
C-rHNG
GL':" N D
~ ErAl NEJt. A
IJf
I)........

\
BACKU P RING
SPR IN G
...... PI Lor
PLU NG ER SEAr
f'~ -:::- JAM NUl
1....7......... WAS HEIt
ACORN NUT

Figure 9 - T1lt and Clam Spool Figure 10 - Main Rellef Valve

3. Remove the spool centering spring lf 4. Remove the plug from the oppos ite end
required. of the valve body and remove the drain
sleeve and seat sleeve f rom tbe r e lief
a. Secure the spool In a SOFT JAWED valve bore. Then remove the O- rlngfrom
vise and compress spring as shown the plug and the 0- ring and backup rtng
in Figure 1. from the seat sleeve. Do not remove the
poppet seat from the seat sleeve unless
b. Remove snap ring from spool and it is to be repl aced.
release spring compressor. Then
remove the spring and spring seats Secondary Relief Valve s
from the spool.
O-RING PLUG , "'---)
4. Remove the spool gland, a - ring retainer SH IM(S)-V
\ --: / ,,-:\
and a-ring from the valve body. Remove SPRIN G GUI DE-... ...- . k~ [A~lRIOGE
SAC KUP RIN G _:;';; ~
~ O - RINGe:
spool gland with tool shown in Figure 1. ~PIW-..j G _ J / •
POPPET ~,II ." aACKU9 RING

Main Relief Valv e ..- , ~~o;-:- 'Sf'l ING

pOP PEr SE..6,T - t:f .l "/ 7 CHEC K :PO'PPf. T
r 'POPPET SEAt
1. Unscrew the main relief valve cartridge A'-<~"
from the valve body. Then pull the car-
tridge from the valve body, Figure 10.

2. Remove the spring and poppet from valve

hody.

3. Disassemble the relief valve cartridge.

a. Remove the acorn nut and loosen the

jam nut. Then remove the adjusting Figure 11 - Secondary Relief Valve
screw from the cartridge.
A secondary rellef valve is loc ated at
b. Remove the spring and pllot plunger the A and B ports of the tlIt spool and at

10
the B port of the clam spool. Identify the that the spools fit their respective bores
~'alveparts so the y will be returned to their with a slight hand pressure and without
respective bores during assembly. noticeable side clearance.

1. Remove the relief valve assemhly from 3. Inspect spools for grooves, deep scratch-
the valve body. es or excessive wear. Valve spools may
be replaced if there is no damage to the
2. Remove the spring a nd check poppet body. The spools are coded to ide ntify
from the valve bore. Do not remove the size and type of spool. The color code
poppet seat unless it is to be replaced. identifies size as follows:

3. Disassemble the relief valve. Black . .73700" to .73709"

Blue .. . 73710" to .73719"
a. Remove plug and shim(s) from cart- Yellow . 73720" to. 73729"
ridge. Green. .7;3730" to. 73740"

b. Remove the .spring guide, spring a nd The letter code s tamped on the eye of
poppe t from the cartridge. the spool identifies the type, D double acting
and F float. When order i ng re placement spools
C heck Valves be sure to include the color and type codes.
Spools are shipped with centering springs
A check valve is located at both lift assembled. .
spool ports. To r emove, unscrew cap, then
remove the s pring and poppe t from the TYPICA L SPO OL
valve bore. Do not remove the poppet seat
unless it is to be replaced. Identify the valve ~'
parts so they will be retLlrned to their re-
spective bores during assembly. \
SPOOL TYPE CO LO R COOE
CODE LETTER 691 9;].9

Figure 13 - Spool Code

4. Inspect the c hec k v alve and secondary

relief valve poppets a nd poppet seats for
grooves or other defect s . Small nicks
and grooves can be r emoved from the
poppet and poppet seat with fine grinding
compound. Lap suffici e ntly to remove
defects. Thoroughly wa sh valve body to
remove all traces of grinding compound.

Figure 12 - Check Valve 5. Inspect main relief va lve plunger a nd seat

for ridges or scoring. Replace if worn
Plugs An d Fittings or damaged.

Remove the power beyond fitting and any 6 . . Inspect all springs for distortion and
other remaining plugs from the valve body. signs of cracking. Also check sp ring
tension, refer to page 3 for spring
specifications.
Inspecllon
Assembly
1. Wash all metal parts in kerosene or
s imilar solvent, Discard all O-rings and Make sure all tools and work bench are
wi pers. clean before assembling the control valve.

2. Inspec t the valve body bores for gooves, Lubricate spools, I)ores and O-rings wah
deep scratches or excessive wear. See hydra ulic oil prior to assembly.

11
Check Valves Main Relief Valve

1. Press new poppet seat Into valve body, 1. Pres s new poppet seat into seat s leeve ,
If removed, Figure 12. if removed , Figure 15 .

2. Place the check poppet and spring in valve

bore. PLUG .......... '' \
(SSt..-- O ~ING
3. Install backup rings a nd new a-rings on ~- DRAI N SLEEv c
valve cap and screw cap Into valve body
until tight. (
r . C . 1, . < j '- - SE,AT Slf:E\fE
~ BACKUP "NG

Secondary R elief Valves

O -RING

SHfM'S~
,\ -' ;r:
P\..UG

/
, / -)

,r'j
~ ~~. "~~ / .. l'J ,;,') PIL O T PlUNGe,

PO PfEr

PO PP ET SEAT-
.u.-;
SPRIN G GU I DE............. ,::-.
BACKUP RI I'JG ~ O ... RINC f)
S ""NG _~
.,' "
/
&
t/ 1-
/ .J/t CART~I DGE
7~
BAC KUP RING
SP.RlNG
't!fJ'/-;- CHE.cKPOPPET
J POppET SEAT
A \
A
-

~
,

IJ '-
.~r. I

O -l<fNG,;::' _
F

r.....-

" PI 1.0 T
-
/"
poppEr
SEAT
POPP ET
PoppEl
SPRING

PLUNGER SEAT
-
d ' - \NASHE~
A1"'-=:- JAJJ. NUT
J .........
.4-CORN NUt
..
//
#-_. _ PL UN GE'
6/- - ADJ US fl NC

WA. SH£9.
SPRIN G
SCREW

....> c"Y.~"'" BAC KUP RING

70\3~1

Figure 15 - NI ain Re lief Valve

2. Ins t all the backup ring' and nelv a -ring

~ '- ",
on the seat sleeve. Then positio n the
6VY~/ ' 7C1 :r:'3
seat s leeve and dra in sleeve in the valve
body. Push the drain sleeve into the
valve body until two or three threads
Figure 14 - Secondary Relief Valve are visible, then screw the r e lief valve
plug with new a- ring Into the valve
1. Press new poppet seat into valve body, body. The seat s le eve Is now properly
if removed . Then install check poppet and positioned.
spring in valve bore.
3. Place poppet and spring in the reli ef
2. As semble the relief valve. va lve bore.

a. Press In new poppet seat, If re- 4. Assemble the relief valve cartridge:
moved.
a. Press new pilot plunger se a.t into
b. Install poppet, spring and spring cartridge, If removed.
guide In valve.
b, Pl ace the pilot plunger a nd spring
c. Place shims on spri ng a nd Install in cartridge.
plug. Use as many shims as were
r e moved. c. Screw the adjus ting screw Into the
cartridge. Then install wa she r, jam
nut , washer and acorn nut on adjust-
3. Install backup rings and new a-rings on ing s crew.
relief valve and Install In valve body.
After the control valve Is assembled , 5. P os ition the backup r ing a nd new a- r ings
check the pressure setting as Instructed on the cartridge , then s c rew cartridge
In Section 42. Into v alve body.

12
 NOTE: Do not adju st the rellef vah'e lift Spool
at this time. Adjust the relief valve with
control valve mounted on the machine.
Refer to Sec tion 42.

Tilt Spool And Clam Sp ool

L Insta ll centering spring, if removed:

a. Secure spool in a SaFT JAWED

vise and position spring se a t, spacer,
spring a nd spring seat on spool.

b. Compress the spring with spring

compressor as s hown in Figure 1
and install snap ring.

2. Install a-ring retainer and new a-ring

on spring end of spool.

3. Carefully slide the s pool into its bore.

Use care not to damage a-ring at spring
end of spool.

4. Screw the spring cap into the valve body

until it bottoms.

5. lnstall the a-ring, a-ring retainer and Figure 17 Lift Spool

spool gland over eye end of spool. Tighten
the spool gland with the wrench shown in 1. Install centering spr ing on spool, if
Figure 1. removed:

a. Secure spool in it SaFT jawed vise

a nd place inne r spring seat, spring
and oute r sp ring seat on spool.

b. Compress spring with spring com-

pre ssor illustrated in Figure 1.

c. Coat detent stud threads with orange

Lodite and screw stud into spoo l.
Torque stud to 9 -10 foot pound s.

2. Position the outer O-ring l'etainer on

spring end of spool. Then install the
small a-ring ancl inner O-ring retainer
on the spool ancl position the large r a -ring
on the inner O-ring retainer.

3. Gra sp the centering spring and c a refully

slide the spool into its bore. Use care
not to damage the 0- rings at spring end
of s pool.

Figure 16 - Tilt and Clam Spool 4. Scre w the detent housing' into the valve
body until it bottoms.

13
5. Install the de tent washer in the detent Ing pl ate and secure in place with four
hou s ing. Make sure the washer Is seated bolts , loc kwashe rs and nut s .
against the shoulder In the detent cap.
2. Connect the hose s and tubes to the control
6. Drop the s teel ba lls (8) Into the cap valve . Refer to HydrauI!c diagram In
a r ound the dete nt barre l. Smear a good Section 42 for proper connec tions .
grade of greas e on the detent cam and
install ca m in detent housing. 3. Connect the control lever li nkage to the
v alve spools. Check and adjus t the float
7. P l ace the detent spring on the detent cam de tent feel. To inc rease dete nt pre s8ure ,
and screw the adjustment plug into the screw the adjusting plug into the dete nt
detent hou s ing until plug is flush with end housing. To decrease detent pre ssure ,
of housing. Re adjust detent fee l as re- screw the adjusting plug out of the de tent
quired a fte r control valve h as been in- housing. The plug contains a nylon inse rt
s talled. to make it self locking. Do not expose the
inse rt when decreasing detent pressure.
8. Pos ition a new wipe r In spool gland and
press the wiper retaine r into place .
The n insta ll two new O- ri ngs in spool 4. Check and adjust the main r e li ef valve
gland . pressure setting as instructed in Secti on
42.
9. Install spool sleeve in valve body a nd
sc rew spool gla nd into va lve body until 5. Check and adjust the secondary I' el ief
It bottoms. valve is settings as instructed in Section
42 if valves wer e not adjus ted alt e r
P lug s And F Ittings as s embly.
Instal l new C)-rings on the pow e r beyond 6. Sta rt the engine and operate t he bucket
fitting and the I'em a ining plugs and ins tall in through several complete cycles to I)leed
valve body. a ir from the hy draul ic sy st em and c heck
for leaks.
In.tallatlon
7. Check hydraulic r e s e rvoir oil le vel and
1. Position control valve against the mount- add as required.

14
 SECTION
44b

BACK OE
CONTROL
VALVE

ser nendly

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 TABLE OF CONTENTS
SPECIFICA TIONS . 3

OPERATION. 3-8

REMOVAL. 9

DISASSEi\1BLING THE CONTROL VALVE 9

Disassembly of Valve Sections 11

Inlet and Outlet Sections 12

Working Sections . 12
ASSEl\IIBLY OF WORKING SECTIONS 12

ASSEl\IIBLING THE CONTROL VALVE 13

DISASSE MB LY, INSPE CTION AND ASSEMBLY OF RELIEF VALVES 13

Secondary Relief Valves 13

Crossover Relief Valves 14

INSTALLATION . . . . . . 15

2
 SPECIFICATIONS

Case pa rt no. . . . . . · . . . . . . . D50560

Desc ription . . . . . See General below
Ma in r ei ief val ve . . . . · .. See Section 42 .
Secondal'y relief valves . Cartridg'e type, screw adjustable, locat ed
in eac h work port.
Pre ssure setting
All except boom section A port 27 50 + 250 - 100 psi @ 10 g-pm
(19 3 + 18 - 7 kg /c m'- @ 3S limn)
Boom section A POI't . .. 1000 + 2 50 - 100 psi @ 10 gpm
(70 + 18 - 7 kg /cm'@ 38 limn)
Cros so ve r r eli e f valves Cartridge type, sc rew adjustable,
connect ed to work po rts of swing section
Pr essure setting . . . . . . . . . . . . 1750 ± 150 psi @1 0 g-pm
(12:3 ± 10 kg/e m'@ 38 !/mn)
Port s and spools
Spool t ravel, ne utral to pr essure .. 15/ 32" (12 mm) in a nd out
Spool in Work port A pressurized
Spool o ut . . . . . . . . . . . . . . . Work port B pre ssu r ized
Port threa d
All ports except swing sec tion . · ... 1-5/ 16" - 12
Sw ing sec tion ... · . . . .. 7/S" - 14
We ight (approx . ) · 123 lbs. (05,8 kg)
Tie rod torque . . . . . . . . 30 foot - pound s (4,1 m-kg)
Springs Free length Co mpr essed le ngth
Hegeneration spool. . . . . . • . , 2-1 / 64"-2-3 /8 " 1-13 / 16" ({f 21-25 Ib5.
1- 13/ 32" @ 40-45 lh s .
Spoo l centering
Boo m, dipper anel bucket 2-1 / 2" -2-25/32" 1-13/32" (g 2:3-27 lhs.
15 / 15" @' 32-36 lbs.
Sw ing . . .. . 2-7 / 8" So lid @ 4 3 Ihs .
Check poppet .. . 55/ 64"-57/ 64" Solid @ 2.5 lbs .
Secondary rel ief
All except beom liown 1-1/16"-1-1/8" 61/64" fa: 74-82 lbs.
57/64" @ 111 - 123 Ihs .
Boom down . . . . 1-1/ 16"-1-1 / 8" I" ~i 19- 21 lhs .
13/ 16" @ 74- 82 lbs.
Crossover (pressure ) 1-35/ 64"-1-39 / 64" So li d {g 93-11 5 lbs .
C r o ssover' (poppet) .. . 353"-.363" Solid @ 9 Ibs .

GE NERAL

The baok hoe control valve is a sectional, The backhoe valve does not contain a
open center with parallel passage valve, The main relief valve. The backhoe hydrauliC
val ve is oompos ed of fou r working sections, syste m pressure is controlled by the main
and an inlet and outl et section . The open center relief valve in the l oade r control valve,
parallel passage is connected to the work ports
in each section and to the regener ation spool
in the outlet section. In addition, each working With the spool s in neutral, oil flows
sec tion has two return passages connected straight through the open center passage to
in series with the inlet and outlet sections. the outlet nnd r e turns t o th e reservoir.

3
 SE CONDARY
REL IEF VA LVE 01 PPER CYL I NDER

REGENmA T 10,'1
CH ECK VALVE
I

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/

co
.....
Ii
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I

g
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~

0
~
I
UJ
'0
0
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;J>
0
~

"
so
~
(l)
0.

RETURN

REC£IlERATIOll
SPOOL

SECOllDMlY
RE Ll Er VALVE
_ PUMP PRESSURE
_ RETURN OIL
STATI C OIL

D ....~" SECTION 71 0994

 OPERATION

011 Flo"" - Spool Aclualed a ir from entering the c lo sed e nd of the d ipper
cylinder.
Refer to Figure 1. With the spool he ld
in a powe r posit io n, the op en center pas sage When pump pressu re is s ufficient to move
is bloc ked. The bloc: kingofopen center diverts the dipper, the r e tu rn pas sage in the outlet
the total oil flow to the open center parallel section is opened in the s a me manne r a s
pas sage, past the check va lve a nd on to work explained under Oil Flow - Spool Actuated.
port A where the oil is directed to the rod
e nd of the dipper c ylinde l' . Simultaneously, 011 Flo_ - S_in g l n g Backhoe
the pressure increase i n the ope n center
pal'allel pa ssage overcomes the spring under The control valve sw ing section is baSic-
the r e gene ration spool, connecting' the return ally the same as the other working sections
pa ssage to the outlet port a llowing the oil with on e exception. The exception is the addi-
displaced by the cy linde r piston to return to tion of two crOSsover r e li ef val ves in the
the r eservoir. swing circuit whose functions will be explained
in the following paragraphs.
If the piston rod wculd stop moving for
any reason and the spool rema ined actuated, R efer to Figur e 3. The I:'oom, d ipper and
pre ssure between the pump and cylinder bucket, being v e ry heavy, pr ovide consider-
would rise untll it was equal to the pressure able inertia to swing (the t ende ncy to remain
setting of the main r elief in the lo ader control stationary). When the pres s ur e between the
v a lve, at which time the r e lief valve would cylinder pistons a nd the c r ossover relief valve
ope n and divert the oil to the reservoir. connected to work port A reaches 1600-1900
psi, the pre ssure force s the poppet away from
011 Flo_ - Regeneration the floating seat for that relie f valve and lUl-
Spool Sealed seats the floating seat of the opposing cross-
over relief valve, diverting excess o il to the
It ofte n h appens that a c ylinder moves return pa s sage. Thus the c rossover relief
fa s ter than the pump can s upply oil. The pump valves permit a smooth s ta rting and control-
is un a ble to keep up with the demand when a able swing.
weight on the cylinder move s the cylinder
rathe r than the appli e d oil, E xample: quickly When the swing is stopped at a point
lower ing a heavy load. If the pump is running other than a full swing, the c;rossover r elief
slowly, this condition is fu rthe r c omplicated valves also serve to cushion the stop . The
bec ause pump output is in direc t. proportion weight of the boom, dipper and buck et , and
to engine speed. the momentum of the swing w ill t.end to con-
tinue the swing motion, Hydr aulic pres s ure
Refer to Figure 2. Assume the dipper is will then inc rease in the r eturn circuit illus-
lowering a heavy object and the engine is trated in Figure 3. The c rOs s ove r relief valves
running at half throttl e. The weight of the ob- the n open, trans ferring oil b etween the c yli n-
ject pulls the piston r od out of the dippe r d e l' s, permitting a c us hioned stop . Shoul d t he
cylinder faster than oil is be ing supplied, crossover r elief vulves be wlable to handle
Without regeneration a large void (air space) the surge of displa ced oil, one of the secondary
would be created in the closed end of the reI iei val ves woul d open anddh'ert the excess
dipper cylinder. Howe ver, this action results oil to the reservoir.
in a pressur e drop thr ough open center and the
open cent e r parallel pa ssage, The pressure At times during the swing, oil will be
drop ena bles the spring under the reg'eneration displaced from the swing cylinde rs slower
spool to seat the spool, partially closing the than the pump suppl ies oil. When this occur s,
return passage in the outlet s ection. With pressure between the cylinder pistons and
this pas sage blocked, the return oil displaced control valve section will rise to the pre ssure
by the cylinder piston is d i verted through the setting of the cros sover relief valves. The
regeneration check valve in the inlet section r e lief val ves then open, r elieVing the pres s ure
to supplement oil from the pump, preventing and diverting the excess o il t o the res er voir.

5
 SECONDARY DIPPER CYL I NOER

REliEF VALVE r-[==(==lJ~~~~~;~;; ; ; ; ; ; ; ; ;

'Tl
~.
..,
CO

'"
I
-
0
t= 0
-
'Tl

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ro
~
"..,
CO

"0
~

"W
'0

-
W
0
0

CO

"
~

SECOH DARY
RE L I EF VALVE _ PUMP PRES SURE
RETURN OI L
STATI C OIL

D IPPER 'Se.CTION
11-_..J~~~;:~~~~~~~~~l.:ONDAR.Y RELIEF VALVE

SWI NG CYlIIIOER RE LIE F

VA LVE S NOT SH(J,/II .

RE TURII

- PUMP Pi\ESSUR E
_ RETURN OIL.
STATIC Oil
OUTLET SECT10N SWING SECTrON
71G995
SECONDARY RELI £.F VALVE
 FlEL I Ef
VALVE

PJ 5TO~ ASSEMB LY 7 10934

Figure 4 - Restricting Oil Flow From Swing Cyl,inder

Slopping The Backhoe The boom down relief valve is set at 1000 +250
AI FuU S_lng -100. psi, its funct ion to be cove red in the
following .paragraph. A secondary r elief valve
As there are no mechanical stops to con- has one function, to protect t he back hoe
trol full swing, stopping the swing motion mechanically and hydra ulically when a cylin-
is accomplished hydraul ically by the swing der is forced to move with it s valve spool
cylinders. in neutral. Example: as the dipp e r and bucket
are b eing retracted during digging, pressure
Refe r to Figur e 4. As the piston in a is often exerted aga inst the boom, forcing
sw ing cyl inder nea rs the end of its stroke, it upwa~·d. When thi s happen s the r elie f
the restrictor pin enters the outl e t passage valve in the boom down (A) port will open,
in the closed end of the cylinder, restr icting allowing the boom to rais e .
the displ acem ent of oil from the cylinder.
At this time , swing motion is slowed a nd The reli ef valve in the boom down port has
pres s ure inc reases in the closed end of the two func tions: (1) to allow the boom to ra ise
cylinder, perm itting a cushioned s top at full as expl a in ed in the prec ed ing example, and
sw ing. (2) work ing in conjunction with the r es tricto r
in the bo om s ec tion B port, controlling the
If the backhoe is sWWlg r a pidly and c om- pressure and speed at which the boom lowers.
pletely to the right or left, pressur e in the The pressure setting of the rei ie f val ve being
closed end of cylinder may rise to 3900 ± 20 0 lower than that of the ma in r elief valves
psi. When this happens, the r elief valve will permits excesS oil to be returned to the
open to relieve the sudden incr ease in pres- reser voir.
sure a nd allow oil to escape from the clos ed
end of the cyl inder. Check Valve.

Eac h working secti on contains a check

Secondary Relie' Valve. valve. The check valve pre vents reverse oil
fl ow between the cylinde r and the val ve
Eac h working section has a secondary section. The check poppet remains s eated
relief valve connected to its work port s . All Wltil the pr e ssur e of the oil being deli vered
reli ef valves except the one in the boom to the cylinder is greater than the pres sur e
clown (A) port are set a t 2750 + 250 - 100 ps i. between the cylinde r and the poppet.

8
Removal sec ur e the control tOIV e r to the main
frame.
1. Fully ret ract the buck et and dipp er arm,
and lower boom until bucket rests on 5. Rem ove control tow e r wit h guards at-
the floo r. tached.

NOTE: As hyd raulic lines are discon- 6. IVlove the control levers in both dir ec t ions
nected, close the openings with cl ean to equalize circuit pressure and discon-
caplugs. Also tag or otherwise identify nect linkage at cont rol valve spool s . Then
lines and parts to ass ur e proper connec- discolmect hoses and t.ubes from the
tions when installing the c ontrol valve. contr ol valve.

2. If the backhoe is equipp ed with optional

features, prepare the contr ol tower for 7. Remove the nuts and lockwashers from
removal: the c ontrol valve mounting bolt s . Take
the weight of the valve off the mounting
a. If equipped with boom lockout, move bolts and remove the bolts.
boo m control le "er in both direc tions
to equalize pressure and disconnect 8. Lift the val ve up and away fr om the
line s to valves mowlted on front of mowlting brackets and remove fro m ma in
control t ower . frame.

b. If equipped w ith Hydra-Guide, l'e- 9. Prior to disassembly, r emm'e accum u-

move the seleutor val ve handl e and lated dirt and grease fr om the control
l oosen the valve ret aining nut. Re - valve.
move the upper fr ont cover mounting
screws and m ove cover away fr om
the tOlVer to gain acc ess to the Disassembling The
se lec tor valve. Remove the "alve Conlrol Valve
retaining nut and po sition the se -
lec tor val ve out of the way. 1. Remove accumulated dirt and grease
from c on trol valve if this has not been
c. If equipped with an Extendahoe, dis- done.
c onnect the control lever a t the
diversion valve lever. 2. Starting at the inlet section, number the
working sections to assu1' C:' propel' as-
3. Remove the upper and lower front covers s embly .
frum the contr ol tOlV er .
3. Remove the nuts a nd washers from e ither
4. Remove the fo ot gu ard to main frame end of the tie rods and rem ove the valve
bolt s , nuts, and washers. Then r emove sections. As the sect ions are rcmoved,
the thl'ee bolts, nuts and washers that remove and dise,ud the o-r ings.

9
 ~ -l O C K "UT
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, - AOJUS T I"lG
- SPORING SEAT
~ - SPRllHi
M - FLOATWC SEAT

O- RI:'O -
BACK UP R" " -
O
O
RfGEtJERATI Ol-i
ClifCK VALVE
~-'""
O- ~I"G - O
PDPPH - - \ j
SPfl.ING - - g__ O ~ R1fIG

. . - fiACKU P Rille
____ D-R.ING
WIPER __ §
~
'--- BACKU P R It\G
- a- RIIIG QUAD _ _ @'
SE C£l ti DAAV - - BACKUP RING
{:t 11:(;
REL I EF \t~LIJ£

I
;::: BACKU P RINC
. "'"" 0- R I uG
""-..BACKU P 1\, tiC
~ ~PPET
~ - SPR I " JG

SWING StiCTI ON

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00
- ()- - -
FlCA TING SEAT -
BOOY-

SPftlNG-
O - Rlri~ "",,""-...-
-'" : : ~.
Q.U;'O ill au
<-
...
BACKUP R'NC- R flETA INH - < :. . '

P~~~;:: i CROSSOV ER
REl I EF VALVE
SPRlt.'G _ ~. ,
SEAT
S~IWJ - ~.
~
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--=
SW"'G _ _ ~
O- RI IIO- I( Sf AT '-,.-;- .

.'; OJ lJSl I NC S(RE\I - ~ SCRElJ -

•
C

LOCK IIUT - ~ /' ~

5PRII'" CM -- ~
5 /1 6"- tiC x. 3/ u" (2 )- - <.,
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Fig-ure 5 - Ex-ploded View of Control Valve

10
 flUT

AOJUST wG SCAN

O-A, l ,~G

CloP SWiNG

O-ltHG

ii --·eAt""P R U·..G

SV OL - ,PIUJ<G
U - -Fl.OATI NG sEAr

/"
RING
BOOM. DI .. pelt A
BUCK.T

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REG.ENERATrO'l SPOOL - _
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-

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A;Ell Ef VALvE

710948

I I
D I.a• • e",bly Of Valve Seclions the crossover relief valves also. See
Disassembly, Inspection 'lild As sembly of
Inlet An d Outlet S ections Relief Valves.

1. Disassembly of the inlet s ection consists In.pectlon

of r emoving the regeneration check valve.
To disassemble the check valve, use a l. Discard all wipers, a-rings a nd backup
pocket knife or other point ed instrument rings.
and r emove the spiral snap ring, Figure
6. Then remove the spr ing seat, spring 2. Clean parts in cl eaning solvent and dry
and poppet from the valve bore. with moisture free compressed air.

3. Inspect the spool bore and spool for

© UserFriendlyC Ds scoring and other defects that would
result in excessive spool leakage. If
either the spool or spool bore is defecti ve
the entire section must be r eplaced.

4. Inspect the machined surfaces (sides) of

the valve section for nicks and burrs.
Use a flat India stone and r emove any
nicks or burrs. Move the stone in a
circul a r motion and keep it fiat at all
times. Do not s tone a section if it has
tOOJJ.§j not been completely disassembled . Thor-
Figure 6 - Removing Spiral Snap Ring oughly wash the valve section incl ean ing
solvent to remove all t rac es of grit.
2. Disassembly oftheoutlet section consists
of removing the regeneration spool cap 5. Inspect the spool centering spring and
and removing the spring, s p ring seat and check poppet spring for distortion and
spool. Use care not to loos e the plunger signs of cracking. Also c heck springs for
or ball in the end of the spool. proper tension, refer to spring' specifi-
cations on page 3.

Working Sections; A • • e",blyo,

Working Sections
NOT~ If more than one section is to
be dIsassembled, identify the parts as they 1. Install a new a -ring on the check vah'e
are removed to assure they will be installed c ap and place the poppet spr ing and poppet
in the proper section dur ing as s embly. in the cap. Screw the cap into the val ve
section and tighten securely.
1. Remove the spring cap and grasp spool
at spring end and carefully pull spool 2. Install new a-rings and a backup ring
from valve section. Do not remove spring on the secondary relief valves. The
retaining screw unless yellow Loctite is backup ring is installed in the top of the
available for use during assembly. groove. Lubricate the a-rings with hy-
draulic oil, screw the r elief val ves into
2. Remove the wiper and quad ring from the the valve section and tighten securely.
top of the spool bore.
N~ If assembling the boom section,
3. Remove the a-ring' retaine r, backup ring make sure the low pressure sec ondary
and quad ring from the s pool or bottom relief valve is installed in the top of the
of spool bore. valve section.

4. Remove the secondary relief valves and 3. If assembling the sw ing section, inst all
check valve from the valve section. If the crossover relief valves. Install new
disassembling the swing section, remove a- rings and backup rings on the relief

12
 val ve bodies. Before installing the middle section. Then in stall theworking sections
a -ring. install the backup ring and posi- in the sequence established at disassem-
tion it at the top of the groove. then bly. As the sec tions are pOSitioned. make
insta ll the a-ring. Insta ll the hottom sure thG a-rings have ren1<1 ined inp lacG.
a -ring be tween the two backup rings.
3. Place the outlet section on the tie rods
4. Ins tall the quad ring and IV ip er in the ancl secur e in place with nat washers
grooves at the top of the spool hOl·e. and nuts. Torque the nuts evenly to 30
Make sure the quad ring is not twisted foot-pounds in incr ements of 10 foot-
and is properly seated. The wiper ShOllld pOlmds. If the nut s a re tightened unevenly
be installed with the lip to the spool eye. or over tighten ed . bind ing spools may
reslll t.
5. Lubricate the spool and spool bore with
hydraulic oil. 4. If a secondary or crossover relief I'alve
adjusting screw has been disturbed or a
a. If installing spool with centering new relief val ve has been installed. check
spl·ing removed. push the spool into the pressure sett ing as instructed in
the valve section with a twisting Section 42.
motion until the spool is even with
the bottom of the val ve sed ion. DIsassembly, Inspecllon And
Lubr icate the remaining quad ring Assembly 0' Relief Valves
a nd install in groove fOl'med h>' the
spool and valve section. Then place Secondary Relief Valves
backup ring over quad ring.
1. Secllre valve body in a vise. Loosen the
c. Place the quad ring r eta in er . a adjusting· scr ew lock nut and remove
spr ing seat. centering spring and the adjus ting screw.
remaining spring seat over the spool.
Coat the spl·ing· r etaining screw with 2. Remove the cap from the valve body.
yellow Loctite. thr ead screw into Then remove the pltmger. spr ing and
spool and tighten. floating seat from the body.
"""-"~ - - - - - t~OJUST t NG 'SCR.EW
d. If installing spool with spring at-
tached. ptace the qu ad ring retainer.
backup r ing and quad r ing on the !~--- LOCl( 'J UT

spool. Push the spool into the spool

bo r e w ith a twisting motion until
the bottom spool land ha s started
into the spool bore. Then work the ~?0,~ ---- C;·.f'
quad ring into the groove formed by
O - RI~{G
the spool and valve sec ti on. Place
the backup ring over the qlll1d ring
PLu.'lGE r\
and push the spool completely into
the va.l ve section. SPR I tIC.

flACKU P k I i:G
6. Place the sprmg cap over the sp ring and
secure in place with screws. I)-HIItG

O-R I f.'G
Assembling The Conlrol Valve I to.\ T Ir~C sc/\ T

1. Plac e a s mall aTnount of grease in the

O·rit1g groove:,; In each section to help
ho ld the 0 - rings in pl ace. The n pl ace a n
-
a · ring in each groove. - {l-Jt J uc, I" 1(l't'JI

2. InsUllI the tie rods thr ough the i.nlGt

3. Discard all 0- rings and the backup ring.
AOJ US T I NG SCR£\1
Inspect the plwlger, float.lng seat and LOCK i'iUT
seat in bottom of val ve body for defects
that would result In l eakage. ~.~'O-RING

SPRING
4. Inspeot the spring for signs of distortion
and cracklng. Also check sprlng tension,
SPR I tlG
refer to spring specifications on page 3.
C-R I
BACI(U PRING

5. Insta ll a new O-ring and backup ring on

the plunge r. The backup ring must be
pos it ioned at the top of the groove.

6. Place the spring over the floating seat FLOATING SEAT

and in stal l the plwlger in the floating
seat. Install this assembly In the val ve O-R I :'G BACKUP R I t~ G
body. lIl<-- fl·· , IN"
BACK UP R I "G·=-I11~
7. Place a new O- r ing on the cap and screw
the cap into the valve body . Ivlake SUre
cap is tight.
8. Install a new a -ring on the adjusting
scr ew anel thread the scr ew into the cap. Figure 8 - Crossover Relie f Valve
To obtaln an approximate pressure set-
tillg. turn the acljustlng' screw in Wltil 6, Inspect the poppet end of the va lve body
the distance between the top of the bore for scoring.
s crew and the bottom of the valve mea-
sur es 2-9/ 16". 7. Inspect the spr ings for distor tion and
signs of cracking, Also check s pring
9. Install ne w a-rings and a backup ring tension, refer to sprlng specifications on
on the valve body. T he backup ring page 3,
should be pos itioned at the top of the
groove . 8. Place the flo ating seat, spring and sprlng
seat in valve body, Then i.nstall the
10. Adjust the pressure setting as lnstructed adjusting scr ew.
In Section 42.
9. Insta ll new a-r ings ancl backup ri.ngs on
Crossover Relief Valve the poppet and valve body . The backup
ring for the valve body middle a - r ing
1. Pu ll the poppe t from the l'alve body. The should be pas itioned at the top of the
poppet is he lel by the fit of the a-ring. groove. The bottom valve body a- ring and
the poppet a-rings should be pOSitioned
2. Secure the val ve body in a vise, Loosen between the backup rings.
the adjusting screw lock nut and r emove
the adjusting screw, 10. Lubricate the poppet with hydraulic oil
and install in valve body, To obtain an
3. Hemove the sp ring seat, sprlng anel float- appro ximate pres s ure setting, seat the
ing seat from the valve body, poppet against the floatlng seat and turn
the adjusting screw in until the distance
4. Remove and eliscard all a- rings and between the top of the screw and the bot-
backup rings. tom of the poppet m ea sures 3-15 /1 6".

5. Inspect the poppet and fl oatlng seat for 11. Adjust the pressure setting as instructed
defects that would result in leakage. in Section 42.

14
In.tallation Refer to Section 42 , page 6 for torque
specifications.
1. POStiOIl the control valve in the m ounting
brackets. As the mounting bolts are 4. Before installing the control tower , start
installed, place a Oat washer between the engine and operate eac h cylinder
the rear mounting brackets and the through seve ral complete cycles and
cont rol val ve . Secure valve in place with check for l eaks . If equipped with boom
lockwashers and nuts. lockout, temporarily cOImect the val ves
mOW1ted on the upper front cover into
2. Connect linkage to val ve spools. the !Joom circuit.

3. Connect hydraul ic 1ines to control val ve . 5. Position control tower on ma in fram e and
Re fer to hydraulic diagram in Section secure in place with bolts, nuts and
42 and c heck for p rop el' connections. washe rs. Install the lower and upper
front covers and secure with capscrews
CAUTION: Improperly torqu ed fittings and washers.
c an result in leaks or damage d fittings .

MOST HYDRAULIC PROBLEMS ARE CAUSED BY

CONTAMINATED OILI

Keep The 011 Cle an

1. Clean the fill er cap area before checking oil l evel.

2. Use a cl ean funnel and container when adding oil.

3. Clean exterior of components, lines, and fittings be for e r e moval.

Close openings with clean caplugs.

4. Make repairs on a clean work bench. Use clean tools .

5. Change o il and service the filter(s) when making repairs.

NOTE: If drained oil is reused , it should be fUtered befo re

reinstalling in the r eservoir .

6. If parts in spection inclicates that metal chips, shredded pack ing,

etc. have entered the hydraulic system, the system s hould be
flushed , filter (s ) serv iced , and new oil install ed .
70\ 167

15
 SECTION
44c

STABILIZE R
CONTROL
VALVE

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 TABLE: OF CONTENTS

SPECIFICA TIONS . 3

GENERAL. 3

OPERATION 3

REMOVAL. 3

DISASS EM B LY 3

ASSEMBLY . 4

INSTALLA TION . 5

2
 Specifications
Case part no . . . . . . . . . . .. . D50420
Description .. . See General below
Main relief valve .. . . . See Section 42
Ports and spools
Spool travel, neutral to pressul'e 5/16" (7,9 mm) in and out
Spool in . Upper work port pressurized
Spool out . . . . . . . . Lower work port pressurized
Port thread
Power beyond port 1-5/ 16"-12
Power beyond fitting, internal 1-1/16"-12
Outlet port . 1-1 / 16"-12
Work ports. .. 7/8"-14
Weight (approx.). . 22 Ibs. (10 kg)

Springs Free Length Compressed Length

Spool centering . . . . . . . . . . . 1-5/ 16" (approx.) 1" @ 22.5-27.5 Ibs.
Check valve . . . . . . . . . . . . . . 1-7/64" (approx.) 3/4" @ 1.3-1.7 Ibs.
Torque, spring cap, a-ring retainer
and centering spring screws .. .. 6-12 foot-pounds (0,8-1,6 m-kg)

3. Disconnect hoses and tubes from the

control valve and close opening's with
The stabilizer control valve is a two clean caplugs. Then remove the nuts and
spool, open center valve. Check valves are washers from the mOlUlting bolts.
connected to the open center passage to
prevent reverse oil flow between the cylin- 4. Remove control valve from mounting
ders and the control valve when a spool is plate.
moved into a power position. Stabilizer circuit
pressure is controlled by the main .relief Dis assembly
valve in the loader control valve. Both spools
may be ac tuated at the same time, however, NOTE: Tag or otherwise Identify parts
the cylinder with the loast resistance wiII as they are removed to as sure proper
move first. asse mbly.

1. Remove the power beyond fitting and

the relief valve plug.
Operation
2. Remove the check valve caps, springs
The operation and all flow through the and poppets.
control valve are similar to the loader
control valve and will not be covered in 3. Remove the 90" elbows fro m the llpper
detail. and lower ports .

Removal 4. Remove the s pring caps and the a-ring

retainers.
1. Lower the stabilizers to the floor or
raise the stabilizers and tie the stabili- 5. Grasp the spool spring and pull spool
zers together with heavy wire or chain. from valve.

2. Wi t h the engine shut off, move the sta- 6. Do not remove the centering s pring
bil izer control lever s in both dir ections unle ss yellow Loctite is available for
to equalize circuit pressure. Then cl!s- use during assembly. To remove the
connect linkage from the spools. spring, insert a 1/ 4" rod in the spool

3
 / 1/4"- UC x 1/2"

O-R IIl G RETAJ IIER __~

f
~ 0 ~

BACK UP R I>IG_O
o
~ RELIEF
o - V ALVE PLUG
O-RI " G - - C )
g _ SACKUP RI NG

O : : ' >O- RI "G

CH ECK VALVE POPPET

SPR H'C \ <>,
O- R1.:: G ; , &#
CAP_(!}~

8 UA.-- - <PACE R

!IllER SPR ItIG SEA r

R SPR ItIG SEA T

<--~) -- FLAT WAS HER

1/4"- NC )(, 1/2 "

~
~U -
7J G95G
- -1 /4 "- NC x 3/ 4"

Figure 1 - Exploded View of Control Va lve

4
 eye or secure spool eye In a vise, with yellow Loctite and install screw
then remove the screw, flat washer, with flat washer. Torque the screw
outer spring se a t, spring and inner to 6-12 foot-pounds.
spring seat.
c. If installing a spool with spring at-
7. Remove the backup rings and 0- rings tached, place the spacer, backup ring
from the spool bores. ring and a-ring on the spool. Push
the spool in until the bottom spool
Inspecllo" land has started into the valve. Work
the 0- ring into the groove formed
1. Discard a-rings and clean parts inclean- by the spool ancl the valve bocly.
ing solvent. Dry with moisture free Position the backup ring on the a-ring
compressed air. and push the spool all the way in.

2. Inspect the spools and spool bores for 3. Place spring cap ove r ce nte ring spring
scoring and othe r defects that would ancl secure in place with screws. Torque
result In excessive spool leakage. If the spring cap and a-ring retainer screws
inspection indicates replacement of a to 6-12 foot-pounds.
spool or the valve body, the complete
valve must be r eplaced. 4. Place springs in check valve poppets
ancl install poppets in their respective
3. Inspect the check valve poppets for bores. Install a new 0- ring on the check
wear. Also inspect the poppet seat in valve caps and screw caps into valve
the valve body. body ancl tighten.

4. Inspect springs for distortion and signs 5. Install new a-rings and backup ring on
of cracking. Also check spring tension, power beyoncl fitting. SereII' fitting into
r efer to page 3 for sp ring specifications. valve bocly and tighten.

Assembly 6. Install new a-rings and backup ring on

relief valve plug. Screw plug into valve
1. Lubricate the a-r ings, spools and spool body ancl tighten.
bores with hydr aul Ic oil.
I"slallallo"
2. Place an a-ring and backup ring in the
top of each spool bore. Place a-ring 1. Place the mounting bolts in the control
retainer on valve body and tighten screws valve.
finger tight.

a. If installing a spool with centering 2. Holcl the control valve aga inst the mount-
spring remover!, install the spool ing plate ancl secure valve in place with
through the bottom of the valve. nuts and washers.
Push the spool in untll the bottom
of the spool is about 1" from the 3. Conn ec t hose and tubes to the control
bottom of the valve body. Install val ve. Reposition the elbows in the lower
the a-ring in the groove formed by work ports as requir ed . Make su r e the
the spool and valve body and place elbow lock nuts a re ti ght.
the backup ring on the 0- ring.
4. Connect linkage to v al \'e spool s. sta rt
b. Install the spacer, inner spring seat, the engine a nd move the stabil izers
centering spring and outer spring through several cycles to r emove any
seat. Coat the spring retaining screw trapped ail' and check for l eaks .

5
 710999

Figu re 2 - Contro l Valve Installation

6
 SECTION
44d

THREE-POINT
HITCH
CONTROL VALV

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 TABLE OF CONTENTS

SPECIFICA TrONS. . . . . 3

OPERATING PRINCIPLES. 4

EXPWDED VIEWS 6

Inlet Section 6

Lift Section. 7

Implement. Pitch. and Tilt Sections. 8

SERVICE . . . 9

Removal . 9

Valve Sections and Spools 9

Inlet Sectio n . . . . . . 9

Pitch. Tilt. and Implement Sections · 10

Lift Sec tion. . . . . · 10

Assembling the Valve .11

Installation · 12

2
 SPECIFICATIONS

Ca se part numbe r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. D52970

Manufacture r's number . . . . . . . . . . . . Hydraulic Industries 5030-4-1
Description '" . . . . . Four-spool directional control valve consisting
of six sections shown in Figure 1. Three parallel
passages in working sections carry oil to and from
cylinders. Orifice plate at inlet restricts oil
flow to maximum cylinder r equir e ments. Comp en-
sating spool in inlet section r egulates oil flow
as follows: first priority to oyl inders. exoess
to ,'eservoir through outlet port. Also see pages 4 to 6.
Relief valves
Main relief val ve
Type. , , . , . . . . . . . Ca rtridge type. direct acting, adjustable
Setting . . . . . 1800 ± 75 psi at full engine rp m (127 ± 5,3 kg/cm')

Secondary reli ef val ve, lift seotion

Type .. Ca rtridge type. direct acting, adjustable
Setting . . . . . . . . . . . . . . . . . . . . . . . . Cracks at 1900 psi (134 kg/ om')
Ports and Spools
Spool travel
Neutral to pressure . . . . . . 5/16" in, 5/ 16" out (8 mm)
Neutral to float . . . . . . . . . . , .19 / 32" (15 nun)
Spool movement into val ve body .. Pressurizes port A
Spool movement out of valve body . Pressurizes port B
Service specifications
Tie rod nut torque .. . . . . . . . .. 28 ft-lbs lubricated (3,8 m-kg)
Spring data
Centering springs, pitch, tilt, implement spools)
Free length. . . . . . . . . ..... · . . . . . . . . . . . . . 2.190"
Compression length . . . 1-1 / 4" unde r 15 pound load
Centering spring (lift spool)
Free length . . . . . . . . · . . . . . . . . . . . . . 2.471"
Compressed length .. . 1-17/ 32" under 15 pound load
Lift spool detent spring .. ,
Compressed length . . . · 21 / 32" under 5 pound load
Plunger spring D53605, inlet section
Compressed length . . . . . . . . . 1-1 / 4" under 14 pound load

LIFT RElIEF-

71 Q4Y YO

Figure 1 - Control Va lve D52970

3
 OPERATING PRINCIPLES

Description ten sion of spr ing (7). As the spool shifts,

the flo ating plunger (8) sli de s down to
General compensate for the oil displ aced by the
shift of the compen sating spoo l.
Valve 052970 is a pre ssure co mpensated
directional control valve cons is tlng of sL" sec- NOTE: A c he ck ball (not shol'ilJ) pre-
tions as follows: an inlet sec tion containing vents movement of oil in the gre en colored
the outlet, inlet, flow regulator , restrictor, passages toward the spool (2).
and main reli ef valve; thr ee sections for the
tilt, pitch, and impl eme nt cylinders with a 5. At the sa me time , the spool (2) opens
three-position spoo l in each; one section for pa ssages which allow the pump supply to
the lift cylinder with a four-position spool; and flow through the orifice plate (9), and
an end section. c heck poppet (10) into the head end ofthe
cylinder (11) caus ing the cylinder to
The thre e position s avail able at all spools extend.
a re power at A port, neutral, and power at B
port. In addition , the lift spool has a fourth 6. Note that the s hift of the compensa ting
pos ition, Float Do wn. In Float Down, the spool spoo l (5) ope ns the pump supply to the
is mechanically he ld (detented) until manually outlet passage (12) at points (1 3) and (14).
released. The spools are returne d to neutral Excess pump supply flows through the
from the powe r positions by center ing springs. outlet port (1 5) to the rese n'oi r (20) .

7. The pre ssure c reated by the cylinder (11)

Flow Regulation movement is transmitted via grooves in
the valve face (16) to the pilot passage
Flow from the inle t sec tion to the cy- (17), then to chamber (18) in the inlet
linders pas ses through a fixed orifice which s e c tion .
pr eve nt s oversupplying the cylinders when a
25 gpm pump is usee!. The co mpe nsating spool
regulates flow on it priority bas is--the cy- 8. This pilot pressure acts against the rim of
linder being operated receives oil first with the compensating spool and the flo ating
the exc e ss (if any) returned to the reservoir. plunger (8) causing the plunger to bottom
ou t in the bore of the compensating spool.
T o e xpl ain the remaining; valve com -
ponents and the ir function, we will de scr ibe 9. Thes e forces, added to tens ion of t he
a typic al operating sequence. spr ing (7), shift the comp ensating spool
downward against pump pressure at t he
Operating Sequence opposite end of the spool. As c ond itions
of s upply, resistanc e , and demand c hange
Refer to Figure 2. In the system, the spool is rcs hifted as
required .
l. The pump (1) Is operating at normal
speed.
10. If the cylinder (11) cannot move, the main
2. The operator pulls a control lever moving relief valve (19) open s at 1800 psi ancI
the spool (2) Into the valve body. vents 011 to the reservoir (20).

3. Pump supply flows through the Inlet port 11. When the operator r e turns the spool to
(3) of the inlet section. neutral, the pilot passa ge s (16 and 17),
chamber (18), and cylinder (11) a re closed
4. Pump oll flows through a s m all hole (4) to pump supply. The compe nsat ing' s pool
In the compensatIng spool (5) filling (5) shifts fully upward and the entire
chamber (6). This causes the compen- pump supply flows to the outle t through
satlng spool to shift upward against the openings at (13) and (14).

4
 _ PUMP OI L
SPOOL
ACTUATED _ RETURII 0 I L
oD'>IM/AR0
• PILOT PnE SSURE OIL

lYP!CAL
CYLJ:lDER

7-1-----
I
-.I
I ORIFICE
PLATE
m i-
-"---r--
CD

PU11P
t
710996
 EXPLODED VIEWS

PLATE

® - - IJASH ER

~
lj
_ _ FLOA TI NG
PLU NGER

-SPRING

O __ O- RING

~- PLUG
7 11 Q;j'?'

Figure 3 - Exploded View of Inlet Section

6
 ~ El l EF
IjAl VE -

/
\- - -DETEI'H SToD

0 -SPRI"G GUIDE

~ CENTERINC
~- SPR I NG

<::)- 0- RII NG

~ -
6 - SPRIfIG CIlIOE

~
' SEA L

f: \..u
RE TAINER
0 - SNA P R I "G

f\ 1 O - a-R I NG .
, '- -'
f:' ""', _:-....
,
<'?
,, ~
, I
. - SPOO L HE - DET ENT HOUS I nG
I
a _ C- RI NG C. CHECK

". ;..," tV ilJ- SPACER

I[)-
~
POPP ET

~ - SPRWG I
~
.~. '

,~'" "n
"'l'/I ~ - SPR1tJG ""'

H-""·
I
, i- (~
\lJ.-- CHE CK! -... SLEEVE

~ )"
e! I
·,,_ S TEEL
BA LLS (4)

1- - - SPR ll'G _1 /4" _"C x 4- 1/2" (2)

~- -"'"

11r~

Figure 4 - Exploded View of Lift Section

7
 O-R I.'IG

- HOUS 11lG
[<>,
" &
O- R l r~G -O (
't/ I PER- e '8 I
SPRING

I
SEl<l _
RET .... HJER,
@)
0
t:)

) ~_SPR I NG GU IDE

~
SPO Ol _ ®
EYE ~ ~_ CE "HR I"" G SPR HIG

S-
O- RI" G- j >

S P ~I N G - ~ SPRHIG GU IDE

0- R H~ G
POPPET- f}

0ia - CE"TE~ It~G ~Ol

0- PRI NG
T
RETA I h I NG

U.~
- SPOO L C.' .P

I
~
~- 1/4"-NC ;; .) /'."

POPPET-B )
7110 ~ 1

L t Pitch, and Tilt Sections

Figure 5 - Ex-ploded View of Im Plemen,

8
Removal from the face of each s ection (11ft, tilt,
pitch, implement).
1. Remove accumulated dirt and grease
from the valve and surrounding area to Inlet Section
prevent entry of dirt into the hydraulic
system. DISASSEiVlBLY

2. Lower the hitch fully or rest implement Refer to Figure 3.

(if attached) on the ground. With the
engine shut off, move the control levers 1. Remove plugs from top and bottom of
back and forth to relieve hydraulic pres- valve. Remove parts shown in Figure 3.
sures.
2. Use an allen wrench to remove the
3. Before removing the valve, tag and orifice screw.
number the hoses that connect to the
valve, starting at the inlet s e ction. Num- 3. Remove the relief valve cartridge and
ber the top port of the inlet section o-ring.
No.1; the bottom port No.2; the top port
of the implement section No. 3, etc. INSPECTION

4. Disconnect hoses and close openings with 1. Inspect the compensating spool andplun-
clean caplugs. ger for scoring, burrs, and excessive
wear. Make sure spool orifice is open.
5. On the tractor, connect the pump supply If either part must be replaced, replace
hose to the return line at the quick the complete valve section.
disconnect coupling.
2. Inspect the housing for cracks. Shine a
CAUTION: Do not dr ive the tractor with- light in the spool bore and check for
out completing step 5. scoring and wear. If the housing must be
replaced, repl ace the complete section.
6. Remove the control lever pins from
the valve spools.
3. Check the spool spring compression with
7. Remove three mounting bolts and lock- a suitable spring testing device. Replace
washers. Carry the control valve to a spring if It does not meet specifications
clean work bench for disassembly. on page 3.

CAUTION: Cleanliness is very Im- 4. The relief valve may be disassembled for
portant. Service this control valve in the inspection and cleaning. Check the plun-
cleanest surroundings possible. ger and seat. If the relief valve is
damaged in any way, replace the entire
Valve Sections And Spools relief valve.
Dis assembling The Valve 5. Replace o-rlngB.

1. Starting at the inlet end, number all the 6. Replace the steel ball and orifice screw
sections in order to assure reassembly in If damaged. Make sure the orifice In the
exact, original position. orifice Bcrew is open.

2. Remove three tie rod nuts at the inlet 7, Clean all parts in solvent and blow dry
section. Slide sections off the tie rods as before reassembly.
required.

3. Remove the three o-rings from the face ASSEMBLY

of each section and inspect for damage.
Take care not to lose the two steel balls 1. Lubricate o-rings with hydraulic oll.

9
2. Assemble parts shown in Figure 3. ASSEMBLY
Lubricate spool and plunger in hydraulic
oil befol'e installation. 1. Lubricate seals and internal pa rts with
hydraulic oil before assembly. Coat the
Pitch, Tilt, And Implement Sections centering spring and spring guides with
grease or hydraulic oil.
DlSASSEMBLY
2. Cl amp the spool in the vise used during
Refer to Figure 5. disassembly. Assemble the centering
spring. poppets. and spool eye as shown
1. Remove two spool cap capscrews. Re- in Figure 5,
mover the spool cap and seal retainer.
3. Install a well lubricated o-ring and wiper
2, Pull the sp ool assembly out of the valve. at each end of the spool bore.

3, Clamp the spool in a SOFT jawed vise 4. Lubricate the spool bore with hydraulic
or between wood or brass strips. oil. Slide the spool into its bor e . Take
care not to damage the o-rings and
4, Unscrew the centering spring reta ining wipers.
bolt. This will permit removal of all
pa rts from the cap end of the spool. 5, Install seal retainers and spool cap.

NOTE: Popp ets must be returned to Lift Section

their original pOSition, if reused.
DISASSEiVlBL Y
5, Unscrew the spool eye. Re move the poppet
and spring from the spool. Refer to Figure 4.

6. Remove the seal retainer. Remove a 1. Remove two long capscrews which reta in
wiper seal and o-ring from each end of the detent assembly.
the spool bore,
2. Remove the detent housing cap and detent
INSPECTION housing.

CAUTION, Do not intermix spools and 3 Pull the spool assembly out of the valve.
sections. Always return a spool to its original
section. If either the spool or housing must 4. Slide the seal retainer and detent as-
be replaced, replace the entire sectlon. sembly off the spool

1. Clean the metal parts in solvent and blow 5. Remove the centering spring:
dry.
a. The centering spring must be com-
2. Replace check poppets if worn or dam- pressed to remove the snap ring.
aged, Replace wipers and o-rings. Fabricate a pa j l' of compressor
plates. Figure 6, or use the com-
3. Inspect the valve body and spool for pressor supplied with Case Kit No.
grooves. deep scratches. and excessive D45700. Compress the springs as
wear. See that the spool slides in and shown.
out with slight hand pressure and without
noticeable side clearance. b. Remove the snap ring, Ca r efully re-
lea se the spring tension, Remove the
4. Inspect the machined faces of the sectlons centering spring and spring guides,
for nicks and burrs, Use a fine oil stone,
working with light rotary strokes. to 6. Clamp the spool in a SOFT jawed vise or
remove any nicks and burrs. Thoroughly between wood or brass strips.
wa sh the valve section in cleaning sol-
vent to remove all traces of grit. 7. Unscrew the detent stud and spool eye.

10
 inspection and cleaning. Check the plun-
Be LT ger and seat. If the reli ef valve is dam-
8 aged in any way, replace the entire relief
NUT

RETAINER
-r1.2~
valve.

ASSE1'IBLY
PLATES
H+-t-_!:I
'-+--f---~ ~ 1. Lubricate seals and int e rnal parts with
I .875 DIA.~ I hydraulic oil before assembly. Coat the
~ -~,- 2 .12 ~~~~ centering spring' and de t ent assemblies
with grease or hydraul ic oil.

2. Clamp the spool in the vise used during

Figure 6 - Compressor Plates disassembly. Ins tall the check poppe ts
and springs, spool eye , a nd detent stud,
8. Remove a check poppet and spring from Figure 4.
both ends of the spool.
3. Assemble the centering spring and spring
NOTE: Poppets must be returned to guides over the detent stud. Compress the
their original position, if reused. centering spring, Figure 4, and install
the snap ring.
9. Remove the seal retainer from the valve
body. 4. Install the seal r e ta iner with a-rings and
wiper at the spool eye end of the \'al ve
10. Remove the relief valve cartridge. housing.

INSPECTION 5. Assemble the detent mechanism parts and

seal retainer on the spool. Use grease if
1. Clean the metal parts in sol vent and required to reta in the steel ball s .
blow dry. Discard the wipers and o-rings.
6. Lubricate the spool with hydraulic oil.
2. Replace check poppets if worn or Slide the spool into the valve housing.
damaged. Take care not to damage wiper and seals.

3. Inspect the valve body and spool for 7. Install the d etent housing cap and two
grooves, deep scratches, and excessive long capscrews.
wear. See that the spool slides in and
out with slight hand pressure and without 8. Install the relief valve cartridge and
noticeable side clearance. If either the a-ring.
spool or housing must be replaced, re-
pi ace the entire section. Assembling The Valve

4. Inspect the parts in the detent assembly Refer to Figure 1.

and l'eplace worn or damaged parts.
Test the spr ing with a suitable spring 1. Lubricate new o-rings with hydraulic oil
testel'--it should compress at the rate and install in the grooves on the faces
specified on pag'e 3. of the valve sections.

5. Inspect the machined faces of the section 2. Clamp the inlet section (tagged no. 1)
for nicks and burrs. Remove any nicks in a vise with the machined face pointing
and burrs with a fine oil stone, working up.
with a light rotary motion. Wash the sec-
tion in cl eaning sol vent to r e move all 3. Install greased o-rings, and orifice plate
traces of grit. on the face of the inlet section.

6. The relief val ve may be disassembled for 4. Stack the implement section on the inlet

11
 section and install the o-rings and steel 3. Reconnect the hoses. Connections may be
balls. checked against the diagram, Sec tion 42.
Torque specifications are on page 6,
5. Assemble the r emaining' sections In the Section 42. The 45° l'estrictor elbows are
numbered order until all six sections are located in the upper (1\) ports of tile tilt,
stacked up. pitch, and lift sections.

6. Install the tie rods and nuts. Lubricate

the threads on the end of the tie rods 4. If the setting of the maIn relief valve was
and the bosses On the end section which disturbed, perform the pressure check
bear agaInst the nuts. Torque the tie rod and adjustment, Section 42.
nuts evenly to 28 foot-pounds.
5. If the setting of the relief valve In the
Installation lift section was disturbed, perform the
pressure check and adjustment, Secti on
1. Mount the valve On the bracket with three 42.
bolts and lockwashers.
NOTE: Replacement relief valves are
2. Connect control lever linkage. preset.

12
 Section

45
LOADER CYLINDERS

TABLE OF CONTENTS
Til t Cylinders .......... .. ....... ....... .. ......... ..... ... ...... .... .... ... .... .. ... .. .. .. ....... ................ ... .. ... ........ .... .... .. 2

Lift Cylinders ... ..... ..... ......... ....... ......... ... .. .. ....... ................ ... ... .. ........ ................ .. .. ... .. ..... ..... .. ..... 4

Hydra Leveling Cylind er ... " .. ... " .. " " ... ... ..... " ." ... " .. .. " ..... " ... ... ....... " " .. " " ... " ",, .. ... " " .... " ... " " ... 6

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Rae . Form 9-80841

.... ' ...
 45-2

TILT CYLINDERS
(Refer to Figure 1)
1. Piston rod "U" cup seal. Install into gland (6) with seal lip toward piston end of rod.

2. Piston rod wiper (outer). Press into gland (6) with wiper lip toward piston rod eye.

3. Gland "0" ring, Inset A.

4. Gland back-up ring. Install with c urved fac e toward "0" ring (3), Inse t A.

5. Piston rod wiper (inner). Install into gland (6) with tapered lip toward piston end of rod, Inset A.

6. Seal gland. Lubricate the bore of the seal gland and slide the seal gland a ssembly over pi s ton
rod.

7. Piston rod (1-1/2" diameter).

8. Piston half , rod end (1 -1/ 2" diameter recess)_ See No. 10 be iow and Inset B.

9_ Piston half, bolt end (1-5/ 8" diameter recess). See No. 10 below and Inset B.

10. Piston "Vee Seal " packing. Install hard outer packing ring on each piston half. Install three
chevron rings on each piston half with the "V" of the chevron ring towards the cen ter of the
piston. See Inset B.

11. Piston seai bearing ring. Install between the "Vee Seal" packing. See Inset B.

12. Piston retaining washer.

13. Piston retaining bolt (grade 8, 314" diameter ). Torque 200-220 ft. Ib s. Clamp rod eye end of
piston rod in a vise and support the piston rod when torquing the bolt.

14. Seal gland retaining screw (R8-32 x 1/ 4" self-tapping). Lubricate the piston seals a nd install
piston rod with g land into the cylinder being careful not to cut. the "0" ring or b a c k-up ring.
Torque the gland 100-200 ft. lbs. using Case s panner wrench D44112, Inset C.

15. Rod pivot bushing. P ress Into place.

16. Tube pivot bushings.

17. Cy linder tube.

 45-3

INSET B ~v'. INlj RING

13

15

INSET C

Figure 1
 45·4

LIFT CYLINDERS
(Refe r to Figure 2)
1. Piston rod "C" c up spal. Inst a ll into gland (6) with seal lip toward piston end o f rod.

2. Piston rod wiper 10\1t0r). Press into gland (6) with wiper lip toward piston rod eye.

3. Gland "0 " r ing, Insot iI.

4. Gland bac k·up ring. In stall wiih curved fac e toward "0 " ring, Inset A .

.). Piston rod wipe r (inner) . Ins ta ll into gla nd (6 ) with tapered lip toward piston end of rod, Inset A.

6. Seal g land. Lubricat e the bor(' of th e sea l gland and s lide the seal g land ove'r pis ton rod,

7. Piston r eel 11.:;0" dia mC'te r ).

S. Piston ha lf, reel enel (1 ·1 / 2" dia m ete r recess) , See 0, 10 below a nd Inset B.

9 . Piston half, bolt e nd (1 -5/ 8" diame te r recess). See No. 10 below and Inset 8.

10. Pi s ton "Vee Seal" pac king , In st a ll hard oute r packing r ing on each piston h alf. Ins tall three
c he vron ri ngs on eacb piSton ha lf with the " V" of the chevron ring tOIVard s the center of the
piston. See Inse t B.

11. Piston seal bearing r ing. Install between the "Vee Sea l" packing . See Inset B,

12. Piston retaining washer .

13. Piston reta ining bolt (graele 8, 3; 4" diame te r), Torque 200-220 ft. Ibs. Clamp rod eye end of
pisto n rod in a vise and suppo rt the pis ton rod when torquing the bolt.

H. Sea l gland r etaining s cre w (0-32 x 1/ 4" se lf-ta pping). Lu,b rica te the pistOll seals and insta ll
pisto n rod with g land in to the cylinder beIng ca re ful not to cut the "0" ring or back -up ring.
Torque the gland 100-200 ft. Ibs. using Case s panne r wrench D44112, Inset C.

IJ . Roc! pivot bushing. Pres s into place.

16. Cy linder tube.

17. Grea se filt ing.

 45- 6

HYDRA LEVELING CYLI NDER

(Refer to Figure 3)
1. Piston rod "U" c up seal. Ins ta ll into gland (6) with seal lip toward piston end of rod .

2. Piston rod wiper (outer). Press into g la nd (6) with wiper lip toward pisto n r od eye .

3. Gland "0 " ring, Inset A.

4. Gland back-up ring. Install with curved face toward "0" ring (3), Inse t A.

5. Piston rod wiper (inne r). Ins ta ll into g la nd (6) with tape r ed lip toward piston e nd of rod, Inset A.

6. Sea l g land_ Lubricate the bore of the seal gland and slide the seal gland assemb ly over piston
rod.

7. Piston rod (1-3/ 4" diameter) .

8_Piston half, rod end (1-3/4" diameter r ecess ). See No . 10 below and Inset 8.

9. Piston ha lf, bolt end (2" diameter recess). See No. 10 below a nd Inset B.

10. Piston "Vee Seal" packing. In s ta ll hard outer packing ring on each piston ha lf. Ins tall three
chevron rings on eac h piston half with the "V" of the chevron ring towards the cente r of the
piston. See Inset B.

11. Piston seal bearing ring. Install between the "Vee Seal" packing. See Inset B.

12. Piston retai ning washer.

13. Piston retaining bolt (grade 8, I" diameter). Torque 475-525 ft. Ibs. Cla mp rod e ye e nd of piston
rod in a vise a nd s upport the pi s ton rod when torq uin g the bolt.

14. Sea l gla nd retaining screw (#8-32 x 1/ 4" self-tapping ). Lubricate the piston seal s and in sta ll
piston rod with gland into the cylinder being careful not to cut the "0" ring 01' back-up ring.
Torque the gland 100-200 ft. lbs. using Case s pa nner wrenc h 044113, Inset C.

15. Rod pivot bu shi ngs . Press into place.

16. Cy linder tube.

17. Grease fitting.

 45·7

INSET A INSET B PACKI RING

-/ r-::::::;-;;---
INSET C
I

044113
 SECTI ON
45

CYLINDER
REMOVAL/I NSTALLATION

ser nendly

http://www.ioffer.com/selling/userfriendlycds

http://stores.ebay.com/UserFriendlyCDs

Burl. Form 9-7 20&5 KHC BO "rlnled In U.S.A.

Approxim a te Cylinder weight., D ry

Dipper cylinder ... . 105 Ibs. (47,3 kg)

Extension cylinder . 96 Ib8. (43,5 kg)
Boom cylinder . 83 Ibs. (37,7 kg)
Bucket cyl!nder 81 Ibs. (36,7 kg)
Swing c yl!nder 61 lbs . (27,7 kg)
Lift cyl!nder 50 lbs. (22.7 kg)
Tllt cyl!nder . 36 lbs. (16,3 kg)

Spanner Wrench inde r pivot pins and fr ee closed

end of cylinder from the dipper,
A spanner wrench kit. part no. D441l0, then disconnect the ho s es at the
is a.vailable from Se rvice Parts Supply. The cyl!nder.
kit contains the va rious sizes needed to
r e move a nd install packing gl ands on Case b. If removing extens ion c ylinder, dis-
manufactured cylinders. c onnect hoses to cylinde r at tubes
secured to the boom. Remove cover
from end of dipper and reroute hoses
out end of dipper.

c. If removing the left hand swing

cylinder, remove the control tower
mounting bolts and r a ise control
tower to gain acce s s to hose con-
WRENCH ROD SIZE
nected to control valve .
044111 2-1/2" To 1-1/2"
044112 J" To 1-1/'2" 5. Note the location and number of shims
~~~~ DAA II3 3" To 1-3/4"
D4411 4 3-1/2" To 2" (spac ers) at cylinder pivot points and
04411 5 4" To 2-1/4" remove the cylinder pivot pins.
D4Allo 4-1/2"& 5" To 2-1/2"
a. If removing a swing cylinder, remove
Figure 1 - Spanner Wrench the rod eye pin retainer from the
bottom of the s wing tower and drive
Removal pin out through bottom of swing
tower. Remove the trunnion pin
1. Lower the loade l' or backhoe bucket mountln~ bolts and remove trunnion s
with bottom of bucket flat on the floor. using 1/2"-NC puller screws in the
Position the backhoe in a safe and com- holes provided.
fortable work position and support the
backhoe at the boom and dipper pivot. 6. Take the cylinder to a clean work bench
for disassembly. Remove any hoses,
2. Remove accumulated dirt and grease tube s and clamps still attached to the
from cyl!nder and fittings. c ylinder.

3. With engine shut off, move the cylinder's In.tallatlon

control leve r In both directions to equal-
Ize circuit pressure. 1. Position the cylinde r on the unit using
a chain hoist. If necessary. Dlustr ations
4. Remove clamps and guard s a s required, which show the snap rings, washe rs, etc .
then disconnect hoses and tubes at points a nd the order of Insta llation w!ll be found
considered most convenient. Close all In Section 92, Loader or Section 93,
openings with clean caplugs. Backhoe, and Section 97, Three - Point
Hitch.
a. If removing bucket cylinder on a
stand a rd backhoe, remove the cyl- NOTE: Grease fittings must be installed

2
 in their origina l position so they are gr ams in Sectio n 42.
no t hidden or hard to get a t.
NOTE: Proper torque of fittings will
2. Connect hoses and tubes. nJustrations prevent damage a nd leaks. Torque sp eci-
which sholl' the fittings, clamps, etc. fic ations a r e below.
and the order of installation will be
found in Section 92, Loader, Section 93,
Backhoe, or Section 97, Three-Po int 4. After the cylinder is installed , s tart the
Hitch. engine and r un the eyli nder through
several cycles to bleed any air f rom
3. Check connec tions against hydraulic dia- the circuit and chec k for leaks .

U.S. AND METRI C TORQUE SPECIFICATIDNS

Hydr aulic Fi llin gs (Sle el)

37"' F lare Str-lligh t Thread

F emale S'.liivel 0- ll ing-
D ash T u be Thread Torque Torque
Size O.U. Sl l..e ft. Ibs. m-kg ft. Ib5 . m-kg

" 1/4" 7/ 16" - 20 6-12 0,8-1,7 12-19 1,7 -2,6

5 5/16" 1/2" - 20 8- 16 1,1-2,2 16-2 5 2,2- 3,5
6 :3/8" 9 /16" - 18 10- 25 1,4 -3,5 25-40 3 ,5- 5,5
8 1/ 2" :)/4" - 16 15-42 2, 1- 5 , 8 42-6 7 5,8- 9,2
10 5/ 8" i /0'1 - 14 25- 58 3 ,5- 8 ,0 58 - 92 8,0 -1 2 , 7
12 3/4" 1-1 / 16" - 12 40-80 5,5-11. 0 80 -128 11-18
14 7/S" 1 -:3/10" - 12 60-1 00 8 ,:3-14, 0 1 00 -1 60 14-22
16 I" 1- 5/ 16" - 12 75-117 10-16 117- 187 16-26
20 1-1 / 4" 1-5/ 8" - 12 125-165 17-2:3 16 5-264 2:3-36
24 1- 1/2" 1- 7/ 8" - 12 2 10-250 29 - 3 5 250-400 35-55
70) 174

3
 Section

4&
BACKHOE CYLINDERS

ser nendly

TABLE OF CONTENTS
Bucke t Cylinder ....... .... ... ....... ......... . .. ..... .. ... ........... ... .. ..... ... ..... .... .... ..... .. .. .. ... .. ...... .. .. .. ....... .. ...... 2

Dippe r Cylinder .. ............. ..... .. .... .. ....... .. .. ... .... ..... ..... ..... .. .......................... .. .. ........ ... .. ........... ...... 4

Boom Cy linder .... .. .. ... .. ... ..... ..... .... .. .. .... ....... .. ... ........... ... ..... .. .... ............... .... .. ... .. .. ........ ..... ........ 6

Swing Cyli nders .......... .. ... ... ......... ..... .... .. ...... ........ ......... .. .. ...... ........ .... .. ... ................................... 8

Stabilizer Cylinde rs ....... .. ..... .. ....................... .... .... ....... ... ..... .... ... ............ . ... ... .. ..... .. .... ... ........ ... 10

E xtendable Dipp er Cylinder ...... .. ......... .... .. .. ... ..... .... .. .. ............ .. .... .. .......... ......... ..................... . 12

Rae. Form 9 ·80851

 46-2

BUCKET CYLINDER
(Refer t o Figure 1)
1. Piston rod "U" cup seal. Install into gland (5) with seal lip toward piston end of rod.

2. Piston rod wiper (outer). P r ess into gland (5) with wiper lip toward piston rod eye.

3. Gland "0" ring, Inset A.

4. Gland back-up ring. Install with curved face toward "0" ring, Inset A.

5. Seal gland. Lubricate the bore of the seal gland and slide the seal gland assembly over
piston rod.

6. Piston rod (2" diameter).

7. Piston half, rod end (2" diameter recess). See No.9 below and Inset B.

8. Piston half, bolt end (2-1/4" diameter r ec ess ). See No.9 below and Inset B.

9. Piston "Vee Seal" packing. Install hard outer packing r ing on each piston half. Install
three chevron rings on each piston half with the "V" of t he chevron ring towards the
center of the piston. See Inset B.

10. Piston seal bearing ring. Install between the "Vee Seal" packing. See Inset B.

11. Piston retaining washer.

12. Piston retaining bolt (grade 8, I" diameter). Torque 475-525 ft. lbs. Clamp rod eye end of
piston rod in a vise and support the piston rod when torquing the bolt.

13. Seal gland retaining screw (#8-32 x 114" self-tapping). Lubricate the piston seals and install
piston rod with gland into the cylider beIng careful not to cut the "0" l'ing or back-up ring.
Torque the gland 100-200 ft. lbs. using Case spanner wrench 044114, Inset C.

14. Rod pivot bushings. Press into place.

15. Grease fitting, straight.

16. Tube pivot bushings. Press into place.

17. Cylinder tube.

18. Grease fitting, 90'.

 46-3

INSET A~~~~
INSET B N G RIN G

INSET C

044114

~~~~~== Figu re 1
46-4

DIPPER CYLINDER
(Refer to Figure 2)
1. Piston r od "U" cu p sea l. In sta ll into gland (5) with seal lip toward piston e nd of r od.

2. Piston rod wiper (o uter) . Press into gland (5) with wiper lip toward piston rod eye.

3. Gland "0" ring, In se t A.

4. Gland back·up ring. In s ta ll with curved face toward "0" ring, In se t A.

5. Sea l g la nd. Lubricate th e bore of the seal gland and slide the sea l gland assembly over piston
rod.

6. Pis ton rod (2" diame ter).

7. Piston half, rod e nd (2" diameter recess). See No.9 be low and Inse t B.

8. P iston ha lf , bolt e nd (2-3/ 4" diameter recess). See :-\0. 9 be low and Inse t B.

9. Piston "Vee Sea l" packing. Insta ll hard outer packing ring on each piston half. Install three
chevron rings on each p iston half with the " V" of the chevron r ing towards the center of the
piston. See Inset B.

10. Piston seal bearing ring. Install betwee n the "Vee Sea l" packing. See Inse t B.

11. Piston re taining washer.

12. Piston retaining bolt (grade 8, 1-1/ 4" dia m e te r). Torque 1000-1200 ft. lb5. Clamp rod
eye e nd of piston rod in a vise and support the piston rod when torquing the bolt.

13. Sea l g la nd r e taining screw ( ~8- 32 x 1/ 4" se lf-tap ping). Lubricate the piston seals a nd install
p is ton r od with gland into the cy linder being careful not to cut the the "0" ring or back-up
r ing . T orque the gland 100-200 ft. lbs. using Case spanner wrench 044115, Inse t C,

14. Rod p ivo t bushings. P ress into place.

15. Grease fit ting , s traigh t.

16. Tu be pivo t bushings _ Press into place.

17. Cy linder tu be.

18. Grease fitting, 90°.

 46-5

INSET A INSET 8 PACKING RING

\
\
'-

14

INSET C

o
 46-6

BOOM CYLINDER
(Refer to Figure 3)
1. Piston rod "U" c up seal. Install into gland (5) with seal lip toward piston end of rod.

2. Piston rod wiper (outer) . Press into g land (5) with wiper lip towa rd piston rod eye.

3. Gland "0 " ring, Inset A.

4. Gland back-up ring. Install with curved face toward "0" ring, Inset A.

5. Sea l gland . Lubricate the bor e of the seal gland and slide the seal gland assembly G-;er
piston rod.

6. Piston rod (1-3/ 4" diameter).

7. Piston half, rod end (1 -3/ 4" d iameter recess ).

8. Piston "Vee Seal " packing. Install hard outer packing ring and the three chevron rings with
th e "V" of the chevron ring towards the center of the pi ston. See Inset B.

9. Piston backing adapter (female ). See Inset B.

10. Piston half, bolt end (2-3 / 4" diameter recess). Install with the recess toward the piston rod
eye. See Inset B.

11. Piston wear ring, Inset B.

12. Piston retaining washer.

13. Piston retaining bolt (grade 8, I" diameter). Torque 475-525 ft. lbs. Clamp rod eye end of
piston rod in a vise and support the piston rod when torquing the bolt.

14. Seal gla nd retaining screw (;8-32 x 1/ 4" self-tapping) . Lubricate the piston seals and install
piston rod with gland into t;,e cylinder being careful not to cut the "0" ring or back-up ring.
Torque the gland 100-200 ft. lbs . using Case spanner wrench 044113, Ins et C.

15. Cylinder tube .

 46-7

INSET A INSET B PACKING RING

INSET C

o 044113

l
,

'~~
" ~@
( 14
\i Vi ! V',~J
/fj :i
I
I
I
, I
'-- J
 46-8

SWING CYLINDERS
(Refer to Figure 4)
l. Piston rod "U" cup sea l. Install into gland (5) with seal lip toward piston end of rod.

2. Piston rod wiper (outer). Press into gland (5) with wiper lip toward piston rod eye.

3. Gland "0" ring. Inset A.

4. Gland back-up ring. Instal! with curved face toward "0" ring, Inset A.

5. Seal gland. Lubricate the bore of the seal gland and slide the seal gland assembly over piston
rod.

6. Piston rod (2" diameter).

7. Pi ston half, rod e nd (2" diameter recess). See No.9 below and Inset B.

8. Piston half. bolt end (2-3 / 4" diameter recess). See No.9 be low and Inset B.

9. Piston "Vee Seal"' packing. Install hard outer pack ing ring on each piston half. Install three
chevron rIngs on each piston ha lf with the "V" of the chevron ring towards the center of the
pis ton. See Inse t B.

10. Piston seal bearing ring. Instal! between the "Vee Seal" packing. See Inset B.

1l. Cushion relief spring spacer, Inset B.

12. Cushion r e lief spring, Inset B.

SPRIl\'G SPECIFICATIONS
Free Length ., ........................ ........... , ......... 5"
Total Coils _................... ............... .......... 24-1/ 2
Wire Diameter ......................................... 080"
:IiIax. Solid Height .................... .. ................ 2"
Compressed to 2-112" .......................... 55 lbs.

J3. Cus hion relief pin , Inset B.

14. Piston r e taining washer.

15. P iston and cushion relief retaining bolt (1-1 / 4" diameter). Torque 1000-1200 ft. Ibs. Clamp
r od eye end of pis to n rod in a vise and support the piston rod when torquing the bolt.

16. Seal gland retaining screw (#8-32 x 1/ 4" self-tapping)_ Lubricate the piston seals and install
piston rod with gland into the cylinder being careful not to cut the "0" ring or back-up ring.
Torque the gland 100-200 ft. Ibs. using Case spanner wrench 044114, Inset C.

17. Rod pivot bushings_ Press into place.

18. Grease fitting.

19. Tube pivot bushings. Press into place.

20. Cy linder tube.

 46-10

STABILI ZER CYLINDERS

(Refer to Figure 5)
1. Piston rod "U" c up sea l. In s tall into gland (5) with seal lip toward piston end of rocl.

2. Piston rod wiper (out er) . Press into gland (5) with wipe r lip toward piston rod eye.

:3. Gland "0" ring, In se t A.

4. Gland bac k-up ring. {ns ta ll w ith curved face towa rd "0" ring , Inse t A.

5. Seal g land. Lubricate the bore of the sea l g land a nd s lid e the spa l gland assembly ovpr
pis ton rod .

6. Pist on rod (2" diam e te r ).

7. Piston ha lf, rod e nd (2" diameter recess)_ See No.9 be low a nd Inset B.

8. Piston half, bolt end (2-1/4" diameter recess). See No.9 below and Inset B.

9. Piston "Vee Sea l" packing. Install hard outer packing ring on each piston ha lf. [nst a ll
three chevr on rings on each piston half with th e "V" of the chevron ring toward s th e
center of the pis ton . See Inset B.

lO. Pi ston sea l bearing ring. [ns ta ll between the "Vee Seal" packing. See Inset B.

11. Pis ton re taining washer.

12. Piston re tai nin g bolt (grade 8, 1" di ameter). Torque 475-525 ft. lbs. Cla mp rod eye end of
piston rod in a vi se and support the piston r od when torquing the bolt.

13. Seal gla nd retaining screw (~8 -32 x 1/ 4" self·tapping ). Lubricate the piston sea ls and install
piston r od with g land into the cylinde r be ing careful no t to cut the "0" ring or ba ck·up ri ng .
Torque the gland 100-200 It. lbs. using Case spa nner wrench DH114, Inset C.

H. Rod pivot bushings. Press into place.

1,). Tube pivot bu shing (self aligning).

16. Bushing r e ta ining snap rings .

17. Cylinder tube.

18. G rease fitting .

 46-11

18

044114

Figure 5
 -16-12

EXTENDABLE DIPPER CYLINDER

(Refer to Figure 6)
1. Piston r od "U" cup seal. Insta ll into gla nd (5) with seal lip toward piston end of rod.

2. Piston rod wiper (ou ter). Press into gland (5) with wiper lip toward pisto n rod eye.

3. Gland "0" ring , Insct A.

4. Gland back-up ring. Install with curved face towa rd "0" ring, Inse t A.

5. Seal g land. Lubricate th e borc' of the sea l gland and slide the seal gla nd assembly over piston
rod.

6. Piston rod (1-1 .'2" diameter).

7. Piston ha lf, rod end (1-li2 " diameter recess). See NO. 9 below and Inset B.

8. Piston half, bolt end (1-5/ 8" diame ter r ecess). See No.9 below and Inset B.

9. Piston "Vee Sea l" packing . Insta ll hard outer packing ring on each piston half. Install three
chevron rings on eac h piston half with the "V" of the chevron ring towards the center of
the piston, See Inset B.

10. Piston sea l bearing r ing. Insta ll between the "Vee Seal" packing. See Inset B.

11. Pis ton retaining washer.

12. Pisto n retaining bo lt (grade 8, 3/ 4" diameter), Torque 200-220 ft. lbs. Clamp rod eye end
of piston rod in a vise and support the piston rod when torq uing the bolt.

J3.Seal gland retaining screw (~-32 x 114" self-tapping). Lubricate the piston sea ls and install
piston rod with gland in to the cylinder being ca reful not to cut (h e " 0" ring or bac k-up ring.
Torque the gland 100-200 ft. lb s. using Ca se spanner wrench 044112, Inset C.

14. Cylinder tube.

 46-13

INSET A IN SET B R ING

NYLON RI N YLON RING

NEOPR

"-
"- ....
....
........
....
.... \
I
I
I
\
\
I

044112

Figure 6
 Sectio n

47
AUXILIARY CYLINDERS

TABLE OF CONTENTS
4 in 1 Bucket Clam Cylinde rs .... .. ............. .. ...... .. .... .... .. .. .... ...... .... .... .... .... .... .. ........... .. ......... .... .. 2

Grapple Fork Cylinde rs ... ........... ..... .... .......... .. ................ ... ... .. .... .... .... .... ......... .. ...... .. ...... .... .. .. ... 4

ser nendly

http://www.ioffer.com/selling/userfriendlycds
http://stores.ebay.com/UserFriendlyCDs

Rae . Form 9-80861

 47-2

4 IN 1 BUCKET CLAM CYLINDERS

(Refer to Figure 1)
1. Pis ton r od "()" c up seal. Install into gland (6) with seal lip towa rd pist on e nd of rod.

2. P is ton r od wipe r (out er). Press into gland (6) with wipe r lip tOlVa r d pis ton r od eye.

:3 . Gla nd " 0 " ring . Tn se t A.

4. Gla nd bac k-up r ing . In sta ll wi th curved face toward " 0" ring (3) . In se t A .

5. Pis to n rod wi per (inner) . In s ta ll into g la nd (6) with ta pe red lip towa r d pis ton e nd at rod , Inset A.

6. Seal g la nd. Lub ricate the bore of the sea l g la nd a nd s lide the seal g land assem bly over pis ton
rod .

7. P is ton rod (1 . 7~" dia me te r \.

8. P iston ha lf. tad end (1 -3 / 4" dia mete r recess) _ See No. 10 be low and Inse t B.

9. Piston ha lf. bolt end (2" diameter recess ). See No. 10 below and Inset B.

10. Pis ton " Vee Sea l " pa ck ing _ Ins tall ha r d ou te r packing ri ng on eac h pis ton half . Insta ll thrce
c hevron ri ngs on each piston half wi th the " V" of the c hevr on ring towards the center of the
piston. See I nset B.

11. P iston seal bearing r ing . Ins ta ll betwee n the " Vee Seal" packIng. See Inset B.

12. Pi s ton retain ing washer.

13 . Pi sto n retaini ng bolt (g r ad e 8, 1" di a m e ter ) . Tor que 475-525 It. Ibs. Clamp rod ey E' end of
p ist on rod in a vise and s upport the pisto n rod whe n to rquing the bolt.

14 . Sea l gland reta ini ng sc rew ( 8-32 x 114" se lf-ta pp ing ). Lubricate the piston seals and Ins ta ll
piston rod wilh gland into the cy linde r bei ng careful not to c ut the "0" r ing or back-up r ing .
Torque th e gland 100 -200 ft. Ibs . using Case spa nner wr e nc h DH113, Inset C.

15. Rod pi vot bushings _ Press into place .

Hi . Tube pivo t bush ings _ Press in to pla ce .

17. Cyl inder Tube.

18. Grease fi ttings.

 47-3

INSET A INSET B

:I "(I)'"
I

:eI NYLON

,
NEOPRENE RING RING
\
'-
""-
13 " ""- 2
" " ""-
"9
"

"
o

INSET C

044113

Figure 1
 47-4

GRAPPLE FORK CYLINDERS

(Refer to Fig ure 2)
1. P is ton rod "U" cup sea l. In sta ll into gla nd (6) with seal lip toward pi s ton end of rod .

2. Piston r od wiper (outer ). Press in to g la nd (6) with wi per lip towa rd pis ton r od eye.

:3. Gla nd "0" ring, Inset A.

4. Gla nd back-up r ing. Ins ta ll with curved face toward "0" ring (3) , Inse t A.

5. Piston rod wiper (inner ). Ins tall into gland (6) with tapered lip toward piston e nd of rod, Inset A.

6. Seal g la nd. Lubrica te the bore of the sea l g land and slide the seal gland assembly over piston
r od.

7. Pis ton rod (1.50" diameter)_

8. Pist on half, rod e nd (1-1/2" diame ter recess ) . See No. 10 below and Inset B.

9. Piston ha lf, bol t e nd (1-5/ 8 dia me te r recess)_ See No. 10 below and Inset B.

10. Pis ton "Vee Seal" packing. Install hard oute r packing ring on eac h piston half. Install
three chevro n rings on each piston half with the "V" of the chevron ring toward s the ce nte r
of the pisto n. Inset B.

11 . Pist on sea l bea ring ring. Inst all be tween the "Vee Seal" packing. See Inset B.

12. Piston retaining washer.

13. Pisto n r eta ining bolt (grade 8, :3/4" diame te r), Torque 200-220 ft . Ib s . Clamp roc! eye e nd of
piston rod in a vise and s upport the piston rod when torquing the bolt.

14. Seal g land re ta ining SCrE N ("8-32 x 1/ 4" self-tapping). Lubricate the piston seals and ins tall
pi sto n rod with g land into the cylinder being careful not to cut the "0" ring or back-up ring.
Torque the gland 100-200 ft. lbs. using Case spanner wre nch D44112, Inset C.

15. Rod pivo t bushings. Press into place.

16. Tube pivot bushings. Press into place.

17_ Cylinder tube.

18. Grease fittings.

 SECTION
47

HYDRA-GUIDE
HYDRAULICS
GUIDANCE SYSTEM
Model 480 and 480B Tractor vvith 26 Backhoe
Mode l 580 Tractor vvith 33 Backhoe
Model S80B Tractor vvith 35 Backhoe

ser nendly s

http://www.ioffer.com/selling/userfriendlycds

http://stores.ebay.com/UserFriendlyCDs

Burl... o.m 9-720815 KHCBO Printed in U.S.A .

 TABLE OF CONTENTS

SPEC IFICA TIOl\S . . . . . . . . . . . . . . . . ... 3

HYDRAULIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Mode ls With Single Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 4

Model s With Dual Boom Cylinders . . . . . . . . . . . . . . . . . . . . 5

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

OPERATI NG SEQUENCE W1TH SELECTOR VALVE IN "DIG" . . . . . . . . . . ... 8

OPERA TING SEQGENCE WITH SELECTOR VALVE IN "TREl\CH" . . . . . . 12

TROUBLE SHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

TESTING AND ADJUSTING TRIGGER POPPET PRESSURE SETTINGS .. . . . . . 18

TESTING RESTRICTOR/CHECK VALVES FOR LEAKAGE . . . . . . . . . . . . • . . . . . . . . . 20

PRESSURE SENSING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . 22

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . • . . . 22

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Hydra-Guide Controls On linits With Side Mounted Sensing Valve . . . . . . . . . . . . . . 28

Hydra-Guid e Controls On 580B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2
 SPECIFICATIONS

Trigg'er popp et pressure se ttings (se e Figu re 15)

Adjusting screw no, 1 . · . . . . 1600 ± 50 pS i @ 2 000 engine rpm
(11 3 ± 3 ,5 kg/em'@ 2000 engi ne t r/m n)
Adjusting Sel'ew no . 2 . · . . . . 1200 ± 50 psi @ 200 0 engine r pm
(8'. ± 3,5 kg/em' @ 2000 engin e tr / mn)
Adju s ting s c r ew n o. 3 . · . . . . 1900 ± 50 ps i @ 2000 engine rpm
(134± 3,5 kg/em'@ 200 0 engin e tr/ mn)

NOTE: Oi l should be at operating temperature.

Main r eI ief val ve p r8s s ure s e tting

Model 480 . . . . . . . . 21 00 + 0, -100 psi at full engine rpm
(1 4 8+ 0, -7 k g/em')
~lod e l 580 and 580B . 220 0 ± 75 pSi at full engine rpm
(1 55± 5 kg/em')
Backhoe hydraulic specifications. . Scee the 40 Series Seetions,
Hydraulics , in thi s m auual
Sp r ing' specifications. pr e ssure sensing val ve
Poppet. spri ngs (3)
Free height . . . . . . . . . . . 1- 1/4" ± 1/32" (31 ± 0, 8 mm)
Compression rat e .. . .720 ± 72 Ibs . per inch (327 ± 33 kg)
Spool centering sp rings (2)
Free heig'ht . . . . .. .. .. 1-:3/16" (30 mm)
Comp ression r at.e. 50 l bs. pel' ineh (22 ,7 kg)
Spo ol diame ter . . . . . . . . . . . . . . . .. 1.001"

U.S. AND METRIC TORQUE SPECIFICATIONS

Hydraulic Filling,," (Sleel)
0
:37 Flare Straight T hr ead
F emale Swi vel O-Ring
Da sh T u~e Thread Torque Torque
Size a .D. Size ft . lbs . m -k g ft. lbs . m-kg
4 1/ 4" 7/16" - 21J 6- 12 0 , 8-1,7 12-19 1 ,i-2,G
5 5 / 16 " 1/2 " - 20 8-16 1 ,1-2. 2 16- 25 2 .2- 3 , 5
6 3/8" 9 / 16" - 18 10-25 1.-1.-3 .5 25 - 40 :3,3-.'5, 5
6 1 / 2" 3 / 4" - 16 15-42 2 .1-5, 8 42-6 7 5, 8-9,2
10 5/0 " 7 /S " - 14 25-58 :3. 5-8 .0 58- 92 8,0- 12, 7
12 :3 /4 " 1-1 / 16" - 12 40 - 80 3,3-11,0 80 - 128 ll- l iJ
14 7 /S " 1-:3/ 16" - 12 60-100 8 .3-14. 0 10 0 - 160 14-22
16 I" 1-5 /16" - 12 75- 117 10-16 117- 18 7 16-26
20 I -J!i" 1-5 /B " - 12 12 5- 163 17- 23 165- 264 23 - :3G
24 1- 1/2" 1-7/S" - 12 21U-250 29 -:35 250 - 100 35 -55
70\ I 7!,

3
 HYDRA ULIC DIAGRAM S

_ _ PRESSUR E RELI EF VENTED

BUC KET _ RET URN

CYLINDER
- PRESSUR E

NOTE:
MOD ELS SELECTOR VA LVE
WITIi

-~--1
TWIN
LEVER
CO N TROLS
O NLY
DIPPER
CYLINDER ("- -
I
--
I 3I I
I '-. I
I I I
- ------~ I
I
I
I
I I
I I
I I
BOOM I I
CYLINDER I I
O'-+-t--~ I
1600 PS I -.n •• ",R I
~~}-Ill- I
1900 PS I

BUCKET I zo o PS ' POPPET

SECTION

PORT NU MBERS
STAMPED O N
SENSING VALVE

CONTRO L VA LVE AS
VIEWED FROM O PE N
END O F BAC KHOE
MA IN FRAM E

Fig'u r e 1 _ Diagram of Hydra -Gutde Hydr aultc System. Model with Sing te Boom Cylinder

4
 BUCKET DIPPER PRESS URE OI L
cn I !l DER CY L INDER
RETUR II OI L

- -- PRES SUR E RE LIE F

VE NTEO 0 I L
BOOM
CY LI NDERS

4- SPOOL
CO ~nROl
VALVE tt:fll~~~.~~~i
..:n,.J...J.1- I 3
I1 _ _ _• _ •
SELECTOR
VA l~ E

• I

.. rot,· •
•

..
I
PRES S~R E
SEN, I NG VALVE

PSI POPPET
TO RESERVO I R
1900 PSI POPPET
7 10998
FR OM PUMP

Figure 2 - Diagram of Hydra-Guide Hydraulic System. Models With Dual Boom Cylinders

5
 DESCRIPTION

General ated, three-position valve whose function is to

determine the type of digging to be done by the
Hydra-Guide is an optional hydraulic backhoe. The three positions are Manual, Dig,
system which give s the operator a choice of and Trench.
two automatic digcyc les or the regular manual
operation. The system Is formed by connecting The valve operate s by opening or clos i.ng
a pressure sensing valve and selector valve to the two vent lines from the trigger poppets to
the backhoe digging cylinders as shown in the reservoir. A closed vent line means that
Figures I and 2. the poppet connected to it is not a functioning
part of the circuit.
With the selector valve in Dig Or Trench
and the bucket properly positioned ,the opera- Manual Position
tor starts the cycle by pulllng the dipper
lever to crowd. The sensing valve monitors When the selector valve is placed in
the system pressure and continually read- Manual, Figure 3, both inlet ports (2 and 3 )
justs the flow of oil to the boom, dipper, and a t the selector valve a re c losed. Oll flow past
bucket cyllnders as long as the dipper lever any of the three trigge r poppets is not poss ible
is held in crowd position. and thus the Hydra-Guide system cannot
function. All digging must be done manually.
NOTE: Hydra-Guide m ay be overridden
at any time by manually operating the bucket
and/or boom leve rs.

A de talled explanation of Hydra-Guide

operation starts on page 8 .

.. ressure Sensing Valve

The m a in component of the system Is the

pressure sensing valve, Figure 22, a direc-
tional c ontrol valve consisting of two pllot
opera ted spools and three direct acting relief
valves (trigger poppets). The trigger poppets
are set at 1200 psi, 1600 p si , and 1900 p s i,
Figure 15. When a poppet opens or closes,
one of the spools in the senSing valve is also
opened or closed, In turn, the shifting of a
spool opens and closes passages to the boom
or bucket cyllnders.
Figure 3 - Selector Valve In Jl;lanual
As the system pressure changes due to
Increas ed (or lowered) resistance to digging,
the trigger poppets sense this change a nd Trench Position
respond by opening or closing, causing the
previously mentioned spool shifts. When the selector valve is placed in
Trench, Figure 4, selector valve ports 2 and
An understanding of the Interaction be- 3 are open. After actuating the crowd circuit,
twee n the poppets, sensing valve spools , and and when system pressure reaches 1200 psi,
backhoe cyllnder s can be gained by careful the 1200 psi poppet opens, causing the boom to
study of the diagrams and text on pages "float up", At 1600 pSi, the bucket starts to
8 to 15. curl. This results in a shallow, fl at cut which
rakes or levels the trench bottom.
Selector Valve
NOTE: See pages 12 to 15 for a detailed
The selector valve Is a manually oper- explanation of this process.

6
 Figure 5 - Se lec tor Va lve in Dig
Figure 4 - Sele c to r Va lve In Trench
ps i poppe ts ope n as s ys tem pre s sure builds ,
D ig Position causing the bucke t to curl and the boom to
power up. Thi s results in a deep cut and full
When the s elec to r valve is place d in Dig, bucke t.
F igur e 5, selec to r val ve por t 2 is cl os ed and
port 3 is op en. Closing port 2 pr e vents the
1200 ps i popp e t fr om ftlncti oning . Afte r actu- N O TE: See page s 8 to 11 fo r a det a iled
a ting the c rowd circu it, the 1600 psi and 1900 e xpla nation of this pr oce ss .

7
 OpaERATING SEQUENCE WITH SELECTOR VALVE IN "DIG"

Refer to Figure 6. sensing valve to shift, opening ports 2 and

5 to the bucke t cylinde r.
1. Move selector valve handle to "Dig"
position. Operate the dipper crowd cir - 5. The dipper crowd and bucke t cu rl ci rcuits
cuit. are now in par allel and the ci rcuit with
least resistance or greatest mechanical
2. Oil from the pump is supplied to the closed advantage will operate.
e nd of the d ippe r c yllnder a nd the pres-
sure sensing va lve through port 6. This oil NOTE: Note that the dipper cylinde r oil
flows through the spools a nd passages in is supplied from the backhoe control valve
the sensing valve to act aga inst the three and the oil for the bucket cylinder is
trigger poppet s. supplied through the senSing valve via
ports 6 and 2.
3. Resistance to dig causes sys tem pre ssure
to rise. As long as sys tem pressure re- Refer to Figure 8.
mains under 1600 pSi, the poppets remain
closed. 6. Resistance to dig incre ases and causes a
further rise in system pressure. At 1900
NOTE.: The 1200 p s i poppe t ve nt line Is psi, the 1900 psi poppet opens a nd relieves
blocked at the selector valve. Thi s poppet through port 4 In the sensing valve a nd the
is not a factor in the "dig" sequence. se lector valve. This causes the boo m
spool to shift, opening ports 7 and 8 in
Refer to Figure 7. the sensing valve to the boom cyl inder.

4. At 1600 psi, the 1600 psi poppet opens and 7. The dipper crowd, bucket curl , anc! boom
relieves through port 4 and the selector raise circuits are now in parallel for
valve. This causes the bucket spool in the digging or filling the bucket.

8
 SELECTOR VALVE IN D IG POSrTlON

NOTE: Operating princ iples are identical for circuits with du al boom cylinders, although
cODtrol valve and hose connections vary from those shown.

o!..Cl(f • _ _ _ _ _ _ _ _• _ _ _ _ _ _ _ _ _. , 5ELEcrOll VOlVE Il~

C'fLlr.QEi\ DIG POSIfI(j\· · ,QRT

j 'PO, to R€SEJ\Y.oIR -
POAT 2 8l 0i KEO

I
0 195>H
en I NVEil

RuCf(ETr ~_.-J~~~!l
SPOOL -
CLOSE D 1m~iii

sao. .
CYll tlDER
BOO.h
S.pOOl
CLOS ED

PUMP Oi l

SlATI C OI L

-
_ A. f TuR Il Ol t TO RE SERVOI :R

CI RCUit TO POPPE1S (SYSTEM PRtSSUR f )

710892

Figure 6 - Dipper Crowd Circuit Operated, System Pressure Below 1600 psi,
All Poppets and Spools Closed

9
 SELECTOR VALVE IN DIG POSITION

NOTE: Operating principles are identical for circuits with dual boom cylinde rs, although
control valve and hose connections vary from those shown.

S"JCKEr SEL[CH1R vALVE 111

U LINDER D IG POS IfIOH-- PO AT
OPJ::N TO R£SER\'O I.R:-
POI\T 2 S\. OCKEIl

OIP'PE R
C"' L. l t~DE R

80C:'1

(lOS EO

'JALI.'E

I11III PUMP Oll!SYSTEK PRESSURE

I11III STAT IC Oil

OIL RELIEVED PAST 1600 PSI POPPET

.-- PATH OF II,ELIEVEO Oil TO SELECTOR vALVE

I11III RETuAt/ Oil TO II.ESEA. VOIR

CIRCU IT TO POPPETS ( SY STEM PRE SSURE) 71 0893

Figure 7 - Dipper Crowd Pressure Between

1600 psi and 1900 pSl, 1600 psi Poppet Open, Bucket Spool Open,
Bucket and Dipper Cylinders Can Operate

10
 SELECTOR VALVE IN DIG POSITION

NOTE: Operating pr inciples are identical for circuits with dual boom cylinders , although
contro l valve and hose connections vary from those shown.

fl; (~E r SElECTOR IIhL\I£ I ~

[HI •• OER DIG POS,I ' IO,.--PORT .3
OPEN TO ~ESEA.VO I R-
POIH 2 'BLOCf,ED

01 P'F'ER
C",L I ~DER

BUCt(ET_+-=19~
SPOOL
SH I FrE D
GPEtl
2

800M
C'I'L I n08t

12009'SI

I
LINE. BLOCKE()
' SELE.craft
BO
VALVE

PUMP Oi l

STA TIC Oil

0 1L RELI EVEO BY ) 600 AND }900 PS I POPPETS

_ _ _ PA1H OF REL I EvED Oi l TO SELE! TOR V':' l Vf

_ RETURN 0 I L TO RESER.Ve I R

: C IRCU I t Til POPPETS (SY STfl'l PR€ss.uP. E)

710894

Figure 8 - Dipper Crowd Circuit Operated, System Pressure

Above 1900 psi, 1600 and 1900 psi Poppets Open , Bucket and Boom Spools Open,
All Three Cylinders Can Operate

11
 OPERATING SEQUENC E WITH SELECTOR VALVE IN ' 'TRENCH''

Refer to Figure 9. 4. At 1200 psi, the 1200 psi poppet opens

and relieves through sensing valve port
1. iI'love selector valve handle to "Trench" 3 and the selector valve. This causes the
position. Operate the dipper crowd cir- boom spool in the senSing valve to shift,
cuit. opening ports 7 and 8 to the boom cylinder.
Note that the bucket spool is closed. This
2. Oil from the pump Is now supplied to the means that pump oil is blocked to port 8--
closed end of the dipper cylinder and the the boom now "floats" up a s the dipper
pressure sensing valve through port 6. continues to crowd.
This oll flows through the spools and pas-
sages In the sensing valve to act against Refer to Figure 11.
the three trigger poppets.
5. Resistance to dig Increases and causes a
3. Resistance to dig causes system pressure further rise in system pressure. At 1600
to rise. As long as system pressure re- psi, the 1600 psi poppet opens and relieves
mains under 1200 psi, the poppets remain through sensing \'alve port 4 and the sel-
closed. ector valve. This cause s the bucket spool
In the sensing valve to shift. opening ports
NOTE: Compare with "Dig" operating 2 and 5 to the bucket cylinder and the
sequence. With selector valve In passage to port 8 for the boom cylinder.
"Trench" position, ports 2 and 3 are both
open, permitting all three poppets to
rel!eve oil. However, only the two lowest 6. The dipper crowd. bucket curl, and boom
of the poppets w!ll work--the 1200 psi raise circuits are now in parallel for
and 1600 psI. digging or fllllng the bucket. The circuit
with the least resistance or gre atestme-
Refer to Figure 10. chanlcal advantage will operate.

12
 SELECTOR VALVE IN TRENCH POSITION

NOTE: Operating principles a re identical for circuits with dual boom cylinders, although
control valve and ho s e connections vary from those shown .

euC'(ET , _ _ _ _ _ _ _ _. ._ _ _ _ _ _ __ ...
SHfCTalt V A LV~ i ll
£ YL HlGER TR.ENC ft POS I TI Of..... •
PORT'S 2 AtlD 3 OPEN
NOTE: 8UCI\ET 110SB $).I IT CHE.:O ON TO ~ESERVG IR
UIl I1"5. 'J ITM DUA L CONTROl... lfV(R S'_~-L-

o 1'?,p£R,
en INDER.

BOOM
CYL IllDeR

I11III PUMP Oil

I11III STATIC Oil

I11III RffUA u Ol~ TO ~[S£~vQIA

CI RCUIT T~ PO~ P( TS ( SrSTEH PRESSuRE )

710592

Flgul'e 9 - DIpper Crowd Circuit Operated, System Pressure Below 1200 psi,
All Poppets and Spools Closed

13
 SELECTOR VALVE IN TRENCH POSITION

NOTE: Operating principles are identical for circuits with dual boom cylinders, although
control valve and hose connections vary from those shown.
B\JCK'Ef • _ _ _ _ _ _ _ _. ._ _ _ _ _ _ _ _...
CYL.I jjD f.R SElfCTOR VALliE Iti
TRENCH P'OSITI()ri--
is 2 ANO ) OPEN TO
RiS£RI)O ,R

r
t•L _________ _
--. I
I
I
Ol PPER I
CYLJ NOER I
I
I
I

t••
I

'(WOK
CVL I NDER

POPPEr OPE/:

_ PUMP OIL
_ STAT l( Oil

OIL RELIEVED 6¥ 1200 PSI POPPET

- - - ~ATH OF REL I EvEO {) I L t o SeLECTOR V':"lVE
_ RETuftN Oil TO ~£S ERVO IR

IlO ft:
(IACUll to PDPPET5 (SYSTEM ~RI SSuRE)
SELECTOR VAl VE 'PERMITS ;'U l tfll.U P P'9ET$ TO OPEt., (Wi
THE. LO'.tEST NO '.JIll 1.,l:;1'\ }200 Ps I ;" .0 1600 PS I .
O~~L V -
Figure 10 - Dipper Crowd Circuit Operated, System Pressure Between 1200 and 1600 psi,
1200 psi Poppet Open, Boom Spool Open, Dipper Operating
By System Pressure With Boom Cylinder "Floating" (Raise Only)

14
 SELECTOR VALVE IN TRENCH POSITION

NOTE: Operating princ iple s are identical for circuits with du a l boom oylinders, although
control valve and hose connec tions vary from those shown.

SUC'Kt:: T SELECTllR \fAL \ IE I II

t 'fl l tlOER TRE r-.'CH POS I TJO tl--
PORrS Z M It) 3 QP EIJ
TO R'ESERV{J IR

r---+--.. t 1. _ _ _ _ 1 ___ -+ _______ ,

I I
-~,-",,,-.
r PS I PtJPP£l .aPEu t I
I
- I
n iP PER I
nt. 1tt OER
I
I
I

.
I
I

(:1.001"1
( YL I NDER
BOCH _.4.----j"" ""
SPOOL
SH I FTED
OPEN

P(}PPET OPE N

_ PUI1 P OIL

I11III STATJC Oil

Oil REUfVfO BY 12 00 Au [) i &OO PS I PO'PP ETS

- _. PATH OF AU I EVE D Oil TO SEL'fCTDR VA LVE

llETUfW Oil TO RESERVOIR

C I HCU IT TO poP P:E.TS ( SVS TE>I ?fl.t'SSU1~ E)

Figure 11 - Dipper Crowd Circuit Operated, System Pressure Above 1600 pSi,
1200 and 1600 psi Poppets Open, Buc ket and Boom Spools Open ,
All Three Cylinders Can Operate

15
 TROUBLE SHOOTING CHART
NOTE: In addition to the pos sible causes included in this chart , poor Hydra-Guide perfor -
mance may be the res ult of incorrec t op erating procedures, a worn pump, control val\'e , or
cylinde r. Refer to the trouble shooting c harts and procedures el sew he r e in thi s ma nual.
Corr ect ope rating procedure is impol'tant-- r efer to the Operators Manual.
THOCBLE PQSS JOLE C At.,E C HE C K I ~G PH()C LOU lE HEAIEDY

Hyd r n-Guide I. Selecto r va lve set in I. Set sc lcc tnr \'Dl ,,' e to Dlg:
1" :3 11 :,:; To wrong po sition. or TI'ene-h. $ee ()pe rrlt~ r'5
Func tion Mnnua l.
2. Ho ses sw i tch ed at se lec- 2. Check hookup aga i nst 2. ne<'.'ol'1l1cct hoses.
to r val .... e aftel' repa ir s. Figure 1 o r 2.
:3 . Low pressu r e .<;etting at 3. Check pressure setting. 3. Adju st to specificatIons.
ma ln r e li ef YJJ ve. Pedo r m ste ps 1 thru 4. 1\1 t'o odjustlng scre w Into
Te sting a nd Ad justing Tri gge r vo.l\'(' to inCl"CIl 5(' th~ pre s-
Poppet Pressure Setttng~ , UI'C 'Setting.
page 18.

Slow Digging I. Gene r ::Jl system p l'oblern- I. T est pu m p and bac khoe with I. Repai r. repl ace , or clc.Ul
Cycl es wo rn pu mp, valve , nowm e te r, ftl\dty oCoT11ponent as
cy linde r. etc , r~4ujred,

Boom O r Buc ke t I. Sensing Y;:live sp()ols v.1 11 I. Refer to Tes ting a nd Adjusting I. 11 curl Dnd 11ft both occu r.
Fails To not s hift. 'rr lgge r Poppet P r essw'e th t! spool s a I'e not SlQ,ck,
f'u ncilon Se.tU ngs , page HI. Perform Adj\..l~t pressure settlng~
steP B 1 thru a and 10 and 11. if requited, U ei ther curl
01' lift does not occ ur,
chec k fo r stuck spoo l.
flefe r to Po ssibl e Cause
3 below,
2. Va lve body di sLorted by 2. Loosen mounU ng bolts and 2. Slllm be twee n bac khoe
mounti ng bo lt pu ll down. r ec hec k. If valv e funcUonS fr ame unrl A~ns\n g valve.
p roperl y . dlsLor t ion was the
proble m.
3. Spool s stuck by fo r e ign 3. Remove plugs and sp rings 3. If the spoo l s mo ve freE ly
m ale ria l. (rom e nds o( spools, Spools DO NOT remo~'e spoclls -
shou ld move tnely with t.est spri ngs QncJ repl ace if
finger preS9 u r e, be low .specifi c ation s , If
spools do not mo\'e fTee ly,
I'emove spoo t ~ for c leani ng:
a. FirBt try to rno\'e
spools aw ay from
i;pr lng end.
b. If thf ~ cannot be
done. try tapping
opposit.e and of spoo ls
with brass dr ift.
c. U s pool s a re tightly
wedged, .remove
v al ve f rom machiT14i!
for !"e p a i r or
rep.1 aceme nt.

Boom Flo:lt s Up I. Worn seiec t.Q r ','a l v\:.', I. Disconnec t hose .:it po rt 2 of I. Repl ace selector Yo1 !ve,
WI th Se lec to r se lec tor vt\ lve, In ~tn ll plug
Vilive In Dig (Case part no, 216-772) in
Posi tI on end of hose , Ope rate backhoe
w ith se l ector val ve in Olg. U
p r oblem Is so l ved . se l ec to r
vah'c h as bee n p r onm b:ld. l!
probl em i s not .soh ·ed . se e
(;"rl And/Or Lift Occurs Too
Qui ckly page 17,

Boo m Drifts I. fiest r icto["jcheck: \' alve I. Pe rfor m c heck as deBc rlhed I. H{'pl.:lC:~ rest n t' t.or/check
DO'o' n Ie:lk:lge at se n:~ lng valve on page 20. \'a l ve.
po rt 8.

Duc ke t L'n('u rl s 1. ReJ;trl c tor /ctv~C'k v olvc I. Pe r form check as described I. l(l-platB rc~tl'l<; to r/ che<: k
l eako ge at 5cn~\ng \' :l lve 0 11 p age 21. \' dlve.
POl't 2 ,

16
 T ROCD LE P()$SIHLE CA tS}:: C HECK r"G PROCEDL'RE nHtE OY

Cu rl And/Or I. Sp<)QI -stuck open. l. Check sensIng va lve spool s: 1. Re move p l\Jg and sp r ing
Li ft OCCUI'S a. P lace 5El Ll!c to r valve 1n f rom end of srnck spool.
Too Quic kly Manua l pos itio n. Remove s pOO ls by tappIng
b. Ope r a.te c l'o\\'d clrcui l. towllrd spring cod . Wash
Have bucket o ff ground. spoo l ~ a.nd bo re s :111 re -
EJCtend cyHnde r cornp l e te- mOve burrs. Reinst all
ly. Pull d ip per le \1f' r. spOOl Iilnd c heCK f or f4E! e
c. if buc ket c u rls, bucket moveme nt. Spool must
s pool is s tuc k ope n. If mov e !z'8el y.
bucket does not curl. p lace
bl\ckhoe in po sitiOn shown
In Figur e r g,
d. Pu ll d ippe l' leve r. li m ach -
ine lowers to ground , t~e
boom spoo l i 5 stuck o pe n.
If m achine does not
lowe r, poppets a re out of
'Rdju5tmenl. See pos sIb le
c au se 2 below.
2. Tr igger poppets out of 2. Check t rigge r poppet pr efl su r e 2. AdNs t popJ>t'1s as described
oojust.me nt. Sf:tt ings . Pages 18 to 20 . on page 19.
3. fo r eign m nle rlal ho lding 3. D i sa sse mble poppe ts (see
pi lot off seal Di sassembly i n tMB sec-
tion) . Cle an aU part'!; in
sol ve nt. Rei ns tall i n va lve.
then adjust poppets.

MOST HYORAULIC .. ROBLEMS ARE CAUSED BY

CONTAMINATED OIL!

Keep The 0 11 Clean

1. C lean t he f ille l' cap are;) before checking o il level.

2. li se n. clea.n wmel find container when addtng oil.

3. Clean exter io r of componen t s . lines . and f1 ttin gs befol'e rt'rno val .

Ciose openi ngs with clean co plugs.

4, ~ 1a."'e
. J'epnirs on a c l ean wo r k bench. Use cl ean tOO l s .

5. Chllnge oU nfld service the fil te r (s) when making r epairs .

NOTE: If dra.lned oil Is r eused. it ~hou.td be filt ere d be fore

r elns ta.ll ing in the reservoi r.

6. If paI'ts ins pectiofl indica tes tha t metal chi~5 , sh r edd ed p:.J cking .
e tc . ha ve e ntered the hydl',f'lu tic syste m . the sys t~rn shoul d 1)e
flus hed . fll te r (s ) s e rv iced . a nd new o il ins tal l ed.

17
TEST ING A ND AD~USTING T RIGGE R POPPET PRESSURE SETTINGS

NOTE: Prior to s t arting chec ks, de te r-

mine the con ec t setting of the vehic le's m ain
r e lie f valv . He fe r to page 3.

The pre s sure check port in th,;, se nsing

valve Is Inaccessible on the m achine : the r e -
fo r e , all pI'essureS a r e measured at the
10::tde:1; c ontro l valve tes t port.

1. Refe r to Flgl.ll'e l2. install a 0-3000 ps i

gauge in the IO:1cle :r control valve tes t port
with a ga uge hose long e nou gh to all ow the
oper ator to see the gauge a nd backhoe
bucket at the same ttme .

Figure 13 - Boom !tilse

7. Ope r ate the dippe r c towd c iroult , fu lly

extending tl\ ~ dipper c·linder. Feather Ule
dipper control lever In I'owd positlon ,
l" ig,ure 14. Watch pressure glluge and
c ontinu e to move the l ever to oau se a
pressure increase.

Pig,u re 12 - Press ure Gauge [nsta lle d

2. Pl ace selec to r' valve in Manu al pos ition.

3. T he hyd "aulic oil s hoUld be ut op e r ating

te mpel'lltur e (a t least 120· F.) If r e-
quire d, start engine Md r aise a s t abi -
Ut eI'. Hold leve r in po si tion Uiltil inle t
line to loade r valve is warm to tOUCh.

4. rta ise st abili zer to end of s troke and r e ad

the press ure gauge. If r e quired, adj ust
loader m a in relief valve .
Figure 14 - Feathering Dippe r Control
5. Pl ace selec tor va lve handle in Dig po-
s ition. Hun engine at full thr ottle. 8. Watc h the bucket and !lOte the pressure at
which the bucket s t arts to cur l. This
6. Ra ise the boOm suffiCie ntly to allow Should be 1600 ± 50 ps i.
ground c le arance for the bucket in a ll
pos itions , Figute 13. 9. Adjust trigger poppet If required :

18
 a. If the bucket curls at less than 1550 10. Curl the bucke t completely. Fe ather the
psi, remove the cap on adjusting dippe r control lever to crowd. Watch the
screw 1\0. 1, I'igure 15. Turn ad- pre ssure gauge and the boom while con-
justing screw clockwise. Repeat tintting to feathe r the dippe r lever, figu re
check and adjustment until correct 16.
se tting is attained.
11. Note the pl'essure at which the boom
b. If the bucket cuds at a pressure starts to raise. Thi s should be 1900 ± 50
higher than 1650 psi or fails to psi.
curl, remove the cap on adjusting
screw 1\0. 1. Turn adjusting screw 12. Adjust trigger poppe t if required:
counterclockwise. Repeat check and
adjustment until correct setting is a. If the boom raises at less than 1850
attained. pSi, remove the cap on adjusting
screw No. 3. Turn adjusting screw
clockwise. Repeat chec k and adjust-
ment until correct setting is attained.

b. If the boom r aises at a pressure

higher than 1950 ps i or fa ils to raise,
"BACKHOE remove the c ap on ad justing screw
NO UI\T II;G FR."-"NE No.3. Turn ad justing screw counter-
5W itlG clockwise. Repeat check and adjust-
TOWER ment until correct setting is attained.

13. Place selector valve handle in Trench

position.

14. With the loader bucket raised to clear

NO. 2 the floo r , fully extend the bucket cylinder
in curled po siti on, then fully exte nd the
dipper cylinder in crowd position. Power
71C908
down the boom to r aise the r eal' wheels
off the floor. Figure 17.
Figure 15 - Adjusting Screws

Figure 17 - Backhoe Position,

Figure 16 - Curling the Bucket Step 14

19
15. Feather the clipper r.nntrollever to crowd. adju s tme nt until corrcct sctt ing is
Wa tch the pres sure gauge anrilloom. Note attained .
the pressu 1'8 at whi ch the unit beg ins to
lowe r . Th is shou lcl be at 1200 ± 50 psi.
b. If the unit s t a r ts to lowe r at a
16. Adju s t trigger poppet if required : p res su r e hi ghe r th an 1250 pSi , r e -
move the cap on adjusting screw
n. If the unit s ta rts to lower at less No . 2. Turn the ad justing screw
than 1150 p si, r e move the cap on counterclockwise. Repe at check a nd
adjusting s c rew ;-';0. 2. Turn adj usting adjustment until corre c t s et t ing is
screw c lockwi se. Hepe:lt. check and attained .

TESTING RESTRICTOR/CHECK VALVES FOR LE AKAGE

A restrictor/ c heck valve is located in 3. Install plug (Ca se p art no. 21 8 - 5158 ) in
ports 2 a nd 8 of the pre ssu r e s ens ing va lve . por t 8 of se ns ing valve.
Leak age past the se valve s will cause drifting
of the bucket or boom cy linde rs. 4. Install the restrictor/che ck valve as -
se m'lly in the boom cylinder hose wbich
Leakage Test AI wa. s dis connec ted from port 8.
Sensing Valve Po r i B

!{efer to Figure 18. 5. Rai se boom. Place boom lever in neutra l

and observe the restr ictor/eheck v alve
1. Lowe r backhoe bucke t to grouncl. Move for leakage . The re should he Ilone . If there
boom control leve r back and forth with the is leakage , r eplac e the entire r estrictor /
engine off. check valve asse mbly.

2. Remove the r es trictor/check vall'e as-

s embly fOt' inspec tion. nepl ace if obvi- NOTE: If the valve is OK, refer to
ously defective. If de fect is not appa rent. Sec tion 42 and c heck the cylinder pack ing
the valve m ay be tested us follows. and ba ckhoe control valve fo r l eakage.

I il G
21&- 5 158 -

HOSE / lUSf S',H VEL V.t. lvE i;$ SEP; LY

"' ~ S£.· ' ·L Y fiTTI NG /'

-f+--=~
~D91 1
Figure 18 - Leakage Test

20
Leakage Test At 4. Install the restrlctor / check valve as-
Sensing Valve Port 2 sembly In the bucket hose which was
disconnected from port 2.
Refer to Figure 19.

1. Lower backhoe bucket to ground. With 5. Position backJlOe a s shown in Figure 19.
engine off, m ove the bucket control lever Run engine at 3/ 4 speed. Operate the
back and forth. crowd circuit slowly and observe the
restrlctor/check valve for leakage.
2. Disconnect bucket hose from port 2 and There should be none. lfthere Is leakage,
remove the restrlctor/ check valve as- replace the entire restrlctor / check valve
sembly for Inspec tion. Replace If obvi- assembly.
ously defective. If defect Is not apparent,
the valve m ay be tested a s follows.
NOTE: lfthe va lve Is OK, refer to Section
3. Install plug (Case p art no. 218-5158) In 42 and check the cyllnder packing and
port 2 of the sensing valve. backhoe control valve for leakage.

Figure 19 - Leakage Test

21
 PRESS URE SENSING VALVE

Removal

R efer to l'igure 38 or 39.

1. Separate the backhoe from the tractor.

2. Place blocks under the bac khoe mounting

frame. Mov e the bo om, dipp er, and bucket
control le vel'S back and fort h to equa lize
pr e ssures.

3. Remove accumul ated dirt and gre ase

from the va lve and fittings.

4. Tag or mark the hoses and tube s for

correc t reassembly. Port numbe rs
s tamped on the valve m a.y be us ed if Figure 20 - Valve Heady F o r Di sas sembly
vIsible.
3. Remove the bucke t and boom s pools:
5. Remove or dis connect hOBes a nd tube s .
Close openings with cle a n caplugs. a. Re move the plug and a-ring , Flg"u re
21.
6. Remove two mounting bolts .

Disassembly

Refer to Fig;ure 22 .

1. Thoroughly cle an the out s ide of the valve

using a so lvent or die sel fu el. Blow d ry
with moisture free ai r.

2. Pl ace the valve on a c lean work be nch

with port s I, 2, 3, a nd 4 facing up,
F igure 20. Port s 7 and 8 should point
toward the di sa s se mbler.

F igure 21 - Removing" Plugs

22
 I
0 1
I6 ____ c - Rr :!G

O- RI NG ___ <!:I ~u
- CONIIECTOR
CO;rNEC TOR -(~
~ ~£STRr CTOR I
f~- CHECK VA LVE
RE STR r C TO R -----~ ~

@ _ " ASH ER 711 C0 5

F igur e 22 - Exp loded View of Pr es sure S ensing Val ve

23
 b. I!c move tho spool ann spring from h. Remove the ad jus t ing' scre ws .
eac h I)O I'e , Figure s 23 and 24. 1\ote
a nd identify the bo r e from whic h each
s pool and spring was removed . Keep
thc spools and springs toge the r.
P a r ts which a r e reused MUST NOT
IlE INTEHMIXED 01\ PLACED IN
i\ DIFTEnEI,T BonE .

Figure 25 - Removing Caps , .Jam Xuts ,

and Adjus ting Sc rews

c. Working on the oppos ite si ele of the

va lve , remove three plugs and 0 -
rings , Figure 26.
Figure 23 - He moving Spoo l Sp ring

7 1 0a~9 ' 2

Figure 24 - TIemov ing Spools Figure 26 - Itemoving Plugs

4. l!emove the three tr igge r poppe t as - d. With a la rge sc r e wdri ve r, Teach into
se mblies : e ach bore and unscrew the se at with
seal ring, Figure 27.
a. Ire move the aco rn c ap and jam nu t
from eac h a ssembly, Figu r e 25. As e. Tu rn valve on e nri $ 0 cone, spr i.ng.
parts a r e re move(; , keep the m toget- and s pring gu ide in each bo r e can
her Jelentify the bore from whic h they fnll out. Take c a r e that these pa l'ts
were r e m ove d. P arts whic h nre do not beco m e mixed, Fig11re 27.
r eused MUST 1\OT BE I:-lTE I!i\UXE D
m! PLACED I}; " DIFF ERE1\T 5. Remove all t.he s m :llI he x plugs and
BOnE . a-r ings.

24
 1. Liberally lubricate the bucket and boom
spools, with hydraulic oil, Figure 28.

2. Install the spools into the proper bores

and In the proper position in the bore s of
the valve. See Figu r e 29. Slide the spools
Into the bores, being careful not to jam
them against corners. Slide the spools
back and forth to make sure there Is no
binding. If either spool does not slide
freely, remove that spool and look for a
buur on the spool or In the bore.

Figure 27 - Disassembly of
Se ats and Poppets

6. Remove all connectors and fittings stIlI

attached to the valve. The connectors in
ports 2 and 8 contain restrlctor/check
valves. Remove the snap rlng--these
valves should fall out.

N OTE: The restrictor In the connector

at port 7 Is Installed with Lactlte. Do
not remove unless it Is to be replaced.

Inspection
Figure 29 - Installing the Spools
1. Replace all o-rings with new parts.
3. Install two plugs and o-rings in spool
2. Wash all metal parts In solvent or diesel bore s opposite the spring end, starting
fuel. Replace damaged or worn parts. the threads of each.

3. Test springs with spring tester, if avail-

able. See Specifications, pag"e 3.

Assembly

Figure 30 - Installing Plugs

4, Install the spring ove r each spool, fol-

lowed Pr a plug and o-ring, Figure 31.
Tighten t he plugs snugly. Do not over-
Figu r e 28 - Lubricating the Spools tighten, do not leave loose.

25
 7I C>9DD - 4

Figure 31 - Installing Springs ,md Plug s Figure 33 - Installing the Poppet

v, In s tall the trigge r poppet assemblies,

a. Stick the cones , springs, and spring

guide s togethe r witll g-rea se, Figure
32,

Figure 34 - Tightening Se3.ts

]1090 1-'i

F igure 32 - Assembling P oppet s with Grease

b, Drop the assemblies into the proper

bores. Figure 33_

c, Install the seat and seal ring in each

bore, using a screwdriver to tigllten
the seat, Be careful not to cross-
thr ead the seats, Tighten all three
seats tight. us ing a wrench or vise
grips on the screwdriver, Figure34. Figure 35 - Installing Plugs

d. Install a plug and o-ring into each e, Screw the adjusting screws into the
bore. Fig-ure 35. valve body, FigUl' E' 3G.

26
 f. Install an o-ring on each jam nut.
Install the jam nuts on the adjusting
screws, Figure 37.

g. Install the acorn caps, but do not

tighten down, Figure 37.

6. lns tall alJ remaining connectors and plugs

with o-rings. Tighten snugly. Ports 2 and
8 have connectors with restrictor/check
valves. Port 7 has a connector with
r e str!ctor.
I nstallation

Refe r to Figurcs 38 or 39.

Figure 36 - Adjusting Screw Ins tallation
1. Mount the valve on the mounting frame
with two bolts, nuts , and four washers.
Use two of the washers as shims between
the valve and mounting frame.

2. Connect hoses and tubes. Check con-

nec tions against Figu re 1 or 2.

3. Reinstall the backhoe onto the tractor.

4. If a repaired va lve is being installed,

adjust the poppet settings, page 18 . Do
not adjust a new valve.

Figure, 37 - Installing J am Nuts

and Acorn Caps

27
 EXPLODED VIEWS

;I -

USED ON
,"" l .L .
EAR LY PRODUCTION
ONLY .!-r ' J ,
,~ ,,,,
"
I

-PUJU'>
TfU:.HCH
t
MANUAL ~ ... DIG

~~:::::!l~ ' /
1/4" NC x I"

\
/
. .....-1, II

/
MANUAL SELECTO R
I
.. """'_.. VALVE
\ //~
19-1/4"~ ll \
/
13-1/2" HOSE
"
I N STALL
ELBO'lI
INTO END
INLET
\ I

S~
ECTl9N ~I
26" HOSE
._ -)1 (
\----1)

SENSING
~
VALVE
~
57" HOSES TO
",,-,::;;""'--7S00M CYLINDER

3/ 8" NC x 5"

I (
----~ --.:=::::~W~FLA WAS~ T

--' 71 CD.t6

Figur e 38 - Exploded View of Hydra-Guide Controls on 480 and 580

28
1 TO CLOSED END OF CVL I'OER

2 TO ROD EUD OF CYL IIiDER

710957

Figure J9 - Exploded View of Hydra- Guide Controls on 580B

29
 a. If the bucket curls at less than 1550 10. Curl the bucket complet e ly. Fe ather the
psi, remove the cap on adjusting dipper control lever to c rowd. Watch the
screw No. I, F igure 15. Turn ad- pressure g auge ancl the boom while con-
justing s c rew clockwise. Repe at tinuing to feather the dipper lever, figl.lre
check and adjustment until correct 16.
setting Is attained.
11. Note the pressu re at which the boom
b. If the bucket curls at a pressu re starts to raise . This should be 1900 ± 50
higher than 1650 psi or fails to psi.
curl, remove the cap on adjusting
screw No. 1. Turn adjusting screw 12. Adjust trigger poppet U· required:
counterclockwi se. Repeat check and
adjustment until correct setting is a. If the boom r aises at less than 1850
attained. psi, remove the cap on adjusting
screw No.3. Turn adju s ting sc r ew
clockwise. Hepeat c heck and adjust-
ment until correct setti ng' is attained.

b. If the boo m r ai s es at a pre s sure

higher than 1950 p s i or fails to r a ise,
BAc KHOE remove the c ap on adjusting screw
i10 urlT l",G FR,i. NE No.3. Turn ad justing screw counter-
SWI NG clockwise. Repeat check and adjust-
. ~OJl.I STI N G - ~ TO~ E R ment until correct setting is attained .
SCHE liS .... . ,,~
13. Place selector v alve h andle in Trench
\ 0 . 1- (
po s ition.
~
~ 14. With the lo ader bucket raised to clear
NO. 2 the floor, fully extend the bucket cylinder
In curled po sition, then fu lly extend the
dipper cylinder in crowd pos ition. Power
710908
down the boom to r aise the real" wheels
off the floor. Figure 17.
Figure 15 - Adjusting Screws

Figure 17 - Backhoe POSition,

Figure 16 - Curling the Bucket Step 14

19
15. fe ather the dippe r co ntr ollc ve r to c r owd. adju s tment until co rrect s etting is
Wa tch the pr e ssure gauge and boom. l\ote atta ined.
the pressure <It whic h the unit begins to
lowe r. Thi s s hould be a t 1200 ± 50 ps i,
b. If the unit s t a rts to lowc r at a
16. Adju s t trigger poppe t if r e qui r ed: pressure higher th a n 1250 psi, r e-
m ove the cap on adjusting sc r ew
>l. If the unit s t arts to lower at le ss No.2. Tu r n thc adjustIng screw
than 11 50 ps i . remove the c ap on counte r c lockwise. Hepeat check and
adjusting s c r e w No.2. Turn ,,(Ijus ting adju stment until correc t se tting is
sc rew c lockwise. Hepeat c heck and attained .

TESTING RESTRICTOR/ CHECK VALVES FOR LEAKAGE

A r e strictor / chec k valve is loc ated in 3. Install plug (C ase part no. 218-51 58 ) in
ports 2 and 8 of the press ure s ens ing' valve. port 8 of sensing valve .
Leakage pas t these valve s will cau se dr ifting
o f the bucket or boom cylinde rs. 4. Ins t all the r estrictor/chcek valve a s-
sem~ly in the boom cylineler hose which
Leakage Tesl AI was disconnected from po rt 8.
Sensing Valve Pori a
Refe r to figu re 18. 5. Ha ise boom. Plac e boo m lever in neutr a l
and obs erve the r es tric tor / check va lve
1. Lowe r backhoe bucket to ground. Move for le akage . The re shoul d be none . Ii there
boom control le ver back and forth with the is le al<age, r e place the e nt ire r e str ictor/
e ngine off. chec k valve a s se mbly.

2. Hemove the l'e stric to r /c heck v alve as -

sem bly for ins pection. Rep lace if obv i- NOTE: If the valve is OK , r efer to
ou s ly de fective. If de fect is not appa rent, Sec t ion 42 and check t he cy[ inel l' packing
the va lve m ay be te s te d as follows. anci back hoe control val ve for l eakage .

2 ' -5'S8

~ESTRILrOR/CHECK
HOSE/TuBE \)Al\lE ..,.SSfr-tE!L Y
",SSEI~8L '( FITTI ,',G /'
\
~~"
\

-&I
Figure 18 - Leakage Test

20
Leakage Test At 4. Install the restrlctor/ check valve as-
Sens i ng Valve Port 2 sembly In the bucket ho se which was
disconnected from port 2.
Refer to Figure 19.

1. Lower backhoe bucket to ground. With 5. Position backhoe as s hown in Figure 19.
engine off. move the bucket control lever Run engine at 3/ 4 s peed. Operate the
back and forth. crowd circuit slowly and ob s erve the
restrlctor/ check valve for leakage.
2. Disconnect bucket hose from port 2 and There should be none. If there Is leakage.
remove the restrlctor/check valve as- replace the entire restrictor/ check valve
sembly for inspection. Replace If obvi- assembly.
ously defective. If defect Is not apparent.
the valve may be tested as follows.
NOTE: If the valve Is OK. refer to Section
3. Install plug (Case part no. 218-5158) In 42 and check the cylinder packing and
port 2 of the sensing va lve. backhoe control v alve for leakage.

Figure 19 - Leakage Test

21
 PRE SSURE SENSING VALVE

Removal

Re fer to Figur e 38 0 1' 39 .

1. Separate the ba.ckhoe fJ'Om the tracto r.

2. Place blocks under the backhoe mounting

fra me . Move t he boom . dippe r . and bucket
control leve r s back and for th to equalize
press ures .

3. Remove accumulated dirt and grea s e

fr om the valve and fittings.

4. Tag or mark the hoses (!.nd tube s for

correct reassembly. Po r t numbers
s tamped o n the valve m ay be us ed if Figure 20 - Valve Ready For Disassembly
visible.
3. Remove the bucket and boom s pool s :
5. Hemm'e or disconnect hose s and tubes.
Close openings with clean caplugs. a. Remove the plllg and a-ring, Figure
21.
6. Remove two mounti ng bolts.

Disassembly

Refe r to F igure 22,

1. Thoroughly clean the out s ide of the valve

using a solvent or diesel mel. Blow dry
with m oisture fre e air .

2. Pl ace the valve on a c lean work bench

with port s I, 2. 3, and 4 f~.c ing llP,
Figure 20. Ports 7 and 8 should po int
toward the cii sasse mbler.

Figure 21 - Hemoving Plllgs

22
 "

.":.,

~
~I (j''", BUC KET
TR IGG ER POP PET -SPOOL
AD J UST I NG 5CR £II5 " ~
_BOOM
\ SPOOL
I
S:/p,p R t NG I c..
/SPRI :'G
,. J WAS HE R
Y(,f~ I
/RE5TR I CTOR/CHE CK VALVE
''([O.P ~. CO ::NECTOR BODY
(~. ~ / G_/PLUG (II)
~ O-RING o 'liif/ O-RI NG

''W&rf~ 0 , 0 ,

711005

Figur e 22 - Explod ed View of Pr e ssure Sensing Val "8

23
 b. Itcmove the spoOl and s pring from b. Hemove the adjusting screws,
eO.e h bore , F igures 23 and 24. No te
and identi fy the bore from which each
spool a nd spri ng was r e moved. Ke ep
the spool s and s pr ings toge ther.
Par ts which a re reused MU ~T NOT
BE Jl'TE RMlXED 011 PLACED IN
A DIFf EREN T BOHE.

Figure 25 - Remov ing Caps , ,Jam l'uts ,

and Adjus ting Scre ws

e. Working on the opposite s ieie of the

valve, remove three plugs and 0-
rings, Figure 26,
Figl.ll~e 23 - He moving Spool Spring

)' 0899-1

Figure 24 - RemovIng Spools Fib'1lre 26 - Hemoving Plugs

4. Remove the three tr igger poppet as- d. With a large screwdr iver , reac h into
se m blies : e ach bore and unsc r ew the s eat with
sea l ring, Figure 27.
.,
u. Hernove the aco rn c p a nd jam nut
f r om eac h as erobly, figur e 25. As e. Tu r n valve on e nd so cone , spring,
part s a re removed, keep them toget- and spri ng guide in e ac h bore can
he r Identify t he bor e from wil iell they fa ll out. T<lke C3re that the s e parts
were removert . Parts which are cia not. hecon lc m ixed , Fi gure 2.7.
,'e used MUST " OT B I': ) ' T EI<i\'IlX£D
OR PLAC ED It-; A DIF FEREl'T o. rremove a ll the smeil I hex pIllgs a nd
BOHE. a- rings .

24
 1. Liber ally lubrica te the bucke t and boom
spools, with hydraulic oil, Figure 28.

2. Install the spools into the proper bores

and In the proper po sition in the bores of
the valve . See Figure 29 . Slide the spools
into the bores, being ca reful not to Jam
them against corners. SIlde the spools
back and forth to m ake sure there is no
binding. If either spool does not slide
freely, remove that spool and look for a
buur on the spool or in the bore.

Figure 27 - Disassembly of
Seats and Poppets

6. Remove all connectors and fittings stilI

attached to the valve. The connectors In
ports 2 and 8 contain r e strlctor/check
valves. Remove the snap rlng--these
valves should fall out.

NOTE: The restrictor In the connector

at port 7 Is Installed '\o1th Loctlte. Do
not remove unless it is to be replaced.

Inspection
Figure 29 - Installing the Spools
1. Replace all a-rings with new parts.
3. Install two plug s and o-rings in spool
2. Wash all metal parts In solvent or diesel bores opposite the spr ing end , starting
fuel. Replace damaged or worn parts. the threads of each.

3. T est spriugs with spring te s ter, if avail-

ab le. See Specifications, page 3.

Assembly

Figure 30 - In s talling P iugs

4. Install the spring olfe r each spool, fol-

lowed pJ' a piug and o- ring, Figure 31.
Tighten the plugs snugiy. Do not over-
Figure 28 - Lubricating the Spools tighten, do not leave loose.

25
 © 2005 UserFriendlyCDs

Figure 31 - Inst a lling Spri ngs 3ncl Plugs F igur e 33 - In stall ing t he Poppet

v. In s t a ll the trigge r poppet a sse m b lies :

n. Stic k the cones, springs, a nd spring

6'1lldes together with grease, Figure
32.

Figure 34 - Tighte ning Sea ts

ll0901-1

Figure 32 - !\ s sembling Poppet s with Grease

b. Drop the assemblies into the proper

oores. Figur e 33.

c. Install the seat and seal ring in each

bore, using a screwdriver to tighten
the seat. Be careful not to cross-
thread the seats. Tighten all three
seat s t ight , u sing a wrench or vise
grips on the screwdriver , Figure 34. Figure 35 - Ins talling Plug s

d. In s tall a pl ug a nd o- ring into each e. Screw the adjusting sc r ews into the
bor e, Fig·LIre 35. va lve body, Figul'(' JG .

26
 f. Install an o-ring on each jam nut.
Install the jam nuts on the adjusting
screws , Figure 37.

g. Install the acorn caps, but do not

tighten down, Figure 37.

6. Install all remaining conne ctors and plugs

with o-rings. Tighten s nugly. Ports 2 and
8 have connectors with restrictor/check
valves. Port 7 has a connector with
restrictor.
Inslallation

Refer to Figures 38 or 39.

Figure 36 - Adjusting Screw Ins talla tion
l. Mount the valve on the mounting frame
with two bolts, nuts, and four washers.
Use two of the washers as shims be tween
the valve and mounting frame.

2. Connect hoses and tubes. Check con-

nections against Figure 1 or 2.

3. Reinstall the backhoe onto the tractor.

4. If a repaired valve is being installed,

adjust the poppet settings, page 18. Do
not adjust a new valve.

Figur" 37 - Installing Jam Nuts

and Acorn Caps

27
 EXPLODED VIEWS

f
,
/
I
USED ON
EA.RLY PRODUCTION
O N LY
,
I

: I
MANUAL
TRENCH

~
t . . DIG I
I
/
/ I~

"i> . ~\
MA NUAL SELECTO R
(
//
'HOSE VALV E
\ //~
'~OSES II
\
/
~.
" l
0'
I
INSTALL
~./ ElBOVI
13-1/2" HOSE / / INTOEND /
/ . / F INLET (
SECTION ., ~

14<-.. .,./ 0/
SENSING
VALVE

3j8" NC)( 5"

! /
FLATWAS~
-----'
7 1CC·l6

Figur e 38 - Expl oded View of Hydra-Guide Controls on 480 and 580

28
I TO CLOSED END OF CY LlIIUER

2 TO ROO E,m OF CYU NOER

Figure 39 - Exploded View of Hydra-Guide Controls on 580B

29
 SECTION
49

BOOM
LOCKOUT
SYSTEM

Burl. Form 9-72085 KHC BO PrInted In U.S.A.

 OPERATION

General is relieved only by the loc kout r e lief ' valve

(3100 psi) permitting a he a v ie r load to be
The optional boom lockout system im- handled. In addition, the boom cannot " s ettle "
proves the craning ability or load handling due to leakage uncleI' pressure past the boom
capacity of the backhoe. The system consists spool (all spools leak slightly due to valve
of a relief valve and lockout valve placed in clearances).
the boom circuit, Figure I,
NOTE: The boom cannot be lowe r ed
When the lockout valve handle is in hydl'aulically with the valve in Lock position,
Lock position, oil can move only in one
direction (see arrow, Figul'e 1). Thus pres- Operalion Of L ockout Valve
sure in the boom circuit caused by the weight
of the load pulling down on the l)oom is not Placing the lockout valve handl e in Lock
applied against the boom spool or the 2750 position moves the cam follower away from
psi relief valve in the boom section. Oil the poppet and allows the poppet to seat,
Figure 2, When a load pulls down on the
boom, oil between the lockout val ve ,uKl rod
TO LOC KOUT end of the boom cylinder is blocked by the
RE S . HL I EF seated poppet. The heavier the load, themol' e
.... i.l. VE firmly the poppet is seated.
3 100:i ;Z OO
PSI
LOCKOU T VALVE If pressure in the locked circuit reaches
3100±200 psi, the reliefvalve opens ,1.ndvents
oil to the reservoir.

l OUT

0 -:P,,\~,l'CIt--.L--'-.L-.J
2 7' ':-
R:ELiEF\r·- l'lE.

n
eOJ],u,
CYLS .

Figur e 2 - Loc kout Val ve Operat.ion.

Figure 1 - Hydraulic Diagram In Loc k-Position

2
 LOCKOUT VALVE

R e m oval
BAC KUP
The lockout valve a nd relief valve are

~\~
r emoved together.

1. CUI'1 the bucket and pull in the dipper. tI @

Lower the boom until the bucket is on O-RING
the ground. The dipper and bucket must

II!f1-~~ti.OVlER
support the boom without moving.
CAt AND
2, Place the lockout valve handle in Open HANDLE ASSEMBLY
position, Figure 1. "'love the boom con-
trol lever in both directions to equal ize B _POPPET
pressure. 0- STEEL BALL

3, Disconn ect two tub e s to the relief valve

-SPRING
and one tube to the lockout val ve. Close
openings witll olean oaplugs.
O-O-RING
4. Remove bolts and washers which attach
the mounting plate to the oontrol console. § -CAP
701314
5. Remove mowlting plate with valves at-
tached. Remove lockout valve and relief Figur e 3 - Exploded View of Lockout Valve
val ve mount ing bolts.
3. Check the spring for signs of cl'acking.
NOTE: If unit is equipped with Hydra- corrosion and di s tortion. The spring
Guide, the mounting plate can be moved should compress to 1-1 / 2" at 10 pounds
far ellJ)ugh to reach the nuts on the lock- of pressure .
out valve mounting bolts without remov-
ing' the sel ector valve. 4. Inspect poppet and steel ball for exc e ssive
wear, scoring and pitting.
Disasse m b ly
5. Inspect the valve body for cracks and
1. Remove plug from valve body. Then re- other defeots. Also inspect the poppet
move the spring and steel ball from bore and sea t for wear. scoring and
poppet. pitting. If wea r or scoring is excessive
the val ve must tle l'eplaced.
2. Remove the poppet and cam follower
from the valve body. A ssembly

3. Remove the handl e aud cam assembly 1. Install the 0- l'ings and backup rings on
from the val ve body. Then r emove the the cam using care not to damage the
O-rings and backup rings from cam. rings.

2. Install the handle a nd eam a ss embly in

Inspection val ve body using c n r e not to da mage the
r'ings.
1. Clean all metal pa rts in cl eaning solvent
and dry with compr essed air. 3. Install the cam followe r in valve body.
Then install popp et in val ve body.
2. It is recomm e nded th at the a-r ings and
backup rings be discardecl. However, if 4. Place the s teel ball and s pring in poppet.
inspec tion reve als no defec ts they m ay be Then screw plug with ()-ring into valve
used aga in . body and tig'hte n s ecure ly.

3
Installation console, then connect the tubes to the
valves.
1. Install the short tube between the lockout
val ve a nd reli ef valve.
4. With the lockout valve handl e in Open
2. Mount the r e lief va lve and lockout valve position, op erate the boom through sev-
on the mounting plate. eral cycles to bleed air from the circuit.
Shut off the engine. Check the hyd r a ulic
:3. Position the mounting plate on the control oil level and inspect circuit fOl' leaks.

RELIEF VALVE

The relie f valve shown in Figur e 4 is 2. Using a suitable adap t e r, Section 42,
mOtmted on the backhoe control console next Figure 21, connect a han d pump to the
to the lockout valve. port.

This valve may be removed for adjust- 3. If t esting the valve off the m ac hine, plug
m e nt, cl eaning, and parts inspection. If any the opposite pres s ure port. If tes ting on
par t must bc replaced, the en tire valve must the machine, place lock valve in Lock
be r eplaced . pOSition.

Removal 4. Actuate hand pump and take a pressur e

reading. The pr essu re should be 2900 to
See Re moval, page 3. 3300 psi.

Disassembly/Assembly 5. To adjust, remove knockout slug a nd

loosen the lock sc rew. To increase pre s -
Refe r to Figure 4. sure, turn the adjusting scre w into the
valve body. To decrease pressure, turn
1. Re m ove knockout slug. the adjusting s c rew out of the \'alve body.

2, Remove lock screw. 6. Tighte n the lock screw.

3. Remove adjusting screw.

4. Clean all parts and the valve body in
sol vent and dry thor oughly.

5. Assemble in the r e verse orde r or dis-

disassemLly. Adjust pre ssure setting as
ou tlined tmde r Adjustment.

Installation

See Install a tion a bove .

Adjuslment
ADJUST I ~:G SC RflJ
T he r ei ief valve call be adjusted on or MID POPPET A SSE ~. lY

off the backhoe. ,..

1. Disconnect line from the port shown in
Figure 5. Re move fitting. Figure 4 - Lockout Reli ef Valv e

4
2 3" La,,,,,; - -

1/4" (1)

a _CAP USED WITHOUT

U HYDRA-GUIDE

71 096 1

Fig'ure 5 - Boom Lockout Hydraulics

5
 Section
52
POWER STEERING PUMP
AND
HAND PUMP

Rac,
Rae Form 99-80611
. Form · 80611
52-2

HYDROSTATIC STEERING COMPONENTS

(Referr to Figure 1)
Figure 1)
Removal
HAND Pli~'!P
PLMP
1- Remove steering wheel
1.Remove whee! medallion and nut. Then pull steering wheel with puller.
2. Disconnect battery o r batteries.
ballery or ballICries.
3.
3, Remove inspec tion plate from rrICar
inspection e a r of steering column.
4. Disconnect the two tubes a t tthe
4.Disconnect he hand pump tube connections and c
cap
a p the tubes and fittings.
fittings .
.5.Unbolt
5. Unboll and remove the hand pump. pump .

CONTROL VALVE
CO:'\TROL
1,Disconnect
1. t he six hydraulic tubes and cap the tubes and fittings.
Disconnect the fittings
2. L:nboll
Unbolt the valve
va lve aassembly
ssem bly from tthe
h e mounting bracket.

RESERVOIR AND PU:VIP PUMP

1.Disconnect
1. thee two hydraulic tubes and cap
Disconnec t th c a p tubes and fittings.
fittings,
2. Unbolt the pump and remove.

STEERl:,\C
STEERING CYLL,DER
GYLLNDER
1.Disconnect the hydrauli
1. hydraulicc hoses and cap
c a p the hoses aand fittings.
n d fittings.
2. Remove the cotter pin and nut from the cylinder ball stud ends.
:l. h e cylinders by tapping on the ball stud ends,
3. Remove tthe ends, being careful not to d a m a g e the threads.
damage

Installation
HAND PUMP
HAi':D PU:VIP
1. pump, steering wheel and medallion.
1.Install the hand pump, medallion.
2. Connect the two tubes at the
t h e hand pump tube connections.
3.
3. Instali
Install inspection plate and reco nnec t battery or
reconnect o r batteries.

COi':TROL VALVE
CONTROL VAl.VE
Reinstall
1. Reinsta
1. ll the control valve and connect the six tubes.

RESERVOIR .-\:,\D
RESERvom AND P UMP
PUMP
1. reservoirr and pump assembly with new gasket and connect two tubes.
1.Reinstall reservoi t ubes_

STEERING; CYU:,\DER
STEERING CYLINDER
Install
1.Ins
1. ta ll thp
th p. cylinder ball stud ends into the radius rod and steering arm.
arm.
2. Install
Inst a ll and tighten the nuts,
nuts, install the cotter pins.

BLEEDING
BLEEDING PROCEDURE
PROCEDURE
the reservoir cap
1. Remove the'
1. c a p and dipstick. Fill the rese
reservoir
rvoir with Case TeH
TCH oil and start the
engine.

2 , Operate the engine at approximately 650 R

2. P M and turn the steering wheel through several
RPM
turns.

NOTE:: The first few times you turn the steering wheel, DO NOT m
NOTE a k e full
make full turns.

3.Shut
J. Shut the eengine off and refill the reservoir to the "F" m
ngine otf a r k on the dipstick.
mark

4. Repeat the above procedure several

several times until the fluid level ceases to drop after turning the
wheel.
steering wheel.
 52-3

,~
( 1
LJ
~ -.

:i
;---t\
PUMP
HAND PUMP
\ \
\. :
\
/'~ ... , . \ \ PUMP
r-~'''~-':?-'=L'-
.L~
;:J;:J.-'
___ ._.\__ L ~_
___ ..!-.
__ -.-t:::..,.... '. . • • _ £----.~
------ ------- -- '-- r---_ -~---~.~ f
I .
.-
(I') \" ', I

. ~.~ - -- -
!
!
i') .- I
....--::.-
..,;/ -
,
I -:- ~ !
" I
.I" , . ~

~..". \. "\
. .;'" \ \.'\ \
./ i ' \
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) '!
""""--
R.I-i . CYLINDER

Figure
Figure 1 1
52-4

STEERIN G HAN D PUMP

(Refer to Figure 2 )
l . PPump
1. u r n p s^haft needleC' bearing.
ha fl necdl bC'a ring . Install
In st all into p u m p body (26).
pump P r e ss
( 2 6 ) . NOTE: Pre s s aga
against thee hardened
ins t th ha rd e ned
end of Ihe
C'nd Iho bbC'a o a "ing
r i n g sshell
h e l l (end
(end oonn which whi c h the numbers n u m b e r s appe
a p p ear)
a r ) when
whe n installing. P rress e s s to a de depth
p th
ooff :33-27 32 inc
-2i / :l2 incheshes fromfr om the t h e rrotor
Ol or e nnd, d , Inset
In set A. A.
Thru.st bearing.
2. Thrust bC'a ring . Insla Installll onto sha shaft ft (4 ( 4) .
3. Thrust
3. Thru s t wawasher.
,he r. Install onto shaft (-1). (4) .
P u m p sha
4. Pump
Â¥I shaft.ft. Install into p u m p body (26).
pump
o.j.Spoo
, Spooll pin. pIn . Install into shaft (4). (i).
6. Upper
Cpper ccommutatoro m m u t a t o r link pin. Install In s ta ll into d r i v e link (7).
drive (7).
7.
7. Commutator
Commutat or drive d r ive link. Install In sta ll intoin to ppump u m p body (26) engaging e nga ging the slots on the sha shaft ft (4
('1).).
P. Commutdtor.
8. Commut ato r. Lightlj
Lig htl y ooil il t[ he
h e c ommutato
o m m u t a t o r aand n d install
ins tall into ppuu mp m p body (26) (26) eenga n g aging
g i n g tthh e spool
s pool
p in ((5).
pin 5).
9 , Space
9. S p a c e r pIa plate. Install onto
Ie. 1n51all onto pu pump m p body bod y (26) aligning plate
(26) aligning pla te holes
ho les with the holes in the body. body .
10. Lower commu
10. c o m m u ttaa ttor o r link
Jink pin. Installll into drive
pin . Insta d r i v e link (7). (7).
11,. Ro
11 Rotor tor va vanene springs. :'NOTE: Io'01'E : Chec Checkk the springs for free free height of .080"-.100 .080"-.1(XIf', ", In set B,
Inset B, aafter
fter
compressing
com p ressing the spr springs
ings fla flat,t, they must m u s t return to aa height he ight of .076"._076".
12.
12. R Rotor
o tor vanes.
va nes. Install Into into roto rotorr (13) (13) with the ssprings prings (11). (11). NOTEN E:: Check ttl thee vvaa nnee he
height and
ig ht and
width. Inse Insott C C.. When the height he ig ht is .250" or less, less, or width is .002" less than rotor
is -002" width, re-
r o tor width,
place
pl ace tthe he vanes.
va nes.
13. P
13. u m p roior
Pump r o tor. Install into s ttaa ttor o r (14)(14) aligning the locating loc a ting marks_m a r k s . NOTE:
NOTE: Check Chec k rotor to
stator
s ta to r thickness.
thickness, Inset 11, D, withw it h a m i c r o m e t e r oorr dial
micromete indicator.
dial indi cator. If If rotor is m oorr e than .002"
less thantha n theth E' thickness
th ickness of the th e slator,
sta tor , replace
r e pla ce the sta s t a ttor,
o r , rotor,
r otor, ssprings
prings aand n d vanes.
1 ~. P
1-1. u m p s ttaa ttoo r.
Pump r . NOTE:
i'iOT E : Check th0 the rotor aand n d stator
s t a t o r c llea r a n c e using a nnarrow
e a rance a r r o w feeler gauge,
Inset
Inse t E T h e clearancE'
F:.. The c l e a r a n c e sshould
ho uld not no t eexceed
xceed .007",.007".
~ O'fE : :Ylar
NOTE: Miirkk th(' the sta>tator tor aand nd rotor with aan n indelible m ar a r kking
i n g pencil when disassembling
whe n disasspmbli ng pump
for
(or proper location when assembling
w he n a ssembling pump.
1:1
15.. RoRotortor sea seal. Lubricate th0
l. Lubricate the ed odge
ge of the seal seal and a n d insinstalltall onto t hhee s tatort a t o r (14
( 1 4).) .
16.Seal
16. Sea l rretainer.
et a iner. 1ns Install
tall oonto nto the rh0 seal (15). (15).
17. End c o o,v·cr.
e r . Install ont ontoo the t h e ppump
u m p body (26) (26) with the la lapped
pped face f a c e towards the rotor. roto r.
IS. PPump
18. u m p body bolts. Torque T orque 18-22 1s-22 ft. f t . lbs.
lbs.
19. Silaft
19. Shaft scal. seal.
20. Bac k-up ring,
20 . Back-up ri ng .
21. SeaSe.11 l retainer.
r e tai ne r.
22. SnaSnap ring . Install
p ring. Ins ta ll the t he seas e a l (1~),
( l g ! , back-up ring r ing (20) (20 ) a n ndd retainer (211 (21) into the ppump u m p body (26) (26)
oonly
nl y ffaa r enoug
enough h totoallow
allo w the s na n a p ring
r ing toengage
to (,ngage theretainingslot
the re ta ining s lot in the ppump u m p body.
body .
2~ . Felt
23. scaling was
F e lt SE'aling w a s her.
her,
2-1. Water
2-1. Wa ter s e a ll..
25.. Wheel nu
2~ nut.t.
P u m p body.
26. Pump
 WORN FLAT
INSET C /ALONG THIS

~(b NJ ~
~
EDGE
/.l__
~ /"'~I '®
250"
i:n) MINiMUM
@1'lI
i!l.'(,

~ . ~U
;,A ~
15 2" lESS
14 .00
THA N ROTOR WIDTH

~
13 ~@
~~~ ~
13
.007" MAXI M UM C LE ARANC E

@}if
®

,/
,/
,/
,/
,/
/

v® f l INSET 0 14

~I
.. 13

Q: ~oc-
AI 0. c. 16

l~ ~
B"IA" IS .0 02"
REPLACE WHAEN
N "8"
SMALLE R TH

A
INSET A

INSET B Ci?_I
r: .-!--=:::---.,.;;;;;;::::::-!
.080" TO . 100 "

Figure 2
02-6

TEERING
POWER STE P MP
ERIN G PU
(Refer to Figure 3)
NOTEE:: Before removing
removing the reservo ir shell,
reservoir shell, mark both the shell and pump body to insure
proper assembling.. This will insu
roper relocation when assembling ood seal and correct oil level
insure a good leve l reading
on dipstick.
dipstick.

1. Pump body oil seal.

1. seal. Apply a thi Permat(>x ''a.. 3 to the bore of pump
thinn coat of Permat pu mp before
be fore install-
install-
ing sea l. Press oil seal
seal. seal with Ihe the metal sside ide int
into pump body (26) (26 ) until flush with the body.
2.
2. Front bearing rings.
"0" nngb.
"(y' Install onto front bear
bearings (3) .
.3,Gear
3. Gear front bearings. In sta ll into pump body (26)_
Install ( 2 6 ) . Do not force bearings, iift they are a r e lined
up properly, they will fall into place. NOTE: Inspect bearings for excessive wear or
grooves. The Tne bearings should all be replaced if one or more need replacing. replacing.
4.Idler
1. Id ler gear. Install
In stal l into pump body (26), (26). NOTE: Inspect the gears fo forr cracked or worn
teeth. Both gears must be replaced if
teeth. it one needs replacing.
replacing.
5. Drivc n gear.
5.Drivcn gear. Install into pump body (26 ).
(26).
6. Gearr rear
6. Gea bearings.. Install
rca r bearings Insta ll into pump body (26). (26).
7. Relief valve.
\·alve. Install int intoo pump intermediate cover (10), ( l o ) , so that valve extends through covcr cover
approxmialely
ap proximat e ly .4~8",
,43Sr', Inset B. E.
8.Relief val ve "0"
8. Relief valve "0"ring.ring. Install
Ins ta ll iinto
nto relief va lve (7).
relief valve (7).
9.Intermediate
9. Inte rmediate cover "0" ri ring.
ng. Install onto pump body (26). (26).
10. Intermediate
10 Intermed cover. Install onto pump
iate cover. pu mp body (26). (26).
11.
11.Rear COvercover gaske
gasket. t. Install
Insta ll onto intermediate cover (10). (10).
12. Rear cover. Ins Install intermediate
ta ll onto inte rmediate cover (10). (lo),
13. CO\'e r bolts. Torque 9-11
baIts . Torgue 9-11 n.
tt. Ibs.
Ibs.
NOTE :: After torguing
torquingcovver cover bolts, torque the relief r elief valve cartridge 10-12 ft. lbs.,
10-12 ft. thenn
lbs. , the
relief valve locknut 18-20
torque "elief 1~ ·20 It. lbs. without
t t . Ibs. wit hout turning the relief relief valve.
14.Drive
14. Drive gear key. Install into the slot on the driven
key. lnstall dri ven gear shan shaft (5).
(5 ).
jO. Pump drive gear
13 gear,. In sta ll onto driven gear sshaft
Install haft (S)(5) engaging
engaging key (14). (14).
washer,
16. Flat washer.
16.
17.Slotted
17. Slotted gear nut and co cotter
tter pin.
18.
18.Filter element. lnstall
&.ilter element. Install on ontoto rear cover shaft (12). (12).
19. Elomcnt
19. El0ment retainer.
re ta ine r.
20 Retaining
20.. Fl spring-. NOTE: Inspect
.e taining spring. In spcct the spring for craiqked craeked coils co ils and the followin
followingg specific
specifications.
ations.

Active Coils ...............................................

..... ..... .............. .......... ........... . 8
Wire Diameter ......................................
. ......................... _ ..041"
ON"
Free Length ....................................... 2,383"
.... ....... .... .... 2.383"
Compressed to 1.:37';"
1.375" ... ................... 2.2-2.8 lbs.
... ........... 2.2·2.8 lbs.

J a m nut. Tighten jam

21, Jam
21. j am nut until a measureme
measurement 4-15/16 inches is ob
nt of 4-15116 obtained
tained measuring
m easur ing from
the outs
outside
ide of the j am nut to sshell
th" jam he ll flange
flange on the pump,
pump, Inset A.
22,Reservoir
22. "0"ring. InstaIl
Reservoir shell "0" Install onto pump body (26). (26).
shell. Inst
23. Reservoir shelt.
23. Install
all oonto
nto pump body (26) (26) aligning location marks.
24. Copper sealing washer.
25. Acorn nut.
25. nut. Torque 20-25 ft. lbs.
2()-2:i ft. Ibs.
26. Pump body.
body,
 52·7

MARK SHELL
M A R K SHE LL A ND PUMP
AND PUMP BODY
BODY

INSET B

INSET A 1

- 4 . 15 / 16 ,, ----:-- 1

Figure 3
3

t..
 Seclion
53
STEE RING CONTROL VALVE

Rae. Form 9-80671

Rac. Form 9·80671
53·2

STEERI NG CONTROL V ALV E

efer to
(Refer t o Figure
Figure 1)
1)
NOTE:: Before ddisassembling
NOTE isassembling control valve,
valve , m
mark
a r k the end ccaps
a p s and body for correct alignment
aand
nd location when reassembling,
reassembling,

1,Control
1. check. Insta
Control valve ball check, Installll into valve body (8),
(8).

2, Ball cchock
2.Ball heck plug "0" ring, Install
"0" ring. In stall onto plug (3),
(3).

3,
3. Check plug.
plug, Install into valve body (8),
(8).

4,Centering washers, Install onto cent

4.Centering washers. ering screw
centering sc rew (6)
( 6 ) before and
a n d after the centering spring (,5)
( 5 ),.
NOTE:: Check that the washers rotate freely
NOTE freely on the sc rew .
screw.

5, Cent e ring sprin

5 . Centering g, Install onto centeri
spring. ng screw (6),
centering Inspec t the spring for crac
( 6 ) . NOTE: Inspect ked coils
cracked
following
and the followin specifications,
g specifications,

Totall Coils ""

Tota ..............................................
'''''",."''" ' ,,'','',, ... ,, .. '''',.,. ,, 6
Wire Diameter ""'''"'' .................................. ,080"
,,'' ''''''',,, .,,'''''' ,080"
I. D. ""
I, D, ...................................................
"""""""" " " ",,, ",,'",'',,''' """ ,625" .625"
F r e e Le
Free Length ......................................
ng th '"'''''''' """",, ""." ",,",'" ,860" .860"
Compress to .824" """","" ...................... Ibs,
1.5-2.5 Ibs,
''',,'' '' 1.5·2,5

6,Spring
6.Spring centering sc rew, Inst
screw. a ll into valve spool (7).
Install (7). Tighten to approximately 1515 ft.
ft. lbs,
Ibs. by in·
in-
serting a sma ll rod in the cross drilled hole in the sspool
small pool and a small rod in the centeri ng screw
centering-
sha nk,
shank.

7, Va lve spool.
7. Valve spool. Install into valve (8). N
va lve body (8), E:: Check that the spool oscillates freely in the body.
NOTE body,

Va lv e body
8. Valve
8. body.,

q, End cap
9.End c a p "0" rings.
rings, Install
Ins tall into eend
nd caps
c a p s (10).
(10).

Va lve body end caps,

l a, Valve
10. caps. Align
Alig-n the loc atin g m
locating marks
a r k s on the caps aand
nd valve body.
body,

11, c a p retaining bolts.

11.End cap bolts, Torque bolts 14·17
14-17 ft. lbs,
It. lbs,
 53-3

Figure 1
 Section

54
STEERING CYLINDERS
AND
ADJUSTMENT

Rac. Fo
Rae. Form 9-80621
rm 9-80621
j4·2

STEERING CYLINDERS
((Refer to Figure 1)
1.Inne
1. Innerr ggland
la nd " 0" r ing sea
0 " ring l. Install into ggland
seal. land (IOJ
(10)..

back ·u p ring sseal.

22.. Leather back-up ea l. Install
Insta ll into ggland
la nd (10).
(10).

3. Retaining ring. Install int

intoo gla
gland (10).
nd (1 0) .

4. Inner seal wiper

\\'ipt' r rretaining
e taini ng rring.
ing . Ins ta ll into gla
Install nd (10)
gland (10) .

J. Gla nd sea
.,?.Gland seall w iper. Install
wiper. Ins ta ll into gland
g land (10)
(10) with lip
li p facing
fa cing outward.
o utward.

6.
6 , 0O utt'r
u t e r sE'a
seall wi per retaining
wiper re ta in ing ri ng. In
ring, sta ll in
Install to gland (10)
into (10)..

7.G a nndd seal aand

. G l la nd wiper reta
retaining
ining ring. Install
ring . Insta ll into ggland (101, making sure
la nd (10), s ure it is sealed
seated in the
retaining groove,, In
reta ining groove I nset
st AA..

Gland
8. Cla
H. outp-rt lc'a
nd oute leather
the r bac k·up ring.
back-up ring. Install onto the gland (10)
(10)..

Gland oouter
9.Gland
9. uter "0" ring
r ing (1,75" I.D.).
(1.75" 1.0. ). Install o nto the gland
onto g la nd ( 10) Inse t A ,.
l o ),, Inset

Ill . Sea l gla

lU.Soal ncl. Lubr
gldnci. ica le
Lubricate' t hhee bore of the sea
seall ,gland
g la nd aand
nd sslide
lide the sseal
eal g la nd
gland assemb
assembly ly over the
pi s to
piston n rod :-.IO'fE:
fl3'i. NOTE:
(13 ). Slide the gland
"land assem bly on
assembly onto to the pis ton r od
piston rod from t h e smallll
the s ma threaded
e n d .-
en

11. assembly.
11. Piston assem bly . Install
Insta ll onto iho
the ssmall
mall end of the piston rod (13)
(13)..
P iston rod se
12.Piston
12. s e lltf locking lock
loch nut.
nu l. Torque
Torq ue loc 30-35 ft.
lockk nut 30·35 ft. lbs. NOTE : W
Ibs . NOTE: using a new
h e n USing
Whe
locking
self 10cl<i ng lock nut, DO NOT
loc k nut. "!OT restake
res take the piston
p iston rod.

13 P
13. Piston
iston rod (11116"
i11/16" diameter
d i a m e t e r).) , Lub rica te the piston seal,
Lubricate seal, ggland in side of the cy
land seals and inside cylinder
lind e r
cubo. Press
tube. P ress the piston rod assem
assembly bly into tthe
he cylinder
cy linder tube.

14.. Gla
14 nd retainer
Gland r eta inN ring riii ., lnslall t he rring
Install the ing into the ccylinder
ylinder tube,
tube, make
m a k e ssure i t is properly sea ted In
u r e it
The rretaini
the ~ t a i nng r oove, Inset A.
i n gggroove, A. .

IIS.
~. Cyli nde r eend
Cylindt?~~ nd plu re..
plate

b. C
l16. nd picite
End plate rf'ta ining
regaining screws (~,,10·24 1 2" pan hd.
1 0 - 2 4x" 112" hd. sslotted).
lot ted) . Line t h e hole's
Lin e up the holes in the end plate
pla te
with ggland
land assembly and torque the screws 5·7 3-7 f t . lbs.
ft. Ibs .

Cylinder
17. Cyl tube,.
inde r lube

18. E nd Clamp

19.. Thread f'vnd

El a s s ~ m bly,l y i'crna
nd assemb lerna
, le.

Thread
20. T hrt'a d ('end
nd assemb male
ly, m
assembly, ale.
 54-3

INSET A

Figure 1
34·4

STEERING CYLINDER ADJUSTMENT

Chl'ck
Check thl' trorit wh
the frollt ee l toe iinn adjustment.
wheel a djustment. It should be 1/4".
1/4". Loosen the two piston rod ball
ba ll stud
l' nd d
end c la
am mps a nd turn piston
p s and pi s ton rod
rodss fu lly into the ball stud ends.
fully

Turn theth e whee

wheels ls to the full ri g ht hand turn position. Adjust the length of the R.H. cylinder
right cy linde r rod
until the R.H.
R .H. steering a rrm m is firmly against
aga inst the axle. Adjust the L.H. piston rod so piston
pis to n bottoms
in the full r e trac ted position
full retracted a t the sa
posi tion at m e time the R.H.
s a me R.H. steering arm is against the axle
a r m is ax le stop,
stop,
re fe r to Figu
refer Figurer e 22..

Turn tthh e wh ee ls to the

wheels t h e full left turn position,
pos mon, adjust the R.H.
R.H. piston rod until iti t bottoms in the
rretracted
e tra cted position
pOSition at the sa s a m ee titime
m e the L.H.
L.H. steering
steering arm is against the L.I-I. stop, rrefer
L . H . axle slOp, e fer to
Figur0 3. Tighten both
Figure bot h cclamps.
lamps.

R .H . STEERING
R.H. ARM
STEERING A R M AGAINST STOP

L.H
L . H. CYLINDER PISTON
PISTON BOTTOMED

Figure
Fi gure 2
2

L.H. STEERING A
L.H. ARM
R M AGAINST STOP
(' . ......... ..'. ,, " .. .. .
,,

... .. .i

R.H.
R PISTON BOTTOMED
.H. CYLINDER PISTON

Figure 3
 Seclion
55
STEERING AXLE
AND
WHEEL BEARINGS

Rac.
Ra e. Form 9-80631
9-80631

.. "- -- - - ---"
05-2

STEERING AXLE
{Refer to Figure 1)
1.Front Axle
1.
2. Front
F r o n t Axle Pivot Bushing - Press P r e s s in place anda n d rream
e a m to 1.744" -- 1.746"
;~.
3. GGrease
r e a s e Fitting
4.
4. Front Pivot Pin
Pivot Pin Snap Ring
5.Pivot
5_
6. Front WIl",el Spindl
F r o n t Wheel Spindle, e , Inset A
7. Spindle Thru Thrust s t Washer
8.
8. Spindle Thru5t Thrust Bearing
9. Spindle
Spind le Lower i'ieedle Needle Bearing
10. Spindle Upper Needle
10. Need le Bearing
Bearing
11Spindle Oil Seal
11.
12. Spindle Dust ShiC'ld Shield
13. Spindle Shim -- UAR (16,
13-Spindle (16, 20 oro r 28 gao)
ga.)
14. Steering
H. Steering Arm R.H.
15.
13. Axle Spindle Washer
16. Spindle Slotted "ut Nut -- Torque 250-300200-300 St.ft. lbs.
Ibs.
17. Cotter
17. Colter Pin - .3110" 3/'16" x 1-3 1-3/4"
/ 4"
18. Tic
18. T i e Rod
Tie Rod Lock Nut -- R.H
19.Tie
19. R.H.. Threads
20. Tie Rod End -- R.H.
20. RH .
221.l.T
Tiei e Rod Lock "ut Nut - L.H.L.H. Threads
22. Tie Rod End -- L.H.
22.Tie L.H.
23. Steering Arm L.H.
2-l. Tie Rod End Slotted );ut
2-1, Nut - To rq ue 65-80
Torque- ft. lbs.
65-80 St. Ibs .
25. Cot ter Pin - 1/
25.Cotter l-'V
8" x 1-1 /4"
1-1/4"
26. Radius Rod
26.
27. Radius Rod Axle Bolt 0"
27. dia.) -- Torque 580 - 696 fft.
(1" dia.) Ibs.
t . lbs.
28. Axle Bolt Heavy Nut (1"
28.1\"le ia.)1..
(1" ddia.
29. Radius Rod Axle Bolt ((33/'4" 4" d ia.) - Torque 270 - 324 ft.
dia.) ft. Ibs.
lbs.
:30_:'<xle
30. Axle Bolt Nut Kw (3 / 4" dia. )1
(3i.1"
:31.
31. Radius Rod F Front
ront Pivot
32.Front Pivot Bushing
:)2.Front -
Bushi ng - Press in place and rream e a m to .86:3"
.863" - .8601",
.86-1", Inset B.
33. Radius Rod Pivot Bolt - Tor
:33. - Torque
que 150-180
150·180 fft.
t . Ibs.
H.
34. Lock Washer
3;3.
35. ;-';ut
Nut
36. Radius Rod R e a r Pin. N
Rear OTE : When removing pin, it must be driven towards the front of the unit.
NOTE: unit.
.37. Groove pin
:37.
38, Grease Fitting
38.

NOTE:: Refer to Section 54 for

for toe-in
toe-in aand
n d turning aang
n g le
l e adjustments.
adjustments.
 55-~~

INSET A

/
•I
I

~ -0
I
I

© -0
~ --CD
©,, -0
)
/
/
 35-4

WHEEL BEARINGS
Pac king I nterva I ----- -- ----- ---- --- -- -- -- --------------------- ------------ ------ ------------- -- --------- ---- --- -------- -- 500 Hours

1. Lock the bbrak

L r a k ees,
s, rraise
a i s e aand
nd block up 4. R e m o v e tbe
Remove the inner ha1 (11 ) ffrom
ha lf of seal (11) rom
tractor front end_
end. spindle.
s pindle.

2. Remove the hub cap (I),cotter

c a p (1). colter pin (2),
(2), 5.R
5. e m o v e tthe
Remove h e iinne
n n er cone (9),
(91, bearing ccups
ups
sslotted
lotted adju sti ng nut (3)
adjusting ( 3 ) and
a n d thru st wash-
thrust wash- ( 6 ) aand
(6) nd outer seal ha
(8) aand
n d (8) lf (10)
half ( 10 ) ffrom
rom
er ( 4).
4). hub. Inspec
Inspectt the bearing cups aand n d cones.
Replace ifif worn or dama
d a m a gged.
ed.
3 . Remove
3. R e m o v e tthe
he outer b e a r i n g cone (5)
bearing (5) aand
nd
pull the wheel hub (7) (7) off the spindle 6. Clean the bearings,
&Clean bearings , inside
insid e of hub and
and
containing bearibearing c u p s (6
ng cups (6)) and (8),
(81,cone spindle.
( 9 ) and
(9) a n d outer half at
ot seal
s e a l (10).
(10)

IN SET B

Figure 2

1_
7. PPack
a c k e ach bea ri ng with No.
a c h bearing wheel bbearing
!'io. 2 lvhwl earing and s s e m b l y onto the spindle.
a n d install the hub aassembly spindle_
ggrease.
r e a s e . :Vlake
M a k e sure t h e sspace
s u r e the p a c e around each
each
filled.
roller is filled. 11. ins tall the thrust washer
11 . Install wa s her (( 4) 4 ) aand
n d slotted
Slo tted
ad justing nut ((3).
adjusting 3 ) . Carefully tighten the nut nul
8. lns tall the bbearing
Install e a r i n g cups (6) and
c u p s (6) (8) if they
a n d (8) (3) against
(3) thrus t washer ( 44)1 until the
agains t the thrust
were removed,
r emoved, inner i n n e r bearing-
bearing cone (9) and
( 9 ) and pressure
p r e s s u r e of lhe
the nut c auses a u s ~ s a noticeable?
noUcea ble
new oouu ter
t e r seal half (10) (10) into hub
hu b until tthe he drag
drag while the hub and
lhe h ub a nd wheel is turned.
seal half
outer seal
aliter half inner
inne r edg js 3;) i 16" below
edgee Js Bac
Back k off nut 118
1/8 of a turn or
t u r n or until the next
the ' inner hhub face. See Inset A.
u b face. slot in thc tho nut lines up with the hole in the
spindle, Check fo
spindle. forr end
e nd plplay.
a y. If
If end play is is
9. Install a new iinner
9.Install n n e r seal half
ha lf (11)
(11) onto tthe
he noted, tighte n until e nndd pplay
noted, tighten is gone-
lay is g(me _
c u r v e d face inward. See
spindle with the curved See
B. Lubricate the Seal
Inset B. seal ssurfaces
ur fa ces with 12.
12. Lock the slotted adjusting-n ut (3)
adjusting-nut with a !le
(3^ wirh new W
No. 2 wheel bearing ggrease.
No.2 rease . cotter (2)aand
cottpr pin (2) n d reinstall tthe h ub cap (1)
h e hub (1).

1
10. Install (5) into the hub (7)
II outer cone (5) (7)
 Section

&1
TORQUE CONVERTER,

POWER SHUTTLE COUNTER-SHAFT,

CONTROL VALVE AND ADJUSTM ENTS

TABLE OF CONTENTS
converter
Torque conve rter removal .......................................................................................................
remova l ." ... "" ... .. " " ............ ......... ................ """ ..... .. ... " ................ "".,, ..... 61-2
61·2

Converter and lu
lubrication .........................................................................
brication oil regulator valve ............................ 61-2
.. ...... " .. "."."" .... " ." ...... ........ 61·2

Torque converter ....................................................................................................................... 61-4

" ................. " ............................................................ " .. ....... .. .. """." ... .. ,, ... 6]·4

Power shuttl
shuttlee control valve
con trol va ....................................................................................................
lve "" 61-6
.... . "." .......... " .. ........ ...... .... ..... " ... ... ... ...... ...... .... ... ,, ........ ....... .. 61·6

Counte
Countershaft ...........................................................................................................
rshaft and gears ....... " ................................................................. ... ................. .... ... ...... 61·8
61-8

Power sshuttle
huttle removal
r e m ova l ·. insta ................................................................................
lla tion ......
installation ........ 61-10
... ............ .. .. ..... ... .... ........ ...... ... ... .. ..... " .. .. ..... " ....... 61 ·10

adjustments
Power shuttle adjustm e nts
Clutch peda ..........................................................................................................
pedall linkage ....... 61-11
. ....... .. " .............. .......... .. "" .. ... ........ " ......... " ... ........ " .. .. ,, ... .. "" ". 6]·]]
...........................................................................................................
Shuttle spool linkage """" 51-12
. " .. ... " ...... " .......... ..... .. .... ... ... ...... .. ................ .... .......... .. ........... 61·12
..........................................................................................................
Control lever linkage ............ ............... .... ............. ......... ......... ...... " ... .. ........ ..... .... ...... .. .. .... 61·13
61-13

Ra .
c Form
ae. 9-80761
Form 9 · 80761
61·2

TO RQUE CONVERTER
(Refer to Figure 1)
Rem oval
Split the tractor between the e ngine and converter housing, refer to the splitting section of
this service manual.

Install lifting fixture A20165 with attaching plate A34900 to thE' converter. These tools are
available through the Case Service Parts Supply.

Remove the torque tube front cover. With a suitable hoist on the lifting fixture, remove the
carrier mounting bolts. Work the converter out of the torque tube.

Reverse the above procedure for installing the converter.

CONVERTE R AND LUB RICATION OIL REGULATOR VALVE

(Refer to Figure 1)

I. Regulator valve body.

2. Valve spool · Make sure spool operates smoothly in the housing bore.
3. Regulator valve spring. Free length ...................... ..... .............. 1·3/8"
Wire Dia . ..... .. ....... ..... .............. ............. 051"
No of Coils ........................................... 6·112
Spring Rate ............... ..... 10 to 12 lbs. at 314"
4. End plug "0" ring.
5. End plug.
6. Snap ring.
7. Gasket.
8. Mounting bolts with lockwashers.
9. ConNrter oil temperature switch.
 61 ·3

1I FTI NG FIXTU R E -......,..".-17)<:::

A34900 ATTACHING PLATE

CARRIER MOUNTING BOLTS

~ TORQUE
CONVERTER

POWER SHUTTLE CONTROL VALVE

,/

---- TORQUE TUBE FRONT COVER

 61·4

TORQUE CONVERTER
(Re fer to Figure 2)
1. Output shalt.

2. Ca rrie r bearing. P res s onto shaft until it seats against the shoulder.
3. Bearing space r .
4. Snap ring, bea ring r eta iner.
5. Hook type sealing rings. Insta ll with end gaps, Inset A, 90 0 apa rt.
6. Snap ring. Used to retain carrier bearing (2) into carrier (10).
7. Pump drive gear.
8. [mpell er w heel.
9. Clamp pla te s a nd impelle r mounting bolts. Torque 19 to 21 ft. lbs.
10. Carrier . [nst all the dri ve gear impell e r wheel assembly onto carrie r.
U. Stator.
12. Clamp plat e s.
13. Roll pins.
H. F erry head ca pscrew s. Torque 24 to 27 It. lbs . to retain the stator to the ca rrier.
15. Sn ap ring. Used to retain the output s haft in the carrier after the bearing (2) has been
sea ted in the carrier.
16. Turbine.
17. Bearing with s na p ring. Install into housing (18) until it is seated.
18. Rota ting housing.
19. He x. head bolts wit h lockwas he rs. Used to retain the rotating housing to the impeller wheel.
Torque 19 to 21 It. lbs.
20.Hook ty pe sea ling ring. Inst a ll onto carrier (21 ), Inset A.
21. Ca rrier.
22. Sncp ring. Used to retain ca rrier (21) onto s haft.
23. Flyw hef'l pilot.
24. Pilot r etai ning bol ts. Torque 19 to 21 ft. lbs.
25. Plug .
26. Snap ring.
27. Housing to fl ywheel seal.
 61 ·5

IN SET A

Figure 2
 61·6

POWER SHUTTLE CONTROL VALVE

(R efer to Fig ure 3)
Lubricate the spools with Ca se TCH all as they are installed.
1. Flow cont rol oil seal. Install with sealing lip inward until seal bottoms in bore.
2. Shut tie co ntrol spool oil seal. Install with sealing lip inward until seal bottoms in bore.
3. Flow control spool.
4. Clutch pressure r egulator valve.
5. Clutc h pressure regulator valve spring. Free le ngth ................. .. ....... ........ .. .... .... ....... .... . 2. 04"
Wire Dia ..... ...................... .. ........ .. ....... .080"
No Coils ............................................ 15·1/2"
Spring Rate ............ 45 lbs. at 1·11/ 32" leng th
6. Clutch press ure r egulator shims. Use as required to adjust clutch pressu re. At tes t port
it should be 170 to 190 PSI at 9.5 GPM fl ow .
The .0209" s him equals S PSI.
The .0418" shim e quals 10 PSI.
7. Clutc h pressure reg ul a tor plug with "0" ring.
8. POWN shuttle control s pool.
9. Spool stop. Ins tall with the tab toward flow control spool.
10. Control spoo l snap ring.
11. Plug "0" ri ng.
12. P lug.
13. Plug r e ta iner snap ring.
14. Adapter pl ate.
15. Valve body gasket.
16. Dete nt spring.
17. Detent ba ll.
18. Va lve ret a ining bolts w / loc kwashe rs. Tight en to torque of 35 to 42 ft. lbs. The two rea r
bolts m ay be loose ned to 25 It. lbs. if the spools arC' not f ree.
19. Pipe plug, clutch pressure test port.
20. Breather assembly.

NOTE: After the val v e is installed, the control linkage will ha ve to be ad justed. Refer to the
a djustm e nts in thi s section.
 61 -7

1~J
CLUTCH PRESSURE GAlJGE

OIL

<> 0
'"
'"
"" ?
'"
<>
~

0
<:>

<.- '"
'-'
"
L-

Figure 3
61·8

COUNTERSHAFT AND GEARS

(Refer to Figure 4)

L Needle bea r ing. Press on number side of bearing to a depth of 1/16", into torque tube housing,
Inset A.
2. Countershaft rear bearing. Press onto countershaft until it bottoms.
3. Countersha ft. Install through rear bore in torque tube.
4. Snap ring, reverse gear rear.
5. Reverse driven gear, large hub toward rear of shaft.
6. Snap ring, reverse gear front.
7. Snap ri ng , rear bearing. Install into torque tube . Lightly tap shaft a nd bearing assembly
into case until rear bearing sca ts aga inst snap ring.
8. Snap ring , rear bearing.
9. Forward driven gear. Install with large hub toward rear of s haft.
10. Retainer washer.
11. !'ylock bolt. Torque 35 to 40 ft. Ibs.
12. Reverse idl er bearing. Press into gear until it bottoms.
13. Reverse idler gear.
14. Bearing r etainer sna p ring.
15. Reverse id ler gear st ud. Press into bearing (12) . Install a ssembly into torque tube and
torque 130 to 145 ft. lbs.
 61-9

t
(1)

Figure 4
61-10

POWER SHUTTLE
(Refer to Figure 5)
Removal
Remove transmission fr ont cover and torque tube rear cover. Aiter the tractor ha s been split
between the torque tube a nd transmission, carefully pry the power shuttle unit rearward to remove,
Inset A. Refer to Section 63 for servicing the "Twin Disc" Power Shuttle Clutch. Refer to Section
64 for Servicing the "Rockford" Power Shuttle Clutch
Installation
Locate the e nd gap of the power shuttle shaft sealing rings 90 0 apart. Lubricate the sealing
rings with grease. Carefully install the power shuttle unit into the torque tube. Tap lightly on
the rear endof the power shuttle unit to seat the front bearing into the torque tube.

Rejoin the torque tube and transmission with new gasket and retain with bolts. nuts and
lockwashers . Torque the bolts 80 to 132 ft. Ibs. and the stud nuts no to 132 ft. Ibs.

Check the amount of end play between the power shuttle unit a nd the snap ring on the
transmiss ion input shaft. Pry the power shuttle unit forward a nd use a feeler gauge to check
the clearance. Clea ra nce mus t be a minimum of .025" to a maximum of .045". Add or remove
shims on the transmission s hart in front of the s nap ring, Inset B.
PRY POWER SHUTTlE UNIT 0
TO CHECK FOR END PLAY

u
CHECK END P L A Y CLEAa~NICt_-,,-l!'\
BETWEEN SHIMS
MIN . 02S " TO MAX .045 ..- - - -

IN S ET A

o
POWER SHUTT LE 0
~;";""j'!T1I@r->'-':::::~
0
\ r-~ ) ,. .,
Figure 5
 61-11

POWER SHUTTLE ADJUSTMENTS

CLUTCH PEDAL LINKAGE
(Refer to Figure 6)
l1\WORTANT: Prior to adjusting the clutch 5. Adjust the cam follower bearing support
pedal, make sure the brakes are properly so the cam follow er bearing pin moves
adjusted. freely in the support.

1. Disconnect the clutch pedal to cam link. 6. Move the cam through a complete cycle
(back and forth) by hand. The movement
2. Loosen the cam pIvot shaft nut. Inset A. should be free. If not, repeat steps 1
thru 5.
3. Check to make sure the cam follower
bearing is in full contact with the cam track. 7. Adjust the clutch peda l stop screw so the
brake pedais and clutch pedal contact their
4. Position the flow spool so the cam follow- respective stops at the same time. Inset B.
er bearing is seated in the upper-most
part of the cam track. Tighten the cam 8. Adjust the cam link clevis, so the clevis
pivot shaft nut securely without turning pin can be installed into the clutch pedal
the cam pivot shaft. NOTE: From the without any binding. NOTE: The cam
center of the cam follower bearing to the follower bearing is sealed and "Parco"
center of the nearest mounting bolt of the lubrlzed. Excess oil or grease on the cam
cam follower bearing support should be or cam follower bearing wll! only collect
3.575". dirt a nd cause undue wear.

CAM BRAKE PEDAL STOP

INSET A

u
CUJTCH
/
PEDAL STOP

M LINK
,,~----~~~-­
CAM FOLLOWER """HIN<'; SUPPORT

Figure 6
61 -12

SHUTTLE SPOOL LINKAGE

(Refer to Figure 7)
1. With the engine not running, move the shuttle spool out by hand until the rear
s huttle control lever on the steering column de tent is felt.
to the forwa rd position_
4. With the spool in the rear de tent, adjus t
2. Disconnec t the shuttle spool link. Loosen the spool s top screw in until it just touches
and back out the spool stop screw. the stop on the shuttle spool. Tighten the
stop sc rew locknut.
3. Move the shuttle spool "in" by hand until
the neutra l detent is felt . Then move the 5. Connect the shutUe spool link.

Figure 7
 61-13

CONTROL LEV ER LINKAGE

(Refer to Figure 8)
Check and adjust the "Clutch Linkage" a nd the "Shuttle Spool" prior to this adj ustment.

L Rem ove the steering column s upport cover tween the fOlw ard a nd reverse detent
and screws. positions.

2. DIsconnect the baU Joint (1) from the shuttle 5. Readjust the ball Joint (1) by turning on or
lever (2) at the lower end of the shuttle off the rod (4) so it ca n be Installed Into the
shift lever (5) . shuttle lever (2) without forc ing Into place.

3. Manually move the shuttle shift lever (5) 6. Reinstall the ball joint retaining nut (9) and
to the neutral position. engaging the slot lockwasher (10) . Tighten locknut (.3i on
in the loc k plate (6) located on top the rod (4).
steering column (7).
7. When the shuttle spoOl and lever are
4. Manually m ove the power shuttle control properly adjusted, the hand lever can be
valve spool (8) to the neutral detent position. moved slightly ou t of any detent position,
The neutral detent position is located be- before the spool is m oved.

Figure 8
 Section

62
ROCKFORD CLUTCH
POWER SHU TTLE C LUTCH PACK

TABLE OF CONTENTS
Force pi ston, housing and shaft ........................... ..... ...... ..... ....... .. ........ , .... ...... .... .... ... .. ... ..... .. 62-2

Forward and reverse clutch pa cks .......................................................................................... 62 -4

Forward a nd reverse clu tch drums ........ .. ................ .. ...... .. ....... ...... ............ .. ....... _.... ...... ........ 62-6

Rae . Form 9-80661

62-2

FORCE PISTON, HOUSING AND SHAFT

(Refer to Figure 1)
Lubricate parts with CasE' TCH oil as they are assembled.
1. Shaft and separator plate asspmbly.
2. "0" ring seal, install in groove on separator plate.
3. Roller bearing - install into place on separator plate shaft until it just bottom s. Use
Drive Case No. G15042 .
4. Reinforc ing disc, install with curved tangs toward separator plate, Inset A.
5. Disc valve, line up holes with reinforcing disc and separator plate.
o. Forward accelerating piston.
7. Hook type sealing ring, Inset 0, install into groove on forward accelerating piston.
8. Snap ring, install into groove on shaft to retain accelerating piston (6).
9. Hook type sealing ring, Inset D, install into grcove on shaft.
10. Force piston housing.
11. Va lve pins.
12. Re inforcing disc, ins tall with the curved tangs toward the separator plate and the holes
engaging the valve pins , Inset C
13. Disc valve, holes must engage the valve pins.
14. Reverse accelerating piston.
15. Hook type sealing ring, Inset D, install into groove on reverse accelerating piston.
16. Snap ring, install into groove on shaft to retain the accelerating piston (14).
17. Hook type sealing ring, Inset 0, install into groove on shaft.
18. Piston seal "0" ring, install into groove on force piston (19).
19. Force piston, fill the snap ring groove in the force piston housing (10 ) with grease and
gently work the piston (19 ) down into the force piston housing until snap ring groove is exposed.
NOTE : Filling the snap ring groove with grease will help prevent the piston sea l "0" ring
(18) from being cut or entering the snap ring groove in the force piston housing when installing
the force piston.
20. Piston retainer snap ring.
 62-3

INS ET A

INSET D

INSET B INSET C

l.--..--------..............-----FigUre 1
 62·4

FORWARD AND REVERSE CLUTCH PACKS

(Refer to Figure 2)
Lubricate parts with Case TC H oil as they are assE'mbled.

1. Clutc h hub assemb ly.

2.Si n tered bronze drive p late \7 used )
:l. Steel driven clutc h plate (6 used)
Alternately install one bronze dri ve plate (2) and one steel dri ven plate (3) ont o the c lutc h
hub (1) until 7 bro nze plates a nd 6 steel plates have been installe d.
4. Clu'ch backing p late.
S.Locati ng dowel · insert in groove in plate (4) a nd hub (1). In se t A.
6. Snap ring. insta ll into groove on c lutch hub (1) . Inset A.
7. Spirol type in ternal snap ri ng. Install into groove in backing plate (4) . Inset A.
8. Force piston, housing and shaft assembly.
9. Forward clutch pack assembly.
10. Snap ring, Inset 8. Install in groove on clutch s haft.
11. Splined spacer . In set C.
12. Snap ring. Inset C. Install in to groove In clutch bac king plate.
13. Revers e cl utc h pack assembly .
14. Snap r ing. Inset 8. Ins tall into groove on clutch shaft .
IS. Spl ined spacer, Inset C.
16.Snap ring. Inse t C. Install into groove in clutch backi ng plate.
 62-5

FO RWAR D

INSET A

-===-

DOWEL GROOV E

INSET C INSET B

Fi gure 2
62-6

FORWARD AND REVERSE CLUTCH DRUMS

(Refer to Figure 3)

Lubricate parts with Case TCH oil as they are assembled.

1. Thrust washer (thin).
2. Thrust bearing ((hin).
3. Thrust washer (thin).
4. Forward clutch drum and gear assembly (line up tabs of steel plates).
5. Forward-Reverse clutches and shaft assembly.
6. Thrust washer (thin).
7. Thrust bearing (thin).
8. Thrust washer (thin).
9. Rever!;e clutch drum and gear assembly (line up tabs of steel plates).
10. Roller bearing.
11. Thrust washer (thick).
12. Thrust bearing (thick).
13. Thrust washer (thick).
14. Bearing. press into place until it contacts the shoulder on the shaft.
1:). Hook type scaling rings, Inset A.
 62-7

FORWARO

(~',
I "
I "-,,-
I ',,-
"-

"-, I
" II
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r r ,
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~
(!)(), rr } iJ
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Figure 3
 Section

63

TWIN DISC

POWER SHUTTLE CLUTCH PACK

TABLE OF CONTENTS
Reverse cl utch pack and shaft assembly ........ ...... .. .. .. .... .. .. .............. ........ .. ............................ 63-2

Forward-reverse pIstons and carrier assembly ... .. .... ..... .............. .. ......... ........... .. .. ................. 63·4

Forward clutch pack assembly .. ...... .... ................................................... ... .... .... .... ............... .. 63·6

Clutch hub shims ...... ... .... ............... .... ... ... .... " ..... ... ...... .. .. .. ..... .. ..... ........ .. .. .. ......... ....... .......... 63·6

Forward-reverse c lutch drums ........ .. .... .... ...... .......... ... .... .......... .............. ..... .. ..... .. ....... .. ........ 63·8
Rac. Form 9 · 80701

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63·2

RE V ERSE CLUTCH PACK AND SHA FT ASSE MBLY

(Refer to Figure 1)
Lubricate the parts with Case TCH 011 as they are assembled.
L Snap ring, clutch s haft· In stall into s nap dng groove on ~tiarl (2 ).
2. Clutc h shaft
3. Needle bearing' Press on numbe red end of be aring until it is r ecessed 1116" beyond end of
shaft (2). Use Drive r , Case No. G15042 .
4. Clutch hub key.
5. Reverse c lutc h hub . Press onto shaft until it bottoms on the s na p ring (1). NOTE: The r everse
c lutch hub has a recess m ac hined for the snap ring .
IMPORTANT: At this tim e, te m porarily in s tall fi ve sinte red c lutc h plates a nd five steel clutc h
pla tes on the reverse clutch hUb . Then proceed to check the hub protrusion above the plates . Refe r
to Pa ge 63·6 "Clutc h Hub Sh ims ". Afte r the hub protru s ion and s him require m ent ha s been
determined , remove the ten clutc h plates a nd proceed with th e asse mbly .
6. Clutch pla te wavy s pring (Free height of ,1285" ) . Install the firs t wavy spring so the tan g en·
gages the two roll pins (one tooth a pa rt) in the c lutch hub, Inse t A, The c lutc h hub must be
mar ked at th is po int, Inse t A, and a lso a t a second point fi ve gea r teeth away .
7. Sintered driven plate.
8. Steel dri ve pla te .
9. Clutc h pla te wavy s pr ing. Ins ta ll the second wavy spring with the ta ng rotated five g ear tee th
from the ta ng of the fi rs t wavy spring (6), Inse t B. The second s pring ta ng would then line up
with the seco nd m a rk on the hub. Proceed to ins tall one sintered plate, one steel pl a te and
s pr ing (a lte rnating the s pring ta ngs be tween c lutc h hub marks ) until a to ta l of five ea c h have
been insta lled.
Ins tall two cla mps and compress the clutch plates and springs down onto the c lutch fia nge
un til four A43071 Special Tool clips ca n be installed. Clips are ava ila ble fr om Cas e Service
Pa r ts Supply. The r everse c lutc h pack assembiy is now comple te, Inse t C a nd D. NOTE: The
A43071 Special Tool Clips are used to keep the c lutch pl a tes a nd wavy s prings compr essed ,
while pressing the ca rrier ass embly on to the c lutch sha ft a nd reverse clu tch pack. If the
c lips are not used, there is a cha nce of squeezing some c lutc h plates be tween the reverse
clutch hub a nd the carrie r assembly s ince the plates have a tendency to ride up over the c lutch
hu b.
10. Reverse hub s hims. Install pre·determined number of shims and press ca r r ier assembly on
s ha ft. Re fer to Page 63·4 and 63·5.

INSET 0
 63-3

INSET C

SPECIAL TOOL, __
CLIP A43071

ROLL PINS FOR

SPRING TANG
LOCATION

SNAP GROOVE

INSET A INSET B MARK FIVE GEAR

CLUTCH HUB FIRST MARK
TEETH FROM

Figur e 1
63·.

FORWARD AND REVE RS E PISTONS AND CARRIER ASSEMBLY

(Refer to Figure 2)
Lubricate the parts with Case TCH oil as they are assembled.
1. Piston Carrier Assembly.
2. Piston ring, (hook type), Inset A. Install in grooves on both sides of carrier (1) .
3. Piston ring seal (5 pieces includes items 4,5 and 6) used in both forward and reverse pistons
(14 and 17).
4. Expander, seal ring. Install into both pistons.
5. Step type rings (3 used) Inset B. Install into both pistons . Slide both pistons onto the carrier
hub to e xpand the rings. The rings must be expanded to correctly align the rings so the ends
do not overlap sideways. Remove both pistons from the carrier and inspect rings for proper
alignment.
6. Square end type ring (1 used). Install into both pistons, next to the step type rings and toward
the carrier.
7. Dump valve spools, Inset E.
8. Dump valve springs, (Free length 1.32"), Inset E.
9. Pin 1/ 8" x 3/ 4". Compress dump valve spring and insta ll pin so it retains spring in each
pi ston (14 and 17), Inset E.
10. Rubber piston seal rings. Install into groove on the pistons (14 and 17).
11. Reverse clutch hub shims. 1~1PORTANT: A t this time the correct numbers of shims for
proper piston travel will have to be determined. Refer to Page 63·6 "Clutch Hub Shims".
Then install the co rrect number of shims over the shaft and onto the hub.
12. Forward lube oil spring (Free Length 1.71"). Instan into hole in reverse clutch hub, Inset C.
13. Forward lube oil spool. Grease the spool and install into hole in reverse piston, Inset D.
14. Reverse piston. Install into carrier (1). Make sure the carrier key way is aligned. Press carrier
onto the shaft until the carrier con ta cts the shims a nd reverse c lutch hub. Then remove special
tool clips installed in step 9, page 63·2.
15. Reverse lube oil spool. Insta ll into hole in top of carrier, Inset F.
16. Reverse lube oil spring, Inset G.
17. Forward piston.
18. Forward clutch hub shims . Refer to Page 63·6 "Clutch Hub Shims" for determining the
corre ct number of shims to be installed.

INSET 0 INSET F INSET G

 63-5

INSET C

INSET B

INSET E

Figure 2
63·6

FORWARD CLUTCH PACK ASSE MBLY

(Refer to Figure 3)

Lubricate the parts with Case TCH oil as they a re as sembled.

1. Forward Clutch HUb.
IMPORTANT: At this time, temporarily install fi ve s intered c lutch plates and five steel
clutch plates on the forward clutch hub. Then proceed to check the hub protru s ion above the
clutch plates. Refer to "C lutch Hub Shims" below. After the hub protrusion a nd shims r eo
quired has been determined, remove the ten clutch plates a nd proceed with the assembly.
2. Clutch pla te wavy spring (Free height of .1285"). Insta ll the first wavy spring so the tang
engages the two roll pins (one tooth apa r t) in the clutch hUb. The c lutch hub must be marked
at this point and a lso at a second point located five gear teeth away.
3. Sintered driven plate.
4. Steel drive plate.
5. Clutch plate wavy spring. Install the second wavy spring with the tang rotated five gear teeth
from the tang of the first wavy spri ng (2). The second spring ta ng would the n line up with the
second mark on the hub. Proceed to install one sintered plate, one steel plate a nd one spring
(alternating the spring tangs between c lutch hub ma r ks) in this order until a total of fi ve each
have been installed.
6. Forward hub shi ms. Install the correc t number of shims as de termined by the hub protrusion
explained below.
Install two c lamps and compress the clutch plates a nd springs down onto the clutch flange
until four A43071 Special Tool clips can be installed, Inset D. Clips are a vailable from Case
Service Parts Supply. Proceed to press the forward clutch pack onto the shaft until the for ·
ward clutch pack contac ts the shims a nd carrie r assembly. Then re move the clips.
8. Locknut, tighten securely. Bend one of the lockwasher tabs into one of the grooves on the locknut.

ICLUTCH HUB SHIMS

After the specified number of clutch plates have been installed on the c lutch hub, insta ll two
clamps, Inset A. Tighte n the clamps until the plates are firmly compressed. Make sure the
clutch plate teeth engage the teet h on the clu tch hub , Inset A.
Usi ng a two inch micrometer, measure the height of the clutch hub and fla nge, Inset B. Then
measure the compressed height of the clutcb plates and flange, Inset C.

Example:

Measurement over clutch

hub and flange Inset B . . . . _ _ _ _ 1.158"

Subtract measurement over compressed

dutch plates and flange Inset C _ ,__ 1.07'2'1

The difference in measurement is __ _ _ _ .086"

the amount 'he hub protrudes
above the clutch plates.
Required clutch piston trovel
(eliminate clutch plate drag) _ _ .095" to .115"

Subtract hub protrusion

above plates _ _ _ _ _ _ _ _ .086" .0 86"

Shims required _ _ _ _ _ Min .. 0 09" to .0'29" Max .

It is recommended that an average

between these two figures be _ _ _ ,019" average PLATES CLAMPED TOGETHER
used when installing shims,
WITHOUT SPRINGS IN PIACl::
 63-7

MEASUREMENT OVER
PLATES ANO FLANGE

Figure 3
63-8

FORWAR D-REVERSE CLUTCH DRUMS

(Refer to Figure 4)

Lubricate parts with Case TCH oil as they are assembled.

1. Thrust washer (2" 1.0.).

2. Thrust bearing (2" 1.0.).
3. Thrust washer (2" 1.0.).
4. Forward clutch drum and gear assembly (line up tabs of sintered plates).
5. Forward-Reverse clutches and shaft assembly.
6. Thrust washer (2-118" 1.0 .) .
7. Thrust bearing (2 -1 / 8" 1.0.).
8. Thrust washer (2-1/8" 1.0 .) .
9. Reverse clutch drum and gear assembly (line up tabs of sintered plates).
10. Roller bearing.
11. Thrust washer (2-1/8" 1.0.).
12. Thrust bearing (2-1 / 8" 1.0.).
13. Thrust washer (2-1/8" 1.0.).
14. Bearing, press into place until it just contacts thrust washer (13).
15. Hook type sealing rings, Inset A.
 63-9

INSET A

Figure 4
 Sec tion

6 4
HY DR OSTATIC DRIVE. GEAR T RAIN

AN D CO NTROL LINKAG E

TABLE OF CONTENTS
Hydrostatic Pump a nd Input Gear Train
Removal and Install ation .......... .. ..... .. ........................................................... .. ........ ....... .. ___ . 64·2
Di sassembly a nd Assembly ........ ... .... ................ ... ........... ..... .. ......... .... ..... .. .................. .... ... 64-4
Hydrostatic ;Vlotor . Mechanica l Disconnec t. Pinion Shaft ..... .. ........ .. ... .. .. ................................ 64-6
Emergency Clutch Pedal Linkage ........... .......... ........................ ... .. ... .... ... ....... ... .. .. .. ... .. .. ........ 64-8
Speed Control Linka ge a nd :->eutral Cam .......... .... ...... .... ...... ........... .. .. .. .. .... .. ...... .... ..... .... ...... 64-9
Adjustments . ___ ........... . _.. .............. ... ..... ... ......... ...... ...... ....... _........ ..... ... ..... ....... ............. ..... .... 64-10
Press ure Checks ..... ............. _... .... ... _..... _....... ... ........................ ....... ............. ................... .... ... 64-13
Troub le Shooting .. _.. ............... ... ............... ... ...... ... ......... ... ..... ................... _... _.......... ... ......... . 64 -14

SPECIFICATION S
Hydrostatic Operat ing oi l pressures ......... .. .... .. ...... ............ .... ................. _...... Refer to Page 64-13
Forwa rd-Reverse pedals " Free Pedal" .... .... .. .. .................................... .. .................... 1/ 4" to 112"
Pinion s ha ft bearin g preload .......... ..... .. .. .............. ...... ... ............. .... 4 to 12 in . Ibs. rolling torque
Dump valve pad to lever clearance .. .... ........ .... ............................ .. ...... .. ........................... _... 045"
Ba njo fitting bol t on hydrosta tic pump ..... ...... .. .. ................ _....... .... ...................... 14 to 16 ft. Ibs.
Servo moun ti ng bolts .... .. ....... ................ ........ ...................................... .. .... .. ....... ... 18 to 21 ft. tbs.
Hydros tatic pump brac ket to housi ng bolts ...... ........................ .. ........................... 35 to 42 ft. Ibs .
Hydros ta tic pump mounting bolt s .......................................... ... ... ......... .... .. ....... ... 80 to 90 ft. Ibs.
Hydrostati c m otor m ounting bolts .... ..... .. .. ............................................................ 80 to 96 ft. Ibs.
Rae . Form 9 -80371

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64-2

HYDROSTATIC PUMP & INPUT GEAR TRAIN

(Refer to Figure 1)

Removal
Split the tractor between the flywheel Remove the HE" ring (14) and servo lever
housing and engine, refer to the splitting pin (15) to disconnect the servo lever from the
Section 92 . speed control spring box and the neutral cam
Remove the torque tube front cover (41), spring box.
rear cover (39) and front cover (48) with Support the torque tube from below and
gaskets . attach an overhead lifting clevice to the fl y -
Remove the link bolts (16), nuts (17), seal- wheel housing. Remove t he flywheel housing
ing washers (18), links (19), spacers (20), to torque tube bolts (47) with lockwasher.
spring washers (21), backup washers (22), Slowly work the flywheel housing (49) and
nylon seals (23) and metal seal retainers hydrostatic pump away from the torque tube
(24) . (44), being very careful not to bend t he oil
Disconnect the make-up pump pressure tube on the hydrostatic pump or the linkage
tube (6) , hydrostatic pump inlet hose (8) , inside the torque tube.
servo va lve tube (1) and suction tube (10) Remove banjo fitting bolt (29), sealing wash-
from the bulkhead fittings (40 ), (42 ) and (43) er (30), adapter union (.31), backup ring (:32),
inside the torque tube. Remove "0" rings "0" ring (33), banjo adapter (35), pump inlet
(4,7 and 9) . tube (34) and "0" rings (36) and (37).
Remove bolt (11) and suction tube clip (12)
at the bottom of the torque tube.

Installation
Assemble the inlet tube (34) and banjo Install the l ower link spacers (20), lower
adapter (35) with new "0" ring seals (36 & link (19), sealing washer (18) a nd bolts (16)
37) to the pump. Install backup ring (32) , from the bottom up. Install the upper link
"0" ring (33). sealing washer (30), adapter spacers (20), link (19), sealing washers (18 )
union (31) and bolt (29). With the pump swashed and lock nuts (17). Torque the nuts 70 to 80
against the stop, line up the banjo adapter 35) ft. Ibs. NOTE : Be sure that the seals are
and adapter union (31) as illustrated in Inset sea ted properly or damage to the links wiI!
A. Then tighten 14 to 16 ft. lbs. occur. Check to be sure that the pump and
Install the make-up pump pressure hose (8), motor swash freely after the link bolts are
hydrostatic pump inlet tube (6), servo valve torqued properly.
tube (1) and make-up pump suction tube (10) Install the servo lever pin (13) and "E"
with new '"0" r ings (4, 7 & 10). Lubricate ring (14). Install the suction tube c lip (12 ) and
a ll the "0" rIngs with lubriplate when re- bolt (11).
assembling. Apply Perma tex No. 3 to the thrcads of the
Install a new gasket (46) to the front of bulkhead fittings (40, 42 and 43).
torque tube (44) . Guide the flywheel housing Install the bulkhead fitting (40, 42, and 43)
and pump assembly into the torque tube. into torque tube. Screw connec tor (3) into
Install the flywheel housing to torque tube fitting (42) from inside the torque tube.
bolts (47) with lockwashers and tighten. Reconnect make-up pump pressure tube (6),
Tilt the hydrostatic pump and motor until pump inlet hose (8) , servo valve tube (1),
the lower link (19) can be installed without and suction tube (10) to the bulkhead fittings.
forcing into place. Install the torque tube fron cover (41),
Assemble into each link seal area spring rear cover (39) and lower cover (48 ) with
washer (21), backup washer (22 ) , inner sea l new gaskets .
(23) and seal retainer (24). Coat these parts
with lubricate as they are installed.
 "'

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FIIIU" 1
64-4

FLYWHEEl. HOUSING, INPUT GEAR TRAIN

AND HYDROSTATIC PUMP
(Refer to Figure 2)
Disassembly
Stand the flywheel housing (1) on its front Remove the idler gear (14), pump input gear
flange for disassembly. Remove the "E" (15) and thrust washers (16). Remove the needle
rings (2), servo lever pivot pin (3), servo leve r bearings (~O) and seal (18) from the flywheel
(27) and mounting bolts (4) from the hydro- housing (1) . Press the needle bearing (19) from
static pump, Inset A. Remove the hydrostatic the idler sear (14).
pump input drIve shaft (5 ) and coupling (6) with
snap ring . If the idler gear shaft (21) is worn and must
be replaced, it will have to be pulled from the
Unbolt pump bracket (9) and remove from flywheel housing. The idler shaft (21) cannot
flywheel housing (1 ) . Remove the snap ring be turned as a ball (22) is used in a groove, to
(10) that retains the input drive gear shaft keep the shaft (21) from turning.
(11) to the r ea r bearing (12 ) a nd remove the
shaft (11 ). Remove the bolts (23) with Iockwashers that
retain the servo cylinder (24) to the bracke t
Remove real' bearing i'Qtalnl>r snap rings (9), Remove the cylinder (24 ), gaskets (25) and
(13) and press out the bearings (12 and 17). servo body (26) from bracket (9) , Inset B.

Assembly
Install new needle be arings (17 and 20) using and place on each side of the moun ting bracket
drive rs A9817 and G15042 on the numbered (9). Make sure the four bolt holes and one oil
sid e of the be arings, to a depth of .010 to .060 hole line up. Install the servo body (26) into
inch into the pump bracket (9 ) and flywhe el the bracket (9 ). iVlake sut'e the holes line up.
housing (1) . Install needle bearing (19) using Lightly oil the servo piston. Compre ss the
driver GI5042 into the idler ge a r (14) so it is piston ring and slide the cylinder (24) over the
recessed .010 to .020 inch on both sid es . pL<ton . Again make sure the holes line up.
Install the bolts (23 ) with loc kwashers, Inset B.
Install the idler gear shaft (21) with a new Tighten in a diagonal sequ ence 18 to 21 ft. Jbs .
steel ball (22) into the flywhee l housing (1)
un til it bottoms. Lubricate the seal lip (18) and input sha ft.
Stand the flywhe el housing (1 ) on its front flange.
Install a new oil seal (18) with the lip in- Assemble the pump bracket (9) to the flywheel
ward. using drive r G15042, into the flywheel housing, engaging the two dowel pins. Retain
housing (1) until it jus t seats against the in place with four bolts. Torque 35 to 42 ft.
chamfer at the bottom of the bore . Ibs. Install the cup plug (7) into the rear bore
of the idler shaft (17) until it just seats.
Press in the rear input shaH bearing (12)
and install two inte rnal snap rings (13) into Install the hydrostatic pump drive coupling
the bracke t (9). Install the input drive gear (6) with snap ring and input drive shaft (5).
shaft (11) through rear bearing (12) and r e- Lowe r the pump down onto the mounting bracket
tain in place with snap ring (10). while engaging the input shaft Spline and the two
dowel pins. Retain in place wIth four bolts (4).
Assemble the pump input gcar (15), idler Torque 80 to 90 ft. Ibs. Reconnect the servo
gear (14) and thrust washe rs (16) . Grease the lever (27) with pin (3) and "E" rings (2).
thrust washers to retain them in position,
so the tabs enga ge the recesses in the housing Lubricate the front spline (11) and the mating
and bracket. coupling on the flywheel with molydisulfide
grease.
Grease the servo mounting gaskets (25)
 64-~

INSET B

15

INSET A 7'0 n f"1

,/ ,

A9B17

G15042

Figure 2
 64-6

HYDROSTATIC MOTOR, MECH . DISCONNECT

AND PINION SHAFT
(Refer to Figure 3)
Removal
Remove the two uppe r pump mounting bolts Slide the sleeve (20) forward and remove the
(30) and install two 1/2" x 4" studs (29). Re· yoke fingers (12). Loosen and remove the
move the two lower mounting bolts. Install pinion shaft nut (21) and output gear hub (22).
the locking bolt (31) (3 /8" x 1" Ui\'F hex. hd. )
into the trunnion mounting (32 ) of the motor. Loosen or remove the right hand brake
Be sure the locking bolt engages the tilting cover and differentia l lock so tha t ring gear
head yoke (33) which should be at 0" tilt and center wheel can be moved to the right.
angle. Work the motor forward until it is This will allow the pinion shaft (35) to be
free from the transmission case. moved rearward enough so that the rear snap
ring (27) on the pinion shaft bearing cup can
Remove the snap ring (19) and output gear be removed_ Remove t.he pinion shaft a nd
sleeve (18) from the motor. Drive out the bearings forward a nd out the case. Remove
roll pin ( !O ) that retains the disconnect yoke the bearing cones (23 & 28) and cups (25 & 26) if
(9) to the shaft. Pull tbe shaft (4 ) s ideways they are worn or pitted.
out of the yoke (9) and remove key (11).

Installation
Press !.be rear bearing c one (28) with cup Install the out.put sleeve (18) onto the motor
(26) onto the pinion shaft as far as it will go. and r e tain with snap ring (19) . Install a new "0"
Install this assembly in throug h the front of ring (34 ) into the groove on the motor mounting.
!.be case until the rear bearing snap ring (27) Lubricate the " 0" ring and leading chamfer
can be installed. of the motor with lubriplate or e quivalent. Slide
the motor into the case . Coat the threads of
Install the front bearing cone (23) and cup the bolts (30) with permatex and install to re-
(25) with snap ring (24) onto the pinion shaft tain motor. Remove the pilot studs as the bolts
part way. Ins tall the output hub (22) and pinion are installed. Torque the bolts 80 to 96 ft. Ibs_
s haft nut (21). Tighten the nut until the bear- Remove the locking (31) from the trunnion
Ing cups and cones have seated properly. pivot.
Adju st the nut (21) for a preloa d of 4 to 12
inch. Ibs. of rolling torque on the pinion Check the mecha nical disconnect for pro·
shaft. Press the thin section of the nut into per adjustment by moving the control le ver
both slots on the pinion sha ft. Install and (4) to the disengage position. The sliding
tighten the right hand brake cover . Check sleeve (20) must be rearward and completely
the pinion to ring gear backlas h, refe r to free of the m otor output sleeve (18). Loosen
the Transmission Secti on "65" of this service the hand lever detent mounting bolts (1 ) and
manual. Install yoke finge rs (12) and sliding move the detent bracket (7) rearward until
sleeve whlle e ngaging the yoke fingers onto the sliding sleeve is free of the motor output
the output gear hub (2 2). Install shaft (4) with sleeve. Then retighten the deten t brac ket
key (11 ) and line up the hole in the yoke (9) bolts (1) 17 to 21 ft. Ibs.
and sha ft. Insta ll new roll pin (10).
 01 -7

L:::::~--~FigUre 3
64-8

EMERGENCY CLUTCH PEDAL LINKAGE

SAFETY START SWITCH

~/
,

..
o I
i I
I
J
<!,

DUMP CONTROL
D
CROSS SHAFT

Figure 4
 ".,
-_._--
SPEED CONTROL LINKAGE AND NEUTRAL CAM

,,
,

>---...- •.•-._-
64·10

ADJUSTMENTS
These a dju stm e nts mu st be m ade in the With the hydrostatic housing d ra ined , reo
ord",r in which they are numbered. The speed move the lower cover from the housing. Check
control rod , clu tch peda l rod a nd control rods the clearance between the clutch d ump va lve
for the forward· reverse peda ls disconnected, pad (8) a nd lever (9) , Figure 8.
Figu re 6.

Isp~ r hCONTROL R,?£....)

'/ • CLUTCH PEDAL ROO

r3~~
Figure 8
Adjust the clear ance to . O ~5" by turning the
pad in or out. Tighten locknut (10 ) after adjust·
m ent is m ade . Rein stall the lower housi ng cover
a nd gasket a nd fill the hydrOS ta tic housing to
the proper oil level as indica ted by th e d ip.
Figure 6 s tick with Case TCH oil. Install the speed
cont rol lever (2) with key a nd reta in with " B"
1. EMERGENCY CLUTCH PEDAL LINKAGE ring (1), Refer to Figure 7.
Remove the "E" ring (I ), speed control lever
(2) and key from the left e nd of the speed can· 2. NEUTRAL CAM Jack up tractor so
trol shaft (3), Figure 7. Install the adjusting rear wheels ate off the ground. Sta rt and run
gauge A43615 over the speed control shaft. the engine at 1500 RPM. Loosen the cam
Move the clutch lever (4) upwa rd a bout 15° and mounting bolts (11), Figure 9 and rotate the
ins tall the adjus ting pin A4 3614 through the ca m (12) clock\vise until the wheels just start
clutch leve r (4) a nd adjus ting gauge . Refer to to turn, m a rk the ca m (12) and hous ing.
P age 64·12 for illu s tratio n of adjusting tools .

Figure 9
Ro tate the cam (12) counter-clockw ise from
the m a r k until the whe Is s top a nd Jus t start to
turn In the opposite di rection. Ma rk the housing
next to the mark on the ca m (12 ). The ca m ca n
now be turned clockwise to a poin t mid way be·
tween these two marks . This will be the neut ral
poSition, tighten the cam mou nting bolt s (11 )
Figure 7 wh ile holding cam (12) in thi s position. Sto p
Adjust the clutc h pedal s top screw (5) so the engine.
it protrudes 1/ 4" upwa rds. Shorten or lengthen
the clutch peda l rod (6) until the lower yoke (7 )
lines up with the a djusting pin A43614.
 64-11

ADJUSTMENTS (Cont'd)
3 . HAN D LEVER SPEE D CO NTROL With the clevis (2) on or off the rod (3) until the clevis
hand speed control rod disconnE'Cted , ad- pin can be Installed without moving the hand
just the hand lever speed control friction disc speed lever or speed control lever (1), Figure
(6), Figure la, remove the inspection cover (7) 11,tlghtenthelocknut (4).
on the steering column. Adjust the locknut (8)
4. FORWARD-REVERSE PEDA LS The re-
verse pedal rod (11) should be adjusted to
10-5/16" between the center of the clevis pin
holes . Then connect thIs reverse pedal rod
(11) to the upper lever (12) on the forward-
reverse cross shaft, Figure 12.

Figure 12
Figure 10
The forward pedal rod (13) should be adjusted
untIl It takes 10 to 15 Ibs. pull at the end of to 10-11116" between the center of the clevis
the hand lever before the lever moves. Then pin holes. Then connect this forward pedal rod
tighten jam nut (9) whUe holding the locknut (13) to the lower lever (14) on the forward-
(8). Install inspection cover (7). reverse cross Shaft, Figure 12. Tighten jam
nuts (15 ). The forward-reverse levers on the
cross shaft should be in a neutral positlon when
rods are adjusted.

Adjust the set screws (16) in the foot pedal

support so pedal free travel is 1/ 4"' to 1/2 ".

NOTE: The pedal pivot bearings should be

lubricated with grease.

Figure 1 1
Move the hand lever to the neutral position.
The speed control lever (1) Is in a neutral posi-
tlon from the neutral cam adjustment. Turn the
64·12
ADJUSTMENTS (Cont'd)
6. SAFETY START SWITCH ON CLUTCH 6. NEUTRAL START SWITCH 0 111 HYD RO-
PEDAL LI NKAGE Jack up the tractor so STATIC PUMP Jack up the tractor so the
the rear wheels are off the ground. Connect rear wheels are off the g round. Connect an Ohm
an Ohm meter across the safe ty start switch meter across the neutral start switc h (4) ter·
(1) te rminals on the hydrostatic housing rear mlnals on the hydrostatic housing front cover,
cover, Figure 13. Start the trac tor and run Figure 14. Start the engine and run a t low idle
in slow forward while lightly pressing brake speed. Slowly move the hand s peed control into
pedals. While holding this condition press the forward then back to neutral a nd into reverse.
emergency clutCh pedal slowly until the wheels The Ohm meter should indicate when the switch
stop turning, indicating that the Hydros tatic (4) is closed. At this time the pump should be
drive has been dumped . Continue pressing on in a neutral position and the rear wheels should
the e mergency c lutch pedal until the switch not turn.
(I) closes as indicated by the Ohm m e ter.

Figure 14
Figure 13 If the wheels do turn add sh ims (3) betwee n
the switch (4) and cove r, until the switch is
If the switch (1) closes before the wheels ope n.
s top, add s hims (2) be tween the switch (I) and
cover, Figure 13. Rechec k for proper adjust· If the switch does not close and the wheels
m ent each time shims are added. stop turning , it will require removal of shims
(3) between the switch (4) and cover.
If the switch (1) does not close after the
wheels stop and the pedal is pressed as far
as it will go, remove shims (2 ) from between
the switch (I) and cover and recheck for prope r
adjustment. ADJUSTING TOOLS
f3"

1 12'·

1 / 2 " DIA .
 64-13

PRESSURE CHECKS
A press ure g auge is loca ted in the Instru- nOO
Insta ll the tes t pressu re g auge PSI), Case
m ent panel to show the m a ke -up oil p ressure No. A20l72. J a ck up the tractor rea r wheels .
In forward, neutra l and r ever se _ The gr een Start the e ng ine a nd run a t low idle speed (650
zone of the ga uge r a nges from 75 PSI to 300 RPM ) and in neutr al until the hyd r ostatic drive
PSL When a m or e accurat e pressure check oil is up to ope rating tempera ture (1l()<J-1400F.)_
is r equired or the gauge is in ques tion. Dis-
connec t the gauge tube a nd fitting from the filter
return tube tee.

F igure 15

Norm a l Ope rating Oil Pressures The ne utral and r eve rse pressure r eading
H an d s hould show a min im um of 150 PS I.
Lever Engi ne RPM
P osition Operate the trac tor in fo r wa r d a nd the pres-
650 1500 2000
s ure reading s hould show a m inim um of 75 PSI.
Neutral 225-255 PSI 235-265 PSI 240-270 P SI If th e press ure is low in all three cond itions
125-1 55 PSI 135-165 PSI 135-165 PSI it is ver y possible tha t thE' oil filt er elemen t
F orward
is sta rting to plug up.
Reverse 215-245 PSI 235-265 PSI 235-265 PSI

LOAD CHECK
Load the Hydrostatlc d r ive, firs t in forward The r esult of this s hould be a ri se in ma ln
and then in rever se drive by pos itioning the pressure to the relief va lve se tting, ti re slip
front, or r ear, wheel s aga inst a s tout obs tacle may occur be for e thi s pressu r e is rea ched .
a nd applying the brakes a nd c a refully e asing However, the fact th a t m ain pressu re increases
the speed control out of ne ut ral in the appropri- up to the onset of tir e slip is su fficient indi-
a te direction. ca tion of satisfac tory ope r a tio n unde r load.
64-14

T ROUBLE SHOOTING H YDROSTATIC DRIVE

Indication Caule Remedy

1. Low make-up oil pressure (a) Leakage in external cir- Check filter , cooler, tubing
cuits. and hoses for leakage.

(b) Low pressure spill valve Renew the hydrostatic drive

or make-up oil pump re- unit.
lief valve stuck open,

(c) Plugged filter element. Replace the fil ter element.

Inspect the old filter element
for signs of excessive bronze
or brass particles. This could
be an indication that a failure
of the hydrostatic pump or
motor has or is about to take
place.

(d) Excessive internal leak- Refer to (4) and (5).

age.

2. Drive continues with emer- Clutch pedal linkage and Check and adjust.
gency clutch pedal depres- dump valve incorrectly
sed. adjusted.

,3. No drive in Forward or Clutch pedal linkage and Check and adjust.
Reverse and make-up dump valve Incorrectly
pressure correct. adjusted.

4. Drive fails under load Leakage from link seals Renew the four link seal
in one direction only: on high pressure link. assem blies on the link tha t
possibly accompanied by should be at high pressure
a fall in make-up oil in the failed direction of
pressure. drive.

5. Drive fails under load Excessive High Pressure (a) Check that the connecting
in both directions: possibly leakage In the hydrostatic link seals are assembled
accompanied by a fall in pump or motor unit. correctly.
make-up oil pressure.

6. Vehicle creeps forward Servo pilot valve not in Adjust the neutral cam and
or rearwards, with speed neutral. speed control linkage.
controls in the neutral or
zero-speed position.
 Section

65
FOUR SPEED TRANSMISS ION
AND FINAL DRIVE

TA BLE OF CONTE N TS
Specifications ............... ...... ... ................ ................................. ................................... .... ........... 65·2
Speciai torques ............... ................ ...... .. ................. .. .... .. ..... .. ....... ............. .. ........................... 65-2
Power Trains
Eight speed dual range ...................... .......................... ...... .. ................ .. ..................... .. ....... 65·3
Eight speed shuttle .......................... ... ............. .. .................................. .. ..... .. ........... .. .......... 65·4
Four speed shuttle ........................................... .... .................. .............. .. ............... .. ............. 65·5
Power shuttle·torque conve rter ............................................................. .............. .. ............... 65·6
General Inspection ........................................................... .. .................... .. .......... ............. .. ...... 65·7
Generai assembiy ......... ............................................... .. ................... .... ... .... .. ........ .. .. .. ............ 65·7
Shifting Sequence ............................... .. ............. ................................... .. ......... .. ..... .. ............... 65·7
Transmission housing ........ .................... .. ............................... .. ................................. .. ............ 65·8
Pinion shaft ................................................................... ........................................................ 65·10
Reverse idier gear (not used with shuttle) .................... .. ........... .. ....... .. ................................ 65·12
Diiferential ... ................................................ .. ............. ........ .. .................. .. .............. ......... ..... 65·14
Main drive shaft ................. .. ........................................ .. .... .. .............................. .. ................. 65·18
Flanged axle ......... .. ..... .. ........................ .................................... ... ........... .. ...... .. ....... .. .... ....... 65·20
Keyed axle .......................... .. ........................ ........ .. .... ................... .. .............. .. .... .. ......... .. ..... 65·22
Gear shift cover ............ .... ....................................... ....................................... .. .................... 65·24
Adjustments ....................................... ........................................ .. ...................... .. ... ............... 65·30

Rae. Form 9·80641

65·2

SPECIFICATIONS

Pinion shaft, 2nd to 3rd gear hub clearance ., ............................................... " .......... 00l" to .006"

Pinion shaft bearing pre-Ioaa (turning torque) ...................... " ............................. 4 to 12 In. Lbs.

Reverse Idler gear bushing diameter ................ ,....................................................... 862" to .863"

Malnshaft bearing end play ....................................................................................... 002" to .005"

Differential pinion to side gear backlash ................................................................... 005" to .015"

Differential bearing pre-load (turning torque) ......................................................... 3 to 8 it Ibs.

Differential ring gear to counter·shaft pinion backlash ............................................. 005" to .009"

Rear axle bearing preload ...... .,., ............. 20 to 30 inch Ibs.rnore than the no load turning torque
Special
Transmission to torque tube bolts ........................................ " ............................. 80 to 132 ft. Ibs.

Transmission to torque tube nuts ...................... ., ............................................... 110 to 132 it Ibs.

Transmission front cover bolts or nuts ................................................................. 35 to 42 ft. Ibs.

Brake housing and carrier bolts and nuts .................. ., ......................................... 70 to 90 ft. Ibs.

Axle housing mounting bolts or nuts ................................................. ., ............... 150 to 190 ft Ibs.

Rear wheel hub clamping bolts .......................................................................... 270 to :i20 ft. Ibs.
EIGHT SPEED DUAL RANGE

f ill"". 1
EIGHT SPEED SHunLE
FOUR SPEED SHUTTLE
POWER SHUTTLE_TORQUE CONVERTER

Figur. 4
 65-7

General Inspection
A thorough visual inspection of all the parts should be made when disassembled, Any parts that show
excessive wear 01' damage must be replaced, Small nicks or grooves can be removed in most cases
with a hone or crocus cloth,

OIL SEALS, "0" RINGS AND GASKETS. When installing any part or parts in the transmission,
always install new gaskets, oil seals and "0" rings,

BEARINGS, CUPS AND CONES - Check bearing for free smooth action, If bearings have loose fit or
rough action, replace the bearings, Always replace cup and cone as a set - never just one part of a
bearing, Wash bearings with a good solvent and let air dry, DO NOT SPIN DRY,

FORKS, SHAFTS AND GEARS - Inspect for cracks, nicks, burrs or excessive wear, Replace those
parts where these conditions exist.

LUBRICATION - Lubricate all oil seals, "0" rings with lubriplate and bearings wi th EP90 gear lub,
When assembling,
General A ssembly
Tapered bearing cups can be chilled to facilitate installation when a press fit into a bore is re-
quired,

Tapered bearing cones can be heated in oil (250"F, ) to facilitate installation when a press fit
on a shaft is required,

Shifting Sequence
The gear shift lever allows the operator to manually select four gear speeds forward and
one gear speed in reve rse without shuttle or four gear speeds in reverse with shuttle,

The range shift lever allows the operator to manually select two range speeds forward and
two range speeds in reverse,

WITH WITHOUT
SHUTTLE SHUTTLE
FORWAR D GEAR SPEEDS 4 4
FO RWARD RANG E SPEEDS x2 x2
TOTAL FO RWARD SPEEDS 8 8

REV ERS E GEAR SPEEDS 4 1

REV ERS E RANGE SPEEDS x2 x2
TOTAL REVERSE SPEEDS 8 2
65-8

TRANSMISSION HOUSING
(Refer to Figure 5)
IMPORTANT If equipped with Draft-O- 3_lt equipped with dipstick extension tube (6),
Matic housing, Inset A, the plastic or rubber apply Locktite Sealant, Case Part No.
drain tube will have to be disconnected and B17068 to threads. Install a new gasket
pushed part ways into rear housing before (7).
the Draft-O-Matic housing can be removed .
4. Transmission case rear covers (8 and 9)
1. Torque tube to transmission case bolts are used without P.T.O.
(1) with lockwashers (2), tighten 80 to 132
{t. Ibs. 5. Plug (10) is used without Draft-O-Matic.

2. Torque tube to transmission case studs (3) 6. Front cover to transmission case studs (11)
with lockwashers (4) and nuts (5), tighten with lockwashers (12) and nuts (13), tighten
110 to 132 ft. Ibs. Coat internal threads of 35 to 42 ft. lbs.
stud thru holes with Permatex #3.

INSET A
TUBE

r. _ _________
~
 65-9

,
,

EDAXLE
CASE USED WITH
FLAN G

o WITH
CA~~y~tE AXLE

Figure 5
 65· 10

PINION SHAFT
(Refer to Figure 6)
IMPORT.4.NT Before dis a ssemb ling the pinion shaft assembly. us e a feel I' gauge to check the
clea ra nce be tween the gear hubs of the 3rd and 2nd gear. Record this informa tion for use whe n the
pinion shaft is ins talled . To m eas ure this clearance, do not mere ly tilt the gears on the s p line but
use two screwd r ivers to spread th e gears. (See Inset Ai. Use a microme ter to check the hub thi ck -
ness of a ny new pa r ts to be installed and a lso of the corresponding replaced parts . E stablish the
total d iffere nce in hub th ickness be tween ne w a nd replaced parts. If the spacf' betwee n the gears
was c hecked befo re rem OVing the p inion shaft, you can now determin e whether or not a spacer (16 )
of differe nt thic kness is r eq uired .
A.Whe n the to tal thickness of the new parts is less than the total thicknes s of the replaced parts ,
add the diffe rence In thickness to the clea rance figure obtained, before disassembly of the pinion
sha ft assembly, between the 3rd speed & 2nd speed gear hubs. If the sum of these two figures ex-
ceeds .006", a thic ker spacer d6) must be used.
B. When the IOtal thickness of the new parts is greater than the to tal thickness of the replaced
parts, subtrac t the difference in thickness fro m the clearance figure obta ined befor e disassembly
0 f the pinion shaft assembly . between the 3r d speed & 2nd speed gea r hubs . A result of less than
.001" indicates that a thInner spacer (16) must be used.

The c leara nce between gears shou ld not exceed .006" and must neve r be less than .001" . Selec -
tive spac er s (16) are furnished In increm ents at .005", ranging from .164 " to .244" . (See Inset B).

After detennining the s pacer req uired, proceed to reassemble the pinion shaft assembly.

1. P ress ['ea r bearing cup (1) a nd sna p ring (2) Tap both ends of the pinion shaft with a
into the transmission case (3) until the s n3p rawhide or plastic head ha mmer to help
r ing (2) is sE'ated sea t the bea rings, the n recheck the rolling
torque.
2 . Install the fron t bear ing cup snap r lhg (4 )
into the transmission case ( 3) . P r ess front NOTE Do not confuse torque requi red to
bearing c up 15) into the transmission case turn the co unters ha ft with the torque generally
(3) un til c up (5 ) sea ts aga ins t the snap ring (4 ). spec ified to tighte n a nut. In this case , the nut
is tightened to a n arb itrary ti ghtness with an
3. Heat rear bea rin g cone (6) in ho t o il (20()!lF .) ordinary socket wrench and the torque wrench
and slide it down over p inion shaft (7) until is then a pplied to de term ine th e torque re-
contact is made with the pi nion gear end of quired to turn the shaft. The ordioary socket
the sh aft (7) . ca n then be use d to tlghten or loosen the nut
until a correct reading is obtained when ap-
4. In sta ll pinion sh aft ( 7) Witll cone (6) into the plying the torque wrench.
transmission case (:J) .
7. The gears on the countershaft mu st be so
5. From in Side the transm ission case (3), in· shImmed as to have a n end play of .001" to
sta ll onto the pi nion shaft (T ) the following, .006" as measured by a feeler g auge betwee n
in pro per sequenc e : 1st speed gear (8), spacer the 2nd speed and 3rd speed gears. This en d
(9) , 2nd speed gear (101. 3rd speed gear (111. play must exist with the beari ng pre loa d pro-
Dll slinge r gear (12 ). reta ini ng washer (131, perly set. End play is a d justed by Ibe selec-
spacer 114). 4.th speed gear (151 an d selec tive tive spacer washer insta lle d be twee n the 4th
space r (16 ) which was predetermined before speed gear and the tapered bearing cone.
assembly was sta rted .
8. AftE'r the! countershaft is corrected Insta lled,
6. Press th e front bearing cone (17) on the the thin section of the adj usting nut should be
shaft (7 ) a nd install adjusting nut (18). Th e peened into both slots on the countershaft to
counters haft bearings should be preloaded lock it in place.
such tlla t a torque of 4 to 12 inc h pounds is
required to turn the pinion shaft assembly ,
Inse t c.
 65·11

INSET C

POU N DSr:lr:lc
~EQUIRED <::? ~
TO 12 INCH TU RN SHA FT
TO
'l

I') ,;9
I')
C
<::?
&

INSET B

FRONT .

Figure 6
 REVERSE IDLER GEAR
NOT USED WITH SHUTTLE TRANSMISSION
(Refer to Figure 7 )

1.Inspect t h e copper lined bushing (1) in the 4. Install shaft (3) and gear assembly (1and 2 )
gear assembly ( 2 ) and replace if necessary. in proper position in transmission case,

2. Bushing is pressed into position and bur- 5.Install set screw (4) with lockwasher (5) and
nished to -862"-.863" inside diameter. The locknut (6) into transmission case. Tighten
notched end of the bushing projects 1/16" set screw ( 4 ) and lock securely with locknut
beyond the outside face of the gear. (See (6).
Inset A ! .
IMPORTANT Note the groove in shaft (3)
3. When installed, the lead of the spirol oil into which the set screw ( 4 ) fits. This set
groove in the bushing must be in the samc screw ( 4 ) , when installed, must seat in the
direction a s the gear operates, which is shaft groove and be securely locked in place
clockwise when viewed from rear of trans- with the jam nut to prevent any movement
mission case. of the reverse idler gear shaft ( 3 ) - Con-
siderable damage to the transmission could
be caused by having this shaft ( 3 ) slipping out
of position.
 65·13

INSET A

Fio'u.'" 7
65-1-1 DIFFERENTIAL
(Refer to Figure 8)
1. Pinions (1) are not provided with bushings, 6, Install the differential shaft (4) and center
Inspect bore for out-aI-round and check wheel (5) with the proper sintered iron thrust
surfaces for rough s pots, Replace pinions if washers (9) and steel shim washers (10) on
worn, damaged o r pitted, each side of the center wheel (5), into the
transmission case, NOTE Coat both ends
2, Insta ll pinions ( 1) and pins (2) and secure of shaft (4) and both faces of washers (9 and
in position with roll pins (3 ) , 10) with "Molylube",

3, Press differentia l s haft (4) into the center 7. Press new bearings (14) onto side gears (6)
wheel (5) from the back side of the ring gear. until they bot to m. Install the side gears (6)
Shoulder on the shaft (4) should bottom on the onto the differential shaft (4)on each side of
shoulder in the center wheel (5), See Inset A the center wheel (5).
for proper positioning on all hydrostatic
models and forklifts without hydrostatic, 8, Press new bearing cups (15) into carriers
(16) until they bottom, Inset E.
4, Side gE'ars (6) are provided with an expansion
plug (7) to prevent the transfer of lubrication 9. Press new oiI seals (17) into carriers (16)
into the brake assemblies, If oil leaks are using driVE'r GI0516, Inset F,
detected, the plug must be replaced, Install
cup plug (7) as shown in rear counterbore 10, Install the same number of shims (18) or
of side gear (6), Inset B. Coat bore with more that were removed onto the carrier
Permatex "1. Do not dilute prior to instal- (16), Make sure enough shims are installed
lation of cup plug, Bore must be clean and to gIve some ring gear to pinion gear back-
oil free prior to sealant application, Make lash, Carrier "0" ring (19) must be left off
certain plug (7) bottoms against shoulder of at this time so as to avoid damage during
gear (6), differential bearing pre-load.

NOTE Tractors equipped with a diffE'ren- 11, LubrIcate outside of G13503 sleeve, Inset
tiallock do not use a plug in the right hand G, and also the inside of the carrier oil
side gear (8), Insets C and 0, seal (16) with "Molylube",

NOTE On tractors equipped with differential 12, Slide wIde end of sleeve GI3503. Inset G,
lock, insets C & 0, press in bushing (11) until over the side gear (6). Slide carrier assem-
the outer edge is even with the shoulder or bly with s hims over the sleeve G13503 and
step in the side gear, Press in two new seals onto the side gear and at t he same ti me
( 12) with the lips inward until the inner one
pulling sleeve G13503 out through the car-
just bottoms on the shoulder or stEeP in the rier assembly,
side gear. Be careful not to damage the new
seals when passing over the splined shaft (13), 13. Install screw (20) locking bearing carrier
(16) to transmission case. Use existing
brake cover hardware to further secure
5, Install the same size thrust washer (9), shim bearing carrier (16) to transmission case.
washers (10) that were removed and side gear Spacers must be used to adjust for the
(6) on the differential shaft (4),
missing brake covers. Torque nuts & bolts
70 to 90 ft. Ibs.
IMPORTANT For differential CE'nter whE'el
to side gear shim adjustmE'nt, refer to Adjust- As an alternative, 1" long bolts can be
ments on Page 65-30, Alter proper backlash used for securemen t.
is reached on one side of th center whE'el,
remove side gear and turn differential over
& check the backlash on the other s ide of the
center wheeL
 G5 ·15

INSET A INSET F

~
19

141{)

INSET B :C:y

INSET E 19

WIT! H DIFFERE
- NTlAL LOCK

INSET G

G 13503 SLEEVE
WITH DIFFERENTIAL l OCK

Figure 8
6.5·16

DIFF ERENTIAL (CONT' D.)

(Refer to Figure 9)
14. With the carrier bolts & nuts properly tor· 17. Install new "0" ring (19)to each differential
qued, adjust the differential gear bearings bearing carrier (16).
for correct pre· load. Refer to Page 65·30 for
Differential Bearing Pre· Load Adjustment. 18. Reinstall differential bearing carrier (16)
using again the s leeve G13503 on the side
15. Adjust the ring gear and countershaft pinion gear spline to avoid damage to the oil seal
backlash. NOTE The differential shaft bear· (17). Work the bearing carrier (16) into
ing and the countershaft bearing pre· loads place by hand. Do not pull it into position
must be adjusted before the ring gear & using bolts or damage to the "0" ring
countershaft pinion backlash can be deter- (19) could result.
mined .
19. Secure bearing carrier (16) to transmission
Refer to Page 65·30 for ring gear and case using screw (20) .
cou nter shaft pinion backlash.

16. After determining and installing the correct

amount of shims (18) to be used between the
differential bearing carrier (16) and the
transmission case, remove each differe n·
tial bearing carrier (16) using sleeve G13503,
Inset G, to avoid damage to the oil seal (17).

\
\
 65-17

INSET A
19

INSET E 19

INSET G

G 13503 SLEEVE
WITH DI FF ERENTI AL LOCK

Figure 9
65-18

MAIN DRIVE SHAFT

(Refer to Figure 10)

IIUPORTANT When disassembling the main seals (14) but without the new "0" ring (16)
drive sha ft the following steps should be ob- when equipped with dry c lutch drive. Install
served: the dual range housing & a new dry gasket.
a. Remove the rear oil seal housing feom th e Retain oil seal carrier (15) In dual range
mainshaft (with P .T.O.) using a suitable housing with snap ring (19) .
puller or the oiling cup (without P.O.O.), 10. Tap both ends of the shaft (5) lig htly with a
before removing the mainshafl. rawhide hammer. Rotate shaft several times
b. Place a G15012 spacer block between cluster and check for end play. Refer to Page 65-20
gea rs on the ma inshafl. (See Inset A). for main drIve shaft adjustments .
c. Install s tep plate adapter (1" to 1-1/ 4" Owa· 11. When adding or subtracting sh ims to ob-
to nna :\0. 630-3 against the rear of the main - ta in proper mainshaft adjustme nt on torque
shaft. converter drive, remove fro nt cover (13)
d. Place a rod against the end of the step plate with oil seals (14) and pilot collar (1l) using
adapter and deliver a sharp blow to the end sleeve G13501, Inset D.
of the rod with a lead or rawhide m allet. 12. When adding or subtracting shims to ob-
This will loosen the rear bearing cone from tain proper mainshaft adjustme nt on dry
the shaft and the front bea r ing cup from the clutch drive, remove dual range housing
case. The rear bearing cup is held in posi- and oil seal carrier (15) using G13501 sleeve,
tion with a snap ring and will I'pmain in case. Inset D.
Do not remove unless there are indic ations 13. ""'hen proper mainshaft adjustme nt Is reac h-
that replacement Is necessary. Slide the gears ed on the dry clutch drive option, Install a
from the shaft as the shaft is removed. ne w "0" ring (16) onto the oil seal carrier
(15) which was previously omitted when c heck-
1. If rear bearing cup (1) and s na p ring (2) Ing for end play.
were removed, install a new snap ring (2) 14. Whe n equipped with P.T.O., insert a new
into the transmission case (3). Press new wear sleeve (18) in Tool A43043, Inset E a nd
bearing cup (1) into transmission case (3) heat the tool and sleeve in oil 14()O to 160"
until sea ted aga inst snap ring (2). for ten minutes. Install the sleeve (18) onto
2. Press front bearing cone (4) on shaft (5). the mainshaft (5) by tapping on the tool until
3. Slide shaft (5) through bore of transmiss ion the tool bottoms on the mainshaft.
case and position gears (6 and 7) and rear 15. Insta ll needle bearing (19 ), preSSi ng on the
beari ng cone (8) on s haft as the shaft is numbe red edge of bearing into oil sea l hou-
moving into position. s ing (20). Press new oil sea ls (21 & 22) into
4. Press shaft (5) and rear bearing cone (8) the oil seal housing (20). Lubrica te the oil
Into position. sea ls (21 and 22) in the mainshatt rear 011
.5. Use a GI:l502 drive, Inset E, to install front sea l housing (20) with Lubriplate .
bearing cup (9). 16. Coat surface of rear oil seal housing (20).
6. Place the same number of shims (10) that Inset F, with bearing retainer Locktite-
were rp.moved onto the front end of the Case No. 345-34. Install the housing assem-
shaft (5). bly into the transmission case llsing Tool
7. Install new oil seals (14) in front cover (13) A43044, Inse t E. Install the housing until
or aU seal carrier (15) using GI5010 driver, It bottoms against the snap ring in the trans-
Inset C. mIssion case, Inset F.
8. Install pilot collar (11) and a dry new gasket 17. When equipped without P.T.O., install new
(12) onto shaft (5) when equipped with tor- cu p plug (23) using Permatex No.2 into shaft
que converter drive. Install cover (13) with (5) . Refer to Inset G for dimensions.
oil seals (14) ontoshait (5) using GI3501 sleeve, Press oiling cup (24) into mainshaft bore.
Inset D. IMPORTANT Insta ll oili ng cup (2.3) such
9. In sta ll oil seal carrier (15 ) w ith new oil that slots line up with cored 011 holes in bore.
 65-19

INSET A

G15012
SPACER

INSET B

G1 3502 DRIVER

INSET G
7 / 16" TO
15 / 32" -

INSET C INSET D

4 SPEED & G150:0 DRIVER G13501 SLEEVE

POWER SHUTTLE

Figure 10
65-20

MAIN DRIVE SHAFT (CONT'D)

MAIN DRIVE SHAFT END PLAY ADJUST MENT
(Refer to Figure 11)
1. Check shaft end play after the gasket (12) a nd 2. If shaft end play is too great, add shims (10)
front cover (13) or dual r a nge housing are between front cover pilot collar (11) or oil
a ssembled and a ll stud nuts a re torqued to seal carrie r (15) and bearing cup (10), Insets
35-40 ft. lbs. The mainshaft must be rota ted H and I.
to seat the ta pe red bearing before checking 3. If end play is insufficient, remove shims (10)
for e nd play_ When properly adjusted, there between front cover pilot collar (11) or oil
will be _002" to .005" end pl ay of the m a in- seal carrier (15) and bearing cup (10), Insets
sh aft. H and I.
 65-21

INSET H

Figure 11
 FLANGED AXLE
(Refer to F i g u r e 12)

1. Press inner bearing cup (1) and outer bear- Method A To check bearing preload when axle
ing cup ( 2 ) into axle housing ( 3 ) . housing is not assembled to transmission case.
2. Press inner oil seal ( 4 ) into axle housing (3) Loosen nut (11)so axle has slight end play (no
using driver G13504, Inset B. pre-load on bearings), Check the turning
3. Install outer oil seal ( 5 ) on axle shaft (6) torque created by the seal drag. Then tighten
using (215043 sleeve, Inset C, the nut (11)until the turning torque is 20 to 30
4. Press outer bearing (7) on axle shaft (6) until inch Ibs. more than the seal drag. Mark the
i t bottoms. nut in relation to the cotter pin hole and count
5. Slide sleeve G13.5OS, Inset D, over splined the number of threads exposed beyond the
end of axle shaft ( 6 ) . Place axle shift (6) nut.
in housing ( 3 ) and pull out sleeve after 9. Remove nut (11), washer (10) and drive gear
passing through inner oil seal ( 4 ) . Install (9).
inner bearing ( 8 ) , drive gear ( 9 ) , washer 10. Install new "0" ring (12) on axle housing
(10) and nut (11). (3) and reinstall flanged axle and axle hous-
IMPORTANT Position drive gear (9) so ing assembly into transmission case far
letters "NUT THIS SIDE" a r e facing to- enough to install final drive gear (9),
wards the adjusting nut (11). washer (10) and adjusting nut (11).
6. Position Case GI3505 Oil Seal Driver a s 11.Secure axle housing ( 3 ) to transmission
shown in Inset E, Hold in place with rub- housing with bolts (13) and lockwashers
ber bands. (14). Torque bolts 150 to 180 ft. Ibs. NOTE
7.Tighten nut (11) on axle shaft (6) and draw On Forklift models torque bolts 220 to
outer oil seal ( 5 ) in until i t is flush with 264 ft. lbs.
the end of the axle housing ( 3 ) , Inset A. 12. Retighten nut (11)on axle shaft (6 j to posi-
Remove oil seal driver. tion marked or noted in Method A.
&Tighten the nut (11) to seat the bearings Method B. To check the bearing preload with
and cups, loosen the nut until the axle shaft the axles, housings, drive gears and differ-
has slight end play (no bearing preload). ential installed, loosen the nut (11)until their
is slight end play of the axle (no preload on
NOTE There a r e two methods that can be bearings). Check the turning torque required
used to check the bearing preload. to turn the axle and differential. Then tighten
the nut (11) until the turning torque is 20
Method A is w i ~ hthe axle housing remove to 30 inch Ibs. greater the no load turning
from transmission case. torque.
Method B is with axle housing assembled
to the transmission case. 13. Install cotter pin (15) .
 65-23

'''~
INS ETC

@--
G15043 SLEEVE

G\ll",.{'' ----m~0 iJ
J

IN S ET 0

G 136 03 SLEEVE

INSET E
3505 DRIVER

SH
BAND

Figure 1 2
 KEYED AXLE
(Refer t o Figure 13)
1,Press outer bearing (1) onto axle shaft (2) 8.Install housing ( 5 ) with new "0" ring (15)
until it bottoms, Inset A, to transmission c a s e (7) using bolts (8) and
2, Press inner bearing c u p ( 3 ) and outer bear- lockwashers (9). Torque bolts 150 to 180
ing cup (4) into axle housing (5) until they ft. Ibs. NOTE On forklift tractors torque
bottom. bolts 220 to 264 ft. lbs.
3. Install axle shaft (2) into axle housing ( 5 ) . 9. Reinstall final drive g e a r (11), spacer (12),
4. Install outer oil seal (6) onto axle shaft washer (13) a n d nut (14).
(2) using GI5018 sleeve & GI502 driver, 10. Retighten nut (14) on axle shaft ( 2 ) to posi-
Insets B & C. tion marked o r noted in Method A.
5 . Install inner bearing ( l o ) , final drive g e a r
(11), (lettered side of gear. "NUT THIS Method B. To check the bearing preload with
SIDE", must face adjusting nut) spacer the axles, housings, drive g e a r s and diff-
(121, washer (13) and adjusting nut (14). erentlal installed, loosen the nut (11) until
6. Tighten the nut (14) to seat the bearings their is slight end play of the axle (no pre-
and cups, loosen the nuts until the axle shaft load on bearings). Check the turning tor-
has slight end play ( n o bearing preload). que required to turn the axle and diff-
erential. Then tighten the nut (14) until the
NOTE There a r e two methods that can turning torque is 20 to 30 inch lbs. greater
b e used to check the bearing preload. the no load turning torque.

Method A is with the axle housing remove 11.Install cotter pin (16).
from transmission case. Method B is with 12. Install axle key (17) with pin (18) a n d install
the axle housing assembled to the trans- wheel and tire.
mission case. 13. Tighten each hub bolt (19) evenly until only
slight resistance is met. Then torque bolts
Method A. To check bearing preload when equally In three increments (1) 70 to 80 ft.
axle housing is not assembled to trans- Ibs,, (2) 150 to 160 ft. Ibs, (3) 270 to 320 ft.Ibs.
mission case. Loosen nut (14) so axle has keeping the wheel hub c l a m p (20) parallel with
slight end play ( n o pre-load on bearings). the hub (21), NOTE R e a r wheel hubs must not
Check the turning torque created by the be set closer than 1-1/2" from end of axle
seal drag. Then tighten the nut (14) until housing. If they a r e , the key will extend into the
the torque is 20 to 30 inch Ibs. m o r e than run-out o r shallow end of the keyway, with the
the seal drag. M a r k the nut in relation to result that hub c l a m p cannot be clamped
the cotter pin hole and count the number against the axle a t the inner end and the wheel
of threads exposed beyond the nut. will not run straight. Hub c l a m p m a y b e
broken and wheel cannot be kept tight.
7. Remove nut (14), washer (13), spacer (12)
and final drive g e a r (11).
 65·25

INSET C

01502 DRIVER

INSEf A,

INSET B

G1 50' 8 SLEEVE

Figure 13
65-26

GEA R SHIFT COVER

(Refer to Figure 14)
IMPORTANT Each of the three shifter rods, in the control cover, are held in position by
means of a steel ball backed by a compression spring. These steel balls, seating in the shifter
rod (horizontal notches), provide a "detent" or holding action thus preventing the transmission
accidentally jumping out of gear. (See Inset A).

Between the shifter rods, in the control cover body, are two interlock plugs. These plugs seat
in the vertical notches in the shifter rods, providing a similar detent holding action on the shifter
rods. When anyone rod and fork is shifted, these interlock plugs prevent the movement of the
other two rods, thus preventing the transmission from being in two gears at once. (See Inset A)

On tractors with Mechanical Shuttle transmission the reverse shift fork Is removed and a reverse
shift rail lug and a (5/ 16 X 3" ) bolt is used to restrict movement of shift lever to the reverse
position, Inset B. With this arrangement the neutral safety starting switch can perform its function.
NOTE Refer to Page 65-32 for neutral safety starting switch adjustments.

SPRIN G SPECIFICATIONS
Check the springs for the following specifications:

DETENT SPRING SUPPORT REVERSE LUG

(15,33 & 37) SPRING (1) SPRING (11 & 20)

Free Length .. __ ................. Optional ........ _.. _....................... 2" .............................. 1-9/ 16"
Spring 0.0..... _.................. 072" .......................................... 1416" _..... _.. ...... _...... _... 056"
No. Coils ........................... Optional ........... _.............. ......... _ .............................. 11
Compress to ..................... 13/ 16" ....................................... 1-5/ 16" ....................... 1-114"
Spring Rate ...................... 35-38 lbs .......... _....................... 35-50 lbs ..................... 19-112 lbs.
 65-27

INSET A DETENT INSE T D

I INSET E

39

3RD 80 4TH
CEfP··
=--=-
TO
3.75 "

" .m ~1~ /
/~
3/ 4"

~~ .
o
®-* ~'@® ~ 2tl
1 -1 / 4 "

0
USE WITH M EC HA NICAL S HUTTLE

Figure 14
65-28

GEA R SHIFT COVER (CONT'D.)

( Ref er to Figure 15)
S. Install reverse shift fork (14) with spacer
(18) onto rod (17)_

NOTE On tractors with mechanical

shuttle transmission, install plunge r (19),
spring (20), nut (21) and cotter pin (22)
THE 3/S" STEEL BALLS ARE HELD IN Into I'everse shifter lug (23). Then install
THE COVER UNDER SPRING TENSION lug assembly with 3/ 4" spacer (24) to the
AND WILL FLY OUT " 'ITH GR.E AT rear and 1-1 / 4" spacer (25) on front side of
FORCE WHEN THE SHIFT HAUS ARE lug. Secure with roll pin (26), Install stop
REl\lOVED FROM THE COVER. bolt (28) and nut (29).

COVER THE OPENINGS IN COVER WHEN 9. Before moving reverse shift rod (17) fully
REMOVING RAILS TO PREVENT INJURY Into position, make certain that s lot for
FROM THE FLYING DETENT BALLS. interlock is turned towar d the center rail
(30).
1. Position spring (1) and shlfl lever (2) Into
control cover (~l), from the bottom up, Inset C _ NOTE The interlock slots in the two outer
Talis (17 & 31) must be turned toward the
2.lf equippe d, insta ll s hift leve r (2), s pacer (49 center rail (30).
a nd snap ring (3) into control "over (3) from
the top down, Inset D. 10. Move reverse shift rail (17) fuJly into posi-
tion so that the ball (16) rides in the detent.
3. Turn dog point ret aining Screw (6) into cover
(3) until it bottoms in the groove and slight 11. Install the interlock plug (32). Refe r to [nset
drag is felt when moving shift le\'er (2) . Back E for plug dimensions.
screw (6) out until lever (2) moves freely and
then IightE'n jam nut (7) to s ec ure screw (6 ) 12. Compress center detent spring (33) into
Into place, position in cover (3) with ball (34). Retain
in place by install ing 1st to 2nd shift rail
IJl.lPORTANT Make certain that projecting
(30) into the cover (3).
ends of support spring (1) do not interfere
with the ac tion of shift lever (2). Make
15. Compress detent spring (37) into position
certain th e two e nd coils of the sup·
in cover (3) with ball (38). Retain in place by
port s pring have not doubled up thereby
starling 3rd to 4th shift rail (31) into the
restric tin g the travel of th e shift lever.
cove r (3).
Int"rCerence a t thi s po int m ight limit the
movement o( the shift rail SO that the ba ll
16. Install roll pins (40) into the s hift forks
would not fall in to the rail detent. (14, 35 & 39) and into the shift rails_
4. Install dust cover (3) and knob (9) onto shift
lever (2)_
5. Assemble plung er (10), s pring (11), nut
(12), cotter pin (J3) Into the !'everse shift
fork (14).

6. Compress detent spring (15) inlO pOSition in

cover (3) with ball (16).

7. Secure ball (16) and spring (1.)) in place by

starting reverse shitt rod (17) into cover
(3) .
 65-29

DETENT

INSET~A~~~~fi~~~~~
INTERLOC K PLUGS INSET D

It
~
(7)0 !
j
t ~
~ '" ·
J. , )1
'"
-f2\ _~ _ _ _ __
-
----;~~
"-<D .-1 ,"m ,

"~~~
.@--:. ~9D ·'i
t[JJ= ~"
,s66 .. ro,s74'~ ..

I
 65·30

ADJUSTMENTS
(Refer t o Figure 16)
1 . DIFFERENTIAL PIN ION TO SIDE 3. DIFFERE NTIAL RIN G GEAR TO
GEAR BACKLASH COUNTE RSHAFT SHAFT PINION
1. With the differential shaft pressed into the GEAR BACKLASH
center wheel, the thrust washer, steel shim IMPORTANT The backlash between the
washers and side gears installed on the diff· differential center wheel ring gear and the
erential shaft, the adjustment can be made. countershaft pinion mus t be adjusted after
the differential shaft bearing pre· load is
2. Install a dial indicator, Inset A, so the point adjusted.
of the indicator is against the pinion gear
tooth. While holding side gear in place with 1. Loca te a dial indica tor on the transmission
one hand, rotate the pinion being checked case as shown in Inset D. Position the gauge
back and forth by hand to check the backlash. carefully so that the dial will not skip on
IMPORTANT Backlash should be .DOS" to the tooth and so that sufficient pressure is on
.015". The differential straight bevel gear the tooth to move the indicator needle .
backlash adjustment is obtained by using, as 2. Take up the slack in both gears by holding
required, the washers or shims. One sintered the countershaft pinion and rotating the
iron thrust washer must be used on each side diffe rential center wheel ring gear as far
of the center wheel and, if required, steel as possible in one direction without moving
shims may be used to obtain the required the countershaft pinion. Set the dial indio
backlash adjustment. If used, the steel shim cator to zero.
shall be placed against the thrust surface of
the center wheel, Inset B. Each differential 3. Hold the countershaft pinion and rotate
side gear should be shimmed to give from the differential center wheel ring gear as
.D05" to .015" backlash. If backlash is not far as possible in one direction without
uniform as the side gear is rota tcd, the moving the countershaft pinion. Read the
minimum backlash measured shall be used dial indicator for the backlash between
to determine the correct shim thickness. gears. Correct backlash is from .005"
to .009".
NOTE A .005" shim adjustme nt changes
the backlash approximately .0035". The sin· 4. If backlash is too great, remove shims from
tered iron thrust washers are available in the left hand differential bearing carrier and
sizes from .089" to .119". The steel shims add them to the right hand differential bear·
are .010" in size. ing carrier. Retorque bearing ca r rier nuts
& bolts.
2, DIFFERENTIAL BEARING PRElOAD
1. Install the same number or more shims than NOTE The differential must be rotated
were removed and torque the carrier bolts to seat the bearings before the backlash ad·
and studs 70 to 90 ft. lbs. Make sure enough justment is measured. A .005" shim changes
shims are installed to give some ring gear this backlash approximately .00.35".
to pinion gear backlash.
5. If backlash Is insufficient, remove shims
2. A special tool can be made from a brake disc, from the right hand differential bearing
Inset C, to be used with a torque wrench, carrier and add them to the left hand diff-
to check the differential bearing pre· load. erential bearing carrier. Retorque bea ring
This is measured as turning torque of 3 carrier nuts and bolts.
to 8 ft. Ibs. on one differential side gear
while the countershaft pinion gear is locked 6. Check the dial indicator after each shim
against rotation. Add or subtract differential change.
bearing carrier shims to the opposite side
until correct pre· load is obtained. Shims are
available in sizes .005", .OOT' and .010".
 65-31

INSET A 1. DiffERENTIAL PINION

TO SIDE GEAR
BACKLASH

" .... '"'L TOOL

SIDE GEAR

INSET B
_
DIAL INDICATOR
.005 " TO ,0 15" BAC KLASH \
RING GEAR

THRUST WA SHERS

2.DlffERENTIAL BEARING PRELOAD

TORQUE WRENCH
3 TO B FT. LBS .

..

INSET 0
DIAL INDICATOR

STEEL SHIMS
~ t::;; (oJ

IN S ET C
SPECIAL TOOL
S / 8" ~EX . NUT /~
1 . 1I 2 " ~ / ~6"
<..

o "
3. DiffERENTIAL RING GEAR TO CQUNTERSHAFT
SHAfT PINION GEAR 8AC~LASi1

Figure 16
65-32

ADJUSTMENTS(Con~)
SAFETY STARTING SWITCH ADJUSTMENT
(Refer to Figure 17and 1 8 )
If the safety starting switch is not properly with the gE'ar shift lever in neutral or in gear.
adjusted it may result in e ithe r the tractor
not starting when the gear shift lever is in the To adjust the safety starting switch, pro-
start position or being able to start the tractor ceed as foHows:

GEAR SHIFT LEVER

IN NEUTRAL POSITION

SAFETY STARTING
SWITCH \

SHIMS AS TRANSMISSION
REQUIRED TOP COVER

Figure 11 Figure 18
A.If engine will not start with the gear shift B. If the engine s tarts with the gear shift
lever in start posi tion: lever In ne utral or in gear:
1. Move the gear shift lever to neutral, 1. With the gear shift lever in neutr al posi-
remove all the shim washers and turn tion, add one shim a t a time be tween the
the safety s tarting switch "i n'· by hand switch and transm ission cover until the
while holding the key switch in the start enginE' will not s tart by turning the key
position. When safety switch makes con- switch to the "start" position.
tac t the engine will s ta rt. At this point
turn off the engine and add enough shim
washers betwee n the switch and trans-
mission cover so the engine will not s ta rt
with the shift lever in neu tra!.

2. Move the gear shift lever to the ·'S·' start

position and turn the key to "start" - the
E'ng ine should start if the safety switch is
adj us ted prope rly.
 Section
66
MECHANICAL

SHUTTLE

Rae . Form 9 · 80771

66-2

SHUTTLE CONTROL COVER

With Linked Lever
(Refer to Figure 1)
There are two types of cont ro l covers used, one for tractors with s hu ttle only a nd one for
tractors with s huttie and dual range . The servicing of the dual range part oi the cove r is
covered in Section 67 of this Service Manual.

Removal and Disassembly

1. Remove bolt (1 ) with loc kwas he r from shuttle ba ll ( 10). spring ( 11 ), fork (12). lug (13) and
lever (3) and disconnect linkage ass emb ly (2). selective spacer (14).
2. Re move the tour bolts (4) w ith loc kwashers 5. Remove the p ipc plug (15) in top 01 cover
f rom cover. a nd using a punch drive the roll pin (16 )
:3. Tap cover upwa rd ligh tl y to r e move. The do wn and o ut o f the cove r .
locating dowels (5) a nd (6) will remain in 6. The lower shut tle lever (3) is s plined to the
cover. Remove gas ke t (7). fork lever ( 17) and can be pulled out of
4. Remove lockwjres a nd setscrews (8). Drive cov~r.

the s huttle ra il (9) out and remove detent 7. Drive au t lever sea l (1 8) .

Inspection
Inspect the shuttle fork, ra il , fork lever Total coils .. ........ ...... .... ..... ......................... 8
and detent ball for excessive wear or r ough- Wire diamete r ... .... .... ....... .............. ....... 072 "
ness . 1.0. dia meter ........... .. ................... .... 25/64"
Inspect the de te nt spring (11 ). Free le ng th ........ ............ ........... ............ . 1"
Spring Speclfica tlon s: Compression to 13/ 16" ........... 35 to 38 Lbs .

Assembly and Installation

1. I nsta ll n w oil seal (18 ) with lip Inwa rd, 7. Selection of the prope r spacer (14) , whic h
until it bottoms in cove r. is availa ble in thickness of .550", .531"
2. Wh ile holdi ng fork lever (17 ) In a vertical and .562 ", can be do ne by m oving the
position inside of cover, Ins ta ll the lower shuttle lever to the fonv a r d position with
shuttle lever (3) a t an approx. a ng le of 60". the dete nt ba ll seated in r a il.
toward the rear of the cover. This wIll 8. Using a feeler gauge check the clearance
engage the s plines correctly. NOTE: Be b e tw een spacer a nd housing (In se t A).
careful not to damage seal. 9. In s ta ll the longest spacer that w ill s tm
3. Drive in the roll pin (16 ) to r etain the lower give a c learance of .010". If this is not
s hu ttle lever In the cover. Insta ll pipe plug done, ove r shifting can result in d am age
(15) . to the shuWe unit.
4. Insta ll detent s pring (11), ba l! (10) and 10. Before ins ta lling the cover assembly, move
while compressing spring, s tart the shut- the dual r ange level' rearward a nd the
tle ra il (9 ) into cover. lower shu ttle lever (3) fonvard. Move the
S. Install the spacer (14 ) and lug (13) while dual ra nge shift collar forward a nd the
d r iving Ihe rail (9) into pos it ion. s huttle collar rearward. Make s ur e forks
6. Insta ll shuttle fork (1 2) and r e tain fork engage th e s hifting collars. I nstall cover
(12) a nd hub (U ) with setsc rews (8) . Make with new gaske t (7).
sure setscrews e ngage r ecess in rail and 11. Install bolts (4) with lockwas hers and torque
torque to 35 It. Ibs. 1 'OTE : Make sure to 35 ft . Ibs.
lod:wire is not wedged betwee n spacer 12. Reconnect linkagE' assembly to shuttle lever
a nd fork. (2) using bolt (1) with lockwasher.
 66-3

INSET A

T
(j)
I I
v
©l...... / /

I
I
I

Figure 1 &--0
66-4

SHUTTLE CONTROL COVER

With D irect Lever
(Ref er to Figure 2)
The re are two types of control covers used , one for tractors with shuttle only and one for
tractors wilh shuttle and dual range. The servicing of the dua l range part of the cover is
cove red in Section 67 of this Service Manual.

Removal and Disassembly

1. Remove brpather (I ) , also brea ther tube ball (10), spring (11), fork (12), lug (13 ) a nd
(2) a nd breather tube nut (3) if equipped selective spacer (14).
from cover, 5. Remove the pipe plug (15 ) in top of cover and
2, R emove the four bolts (4) with lockwashers using a punch, drive the roll pin (16) down
from cover, and out of the cover.
3. Tap cover upward lightly to remove. The b. The shuttle lever (19) is splined to the
loca ting dowe ls (5) a nd (6) will remain in fork lever (17) and ca n be pulled out of
cover. Rem ove gasket (7). cover.
4, Remove lockwires a nd setscrews (8 ). Drive 7. Drive out lever seal (18).
the shu t tle rail (9) out and remove detent

Inspection
Inspect the shuttle fork, rail, fork lever Total coils .................................................. 8
and detent ball for e xc essive wear or rough· WIre diameter ...................... .. ............... 072 "
ness. I.D. diameter ..................................... 25/ 64"
Inspect the d e tent spring (11), Free length ...... .. ............ .. ........................ I"
Spring SpeCifications: Compression to 13116" ............. 35 to 38 Lbs.

A ssembly and Installation

1. install new oil seal (18) wlth IIp inward , 7. Selection of the pro per spacer (H) , which
unt il it bottoms in cove r . is available in thicknes s of . .550" , .531"
2. While holding fork lever (17) in a vertical and .562" can be done by moving the
position inside of c over, ins ta ll shuttle s huttle lever to the forwa rd pos ition with
leve r (19 ) at a pproximately a right angle the dete nt ball seated in rail.
to the c over. This will engage the splines 8. Using a feeler gauge check the clea rance
correct ly. NOTE : Be careful no t to damage be tween spacer and housing (Inset A) .
the s ea l. 9. In s tall the longest spacer tha t will st ill
3. Drive in the roli pin (16) to retain the give a clearance of .010". If this is not
s huttle lever (19) in the cover. Install done, over s hifting can result in damage
pIpe plug (1~), to the shuttle unit.
4.Insta ll detent spring (11), ball (10) and 10. Before installing the c over assembly,
while compressing spring, s tart the shut- move the dual range lever rearward and
tle r a il (9) into co ver. the shuttle lever (19) forward. ;Vlove the
,j. Ins tall the spacer (1i) a nd lug (13) while dual range shift colla r forward and the
driving the rail (9 ) into position. shuttle colla r r en rward . Make sure forks
6. Install shuttle fork (12 ) a nd retain fork (12) e ngagE' the s hifting coll a rs. Install cover
and hub (13) with se tscrews (8). l\'l nke sure wi th new gasket (7) .
setscrews enga ge r ecess in rail a nd to rque 11. Insta ll bolts (4) with lockwa shers and tor-
to 35 ft. lbs. NOTE : Ma ke su re lockwire que to 3.5 ft. Ibs.
is not wedged between spacer and fork. 12. Ins tall brea the r tube (2) and nut (3) if
equipppd, a nd breather (1).
 66-5

I
I
®-I
®-o

Figure 2
66-6

SH U TTLE TRANSM I SSION

( Refer to Figure 3)
Rem oval and D isassembly
For sp lit ting t he trac tor between the torque t.ube and transmission case, follow the ins tructions
as given in Section 92 of this Service Manual.

1. Re move the reverse idler stud nut (1). Use (2,3,4,5) from case. Remove s na p r ing (3)
a brass rod and drive the stud (2) from the and press bea ring (4) from gear (5) and
C3se (6). Lea ve idler g ea r a ssemb ly (2,3 ,4,5 ) shaft (2) .
in case until the shuttle gears are re moved. 8. Remove countershaft bushing bolts (28 )
2. Remove bea ri ng retainer bolts (7) with tock- with lockwashers, countershaft lock (29),
wa shers a nd reta iner (8). countershaft bushing (30) a nd shi ms (31)
3. Remove the in put shaft (11) Or (39 ).
from case .
9. Pull countershaft (32) from case and remove
4. Remove snap ri ng (9) bearing (10) and counte rshaft gear (36), thrust bearings (34)
needle bearing (12 ) from inpu t shaft (11 ) a nd thrust washers (33) and (35).
if they are to be replaced. 10. R emove needle bearin gs (37) from counter-
5. Rem ove snap ring (13) nuts or bolts that shait gear (36 ) If they are to be replaced .
reta in the shuttle unit to the dual range 11. Rem ove e xpans ion plug ( 38) from case if it
or transmission case. While moving the has been leaklng .
sh uttle housing (6) forwa rd . remove the
synchronizer unit (14 thru 19 ), thrust collar 12. Disassembly of the synchronizer unit can
(20), outpu t gear (21) and sleeve (22). be done by removing both the blockin g rings
(14 and 19), springs (15 and 17 1 and the shifter
6. Remove the pinned thrust collar (23).
plates (18) fro m the hub-sleeve assembly
7. Remove reverse idler gear assembly (16) .

I nspection FRONT
Thoroughly clea n all pa rts before inspec'
tion . Replace damaged or worn parts.
•
Insp c t the tape red surfaces of the input
gear and ou tput gear tha t makes contact
wi th the synchroni zer unit. These tapered
sur fa ces m ust be free of nicks , burrs and
fo reign m ate rI al. The blockIng rlngs (14 ) and
(9) m ust t urn freely on the tapered sur·
fa ces , and if e xcessive wear is noted on the
inside thread, they m ust be replaced.
Inspec t the shift collar of the synchronize r
uni t whe re it makes contact with th e shuttle
for k, for excessive or uneven wear, Th is would
be an indlcaU on that the sh uttle fork is bent or
cocked,

Inspec t all the needle bear Ings and thrust

bearings for wea r , looseness or damage.

Inspect all gear teeth for wear or damage.

66-7
66·8

SHU TT LE TRANSMISS ION

(Refer to F igu re 4)
Assembly and Insta llation
J. Install new expansio n plug (38) and start 9. Select the proper sna p r ing (13) to give
countershart (32) into casco the synchronizer unit a minimum of e nd
2. [nstall needle bearings (37) in to gear (36) play. This s nap ring is ava ilable in .076"
using GI5021 driver. Drive on the numbered .080", .08.3", .087" a nd .091" thickness.
edge of bearing untit it is even with the Install the proper snap ring (1:3) onto the
chamfer. (Refer to In set A.) sha ft.
3. Lubricate t he coun tersha ft gea r bearings. 10. Press new need le bearing (12) into input
Install countershaft gear (36) on shaft (32) gea r (11 ) using driver G15042. Use tbe
with a thick .12.5" thrust washer (33) on proper end of the dr-i ver and press on the
each s ide of gear. In sta ll thrust bear· num bered s ide of the bearing. (Refer to
ing \:H ) a nd thin (.031") thrus t washer Inse t B.) The driver will allow the bearing
(35) on each side of gear. Push s haft to stop at a point inside of the input gea r ,
all the way into gear. so that the oil hole is open to the bearing
~. Insta ll the sa me number of shims (31) and it will allow for proper lubrication.
that we re removed, bushing (30), lock (29) 11. Press bearing (10) on to inpu t s haft and
and bolts (28) with loc-kwashe rs. Tighten retain with sna p ring (9).
bolts 15 to 20 ft. Ibs. torque. Using 12. Install input s haft (11) or (39) , retainer (8),
feeler gauge between gea r (36 ) and thrust bolts (7 ) with lockwashers and tighten 35 to
wa sher (33) c heck for proper end play of 40 fl. Ibs .
.004" to .009". Remove or add shims (31) 13. Position the idler gear shaft assem bly
untit proper end play is reached. in its proper opening in case . Install nut
5. Press bearing (4) into idle r gear (3) and (1) and lig hten secure ly. Stake nut to s hafl.
insta ll sna p ring (3). Press idler gear and 14. Reassemble the trac tor and fill torque
bearing assembly on to the idler shaft (2) tube to proper level wit h Case T CH oil.
with the sn ap ring s ide toward threaded
end of shaft . Lay t his idler s haft assembly FRONT
in the shut tle ease (6) in it s pro per position ,
but do not install until after input gear is
installed.
6. Assemble the synchronizer un it as follows:
Install three shifter plates (l8) and retain
in place wit h spri ngs (1.5 a nd 17). Insta ll
b locking ri ngs (14 and 19) to hub·sleeve
assembly (16).
7. Install thrust collar (23) with pin (24) en·
gaging sp line in sha ft.
S. In s tall new gasket be tween t he s huttle
housing arrel transmi ssion case. "0
is used be tween shuttle housing and dual
gasket

ra nge housing. Be surf> gaske t is not reo

versed o r oil transfer be tween torq ue
tube and tran smission can result. While
installing shu tlle housing, install sleeve
(22), ou tput gea r (21) collar (20) and syn·
chronizer unit (16) with the 5/1S" hub
toward front of case. NOTE : rear hu b
is 7/ 16 '1 high.
 66-9

TOOL G15021

INSeT A

\
io ' INSET B
 Sec tio n
6 7
DUAL RAN GE

ASSEMBLY

R ae. Form 9 ·80781

67-2

DUAL RANG E CONTROL COVER

With Welded Lever
(Refer to Figure 1)
There are two type of co ntrol covers used, one for tractors with sh ullie only and one for
tractors with s huttle and dua l range. The servicing of the shuttle part of the cover is covered
in Section 66 of this Serv ice Manua l.

Removal and Disassembly

I. Remove bolt (1) with lockwasher from (9), s pr ing (10) and fo rk (11).
lower sh uttle levC'r (2 ) ancl di sconnec t
linkage assembly. 5. Remove the pipe plug (12) in top of cover
a nd usi ng a punch drive the roll pin (13)
2. Remove the four bolt s (3) with loc kwashe rs down and out of the cover .
from cove r.
6. Pull dual range lever (14 ) out of fork
3. Tap cover upward lightly to remove. The lever (16) , remove key (15 ) and pull range
locating d owels (4) and (5) wi ll rem a in in lever out of c over.
cover. Remove ga sket (6).
7. Drive out lever seal (17).
4. Remove lockwi re and setserC'w (7) . Drive the
dua l range rail (8) out and remove detent ball

Inspection
Inspect the dual rangC' fork, ra il, fork Total coils .... ........ .... .. ......... ... _............... _ 8
lever and deten t ball for excessive wear or Wire dia meter ........ .... .. _.. .................. .072"
roughness. I.D. Dia meter ................................. 25 / &1"
Inspect th e dete nt spring (](I ) _ F ree length ........................................... 1"
Spring spec ifications: Compression to n / 16" _........ .. 35 to 38 lbs.

Assembly and Installation

l.lnstall new oil sea l (17) with lip inward setscrew engages recess in rail a nd torque
until it bottoms in cover. to 35 ft. lbs. NOTE: Make sure the loc kwire
Is ins talled.
2. While holding fork leve r (16 ) in a vertical
position inside of cover, install the dua l 7. Before insta iling the cover assembly, move
range lever (14) and key (1')). the dual range lever (14) rearward and the
lower shuttle lever (2) forward. Move the
3. Drive in the roll pin (13 ) to retain the dual dua l range s hift collar forward a nd the
r ange lever in the cover. Ins tall pipe plug s huttle collar r ea rw a rd. iI'lake s ure the
(12 ) . forks engage the shifting collars. Inst a ll
cover with new gasket (6).
4. Insta ll detent spring (10 ) ball (9) and while
compressing spring , start th" dual range 8. Install bolts (3) with lockwashers and tor-
rail (8) into cover. que to 35 ft. lbs.

5. Insta ll the dual ra nge fork (11) while 9. Reconnect linkage assemb ly at lower
driving the rail (8) in to position. shuttle lever (2) using bolt (1) with lock-
washer.
6. Retain fork (11 ) with setscrew (7). Make s ure
 67-3

®-I
CD--o

~ ...•"" ---(D

Figure 1
67 -4

DUAL RANGE CONTROL COVER

With One Piece Lever
(Refer to Figure 2)
The re are two type of control covers used, one for trac tors with shuttle only and onE' for
tractors with s huttle a nd dual r ange . The servic ing of the shuttle part of the cover is covered in
Sect ion 66 of this Servi ce' :Vlanual.

Removal and Disassembly

I. Remove brea the r (I) a lso brea th er tube (10 ), spring (11) and fo rk (12).
(2 ) and breat her tube nut ( 3) if equipped
from cover . 5. Remove the pipe plug (13) in top of cover
and using a punc h drive t he roll pin (14)
2. Remove the four bolts (4) with loc kw 3shers down and out of the cover.
from cover.
6_ Pull dual ra nge lever (15 ) out of fork [ever
3. Tap cover upward lightly to I·emove. The (17) , remove key (16) and pull range lever
locatlng dow els (5) and (6) will re main in ou t of cover.
cover. Remove g askN (7 ).
7. Drive ou t le ver seal (18).
4. Remove lockwi re a nd setsc rew i8) . Drive the
dual ra nge r ail ( q) ou t a nd remove detent ba ll

Inspection
Jnspect the d ua l range fork, rail. fork lever Total c oils ... _....... __ .... .. .. ...... . _........ .... ... _.. 8
a nd deten t ball for e xcessive wea r or ro ugh- Wire Diam e te r .... ...... _.. .... .. .. ....... .. ..... 072"
ness. I.D. DIameter ...... ..... .... _................. 25/ 64"
Inspect t he deten l sp ring (11). Free length ......... _................................. 1"
Spring spec ifica tions: Compres sion to 13116" _.......... 35 to 38 lbs.

Assembly and Installation

I. Insta ll new oi l s ea l (18) with lip up ward se tscrew engages recess in rail a nd torque
unti l It bottom s in cover. to 35 ft. lbs. NOTE : Ma ke sure the lockwire
is ins talled.
2. WhUe holding fork lev er (17) in a vertical
posit io n insi de of cove r , in.'ita lJ the d ual 7. Be fore installing the cover assem bly, m ove
range lever (15) a nd key (16). the dual range lever (15) rearward and the
shuttle lever (20) forward. M ove the dual
.3 . Drive in the r ol l pin (14 ) to retain the du a l range s hift collar forwa rd a nd the shuttle
range lever in t he cover. Insta ll pip!' pl ug collar r eanva rd. Make sur e t he forks
11.3) . e ngage t he shilling colla rs. Insta ll cover
with new gaske t (7).
4. Inst a ll detent spr ing (ll ) ball (10) a nd while
compr essing spr ing. start t ho dual ra nge 8. Install bolt s (4) with lockw3shers and torque
rail (9 ) into cover. to 35 ft. Ibs.

5. In stall the dua l ra nge fork (12 ) while driving 9. Insta ll breat her tu be (2 ) a nd nu t ( 3) if equip-
the rail (9) i nto position . ped and breather (1).

6. Retain fo rk (12) wit h setscrew. Make sure

 67-5

®-
@-- o

FigurQ 2
67-6

DUAL RANGE TRANSMISSION

(Refer to Figure 3)

Removal and Disassembly

For sp litting the tractor between the torque tube and transmission case, follow the instructions
as given In Section 92 of this Service Manual.

1. Remove the shuttle assembly, refer to on the ro ll pins (15) with a pair of pliers.
Sec tion 66 of the Servic e :'"Ianual. Remove the countershaft gear (16 ), thrust
bearings (17) a nd thrus t washers (18) a nd
2. Remove the input shaft (1) by pulling (19 ) .
forward.
6. Remove roll pin (20) and disassem ble
3. Remove bearing (2) with snap ring , a nd co llar (13 ) from shaft (14). Remove roll
needl e bearing (3) fro m input shaft (1) if pins (15) from collar (13).
they are to be replaced.
7. Remove need le bea rings (21) from coun-
4. Remove snap ring (4) and nuts that retain tershaft gear (16) if they are to be re -
housing. While pulling the housing forward placed.
remove the shifting collar (5 ), shift collar
carrie r (6), output gear (7), sleeve (8) a nd 8. Remove the expansion plug (22) from hou -
pinned thrust collar (9 ). Remove snap ring (11). sing if it has been lea king.

.J. Remove the coun tershaft collar shims 9. Remove gasket (23) a nd discard .
(12) , collar (13) with s haft (14 ) by pulling

Inspection FRONT
Thoroughly clean all parts before inspec-
tion. Replace any da m a g ed or worn parts_

Inspect the shift c ollar where it makes

con ta ct w1th the dua l range fork, for exces-
sive or uneven, wear. This would be an in-
d ica tion that the s hifter fork is bent or cocked.
Inspect a ll the needle bearings and thrust
bearings for wear, looseness or damage.

Inspect all gea r teeth for wear or damage.

Check the gear teeth radius of the input

gea r (1), output gea r (7), (Refer to Inset Ai, shift
colla r (5). (Refer to Inset B. ) It any of these
radii exceed 114", replace these parts.
 67-7

~~
''''SET A

~
/l 1 / 4 " RADIUS

OIL GROOVES"'J

''''SET B

~ CHAMfER "'OT TO
r==1 EXCEED 11 4 " RADIUS

Figure 3
67·8

DUAL RANGE TRAN SM ISSION

(Refer to Figure 4 )

Assembly and Installation

1. Install new expansion plug (22) in case. 8. Select the proper snap ring (4) to give a
minimum of end play between the shift
2. Install needle bearings (21) using driver collar carrier (6) and snap ring (11). This snap
G15044, press on the numbered edge of ring is available in .076", .080", .083"
the bearings until they are even with the .087" and .091" thickness. Install the
chamfer in the countershafl gear (16). proper snap ring (4) onto shaft.
(Refer to Inse t A.)
9. Press new needle bearings (3) into input
3. Install the countershaft (14) into collar (13) shaft gear (1) using driver G15042. Use the
and retain with roll pin (20) . proper end of the driver and press on the
number edge of needle bearing, (Refer to
4. Lubricate the countershaft needle bearings. Inset C.) The driver wiJ1 allow the bearing
Install countershafl gear (16) on shaft with to stop at a point inside of gear, so that
a thick .125" thrust washer (18) on each the oil hole is open to the bea r lng and it
side of gear. Install thrust bearings (17) and wll! allow for proper lubrication.
the .0:31" thrust washers (19).
10. Press bearing (2 ) onto s haft (1) until it
5. Ins tall roll pins (15 ) into collar (13). Tap bottoms. Install sha ft assembly in to the
the countershaft in place. Check the shaft dual range housing.
end play by using a straigh t edge and feeler
ga uge, (Refer to Inset B.) Place the feeler 11. Install shuttle assem bly, refer to Section
gauge between the straight edge and the 66 of this Service Manual.
shims (12). Add shims (12) unUl .004" to
.009" clearance is reached. This will allow FRONT
for proper s haft end play.

6. Install snap ring (11 ) and new gasket (23).

Make sure the gasket is not reversed or
oil transfer between transmission and tor·
que tube can result.

7. While installing dual range housIng, in·

stall the thrust collar (9) with pin (10) en·
gaging spline in shaft and then sleeve (8),
output gear (7), shift collar carrier (6) and
shifter collar (5). Install housing nuts with
lockwashers and torque 35 to 40 ft. Ibs.
 67-9

INSET C

HOLE IS OPEN AFTER

MAKE SURE OIL RESSED IN PLACE
BEARING IS P

INSET B

c _

TOOL 015042
Figure 4
 Section
S8
11 INCH

TRACTION CLUTCH

Rae . Form 9-80791

68-2

TA BLE OF CONTE NTS

INTRODUCTION ............... .... ........... ... .... ..... ......................... .............. ..................... ............... 68-3

TRACTION CLUTCH
Removal-Disassembly-Inspection .................................................................. .._..................... 68-4

MAIN DRIVE SHAn'

Removal-Disassembly-Inspection .... ................... ... .................. .. ................ ......................... ... 68-6
Assembly-Installat ion ............................................................................................................ 68·8

TRACTION CLUTCH
Assembly·lnstallation ........................................................................ .................................. 68-10

RELEASE LEVER AD.JUSTMENT ....................................................................................... 68-10

CLUTCH LINKAGE ADJUSTME'iT

Suspended Pedal ............................ ........... ....... ..................... ....................... .. .................... 68·12
Floor·mounted Pedal ..................................................................... .. .................................... 68·13

S PECIAL TOOLS
The special c lutch adjusting tool G15048 is used with the special splined gauge, with 21 splines.

AJ7966 GAUGE G1S048 TOOL

This special tool. A38461 , is used to press the seal into the bearing carrier.

AJ8461 TOOL

These tools and the gauge are available through service parts supply, J I Case Co.
 68-3

INTRODUCTION
The operation of the clutch assembly is basically the same as the operation of any sta nda rd
single disc type clutch.

The clutch cover is attached to the engine flywheel. The press ure pl ate is driven by means of
driving lugs and mating slots in the clutch cover.

Depressing the clutch pedal disengages the clutch by forc ing the rel ease bearing into contact
with the release leve rs. moving the m toward the eng ine flywheel. This retracts the pressure
plate from conta ct with the drive n disc assembly thereby disengaging the clutch .

Releasing the clutch pedal engages the clutch by allowing the release bearing and release
levers to move away from the eng ine flywheel and the press ure springs to exert pressur e
against the release lever, resulting in the disc assembly being g ripped between the fric tion
surfaces of the e ngine flywheel and the pressure plate ; thereby completely engaging the clutch.

PRESSURE PLATE

ENGINE FLYWHEEL
PRESSURE SPRING

RELEASE SEARING

1JIr-o;t-~A-DRIVEN DISC

RELEASE LEVER
68·4

TRACTION CLUTC H
(Refer to Figure 2)
Removal
Prior to removal of the clutch it will first be necessary to split the tractor at the engine and
transmission.

1. Remove the clutch covel' assembly mount· 2. Remove oil seal (2), snap ring (3) and in·
ing capsc rews ( 1), washers, cover assembly spect bearing (4) for smooth free action.
and clutch disc assembly. If damaged use suitable puller for removaL

Disassembly
1. Place the clutch cover assembly in a press between top of lever (8) . Push spring ring
(pressure plate down) and apply pressure (9) away from lever (8) to be removed.
to compress the clutch springs. Loosen lock Pull lever (8) free of spring ring (9). Repeat
nuts (5). Remove the adjusting screws (6) for remaining levers.
washer and nut (5) . This allows pressure
plate (7) to drop out of bracket. 3. Release pressure from spring ring. Lift
the c lutch cover (10) off the pressure pla te
2. Press spring ring down until there is (7) .
approximately .060" to .125" clearance

Inspection
Whenever th e clutch is completely disassembled, the component parts ca n easily be cleaned
and inspected for wea r, cracks, score marks and pitting. Any parts that are damaged or Warn
m us t be replaced.

PRESSU RE PLATE

The pressure plate must be r e pla ced if the friction surface is severely heat checked, warped
in e xcess of .015" when checked on flat surface. Replace If damaged.

CLUTC H COVER

Inspect the clutch cover for distortion , cracks and wear. Bolting flanges should be flat to
within .015" when checked on a flat su rface. Replace if damaged.

DISC ASS EMB LY

The disc assembly must be carefully inspected for worn hub splines, distortion of the disc,
cracks and worn facing. If the disc is dama ged or facings worn, it must be replaced.

PR ESSU RE SPRING
To ta I Co i Is . -- -- ........ -- .. -- .-.. ---- ---- .. -- -- .. -- -- .----.. -- ------ --.-- --. ---- ... ---- ... ---- --' 8
Ac Ii ve Coi Is ......... ---- ---- .... -------- .... ---- ------ .. " ,,--.... ---- . ------.. --.-- .. ---- .... -- 6
Wire Dia m e t cr ... -- .. ---- ... --------- -- .... " --- ----- -- -------. --. ----. ---- ------- ------ --. .148
Free Le ngth " ..... -- -- .... --- -- ........ ------- ...... --- ...... -- --. --- -- .. ---- .. ------ .. -- 2.774"
110·120 Lbs. at compressed height of 1.52"
 68- 5

Figure 2
68-6

MAIN DRIVE SHAFT

(Refer to Figure 3)
Removal and Disassembly
1. Remove front cover or hydraulic assembly 5. Remove capscrews (7), retain er lock (8).
from torque tube and drain torque tube _ bearIng re tainer (9) and press bearing
(10) and pump drive (11) from the carrier (12).
2. Remove the snap ring (1 ) from the pivot
shaft (2 ) and remove pi vot shaft (2) and 6. Remove capscl'ews (13) retainer lock (14),
yoke (3). bea ring retainer (15 ), clutch shaft (16) and
bearing (17).
3. Slide off bearing carrier (4) and throw-
out bearing (5). 7. Remove oil seal (18) from pump drive (11)
and oil seal (19) from bearing carrier (12).
4. Remove ca pscrews (6) a nd pull out the
bearing carrier assembly.

Inspection
Thoroughly clea n and inspect a ll parts free opera tion. Replace if damaged.
for wear or damage. Replac e a ll parts that
are worn or damaged. Replace all oil seals and gaskets during
assembly.
Carefully inspect bearings for smooth
 68-7

Figure 3
68-8

MAI N DRIVE SHAFT

(Refer to Figu re 4)
Assem bly and I nstallation
1. Press a new oil sea l (19) into the bearing 6_ I! the bearing (17) was removed from the
carrier (12) using tool A38461. Be s ure clutch shaft (16), press the bearing on, un-
seal lip is towards rear of carrier (Refer til seated against the shoulder.
to Inset A).
7. Insta ll clutch shaft w ith bearing retainer
2. Press a new oil seal (18) in the pump (15), retainer lock (14 ) and secure with cap-
drive (11), lip towa rds rcar of pump drive. screws (13).
(Refer to Inset A. ).
8. Install bearing carr ier and pump drive
:3. If the throwou t bearing ca rrier sleeve assembly gasket (22) and secure with
(20) is damaged, press in sleeve usi ng lockwashers and capscrews (6). NOTE:
Locktite in beari ng carri er (12 ) until Ma ke sure holes in sleeve (20 ) are down-
flu sh with shoulder in hou sing. NOTE ; wa rd .
The oil holes in the sleeve must be
centered on one of the bearing carrier 9. [f the throwout bearing was removed, press
mounting holes. l)('aring (5) on bearing carrier (4 ) so the
grOOve in the bearing lines up with the
4.lf the bea ring (10) was removed from the grease hole in the bearing carrier. (Refer
pump drive (11), press bear ing on until to Inset B.).
sea ted on pump drive. In sta ll snap ring
(21) . 10. Install throwout bearing assembly, yoke
(3), pivot shaft (2) and snap ring (1).
5. Using Gl ,1501 sleeve , install the pump
drive assembly in th e bea ring carrier (12) 11. Connect clutch linkage and install torque
and in sta ll bearing reta ine r (9), retainer tube front cover or hydraulic cover assem-
lock (8) a nd sec ure with capscrews (7). bly.
 68-9

INSET B

Figure 4
68·10

TRACTION CLUTCH
(Refer to Figure 5)
Assembly
L When assembling the clutch apply a small 3. Install spring rings (9) on levers (8).
amount of high melting point grease to all
pivot pins. 4. Place the pressure plate and clutch cover
assembly in a press. Apply pressure to
2. Place the clutch cover (10) on the pressure compress the springs. Install the washers
plate (7). and locknuts (5) and adjusting screws (6).

I nsta lIation
L If necessary. press in a new bearing (4) 2. Install the clutch disc assembly and clutch
and install snap ring (3). Press in a new cover assembly on the fly.vheel using the
oil seal (2) (lip in) until flush with fly· capscrews (1) and washers.
wheel.

Release Lever Adjustment

The release level' adjustment must always be made when the clutch is rebuilt and only after
the clutch assembly is correctly reinstalled on the flywheeL If a new clutch cover assembly is
installed . always check the release lever adjustment.

L Install the clutch adjusting gauge A.17956 2. The release lever should just touch the
through the disc assembly and into the underside of the G15CH8 tool. If not turn
flywheel. Then install the G15048 clutch the adjusting screw until the lever does
adjusting tool in the adjusting gauge with touch the tool. Repeat this procedure for
the 1116" step against the adjusting all three release levers.
gauge.

FLYWHEEL

G15048 TOOL

RELEASE LEVER
 68·11

Figure 5
68-12

CLUTCH LINKAGE ADJUSTMENT

With Suspended Pedal
(Refer to Figure 6)
The fo ot clutch pedal will ne~d adjustment occasionally to compensa te for normal wear_ The
correct free pedal movement should be 1-3/ 8" to 1-5/ 8"_

As the clutch wears, this free movement decreases _ Adjustment must be made before the
free pedal movement becomes 1 inch,

NOTE: When the tractor is new , it may be necessary to adjust the linka ge several times
during the first 50 to 150 hours of operation until the clutch facin gs have " run-in", After
this the clutch will seldom require adjustment.

ul
,,-==y.~!!:r~_, ~lUTCH PEDAL

:1_3/1'" TO '-5 / 8-' FREE MOVEMENT

()

HEX NUT

Figure 6

To ob tain the necessary free pedal movement, loosen the hex nut on the clutch rod and
remove the pin from the yoke, Turn the yoke off or on the rod until the 1-3/8" to 1-5/8" free
peda l is obtained, Install the yoke and pin, Tighten the hex nut.

CAUTION

Clutch slippage will seriously damage the clutch fac ings in a short time, If slippage is noted,
stop the tractor immediately and make the adjustment listed above,
 68-13

CLUTCH LINKAGE ADJUSTME NT

With Floor Mounted Pedal
(Refer to Figure 7)
The foot clutch will need adjustment occasionally to compensate for normal wea r. The correct
free pedal movement should be 7/8" to 1-1 / 8" .

As the clutch wears, this free movement decreases, Adjus tment mus t be made before the
free pedal movement becomes 1/2 inch.

NOTE : When the tractor is new, it may be necessary to adjust the linkage several times
during the first 50 to 150 hours of operation until the c lutch facings have "run-in ". After
this the clutch will seldom require adjustment.

7 / S" TO l-l / S" FREE MOVEMENT

CLUTCH ROD HEX NUT

j \
/
YOKE

Figure 7

To obtain the necessary free pedal movement • loosen the hex nut on the clutch rod a nd
remove the pin from the yoke. Turn the yoke off or on the rod until the 7/8" to 1-1/ 8" free
pedai is obtained. Install the yoke and pin. Tighten the hex nut.

CAUTION

Clutch slippage wiil seriously damage the clutch facings in a short time. If slippage is noted.
stop the tractor immediately and make the adjustment listed above.
 Seclion
69
IND EPE NDENT

POWER TAKE-OFF

Rae . Fo rm 9 · 80811
69·2

TABLE OF CONTENTS
PTO ASS F::VIB L Y

Removal and Installation ................ .. , ................................ , ................ .. ..... , ......................... 69·3

PTO CLCTCH

Disassembly and Inspec tion ,., ....... ' .... ...... .... ... ..... ...... ......... ..... .... ....... ....... .......... ....... ......... 69·4

PTO CLCTCH

Assembly .. " ..................... , ...... , ................................................ .... ..... , ....... .... ,........................ 69·6

INPUT SHAFT Ai\ D CLUTCH DRUM

Disassembly Inspection and AssE'mbly ................................................................................. 69·8

PTO CLCTCH AD.J USTMEi\T .. ,.. ...... .......... .. , ......................... ................. ......... .. ...... ........... . 69·10
 69·3

PTO ASSEMBLY
(Refer to Figure 1)
Removal
3. Remove the four retaining nuts and twO
1. Drain the transmission oil at both the Allen Head capscrews (3).
transmis Ion drain (1) and PTO drain (2).
4. Remove the PTO assembly (6) from the
2, Remove the outer and inner PTO shields transmission case.
(3 & 4;,

""-I
o
/

Figure 1

Installation
(3 & 4),
1, Install the PTO assembly (6) on the trans·
4, Install the transmission drain (1) and PTO
mission case.
drain (2).
2, Install the two Allen head capscrews (5)
and four retainer nu tS. 5, Fill thE' transmission with 17 quarts of
clean SAE 90 EP oil.
3, Install the outer a nd inner PTO shields
69-4

PTO CLUTCH
(Refer to Figure 2)
Disassembly
NOTE : The PTO a ssem bly can be serviced In two ways If desired; 1. The PTO Clutch and
Shift Linkage. 2. The PTO Inpu t and Output gears and shafts.

1. Remove tho two Phillips head capscrews 7. Remove sliding sleeve a nd yoke assembly
(I ) that holds th p rear hou si ng (2) to the out of the rear housing (2).
front hOUSIng (3). Rem ove gasket (4). (Re fer
to Inse t A. ). 8. Remove the nuts (27), bolts (28) and yoke
halves (29 & 30 ) from the sliding sleeve
2. Re movE' the s nap ring (5) a nd press the (31). If roll pin (32) is not damaged do not
c lutch a nd output shaft assembly out of the remove.
boa ring (6) and rear housing (2).
9. Remove the roll pin (33) and sna p r ing (3'1 ).
3. RE'movC' the washer (7). spring (8) and Pull out the hand brake lever a nd cross-
a dju s ting plate (9). s h aft (35 ), pivot arm (36 ), s pring (:l7),
washer (38) and over center loc k pin (39).
4. Unscrew th e carrier (10 ) a nd remove
cotter pins (11). pivot p ins (12 ) . lin ks (13), 10. Remove the yoke (40 ) and keys (41).
spacers (14). link pins (15 ) , outer rollers
(16) and inner rollers (17 ) . 11 . Remove t.he outer snap ring (4 2). bearing
and seal (6) with "0" ring (43 ). Remove
s. Remove roll pin (18). spring (19) and lock inner s nap ring (44).
pin (20).
12. The needle bearing (45 ) need only be re-
6. Remove the pressure pla te (21) driven m oved if worn or damaged.
plates (22). separator springs (23), drive
plates (24) and backing plate (25) from 13. Remove the oil seal (46).
the output s haft (26).

Inspection
With the power take-off clutch complet e ly BEARINGS . Inspec t the bea rings for worn
disassembled, thoroughl y inspect all parts or pitted balls and needles . They should turn
for nic ks, burrs. wear and da mage. Any smoot hly in the bearing races. Re place if
parts that are excess ively worn or damaged worn or damaged.
must be replaced.
Replace all "0" rings and oil seals during
DRIVE:; Ai\D DR[VE PLATES Inspect the assembly. The bearing and oil seal assembly
plates for excessive \vear, cracks . grooves (6) must also always be replaced every tIme.
and flatness. Replace a ll plates that are
craCked. worn exeessively or wa r ped. All machined surfaced parts having small
nicks or burrs can be removed with a hone
SEPARATOR SPRINGS· ReplacE' the s e pa- or croc us cloth.
rator plates anytime the clutch plates are
replaced.
 69-5

INSET A

Figure 2
69-6

PTO CLUTCH
(Refer to Figure 3)

Assembly
1. Press in u new oil s eal (46 ) . lip in. are installed on the output shaft (26). In-
(Re fer to Inset A. ) stall the pressure plate (21).

2. If needle bea ri ng (4.5 ) lVa s re moved, press 10. lniflllll the lock pin (20). spr ing (19 ) and
the bearing in as shown in (Inset B.) Press rell Ilin (18) in the carrie r (10).
only against the numbered side of the
bearing . Ji.In.sUill links (13). space r (H ), pivot pin
(12 ) and cotter pins (11).
3. Install the inner snap ring (44 ). new bear-
ing and seal (6) with new " 0" ring (43), 12. Install inne r roller (17 ). outer rollers
Install outer s nap ring (42 ) . (16) and link pins (15).

4_ In s tall the hand brake leve r (35), yoke 13_ Screw the carrier asse mb ly on the out -
(40 ) keys (41) a ncl roll pin 13.3 ). put shaft (26). Place the clutch a sse mbly
in a clutch drum out of s toc k and screw
5.lnsta ll the pivot arm (36 ), s pring (37 ) , the carrie r down tigh t <·noug h to hold the
washer (21), over c e nte r lock pin (39 ) clutch plat es securely whe n r emove d from
and snap ring (34). the drum .

6. If the roll pin (32 ) wa s r e mo ved, install 14. Install adjusting pia te (9 ), spring (8).
roll pin in the sliding slee ve (31) as and washer (7).
shown in ( Inset C.)
15. Press the clutc h and output shalt assem-
7. Install the yoke halves (29 & 30) on the bly in the bea ring (6) until the snap ring
sliding s leeve (31 ) and secure with bolts (5) can be installed. Il\'lPOR'fANT : When
(28) a nd nuts (27). press ing in the shaft make sure the r oll
pin (32) lines up with the slot In the carrier.
8. P la ce the sliding sleeve a ssembly in the
rea r housing (2) and yoke ('llil. 16. Insta ll the rear housing (2 ) to thc front
hous ing (3) using a new ga sket (4 ) and
9. Install the backing plate (25)' drive plate Phillips head sc rews (1) . NOTE: Make
(24 ). sepa rator spring (23), and driven sure the clutch plat.es line up in the drum.
plate (22 ) until eight drive pla tes . eight
sepa rater springs a nd seve n driven plates
 69- 7

INSH B INSET A

46

SEATED IN HOU~ING

INSET C
69·8

INPUT SHAFT AND CLUTCH DRUM

( Refer to Figure 4)
Disassembly
1. Remove the two Phillips hea d c-apscrews
(1) tha t holds the rear housing: (2:1 to 100
front housi ng (3). R('movc g a sk~l (il. 4. [).n lake nuC (8) lind remove .
(Re fe r to Inset A.).
5. Press tht' clutch drum assembly out of the
2. Remove snap ring (5) and pr~s'3 th~ input bear~ng (9) alld fr ont housing (3).
shaft assembl y out of the front housing (3).
6. The needle bearing (10)' bearing cone (11 ),
3. If the bearing (6) is damaged, remove hearing cup (12) and bea r ing c up (13 ) need
snap ring (7) and using a suitab le puller only be removed if damaged.

Inspection
Inspect the bea rings for worn or piHed All machined surfaced parts having small
balls and needl es . They s hould turn smoothly nic ks OF !JUfFS can be removed with a hone
in the beari ng races. Replace all worn or or crocus cloth. Replace all d amaged parts .
damaged beari ngs .

Assembly
1. If.the bearing cups (12 & 13) were removed cll~ tront housing until the bearing (6) is
press in until sea ted aga inst the snap rings sealed against the snap ring (18). Install
(14 & 15 ) . snap ring (5).
2. If the bearing (11 ) was removed . press the S.ln&UI1I the clutch dru m assembly and press
bearing on the c lutc h dr um (16 ) un til seated on the bearing (9) until there is no e nd
agains t the drum. play in the clutch d t'l!Im a nd shaft (16 ).
3. If the need le bearing (10) was removed 6. Install thE' nut (8). Tighten nut until :3-7
press the bearing in the ('Iutc h drum (16) inch pounds of torque is required to turn
as shown in (Inset E.) Press only against .the shaft lI6) . Stake the nut.
the numbe red side of the bearing. I.Jnstall tne front hOusing (3) to the rear
4. If the bearing (6) was removed . press the housing (2) using a new gasket (4) a nd
bearing on the input s haft (17) and install Phillips headscrews 0).
snap ring (7). Press the shaft assembly in
 69-9

Figura 4
69·10

PTO CLUTCH ADJUSTMENT

(Refer to Figu re 5)
The Independent PTO clutch will need adjustment occasionally to compensate for normal wear.
Adjust the clutc h immediately if slippage is noted when a power take-off driven machine is
a ttached and started. Failure to make the adjustment will cause excessive wear on the clutch
plates resulting in eventual breakdown.

((
A
CAUTION : THE TRACTOR ENGINE MUST
BE STOPP ED WHEN ADJUSTING THE PTO
Figure 5

CLUTCH.
To adjust the power take-off clutch:
1. Have the power take-off clutch hand lever in the disengaged (fully downward) position. Remove
the PTO guards.
2. Remove the pipe plug from the PTO housing. Using a nashlight, look through the hole and
manually turn the PTO shaft until the spring loaded lock. pin is vIsible.
3. Insert a screwdriver or similar tool through ~lle hole an.<:! pUSh the engaged lock pin in as far
as possible. While holding the lock pin in, tllrn the PTO Qutput shaft.
4. To tighten the clutch, turn the PTO output shaft (o1.mrel'-Clockwise, until the lock pin engages
the ne xt notch. One notch is usually sufficient.
5. After each adjustment, check the engagement of t ~ ])Owe. lake-off clutch hand lever by moving
it fully upward. A correctly adjusted clutch will req\ilfre approxImately 50 to 65 pounds pull
and will engage with decided "snap" of the ~er .
6. CAUTION: Replace pipe plug and PTO guards.
 Section

74
DIFFERENTIAL BRAKES, DIFFERENTIAL LOCK

AND PAR KI NG BRAKE

SPECIFICATIONS
Brake pedal free travel ... ........................................................... .......... ... ... ... ......"... 1·1/4 to 1·.314"
Brake lower rod length (Flanged Axle Only) ................. ......................... ......... .................. }4·3/ 4"
Maximum pedal free travel (Prior to adjustment) ............ ....... ........................................ ... 2·1 / 4"
P arking brake ten sion a djus tme nt ............ .............. ... Turn handle clock-w ise to increase tension.
turn counter- clockwise to release tension.
Brake lever return spring:
Number of coil s ................................ .......... .. ........... ....... ..... .. .. .... ... ....... ..... .. .............. ...... 22·1 / 4
Free length .......................................................................................................... ............. 4.625 "
Wire diameter ... ................................... ........... ... .... ....... ................ ................ ..................... . 135"
Outer differential lock lever spring:
Length ........................... .... ......................................... ........ ...... ........................ .. ............. 2· 1/ 16"
LD ......................... .......... .............. ............................ .... ... ... ...... .. ........................................ 844"
Wire diameter ....... ......... ...................... ..... ...... .. .. ............................. ... ...... .. ........................ 192"
No. of coils .................................... .. .. ...... .................. ......... .. ............... .. .... ... ........................ .... 5
Free angle between wire ends ................ .......... ... .... ....... .... ........ .. ..... ..... ............... .. ............ 1380
Torque wl ends at 1120 angle ..................... ................ ... .. ............................... 42.1 to 94 .7 in. Ibs.
Inner differential lock lever spring:
Length ............................... ............ ............. .. ....................... .... ... .. ...... ............ ................ 1· 13/ 16"
LD ..... ..... ... ....... ... ...... .. .......... ....... ..... ............ ......................................... ..... .......... .. ............ 844"
Wire diameter ........................ .......... ... ... ............................................................ ................. 135"
No. of coils ......................... ...... ........................................... ............................................... 5·1 / 2
Free angle between wire e nd s ....................... ............................ ....... ...... .. ............................. 81"
Torque w l short end at 24 0 a ngle ................................................................... 17.8 to 28.1 in. lbs.

SPECIAL TORQUE
Bra ke cover to transmission bolt ............................................. ............................. 70 to 90 ft. lbs.

Rae . Form 9-80691

 74-2

BRAKE PEDA LS AND LINKAGE

(Refer to Figure 1)
l. Cotter pin, 118 x I " (4),
2. Yoke pin, (4).
3. Pivot rod, brake pedal (2).
4. Snap ring, pedal reta ini ng.
5. Brake pedal, R.H.
6. Equalizer lever (power Shuttle Only), At installation, press onto shaft with key (11) to allow
.05" e nd play between L.B. orake pedal aDd steering ~olumn.
7_ Bolt, I ! 2 x 1-1 / 2" N.C. Hex . Hd.
8. Link spacer (POWer Shuttle Only).
9. Equali zer li nk (Power Shuttle Only)_
10. Roll pin, :3/16" x I ". At installation , install so that protrudes approximately li2" of bottom
of the equalizE'r level'.
Il. Key, Woodruff ~A.
12. Brake pedal, L.H.
13. Stop stud , brake pedal.
14. Equalizer insert, brake pedal (2) (Power Shuttle Only).
15. Spiral pin, 1 / 8 x 9/ 16" (4).
16. Lube fitting, 1/8" P.T., 90 0 iC2)
16. Lube fitting, 1/8" P. T., 90" (2) .
17. Roll pin, 5116 x 1-1/4"
18. Interlock , brake pedals_
19. Cotter pin, 1/8 x 1" (4) .
20. Washer, 1/ 8 x I-l i S x 21/32" 1.0. (2)_
2l. Clevis pin ('1).
22. Lower brake lever rod (2 ) .
23. Rod yoke (2) .
24. ,Jam nut, 1 /2" :-':.F_ hex. (2).
25. Snap ring, pivot level'
26. Brake r od pivot lever, R.H.
27. Brake rod pivot lever, L.H.
28. Lube fitting (1/8" P.T. Straight) (2).
29. Stub shaft, pivot levers.
30. Return spring, lever. Check spring for broken ooil~ ~nd for th e following specific at ions.
Number of coils ............... __ .. _........ _................. " .. ............................................... _........... 22-1 / 4
Free length ................... ....... .......... ........ _. ... ...... " ........................................... _........... .... 4.625"
Wire diameter ............ ........ ............ ... , ..................................... _........... , ... , ... , ........... 1:35"
3l.Jam nut, 7116" :-':.F. hex. (2).
32. Adjusting nut, iil6" :--:.F. (2).
33. Snap ring, brake pivot shaft (2).
34. Washer, cross sha ft (2 ) ,
35. Brake lever, R. H. Outer
36. Brake lever, R.H. inner, Install with key 1I00 a)l(lw .06" clearance between the lever and
transmission hOll sing.
37. Brake leve r, L.H.
38, Key, Woodrllff ~15 (2).
39. Spacer, L. H. bra ke lever.
40. Cross shaft, brake.
4l. Lube fitting.
42. Spring Anchor
43. Spring Anchor (Hydros tatic )
44. Bolt, 3/ 8 x 1-3/4" :--:. c. hex. hd. (2).
45. Loekwasher, 3/8" Std. (2).
46. Nut, 3/ 8" N.C. hex. (2 ) .
47. Bolt, 3/ 8 x 1" N.C. hex. hd . (2) .
4S. Lockwasher, 3/ S" Std. (2).
 74 ·3

Figure 1
7~-4

DIFFE RENTIA L BRAKES

(Ref er to Figure 2)
Disassembly
l. Remove locknut (1) and ad ju sti ng nut (2) Re move expansioll plugs (1'6) and retractor
from brake rod (3). springs (17). Re move dust seal (23).

2. Remove fasteners (4) and rea r stud (5). 4. Unhook disc :spr'ings (18.and 19) with a slotted
Depress brake pedal. Remove cover (6) screwdriver, as shown i n Inset A.
and brake band assembly (items 7 thru
14) from the transmission case, 5. Remove spUned disk (20, and balls (21) from
actuating drum ,(22),
3. Remove pivot capscrew (13 ), Unhook re-
tractor spri ngs (17) from up per and lower 6, Remove cotter pins (10) {rom clevIs pins
bands (13 a nd 14), and remove bands, link (7,8 and 9) a nd disassemble bands (1.3 and
and rod assembly from bra ke cover (6)_ 14), Unks (11 .a nd 12) and rod (3) _
Inspection
Thorough ly clean all pa rts before inspec- cations:
tion, Replace a ll badly worn or damaged parts.
Disc springs (18, 19):
Check d iscs, bands and linings for -exces- Wire Dia meter ... ........ ..................... , ,0857"
sive wear , warpage, loose li nings, or -oil Total Coils ....................................... 10-114
sat uration. Check ba lls for roughness. Free LE'ngth ............. .... .............. .... .. . 1.27"
E xtended t-o 1,37" ....... 22-1 12 to 27-1 / 2 lbs ,
Inspect dust seal. Repla ce if cracked or
deter iora ted, Retractor Spring (17):
WIre Diame ter ............. .. ..... ...... ....... , ,060"
Inspec t disc springs, They should hold the Total CoIls .. ............. .. ............. ..... ...... 5-3/4
actuating disc and drum unde r tension whert Free LE'ngth ..................... .. .......... ...... .66"
assembl ed, and meet the fol lowing specifi· Extend to .74" ......................... 9 to 11 lbs.

Asse mbly
1. if new linings are to be installed on discs (6) and asse mble dust cover (23) over rod and
(20) a nd (22) and ba nds (13 a nd 14) , remove into cover, Insert springs (17) thro ug h holes in
old linings and procE'ed as follows: cover a nd hook to link ends of upper band s,
Install new expansion plugs (16) .
a. Clean the lining mating s urfaces.
b. Clamp new linings in place , being careful 6. Align pivot e nd of bands (13 and 14) and in-
as not to damage linings. stall pivot capscrew (15) and washer. Tigh ten
c. Drive ri vets through holes . from rivet pivot capscrE'w secure ly.
head with a tubular rivet set.
7. Slide actuating drum (22) and splined disc
2. Place four balls (21) in pOSition on actuating assembly (20) over splines of differential
d r um (22), then assemble splined disc (20) in side g ea r with splined disc (20) next to
pOSition over balls with spring holeS in the transmissIon case.
disc in line with projec tion ear OIt dru m .
8. Place e nd of brake rod (3) into brake lever
3. Att ach hook e nd of disc s pring (19) to ear of and assemble cover (6) a nd band assembly
act ua ting drum (22) through s plined disc (20). over drum (22). Torq ue bolts (4) 70 to 90
Hold disc and drum together, turn over , and fl. lbs . Install rear stud until seated and
attach hook end of disc spring (18 ) to ear of install nut (4), Torque the nut 70 to 90 ft.
d isc through act uating drum. lbs .

4. Assemble bands, bra ke rod and link (items 3 9. Install adjusting nut (2) and locknut (1) to
and 7 thru 14 ), brake rod (3),

5. Insert brake rod (3) throug h opening ill <:-over

 74-5

INSET A

SLOTTED SCREWDRIVER

I @)
ij t ,
'-
.r
I~
---
/

,,
(

Figure 2
 DIFFERENTIAL LOCK
(Refer to Figure 3)
Disassembly
1. The differential lock assembly can be re- 4. Remove pin (15), collar (16), spring (17) and
moved for servicing as an assembly. lever (18) or pedal (4), Inset C, if equipped.
2. Remove the differential lock pedal (1) or (2) Remove pin (19). Remove the lock assembly
in Inset A, or (3) in Inset B, if equipped. Re- (rom the brake cover. Remove pin (22) from
move grommet (5) from platform. lever (24) and remove shaft (23) from the cover
3. For tractor with Power Shuttle or Hydro- (201. Lever (24), spring (26), fingers (25) and
static only, disconnect the yoke ends (8), locking collar (21) may be lifted from cover
cotter pins (7) and remove the lever (9) witll (20). Remove bushing (27) from cover (20).
washers (10 ). Remove rod (12).

Inspection

Replace broken and worn part s . Replace grom- Free angle between wire ends ............ 138"
met, roll pins and cotter pins. Re place a ll yoke Torque w l ends
pins if worn a nd grooved. Clleck the locking al 112" angle ................ 42_1 to 94.7 in. lbs .
collar splines for wear or damage. Cllec k th e Inner lever spring (26):
springs for broken or cracked coils or ends a nd Length ....................................... ... 1-13/16"
for the following specifications. l.D .................................. ... ................ 844"
Outer lever spring (17): Wire Dla. .. ......................................... 135"
Length ............................... .. ........... 2-1 / 16" No. of Coils ...... ................................ . 5·1 / 2
J.D. .. ................................... ...... ......... 844" Free angle between wire ends ............. 81"
Wire Dia ............................................ 192" To.rque w Ishor! end
No. of Coils ....... ..... .. .... ........... ............... 5 at 2«<' angle ................. 17.8 to 28.1 in. lbs.

Assembly

1. Press new bushing (27) into cover (20) until In lew I' (18) or peda l lever (4), Inset C, and
flush with outside edge. hole In retainer (16) a ligning with shaft (23).
2. Coat the shift collar (21), groove and internal Install pin (15). Install grommet (5) into plat-
splines, shaft (23), springs (17) and (26) and fOl1ffi. if equipped . Install the differential lock
inner walls of lever (18) and foot pedal (4), assembly to the brake housing, engaging the
Inset C, with Case Anti-Seize Lubricating splines of locking collar (21) with differential
Compound or equivalent. <:l'(lli~ shaft splines. Install retaIning bolts
3. Install pin (19) to shaft (23). Instal l fingers (:l5) t() CQv"r (20) and torque 17 to 21 ft. lbs.
to yoke lever (24). With the short end of spring 6. (nstaU pedal (3) wi th yoke (8) , Inset B, to lever
(26) engaged wit h hole in yoke lever and the (Ill) -Or pedal (2), Inset A, to lever (14 ), if e-
fingers engaged with groove of locking collar .quipped with pin (6) a nd new cotter pin (7).
(21), place into cover (20). 'I. For tractors with Power Shuttle or Hvdro-
4. Install shaft (23) into cover (20), engaging static, ins ta ll rod (12) with yoke (13) to lever
spring (26) and yoke lever (24). Align boles (is). 1nstall rod (9) and washers (10) with the
and install roll pin (22). Install lever (181 or twtl drilled holes a t the L. H. bracket. Install
lever (14), Inset A or pedal le ver (4), Inset C. yokes (8) and connect rod (12) with pin (11 ).
5. Install spring (17) a nd retainer (16) with spring Install the pedal (1) to rod (9) . Install new
ends engaged with hole in retainer and groove cotter pins (7).
 74 -7

INSET A I INSET 8 I INSET C

t~
e·-CD
I ,

e~
cor-~~
~ ~ -
74-8

PARKING BRAKE AND ADJUSTM EN T

(Refer to Figure 4)
Disassembly
1. Position the parking brake lever in the down 2. Remove the pulley pivo t pin (5 ), cotter pin
r e leased position. Turn the handle portion in (6) with washer (7) and remove the cable
th e counte r-clockwise direction. Inset A, pulley (8) from the brake lever bra cket (9).
seve ral turns. Remove the cable pins (1 and
2), cotter pin (3) a nd r emove the brake-cable
(4) .

Inspect ion
Check the brake cable (or excessive wear or in the pivot pin holes or oth er damage. Replace
fraying and if the clevis pin ilOles are worn and if necessary.
elonga ted. If these areevicient , replace t oe cable
assembly. Check the operation of the brake le ver assem·
bly. If the handle docs not go into the engage d
Check the pulley for e xcessive wear or elan· or released position with a decided s nap, it is
gation in the pin pivot hole . Repla ce the pulley an indication the linkage is worn. R ep lace the
if these conditions exist. lever a ssembly.

Chec k the brake le ver brac ke t 'for elongation

Assembly and Adj ust ment

l. Ins tall the brake lever a ssembly (10) with the and new cotter pin (6).
space rs (11 ) to the lever bracket (9 ). Torque
the mounting bo lt s 17 to 20 ft. lbs. 4. With the brake lever in the downward position,
turn the handle portion cloc kwise seve ral
2. Install the brake ca bl e (4) to til e brake lever turns to lncl'€ase the te nsion, Inse t A. Pull
linkage (10 ), and bra ke rod pivot lever (12 1 the brake hand lever to fuJI upright e ngaged
with yoke pins (2) and new colte r pins (H. position and check that the brake applies
fully. Turn the ha ndle counter-clockwise in
3. With the b rake l ever in the down position, the downward pos i tion to dec r ease the tension
install the cable pulley (8) with brake cable if necessary . Repeat the procC'dure it neces -
tothe le ver brake (9) with pin (5) , washe r (7) sary until the prope r a djustment is reached.
 74-9

INSET A
ENGAGED , "\

RELEASED

Figure 4
74-10

BRAKE AN 0 LI NKAGE ADJUSTMENTS

(Refer to Figure 5)

After considerable service, the brakes may r equire adjustm e nt to compe nsate for lining
wear. The need for adjustment will be indicatc'd when the pe dal free trave l exceeds- 2-114".

1. Check a nd adjust, if necessary, t he brake 5. Repea t the same adjustment of the other
pedal lower rods (1) (Fla nged Axle Only). brake. When brakes are adjusted, test brake
These rods when properly a djusted should act ion with the interlock (6) holding both
measure 14-3/ 4" from the ce nter of a d- pedals toge ther. Whe n set correc tly with
justed yoke end hole (2) to the center of the pedals locked togethe r, both brakes will
stationary yoke (3). apply evenly a nd have 1-1 / 4" to 1-3/4" free
ped a l (ravel.
2. Bloc k fron t wheels securely and raise !lP
tractor so rear wheels are just clear of the IMPORTANT Brake pedals must apply
ground or floor. Check tha t the parking brake evenly so that both wheels will stop simul-
lever (7) is in the di sengaged position (down- (aneously when bra kes are applied.
ward).
6. Refer to pages 8 and 9 to ad just the parking
3. Tighten brake adjusting nut (4), until a slfght brake.
drag is felt when the tire is rota ted.

4. Loosen the ad jus ting nut (4) three turns

and tighten the Jam nut (.J).
 .. ~ -JJ

' · 1 /4 TO 1 3/4·· fR EE " " " ....

a J'''..

Figur. 5
 Seclion
81
WIRING DIAGRAM

580 SERIES ' 8 ' DIESEL AND

SPARK IGNITION TRACTORS

Rae. Form 9-80661

81-2

DIESEL BASIC LOADER TRACTOR WIRING AND CODE

WIRE
REF . FROM TO COLOR

'1 Amm eter Gauge Alternator {+} Orange

lA Ammeter Gauge Key Switch " BAT" Orange
2 Neutral Sta rt Switch Starter Motor "S" Yellow
2A Start Button Neutral Start Switch Yellow
2B Key Switc h " IGN " Starter Button Yellow
3 Alternator Resistor Alternator " AUX " Brown
H Alternator Resistor Brown
3A Key Switch " IGN
4 Engine Temp . Gauge Engine Temp. Sender light Green
5 light Switch A u x. Lamp Outlet Pink
6 Key Switch " 5TH Heater Solenoid White
7 Light Switch Headlight Connector Black
.8 Transmission Temp. Light Hydrostatic Temp. Sender Black
*9 Transmission Temp. light Converte r Temp. Sender Black
10 Circuit Breaker " BAT" Starter Motor " BAT" Red
lOA Ammeter Gauge Circuit Breaker .. AUX " Red
11 Engine Oil Press. light Engine Oil Press. Switch Red
12 Fu el Gauge Fuel Send er Blue
13 light Switch Fuse Holder Red
13A Key Switch " BAT" Fuse Holder Red
14 Key Switch " IGN " Fuel Gauge Purple
14A Fuel Gau ge En gine Temp. Gauge Purple
.15(2} Neutral Start Switch Neutral Start Switch Yellow
16 Harness Connector Headlights Black
17 Headlight Ground Black

• Hydrostatic Tractors Only

* Converter T ractors Only
 ' NG'N' II ... ~.".. ."
'NO . O~
. . . . .. UGO<l .....,,,. o ...... C.,....'Clq.
@oo
CD • • ''''''' """"~US
. . ..... " £O""CIO"

.......

(
I ~"_H .......
I
I ......,. ".".
I
I
I
'" ....,.

" . ...'''''.
...." - --; '" ':'" " .. . .. vo.
'" (I' eo
(j). oo 01 . . . . . " .......

....,_....
, ........
-"
.. ... '-
/ /
/' ~ ............
( -'" " ~- ,

I' ....... ",",'''' ---! \

.cO
I

..m .. i.~

........",.
 81-5

SPARK IGNITION BASIC LOADER TRACTOR WIRING AND CODE

WIRE
REF . FROM TO COLOR

1 Ammeter Gauge Alternator (+) Orange

1A A mmeter Gauge Key Switch "BAT" Orange
2 Neutral Start Switch Starter Motor "S" Yellow
2A Starter Button Neutral Start Switch Yellow
2B Key Switch " IGN " Starter Button Yellow
3 Alternator Resistor Alternator " AUX " Brown
3A Key Switch " IGN " Alternator Resisto r Brown
4 Engine Temp. Gauge Engine Temp. Sender Light Green
5 Light Switch Aux . Lamp Outlet Pink
6 Key Switch " IGN " Ballast Resistor White
6A Ballast Resistor Ignition Coil (+) White
7 Li ght Switch Headlight Connector Black
.8 Transmissio n Temp. Light Hydrostatic Temp . Sender Black
*9 Transmission Tem p. Light Converter Temp. Sender Black
10 Circuit Breaker " BAT" Starter Motor " BAT" Red
10A Ammeter Gauge Circuit Breaker " AUX " Re
11 Engine Oi l Press. Light Engine Oil Press . Switch Red
12 Fuel Gauge Fuel Sender Blue
13 Light Switch Fuse Holder Red
14 Key Switch "IGN " Fuel Gauge Purple
14A Fuel Gauge Engine Temp. Gauge Purple
15 Carburetor Solenoid Ballast Resistor Red
.16(2) Neutral Start Switch Neutral Start Switch Yellow
17 Harness Connector Headlights Black
18 Headlight Ground Black

• Hydrostatic Tractors Only

* Converter Tractors Only
81·6

ELECTRICAL ACCESSORY WIRING AND CODE

WIRE
REF. FROM TO COLOR

5 L.H . Warning light Harness Black Plug Yellow

5 R.H. Warnin g light Harness Red Plug Yellow
6 L.H. Flood Light Harness B lack Plu g Black
6 R.H . Flood Light Harness Red Plug Black
7 L.H. Tail light Harness Black Plug Green
7 R.H . Tail Li ght Harness Red Plug Green
8 L.H . Tail Light Harness Black Plu g Black/White
8 R.H . Tail Light Harness Red Plug Black/ White
21 Start Button Fuse Holder Red
22 Fuse Holder L.H. Brake Switch Tan
22A L.H. Brake Switch R .H. Brake Switch Tan
228 R.H. Brake Switch L. H. Brake Switch Ta n
22C L.H . Brake Switch Direction Signal Switch Ta n
23 Fus e Holder Flood light Switch Gray
23A Flood Light Switch Harness Splice w/23B,23C Gra y
238 Black Harness Plug Harness Splice w / 23A Gray
2 3C Red Harness Plug Harness Splice w /23A Gray
24 Headlight Switch Warning light Flasher Red
25 Warning Light Flasher Wa rning light Switc h Brown
25A Warning Light Switc h Harness Splicew/25B,25 C Brown
2 58 Black Harness Plug Harness Splice w / 25A Brown
25C Red Harness Plug Harness Splice w /25A Brown
26 Headlight Switch Harness S plice w /26A ,26B Black/White
26A Black Harness Plug Harness Splice w / 26 Black/White
268 Red Harness Plug Harness Splice w / 26 Black/White
27 Direction Signal Switch Black Harness Plug Green
28 Direction Signal Switch Red Harness Plug Red
29 Direction Signal Flasher Directio n Signal Switc h Brown
30 Direction Signal Switch Right Tu rn Indicator Light Red
31 Direction Signal Switch Left Turn Indicator light Green
32 Warning light Flasher Direction Signal Flasher Red
34 Key Switch " BAT" Horn Button Black
35 Horn Button Horn Black
36 Back·Up Alarm Gro u nd Black
37 Back-Up Alarm Switch Back·Up Alarm Black
38 Key Switc h " BAT" Back-Up Alarm Switch Black W /Fuse
 .. .' ...
..,

.....,...-..... '''''.-

........ """' ~rn.

' .'
"""" .-. .~.-

.......
.. ,.,
,~

0 ..... _ ••c_
. . ....... _HIe",,"
..... ·UP . . . . . . . . """'"

{ @]
.........
......_..._.. -
•• 0 .....

---
.....
""''" ' .,,- . .n ..... 'e.
 SEC T I ON
9 1

MISCELLANEOUS
EQU I PMENT

B u rl. Form 9-7208S K H CBO Printed In U.S.A.

 TABLE OF CONTENTS

REkIR ATTkICH&IENT SUPPORT kIR&IS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

COUN'rERI!iEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3IOLDBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

LmINGkUTDPALLETFORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
ROLLBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.
 REAR ATTACHMENT SUPPORT A RMS

To inc rease the versatlltty of the ma- instructions.) Connec t hydra ul ic 1ines on
chine, the 35 Backhoe, rear counterweight and tractor and drive tractor away.
3 point hitch are all attached to the machine
using the same support arms. To Install an attachment. bac k the tractor
Into the attachment and lower it onto the lower
To remove an attachment, loosen the nut support arms. Install the uppe l' mounting pins
on top of each tens Ion rod and remove the and connect hydraultc line s and wiring as
upper mounting pins. Disconnect hydraultc required. Loosen the lower tension rod nuts
lin es at the quick diSconnect couplings and and torque the top tension rod nuts to 140-170
wiring as required and lift the a ttachment foot-pounds. Then tighten the lower nuts
from the lower support arms. (Refer to until snug and r etorque the top nuts to 450-550
Series 90 Sections 92, 93. and 97 for detailed foot-pounds.

N OTE t, TORQU E TO 290-) 00 FOOT-P OU IWS

I " - NF NU T(4)-- ~
SEE NOTE ) NOT_ 2, TORQU E TO 25 0-290 FOOT- POU NOS

NOTE 3; AFTER UP PER MOUrniNG PIN S ARE

INSTALLED, LOOSE" Ul',ER NUTS ANO TORQUE
UPPER NUTS TO 1 ~0 -17 D FOOT- PDUNDS. THEN
T I GHTE Il LOIJE R NUTS \J Nll l SN UG AN D
~ RETORQUE UPP ER llUT S TO 450- 55D FOO T-POU I,"S.

TE NS 1011 ROO( 2) _ C'~ :f7

5 / S" - IIC x 8" (8) ~_J/4 " - IiC NU T
,RAD E 8-- 00 NOT
SU8 ST ITUTE

~ ",:" I" c ,
rn
a

5/8" - IiC
&
a
""

N~
-

(i)) ~)( ,I
I, / /"/:;.----

. / >lASHER ( B ) / SNA P R ING(4)/'

/1
/ 3 / 4"- "C x 6-3 / 4" (2)

I:l:!;tZ
1
SEE NOTE I

.::;;.--~
./

SE E 1101£ 2 // % "
fI" -:/
/C /

S/iA P RI NG( 4 ) - - f J/ ;

/ eX
/1-,)1'1 '
/"
rn°
Ii
0 @
BOLTS /lUST BE I I/S TALL£O ON
EACH SIDE AS ILLUSTRA TED

LOVER Su PPOR T ARfI ( 2 ) - - T ~"" / L

~ ., REVERSE THIS BOLT IF EQU IPPED
TENS I ON RO~ Pln ( 2) !,.JITH DIFFERE :HIAL LOCK OUT

Figure 1 - Hear Attachment Support Arm s

3
 COUNTeRWEIGHTS

WARNING: Use extreme caution when removing, ins talling, 01' handling a ny cou nterweight.

S80 Lb. Front Count.r_elght

The counterweight is bolted to the tractor

frame by two 3/ 4" x 9-1/2" hex. boIts and
lockwasher s . Four raised pads on top of the
counterweight keep it steady against the loader
frame.

....14.0-""

Figure 2 - Front Counterweight

1400 Lb. Rear Counter_eight

Removal Installation

1. Attach chain holst to counterweight. 1. Attach chain hoist to counterweight and

position on lowe r support arms.

2. Loosen the top nut on e ach tension rod 2. Install the upper mounting pins and loosen
and remove the upper mounting pins. the lower tension rod nuts.

3. Torque the top nuts to 140-170 [oot-

3. Lift the counterweight from the lower pounds and tighten the lower nuts lmW
support arms and lower to the floor. snug. Then retorque the top nuts to 450-
550 foot-pounds.

4
 l " - :IF rWT(4)- ®

~2s: - (~l
uPPER ,,,,aura I riG
BR;\CK ET
<qJ- KLiK PI N(4)
/ UP PE R SUPPO RT " R,"(2)

I ®
, ,~ ==r1
MOUI<T!NG PI N(2P (?>--." ~~' - 3
TH' SION ROO (2) /~ ~ - J/4"-'iC "UT

COUNT ERWElG HT

\ -~
UPPER SU PPORT
ARM PJ N( 2)

7 1C956

Figure 3 - Rear Counterweight

MOLDBOARD
The Model 35 Loader can be switched piece can be unbolted and rotated 180' to
from a loader to a dozer by lnstall!ng a mold- present a new edge to the ground. Cutting
board In place of the loader bucket. This can edges are also replaceable.
be done In the field, using the existing loader
frame and mounting pins, or as a fa ctory To replace or rotate the cutting edge
Installation. pieces :

1. Remove the plowbolts, lockwashers, and

Replacing Culling Edge hex. nuts used to attach the cutting edges
to the moldboard.
The cutting edge consists of t1u'ee pieces
-a 55-7/8" long center section, fl anked by 2. Clean accumulated mud off the mold-
two s hort end sections 7" long. The pieces board. Install replacement edge(s) with
are made of hardened steel and have two plowbolts , lockwashers, and hex. nuts.
edges so that wben one edge Is worn, the Tighten securely.

5
 ~c\_"_ '-..
~~ REPLACEAB LE CUTTING EDGE BM66 0 744

figu r e 4 - Moldboard Assembly

L OGG ING AND PALLET F ORKS

The Model 35 Loader arms can be u sed fork assembly. Both insta ll ations are mounted
to install a palle t fork assembly or logging to the loader armS In pl ace of the bucke t.

FCRK SUPPO RT SHAFT

:>

"" _ _ l OGG 1NG FO ~ K

';

•
PAll ET FORKS

Fig'tlre 5 - Pallet and Logging Forks Without Grapple

6
Figure 6 - Pallet and Logging Forks With Grapple
5/8'
SEE

H 1: TORQUE TO 160- 180 FOOT- POU.'iOS

MOTE St: TORQUE TO 250- 290 FOOT- P O U N D S A WARNING! ROLL8AR MOb'NTINL BOLTS ,+RE
GRADE & - D O W T SUBSTITUTE 7,091 5

Figure 6 - Roll B a r Installation

 SEC TION
92

LOADER

Burl. "orm .. r'nled In U.S.A.

 TABLE OF CONTENTS

HETUHN-TO-DJG .. 3

Operation . . . . 3

Adjustment of Bucket P os ition. 3

ANTI-ROLLBACK .. 4

Adjustment ... 4

STANDARD BUCKET. 5

Cutting Edge Removal a nd Replacement 5

Tooth Shank Removal a nd Roplace ment .. 5

Tooth Replacement 6

4-IN-l BUCKET . . . .. 6

Clam Cutting Edge Removal a nd Repl acement .. 6

Blade Cutting Edge Removal and Replacement . . . ..... . . . . . . . . . . . . .. 6

REiIIlOVING LOADER FRONI THACTOR . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . .. 8

Removing Loader to Service Tractor . . . . . . . . . . . . .. 8

Removing Loader to Use Tractor as Drawbar Unit . • . • . • . . .. 9

EXPLODED VIEWS . . . . . . . . . 10

Control Lever Install ation . 10

Exploded View of Loader .11

Basic Hydraultcs. . . . .. . ............ . . . . . . . . . . 12

Lift, Hydra-Leveling and Tilt Cylinder Hydraulics . . . . · . . . 13

4-in-l Bucket Hydraulics · . . . 14

4-in-l Bucket Hydraulics, Loader Frame . • . . • . . . . . . . . . . . · . . . 15

2
 RETURN-TO-DIG

Operalion to rollback. The ro lling bacl< of the bucket

causes moveme nt all along the return-to -dig
Assume that the operator has the bucket linkage , the most important being the for war d
r a ised and his load du mped. If he now pushes movement of the r e turn - to-d ig latch. When the
the control lever to the left and forward as bucket is in the desired digg"ing position, the
far as it will go, the control lever wlll be return-to- dig l atch will have ph'oted forward
e ngaged and held by the return-to- dig latch. far enough to allow the bucket (tilt) s pool to
return to neutral, hold ing the bucket in
The bucket and lift cylinders are now position" However , the lift cylinder spool re -
ac tu ated- -control valve spools are simultan- mains in the flo at pos ition and the bucket
eously in rollback and float positions. continues its downwa r d movement. The lift
cylinder spool will rem ain in the float position
As the 11ft arms lo wer, the bucket starts until manu all y released by the operator.

Figure 1 - Return-To-Dig Operation

Adjustment 01 tOUChing the control valve mounti ng plate.

Bu·eket "osilio,", If the c r ank contacts the mounting plate,
shorten the linkage between the crank
The return-to-dig linkage is initi ally set and the control lever.
to poSition the bucket level with the ground.
2. Positio n the control lever In the return-
to-d ig position (left and forward). Loosen
1. Position the bucke t flat on the floor the set sc rew in the collar, Fig"ure 2, and
(ground). Hold the control lever in the slide the pipe and co ll ar slowly to the
rollback position and make sure the rear unt!! the control lever is rele a sed.
anti-rollback c rank, Figure 3, is not Then tighten the collar set sc rew.

3
3. To check the adjustment, r aise the bucket
to full height a nd completely dump the
bucke t. Position the control lever in the
return-to-dig position. When the bucket
touches the floor it s hould be in the
desired position.

4. If bucket position Is not as desired, re-

position the collar as required:

a. If bucket rolls back too far , move the

colla r to the r ea r.

b. If bucket does not roll back far

e nough, move the coll ar to the front. F igure 2 - Adjusting Bucket Position

ANTU -ROLLBACK

Gener al positions bucket flat on fl oor(grounc!) --

adjus t return-to-dig as required.
The purpose of anti-rollback is to prevent
the buc ket from roll ing back too fa I' and
dumping t he load on the operator. 2. Roll the bucket back ag'a inst buc ket stops
on 11ft arms and lowe r bucket to the floor.
Refer to Figure 3. The ant i- rollback rod
is actu ated by the retu rn-to-dlg I1nkage. As the
bucke t is raisec! anc! rolled back, the return- 3. Lengthen the an ti-rollback roc! W1til it
to-dig latch pivots forward W1W finally the contacts the anti-rollback cra nk and
ant i-roll back roc! contac ts the anti-rollback tighten the lock nut. Hefer to ngure 4.
crank whi ch returns the bucket s pool to neutral
and/ or prevents moving the bucket spool Into
the rollbac k positio n. A
WARNING: DO NO T deviate from thi s
ad jus tme nt procedure.

Figure 3 - Anti-Rollback Operatio n

Adiu. t tne .,t

1. Make sure that return- to-dig operation Figure 4 - Antl-Hollbac k Adj ustment

4
 DARD BUCKET

6. Refer to 5 and weld cutting

edge to IT se we ld rod spec ifled
in step 5. When welding cutting edge to
CAUTION: rf is not to be front of bucket:
disconnect the wiring
1'PrY1,,,,,,rl alter~
nator and voltage regulator. Also block the a. Start at one end of the bucket and
bucket in position to prevent lJOr8,)nl,1 weld toward the center until one rod
is used.
1. Remove bucket teeth if so equipped.
t 1se carbon arc rod or an acetelyne h. Repeat at the center of the bucket.
cutting torch to remove \\elds. 0:1 8uccee,dirlg center welds work out
from both of center.
2. Remove all cutting edge welds
bon arc rod. If carbon arc c. Repeat 6a at the other end oHhe
a "allable an acetclyne cutting torch may bucket.
be used but care should be taken to
distortion to the minimum. d. Continue ""LCU.U" in this manner until
the i::; completely
3. To aid in removal. cut welded.
off the wrap around ends of the cut~
Cut through from the inside Teeth
corners the bucket.

4. Ramm'e the edge and

any weld (Uld/ot excess metal
to provide a smooth surface for the new

5. Place edge on bucket.

C to hold it in position.
a weld rod A. \V.S. specification
E·7018. flll opening made in each corner.

50S I TI Oil Toe Hi CLOSt ;}::i

?OS S aL£ TO CUH I +!G ,t[ 1m
/ J.'!1ILf: I*iTAINHH; wJ£ft/\LL VlrifN'jj
/

, C
64 j
B"CKET 6Lj" ;;_ ' /q'
J
3-7/8 1 '
7'" , BuCr<r:T 74" 9- 1fL!." 9" 710932

Figure 6 - Bucket Teeth Location

3/16"
__-·-r-fILLET
Tooth Shank Removal
And lIation

L Remove all shank welds carbon

arc rod or an acetelyne torch.

2. Remove shank and grind off any :cemaining

Figure 5 - Cutting Edge Welds weld on the cutting edge.

5
3. Refer to Figures 6 a nd 7 for location BUCKE T - CUTT I NG E~GE
a nd weld s pec ification s. Cse a weld rod
,r.<L
--------
~
mee ting A. W.S. specification E-7 018 and 3/8 " FILLET ~
weld s hank to cutting edge. TWO P
~SS '. ELO~i #'#
Tooth Replacement
W~ A'p -C-OR ~ER
3/8 '1 BOTH SIDE S
Fn ' t
TOOTH

1. Refer to F igure 7. Cse a suitable tool a nd \ ,..../CUrTl tlG EDGE

r a ise the peened portion on each side of ,,
the tooth and remove tooth from shank. 3/8" FILL ET ~ __ • __ J r

T he pe e ned a r ea may be heated with a =rwo

I ____ ...I _..t.' ....... ...--
PASS 'JEl D -----.,
torch to a id in r e mova l.
~I ;~~i~
1_ 2 ~-=.:.::="-i::..:..::.::..:..:~~
2. Sl ide the new tooth onto the s hank as far
as it will go and peen e ach side into Figure 7 - Bucket Too th and
depression in shank. Shank lnstall ation

4-IN-! BUC KET

Clam Culling Edge Removal b. Repeat at c ente r of bucket. On suc-

And Replacement ceeding welds work out from both
sides of cente r .
CAUTION: If the bucke t is not to be
removed , disconnec t the wi ring from the c. Repeat s tep 5a a t ot her end o f
alternator a nd regu lator . Al so block the bucket bucket.
in pos ition to prevent per sonal injury .
d. Conti nue we ld ing in thi s manner
1. Remove a ll cu tting edge welds using until the cutting edge is completely
carbo n arc rod. An ac ete lyne cutti ng welded.
torch may be used but c a re s hould be
taken to kee p d istortio n to the min- Blade Cutti ng Edge Removal
inlum. And Replac emenl

CAUTION: If the bucket is not to be re-

2. Remove the cutting edge. If nece ssa ry. moved , di sconnect the wiring from the a l-
cut o ff the wrap a round c orner s of the ternator and regu la tor . Al so block the bucket
cutting edge to a id in removal. in po si tion to prevent persona l in jur y.

:3. Grind any re m a in ing weld aU the clam 1. Remove all cutting edge welds u sing
to provid e a s mooth surfac e for the new carbon a rc rod. An acete lyne cutting
c utting edge . torch may be u sed but ca r e shou ld be
t ake n to keep dis tortion to the m inimu m.

4. Pl ace cu tting edge on clam us ing C- 2. Remove cu tting edge.

cla mps to hold it in posit ion. Position
cutti ng e dge as s hown in Figure S. 3. Gri nd the remaining weld off the bl ade
to provide a smooth su dace for the new
5. We lcl cutting edge to bucket using E- 701S c utting edge.
we lding rod. Refer to Figure 8. To pre-
ve nt dis tortion we ld the cutt ing edge a s 4. Place cutting edge on blade Llsing C-
fo llows: cla mp s to hold it in posi t ion.

a. Star t at one end o f bucket and we ld 5. Weld c utting edge to blade as s hown in
toward ce nter unt il o ne rod is used. Figure 8.

6
 USE ELECTRODE MEETING A.W.S.

\ E 70'8 OR E 9015 SPECIFICATIOi'lS

ON ALL WELDS.

CLAM ASScMBL v

BLADE ASSEMBL v

I
CUTTING EDG E

Figure 8 - Cutting Edge Welds

7
 REMOV IN G LOADER FROM TRACTOR

The loader can be removed from the

tr ac tor by either of two means- -as a complete ,q
unit for ease in servicing, or with the rad-
iato r guard left on so the tr actor can be used
as a deawbar unit.

NOTE: If loader Is removed to use

tracto r as a drawbar unit, floor plate support s ,
part numb er 050285 and 050286, andwa s hers,
part number A28084 must be used.

Rem ov i ng Lo a der To
Serv ice T ra ctor

1. Re move the rear mounted attachment in

an are a that will not hinder se rvicing the
trac tOl' .
Figure 9 - Reservoir Drains
2. Drain the hydraul ic reservoirs and re-
m ove the cros sover tube and the lift 4. Olsconnect hydraulic lines at pump and
cyl inder cross tub es . Plug' open ings with remove pump. Plug openings with clean
cl ean caplug's. caplugs.

3. Remove the grille and disconnect the

he adlight wiring. Then remove capscrews 5, Remove the fuel tank cover retaining cap-
that secure the hood and side plates to sc rews and remove cover.
the radiator guard, 00 not r e move rad-
Iator guard to ch assis m ounting bolts at 6. Att ach a chain holst to the loader sub-
this time, frame cross tube and take uR s lack.

UPP£R SUPPORT AR,~

TE NS I DOl ROD '-......!....

/
I
BACKHO E
MOUN T I NG
FRAM E

Figure 10 - Re moving SUppOl·t Arms

8
7. Remove the floor plates. Then remove 4. Remove the short section of pressure llne
the nuts from the top of each tension rod, tube and remove pressure line tube se-
Figure 10, and the mounting pin from cured to the right hand reservoir.
each upper support arm and remove the
support arms. 5. Remove suction line from reservoir
sterns and remove sterns from reservoir.
8. Disconnect the hydraullc tubing to the
rear of the tractor at the loader control 6. Remove the fuel tank cover retalnJng
valve and remove the tubing. capscrews and remove cover. Then attach
a chain holst to the loader subframe cross
9. Remove the nuts, washers and bolts from tube and take up slack.
the front of the lower support arms. Then
remove the nuts and washers that secure 7. Remove the floor plates. Then remove the
the support arms and loader subfrarne to nuts from the top of each tension rod,
the rear axle and remove the support Figure 10, and the mounting pins from
arms . each upper support arm and remove the
support arms.

10. fie move the nuts, washers and bolts that 8. Disconnect the hydraulic tubing to the
secure the radiator guard to the tractor re ar of the tractor at the loader control
frame. valve and remove the tubing.

11. Make sure everything Is disconnected and 9. Remove the nuts, washers and bolts from
slowly and c arefully llft the loader from the front of the lower support arms. Then
the tractor. remove the nuts and wa shers that secure
the support arms and loader sUbfrarne to
the rear axle and remove the support
Ren'lovlng Load e r To arms.
U • • Tractor A. Ora_bar Unit
10. Make sure everything is disconnected and
1. Remove the rear mounted attachment. slowly and carefully 11ft the loader from
the tractor.
2. Drain the hydraullc reservoirs and re-
move the crossover tube and 11ft cylinder 11. Attach the D50285 and D50286 supports
cross tubes, Figure 9. Plug openings with to the rear axle. Use existing nuts and
clean cap lugs. bolts with an A28084 washer under each
nut.
3. Remove the grille. Then di s connect hy-
draullc llnes at pump and remove pump. 12. Install floor plates and fuel tank cover.

9
 EX P LODED VIBWS

3/8' '- l.'C x 4"

3/8" - NC x 2-112"",--ij' <" (4)
__

FLAT IIASHERX~/
3/8"- NC NU T .......... ~ ~ ' - '-"
ROL L PI i: LOC KIoJASHER ~~') .... l.J)

1/ 8" x I" " " 3/ 8" - Nc x"'; -0'4"-+1 -----:: RETURtI- TO- OIG LATCH

COTTE~ fJ~- " ~ MOUNTI NG

K"!lOB LOAOER CONTRO L
LE VER P IVOT SHA FT "

COTTE R Pi li
. ."1 D
1- PI N
1/ 8
H
x
...
•

/
'J ~ -
~
LOAOER CONTRO L LE VER BR'CKET
PLATE

O /
K" OB LOCK I NG
RING (2)
~~J~~'
"
x 5/8" \ -"\
~o~ OPTIONA L
I ANT I- RO LL BACK CRANK Ail O
L EVER SHAFT

h
I'
RO LL P I N (2)
1/8" x I "
'\.. l OA O£R
'J.-
--.1;
'!:di2
t
I
.
,
J/8" - I'I C x I "
... 8
It .........
J/B" - NC NUT
I
~ J--
........
LOCKII"SH£ R

'J CO NTRO L - - SPOO L LI NK - /:~L;:.?\l

1 LE V~~ ~ ..-c FLAT WAS HER
:~ PIVO~ : AIm - ROLL BAC K _ _ 2- SPOOL V':"LV E

J V'--~LLf2, f'.~CRAI~:EVIS PIN I

~h JOIl10~ . (4- 6) " '
.v::l L I NKAGE .~ .c -r ~ < Q;''''"'!§iJ:t::;<,
~. .;:-
,- ,.., LOCK'-IASHER ' " SPACER QBl___ SPOOL
, "" - J/8 " - tlF ~ ( 2- 4) ~- 3/8"- >lC NUT
LOADER CONTRO L \'d-..
. ilt _
LEVfR ' \ ..:::::-- 3/8" - ~: F NU T

FLAT \lAS HER

OPT! OliA L COllTRO L

LEVER

71 0928

Figu r e 11 - Contro l Lever Ins ta ll ation

10
Figure 12 - Exploded View of Loader
 F I L TER COimjlTlmi GIIUGE
BREA CHER (2l
~/900 PIPE ELBa'" ~~~ CO",' ECTOR ,

I 90
0
HOSE
" .~"'" ~bl~
~~:,'''~
~-'
,

HYDRAULIC
OIL FILTER I -..;~...
. /"- ' ." 'I - }lC

fp
X II I

SE STEM (2)
)~.

'..J~\SHEfl-- ~
0
FLAT 90 x 1-3/4" (2)
LOCKWASHER~ n I E,
~~
LOC K ~A SH ER

1/2"-"C ,
" xl" (2)
PC'..JER / O-RIIlG / ./
BEYr~~
eROS ,RESERV,OIR'
SaVER TUBE l::
FlTTIIlG / '

~/ O-RII'
O-R I

~?
)t~ -9G" ELBO\I
\t;"'
~ °V a- RI

~
1/ 2" NPT '"
--P'/.. , 1

I ) - l!3.~(
CO;:"ECTOR - - ,

'.1 , ~/ '\ " 45

0
~aSE STE"
--",
c.Q
LOCKWASHER
3/8"_~IC 3/4'1~/~
I. X
(I PIPE TEE

I
~/
A

01 QUICK ~ 3/4"-IIC x 3/4"

)/8"-'~"!C.X6 ~ ~ I"

COUPLI"G
v .,~d
-............. ~ /a~-<.
SCOliliECT-------
,-. \

90° ELBOW--0 "1,0' .--:::::

" ~NC x
"'" J/ B"- 3/4"

33" HOSE--

Figure 13 - Basic Hydraullcs

12
 TO ROD END OF L IFT , T I LT AND
A HYDRA-L EV El iNG CY lI 'WER S, AN D
CLOS 0 EI/O OF CLAA CYli NDER

TO CLOS ED EIIO OF Lin , TILT AN D

B HY DRA-L EVELI NG CY LI NDER S, AllO
RO D EIIO OF CLAM CYLI NOER

CLAl1

0- R I 1111; ---'~:>~/j

1~
1J ~ .I~" l' _-';,..', l 6"-ac x I"

~~
LOCKIIASHER

O- R I" G jQADJ
COIltI£[ TOR I ' TEE'
......... Lln
T I LT --
FIG . "A"

/
7 10955

Figu re 14 - Lift, Hyd r a-Le ve ling and Tilt Cyli nder Hyd r au lics

13
 1'/
/

3/8"- :IC

8LJ,OE: CuTT u,~ EO::iE

~-. /

C YLI~mE R ?I:~

7109;3.7

Figure 16 - 4-ln-1 Bucket Hydl'aullcs

14
 Section
92
SPLITTING THE 480-580 SERIES B TRACTORS

BETWEEN THE TORQUE TUBE AND FINAL DRIVE

THE FOLLOWING ILLUSTRATION
SHOWS THE SPLITlING OF A
HYDRO-STATIC DRIVE TRACTOR
BUT THE BASIC SPLITTING PRO-
CEDURE IS TH E SAME FOR ALL
TRACTORS EXCt:PT FOR THE
HYDROSTATIC PECU LlARITIES.

SUPPORT SHEET METAL, STEERING COLUMN AND FUEL TANK FROM ABOVE
BEFORE STARTING SPUTTING PROCEDURE.

SUPPORT LOADER FRAME FROM BELOW

BEFORE STARTING SPLITTING PROCEDURE

Rae . Form 9 -80711

__ ~~ _ _ . ___
. ~'~~
m
 SECTIO N
9 3

BACKHO E

Burl. Fo ..... 8-720Be K H C BO ...Inled In U.S.A.

 TABLE Of' CONTENTS

t:NCOUPLING BACKHOE FRO:VI TRACTOR. . . . • . • . • . . . . • • . • • • • . . . . • . . . . .. 3

COliPLlNG BACKHOE TO TRACTOR . • . • . . . • • . . • . . • . . . . . • . . . .......... 4

SWIl\G TOWEH REMOVAL Ai\D INSTALLATION .......... 4

DLd""" THE BACKHOE ......... . .. ......... 6

ASSEMBLIl'.'G THE BACKHOE. . • . . • • • • • • . . . . . . . . . • • • • • . . . • . . . . . . . . . .. 7

DIPPER EXTENSION . . . . • . • . . . . . • . . . . • • . • . . • . • . . . . . . . . . . B

BUCKET CeTTlNG EDGES A\;D TEETH. 9

EXPLODED VIEWS . • . . . . . . • . . . . • . 12
Standard Control Levers . . . . 12

Twin Le\·er Controls . . . . . . . • . . . . . . . . . . . . . . . . .. 13

Backhoe (Boom, Bucket, Dipper) . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . . . .. 14

Intermediate Hydraulics . . • • . • • . . . • • • • • • . . • • • . • . • . . . • • • . . • . . • . .• 15

Boom, Dipper, and Bucket lIydraullcs . . . . . . . . . . . . 16

Extendable Dipper . . . . . . . . . . . 17

Extendahle Dipper Hydraulics .. . 18

::Hounting Frarne . 19

Swing Hydraulics . . . .. 20

Stabilizer Hydraullcs 21

Boom Lockout Hydraulics . . . . . ., ., ~ . . . . . . . . . . . . ..

~ ~ ~ 22

Hydra-Guide Hydraulics 23

Control Tower . . . . . . . . . . . . . . . 24

2
 UNCOUPLING BACKHOE FROM TRACTOR

1. Park the tractor on a hard level surface 5. Start the engine and raise or lowe r the
a nd lower the loader bucket to the ground . boom as requir ed (which tips the mount-
ing frame in Ql' out) to r e move backhoe
2. Start tlle engine anel use the backhoe weight from the upp er mounting pins and
control levers to form a tripod as shown drive the pins out. It may l)e necessary to
in Figure 1. Lower the stabilizers Wltil use stabilizers to level the mounting
they just touch the gound. frame.

NOT~ The stabilizers have a two po- 6. With the stabilizers. I'aise the backhoe
sition pivot. The backhoe can be r emoved until the lowe l' mounting studs are clear
with the stabilizers in either pOSition. of the lower support a rms.

3. At the r ear of the tractor there are two 7. Drive tlle tractor forward about one foot
tension rod assemblies. Loosen the nut on and disconnec t the pressure and return
top of each tension roel. hoses at the quick d iscon nect couplings,
Figure 2.
4. Loosen the lower nut on each tens ion r od
a nd remove the k1ik pins from the upper 8. Connect the r eturn hose tc the pressure
mowlt ing pins. Disconnect the dipper light tub e On the tractor. The tractor is now
wirc if s o equipped. r eady to drive away ,

Figure 1 - Forming a Tripod

3
 Figure 2 - Uncoupling The Backhoe

COUPLING BACKHOE TO TRACTOR

1. Line up tractor with backhoe and back up support ar ms and the mounting frame.
close to the backhoe mounting frame. Then drive the mounting pins in and install
the klik pins. It may be necess ary to
2. Stop the engine and reconnect the hy- use the stabilizers to level the mounting
draulic lines. Be sure the couplings are frame.
fully engaged.
5. Make sure the lower nuts on the tension
3. Very carefully back the tractor Into the rods do not contact the upper' mounting
backhoe. If necessary, raise the backhoe arms, and torque the upper nuts to HO-
with the stabilizers. Lower the backhoe 170 foot pounds. Then tighten the lower
onto the lower support arms. nuts until snug and retorque the upper
nuts to 450-550 foot pounds.
4. Ca refully raise or lower the boom (which
tips the mounting frame in or out) to 6. Reconnect dipper light wire if so e-
align the mounting pin holes in the upper quipped.

SWING TOWER REMOVAL AND I NST ALLATION

Removal 3. Number or otherwise identify the control

valve ports and hoses to assure proper
1. Completely extend the backhoe and rest assembly. Then disconnect the bucke t and
the bucket on the floor. Place a suitable dipper hoses from the control valve and
support under the boom and dipper pivot the boom ho ses from tube s from control
to help stabilize the backhoe. valve. Also remove hose clamp fro m
inside the swing tower.

2. Move the boom, dipper and bucket control 4. If equipped with an extendable dipper, re-
levers In both directions to equalize move the hose guard on bottom of boom
circuit pres s ure. Then remove the front and disconnect hoses from tubes. Then
cover fr om the control tower. free the hoses from the swing tower.

4
 5. Remove the swing cylinder rod pivot pin 8. Raise the swing tower to take weight off
retainer from bottom of swing tower. bottom pivot. Then slowly and carefully
Drive the pivot pins out the bottom of the move the tractor forw a rd.
swing tower.
9. Provide additiona l support fOJ.' the boom;
6. Remo\'e the boom l atch mechanism from use a chain hoist or block up. Remove
the swing tower and install a rod (1" dia. the retaining bolts from both boom cy-
x 18") in the boom latc h pivot pin holes. linder pivot pins. Then remove a pivot
Attach a chain to the outer ends of the pin and lower the boom cylinder (repeat
rod. Then attach a chain hoist to the chain for the remaining boom cylinder).
and r e move the slack.
10. Remove the reta iner from each boom
7. Remove the snap rings from the swing pivot pin and r e move the pins. Then
tower pivot pins and remove the pins. remove swing tower from boom.

Figure 3 - Removing/ Installing Swing Tower

Installation in place with bolt. Repe at for the re-

maining boom cylinder.
1. Attach chain hoist to swing towe r and
position swing tower to boom. Then 3. Back the tractor into position to mount
install the boom pivot pins. Secure pins the swing tower to the mounting frame.
in place with pin retaining ha rdware. Install the upper and lowe r swing tower
pivot pins and secure in place with snap
rings.
2. Position a boom cylinder to the swing
tower and install the pivot pin. Coat 4. Remove chain hoist and rod from swing
one side of a washer with grease and tower.
po s ition on swing towe r. Make sure hole
in pin and cylinder are aligned and drive 5. Align swing cylinde r rod eyes with swing
pin in until holes are aligned. Secure pin tower and install pivot pins through bot-

5
 tom of swing tower. Secure pins In place If hoses and ports were not identifiea.
with pin retainer. refer to Figures 11 and 13 for proper
COnnections.

6. Connect hoses to contro l valve and tubes. 7. Reinstall front cover on control tower.

DISASSEMBLING THE BACKHOE

NOTE 1: This procedure outlines the tubes secured to boom and c lose all
complete disassemb ly of the backhoe. There openings with clean c aplugs .
may be occasions when comp le te disassembly
is not required. therefore use the steps 5. If the backhoe is equipped with the
necess ary to remove the affected com- standard dipper arm:
ponent(s). Refer to Section 45 when removing
cylinders for repair. a. Attach a chain hoist to the dipper
arm . Move the dipper control lever in
NOTE 2 : Shims are used a t pivot points both directions to equalize circuit
to r educe side play. When disassembling the pressure.
backhoe. note the number and location of
these shims for proper parts positioning b. Place a block of \Vood under the dip-
during assembly. per cylinder to provide support when
the rod pin is removed. Then remove
Refer to Figures 9 thru 19 to aid in a snap ring and washer from the
disassembly. dipper cylinder rod pivot pin and re-
move pivot pin.
Buckel Remov al
c. Remove a snap ring and washer from
1. Lower the bucket with bottom of bucket the dipper arm pivot pin and remove
flat on the floor. pivot pin.

2. Remove a snap ring and washer from the d. Lift the dipper away from the boom
two pivot pins that must be removed. One and lower the dipper arm to the floor.
attache s the bucket to the dipper arm and
one attache s the linkage to the bucke t
cylinder rod eye. 6. If the backhoe Is equipped with a hydrau-
lically extendable dipper arm:
Dipper Arm Removal
a. Attach a chain hoist to the dipper
1. Remove bucke t a s instructed under Buc- arm . Then push the diversion I·alve
ke t Removal. control down a nd move the le ft hand
stabilizer control lever in both dir-
2. Extend the d ipper arm and lower the boom ections to equali ze circ uitpressure.
until the end of the dipper arm rests on
the floor. b. Disconnect hoses to the e"iension cy -
lind e r at the tuiJe s sec ur ed to the
3. Move the bucket control lever in both boom and close op ening's with clean
directions to equalize circuit pressure. caplugs.
Provide support (chain hoist) for the
bucket cyllnder and remove a snap ring c. Place a block of wood under the
and washer from the cylinder pivot pin. dipper cylinder to provide support
Then remove pivot pin. when the rod pin is removed. Then
remove a snap ring and wa sher from
4. Free the bucket cylinder from the dipper dipper cylinder rod pivot pin and
arm and disconne ct hoses at bucke t cy - remove pivot pin.
l inder and lowe r bucket cylinder to the
floor. Then disconnect bucket hoses at d. Remove a snap ring and washer from

6
 the dipper arm pivot pin and remove disconnect hoses from cylinder. Close
pivot pin. openings with clean caplugs.

e. Lift the dipper away from the boom 5. Provide suitable support for the boom
and lower the dipper arm to the floor. and move the boom control lever in both
directions to equalize circuit pressure.
Boom Remov al
6. Disconnect hoses from each boom cy-
1. Remove the bucket and dipper arm as linder as required and close openings
previously instructed. with c le an caplugs. Then remove the
pivot pin retaining bolts from each cy-
2. Attach a chain hoist to the dipper cylinder. linder and rod pivot.
Then remove the dipper cylinder pivot pin
retaining bolt and pivot pin. 7. Attach a chain hoist to a boom cylinder.
Remove the cylinder pivot pin. Then drive
3. Remove the hose clamp Inside the boom. the rod eye pivot pin into the rod eye to
Then remove the hose guard from the free rod from pin and lower cylinder to
bottom of the boom If equipped with an the floor. Repeat for the remaining boom
extendable dipper arm. cylinder.

NOTE: As the remaining hoses are 8. Attach a chain hoist to the boom and
di s connected , number each hose and its disconnect the remaining hoses from the
connect ing point to assure proper as- boom.
sembly.
9. Remove the boom pivot pin (2) retaining
4. Carefu lly move the dipper cylinder away hardware and remove the pivot pins. Then
from the cylinder mounting bracket and lower boom to floor.

ASSEMBLING THE BACKHOE

NOTE: Install shims in same location and pivot pin. Make sure the bolt hole In the
quantity as noted during disassembly. pin and eye are a ligned and drive pin
Into the rod eye until the holes are
Refer to Figures 9 thru 14 to a id In as- aligned. Secure the pin In place with bolt
sembly. and nut.

Boom Installation 5. Repeat steps 3 and 4 for the remaining

boom cylinder. Then connect hoses to the
1. Attach a chain hoist to the boom and lift boom cylInders and tubes attached to the
boom into position to attach to the swing boom. If hoses were not numbered or
tower. otherwise Identified during disassembly,
refer to Figure 11 for proper connections.
2. Align the boom with the sWing tower and
install the boom pIvot pins. Secure the 6. The boom can now be raised or lowered
pins In place with the pin retaining hydraulically. Position the boom In a suit-
hardware, Figure 9. able position, a nd with the aid of a chain
"holst position the dipper cylinder over
3. Position a boom cylinder to the swing the boom.
tower and install the pivot pin. Coat
one side of washer with grease a nd place 7. Connect the hoses to the dipper cylinder
on swing tower. lVIake sure hole in pin is and position cylinder In mounting bracket.
aligned with hole in cylinder and drive Install pivot pin and secure In place with
pin In until the hole s are aligned . Then bolt and nut.
install the pin retaining bolt.
8. Install hose c l amp Inside of boom, making
4. Allgn the cylinder rod eye with the rod sure hoses are properly positioned.

7
9. If equipped with an extendable dipper, 4. Coat the sides of the cylinder eye with
connect hoses to tubes on bottom of boom grease and place a washer on each side of
and Install hose guard . the eye. Then carefully move the cylinder
into position and install the pivot pin. Se-
Dipper Ann Installation cure the pin in place with washers and
snap rings.
1. Attach a chain hoist to the dipper arm
and position the dipper on the boom. Use 5. If equipped with an extendable dipper arm,
the same number of shims between the cOlUlect the extension cylinder hoses to
boom and dipper as were removed. Install the tubes secured to the boom.
the dipper arm pivot pin and secure In
place with washers and snap rings.
Bu cket In s l allatlon
2. Coat the sides of the dipper cylinder rod
eye with grease and place a washer on 1. Pos ition bucket to dipper arm and install
each s ide of the rod eye. Allgn the rod pivot pin. Secure pin in place with
eye with the dipper arm and Install the washers and snap rings.
pivot pin. Secure the pin In place with
washers and snap rings. 2. Extend or retract the bucket cylinder to
align the cylinder rod eye with the upper
3. Position the boom and dipper arm to a id and lower bucket control links. Coat the
in ins talling the bucket cylinder. Attac h a sides of the rod eye with grease and
chain hoist to the bucket cylinder a nd place a washer on each side of the rod
po s ition cylinder over dipper arm. Con- eye . Align bucket links with rod e ye and
nect hoses to bucket cylinder and tube s install pivot pin. Secure pivot pin with
attached to the boom. washers and snap rings.

DIPPER EX TEN SION

Removal of the dipper arm about half way a nd a ttac h

a chain hoist to the extension.
Refer to Figure 12.
6. Continue pulling the extens ion from the
1. Remov e bucket as inst r uct ed on page 6. dipper arm while being alert for an un-
balanced condition when the extension is
2. Make SUl'e dipper extension is full y re- fr ee of the dip per arm . Low er the e x-
tracted and pos iti on boom a nd dipper to tension to the floor.
facilitate removal of dipper extension.
NOTE: If l' eplacing E'xtension weal'
3. Remov e s nap rings and was hel's that strips, torque the Weal' s tr ips retaining
secure bucket links to dipper extension screws to 45 inch pounds.
a ncl remove bucket I inks.

A Installati on

Refer to Figure 12.

WA RNING: Keep fingers clear of sliding
collar when completing step 4 as the 1. Block up rod end of extension cy linder
collar will drop when the pin is removed. In dipper arm about 1 inc h with a
small piece of wood. Also make sure the
4. R emove pin that attaches sliding collar to rod eye is straight up and down.
dipper exten sion.
2. Attach a chain hoist to the dipper exten-
5. The dipp e r e xtension weig hs approxi- sion and pu s h the extension Into the dipper
mately 230 pounds and is approximately arm about half way. If nec ess a r y , drive
7 feet long. Pull the dipper extension out the extension Into the dipper arm.

8
3. Start the engine and SLOWLY extend the the collar into alignme nt with hole in
extension cylinde r to bring rod eye into dipper extension.
alignment with hole in dipper extension.
If the rod eye contacts one of tile bosses
inside the dipper exten s ion and pushe s
the extension out , move the extension
A
WARNING: Use care in moving s liding
sideways to align rod eye with bosses. collar as the weight of the co llar 11'111
cause it to slide downward on the dippe r

A
WARNING; DO NOT put fingers in pin 5.
a rm when the pi n end is r a ised.

Install the collar and rod eye retaining

hole while extending the extension cy - pin. Then install the bucke t links on pin
linder. with I1nks on top of bucke t pivot bosses.
Secure pin with washers and snap rings.
4. After the rod ey e is aiigned with the pin
hole, grasp the slid ing collar and move 6. Install bucke t as instructed on page 8 .

BUCKET CUTTING EDGES AND TEETH

CAUTION: If bucket is not removed for 8. If old tooth shanks a re to be used , remove
repair, disconnect alte rnator leads and unplug any r em a ining weld before reinstalling.
VOltage r egulator.

Wrap Around Culling Edge Side Culling Edges

Removal And Installation Removal And Installation

1. Remove the bucket teeth if so e qu ipped. 1. Remove all cutting edge welds using
Use carbon arc r od or an acetelyne carbon arc rod or an acetelyne cutting
cutting torch to remove welds. torch.

2. Remove all cutting edge welds using 2. Remove the cutting edge and grind off any
c arbon arc rod or an ace telyne cutting rema ining weld and/or exc ess metal to
torch. provide a smooth surface for the new
cutting edge.
3. Cut through the corner of the bucket and
cutting edge. 3. Place cutting edge on buc ket, using C-
clamps to hold it in position.
4. Remove the cutting edge and grind off any
remaining weld and/ or excess metal to 4. Refer to Figure 4 and weld c utting edge to
provide a smooth surface for the new bucket. Use a weld r od meeting A. \V.S.
cutting edge. specific ation E-7018.

5. Place cutting edge on bucket, using

C-clamps to hold it in position. Using a Buckel Teeth
weld rod meeting A. W. S. specification
E-7018, fill opening made in e ach corner. Tooth Shank Removal And Installation

6. Refe r tc Figure 4 and weld cutting edge to 1. Remove all shank welds using carbon
bucket. Use weld rcd speclfled in step 5. arc rod 01' an acete lyne cutting torch.

7. Install bucket t eet h. Hefe l' to Figures 5 2. Remove shank and grlne! off any remaining
and 6 fa I' loc ation and weld sp ec ifications. weld on the cutting edge .

9
 \

2 PJ',SS 'dEL:)

FI LLET - - - j -:'/"~
! lQ - !-- I 1/4" FILLCT~

HEAvY DUTV TRENCHING .UCKET

3/i6"
F' LLET \r'----t-.,.-'

i '

"I'"
,JlQ' ~- ...- LeT---
:.:.

DELLH08 BUCKET

Figure 4 - Cutting Welds

10
3. Refer to Figures 5 and 6 for location and
weld specifications. Use a weld rod BUCKET - - CUTT I NG EDGE
meeting A. \V.S. specific ation E-7018 and -
~
--- - ----
weld shank to cutting eelge. )/8 " F I LLE T
]',10 PASS \oI E LD ~
~
T ooth Replacement
c-OR" ER~
WRA:"'P-
3/8" BOTH S I DES
11 "
I
TOOTH
1. Refer to Figure 5. Use a suitable tool
and raise the peened portion on eac h
side of the tooth and r emove tooth
from shank. The peened area may be
heated with a torch to aiel in removal.
On heavy duty buckets, drive out pin . .

2. Sllde the new tooth onto the shank as

far as it will go and peen each side into
depression in shank.
Figure 5 - Bucket Tooth and
3. Drive pin in place (heavy duty buckets). Shank Installation

' '' 3
18" BUC KET

3-1/8" 24 " BOCKET

6-1 /2" 30" BUCKET

A LL BUCKETS EX CEP T 12" BUCK ET
,;
pos I TJ ON TOOTri SHA NK AS CL OS E 9-)N' 36" SU CK ET
AS POSS I BLE TO CUTT I f-lG ED GE

__ ~2- 3/4'~
BEN D WH I LE MA IrHA IN I NG THE 1/ 2" 36" BUCKET t
AIl D OVERALL DI MEI1 S ION S.
1--' I I '-, r- -\
1111 r-; I I I I
I
I
I
t
I
\
\
\
\

IT,' "
I
I : I
I I I
: \ I
\

./ H r-(--'r 1
I L 1 I

36" 8u cr~ET

30" BUCKET
U 18-5/8" (J7-IN' OV ERA LL )

15-5/8 '1 (3 1-1 / 4" OVERALL )

,
CE~TOOTH - US ED o r~
12" AND 30" BUCKET S DillY

1-6- 1/ 8" (\ 2-1 /4" OV ERALL}-

24" BUCKET 12- 5/8" ( 25-1/4" OVERA LL ) 12" SUCK ET ~NLY. pas I TIO N
TO OTH SHANK AS CLO SE AS
18" BUCKET 9-5/8" ( 19-1 / 4" OVER ALL) POSSIB LE: TO CUTT !NG EDGE
BE ND AN O MA INTA I i: 0 1•'ERA LL
D ',..,ENS I DH.
I
CEilTER l HJE 7 \0929

Figure 6 - Bucket Tooth Location

11
 EXPLODED VIEWS

BOOM ,
LEV ER
BUCKET

DIPPER

- CLEV I S "!lPO)

- - - - - CU,V I S (7)

SWIN G --CLEVI S ROO (j }

-I· COTTER PiN(I)

- - J/ 3211 X sial!

CO IHROL LE\'!ER

- - 5'.01 "'GLE'JE R ( 2 )

CON TROL VALV E

MOUNT "'G BR ACKET

CLEVIS ROD(2}

)/S" · :K x 7/S"(4) - B

S'.oIING PEDAL SHAH (2)

COTTER n '
1/16" x II '

CLEV I S P",(2 ) ,'" MO Uil T (2)

71 0954

Figure 7 - Exploded View of Standard Control Levers

12
 Â STABILIZER

FLAT wASHER(2)
BOOM-SW 1% 1
JO I HT AND

378"- ¥-,'x I - 1 / 2 " ( 2

CONTROL LEVER BRACK

@flD STAB I L I ZER ROCK
WH ASSEMBLY

COHTROL VALVE
MOUNT I NG BRACKET
C L E V I S ROD(2)-

COTTER P I H (6)
II
l / l O " x 1/2"

CLE'! I S P I N ( 2 )

710953

Figure 8 - Exploded View of Twin Lever Controls

 BUCK Er CYL INDE R '
,

\
1
~ DIPPER
, CYL I NDER
, 'I

i II

P ig-u r e 9 - [,; xP1 ortecI Vie w of Backhoe

14
 CONNECTOR " ' -

CONTR~VE__.....,,,,,_,,q O-R I N G : . ~
BACKH oe

ro
A~ _9GO ADJ.
. . El6G~.J

BULKHEA D ~ ~
\
QUICK I
CO I!N ECTOR
' '\ .l"~"
\ O-R I NG

"'''"~~~.~''''J'~,-,"- _-" HOSE

~ A-
lO:~ G

FLAT WASH ER ' .

~ ~yd 'f ,
~~
C O"NECTOR -~",
I '
' •
.C; , ·.· '-; j-STAB IL IZER CONTROL VA LVE
r ' ~i
<>V, : , '_
) "'-.A"
-A .......0
.,/' O-R I IiG
QU I CK _ O- R I NG ? ~ - 90" ADJ. ELB O"
O ISCO I~IIEC T ~ ,~

90° El8 0''' ----U

HOS E
)6" LO t:G

71 0?49

Figure 10 - Intermediate Hydraulics

15
 0 ' PPE R CYL ' iW€R

O-R ING ___

/~~
CONNEC TOR BUCKET CYLI NDcR
INTERME DIATE ,UB E

ROTATED 1eO '

BOol' cn INOlo'--- 1
•

L. H.

R. H. S·'IVEL
c· JOINT

E
"'-! --- )JII"
0·· ~~~ -HOSE
\~ ~
.....·
?
CLMIP

X . /'" \
1/2"-,', [ " I -J/4 " (4)
LQ£KIiASH ER

HOSe: LENGTH , COlrtROl VALVE TO;

BOOM cn, IWIVE L JO I IlT }8" DIPPER cn. CLOSED [lID 82"
800M cn. CROSS OVl'R , CLOSE D END 2, - 3/4" DIPPER CYL. ROD END 89"
80DM CYL. C~ O SSO '/ER., ROD END 23" BUCKET cn. IIlTERMED I ATE TuBE 94"
IIITER.'ED IAT E TUBE TO BUCKET cn . jI."
7109 ':'4

F igure 11 - Boom, Dipper, and Bucket. Hydraulics

16
 3/8"- I-;c x 1" (4)
:~ LOCKVASHER
S'lAP RI NG (2)

\
EXTE"S ION~ /~ - .,." . ",,,,
CY L "' DE R P IN ?,f ."''"'' ')
FLAT WASHER (1)- 7 ' 9'~ I )
I~ OIPPER CYLI ND ER Prr~
~9' ~, / E
IJi1~y( ~UCKfT CY lI NDfR
DIP PER _ I .I I
(j PI:I

I /.:' I ' 6", C- SiiAP R I riG (2)

SPA CER /.':, . ._ t£--<..:: I , ~
......_~I I ( ) P RING
"SNA
I EACH SlOE-WJ - ~'W I, 2
~-t ~ - SL I Oli:G COL LAR

____ DIPPER P IVO T PII

\
'''A
V - SIIA? R IIIG ( 2)

l i I (

•
S TO P ~
'- ij~ ,.:'b t~r
I aol I 1/2 " - 1<C x 1- 1/ 4"( 4)
GRAD E 8 -0 0 NOT SUBSTIT UTE
WEAR STR I P(8) ---

'-J Q- BUSH ING (2)

1"'--.. SPACE R

- - EXTE I:S I 0 ;) CYL I NOE R

(2 )

12-24 x 1/2 "

/"
PH I LLJ PS HEA D

~(;clJli
TORQUE TO 45 IN.-L6S .

BUSH IIIG (2) ~

SPACf R (2)
I
USED '.... rTH STAN DAR D 711C 03
BUCKU S ONLY

l'igure 12 - Exploded Vi e w of Extend able Dipper

17
 70" Loue ('-)

\, r
3/B"-t.:C x 1- 1/2 "' - _.n. FL AT ' 'ASHER_ "
,
I _",0 _
ro" LOCK,'ASHER
_
I I

/~ I 1
x 1-1/2" - '"

<~\
900 ADJ .
fLaO>l -
A",
W
.
I I

EX TENS IOIJ _ _
!
en INOER

STAalLIZER
CON TROL V,.LVt
67" LONe (2)

3/8"- NC x 3- 1/4"

HOSES TO L.H .
\/ .~,.
r
"'
STAB I L I ZER

900 A~J.
ELB{)\I

9 00 ADJ .
711004
ELB"" (2)

Figure 13 - Extendable Dipper Hydraullcs

18
 ST.4SIUlE R
--CYL lt-IOE:R

LOCK',IASHER _ .,

)/8"- ,,( x I" (2)./~ STABILIZER-

SNAP R I t'iG

Figure 14 - Exploded View of Mounting Frame

19
1/2"- :! C x

- HOSE 23 - 1/2 " l Oi,G

900 AOJ
ElS"'; . . - - -

HOS E
25-1 /2 "

PLUG

SH I"(S

A
Q- RING
ROTATED 90·

"_ ~
RESfR t C10 n ~ 0- HO SE 20- 1/2" L O j~G

9) AD~.~r\
El BaJ

Figure 1-
;J - !:)wino-
o 1-1 ydrauli c s

20
 3 /8"-~~C x I " _~

~- J /8"-"C K 1- 1/4"

..." PLAT E

3/8 "- :IC x 2" (3) __ .-:}P> ~'

.."

HOSE (4)
33 " LO;IG

900 ADJ.

co:n~ECTOR

Figure 16 - Stabilizer Hydraulics

21
23" LOii G

CAP USED WJTHOUT

- HYDRA-GU 1DE

71 0961

f'igure 17 - Doom Lockou t Hyclraulics

.

22
1TO CLOSED EllD OF e Vl n lDER

2 TO RO D EIID OF CVl l NDER

7 10957

Figure 18 _ Hydra-Guide HydrauliCs

23
 UPPER FRO~n COVER

/
0_ )/8"- "C x 3/4" (5)
-LOW,/ASHER

'''' - - FLAT WASH ER

3/4" (4)

.f'
" _ LOII eR FRONT COli ER
/_
c'"

tx
QU ICK EDGE
...........24 11 LONG

'to.. /
QU I CK EOG£
)8" LONG
L.H. FOOT
3/8"- ;;C
I
"
I CONTROL
TO\IER

I LOCKWASH £R ~~. " \ I

3/8"- ;!( x 3/4" - ,::--:,' t I
\ MQU"TING.........-~
" - BR ACKET I

L OCKWASH~ ____ "

,/ ~ - ,.I-

)/8 "- " C NUT (&) - " •

. : _LOC KIIASHER

~ '- ~
' - I /Z " - NC IIUT (3 )
~ ~

1°
J .

Figur e 19 - Exploded View of Control Tower

24
 SECTION
97

THREE- POINT
HITCH

B u rl. Form 9-72085 KHCBO Prlnled In U.S.A.

 REMOVAL AND INSTALLATION

Rem oval arms. Raise the hitch until the

control valve mounting arm clears
1. Locate the m achine on level surface the tension rod.
and lower the implement. Then raise
the seat so the seat adjust ing lever will
not catch in ho ses from control valve.

2. At the re a r of the tractor there are

two tension rod asse mblies, Figure 1.
Loose n the llpper a nd lower nuts on each
te ns ion rod. The n remove the klik pins
from the upper mounti ng pi ns .

Figure 2 - Hitch Raised With .Jack

5. Carefully drive the trac tor forw ard about

one foot. stop the engine and disconnec t
the pressure and return ho se s at the
quick disconnect couplings .

6. Connect the return hose to the pressure

tube on the tractor. Be sure the coup-
Figure 1 - Hitch Removal ling is fully engaged. Care full y drive
the tractor away fr om the hitc h.

3. Lse the lift and pitch control leve rs as 7. If the hitch is to be left standing for
requ ired to remove the we ight of the an extended period of time, block up
hitch from the upper mounting pins. the hitch as s hown in Figure :3 to pre-
Then drive the mounting pins out. vent loss of position.

4. Remove the hitch from the lower support © UserFriendlyCDs

arms.

a. If the real' mounted implement

weighs less than 500 pounds , use a
hoist or Jack to lift the hitch out
of the lower su ppo rt ar ms . Ra ise the
hitch until the cont rol valve mount-
ing arm c lears the tension rod.

b. If the rear mounted implement

weighs more than 500 pounds , use
the lift cylinder to raise the hitch
out of the lower support ar ms.
Slowly move the lift control lever
into the lower position and the hi tch
will raise out of the lower support Figure 3 - Hitch Prepared For Storage

2
 Lse the and pitch control levers as
required and align the mounting frame
1. Align the tractor with hitch ami raise with the upper support arms.
the seat high enough to prevent the seat
adjusting lever from catching in the 5. Drive the upper mounting pins in and
hoses from the control valve. secure in place with klik

2. Back the tractor into the hitch until

the hitch mounting frame enters the 6. J;l.ake sure the lower tc;n:oion rod nuts
lowe r support arms. Stop the and do not contact the uppe,' support arms
connect the hydraulic lines to and from and torque the upper nuts to 140·170
the control valve. foot-pounds.

3. Carefully hack the tractor completely 7. Tighten the lower tension rod nuts until
into the hitch. Then lower the hitch into snug and retol'que the nuts to
the lower mounting [lrms. 450-550 foot-pounds,

3
 II FT .4R11

LIFT ARM $H4:fi

I
\
LJFT CYLIIHlER PI"

SUSHI (2)

TiLT CYLI~dJER f)I::

LO~KwP.SHER

".-4- 1/8"- flC :lUT

PITC,,; CYliNOER

:",
3/8' '- ~;C liUT
SPACl:R

- - - t l LT CYL: ~mEK

$!,JAY
BLOCK (2)
P iVCT P 11,1

Figure 4 - Exploded View of Three-Point Hitch

4
HOSE LENGTM S, IJALVE TO : 450 ADJ. ELB OW () -4)
RESTR ICTE D FLOII
LIFT CYLINDER CLOSED Efj D - 56" LETT ER ~ STAM PED
LIFT CV L I NOER ROO END - 45"
TI LT CY LINO eR CLOS ED END - 66" HOSE CLAMP
TILT CY LINOER ROD 10110 - 54"
PI TCH CYLI NDER CLO SED EIIO - 42"
PITCH CYL I ND£R ROD EflO - 45" .r,~
I
"

90')

PITCH CYLI NDER

f.
I:l ~ _ T ILT CY LlllOER
- - HOS E 36"

,l ~ QUI CK DISCONNECT
'f!::!.~ - COU PL I NG

- 90 0 PIPE ELHCIIi
710927
L IFT CYLIUOER

Figure 5 - Three-Point Hitch Hydraulics

5
 f' l TER MOUtlT I NG BOLTS
l / Z"-IlC x 1-1 /4" .... ,TH
FLAT ~AS H E R AND LOC K-
wASHER. .

fl LT£R

~ oo HOS E

) /2" - NC x - 3/4" (2)

~
o- R lHG

COUP U he

REL IEF
/
CONNECTOR
/
3/8"- tiC x 2- 1/4"
'" //
3/'~~~~~:'~l~OGKWASH~ ~. .
' / 2' '- NC flU T

::;r::::::::;~~= L OC~SHER
/
3/S"·IIC NU T

HOSE 36"

110952

Fil,,"ure 6 - Basic Hydraulics for Three- Point Hitch Only

6
 Sectio n

101
HYDR AULIC TESTING

TORQUE CONVERTER-POWER SH UTILE

RAe FORM 9 -80981

 101-2

CHECKING OPERATING PRESSURES

Engine speed 2000 RPM
Converter - Power Shuttle oil tempera ture 1100 to 1300F.
Pump output - 9.5 GPM minimum

CLUTCH BRAKE SHUTTLE SHIFT CLUTCH CONVERTER POWER SHUTTLE

PEDAL POSITION LEVER POSITION PRESSURE CHARGING LU B OIL PRESS.
TEST PORT "c" TEST PORT "B" TEST PORT "0"

1 Depressed Forward or 0 30 to 40 PSI o PSI

Reverse

2 Released Forward and 170 to 190 PSI 30 to 40 PSI 15 to 40 PSI

Revers.e

3 Released Forward and 150 PSI Min. 15 to 40 PSI 15 to 40 PSI

Reverse

4 Re leased Neutral 180 to 200 PSI 30 to 40 PSI 15 to 40 PSI

• Engine .peed reduced to 600 to 650 RPM

If clutch pressure at test port "C" is not within the specified ranges, shims can be added
or removed under the clutch pressure regulator v".lve plug. See Page 61-6. It is possible that if
the clutches are worn or leaking that this pressure cannol be reached . Never over shim to a point
where the regulator spring becomes solid .

If the converter charging pressure test port "8'" Is not within the 30 to 40 PSI range the con-
verter regula tor va lve spring page 61-2 should be cha nged or the converter regulator valve spool
. could be sticking In its bore. The spool should have a smooth free act ion in the bore.

The power shuttle lub oil pressure test port "D" is cont rolled by the converter regulator
valve and also by the a djustment of the power shuttle flow spool page 61-11.
 101-3

POWE'R SHUITLE CONTROL VALVE

CONVERTER CHARGING
~r.;I1~p~~L,.~Sl;!!f1.~::::::'~-PRESSURE TEST PORT " B"

TORQUE TUBE
NT COVER

CONVERTER AND LUBRICATI ON

OI L REG ULATOR VALVE

POWER SHUITLE "n,N'"R('L

A20,72 RESSUR E GAUGE 30 0 PSI

BE FRONT COVER

POWER SHUITLE LUBRICATION

OIL PRESSURE TEST PORT " 0 "

\
TORQUE TUBE FRONT COVER
101·4
FITTINGS REQUIRE D FOR TESTING POWER SHUTTLE PUMP
OUTPUT AND MAIN RELIEF VALVE
(----------, fl
®(iY
(O(~ fl'
L'>19~ , 'Co,<,:q(J~,J!J
~- JJ)

~ r "')
...
O" .
,f,
f'5\-- <t~,~ , (1) ............. .
I.V .' ' I(J

REF. PART NO.

NO. NO.
DESCRIPTION
NO;;.P
REQ'~
'" P
~. ~ ~
i1" .
•
L~
· 111(.
1 R21817 314" Shut off Valve 1 ",
2 221-211 314" Close Nipple 1
3 221-425 314" Female Pipe Tee 1
4 A21568 5/ 8" LD. (-12) Bulk Hose 2
5 220·128 3/ 4" -14 Male pipe 3
6 220·145 7/8" -14 JIC 37° Male Flare 1
7 220-127 112" ·16 Male Pipe 1
8 220·105 718" ·14 JIC 370 Female Swivell HYDRA·SLEUTH
9 A21567 1/2" LD. (·10) Bulk Hose 2 M20270 60GPM
10 221-93 314" to 1/ 2" Pipe Bushing 2 M20271 30GPM

L I
/.J
~/";

~c~~

TORQUE TUBE DIPSTICK HOLE

HYDRA·SLEUTH

I
SHUT·OFF VALVE OPEN

I~~=-LOAD VALVE

RPM SHUT·OFF VALVE LOAD VALVE GPM

2000 Closed Adjust to 375 10 500 PSI 9.5

2250 OOled Adjust to 200 PSI Minimum 11.3

I .fer '0 43·4 for relief valve adjustment.

 HOW IT WORKS

HYDROSTATIC POWER STEERING

TABLE OF CONTENTS
Introduction ........................................................................................................................... 151-2

Oil flows
Right turn - Engine running ............................................................................................... 151-4
Left turn - Engine running ................................................................................................. 151-6
Right turn - Engine not running ......................................................................................... 151-8
Left turn - Engine not running ......................................................................................... 151-10

Rac. Form 9-80801

 Reservoir, Filter and Engine Driven Power Pump
The- ~ I J W P T I- > ~ . I ? [ )is i t pi>:iit.i~ I- ~ - f i s [ d ~ ~ e n war ~ ~ f p u ~ n p .A r e s e r v o i r : i ~ ~ <filti-:-i-
- i ( - ! type' i u i n t are
ln-iil? into t 1 1 ~;i:?:-wnlil;,-. .\, i'ii11-r:incl Ipvel indicator <:rap a s s f t r i M y is ii-icorporated it: rhc .rc)s~!r-
vnir. A sysrcn-I prf-m1.11-r.rolii-af \ ' i i l v : \ i-5 .ns.si:nibled i n t h e ¥pum ini-errtic-iliii* e o v ~ tro protect'.
!he.# ~?-slein-i i m m i ; s t t - ~ < i ~pvi - ~ - ~ - i s i i i - i - ' nn(J clilmage to [tic st.efpriri";components.
H:,-(h-:ji.ilii.~~ I T .1 I. r : ~ * : i l o i l :<Â¥iippl~ for tht:' powi-%r steering eylinc&r'; is p.~"ol>-idr+'i 1'17: iii(: ~ o ! , ~ P I *
lii-inip cktriri~;~ - n q i i - ~op/"rtiliun.
e
Steering Control Valve

Manual Steering Pump

A 1~0'sitii.-t?rli?;pl :wt-'m;?nt FT.'M'hi-direc?tion?11
.Q', puinp is d r i v e n by the steering w l i e ~ l .11- pro-
vidcs .st.~erinc;cmli.wl iincl ol~~r;ii:ioii:!.l pressure through the steering control v;ilvc. T h e m:+nurti
pi.inip con~.i.ss?of :I ~ u i ~ p s i i ?i gI t - i n ~ n t frotor and stxtor), commutat.or, cirive lit& nnc.t ronpling
5h:ift aiid l-indy. Tho st~eringv.'h~'f-!d r i v e s t h e coupling silijft, commutator and rotor (iirectty a t
;.t 1 to 1 riitio. A fiiii-sde l ' - i - 4 1 . i ~ ~ ~exists
'£ i n t h e event of power pump f a i l u r e , manual pump only
~terriiig,!which r e q u . i i - ~ 5inc~r-ni-:.;pet opc.r:Itor effort on t h e steering i~hce1,
 151·3

/--7',
J 1/
,If
j]
PUMP
I
I

i
~1 I
/ ' 't
CONTROL vAI.VE--·

J! .,\\
\\
\. \j
\ I
'-. .../
R.H. CYUNDER-.......,P=--<'~

1
1.51-4

RIGHT TURN -ENGINE RUNNING

(Refer to Figure 2)

Reservoir, Filter and Engine Driven Power Pump

\\111ellE' \"C'l' the ('nginp is running the power stee ri ng pu n1p ope r ate s con t inuous ly , fir:1\Qng oil
[ m nl Ihl' l't'O",'l "\'oir , The resc'l' voit' h as a l)ui lt- in filter r e li e f ,'al v c , If the filte ,' e le m ent be -
(,Onlt's p luf\~ecl d u(' la llL'gll'ct th" relie f val ve will open a nd a ll ow wlfi lte red oil to pass in to t h,,'
pum p. Tile pump has <l iJ ui ll i n re lief va lve whi e h pI'aleels the steer ing system a gainst exces -
';i l'(' pr<,s sur s ,mel (l:llililgl' 10 the stee r ing c ompon ents . Th e oil is di rected to the stteri ng CO n-
tro l \'u l,'''' lIndt' ,. pump pn's-ul'( ' th rough tubi ng.

Manual Steering Pump

manu: tI ojteer in~ pump in a f1.H. t\lJ' n pr ess u r iz es o il from th r ee stato r a nd r oto!'
T I1('
eavi tie ~
tht'ough th ree holes in the pump bocly in to three holes in thc commu tato r . Th oi l the n
p,15ses from thl' thl'~l ' hol e s thro ugh the center of the commu ta to r to the r earw a rd cavity a nd
out th m ugh th p I., II. port to ill(' con tI'ol \'alve .

Steering Control Valve

ThE' pr essu r ized oil fro m lhe m a nu a l [Jump R.H. po rt e nte r s the n.H. valve i nl et port . Thi s
pressu !'iz <I oil lllo ,'es the ~JlOO I t o the le ft uncove ri ng pas sages wh ich per mits oil frail} tb e
power pu mp 10 JlJSS th rough the ~poo l a nd out the L . H. m an u a l pump po rt. The o il then e n te rs
the L.B. port o f th(> manual pu m p. The m anu ul pump inc r e as es thi s powe r pu mp pres8Ul'e and
dir pcts it to aneI through the c Ontrol vul ve to the f1.H. port to the s te r ing cyli nde rs ,
Steering Cylinders
Thc pres ur ized o il i~ ciirected to the two cylind e rs and e xte nds the R.H. c ylind e r a nd r e -
t!':lct s the L.H. c"li nder t u m ing thc wh ee ls in a righ t h a nd turn. Re t.urn oi l be ing'd is pla ced
r,'om th., steering c yli ncl", r s re turns through the L.H. s tee ring cy linde r port and passug s in the
cont r ol ' "R i ve and r c turns to th'" fil ter Rne! r eservoi r .

LH , STEERING CYLIN DER

R,H, STEERI N G CYLI N DER

 J51-5

MANUAL PUMP

STEERING SHA FT

MANUAL PUMP

CO"'IlOL VALVE

o
•
POWER PUMP PRE SSU RE

MANUAL PUMP PRES SURE

o
•
RETU RN O il

SUMP O IL

L H. CYLI N DER
INTERMEDIATE
COVER " "

" '- - • . H . CY LI N DER

R"'I,ve•• POWER PUMP

FILTER

Figure 2
 151-6

LEFT TURN-ENG INE RUNNING

(Refer to Figure 3)
Reservoir, Filter and Engine Driven Power Pump
\\ l)~Il l'\ ' <:r i ~ runnillg" the pOWel" s t-e e l'ing pump op el'tl les eontilluo us l.\", dl'<lwing oil
11w 1,..Iltgilll'
fl"<lm til l' l'l'~<'n-u il ',
1'1,,' n ''',·'rQ)il' il:tS" llU ilt in fil ter l't' li ef n ll ve. If tile fill e r element be -
('() Il1 L'~ plug-g-L'd d l l<' \n H'gi<'(' I 1 ill.' l'eli d n lIq> \dll open and a llow unfil ter ed oil to p ass in to the
pump. Tl w pump IL'S :J buill- iII I'c'l i <"!' va lve whi ch protects the s tee ring s ys te m again s t 8.X(:es-
s il t' P 1 T~ S\ln '~ :llld (i:J lll ;(gV l()llw ~t"'(,I ' in g col1l p011 e nts , The oil is dir ec ted to the 5 t el' i ng 1.'011-
11'001 \ -~ lln." unck ' }' pum p lll'{&:-;:-:'Ul'.t' th rDugh lul) i ng" .

Manual Steering Pump

n w l11:H\ua l st l'L'l'illg pump in:J L II tUl'lI , pl'eSS lIl'i z('s o il h'o m t hr ee s tator and rotor c a vHies
rllr,)ugh III rl'C' holes in Th" Jlump hod ~' into three s lo ts on the co mJmlt ~to r. T he o il thell ptl"se s
ft'n m tlw llll'l'l: " Iuh to llll ' rnl'\\' ard cavity and out through t he LH pO.r t to t he co ntrol v al ve .
Steering Control Valve
The press ur .,,,1 oi l from Ihe 111:lllua l pump LH port enters tile LH va lve in le t por t . Th is
I'r'--' '; ~llr iz. l'il
oil m o\'l'S the ~ plln l to the r ight uncove r in g passag es which pe rmits oil fro m the
PO\\·o.:1' [l1l 111P lO pas,; thr ough ti le spool a nd o ut the TIH m a nua l pump po r t. T he o il then ente rs
th~ lUI pori of IIle m 'll lLu l )Jllmp , The m a nual pump in creas es th is power p ump pressure and
direCI" it td :> !leI lh l'Oug-h the contl'ol va l ve to the LH port to the stee r ing cylinders ,

Steering Cylinders
The [ll' estiur ized oil is di reded ( 0 the two cy lind e r s and e xte nds t he L.H. ~ y li nd cr and ra-
Il' ac ts the H. H, cy l inder , tur nin g llw whee ls in a LH tU111. {( eturn oil being cli s placed fro 111
Ih e stl"el'ing C'\'lind e r s ,,<,turns Ihrough the Il.H, Slee l'ingcylint.l er po r t ancI [1a ss ages in the: con-
ll'ol \-"In, a"d r<?turilS 10 Ihe fiill')' uncI )'c s en'o ir.

LX STEERING CYLINDER

R. H_ STEERING CYLINDER
 151-7

STEERING MANUAL PUMI"'

CONTROL
VALVE

'EAL

MANUAL PUMP

CONTROL VALVE

D
•
POWER PUMP PRESSURE

MANUAL PUMP PRE SS URE

D
•
RETURN OIL

SUMP Oil

INTERMEDIATE
COVER ~
,

.:'\:- - ' . H. CYLINDER

POWER PUM P
FilTER ''', ....,,''

Figure 3
151"8

RIGHT TURN-ENGINE NOT RUNNING

(Refer to Figure 4)

Manual Steering Pump

Th e manual steering pum p Ll1 " HI-! turn pressurizes oil from thr ee s t ator and ro tor (·. Lvi ties
through th r ee holes in th e pumJl bexly into three hol cs in th e commut ato r . The oil then passes
fro m the tll r e holes through the center of the c ommutator 10 the' 1'ea1"\\' 0.1"(1 ell"i ty ;mel out
through thc HH port to the con tt'o l valve .

Steering Control Valve

Stat ic oil from the power pump e x ists i n the control valve po\\'e r pump inl et «nel DUll e pt\s-
sages . The prezzurizecl oil f rom th e manual pump HH IXl l' t ente rs tht· H nLh" [niP.! POrL "
This pr essurized o il moves the manua l valve spool to the le ft. , uncove'ring passa~es \\'hi"h
pe rmit }Jl'essllized o il to ente r awl pas s through the IU I.(;yli nd er porI.

Steering Cylinders
Th is pl'essuized oil is di r"cted to the two cy li nd ers and e:"<tends the H. H. cdi ndel" and re -
tracts th e L"H . cyli nd e r . Heturll oil beingd i5pl :l<!ed fro m the two cyli nd<,l'S l""turns through the
L , H . cy linder POl't, ba ll c h eck and th e s pool to the LH manua l pump P'Ht. T he oil h then n'-
tLLl'lled to the inl At port of the nlO.nual pump . Atmospheric pressul'e ill thE' resel"voil' w ill fo rce
oil into the manu a l pump ci r cuil to r ep lace any oi l lo s t through leaka ge ' " the lnOUllIo,! ~tl'f' l' il1 g
cir cui t ,

l.H . STEERING CYLINDER

R.H. STEERING CYLINDER

 151-9

MANUAL PUMP

SHAfl

",.

MANUAl PUMP

CONTROL VALliE

•oo MANUAL PUMP PRESSUU

RETURN Oil

STATIC on

"111,, ,--•.H. CYLINDER

Figure 4
 101-10

LEFT TURN - ENGINE NOT RUNNING

(Refer to Figure 5)
M anual Steering Pump
'I'll(" 111:mu:tl ~1I ' vt' iJlgpu n )p , ill:i I.E tUl'll, pI'eS .: ul'iz es o il [rom three stator and l.'o tor t:a vi Cie~
11l1'oug'll [11 1'1 '<-' h o lc-~ i ll Ille )lump \jod,\- into 1I11'el' s lots 011 the commutator , T he oil then passes
l l'll m Ill<' threl' ~1{)I~ 10 1111.' fOI'\\ " rd c<lv ity a lld out throug'h tilE' LH port to the control val ve ,

Steering Control V alve

" Lltie o i l f r om tht' PO\\',' I' pu mp ex i s t s il1 the c ontro l va lve power pump in le t and outle t pas -
T hl> }ll't'SSlI l'iz lCli oi l 11'0111 the ma nual pu m p LH port e nters the LH ""Ive inlet port ,
,;<If!:(',; ,
T hh }ll'<,ss\ll'i zl'ri oi l fro m l h t' 11 1:1l1ll a l pu m p moves the s pool to the right, u)'l coverillg passage"
\\ hid, pt'rmit l)re ssu r iz ,'d oi l to (>l\ter al1d pass th r ough the LH cy linde r port.,

Steering Cylinders
Tl,i, pI'eSSllri7yd oil i5 di r ected to the two cyli nd e rs and p.x l e nd s the LH cy lL ncler anel re-
t )':lCIS IIIf' HI I ~ d; n{le,. . Ht'\Ill'n o i l h l?ing di spl aced from the two ,-,yli nd " rs r eturn $ t hrough
the' I( H " dind.-,. POl't , h a ll dwl'i, anti the s poo l to the HH m:mual pum p port . T he oil b the n
'-('('11'1\, '(1 to th£, inlel port of thL' manua l pum p. ,\ tm osphe ri c pr es"ure in Ihe I'eset' \'oil' \\' i ll
fo r C'~ oi l int<1 tilt' mCll1ual pum p l' i reui( to replace any oi l lost t hrough l Citkage in the manual
stL'C:l' i ng c i rc uit.

L.H_ STEERING CYLINDER

R. H. STEERING CYLINDER
 151-11

S T EERIN G
CONTROL
VA L..V E

MANUAL PUM P

CONTROl VA LVE

MAN UAL PUMP PIH SSUIlE

o RETURN OIL

o STATIC OIL

iii . H. CYLIN DER

Figure 5
 Section

162
HOW IT WORKS

TORQUE CONVERTER

WITH ROCKFORD POWER SHUTTLE

TABLE OF CONTENTS
l nt rod u ~t i o n

Tor que Converter ............... ........... ... ...... ......... ... .. ... ........... ................. ......... ..... .. ......... ....... 162.2
Power Shuttle .................... .. ...... .. ........ .. ..... ....... ..... .... .. ...... .. .... .. ... ... .. .... ........... ....... ... ....... 162.3
:"\ eutra l .. ..................... ... ... ... .. ...... .......... ....... ........ ..... .. ... ..... .......... .. ....... .. .............. .. ............. 162.4
Forward ............ ...... .. .... ... ........... .............. ........ .... .... .......... ..... ..... ........ .. ............................... 162.6
Reve rse .......... .... ...... ...... ........... ..... .... .............. .. ...... ........ .... ...... ... .. .............................. ......... ]62.8
Clutch pedal depressed (dumped ) .. ....... .. .. ....... .... ......... .. ...... ..... ..... .. ..................... ... .. ....... 162.10

Rae. Form 9-8 0 4 8 1

162·2

INTRODUCTION
Torque Converter
Th e 1'Ol''1ue Converte r i s mounted to a nd housed in the to rque tube helw een tbe ngille LInd
tr ans m iss ion, The to rque c onverter is splincd to a.nd drive n 11Y the e ng ine Oywhe el . Th e
o il supply for the tor que convel't.er is s upplied by fL gear tYllE' ]lump driven by th e tOl'qUO con-
verter,

The tOI'US is a pass a ge l ocated in

the rotating hOll s ing which l' t::'ct! i \ ,"('-:5
oil from th e impellel' and ciirects
T be i mpe lle r is loc ated a t the
renr o f th e to r qu e c onverte r a nd
rIri \'en by the r ot atin g housing ,
which i s conn ecte d to and drive n by
----
this oil to the turb in (; .

the e ngin e O}-",\'hee L The oil s uppl y

io the to r que converter is picked
u p by t he i mpel le r and forced out-
,,·a1'd to "pass - the tor·us .

The stalor r ccei ves the o il rom

the tu.rbine and by means of cu rved
vanes , ch anges the cii r ection of the
oil IDld cii rects the o il back to the
i mpeller .
The turbine receives the o il rom
th e torus. The force o f the oi l a -
gainst the curved \'" a.nes callSt'S the
turbine to turn. The tur hine is
connected to and turn s the outpu t
sle eve . The oil leaving the turbine
Figure 1 is directed to the slator.
 162,3

INTRODUCTION (Cont'd)
Power Shuttle
T he Hyd rauli c Power Shuttle is loca ted between the torque c onverter a nd tra nsmi ssion, The
power s hut Ie is driven by the torq ue converter and drives the transmi ssion input shaft. The power
shuttl e is hydraul ically ac tuated by a ha nd le ver, located on the left hand s ide of the stee ring colu mn ,

The Clutch Piston con sists of a force

pis ton ancl forc e pisto n hou sing, Th e
for ce pi , ron housing m m 'es forward
or rearward as an assembly to squ e<?w
the cl utch
T he InpLIl Sh"rt h d i r ~Ct l\' , 'olll)('cleci
to tIH...~ T Ol'ClUf:> C()nverrl:..~ I'()U1PUl !"> !t..'t','e
and cont:l ill~ pa 8;';:1gl'~ to)' [l ressuri-
zed oil to aclUa thf' dut c h on ,

lutdl h " mulriple

d i ~c du tc h, hydroulkril l:: ac tu ated The Re\'('J'se Clut<;h i ~ 'I m Ult ipl e
,Old 10c"l('(1 0)1 th l' rear" ,"'d end of dis c c lutc h, hycll'auli,'al1y actuHll:cl
the I nput ,.,h alt , Ilh pl) th," c lutch is [lOci 10c ,,[<,cI on 111e f'Jl'\\ ;!l' r! end of
(~ng'ag'l:'rt, Llu.' drh'l~ and dl'j n ,..'n plat es the inp ut "h~r t, 11 11~n Ih .. c l utch is
a re squeezed toget he r' by the force pngag -d . t h l..~ drivl;' :Hu l dr i\-en L11es
piston hoUSing, The driven pla tes are Clre sq uee zerl together b y the c luteh
s plined to the cl utch drum a nd gea r, p iston , T he d J' i \'''n pl'l! "" are "pli ned
th e drive plates are spliJled to the to ihe c lut eh d n l111 ;lllri geal' , the
clutc h hUb, drive plat es 3 1'e opl ined to tht-c l utch
hub,
Figure 2
162·4

NEUTRAL
(Refer to Figure 3)
Oil Pump . Draws oil from the rese rvoir and supplies the conver ter / power shut tle system.

Filler· Filte rs all the transmission oil in the system.

Cooler· Co ntrols transmission oil tempera ture.

Flow Spool· Controls the flow of oil to ttle converter and clutch spool. Opera ted by the c lu tch
pe dal.

Power· Shuttle Control Spool . Di rects the flow of oil to e ither the forwa rd or reverse clutCh.
Ope r ated by the left ha nd lever on the stee ring column.

Clu tch Pressure Regulator· Regulates the c lutch pressure and converte r flow .

Converter Press ure Regulator [{egu la tes the converter and lubrica tion oil pres sure.

Conve rter· :Vlultiplies engine torque .

Forward Clutc h Delivers torque to the transmission for forward trave l.

Reverse Clutch Delivers torque to the transmission thru a counters haft for reverse travel.

Shuttle Lever in Neutral

When t he e ng ine i s running, the oil pump ope r a tes continuous ly , drawing oi l from the reser·
voir. The oi l flows fro m the pump th ro ugh th e to rque tube adapter ho us ing, distribution manifold
and out of the cont ro l valve th r ough a tube and hose to the filter. F oreign particles a re removed
before the oil e nters the cooler. The oil flows from the cooler through a hose and tube back to the
control valve.

From the cooler the oil e nters the control valve a nd flows around the flow spool to the cl utch
pressure reg ulator valve. This maintains the clutch pressure at the shuttle spool an d tile oil not
required is allowed to fl ow throu g h the regulator va lve to the torque converter inle t. Oil from the
torque converter out let fl ows to and throug h the fl ow spool a nd into t he c lu tc h c ircu its to supply
lubrication oil to the power sh u tt le c lutch. Oil not r eq uired by the converter a nd clutch lubrication
is a ll o·Ned to fl ow back to the reservoi r by the converte r pressure reg ula tor valve.
 ,.,

• "GH ..... ""

• ,"<TIO~
'""
'"'I ,"''''''' .,"'
.. "' '""' .,,"''''
0 CON"' ANO
I " , .. , , " "
[i)"'U'N Q'
162·6

FORWARD
Clutch Engaging
(Refer to Figure 4)
Wh en the tractor engine is running . the oil pump operates continuously, dra\\'ing oil from the
r eservoir. The oil flows from the pump through the torque tub" adapter housing, di st ribution
manifold and out of the control valv" through a tube and has" to the filter. From the filt"r the
oil then flows to the cooler. The oil flows from the cooler, through a hose and tube back to the
cont rol valve.
FLOW CONTROL SPOOL AND CLUTCH PRESSURE REGULATOR VALVE
With the control valve fl ow spool in the clutch pedal released position , the oil flows around the
flow s pool through a passage to the pressure regulator valve. The pressure regul ator va lve reo
gu la tes the pressure and flow of oil to the pow" r shuttle control spool a nd by passes the remainder
of the oil to the torque converter.
TORQU E CONVERTER
The oil for the converter flows [rom the control valve through the distribution manifold and
torque tube adapter housing to a passage in the torque tube to the converte r carrie r. The oil
flowing into the converter is picked up by the impeller, which forces the oil through the torus
to the turbine. The force of the oil against the turbine turns the turbine and output gleev". The
oil that is deflec ted off the turbine does not flow back to the reservoir, but Is direc ted back to
the impeller by the stator. The oil returning from the converter flows through a passage in
the torque tube and adapter housing to the converter pressure regulator valve.

The converter pressure regulator valve is located on the return side of the converter circuit
and regu late s the pressure within the converter and for lubrication of the power sh!1ttle . An
elec trica l sending unit loca ted on the pressure regulator valve indicates the con verter oil
temper a ture.
POWER SHUTTLE
When the operator moves the sh uttle control lever forward, the power shuttle spool in the
control valve moves inward, directing the flow of oil down through the distribution manifold,
to rque tube adapter housing, and torque tube to the front port of the clutch shaft. The pres·
surized oil flows from the front port of the clutch shaft through a pa ssage in the c lutch shaft
(between the clutch shaH and clutc h shaft tube) to a drilled pa ssage which leads to the accel·
erator pIston cavity.

Pressurized oil entering the accelerator piston ~avity forces the accelerator piston, disc
valve and reinforcing disc against th" separator pla te . The disc valve and r e inforcing disc in
turn moves the dowel pin, the opposite disc valve, reinforcing disc and accelerator piston away
from the separator plate. Then t he pr essurized oil in the accelerator piston cavity starts to
move the force piston housing toward the forward clutch. As the force piston housing cavity
on the forw a rd clutch side increases , the torce piston cavity on the reverse clutch side decreases
an equal amount. The oil from the force piston cavity on the reverse clutch s ide pushes open the
disc valve and enters the force pist on housing cavity on the forward clutch side.
Clutch Modulation
Once the force pi ston housing ha s begun engagement of the clutch pla tes agains t the clutch
baCking plate, the or ific e in th a ccelerator pIs ton allows the clutch pressure Jil from the supply
pump to increase the pressure in the force piston housing cavity on the forward clutch side
clOSing the disc valve , thereby bu ilding and maintaining clutch pressure. The oil in the fo rce pi s ton
cavity on the reverse clutch side is returned to lube pressure and to reservoir.
Clutch Engaged
The tra nsferring of oil through the separator plate accelerates the force piston travel and obtains
faster engagement since only a small a mount of oil is re quired from the supply pump, therebyeliminating
the tim e lag reqUired in a large volume fill.
ISH

. - .......
I!J" ...... ."•
"
O ·v.. ......... .....
CONVI ......,,"'. ,
0 _."",.
. ~-
162-8
REVERSE
Clutch Engaging
(Refer to Figure 5)
When the tractor engine is running, the oil pump operates continuously, drawing oil from the
reservoir. The oil flows from the pump through the torque tube adapter hose, distribution mani-
fold and out of the control valve through a tube and hose to the filter. From the filter the oil then
flows to the cooler. The oil flows from the cooler, through a hose and tube back to the control
valve.
FLOW CONTROL SPOOL AND CLUTCH PRESSURE REGULATOR VALVE
With the control valve flow spool in the clutch pedal released position, the oil flows around the
flow spool through a passage to the pressure regulator valve. The pressure regulator valve regulates
the pressure and flow of oil to the power shuttle control spool and bypasses the remainder of the oil
to the torque converter.
TORQUE CONVERTER
The oil for the torque converter flows from the control valve through the distribution manifold
and torque tube adapter housing to a passage in the torque tube to the converter carrier. The
oil flowing into the converter is picked up by the impeller, which forces the oil through the torus
to the turbine. The force of the oil against the turbine turns the turbine and output sleeve. The
oil tha t is deflected off the turbine does not flow back to the reservoir, but is direc ted back to
the impeller by the stator. The oil returning from the converter flows through a passage in the
torque tube and adapter housing to the converter pressure regulator valve.
The converter pressure regulator valve is located on the return side of the convertf'r circuit and
regulates the pressure withing the converter while also supplying lubrication oil to the power shuttle.
An electrical sending unit localed on the pressure regulator valve indicates the converter oil te m-
perature.
POWER SHUTTLE
When thf' operator moves the shuttle control lever rearward, the power shuttle spool in the
control valve moves outward, directing the flow of oil down through the distribution manitold,
torque tube adapter housing and torque tube to the rear port of the clutch shaft. The pressurized
oil flows from the rear port of the clutch shaft through a passage in the clutch shaft (between
the clutch shaft and clutch shaft tube) to a drilled passage which leads to the accelerator piston
cavity.
Pressurized oil entering the accelerator piston cavity forces the accelerator piston, disc
valve and reinforcing disc agains t the separator plate_ The disc valve and reinforcing disc in
turn moves the dowel pin, the opposite disc valve, reinforcing disc and accelerator piston away
from the separator plate. Then the pressurized oil in the accelerator piston cavity stalts to
move the force piston toward the l"everse clutch. As the force piston cavity on the reverse clutch
side increases, the force piston housing cavity on the forward clutch side decreases an equal
amount. The oil from the force pis ton housing cavity on the forward clutch side pushes open
the disc valve and enters the force piston cavity on the reverse clutch side.
Clutch Modulation
Once the force piston has begun engagement of the clutch plates against the clutch backing
plate, the orifice in the accelerator piston allows the clutch pressure oil from the supply pump to
increase the pressure in the force piston cavity on the reverse clutch side, closing the disc valve
thereby building a nd maintaining clutch pressure. The oil in the force piston housing cavity on the
forward clutch side is returned to lube pressure and to reselvoir.
Clutch Engaged
The transferring of oil through the separator plate accelerates the force piston travel and
obtains faster engagement since only a small amount of oil is required from the supply pump,
thereby eliminating the time lag required In a large volume fill.
 [iJ .,,"._,""'
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162-10

CLUTCH PEDAL DEPRESSED

DUMPED
Shuttle Lever in Reverse
(Refer to Figure 6)
When the tractor engine is running, Ule oll pump operates continuously, drawing oil from the
reservoir. The oil flows from the pump through the torque tube adapter hose, dis tribution mani·
fold and out of the control valve through a tube and hose to the filter. From the filter the oil then
flows to the cooler. The oil flows from the cooler, through a hose and tube back to the control
va lve.

FLOW CONTROL SPOOL AND CLUTCH PRESSURE REGULATOR VALV E

Wh en the clutch pedal is depressed, the control valve flow spool is moved to a dump position.
This blocks the flow of oil to the power shuttle control spool and directs the oil flow to the can·
verter. Oil flowing from the converter must return through the pressure regulator control valve.
The pressure regula tor valve maintains the lubrication and converter oil pressure in t.he system
and the e xcess oil is returned to sump.

TORQU E CONVERTER
The oil for the torque converter flows from the control valve through the distribution manifold
and torque tube adapter housing to a passage in the torque tube to the converter ca rrier. The oil
flowing into the converte r is picked up by the impeller, which forces the oil through the torus to
the turbine. The force of the oil agai nst the turbine turns the turbIne and output sl eeve. The oil
that is deflected off the turbine does not flow back to the reservoir, but is direc ted back to the
impeller by the stator. The oil returning from the converter flows through a pa ssage in the
torque tube and adapter housing to the converter pressure regulator valve.
 l i2-11

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 HOW IT WORKS

TORQUE CONVERTER

WITH TWIN DISC POWER SHUTTLE

TABLE OF CONTENTS
Introduction
Torque Converter ........ ........,.........,..................-...... ............................... ........... ... . . ..........,. 163-2
+

Power Shuttle .......,......... ........ ..... ....................... ............... ........ ... , .... . ...,, , .,., .,... . .......,. ,. ... 163-3
.+

Neutral .......,,...........................................,.............,,.........,.~............~.~,,,,,...........,.................. 163-4

Forward .,. ,.,.....,............ . , .,.., ....................................... ...............,..........-.......... ...,,.-.............-.163-6
. .
Reverse ,....... ..... ....., .,...,....,................ ... .............................,..,..,........., . , ......... ...-... ..........., ... m-8
Clutch pedal depressed (dumped) .......,.,..,....,...............,.,..,.................................................163-10

Rac. Form 9-80491

163·2

INTRODUCTION
Torque Converter
The Torque Converter is m ounted to and housed In the torque tube between the eng ine and
transmission. The torque converter is splined to and driven by the engine flywh eel. The oil
supply for the torque conver ter is supplied by a gear type pump driven by th e to rque can·
verter.

The impeller is located at the The torus is a passage 10ca te d in

r ear of the torq ue converter and the r o tating housing wh ich receives
driven by th e ro tating housing, oil from the impeller a nd direc ts
whic h is con nected to and driven by this oil
the engine fl ywheel. The oi l s upp ly
to the torque converter is picked
up by the impeller a nd forced ou t·
wa rd to a pa s

The ves
by means
vanes, changes the direc tion
oil a nd directs the oi l bac k to the the torus . The force of the oU a·
impeller. gainst the cu rved vanes causes the
turbine to tu rn. Th e turbine is
connected to a nd turns the output
sleeve. The oil leaving the tu r bine
is directed to the st ator.
 163-3

INTRODUCTION (Cont'd)
Power Shuttle
The Hydraulic Power Shuttle is located between the torque converter and transmission. The
power shuttle is driven by the torque converter and drives the transmission input shaft. The
power shuttle is hydraulica lly actuated by a hand lever, locate d on the lef t hand side of the steer-
ing column.

The piston carrier assembly is equIp-

ped with two lubrication va lve s pools .
In either forward or reverse clutc h The forward and reverse cl u tc h
e ngagem ent, one of the valve spools pistons are equipped with dump valves
moves and direc ts lubrication oil to which allow for positive c lutc h disen -
the clutch that is being applied. gagement. The dump valves a lso work
to smoot h out the clutch t.

The Input shaft is directly connected

to the Torque Converter outpu t sleeve
and contains passages for pressuri-
zed oil to ac tua te the clu tch pistons .

The forward clutch is a multiple The reverse clutch is a multiple

disc clutch. hydraulically actuated d isc c lutch , hyd ra ulical ly ac tuated
and located on the rearward end of a nd located on the fonvanl end of
the input shaft. When the c lutch is the input shMt. When the clutc h is
engaged, the drive a nd dri ve n pla tes e ngaged , the dri ve and driven p la tes
a re squeezed toge the r by the c lutch a re squeezed together by the c lutch
piston. The s inte red driven plates are pi ston . The s intered driven plates are
splined to the clutch drum and gear, splined to the clutch drum and gear .
the steel drive plates are splined to the stee l drive plates are splined to
the clutch hub. the c lutc h hub.
 NEUTRAL
(Refer to Figure 3)

Oil P u m p - Draws oil from the reservoir and supplies the converter power shuttle system.

Filter - Filters all the transmission oil in the system.

Cooler - Controls trbansmission oil temperature,

Flow Spool - Controls the flow of oil to the converter and power shuttle control spool. Operated
by the clutch pedal,

Power Shuttle Control Spool - Directs the flow of oil to either the forward o r reverse clutch,
Operated by the left hand lever on the steering column.

Clutch Pressure Regulator Valve - Regulates the clutch pressure and converter flow.

Converter Pressure Regulator Valve - Regulates the converter and lubrication oil pressure.

Converter - Multiplies engine torque.

Forward Clutch - Delivers torque to the transmission for forward travel.

Reverse Clutch - Delivers torque to the transmission thru a countershaft for reverse travel.

Shuttle Lever in Neutral

With the engine running, the oil pump operates continuously, drawing oil from the reservoir
(torque t u b e ) . The oil flows from the pump through the torque tube a d a p t e r housing, oil distri-
bution manifold a n d out the control valve through tubing to the oil filter. Foreign particles a r e
removed before the oil enters the cooler. T h e oil flows from the cooler through tubing back
to the power shuttle control valve.

Oil flows around the flow spool to the clutch pressure regulator valve which maintains the
clutch pressure and allows excess oil to flow to the converter,

T h e converter pressure regulator valve maintains the lubrication and converter oil pressure
in the system. The lubrication oil is allowed to enter the power shuttle control valve and flows
around the flow spool to both the forward a n d reverse clutch spool ports. This oil is directed
down through the distribution manifold, torque tube housing and torque tube to the two ports in
the front of the clutch shaft. The oil flows through these ports in the clutch shaft and out through
the lubrication valves to each piston, then through the open d u m p valves back to the reservoir.
In the neutral position, no oil is directed to the clutch plate a r e a .
 ,~ .

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 FORWARD
(Refer to Figure 4)
With the engine running the oil pump operates continuously, drawing oil from the reservoir
(torque tube). The oil flows from the pump through the torque tube a d a p t e r housing, oil distribution
manifold and out the control valve through tubing to the oil filter. Foreign particles a r e removed
before the oil enters the cooler. The oil flows f r o m the cooler through tubing back to the power
shuttle control valve.
FLOW CONTROL SPOOL AND CLUTCH PRESSURE REGULATOR VALVE
With the control valve flow spool in the clutch pedal released position, the oil flows around the
flow spool through a passage to the pressure regulator valve, The pressure regulator valve re-
gulates the pressure and flow of oil to the power shuttle control spool and by-passes the remainder
of the oil to the torque converter.
TORQUE CONVERTER
The oil for the converter flows from t h e control valve through the distribution manifold and
torque tube a d a p t e r housing to a passage in the torque tube to the converter carrier. The oil
flowing into the converter is picked u p by the impeller, which forces the oil through the torus
to the turbine. The force of the oil against the turbine turns the turbine and output sleeve. The
oil that is deflected off the turbine docs not flow back to the reservoir, but is directed back to
the impeller by the stator. The oil returning from the converter flows through a passage in the
lorque tube and adapter housing to the converter pressure regulator valve.

The converter pressure regulator valve I?located on the return side of the converter circuit
and regulates the pressure within the converter and for lubrication of the power shuttle. An
electrical sending unit located on the pressure regulator valve indicates the converter oil tem-
perature.
POWER SHUTTLE
When the operator moves ihe shuttle control lever forward, the power shuttle spool in the
contr'ol valve moves inward, directing the flow of oil down fhrough the distribution manifold,
torque tube adapter housing, and torque tube to the front port of the clutch shaft. The pres-
surized oil flows f r o m the front port of the clutch shaft through a passage in the clutch shaft
(between the clutch shaft and clutch shaft tube) to a drilled passage which leads to the forward
clutch piston.
Clutch Engagement
The forward clutch lubrication valve moves forward and allows clutch lubrication oil to flow to
the forward clutch plates to c a r r y away the heat caused by engagement. When the clutch oil
pressure enters the forward clutch, t h e pressure is applied to a step on the forward piston. This
starts to move the forward clutch piston and begins to compress the springs between the forward
clutch plates, At the s a m e time, the forward d u m p valve spool is moved to a closed position by
t h e clutch oil pressure, allowing the oil pressure to build up against the forward piston. In so
doing, it allows clutch oil pressure to be applied to the large a r e a of the piston. This moves the
piston further and fully engages the for-ward clutch plates f o r forward travel,

Clutch Disengagement
When the operator moves the shuttle lever to neutral o r depresses the clutch pedal, the pressure
is reduced in the piston a r e a to a point where the d u m p valve opens. This allows the oil to be
dumped to s u m p and the springs between the clutch plates return the piston to a disengaged position,
 ,~,

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Figur. 4
 REVERSE
(Refer t o Figure 5 )
With the engine running the oil pump operates continuously, drawing oil from the reservoir
(torque tube). The oil flows from the pump through the torque tube adapter housing, oil distribution
manifold and out the control valve through tubing to the oil filter. Foreign particles a r e removed
before the oil enters the cooler. The oil flows from the cooler through tubing back to the power
shuttle control valve.
PLOW CONTROL SPOOL AND CLUTCH PRESSURE REGULATOR VALVE
With the control valve flow spool in the clutch pedal released position, the oil flows around the
flow spool through a passage to the pressure regulator valve. The pressure regulator valve
regulates the pressure and flow of oil to the power shuttle control spool and bypasses the re-
mainder of the oil to the torque converter.
TORQUE CONVERTER
The oil for the torque converter flows from the control valve through the distribution manifold
and torque tube adapter housing to a passage in the torque tube to the converter carrier. The oil
flowing into the converter is picked up by the impeller, which forces the oil through the torus to
the turbine. The force of the oil against the turbine turns the turbine and output sleeve, The oil
that is deflected off the turbine does not flow back to the reservoir, but is directed back to the
impeller by the stator. The oil returning from the converter flows through a passage in the
torque tube and adapter housing to the converter pressure regulator valve.
The converter pressure regulator valve is located on the return side of the converter circuit
and regulates the pressure within the converter and for lubrication of the power shuttle. An
electrical sending unit located on the pressure regulator valve indicates the converter oil temperature-

POWER SHUTTLE
When the operator moves the shuttle control lever rearward, the power shuttle spool in the
control valve moves outward, directing the flow of oil down through the distribution manifold,
torque tube adapter housing and torque tube to the r e a r port of the clutch shaft. The pressurized
oil flows from the rear port of the clutch shaft through a passage in the clutch shaft (between
the clutch shaft and clutch shaft tube) to a drilled passage which leads to the reverse clutch piston.
Clutch Engagement
The reverse clutch lubrication valve moves rearward and allows clutch lubrication oil to flow
to the reverse clutch plates to carry away the heat caused by engagement, When the clutch oil
pressure enters the reverse clutch, the pressure is applied to a step on the reverse piston, This
starts to move the reverse clutch piston and begins to compress the springs between the reverse
clutch plates. At the s a m e time, the reverse dump valve spool is moved to a closed position by
the clutch oil pressure, allowing the oil pressure to build up against the reverse piston. In so
doing, it allows clutch oil pressure to be applied to the large area of the piston. This moves the
piston further and fully engages the reverse clutch plates for reverse travel.
Clutch Disengagement
When the operator moves the shuttle lever to neutral or depresses the clutch pedal, the pressure
is reduced in the piston a r e a to a point where the dump valve opens. This allows the oil to be dumped
to sump and the springs between the clutch plates return the piston to a disengaged position.
 OIL COOL ..

E: U )oJ 01

I CLUTO PRESSU RE
10 ' A ·. D
Eft P RESS .

OI L

FOfl:'i.%'AR D
CUJTCH
,Ai- S

co

~
INPUT SHAFT

REVERSE CLUTCH

FOR ARO G Afil

F igur
 CLUTCH PEDAL DEPRESSED

[ R e f e r to Figure 61

{!'hen t h e operator depresses the clutch pedal (dumped pabition) while the shuttle lever i s in
fontVardor i-ewrse ( r e v e r s e 15 iltus[ratedl, the clutch pressure and lubrication oil pressure is
reduced. This reduction of pressure will c a u s e the r c ~ ~ w slubrication
e v a l ~ ~toe c:lose and the
reverse dump valve to open. This allo~vsthe oil to return to s u m p and the springs bet\vecn the
cIuteh platm return the piston to a dlsenga.yd position.
 HOW IT WORKS

HYDROSTATIC TRANSMISSION

TABLE OF COWTENTS
Tntroduc tion ................................. ......,....+.,....-........................,...,..+.....................,.,,,.,..,....... . 164-2
Ho\v it Works .........,...,..+.-.........164-4
~,.,...............................,...,...,..,............,,,,,..,,,........................
Neutral o r Zero Speed Condition .....,...-,..,......-..........,.,...........,..-.........................,.,,..... ......,, 164-6
Forward Drive Condition ......... ................................................................-..........-.................. 164-8

Reverse Drive Condition ..,..,.,........,...................,...........................................................,.....

164-10

Overload Condition in Forward Drive ...............................................-,.,............................... 164-12

Unload Condition ............,.....,.......................................................................-.,.,...........,..,,.., 164-14

Rac. Form 9-80281

164-2

INTRODUCT ON
I( Refer to Figure 1)
In [his hydrostatic drive unit the power transfer medium is fluid under pressure which gives
a stepless variation of speed and torque throughout t.he power range in both forward and reverse
drive. In the hydrostatic drive system the dl'lve Une comprises a variabte displacement hyd-
raulic pump and motor arranged in tandem In the torque tube, between the engine and ~he
final drive. Both the pump and motor are of the> axial piston , tilting head type and are of simi-
lar constl'uction although the motor is larger in displacement.

The pump is driven at engine speed and rotates in a clockwise direction. Pump delivery is
varied by alternlng the angle of the tHting head. maximum oil flow being obtained at maximum
tilt angle.

The motor is connected to the final drive pmlOfi shaft and is a reversible unit. Motor speed
depends on the input (low of oil from th'e pump and on the motor displacement. Changing the
angle of the motor tilting he-ad varies the displacement and , for a given inpu t flow , the motor
turn s at maximum speed when set at minimum tilt angle.

The pump and motor tilting heads are connected by two tubular links so that they move to-
e ither. This ensures continuous ma tc hing of pump output and motor displac ement through the
speed range, so that the per formance follows the designed pattern. The links also carry oil to
and from the two units. The hydraulic servo supplies the effort requtred to move the pump tilt-
ing head . Servo movemen t is controlled by a small servo valve connected to the operator's
hand and foot speed controls.

Once the engine has been set to give the power requlred, this power can be transmitted to
the output drive through an infinite number of drive ratios,. forward or reverse, simply by
movement of the speedcontro(s. Speed increases progressively from zero to maxImum in
proportion to the amount of foot pedal, or hand lever movement. Because there is a positive
hydraulic link betw een the pump and motor at all times any reduction of pump oil flow slows
the motor and provides a brakingeHect. This is the case in both forward and reverse drive.

The pressure developed in the system depends on the torque demand at the motor shaft.. To
prevent overloading. a relief valve is set to limit the maximum pressure obtainable .. A clutch
pedal operated unloader valve is provided so that the hydros tatic drive can be rendered inopera-
ti VE' when the engine is runnjng bu t no drive is required.
 ·.,

- _.

:= . ."'" .... .,
.~"
•
 HOW IT WORKS

",., bo>.W; .nnei .... 01 Ol"',,')on I. _"",,'n 'n "'I;U"" Z, l .001 •. For .'rnpllc't~.only ,~,.,.,.
irn"m ."""" C<lMIOIotIo . ".""wn. Tht p"n-.. I. "'''''.8 ,""''''' ... OOft".""''''· ....."",.'" til<
•• <1". " ",nn;"" ,
Neutral or Ze ro Speed Cond ition
CR.f.r to Figur. 2)
n .. _hOw> 'k<' _n_" "',.,,"" <<0<..."", ."" thO . '"'p ""'''f ""00;1 .., .,
.''''1' ,hi. (1'. ,.
»O$lUoo ''''' .'>!O", , . " ""
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,no 101,
to
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,h. lI"k _''Y. "]'ll . .... is "" inO"' flCN' ""m to.
by
I"mo, ,h. mo'or ,,,,,,,I.. ," 'lono'Y '''' .. hyd",'lcolly lock«!,
Forward Drive Condition
(Re fer to Figure 3)
'!off ,.. pumo tiltl ... "000;1 lJ >11.,.'. . . t .,
"" " 'mum 0" <IOhv.,y '" t. .
,h. ",..
"""or ,t\o m'ttl'"'' ...'''t>ot''''''
,"",u~"
Im,m .",,1. 0' 1'>' to ,h. ~" ~1t'll1<:
hn •. OJ, ,... lOok ",,10« ,to. _or ... '"
h., "'-"<. r«l"'-'O<l '0 1" '0 'hO ",I,. dtspl.loo"",", i>QlJ',"n, 0;, .... u, •• '0 , ... p>mp
"'<1 'h""''''' ,h. «. link.
TIl< Nmbl""tlon or ",. .Im"m »(lmp .... II"'!')' ."" mlnlm"m _or dl'plo""""",' r...u .. In , ...
mo' ' ' 'u,"'"" 0""'••" '" . , "'''''''om .""",. 'n "" """'''"",, •• 0'.......1"" .. , ," I ." ' 0 I
I> obtoln....
q!

Rev., • • Drive Condition

(Refer to Figure 4 )
'n \~I. """"'''" ....."..mv
link ..,,,"" ,II< ""I:OX ."... I,
'"""I' '..,.dto "U ·....,H'I;'
.-«I""" ., tt.'p.....
"'''''''0'''
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ant '" 0' ,.. 'e 'k< .. " . \ly ,,,.
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th. '00 Iln •• nd ,II< mo'or ,u,n. oo.mto...,locJcwlM., ' " ' hi, "".i<n"m <"<"''''•• 'p<Od 0<IJId!,1ort
• dri", "'''' 0' O.iIl '" I " <>b,oW<!.

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'\"Y s;>«<I trom «''''
b\' uo< q! ,II< h. M .p<Od ">ff or ''"'. ,.,.,., ••
 164 -5

MOTOR

NEUTRAL CONDITIO N
Figure 2 SERVO

/~ 25°

FORWARD D RIVE
Figure 3

REVERSE DRIVE
SERVO
Figure 4
 NEUTRAL OR ZERO SPEED CONDITION
(Refer to Figure 5 )
When the engine is running, the hydrostatic pump and the make up gear pump a r e driven
a t engine speed. The hydrostatic pump is a t zero angle, the pistons have no stroke, therefore no
delivery of high pressure oil to the motor takes place. The motor and output drive remain
stationary because there is no oil delivery from the pump. The make up gear pump takes oil
from the torque tube and delivers it through the oil cooler, oil filter flow control valve, oil
filter element and to the hydrostatic pump timing plate. From the timing plate the oil passes
to the pump inlet port to make up any internal leakage and to insure continuous flushing of
the low pressure circuits.
When the oil filter gets plugged the oil pressure a t the spring end of the flow control valve
starts dropping until the oil pressure acting on the opposite end of the valve spool overcomes
the spring pressure and the spool starts to move. This movement of the valve spool starts to
restrict the flow of oil to the filter and prevents damage to the filter element and thus pre-
venting contamination of the system. The restriction to flow will be indicated by the trans-
mission oil pressure gauge. The gauge pointer will start to move into the (low pressure) red
zone from the green zone. The make up gear pump also has a pressure relief valve to pro-
tect the oil cooler system from high pressure oil.

Oil from the hydrostatic pump passes through the two open check valves in the pump, into the
connecting links and to the shuttle valve in the pump.

The shuttle valve has equal pressure on both ends of the valve spool and remains in a neutral
position, isolating the low pressure spill valve. In this neutral o r zero speed condition the make
up pump pressure is controlled by the make up pump relief valve.
 o lQW ' M. . . _.... """ _ _

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 FORWARD D R I V E C O N D I T I O N
(Refer to Figure 6)
When the engine is running, the hydrostatic drive pump and the make up gear pump a r e driven
a t engine speed. The make up gear pump takes oil from the torque tube and delivers it through
the oil cooler, oil filter flow control valve, oil filter element and to the hydrostatic pump timing
plate. From the timing plate the oil passes to the pump inlet port to make up any Internal leakage,

Depressing the forward speed control pedal, or moving the speed control hand lever In a
forward direction, allows the servo lever to pivot a t point "B" which moves the servo valve
spool rearward. This allows low pressure oil to enter the servo cylinder and the servo piston
starts to travel forward, through mechanical linkage the pump head 1s tilted from the zero
angle position to the right.

The pump pistons now start to reciprocate in their cylinders, building up oil pressure through
the lower link to the motor, the motor pistons then begin to reciprocate and the output shaft
starts to turn clockwise. The build up of oil pressure is In direct proportion to the torque tube
demand on the output shaft. This high pressure oil closes the pump lower check valve, The pump
upper check valve remains open so the make up oil flow can still flow to the pump cylinders to
lubricate and flush the cylinders.

This high pressure oil moves the shuttle valve spool upward to allow the low pressure oil to
flow to and through the spill valve. This dumps the surplus output oil of the make up pump not
needed for the pump cylinders and returns It to the torque tube.

The high pressure oil entering the motor through the lower link is directed to the cylinders
and through the motor lower check valve, to the high pressure rellef valve and the unloader
valve. The unloader valve spool Is held in a n upward position by the high pressure oil and
spring force acting on the lower end of the spool. The motor upper check valve is held closed
by the high pressure oil. Oil discharged from the motor cylinders returns to the pump inlet
through the upper link.

As long a s control movement continues, the pump tilt angle will increase until I t reaches its
maximum of 250 to the right. At anytime movement of the hand lever or the forward speed con-
trol pedal stops, pivot point "A" becomes stationary and the servo piston returns the servo
valve to the cut off position, stopping any further movement of the servo piston and pump head
tilt angle is held In place.

When the oil filter gets plugged the oil pressure a t the spring end of the flow control valve
starts dropping until the oil pressure acting on the opposite end of the valve spool overcomes
the spring pressure and the spool starts to move. This movement of the valve spool starts to
restrict the flow of oil to the filter and prevents damage to the filter element and thus pre-
venting contamination of the system. The restriction to flow will be indicated by the trans-
mission oil pressure gauge. The gauge pointer will start to move into the (low pressure) red
zone from the green zone. The make up gear pump also has a pressure relief valve to pro-
tect the oil cooler system from high pressure oil.
 , . . . . . ~" .. O ~ 0 '1
.,. . . . "., G >C G'

. ..,"" '''''U.'
o ",.. 00l
1M . . . , " ", 001. _ OSU ••

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o <O M. ""
o . """~ O.

Fig .. , . 6
 REVERSE DRIVE CONDITION
( R e f e r to Figure 7 )

When the engine is running, the hydrostatic drive pump and the m a k e u p gear pump a r e driven
a t engine speed. The make up gear pump takes oil from the torque tube and delivers it through
the oil cooler, oil filter flow control valve, oil filter element and to the hydrostatic pump timing
plate. F r o m the timing plate, the oil passes to the pump inlet port to make up any internal leakage.
Depressing the reverse speed control pedal, or moving the speed control hand lever In a
reverse direction, allows the servo lever to pivot a t point "B" which moves the servo valve
spool forward. This allows low pressure oil to enter the servo cylinder and the servo piston
starts to travel rearward, through mechanical linkage the pump head is tilted from the zero
angle position to the left.

The pump pistons now s t a r t to reciprocate in their cylinders, building u p oil pressure through
the upper link to the motor, the motor pistons then begin to reciprocate and the output shaft
starts to turn counter-clockwise. The build up of oil pressure is in direct proportion to the
torque demand on the output shaft. This high pressure oil closes the pump upper check valve.
The pump lower check valve remains open so the make up oil flow can still pass to the pump
cylinders to lubricate and flush the cylinders.

This high pressure oil moves the shuttle valve spool downward to a closed position and isolates
the low pressure spill valve. The make up pump relief valve dumps surplus make up oil not needed
for the pump cylinders and returns it to the torque tube.
The high pressure oil entering the motor through the upper link is directed to the cylinders
and through the motor upper check valve, to the high pressure relief valve and the unloader
valve. The unloader valve spool is held in and upward position by by the high pressure oil and
spring force acting on the lower end of the spool. The motor lower check valve is held closed
by the high pressure oil. Oil discharged from the motor cylinders returns to the pump inlet
through the lower link.

As long a s control movement continues, the pump tilt angle will increase until it reaches its
maximum of 25" to the left. At any time, movement of the hand lever or the reverse speed
control pedal stops, pivot point "A" becomes stationary and the servo piston returns the servo
valve to the cut-off position, stopping a n y further movement of the servo piston and the pump head
tilt angle is held in place.

When the oil filter gets plugged the oil pressure a t the spring end of the flow control valve
starts dropping until the oil pressure acting on the opposite end of the valve spool overcomes
the spring pressure and the spool starts to move. This movement of the valve spool starts to
restrict the flow of oil to the filter and prevents damage to the filter element and thus pre-
venting contamination of the system. The restriction to flow will be indicated by the trans-
mission oil pressure gauge. The gauge pointer will start to move into the (low pressure) red
zone from the green zone. The m a k e up g e a r pump also has a pressure relief valve to pro-
tect the oil cooler system from high pressure oil.
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164·12

:RLOAD CONDITIO N IN FORWARD DRIVE

(Refer to Figure 8)

When the torque demand at the output shaft becomes excessive. the high pressure oil in the
motor will rise to 5500 PSI at which time it will unseat the high pressure relief valve. This
lowers the oil pressure at the spring end of the unloader valve spool. The high pressure oil on
the other end of the unloader spool causes the spool to move the downward.

Sufficient oil is then by· passed into the low pressure make up on to maintain the system
pressure at the relief valve setting.
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 UNLOAD CONDITION
(Depressing Emergency Clutch Pedal)
(Refer to Figure 9)

When the hydrostatic drive is in forward or reverse drive condition and the emergency clu
pedal is depressed, the unloader valve is put into operation. The external spring force is relaxed
on the dash pot piston. The internal spring force allows the dash pot piston to move downward
slowly a s the oil behind the piston has to bleed off out through a n orifice. The spring force is re-
laxed on the valve poppet, which is then unseated and allows some oil to return to sump. Both the
upper and lower hydrostatic pump check valves will return to a n open position, the shuttle valve
will return to a neutral position and the m a k e pump relief valve will open and allow excess oil to
return to the torque tube. At the s a m e time this creates a pressure differential across the ends
of the unloader valve spool, causing the spool to move downward. This allows the high pressure
oil to flow to the low pressure side of the system. This stops the power transfer to the r e a r
wheels and the tractor is allowed to free wheel,

The hydrostatic pump and motor will stay in their tilt positions, a s they do not return to neutral
when the emergency clutch pedal Is depressed.
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