Case 580CK Model B

Backhoe Loader Tractor

Service Manual
v 8.0

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TABLE OF CONTENTS
SERIES/ SECTION
10

20

30

40

50

60

SECTION NO.

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

11
12
13
13
13

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

22
22
23
24

SERIES - FUEL SYSTEM

Fuel System & Filters
Roosa Master Model DB Fuel Injection Pump
Roosa Master Fuel Injectors
Model 267 Carburetor

31
32
33
35

SERIES - HYDRAULICS
Hydraulic Diagrams, Trouble Shooting, Testing, & Service
Hydraulic System & Power Steering Oil Filters
Torque Converter - Power Shuttle Hydraulic Pump
Equipment Pump
Three-Point Hitch Cylinders
Loader Control Valve
Backhoe Control Valve
Stabilizer Control Valve
Three-Point Hitch Control Valve
Cylinder Removal/Installation
Loader Cylinders
Backhoe Cylinder
Auxiliary Cylinder
Hydra-Guide Hydraulics Guidance System
Boom Lockout System

42
42
43
43
44
44a
44b
44c
44d
45
45
46
47
47
49

SERIES - STEERING
Power Steering Pump & Hand Pump
Steering Control Valve
Steering Cylinders & Adjustment
Steering Axle & Wheel Bearings

52
53
54
55

SERIES - POWER TRAIN

Torque Converter, Power Shuttle Countershaft, Control Valves, & Adjustment
Power Shuttle Clutch Pack, Rockford Clutch
Power Shuttle Clutch Pack, Twin Disc
Hydrostatic Drive, Gear Train, Control Linkage
Four-Speed Transmission & Final Drive
Mechanical Shuttle
Duel Range Assembly
11-Inch Traction Clutch
Independent Power Take-Off

61
62
63
64
65
66
67
68
69

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

Torque Converter-Power Shuttle Hydraulic Pump

43

70

80

90

100

SERIES - BRAKES
Differential Brakes, Differential Lock, and Parking Brakes.

74

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

81
81

SERIES - MOUNTED EQUIPMENT

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

91
92
93
97

SERIES - HOW IT WORKS - TROUBLE SHOOTING

Hydraulic Testing - Torque Converter - Power Shuttle
How It Works - Hydrostatic Power Steering.
How It Works - Torque Converter with Rockford Power Shuttle.
How It Works - Torque Converter with Twin Disc Power Shuttle
How It Works - Hydrostatic Transmission.

101
151
162
163
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 2

Figure 1

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) ....,.......,.,,.,
......................................
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)
.................+.......
(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 .......................

............+..........+.......................................+......................
... 1
Type Pins ..............................................................................................
.-....... Full Floating Type
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

................... 50

(3.5 to 4.9 kgicrn2)with Engine Warm and Operating

at Rated Engine Speed.
Type System ,...............................................................................
Pressure and Spray Circulation
Oil Pump ..............................................................................................................
..... Gear T y p e
Oil Pressure

Oil Filter

to 70 Pounds

........................,.... ............,..............................................,.,......
Full

Flow Spin

OH

Type

Fuel System
fuel Injection Pump

................................................................................................
Roosa-Master

Pump Timing ..,...,................................................

*...........,...,. 8 Degrees Before Top Dead Center

.............................................................................................................
Pencil

Type
(Opening Pressure 2800 PSI).
Fuel Transfer Pump .,................................
,, ,.,...
......,...................,. Vane Type, Integral Part of
Injection Pump.
Governor .......,-, ....................................
Mechanical, Fly-Weight, Integral Part of Injection Pump.
1st Stage Fuel Filter ......................................................................................... Replaceable Type
2nd Stage Fuel Filter .....,,.,,,,.......,......,......,-.--..,.....,.......................................
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 ......................................................Electric, Located on Instrument Panel,
Fuel Injectors

General
Type .............................................................................
4 Cylinder, 4 Stroke Cycle, Valve-in-Head
Firing Order ...,..,...
-, ............................
......,...... .. .. ... ............................................. 1-3 4-2
Bore (188G) ..,...................................
..--,............................. ..,.,...............3-13/16 Inches (96Amtn)
(159G),,,.,..
...-.,-............,,- ....................................,.........................
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) ................................
,,.,...,.,,..,...,
.......,.....,,...
2250 RPM
RatM Engine Speed (188G1 .............. .+.....
.................................................................
2100 R P M
( 159G 1 ...........................................................................................
1900 R P M
Engine Idling Speed .............................................,...,..................................,.......
. ......... 600 RPM
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
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)
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

.........................................................................................,.......
...
......,.. ...........................,-,......,............,...........

......
TDC
(159G) .................-..,,.............................................................................. 3QATDC
Running Timing (18SG) ........................................................................ 34" BTDC at Rated Speed
(mG)
-,
;JOifBTDCat Rated Speed

Static Timing UWG)

Cooling System

..x....

GENERAL SPECIFICATIONS

Capacity (188D & 188G) ................................................................16-1' 2 U.S. Quarts (15.6 liters)

(159G) .......................................................
...-.. ..... 14 U,S. Quarts (13.3 liters)
Type of System ...................................
..,.............--...............
Pressurized Thcrmosia t Con trolled
Impeller Type Pump,
Radiator .,........,,,,....,.,.................................. ,..,,....,.................. 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 ......................,........................
.....,.,-,,..,,..,--......,,--,..r.......,..,,.,
11 Inch {279,4mrn)
Throwout Bearing .............................................................................
Ball Thrust wfgrease fitting
Transmission ............................................................................................................
8 Speed Gear
Dual Range Shuttle ................................................................Mechanical Actuated Forward and
Reverse Clutch
P.T.O. ..............................................
,,...................+..,...,..,
......~.,..............,.....,......,...
Independent

Power Shuttle
Torque Converter .......................................................................................................
Single Stage
Power Shuttle ..........................................
Hydraulically Actuated Forward and Reverse Clutches
Transmission ............................................................................................................4 Speed Gear
P,TdO....................................,..,,.,.,,..,.,.,..,,,,.,.-. ...............................
,,,,.......... Independent
b , ,

Hydrostatic Power Steering

Relief Valve Pressure .................
,.............
,.,..................................................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 ..,,
.......................................................,..............,...
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
2.68 Feet (Q.S72m) Per Minute Belt Travel
1 RPM o f Belt Pulley
..+...,.....,

................

...............

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) ......................
.................. 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).
L...4.a..,.

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

:\[otOI' Ile sen rch

Hescarch :'I'Jelliod

:-lumber I\atings for Ile gular Grade g aso line are:

,86.2 Octane Number
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
Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 0- 625 Fnhrenhe it
End Point. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 67 5 0 Fahr enhe it

90~6

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. . . . . . . . . . . . ..
Cetane No. (Minimum) . . . . . . . . . . .
Wa ter a nd Sed ime nt Vo l. (Maximum) ..
As h, wt . (i'Vl aximum) . . . . . . . . . . . . .
Sulphur wt. (Maximum) . . . . . . .
Carbo n Res idue on 10% (M aximum) . .
Co r r osion, Copper Strip,
3 hrs . @ 212 0 F ahre nhe it . . .

2.0-4 .3 Seoond s*

40 (45 -55 fOl' win te r or hi gh a lti t ude use)

.05%
.01%
.5 %

.2%

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
Fuel
Conditioner

~
:~:~~~~~"

Condition er
M20426

UserFriendlyCDs

..-".
----'''-'".. _-.----- ._ ---

CASE DIESEl FUEL CONDIT IONER

Prevents gLlmmy deposits fr om fOl'ming

in t he fuel sy stem,
Improved lub ri c ation to th e Up)l8 1' intema l
p;l l' ts of the engine,
Elimin ates fo uling of injector no zz les ,
v alves and nW.nifolcls.

He lps keep co nden satio n suspe nded in the

fuel, all owing it to be bUl'ned with the fu e l.
l\Iaintnins a hi ghe r degree of fuel com-

bustion and engine pel'formaIl CE' frorn fu e l

t h e engi ne UU l'llS.

CA SE LU 8RA-GAS CONDIT I ONER

Improved lubri cation. to uppe ,' int.ern al

parts of the engine,
Reduces cylinder and ring we ar , improved compress ion, reduced cor r oSion of
the internal. engine parts,
Reduces crankcase 0!1 dilution_
H elps keep condensation suspend ed i n the
fu el, allowing it to be burned with. the fuel.
Maintai ns a higher engin e performance
fl'OM {!.leI the engine bu rn s .

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': ...................... .. ..... .. ....... .... .................... ..........................
STEE R ING ............... ....

........ ......... 15

... ..... ...... ......... ........... .......... .......... .. .. ..... . ..... .............. 16

GENE RAL TORQUE TABLE ..... ......... ........ .. .......... ....... ...... ...... .... .... ..

.............. .. .... 17

SPECIAL TORQUES ........................................... ..... .......... ........... ... .. .. ..... .. ..... ... ........... ....... ... 17

R,Jc. Fonll 9-80731

122

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 outairound .... ......................................... ...... ....................... ....... .. .. ........... ..... ....... .. .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

.001

Tape)"
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

.......... ....... .... . ... ............ 9992 to .9994

.001

(148G) ............................. ...... ............... 8592 to .8594

.001

(l8RG, 159G )

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)
(188G, 159G, 148(; )

.1 895 to .1885
.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
Including Wear

PI STON RINGS (Continued)

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
.182;') to .1 888

Width (1880 )

(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-']~:

Pu ll F loa ting

Typt> ... ..... ...... .

1.2497 to 1.2498

0.0. of pin 11811 01 ... . ... .... .

i188G . 1:;9(; )

.9991 to .Q992

IH8G )

.8592 to .8593

.0002 to .0006

F it in pi ston ( ISSD)
OSSC, 159(;)

.0000 to .(J003

( 1)8(;)

.0000 to .0002

.............. ..

F'i t in r od bushi ng (I88D ) ....... .. ......... ...... .... .. .......... . . 0002 to .0006
.000.3 to .0006

(188G ,lJ9C.1 4HC )

CO, ' J IXTl J ' C ROD

............ Repl acea bl e Bronze

Bu shing
Bushing LD. installed (rca rn t'd 10 size' )

(188G ,159G)

...... ........ .......... .... .. 9995 to .9997

.001

1.2502 to 1.2504

.001

.. .... ...... .... ...... .... ... 8590 to .8598

.001

1188D )
t1~8G

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

.0010 to .0035

Bearing oil clearance ... . "

Cnd ers ize be ari ngs ror ,crvice

....... ... ............ .......... 006

.002,.010 ,. 020, .030

..... .005 to .fil l

Side clearance

.... Self locking type

Ca p baits ............... .... ..

CRA l"KSHAFT

... .. .... .. ...... ..... Balanced

Typc

: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.

G rind to .010" 0.0. u nd ers ize

2.0605 to 2'(J613

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 ofround .

.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
................ ..

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

:l1alll bearing line r wi dth 2nd (lSSG)

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)

.,

.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
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

..... ....... . .. ... ... 2. 8630 to 2.8610

.010" 0.0 . undersiz(>, (10';9(;, 148GI .......

' "

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) .. ...

2nd and 4t h (1880)

1.499 to 1..')(12
1.183 to 1.189

2nd (188G)

Ll770 to 1.3740

3rd (188D )

L J740 to 1.3770

1. 74 1 to 1.7')1

3rd tl.S9G ,148G )

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.
Gravity [low lubrica ted

Int er mediate bushing

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)
4th (rear) (188(; )

...... . . ................... ... , ..... .. .....

l.l77 to l.l97

., ......... ,', . ..... .... ...... .. .. . ... . . .. ...........

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

l. 750

.004

0.0. of each hearing s ur face (148(;,188G)

1.749 to 1.750

.004

to

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

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

.0015

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"

128

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 RunOut
... ...... ............. ......................................... ....... .................. ........ ................. 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 RunOut ............ ... .... ...................... .. ........................................................... .. ... .. .... 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"
V al ve SteIn Clearance in GuidE' . ......... " ... . ............................. ....... , ... ,002/1 to .004

11

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

......... 006"

........ _..... .. ............... _................................................. ...... 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 RunOut ........... ......... ................. . _.............. ...... . ........... .................... _.................. ....... 002"
Insert Height (188 and 201) ........ ... ............................ ................ ..... 247.5" to .255"
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) ......... ............ ..... .. ...... . ........ ...... .... .... .. .............. ... ........
Leng th (14 8 and 1.)9) ......... ...... ...... .. ......... ........ ................ ......... .................
0.0 ........... ..... ..................... .... ........ .... .. .. ... ........ ........... .... ....... .. ..... 6565" to
LD. (I nstalled and Ream ed) .......... .... ............. .. ... ... ..... .................. 3422 " to
Protr usion ."\bove Cylinder Head ........ .... .. .. .. ....... ... ....... ...... .. .......................

3.1 25"
2. 688"
.6575"
.34:12" .... .. .. ..... 002"
1.000"

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

Free Leng th .. ..... ........ .................. ...... ...... ..... .......... .. ... .. ............. ........ ....... 2-:3 / 16"
To tal Coils ..... .......... .. .. .. .. .......... .... .. ....... .. ...... ..... ... ... ..... ..... ........ ..... ............ 73 / 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 .............. ....... ................ .. .. ... ..... .... ............ .... ............ ...... .... . 13116"
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.
PRESCREEN 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.
DONALDSON
NO .

INCHES OF
WATER

I THES OF

:--:0.
A59568

RBXOO2 254

27.7" to 32.3"

2,(14" to 2.37"

CAS E

ME RCCRY

1212

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) ................ .... .................. .. .................... .................... .. .. . ................. 51 / 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
18501900 RPM Rated F: nginc Speed

8 BTDC

20002100 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"
.012"

Sac hole size

:\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 shuto~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 "

1214

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:
Number of coils ............... ..... .......... .... 18
Wire diameter ................ ........ .......... .031"
Free le ngth ..................................... . 1.000"

Idle adjusting need le spring:

Number of coils ............................... 41/2
Wire diameter ................................... 040"
Free length .......... .. ...... ...... .......... .... .469"

CARBURETOR (148G)
Type ..............................

.. ............. ... ................. MarvelSchebler Updraft, Single Ven turi

with shut off sole noid.
ylagnetic fuel shu toff 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:
Number of co ils .................................... 5
Wire diameter .................. ....
.0317"
1. O. . ...... .. .. ..... .. ............ .. .. ...... ....... .281"

Idle Adjusting Needle Spring:

Number of co ils " ...................... ...... ..
5
1.0. ... .. .. ........... .. .... ........... ... .. . . .203"
Free length " ....... "" .. " .. .. " ........ ..... . .531 "

Choke Valve Spring:

Numbe r of coil s ....... .. .. ............. 26 to 27
Wire diameter ........... ".................... .029"
Free le ngth " ...... .. .... .. .. .... .. .. " ."" ... 1.062"

Throttle Lever Spring

Number of coils ............. ..... ..... 4112 to 5
1. D. . .. " .... "" " ...... ",, .. ".................... .165"
Free le ngth .......... ........................... .281"

Brakes
Type flui d

......... ..... .............. ..... .................................... .......... .... .. .............. ... .. .......... Case TCH

Free pedal

........................... .... .......... .. ...... ...... ..................... 11/4" to 13/4"

Brake Pedal Return Spri ng:

Free Length .................................................................................................. " .. ... .... ....... 4.625"
Wire Diameter .............. ....... ........................................................................ ........................ 135"
:\0. of Coils

... .. ................ .. .................................... ....... .............. .. ........ .. .. ...... .. ........... 221/ 4

12 -1:;

Brakes (Continued)
Disc Spring:
Free Length

................... _............ . ...... _...... ................ ........ .. ......... ............ ... ......... 1.27"

Wire Diamete r ... _... . ......... ... ................................................................................. .. ....... .. .0857"

No. of Coils ............... ..... ..... .. _.............. . _................ ... .. ... .. ..

10114

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"
Co untershaft bea ring pre-load .... ........ .................... .. ....... 4

10

12 in. Ibs. required

[0

10

.863"

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"
Countershafl e nd play (between 2nd and 3rd speed gear ) ... .. _............. ...... ......

10

.001"

_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 ..................... .. ................ ..... ..................... ..... . .. .... ......... ............... ........ ........ 1911 6"
Wire Diameter ...... ................ ...... .. ... ............. .......... .... .. . .. .. ................ .. ... . ........ ...... .............. 056"
No. of Coil s ................. ..... ............. ............ ....... .......... .......... ....... ................... ... .. .. . ..... ........... 11
Compress to 1.2;;0" .............................................. .... ...................... .. . ..... ........ ..... ..... ... 19-112 Ibs.

1216

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" ................................................ " .. ............................................ 1.52.5 lbs.
STEERING AXLE
Front wheel toein ........... ...... ....... ....................... ............ ...... ............. .............. ... .. .............. 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.
8 ..
5
SAE Grade No .
Bolt head identification
ma rks as per grade
I \
Note: Manufacturing
To rque Fo ot Po unds
Torque Foot Pounds
Ma rks Will Vary

0 0

Bolt Size
1 .' 4"
5 ' 16
3B
7 16
12
916
5. 8
3 4
7 8
1"
1-1 8
1-1 4
1-3 8
1-12
Thick nuts mus t be used

Min.
9
17
35
54
80
110
150
270
400
580
800
11 20
1460
1940
wi th Grade 8

Max .
11
20.5

42
64
96
132
180
324
480
696
880
1240
1680

2200

0
Min.
12
24
45
70
110
160
220
380
600
900
1280
1820
2 380
316 0

M ax.
15
29
54
84
132
192
264
456
720
1080
1440
2000
2720
35 6 0

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 980761

Rat. Form 9-80741

SECTION
13
MAINTE

ANCE

AND
LUBRICATION
FOR
LOADER AND BACKHOE

Burl. Form 9720815 KHCa O

Printed i n

U .S .A.

L UBRICAT ION
Backhoe L ubr l callo n I"olnls

Lub
r l c anls
Lubricants

G rt?ase
rease Fitti
ng s
F ittirigs
A
lJO \' e 32' fI-.. (0' C.)
Above
C. )

d 00
lu bricate d every
V& l'y
The backhoe pivot points Shoul
should
be luhrifatticl
10
hou l's. If the backhoe is
ve r e o rr abnor
mal
1 0 hours.
is u sed
s e d In
in se
severe
abnormal
wo r king conditions
me lnte
r vtLl hyonchfitf.
by One ha lf.
working
conditions,. reduce the
the ti
time
interv;il

rpo se or
:-.io. 2
Multipurpose
o r No,
. . ... . i\Jultipu
l U h S u m - s o ~ pbase grease
grease
No.11
. . .... Multipurpose or
o r NO.
IH h\.u m - ~ oa p

Below :32'
F. (0'
32' F.
(0"C.)

~ l1Jl t ; pu l' pose

1.
2.
3.
.; .
O.
6.

Load
er L
ubricallon I"olnts
Loader
Lubrication
The
oade rr pivots
p ivots shou
ld be llubricate
The lloads
shank?
u l ~ i - i c ' a tde de ve
v e ry
r y 10
10
hou
If the
loade r is
en in severe
h o u r ss,. If
the' 1oadt;r
is us
u$erl
severe o rr abnorm
a b n o r ma l
\\'orking
r educe
v al by one
~i-orkir'igconflitions
conlHtion5,. w
i n c e the Orne
t i w Inter
interval
Half
half.
I.

2.
3.
4,

5,
6,
j ,

R,

9.

..........

one
St
abi lizer c y l iinde
Stabilizer
n d err .
oni-. e;Jch
ear'ti r;~i.(}ej e
1\\'0
t.de
Swing
tho eac
e a c h sside
S w i n g c~ yylinder
l l n r t ttrunnion
~runn
r ion
ne each
8-ide
one
e-ich side
Swing
cyli nder rrod
oc! eye
Sftlngcyllnder
Swing
towe r pi
vot s . . . . . . . . . top
Swing to\w>r
pivots
to',?and bo ttom
side
ne each
Boom pi
vots .. . . . . . . . . . . . . . .o
pivots
one
ei~~
S I~ Lh~
Boom c yyli
l i nder
n d e r . . . . . . . . . . . . . t\\'o
two eeach
a c h si
s i de
de
e
n e each sirl
hirle
7. Dipper
cy li nde r. . . . . . . . . . . . . o ne
Dipper cylinder
pivot.. . . . . . . . . . . . . . . . ...
O. Dippe
Dipperl' pivot
. . . . . .one
Bucke t cylinder.
e w h end
enri
9.
Bucket
c y l i n d e r . . . . . . . . . . . . .. otle
.oni: eJ.(!h
10. Bucket pivot
pil'ot . . . . . . . . . . . . . . . . . . ...
. . .one
pe rl al . . . . . . . . . . . . . . . one each sside
ide
I I. Swing pedal

lith iu m -soap buse

ba s e ggrease
r e ase
lithium-fcoap
Dipper
r ips (Extencliihi~<?)
( Ex te tldohoe)
Pippt.'). ex
u ~tension
t e f l : 'we
N
l ie~aar
t - st
strip?
STP 011
Oil Treatment

One each side

I.oatle-r
pivott .. .. .... . . . . . . one
.oaner frame
fr ame phro
en
cylindpr.
one eeaoh
~ c end
h d
H:-r'dra - Le,~ el1ng cyli
nder .
de
two e aacc h si
aide
Li ft cylinde r ... , ...
e ac h side
s id e
one each
T!lt cylinder.
cyli nde r .. , , , ..
Tilt
sIde
tru nnI on . . . . . . . . two each side
Tilt
T ilt cylinder
c yli nder trunnion
l\vo each
e ach side
BLlc
ket link
li nk
bucket
tivo
sl de
. . . . . . . . . . . . . . . one each side
Bucket
pi vot ..
B
u i h e t pivot
two each
e a.ch sirle
sirte
Cla m cc!~lirider.
yli nde r .
('Urn
one
ach sside
ide
C
l ~ mpivot ...
o n e eeach
Clam

.......
........

......

. . . . . . . .
..............

...............
.............
................

f' igu re 2 - Backhoe Lu"bricaUon Point5

Backhoe
Control
Backhoe C
o n t r o l Lever
Levers
leve r pivot is
i~ p
rov ided 5%
wiith
lh ll.:igr~tlSe
Each control lever
provirie4
gre~sc
filting. The pivots aare
itiall y luiiru-atesl
lubricated at
fac to r y.
fitting.
r e in
initidlly
ai the
thefiictory.
T l1e pivots
p tvots sshould
hou ld r('aare
l'equ! 1'e lui)1'iciltion
The
r e lly
y require
lul'incation kbecause
c a u s e of
protec tion provided
provi ded by the contr
ol tower. Lu
bdc a te
the protection
control
Lubricate
pi\'ots every
e very ssix
ix months
m onth soorr ever)
every 1000
1000 hou
rs.
the leve
leverr pivots
hours.

71()QBS

F lg-ure I . Lo ade r Lu1)),lcatinn Pojnts

T h ree-Point H itc h L ubrication Points

ess to
s fittings,
htt~ l1 gs , rremove
emo ve the
To guln
gain acc
access
t o the greEl
grew=
upp
er front con
t ro l tower c(J
ve r . If
upper
control
covt-r,
It" the
thv bbJ).c
~ ckh.o
k h oec -is
equipped with boom
b oom lockout,
l ock out, d
isconnect the IILOL'S
ines from
from
diftconncct
tthe
he lockout ccontr
eli ef val v es . lt
t5 [wt
o n t r ooll and
arid rreliefva-lvc-"..
I t is
nut oecessal'y
ncc'essa-ry
to remove
remov e tthe
he val
ve s fr
o m the front
fr on t cco+,'er.
a ...er .
valves
from

The
~poin t h
itc h pivot
pi vot pint
po int s- shoul
rhe j3-point
hileh
shouldci 'be
he lubricated
. " ~ ~ e r v10
10 hours
hour';. . If the hitc
hitch
i s used
used in
ii-i se
s e ve
v e re
r e or ab
ah-every
h is
nnrm.jl
w o r k iing
n g cond
t:onriitlon$,
rt:rince
the time inte
interval
itlon s . redu
ce the
n Ta l by
no
r ma l work
13ne ha.lf.
half. Ilemove
d i rt
r t [roro
f r o m grea,5e
gie.i'so flfittings
One
Hemo\'e di
tt lngs before
sppl?
greasii gu
gunn.
3ppl ~r ing grease
,!.
1.

2.
:j
3.

1 ift
cylinder.
one each
Li
ft cyli
ncte r ... . . . . . . . . . . . . . onE:
e ach end
Li
ft arm
... .. .. . . . . . . . . . . . . . . . . . . . . one
Lift
4 ~ t i.
T11tc:~linrlerrodeye
, oone
ne
Tilt cylimler rod eye .. . . . . . . . . ., ,. .. ,. . ..

Dipper Extension
E x t e n s i o n Wear
W e a r Strips
Strips
Lubrie fl te the
a r strips
s t. ri ps .onCe
w ith
Lubricate
the we
wear
once a month with
STP Oil T
r e a tm e nt.
Treatment,
Exce ss i\'e lubrication
lu brication of the M
\Veal'
Excessive
@ i I r strips
f r t r ~ p :will
u~i i l
r esult
r apid weal'
tr; ps bec~mse the liiln'scxnt
ltlb~'i c anl
e s u l t iinn rapid
wear of the sstripsbecniise
grit.
also act
actss aa.ss a colle
c o l l ectot'
c t o r of dirt
d i r t and
+in'%grit.

Too lubricate
lu br icate the
we Dr sstrips,
tr Ips , fful
tend the dipper
T
thewear
u l ly
l y ex
?iienll
eextension
x ten5i on and apply a light cotit
coa t of
EH"I ch
a!. llutrrtcant
u l ~ r i itint
: to tach
e xtenSiD r1 311d
r e Q'lQve excess
s t r lp. Ret
strip.
R e tract
r a c t the dipper extensson
an11 remove
lubri
ca nt.
lubricant.

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 RunOut ........ ................... ........ ....... ....... .. .............. .................................................... 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 RunOut ......................................... ....... ..................... .. .......... .... ..................... ............. 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

222

SPECIFICATIONS (Continued)

Max
imum Limit
Maximum
Includ
ing Wear
Wea r
EXHAUST VALVE GeIDES
GLIDES
IncJuding
LC'ngth ........
........ .........
. ...................................................................... 3.125"
Length
.........................................................................................................
,,
0.0.
......... .. . . . . ...... ............................... .. ...............6565"
6565" to .6575"
O.D. ..........
..........................................................................................
.toto
.001"
l.ll
lle d aand
nd R
Hpamecl)
........ ........ ... ... .... ...........................,3429"
3429" to -3439"
.3439" ...............
.
1.1).. (Insta
( Installed
o a m e d ) .........................................................
.OUI1'
Vaa!vt>
a ranc(' in GlI
iCle ............................
.............................,002"
002" to .
.004"
.......................................................
V
k e Stc~m
Stpm Cle
Cl~.:nanrc
CuirU%I"
Protrusion Above Cy
lincler Head ............
...... ............... ...... ....... .. ....................,875"
875"
Cylinder
...................................................................
1

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

SPRII\C
VALVE SPRING
F
r ee Length ..............................................................................................
... .. ...... .. ... ....................... .. .................... .. .......... .......... 2.3
75 "
Free
2,375"
Tota
.. ....... .... .... .. ....... ......................................... ..................... .. 8.25
I olall Coils .........
......................................................................................................
F.25
Wire D
Diiaam
.... ... .. .............
.. .........................................................-162"
lfi2 "
me tN
t e r ...
...........................................................................................
l.D.
.........
.. ............................................. .. .............. .. ........958"
958" to .978"
I.D. . .....
...............................................................................................
.978"
Compressed to 1.52]"
.. ................... ... ................ 110
no to 118
1.521'' (Valve
(Valve Open)
Open) ........
................................................
118 tbs.
lbs.
Compressed to l.875"
.. ............... ... ........................53
')3 to "in
1.875" (Va
( V alve
l v e Closed)
Closed) ......
.................................................
59 Ibs.
Ibs.

ASSEMBLY
ROCKER ARM ASSI-;&IDLY

,
..... ........................................ .. ............b22
622"
to ,623"
.623"
O.D. of Shaft ........................
....................................................................................
1.0.
................................................ ................. .. ..........,624"
624" to .625"
1.11, of Arm Bore
Boro ..............................................................................
.d

!f

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

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

Ibs .
IbsIbs.
lbs.
Ibs.
Ibs.
Ibs.
ibs.

CHECKING COMPRESSION PRESSURE

1.
ng ine thoroug
hly, preferably
pre ferab ly by
1. Clea
Cleann the eengiinc
thoroughly,
steam cleaning.
cleani ng.

2.
Be fore cranking
cranking the eengine
ngine make sure
a ll
2.Ec'foro
s u r e all
operating
controls
a r c in neutral,
neutral, brakes
ope
rating con
trols arc
are
nd the
re ly blocked.
bloc ked.
a r e set aand
t h e wheels a rree secu
securely

com3.Thero
a r c Iwo
two methods
3.
The re are
mct hods of checking
chec king com
preshion
pressure
t h e cranking method
pression pressu
re
the

ning method.
NOTE: The
ThE'
aand
n d tthe
h e engine l'un
running
method, NOTE:
engine must be at
r ating
tempe rat ure
a t ope
operaf
ing temperature
for either
c i t h e r method used.
A.CRANKING
ATCRANKING METHOD -. Close the needle
ll high
valve at the
t h e ffuel
u e l tank
tank.. Disconnec
Disconnectt aall
p r e s s u r e fu
fuel
a n d leakoff
leak-off lines
pressure
el lines
lincs and
lines betbet
wee
weenn injectors. Remove all of tt. he
h e injec'
injectors. R
Refer
P age 3.
e f e r to the chart
c h a r t on Page

22-3

CHECKING COMPRESSION PRESSURE (Continued)

teaspoon) of
tlle
a small amount (a
(a teaspoon)
of oil into the
cylinder and reclleck
recheck tlle
the compression. If
If
tlle
comthe pressure rises to near normal, comtlle rings.
r ings. Very little
pression loss is past the
cllange in compression indicates leakage
change
tlle valves.
past the
valves. A low pressure reading
will ccause
a u s e difficulty in starting particularly at
a t low temperatures.

B.RUNNING
ELRUNNING METHOD - Disconnect tlle
the lIigll
high
pressure fuel line and
a n d leak-off line from
from
nnumber
umbe r one injector. Using an
a n appropriate
lengtll
tlle fuel from
length of tubing or
o r 1I0se,
hose, route the
tllese lines back to the
tlle fuC'1
these
fuel tank oorr a clean
container. Refer to chart
c h a r t below.
4. Clean the
tlle injector bores of loose carbon and
4,
and
residue.
tlle compression seal in the
tlle
residue. Replace the
injector bore of the cylinder to be cllecked
checked
and install a Bacllarach
70-314 (0-558).
Bacharach 70-314
(D-558). ComCompression Gauge Adapter, Figure 1.
1. Secure
witll
with an
a n original injector cclamp
l a m p assembly
and spacer,
Tigllten bolt
1, Inset A.
A. Tighten
spacer. Figure 1,
to 20 ift.
t . lbs.
Ibs. Connect Case No. CD-504
CD-504
Compression Gauge to the aadapter,
d a p t e r , Figure 2.
IMPORTANT:: It is very important tllat
that
approxfmately alike.
all cylinder pressure bbee approximately
alike.
For
F o r tlle
the allowable compression pressure
variation refer to chart
c h a r t below.

NOTE :: Take several compression reading

on eeacll
a c h cylinder. TlIis
This is done by pressing the
vent valve button, Figure 2, to relieve gauge
pressure. WlIen
tlle
When tlle
the button is released the
gauge will again indicate compression
compre ssion pressure.
sure,
COMPRESSION ADAPTER
COMPRESSION
70-314
70-314 (0658)
(D558)

ORIGINAL CLAMP
ASSEMBLY A
ND
AND
SPACER

VENT

IN SET A

1(' 1

I..~

CLAMP
ASSEMBLY

u---

........'" :------~~~A

~'

CD504
C D 5 0 4 COMPRESSION
GAUGE

SPACER

Figure 2
IMPORTANT : Replace tlle compression seal
on all injectors at the time
1e of installation,
Figure 3.
COMPRESSION ADAPTER
70-314 (0558)

Figure 1
5.
5. If
If tlle
the compression is ggreater
r e a t e r than the figure
mentioned, carbon deposits are
a r e indicated.
If
tllese figures,
figures, leaking
If tlle
the reading is below these
invalves oorr excessive ring clearance is indicatccl. NOT"E:: To make a simple clleck
check
wllen a compression leak is indicated, squirt
when

CARBON s l : : : C T O \
CARBO

~~_----COMPRESSION

COMPRESSION SEAL

Figure 3

200
1 Approxfmately
Approximately200
RU NNING
RUNNING
I
PM
800 R
RPM
-

CRANKING

ALLOWABLE
VARIATION
BETWEEN
CYLINDERS

NORMAL
COMPRESSION
PRESSURE

ENGINE
SPEED
SPEED
RPM
R
PM

1
I

400 PSI"
PSI'
480 PSI"
PSI*

1
1

25 PSI

20 PSI
PSI

NOTE:: -A
u s t be allowed for every
e v e r y 100D
1000 ft.
ft. above sea
s e a level.
NOTE
A 4%
4% reduction in PSI m
must

1
1

CYLIND ER HEAD AND COMPONENTS

(Refer to Figure 4)
Disassembly
Re move the muffle r and hood from vehicle . Disconnect
e xha us t system and aair
ir cleaner
isconnect the exhaust
from the m anifolds. Loos e n the a lternator ad justing
Remove the
ing bolt and remove the fan belt
belt.. Remove
water pum p and all s tud nut s sec uring water manifold
m clean
clea n the en
tire
nifold to cylinder
clyIinder head. Stea
Steam
entire
area where service work is to be performed.
5. R emove the intake manifold (4 ) and discard
1. Drain the cooling system . (..\UTION: [[
the gaske ts (5).
thE' enginE' is hot , do not remove the r adi6. Remove the e xhaust stack (6) a nd gasket (7) .
ator ca p until the coolan t ha s had s ufficie nt
7. Re move the exhaus t m anlfold (8) and d is
ti me to cool. Loosen the cap to the first
card the g aske ts (9).
sto p carefully to relie ve a ny excess pres
8. Re move the va lve cover (10) and cover
sure before removing it completely. Re
g asket (11 ) . Discard gasket.
move the upper rad iatOl' and wa ter pump
9.
Remove the bol ls and washers (12), and
hoses.
2.0isconn<"c t the hig h pressu re fuel li nes
the r ocker arm a ssembly (1.3) . Remove the
push rods (11 ) and tag them fo r proper refrom the in jector s a nd th e lea k-off tu bes.
ass embly .
Ca p t hem \0 preve nt a ny forei g n pa rticles
10. Remove the fl a nged nu ts (15 ). Remove the
from enter ing . Remove the injectors as
cylinde r head assE'mbly (16), fire rings (17)
d escribed in Sec lion 33 of the Sel'vlce
and head g asket (18). Discar d the fire rings
Ma nua l.
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
new
cylinder
f i d ~ k e t(IS)
1.
W cyli
nder head gasket
(18) on the
engine block
NOTE : Be
block.. NOTE!
BP sure
sure the two
re ins
talled in theil'
prope r
dowel ri
ngs aare
rings
installed
their proper
locati
on, Inset
Inse t A.
location,
2. Install
Ins ta ll the new fire
fire rings (1
7) with either
e ithe r
(IT)
side
fire rings
rillgs must be
side up. NOTE
NOTE;: The fire
In sta lled dl'Y.
Installed
dry.
3. Install
Ins tall new gaskel
gasket (19)
(19) between timIng
timingcover and cyli
nder head,
head , coating
cylinder
c ~ ~ i t i nitg with
ea le r .
a ssealer.
4. Ins tall the cy li nde r head (1~ ) a nd fl anged
nuts (151. Lubricate thread s with clean engin e oil pr ior to torq uing . Torque the fla nge
nu ts to 60 (t. Ibs . and then to 90-100 ft. lbs.
usi ng the torqui ng seq uen ce shown in Inse t 8 .
5. Ins tall the water pump and a new gas ke t,
co ating t.he g asket with a sE'aler . Torque the
wa ter pump st ud nuts 20-25 ft. Ibs. Ins tali
the fa n be lt and adjust .
6. Co a t the p ush rod s (14 ) with clean e ng ine
oil and insta ll the m in their original location.
7. Install the roc ker arm a ssembly (13) . NOTE:
The l' ar mount ing bolt is d ri lled for oil
passage to the ['Ocker arm shafts . Torque the
bolts (12) to 2530 ft . Ibs. Adjust the valve
tappet cl earance, refer to P age 16.

8.
ta ll the
) and ee.xhau.51
xhaust (8)
an i
8. Ins
Install
t h e Intake
intake (4
('1)
(81 m
manids using new gaskets fi
(5 &
fol
folds
& 9).
9 ) . Torque
Torque the
stud nuts and bolts 25-30 fft.
t . Ibs
Ibs..
9. Install
lnstall the intake el
bow (2)
usin g new gasket
elbow
( 2 ) using
ust stack (6)
(2). Install the exha
exhaust
( 6 ) using
using new
gaske
gaskett (7).
10.
Reins tall the air
a il' cleanei
cleaner sy stem and e x
10. Reinstall
haust system
.
Refill
the cooling
system.
cooling system.
system.
Reconnect the high pressure fuel
fuel lines to
inj ectors and the leak-riff
leak-off tubes.
the Injectors
11.
Apply clean englne
oil to the rocker arm
arm
11.Apply
engine Oil
assem
bly and start the eengine.
ngine . Chec
assembly
Checkk that
r e receiving
receivIn g lubricating
lubricatin g
the rocker arms aare
oil. Operate the engine for aapproximately
pprOxima te ly
oil.
one hour,
hour , (under load if possible)
thor
possible) to thorenglne seat the hea
oughly warm up the engine
headd
gaskets
gaskets..
12.
Sh ut tthe
ne off. Bac
cyllnder
12.Shut
h e engl
engine
Backk off each cylinder
nged nut individually
indi vidually 114
head fla
flanged
I 4 aand
n d reo
reft . Ibs. NOTE: DO NOT
NOT
torque to 100
100 ft.
RACK
OFF
THE FFLANCED
L A N G E D NUTS
NGTS
F ALL THE
BACK OF
TIME .
AT THE SAME
SAME TIME.
n.
Ins ta ll new valve cover gas
ket (II
) aand
nd
li3.1nstall
gasket
(11)
Torque the valve
va lve cover
valve cover (10)
(10).. Torclue
sstud
tud nuts 5-8
5-8 ft. Ibs.
lbs . IInstall
nst<lU breather tube
(1
(1) .
+

22-5

---

, .'

@I-- -

\-

e.,

I
I

o --
INSET A

TIGH TEN IN G SEOU ENC E

226
22-6

CYLINDER HEAD
AND COMPONENTS
H
NTS (Continued)
(Continue
Inspection
Inspection
gaskets, seals aand
nd worn or defective parts.
Replace all gaskets,
1.
Clean the top surface
surface of the block and
1,Clean
sleeve flange
ca
refully . All traces of car
flange carefully,
carbon and other deposits must be removed.
During cleaning,
cleaning, the use of a rag dampened
in solvent is recommended.
2. Using extreme care not to scratch surfaces.
Remove any small burrs in the areas
areas to be
urate readings can be ob
measured so acc
accurate
obtained.
3. Sleeve protrusion must be checked to deter
determine which fire ring is used, Figure 5.
5. Make
sure the correct
cor rect fire ring is used.
NOTE:
used. NOTE:
Only the stanclard
standard size fire ring is
Is included
in the valve grind gaske
gaskett kit. However, a
thicker fire
profire ring is available if the pro
trusion chart indicates a need for it. The
identified by a
thicker fire
fire ring can be identified
black marking stripe.
stripe. Either a magnetic
tor or a depth micrometer
base dial indica
indicator
can be used to determine the cy
linder sleeve
cylinder
protrusion as
a s indicated in Figure 6. Measure
cylinder sleeve protrusion at points A,B,C
A,B,C
and D.
D. Using ball (A283121,
(A28312), clamping bar

(A40682)
mp the
(A40682) and plate (OTC 9707),
970-7), cla
clamp
NOTE :
cylinder sleeve in place, Figure 7. NOTE:
The plate OTC 970-7
9707 is available through
loca l Owatonna
local
Owa tonna Tool dealers or the Owatonna
Owa tonna
Tool Co., Owatonna,
Minnesot a. Torque the
Owatonna, Minnesota.
hold down capscrews to 50 (t.
t t . lbs.
4.
Clean and inspect the cylinder head thorthor
4.Clean
oughly. If
fretting or erosion
If evidence of fretting
ring contact or
exists in the area of fire
fire-ring
tha n .006"
if the head is warped more than
.006",, the
head must be resurfaced or
replaced.
o r replaced,

5. Inspect push rods for straightness,

straightness, cracked
or worn ends. Replace if necessary.
6.CClean
s.
6
l e a n all bolt and stud thrcad
threads.
7.
Clean the rocker arm
7.Clean
a r m cover and discard
the old gasket.
8.
Replace all hoses if cracks and deteriordeterior
8,Replace
ation Is
is found.
found. Replace hose clamps to assure
a tight connection.

INOER SLEEVE PROTR

TRUSI
CYLINDER
USION

USE
STANDARD
FIRE RINGS

USE OVERSIZE
(THICKNESS)
FIRE RINGS

MORE THAN .003""

.003"*
MORE

.001" .. 003""

LESS THAN .001 ""

F igure 5
"If sleeve protrusion varies more than .003" around circumference, change that sleeve and
check again.
NOTE:: Cylinder head warwar
again. If
If sleeve shows severe erosion, replace the sleeve. N
page should not exceed .006"
,006" (maximum)
(maximum) measuring from
from end to end.
end.

22 -7

DIA
CATOR
D I A L IND
INDICATOR

CYLINDER SLEEVE

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.

ure 7
7
Figure

22-8

ROCKER ARM ASSEMBLY

(Refer to Figure 8)

Disassembly
1.
1.Remove the rocker arm shaft bracket bolts
(1
(1&
& 9).
9 ) . NOTE
NOTE:: The rear bracket bolt is
drilled for oil passage to the rocker arm
shafts.
shafts.

3. Remove the shaft springs (6)

( 6 ) and tag the
( 8).) ,
front and rear shafts (8

2. Remove and tag each rocker arm (4

(4 &
& 7)
7 ) and
bracket (3,
(3, 10,
10, 11
11 &
& 12)
1 2 ) for proper location

4.
(5) from
4. Remove each tappet adjusting screw (5)
each rocker arm,
arm, refer to Inset A.

assembling.
when assembling.

Inspection
Check the shaft springs for damage and
tension.
proper tension,

shaft and rocker arm is .010".

,010". Replace the
shaft and rocker arms when wear is beyond
this point
point..

SPRlO'lC
SPRING SPECIFlCATIOO'lS
SPECIFICATIONS

......................... ... ....... '" 2.5"

Free Length .......................................
2.5"
.. _............................,072"
072"
Wire Diameter ....
..................................
Compressed to 1.75" ............
Ibs.
............ 7.5 to 8.5 Ibs,

Flush the shafts to remove any residual

material.
material. Inspect the shalts
shafts for excessive
wear or
o r worn spots on the bottom side of the
shafts.
Inspec
Inspectt the rocker arm shaft passages for
wear. The maximum clearance between the

Clean the oil passage in the rocker arms to

insure free oil flow.
flow. Inspect the valve stem
contact area on the rocker arm for wear. ReReplace if worn.
Clean and check the oil passages in the tap
tap-the rear bracket bolt.
pet adjusting
adjusting"screws and (he
Inspect the push rods for straightness,
straightness ,
cracked or worn ends, replace if
if these conconditions exist.
exist.

Assembly
With all component parts cleaned thoroughly and worn parts replaced, coat them with clean
engine oil.
1.
ll the intermediate brackets (10)
1. Insta
Install
(10) on the
shafts (8),
(8), starting with the front shaft.
shaft. The
front shaft is installed with the short end of
the shaft (from
(from the cut-out)
cut-out) toward the front
of the
thE' engine,
see
Inset
B.
B. The rear shaft is
engine,
install
E'd with the short end of the shaft (from
(from
installed
the cut-out)
cut-out) toward the rear of the engine.
engine.

(6)
).
(6) on the rocker arm shafts (8
(8).
5.
Install the center bracket (11)
5.Install
(11) to the long
Inend (from
(from the cut-out)
cut-out) of the shafts (8).
(8). Install the front (12)
rea r (3)
(12) and rear
( 3 ) brackets to
(8).
the shafts
shafts (8).

3. Install the tappet adjusting screws (5)

(5) into
(4 &
& 77),
) , make sure the screws
the rocker arms (4
are turned into the rocker arms as far as
possible.
possible.

6. Before installing the rocker

roc ker arm assembly
on the cylinder head, crank the engine (fuel
(fuel
removed) with the starting
injectors removed)
starting- motor
minutes ) until oil
(approximately 11 to 3 minutes)
appears at the rear oil passage in th
head,
thee head,
see Inset C. Install the rocker arm
a r m assembly
(1 &
& 9),
9),
to the cylinder with bracket bolts (1
making sure the rear bracket drill
ed bolt (1)
drilled
(1)
is installed the cylinder head oil passage hole.

4.
Install the rocker arms (4
(4 &
& 7)
7 ) and springs
4.Install

7. Adjust the tappets, refer to Page 16.

7.Adjust
16.

2 , Insert the bracket bolt (9)

(9) into the interinter2.
m
ediate bracket (10)
(10) -- it must line up with
mediate
the cut-out
cut-out in the shaft.
shaft.

229

INSET C

INSET
INS ET A

OI
OILL PASSAGE
PAtSAGE

OIL PASSAGE--\ \
OIL HOLE PLU(,GEI)"""'-

~~~
TAPPET SCREW

/OIL

HOLES ~

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

-SHORT
ENDI-SHORT
END-I

CUT OUT

CUT OUT/

Figure 8

-SHORT
END
I-SHORT
ENO-l

INSET B

FAN.

22-10

CYLINDER HEAD
HEAD ASSEMBLY
(Refer to Figure 9)
Disassembly
L Using a valve spring comp
ressor, com1.Using
compressor,
emove the
press the spring (1)
(1) enough to rremove
re tainer locks
loc ks (2).
pring
( 2 ) . Release the sspring
valve retainer
compressor and remove
re move the valve spring
va lve sspring
pring (l),
( 3 ).. Remove the valve
(I),
retainer (3)
valve stem oil seals
seals (4
( 4 ) and valve spring
seats (5).
Re move any carbon
car bon from the
( 5 ) . Remove
r emoved from
valve stems before they are
a r e removed
the cylinder head.

3.
ide (8) and exhaus
3. Drive the intake valve gu
guide
exhaustt
(9) down through
valve guide (9)
throu h the head using
an arbor.
arbor.

2. Remove the intake valves (6)

e x( 6 ) and the ex2.Remove
haust valves (7)
from
the
cylinder
head
(13)
(7)
(13)
and set them in a rack
rac k or holder. NOTE:
NO'IE:
Mark them on removal so they may be installed in their original location.

) or expansion
expa nsion
5. T
Too remove the cup plugs (11
(11)
a nd pryed out.
(t2) they must be drilled and
plug (12)

4. The exha
ust valve sca
ts (10
re4.The
exhaust
seats
(10)) can be rewith a special
ial seat removing tool,
moved w
Inset B. NOTE : Never
ttempt to remove
ever aattempt
a valve seat with a center punch, cold chisel
or pry bar.

Inspect ion and Servi

ci ng
NOTE : Refer to Inspection
Servicing
on P ages
I.->prior to assembly.
assembly.
es 12,13,14
12,13,14 and 15

Assembly
1.
rep laced, install
1. If
If the valve guides have been replaced,
the new gguides
uides (8
(8 & 9) usingusing an arbor. Press
the guides into the head from the top of the
head . The guides must protrude above
cylinder head.
the cylinder head (intake
.873",
(intake and exhaust)
exhaust) .875",
Inset A.

(30) cclean
2. To install new exhaust valve seats (10)
lea n
the recess in the cylinder h
head.
e a d Place the
k them. Invalve seats in dry Ice
ice to shrin
shrink
sert the valve seats in the head and press
them in place, using a suitable press.
press,
3.
Lubricate the intake valves (6)
a nd exh
a ust
( 6 ) and
exhaust
3.Lubricate
valves (7)
( 7 ) with
wi th clean eengine
ngine oil and install

the m in their original locations

them
locations..
4.
va lve sspring
pring seats (5)
va lve
4. Install the valve
( Z ) ,, valve
springs (1),
the valve
valve retainers
reta iners (3).
( I ) , the
( 3 ) . Compress the valve springs so
so tthe
h e valve stem
stern
seals (4)
(4) can be installed in the lowe
lowerr grooves
Insta ll the valve retainer
re tainer
of the valve stems.
stems. Install
locks (2
( 2)) . Remove the spring compressor
ccarefully.
arefully.

5. Install new plugs (11

(11&
& 112)
2 ) if they were
re-
5.
we re re
(11)lip m
must
moved. NOTE:: The
Theccup
up plug (11)
ust be
head . The
flush with the top of the cylinder head.
eexpansion
xpansi on plug (12)
fiIm ly sea
ted
(12) must be firmly
seated
against the ridge in the cylinder
cyli nder head.
he<l d_

22-11

A
INSET A

.875"

EXH AUS T SEAT REMOVI NG TOOL

.~,
I

EXHAUST VALVE
ASSEMBLY

INTAKE VALVE
ASS EM BLY

1',

I
I

'

"

Figure 9

2212

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

ly. ReRe Clean the cylinder head complete
completely.
mov e all traces
tra ces of carbon
ca rbon a nndd other deposits.
move
nd any evidence
e .-idence of fret
Check for cracks aand
fretti
ng or erosion existing
exis ting in the area
a rea of fire
fi re
ting
ring contact. Check the head [or
for evidence of
of
warpage. If warpago
warpage exists
and is more tha
warpage.
exists w6
thann
_006", the cylinder
cyl!nder head
h('ad must
mu st be resurfaced
.006"
or replaced
replaced..
hecked [or
Va lve springs should be cchocked
Valve
for flat
squa
red eends.
nds, broken coils
coil s aand
nd correc
correctt
squared
press ure. Use a Val
ve Spring Tester
spring pressure.
Valve
r eferring to the spring s&pecitir'ations
pecl fica tions below.
below:
referring
Free Le ngth -- ----- --- .------- ...... ------.... --- -- 2.375"
To ta l Coils .... -- .... -.. ---- -- ----- -- --- --... -- ---- --- 8.25"
Wi re Diameter --- ----- -- -----.-- --.----- ----- ------ .1 62"
Valve
ICompressed
~ o m ~ r e s s e dSpring
[
Replace if
Pos
ition
Hei
ht 1 ~
Pressure
r e s s u r [eLess than
Position
Height
Valve Open 1 1.521"
Ibs . I llO
1.521"
I 114
134 Ibs.
110 Its.
lbs.
Valve
~ i o s e d ) 1.875"
ibs.
53
Ibs,
Va lve Closed
56 Ibs.
33 Ibs.
the
a ll carbon from the bore of tho
Remove all
va lve guides with a fine
fin e wire brush
br ush and blow
valve
cclean
lean wit
Val ve guides ca
withh compressed air. Valve
cann
usi ng a bore gauge
be checked (or
for wea
wearr by using
and micrometer,
re fer to Figure
Fi gure 10,
10, Inset A.
micrometer, refer
Th
va lve guides should be
chec ked aatt the
The valve
be checked
top , middle
midd le and bottom of the guide bore for
top,
weal',
meter is grea
ter
10. If the dia
diametw
greater
wear, Figure 10.
.3440 " at
ny point aalong
long the
tthh an
a n .34411"
a t aany
[lie bore, the
mus t be replaced
n aarbor
rbor equal
guide must
replaced.. Use aan
ide diam
eter of
va lve gguide
uide to
to the ins
inside
diameter
of the valve
uide from colla
psing when pressed
keep the gguide
collapsing
into
re ss in from the trip
top of the head
info place. P
Press
until
(Intake and Exhaus
Exhaust)
unti l the guide
guIde (Intake
t) protrudes
.875" above the head
efer to
ta nce of ,875"
a dis
distance
head,, rrefer
9, Inset A, Page 11.
11. Replacement guides
Figure 9,
must
m
ust be reamed
rE'amed after installation
ins ta llati on . Ream the
.3439" diameter.
uide .3429"
.3429" to .3439"
gguide

,.411
GAUGE'~~

EXPANDABLE
BORE
EXP
A ND A BLE BOR
E GAUGE-

CHECK WE A R
OF GUIDE AT
TH REE POI NTS

IN S ET A

GU IDE
R EB ORE
A RE A

MI C ROM ETER

Figure 1 0

Clea
powe r driven fine
fine
Cleann the valves with a power
wire bru
sh, being very careful not to scratch
brush,
the valve stE'ms.
F igure "H
II for valve
va lve
stems. RE'fer
Refer to Figure
nomencla ture.
nomenclature.
FACE

STEM

RETA INER GROOVE

TIP

Figure
va lve s for
fo r excess
ive wear
wea r or
Inspect the valves
excessive
ne<;ked stem
s, Figure 12.
12. This ca
cann be caused
necked
steins,
by lack of
ion, plugged water paspasof lubricat
lubrication,
sages
ting the eengine
ngine under contin
sages or opera
operating
contin-o
uous overload aatt excess
ive engi
ne RPM.
RP1Vl. Reexcessive
engine
Res ts.
place valves if this condition exi
existsMARGIN

ill'~~~=rnn=mo
NECKED VALVE STE M

Fig
ure 12
Figure
1

Inspect the valves for deep grooves in the

fac e, Figure 1.3
ca n be cau
sed by abra1.3.. This can
caused
face.
ssives
ives entering the engine through t\'le
the intake
a ir cleaner
cleane r resystem or not servicing the air
rogula
rly. If
If grinding the valve face
f<lce will
wi ll not
gularly.
repl ace the valve.
correct this condition, replace
GROOVE IN
IN VALVE FACE
FACE

Figure 13

fnspect
va lve face a nnd
Inspect the valve
d stem for rust
or pitting, Figure U.
1 4 Rust
s t or pltUng
pitting ca
can
val ve
usually be removed by gr indlng
inding the
t h e valve
face. If rust
rus t or pitti ng on the valve stem
stem
exis
ts , replace
repla ce the vvalve. These conditions
exists,
ca n be caused by using
usi ng poor qua
lity eng
ine
quality
engine
can
fuel
specificoil or fu
el that
tha t does not meet the specifIc'
aation
tion given in Section 11
11 and by improper
engine.
storing of
of the engine.

~.
" '

RUST OR PiniNG
PITTING

"

"

, \

. ",

Figure 14

111 1 :1

22-13

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

Hea vy carbon oorr varnish
varni sh deposits
Heavy
deposits on the
valves, Figure 15, should bfbe removed before
befo re

valves are ground.

usua lly
ground. This condition is usually
caused by worn piston rings and sleeves
which allow
a llow too much oil to reach the comcombustion chamber.
cham ber. Th.is
conditions
could
also
This c'otiititions
ls
be caused by worn valve guides or bad sea
seals
on the valves. Low oper
a ting temperature
templ?rature is
operating
nothl?f ca
use.
sti ll aanother
still
cause.

A T 1tiflEE
THRE E pOIr.lTS
CHECK DIAMETER
DIAMETER OF STEM AT
POINTS

*B'
-.*

.3409
.3419

INTAKE V A L V E
,3419 [NTAH VALVE

.3;.-:3:-:::9,,9_
U ST VA
LVE
*_-,;3
3 3 3 EXHA
EXHAUST
VALVE
.3340
4 0 99

HEAVY CARBO
V ARN ISH OEP0SlTS
DEPOSITS
C A R B ON
N AND VARNISH

Figure 15

Inspec t the vaivcj

va lve head Kir
tor dishing and
Inspect
and the
va
lve face
face for deep burned spots, Figure 16.
valve
16These conditions cannot be corrected by
ves . The vdlves
"a lves must be regri
nding tthe
grinding
h e val
valves.
replaced. These conditlon
conditionbs are
a rp usually
usua lly caused
excessive loads
by running
runnin g the
t he engine under
undcr excessive
at
ng ine temperatures,
tempera tures,
a t high eengine

DEEP BU
BURNED
DEEP
RNED
VALVE
PACE
VALV E FACE

DI SHED VALVE HEAD

Figure 16

Va
lves with worn keeper grooves or if the
Vahes
stem
\\'orn oorr dished beyond thl?
hamstern titipp is worn
the ccham[-e 17.
fer, replace tthe
h e valves, Figu
Figure
17.
WORN s TEM TIP

WORM
RETAINER
GROOVE
WORN R"
TA INER GRO
OVE

Figure 17
The checki
ng of
lve stem diameter
checking
of the va
valve
ca n be
be best be done with a good,
good, accurate
acc urate
can
micrometer,
micrometer , Figure 18. The valve stem
s tem
being straight, should be measured
meas ured at three
igure 18.
points along the stem
stem,, F
Figure
18, Wear limit
.002" at
ll points
poin ts of meamu st not exceed -002"
must
a t aall
surement.
If the wear is greater
greater,, repla
replace
surem ent. If
ce
the valve.

Figure 18

The check ing of the

valve fa ce runou ! should
be do ne after th e valves
have been ground. A Vee
block type holder wi th a
dia l Indicator , Figure 19
can be used to c heck the
va lve face and stem runout. The valve face runau t should not exceed
more tha n .002". The
valve stem r unout should
lIot exceed _002". If the
valve face and i or val ve
stem runout is greater,
the valve m ust be reo
placed.

OI A L I r.lO ICATOR

figure 19

I OTE : Sma ll amounts Of ' -ery line pitting,

Figure 20, may b found on the s urfaces of
the va lves faces a nd seats afler Ille va lves
a re cleaned . These are normal a nd wil l not
affect engine perrOtma 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
or seats if Lhis fin e pitting is found a s thE'
pitting will generally reoccur after the en
gine is run for a few hours.

FINE PI TTING

Figure 20

22-14

REFACING INTAKE AND EXHAUST VALVES

Before refacing the valves, they should be
Before refacing the valves. t hey should be
wire
brushed, cleaned and inspected. A 440
wire br ush ed, cleaned and inspected. A 44"
angle
is the correct valve face grinding angle.
angle is the correc t valve face grinding angle .
Set
the
refacing machine protractor a t this
Set t he refacing machine pro trac tor at this
angle.
Be
s u r e the chuck of the machine is
a ngl e. Be sure the chuck of the m achine is
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
light
cuts as
a s tthe
valve
is
val ves . Take only lig
ht cuts
he val
ve' is
refaced.
The
last
cut
must
be
very
fine
so
r efa ced . The l ast cu t must be very 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.
VALVE F
VALVE
FACE ' "
GRINDIN
GR IND IN G ANGL'0-

I1
11

~~;5~" ===c=

Correct refacing of intake and exhaust

Correct refacing of i ntake and ex haus t
valves and valve s e a t s will provide a l
h
inval ves and va lve sea ts will provide a 10 Interference angle. This angle is important
terference angle. Thi s angle is importan t
since it aids in cutting carbon and helps seat
since it aids in cutting carbon and helps seat
the valves.
the valves.

l ' INTERFERENCE ANGLE /

//)

INTAKE VALVE AND VALVE SEAT

INTAKE VALVE AND VALVE SEAT

MARGIN
MARGIN

/
CHAMFER --------CHAMFER

T
-

Figure 21
The tip end of the valve should be checked
The tip end of the valve shou ld be checked
for
roughness o r wear. Usually this c a n be
fo r roughness or wear. usua lly t his can be
removed with some very light cuts against
rem oved with some very lig ht c ut s against
the side of the grinding wheel and will square
the side of the g rinding wheel and will square
up the end. Never grind off the valve s t e m
up the end . Never grind off the valve stem
end beyond the chamfer.

end beyond the chamfer .

EXHAUST VALVE AND VALVE SEAT

EXHAUST VALVE AND VALVE SEAT

Figure 22
When the top edge of the contact a r e a is
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
contact area must be moved. This is done
contact area must be moved. This is done
by using the narrowing stones. Refer to
by using the narrow ing stones. Refer to
P a g e 15, The contact area width should
Page 15. The contact area width sho uld
never exceed the specified dimension of
never exceed the speci fied dimension of
.0608" to .0962" (exhaust valve) and -704"
.0608" to .0962" (exhaust valve) and _7(14 "
to ,1057" (intake valve).
to .1057" (intake va l ve).

2213

GRINDING INTAK E AND EXHAUST V ALVE SEATS

Alwa
y s use
USE' a precision seat grinder.
grinder. Take
Always
ve
ry light ccuts
uts with the ggrinding
r inding stones so
very
just eenough
noug h metal is removed
rem oved to end up with
just
mooth sca
finish.
a good ssmooth
scatt finish.
The proper angle of grind is 45"
ex
450 for exva lve seats,
Fig ure 23.
haust valve and intake valve
seats, Figure
The sea
le of
s tone sshould
hould be
seatt grinding ang
angle
of the
tho stone
drE!ssed
dressed frequenctly on a stone dresse
dresscrr to
maintain a clean aaccurate
ccurate surface
surface..

The valve
va lve sea
ontac t area width
wi dth and 10
seatt ccontact
Iocation ccan
a n be cha
nged by using
usi ng the :30"
changed
.30' and
60')
rrowing stones,
stones, Figure
Fi g ure 25.
2:;.
60') na
narrowing

t<::::/

30'
30" NARROWING STONE

\
.0608 TO .0962

~Offl

VALVE SEAT GRINDING

G R I N D I N G AREA

60 ' NARROWING STONE

STON E
60D

C3

EXHAUST
EXHAUST VALVE SEAT

EXHAUST VALVE SEAT

~~:g1'

1057
IDTH

INTAK E
INTAKE

VALVE SEAT

F
igure 25
Figure
2
INTAKE
INTAKE VALVE SEAT

Figure 23
ll\lPORT.4.NT:: The
va lve
seat
runou t
wive
runout
sshould
hould be checked after finish grinding with
aa ddial
ial indicator aand
nd SE?a
rind ing pilot, FigFig
seatl ggrinding
ure 24.
The run
out of the valve
va lvE' seat must
m ust
2-4. The
runout
xceed .002"
not eexceed
,002" .,

DIAL INDICATOR

No'rE:
valvE' hea
recE'ded more
morc
E: If
If the valveheadd hhas
a s receded
(e xhaus t valve and intak@
intake valve)
valve) bebe
than .010
,010"" (exhaust
low tho
the cylinder
c ylinder head
he ad ssurface,
urface , F
igure 26, the
Figure
valve or
vE' ins(>rt
hould bE'
reo
o r val
valve
insert. or both sshould
be repi ac ('d to keep the compression ratio
ra1io equa
placed
equall
be twe en cylinders
cy linde rs for
a n efficien
r unning
between
tor an
ffficiontt running
eengine.
ngine.

.010"

EXHAUST VALVE

I
.01 0"

INTAKE VALVE

Figure
ure 26
26
Figure 24

22 16

LOCATING TOP DEAD CENTER AND TAPPET ADJUSTMENTS

F)RIN(; ORDER
ORDER -------.--.-.-.-----.-------- - 1-.,-42
l-:j-4.2
FJRI);G
-- ----------- ---- -- --- ---------ThE'
The Top Dead Center
Center position of number 11
and -1~ cyli
nders iiss indicated
indica ted by the
TD C m
mark
cylinders
OIP TDC
ark
On
fl yw heel. Refer
ur e 27
on Ih
the~ ilywhocl.
R ~ f e rto Fig
Figui
Th", tappet adjustments can b('
do ne in two
The
be done
ribed in
th e foll
owi ng manner.
steps aass desc
described
i n the
foliiwing

TIMING
T I M I N G POINTER

COLD SETIING
STEP 1 - Rem ove the val ve ('O\-er
-pr,. Crank the
ngi ne until
ing pointer is
ligned with
w i th
e
engine
unHI the tJm
timing
i s aaligned
TOC ti
ming mark on the fl)whee
l, Figure
the
rhe TDC
timing
fhwheel,
27_
ods on ,-0
inder
7 . Check
h w k the
t h p push rrods
S o .. 11 cyl
cylinder
fo
ness _ If the push rod
loose,
looseness.
rodss arE'
a r e loose,
torr loose
1\0.
1 cyli
nder is a
C on tth~d
he compression
co mpress ion
No. 1
cylinder
att TD
DC
stroke.
s t r o b . If
If th
t h e push rods
d s are
arc tight,
tight, crank the
lete rrevolution
evolu tion and align the
engine
complete
engin(> one comp
TO C mark
m ar k on tthe
he n
ywheel ,
pointer
flywheel,
pnmtt'r and the TDC
F
igu r e 27.
Figure
Ch eck and adjust the followin
va lve clearChock
followsngg valve
ances ; int akC' valve at .014"
14" Clearance
clearance on
cyl
i nders 11 and
aus t valvcs
valves on
cylinders
a n d 2,
'I. and tthe
h e exh
exhaust
cylinders 1
nce, Figure
1 and 3 at .01'1"
,011" cleara
clearance,
28.
S 8.
STEP 2 -- Cra
nk tthe
plete reCrank
h e engine one com
complete
revvolution
olutio n and align the timing pointer and tthe
he
TDe
fl y wheel. Figure
Fig ure 27.
27 . CylTDC mar
m a r k on the fivwheel.
Cyl-

\
\

FLYWHEEL HOU S ING OPENING

Figure 27

inder No.
No, 4 should be at TDC
t h e COIll
com-inder
T OC on tho
thee push
pression stroke. Check th
pu sh rods
roel s on
1\
' 0. 44 ccylinder
yl inder for looseness
No.
looseness..
Checkk aand
ollowing valve clearclearChec
nd adjust the ffollowing
ances; intake
inta k e valves a t .01-1"
_014" clearance
cl ea r ance on cylcylt h e exha
exhaust
inders 3 and 4, and the
uot xalves
\'alves on
cylinders 2 a
nd 4
.014" cclearance,
learance, Figure
F igu r e
and
4 aatt .014"
28.
28.

HOT SETTING
SE
G
ile tthe
ne is
Follow steps 11 and 2 wh
while
h e engi
engine
hoI.
lear ances ffor
set ti ngs
hot. The tappet cclearances
o r hot settings
are
take valves and .020"
f or
a r e .014"
.014" for the in
intake
,020" for
xha ust va
lves.
the eexhaust
valves.

FAN

FEELER

INTAKE

INTAKE

INTAKE

INTAKE

Figure 28
JMPORTANT:
Th
e
valve
tappet
c
lea
r
a
nce
adju stment.
PORTANT: Tho
clearance is
Is a critical
criti
The en
tire combustion system of tthe
ously affect
ed by adjusting the valve
h e engine will be seri
seriously
affected
entire
ther ssetti
t'lppe t clearance to any o
tappet
other
~ t tng
i n .g .
th e valve
va lve timing and could result in overh
ealJng , power loss
E
;, cessive cclearance
lea ran ce will chang
changee the
overheating,
Excessive
and possibl
va l ve breakage.
dnd
possiblee valve
breakage.
Insufficien
nce would all
ow the valve
emain open and be burned by the hot exhaust
exhau st
Insufficientt cleara
clearbance
allow
valvess to rremain
ga
ses.
gases.

ion

22
CYLINDER HEAD AND VALVES
148. 159. 188 AND 201
SPARK IGNITION ENGINES

UserFr~endlyCDs
TABLE OF CONTENTS

..

.. ...... " ................. .................... ...... ..... .. _.. _.. . _ , .. .. .. .

.. , .. ..
..... ... ., "'
Specl31 Torq \l(, s .... .... __ ...... .. . _.... .. .. ..... .... .. ....... . ... ..... .... . ", ...... ...... " ..... _. ..... . .. .... , ..... ... .... .. .. ,', ..... , 3
Checking: Compn'ssion Prl'ssu ro:> " ", .................. .. ", .. .............. ......... ,............. _.. ................... __ t,;
Cylinder Hf.>ad and Com;xm e nl'<;
S pec l ftc at io n~

~,-'

(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

http://www.ioffer.com/sell i ng/userfriend Iycds

http://stores.ebay.com/UserFriendlyCDs

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)
INTAKE VAL E GUIDE
Length (1 88 and 201 ) _.. ....... ... .... ............................. .... ................. _.............
Length (148 and 159) .. ..... ................... .................. ..... ......... ..... ... ...... .... .. ......
0.0 .... ...... .. .............. ........................... ................... _...... _.. .. ............ 6565" to
1.0 . (In sta lle d and Reamed) ................. ........... ........ ..... .. ....... .... '" .3422" to
Protrusion Above Cylinde r Head ..... ... ............ .... ....... .......... .........................

Maxim um Limit
Incl uding Wear
3. 125"
2. 688"
.6575"
.3432" .............. 002"

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 ..... ..... ..... .. ................ ...... _.................................. .... ... ... _.... ........ 23/8"
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
steam cleaning.
2. Before cranking the e ng ine for compress ion checking , make sure all operating
controls are in neutra l, brakes are set and
the wheels are securely blocked.

A. Wh e n using the remote control type of

compression tester, F igure I, make sure
the wires are correc tly a ttached to the
s tarter termina ls . Incorrec t attac hing of
wires will ca use damage to the testing
equipme nt , Figure 1.
B. When using the ignition switch operation

3. Only the cranking method is advised to be

used when c hecking compress io n pressure.
NOTE : The e ngine must be at ope rating
tempera t ure at the time of compression
checking.
4. With the engine at opera ti ng tempera ture,
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 minimum loa d on the starting m otor and battery.

type of compression tes ter , Figu r e 2, be

sure the carbure tor thro ttle plate (bu tterfly) val ve is he ld in the wide open position.
Drain the ca rburetor to prevent fue l fr om
e ntering the cylinders.
COMPRES'510N

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

Page 5.

6. Two common ty pes of compression gauge

equipment used are the remote control and
the ignition switch ope ration type.
COMPRESSION TESTER -

_ _ __

(18mm~

Figure 2
7. It is very important that all cylinder pressures be approximately alike. For the allowable compression pressure variation, refer
to the chart on Page 5.

SWITCH -----~

SOLENOID

Figure 1

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
indicated, squirt a small amount (a te aspoon )
of oil into the cylinder and recheck the compression. If the p ress ure ri ses to near no rmal, 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.

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 electrodes 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, before 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

ENGINE SPEED
A PPROXIMATELY

CRANKING

NORMAL
COMPRESSION
PRESSURE

ALLOWABLE VARIATION
BETWEEN CYLINDERS

(1 48) 150 RPM

140 PSI'

20 PSI

(159) 150 RPM

125 PS I"

20 PSI

(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.
the cooling sy s te m. CAUTJON: If
the e ngine is hot, do not r emove the radi a tor
cap until th e coolant ha s had suffi cient time
to cool. Loosen th e cap to the first stop
carefully to relieve any exc ess pressu.r e
before r emoving it complete ly.

L Dra in

2. Remove the hose from the the the rm ostat

housin g (I). Remove the therm osta t housing
(1 ) a nd gaske l (2). Di sc a rd the g ask et. NOTE ;
If the thermostat is to be serviced, refer
to Sec tion 23.

4. Remove the bolts that c on nect the inta ke

manifold (7) 10 the exhaust manifo ld (8) . Re-

move the inla ke m a nifold (7) a nd e xha ust

m a nifold (8)_ Remove m anifold gaske t ( 9 )
and discard_
5. Remove th e valve cover ( 10 ) , gaske t (11) and
breather tube (12). Disc a rd the gasket.

6. Remove the roc ke r arm brac ke t bolts (13 )

and th e stud nu t, ( 14) . RemQve th e roc ker
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

the c arbure tor (3). Remove t h e carbure tor

assembly (3 ) and gasket (4 ) . DI scard the
g asket. Di sconnect the hi gh tension wires
from th e spark plugs and r emove the spark
plugs (5) and g askets ( 0 ) .

tag them so
they c a n be installe d in their proper loca tion
whe n r ea ssem bllng .

7. Remove the push rods (15) and

8. Remove the c ylin der head stud nuts (1 6) a nd

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

parts.
2. Clea n the top surface of the cylinder block
a nd sleeve flange ca refully. Tlw top of the
pistons may be c leaned with a powe r driven
wire brush. NOTE : The pistons must be a t
top dea d ce nter whe n be ing cleaned_ All
traces of c arbon and ot her de posits must be
r emoved. During cleaning , th e use of a clean
lint fr ee c loth dampe ned In solvent is r e commende d.
3. Clea n all bolt a nd slud threads.

4. Cle an and ins pect the cyli nde r hea ds thoroughly . If evidence of fretting or e r os ion
exists or if the head is wa rped more tha n
_006" , the head must be r esurfaced or r e placed.

5. In spe ct the push r ods [or straightness ,

c ra cked or worn end s . Repla ce if necessa ry .
6. Clean the valve cover a nd fl usll au! the
brea the r tube.
7. Clea n and check the s park pl ugs . If replacem 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
TOP mark up.
2. Install the cylinder head (17) and stud nuts
(16), tighten the stud nut s (16) finger tight.

3. Install new intak e and ex haust manifold gasket (9). Install th e e xhaust manifold (8) and
intake manifold (7), leaving the stud nuts
finger tight4_ Install the thermosta t housing (1) and new

gasket ( 2), leaving stud nut s finger tight.

5_ Torque the cy linder head stud nuts to 60
ft. Ibs. and then to 95 - 105 ft. Ibs. NOTE :
Lubricate threads with clean engine oil
prior to torquing and use the tightening
sequence shown in Inset A.

6. Torque the e xhaust manifold and intake manifold stud nuts 25 - 30 ft. Ibs. Torque the
thermostat housing stud nuts 20 - 25 ft. Ibs.
7. Coat the push rods (15) with c lean engine oil

and install them in their original location.

8. Insta ll the rocker arm assembly (19). Make
sure all of the push rods (15) are engaged with
the a djus ting screws on the rocker arms. Torque the mounting bolts ( 13) and stud nuts (14)
25 - 30 ft. Ibs .
9. Adjust the valve tappet clearance, refer to

Page 26.
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.

11. Install the carbure tor (3) with a new gas ket
(4) to the intake manifold (7)_ Torque the
mounting baits 35 - 42 ft. Ibs. Recon nect the
linkage and fuel line to the carburetor.
12. Reconnect the hose to the thermostat housing
(1) and clamp securely_ Make sure the drain
valves are closed and refill the cooling system. Reinstall the air cleaner system making
sure all connections are tight. Install the
spark plugs (5) with new gaskets (6) and torque
32 - 35 ft. Ibs. Reco nnect all of the hig h tension
wires to the spark plugs.
13. Apply clean e ngine oil to the rocker arm
assembly and start the engine. Check that the
rocker arms are receiving lub r icating oil.
Opera te the engine for approximately one hour,
(under load if possible) to thoroughly warm
up the e ngine and seat the heacl gaskets.
14. Shut the e ngine off. Back off each s tud nut
individually 1/ 4 turn and retorque to 95 .
105 ft. Ibs. in the proper sequence, Inset A.
NOTE : DO NOT BACK OF F ALL THE
STUD NUTS AT THE SAM E TIME . Recheck
the torque to make sure all stud nuts have
retained their proper torque. Recheck the
rocker arm stud nuts and mounting bolts to
make sure they have retained the 25 -30 ft.
Ibs. torque.

15. Install a new valve cover gasket (11 ) and

valve cover (10). Torque the cover nuts 5 to
8 ft. Ibs_ Do not over torque the cover nut s .
Install the breather tube (12).

lN"imA-- - - - - - INSET A

1'0 11

10

OS

<oj~
I
7
I

Figure 5

22-9

2210

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
the engine is hot. do not remove the radiat or
cap until th e coo lan t has had s ulficient time
to cool. Loo se n the cap to the first stop
carefully to r e li('v(' a ny excess pre ssure
before removing it completely.
2. Re move the hose from the the the rmos tat
hous ing (I). Remove the thermostat housing
( 1 ) and gaske t (2). Disca rd the g asket. NOTE;
If the thermostat is to be s erviced, refer
to Section 20.
3. Disconnect the linkage a nd fuel lines from
the carburetor (3). Remove the carburetor
assembly (3) and gasket (4 ). Di sca rd the
gasket. Disconnect the hig h tension wires
from the spa r k plugs a nd remove the s pa rk
plugs (5) and gasket" (6) .

4. Remove the bolts tha t connect the in take

manifold (7) to the exhaust manifold ( 8). Re
move the in ta ke manifold (7) and exhaust
manifold (8) . Remove m anjfold gasket (9)
and discard.
5. Remove the valve cover (10), gasket (11 ) and
b reather tu be (12). Disca rd the g as ket.
6. Remove the rocker arm bracket bolts (13 ) .
Remove th e roc ker arm assembly ( 19) . See
P a ge 16 a nd 17 for servicing of the rocker
a rm assembly.
7. Remove the push rods (l,)) and tag them so
they can be installed in th eir prope l' locat ion
when reassembling.
8. Remo ve the cylinder head s tud nuts (16) and
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

part s.
2. Clea n the lop surface of the cy linder block
a nd sleeve flange care full y . The top of the
pistons may be clean ed with a power driven
wire brush. l\'OTE: The pistons must be at
top dead center when being ('leaned. All
traces of ('a r bon and other de posits mu s t be
r e moved . Duri ng cleaning. the use of a clean
lint free clo th dam pened in solvent is 1'1"
comm e nded.
3. Clean a ll bolt and stud threa ds.

4. Clean and ins pect the cyl inder heads thor

oughly. If evidence o f fre tti ng or erosion
e xists or if the hea d is warped more tha n
.006", the head must be resurfClc pd or reo
placed.
5. Inspect the pu sh rods for stra ig htnes s,
c racked or worn e nd s. Replace if necessary .
6. Clean the valve cover and flush out the
breather tube.
7. Clean and check the spark plugs. If repla ce
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
TOP mark up.
2. Install the cylinder hear! (17) and stud nuts
(15), tight e n the stud nuts (16) finger tight.

11. Ins ta ll the c ar buretor (3) with a new gasket

(4) to the in ta ke manifold (7 ) . Torque the

mount ing bolts 35 - 42 ft. Ills. Reconnect the

linka ge and fuel line to the c a rburetor .
12. Reconnect the hose to the thermostat housing

,1. Ins tall new intake and exhaust manifold gasket (9) . In s tall t.he exhaust man ifold ( 8) and
inta ke manifold (7). leaving t ile stud nuts
finger tight.
4. Insta ll the the rmostat housing Il ) and new

gasket

(2 ).

leav ing st ud nuts finger tight.

th(~ cylinder head fl anged nuts to

60 ft. )bs. a nd then to 90-100 ft . los. 'O'J'E :
Lubrica te t hreads with c lean eng ine oil
prior to torq uing a nd usc the tightening sequence s hown in Inset A.

J. Torq uE'

(1) and clamp securely. Mcke sure the drain

valves are close d and refill the c ooling system . Reinstall the air cleaner s y ste m m a king
su re all connections are tigh t. In s tall the
spark plugs (5) wi th new gasket s (6 ) and torq ue
32 - 35 ft. Ibs. Reconnect all of t he high tens ion
wires to the spark plugs.

13. Apply clean engine oil to the rocker arm

assembly and start the engine. Check tha t the
roc ke r a rms are recei ving lubricating oil.
Opera te the engine for approxlma te ly one hour,
(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

thermo sta t housi ng stud nuts 20 . 25 ft . lbs.

wi th th f' ac!j us ting scr('ws o n the rocker arms.

Torque t he m ounting boits (U) 25-30 ft. Ibs.

14. Shut the e ngine off. Back of[ each cylinder

head fla nged nu t individually 1/4 turn a nd
retorque to 90-100 ft. Ibs . in the proper
sequence, Inset A. NOTE : DO NOT BACK
OFF ALL TH E FLA NGE D NUTS AT THE
SAME TIME. Recheck the torque to make
sure a ll flanged nu ts have ret;Jined their
proper torque. Rechec k the rocker arm
bolts to make su re they have reta ined the
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

7. Coat the pu s h rods (1;;) with clean engine oil

and insta ll the m in the ir ori gina l location.

8. Ins tall the r oc ke r arm assem b ly (19). Make
sure all u t the push r ods (15 ) are engaged

P age 26.
10. Install the e xha us t s tac k (21) and new gasket

(20), if it was remo ved. Torque the mo unti ng

bolts ;15 to 42 ft. Jbs.

valve cover (10) . Torque the cover nuts 5 to

8 ft. lbs. 00 not over torque the cover nuts.
In s tall the brea the r tube ( 12).

22-13

13

Fi gure 7

INSET A

22-14

ROCKER ARM ASSEMBLY

148 AND 159
( Refer to Figure 8)
Disassembly
I. Hem ove

the rocker arm s haft bracket

bolts (I) an d studs (9). !l;OTE : The ce nter
bracket is drilled for oil passge to the
rocker arm sha fts .
2. RemovE' and tag ea ch rocker arm bra c ket
(2 & l UI for proper location \\"h('n assem bling. ~OTE: The e nd brackrts will ha ve
to bEe' moved uU lwanl sl igh tl,' in order to
re m ovE' the' retainer pins ( 4) from the s hafts

(5) be fore the e nd brackets can be removed.

3. R em ove the shaft sprin gs (8) and s pacers
(11) from the sha fts (5). T ag the fro nt and
rear shafts (.5) for proper locat ion when
assemblin g .
4. Remove the tappet a dju s ting screws (12) fro m
the roc ke r a rm s_ Remove the pu s h rods a nd
tag them for proper locat ion.

Inspection
Check the s haH s prings for da mage and
pro pel' tensio n.
SPHI:\ C SP E CJF!C.\TlO:'<S
Free Le ngt h .. .. ...........
.. ... ...... ... ].;l/16
Wire Diame ter . .... ................... ..... ... . 072"
l. D. ................. ..........
.. ........... 11116"
1_5 to 8.5 Ibs.
Compressed to 11 116"

The roc ker arm mus t be ft'ee on the shaH

without a ny s ide wob ble. !f any is noted, r e o
place t he rocker a rm bushing, Clea n the oil
passage in the roc ker arms. Inset A , to insure
free oil flow. Inspect t hE' valve stem contact
area on the rocker arm for wea I'. Replace if

Flu sh the s haft s to r emove any residual

m ater ial. Inspect the s halts for e xcessive
wear or worn spells on thE' bo ttom side of the
s haft. Replace the sh aft if any of these condition s exists.
In spec t the rocker a rms by in st alling each
r ocker ann on the shafts in its proper loca tion.

adjusti ng screws ,

worn.

Clea n and check the o il passage in the tappet

Ins pect the push ['ods for straightness,
cracke d or worn ends, r e place if these conditions exis t.
Clean and c heck the oil passage in the cen ter
rocke r arm bracket, Inset B.

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
the s halts (5), if they were r emoveel , to a

point w hich will allow the re tai ner pins (4)

to be installed and not block any oil holes.
NOTE : If the pl ugs (3) are installed too
far they will block the flow at oil to one or
more roc ker a rms .
2. Inst a ll t he e nd bracket s (2 ) part wayan the
shafts (5) so the retaining pins (4) ca n be installed in s haft. Tap the end brackets further
on the shafts so the pi n engages the s lot in
the bracket and the oil holes in the sha ft are
toward the valve side of the bracket.
.3. Install new roc ker arm bu shi ng ( 13) in to
the roc ke r a rm s ( 6 & 7) if they are be.ing
replaced, :-.'OTE : The bushing (13) must
be pressed into the r ocker arm and reamed
to ,624" -.625", In set A.
4. Starting with the front s haft install a r ear
r ocker arm (7) , spri ng (8), fron t rocker arm

(6), inte rmedia te bracket (2) . spacer (11), red I'

rocker arm ( 7), spri ng (8 ) a nd front rocker
arm (6).
5. Starling wit h the rear sha tt insta ll a fro nt
rocker a rm (6) , spring (8) , r ea r roc ker arm
(7 ). interm edi a te bracke t (2) . spacer' ( 11 ),
front rocker arm (6), spring (8) a nd rear
rocker arm (7).
6. Ins tall these two rocker ~rm shaft assem
blies into the center bracke t ( 10) a nd wire
the c omplete assem bly together.
7. Install the ta ppet a dj us ting sc rews (12) into
the rocker a rm s (6 & 7) as far as possible.
8. Install t he push rods in thei r proper location .
Ins tall the r oc ker arm as sembly to the cyl
ind er head with th e bracket bol ts (1 ) and
stud s (9). Torque the bracket boIlS a nd stud
nuts 25 30 t t. Ibs .
9. Adjust the tappets, re fer to Page 26.

INSET A

TAPPET SCREW
OIL HOLE

CROCKER A RM
. '

INSET B

r;rV' L.C

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
bolts (l & 91. I'o- OTE : The c e nter bracke t
bolt is d r ill ed for oil passage to the rocker
arm shaHs.
2. Rc'mo\-e and lag !?aeh roc ker ann (-1 & 7) and
brac ket (:l . 10. 11 & 12 1 fo r proper local ion

when asse mb ling .

3. Remove the shaft sp rin gs (6) a nd tag the

front and rcar shall s (8).

4. Remove cac h tappet adj usting screw
ea ch r ocker orm , r !? fer to Ins E't 1\.

(~ )

from

Inspection
Cheek Ihe sl1a ft spr ings for damage and
proper te nsion.
SPRI~G SPEC (FICATIO~ S

Free Length . ...............

. ...... .... . 2. 5"

Wire Diam e ler

.................. 072"
Compressed to 1.70," ............ 7. :; to 8,,) Ibs.
Flush Ihe s haft s to remove a ny residual
mat e rial. InspC'c l Ihe shafts [or e xcess ive
wea r or worn spots on Ihe boltom sid e of the
s ha ft . Replace the shaft if any of these conditions exist.s.
Inspect th C' r oc ke r arms by installing each

rocker a rm on the shafts in its proper loca tion . The rocker arm must be frce on the
shaft without any side wol;Jblc. If any is noted,
replace the rocker a 1'111_ Clean the oil passage
in the rocke r arms to illsure fr e e oil flow .
Inspect the valve ste m contact area on the
rocker arm for wear. Replace if worn.
Clean a nd check the oil passage in the
tappet adjusting screws, Inse t A, and the
center ,I )rack.et retaining bolt (1).
Inspect the push rods for st raightness.
cracked or worn e nds, replace if th e~e conditions 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 apmediate 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 sembly 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
(6) on the rocker arm shafts (8 ) .

7. Adjust the tappets, re fer to Page 26.

22-17

INSET C

INSET A

OIL PASSAG E

OI L PASSAGE

OIL HOLE PLUGGED

TAPPET SCREW

~OILHOLES~

t:'l;::::(: : ~ -: --::--1
I-sHORT END-I

~CUT OUT

Figure 9

2:118

CYLINDER HEAD ASSEMBLY

148 AND 159
(Refer to Figure 10)
Disassembly
a valve spring com p ressor, com
press the v alve spring (1) enough to remove
the va lve ret ain er loc ks (2i. R elease the
spring compressor and r emo\"(' the intake
va l\'(' seals i3 ), in take val "" retain ers (4)
a ncl the exlla ust valvE' rotators (5). Remove
the spring s (J).
2. H emov!? any carbon from the valve s tems
bC'fon? they ue r emoved f rom the cylinder
head. He'move the inl a ke valves (6) and ex
hau st \'alves 171 from the cyli nder head (9)
and "Pt t hem in a rack or hold er. N OT E:
:Vlark the valv es on remova l SO they can
bo installed in their original loca tion.
:l. Hemove t he int a ke valve g uides (10) and the
c xhoust v<l l ve g uide s ( 11 ) by driving them

1. U sing

down through the cy linder head (9 ) using

an arbor.
4. Remove the exhau st va lve seats (8) fr om
the cy linder head (9) using a special seat
removing tool, Inset B. NOTE: Nevt'r Jt
tempt to remove a valve st'at with a center
punc h, cold chisel or pry bar.
5. Remove the push rod tubes (12 ) from the
cylinder head (9) by driv i ng them down
throug h the h ead, Rem ove tile puSh rod tube
"0" ri ngs (13) and discard them .
6. To remove t he expansion pl ug (14 ) f r om the
cylinder head (9) it must be elrUled anel
pryed out,
NOTE : Refer to Inspec tion and Servicing
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, insta ll new guid es (10 & 11) in the cylinder
head using a n arbor. Press the guides into
the head [rom t hl' top of the cylinder head.
The guides must protrude above the cylinder
head (intake 1.1'100" and ex ha ust ,844"),
I nse t A. After the gu ides have been pressed
in to place, the'), must be ream ed to .3422"
. . 3132", lns('\ A.
:2. To ins tall new exhaust valve se ats (8),
clean the r('cI'Ss in tlle cylincl er heael (9),
Plac(l the valve scat s in dry ice to shrink
them . Insert thE' valve seat s in the head
and pr ess them in pla ce , usi ng a suitable
pl"(~SS

valve seals (3) can be i nsta lled in t.he lower

groove on tht' valve st.ems . I nsta ll the
valve retai ner locks (2 ) and r em ove the
spring compressor c ar eful ly.
6. Ins ta ll the valve springs (1) and t.he ex
haus t valve rotators (5) on the exhaust
valves (7), Compress the valve spr ings so
that the valve r eta iner locks (2) ca n be in
s talled , Remove the spring compressor
care f ully.
7. [n sta ll new expansion plug (14 ) i f it. was
r emoved. The plug must be pressed in place
and firmly seated aga inst the retaining ridge
In the cylinder ht'ad.

1. Install new pu sh rod tube " 0" rings (13)

in the eylincicr head r ecesses , Lubric at e
the push rod tubes (12) with clean engine
oil anel install t hem into the cylinder head,
:\,OTE: Th e tubes m us t be i nstalled from
the top with the tapered end dQ>.vn. Be sure
t hey DO 1\'OT protrude below the cylinder
head, Sec In set C
'1. Lubrica te the intake valves ( 6) and exhau st
val ves ( 7) with clean engi ne oil and in sta ll
them in their ori g ina l location.
,j . [nsta ll thE' valve spri ngs (1) a nd valve re~
ta int'rs (4) on t he intake va lves (6). Com
press the val v e springs so that the intake

NOTE: When engine assem bly is complete,

a check of the opera tion of Ihe r otators
mu st be made. It is impossi ble to d etermine
whether or no t the r ota tor i s turning without
an identifying rnark .
P la ce a dab of white paint on ea ch oJ the 1'0'
tators and note it's position , Sta rt the eng ine
and observ e whether or not the rotator is
turning. DO "OT a ttempt r ep ai rs on rota tors .
There i s not a set speed a t whic h the rot ators
should turn. Some ro tators will turn faster
than others. As long as the rotator is t urning
the valve, it is functi oning proper ly.

22-19

INS ET A

R EAM/ .3422 " . . 34 32"

INSET B

.844"

"

"

-'-

INSET C

.0312 "

INTAKE VALVE
A SSE MBLY

EXH AU
AS SSE VALVE
SLY

2220

CYLINDER HEAD ASSEMBLY (Continued)

188 AND 201
(Refer to Figure 11 )
Disassembly
1. Usi ng a valve spri ng compressor, compress

tIl!' s pring (1 1 enoug h to remove the valve

reta ine r locks (21. Release (he s pring com
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
valvE' r Olators (5). Remove the s prings (1)
a nd va lve' s pri ng sea ts (6) .
2. Remove any carbo n from t he va lve s tem s
belorc they are r ('moved from the cylin der
head. Remove the in take valves (8) and the
e xhaust valves (7) fro m the cyli nder head
(9 ) a nd se t them in a r ac k o r holder. NOTE:
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 .

exhaust va lve g uides (11) by driving them

d own through t he cylinde r hea d (9 ) using an
a rbor .
4 . Remove the e xhaust va lve sea l, (12) Iro m

the cylinder head (9) using a specia l seat

r emovIng tool, In set B. NOTE: Never at
tempt to remove a va lve s ea t with a cent er
punch, cold c hisel or pry bar.
5. To r e m ove Ihe expansio n plug (13 ) from the

cylinder head (9) it must be drilled a nd p ryed

out.
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
new valve g uid('s (10 & 11) into the cylinde r
head us ing a n arbor . P ress the g uides into
the head from the to p of t he cy linder head.
The guides must protrude a bove the cylinder
head I intake a nd e xhaust) 1.000", Inset A.
After the g uide s have been pressed into place,
t hey mus t be reamed to ..1422". 34.32", Inset A.
2. To ins ta ll new ex ha ust va lve seats 02), c lea n
the r ecess in the cy linde r head ~S) . Place the
valve s ea lS in dry ice to shri nk the m. Insert
the valve seats in the hea d and press them in
pla ce . using a s ui table press.
3. Lubrica te th e intake va lves (8 ) 'l nd e xha us t
valves (7) with c lea n e ng ine oi l and instal l
them in thE'll' original location.
~.

Install the valve spring sea ts (6), valve springs

(1) a nd the va lve reta ine rs (4) on the int ake
valvE'S (8) . Compress the valvc spring so the
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 va lve re ta iner loc ks (2) ancl r e m ove the
spring compressor c are fully.

5. Install theval"" spring sea ts (6). valve s prings

(1) and the exhaust valve rotators (5) o n the
exhaust valves (7 ) . Compress .the valve springs
so that the va lve re ta iner loc ks (2) ca n be in
stalled. Re m ove the spring compressor care
fully.
6. [nstall new expans ion plug (13) If it was re o
m oved . The plug mus t be pressed in place
a nd firml y seat,ed aga in s t the r eta iner ridge
in the cylinder head.
NOTE : When engine as sembly is complete ,
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
whether or not the ro tator is ttl nting w Ithout
a n ide ntifying mark.
Place a dab of whUe pa in t o n each of the roo
tators and note it 's position . Start the e ng in e
a nd observe whethe r or no t the rota tor Is
turnIng. DO NOT attempt repairs on ro taiors.
The re is not a set s peed a t w hic h the rotators
shOuld turn. Some rOtators wi ll turn fas ter
than olhers . As long as the rotator is turning
the valve, it is functionin g pro pe rly.

22 21

INS ET A

INS ET B

-I

-1-

1 .0 00"

~~:-'-,.l _I

'EXHAUST S EAT RE M O VI N G TOOL

i
o

J ~ '"

!
INTAKE VALVE
ASSEMBLY

I:

~I

".

~---<D

I
1 t.:: 11
~ I "L...

CD

Figure 11

EX HAU ST VALVE
ASSEM BLY

1-_ _ _ _ _ _....

22-22

INSPECTION OF VALVES, GUIDES, HEAD AND SPRINGS

Clean the cylinder head completely. Rem ove all traces of carbon and other deposits.
Check for cracks and any evidence of fretting or erosion existing in the area of fire
ring contact. Check the head for evidence of
warpage. If warpage exists and is more than
.006", the cylinder head mus t be resurfaced
or replaced_
Val\'(, springs should be chccked for flat
squared ends, broken coils and correct
spring pn'ssure_ Cse a Valve Sp ring Tester
fEfelTing to the spring specifica tions be low:
EXH,\UST VALVE SPRIKGS
Va l\"('
Comprps sed Spri ng Replace if
Position
Height
PressurE- Lcs s than
Valye Open
U~l2"
114 Ibs . 110 Ibs.
\'al\'e Closed
1.686"
56 Ibs.
50 Ibs.
L\TA]{E VAL VI-: SPRl:'\GS
Compressed Spri ng Replace if
\'al"c
Hei.ght
Posillo n
Press ure Less than
U21"
114 Ibs. 110 Ibs.
Vain' Open
Valve Closed
1.87:;"
56 Ibs.
50 Ibs.
Remove a ll carbon from the bore of th e
\'a lve guides with a fine wi re brush and blow
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,
middle and bottom of the g uide bore for wear,
Figure 12. If the diameter is grea te r than
.3.52" at any point al ong the horC', the guide
mu st be (('placed. Cse an arbor equal to th e
insid e diameter o t the valve guide 1.0 keep the
guide from collapsi ng when pressed into
place. Press in fl'Om the top ot the head until
the g uid e protrudes a distance of ,84," on
148 & 1';9 exhaust valves, 1.000" on 188 & 201

EXPANDABLE BDRE

tNSET A

GAUGE~
CHECK WEAR
OF GUIDE AT
THREE POINTS

GUIDE
REBORE
AREA

exhaust valves a nd 1.00(J " on a ll intake

valves, above the hea d. Repl a cement guides
must be reamed after insta llation. Ream
new guides .3422" to .3432" diameter.
Clean the valves with a power driven fin e
wire brush, being very careful no t t o scratch
thE' valve stems. Refer to Figure 13 for valve
nomenclature.
HEAD

FACE

STEM

RETAINER

SEA L GROOVE
MARGIN

Figure 13

Inspec t the valves for e xcessive wear or

necked stems, Figure 14. This ca n be caused
by lack of lubrication, plugged water passages or operating the engine under continuous overload at excessive engine RPM. Replace valves if this condition e xists.
NECKED VALVE STEM

Figure 14
Inspect the valves for deep grooves in thE'
face, FIgure 15. ThIs can be caused by abrasives entering the engine through the intake
system or not servicing the air cleaner r egularly. If grinding the valve face will not
correct this condition, repla ce the valve.
GROOVE IN VALVE FACE

Figure 15
Inspect the valve fac e and ste m for rust
or pitting, Figure 16. Rust or pitting can
usually be removed by grinding the va lve
face. If rust or pitting on the valve stem
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 ation given i.n Section 11 a nd by improper
storing of the engine.
RUST OR PITTING

,'

.'

"

Fi gure 12

TIP

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
valves, F ig ure 17, should be removed twfote
va lves arC ground . Th is condition is usually
ca used by worn piston ri ngs and s leeves
wh ich allow too muc h oil 10 reach the combustion chamber. This c ondit ions could also
be caused by wo m va lve gUides or bad sea ls
on the valves . Low operating temperature is
sill! another cause.

CHECK DIAMErER Of STEM A T THREE PO I NTS

~:06
14

INTAKE VALV E

_ ;.::
.3c:
3..:
8.;:.2_ EXHA UST VALVE
.3390

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
va lve fa ce for deep bu r ned s pot s, Figure 16.
These condi tions cannot be corrected by
grindi ng the valves , T he va lves mus t be reo
placed . These conditions are usually cau sed
by runn ing t he engi ne under excessive loads
at hig h engine temperatu res .

DEeP BURNED
VALVE FAC E

OI SHED VALVE HEAD

Figure 18
Valves with worn keeper grooves Or if the
s tem tip is worn or d is hed beyond the chamfe r, r ep lace the valves , Figure 19,

WORN RETAI NER GR OOVE

Figure 19
The checking of th e val ve stem diameter
<;an be hes t be done wi th a good , accur ate
micrometer, Flgure 20 . T he valve s tem
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 measu rement. If the wea r is grea ter, replace
the val ve.

Figure 20
The checking of the
valve face runout should
be done a fte r the valves
have been ground. A Vee
block type h older with a
dial indicator , Figure 21
ca n be used to check the
valve face and s tem r unout. The valve face 1'110out should no t exceed
more th an .002". The
valve stem runo ut s hould
not exceed .002". J( t e
va lve face and lor val ve
stem runout is greater,
the valve must be eplaced _

D IAL INO IC A TOR

Figure 21

NOTE : Small amounts of very f ine pi tti ng,

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
or seats if this fi ne pitting is found as the
pitting will genera lly reoCCur a fte the e ngine is run for a few hours .
FINE PITTIN G

Figure 22

222i

REFACING INTAKE A ND EXHAUST VALVES

Correct r efac ing of intak e a nd ex haust v alves
and al ve seats wi ll provide a 1" in terference
a ngle. This angle i s im portant ,ince it aids i n
cutti ng carbon and Mips seat the valves.

Before r efacing the v alves, t hey sh ould be

wire brushed , cleaned and in ~pected .
44"
angle on xhaust valves and 29" angJe on
intake va lves i s t he correct va[\' face g r i ndIng 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~ ~~=~~=~=

IN TAKE VA LV E AN D VALV E SEAT"

MA RGIN

T
CHAMFER-------

Figure 23
T he ti p end of the val ve should be checked
fo r rou ghness or wear . Usually t his can be
r em oved wlth so m e very ligh t cuts aga inst
the side of the g r ind in g w heel a nd will square
up the pnd . Neve,- gri nd off the valve stem
end beyo nd the ch 'l m f er .

F igure 2 4
Wh en the top edge of the contact area i s lOa
high or lOw On the valve face. I he seat contac t
area must be m oved. Th is is do ne by using the
n3l'l'Owjng stones . Refer to Page 25. The contac t area w idth should n("vcr pxceed the speci fi ed dimensi ons.

22 .25

GRINDING INTAKE AND EXHAUST VALVE SEATS

Always use a precl sion seat grinder. Take
very li gh t cuts with the grinding s tones so
jus t enough metal is r emoved to e nd up with
a good s m ooth seat fin ish
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 ,
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 .

The valve sea t contact area w idth a nd 10 '

cation can be c hanged by using 15", ;1/]" and
60" narrow ing st ones, Figure 27 .
i~

"'=7

30 ' NARROWING STO NE

(1 488. '69 1
.090 TO .100

60' NARRO W ING

STONE

VALVE SEAT GRINDIN G AR EA

\ \ ...

SEAT W IDTH

(~~~ ~D2~~5/\(

LJ

45 '

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

~ ./

StON E

/148 8. ' 59)

.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
IJI.IPORTANT: The
valve
seat
runout
s hou ld be c hecked after fin ish grinding with
a d ia l ind icatDr and seat grinding pilot, F igure 26 . The runou! of the valve sea t must
no t. exceed .002" .

If the va lve he ad ha s receded more than

the " A " and " B" dimensions be low the
cylinder head surfa cE', the valve , va lve insert
(exhaust ) or cylind er hea d must be rep laced .
NOTE: Meas ure rcom the '.'alve head edge
to the cylinde r head face using a dept h m ic
rometer.

EXHAUST VALVE

INTAKE VALVE

Figure 28
Engi ne
148 &

1~9

188 & 201

Figure 2 6

.940"

. ~{) "

1.060"

l. OOO"

IMPORTANT : Do not attempt to sah'age a

cylinder head by install ing inserts for Intake
valves.

22-26

LOCATING TOP DEAD CENTER AND TAPPET ADJUSTMENTS

FIRrNG ORDER .............. .... ............. . 13+2
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.

TIMING POINTER

COLD SETTING
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
stroke . If the push rods are tight, cra nk the
engine one complete r evolution ;md a lign the
pointer a nd the TOC m ark on the flywhee l.
Figure 29.
Chec k and adjUst t he followin g valve c lear
ances ; in ta e valve at .014" clearance on
c ylinders 1 and 2, a nd the e xhaust valves on
cylinders 1 and 3 at .014" clpara nc', FigurE'
30.
STE P 2 . Crank thc engi ne o n,,' complete reo
voluti on and align the lim ing pointe r a nd the
TOe m ark on the n y\vhe"l . Fi g ure 29. Cyl

flYWHEEL HOUSING OPENING

Figure 29
illder No. 4 should be at T OC on the com
pression stroke . Clleck the push rods on
No.4 cylinder for looseness.
Check and adju st the foll ow ing valve clear
ances; intake valves at .014 " c learance on c yl
inders 3 and 4, and the exhaust valves on
cylinders 2 and 4 at .014" cl ea rance. Figure

30.

HOT SETTING
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~

. .. ... . ", ...... ...... .... ........ ...... .. " ....... ...... .. ....... .... ..... _............... ... ......... ... 232 10 23-7

Spcda l Torqlle~ .. , .. ... ......... _.. __ . " .' ........ .... _... ... , ... .... .. .. ..... , ...... ..... .............. . _......... ,_ .. ............ 23i
Engi ne Lu br lc.:lt ion .. . .. .......... ... ..... " ....... ...... .... ..... . .. , ..... _.. " ... _." .... .......... . __ " ,., ... ... " ... " .. . 23&, 239
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 ........ ... _.. ........... .............. ........ .... ........ ........ _ ... , .... . , 2322 10 2325
P isTons . Rings, Sk'cl-'es a nd ConnecTing Rods - Dis a sseml)ly . inspeCT ion ____ .... .... .... ... ~ 32.(j , :13-27
Cy li nde r Sleev('s . Inspco:.'t lon . .. ...... ... ... _. ..... .. ...... ... ............ .. ... .. .. .. .. ..... ....... .... .. ..... ..... .. ... _, .. 2.128
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,l31
P IsTons. Ri ngs, Sleeves and Co nn ecl!n g Rods AsS("m bly .... __ . .. ...... .. ..... __ .. .. ..... ...... 23 ,1~ to 2335
Cra nkshaft , Bear ings, Linc n and Oil f'wn p .. " ... ....... .. .. " .... " ..... " ... ... ... .... ..... ..... .. :!3-3G to 2339
0 11 Pum p ... ....... ..... .. ...... ..... ......... " " ', .......... . ..... ... .. ,_.... ..... ... .. .. .. .. .... ........ . .. ......... _... 23 ~O. 234;
Thermos ta t and F .ltl Bell , .................. .... ..... " ... .. ... .. .. .... .......... ___ .. ............ _ . .. . _... __ ... 23- 12.2J1:I
Loea llng: Top o.~a d CenTe r ..... .. ... ..... .. .. .... .......... ... ..... ......... .... ..... ... ....... " ........... .... ... . _. , ..... .. 23-4-1

R:>e f a.m 9_8043 1

232

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;)

....... . .......................... 3.8130 to 3.8145

.OO~

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

.OOS

(188G )

Sleeve out ofround ............................................................................................................ . .004

Clearance to bottom of piston skirt (l 88D) ................. 0035 to .0055
(188G) ................. .............. ........ ......... 0025 to .0035
(159G)

.0015 to .0043

(148G)

.0030 to .0035
.001

Taper
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
Including Wear

PISTON RINGS (Continued )

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

234

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 outofround

.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:,

236

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
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

.............................. , ,0015

237

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) '''",,'' "",," "'"'' """. "" "" """ """" """,",," 2118
Load at 1.:38 inches (188G,159G,148G) " ",," ,, """ " 63/ 4 to 71 / 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

DIESEL ENGINE

-..

ROCKER ARM SHAFT

FULL PRESSURE

METERED FEED

o
o

SUCTION FEED

INSET A
Engine 61

I dl o, G e a r

DRI P 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/
Thrust Plate

ROCKER ARM SHA FT

Cam shaft G(!ar

CAMSHAFT
BUS H I N\ClJG

CAMSHAfT GEAR
LU BRI CATION
OIL GALLERY

~r:::':::::::::'~lf::::!:~===:::::::::::::~S~EI
_

I NSET C

INSET A
E
Crankshafl Ma i n Be ari n g

SEE
INSET B

CR~KSHAFT

BEARING
f! /";;---___

Connoct ing lied Journal

FLOATI NG
INTAKE
SCREEN

CO NNEC TI NG RO D
LU BRICA TI ON

Figure 1

23-9

ENGINE LUBRICATION
INSET E

INSET D

Cyli nder Wall

ting Rod
Connl!'cling Rod Journal

ROCKER ARM AND

PUSH ROD LU BRI CATI ON

CYLINDER WALL LUB RI CATIO N

Figure 2

OIL FILTER

o FILTERED OIL
o

UNFILTE RED OIL

0
Q

0-00 0

.s..
O~ 0 0

0
Q

0 O~

...
r

")

- ,..

w::~=rl
\

- .

000-0

o~

""O~:;:;:=l[::~:

\'---- ----...1:

PRESSU RE Rel i Ef VAL VE

( Set 710 9Ib s. )

PLUGGED Oil FILTER

CLEAN OIL FILTER

Figure 3

2310

FLYWHEEL, OllPAN, SEAL RETAINER AND Oil FilTER

(Refer to Figure 4}

Disassembly
1. Remove the oil pan drain plug (1) lVith
gasket (2) to drain the engine and r em ove
the engine oil filter (6) and di sca rd.
2. Remove t he oil pan bolts (1.3) and gasket
(14). Remove all the gasket material from
block a nd oi l p an.
3. Remo \'e the dipstick (3). extension tube (2) .
"0" rin g and clamp (4) if equipped, and the
dipstick socket (5 ) if it need s replacing.

output hub (29) (Hydrostatic Tractor Only).

If the ring gear (17 or 20) is worn or dam
aged, it must be dri ven or broken off the
flywhee I to be removed .
6. For dry clutch tractor flywh eel. Inse t A.
r emove oil seal (21), snap ring (2.3) and "0"
ring (22). Press bearing (24 ) out of flywh eel.
7. Remove the rear oil seal retainer (26) and
gasket (27) . Press seal (28) from retainer
(26) .

4. Remove ada pter (8) and plug (7) if adapter

requires r epl acem enl.
NOTE : On engines equipped with the
timing marks on the flywh ee l it is advisable
to rotate the flywheel until the TD C mark i s
lined up with liming painter. Then seribe a
mark on the front crankshaft pulley and timing

cover.
5. Remove the flywheel mounting bolls (15) or
(18) and flywheel assembly (16 or 19) and

8. Rem ove any cup plugs from block that need

replacing by drilling a hole i n them and
pulling them oul.
9. To remove the Diesel tac hometer drive
(30). a puller can be made f rom an old
tachometer drive cab le. Cu t off the end
that screws into the drive and weld a stud
to it. With this tool, pull tile tachometer
drive.

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

cup plugs un til the oUiE'r edge is even with
thE' inner edge of th e' c ha mfe r in th e bore.
Install the tac hom e ter driv<' 130) (Diesel

the crankshaft with output hub (29 ) (Hyd ros talic Tractor onl y ). IMPORTAJ"I T : Prior
to installing output hub ( :19). lubricate th e
spline hole and fa ce of hub libprall y w it h
;2 Mol y Di sulfid e Greas e . Torque the r e taining bolts 6'; to 70 ft. lbs.

onl:-,' ) into the block, engaging the gear on

th e ca mshaft .
2. Press in new rear oil seal (lXt into the re-

tain er 1261 (st'<lI lip in tow ard block) flush

0) into the block to

the depth s hown in In set l".

10. Ins tall di psti c k socket

with rea r of rc tain('r, In set A. A ssemble

gaske t (27 ) to retai ner and lay a bead of

Perma tex :\0. 2 on bot h sides at t he gasket.
3. C'sing a Ca se :\0. (;1;)028 Sleeve. [nset C,
s lide the oil sea l (28) a nd re ta iner (26) onto

the cra nk shaft.

a Case :\0.
G1.3.')06 Aligning Tool. Inset D with the too l
pins in the aligning pin holes in the flange,
refer to InSPt G, below. T he tool must be
installed over th(' fl ange on th e crankshaft.

4. Remove th e 51",-'\'e and in s tall

11. Prpss the filler adapter ( H) into the block

flan ge unt it seated. Press pl ug (7) in until

seat ed a gainst the adapte r. App ly a thill
coat of new oil or grease to the ga s ket of
new oil filt er (6) a nd insta ll turning clockwise until gasket c ontact is made. Hand
tighten 112 of a turn and loose n fi lter. Retighten until gasket contact is m ade and
hand tighten 112 to 3/ 4 of a turn to obtain
the proper sC'a ling without da magi ng the
filter.
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).

T ig hten the bolt s s ligh tly the n remove the
aligning tool.

6. Insta U the remaining bolts and lockwa s hers

(2.'> ). then torque 12 to 15 f1. Ill, .
7. Preheut the npw flywheel ring gear (17 or
20) <100 to t50nF .. e it hpr in oil or a n oven.
Do not us' a torch. In stall th e rin g gear

pa n (13) to block with t he

rear. Torqu e the bolts 24
cast iron pan, 10 to 12 ft.
s teel oil pan. Torque the
20 ft. Ibs.

long bolts to the

to 28 ft. lbs. ior
Ibs. for sta m ped
rear bolts 15 to

13. Install the oil pan drain plug (9 ) with new

ga sket (10). Torque 18 to 20 ft. Ibs . Refill

the C'ngin e crankcase wi th the prope r amount of oil.

with the large ('J1amfcr toward the flywh eel,

Ins0 t E.
8.0 n dry clutch tractor fl ywheel ( 19), Inset B,
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 vcway oil.

INSET G
G13506 ALIGNING TOOL

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
pum p I:n and g ask C't I~ ) .
2.

( 2 ),

w dter

~' 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
loc kw 3S hC'r ('II unci pump d r i \'e gC'ar (10 ).

3. Rem ove lock platc' poinl e'r ( 11 ), thru st

pla te (12), shim s ( 13 ), id ler gea r (14 ) a nd
journal (1.1) .

(18) a nd fl exible coupler (i f equipped) . E e

m ove p ulley r etainer nut (21l ), a nd pull the
crankshaft p ulley (21) w ith key (22) .
5. R emovc t he timing gear cover (23 ) and gas
k et (24 ) a nd (30). Press the seal (2;)) from the
timi ng gea r cover.
6. Remo vethe nut (26) and loc kwdsher (27 ) . Pull
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
Inspec t th e gears for ch ipped teet h, burrs. or
excessi ve wea r. Light burrs and ni cks ca n be
r emoved with a hone or "roc us clot h. Replace
if da rn aged or worn.
LTsing a n inside micrometer or a bo n? ga uge
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
mum allowable in side d i am eter i s 1.378" . Re
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.

In spec t t he idle r gear i ourn al for a plugged

oi l hol e. Blowou t w ith compres scd a ir.
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
the bore of the inj ec tio n p um p dr i \'e shaft. Re
place i f necessary .
Inspect th e i dle r gear j ourna l w ith a micro
meter . as show n in In se l A. The m ini mu m ou t
si de dim ension is 1..374". Rep la ce t he j ourna l
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.

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
clot h.
Inspect the oil passage in the (' ng ine hlock
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
dirt or other fo rei gn pa rticl es.
Inspec t the th r ust spr ing f or t he follow ing
specifications:
F ree l ength ..... ... .. .. .... .. .. ...... .... .. ... .... 1.22"
0.0 ... .... .. .. .. .. .. .... . ......... ..... .... ........ 255"
T ota l coil s .. ....... .. .. .. .... ....... ...... ..... .... .... 15
Wire d i am eter .. .... .. ...... .......... .. ..
.0.18"
Compressed 10 .950" ... ..... ...... . 6 Ibs. 4 oz.
Inspect the wa ter pump for leaks or worn
bea rings . If th ese condition s ex ist, r eplace the
pum p assemhly.
Chec k the fa n p ullcy for woa r and the fan
blad e fo r d amago. R epl ace them i f these can
diti ons exist.

~,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
(2~) wilil " Pe rrn<.lI ex" or eQui \-a l('nt , and
inSlali rhe seal inlO t h(' ti ming gear ('ov('r
12:)1 with thE' lip tu rnro tow ard~ th(' block to
a d ep lh oi _::;6" irom the o utc'r edge . In se l A.
2.

In s la ll kC'y (2~1J and pre'ss t he gear ( 28) 10 Ihe

cams ha lt. Insl all Ihe lockwash<;r 127 ) a nd nu t
126). :-':OTE: :VIaKe sure the gea r is in s la llC'd Ivith th c' timing marks outward . Torq ue Ih C'
nut 80 to 90 ft. Ibs.

.J. Apply " PC'I-n1;;Iex" or equivJlcnt to both

s ides of th e timing gea r cover gaske t (24 ) and
(l lii and in s tall with the cover 12.11 _ A specia l
zinc -platC'd capscre\\' is used in th e water
pump ca \iI O' . Torque th e cover c apscrews 35
to 42 ft. Ibs.
4 Coa t the inside of the oi l sca l w ith ciC'3n oiL
CAUTIO]\; : Do no t a llow gas kC't se<1 l('r to

plug oil hole in pipe plug in oil g a llN:\'.

:J.

Insta ll the p llm p dril'e idle r gear journal

( 1'; )

in th0 lim ing g0ar ('OVPf. Align The oil groove

as s hown in lnsC' t O.

".InSla ll tile iel ler gear ~ !4 ! with ir s large hub

s iele toward the ('ng ine block. In s tall the
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
gear jou rn a l (I ;' ). Wh en instal ling tile thru s t
plat e the rE' must b e .003" c lea r anc e between
the face 01 the gear and Ih thrust plate , Inset
C. Adcl or clelete the shi m s until the pr oper
clearancC' is obtained . T be pointers should
poin t tOwa rd the cen ters of the cam s haft <lnd
in jection pump drive gea r. Torque the cap
seres 35 to i2 It. Ibs. Bend Ihe e a rs 01 the
loe k pl ate over 10 prevent t he capscrews fro m
loosening.
7. }{otate the camsilaf t ge a r ( 281 unli 115 single

ti mi ng mark is aligne d with Ihe poi nter. In

stall the pump drive gea r (10 1 so that its
timing mark is a ligne d lVil h thE' pOint0r (11).

I nsta ll lockwa s hpr a ncl nut (9 ) a nd to rque .15

to 40 ft. Ibs.
8. Install key (22) a nd press on th cra nkshaft
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
coupler (191, bushing (18) wa s her (1 71 and re-

lain wit h bolts and

IDckw a~her,

torquf'd 54 to

64ft. Ibs. , ( If equippe d) .

9. Check lor timing gea r tra in backl as h. Loca te

a e1ial indicator on the in jection pump d r ive

gear. Inset D_ Rotate the pu mp dr h 'e gear
(10) to the right as fa r as possible witho u l
m oving the crankshaft gear. SC'l tt1 0 di a l in dicator to zero.
NC'xt, r otate the pump drive gear to the le ft
as fa r as possi ble witholl t moving t he cranks ha ft gea r. The dial ind icator will Indica te
the a m ou nt of bac klas h in the gear tra in .
T ht' bac klash mus t not excee d .006" for
cam s haf t gear to crankshaft gea r , .006" fo r
cam s /la fl gear to idler gear a nd _007" lor
idl e r gear to pump dri ve gea r.
If th e backlash is greater than as specified.
r epl ace the timing gea rs r equi r ed . Excess iv e backlas h will cause e rratic pu mp act ion.

Excess iv e bac klash be twee n Lhe gears can

a lso be ca used by worn camshaft bushings.
10. Insta ll thC' t hrust spring

(8) and thrust

plunge r (17) into t he drive sh alt. Install th e
drive gear covC'r (5) a nd g asket ( 6 ) . Torque
the bolts and nut s ;15 to 42 It. Ibs .

11. Apply "Permatex " or equival en t to t he

wa te r pump g asket ( 4 ) and inst all the water

pump (3). Torque the bolts 35 to 42 ft Ibs.
12. In s ta ll the Ia n pulley (2 ) a nd fa n (1 1 to the
water pump and torque ttle bolts :35 to 42
ft. Ibs.

INSET

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) . Remove the wat er pump assembly (3 ) with
gasket (4).
2. Remove washer (5) and cou pling assembly

5. Punch out the roll pin (12) from the govE-rnor le ver, Inset A. Rem ove thrus t spacer
(16), governor leve r (13) , fe lt was her (l4J
and thrus t ball (19). Using a s ui ta ble puller,
remove needle bearings (15) and OS).

(7) with bushings (6) (if eq ui pped) .

3. Remove nut (8) and pull the crankshaft
pulley (9) a nd remove key (2'.

6. Rem ove the gove rn or shaft (20) from cams haft gear. Remove nut (21 ), lip washer (22)
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-

tion. Re place a ll worn or damaged parts,

ga skets and oil seals.
2. Check the governor s haft assembly for
run-out, Inset B. A[so , be su re the assembly opera tes smooth ly in the c 'lms ha ft bore.
,3. Inspect the go vernor weights on the camshaft gear. The weights mus t swing freely
on the hinge pi ns. The pin s houlder must be
tight against the gear. A[so , ch eck the
weights for excessive wear in the grooves
where they m a te with the go,'ernor shaft
assembly.
4. Inspec t the thrust ball for excessive wear.

5.lnspect the needle bearings fo r pi ts , wear

or other damage .
6. Check (he lever and s haft a ssembly for
damage or wear. Check the leve r for a p itted rna ting surface with (he governor shaft
assembly.
7. Check the water pump for lea ks or worn
bearings. Replace lhe pump if these ca n
d itions e xist.
8. Ch eck tbe belt pulley and fa n for wear or
damage. Replace them if these condit ions
exist.

23-19

INSET A

'\

I
I
I

I
I
I

INSET B

-RUN-OUT NOT
TO EXCEED .010 "

FACE MUST
....---BE SMOOTH

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

camshaft gear (23). Install the lip washer

(22) and nut (21). Torque the nut 80 to 90
ft. Ibs. Using a dial indicator, check the
backlash between the camsh a ft gear a nd
crankshaft gear. If the backlash is more
than .006", the gear may have to be replaced. Excessive backlash betwee n gears
can also be caused by worn c a m s ha ft bushings.

2. Install the governor shaft (20) to the governor weights on the camshaft gear (23).
3. Press a new oil seal (26) into the timing
gear cover to the depth s'LMn in, Inset A.
4. Press needle bearings (18) and (15) into the
timing gear cover (P r essing on numbered
side of bearing only) as shown in, Inset B.
5. Install the dust seal (14). Coat the LD. of
the seal with Lubriplate or equivalent. Install the thrust ball (19), governor lever
(17), thrust spacer (16) governor lever (13).
Align the holes in the levers (17) and (13)
and insta ll pin (12). Install the pipe plug

(27). Lubricate the LD. of oil seal (26)with

Lubriplate or equivalent.
6. Apply Permatex or equiva len t to b ot h s ide s
of g aske t (11). Install the a ssemb led timing
gear cover (10) with new ga s ket (11 ) to en gin e
blockwlthlocatingringdowels (28) and bolts.
Torque the retaining bolts 35 to 42 ft. Ibs.
7. Install key (25) to the cran ks ha ft and pres s
on crankshaft pulley (9). Ins tall nut (8) a nd
torque 125 to 135 ft. lbs.
8. Install flexible coupling (7) with bushings (6)
and hea\'ywasher (5) (if equipped) and torque
bolts 54 to 64 ft. lbs.
9. Apply Permatex or equivalent to both sides
of gasket (4). Install water pump (3) with
gasket (4) and torque retainlng bolts and
nuts 35 to 42 ft. lbs.
10. Install fan pulley (2) and fan (1) to water
pump and torque retaining bolts 35 to 42
ft. lbs.

23-21

INSET B

INSET A

.560"

-:PZZZl

FAN .
Figure 9

2322

CAMSHAFT, BUSHING S AND LIFTERS

(Refer to Figure 1 0 )
D isassembly
1. Remove

the camsh a ft

thrust

pla te

(3).

NOTE : The pu sh rod lifte rs (.1 ) will have

to be held in a rais ed p ositi on [or r emoval
of the c amsha ft.

2. Raise the push rod lifters (5) using eight

long, round stick s slightly large r in dia
meter tha n the push rods. Taper the end
of each stick a nd force the ta pered end
into th e inne r bore of each pus h r od lifte r.
Lift up th e lifte r s as fa r a s possible with
the s ticks ; lock the sticks in place with
c loths pins or other suita ble de vices .
3. Remove the camshaft (4 ). CAUTION : Ex

e rcise care when rem oving the camsha ft

so as not to damage the bus hings .
4.Remove the valve lifte rs (5 ) one at a tlmc
and mark them so they can be insta lled in
their original locations.
5. Check the camshaft bus hIngs (6,7, and 8)
for wea r . If the c leara nce Is .005" or
more between the O.D. of the ca m s ha ft
bearing surfaces and the I. D. of the bush
ings, th e bushings must be r eplaced. Cse
an a rbor puller similar to that shown in
Inset A, Case P a rt ;:-;0. A41103. T his puller
should be used to preven t damage to the
engine block.

Inspection
Clean the c a msha ft thoroughly a nd blowout
the oil hol es with compr ess ed air. Check the
camshaft for r oughne ss, scoring, scratches,
grooves or wea r. If any of the se conditions
e xist , the camshaft shou ld be r e pla ced , Check
the bea ring surfa ces of the cams ha ft with a
micromete r. If any diam e te r is le ss than
2.242" , replace the c a msh aft. Check the
thic,kness of the tHrust pl a te. If exce ss ive
wea r is seen, It sholltcl be repla ced .

Clean the Jifters a nd c heck the body outside

diameter for exce ssive wea r which should not
be less tha n .5600".
Check the lifte r bore in the bloc k for ex
cessive wear or ou t o f round ness wh ich s ho uld
not exceed .5650" diam e ter at a ny paint.
Check the lifter bore in tht' block for scoring
or g rooves.

23-23

Jl"cD
REAR
BUSHING

1-7/ 32"

1 88

DIESEL ENG INE

~@

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

~0 ~? ~~~
::::,~, ~ -0
' 7 / 32

INTERMEDIATE
B US HINGS

1 / 2"

@"..

V~

"-V

FRONT BUSHING

' 7 / 3 2 "

Figure 10

FRO NT BUS>iING
1 5 / 1S "

23-24

CAMSHAFT, BUSHINGS AND LIFTERS

(Refer to Figura 11)
Assembly
1. The camshaft bushing kits inc lude a 1-7 / 32"
inch wide rear camshaft bushi ng . The holes
in the 1-7/32 inch wide rea r bushing are
offset toward the chamfe red edge of the
bushing.
2. The 1-7/32 inch wide r ea l' bushing is used
in the 188 Diesel Engines and also in the
188 Spark Ignition Engines. The 1-7/ 32
inch wide rear bushing must be ins talled
with the chamfered edge in to the block to a
specified dep th .

Ignition Engines the intermediates and

center bushing oil holes m ust line up with
the oil holes in the block when ins ta lled,
Inset D.
7. On the 188 Diesel, 188, 159 and 148 Spa rk
Ignition engines the front bu shin gs a.re
pressed 1/ 32 inch below the front face of
block, Inse t E.
8. Press new c amshaft bushing s into the camshaft 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
two oil holes in the block when the bushing
is installed to a depth of 5116 inch, Inset A.

9. Line ream the bushings 1.752 to 1. 75.3 inches

diameter.

4. On the 188 Spark Ignition Engine, only one

of the rear bushing oil holes must line up
with the oil hole in the block when the bushing is ins talled to a depth of 191:J2 inches,
Inset B. The other rear bushing oil hole
will not line up as it is not required for
engine lubrication.

10. Install the push rod lifters in their origi na l

location using the eight long, round sticks
slightly la rge r in dia meter than the push
rods used in removal. Force the tapered
end into the inner bore of eac h push rod
lifter. Lift up the lifters a s fa r as possible
with the sticks; lock the sticks in place
with cloths pins or other sui ta ble devices.

NOTE: On the Spark Ignition Engin es,

the 1-7/32 inch wide rear bushing will
protrude inside the block approximately
1 / 4 inch when installed. THIS I S NORMAL.

11. Lubricate the bushings and camshaft with

new engine oil a nd carefully install the camshaft (4) into place being careful as not to
damage the bushings.

5. On the 148 and 159 Spark Igni[ion e ngines

it is only required to line up the all holes
in rear bushing, with the oil holes in the
block when the bushings are installed,
Inset C.

12. Install the thrust plate 0 ). Rota te the ca mshaft to insure that it does not b ind On the
thrust plate. If it does, loosen the thrust
plate bolts and l'ecenter the pla te. Torque the bolts 17 to 20 ft. lbs .

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

23-2.';

J!'\D

DIESEL ENGINE

'48 AND 159 SPARK

IGNITION ENG INE

0
? Cf, :~~~~~' ~

REAR
BUSHING
1-7 / 32"

~@

INTE RMEDI A TE
BUSHI NG S
1 /2 "
REAR SURFACE
OF BLOC K
'///7

@fJ
O~

REAR
OF

~
6

~?~~~m'"
0. t! JJ!
SUR ~FA:-:C:::E:---::IN"'S::-:E::T=-=C-'
'@

BLOCK'~~~~q~
'

\.V

FRON T BUSHING
1 -5 / 16 "

I NSET A
FRONT BUSHING

:>I

J:~~L

1-7/ 32 "

ALIGN OIL HOLE

HOLES
WILL LI NE UP

(~j

5 / 16" -

PRE SS flUSH WITH BLOCK

CD\---

~
REAR

T
/':\0

cP

REAR

INSET E
188D,188G,159G
AND 148G ENGINES

0 0
&-0

B1U_'7S/ H312N"G

INSET B

ALIGN
OIL HOLE

~~CD~,
1 / 32"~

PRESS FRONT BUSHING

WITHIN 1/32" OF FRO NT
FACE OF BLOCK

---- -

BU SH iNGS flUSH WITH

FORWA RD FACE OF
BLO CK

,~~~~~~~~~~~~~~~~~~~~~

'

INSET F

FRONT BUSHING
" 1 -7 /3 2"

ONLY ONE Oil

HOLE WILL
LINE UP

19 / 32 "

THIS D IMEN SI O N - i
WILL VARY

ALIGN
OIL HOLE

@o olpRESS INTERMEDIATE
-v

INTERMEDIATE
BUSHINGS
1 / 2"
REA R SUR FA CE
OF BLOC K

~ l ".

' 88 SPARK IGNITION

ENG INE

INSET 0
188 D,188G _159G
AND 148G ENGINES

I
rFigure 11

23-26

PISTONS, RINGS, SLEEVES AND CONNECTING RODS

(Refer to Figure 12)
Disassembly
:'I;OTE: When the pistons and rods are to
be removed. check for a rid ge formed in
the piston s leeve a t the lop of the rin g
travel, Inse t .-\. If a ridge is present, use
a ridge reamer to remo vE' the ridge or
dam a ge to the piston rings anc! la nds will
resuit.
l. Check to be sure that the roc! s and ca ps
are numbered as to their location in th e
block. If not , they mus t be num bered for
r e installation in their sanw location.

piston

rings

(1),

with

ring expand er,

Inse t C.
6. Remove the roc! cap (6 ) an d bearing linprs
(12) from th e connec ting rod 15) .
7. The pis lon pin bushing (9) m ust be replaced
when th e inside c!ia mete r exce ed s Ihe maxi
mum wear limit , refer to inspectio n below,
when checked at a numbe r of poi nts. Press
the piston pin bushing (9 ) from the rods (5)
us ing the proper size a rbor, Inset O.

2. Using a feele r ga uge, check each connecting rod for excess ive s ide c leara nce. In se t
D, Page 34. If it exceed s .oJ 1", the rods
must be repla ced.

8.11' the cylinder sleE'ves (10) are to be rem oved, mark th em with pai nt in r elation
to Ihe block. (;se a s leeve pull er and adapter 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 ssem bly up and out through the top of the
bl ock. Reinst a ll rod c ap (6) to a void mixing
of the caps.

CAUTION : To prevent sedimen t from the

block from damag ing Ihe cra.nkshaft and
main bearings, cover them with cl ~a n clo th s
befo rp the sleeves are removed.

4. Remove Ihe two pis ton pin r eta iner rings

(.'l i from each pi s ton (2 ) and r emove the pin
(4) from the rod 15) a nd piston (2) .

9_ Re m ove and c!isca rd the slc'eve "0" rings

(11). NOTE : ','e ver a ttempt to re-use
them .

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

Inspection
Thoroughly clean and ins pect a ll parts for
nicks, burrs, sera tches,

gTOOVC'S

and

exces-

sive wear. All paris that arc worn or dama ged must be replacec!.
Check the connecting rods and cal's for

the polished surfaces are d ull , r oug h or

c heck0d by acid corrosion. If thE' pin bore
in th e pis tons e"ceeds 1.25013" (l 88D j, 1.0004"
(I8SG, 159G) . 8604" (14RG) , re place pIs to ns.
If the Il llshing in Ihe rod e xceed s 1.25 l~" (1880),
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

of these cond it ions e xist.
Remove all c arbon d e pos its fr om the
piston . Be care full not 10 sc ratch the piston
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

Cle an the oil holes in the

block. Pipe plugs at the en d
lery in the bl ock will have
Coat the threa ds of the pipe
mat ex ~2 before ins ta llat ion.

cran kshaft and

of each oil g alto be r emoved .
plugs with Per-

23-27

r'N~S~ET~A~--------

SPAR K IGNITION
DIESEL

INS ET C

~ ~;f
RING EXPANDER

INSET B

-{S

SLEEVE PULLER

Figure 12

IN SET

2.3-28

CYLINDER SLEEVES
Inspection
NORMAL WEAR
Fig ure 13, illu s tra tes normal wear of the
cylind('r slcevE' identified by a smooth s hiny
surfac(' be tween the upper and lower limits
of the ring tra vel. There is a lways a sligh t
wear presC'nt due to combustion pressures
forcing the top ring outward agaillst th e cyl-

inder sleeve, Figure 13 indicates satisfactory

sleeve condition s and the s leeve need not be
repla ced ,
Figure 14, illustra tes a worn out cylinder
sleeve due to normal wea r and should be replaced.

Figure 13

Figure 14

SCUFFED CYLINDER WALLS

A scuffed cylinder wall, FigurC' 15, call be
iden tified by heavy vertical linE'S f r inged by a
discolored band caused by m etal transferring
from one spot to another, The ver tical scuff
marks arc ca used by the m etal coming in
contact with the pis ton_ The scuffing may be
In one particular a rea or it may occur the
e ntire length of the piston tra vel.

Figure 15

Figure 16, illustrates complete s coring

failure with its hea t discoloration and m etal
transfer. If you have cyli nder sleeves tha t
compare with either' Figures 15 or 16, the
sleeves must be replaced.
NOTE: It is not necessary to r eplace all
the sleeves in an e ngine. Replace only those
sleeves that have been damaged as descri bed
above.

Figure 16

23-29

CYLINDER SLEEVES (Cont'd)

Deglazing
Figure 17 illus trates a se U-ce ntering pow e r brush deglazer that can be used to r E'move
thC' g laze form('d on th e Inner surface of the
cyllndl'r slervC's.

Power t he brush with a 31 " or 112" drill

with a 300 to :350 RPM s pee and uS ing a good
gradC' of oil as a lubr icant. The heav ier the
lubrican t, the fin er the finish.

T hl:! g laze must be rCll10vcd so thaI the

piston rings ca n properly sea t themselves
within a reasonable period o f run-in-time.

The brush must be rotating b fOto entcring the cyl inder sl0eve rod ,,'hen re moved to
prevent scratches and to insure an even
finish. This will also brin the cross hatel,Ing up and au t On r e moval.

The necessary degl azi ng can be done by

usIng 180 grit silicone carbide double spiral
brush. 'l'he necessary size brush can be purcha d from the J r Ca e Co. Service Pans
Suppl y , Racine ,Wise ,
Part :\0.
A-12451
.0.42452

Bore Range
3.00" thru 3..50"
:3_50" thru 1.00"

Actuating the brush up and down at a r a te

of 30 to 40 times per minut , a fast (>ven and
perfect cross hatch finish Is obta ined in 20 to
30 second s , Figure 17 .
IMPORTANT : Use the following procedure 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, reSUlting 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 MOVE THE AB RAS rV}:;S FRO:V! THE SURFA CE OF TH}': SLEEVES.

POWER BRUSH
CROSS HATCHED SLEEVE

Figure 17

23-30

CYLINDER SLEEVES (Cont'd)

Honing
Excessive glaze (sm oo th shiny surface) for
med on cylinder sleeve walls 01 a new or
overhauled engine is due to imprope r Runln
Procedure. Excessive oil con Sllm ption results
from the glaze build up not allow ing the rings
to seat properly in the cylinder sleeves. Ex
cessively glazed cylinder sleeves Can be a
voided by properly in structing your customer
in the correct RunlnProcedure in the Op
erator's Instruction Manual. The two mos t
important lac tors are:
L Maintain the correct Operating Temperature.
2, Maintain a "'ormal Load on The Engine for
the firs t 8 hours. Do not " baby" the engine,
but do not "lug" it. Engine must not be
"lu gged" down below its Itated Engine
RPiVI, to avoid prolonged hydraulic stall.
(Do not exceed 10 seconds of stall). If the
tractor has a mechanic al transmission and

1 ' 7 INCH
DRill

180-220 GRIT STONE

POWER CYLINDER HONE

is perf aiming hitch and drawbar work ,

shift to a lower ge ar to prevent lugging ,
These two factors will permit the slig ht wear
necessary for seating of rings to the cylinder
sleeves ,
Use a power hone as illu strated in FIgure 18,
to r emove the glaze formed on the Inner sur
face of cylinder sleeves.
The necessary deglazing can be done by
using 180 . 220 grit honing stones and honing
oil.
The glaze must be removed so that the piston
rings can properly seat themselves withIn a
reasonable period of runin time ,
r~IPORTANT: Use the following procedu1'(';
to protect the e ngine from a brasives.

1. BEFORE HONING :
Cover the crankshaft journa ls with clean rags
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
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!

Figure 1 8

CAUTION : DO NOT USE GASOLINE,

DIESEL FUEL OR KERO SENE TO CLEAN
THE SLEEVES AS THIS WlLL lOT RE
MOVE THE ABRASIVES FRO M THE SURFACE 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
IMPOR'fANT: When c hecking the m ea surements of the pistons a nd sleeves, the parts
s hould be at or close to 70" Fahre nheit.

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

gauge or a taper ga uge, Figure 22, check the
sleeve dia m e ter just below the top ring location at its upper most travel a nd a t several poin ts down the length of the sleeve.

Figure 2 0
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
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.
If th e out of roundnes e xceeds .005", the
s lee ves should be r<:'placed.

Figure 22
Subtracting the smalies t reading from th e
largest r eading wili g ive the a mount of taper.
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
bus hi ng hole in th e conne cting rod before
ins ta lling new bushi ng.

of the cylinde r bloc k and t he "0" ri ngs with

c lean drive -away oil.
10. Carefu lly install t he sleeves ( 10 ) into block

In s ta ll the new bushing (9 ) into the r od (8)

while aligning t he oil holes in t he bus hing
a nd rod, In set A. Press in the bus hing using
the n rbor used tor removal, In set H.

and pre ss into p lace by hand. Do no r ro ta te

s leeves wh ile they are be ing in stalle d , they
mu s t be ins ta lled in the same position and
location they WE're in before r e mova l.

;1, Carefu lly ream the bushing 1. 2502" to 1.2504"

for the ( ] 880 ), .9995" to .9997" fo r the (I 88G
and 159G) and .8596" to _8598" the (148G) if
new pis ton pins are to be inswlled . If piston

NOTE : Prim' to in stalli ng the pis ton c ompression top ring (1 ) , s!?concl c om press Ion
rin g (2) and t hir d compre ss ion r ing (3) I Sp a r k
Ignition) and oil ri ngs 141 to pis ton (5) , th e
r ing e nd gap must b ch(>c ked I ns ta ll each
ring i nto the cyli nde r slee ve a pprox ima tely
I " from the bo ttom of t he sle ev a nd c heck
end g a p with a f!?e le r gauge . The pnd g a ps
must mect spec ifica tion s as listed on P a ge 3.

2.

pins (6) are to be reused, re am t he bus hi ngs

for th e (1880 ) .0004" to .0007", (I83G , 159G,
148G) ,0003" to .0006" la rger tha n pis ton
pin diame te r. Chec k the bus hin g (9) a fter
r eaming for a cle a n s m ooth surfa ce. NOTE :
This is a full floati ng type pis ton pin a nd a
press fit mus t not be used.
4. Che ck the pis ton pin bore in the p iston ( 5).
It shou ld not e xceed .0002" to .0006 " for the
(1 88 D) .0000" to .OOOJ" for the (l88G and
l 59G) and .000 1" to .0002 " fo r the (148G )

la rger than the pi ston pin dia m eter .

.J.

Insta ll one pi ston pin r(' ta in e r r ing (7) and

warm the pisto ns to 50"F . wa rm e r than t he
pis ton pin te mperature.

11. Each r ing e xcept the (1880 ) top r ing must be

checked for s ide c lea rance , Ins",t B , befor e

ins tallation. Wh en the sic!e cleara nce e ,'(ceed s

the m axi mum s pecifi ed c lea ra nce, lis ted on
Page 3, of any one rin g , t e p iston mus t be
replaced.
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
grooves firs!.. Do not o,-e rl a p, h um p or cut
of[ t he e nd o f e xpa nd e r. Install t he upper a nd
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

the piston (5) to th(' rod wit h the a rrow in the
pi ston top (Oi e s!?l ) toward s tam ped numbered
side of the r od . Use ha nd pr ess ure only to
ins ta ll the pis ton pin a nd r e ta in in plac(' with
reta ine!" ri ng (7).
I. Th oroughly clean the inn!"r su rfa ces of the
cy lind ~ r bloc k t ha t contacts t he s leeves anel
the ou te r s ur fa ce s of the cyli nder sle" ves
(10), including the "0" ring grooves .

R. In s ta l! ea ch s)('eV(: into t he block without

"0" rings to ch('c k for the free m oveme nt.
9. Remove the sle rv('s fr om the bloc k a nd careful ly install new "0" r ing s (11) int o the groove
On ('a eh sleeve. Lubricate the Inside s ur fa ces

13. The second type of oil r ing Inset Y , insta ll

the oil ri ng int o the bottom groove of thi"
piston. The oil ring can be insta ll ed wi th
th e s pring e ither up Or down .
14. There a re two ty pes of 2nd and 3rd com preSSion rin.gs used, In set C and inset S .
Install the rings with the "1' '' or " TOP"
mark towa rd the top of the pi s ton. The ta per
Inse t E or t he groove Inset C m u ~t. a Iso be
toward t he lop of the piston.
15. The re a re two types of top com pre ssion
rings used. Ins tall t. he firs t type of top com pression ri ng , Inset 0 with th e groove side
up. Insta ll the sec ond type of top c om pression
ri ng , Inset E, wi th the "1''' or " TOP " and
taper towa rd top of pis ton.

23-33

DIESEL

INSET B

INSET A

SPAR K IGNITION

OI L HOLE MUST BE
ALIGNED IN ROD
AND BUSHING

O -w-o

0 --0--,.0
o 0---.--..0
0 4
.
INSET

INSET

KEYSTONE
TYP E

~~---0

,""WJ~~
. 'r~
J'C ft~ ~~ ,0
cb
Q)

STAMP ED
NU MBER

Ii

(]) (j)

._ _

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

TAPER

FAce

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
piston asse mblies with new engine oil.
IMPORTANT: Hotate the piston rings
so tha t the ring end gaps are staggered
as illustrated in Inse t A. NOTE : If three
piece oil ring is used. place t he expander
in the oil ring groov e . Install one rail 90 0
to the le ft of the expander ga p and the other
rail 9()1l to th e righ t of th e expa nder gap.
CAUTION : Check to assure that the expander ends are not overlapped.
17. P lace a ring compressor over the piston.
[nset B. :VI:lke sure the piston r ings are fully in the groov<'s before tigh t... ning the ring
compres sor. Tighten the ring compresso r a
little at a tim .... making sure the r ings ar...
free to compress.
18. :Vlake s ure the cra nks haft rod journals are
c lean . Install the bearing lin ers (.3) into the
connecting rod :l nd cap (2). Inset C. making
sure that the bearing liner lock lines up with
the groove in the rod and cap. l:se a sliding
moveme nt when installing the bearing liners.
NOTE : Never press on the center of the
liner when installing.
19. The connecting rods and caps are s tamped
consecutively 1 th r u 4 on the bea ri ng end of
the rods and caps. ""umber 1 connecting rod
and cap must go in I\umber 1 cyl inder (front).
The number must bedown and tow a rd the camsha ft side of the e ngine. The arrow stamped
on top of the diesel e ngine piston must point
toward the fan.
20. Ins tall the piston rod assembly into its
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.

21. Ins tall the rod w/ liner. keeping the same

numbered cap with the same num bered rod.
Install the re taining bolts (4) and nuts (5) and
torque 45 to 55 ft. Ibs .
Check the connecting rod side clearance
which must be within .005" to .011". Inse t D.
If the side clearance exceeds .011" t he rod
ma y have to be rep lace d.
CHECKI 0iG BEAHI0iG CLCAHA:\CE:

A plasti gauge materia l manufactured ('am mercially ca n b e used for c hecking connecting
rod clearance.
1. Remove the connecting rod cap a nd wipe the
oil from the bearing s hell a nd cra nkshaft
journa l.
2. Place a piece of plasti ga uge full width on
the bearing liner. Inse t E.

3. Torque the connecting rod cap baits and nu ts

45 to 55 ft. Ibs.
4. Re move the rod cap. Th(' fl attened p lasti
gauge will be found eithe r on the rod cap or
crankshaft .
5. Compare the flatte ned ga uge m ateria l at its
widest point with the sca le that is furniShed,
Inset F.
6. The number within th e g raduation indicate s
the c learance in thousand ths of an inch. The
r od bearings clearance should be .0010" to
.0035".

23-35

INSET B
PISTO N

2ND
COMP
H-+R ING

OIL RING +-+--of

OIL RING

2 0"~-I-__

90

RING

COMPRES S ~~

3RD CO M PR ESSI ON RING

DIESEL

SPARK IGNITION

STAMPED

NUMBER

INSET

INS H

\S~
"--cD

PLASTI G AU GE

INSET C

Figure 24

2.336

CRANKSHAFT, BEARINGS, LINERS AND OIL PUMP

(Refer to Figure 25)
Disassembly
1. Wi t h the oil s linger (1) removed, use a
gear type pulle r and remo ve the crank

s haft gear (2) . Remove the th l' ust spa cer

( 3), thrust shirn ( .J ) (S park igniti on e ngines )
and k ey (5) ,

3, Rem ove the cap bolt s ( 11 ), oil p ump as sem

bly (12 ) , sh im (13), ca ps (14 ) a nd lower
bearing lines (16 ), Refer to Page 40 for

servi cing of the oil pump ,

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
diesel fuel and blowout all oi l holes with
com pressed a iI',

The crankshaft j ournal s mus t be g round with

preciSion equ ipmen t a nd checked w ith a micrometer 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
cessive wear. If t he out of round ness e x
ceeds ,00l" or the main journal diamete rs
are s ma ller tha n 2,8725" (1880, 188G)
2, ii225" 1l59G , 148G)' it is possible the
cra nksh aft is worn only ,002", The ,002"
underSize bearing liners can be installed
providing t he oil clearance is m ainta ined
at ,0012" to ,0012 ",
When the c r anks haft journals are worn
more than ,002", the cra nksha ft wi ll ha ve to
be g rou nd undersize ,010", .020" or .030".

The c ra nksha ft must be Clea ned tho rough ly

after g rinding and chec ke d for runou! with
a dial indicator. If the crankshaft r unout is
more than ,002", th'" cra nk s haft must be
re placed,
Check the crankshaft g ear for worn teeth
a nd r eplace if nec e'3sary,
Clean the oil flo a t screen in clean diese l
fuel and blowou t with com pressed air. Re
place if th'" scree n is d am aged,

figure 25

23 -38

CRANKSHAFT, BEARINGS, LINERS AND OIL PUMP

(Refer to Figure 26)

Assembly
CAUTION: TH E BORE IN THE BLOCK
AN D THE BEA R I:\ G CAP S MUST BE ABSOLUT E LY CLE AN A ' 0 FR EE OF DIRT
OR GR E ASE . ANY DIRT LE F T BEl-ll~D
THE LIN ER S WILL INTE RFER E WITH
T HE COOLI NG OF THE L1l':E RS AND WILL
R ESULT IN ' HOT SPOTS" A:,oo PRE
:VIATURE FAIL URE .
1. Insta ll the key (5). thru st sh im (4) (Spark
I g niti on Engine) thru st spa cer C-j) and press
the cranksha ft gear (~) on cra nkshaft (6),
with the timing m a r ks to the outside.
~.

Ins tall the main beari ng liner uppe r ha lves

(17) in the block wit h the lock enga ging the
loc k groove, Inset A, (liner half wi th oil
groove in center) . Lubricate the liners a nd
crankshaft journals wi th d r ive away oil.

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

the block a nd insta ll the bea r Ing caps (H
and 15) with new Uners (16) e ngaging the
lock grooves, Inset B. The number ed side
or arrowed sid~ of the main bea ring ca ps
must be toward (he ci.lmshaft . Lubricate
the liners with driveaway oil.

CAUTION : THE MA IN BEARlJ';GS AR E

NUMBERED FROM 1 1'HR U 5 DIeSEL
AN D 1 THRlJ 3 SPAf(K IGNI TION START
I:.I G WITH THY. P[JLL E Y E ND OF THE
CRA KSHAFT. MAKE SUR E THE NUM
BERED SIDE OR ARROW OF TH E MAI N
BEA R l.NG CAPS ARE INSTALLED ON
TH E CAMSHAFT S lOE AND IN THE RIGHT
LOCA TIO;'; 1:,\ THE BLOCK.
4. The ma in bea ring capscrews mus t be tor

q ued e venly 90 to 100 ft. Ibs.

5. Chec k the c ranksha ft end play as follows:
T he cran kshaft e nd thrus t is taken up by
the cen[('r bearing liner flange.

To obta in an accura te r eadi ng use a pry

bar between Ihe crank throw a nd number 4
m ai n bearing cap (Diesel Engi np) and num
bel' J main bearIng ca p (Spark Ignition En
gi ne), Takp up a ll end play with the pry bar.
Che ck the clearance between the cente r

bea ring (15) a nd c ran kshaft fl3nge with a

feeler g auge, In set C or dial indicator .
6. Normal cra nksh aft end play is .001" to
.005" . If excessive e nd p la y canno t be
ta ken up the crankshaft must be replaced .
7. Check the bea ring oil c learance as follow s:
A plasti ga uge materia l m a nufactured com
mercially may be used for checkIn g bearing
clearances as follows:

NOTE : WHEN CHE CKING BEARING CLE AR

ANCE DO NOT HAVE THE WE IG HT OF THE
CRANK SHAFT ON THE BEA R ING CAPS.
8. Remove only one of the bearing caps at a
time and wipe the oil from the bearing
s hell a nd cra nk shaft jo urnal.
9. Place a pi ece of plasti gauge full width on
the bea ring liner , as show n In Inset D .
10. Tighte n the bearing ca p 80 to 100 ft. Ib s.

Torque.
11. R emove the bea ring cap. The fl a ttened
pla sti gauge will be found ei ther on the
bearing shell or crankshaft.
12. Compa re the flattened gauge material a t
its widest point with the scale that is fur
nish~d as sbown in Inset D.
13.Tbe number within the gra du a tion indica tes
clearance in thou sandths of an inc h. Oil
bearing clearance shou ld be .0012" to .004~".
NOTE: UNDERS IZE LI NEB. S ARE AVAIL
ABLE. IF' IT IS NECE SSARY TO GRiND
DOWN ONE OR MORE JO URNA LS IT IS AD
VISA BLE TO GRI:\,D ALL THE JOURl':ALS
14. Check the pump drive gear lor cor rec t
backlash a s shown in Inset E. usi ng a dial
indicator. Cor rec t bac kla sh may be ob
tained by adding or removing shi m s Ioea ted
between the oil pu m p body and the front
main cap. Inse t E. Correct backlash is .002"
to .008" .

23- 39

INSET

INSET C

BEARING CAP

..

PLAS TI ~AUGE SCALE

188 DIESEL

FEELER GAUGE

PLASTi GAUGE
INSET A

IGNITIO~8

188, 159 AND 1

SPARK

INSET

INSET B

10

__

F Igure 26

~______~L~O~CK~GR~O~O~VE~..J

23-10

OIL PUMP
(Refer to Figure 27)

Disassembly
1, Re move the pum p cover (3) from the pump
bod", I"),

val ve (10), RemoVE' "0 " r ing (6 ) a nd disca rd,

2, If se rvicing of the relie f valve is necessary,

r emove co ller pin (7 ) , the cup plug (8 ) by
drilling a hole? thru it and pull ing the cup
plug out. Remove the >pring ( 9 ) and r elief

NOTE : The m a jor interna l parts of the

pump are not se rviced , If the r equi reme nt s
during ins pec tion are not sat isfac to ry the
pump assemb ly must be r e placed,

Inspection
Check the reli ef valve sp rin g to m ee t the
following spec-ifica tions:

Wire Th ickness ,_". " "."" " .", ..

.0625 "
Maximum 0,0, .,, '" " "" " "" .. "" """ .469"
Free Le ngth ( Diesel ) """,,,,,.,, .. ,,_ .. ,,, 2,06"
Spark Ig nition .... "" ...... ," " " """"'"'''' 2"
Compress to 1,44" ( Di esel ) '" 18 to 19 lbs,
Compressed to 1.38 " (Spark Ign ,) '" 6, 75 to
7,25 Ibs,

cover (3) on the body (5) a nd to rque the cover

bolts 6 to 8 ft. Ills. Re mo ve the cover and
c heck the gear to cove r clearance Inset g , If
m ore? than ,0055 " c lea r a nce , 11 new pu mp
assembl y is req uired ,
Chec k the te(> th on the pump drivE' gear a nd
the pump body , If exce?ssive wear is no ticed
o n the gear or the c lea ra nce is not ,0065" to
,0035" DIE SEL and ,003" to .006" ( PAR K
IGNTION), replace m e nt a t th e pum p is required , 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
gasket (4) to th(> pump body (5 1 and torque
capscrews 6 to 8 ft. lbs, NOTE : While
tig htening bol ts and

co ve? r to p rov ide

a nd gea r"

sc rews,

free

position

the

rota lion of s ha lt

2, Insta ll relief valve

sta ll the cup plug
yond co tter pin hole
with co tte r pin (7),
(6) .

(10) , s pring (9) an d in(8) to a de pth ,iu st beInset 0, Retain in pla ce

Ins tall a new " 0 " ring

23-41

INSET B

INSET A

PLASTI GAUGE

SCALE

.0015" TO .00 5 5" ClEA RANC E

.002" TO .005" ClEA RANCE

~SP@

l"

~c

c
c

fIJ

Oc

0
0 C-

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

- - ---11--

INSET

Figure 27

2342

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
C.~lITION ; Re
m ov(' the radiator cap carefully as des
cribed above .
2. Remove the upper radiator hose (2) , hos e
cl a mps (1) and th ermost at (~ ) on the spark

1. Dra in tho cooling system .

ignition engine.

:J. Remove the t he rmos t" t housing

(~l)

gasket (4) and thermos ta t (5) on the diesel

engine. Discard gas ket.

4. Remove hose c lamp (6) a nd s upport (7)

from hose (2) on the spark ignition engine.
5. L oosen the a lterna tor adjusting bolt and
remove the fan belt.

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.
conditions exis t.
THERMOSTATS . The thermos ta ts should
HOSES Check the radiator hoses for cracks
be checked for prope r operat ion. Thi s can
and deteriora tion. Replace if npcessa ry.
be d one by submerging the th ermosta t with
RADIATOR CAP - Inspect radiator ca p for
a the rmometer in a containe r of hot wa ter
any d e fec ts or d amage w hich might impair
at a tempe rature of 1750 to 18311 F. The
its sea ling powe r. Tes t the cap for leaks.
thermosta ts should Ile comple te ly open at
If the radiator cap is defective, replace
202"F. Re plac e the thermos tat if it is not
it.
IMPORTANT: The replacement ca p
rea sonably c lose to t he a bove s pecifications.
must
have the same PS I r ati ng a s t he ori
FA); BE LT Ch eck th(' fa n belt for wear,
ginal
c
ap.
c racks or fray ing. Repla ce if a ny of these

Assembly
1. On the spa rk igni tion engi ne. install the

the rmost a t housing (.3 ) wit h bolts and new

ga ske t (4). Torque thE' bolt s 20 to 25 foot
pounds.
2. Ins ta ll the thermos tat (~i. ;'viake certain
they arc properly ins tall e d as indicated
in In se ts i\ a nd B.
3. On the diesel e ngine in s tall t he housing (3)
wi th new gasket (4). Torque retaining bolts
35 to 42 ft. Ibs. Install t he hose (2) wi th new
clamps (1 ) a nd secure .
4. On the spark ignition engine. install the
s upport (7) into hose (2) il nd install with
clamps (1) and (6). ~'lak e sure th e clam p
(6) is centered ove r the su pport (7) and se
c ure the clamp s.
:i. Install the fan belt. Adj us t the fan belt for
proper deflectio n as show n a nd desc ribed
in Inset C. NOTE : Th e mo st a ccura te

method of chec king the be lt tension is using

a Belt Te nsion Gauge , Ins('t C. The proper
be lt adjustment will give 1/ 2" de(lec tion or
60 pou nds te nsion on the ga uge be tween the
alte rnator and cra nksha ft pulley. IMPORTANT: U th e tension is too great, the al
terna tor, wa ter pump bearings and fa n bell
will wear excessive ly . It the belt is loose,
excessive belt wear ar:d slippage will ress uIt. CAUTION : When us ing a pry bar to
put tension on the fan be lt, apply only to the
fr ont cast housing a rea, Inset C.
6. Close a ll drain va lves ancl fill the sys tem
with c lean coola nt. Stan the engine a nd run
appro ximately 10 to 15 minutes a nd check
for lea ks. Shut e ngine olf dnd c heck the
c ool ant level. Add c oolant it necessa ry.

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

INSET B

SPARK IGN ITION ENGINE

o
Figure 28

CRAN KS HAFT PULLEY

"--./

23-44

LOCATING TO P DEA D CENTER

It is required that the fl ywhee l be se t on
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
poin ter. Then proceed as follows to check the
timing pointe r in the flywheel housing.

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

on the flyw he el is al igned with the timing
pointe r.

FLYWHEEL

c
TOC MARK 0 '

TIMING POINTER

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.
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.

NO . 1 CYLINOER

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).

2. Loosen th e th umb sc rew (2 ! on the du s t
cup c lam p as sembly (3). Rem ove the dust
c up (4 ) with clamp assembly (3) from the
cleaner body (9).

3. Re move wi ng nut (6 ) a nd washer gasket (7).

Remove the filter e le ment (8) from the ai r
cleane r body (9).
4. Remove the rubbe r baffle (5) fr om the dust
cup (4 ) _

Inspection
Clean the dust cup, ba ffl e and air clea ner
body with a clea n c lo th.
There are two m ethods in whi ch the elemen t
m ay be cleaned.By c om pressed air or washing.
CO MPRESSE D AIR METHOD - If conta m ination Is chie fly du st , di r ec t a jet of dry c lean
a ir fr om the in side of the fil ter to the outside
using a curved exte nsion. Keep the a ir nozzle
a r easona ble dis tance from the element and
m ove t he nozzle up and down wh ile r ota ting
the e leme n t. ll\-lPORT..\.t'llT : :\02z1e press ure
must not exc eed )00 P SI.
WA SH iN G METHOD - If the el ment a ppears
oily or sooty, the wash ing methOd should be
used. Wash the filter element using Case
!'"i1 ter Elem en t Cleaner Par t No. A40910,
Inset A, which is ava ilabl e tllrough yo ur
Authorized Case Dealer.
sing a s ui ta ble
con taine r, Inset B, mix two ounc es of clea ner to one gallon of wa ter a t a tem pe ra ture
of ap prox imately IOO"F . Soak the e lement
for 4 hours and then a gitate in the so lution
for approximately 2 m inutes. Rinse filte r

(bot h sides) with clean wate r until the drain

water shows no evide nce of dirt. Use a hose
without a nozzle a nd flush from the inside of
the elem en t to th e outside, P ressu re s hould
not e xceed 40 PSI. Let the elem en t a ir d ry
complete ly before installing . I 'O'fE : Re place
the filter e le m e nt afte r every s ix clea n Ings .
Inspect th e filter e lement after clea ning by
using a d rop cord, Inset C, and rota tlng \0
check for damage or holes. Visuall y chec k
the rubbe r gas ket for d amage a nd any dents
in the m etal. Re place the ele ment if a ny of
these cond itions exist.
Once a year, remove the e ntire air clea ner
(10) and tubes (12). Submerge them in Case
Filter Element Clea ner P art No . M0910, In set 1'1._ Wh en insta ll ing the a ir cleaner ( 10).
tubes (12) and hoses (11 ). ma ke s ure all connections are tight. Air cleane r efficiency is
direc tly depend nt upo n air- tigh t con nec tions_
Che ck the pre -screene r for punc tures in the
screening. Clean with com pressed a ir.

Assembly
1. Install the filt er element ( 8) in the body
(9) and secure with wing nu l ( 6 ) and wa sher ga sket (7 ).
2. Place th e ba ffle (~) in the du s t c up (4)
with the le ttering up.

.3. Pl ace the dust cup On the body and secure

with the clamp asse mbly (3). Make s urE'
the dust c up (4) is ail the wayan with the
arrows pointing up.
4. Replace the hood and pre-screener (1).

243

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

filter fitting and attach the manometer hose.

3. Replace the indicator if it does not meet

s pecifica tion s. There are no adj ustme nts .

2. Turn the tester vac uu m rcgula tor switch

on a nd s lowly inc rease thc vacuum until the
red signal appears and remains in the c lea r
window of the indicator. L's ing the part
number marked on the restriction ind icator
body. refer to the chart for the proper
speci fi cations, F igure 2.

4. If the restriction ind icator is faulty. a lso

replace the filt er fitting, Inset E, Diesel
or In se t A, Spark Ig nition. This fitting contains a fine s intered aUoy filter tha t is
readily fouied if contaminated a ir is a ilowed
to pass through it.
MOD EL NUMBER
RESET BU

INSET A

TTON~

~/~

1/

MODEL NO . 'RBXOO

VACUUM TUBE

FILTER FITTING
CLEAR OR
RED SIGNAL

IN S ET B

~~~_ _ _- VAC UUM TUBE

FI LTE R FITTING - -

RESTRICTION

INDICATOR" ,

AIR TUBE _ _

~.

-d!..
VACUUM TUBE

CASE NO.

DO NALDSON
NO .

INCHES OF
WATER

INCHES OF
ME RCURY

A59568

RBXOO-2254

27 .7 TO
32 .3 INCHES

2 .04 TO
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

f'in ill

."td ~('

l~ r i/ll , .ry

{~-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.

fillrr ,. " , .. " .. ,'" .. , .. ... ........... . " .. " , .. ,', ... .......... .... ..... " ...... ........ :l() :>'I Ic:ron

F iltr aTion

s(;Jgc> ! llter ... ... ...... .. ... ........................... . _.. .. " ....... ... .......... .... :.l to :) MiCron

F'il t ral iolL

:-"um bPr 01 coils .. ... .. ... ... ... _..... ............ " .... _.. ,. ........ ........ ... ,' ... .... _.. ...... .. .... ... ... ....... .... ... .. . 51 2
F' re<> lC' ng l h .. .. , .. .. " ... .... ,. _.. , .. .. .. .... .. ...... . ... .... ... ... .. , ..... ... ... .. .... ... .. " .. . ", . .. .......... ........ _..... 1.120"

IIIf!? 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
area adjacent to til e' f ilters.
I 'OTE : Service
both the primary and
fina l filter a t the same time.

eng ine

(14) and in sta l l with now ga skel (13 ) with

r eta iner llut (12 ) and nell' gasket 113 ) . Close
the dra in va lve ( 11) .
8. Install the drain valve (9) with nell' "0" ring

1. Close the fu el tank shutoft valve and remove th(' bleed va l\'e (2) w ith gasket (:l)
and drain plug (9 ) with "0 " ring (10 ) fro m
final filte r (l). Open the dra in valve (11 )
on th e primary filt er.
2. Unscrew th e filter c ap (1) until the element
(4) , and gasket ('1) c an be r emoved with the

fil ter cap.

:J. Remove the rubber sea l

(6 ), "'asher ( 7) and

spring ( 8) .
4. Remove the retainer nut (12) with gas ket
(1.1) and remove the primary filter shell
(14) with t he filt er elem",nt (16) and gasket
(15) from filt er head (17 1_ :'IIOTE: Replace
all gaske ts, seals and "0 " rings when replacing W ter etement s.
'i. If filter head ports and pa ssages appt'3r
d i rty . disconnect f uel lin es fro m the filter
h ead (17 ) and remove f rom blo ck. Flush
the head thorough ty in clean diesel fuel and
b low pa ssages and ports ou t clear with
compre ssed ai r. Install the hea d to the
block a nd connect fuel lines.

G. Flush the primary f ilter shell tl4) in clean

diesel fu el and wipe with clean lint free
cloth.
7. Install J

new clement (16) in to the shell

(10) .

9. Check the element spring

follow ing specifica tion s:

(8)

for

the

No. of coil s .............. . ...................... . 0-112

1.120"
Free length ...... ....... .
.(16U "
Wire did . .............. .. .......... .
. 6:;')" to . {j6J"
1.0. of spring .......
10. Insta ll spring

(8) , wa shel'

(7)

and new

seal (6) .

11. Ins tall a new final fil ter ( oj ) and lower gas ket (5) to the filter hea d (17) stand pipe with
the four holes and notc hes up. I nstall new
upper gasket (5) and cover (1 ) and tighten .
CAUTIO. ': Do not over tighten or the (> 1('ment m ay be cr ushed and become inoper<ltive. Ins ta ll bleed v alve 12) with new gas ket

(3).
12. Fill the fuel tank and open the fue l tank
shut-off valve. Wa i t a few minutes to make
sure the filters are f ull 01 fue l.
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
bubbles, then C105(> the bIped va l\'E'. Wipe
the filt er fre e of diesel fuel.
14. Start the engine and op('rate for several
minutes and check for lea ks .

FUEL FLOW
RETURN LINE

~~i--~~~\--~--~~
J ~'-

tIl

--

FUEL TANK
FUr:
IN J EC TO RS

!t

\t

--

TRANSFER PUMP

Itirl:. ~~l'~~~?~~~lj
VALVE

,-I>'f) I '

'-r'(r t ~

~.~~7

I
t

_ ,___J
DRAIN

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

Figure 1

. ....
DRAIN

FINAL FILTER

DRAIN

PR IMARY FILTER

=
=

WATER TRAP

rf ':- ~ _-@
~ .15

---0

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
s tra iner a nd filt e r before servicing .

1. Close the fu e l s hut-off valve

(1)

on the

fue l s tra iner (2 ).

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 .
3. R.' m ove the fuel bowl (5) with a gentle downwa rd pu ll. Clea n the fu e l bowl a nd rinse in
c lea n fu el.
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
re m a in s plugged or is punct ured , rep lace
th e screen.

hose (9). Check hose for cracks or d e te riora tion, replacE' if these co nditions E' xi s t.
6_Remove fuel filte r (10) fro m fu el s trainer.
Check fuel line (11). If the line is c rimped
or pinched to res tric t fue l fl ow, replace it.
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 ec ure cla mps.
8. Ins ta ll sc re en (7) with new gaskC't (6) to
s tra iner head (12).
9. F ill th e fuel bowl (5) with clean fue l a nd
c arefully install to s tra in er head. Swi ng the
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

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 .. . " , .. ........... ... ...... .... ... ....... ', .. ... .... ... ,.,_. _._. ,.
__ ___ ___ .. _.... 323
I n ~tall(ng the Fue l Injt'CtiOfl P l!mp .. .. ,", ......... ........... .... ........... , ....... ... ... ..... .. ...... ' ..... .. ....... .... :32 - ~
'nmlng the Fllel I nj(,('tion Pump to EngIne ..... ........... ... ..... ..... ... ... _...... .. ... ..... ...... ,..... .... .. .... . nB
E ngi ne Spt>ed ... .. ... .. ... . ..... .... .... ....... .. " . ....... , ... " ........ .......... .... . , .......... ..... ... ... ... .. "', .. ... ..... ..... 327
Check ing Engine S(X.'(.'{l . ..... ...... .... .... ........... ....... ......... ...... ............ ...... ...... . . __._._ , ____ ___ ...... __._ 327
No Lo;J(] Governed E ng ine Speed . .. .... ...... ........ " ..... " ................ .. ......... ... ...... ......
. ... . , .. 32 -8
Low Idle Speed A dj ustm en t .. ... .... .. .. ," .. ... ...... . , ......... ....... , ....... ..... ...... .. .. _. . .. __ , ______ _____ .. ___ . 329

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
with a Roosa M aster :VI ode l DB Fuel inj ec tion
P ump , Figure 1. This i s an ex tremely compact and precision unit wh ic h incorporates a
high press ure inj ec tion pump, a mech an ical
variable speed cE'ntrifugal type governor .
vane ty pE' fuel transiE'r pump and is self
lubricated by the f uel.

The function of the fuel i njeCtion pump is

to deliver accurately m etered quantities of
fu el und er high pres sure to the fu el inj ectors.
This must be done with accur ate t iming in
r ela tion to the engi ne firing ord er and for a
ver y definite period of tim e i n rela tion to
load and E'ngine speed requirem ents .

CAS E PART NO

'\

Figure1
T o m eet th ese rigid requirement s, the
M odel DB Injection Pump is of necess ity,
man ufactured to unusually close to lerances.
Wh i le the pum p ca nnot be considerab le delic ate , the preCis ion wi t h which it i s m anufac tured can be compared to that of a fine
watc h.

It is therefore doubly impor tan t that yo u

ta k e extra precautions to prevent th e entry
of dust or simil ar abrasi ves w hen yo u perform service work tha t invol ves t he fu el in jection pump or other components of the fu el

system.

32 -:3

Removing the Fuel Injection Pump

NOTE: : Ste a m clea n the 'ng ine tho roughl y
in the a r ea of the fu el inject ion pump and
lines prior to pe rformi ng any service work.

Use every possible precaut ion to ob ta in a b solute clean liness , to preve nt en ll-y of fOl'(' ign
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-

rect pump timing on '1 cylinder, refer to

Page 32-6.
2. Close the fu e l tank shu t- off valve.
3. Remove hig h press ure (uel lines, fue l inlet line a t pump a nd leak-off lin E', Figure 2.
4. Di sconnec t the throttle r od from the governOr control le ver and the fue l s hut-off cable
from the s hu tof[ lever.
'j.

It is advisabl' to put a sma ll scribe mark

on pump [lang' a nd t im in g gear housing if

th e sa me pump is goi ng to be r eins talled,

and then line up sc r ibe m arks on insta llation of pump,
6, Remove the three nut s and washers from
pump flange stu ds .
7. Cal'~ fully pull pump rear'ward off of the
pump drive sh a [1.
8. l{emove the tlming gea r cove r if the re is
an occaSion to remove the pump d rive
sha ft. Re fer to Sec ti on 23 o f this servic('
m a nu aL

Installing the Fuel Injection Pump

(Refer to Figure 3)
1. Any time the inject ion pump is removed

from the engine fOl' a ny l'eason, the two

d r ive shaft seals and the pi lot tu be "0"
ring seal m ust bl? r eplacE'd.
2. Lubricate the seals fre<- Iy an d Install on th<CO.322 slee ve tool wit h the lips of the sea ls
ou tw ard , lSL'a ls back to back) ,In se L".

3. Slide C0322 slee \'(' tool over pump drive

sh aft a nd ins tall seals in thei r respec tive
grooves, Inset A and B.
U IPORl'A T: Thorough ly

lubricat E' the

two sea ls on pu m p drive shaft with "I ullfipla te" to a void damage a nd fac il it a te ease
or in s tallation, InsetC.
. Be su re to exam ine pil ot tube "0" ring
sea l on f tOllt of pump for damage or nicks.
Replace if ne cessa ry .
IMPORTANT: J[ front s ide of flang-e on in -

jec tion pump as well as ma ting s urfa ce on

timI ng gear hou sing has any bllrrs or nicks
where the 1'.1'0 su rfaces m ake contact, be
sure they are r e moved . A burr or nic k
could resu lt in mi s-a lignment o f the pum p,
in turn ca using seizure.
~.

Re ar e nd of s ha ft is equippe d w!th drive

tang whic h has a hole in one side. Thi s hole
mus t lilH? up with hole loca ted interna lly in
pump o n th e rotor toward rear end of pump
hous ing. Wi th a cl iJ n Screw driver turn
pum p rolor to approximately the position
as ta ng on e nd of d ri ve shaft so tha t both
holes '.vill correspond with eac h other whe n
assem bl ed. If holes a re not aligned, pump
wou ld I)E' 180" out o[ tim e, Inset B.

6. Using specia l tool 1'0. CD331, compress

sea ls on drive sha ft ,Inset D, Slide pump
onto sh a ft be ing careful not to damage seals
du ring a ssemb ly. If sea l is rolled over on
shaft in asse mbly, remove pump and re place r ear seal eve n though no vis ua l dama ge
is appa rent. DO NOT FORCE afte r pu m p is
moved forwa rd. It may be nec essa ry to rotate p ump Sligh tly 10 permit tang on shaft
to engage slot In pump .
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 .

timing gear housing and tighten nu ts on

flange .

8. Recheck timing and adjust if nec essa ry.

Wa sh re moved fuel li nes, in c lean d iesc'l
fuel. Blow them c le an with flltered compressed air. Reinstall lines in same orde r
as removal.
IJI,IPORTANT: Before installing fuel line
connector scrcws into high pressu r e lines
at pump, be sure tha t two ne w copper was hers are used on eac h connec tion . Also make
SU1'e both washers are in p la ce befo re tigh ten ing up co noc'c tol' scrcws. Torq ue connec
tion sc rews 35 1'1. Ibs.

Do not tighten connec tor screws wi thout

washers in place :IS p ump seizure c ould res ult. This is due to connector screw going
too deep into pump body.
9. To remove the cap a nd filter assembly.
disconnect fue l s upply lin e at pump inlet
and re move nut on top of pum p. This screen
assembly is an assem bled unit . If "0"
ring or screen on c ap a nd e lem ent Is dam ,
aged in an y wa y, replace the damaged par ts.
Tighten to 20 ft. Ibs when insta lling .
Do not attempt to be nd either of the levers
on pump pivot s haft [o r any r aSOn as this
could result in leakage at-Ound the pivot s haft
seals due to s ha ft be ing spru ng w hen bendinglevers.
NO'I'E : When re placing an in jec tion pu mp
be sure replacem ent pump is for- t he COIT(>Ct
[ull load RP:VI of e ngine.
The full RPM is stamped on serial pla te of
pump. It would be possible to insta ll a n incorrect pump. th(>l'efol'E' always refe r to the
part s cata log when ordering a replacement
pump.

If pump is be ing returned to an aul horized

Roosa-Master service stat ion, be su re it is
complete with drive shalt. He placemen t pumps
are complete with drive shaft and necessa ry
pump m ou nting part s.

.t2.)

IN SET B

I
t

,
i

DRI VE

----~

DRIVE TANG LINE UP HOLE

FUEL LINE
C ONNECTOR

CAP AND
FILTER

SCREW~

ASSEMBLY

COPPER

____

__THROTIlE LEVER

[@

WASHERS~

NO LOAD GO V ERNED
SPEED ADJUSTING SCR EW

ai

C;,

SCREEN
/ASSEMBLY

/" "O"~' NG

@ @

.~

LO CK NUT

SCREW

'-....

\
THROTILE STOP PL,nE

SHUT-OFF ADJUSTING

SCREW~'

LOCKNUT- ~

~- ~

() ..... '"

~ ~~
t?

~-~

;., \ J

!Q,'b

SHUT OFF LEVER

SHUT-OFF LEVER RETAINING SCRE W

IN SET 0

IN SET C
LUBRI CATE THIS AREA OF SH AFT WITH
LUBRIPLATE BEIFO flE INSTALLI NG PUMP

SEA L CO MPRESSION
TO OL CD 331

Figure 3

.1'2-()

Timing the Fuel Injection Pump to Engine

T o dCI('rm ine top () ('~d Center o n '.:0. 1
cyl i nder:
1. SimI off f uel. A sh ut,off i s loca led o n bottom
ot Ihe fuel l ank. Ru n engi ne un lil il SlOpS.

.'3. Remove the ti ming hole plug on the plug

f1 ywh ee i housing and turn eng ine i n d irec tion
of rotation until fl y whee l is alig ned with
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
ar C' loose on 1'.:0. 1) cylind er [ top of com
press ion stroke ) and the rocker a rms on
th e opposing cylin der ('.:0. 4\ ca n be rock
('d op<:n Or closf'd I"i th a sligh t back and
forth m ovem ent of Ihe crankshaft.

Rated Spe",d

T iming

1750 .... , ..................... ........ ......... .

1850, 1900 .... . ......... .. .... ... ......... .. . .
2000. 2100 .......... ......... ..
2200 , 22~0 ............... .

BTDC
8" BTDC
80 BTDC
8" BTD C
oj "

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

FLYWHEEL HOUSING TIMING HOLE

Figure 4

.1. PemO\' e the cover from in '",c lion pump

windO\\', F ig ure 4 . If pump is co r r ectly
timed, the timing m arks in t he window will
be in alignment.
5. In t he event t iming marks are not in align
ment , it m ay be necessary to adju st pump
tim i ng . To do thi s put a scr ibe l i ne on
timi ng g<:ar housing a nd pump mounting
flan ge to use as a refer e>nce mark . Next
l oosen the th ree nut s on pu mp fl ange and
r ota te pump until timing ma rks are in
alignment in the window on the pump,
F igu r e 'l. NOTE : You wi ll not ice there
are 012" m arks on top siele o f the pump
flan ge. Disrega rd tht'sf:' m arks as t hey
are calibr at ion m arks for Service Sta tion
use only.

Figure 5

To advan ce timin g, move top of pum p aW'ay

from the cy li nder b lock, Figure 5.
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
flange after ro tating pump to th e speci fi ed
tim ing.
6. Turn engine over at l east two turn s a nd
recheck timing. R eadjus t if necessa r y . It
m ay be> necessary to r epeat this procedu re
sever al times befor e cor rec t timing i s ob
ta ined.

CAUTION : '.:ever attem p t to a dj ust timing

with the eng ine runnin g . This could re su lt
in serious injury to I he mechan ic or d amage
to i nj ec tion pump.

32-7

ENGINE SPEED
The Authorized E ngine Speed Adjustments
desc ribed In the follow ing paragraphs of this
manual are for the informa tion a nd use of
Authorized Case Dealers only.
Unaut horized changes in the governed e ngi ne speed of the Ca se Diese l Engine will
au tom a tica lly void a nd waive any Warra nty
whatsoever by the J. I. Ca se Compa. ny.
Before m aking a ny cha nges in the no load
governed e ngine speed, c he ck that the e ngine
s peed is no t a ffected by one or more of the
followin g conditions:
1. Check to be sure the engine is equipped
wi th rhe correct injection pump. The pump
can be identified by the number sta mped
on rh(' governor housing, refer to P age

32-2.

2. E ng ine mus t be carefu lly "Run-In" (Whe n

ne w or overha uled).
3. Eng ine lub r icati ng oil v iscosity not accordin g to recomm e nd a tions.

4. Incorrect oil viscosity In the tran smi ssion,

Or the hydraulic sys tem. NOTE : The transml s ~ ion and hydraul ic oil must be warmed
up to the proper tem peratu re before a t-

tempting. to ta ke an accura te engine speed

reading.
5. Fuel does no t meet the re quir ed specifications for Number 2 Diesel Fuel.
6. Plugged a ir c lea ner.
7. Fuel ta nk breather partl y plugged.
8. Fuel filt e r bleed by -p ass va ive not closed

completely.
9. Lack of fuel to the Inj ectors due to plugged

fuel filt ers, air or water in the fuel system.

10. Fuel injection pump not timed as describecl

in this seetlon.
11. Va lve tappet cleara nce not adjus ted a n d
set correc tly. Refer to Cylinder Hea d
Se ction.

12. One or more faulty injE' c tors.

13. Loss of compress ion
cylinders.

in

one

or

mo re

14. Fue l s hu t off ou t of a d justme nt.

Checking Engine Speed

CAUTION: MAKE SliR E THE POWE R
TRAI l 1 IS [1\ ~EUTRA L.
Checking engine s peeds is c ritical and ca n
onl y be m ade with a lachometer that is know n
to be accurate. nevolution counters of a ny
t yp~ or tachome te rs tha t ha ve been in use for
a long tIme withoul being checked for accuracy 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 thermome ter.
Ra ted Speed
No Load Governed Speed
1750
1890 to 1925
1850
2000 to 2030
1900
2050 to 2090
2000
2160 to 2220
2100
2270 to 2310
~200
2380 to 2420
2250
2440 to 2480

1. Take the s peed readi ng from the tac hom e te r

drive shaft , which run s at one ha lf the e ng ine speed. Hold the conical rubber tip a -

gainst the tachometer d rl \'(' shaf t.

2. Hold the tachometer in position until the
ha nd stops moving. Ta ke th'" reading and
double it to arrivC' il t the no load governed e ngi ne speed .

-------~~~~-- --RUBBER CONICAL TIP

Figura 6
3. To eliminate the pos sibility of e rror, check
the engine s peed with t.he tachometer at
least three times.

32-8

N o Load Governed Engine

CAUTION: Before changing or adjusting
the !'-' o Load Governed speed adjusting screw
on the pu mp , m ake sure the i? ngine is operating w ith the correc t injec tion pump. The
pump can be identified by the number stamped
On the Serial "'umber plate located on side of
pump hou si ng.
Set t he engine throttle in the "'0 Load Governed Speed Position_ Check the position of the
governor co ni rol levcr. Th e 0 Load Governed speed sere'" shou ld be ag~ins t the pump
boss. RC'fcr to Figure 7.

If the "'"A Load Governed speed adjusting

screw is not against the pump boss, adjust
until it holds the control lever aga inst the
pump boss.
If the No Load Governed speed screw is
against the pump boss bu t the No L oa d Governed speed is still low, the speed c an be i ncreased a limited al1lount by m eans of the 1\'0
Load Governed spE'd adjusting screw ,

NO LOAD GOVERNED SP EED

ADJUSTING SCREW
COUNTERCLOCKWISE
TO REDUC E NO LOAD
~_.,p,\:'!j GOVERNED SPEED
~

......~Iil"--1.

CLOCKWISE TD INCR EASE

NO LOAD GOVER NED SPEE D

Figure 7
TO r;\ CR EASE t he e nginE' 1\0 Load Governed
speed by means of the ;\0 Load Governed speed
adjusting screw , loos en the lock nut and turn the
:"\0 L oa d Governed speed adju sling screw out
(counter-clockwise) 112 tu rn a t a time and
tigh ten lock nut , Figure 7. Check Ihe No Load
Governed engine speed aft er ea ch 1/ 2 turn.
TO DECREASE the engine No Load Governed
Speed_ Set the e ngine thro ttle lever in the :-;0
Load Governed Speed position. Loosen the lock
nut on the :\0 Lo ad Governed spc'C'd adjusting
screw a nd turn the screw in (c lockwi se) un t il'

the correc t ","0 L oa d Governed engine speed

is obtai ned, Figure 7. Check the Ko Load Governed engine speed after eac h 1/2 turn.

IMPORTANT: The No Load Governed speed

adjusting screws are sealed with a wire and
lead sea l. You musl have the necessa ry equipm ent to resea l the adjusting screw when th e
adjust.ment is complete_ Alw ays m ake a record of the datE' you broke the seal, the serial
number 01 the machine or engi ne and t he rea son why you broke the seal.

Low Idl e Speed Adjustment

low speed stop.

Set the engine throttle in the Low I d le spcC'd

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
be aga I nst the pump bos;:, Figure 8.

If til(' Low Idle speed serf'\\' is aga i nst th e'

pump boss I) " t he engine speed ;s sti ll low,
ill(' C'ngine speed can be i ncrea sed a lim it ed
amou nt by means (l[ The Loc,' I d le speed adju sting ser eI\'.

l! t il(' L ow Idle speed screw i s not aga in st

tile pump boss, ad ju!i t. the t hrottle linkage rod
un til It holds til<' co ntrol lever agai nst the

FigureS
TO DECREASE the engine speed by m ea ns of the
Low Idl e speed a dju sting screw, loos en the locknut and turn the screw ou t (counter-clockwise)
until the corr ect engi ne spe0d Is obta ined, Figure 8, check !'ngin!' speed after eac h 1/ 2 turn.
TO INCREASE the !'nginp speeci by means of
the Low Id le speed adjusting screw, l oosen the
lock nut and t urn the adj usti ng screw in (Clockwise ) 112 turn at a tim e, Figu r C' 8. Cheek engine speed after each 1 12 t urn.

After the correc t engi ne specll is set t igh ten

the lock nut s whilE' holdi ng Tb0 ad.iusT ing scr (''.'/.

IMPORTAN T: The Low lClle speed adjusting screw is seajpC\ with a w ire a nd leac\
seal. You must ha\-e the necessary eq u ipment to reseal ttle adju stIng screw when the
adjustment is com plete. Alwa y s m ake a re cord of t he d ate you broke the eaI , the
seria l number of the engine and t he r eason
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 ..
Comp r('~sed

to

-- .....

.4 1~" .

., .. , ........ .... -.. . .............. .. ..... .... ............ .................... ..... .. .. .. .... .. .. .

Xlj"

.,.... ..... .. .. " ... ..... .. ........ ... .. .. .......... ,'" ... ,... .. .. '. __ .. "2.,

' ''''
-I
~ 1<.

Ibs. pressur('

Special Torques
E'"u ('1

injector pn.'sur(' adjllstinz

Fu el

injeNo ~

~Cf{'W

locknu t ............... ......... .... ............... .

TO 10 75 Inch Ibs.

c la m p c,lpscrcws ............... _...... _.... .... ............. " .............. .. ... ___ .. _.. _.. . .... .

Roo _ F""" 9 604 11

to It.

l bs ,

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,.

/I.,

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

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

'OW" '0

,It,

'.",oy

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"
;"ju,,' lillf.' 0' A.If' wif"
.If'
.Iilff
illj,,'" ,." will ,.mllill 116'0 I,,'./y ., ,,,,
UII 'illI ,"g.ioi." 0." .It.mill. if.

,/I.
.0 ,/I.

,,/ill'

33-:3

D e scription
Th e fue l inj e ctor is a cl osed end (injector
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, hydr a ulically ope r a ted hole type injector.
The fue l injectors are located in the cylind e r head - ol1e for eac h cylinder. It is the
fu nc tion of the fue l in jecto r to di rect a metere d quantity of fu e l r eceived from the injection pump to the c ombus tio n chamber. Eac h
c h a r ge of fuel must b e d elivered into the
combustion c hamber with a definite spray
pa ttern to insure complete combustion and

efficient e ngin e pe rform ance .

IMfI()llTANTThe

inj ecto t' body a nd valve is

a m ated assembly, accur ately lapped to a
ve ry c los e fit fo r pre cise mete ring of fuel
to e'ac h cyli nd e r , The bod y or va lve cannot
be install ed individ ually for servic e. If it is
necessar y to replac e e ithe r the valve or
body , repl ace the comple te as s embly,

CAIITlDN

Do not mix val ve s and bodies

while disas s e mbling the injector.
PRE SS URE ADJUSTING SCREW

INJECTOR BODY

TIP\~
VALV~ ~/

SP~AY O~IFIC~S

LOCKNUT

CARBON SEAL

LIFT ADJUSTING

SC~EW

COMPHSSION S~AL

INLET FITTING---..

Figur e 1
L\;JECTOR BODY - Hou ses the injector parts
in their co rrec t position in the cylinde r he ad.
The part of the inj ector body whi c h proje cts
into the c ylinde r head is Teflon coateel to

presses the opening pressure control spring

to maintain a predete rmined s pring pressure
on the val ve,

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.
VALVE GUm E - Supports a nd guide s the
moveme nt of the va lve in the b oel y .
OPE:--:ING PRE SS liHE CO I\TRO L SPRINGControls fu e l pre s s ure nece ss a ry to lift the
valve fr om its seat.
PRESSURE ADJlI ST[i\; G SCREW - Com-

[i\;JECTOR TIP - Contain s the va lve se a t

anel four spray orifi ce s whi c h direc t the fuel
spray in the combustion c h a mber.
CARBor; SEAL - Pre ve nts carbon ac c umulation in the cylind e r head openings.
COMPRESSIor; SEAL - i\ nylon s e al under
the inlet fitting that pre ve nts e ngine COmpression leakage,

Operatin g Princ iples

The ope ration of the injector is sllllp le
and posit i ve .
A m e te l'ed quant ity of fLkl und e r high
pressure from the i nje c tion pum p flows
through the i nl e t line of the inj ec t or ar ound
the inj ecto r va lve.

ilt the in s tan t the pressure of the fuel

agains t the valve exceeds the p r edete rmined
spring fo r ce. the valve is for ced from its
seat allowin g fu e l und e r high pressure to
no\\' th rough the four spr ay orifices to the
co mbustion c ha mber .

LIFT ADJUSTING SCREW

INJECTOI BODY

PRE SSU RE
CO N TR O L
SPR ING

VALVE
TIP

\
\

SPR AY ORi f ICES

CAliON SEA L
P AE SSU IlE ADJUSTING SCREW

CO MPO!SS ION HA L

INLET FITT I NG

Figure 2
The instan t t he fuel deli very ce ases , the
pr essu r e against the valve i s reduced a nd
the c ontrol s p ri ng sn a ps the valve to its
s eat . T hi s eli minates any poss ibility of
drippi ng aIte r the m ete r ed amount of fuel
h as been deli ve red. In actual operation, the
val ve ope ns and closes ve ry rapid ly with a
distinct c l\"tter .

During inj ec ti on, a small amount of fue l

leaks through th e c lose ly contro ll ed cle a r ance at th e guid e, lu bric ating all the mo vi ng
part.s in th e inj eo to I'. Th is fuel U, e!) flows off
through le"leaff lines at th e top o f the i njector anel r eturns to the fuel tank .

: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

SA C HOLE
o /Il L LI
l ET OF I ,

TIP S EA T
SCRA Pf R

.010 "

66 -0 14 9

OR IFICE

INJECT O R

CLEANING W I RES
66- 0 0 36

HOLDING TOO L

66 - 0147

M A G N fFV ING G LASS

66 0135
TO RO UE

WRE N CH
AO APTEi
66-0146

66 0 151

VA LV E
RE H PA C TOIiI

ENGINE
COMPREISION
ADAPTH
70.314 ( 0 .558)

66- 0 148

LA P P I N G

TEIT PU MP AO A PT ER

CO M P 0 UN 0
66.0 H '

651 7 8 i N 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) .

TEST STA N D
CASE: PA RT N O. M 2 0322
BA CH ARACH PA RT N O. 65 93 4D

BOR E C U'ANI NG TOOL

CAS E PA RT N O. A43277
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
of th e injec tors is suspec ted, th e following
procedure can be uti! ized to iso late the
fa ulty inj ec tors.

Loosen the fuel i nle t tube nut (1) in turn on

each in jecto r. This will allow fue l to es cape
and r ende r the inje c tor i no perative. The injector 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

Figure 5

33-7

Removing InJectors
Clean the cylinde r head area around the
inj e.c tors. Disconnect thc le ak-off line nuts
from the tee . Remove the li nes (6) and tee
(7) from the inj ector , Figure 7.

Re move the in jector (8) from the cylinder

head by pulling upward and turning . If the
inj ecto r cannot be easily r emoved by hand,
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 injector 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

(2 and 3) and spacer (4). The locating plate
(5) r e mains with the inj ector , Figure 7.

These two seal s mus t al ways be replaced

whenever the inj e ctor is re moved and ins tall ed in the cylinder head. In stall protecti ve caps on the injector.

Installing Injectors
Clean the inj ector bo r e i n t111' cyline!er he ad
a nd Ilia\\' ou t \\'ith co mprps~ ed ai l' .NO TI Use
bore c leaning too l C" H' ~: o, ,.14 3277 a nd
g radu:1l 1y turn it by h and in t<) the bo r e . Always 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, injAc 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.

cla mp caps c r e\\' 20 ft. Ibs , [nsta ll tec and

leak- off line s , Cr ank th e engine with the
st arter until the fue l fla Il'S fl' om U,e loose ned inj ec to r inl e t fltting .

H." l rOOl

TIGHTENI NG INlET f i TTING

Figure 11
Then tighte n the inlet fittin g' us ing the onehand two-wrench squee ze method , figu re 11 .
Start the e ngi ne and ch eck [o1' l"'''ks .

Fi g ure 9
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 ,
10.
Case 1'0 . .'\42H9 , FIgures 9

"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
connection (1) t.o, the ,~
~
Ub~ Torq ue injector

/~" ':'Of~~.~

: : : -.,: . --.--

, ;1

?~~

??

' J~._ ,,:iJ2:.'S..,

'-"

-~-------==----------

'I .-._- ->~.

. >t --:c

~~. C. ; __~d

'...--(D

""
~ .~

----cD

Ol.,
.~

j#r--

- jii) ":.>::::.
--. J

~, 0, ~ ~
~~ ir~'~
'"
I

f:i~

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 rformed , the injectors should be remo ved
and checked on the test stand .

Figure 12
An " Approved" Injector Test Stand, Case
Part No. 1\<120322 (Bachar ach No. 65-9340 ),
is r equired fo r testi ng and arl justing the injectors and c all be pur ch as ed through the
Se rvice Par ts Supp ly, J.l. CaseCo .,Racine,
,Visc o Exc ept for descripti ons r eferr ingespec ially to adjus tme nts on the test stand itself , all of the following instructions will
apply to a ll makes. Operating instructions
are also furnished with the test stand.
An injector tool kit, Case P art No. M2 0520
(Bacha r ach No. 60-00 10) , is required to service the i njecto .'s . A new compression ga uge
adapte r, Bac harach 1\0. "70-314(D-558) i s
also included in t.he tool kit . This kit is used
in con junction with the Case Diesel Tool Kits
Case Part No . M20247 (CD- 800) <Uld Case
Part No. M20246 (CD- 350) .
The test stand is used to perform the follow ing' checks :
1. Check and adj us t the injec tor opening

pressure . T his is aduplicate of the fac tory

procedure .
2. Check

the

in jector asse mhly fo r f ue l

4. Whe n an injecto r is suspected to be the

c ause of unsatisfactory engine pel'fo rm mance , it shoul d he r emoved from the
cylinder head and checked on the test
stand prior to dL as:oemhling it.

IItIPOIlTANT ALWAYS CHECK T HE PER fORMANC E Of A~ Ii"JEC TOH ON THE

T EST ST AN D BE fOR E DISASSEMB LING
IT . IF IT CH ECKS OUT S ATISfACTOH ILY, TH En E IS NO :-IEE D TO DI ' ASSElI-l BL E on ADJe ST IT.

Preparing Test Stand

1. After filling the test stand fuel r e servoir ,

loosen the bl eeder scr ew .

2. When the fue l flowlng fr om the bleeder
screw ope ning is free of air bubb les ,
tighten the s crew .
3. Wash the COnIlector tube and adapte r in
clean diese l fu e l. Blow clean with filte r ed
compressed air and cO!lI1ect securely to
the test stand, Figure 12 .
4. Operate the hand lever slowly unt il cl ean
fuel flows from the adapter,

leakage.

3 . Check and acl just the i nje ctor leak- off.

4. Accurate ly (,heck the in jector sp r ay patte rn.

5. The te st st and is now ready for use.

NOTt Complete m aintenance in structions
are furnis hed with the test stand . FOllow
the instr uct ions carefull y .

TESTING IN.JECTORS
Phor 10 l e stling an inj ector, r~m o ve the
loose carhOn from the tip \\'i th the inj e ctor
c l e aning b rush, Figure l3. C lean the carbon
seal groove a nd body be lo w the groove in
t he sam e manne r. CAtlTlOII Do not s c rape
or brus h the Te flon co a ting above the carbon
seal g-roove.
BRASS WIRE BRUSH

SEAL GROOV

enclo sed in a rece ptacl e , pr e ferab ly t r a nsp a rent, to conta in the spray.

Checking Opening Pressure

Cl os e the pre ssure gauge val ve and flush
the injec tor by o pera ting the te st pump r a pidl y. Open the g auge a nd r aise the pre ssure
Slowly until the injecto r va l ve ope ns . (The
gaug~ reading will drop sh a rply at this poi nt).
Check o pening pre ssure against th ~ spec ifications.

NOTE When t e sting' m o re than one i njecto 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 .
I
/

Figure 13
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
fac ing downward, Figllre 14.
TEST PUMP ADAPTER

If the injectors do not me e t the spe Cified

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

2. Used injecto rs should be di sassembl ed

and clea ned. See P age 12.
3. Va lve lift screw may beoutofad justment.
See Page 15.
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 permiss 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
or 60 s\\'age d type line a s damage to the
tubing c a n r e s ul t.

CAtlTlfJ1I THE DfJECTO fl TIP SHOULD

ALWAYS B E DIR ECTED AW i\Y FflONITH E
OPEfl ,\TOfl. F ue l fro m the sp n y orifi ces
can pe ne tr ate clothi ng and s kin c ausing
seriou s infec tion. The tip s hould al ways be

2. Valve is not free in guide. L ap va lve to

guide. See Page 14.
3. Inspect for pitted or c racke d valvE' tip.
eroded va lve seat or pit ted a nd dis tort ed
body . These conditions r equi re replace
m e nt of the compl e te in jector assembly .

33 -11

T ESTING INJECTORS (Cont)

Spray Pattern
Close the p r essure gauge . Ope r ate the
teste r at 60 strokes pe r minute and obs erve
the s pray pattern. Fue l should be fine ly
a tomi zed , Fi gure 15 and not a so lid ilTegu ar spray patte rn , Fi gure 16 .

2. Dis a ssemble and c lean inj ector , See Page

12.
3. Lap the valve to guide a 'ea . Page 14.
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

Figure 15
Fi ne Alomi z .. d Sprll.\ Pattern

F igure 1 6
So li d Type Ir r egul ar Sp ray Pattern
The injector will ch atter when th e teste r
i s o perated r apidly. Although thi s chatter
m ay not occur in oper ati on of the injec tor
in th e engine , it is an indic ation of val ve
fr eedom and wi 11 i mprove atomi zation.
Chatter is gen er all y an ind ication of good
s e at width and inter fe rence angl e cond itions .
If the in jector produce s a solid type irregular s pr ay patte rn proceed as fo ll ows :
l. Check lor

e r ooed , clogged o r chipped

or ific e s. See Page 13.

Lo osen connector nuts and r epos itio n injecto 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 emper ature (65' -7 5' F. )

figure 17
If the leakoff does not m eet this spec ification proceed as follows :

1. If exce ssive le akoff is noted , injector

mus t be rep Iaced .

2. If low le akoff is noted elis as s e mb le and

c lean injec tor. Se e Pages 12 thru 14.
3. Lap the val ve t.o gu ide area to inc r ease
th e nozzl e le ak off. See Page 14.

~3-12

SERVICING IN..JECTORS
Disassembly
It is impor t ant to r emember that the injector contaI ns c losely fitted parts which
are precision grou nd and finished . Dirt is
it s g r eatest enemy. Exe rci se ut most Gare
in keeping the wo rk area and tool s clea.n.
Hand le all par ts car efully to avoid d a mage .

2. Holding the inj ector in on hand , invert

it and back out the pressure adjusti ng
screw allowin g the spring, sp r ing s eats
and ball washer to fall into your hand ,
Fi gure 20. The valve may sl ide out ofthe
body at this time and should be handled
careful ly by its stem .
PH<suae
ADJUST ING

SCREW

LI FT A D J USTING SC.EW
LOCAT I NG PLAH

"""'

-.........,

I,

PI5IUIE
'

~ / II
ADJUST I N G

"~CIfW"

'Q

~,

\!l

/
/
INHCTOI/
IODY
I

II
.

WASH ER

UPPU

~ " " HAT

SPIING

----.All

LOCKNUT

l OWEI SlAT

~ \

Figure 20
3. If the valve doe s not. slide f r ee ly fro m the
body, a val ve r etractor , No . 56 - 01 48, Fig-

ure 21 may b e used . To prevent bendi ng

the valve, bottom it in the body with the
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 .

VAL VE RETRAnoR

CO MPRESSION/

HAl
r. AUON HAL

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 locknut, 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

from spray orifices. use clean ing wirE'S
.008", .009" and .010" di a . Scure 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.

IN HC TO'
HOLDING TOOL

Figure 19

33- 13

SERVICING INJECTORS (coni)

ORIFI CE

Figure 22
Use a stone to r move cutting burrs from
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 .
3 . Insert sac hole drill No . 66-0151 into the
sac: hO le , rotate it to clean deposits from
t he sac hole; repeat or i fice c l eaning.
SAL HOL E D RIll

TIP H AT

jector to proper operating condition , use

t he methods o utlined below;
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
the seat and valve, causing alossofchatter with poor atom i.zation

VALVE

TIP

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
,u'ea . Varnish should be remQved with a
solvent and fe lt cle aningpad . Do not chuck
the vaj l'e in a motor d ri ven lapping l athe
fo r clean ing, as this technique will bend
the valve . Inspect the valve for pitting or
erosio n which cou ld c a use leakage.
5 . Inspect the adjusting s crews fo r th read
damage and replace if neceasary .

Reconditioning Injectors
U 5i Ol[JI e c leaning does not l'e store a in-

Figure

Hotate the val ve by hand, first c lockwise

then counte r - clockwise for a to tsl of 3 - 5
r evolutions. tAlITlOIi Never attempt to use
motor d r iven chucks of any kind for th is
purpose . Flush the body thoroughly. Wash
the valve and reassemble injector .
The injector may be then retested. IT t he
valve and seat is worn, the seat may be
tight, but chatter may be lo stin the l apping
process . In such a case, the injector must
be replac ed .

33 - 14

SERVICING IN.JEC TORS (cont)

2. VALVE GUIDE SERVICl:-\G: Low r e turn
.l e ak-off is an indication o f varn is h accum ul ation bet ween the guide and \'al ve . In suffici ent clearance ean c ause s ti cki ng and
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 lapping.

seat, s pri og, aod lowe r seat to the lift and

pressure adjus ting screw assembly . THt
the injector body and with the lower s eat
Lown Sf AT

VALVE GUIDE AtEA

VALVE

Figure 28
in contact with the top of valve, Figu re 28,
pu sh the va lve a nd spring components ini o
the body. Exe rcise care not to dislodge' the
lower spring scat du r ing this assembly.
Thread the pressure a d justing screw by
ha nd un til the spring is compressed with
e nough forc(' to hold a ll parts in place

Place a s ma ll a mount of lapping compound

So. 66 -014 5 on the guide are a of the valve,

Figure 26. Botto m th e valve ill the body and

g ras p with th e r etractor a s previously desc ribcd. n ot ate the valve ten revolutions
whi le rai s ing' and lowering it very slightly.
Flus h and was h compowld fro m both component s . i~ sse mbl e and r eche ck r e turn leakoff. li le akoff is s till low, la p th e guide until
correct le ak age is obtained . Always flush
th e inj ector thor oughl y rLfte r lapping.
tAUT/Oil The r equired amourl t of m ate ri al
r e moved is us uall y onl y a few milli onth s of
an inch . i\:e ver use moto riz ed chucks for this
ope r ation .

(8-10 fu ll t urns).

2. Install inj ec tor as sembly on t e st st and.

Test and adjus t open ing pressur e , va lve
lift and leak-o ff, r efer to P age 15 .
3. Tighten locknut 70 t o 75 inch Its . and ins t all ne w seals . Figure 29 .
LOCATING PLATE

LIFT ADJUSTI N G SCREWI

PRES SURE

\~
/~" ~D J USI I NG SC I-!...W

",L OC~NUT - ,

Assembly

;'

Wash and flush all parts tho roughly be for e

assemb ly. Asse mb le with hand s and all parts
wet with c lea n fuel.
1. Handl e the valve by its sh ank as s hown in
Figure 27. Shde it pa rtiall y into th e body.
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.

/
!

INL ET

B All
WA5HfI

UPPEI

FITTI NG /

/
/
/
/
/

~\

VA LV E

COMPtESSION/

SEA l

CARBON

Figure 2 7
2. ,>' sse m ble the ba ll

WitS he r

, uppe r s pri ng

SEAL

(,

"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
tUI'll required and compare to specifications. Back out the li ft adjusting screw
far enough to prevent bottoming when the
prestiure adjusting screw is turned.
PRESSURE
ADJUSTING SCREW

Figure 32
3. Turn the lift ad justing screw coun terclockwise 1/2 of a turn to obtain the speCi fied lift. After setting the valve lift, hold
the pressure adjus ti ng screw and s ecure
the locknut.
4. Recheck the opening press ure. Note that
the lift is set before checki ng spray pattern fmd chatter as the a mount of lift will
affect these characteristics .

Tightening Locknut

F igure 31
3. Turn pressure adjusting screw clo ckwi se
to increase, or counter-clockwis e to decrease opening' pressure. Do not tighten
locknut at this time.

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 adapter, No. 66-0146. The press ure adjusting
screw must be held while securingtbe locknut. Recheck opening pressure on the test
stand.

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
injector opening pressure . Al though so me
fue l may collect on the t ip, a rapid dribble
should not be app,lrent. Do not manu ally

INHCTOR
HOLDING TOOL

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(;) ... .. ...... .. .. ..... ........... ........ . , .... ................................. .......... ...... _ .. ... .......... .. . "
. 1I8~
;\'la in dischargc Jet ..... .............. ..................... .......... .. ... ....................... . ................ .
Wel l vt'n1 Jl't (188G ) ... _............................... ....... ... ... ... ...... .... .. .. .................... .. _....... _.. ... .. .0"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

Wi re dianlNE'r ........ ..... .... ... .... ...... ... . .OJ)",

F"rC(' length ... ... ......... ... ..... .. ,...... , .. .. 1.000"

............
...

...

.........
Wln' d imn(! l('r . . ..
.....
..
Free l en gl h ... .
.................... ...
Number of ('olls .......... .. ... .

'

Hl!
.O~ O"

.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 (counterc 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
from the carburetor.
2. Disconnect the choke cabl e and the gove rnor
linkage
(rom
the
carburetor.

3. Remo ve the two carburetor ret ai ning bolts

and remove the c arburetor assembly from
the intake manitold.
'J. Remove and d iscard carburetor m o unting

(14) and (13) fro m the throttle body .

14. Using a suitable size and length of rod
inserted through the throttle shaft hole,
punch out the plug (19).

15. If bushings (20) are to be re moved. use

a suitable size tap and lap the bushi ng ro
a pproxima tely four (hreads. Ins ta !! a bolt
or s tud and pull the bu sh ings (20) from the
throttle body.

gaske t (1).

5. Remove the fou r screws and lockwashers

which retain the throttle body (2) to the
fue l bowl 0 ) .
6. With the throttle body and fu e l bowl sepa rated . remove the gasket (4) a nd discard.

7. P ress a screw driver agains t fl oat axle

('l) at slotted side of fl oat hinge bra c ket
and force through the hinge brac ket. Remove the floa t a xle (5) fr om opposite side
and remo ve t he float (6).
8. Remove t he float valve (39), soat (7 ) and
th e fiber sea t wash('r (8) . Discard the
washer (8).
9. Remove the venturi (9) and idle jet (10)
from the throttle body (2) .
10. Remove the idle adj usting
spring (12 ) a nd plugs (13 ) .

needle

(11),

NOTE : Scribe or m ark the throttle body

(2) and levers to aCI as a g uide for proper
reassembly of the fo!!owing parts.

16. Remove the magnetic fuel shut-off solenoid assembly (21) from the fue l bowl (3)
Refer to Page 14 and 1.5 for servic ing.
17. Remove the discharge j e t (22) and fiber
washer (23). Discard the fiber washer (22).
18. Remove the m a in jet (24) a nd fi ber washer (25) . Disc a rd the fib er wa sher (25) .
19. R emove the weI! vent (26) a ncl drai n plug
(27 ).

20. If the drain disc (28) is to be replaced.

punch a hole through il a nd r emove.
21. Remove the choke plate (29). NOTE:
Scribe or mark the choke bracke t, lever
and t.he adjacent s haft boss 3S an aid to
proper reassembly.
22. Remove the choke level' spring (30). Remove the ch oke shaft (31) w ith lev" ,. assembly (32 ) a nd swi vel snew, wa s her a nd nul.
(33).

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
lever (H) .

12. Remove Ihe two thrOl\le plate screws

a nd the thro ttl e pla te (15 ).
13. RemoVE' the throttle shaft aS 5('mbly (16).

24. R e move the packing r('tain er

pac king (37) .

(36)

and

25. Using a suita ble size and leng th of r od

punc h out plug (38) .

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

in the fuel bowl. Reverse the flow of compressed air in all passages to insure all
dirt h3 s been removed. Check drain disc
(28)_ If dam aged or if it remains clogged
after bowl c lea ning, replace.
2. THROTTLE BODY (2) - Blow ou t all passages in the throttle body with compressed
a ir_ Reverse the flow of com pressed air
in all passages to insure that all di r t has
been r em oved . Check the bushings (20) for
any
wear.
Replace if wear is detected.
3.FLOAT ASSEMBLY (5) (0) - Check float
(6) for leakage ca used by pin holes or
other damage. Chec k the top side of the
floa t leve r where it conta c ts the fuel
needle valve for wear. Replace fl oat If
any of these conditions exist. Check the
float shaft (5 ) bearing surface for wear.
Replace if necessa ry.
4.FUEL VALVE SEAT AND VALVE (7)(.39)Chec k the seat a nd needle for wear. If replacement is necessary for either part,
replace both at the sa m e time.
5. IDLE ADJUSTING NEE DLE (11) AND
SPRING (12) - Inspect the needle point. It

must be smooth and free o f ridges. Check

the spring for a ny cracked or bro ken coils
a nd for specific a tions listed below. Replace if necessary.
6. THROTTLE PLATE (15 ) - Inspect the plate
for burrs, damaged e dges a nd flatness.
Never clea n the plale with a buffing wheel
or sharp ins trume nt.
7. THROTTLE SHAFT (l6) - Repiace the
throttle shaft if there is evidence of wear
on bearing surfaces . Check the s ha ft for
straightness .
8. CHOKE PLATE ASSE MBLY (29) - Insp ec t
the plate for burrs or da m aged edges .
Make sure tha t the plate is nat. Insu re
that poppe t va lve works freely and does not
stick.
9. CHOKE SHAFT (31) - Check the sha ft
bearing surfaces for wea r and that the
shaft is straight.
10. SOLENOID ASSEMBLY (21) - For chec k
ing and servicing of the sole noid , refer to
Pages 14 and 15. NOTE: Replace the fiber
washers (8), (25), (23), (41) packing (37), sea l
(18) , plugs (19), (38) a nd ga skets (1) a nd (4).

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
:\umber of coil s ................. ....... ............ 18
Wire diam('ter .................................... 031"
Free le ngth ........... .... .. .. _, .............. ... 1.000"

Idle adj. need le spring (12) .... Specifica tions

Number of co ils ............ .......... ............ . 4112
Wire diameter .............. _.. _.. .................. . 040"
Free iength .......................................... .469"

:1';7

Figure 4

358

CARBURETOR (Cont'd)
(Refer to Figure 5)
Assembly and Installation
1.1nstall a new plug (38 ) a nd a new choke
shaft packing (37) into the fue l bowl (3)
a nd the packing retain e r (36).
2. Referring to scribe m arks tor correct
posi ti on. install cho ke bracket (34) assem
bled with clip. screw a nd nu t (35) to the
fuel bowl and r e ta in with mounting screws.
3. Insert the choke pla te assembly (29) with
the poppet valve fi rs t a nd the stem down
into the air int ake. Holding the choke plate
up, insert the c hoke s haft (31 ) assembled
with the lever (32 ), swivel screw, nut and
washer (33 ) into place with the shaft cut
ou t section fac ing up. Rot ati ng the shaft to
the closed posit ion , place the choke plate
(29) in the c utout a nd inst a ll screws to
retain. NOTE : Be s ure the choke plate
is properly centered before tigh tening the
scre\Vs.

4. Install the c hoke lever spring (30) to r eo

turn the c hoke to the wide open position.
5. Install plug (27) a nd drain disc (28) if reo
place m ent was required.
6. In sta ll the m ai n je t (24) with a ne w fiber
washer (25 ). Ins tall the well vent je t (26 )
a nd the je t (22) with a new fiber washer (23).
7. Install the venturi (9) In the fuel bowl (3)
wi th the small opening down. ]'I;OTE : The
notched side of the venturi (9) must be
pla ced toward the well vent jet (26).
8. fn sta ll new throttle shaft bushIngs (20), if
r eplacem e nt was required.
9. Inst a ll th e e nd plug (19) and plugs (1 3).

10. Press in a new stop pin (40) if rep la ce

m e nt wa s required, Figure 5, Inset A.
11. install idling jet (10) and float va ive seat
(7) with a new fiber washer (8) int o th e
throttie body (2) .
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).
13. Referring to scribe marks for correct
positioning, install throttle shaft (16) as
sembled with lever (14). Back out the stop
screw (13) far enough to pe rmit com plete
c losing of the throttle plate.
14. Rotate the throttle shaft to the open posi
tion a nd insert the throttle pla te (15 ) in the
c utout section of the shaft.
IMPORTANT: The throttle plate

(15) is
made with two opposite edges beveled to
fit the throttle body bore whe n the plate
is in the closed position. Whe n properly
Installed, the side of the throttle plate (15)
farthest away from the m ountin g flange wiiI
be aligned with the idle port a nd beveled
edge is facing the moun ting fl a nge when the
plate is closed, Inse t B.
15. Install the throttle plate sc rews, being sure
that the throttle plate is properly centered
in the throttie bore. A s light pressure on the
plate must be maintained with fingers until
the screws are tightened.
16. Install the idle adjusting nee die (11) with
spring (12) into the throttle body (2). Seat
lightly and bac kout one full turn as a pre
liminary adjustme nt.

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
fuel valve ( 39) into the seat ( 7).
18. Install the fuel float (6) wIth the axle (5)

to the body. Viewed from the free end of

float, the flo a t (6) must be centered and
at right angles to the machined surface.
The float setting Is m easured from the
machined surface (w /o gasket ) of the body
to the top of the float at the highest point,
Inset A . To increase or decrease the
distance, use long nosed plie r s and bend
the lever close to the float body, Figure
6, Inset A. Replace the float if position
is off m ore than 1/16".

tlon and turn the throttle s top sc rew (l:J)

In until it just contacts the stop pin (40),
then turn the stop screw (13 ) in an additional 1-112 turns as a preliminary ad justment.
21. Install the shut-off solenoid (21) with a

new fiber washer (41) to the carburetor.

Turn the adjusting screw all the way in,
then turn out one full turn for a preliminary ad justme nt.
22. With a new mounting gasket (I), insta ll

the carburetor to the intake manifold with

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).

Assemble the throttle body (2 ) to the fuel
bowl (3) and retain with screws and lockwashers. Tighten th e screws evenly and
firmly.
20. Hold the throttle lever in a closed posi-

23. Connect the governor linkage to the car buretor a nd the choke cable to the choke
le vel' of the ca rbureto r. Connec t the fuel
line and air cleaner tube to the ca rbu retor .
Ma ke s ure the connections are tight.

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 carbure 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 engine 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.

3513

..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
the Main J et Asse mbly:
l. D isconnect th E' soleno id lead wire from the
wire on the i gni t ion switch side of ballast
r es istor.

2. Remove t he assembly from thc carb uretor.

3. Connect the lead wire to the i gni t ion switch
and ground the solenoid assemb ly .
4. Wh en the ig nition key is tu r ned "ON " the

main jet in the shut-otf assemb ly must be

drawn and held against the m ai n jet adjusting screw with a decided "snap" or
('click",
5. When ignition k ey i s turned to "OFF" the
main j et in the shut-all assembly must be
released and forced by spring pr essure a gai nst its seat in th e assembly with a decided
"snap" or Hclick". If action is sluggish in
Nos. 4 and 5 - remov e a nd c lean parts as
described below and r e-check - if still
sluggish, replace comple te assembly.

Disassembly and Cleaning

l. Remove the main jet adjusting screw (1) ,
spring (3) a nd main j et (4 ) f rom the solenoid body (5) . Remove "0" ri ng (2) from
adjusting screw.

2. Clean the main j et adjusting screw a nd jet

by submerging in a solvent such as Bendix
Speed Clene.

assembly by carefully submerging the body

partially (10 not let wire or plastic insul ation contact solvent) into a so lvent such as
B endix Speed Clene - The body need only be
su bmerged enough to fl ush out the inner bor e
and seats.
After clea ning parts - blow dry with compressed air.

CAUTION : Clean the solenoid body of the

Inspection and Assembly

1. Inspect seat on both ends of jl?t - if nicked
or scored - replace jet. Install jet (4 ) in
solenoid body (5).
2. Install spring

(3)

in solenoid

booy

(5) .

3. R eplace "0" rin g (2) on adjusting screw (1)

and install screw in solenoid body.
4. Install main j et assembly in carburetor and
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
is ve ry important to the service life of the

hyd r au lic system. The filter is eas ily acces sIble and is located forward of the radiator.

,'

,c ",
c

CD
CD
Figure 1
1. Rl'move

the radia tor g rille. Thor oughly

clean the filt er hou sing beCOTe attempting
to change the filter e lement.
2. Remove the draIn p lug (5) wit h "0" ri ng (6).
Disca rd the "0 " ring (6) .
3. Remove the fo ur hex. bolts (1 ) from the fil ter
CdP (2).

4. Rem ove the filter cap (2 ), "0" r ing (3 ) and

the filter el"ment (4). Discard the " 0 " r ing
(3 ) .

3. Cl ean out the filte r body (7) with a clea n lint

free c loth .
6. Remove the hex. bolt (8). retainer (9) and
spring (10) _Check the spring for damage a nd
proper tension.
Spring Specifications:
Total Coil s ...... ...... . . ......... .. .... ...... . 6112

'0

,~

Figure 2

Figure 3

Wire Diameter ........ .... ..... .. ....... .. ...... .092"

I. D. Diameter .................................... 813 "
Free LengUl .................... , ........ ... ... ... 2.00"
Compressed to 1.125" .. _..... _.. _... 2733 Ibs .
7. Install the s pring (10), relainer (9 ) and hex .

bol t (8 ) to the filter cap 12).

8. Install the drain p lug (5) with a n w "0"
ri ng (6). Instal! new element (4 ), new "0"
r ing (2) a nd filter cap (21.
9_P ress the ca p dow n into p lace by hand and
secure with the four hex . bolls \ 1).
lO.Start a nd rUn the engine at idle speed for
approx!mate ly 5 minutes and check the fllter
assem bly for oil leakage. Check the trans rrUss ion oil level immedia tel y after sh utting
the e ngi ne down .

423

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
is very important to the service life of the hyd

0-..... j

raulic system, The fi lter is easily acce ssib le

and is located forward or the radiator.

CD

:-0

Q --<D
O -<D

G --<D

O -(f)

0--0
10

@ -o

~
Figure 4
1, Rem ove

the radia tor g ri lle , Thoroughly

clea n the fil te r housing before attem pti ng
to c hange t he filter eleme nt.
2, Loosen the loc k nut ( 1 ) a nd back out the s lot
ted hf'ad s c rew (2 ) four or fiv e t urns ,
:1. Remove the four hex . bolts (3 ) from t he filter
c a p (4 ).
4. Remove the f!itercap (4), upper "0 " ring (5),
retainer (6 ), gasket (7) , filter element (8) a nd
lower "0 " ring (9) . Disca rd the "0" rings
( 5 & 9) and gasket ( 7).
'), Remove the d rai n plug (11) w ith "0" ring
(12) . Discat'd the " 0" r ing (12) ,
,i. Clean o ut the fil ter body (10) with a clean
lint free c loth ,

F igure 5

Figure 6

7, Install the drai n p lug Ill ) with a new "0"

rI ng (12), Install new lower " 0" ring (9),

elem e nt (8), ne ',v gdsket (7), retaille r (6 1 and
up pe r "0 " ri ng (51 .
8, Install the HI le r cap (4 ) witt1 the fou r he x.
bol ts (3) ,
9, TIghten t he slotted head screw (2 ; s nugly ,
Tighten the lock nul (1). locking the screw
(2) in pl ace,
10, Start and run the engine at idle speed for
a p proximate ly 5 minutes and c heck tile filter
aSsembly for oil leakage, Check Ihe trans
mi ssion oil level immediately afte r shutting
the engine down.

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 lemen t is very importa nt to the service liie of
the steering system . The re placeable fllter
clement is located inside the powE'r steering

pump reservoir shell. The reservoir shell

is located on the R.H. side of the engine .iust
be low the a lternator.
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

area before atte mp ting to service the elem e nt.

1l\IPORTANT: Before removing the reservoir shell. mark both the she ll and pump
body to insure proper relocat ion whe n ass",mb ling. This will insure a good seal and
correc t oil level r eading on dips tick.
2. Remove the acorn nut (I) and copper seal ing
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
e lement (8) .
NOTE : On gasolinp tractors it require s removal of the distributor.

4. Check the re taining spring for damage and

proper te nsion.
Spring Spec ifi ca tio ns:
Ac tiveCoils ............... .. ..... . ..... .. .............. 8
Wire Diameter .............. _.. .. ..... ........ .. . 041"
Free Length .................................... 2.383"
Compressed to 1.375" .. .... .. .. .... .. 2.2-2.8 Ibs.

5.1nstall new e lemen t (8), reta ine r (7) , spring

(6) and jam nut (5) . Tighten the ja m nu t until
a m easurem ent of 4-15/1 6 inch is obtai ned
m easuring from the outside of the jam nut
to the she ll fla nge on the pum p. Refer to
Inset A.
6. Install a new "0 " ring ( i ) , reservoir she ll
(3), copper sealing washer 12) a nd acorn nut
(1 ) . Torque the acorn nut 20-25 ft. lbs.

BLEEDING PROC EDURE

1. Remove the rese rvoir cap and di ps tick. Fill
the r eservoir with Case TeB and start the
engine.
2. Operate the e ngine at aprox lm ately 600 RPM
a nd turn the steering whee l throug h several
t urns . NOTE : The fir st few tim es y ou turn
the steering wheel, DO NOT m a ke ful! turns.
3. Shut the e ngine oft and refi ll the reser voir
to the "1-'" ma r k On the dipsti c k.
4. Repeat the above procedure un til the fluid
leve l ceases to drop after turning the steering wheel.

ECTION

42
HYDRAULIC DIAGRAMS
TROU

SHOOTING

ING AND S

Burl. Fonn 9720815 KHCBO

IC

P,inl.d in U . S .A.

TABLE OF CONTENTS
HYDRAULIC D1AGRANIS . .

Loader With 4 - In-l Bucket

Standard Backhoe . . . .

Backhoe With Extendable Dipper.

HYDRAULIC SPECIFICA TIONS.

HYDRAULIC SYSTENI SERVICE.

HYDRA-LEV ELING CIRCUT . .

9
10

HYDRAULIC SYSTEM TROUBLE SHOOTING

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

R.H. CLAM
CYLI N DER

L.H. CLAM
CYLINDER

OIL FROM PUMP TO

LOADER CONTROL VA LV E

DUMP

SUCTION AND RET URN OIL

OIL FROM "A" PORTS TO
CYLINDER

L.H. TILT
CYLINDER

R.H. TILT
CYLINDER
NOT~ PUMP I NLET
MID OUT LET POR TS
REVERSED ON HYDRA-

OIL FROM" B" PORTS TO

CYLINDERS

STATIC MODELS

HYDRAULICS FOR STANDARD

LOADER ARE THE SAME EXCEPT CLAM
HYDRAULICS ARE REMOVED.

NO....

L.H. LIFT
CYLINDER

HYDRA-LEVELING
CYLINDER
701308

Figure 1 - Loader With 4-ln-l Bucket

'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 . RSTRI CTOR / CHECK V~ l VE
}. P.(GE .... ER.:..TIO, CHECK V':" L.VE
{I .

HGEI/ER,.. rI O ~l

5.

P ER BE "'01,0 flTTI 'lG

PUMP SUPPLY AND RE TU RN OIL

sP Ol

OIL FROM lO'.lER ( " 8") PORT S

OF CONTRO L VA LVE S

D IP PER

CY L iW ER

Oil f ROM UPPER (HA il ) PORTS

OF CO':TROL VALVES

BUCKET
CY LI NDER

BOOM CYlI NDERS

SI,.,IIN{;

CYL INDER S

A~ R~E~R~E~V~ER~S~E~o~~~i1

THES E LI lIE S
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

_
-

PUMP SUPPLY ANO RETUR N 0 I L

0 1L FR OM UPPER (A) PORT S OF CON TROL VALVES
0 1L FRCM LG;J ER (B) PORTS OF CONTROL VALVES

PUMP OUTPUT
23 GPM @ 1900 RPM
2000 PS I
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

EXTEj~SIOij

DIPPER
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
CYLiNOER

STAB IL IZ ER

CYLJ rmER

STAB I LI ZER
CO NTROL VA LVE

TO RE SER VOIR

..I

FRO,'1 PUM P

Figure 3 - Hydraulic Diagram of Backhoe Wit h Extendable Dipper

710991

HYDRAULIC SPECIFICATIONS

Descripti on of pump, valves, etc . . . . . . . . .

~l ain relief valve setting (loader / backhoe)

. Refer to sect ions 43 through 49.

22 00 75 psi at full thr ottle
(155 5,2 kg/ cm')
1800 75 psi a t full throttle
(127 5,2 kg/ cm2 )
. . . . . . . . . . . . See page 26.

Main relief valve setting (hitc h)

Secondary reli ef valve settings

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
. . . . . . Engine oil m eeting API des ignation
Alternate oil. . . . . . . . . . . . . .
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

Tube
0.0.

Thread
Size

1 / 4"
5/ 16"
3/8"
1 /2 "

10

5/8"

IZ

3/4"
7/S "
I"
1-1 / 4"
1-1 / 2"

7/ 16" - 20
I / Z" - 20
9 / 16" - 18
3 / 4" - 16
7 / S" - 14
1-1 / 16" - 1 2
1- 3/ 16" - 12
1-:5/ 16" - 12
1-5/0 " - 12
1-7 /8"-1 2

Da sh

Size

:;
6

14
16
20

24

Straight Thread

F em:1l (:: S\vivel

T Ol'que

ft. I bs .

6-I Z
8 -1 6
10- 25
1 3- 42
2 5 - 58
-l 0- 80
60 -1 00
75-1 17
125-1 65
2 10 - 250

U -Hlll g

To rque

m - kg

ft.l b5 .

m-kg

0,8-1,7
1,1-2 .2
1,4-3.5

12 -1 9
16 - 25
23-40
42-67

1. 7-2 ,6
2 . 2-3 ,3
3. 5- 5 . 5

2. 1-5 .8
3 ,5-8,0
5.5-11.0
8 . 3-14 , 0
1 0-1 6

1 7- 23
29 - 35

58- 92
80-1 28
100 - 160
117 - 18 7
165- 26 4
250-400

5,8- 9.2
8.0-1 2,i
I! -I S
14- 22
15-26
23 - 36

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
r efill capacity of 5-1 / 2 U.S. gallons.

NOTE: The hydrauli c oil should be at or

near operating temperatur e when checking the oil level.

Check ing Reservoir Oil Level

1.

Have the trac tor standing on a l evel spot.

2.

Have the backhoe (if so equipped) in the

3.

Remove the oil level plug. The oil s hould

be level with the plug opening . If additional
oil is required, r emove br eat her and reduc er from re s ervoir and add oil through
this opening until the proper oil level is
obtained.

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

plug~

Figure 4
Reservoir Oil Level and Vent Plugs
5.

Start engine and operate the loader and

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.

Hydraulic System Filter

Draining Reservoirs

Have the tractor standing on a level

surface.

."

' -~

HOUSING

-: ~ :--~.'~. RESERVOIR

.. ~,

/'

/:/'

'l -/"

.-

.- I ' .
'

,:.-. '

.,,:;.

If
l

0 - O- ~ I ,'JG
'9

10 FillER

CRAIN

3.

_ E LEMEN T

_ _ O-:\ING

PLUG
&<I ..... ,~O()

"" -

PLAIN

'NASHE!~

\
.. _LOCKIVA SHER
BYPASS
CAPSCREW
RELI EF

Figure 5 - Reservoir Drain Plugs

2.

~
~ _HEAD
~

.'
./

/i

\ PLl:G

CRlI'N

"

:;

I[

J)'

.:-

.,

P
/1 .

Have the backhoe (if so equipped) in the

transport position and the loader bucket
rolled back at ground level.

A-

Figure 6 - Hydraulic System Filter

The filter element must be changed at
every oil change or when filter condition
gauge moves into the red (change) zone.

Remove drain plugs from elbow at bottom of reservoirs. Approximately 5-1/2

U.S. gallons will drain from each reservoir.

The filter is located in the hydraulic

return line, just forward of the loader control valve.

2.

R eplace hydraulic system filter eleme nt.

3.

Reinstall drain plug(s) and fill res erVOll'S

with flushing oil. Use Case TCH Fluid
and di esel fuel mixed half and half for
flushing oil.

4.

Operate the loader and backhoe through

several (3 or 4) complete cycl es. This
will allow most of the Hushing oil to
pass through the filter.

5.

Drain the hydraulic reservoirs. Then

drain the remainder of the hydraulic
system as completely as poss il)le.

6.

Depend ing on the amowlt of contamination, it may be necessary to r e move,

disassembl e , and clean each valve, cylinder, hose e tc. in the s y s t e m . Whether
this should be done is a matter of
judgme nt by the mecrumic.

7.

When replacing filter element, clean

filter head and housing befor e installing
new element.

8.

Fill r e servoirs with new CaseTCH Fluid.

9.

Bleed air from the syste m by cycling'

each cylinder until it runs smoothly.
Considerable oil will be transferred from
the reservoir to the valves, c ylinders,
etc. during this proc e ss. Keep adding
oil. When all the air has been r emoved,
recheck the oil level and add if r equired.

To chang'e the elem ent:

1.

Unscrew the filter housing from filter

head.

2.

Remove the elem e nt and discard. Then

r e move o-ring from filt e r housing and
discard.

3.

Position element on filter head.

4.

Install o-ring' on filter housing and lubricate o-ring and housing thr eads. Screw
housing into filte r head and tighten secur e ly. Do not exc e ed 90 foot-pounds
torque.

Cleani ng Hydraulic S y stem

If one component in the hydraulic system

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 contamination of the hydraulic oil caused the failure
or entered the system as a result of the
failur e .
P roper cleaning of the hydraulic system
requires considerable time--whethe r to undertake the task is a matter of good judgment
on the part of the mechanic.
Cleaning Procedure

1.

Drain the hydraulic reservoir(s). Then

drain the remainder of the hydraul ic
system as completely as possible.

10. Reinstall breather on reservoir.

HYDRA-LEVELING CIRCUIT

The Hydra-Leveling circuit keeps the

bucket level as the load is lifted from the
ground to dump height \Vithout attention from
the operator.

the tilt cylinders. This displacement causes

the bucket to roll forward as the arms are
rais ed.
As the lift arms are lowered, the rod
is pushed back into the Hydra- Leveling cylinder. This forc es oil from the bottom of
the Hydra-Leveling cylinder into the rear
of the tilt cylinde rs. This displacement causes
the bucket to roll back gradually as the arms
are lowered.

This is accomplished by mechanically

causing oil to be transferred between the
Hydra-Leveling cylinder and the two tilt
cylinders.
As the lift arms are raised, the piston
rod is pulled out of the Hydra -Leveling
cy lind er. This force s oil from the top of the
Hydra -Leveling' cylinder into the front of

Hydra- Level ing act ion may be overridden

at any time by actuating the tilt cyl inder spool
of the loader control val ve.

OIL DISPLAcm 8Y HYDRAltvELING CYU hiDER

OIL DISPL ACED BY

TILT CYU ND.fRS

HDnI

COLO RS kEVERSED

WHEN LOWERI NG 8UCKET.

701309

Figure 7 - Hydra-Leveling' Circuit

HYDRAULIC SY STE M TROUBLE SHOOTING

Problem: Poor Or No Operallon
01 One Circuli Only

e.

repeat the test for the other cylinder.

If only a single circuit is performing

poorly, the problem is in that circuit--worn
cylinder packing, faulty secondary relief
val ves or worn val ve spool.

1.

CAUTION: P erform this check ca re-

fully. Move control l ever so that the

open line is al ways on the RETU RN
side. Build engine speed gradually;
a badly worn cylinder wil l allow a
consider a ble amowlt of oil to leak
past a t maximum system pres s ure.

Check cylinder packing:

a.

b.

If the Cil'CUit contains two cylinder s ,

Run the cylind e r to the end of its

stroke. Shut off the engine. Provide
support for the equipment if raised.

2,

If cylinder leak age was found, remove

and rebuild the cylinder, Then, if pos -

sible, operate the circuit under working

conditions to see if the problem has
been solved. If the c ircuit still is not
sa ti s factory, there is additional l eakage
in the control valve.

Disconnect the hos e 01' tube on the

RETURN' side at the cylinder.

If there are no s econdary r elief

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

NOTE:

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, remove 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'equired. 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.

d.

Start the engine and run at hal f

speed. Continue control lever movement in sam e di rection to force
oil over the main relief \'al ve and
build system pressure to maximum.

the attachinent must be r es ting on the

ground or supported.

Increase eng ine speed gradually

while holding control leve l' in pow er
position. Check for leakage through
the open I ine ; there s hould be no
leakage. Any leakage indicates worn
cylinder packing. Slight leakage is
pe rmis s ible .

10

5,

One final c heck is advi sable before

removing the control val ve. rremove any
secondary reli ef valve in the circ uit
which was not removed previou s ly. Check
the external o-ring a t the poppet end of
the cartridge--replac e if damaged . Reinstall the relief valve a nd op erate the
mac hine.

6.

If thi s did not solve the problem. ex-

8.

cessive spool leakage is almost certain.

Remove the control valve and replace the
spool, valve, 01' valve section as required.
Problem: Poor Or No
Operation Of ~ Circuits

Make a field check for oil contamination.

RW1 engine, then draw oil sample from
the top of the r ese rvoir . Compa re the
drained oil with new oil-look for the
following Signs:
a.

Feel the oil with your fingers. If

the oil is gritty 01' contains particles
large enough to be felt, the oil must
be replaced. Probably the pump or
a valve or cylinder has been severely
damaged. In addition, the foreign
matter m ay have damaged other
parts in the system. The system
shoul d be tested with a flowmeter
after changing the oil to determin e
the l ocation and extent ofthe damage.

b.

Milky color, a sign of water in the oil.

c.

Foam, a Sign tha t a ir is entering

the system.

d.

Scorched smell or da rkening or

thickening, signs of s ever e overheating.

If all the cil'cuits are performing W1satisfactorily, a worn pump is the most probable cause. However, the pump never should
be removed for repairs or replacement W1til
obvious system faults have been corrected
and a flowmeter test has been rW1. Make the
following checks:

1.

Check hydr aulic oil level. Fill to proper

level with Case TCH Fluid.

2.

Check filter gauge and service the filter

element if required.

3.

Clean the reservoir bl'eather(s).

4.

Check the suction line to the pump for a

loose or damaged connection that could
cause a ir leakage. Tighten or rep a ir.

Q.

6.

Install a pressul'e gauge in the loader

control valve, page 27. Check the setting
of the main relief valve. Adjust if r equir ed.

9.

the oil, drain, flu s h, and clean the system

a s outlined on page 8. Reflll with new
Case TCH Fluid. Replace the filter
el ement.

If corrections made to this point did not

solve the problem, pe rform the Equipment Hydraulics-Engine Stall Test outlined on page 11. Titis test will determine
if a ll or part of the problem is in the
engine. A faulty engine will lug down
excessively when equipment is operated
near the rei ief val ve setting and cause a
corresponding loss of oil volume from the
pump. If the engine is fOW1d to be at
fault, refer to the engine and fuel systems
sections (Series 20 and 30) of this manual
as required.
7.

Determine, if possible, the number of

operating hours since the last hydraulic
oil change. Also de termine, if possible,
whether the proper oil wa s installed
(non-foaming type of correct viscosity
such as Case TCH Fluid or approved
substitute, page 6). If the oil bas not been
changed within 500 hours or if an incorrect oil was installed, drain and refill
the reservoir with Case TCH Fluid.

If any of the above signs are found in

10. If the problem still has not been cor-

rected, check the pump and other system

components as required with a flowmeter.
Hook up the flowmet e r as shown in Figure
11. Start by t esting pump output and
continue W1til the trouble is fOW1d.
Problem: Sluggish Operation
In All Backhoe Circuits;
Loader Clre .... i'S Ok

Check the condition of the internal o-ring

On the power beyond fitting at the loade r
and stabilizer control valves outlet.
Equipment Hydraulics Engine Stall Test

1.

In this test, rpm lmder load s hould be:

a.

11

1900 rpm - Dry clutch model.

b.

2100 rpm - Torque converter or

If engine speed is below s pecified rpm, it

indicates either engine wear or excessive
pressure in the hydraulic system. Check the
main relief valve pressu,'e setting. If faulty,
repair or adjust. Repeat the stal l test described above. If engine speed 1.s s till low,
the engine is likely at fault.

hydrostatic model.
2.

Place bucket on ground. Run the engine

at full throttle.

3.

Tilt the bucket back and hold lever in

power position to open the main ,'eli ef
valve.

If engine speed is above specified rpm,

the equipment hydra ulic system is ineffic ient,
indicating leakage, pump wear, or a low
m a in relief valve pressure setting. Continue t esting the hydraulic sy st em with a
flowmete r.

Test Summary

Engine speed when the oil is going ove,'

the main relief valve should be approxim at ely the specified rpm.

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

Poor or ,,"0 Operation

of ALL Circuits

1.

Worn pump is probable but

1.
other possible causes include
low oil level, use of improper oil, loose fitting in suction line to pump, and
contaminated oil.

Refe r to pag"e 11 and check

out the hydraul ic syste m us
outlined. Correc t any defect
before prooeeding with
o hecks. Conclude with a flowmeter te st if checks and
correction do not sol ve the
problem.

Poor no No Operation
of ONE Circuit Only

1.

Worn cylinder packing,

worn valve spool, or low
secondary relief valve setting (if in circuit) can cause
this problem.

1.

Refer to page 10 and check th e

circuit a s described. Clean,
repair, or r eplac e the item
found to be defective.

Poor or No Operation
of ALL Backhoe or
Hitch Circuits;
Loade r OK

1.

Defective O-ring on power

beyond fitting in loader or
stabilizer control valve
outlet.
De fective qui ck disconnect
f itting.

1.

Disconnect the hose fr om the

power beyond fitting. Remove
fitting and r e pluce o-ring, if
damaged .
Uncouple and in spect both
quiok d isconnects . Repair or
replace if r equired.
Remove buckhoe valve. Disassemble inlet and outlet
sections . Cl ean and replace
pa r ts as r equired. Check
spring te nsion.
Inspec t inlet s ection for
cracks. Replac e if a crack is
found.
Remove valve. Disassemble
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.
Di s assemble the val ve s ections 'Uld clean thoroughly.

2.

Control Moved To
Power Position-Cylinder Moves In
Wrong Direction

REMEDY

2.

3.

Dirty or defective part in

regeneration mechanism in
backhoe valve.

3.

4.

Inl e t section in backhoe or

hitch val ve cracked.

4.

5.

Hitch valve only: Dirty or

worn parts in inlet section.

5.

6.

Hitch valve only: Orifice

plate or orifice pa ssage
through val ve sections closed
by dirt.

6.

1.

Hoses cr ossed.

1.

13

Refer to hyd raul ic diagl'um in

this man.lal , Disc onnect hoses
and reconnect as shown,

SY MPTO"I

POSSIBLE CAUSE

Control Lever
F ea ther ed- - Cyl inde r
Move s Sl ightly In
Opposite Dire ction

1.

Chec k poppet in control

va l ve worn or held off
sea t by dirt .

l.

Refer to control vnl ve s ec tion

of this ma nual and d ete rmine
location of p oppet. Lowe r
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
With Control Lever
In Nelltrnl, Engin e

l.

Faul t in spool cap prevents

spo ol f1'onl returning to true
ne lltrnl.

l.

2.

Spool binds .

2.

Lower a ttac hment to growld.

Re move spool cap. Inspect
cente ring sp ring; a nd parts for
cor r ec t as se mbly. If r e qll ir ed
remove spool and c ap for
repa irs .
See Spool Binds , page 17.

l.

Worn piston packing.

1.

2.

Spool o r relief valve

2.

REMEDY

Running

Cylinder Drifts,
Cont rol Lever
In Neutral, Engine
Off

l eakag'e.

Boom Swings
Normally--Stops
With Jarring Impact

Boom Raises
Normally To Full
Heig"ht--Stops With
Jar r ing Impact

l.

Crossover (low pressure)

r elief val ve(s) in swing
sect ion s et too high.

1.

2.

Re strictor(s) at closed end

of s wing cylinders missing"
o r improperly installed.

2.

3.

Defec tive swing cushion

r elief valv e , spring , o r
r estr ictor pin in swing
cylinder.

3.

l.

Hes t r ictor pin or s pring

in \lOom cy linde r piston is
missing or damaged.

1.

14

Check c yl i nde r pack ing as

outlined ill step 2, Problem:
Poor Opera tion of One Ci rcuit Onl y, p age 10. Rebuild
cylinder if d efective.
Continue w it h circui t c hecks
outlined tmde r Problem: POOl'
Op e ration of One Circuit Only.
Test and adjus t settin g of
crossover rel ie f val ves . Se e
pa ge 28. If t he rel ief val ve
oarmot be ad justed, r emove
and clea n o r repl ace parts .
Disconnect hose at c l osed end
of swing cylind e r. Inspect
restricto r- - smal l e nd goes
into cylinde r fi rst .
Remove reli ef va lve from
swing cylinde r being retracted
when jarring impact occuned .
Add shims and clea n the relie f
valve . If this does not solve
proi)l e m. r e nlove and disa ssemble 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.
Remove cyllnder a nd disassemble . Install restrictor pin
if missing or repl a c 0 with new
part if dama g"ed.

SYi\IPTOM

POSSIBLE CAUSE

Boom Drop s
Too Fast

1.

Restrictor in lower port of

boom section in control
val ve is missing or improperly installed.

lo

Lower bucket to ground . Disconnect hose at lower port of

boom section . Install rest r ictor correctly - -the big end
goes in the val ve port first.

Boom S\vings

1.

Crossover (low pl'essuI'e)

relief valve in swing section
of control valve set too low
or held open by dirt.

l.

2,

Spool not returning to

neutl'al.

2,

T est and adjust setting of

crossover rel ief valves . See
page 28, If the relief valve
cannot be adjusted , remove
a nd clean 01' r epair .
See Cylinder Creeps With
Control L ever In Ke utral,

Normal l y--Coasts
When Controls Are
Re turned To
Ke utral

RENIEDY

Engin e Hunning on page 14.

Control Lever
Hard To Operate

lo
2

Loader Control Lever

Moved To Float, Will
Kot Stay In
De te nt

1.

Boom Lockout
Does Not Operate
Properly

1.
2,

3,

Hydra-Guide Does
Not Operate Properly
Hydra ulic Extendable
Dipper Does Not
Operate Properly
l. Slow

Linkage or control lever

r equires lubrication.
Spool binds.

3.

Dippel' Does
Not Maintain
POSition
Binding

2,

\VOl'll 01' missing parts in

detent housing in lift spool
portion of loadet' control
val ve.

1.

Hoses connected to wrong

ports.
Poppet in lockout val ve
worn or held off seat
by dirt.

lo

Relief va.! ve in lockout

circuit is set too low or
or held off sea t by dirt.

L ubricate as r equir ed. Backho e levers ha ve grease fittings

See Spool Binds , pag'e 17 .
Remove detent housing for
inspection. Replace WOI'Il or
missing parts.

2.

3.

Refer to hydraul ic diagram in

this manua.!, Sw itc h hoses.
Remove lockout va.! ve for
inspection. Dis assembl e valve
--cl ean or r eplace parts as
required.
Remove r e li ef val ve. Check
setting with luUlcl pun'lp , page
26. Adjust to speCificati ons .
The valve also may be disassembled for cleaning.

See Section 47.

l a o Diverter val ve linkage

out of adjustment.

l b , Wear or damage to di verter

val ve hous ing or spool.
2.

lo

l c . Worn cylinder.
2
See possible caus es Ib and
lc under "Slow" (above).

:3.

lI'1 ec hanical bind.

lao Check linkage--make sure

spool can be pOSitioned properly. Adj us t linkage as
required ,
lb. Remove diverter valve. Clean,
repair , or replace parts as
requ ired,
l c. Remove and rebuild cylinder,

3.

15

In spect dipper for bind.

SYMPTOM

POSSIBLE CAUSE

REMEDY

Problem: Failure Or Poor Operation 01 Major Co mponent

Pump is Noisy

1.
2.

3.

Loose mounting bolts .

Loose [lump ti e bolts.

1.
2.

\Vorn or durrluged bearings

3.

Tighten.
Check bolts wit h 11 torque
wr e nc h. Tig"hte n to spec ifica tion s .
Remove and rebui l d pump.

or gea rs.
Flowmeter Tes t
Shows That Pump
Output Is Low

External Oil
Leak age

1.

Wo r n or damaged pump.
(Al s o see Pump Damag'e
below.)

I.

2.

Us e of improper oil.

1.

Worn se,ll or pump sha.ft .

1.

2.

Drai n passage t o suc tion

side of pump plugged.
P ump tie bolt s loose.

2.

3.

Pump Dam age:

1.
We ar Plates
Sco red
2.

3.

4.
5.

6.

7.

Heavy Wear
Or Scoring
At Inlet
Gea rs, Sha fts
And Bea rings
Corrod ed,
Pitted, Etc.
Drive Shaft
B r oken
Gear (s)
Damaged

Disc olored
Shaft At
B earing
Sul'face 01'
Sides of
Ge ars
Gear Housing
Cracked

3.

Remove pump fr om tractor .

Replace or d isassemble and
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 .
Use Case TCH Fluid.
Re move [lump and r epl ac e
seal. Check s haft at sealing
s urface for damage.
Disas semble pump and c lean
the pa ssage .
Check bolts with a to r que
wrench. Tighten to specifications .
Dis asse mbl e pump and repl ace
s eal s.

4.

Pump hou sing seal s

damaged.

4.

1.

Contaminated Oi l.

1.

2.

Contamin a t ed oil.

2.

Rebuild pump . D rain, flus h,

and refill sys te m with Case
TCH Fluid. Se r vice t he filter.
Same as 1.

3.

Contaminated or improper
oil .

3.

Same as 1.

4.

Da m aged or mi s aligned
coup ling.
Contaminated oil, misal igned coupling, high ma in
r e I lei va l ve setting, d a maged
shaft bea r ing.
Ve ry low oil leve l or
contaminated or
improper oil.

4.

Rebuild p ump. Rep lac e coupling.

Replace both g ears. CheCk
bea rings . F ill syste m with
Case TCH Fluid. Check and
adjust relief val ve setting.
Bring oil up to prop e r level
or drain, flush and r efill
sy stem with Case TCH Fluid.
Se r vice the filter .

High m ain r eI ief val ve

pr es sure setting.

7.

5.

6.

7.

16

5.

6.

Rep lac e housing or pump .

Chec k and adj us t main reI ief
valve.

SYMPTOM

Pa:;SIBLE CAU SE

Valve Spool
Binds--Lever
Hard To
Operate

l.

Excessive
Cyl inder
Bushing Wear

Excessive
Cylinder
Packing Wear

Bent Piston
Rod

REMEDY

Tie nxl torque too high

(sectional valves).

1.

2.

Valve distorted .

2.

;J .
4.

Cap full of oU.

Sludge in val ve.

3.
4.

5.

BWT on spool.

5.

6.

Scored spool bore.

6.

7.

Bent spool.

7.

1.

Failure to lubricate fittings

as specified.

l.

2.

Excessive relief valve

pressure settings.

2.

1.

Contaminated oil.

l.

2.

Excessive relief val ve

pres sure settings.

2.

l.

Failure to lubricate
cylinder pivot pins.

l.

2.

Bent dipper arm or other

misal ignment in loader or
backhoe .
Excessive relief valve
pressure settings.

2.

3.

Check tie rods with torque

Tighten to
specifications.
Shim between val ve and
nlolUlting plate .
Replace spool seal at cap end.
Remove valve and clean
thoroughly.
Remove burr with crocus
cloth.
Replace val ve (loader val vel
or val ve section (sectional
valves).
Replac e spool (loader val vel
or val ve section (sectional
type valves).
WI' enc h.

3.

Lubr icate fittings daily or

more often if operating in
severe conditions.
Check a nd adjust main relief
val ve and secondary relief
val ve(s) if in circuit.
Drain, flush, and refill system
with Case TCH Fluid. Service
the filter.
Check and adjust main reli ef
val ve and secondary relief
val ve (s) if in circuit.
Lubricate fittings daUy or
mOY'e ofte n if operating in
severe conditions .
Make inspection for misalignment. Replace parts as
requi red.
Check and adjust main relief
val ve and secondary relief
valve(s) if in circuit.

Outer Hose
Cover Separated
From Wire
Braid

l.

Hose twisted.

l.

Install hose properly--the

hose must not be hvisted whe n
fittings are tightened. TUTn
swivel fitting only.

Fitting Pulled
From End Of
Hose 01' Burst
Hose

l.

Hose hvisted.
Torque applied to hose
instead of fitting.
Loader dropped at fast
r ate, then suddenly stopped
by returning control
lever to neutral.

1.
2.

Same as Remedy 1 above.

Turn sw i vel fitting onl y.

3.

Follow correct operating

procedures.

2.
3.

17

SYMPTOM

POSSIB LE CAU SE

REMEDY

Fitting Pulled
From End Of
Hose Or Bur s t
Hose (Cont.)

4.

F a ulty secondary relief

valve .

4.

Da maged Thr eads

On Hose Or Tube
Fitting'

1.

Ove r torqued.

1.

Check and 8,djust relief valves

to specifications.

Torque to specifica t ions

See page 6.

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

crawlers. 0-250 tempera ture gauge; 0-3000 .
psi pressure gauge, No. M20271, Figure 9.

Description o' Tests

The fl ow meter s imulat es the load con ditions identical to those met during operation
of the tractor and meaSll r cs the temperature,
volume, and preS SU1'e of the oil passing
through the flow meter.

60 GPM Flowmeter
Handles ail but the largest Case machines, 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 operating 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
t he sUe!ion line.

b.

Not being delivered to the cylinders

because it is leak ing back to the
reservoil' by passageways that are
supposedly closed, namely, valve

Figure 9 - 30 gpm and 60 gllm Flowmeter

100 GPM Flowmeter

Capable of testing ali Case machines.
0-250 temperature ga uge ; 0-3000 psi pressure gauge. No. M20512. Figure 10.

leakage.

19

c.

In this hookup. there is no

r elief valve in the circuit. Ther efore ,
make certa in the flowmeter load val ve is
open before sta rtinp; the test. When t e sting, close the flowm eter load valve
gradually . Limit the test tim e a thigh
pressur e s to 30 seconds . Do not exceed
the tractor's main reli ef valve setting
(2200 psi) WIder any circumstanc e .

Not being' used by the c yl inde r beca use it is leaking past the cylinder
piston packing and returning' to the
reservoir.

CAUTION :

Hooking Up T he Flo_meier
Befor e installing the flowmeter, perform
the suggested checks described under P 1'0bl em: Poor Or No C1Je ration Of All Circuits,
page 11.

Interp r eting Test Results

Refer to Figure 11.

1.

Lower the lo ader and rear H.ttachment

to the ground.

2.

Disconnect the high pressu re 1ine on the

right hand side of the trac tor. Connect
the flowmeter hose to the tube as shown.

1.

In the ft'e e flow test, the readings wer e

tak en with the lo ael val VC' opeo --t\o restriction was applied to the oil. Even a
baclly worn pump will usually ha.ve near
capacity output at fr e e flow. How e ver,
if the fr ee flow reading is I ess than
90% of specifications, a restric tion or
a il' leak caused by a loos e fitti ng in the
suction l in e is fl strong poss ibility.

2.

The a mount of gllm dropoff at incr easingly higher pressur es i ndic ates the
amount of pwnp weal'. Although pump
r epai r or repl ac ement is a m atter of
judgment, a gllm reading of about 80%
of the pump's rated capac ity indic ates
the pump is still efficient enough to use.

NOT..,
Have a contamer under the
disconnected line to catch oil .

3.

Connect the flowmeter r eturn hos e at

the r eservo ir as shown.
If the return hose is inserted
into the rese r voil' op ening , it must be
t ied securely or held down during the
tests.
NOT..,

T esl No. 2 - Main Relie' Valve

4.

5.

Turn the flowmetel' load val ve to completely OPE N. Set the volume control to
handle 30 gllm.

Refe r to Figur e 12.

St a rt the engine and heat the oil by

closing the load valve un til the pr e ssure
is a bout 1000 psi. Rllll the engin e under
this load until the flow m etel' te mper ature
gauge r ecords 120" I'. Open the load va l ve.

1.

Shut off engine . Re move plug from tee.

Connect tee a s shown. Thi s hookup will
be used for all remaining tests .

2.

Make sure tire load valve is fully open .

3.

Run engine at specified rpm.

4.

Completely roll back the bucket and

gradually close the flowmeter load val ve
with the control level' held in power
pOSition. Watch the flowmeter flow gauge .
When the g(lllonage start s to drop, the
"cracking point" for the main r elief
val ve has been reached. Record this
reading. Continue to c lose the loael valve .
When gallonage drop s to 7.ero. read the
pressur e gauge again. Thi s is the setting
of the m a in reli ef valv e . Record thi s
r eading on the check sheet.

Tesl No. 1 - Pump OulpUI

1.

With the engine running at 1900 rpm,

take the gllm r e ading with the load val ve
wide open.

2.

\V i th the engine running; at the specifiecl

sp eed, graduall y apply a loa d with the

lo ad valve. Take readings at
850. 1000, a nd 1600 psi. Eng ine speed may
drop at high test pressures. Make corrections as required to m ai nta in the spec ified
speeds.
flo\\~neter

20

TEST NO. 1 - FfTTINGS AND HOSES REQUftED

HE!".

CASE NO.

1.

A21574
220-226

2.
3.
4.
5.
6.

7.

218-779
D39149
220-206
221-1604

FLOWM ETER
KIT NO .

NO.
REQ ' D.

DESCRIPTION
3/4" I. D. (-12) bulk hose
3/4" - 14 male pipe fitting
1-5/16" - 12 J.I.C. swivel tee
1-5/ 16" - 12 J. I. C. plug
1-5/ 16" - 12 J.I.C. swil'el tee
1-1 / 16" - 12 J. I. C. swivel fitting
1" to 3/4" pipe re duce r bush ing

T42
T63
T74

'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

2
2*
1
1
1
1
1*

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

FLOWMETER
REF.

CASE NO.

l.
2.
3.
4.
5.
6.

A21 574
220-226

KIT NO .

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

3/ 4" - 14 male pipe fitting
1-5/ 16" - 12 J.I.C. swivel tee
1-5/16" - 12 J. I.e. swivel tee
1-1/16 " - 12 J.I.C. swive l fitting
1" to 3/ 4" pipe reducer bushing

T42
D39149
220-206
221-1604

NO .
REQ 'D .

DESC RIPTION

T74

' 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

3'
1
1
1
1*

Interpreting Test Results

1.

2.

2.

The "cracking point" of a relief valve

in satisfactory condition will be within
10% of its setting at full flow. Make any
adjustments necessary before continu ing
the tests.

NOTE:
Check the boom down circuit
under 850 psi system pressure .

3.

If the relief valve is adjusted, repeat

T est No.2.

Test No.
1.

Loader C irculis

Partially close the flowmeter load valve

to develop 1600 psi system pressur e and
swing the boom against the stops in both
directions. Record the gp m readings .

Test the tilt circuit.

Interpreting Test Results

a.

1.

The gpm readings for e ach cylinde r

should compare closely with the pump
output dete rmined in Test No. 1.

2.

If ALL cylinder circuit readings al'e

b.
2.

a -

Fully extend and retract individually the

boom, crowd, bucket and stabilizer cylinders. Record the gpm re ad ing at the
end of their strokes,

With engine running a t specified

speed, close load valve until 1600
psi is reached on flowmeter pressure
gauge. Dump the bucket and hold
l e ver in pow er pos ition--take gpm
reading.

below the pr e viously recorded gpm, it

indic ates that oil is leaking at som e
point in the system before it r eac hes
the backhoe control valve . The most
I ikely spot is the pow e r beyond fitting.

Completely roll back the bucket and

take the gpm reading at 1600 ps i.

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
stabilizer cont rol valve outlet,

b,

Check the main reli ef valve pa rts

and seals for damage or dirt.

Interpreting Test Results

1.

2.

3.

The recorded S'j"lm rcadings for each

cylinder tested at 1600 psi should compare closely with the pr e viously recorded
pump gpm at 1600 psi.

3.

If the gpm readings for ONE pair of

cylinders ar e below pump gpm r eadings
in both the extended and retracted positions, it indicates leakage past the
cylinder packing in e ither or both of
the cylinde rs. If the S'j"lm r eading is low
in just one pOSition , spool leakage is
probable.

NOTE: If the S'j"lm r eadings for the swing

cylinders a re low, check and adjust the
crossover relief valves crest No.5) to the
high end of the range. Repeat Test No.
4 for swing cylinders. If readings are
still low, cylinder l eakage is indicated.

If ALL cylinder gpm readings ar e low,

it indi cates tha t oil is leaking before

it r eac hes the cylinders. Check the m ain
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.

If the g'j"lm r eadings for ONE pair of

cylinde rs ar e below pump g'j"lm readings
in both the extended and r etrac ted positions, packing leakage is p r obabl e in
either or both the cylind e rs. If the S'j"lm
reading is low in just on e position, spool
l eakage is the probabl e cause.

With engine running at specified speed,

close the load valve until 1600 pSi is
reached on the flowm eter pressure gauge.

Swing Crossover Relief Valve

1.

23

With the

engine

running at 800 rpm

swing boom to
stops.
2.

3.

Boom Down Relief Valve

right or left until it

Hold swing pedal down with the tester

load valve closed. Read the gauge. It
should read 1600 to 1900 pSi. Sw inging
boom to right tests the relief valve at
port "8" (nearest spool cap).
To test the opposite secondary reli ef
val ve, sw ing boom in opposite direction.

24

1.

This relief valve is located in the top

("A") port of the boom section of the
control valve. Extend bucket, clipper,
ancl boom to gl'ouncl level.

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 ,
re acl the gauge. It s hould read 900 -1250
psi.

Flo_meter Check Sheet

DATE ________________________

OWNER _ _ _ _ _ _ _ _ _ _ _ _ _ __

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'-----_________
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

Tilt

1600

Lift

1600

Clam

1600

TEST NO. 4

TEST PSI

Bucket

1600

Dipper

1600

Dipper Ext.

1600

GPM EXTENDED

GPiVI RETRACTED

GPlVI EXTENDED

GPM RETRACTED

Boom raise 1600

Boom down
Swing

850
1600

R.H. Stablltzer

1600

L. H. Stablltzer

1600

TEST NO. 5

Swing right at ________ psi

Boom down ______________ psl

25

Swing left at _ _ _ _ _ _ _ psi

psi

TESTING AND ADJUSTING RELIEF VALVE PRESSURE SETTINGS

Specifications
The Hand Pump column shows the approximate r ange within whic h eac h reI ief va lve
should crack or bypass with the hand pump

actuated. The Full Flow column shows the

pressure range within which the reI ief val ve
should bypass during' normal operation.

BACKHOE VALVE

j:.=~==~L-L~ 1\:'J "

PUMP "_LIEF

VALVE:

~ElIH

BOOM
LOCKOUT

VALVE

71()990

Fig'ure 13 - Location of Relief Valves

REF.

1.
2.
3.
4.

5.
6.
7.
8.
9.
10.

NO'"

HAND PUMP
750
2100
1400
1550
2000

to
to
to
to
to

1050
2500
1700
1750
2400

FULL FLOW
psi
psi
psi
psi
psi

1000 + 250,-100 psi @ 10 gpm

2750 -'- 250,-100 psi @ 10 gpm
1750 150 psi @ 10 gpm
2050 100 psi @ 10 gpm
2500100 psi @10 gpm
2200 75 psi @ full throttle
2200 100 psi @ full throttle

1800 to 2000 psi

2900 to 3300 psi

1800 75 psi @ full th.rottle

2900 to 3300 psi @ 1. 5 gpm

Settings with warm oil, approx. 120 F.

26

TEST PROCEDURE
Page 28
Page 33
P age 28 or 33
P age 29 or 33
P age 29 or 33
Page 27
Page 28
Page 33
Page 27
Pa<>e
30
'?

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

psi at full throttle with the oil warm (about
120' F.). The valve is located at the inlet
to the loader control valve .

The main relief valve is set at 1800 75

psi at full throttl e with the oil warm (about
120 F.). The valve is located in the inlet
section of the three point hitch control valve.
1.

Install

0-3000 psi pre ssure gauge .

If the unit is equipp ed with a loader,

remove the 1/4" pipe plug from the

loader control valve and install pressure gauge as shown in Figure 14.
b.

If the
move
vah'e,
gauge

unit is a drawbar mod el, r ethe plug at the pump relief

Figure 16. Install pressul'e
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
completely.

Figure 15 - Relief Valve Loc ation

2.

4.

Hold lever in the dump position. The pressure gauge should read 2200 75 psi.

5.

If adjustment is required, remove acorn

nut on relief valve and loosen jam nut.

With the engine rlUtning at full throttle,

hold the pitch control lever in the pitch
forward pos iti on and r ead p ressure
gauge.
If oil is cold, operate a cylinder
over relief until the oil is at 1200 F.
(re servoir warm to touch).

NOTE:

To Increase pr essure, turn tile adjusting screw clockwise.

3.

If tile setting is not as specified, adjust

the main relief valve.

b.
6.

To decrease pressure, turn the adjusting" screw cOlU\terclockwise.

Wilen tile pressure gauge indicates tile

specified pressure, tigllten jam nut and
r e install the acorn nut.
27

a.

Remove the acorn nut and loosen the

jam nut .

b.

Turn the adjustulg screw clockwise

to raise the pressure setting or

,?

counterclockwise to lower the pressu re setting.

c.

When the relief valve is properly

adjusted, tighten jam nut.

SI,i

"/l
l"<:)

Pump Relief Valve

(Non-Loader Models Only)

TO FIL TER_&l
,I

The relief valve is set at 2200 100

psi at full throttle with oil of 120 F.
0

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.

3.

Start engine. If the oil is cold, allow

the engine to operate until the oil is
warmed to 120 F. (pump supply line
warm to touch).
0

4.

With engine at full thr ottle read the

pressure gauge.

5.

If the setting is not as specified, adjust

the relief valve:

a.

Remove acorn nut and loosen the

jam nut.

b.

Turn the adjusting scr ew into the

val ve to raise the setting; turn the
adjusting scre,,, out of the valve to
lower the setting.

c.

Recheck pressure. When correct,

tighten the jam nut and reinstall
acorn nut.

Testing Lo_ f"ressure Secondary Valves

Secondary relief valves with a setting
LOWER than the main relief valve can be
tested with a pressure gauge installed in the
inlet to the loader conll'ol valve. The valves
which can be tested in this manner include:
a.

Backhoe boom (at port "A"),

b.

Backhoe
ports).

swing

crossover

(both

3.

Lower stabilizers to normal diggingposition.

4.

Fully extend the bucket and dipper arm .

Lower the boom until the bucket touches
ground directly behind the tractor at
maximum reach.

5,

Run the engine at 800 rpm and apply

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
properly adjusted .
1.

fnstall a pressur e gauge as shown in

Figure 14.

2.

Lower the loader bucket to gTound level.

Swing Crossover Relief Valves

These two relief valves a re identified as
item 3, Figure 13.
1.

28

install a 3000 psi gauge as shown in

Figur e 14.

2.

Swing crossover valves are tested in

the port OPPOSITE the side on which
the valve Is located. Run the engine at
800 rpm when testing.

b.

3.
a.

To test the valve at the top ("A")

port, swing the boom all the way
to the left.

To test the valve at the lower ("B")

port, swing the boom all the way to
the right.

Hold the foot pedal down until a steady

gauge reading is obtained. The pressure
should read 1600 to 1900 psi. Adjust the
val ve(s) if necess ary, see page 34.

Tesllng Loader Tilt Spool Relle' Valve.

1.

2.

To check the secondary relief valve

nearest the spool cap (at port "B"):

To check the secondary relief valve

nearest the eye of the spool (at port
itA"):

a.

Install service tee 026337 in the

line from the tilt cylinders to port
"B" in the control valve. See Figure
17.

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.

a.

Install service tee 026337 in the

line from the tilt cylinders to port
"A" in the control valve. See Figure
18,

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
bucket.

d.

With the engine running at 800 rpm

under hydraulic load, raise the loader and read the gauge as it ascends.
If the reading is not between 2400
and 2600 pS i , the secondary relief
val ve should be adjusted.

Figure 17 - Checking Rollback Relief Valve

d.

With the engine running at 800 rpm

under hydraulic load, lower the loader and read the gauge as it descends.
If the reading is not between 1950
and 2150 pSi, the secondary relief
valve should be adjusted.

29

Testi ng And AdJusting B oom L ockout Relle' Valve

Refer to Figure 19.

a.

Loosen the locking screw.

1.

b.

Turn the adjusting scr ew into the

valve to increas e pressure; turn
the adjusting screw out of the valve
to decr eas e pressur e .

c.

Recheck setting. If c or rect, tighten

the locking screw.

If the oil is cold, start the engine and

hold a control 1ever In full power position until the oil is 120' F. (reservoir

warm to touch).
2.

Lower the backhoe bucket to the ground.

With the engine shut off, move the boom
control lever in both directions to
equalize pr e ssur e .

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.

7.

Re install relie f val ve.

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

r e lief valve and adjust as follows:

Figure 19 - Boom L ockout Relief Valve

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
te s ting unit. The hose and fittings- are availa ble through the Case Reu sable Fittings and
Flexible Hose Line s Program. Refer to Parts
Catalog Bl 044.

The pressure settings of all relief valves

excepting main reJlef valves can be checked
with the hand pump outfit shown in Figure 20
and the adapt e rs in Figures 21 and 22.

710912

Figure 20 - Hand Pump Assembly

Hand Pump A ssembly - F ittings And Hoses

REF.

CASE NO.

I.
2.
3.
4.
5.
6.
7.
8.
9.
10.

];120276
220-204
A21572
220-224
D23911
221-88
221-130

II.

220-203
Dl2806
A22789
331-55

DESCRIPTION
Hand pump assembly . . . . . . . . . . . . . . . . . . . . .
7/ 8" - 14 JIC s wivel fitting . . . . . . . . . . . . . . . .
1/2 " ill bulk hose, cut to length . . . . . .
1 / 2" - 14 male pipe fitting. . . . . . . . . .
1/2" - 14 female pipe tee . . . . . . . . ,.. ..
1/2" to 1/ 4" pipe reducer bu shing , . . . . . .
. ... ,
1 / 4" pipe nipple . . . . . . . .. . . . .. . . . . . . . . . . . . . .
Mounting bo ar d , make localJy . . . . . . . . . . . . . . . . . . ..
3 / 4" - 16 JIC swivel fitting . . . . . . . . . . . . . . . , , . .
Kit for off-machine te s ting of Commerlcal- Shearlng
seconda ry relief valves ... , .. ... . . . . , . , . .
Pressure gauge, 0 to 3000 psi ., . . . . " ... , .. ,"
Case TCH Fluid . . . . . . . . . . . . , . . . . , . . , . . . . . .. 1

31

REQ'D.
1
1
2
2

1
1
1
1
1
1
1
gal.

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
JIC Thread , 37" Flare
3/ 4"
3/4"
3/ 4"
3/4"
7/ 8"
7/ 8"
7/ 8"
7/8"

16
16
16
16
14
14
14
14

.JIC
JIC
.JIe
JIC
JIC
JIC
.JIC
JI C

ADAPTER REQUIRED
Cas e Part No.
218-5059
21 8-5060
21 8-5070
218-5071
218-5066
218-5062
218-5063
218- 5078

CONTROL VALV E PORT

Straight Th r ead With O-ring
3/ 4"
7/8"
1-1 / 16"
1-5/ 16"
314 "
7 /8"
1-1 / 16"
1-5/16"

14
14
12
12
16
14
12
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
J IC Thread, 37" Flare
3/ 4" - 16 JIC
7/ 8" - 14 JIC
7/ 8" - 14 JIC

ADAPT E R REQUIRED
Ca se Part No.
218 -43 0
218- 430
218-736

CYLINDER HOSE O R TUBE

JIC Thread , 37" Flare
7/ 8" - 14 JIC
3/4" - 16 JI C
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
From The Tractor.

Refer to Figures 20, 21, and 22 to determine 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 removed for servicing, the hand pump can
be easily joined directly to the control
valve ports, Figure 21.

Figure 23 - Hand Pump

CHECKING PRESSURE SETTING WITH
THE CONTROL VALVE ON THE TRACTOR
1.

Warm up the hydraulic oil to normal

operating temperature of approximately
125 F.

1.

Join the hand pump to the port adjacent to the valve being tested.

2.

To test swing cross over relief valves:

2.

Have the buckets resting on the ground.

3.

Move the control lever back and forth

for each circuit to be tested. This will
equalize hydraulic pressure within the
circuits.

4.

a.

Join the hand pump to the port

OPPOSITE the side of the relief
valve being tested. Test the top valve
from the bottom port, and vice versa.

b.

Leave the opposite port open to

provide an outlet for the hand pump
oil.

Connect the hand pump to the circuit

at either of two locations:
3.
a.
b.

To test swing hlghpressure relief valves:

The port next to the relief valve

being tested.

a.

Any convenient swivel fitting in the

line leading from the port next to
the relief valve being tested.

Join the hand pump to the port on

the same s ide as the relief valve
being test ed .

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.

33

Actuate the lever on the hand pump,

building' up pressure until the valve

"cracks" open or bypasses. Make several
checks,

5.

Compare the r e ading with specifications

on page 26, Adjust the val ve as r equ i red,
See topic below.

Adlustln g Relle ' Valve.

Loader M ain Re lief Valve

1.

2,

Ba ckhoe Second ary Relief Valves

Remove the acorn nut On the main r elief

val ve and loo s en the j am nut, To dec r ea se pressu re, turn the adjusting
s crew cOlUlter clockwis e (out), To increase pre ssure, turn the adj usting s c re w
clockwise (in),
When the correct pressure has been
obtained , secure the setting with the
jam nut (without disturbing the setting).
Replace the acorn cap.

1.

Loosen jam nut.

2.

Turn adjusting scr ew clockwise to incr ease pr e ssure; counterclockwise to

decrea.se pressure .

3.

Again check pressure, then s ecure pr essure setting with jam nut (without disturbing setting).

Backho e Swing Crossover Valves

1.

Loosen jam nut.

2.

Turn adj usting screw clockwise to increase pressure; counterclockwise to

decrea se pressure.

3.

Again check pr e ssure, then secur e setting with jam nut being c a reful not to
change the setting.

Loader Secondary Relief Valve

These secondary relief valves are adjusted by adding or removing shims.

1.

Use an Allen wrench and r emove the

plug from the end of the valve. Shims
are loc at ed ben eath this plug.

2.

To increase pressure--add shims. To

decrease pressure--remove sllims.

3.

Install plug, tighten sec urely, and recheck the setting.

Pump Relie f Valve

Used on non-loader models only. See
page 28.
Boo m Lockout Relie f V alv e
See page 30.

34

4
TORQUE CONVERTER - POWER SHUTTLE
HYDRAULIC PUMP

A_

Fo ,m !I8 oo0 1

TORQUE CONVERTER HYDRAULIC PUMP

(Refer to Figure 1)
Disassembly
1. R emove tile adapter plate (2-1 I from th e
torque tube (28)

through 22 ).

2. Remove hex. bolls (231 and remove the

all pump (11) from the adapter plate .

6. Remove roll pin (18 ), washer (22) if equiped, roll p in (21 ). spring (20) , ball 119 1 from
relief valve body (17 ) .

3. Remove the Allen head seli-locking scre w

<15) from the end of shaft no!. then remove
snap ring jl-l) and '."asher <131 .

7. Remove hex . bolts (1), lockwashers 12 1 and

carefully Jift cover assembly 13) off of
p ump body assembly Ill) .

4. With a 5ultabl puller. remo'.'e the oil

pwnp drive gear (12). The gPJr is keyed
to the s haft (lO! with ke:! 19 ; .

8. Pull out drive shaft (10) and d rl ve gea r

(6), i dler shaft (8) and driven gear ( S) .

5. Remove relief va!\'e assembl}

(items 17

9.lf necessary , press Shafts (10 and 8) from

gears 16 and 5).

Inspection
Thoroughly cJea n a 11 parts bpfore inspectio n. Replace all damaged or worn parts .
Inspect all metal parts for scoring, nicks,

burrs or other damage . SUght burrs and

nicks can be removed wi th a hone
clo th .

Of

12(J)

. . .. .. ...... . i 90 "

.. .... .. .... .... ... ....... 22

. ... .... 20
. .. .. 052"

.... . .. IT .521'i lbs .

crocus

Chec k cover assembly (3) and oj) pump

body assembly ( ll) for excess II-ea r and outof- round ness.
Check re lief valve spring

Free Length .. ... .

Tota l CoJls .. ... .... .
Working Coils .. . .
Wire D ameter ... .
Compressed to1 .27"

Check gears (S and 6) for wear. Width of

new gears is .7490" to .7500" . Outside dla
metel' of new gears is 1.707" to 1. 709" . Excesslvely \Vorn gears Should be replac ed .

Check shafts (8 and

di ameter is .4912" to

for:

for wear. Shaft

.4915"' when new.

J(J)

Assembly
l.Press shait (10) into gear (6' .594" from
outside of gear t o end of shall lend opposite
snap ring groove I. Inset A. Th e gear is keyed
127) to tlle shaft.

2. Press shaft (8) Into gear ,.'i ) .594" f r om

eithe r end of the shaft, Inset 8. The gear
is keyed ( 7) to t h shaf l.

and r oll pin (18) 118" x 3 '4 " into body 1171,
Inset C. Assemble the relief valve assembly
to tbe oil pump body. Torque :30 to 40 ft. lbs .
5. Assemble key (9) and the Dll pump drive
gear ( l2) tosha!t (10) . the assemble washer
(13) , snap ring [14) and the Allen head screw
(1 5) .

:l . Place shafts (8 and 10) into ady assembly

(11 ) and replace cover assembly (3). Torque hex . bolts (11 to 9-11 ft . lbs.

6. Place new gaskets (25) in oil pump body Ill).

then assemble the oil pump 10 the adapter
plate (24) . Torque hex. bolts to 3';-42 ft.lb .

'L Assemble the relief valve assem bly by installing t he baJl (19) , sprlng 120\ . roll pln
(2 1) 3/ J6" x 1", washer (22\ i f equIpped

7. R eplac the adapter plate \ 2-11 on the Il'act r .

Tor que the adapter plate mounting hex. bolts
(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-

sure Gauge in filter housing , Fig ure 2.

4. If Pressure is Low - check for a plugged

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 press 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

HYDRAULIC PUMP 048950 (CESSNA)

Used on all mod els exc ept drawbar

tractor with three-point hitch. Ca n be inte rchanged with hydraul ic pump D49241. page 10.

Operation

A bronze faced steel plate called a

diaphragm reduces gear end clearance by
applying hydraulic pressure from the outlet
side of the pump. The area behind the
diaphr agm is divided into pr e ssure compartments fOI"med by grooves in the fac e
of the front cover. A rubber "V" seal and
two gask ets are Ins talled in the groove in
the front cover.

Gener al

The two gears revol ve in a close fitting

housing a nd tr ap oil between the gear teeth
as the teeth move out of mesh. The oil is
carried around the edge of the housing
and discharged at the outlet side. Refer
to Figur e 1.

Pressul'ized oil from the outlet side of

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.

VIE '0\' FROM REAR Of PUMP

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.

HIGH PRESS URE OUTLET OIL

L OW PRESSURE INLET OI L.

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
shaft luhrication pressur e exc e eds either
the suction pressure or the outl et pres sure ,
One of the steel balls will be forced from
its seal and oil w ill flow past it.

U.UU'8

Figure 1 - Pump Operation

Specifications

Output

. . . . 24-25 gpm @ 2000 rp m @ 2000 psi

(91-95 l/mn @ 2000 tr/mn @ 141 kg/em' )
. . . . . . 40 foot-pounds (5, 5 m-kg)
. . . . . . 80-8 5 foot-pound s (11-12 m-kg)
Count e rcl ockwise viewed fro m shaft end.

Tie bolt torque.

Mounting bolt torque .
Rotation . . . . . . .
Wear allowances ...

. . . . . . . . . . . . . . . .. Se e pages 6 and 7.

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

Removal

1.

Dra in hydraulic r eser voirs.

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.

5.

Remove the two capscr ews that mount

the pump to the trac tor. Pull the pump
straight out to disengage it from the
crankshaft coupling.

htt,:lIstores.eba~comi UserfriendlyCDs

Figu re 4 - Front Cover Removed

4.

Disassembly
1.

701356

To s ep arate r ear- cover fro m gear pl ate,

tap end of drive s ha ft with soft ham mer.
Do not allow gear plate to cock on dowel
pins. Figure 5.

Scribe a line across the three sections

of the pump so that the front cover,
rear cover , and gear plate can be reassembled 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.

Slip a sharp instrument under the diaphr'agm on the fronl co ve r and gently
pry the diaphragm loo se . Figure 6. Remove the springs and bal ls, nylatron gasket, protector gaske t, and V-seal. Discard the gas kets and s eals. Figure 7.

REPLACE GEAR IF
DIMENSION " A" IS

LESS TH AN 873"

7Dl 361

Figure 9 - Idler Gear and Shaft

~- " \/'" SEAL

2.

~NYLATRON
l;g;;r
GASKET

701359

Figure 7 - Removing Seals

6.

Remove and discard the shaft seal from

the front cover.

Inspect the idler gear and shaft, F igur e

9. If the bearing area of the Shaft measures less tha n .873", the s haft and gea r
assemblies should be replaced. Check
the gear ends for scoring, biuing due to
he at, and excessive wear. Check gear
width, if less than 1.297", r e pl ace gear.
Make sure the snap rings are in plaCE:.
If the gear teeth have sharP edges,
break corner with emery cloth.
Shafts and gears are serviced as
an as sembly only, and a l'e not ava ilabl e
separately.

NOTE:
SHAfT SEAL

701360

Figure 8 - Front Cover and Shaft Seal

Inspection

701362

Clean all parts and inspe ct for nicks

and burrs. Remove all imperfections On
machined surfaces with fine e mery cioth.

Figure 10 - Checking the Wea r Plate

3.

1.

Inspect the driveshaft. Check the spline s

fa r small cracks, wea r a t shaft seal
contact area, and rough spots.

Inspect
marks
eroded
burned,

the wear pl a tes. Check for score

and e rosion pits. If noticeably
in c e nte r, deeply scored or
replac e .

1.

Insp ec t the bushings in lJoth the front

and back covers. Figure 11. If the
bearing inside diameter is more than
. 879 ". lJoth the front and rear covel'S
mu st be repl ac8d as an assem llly with
the bushings. Bushings are not supplied
sep ara tely. Bushings in t1,e front cover
are flus h with the edge of the cover.

Place a new V-s ea l on the front co ve l'

the V down. Use a dull ins t rument
and install the s ea l into the co ver.
In stall new pro tector gas ket on the Vseal. Ins tall new Nyl at ron ga s ket.

REPUCE COy~R IF
OIMENS~'lI. IS MORE
THAN .8 79 INCHE5

"V"S EAl
PROTECTOR

"~.~

~.

NYLATRCN
GAS KET
701359

Figure 13 - Ins tall ing Seals in Flont Cove r

701363

Figure 11 - Checking the Bushings

5.

2.

Inspect the gear plate . Figure 12. Check

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.

Pl ace one ball in eueh hole in the front

cover. Plac e a spr ing on top of eac h
ball.

REPLACE IF
DIMENS ION ''A"
IS MORE THAN
2.107 INCHES

Figure 14 - Installing Balls and Springs

701""

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
the rim on the V- seul. Mak e sure co il s
of the sp rings a r e not wedged be tween
diap hragrn and front cover. Figul'e 15 .

4.

On the r ear co ver . install the thrust

plate (wea l' pla te ) with Ill'onze siele to-

Assembly

A service kit is ava ilable for replacing

a ll the pump seal s and gaskets . Tlti s kit
contains a new thru st pl ate. diaphragm.
gaske ts , shaft seal, diaphragm seal, and two
steel balls and s prings . Refe r to the Case
Parts Catalog.

wa rd the gea rs. Sicle with cutaway nlust

be on the suction sick: of the pump (side

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.
Figure 15 - Front Cover a nd Diaphragm
".

Lubl'ic a te the ge ar s in hydraulic oil

a nd In s tall assemb l ie s in rear cover.
Figure 17.

Install seal protec tor (sleeve. tape. e tc .)

o n pump s ha ft. Carefully install s e al
over the shaft. Use a 1-5/16" 0 .0. s ea l
driver and hammer. tap the seal until
it is seated In the counterbore of front
cove l'.

TIGHTEN TO 40 FT. LBS. TORQUE

70llto7

Figure 18 - Assembling Pump

Figure 16
Re a r Cov er. Ge ar Pl a te . and We ar Plate
6.

7.

9.

Appl y a thin coat of he avy grease to

mac hined surface s of gear plate and
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
cover. Notice the s mall ho l e drilled in
one of the half moon cavitie s . This
must be on the high pr ess ure port side.

Us e a wr ench o r simila r tool and rotate the pump shaft 10 r e volutions. Pwnp
shoul d be almost fr e e enough to rota te
s haft by hand. If not. disas sem ble pump
to find the c ause of the bind.

Testing And Installing Pump

Slip rear cove l' In place . ins tall bolts.

and tighten evenly to 40 ft. pounds torque.

1.

Pour hydraulic oil in the la rger (suction)

port of the pump. Rotate the pump a few
r evolutions.

2.

If shop test stand is available the fol-

lowing procedure for testing a rebuilt

pump is recommended:
a.

3.

MOlmt pump on test stand making

sure the proper level of clean oil
is availabl e in the rese rvoir.

b.

Start pump and run for three minutes at zero pressure.

c.

Interm ittently load pump to 500 psi

for three minutes.

d.

Int e rmittently load pump to 1000

psi for three minutes.

e.

Intermittently load pump to 2000

psi for thre e minutes.

f.

Remove the pump from the test

stand. Check the pump for leaks.
Check the driveshaft for freed om of
movement (it should move by hand
pressure).

If a shop tes t stand is not available the

following procedure for testing rebuil t
pumps is recomm ended .

a.

Install the pump on the tractor with

two capscrews and lockwashers.
Torque the capscrews 80- 85 ft.-lb s .
Reconnect the hydraulic lines and
fill oil reservoir.

b.

Start the engine and run the pump

at zero pressure (all control levers
in neutral) for three minutes. Have
the engine set at half speed.

c.

With the engine still at half spe ed ,

operate the control levers intermittently for thr ee minutes .

d.

Increase engine speed to full throttle

and operate the control levers intermittently for three minutes.

e.

Idle the e ngine and check the pump

and hydraulic connections for leaks.

HYDRAULIC PUMP 049241 (TRW )

U sed on all models except drawbar
t!'actm' with thre e-point hitch, Can be interchanged with hydraulic pump D48950, page 3,

the oil groove in the end cove r, Oil fr om the

discharge sid e of the pump is dir ected to the
oil groove cast into the end cover by the two
slots and groove in the pressure plate. As
discharge pressur e incr eases hyd raulic pressure forces the seal package again s t the
gears and pre vents leakage from the pr e sSU1'e side to the suction s ide of pump,

General

The two gears r evolving in aclosefitting

housing trap oil between the gear teeth as
the teeth move out of mesh, The oil is carried
around the edge of the housing and discharged
at the outl et side. Refer to Figur e 1.

Holes in the pressure plate permit pump

oil to fill the pressur e "compartments "
formed by the seal pack. With pressure on
both s ides of the gear plate thus equal i zed,
the pr essure plate maintains conta ct with the
gear sides through all pres sure ranges.

Operation

A bronze faced plate call ed a pressure

plate reduc es gear end clearance by applying
hydr aulic pressure from the discharge side
of the pump, A seal package consisting of
a rubber web seal, two paper backing webs
and a phenolic backing web is pr essed into

A positive pressure on the shaft seal is

maintained by the oil passed through the end
cover shaft bushings and a check valve in
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<)
. 25-35 foot-pounds (3.5-4.8 m-kg-)
. . 80-85 foot-pounds (11-12 m-kg)
Counterclockwise viewed from s haft end.
. . . . . . . . . . See page 12.

Tie bolt torque.

Mounting bolt torque
Rotation ., . . '.
Wear allowances . . .

10

~ DOWEL
END COVER

:\j
<.\j~ \
PRESSURE PLATE

3/8" - 16 x 1
FERR Y HEAD

"

-J/4~"~~~~~
'

~::::3/8"
-16 x 3/4"
FERRY HEAD
;

Fig"ure 20 - Exploded View of 049241 Pump

Removal

1.

2.

Remo ve the eight end cover mounting

bolts (four long and four short).

3.

Using a soft hammer, strike the mounting

ears alternately to separate the end
cover from the body.

Drain hydraulic reservoirs.

2.

Remove radiator grille, Then remove

dirt and grease from pump and surroundIng 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 lockwashers 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

from the end cover.

CAUTION: DO NOT attempt to remove

the seal package from the end cover.

These parts are serviceable only as
part of a new end cover assembly.
5.

Using an inside n1icron1etcr, measure the

diameter of the gear bushlngs. If either
bushing exceeds 0.8777" in diameter the
body must be replaced.

Gears
1.

Measure the diameter of both gears. If

either gear has a dimneter less than
2.1203" the gears must be replaced.

2.

Measure the diameter of the gear

journals. If the dimnete r o f a journal is
less than 0.8737" the gears must be
replaced.

3.

Measure the thickness of both gears . If

one gear measures less than 1.5110"
the gears must be replaced.

Remove the drive and driven gears from

the pump body. Do not remove the spring
or check valve from the driven gear.

Inspection
Body
1.

Check the sealing surface for nicks and

burrs. Ifnlcks or burrs are noted, remove
with a piece of crocus cloth or flat India
stone.

2.

Clean the body in cleanlng solvent and

make sure all passages are free of
foreig1l matter.

4.

U sing an inside micrometer, measure the

gear bores. If either bo re dlameter
exceed s 2.1253", the lJody must be replaced.

End Cover

:3.

NOT.: The thlckness of the gears must

mea sure the same within 0.0005".

Check gear faces and journals for

scoring. Replace the gear set if heavy
scoring is evident. The gear teeth should
have sharp corners and not rounded.

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 exceeds 0.8777" in dlmneter the end cover
must be replaced.

4.

Inspect the shaft seal for cracks, deterioration and other defects.

5.

If the pump has been disassembled because of low output and the pump tXldy
and gears are found to be serviceable,

704l1''7

Figure 22
4.

Using a depth micrometer, measure the

depth of the gear bores. If either bore
depth exceeds 1.5155" the body must be
replaced.

12

a soft hammer until thE' body is seated

against the end co ver .

it can be assumed tha t the s eal package

is pmbablydefective , r equ iring end cover
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 sequence 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

and instal l end cover over gears being
ca r eful no t to damage the shaft seal.
When end cover starts On dowel pins
invert the pump and s et the pump on
open jaws of vise. Strike the body wi th

Figure 25 - Torque Sequence

In stallation

See Testing a nd Ins t alling Pum p on

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)
Counterclockwise viewed from s haft end.
Rotation . . . . . .
Wear allowances
. . . . . . . . . . . . . See page 16.
General

Di s assembly

The two gears revol ving in a close fitting

hous ing tra p oll between the gear teeth as
the teeth move out of mesh. The oU is carr ied
al'ound the edge of the housing and discharged
at the outlet side. Move m ent of au thr ough
the pump is the same as s hown in Figure 1.

1.

Scribe a m ark across the thr e e sections

of the pllmp to assure proper r eas sembly.

2.

Remove the eight tie bolts (six hex.

head ruld two socket head).

3.

Secure the pump U1 a vise. USU1g a soft

hammer, strike the mounting ears alternately to sepera te the body fro m the
gear plate.

4.

Remove the pressure pl ate , pressure

plate seal , backup ring and sealu1g rU1g
fr om the body. Do not remove the shaft
seal unless it is to be replaced.

5.

Remove the drive and driven gear s from

the end cover. Then rem ove the gear
plate fr om the end cover. T ap the gear
pl ate with a soft hammer to aid removal.

Drill ed passages from the suc tion side

of the pump provide bearing lubrication.

6.

Rem ove the pressure plate, pressure

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
indicates need for replacement.

Operation
Two br onze faced pressure plates reduce
gear end clearance and internal leakage by
applying hydr aulic pressure fr om the discharge side of the pump. Oil from the discharge side of the pump is directed to the
pock et for med by the sealing ring a nd its
backup ring under each pressure plate. As
discharge
pressure increases, hydraulic
pressure forc es the press ure pl ates more
firmly against the gears.

1.

Dra in hydr a ulic reservoir.

2.

Remove r adiator grille. Then remove

dirt and grease from pump and su rrounding' area.

3.

Disconnect suction line a t pump and plug

with clean caplug.

4.

Disc onnec t tuhe at elhow on outlet side

of pump and plug with clean caplug.

5.

Remove the tw o capscrcws with lockwashers that mount the pump to the
tractor. Pull the pump straight out to
disengage it fro m the crankshaft coupling.

Inspection

Body
1.

Check the sealing sur face for nicks

anci hurl'S that m ay result in leakage
when the pump is reassembled. Use a
flat India stone to re move defects .

2.

Inspect the gear shaft beurings for flat

spots, pitting and othe r d efec ts . If the
bearings are to be removed, use a suitabl e bearing jlull er being' careful not to
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.

4.

Clean the body in cleaning solvent and

dry with compressed air. Make surc all
passag'es are open.

NOTE: Whenever the gears are replaced,

the four
placed.

Sealing Rings And Pressure Plates

Inspect the shaft seal for wear, deterioration and other defects.

1.

Discard the pressure plate seal rings and

the two sealing rings.

2.

Inspect the two backup rings for signs

of cracks and other defects.

3.

Gear Plate

1.

shaft bearings must be re-

Check the sealing' surfaces for nicks

a nd burrs that may result in leakage
when the pump is reassembled. Use a
flat India stone to r e move defects.

2.

Measure the diameter of the gear bores.

If either bore measures over 2.181"
the gear plate must be replaced.

Check the pressure plates for excessive

wear. Place a straightedge on the pressure plate; if wear exceeds .005" where
the gears contact the pressure plate the
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
hydraulic oil for contamination (water,
metal particles. etc.).

End Cover
1.

2.

3.

Check the sealing surface for nicks and

burrs that may result in leakage when
the pump is reassembled. Use a flat
India stone to remove defects.

As sembly

Inspect the gea r shaft bearings for flat

spots, pitting and other defects. If the
bearings are to be removed, use a suitabl e
bearing puller being careful not to damage
the bearing bore.

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.

If the gear shaft bCJarings were re moved

install new bearings. Press the drive
shaft bearing into the bo<ly until it is
approximately 3/32" below the edge of
the bearing bore, Figure 27. Press the
remaining body bearing and the end
cover bearings in until the bear ing is
seated On the shoulder in the bearing
bore.

Clean the end cover in cleaning sol vent

and dry with ccmpressed air. Make sure
all passages are open.

PRESS BEARING IN APPROXII/,ATELY

3/3 " BELOW THIS EDGE

Gears
1.

Inspect the gears for excessive wear,

scoring, grooves and pitting. A dull
finish on the gear faces, bearing journals and teeth indi cate abrasive mate rial in the hydraul ic all.

2.

If the gears measure less than 2.173"

in diameter or .6995" in width the gears
must be replaced.

3.

701370

Figure 27 - Driveshaft Bearing Install a tion

If wear in the shaft seal area is easily

detectable with a fingernail, the gears
should be replaced.

3.

16

Secure the end cover in a vise with the

ports down. Install a sealing ring followed
by a backup ring in groove in end cover.

4.

Lightly coat the pr essure pl ate seal ring

with grease and place pressure plate
(with aU grooves ) in seal ring with
bronze face up. Place the pressure
pla te (bron ze face up) with seal ring on
end cover making sur e hol es in plate
co rr e spond to po rt openings in end cover.

5.

Pl ace ge a r plate on end cover aligning

mark madc during disassembly.

6.

In stall the d rive and driven gears in

their respectiv e bo res.

7.

Ins tall
the renlaullng sealing ring
followed by the backup ring in groove in
the body.

8.

Lightly coat the pres sure plate seal

ring w ith grease and pl ace press ure
pl ate in s eal ring with bronze face
up. Place the pre s s ure plate (bronze

face up) with seal ring On body. Make

sure the r owlcl port hol e is on the
pre ss ure side of the oody.
9.

Lubricate s haft seal with bear ing gr ease

and position body on gea r plate . Use
care not to damage the s e al lip.

10. Ins tall the e ight tie bolts a nd tighten

eve nly. Torque the oolts to 25 -35 foot
pounds.
11. After the tie bolts have been torqued,
rotate the dri veshaft to check fr eedom
of movement. If movem ent Is jerky o r
turning effort is gre ater than 3 inch
pounds, the pump should be di sa ssembled to deter min e cause cf bind.
Installation
See Testing a nd Ins talling Pump on
page 8.

17

Section

4
3 POINT HITCH CYLI NDERS

TABLE OF CQNTENTS
Til t Cylinder ..... ........... .. ..... ........... ..... .................. ......... ..... ... ... ............. ... .... .... .. .... ............. ...... 2
Lift Cylinder ............... .... ... ......... .. ... .... ... ... ......... ..... ......... .. ... .... .... .... .. ........ .. ......... ... ... .............. . 4

Pitch Cylinde r ... .... ........ ,...... ...... ... .. .... ............ , ..... .. ... ....... .. .... ..... , ........ ... .. . ,...... ,..... .. ........... ... ,.. 6

ser

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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 lftapping ) . 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 backup 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.

445
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
rod .

0\-'(' 1'

piston

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

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 .

GENERAL . . .

OP ERATION ..

. .. 6-8

i\Ia!n Relief Valve .

on

Flow - Lift Spool Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

on

Flow - Lift Spool In Float..

Float Detent .. . . . . . . . . . . .

SERVICING WADER CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-14

Removal . . . . . . . . . . . . . . .

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

SPECIFICATIONS
Case part no.
2 spool val ve
3 spool valve
Description . . . . . .
Relief val've p ressur e setting
Ma in relief val ve . . .

. .. D45040
. . . D52 0 42
See page 5.

.. 2200 75 psi @ full throttl e

(155 5,2 kg/ cm'@full throttle

Secondary reI ief val ve

Clam B port
Tilt A port.
Tilt B port,
Oil t emperature when c hecking pressure settings
Spools and ports
Spool travel, neutral to pressure
Sp ool in . . . . . . . .
Spool out .. , .. . .
Spool travel, neutral to float
Port threads
All work ports .
Inlet port .. ..
Outlet port, power beyond ..
Power beyond fitting, internal.
Outlet port, return oil
Weight (approx.)
2 spo ol valve .
3 spool valve ..
Spring specifications .
Ma in r'elief plunger.
Ma in relief poppet
Secondary rel ief
Check valve.
Detent

.. 2500 100 ps i @ 10 gpm

(176 7 kg / cm z @ 38 l i mn)
, 2500 100 psi @10 gVm
(176 7 kg/e m' @38 1/mn)
, 205 0 100 psi @ 10 gpm
(144 ,_ 7 kg/ c m"@ 38 1/mn)
. . . . . . 120" F. (49 " C.)
3/8" (10 mm) in an d out
A port pr e s s uri zecj
B port pressuriz ed
. 11/16" (17 mm)
7/8 "-14
1-1/16"-12
1-5/ 16"-12
1-1/ 16"-12
1-1 / 16"-12

st r a ight
str a ight
straight
straight
s traight

.. 28 Ills. (12,7 kg)

.. 36 Ibs. (16, 3 kg)
. Compre s sed length
. . . 13 / 16" @ 4-6 Ibs .
11 / 16" @ 25.5-28.5 Ibs .
. . 21/32" @ 4 .5-5.5 Ibs.
27/ 32" @145.5-178.5 Ibs.
. . . .. 3/8" @ 3/4 lb.
5/8" @ 1/ 4 lb.
1-3/8 " @ 153-187 Ibs .

U.S . AND METRIC TORQUE SPECIFICATIONS

Hydraulic Fillings (Sleel)

37

Flare

St r aight Threa d
O- Rmg
Torque

F em ale Swive l

D <.J sh
Size

T ube
U .D.

Th re ad
Slze

1 / 4"
:) / 16"
3 / 8"
1/2 "

7 /16" - 20
1 /2 " - 20
9 / 16" - 18
3 / 4" - 16
7 /8 " - 14
1 -1 / 16 " - 12
1-3/ 1 6" - 12
1-5/ 16 " - 12
1- 5/8" - 12
1- 7/8 " - 12

.)

6
b

10
12
H

16
20
24

5/6"
:J / 4 "
7 / 8"
1"
1-1 /4 "
1-1 / 2"

Torque
ft.

illS .

6- 12
8-16
10- 25
1 5- 42

25- 58
4 0 - 80
60-1 00
75 -117
125-1 65
210-250

m-kg;

flo los .

Ill - kg

0.8 -1,7
1,1-2 ,2
1 ,4 - 3 ,5
2 ,1-5, 8
3, 5- 8 ,0

12-19
16-25
25- 40
42- 67

2, 2- 3,5
3 ,5- 5 , 5
5 , 8- 9 ,2

58-92

0 ,0-12,7

5,5-11,0

50-12 8
10 0- 16 0
117-1 8 7
165- 264
250-400

11-1 8
14. - 22
16 - 26
23-:J 6
36- 55

8 ,3-1 4,0
10-16
17-23
29 - 35

1,7-2, 6

70117':

SPECIA L T OOLS

The tools (kit part no. D45700) illustrated in Figure 1 are available from

Service Parts Supply to aid In servicing

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

GENERAL
ce nter outlet which contains a power beyond
fitting.

The loader contro l valve Is a two spool

(three spool with 4-in-1 bucket), open center,
parallel circuit (passage) valve . The parallel
passage is connected to the Inlet port and
dead ends at the lift s pool, supplying oil to the
work ports. Check valves between the work
port s and the parallel passage prevent rever se
oil flow between the cylinders and the control
valve as a spool is moved into a power pos ition. An adjustable maIn relief valve at the
cont rol val ve inl et prevents excessive pressur e in the hyd raulic sys tem. Seconda r y r elief
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 cylinder is forced to m ove with the spool in
neutral. The valve contains two outlet ports,
one connectln~ the wo rk port return passage s
to the r eservoir retur n line and the open

CHECK VA LVE
LIFT SPOOL PORTS A

CLAM SPOOL paRT

A~H}

The power beyond fitting permit s the installation of rear mounted hydraulic s without
additional valves to control oil flow. It also
permits the use of the main relief valve to
protect the backhoe hydraulic system from
excessive pre ssu re. However, o nly one sys tem can be operated at one time -actuating
a loader 80ntrol valve s poo l blocks 011 flow
to the rear mounte d hydraulic system.
With the loader control v alve spool s In
neutral, oil flow s stra ight through the open
center passage and the power beyond fitting
to the rear mounted hydraulic s control
valve( s ) to the re servoir.

HIGH PRE

STATIC

OIL

s . !t~=:=~'11

~.

",...7.."...,~

POVIER .n'~ ''' '

FITTING

'POPPET

PARA ll EL
CIRC UIT

SEC m mAR Y RUE F

TILT SPOOL PORTS A Atl D fs ,

CLAM SPOOL PORT 8 ,

BM66 11 ~3

Figure 2 - all Flow - Spools In Neutral

OPERATION
m ai n relief valve opens to protec t the hydraulic system from damage. When the relief
I'alve is open, oil is diverted to the r e servoir.

Main Relle. Valve

The main reltef valve is located at the

inlet of the control valve. The valve poppet
protrudes into the open ce nter pa ssage a s
illustrated in FIgure 2.
The main r e ltef valve is pilot operated.
This me ans a spear shaped pilot plunger
controls the pressure at which the valve
opens and permits a gradual opening of the
r e llef valve. Note that a small hole is drilled
through the poppet. This permits the same
pressure to be maintained on both s ides of
the poppet during normal operation and helps
control the gradual opening of the l'eliefvalve
when pressure r e ac hes the spec ified set ting.
When a cylinder reaches the end of its
travel or is held for any reason with the control va lve spool in ;) power positIon , the

CD

1.

When pressure in the open ce nter passage

reaches the pres s ure se tting of the relief
valve, the pilot plwlger is fo rc ed off its
seat.

2.

Oil flows through the plunger seat fas ter

than it can be s upplied, creating a
pressure differential (lower pressure )
between the poppet and plunge r.

3.

The pressure in the open cente r passage

then unseats the poppet and oil is diverted
through the seat sleeve to the r eservoIr.

4.

The relief valve will remain open until

the cylinder move s a r the control valve
spoo I Is returned to neutral.

PRESSURE BELOW snTl N G

PRE SStJIIE ABOVE SHfi NG

Of MA I N RELIEF V. . . LVE

OF MA.1N REliEf VALVE

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

RFlAC Oil !lED

PAST PILOT PlUNGfR

STEPC!)
P ~ ES SJJR E

CAUSES
PILO T PLUNGEr.

TO UNSEAT

STATIC Oil

HI GH PRE SSURE Oi l
AREA Of PRES SURE
J>l FFERfNTIAl

Ou. aHOw
IAA I N RE LIEF
SUTI NG

Qll BElOW NAIN

REU EF SE rTt NG

Figure 3 - ?vlain Relief Valve Operation

the r od end of the lift cylinders

c ausing the loader fram e to lower.

Oil Flow Lilt Spool Actuated

c.

In Figure 4 the lift spool Is moved Into

the valve body which:

a.

b.

Blocks the open center passage. With

open center blocked, all 011 from the
pump flows through the parallel
pas sage.

Simultaneously, the [J port is opened

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 voir.

When the spool Is returned to neutral, 011

Is locked be tween the control valve a.nd lift
cylinde rs, preventing further movement of the
loade r frame.

As pressure in the para llel passage

increases, the check poppets open,
permitting oil to flow to the A port.
From the A port, 011 is directed to

To r a ise the loader frame, the spool Is

moved out of the valve body and 011 flow i s
reversed .

HIG H PRESSURE OIL

STATIC OIL
LOW PRESSURE 01 L

OPEN

TO CYLINDER

SPCOL ACT UATED

INTO VALVE BODY

Figure 4 - 011 Flow - Llft Spool Actuated

711 0jS

lOW eKt,> ",,<t

all

Flo_ Lift Spool In Float

STATIC

When the 11ft spool is in the float position, 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

The amount of pressure required to
engage or disengage the detent is dete rmined
by the pOSition of the adjus tment plug in the
detent housing.

Float Detenl

The float detent hold s the 11ft spool in

the float position mechanically. Refer to
Figure 6. As the spool is pushed into the valve
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
the control lever will allow the spool to r eturn
to neutral.

DO Eti T SPR I r<G

OE TEI

SPOOL

C ~. f"1

BALL S (6)

"em,

Figure 6 - Float Dete nt (Spool In Neut ral )

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.

3.

With the engine shut off, opera te the

control lever In all directions to equalize
elr cu it pres sures.

4.

Disconnect the hoses and tubes from the

control valve. Plug the hoses and tubes
with c lean caplugs.

5.

Disconnect the (;ontrollever linkage from

the spools.

6.

Remove the control va lve from the mounting plate by removing the four bolts with
nuts and lockwasher s.

Figure 8 - Lift Spool

4.

Grasp the spool centering spring and

pull spool from valve body. Then remove
the two a-ring retaine rs a nd a-rings
from the spool.

5.

Remove the spool gland a nd sleeve from

the control valve. Then remove the wiper
reta iner, wiper and a-rings from the
spool gland.

6.

Do not remove cente ring spring from

spool unless orange Loctite is avatlable
for use during asse mbly. To remove
the spring, secure spool in a SaFT
jawed vise ane! install spring compressor
illustrated in Figure 1. Compress spring
and unscrew the de te nt stud. Remove
spring compl'e s sor from spring.

DI.a embl~

Lift Spool
Tilt Sp ool And Clam Spool
1.

2.
3.

Remove the detent adjusting plug and

spring from the dete nt housing, Figure 8.

1.

Unscrew the spool cap from the valve

body.

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
a -ring and O- ring ret a iner from the
spool.

Unscrew detent housing from oontrol

valve.

SPOOlCA~

from the cartridge. Do not remove

the pilot plunger seat unlesa it is to
be replaoed.

Sf'.lJo,P -R ING \.
SPRI

" -.

G SEA 1 "

'(,II
(C'.

5PAC Ert ......

PLUC ............. ~0

@--c.-C EN f ER:ING S'i'R 1I.... jG

~s:PRJ NG $~A r

~-O-Rn..JC RETAINER
-"- O -R IN G

k\~'; V
(92
/]

.
k

-c R..l
(,f'.

C-rHNG

/ /

'

J ./
>::1~

,J

~)

..J
'-

Secure the spool In a SOFT JAWED

vise and compress spring as shown
in Figure 1.

b.

Remove snap ring from spool and

release spring compressor. Then
remove the spring and spring seats
from the spool.

-'O -R ING

~C""TRlOG'
&'1
#,1'--

Figure 10 - Main Rellef Valve

4.

Remove the plug from the oppos ite end

of the valve body and remove the drain
sleeve and seat sleeve f rom tbe r e lief
valve bore. Then remove the O- rlngfrom
the plug and the 0- ring and backup rtng
from the seat sleeve. Do not remove the
poppet seat from the seat sleeve unless
it is to be repl aced.

Secondary Relief Valve s

2.

Remove the spring and poppet from valve

hody.

3.

Disassemble the relief valve cartridge.

PLUG

, "'---)

SH IM(S)-V
\ --: /

,,-:\

k~ [A~lRIOGE

SPRIN G GUI DE-... ...- .

SAC KUP RIN G _:;';;
~
~ O - RINGe:
~PIW-..j G _ J /

Main Relief Valv e

Unscrew the main relief valve cartridge

from the valve body. Then pull the cartridge from the valve body, Figure 10.

w-

; : I.,..I _ - WA.SHfR

SPR IN G
f'~ -:::- JAM NUl
...... PI Lor
1....7......... WAS HEIt
PLU NG ER SEAr
ACORN NUT

POPPET

1.

/: '?LU NCER SPRING

//
- A DJUSTlNG $CREw

BACKU P RING

Remove the spool gland, a - ring retainer

and a-ring from the valve body. Remove
spool gland with tool shown in Figure 1.

b.

5lEeVf

SAC KUP I? ING

I)........

GL':" N D

a.

~"'- POPPET

IJf

~ ErAl NEJt.

Remove the spool centering spring lf

required.

a.

~, _

PIlO T PLUNG ER

""'''''''''''-' POPPEl'
SEA T
O -RING
_ POP PEl

O-RING

4.

~- '5EA T

-"

Yl

~.

Figure 9 - T1lt and Clam Spool

3.

..rtV-- O!:!AIN SLEEVE

O - O -<lN G

1I!!I\-

. \S)~O-AING

'""

pOP PEr SE..6,T -

~,II

..- ,

."

aACKU9 RING

~~o;-:- 'Sf'l ING

t:f .l "/ 7

CHEC K :PO'PPf. T

'POPPET SEAt

A'-<~"

Remove the acorn nut and loosen the

jam nut. Then remove the adjusting
screw from the cartridge.

Figure 11 - Secondary Relief Valve

A secondary rellef valve is loc ated at
the A and B ports of the tlIt spool and at

Remove the spring and pllot plunger

10

the B port of the clam spool. Identify the

parts so the y will be returned to their
respective bores during assembly.

that the spools fit their respective bores

with a slight hand pressure and without
noticeable side clearance.

~'alve

1.

Remove the relief valve assemhly from

the valve body.

2.

Remove the spring a nd check poppet

from the valve bore. Do not remove the
poppet seat unless it is to be replaced.

3.

Disassemble the relief valve.

a.

Remove plug and shim(s) from cartridge.

b.

Remove the .spring guide, spring a nd

poppe t from the cartridge.

Inspect spools for grooves, deep scratches or excessive wear. Valve spools may
be replaced if there is no damage to the
body. The spools are coded to ide ntify
size and type of spool. The color code
identifies size as follows:

3.

Black .
Blue ..
Yellow
Green.

.73700"
. 73710"
. 73720"
.7;3730"

to .73709"
to .73719"
to. 73729"
to. 73740"

The letter code s tamped on the eye of

the spool identifies the type, D double acting
and F float. When order i ng re placement spools
be sure to include the color and type codes.
Spools are shipped with centering springs
assembled.
.

C heck Valves
A check valve is located at both lift
spool ports. To r emove, unscrew cap, then
remove the s pring and poppe t from the
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 respective bores during assembly.

TYPICA L SPO OL

~'

CO LO R COOE

SPOOL TYPE
CODE LETTER

691 9;].9

Figure 13 - Spool Code

Figure 12 - Check Valve

Plugs An d Fittings
Remove the power beyond fitting and any
other remaining plugs from the valve body.

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.

5.

Inspect main relief va lve plunger a nd seat

for ridges or scoring. Replace if worn
or damaged.

6 . . Inspect all springs for distortion and

signs of cracking. Also check sp ring
tension, refer to page 3 for spring
specifications.

Inspecllon
Assembly
1.

2.

Wash all metal parts in kerosene or

s imilar solvent, Discard all O-rings and
wi pers.

Make sure all tools and work bench are

clean before assembling the control valve.

Inspec t the valve body bores for gooves,

deep scratches or excessive wear. See

Lubricate spools, I)ores and O-rings wah

hydra ulic oil prior to assembly.
11

Check Valves

Main Relief Valve

1.

Press new poppet seat Into valve body,

If removed, Figure 12.

1.

2.

Place the check poppet and spring in valve

bore.

3.

Pres s new poppet seat into seat s leeve ,

if removed , Figure 15 .
PLUG .......... '' \

(SSt..-- O ~ING

Install backup rings a nd new a-rings on

valve cap and screw cap Into valve body
until tight.

r .

~- DRAI N
C .

SLEEv c

< j '- - SE,AT Slf:E\fE

1, .

~ BACKUP

"NG

Secondary R elief Valves

O -RING

-' ;r:
P\..UG

SHfM'S~
,\

.u.-;

SPRIN G GU I DE............. ,::-.

/
BACKUP RI I'JG ~ O ... RINC f)

S ""NG _~
.,' "

PO PfEr

PO PP ET SEAT-

....>

&
t/ 1-

~~. "~~

, / -)

,r'j
.J/t CART~I DGE

/"
.~
r. I
poppEr
F
SEAT
O -l<fNG,;::' _
POPP ET
A
r.....PoppEl
SPRING
" PI 1.0 T
J
A \
PLUNGER SEAT

7~

BAC KUP RING

IJ '~

SP.RlNG

't!fJ'/-;- CHE.cKPOPPET

/ .. l'J

POppET SEAT

c"Y.~"'"

,;,')

PIL O T PlUNGe,

..
#-_. _ PL UN GE'
//
6/- - ADJ US fl NC

SPRIN G

SCREW

d ' - \NASHE~

A1"'-=:- JAJJ. NUT

.........

WA. SH9.

.4-CORN NUt

70\3~1

BAC KUP RING

Figure 15 - NI ain Re lief Valve

6VY~/

2.

Ins t all the backup ring' and nelv a -ring

on the seat sleeve. Then positio n the
seat s leeve and dra in sleeve in the valve
body. Push the drain sleeve into the
valve body until two or three threads
are visible, then screw the r e lief valve
plug with new a- ring Into the valve
body. The seat s le eve Is now properly
positioned.

3.

Place poppet and spring in the reli ef

va lve bore.

4.

Assemble the

'- ",

'

7C1 :r:'3

Figure 14 - Secondary Relief Valve

1.

Press new poppet seat into valve body,

if removed . Then install check poppet and
spring in valve bore.

2.

As semble the relief valve.

3.

a.

Press In new poppet seat, If removed.

b.

Install poppet,
guide In valve.

c.

Place shims on spri ng a nd Install

plug. Use as many shims as were
r e moved.

a.

Press new pilot plunger se a.t into

cartridge, If removed.

b,

Pl ace the pilot plunger a nd spring

in cartridge.

c.

Screw the adjus ting screw Into the

cartridge. Then install wa she r, jam
nut , washer and acorn nut on adjusting s crew.

spring and spring

Install backup rings and new a-rings on

relief valve and Install In valve body.
After the control valve Is assembled ,
check the pressure setting as Instructed
In Section 42.

5.

12

relief valve cartridge:

P os ition the backup r ing a nd new a- r ings

on the cartridge , then s c rew cartridge
Into v alve body.

lift Spool

NOTE:
Do not adju st the rellef vah'e
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

spool gland over eye end of spool. Tighten
the spool gland with the wrench shown in
Figure 1.

Figure 17
1.

Figure 16 - Tilt and Clam Spool

13

Lift Spool

Install centering spr ing on spool, if

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 compre 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.

4.

Scre w the detent housing' into the valve

body until it bottoms.

5.

Install the de tent washer in the detent

hou s ing. Make sure the washer Is seated
against the shoulder In the detent cap.

6.

Drop the s teel ba lls (8) Into the cap

a r ound the dete nt barre l. Smear a good
grade of greas e on the detent cam and
install ca m in detent housing.

Ing pl ate and secure in place with four

bolts , loc kwashe rs and nut s .
2.

Connect the hose s and tubes to the control

valve . Refer to HydrauI!c diagram In
Section 42 for proper connec tions .

3.

Connect the control lever li nkage to the

v alve spools. Check and adjus t the float
de tent feel. To inc rease dete nt pre s8ure ,
screw the adjusting plug into the dete nt
housing. To decrease detent pre ssure ,
screw the adjusting plug out of the de tent
housing. The plug contains a nylon inse rt
to make it self locking. Do not expose the
inse rt when decreasing detent pressure.

7.

P l ace the detent spring on the detent cam

and screw the adjustment plug into the
detent hou s ing until plug is flush with end
of housing. Re adjust detent fee l as required a fte r control valve h as been ins talled.

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
gland .

4.

Check and adjust the main r e li ef valve

pressure setting as instructed in Secti on
42.

Install spool sleeve in valve body a nd

sc rew spool gla nd into va lve body until
It bottoms.

5.

Check and adjust the secondary I' el ief

valve is settings as instructed in Section
42 if valves wer e not adjus ted alt e r
as s embly.

6.

Sta rt the engine and operate t he bucket

through several complete cycles to I)leed
a ir from the hy draul ic sy st em and c heck
for leaks.

7.

Check hydraulic r e s e rvoir oil le vel and

add as required.

9.

P lug s And F Ittings

Instal l new C)-rings on the pow e r beyond

fitting and the I'em a ining plugs and ins tall in
valve body.
In.tallatlon

1.

Position control valve against the mount-

14

SECTION
44b

BACK

OE

CONTROL
VALVE
ser

nendly

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Bu r l. For", 9-72085 KHCBO

TABLE OF CONTENTS
SPECIFICA TIONS

. 3

OPERATION.

3-8

REMOVAL.

DISASSEi\1BLING THE CONTROL VALVE

11

Disassembly of Valve Sections

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

SPECIFICATIONS

Case pa rt no. . . . . .
Desc ription . . . . .
Ma in r ei ief val ve . . . .
Secondal'y relief valves .

. . . . . . . D50560
See General below
.. See Section 42 .
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)
.. 1000 + 2 50 - 100 psi @ 10 gpm
(70 + 18 - 7 kg /cm'@ 38 limn)
Cartridge type, sc rew adjustable,
connect ed to work po rts of swing section
. . . . . . . . . . . . 1750 150 psi @1 0 g-pm
(12:3 10 kg/e m'@ 38 !/mn)

Boom section A POI't .

Cros so ve r r eli e f valves
Pr essure setting
Port s and spools
Spool t ravel, ne utral to pr essure ..
Spool in
Spool o ut . . . . . . . . . . . . . . .
Port threa d
All ports except swing sec tion .
Sw ing sec tion ...
We ight (approx . )
Tie rod torque . . . . . . . .
Springs
Hegeneration spool. . . . . . . ,
Spoo l centering
Boo m, dipper anel bucket

15/ 32" (12 mm) in a nd out

Work port A pressurized
Work port B pre ssu r ized

Free length
2-1 / 64"-2-3 /8 "
2-1 / 2" -2-25/32"

Sw ing . . .. .
Check poppet .. .
Secondary rel ief
All except beom liown

1-1/16"-1-1/8"

Boom down . . . .

1-1/ 16"-1-1 / 8"

Crossover (pressure )
C r o ssover' (poppet) ..

2-7 / 8"
55/ 64"-57/ 64"

1-35/ 64"-1-39 / 64"

. 353"-.363"

... 1-5/ 16" - 12

. . . .. 7/S" - 14
123 lbs. (05,8 kg)
30 foot - pound s (4,1 m-kg)
Co mpr essed le ngth
1-13 / 16" ({f 21-25 Ib5.
1- 13/ 32" @ 40-45 lh s .
1-13/32" (g 2:3-27 lhs.
15 / 15" @' 32-36 lbs.
So lid @ 4 3 Ihs .
Solid @ 2.5 lbs .
61/64" fa: 74-82 lbs.
57/64" @ 111 - 123 Ihs .
I" ~i 19- 21 lhs .
13/ 16" @ 74- 82 lbs.
So li d {g 93-11 5 lbs .
Solid @ 9 Ibs .

GE NERAL

The backhoe valve does not contain a

main relief valve. The backhoe hydrauliC
syste m pressure is controlled by the main
relief valve in the l oade r control valve,

The baok hoe control valve is a sectional,

open center with parallel passage valve, The
val ve is oompos ed of fou r working sections,
and an inlet and outl et section . The open center
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
sec tion has two return passages connected
in series with the inlet and outlet sections.

With the spool s in neutral, oil flows

straight through the open center passage to
the outlet nnd r e turns t o th e reservoir.

SE CONDARY

REL IEF VA LVE

01 PPER CYL I NDER

REGENmA T 10,'1
CH ECK VALVE

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RETURN

RECIlERATIOll
SPOOL

SECOllDMlY
RE Ll Er VALVE

D ....~" SECTION

_
_

PUMP PRESSURE
RETURN OIL
STATI C OIL
71 0994

OPERATION
a ir from entering the c lo sed e nd of the d ipper
cylinder.

011 Flo"" - Spool Aclualed

Refer to Figure 1. With the spool he ld
in a powe r posit io n, the op en center pas sage
is bloc ked. The bloc: kingofopen center diverts
the total oil flow to the open center parallel
pas sage, past the check va lve a nd on to work
port A where the oil is directed to the rod
e nd of the dipper c ylinde l' . Simultaneously,
the pressure increase i n the ope n center
pal'allel pa ssage overcomes the spring under
the r e gene ration spool, connecting' the return
pa ssage to the outlet port a llowing the oil
displaced by the cy linde r piston to return to
the r eservoir.

When pump pressu re is s ufficient to move

the dipper, the r e tu rn pas sage in the outlet
section is opened in the s a me manne r a s
explained under Oil Flow - Spool Actuated.

011 Flo_ - S_in g l n g Backhoe

The control valve sw ing section is baSically the same as the other working sections
with on e exception. The exception is the addition of two crOSsover r e li ef val ves in the
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,
pre ssure between the pump and cylinder
would rise untll it was equal to the pressure
setting of the main r elief in the lo ader control
v a lve, at which time the r e lief valve would
ope n and divert the oil to the reservoir.

R efer to Figur e 3. The I:'oom, d ipper and

bucket, being v e ry heavy, pr ovide considerable inertia to swing (the t ende ncy to remain
stationary). When the pres s ur e between the
cylinder pistons a nd the c r ossover relief valve
connected to work port A reaches 1600-1900
psi, the pre ssure force s the poppet away from
the floating seat for that relie f valve and lUlseats the floating seat of the opposing crossover relief valve, diverting excess o il to the
return pa s sage. Thus the c rossover relief
valves permit a smooth s ta rting and controlable swing.

011 Flo_ - Regeneration

Spool Sealed
It ofte n h appens that a c ylinder moves
fa s ter than the pump can s upply oil. The pump
is un a ble to keep up with the demand when a
weight on the cylinder move s the cylinder
rathe r than the appli e d oil, E xample: quickly
lower ing a heavy load. If the pump is running
slowly, this condition is fu rthe r c omplicated
bec ause pump output is in direc t. proportion

When the swing is stopped at a point

other than a full swing, the c;rossover r elief
valves also serve to cushion the stop . The
weight of the boom, dipper and buck et , and
the momentum of the swing w ill t.end to continue the swing motion, Hydr aulic pres s ure
will then inc rease in the r eturn circuit illustrated in Figure 3. The c rOs s ove r relief valves
the n open, trans ferring oil b etween the c yli nd e l' s, permitting a c us hioned stop . Shoul d t he
crossover r elief vulves be wlable to handle
the surge of displa ced oil, one of the secondary
reI iei val ves woul d open anddh'ert the excess
oil to the reservoir.

to engine speed.

Refer to Figure 2. Assume the dipper is

lowering a heavy object and the engine is
running at half throttl e. The weight of the object pulls the piston r od out of the dippe r
cylinder faster than oil is be ing supplied,
Without regeneration a large void (air space)
would be created in the closed end of the
dipper cylinder. Howe ver, this action results
in a pressur e drop thr ough open center and the
open cent e r parallel pa ssage, The pressure
drop ena bles the spring under the reg'eneration
spool to seat the spool, partially closing the
return passage in the outlet s ection. With
this pas sage blocked, the return oil displaced
by the cylinder piston is d i verted through the
regeneration check valve in the inlet section
to supplement oil from the pump, preventing

At times during the swing, oil will be

displaced from the swing cylinde rs slower
than the pump suppl ies oil. When this occur s,
pressure between the cylinder pistons and
control valve section will rise to the pre ssure
setting of the cros sover relief valves. The
r e lief val ves then open, r elieVing the pres s ure
and diverting the excess o il t o the res er voir.

SECONDARY

DIPPER CYL I NOER

REliEF VALVE

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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

_
OUTLET SECT10N

PUMP Pi\ESSUR E
RETURN OIL.
STATIC Oil

SWING SECTrON

SECONDARY RELI .F VALVE

71G995

FlEL I Ef

VALVE

PJ 5TO~

ASSEMB LY

7 10934

Figure 4 - Restricting Oil Flow From Swing Cyl,inder

The boom down relief valve is set at 1000 +250
-100. psi, its funct ion to be cove red in the
following .paragraph. A secondary r elief valve
has one function, to protect t he back hoe
mechanically and hydra ulically when a cylinder is forced to move with it s valve spool
in neutral. Example: as the dipp e r and bucket
are b eing retracted during digging, pressure
is often exerted aga inst the boom, forcing
it upwa~d. When thi s happen s the r elie f
valve in the boom down (A) port will open,
allowing the boom to rais e .

Slopping The Backhoe

AI FuU S_lng
As there are no mechanical stops to control full swing, stopping the swing motion
is accomplished hydraul ically by the swing
cylinders.
Refe r to Figur e 4. As the piston in a
sw ing cyl inder nea rs the end of its stroke,
the restrictor pin enters the outl e t passage
in the closed end of the cylinder, restr icting
the displ acem ent of oil from the cylinder.
At this time , swing motion is slowed a nd
pres s ure inc reases in the closed end of the
cylinder, perm itting a cushioned s top at full
sw ing.

The reli ef valve in the boom down port has

two func tions: (1) to allow the boom to ra ise
as expl a in ed in the prec ed ing example, and
(2) work ing in conjunction with the r es tricto r
in the bo om s ec tion B port, controlling the
pressure and speed at which the boom lowers.
The pressure setting of the rei ie f val ve being
lower than that of the ma in r elief valves
permits excesS oil to be returned to the
reser voir.

If the backhoe is sWWlg r a pidly and c ompletely to the right or left, pressur e in the
closed end of cylinder may rise to 3900 20 0
psi. When this happens, the r elief valve will
open to relieve the sudden incr ease in pressure 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
valve. The check valve pre vents reverse oil
fl ow between the cylinde r and the val ve
section. The check poppet remains s eated
Wltil the pr e ssur e of the oil being deli vered
to the cylinder is greater than the pres sur e
between the cylinde r and the poppet.

Secondary Relie' Valve.

Eac h working section has a secondary
relief valve connected to its work port s . All
reli ef valves except the one in the boom
clown (A) port are set a t 2750 + 250 - 100 ps i.

Removal
1.

sec ur e the control tOIV e r to the main

frame.

Fully ret ract the buck et and dipp er arm,

and lower boom until bucket rests on
the floo r.
NOTE: As hyd raulic lines are disconnected, close the openings with cl ean
caplugs. Also tag or otherwise identify
lines and parts to ass ur e proper connections when installing the c ontrol valve.

2.

If the backhoe is equipp ed with optional

features, prepare the contr ol tower for
removal:

a.

b.

c.

If equipped with boom lockout, move

boo m control le "er in both direc tions
to equalize pressure and disconnect
line s to valves mowlted on front of
control t ower .
If equipped w ith Hydra-Guide, l'emove the seleutor val ve handl e and
l oosen the valve ret aining nut. Re move the upper fr ont cover mounting
screws and m ove cover away fr om
the tOlVer to gain acc ess to the
se lec tor valve. Remove the "alve
retaining nut and po sition the se lec tor val ve out of the way.

5.

Rem ove control tow e r wit h guards attached.

6.

IVlove the control levers in both dir ec t ions

to equalize circuit pressure and disconnect linkage at cont rol valve spool s . Then
discolmect hoses and t.ubes from the
contr ol valve.

7.

Remove the nuts and lockwashers from

the c ontrol valve mounting bolt s . Take
the weight of the valve off the mounting
bolts and remove the bolts.

8.

Lift the val ve up and away fr om the

mowlting brackets and remove fro m ma in
frame.

9.

Prior to disassembly, r emm'e accum ulated dirt and grease fr om the control
valve.

Disassembling The
Conlrol Valve

If equipped with an Extendahoe, disc onnect the control lever a t the

diversion valve lever.

1.

Remove accumulated dirt and grease

from c on trol valve if this has not been
done.

2.

Starting at the inlet section, number the

working sections to assu1' C:' propel' as-

3.

Remove the upper and lower front covers

frum the contr ol tOlV er .

4.

Remove the fo ot gu ard to main frame

bolt s , nuts, and washers. Then r emove
the thl'ee bolts, nuts and washers that

s embly .
3.

Remove the nuts a nd washers from e ither

end of the tie rods and rem ove the valve
sections. As the sect ions are rcmoved,
remove and dise,ud the o-r ings.

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AOJUS T I"lG

SPORING SEAT

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BACK UP R" " -

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RfGEtJERATI Ol-i
ClifCK VALVE

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10

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710948

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the crossover relief valves also. See

Disassembly, Inspection 'lild As sembly of
Relief Valves.

D I.a e",bly Of Valve Seclions

Inlet An d Outlet S ections

1.

Disassembly of the inlet s ection consists

of r emoving the regeneration check valve.
To disassemble the check valve, use a
pocket knife or other point ed instrument
and r emove the spiral snap ring, Figure
6. Then remove the spr ing seat, spring
and poppet from the valve bore.

In.pectlon
l.

Discard all wipers, a-rings a nd backup

rings.

2.

Clean parts in cl eaning solvent and dry

with moisture free compressed air.

3.

Inspect the spool bore and spool for

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
not been completely disassembled . Thoroughly wash the valve section incl ean ing
solvent to remove all t rac es of grit.

5.

Inspect the spool centering spring and

check poppet spring for distortion and
signs of cracking. Also c heck springs for
proper tension, refer to spring' specifications on page 3.

UserFriendlyC Ds

tOOJJ.j
Figure 6 - Removing Spiral Snap Ring
2.

Disassembly oftheoutlet section consists

of removing the regeneration spool cap
and removing the spring, s p ring seat and
spool. Use care not to loos e the plunger
or ball in the end of the spool.

Working Sections;

A e",blyo,
Working Sections

NOT~ If more than one section is to

be dIsassembled, identify the parts as they
are removed to assure they will be installed
in the proper section dur ing as s embly.

1.

Remove the spring cap and grasp spool

at spring end and carefully pull spool
from valve section. Do not remove spring
retaining screw unless yellow Loctite is
available for use during assembly.

2.

Remove the wiper and quad ring from the

top of the spool bore.

3.

Remove the a-ring' retaine r, backup ring

and quad ring from the s pool or bottom
of spool bore.

4.

Remove the secondary relief valves and

check valve from the valve section. If
disassembling the swing section, remove

1.

Install a new a -ring on the check vah'e

c ap and place the poppet spr ing and poppet
in the cap. Screw the cap into the val ve
section and tighten securely.

2.

Install new a-rings and a backup ring

on the secondary relief valves. The
backup ring is installed in the top of the
groove. Lubricate the a-rings with hydraulic oil, screw the r elief val ves into
the valve section and tighten securely.
N~
If assembling the boom section,
make sure the low pressure sec ondary
relief valve is installed in the top of the
valve section.

3.

If assembling the sw ing section, inst all

the crossover relief valves. Install new

a- rings and backup rings on the relief

12

val ve bodies. Before installing the middle

a -ring. install the backup ring and position it at the top of the groove. then
insta ll the a-ring. Insta ll the hottom
a -ring be tween the two backup rings.
4.

Ins tall the quad ring and IV ip er in the

grooves at the top of the spool hOle.
Make sure the quad ring is not twisted
and is properly seated. The wiper ShOllld
be installed with the lip to the spool eye.

5.

Lubricate the spool and spool bore with

hydraulic oil.
a.

c.

d.

If installing spool with centering

spling removed. push the spool into
the valve section with a twisting
motion until the spool is even with
the bottom of the val ve sed ion.
Lubr icate the remaining quad ring
a nd install in groove fOl'med h>' the
spool and valve section. Then place
backup ring over quad ring.
Place the quad ring r eta in er . a
spr ing seat. centering spring and the
remaining spring seat over the spool.
Coat the spling r etaining screw with
yellow Loctite. thr ead screw into
spool and tighten.
If installing spool with spring at-

tached. ptace the qu ad ring retainer.

backup r ing and quad r ing on the
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
quad ring into the groove formed by
the spool and valve sec ti on. Place
the backup ring over the qlll1d ring
and push the spool completely into
the va.l ve section.
6.

section. Then in stall theworking sections

in the sequence established at disassembly. As the sec tions are pOSitioned. make
sure thG a-rings have ren1<1 ined inp lacG.
3.

Place the outlet section on the tie rods

ancl secur e in place with nat washers
and nuts. Torque the nuts evenly to 30
foot-pounds in incr ements of 10 footpOlmds. If the nut s a re tightened unevenly
or over tighten ed . bind ing spools may
reslll t.

4.

If a secondary or crossover relief I'alve

adjusting screw has been disturbed or a

new relief val ve has been installed. check
the pressure sett ing as instructed in
Section 42.
DIsassembly, Inspecllon And
Assembly 0' Relief Valves
Secondary Relief Valves
1.

Secllre valve body in a vise. Loosen the

adjusting scr ew lock nut and remove
adjus ting screw.

2.

Remove the cap from the valve body.

Then remove the pltmger. spr ing and
floating seat from the body.
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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

1.

2.

Plac e a s mall aTnount of grease in the

Orit1g 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.
InsUllI

the tie rods thr ough the i.nlGt

I to.\ T Ir~C sc/\ T

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3.

4.

Discard all 0- rings and the backup ring.

Inspect the plwlger, float.lng seat and
seat in bottom of val ve body for defects
that would result In l eakage.

AOJ US T I NG SCR\1

LOCK i'iUT
~.~'O-RING

SPRING

Inspeot the spring for signs of distortion

and cracklng. Also check sprlng tension,
refer to spring specifications on page 3.

SPR I tlG
C-R I

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

and in stal l the plwlger in the floating
seat. Install this assembly In the val ve
body.

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.
To obtaln an approximate pressure settillg. turn the acljustlng' screw in Wltil
the distance between the top of the
s crew and the bottom of the valve measur es 2-9/ 16".

9.

FLOATING SEAT

O-R I :'G
BACK UP R I "G=-I11~

6,

Inspect the poppet end of the va lve body

bore for scoring.

7.

Inspect the spr ings for distor tion and

signs of cracking, Also check s pring
tension, refer to sprlng specifications on
page 3,

8.

Place the flo ating seat, spring and sprlng

seat in valve body, Then i.nstall the
adjusting scr ew.

9.

Insta ll new a-r ings ancl backup ri.ngs on

the poppet and valve body . The backup
ring for the valve body middle a - r ing
should be pas itioned at the top of the
groove. The bottom valve body a- ring and
the poppet a-rings should be pOSitioned
between the backup rings.

10. Adjust the pressure setting as lnstructed

In Section 42.

Crossover Relief Valve

Pu ll the poppe t from the l'alve body. The

poppet is he lel by the fit of the a-ring.

2.

Secure the val ve body in a vise, Loosen

the adjusting screw lock nut and r emove
the adjusting screw,

3.

Hemove the sp ring seat, sprlng anel floating seat from the valve body,

4.

Remove and
backup rings.

5.

Inspect the poppet and fl oatlng seat for

defects that would result in leakage.

BACKUP R I t~ G

lIl<-- fl , IN"

Figure 8 - Crossover Relie f Valve

Install ne w a-rings and a backup ring

on the valve body. T he backup ring
should be pos itioned at the top of the
groove .

1.

BACI(U PRING

10. Lubricate the poppet with hydraulic oil

and install in valve body, To obtain an

appro ximate pres s ure setting, seat the
poppet against the floatlng seat and turn
the adjusting screw in until the distance
between the top of the screw and the bottom of the poppet m ea sures 3-15 /1 6".

eliscard all a- rings and

11. Adjust the pressure setting as instructed

in Section 42.

14

Refer to Section 42 , page 6 for torque

specifications.

In.tallation
1.

POStiOIl the control valve in the m ounting

brackets. As the mounting bolts are
installed, place a Oat washer between
the rear mounting brackets and the
cont rol val ve . Secure valve in place with
lockwashers and nuts.

2.

Connect linkage to val ve spools.

3.

Connect hydraul ic 1ines to control val ve .

Re fer to hydraulic diagram in Section
42 and c heck for p rop el' connections.
Improperly torqu ed fittings
c an result in leaks or damage d fittings .

CAUTION:

4.

Before installing the control tower , start

the engine and operate eac h cylinder
through seve ral complete cycles and
check for l eaks . If equipped with boom
lockout, temporarily cOImect the val ves
mOW1ted on the upper front cover into
the !Joom circuit.

5.

Position control tower on ma in fram e and

secure in place with bolts, nuts and
washe rs. Install the lower and upper
front covers and secure with capscrews
and washers.

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 .

GENERAL.

OPERATION

REMOVAL.

DISASS EM B LY

ASSEMBLY

INSTALLA TION .

Specifications

Case part no . . . . .
Description .. .
Main relief valve ..
Ports and spools
Spool travel, neutral to pressul'e
Spool in .
Spool out . . . . . . . .
Port thread
Power beyond port
Power beyond fitting, internal
Outlet port .
Work ports.
Weight (approx.).

. . . . . .. . D50420
See General below
. . . See Section 42
5/16" (7,9 mm) in and out
Upper work port pressurized
Lower work port pressurized
1-5/ 16"-12
1-1/16"-12
1-1 / 16"-12
.. 7/8"-14
. 22 Ibs. (10 kg)

Springs
Free Length
Spool centering . . . . . . . . . . . 1-5/ 16" (approx.)
Check valve . . . . . . . . . . . . . . 1-7/64" (approx.)
Torque, spring cap, a-ring retainer
and centering spring screws ..

The stabilizer control valve is a two

spool, open center valve. Check valves are
connected to the open center passage to
prevent reverse oil flow between the cylinders and the control valve when a spool is
moved into a power position. Stabilizer circuit
pressure is controlled by the main .relief
valve in the loader control valve. Both spools
may be ac tuated at the same time, however,
the cylinder with the loast resistance wiII
move first.

Compressed Length
1" @ 22.5-27.5 Ibs.
3/4" @ 1.3-1.7 Ibs.
.. 6-12 foot-pounds (0,8-1,6 m-kg)

3.

Disconnect hoses and tubes from the

control valve and close opening's with
clean caplugs. Then remove the nuts and
washers from the mOlUlting bolts.

4.

Remove
plate.

control valve from mounting

Dis assembly
NOTE: Tag or otherwise Identify parts
as they are removed to as sure proper
asse mbly.

1.

Remove the power beyond fitting and

the relief valve plug.

2.

Remove the check valve caps, springs

and poppets.

3.

Remove the 90" elbows fro m the llpper

and lower ports .

4.

Remove the s pring caps and the a-ring

retainers.

5.

Grasp the spool spring and pull spool

from valve.

6.

Do not remove the

unle ss yellow Loctite
use during assembly.
spring, insert a 1/ 4"

Operation

The operation and all flow through the

control valve are similar to the loader
control valve and will not be covered in
detail.
Removal
1.

2.

Lower the stabilizers to the floor or

raise the stabilizers and tie the stabilizers together with heavy wire or chain.
Wi t h the engine shut off, move the stabil izer control lever s in both dir ections
to equalize circuit pressure. Then cl!sconnect linkage from the spools.

centering s pring
is available for
To remove the
rod in the spool

1/4"- UC x 1/2"

O-R IIl G RETAJ IIER __~

RELIEF
o - V ALVE PLUG

BACK UP R I>IG_O
O-RI " G - - C )

SACKUP RI NG

O : : ' >O- RI "G

POPPET

CH ECK VALVE

SPR H'C
O- R1.:: G ; ,

\ <>,

&#

CAP_(!}~

UA.--

- <PACE R

!IllER SPR ItIG SEA r

R SPR ItIG SEA T

<--~) -- FLAT WAS HER

1/4"- NC )(, 1/2 "

~
~U -

-1 /4 "- NC x 3/ 4"

Figure 1 - Exploded View of Control Va lve

7J G95G

eye or secure spool eye In a vise,

then remove the screw, flat washer,
outer spring se a t, spring and inner
spring seat.

with yellow Loctite and install screw

with flat washer. Torque the screw
to 6-12 foot-pounds.
c.

7.

Remove the backup rings and

from the spool bores.

0- rings

Inspecllo"
1.

Discard a-rings and clean parts incleaning solvent. Dry with moisture free
compressed air.

2.

Inspect the spools and spool bores for

scoring and othe r defects that would
result In excessive spool leakage. If
inspection indicates replacement of a
spool or the valve body, the complete
valve must be r eplaced.

3.

Inspect the check valve poppets for

wear. Also inspect the poppet seat in
the valve body.

4.

Inspect springs for distortion and signs

of cracking. Also check spring tension,
r efer to page 3 for sp ring specifications.

Assembly
1.

Lubricate the a-r ings, spools and spool

bores with hydr aul Ic oil.

2.

Place an a-ring and backup ring in the

top of each spool bore. Place a-ring
retainer on valve body and tighten screws
finger tight.

If installing a spool with spring attached, place the spacer, backup ring
ring and a-ring on the spool. Push
the spool in until the bottom spool
land has started into the valve. Work
the 0- ring into the groove formed
by the spool ancl the valve bocly.
Position the backup ring on the a-ring
and push the spool all the way in.

3.

Place spring cap ove r ce nte ring spring

ancl secure in place with screws. Torque
the spring cap and a-ring retainer screws
to 6-12 foot-pounds.

4.

Place springs in check valve poppets

ancl install poppets in their respective
bores. Install a new 0- ring on the check
valve caps and screw caps into valve
body ancl tighten.

5.

Install new a-rings and backup ring on

power beyoncl fitting. SereII' fitting into
valve bocly and tighten.

6.

Install new a-rings and backup ring on

relief valve plug. Screw plug into valve
body ancl tighten.

I"slallallo"

a.

b.

1.

Place the mounting bolts in the control

valve.

2.

If installing a spool with centering

spring remover!, install the spool
through the bottom of the valve.
Push the spool in untll the bottom
of the spool is about 1" from the
bottom of the valve body. Install
the a-ring in the groove formed by
the spool and valve body and place
the backup ring on the 0- ring.

Holcl the control valve aga inst the mounting plate ancl secure valve in place with
nuts and washers.

Install the spacer, inner spring seat,

centering spring and outer spring
seat. Coat the spring retaining screw

3.

Conn ec t hose and tubes to the control

val ve. Reposition the elbows in the lower
work ports as requir ed . Make su r e the
elbow lock nuts a re ti ght.

4.

Connect linkage to v al \'e spool s. sta rt

the engine a nd move the stabil izers
through several cycles to r emove any
trapped ail' and check for l eaks .

710999

Figu re 2 - Contro l Valve Installation

SECTION
44d

THREE-POINT
HITCH
CONTROL VALV

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TABLE OF CONTENTS
SPECIFICA TrONS. . . . .

OPERATING PRINCIPLES.

EXPWDED VIEWS

Inlet Section

Lift Section.

Implement. Pitch. and Tilt Sections.

SERVICE . . .

Removal .

Valve Sections and Spools

Inlet Sectio n . . . . . .

Pitch. Tilt. and Implement Sections

10

Lift Sec tion. . . . .

10

Assembling the Valve

.11

Installation

12

SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . .. D52970
. . . . . . . . . . . . Hydraulic Industries 5030-4-1
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 ensating 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.

Ca se part numbe r . . . .
Manufacture r's number
Description '" . . . . .

Relief valves
Main relief val ve
Type. , , . ,
Setting . . . . .

. . . . . . . Ca rtridge type. direct acting, adjustable

1800 75 psi at full engine rp m (127 5,3 kg/cm')

Secondary reli ef val ve, lift seotion

Ca rtridge type. direct acting, adjustable
Type ..
. . . . . . Cracks at 1900 psi (134 kg/ om')
Setting . . . . . . . . . . . . . . . . . .
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

OPERATING PRINCIPLES

Description

ten sion of spr ing (7). As the spool shifts,

the flo ating plunger (8) sli de s down to
compensate for the oil displ aced by the
shift of the compen sating spoo l.

General

Valve 052970 is a pre ssure co mpensated

directional control valve cons is tlng of sL" sections as follows: an inlet sec tion containing
the outlet, inlet, flow regulator , restrictor,
and main reli ef valve; thr ee sections for the
tilt, pitch, and impl eme nt cylinders with a
three-position spoo l in each; one section for
the lift cylinder with a four-position spool; and
an end section.

NOTE: A c he ck ball (not shol'ilJ) prevents movement of oil in the gre en colored
passages toward the spool (2).

The thre e position s avail able at all spools

a re power at A port, neutral, and power at B
port. In addition , the lift spool has a fourth
pos ition, Float Do wn. In Float Down, the spool
is mechanically he ld (detented) until manually
released. The spools are returne d to neutral
from the powe r positions by center ing springs.

5.

At the sa me time , the spool (2) opens

pa ssages which allow the pump supply to
flow through the orifice plate (9), and
c heck poppet (10) into the head end ofthe
cylinder (11) caus ing the cylinder to
extend.

6.

Note that the s hift of the compensa ting

spoo l (5) ope ns the pump supply to the
outlet passage (12) at points (1 3) and (14).
Excess pump supply flows through the
outlet port (1 5) to the rese n'oi r (20) .

7.

The pre ssure c reated by the cylinder (11)

movement is transmitted via grooves in
the valve face (16) to the pilot passage
(17), then to chamber (18) in the inlet
s e c tion .

8.

This pilot pressure acts against the rim of

the compensating spool and the flo ating
plunger (8) causing the plunger to bottom
ou t in the bore of the compensating spool.

9.

Thes e forces, added to tens ion of t he

spr ing (7), shift the comp ensating spool
downward against pump pressure at t he
opposite end of the spool. As c ond itions
of s upply, resistanc e , and demand c hange
In the system, the spool is rcs hifted as
required .

Flow Regulation

Flow from the inle t sec tion to the cylinders pas ses through a fixed orifice which
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 cylinder being operated receives oil first with
the exc e ss (if any) returned to the reservoir.
T o e xpl ain the remaining; valve com ponents and the ir function, we will de scr ibe
a typic al operating sequence.

Operating Sequence
Refer to Figure 2.
l.

The pump (1) Is operating at normal

speed.

2.

The operator pulls a control lever moving

the spool (2) Into the valve body.

3.

Pump supply flows through the Inlet port

(3) of the inlet section.

4.

Pump oll flows through a s m all hole (4)

In the compensatIng spool (5) filling
chamber (6). This causes the compensatlng spool to shift upward against the

10. If the cylinder (11) cannot move, the main

relief valve (19) open s at 1800 psi ancI
vents 011 to the reservoir (20).
11. When the operator r e turns the spool to
neutral, the pilot passa ge s (16 and 17),
chamber (18), and cylinder (11) a re closed
to pump supply. The compe nsat ing' s pool
(5) shifts fully upward and the entire
pump supply flows to the outle t through
openings at (13) and (14).

SPOOL
ACTUATED

oD'>IM/AR0

PUMP OI L

RETURII 0 I L

PILOT PnE SSURE OIL

lYP!CAL
CYLJ:lDER

7-1----I

I
-.I

ORIFICE
PLATE

i-

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PU11P

t
710996

EXPLODED VIEWS

PLATE

- - IJASH ER

lj

FLOA TI NG
PLU NGER

-SPRING

O __

O- RING

~- PLUG
Figure 3 - Exploded View of Inlet Section

7 11 Q;j'?'

~ El l

EF

IjAl VE -

/
\- - -DETEI'H SToD

-SPRI"G GUIDE

CENTERINC

~- SPR I NG

<::)-

~
<
~
'

f:

f\ 1
, '- -'
f:' ""', _:-....
,

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0- RII NG

SPOO L HE
I

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C- RI NG

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,~'" "n
"'l'/I
, i-

SNA P R I "G

. -

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SPRIfIG CIlIOE

0 -

RE TAINER

a-R I NG

SEA L

SPACER

DET ENT HOUS I nG

CHECK
POPP ET

~ - SPRWG I

""'

~ - SPR1tJG

H-""

(~

\lJ.-- CHE CK!

-...

~ )"
~-

SLEEVE

e!

,,_ 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

O-R I.'IG

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SPO Ol _
EYE

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'8

't/ I PER- e

SEl<l _

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O- R l r~G -O

RET .... HJER,

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SPRING

~_SPR I NG

GU IDE

~_ 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-

RETA I h I NG

.~

PRI NG
T

SPOO L C.' .P

~-

POPPET-B

1/4"-NC ;; .) /'."

)
7110 ~ 1

t Pitch, and Tilt Sections

Figure 5 - Ex-ploded View of Im Plemen,

Removal

1.

2.

3.

from the face of each s ection (11ft, tilt,

pitch, implement).

Remove accumulated dirt and grease

from the valve and surrounding area to
prevent entry of dirt into the hydraulic
system.

Inlet Section

DISASSEiVlBLY

Lower the hitch fully or rest implement

(if attached) on the ground. With the
engine shut off, move the control levers
back and forth to relieve hydraulic pressures.

Refer to Figure 3.

Before removing the valve, tag and

number the hoses that connect to the
valve, starting at the inlet s e ction. Number the top port of the inlet section
No.1; the bottom port No.2; the top port
of the implement section No. 3, etc.

1.

Remove plugs from top and bottom of

valve. Remove parts shown in Figure 3.

2.

Use an allen wrench to remove the

orifice screw.

3.

Remove the relief valve cartridge and

o-ring.

INSPECTION

1.

Inspect the compensating spool andplunger for scoring, burrs, and excessive
wear. Make sure spool orifice is open.
If either part must be replaced, replace
the complete valve section.

2.

Inspect the housing for cracks. Shine a

light in the spool bore and check for
scoring and wear. If the housing must be
replaced, repl ace the complete section.

3.

Check the spool spring compression with

a suitable spring testing device. Replace
spring if It does not meet specifications
on page 3.

4.

The relief valve may be disassembled for

inspection and cleaning. Check the plunger and seat. If the relief valve is
damaged in any way, replace the entire
relief valve.

Dis assembling The Valve

5.

Replace o-rlngB.

1.

Starting at the inlet end, number all the

sections in order to assure reassembly in
exact, original position.

6.

Replace the steel ball and orifice screw

If damaged. Make sure the orifice In the
orifice Bcrew is open.

2.

Remove three tie rod nuts at the inlet

section. Slide sections off the tie rods as
required.

7,

Clean all parts in solvent and blow dry

before reassembly.

3.

Remove the three o-rings from the face

of each section and inspect for damage.
Take care not to lose the two steel balls

ASSEMBLY

4.

Disconnect hoses and close openings with

clean caplugs.

5.

On the tractor, connect the pump supply

hose to the return line at the quick
disconnect coupling.
CAUTION: Do not dr ive the tractor with-

out completing step 5.

6.

Remove the control lever pins from

the valve spools.

7.

Remove three mounting bolts and lockwashers. Carry the control valve to a
clean work bench for disassembly.
CAUTION:
Cleanliness is very Important. Service this control valve in the
cleanest surroundings possible.

Valve Sections And Spools

1.

Lubricate o-rings with hydraulic oll.

2.

Assemble parts shown in Figure 3.

Lubricate spool and plunger in hydraulic
oil befol'e installation.

ASSEMBLY
1.

Lubricate
hydraulic
centering
grease or

2.

Cl amp the spool in the vise used during

disassembly. Assemble the centering
spring. poppets. and spool eye as shown
in Figure 5,

3.

Install a well lubricated o-ring and wiper

at each end of the spool bore.

4.

Lubricate the spool bore with hydraulic

oil. Slide the spool into its bor e . Take
care not to damage the o-rings and
wipers.

5,

Install seal retainers and spool cap.

Pitch, Tilt, And Implement Sections

seals and internal pa rts with

oil before assembly. Coat the
spring and spring guides with
hydraulic oil.

DlSASSEMBLY
Refer to Figure 5.
1.

Remove two spool cap capscrews. Remover the spool cap and seal retainer.

2,

Pull the sp ool assembly out of the valve.

3,

Clamp the spool in a SOFT jawed vise

or between wood or brass strips.

4,

Unscrew the centering spring reta ining

bolt. This will permit removal of all
pa rts from the cap end of the spool.

Lift Section

NOTE:
Popp ets must be returned to
their original pOSition, if reused.

DISASSEiVlBL Y
5,
6.

Unscrew the spool eye. Re move the poppet

and spring from the spool.

Refer to Figure 4.

Remove the seal retainer. Remove a

wiper seal and o-ring from each end of
the spool bore,

1.

Remove two long capscrews which reta in

the detent assembly.

2.

Remove the detent housing cap and detent

housing.

Pull the spool assembly out of the valve.

4.

Slide the seal retainer and detent assembly off the spool

5.

Remove the centering spring:

INSPECTION
CAUTION, Do not intermix spools and
sections. Always return a spool to its original
section. If either the spool or housing must
be replaced, replace the entire sectlon.

1.

Clean the metal parts in solvent and blow

dry.

2.

Replace check poppets if worn or damaged, Replace wipers and o-rings.

3.

Inspect the valve body and spool for

grooves. deep scratches. and excessive
wear. See that the spool slides in and
out with slight hand pressure and without
noticeable side clearance.

4.

Inspect the machined faces of the sectlons

for nicks and burrs, Use a fine oil stone,
working with light rotary strokes. to
remove any nicks and burrs. Thoroughly
wa sh the valve section in cleaning solvent to remove all traces of grit.

10

a.

The centering spring must be compressed to remove the snap ring.

Fabricate a pa j l' of compressor
plates. Figure 6, or use the compressor supplied with Case Kit No.
D45700. Compress the springs as
shown.

b.

Remove the snap ring, Ca r efully relea se the spring tension, Remove the
centering spring and spring guides,

6.

Clamp the spool in a SOFT jawed vise or

between wood or brass strips.

7.

Unscrew the detent stud and spool eye.

inspection and cleaning. Check the plunger and seat. If the reli ef valve is damaged in any way, replace the entire relief
valve.

Be LT
8

-r

NUT
RETAINER
PLATES

1.2~

ASSE1'IBLY

H+-t-_!:I
'-+--f---~
I .875 DIA.~
I

1.

Lubricate seals and int e rnal parts with

hydraulic oil before assembly. Coat the
centering spring' and de t ent assemblies
with grease or hydraul ic oil.

2.

Clamp the spool in the vise used during

disassembly. Ins tall the check poppe ts
and springs, spool eye , a nd detent stud,
Figure 4.

3.

Assemble the centering spring and spring

guides over the detent stud. Compress the
centering spring, Figure 4, and install
the snap ring.

4.

Install the seal r e ta iner with a-rings and

wiper at the spool eye end of the \'al ve
housing.

5.

Assemble the detent mechanism parts and

seal retainer on the spool. Use grease if
required to reta in the steel ball s .

6.

Lubricate the spool with hydraulic oil.

Slide the spool into the valve housing.
Take care not to damage wiper and seals.

7.

Install the d etent housing cap and two

long capscrews.

8.

Install the relief valve cartridge and

a-ring.

~ -~,- 2 .12 ~~~~

Figure 6 - Compressor Plates

8.

Remove a check poppet and spring from

both ends of the spool.
Poppets must be returned to
their original position, if reused.
NOTE:

9.

Remove the seal retainer from the valve

body.

10. Remove the relief valve cartridge.

INSPECTION
1.

Clean the metal parts in sol vent and

blow dry. Discard the wipers and o-rings.

2.

Replace check
damaged.

3.

Inspect the valve body and spool for

grooves, deep scratches, and excessive
wear. See that the spool slides in and
out with slight hand pressure and without
noticeable side clearance. If either the
spool or housing must be replaced, repi ace the entire section.

4.

5.

6.

poppets

if

worn

or

Assembling The Valve

Inspect the parts in the detent assembly

and l'eplace worn or damaged parts.
Test the spr ing with a suitable spring
testel'--it should compress at the rate
specified on pag'e 3.

Refer to Figure 1.
1.

Lubricate new o-rings with hydraulic oil

and install in the grooves on the faces
of the valve sections.

Inspect the machined faces of the section

for nicks and burrs. Remove any nicks
and burrs with a fine oil stone, working
with a light rotary motion. Wash the section in cl eaning sol vent to r e move all
traces of grit.

2.

Clamp the inlet section (tagged no. 1)

in a vise with the machined face pointing
up.

3.

Install greased o-rings, and orifice plate

on the face of the inlet section.

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

balls.
5.

Assemble the r emaining' sections In the

numbered order until all six sections are
stacked up.

6.

Install the tie rods and nuts. Lubricate

the threads on the end of the tie rods
and the bosses On the end section which
bear agaInst the nuts. Torque the tie rod
nuts evenly to 28 foot-pounds.

3.

Reconnect the hoses. Connections may be

checked against the diagram, Sec tion 42.
Torque specifications are on page 6,
Section 42. The 45 l'estrictor elbows are
located in the upper (1\) ports of tile tilt,
pitch, and lift sections.

4.

If the setting of the maIn relief valve was

disturbed, perform the pressure check

and adjustment, Section 42.

Installation

If the setting of the relief valve In the

lift section was disturbed, perform the
pressure check and adjustment, Secti on

1.

Mount the valve On the bracket with three

bolts and lockwashers.

42.

2.

Connect control lever linkage.

preset.

5.

NOTE:

12

Replacement relief valves are

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

13

15

INSET C

Figure 1

RING

454

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 kup 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.

457

INSET A

INSET B

PACKI

RING

-/ r-::::::;-;;--INSET C

044113

SECTI ON

45
CYLINDER
REMOVAL/I NSTALLATION

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Burl. Form 9-7 20&5 KHC BO

"rlnled In U.S.A.

Approxim a te Cylinder weight., D ry

Dipper cylinder ...
Extension cylinder .
Boom cylinder .
Bucket cyl!nder
Swing c yl!nder
Lift cyl!nder
Tllt cyl!nder .

. 105
96
83
81
61
50
36

A spanner wrench kit. part no. D441l0,

is a.vailable from Se rvice Parts Supply. The
kit contains the va rious sizes needed to
r e move a nd install packing gl ands on Case
manufactured cylinders.

044111
044112
~~~~ DAA II3
D4411 4
04411 5
D4Allo

5.

To 1-3/4"
To 2"
To 2-1/4"
To 2-1/2"

Removal
Lower the loade l' or backhoe bucket
with bottom of bucket flat on the floor.
Position the backhoe in a safe and comfortable work position and support the
backhoe at the boom and dipper pivot.

2.

Remove accumulated dirt and grease

from cyl!nder and fittings.

3.

With engine shut off, move the cylinder's

control leve r In both directions to equalIze circuit pressure.

6.

kg)

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 connected to control valve .

Note the location and number of shims

(spac ers) at cylinder pivot points and
remove the cylinder pivot pins.
If removing a swing cylinder, remove
the rod eye pin retainer from the
bottom of the s wing tower and drive
pin out through bottom of swing
tower. Remove the trunnion pin
mountln~ bolts and remove trunnion s
using 1/2"-NC puller screws in the
holes provided.

Take the cylinder to a clean work bench

for disassembly. Remove any hoses,
tube s and clamps still attached to the
c ylinder.

In.tallatlon
1.

Remove clamps and guard s a s required,

then disconnect hoses and tubes at points
considered most convenient. Close all
openings with clean caplugs.
a.

kg)
kg)

If removing extens ion c ylinder, disc onnect hoses to cylinde r at tubes

secured to the boom. Remove cover
from end of dipper and reroute hoses
out end of dipper.

a.

4.

kg)
kg)

To 1-1/2"
To 1-1/'2"

Figure 1 - Spanner Wrench

1.

(37,7
(36,7
(27,7
(22.7
(16,3

b.

ROD SIZE

2-1/2"
J"
3"
3-1/2"
4"
4-1/2"& 5"

Ibs.
Ibs.
lbs .
lbs.
lbs.

inde r pivot pins and fr ee closed

end of cylinder from the dipper,
then disconnect the ho s es at the
cyl!nder.

Spanner Wrench

WRENCH

Ibs. (47,3 kg)

Ib8. (43,5 kg)

If removing bucket cylinder on a

stand a rd backhoe, remove the cyl-

Position the cylinde r on the unit using

a chain hoist. If necessary. Dlustr ations
which show the snap rings, washe rs, etc .
a nd the order of Insta llation w!ll be found
In Section 92, Loader or Section 93,
Backhoe, and Section 97, Three - Point
Hitch.
NOTE:

Grease fittings must be installed

gr ams in Sectio n 42.

in their origina l position so they are

no t hidden or hard to get a t.

NOTE:
Proper torque of fittings will
prevent damage a nd leaks. Torque sp ecific ations a r e below.

Connect hoses and tubes. nJustrations

which sholl' the fittings, clamps, etc.
and the order of installation will be
found in Section 92, Loader, Section 93,
Backhoe, or Section 97, Three-Po int
Hitch.

2.

3.

4.

Check connec tions against hydraulic dia-

After the cylinder is installed , s tart the

engine and r un the eyli nder through
several cycles to bleed any air f rom
the circuit and chec k for leaks .

U.S. AND METRI C TORQUE SPECIFICATIDNS

Hydr aulic Fi llin gs (Sle el)

D ash

T u be

Size

O.U.

"
5

1/4"
5/16"
:3/8"
1/ 2"
5/ 8"
3/4"
7/S"

6
8
10
12
14
16
20
24

I"

1-1 / 4"
1- 1/2"

Thread
Sl l..e

7/ 16" - 20
1/2" - 20
9 /16" - 18
:)/4" - 16
i /0'1 - 14

1-1 / 16" - 12
1 -:3/10" - 12
1- 5/ 16" - 12
1-5/ 8" - 12
1- 7/ 8" - 12

37"' F lare
F emale S'.liivel
Torque
ft. Ibs.
m-kg

Str-lligh t Thread
0- ll ingTorque
m-kg
ft. Ib5 .

6-12
8- 16
10- 25
15-42
25- 58
40-80
60-1 00
75-117
125-165
2 10-250

12-19
16-2 5
25-40
42-6 7
58 - 92
80 -128
1 00 -1 60
117- 187
16 5-264
250-400

0,8-1,7
1,1-2,2

1,4 -3,5
2, 1- 5 , 8
3 ,5- 8 ,0
5,5-11. 0
8 ,:3-14, 0
10-16
17-2:3
29 - 3 5

1,7 -2,6
2,2- 3,5

3 ,5- 5,5
5,8- 9,2
8,0 -1 2 , 7
11-18
14-22
16-26
2:3-36

35-55
70) 174

Section

4&
BACKHOE CYLINDERS

ser

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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 backup 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
eye e nd of piston rod in a vise and support the piston rod when torquing the bolt.

rod

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

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 B

INSET A

PACKING RING

INSET C

o
l

044113

'~~
"
(

14

\i
I
I
I

'-- J

~@

Vi ! V',~J
/fj :
i

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" selftapping ). 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 ckup 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
6

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

IN SET B

INSET A

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

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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
\

'-

""13

"

""-

" " ""-

"9
"

"

NYLON
NEOPRENE RING

RING

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

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Burl... o.m 9-720815 KHCBO

Printed in U.S.A .

TABLE OF CONTENTS

. . . . . . . . . . . . ... 3

SPEC IFICA TIOl\S . . . .

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

SPECIFICATIONS
Trigg'er popp et pressure se ttings (se e Figu re 15)
. . . . 1600 50 pS i @ 2 000 engine rpm
(11 3 3 ,5 kg/em'@ 2000 engi ne t r/m n)
. . . . 1200 50 psi @ 200 0 engine r pm
(8'. 3,5 kg/em' @ 2000 engin e tr / mn)
. . . . 1900 50 ps i @ 2000 engine rpm
(134 3,5 kg/em'@ 200 0 engin e tr/ mn)

Adjusting screw no, 1 .

Adjusting Sel'ew no . 2 .
Adju s ting s c r ew n o. 3 .

NOTE:

Oi l should be at operating temperature.

Main r eI ief val ve p r8s s ure s e tting

Model 480 . . . . . . . .
~lod e l

21 00 + 0, -100 psi at full engine rpm

(1 4 8+ 0, -7 k g/em')
220 0 75 pSi at full engine rpm
(1 55 5 kg/em')
. Scee the 40 Series Seetions,
Hydraulics , in thi s m auual

580 and 580B .

Backhoe hydraulic specifications.

Sp r ing' specifications. pr e ssure sensing val ve
Poppet. spri ngs (3)
Free height . . . . . . .
Compression rat e .. .
Spool centering sp rings (2)
Free heig'ht . . . .
Comp ression r at.e.
Spo ol diame ter . . . . .

. . . . 1- 1/4" 1/32" (31 0, 8 mm)

.720 72 Ibs . per inch (327 33 kg)
.. .. .. 1-:3/16" (30 mm)
50 l bs. pel' ineh (22 ,7 kg)
. . . . . . . . . . .. 1.001"

U.S. AND METRIC TORQUE SPECIFICATIONS

Hydraulic Filling,," (Sleel)
0

:37 Flare
F emale Swi vel

Da sh

T u~e

Thread

Size

a .D.

Size

1/ 4"
5 / 16 "
3/8"
1 / 2"
5/0 "
:3 /4 "
7 /S "
I"
I -J!i"
1- 1/2"

5
6
6
10
12
14
16

20
24

7/16" - 21J
1/2 " - 20
9 / 16" - 18
3 / 4" - 16
7 /S " - 14
1-1 / 16" - 12
1-:3/ 16" - 12
1-5 /16" - 12
1-5 /B " - 12
1-7/S" - 12

ft . lbs .

Straight T hr ead
O-Ring
Torque

Torque

6- 12
8-16
10-25
15-42
25-58
40 - 80
60-100
75- 117
12 5- 163
21U-250

m -k g

ft. lbs .

m-kg

0 , 8-1,7
1 ,1-2. 2
1.-1.-3 .5
2 .1-5, 8
:3. 5-8 .0

12-19

1 ,i-2,G

16- 25
25 - 40
42-6 7

2 .2- 3 , 5
:3,3-.'5, 5

3,3-11,0

8 .3-14. 0
10-16
17- 23
29 -:35

58- 92
80 - 128
10 0 - 160
117- 18 7
165- 264
250 - 100

5, 8-9,2
8,0- 12, 7
ll- l iJ

14-22
16-26
23 - :3G
35 -55
70\ I 7!,

HYDRA ULIC DIAGRAM S

_ _ PRESSUR E RELI EF VENTED

BUC KET
CYLINDER

RET URN

PRESSUR E

NOTE:

MOD ELS
WITIi
TWIN
LEVER
CO N TROLS
O NLY

SELECTOR VA LVE

DIPPER
CYLINDER

("- I
I
I
I

--

-~--1
3I

'-.

- ------~
BOOM
CYLINDER
1600 PS I -.n

",R

I
I

I
I

I
I
I
I
I

I
I
I
I
I
I
I

O'-+-t--~

~~}-Ill- I
1900 PS I

I zo o PS ' POPPET

BUCKET
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

BUCKET

DIPPER
CY L INDER

cn I !l DER

PRESS URE OI L
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
..
I
3
I1 _ _ _ _

..:n,.J...J.1-

SELECTOR

VA l~ E

rot,

..

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

DESCRIPTION

ated, three-position valve whose function is to

determine the type of digging to be done by the
backhoe. The three positions are Manual, Dig,
and Trench.

General

Hydra-Guide is an optional hydraulic

system which give s the operator a choice of
two automatic digcyc les or the regular manual
operation. The system Is formed by connecting
a pressure sensing valve and selector valve to
the backhoe digging cylinders as shown in
Figures I and 2.

The valve operate s by opening or clos i.ng

the two vent lines from the trigger poppets to
the reservoir. A closed vent line means that
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 operator starts the cycle by pulllng the dipper
lever to crowd. The sensing valve monitors
the system pressure and continually readjusts the flow of oil to the boom, dipper, and
bucket cyllnders as long as the dipper lever
is held in crowd position.

Manual Position

When the selector valve is placed in

Manual, Figure 3, both inlet ports (2 and 3 )
a t the selector valve a re c losed. Oll flow past
any of the three trigge r poppets is not poss ible
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 directional 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
respond by opening or closing, causing the
previously mentioned spool shifts.

Trench Position

When the selector valve is placed in

Trench, Figure 4, selector valve ports 2 and
3 are open. After actuating the crowd circuit,
and when system pressure reaches 1200 psi,
the 1200 psi poppet opens, causing the boom to
"float up", At 1600 pSi, the bucket starts to
curl. This results in a shallow, fl at cut which
rakes or levels the trench bottom.

An understanding of the Interaction betwee n the poppets, sensing valve spools , and
backhoe cyllnder s can be gained by careful
study of the diagrams and text on pages
8 to 15.
Selector Valve

NOTE:
See pages 12 to 15 for a detailed
explanation of this process.

The selector valve Is a manually oper6

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 ,
causing the bucke t to curl and the boom to
power up. Thi s results in a deep cut and full
bucke t.

D ig Position

When the s elec to r valve is place d in Dig,

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 actua ting the c rowd circu it, the 1600 psi and 1900

N O TE: See page s 8 to 11 fo r a det a iled

e xpla nation of this pr oce ss .

OpaERATING SEQUENCE WITH SELECTOR VALVE IN "DIG"

sensing valve to shift, opening ports 2 and

5 to the bucke t cylinde r.

Refer to Figure 6.
1.

2.

3.

Move selector valve handle to "Dig"

position. Operate the dipper crowd cir cuit.

5.

Oil from the pump is supplied to the closed

e nd of the d ippe r c yllnder a nd the pressure sensing va lve through port 6. This oil
flows through the spools a nd passages in
the sensing valve to act aga inst the three
trigger poppet s.

NOTE: Note that the dipper cylinde r oil

is supplied from the backhoe control valve
and the oil for the bucket cylinder is
supplied through the senSing valve via
ports 6 and 2.

Resistance to dig causes sys tem pre ssure

to rise. As long as sys tem pressure remains under 1600 pSi, the poppets remain
closed.

Refer to Figure 8.
6.

Resistance to dig incre ases and causes a

further rise in system pressure. At 1900
psi, the 1900 psi poppet opens a nd relieves
through port 4 In the sensing valve a nd the
se lector valve. This causes the boo m
spool to shift, opening ports 7 and 8 in
the sensing valve to the boom cyl inder.

7.

The dipper crowd, bucket curl , anc! boom

raise circuits are now in parallel for
digging or filling the bucket.

The 1200 p s i poppe t ve nt line Is

blocked at the selector valve. Thi s poppet
is not a factor in the "dig" sequence.

NOTE.:

Refer to Figure 7.
4.

The dipper crowd and bucke t cu rl ci rcuits

are now in par allel and the ci rcuit with
least resistance or greatest mechanical
advantage will operate.

At 1600 psi, the 1600 psi poppet opens and

relieves through port 4 and the selector
valve. This causes the bucket spool in the

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

C'fLlr.QEi\

Il~

DIG POSIfI(j\ ,QRT

j 'PO, to RSEJ\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

SELECTOR VALVE IN DIG POSITION

Operating principles are identical for circuits with dual boom cylinde rs, although
control valve and hose connections vary from those shown.
NOTE:

S"JCKEr

SEL[CH1R vALVE

U LINDER

D IG POS IfIOH-- PO AT
OPJ::N TO RSER\'O I.R:POI\T 2 S\. OCKEIl

111

OIP'PE R
C"' L. l t~DE R

80C:'1

(lOS EO

'JALI.'E

I11III
I11III

PUMP Oll!SYSTEK PRESSURE

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)

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

71 0893

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

SElECTOR IIhL\I I ~
DIG POS,I ' IO,.--PORT .3

[HI OER

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

800M
C'I'L I n08t

12009'SI

LINE. BLOCKE()

BO
' SELE.craft
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 PRss.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''

4.

Refer to Figure 9.
1.

iI'love selector valve handle to "Trench"

position. Operate the dipper crowd circuit.

2.

Oil from the pump Is now supplied to the

closed end of the dipper cylinder and the
pressure sensing valve through port 6.
This oll flows through the spools and passages In the sensing valve to act against
the three trigger poppets.

3.

At 1200 psi, the 1200 psi poppet opens

and relieves through sensing valve port
3 and the selector valve. This causes the
boom spool in the senSing valve to shift,
opening ports 7 and 8 to the boom cylinder.
Note that the bucket spool is closed. This
means that pump oil is blocked to port 8-the boom now "floats" up a s the dipper
continues to crowd.
Refer to Figure 11.

5.

Resistance to dig Increases and causes a

further rise in system pressure. At 1600
psi, the 1600 psi poppet opens and relieves
through sensing \'alve port 4 and the selector valve. This cause s the bucket spool
In the sensing valve to shift. opening ports
2 and 5 to the bucket cylinder and the
passage to port 8 for the boom cylinder.

6.

The dipper crowd. bucket curl, and boom

raise circuits are now in parallel for
digging or fllllng the bucket. The circuit
with the least resistance or gre atestmechanlcal advantage will operate.

Resistance to dig causes system pressure

to rise. As long as system pressure remains under 1200 psi, the poppets remain
closed.
NOTE: Compare with "Dig" operating
sequence.
With
selector valve In
"Trench" position, ports 2 and 3 are both
open, permitting all three poppets to
rel!eve oil. However, only the two lowest
of the poppets w!ll work--the 1200 psi
and 1600 psI.

Refer to Figure 10.

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

YL HlGER

V A LV~

i ll

TR.ENC ft POS I TI Of.....

PORT'S 2 AtlD
NOTE: 8UCI\ET 110SB $).I IT CHE.:O ON
UIl I1"5. 'J ITM DUA L CONTROl... lfV(R S'_~-L-

TO

~ESERVG

OPEN

IR

o 1'?,pR,
en INDER.

BOOM
CYL IllDeR

I11III
I11III
I11III

PUMP Oil
STATIC Oil

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
RiSRI)O ,R

L _________ _

--.
I
I
I

I
I
I

Ol PPER
CYLJ NOER

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

(IACUll

IlO ft:

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'\

O~~L V

}200 Ps I ;" .0 1600 PS I .

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
t 'fl l tlOER

SELECTllR \fAL \ IE I II
TRE r-.'CH POS I TJO tl--

PORrS Z M It) 3 QP EIJ

TO R'ESERV{J IR

r---+--.. t

1. _ _ _ _ 1 ___

I
r

-+ _______ ,

-~,-",,,-.
PS I PtJPPl .aPEu

n iP PER
nt. 1tt OER

I
I
I

I
I
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.

Hyd r n-Guide
1" :3 11 :,:; To
Func tion

C HE C K I ~G

PQSS JOLE C At.,E

THOCBLE
I.

HEAIEDY

PH()C LOU lE

Selecto r va lve set in

wrong po sition.

2.

Ho ses sw i tch ed at se lec-

:3 .

to r val .... e aftel' repa ir s.

Low pressu r e .<;etting at

I.

Set sc lcc tnr \'Dl ,,' e to Dlg:

or TI'ene-h. $ee ()pe rrlt~ r'5
Mnnua l.
ne<'.'ol'1l1cct hoses.

2.

Check hookup aga i nst

2.

3.

Figure 1 o r 2.
Check pressure setting.
Pedo r m ste ps 1 thru 4.

3.

ma ln r e li ef YJJ ve.

Te sting a nd Ad justing Tri gge r

Poppet Pressure

Adju st to specificatIons.

1\1 t'o odjustlng scre w Into

vo.l\'(' to inCl"CIl 5(' th~ pre sUI'C 'Setting.

Setttng~ ,

page 18.

Slow Digging
Cycl es

I.

Gene r ::Jl system p l'oblernwo rn pu mp, valve ,

I.

T est pu m p and bac khoe with

I.

nowm e te r,

cy linde r. etc ,
Boom O r Buc ke t
Fails To

I.

Repai r. repl ace , or clc.Ul

ftl\dty oCoT11ponent as
r~4ujred,

Sensing Y;:live sp()ols v.1 11

not s hift.

I.

f'u ncilon

Refer to Tes ting a nd Adjusting

'rr lgge r Poppet P r essw'e
Se.tU ngs , page HI. Perform
steP B 1 thru

2.

Va lve body di sLorted by

mounti ng bo lt pu ll down.

2.

3.

Spool s stuck by fo r e ign

3.

m ale ria l.

a and

I.

10 and 11.

Loosen mounU ng bolts and

r ec hec k. If valv e funcUonS
p roperl y . dlsLor t ion was the
proble m.
Remove plugs and sp rings

2.

3.

(rom e nds o( spools, Spools

shou ld move tnely with
finger preS9 u r e,

11 curl Dnd 11ft both occu r.

th t! spool s a I'e not SlQ,ck,
Adj\..l~t pressure settlng~
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,
Slllm be twee n bac khoe
fr ame unrl A~ns\n g valve.

If the spoo l s mo ve freE ly

DO NOT remo~'e spoclls t.est spri ngs QncJ repl ace if
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

b.

i;pr lng end.

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
WI th Se lec to r
Vilive In Dig

I.

Worn seiec t.Q r ','a l v\:.',

I.

Posi tI on

Disconnec t hose .:it po rt 2 of

se lec tor vt\ lve, In ~tn ll plug
(Case part no, 216-772) in
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

I.

Repl ace selector Yo1 !ve,

Qui ckly page 17,

Boo m Drifts
DO'o' n

I.

fiest r icto["jcheck: \' alve

Ie:lk:lge at se n:~ lng valve

I.

Pe rfor m c heck as deBc rlhed

I.

H{'pl.:lC:~ rest n t' t.or/check

\'a l ve.

on page 20.

po rt 8.
Duc ke t L'n('u rl s

1.

ReJ;trl c tor /ctv~C'k v olvc

l eako ge at
POl't 2 ,

5cn~\ng

\' :l lve

I.

Pe r form check as described

0 11

p age 21.

16

I.

l(l-platB rc~tl'l<; to r/ che<: k

\' dlve.

T ROCD LE
Cu rl And/Or
Li ft OCCUI'S
Too Quic kly

P()$SIHLE CA tS}::

I.

Sp<)QI -stuck open.

nHtE OY

C HECK r"G PROCEDL'RE

l.

Check sensIng va lve spool s:

Re move p l\Jg and sp r ing

f rom end of srnck spool.
Remove s pOO ls by tappIng
towllrd spring cod . Wash
spoo l ~ a.nd bo re s :111 re -

1.

P lace 5El Ll!c to r valve 1n

Manua l pos itio n.
Ope r a.te c l'o\\'d clrcui l.

a.
b.

Have bucket o ff ground.

EJCtend cyHnde r cornp l e te-

mOve burrs. Reinst all

ly. Pull d ip per le \1f' r.

c.

if buc ket c u rls, bucket

spOOl Iilnd c heCK f or f4E! e

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,
Pu ll d ippe l' leve r. li m ach -

d.

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.

oojust.me nt.

3.

Check t rigge r poppet pr efl su r e

Sf:tt ings . Pages 18 to 20 .

fo r eign m nle rlal ho lding

pi lot off seal

2.

AdNs t popJ>t'1s as described

on page 19.
3.

D i sa sse mble poppe ts (see

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
.

5.

Chllnge oU nfld service the fil te r (s) when making r epairs .

J'epnirs on a c l ean wo r k bench. Use cl ean tOO l s .

NOTE:
If dra.lned oil Is r eused. it
r elns ta.ll ing in the reservoi r.

6.

~hou.td be

filt ere d be fore

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 rmine 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 clinder. 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 equire 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 .

5.

Pl ace selec tor va lve handle in Dig pos ition. Hun engine at full thr ottle.

8.

Ra ise the boOm suffiCie ntly to allow

ground c le arance for the bucket in a ll
pos itions , Figute 13.

Watc h the bucket and !lOte the pressure at

which the bucket s t arts to cur l. This
Should be 1600 50 ps i.

9.

Adjust trigger poppet If required :

Figure 14 - Feathering Dippe r Control

6.

18

a.

If the bucket curls at less than 1550

psi, remove the cap on adjusting
screw 1\0. 1, I'igure 15. Turn adjusting screw clockwise. Repeat
check and adjustment until correct
se tting is attained.

b.

If the bucket cuds at a pressure

higher than 1650 psi or fails to
curl, remove the cap on adjusting
screw 1\0. 1. Turn adjusting screw
counterclockwise. Repeat check and
adjustment until correct setting is
attained.

10. Curl the bucke t completely. Fe ather the

dippe r control lever to crowd. Watch the
pre ssure gauge and the boom while contintting to feathe r the dippe r lever, figu re
16.
11. Note the pl'essure at which the boom
starts to raise. Thi s should be 1900 50
psi.
12. Adjust trigger poppe t if required:

"BACKHOE
NO UI\T II;G FR."-"NE

5W itlG
TOWER

a.

If the boom raises at less than 1850

pSi, remove the cap on adjusting
screw No. 3. Turn adjusting screw
clockwise. Repeat chec k and adjustment until correct setting is attained.

b.

If the boom r aises at a pressure

higher than 1950 ps i or fa ils to raise,
remove the c ap on ad justing screw
No.3. Turn ad justing screw counterclockwise. Repeat check and adjustment until correct setting is attained.

13. Place selector valve handle in Trench

position.
14. With the loader bucket raised to clear
the floo r , fully extend the bucket cylinder
in curled po siti on, then fully exte nd the
dipper cylinder in crowd position. Power
down the boom to r aise the r eal' wheels
off the floor. Figure 17.

NO. 2

71C908

Figure 15 - Adjusting Screws

Figure 17 - Backhoe Position,

Step 14

Figure 16 - Curling the Bucket

19

adju s tme nt until corrcct sctt ing is

attained .

15. Feather the clipper r.nntrollever to crowd.

Wa tch the pres sure gauge anrilloom. Note
the pressu 1'8 at whi ch the unit beg ins to
lowe r . Th is shou lcl be at 1200 50 psi.
b.
16. Adju s t trigger poppet if required :
n.

If the unit s ta rts to lower at less

than 1150 p si, r e move the cap on

adjusting s c rew ;-';0. 2. Turn adj usting

screw c lockwi se. Hepe:lt. check and

If the

unit s t a r ts to lowe r at a
p res su r e hi ghe r th an 1250 pSi , r e move the cap on adjusting screw
No . 2. Turn the ad justing screw
counterclockwise. Repe at check a nd
adjustment until corre c t s et t ing is
attained .

TESTING RESTRICTOR/CHECK VALVES FOR LE AKAGE

A restrictor/ c heck valve is located in

ports 2 a nd 8 of the pre ssu r e s ens ing va lve .
Leak age past the se valve s will cause drifting
of the bucket or boom cy linde rs.

3.

Install plug (Ca se p art no. 21 8 - 5158 ) in

por t 8 of se ns ing valve.

4.

Install the restrictor/che ck valve as se m'lly in the boom cylinder hose wbich
wa. s dis connec ted from port 8.

5.

Leakage Test AI
Sensing Valve Po r i B

!{efer to Figure 18.

1.

Lowe r backhoe bucke t to grouncl. Move

boom control leve r back and forth with the
engine off.

Rai se boom. Place boom lever in neutra l

and observe the restr ictor/eheck v alve
for leakage . The re should he Ilone . If there
is leakage , r eplac e the entire r estrictor /
check valve asse mbly.

2.

Remove the r es trictor/check vall'e ass embly fOt' inspec tion. nepl ace if obviously defective. If de fect is not appa rent.
the valve m ay be tested us follows.

NOTE:
If the valve is OK, refer to
Sec tion 42 and c heck the cylinder pack ing
and ba ckhoe control valve fo r l eakage.

I il G

21&- 5 158 -

HOSE / lUSf

S',H VEL

"' ~ S. ' L Y

fiTTI NG

V.t. lvE i;$ SEP; LY

/'

-f+--=~
~D91 1
Figure 18 - Leakage Test

20

Leakage Test At
Sensing Valve Port 2

4.

Install the restrlctor / check valve assembly In the bucket hose which was
disconnected from port 2.

5.

Position backJlOe a s shown in Figure 19.

Run engine at 3/ 4 speed. Operate the
crowd circuit slowly and observe the
restrlctor/check valve for leakage.
There should be none. lfthere Is leakage,
replace the entire restrlctor / check valve
assembly.

Refer to Figure 19.

1.

Lower backhoe bucket to ground. With

engine off, m ove the bucket control lever
back and forth.

2.

Disconnect bucket hose from port 2 and

remove the restrlctor/ check valve assembly for Inspec tion. Replace If obviously defective. If defect Is not apparent,
the valve m ay be tested a s follows.

3.

NOTE: lfthe va lve Is OK, refer to Section

42 and check the cyllnder packing and
backhoe control valve for leakage.

Install plug (Case p art no. 218-5158) In

port 2 of the sensing valve.

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
vIsible.

Figure 20 - Valve Heady F o r Di sas sembly

3.

5.
6.

Remove or dis connect hOBes a nd tube s .

Close openings with cle a n caplugs.

Remove
a.

the bucke t and boom s pools:

Re move the plug and a-ring , Flg"u re

21.

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

0 1

I6

O- RI NG ___

<!:I

____

~u

CO;rNEC TOR -(~

~
RE STR r C TO R -----~

c - Rr :!G
CONIIECTOR

~STRr CTOR I

f~- CHECK VA LVE

~

@ _

" ASH ER

F igur e 22 - Exp loded View of Pr es sure S ensing Val ve

23

711 C0 5

b.

h.

I!c move tho spool ann spring from

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 .

Remove the ad jus t ing' scre ws .

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 26 - Itemoving Plugs

Figure 24 - TIemov ing Spools

4.

d.

l!emove the three tr igge r poppe t as se mblies :

With a la rge sc r e wdri ve r, Teach into

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
parts a r e re move(; , keep the m together Jelentify the bore from whic h they
were r e m ove d. P arts whic h nre
r eused MUST 1\OT BE I:-lTE I!i\UXE D
m! PLACED I}; " DIFF ERE1\T
BOnE .

e.

5.

24

Tu rn valve on e nri $ 0 cone, spr i.ng.

and s pring gu ide in each bo r e can
fnll out. Take c a r e that these pa l'ts
do not beco m e mixed, Fig11re 27.

Remove all t.he s m :llI he x plugs and

a-r ings.

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.
The restrictor In the connector
at port 7 Is Installed with Lactlte. Do
not remove unless it Is to be replaced.

N OTE:

Inspection

Figure 29 - Installing the Spools

1.

Replace

all o-rings with new parts.

2.

Wash all metal parts In solvent or diesel

fuel. Replace damaged or worn parts.

3.

Test springs with spring tester, if available. See Specifications, pag"e 3.

3.

Install two plugs and o-rings in spool

bore s opposite the spring end, starting
the threads of each.

Assembly

Figure 30 - Installing Plugs

4,
Figu r e 28 - Lubricating the Spools
25

Install the spring ove r each spool, followed Pr a plug and o-ring, Figure 31.
Tighten t he plugs snugly. Do not overtighten, do not leave loose.

7I C>9DD - 4

Figure 31 - Installing Springs ,md Plug s

v,

Figure 33 - Installing the Poppet

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 crossthr ead the seats, Tighten all three
seats tight. us ing a wrench or vise
grips on the screwdriver, Figure34.

d.

Figure 35 - Installing Plugs

e,

Install a plug and o-ring into each

bore. Fig-ure 35.

26

Screw the adjusting screws into the

valve body, FigUl' E' 3G.

6.

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.

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.

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 connec 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 36 - Adjusting Screw Ins tallation

Figure, 37 - Installing J am Nuts

and Acorn Caps

27

EXPLODED VIEWS

;I USED ON
EAR LY PRODUCTION
ONLY

,""

.!-r '

.L .

"

,~ ,,,,

-PUJU'>
TfU:.HCH
MANUAL ~

1/4"

~~:::::!l~ ' /

t
... DIG

NC x I"

.....-1, II

//~

19-1/4"~ ll

I N STALL
ELBO'lI
INTO END
INLET

HOSE

"

13-1/2"

MANUAL SELECTO R
VALVE

.. """'_..

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

If the bucket curls at less than 1550

psi, remove the cap on adjusting
screw No. I, F igure 15. Turn adjusting s c rew clockwise. Repe at
check and adjustment until correct
setting Is attained.

a.

b.

10. Curl the bucket complet e ly. Fe ather the

dipper control lever to c rowd. Watch the

pressure g auge ancl the boom while continuing to feather the dipper lever, figl.lre
16.
11. Note the pressu re at which the boom
starts to raise . This should be 1900 50
psi.

If the bucket curls at a pressu re

higher than 1650 psi or fails to

curl, remove the cap on adjusting
screw No. 1. Turn adjusting screw
counterclockwi se. Repeat check and
adjustment until correct setting is
attained.

12. Adjust trigger poppet U required:

SWI NG
SCHE liS

.... .

,,~

\ 0 . 1-

If the boom r aises at less than 1850

psi, remove the cap on adjusting
screw No.3. Turn adju s ting sc r ew
clockwise. Hepeat c heck and adjustment 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,

remove the c ap on adjusting screw
No.3. Turn ad justing screw counterclockwise. Repeat check and adjustment until correct setting is attained .

BAc KHOE
i10 urlT l",G FR,i. NE
. ~OJl.I STI N G

a.

TO~ E R

13. Place selector v alve h andle in Trench

po s ition.

~
~

14. With the lo ader bucket raised to clear

the floor, fully extend the bucket cylinder
In curled po sition, then fu lly extend the
dipper cylinder in crowd pos ition. Power
down the boom to r aise the real" wheels
off the floor. Figure 17.

NO. 2

710908

Figure 15 - Adjusting Screws

Figure 17 - Backhoe POSition,

Step 14

Figure 16 - Curling the Bucket

19

15.

adju s tment until co rrect s etting is

atta ined.

fe ather the dippe r co ntr ollc ve r to c r owd.

Wa tch the pr e ssure gauge and boom. l\ote
the pressure <It whic h the unit begins to
lowe r. Thi s s hould be a t 1200 50 ps i,
b.

16. Adju s t trigger poppe t if r e qui r ed:

>l.

If the unit s t arts to lower at le ss

than 11 50 ps i . remove the c ap on
adjusting s c r e w No.2. Turn ,,(Ijus ting
sc rew c lockwise. Hepeat c heck and

the unit s t a rts to lowc r at a

pressure higher th a n 1250 psi, r em ove the cap on adjusting sc r ew
No.2. Tu r n thc adjustIng screw
counte r c lockwise. Hepeat check and
adju stment until correc t se tting is
attained .
If

TESTING RESTRICTOR/ CHECK VALVES FOR LEAKAGE

A r e strictor / chec k valve is loc ated in

ports 2 and 8 of the press ure s ens ing' valve.
Leakage pas t these valve s will cau se dr ifting
o f the bucket or boom cylinde rs.
Leakage Tesl AI
Sensing Valve Pori

3.

Install plug (C ase part no. 218-51 58 ) in

port 8 of sensing valve .

4.

Ins t all the r estrictor/chcek valve a ssem~ly in the boom cylineler hose which
was disconnected from po rt 8.

5.

1.

Lowe r backhoe bucket to ground. Move

boom control le ver back and forth with the
e ngine off.

Ha ise boom. Plac e boo m lever in neutr a l

and obs erve the r es tric tor / check va lve
for le akage . The re shoul d be none . Ii there
is le al<age, r e place the e nt ire r e str ictor/
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 iou s ly de fective. If de fect is not appa rent,
the va lve m ay be te s te d as follows.

If the valve is OK , r efer to

Sec t ion 42 and check t he cy[ inel l' packing
anci back hoe control val ve for l eakage .

Refe r to figu re 18.

NOTE:

2 ' -5'S8

~ESTRILrOR/CHECK

HOSE/TuBE
",SSEI~8L '(

\)Al\lE ..,.SSfr-tE!L Y
FITTI ,',G

/'

~~"

-&I

Figure 18 - Leakage Test

20

Leakage Test At
Sens i ng Valve Port 2

4.

Install the restrlctor/ check valve assembly In the bucket ho se which was
disconnected from port 2.

5.

Position backhoe as s hown in Figure 19.

Run engine at 3/ 4 s peed. Operate the
crowd circuit slowly and ob s erve the
restrlctor/ check valve for leakage.
There should be none. If there Is leakage.
replace the entire restrictor/ check valve
assembly.

Refer to Figure 19.

1.

Lower backhoe bucket to ground. With

engine off. move the bucket control lever
back and forth.

2.

Disconnect bucket hose from port 2 and

remove the restrlctor/check valve assembly for inspection. Replace If obviously defective. If defect Is not apparent.
the valve may be tested as follows.

3.

NOTE: If the valve Is OK. refer to Section

42 and check the cylinder packing and
backhoe control v alve for leakage.

Install plug (Case part no. 218-5158) In

port 2 of the sensing va lve.

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
visible.

Figure 20 - Valve Ready For Disassembly

3.

5.
6.

Hemm'e or disconnect hose s and tubes.

Close openings with clean caplugs.

Remove the bucket and boom s pool s :

a.

Remove the plllg and a-ring, Figure

21.

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''",

TR IGG ER POP PET

AD J UST I NG 5CR II5

"

BUC KET

-SPOOL
~
_BOOM

SPOOL

S:/p,p R t NG

c..

/SPRI :'G
WAS HE R
Y(,f~
/RE5TR I CTOR/CHE CK VALVE

,. J

''([O.P ~.

(~. ~

CO ::NECTOR
/

O-RING

''W&rf~ 0 ,

BODY
G_/PLUG (II)

o 'liif/ O-RI NG
0

711005

Figur e 22 - Explod ed View of Pr e ssure Sensing Val "8

23

b.

b.

Itcmove the spoOl and s pring from

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.

Hemove the adjusting screws,

Figure 25 - Remov ing Caps , ,Jam l'uts ,

and Adjus ting Scre ws
e.
Figl.ll~e

Working on the opposite s ieie of the

valve, remove three plugs and 0rings, Figure 26,

23 - He moving Spool Spring

)' 0899-1

Figure 24 - RemovIng Spools

4.

Fib'1lre 26 - Hemoving Plugs

Remove the three tr igger poppet asse m blies :

.,

u.

Hernove the aco rn c p a nd jam nut

f r om eac h as erobly, figur e 25. As
part s a re removed, keep them togethe r Identify t he bor e from wil iell they
were removert . Parts which are
,'e used MUST " OT B I': ) ' T EI<i\'IlXD
OR PLAC ED It-; A DIF FEREl'T

d.

With a large screwdr iver , reac h into

e ach bore and unsc r ew the s eat with
sea l ring, Figure 27.

e.

Tu r n valve on e nd so cone , spring,

and spri ng guide in e ac h bore can

fa ll out. T<lke C3re that the s e parts

cia not. hecon lc m ixed , Fi gure 2.7.
o.

BOHE.

24

rremove a ll
a- rings .

the smeil I hex pIllgs a nd

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.
The restrictor In the connector
at port 7 Is Installed '\o1th Loctlte. Do
not remove unless it is to be replaced.

NOTE:

Inspection

Figure 29 - Installing the Spools

1.

Replace

all a-rings with new parts.

2.

Wash all metal parts In solvent or diesel

fuel. Replace damaged or worn parts.

3.

T est spriugs with spring te s ter, if availab le. See Specifications, page 3.

3.

Install two plug s and o-rings in spool

bores opposite the spr ing end , starting
the threads of each.

Assembly

Figure 30 - In s talling P iugs

4.
Figure 28 - Lubricating the Spools

25

Install the spring olfe r each spool, followed pJ' a piug and o- ring, Figure 31.
Tighten the plugs snugiy. Do not overtighten, do not leave loose.

 2005 UserFriendlyCDs

Figure 31 - Inst a lling Spri ngs 3ncl Plugs

v.

F igur e 33 - In stall ing t he Poppet

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 crossthread the seats. Tighten all three
seat s t ight , u sing a wrench or vise
grips on the screwdriver , Figure 34.

d.

Figure 35 - Ins talling Plug s

In s tall a pl ug a nd o- ring into each

e.

bor e, FigLIre 35.

26

Screw the adjusting sc r ews into the

va lve body, Figul'(' JG .

f.

Install an o-ring on each jam nut.

Install the jam nuts on the adjusting
screws , Figure 37.

g.
6.

Install the acorn caps, but do not

tighten down, Figure 37.

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.

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 connections 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.

Figure 36 - Adjusting Screw Ins talla tion

Figur" 37 - Installing Jam Nuts

and Acorn Caps

27

EXPLODED VIEWS

f
,
I

USED ON
EA.RLY PRODUCTION
O N LY

,
I

TRENCH

MANUAL

t . . DIG

"i>
'HOSE

~\

I~

//

MA NUAL SELECTO R
VALV E

//~

II

'~OSES
~.

"

~./

13-1/2" HOSE

INSTALL

ElBOVI

/ / INTOEND
/
. / F INLET
SECTION .,

14<-.. .,./ 0/
SENSING
VALVE

3j8" NC)( 5"

!
/
FLATWAS~

-----'

7 1CCl6

Figur e 38 - Expl oded View of Hydra-Guide Controls on 480 and 580

28

/
(

0'

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
is relieved only by the loc kout r e lief ' valve
(3100 psi) permitting a he a v ie r load to be
handled. In addition, the boom cannot " s ettle "
due to leakage uncleI' pressure past the boom
spool (all spools leak slightly due to valve
clearances).

General
The optional boom lockout system improves the craning ability or load handling
capacity of the backhoe. The system consists
of a relief valve and lockout valve placed in
the boom circuit, Figure I,

NOTE:
The boom cannot be lowe r ed
hydl'aulically with the valve in Lock position,

When the lockout valve handle is in

Lock position, oil can move only in one
direction (see arrow, Figul'e 1). Thus pressure in the boom circuit caused by the weight
of the load pulling down on the l)oom is not
applied against the boom spool or the 2750
psi relief valve in the boom section. Oil
TO

Operalion Of L ockout Valve

Placing the lockout valve handl e in Lock
position moves the cam follower away from
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
end of the boom cylinder is blocked by the
seated poppet. The heavier the load, themol' e
firmly the poppet is seated.

LOC KOUT
HL I EF

RE S .

.... i.l. VE
3 100:i ;Z OO

PSI

If pressure in the locked circuit reaches

3100200 psi, the reliefvalve opens ,1.ndvents
oil to the reservoir.

LOCKOU T VALVE

OUT

2 7' ':0 -:P,,\~,l'CIt--.L--'-.L-.J

R:ELiEF\r- l'lE.

n
eOJ],u,
CYLS .

Figur e 2 - Loc kout Val ve Operat.ion.

In Loc k-Position

Figure 1 - Hydraulic Diagram

LOCKOUT VALVE

R e m oval
BAC KUP

The lockout valve a nd relief valve are

r emoved together.

1.

2,

tI @
~\~

CUI'1 the bucket and pull in the dipper.

Lower the boom until the bucket is on
the ground. The dipper and bucket must
support the boom without moving.

O-RING

II!f1-~~ti.OVlER

Place the lockout valve handle in Open

position, Figure 1. "'love the boom control lever in both directions to equal ize
pressure.

3,

Disconn ect two tub e s to the relief valve

and one tube to the lockout val ve. Close
openings witll olean oaplugs.

4.

Remove bolts and washers which attach

the mounting plate to the oontrol console.

CAt AND
HANDLE ASSEMBLY

_POPPET

0-

STEEL BALL

-SPRING
O-O-RING

-CAP
701314

5.

Remove mowlting plate with valves attached. Remove lockout valve and relief
val ve mount ing bolts.
NOTE:

Figur e 3 - Exploded View of Lockout Valve

3.

Check the spring for signs of cl'acking.

corrosion and di s tortion. The spring
should compress to 1-1 / 2" at 10 pounds
of pressure .

4.

Inspect poppet and steel ball for exc e ssive

wear, scoring and pitting.

5.

Inspect the valve body for cracks and

other defeots. Also inspect the poppet
bore and sea t for wear. scoring and
pitting. If wea r or scoring is excessive
the val ve must tle l'eplaced.

If unit is equipped with Hydra-

Guide, the mounting plate can be moved

far ellJ)ugh to reach the nuts on the lockout valve mounting bolts without removing' the sel ector valve.

Disasse m b ly
1.

Remove plug from valve body. Then remove the spring and steel ball from
poppet.

2.

Remove the poppet and cam follower

from the valve body.

3.

A ssembly
1.

Install the 0- l'ings and backup rings on

the cam using care not to damage the
rings.

2.

Install the handle a nd eam a ss embly in

val ve body using c n r e not to da mage the
r'ings.

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.

It is recomm e nded th at the a-r ings and

backup rings be discardecl. However, if
inspec tion reve als no defec ts they m ay be

4.

Place the s teel ball and s pring in poppet.

Then screw plug with ()-ring into valve
body and tig'hte n s ecure ly.

Remove the handl e aud cam assembly

from the val ve body. Then r emove the
O-rings and backup rings from cam.

Inspection
1.

2.

used aga in .
3

console, then connect the tubes to the

valves.

Installation
1.

Install the short tube between the lockout

val ve a nd reli ef valve.

2.

Mount the r e lief va lve and lockout valve

on the mounting plate.

:3.

Position the mounting plate on the control

4.

With the lockout valve handl e in Open

position, op erate the boom through several cycles to bleed air from the circuit.
Shut off the engine. Check the hyd r a ulic
oil level and inspect circuit fOl' leaks.

RELIEF VALVE
The relie f valve shown in Figur e 4 is
mOtmted on the backhoe control console next
to the lockout valve.

2.

Using a suitable adap t e r, Section 42,

Figure 21, connect a han d pump to the
port.

This valve may be removed for adjustm e nt, cl eaning, and parts inspection. If any
par t must bc replaced, the en tire valve must
be r eplaced .

3.

If t esting the valve off the m ac hine, plug

the opposite pres s ure port. If tes ting on

Removal

4.

Actuate hand pump and take a pressur e

reading. The pr essu re should be 2900 to
3300 psi.

5.

To adjust, remove knockout slug a nd

loosen the lock sc rew. To increase pre s sure, turn the adjusting scre w into the
valve body. To decrease pressure, turn
the adjusting s c rew out of the \'alve body.

6.

Tighte n the lock screw.

the machine, place lock valve in Lock

pOSition.

See Re moval, page 3.

Disassembly/Assembly
Refe r to Figure 4.

1.

Re m ove knockout slug.

2,

Remove 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 disdisassemLly. Adjust pre ssure setting as

ou tlined tmde r Adjustment.

Installation
See Install a tion a bove .

Adjuslment
ADJUST I ~:G SC RflJ
MID POPPET A SSE ~. lY

T he r ei ief valve call be adjusted on or

off the backhoe.
1.

,..

Disconnect line from the port shown in

Figure 5. Re move fitting.

Figure 4 - Lockout Reli ef Valv e

2 3"

La,,,,,; - -

1/4"

(1)

_CAP USED WITHOUT

HYDRA-GUIDE

71 096 1

Fig'ure 5 - Boom Lockout Hydraulics

Section

52
POWER STEERING PUMP
AND
HAND PUMP

Rac,
Form 99-80611
Rae
. Form
80611

52-2

HYDROSTATIC STEERING COMPONENTS

(Referr to Figure
Figure 1)
1)
Removal
HAND Pli~'!P
PLMP
1Remove steering wheel
whee! medallion and nut. Then pull steering wheel with puller.
1.Remove
2. Disconnect battery
ballery or
ballICries.
o r batteries.
3.
tion plate from rrICar
3, Remove inspec
inspection
e a r of steering column.
4.
Disconnect the two tubes a t tthe
he hand pump tube connections and c
cap
fittings .
4.Disconnect
a p the tubes and fittings.
5. Unboll and remove the hand pump.
pump .
.5.Unbolt
CO:'\TROL
CONTROL VALVE
1.
Disconnect the
t he six hydraulic tubes and cap the tubes and fittings.
fittings
1,Disconnect
2. L:nboll
va lve aassembly
ssem bly from tthe
Unbolt the valve
h e mounting bracket.

RESERVOIR AND PU:VIP

PUMP
1.
Disconnec t th
1.Disconnect
thee two hydraulic tubes and cap
c a p tubes and fittings.
fittings,
2. Unbolt the pump and remove.
STEERl:,\C
STEERING CYLL,DER
GYLLNDER
1.
fittings.
1.Disconnect the hydrauli
hydraulicc hoses and cap
c a p the hoses aand
n d fittings.
2. Remove the cotter pin and nut from the cylinder ball stud ends.
:l.
ends, being careful not to d
damage
3. Remove tthe
h e cylinders by tapping on the ball stud ends,
a m a g e the threads.

Installation
HAi':D PU:VIP
HAND
PUMP
1.
medallion.
1.Install the hand pump,
pump, steering wheel and medallion.
2. Connect the two tubes at the
t h e hand pump tube connections.
3.
nnec t battery or
3. Instali
Install inspection plate and reco
reconnect
o r batteries.
COi':TROL
CONTROL VAl.VE
VALVE
1.
ll the control valve and connect the six tubes.
1. Reinsta
Reinstall
RESERvom
PUMP
AND P
UMP
RESERVOIR .-\:,\D
1.
t ubes_
1.Reinstall reservoi
reservoirr and pump assembly with new gasket and connect two tubes.
STEERING
STEERING; CYU:,\DER
CYLINDER
1.
ta ll thp
th p. cylinder ball stud ends into the radius rod and steering arm.
1.Ins
Install
arm.
2. Install
Inst a ll and tighten the nuts,
nuts, install the cotter pins.

BLEEDING
BLEEDING PROCEDURE
PROCEDURE
1.
rvoir with Case TeH
1. Remove the'
the reservoir cap
c a p and dipstick. Fill the rese
reservoir
TCH oil and start the
engine.

2.
RPM
2 , Operate the engine at approximately 650 R
P M and turn the steering wheel through several
turns.

NOTE:: The first few times you turn the steering wheel, DO NOT m
a k e full
full turns.
NOTE
make
J.
Shut the eengine
ngine otf
mark
a r k on the dipstick.
3.Shut
off and refill the reservoir to the "F" m

4. Repeat the above procedure several

several times until the fluid level ceases to drop after turning the
steering wheel.
wheel.

52-3

,~

( 1

LJ
:i

~ -.

;---t\
\

PUMP
HAND
PUMP

/'~

...

\.

r-~'''~-':?-'=L';:J;:J.-'
___ ._.\__ L ~_
___ ..!-.
.L~
t:::..,....
'. .
------ ------- -- '-r---_

__

-.-

. ~.~ - -- -

PUMP
----.~

!
!

---~.~ f
\" ', I
i') .- I
....--::...,;/ .(I')

-~

I -:- ~

"

I
.I" ,

./

"\

'

\ \.'\

. .;'"

""""--

Figure
Figure
1 1

.\ .
)

R.I-i . CYLINDER

. ~

~..". \.

'!

52-4

STEERIN G HAN D PUMP

(Refer to Figure 2 )
1.
ha fl necdl
bC'a ring . Install
In st all into p
pump
ins t th
ha rd e ned
l . PPump
u r n p s^haft
needleC' bearing.
u m p body (26).
( 2 6 ) . NOTE: Pre
P r e ss
s s aga
against
thee hardened

C'nd
whi c h the numbers
whe n installing. P rress
p th
end of Ihe
Iho bbC'a
o a "ing
r i n g sshell
h e l l (end
(end oonn which
n u m b e r s appe
a p p ear)
a r ) when
e s s to a de
depth
ooff :33-27
-2i / :l2
hes from
fr om the
Ol or e nnd,
In set A.
32 inc
inches
t h e rrotor
d , Inset
A.
2. Thrust
bC'a ring . Insla
ft (4
Thru.st bearing.
Installll onto sha
shaft
( 4) .
3.
s t wa
,he r. Install onto shaft (-1).
(4) .
3. Thru
Thrust
washer.
4. Pump
ft. Install into p
pump
I
P u m p sha
shaft.
u m p body (26).
o.j.Spoo
pIn . Install into shaft (4).
,
Spooll pin.
(i).
6. Upper
Cpper ccommutator
In s ta ll into d
drive
o m m u t a t o r link pin. Install
r i v e link (7).
(7).
7. Commutator
Commutat or drive
d r ive link. Install
In sta ll into
in to ppump
e nga ging the slots on the sha
ft (4
).
7.
u m p body (26) engaging
shaft
('1).
8. Commut
ato r. Lightlj
Lig htl y ooil
il t[ he
ins tall into ppuu mp
s pool
P.
Commutdtor.
h e c ommutato
o m m u t a t o r aand
n d install
m p body (26)
(26) eenga
n g aging
g i n g tthh e spool
5).
p in ((5).
pin
9.
Ie. 1n51all
m p body
bod y (26)
pla te holes
ho les with the holes in the body.
body .
9 , Space
S p a c e r pIa
plate.
Install onto
onto pu
pump
(26) aligning
aligning plate
10.
pin . Insta
Installll into drive
d r i v e link (7).
(7).
10. Lower commu
c o m m u ttaa ttor
o r link
Jink pin.
11
tor va
ne springs. :'NOTE:
Io'01'E : Chec
free height of .080"-.100
", In
set B,
B, aafter
11,. Ro
Rotor
vane
Checkk the springs for free
.080"-.1(XIf',
Inset
fter
com
p ressing the spr
ings fla
t, they must
he ight of .076".
_076".
compressing
springs
flat,
m u s t return to aa height
12.
o tor vanes.
va nes. Install Into
into roto
prings (11).
ig ht and
12. R
Rotor
rotorr (13)
(13) with the ssprings
(11). NOTE
N E:: Check ttl
thee vvaa nnee he
height
and
C.. When the height
he ig ht is .250" or less,
less, or width is
is -002"
.002" less than rotor
r o tor width,
width. Inse
Insott C
width, repl ace tthe
he vanes.
va nes.
place
13.
Pump
r o tor. Install into s ttaa ttor
loc a ting marks_
NOTE: Check
Chec k rotor to
13. P
u m p roior
o r (14)
(14) aligning the locating
m a r k s . NOTE:
s ta to r thickness.
thickness, Inset 11,
D, with
w it h a m
micromete
cator. If
stator
i c r o m e t e r oorr dial
dial indi
indicator.
If rotor is m oorr e than .002"
tha n the
th E' thickness
th ickness of the
th e slator,
sta tor , replace
r e pla ce the sta
r otor, ssprings
prings aand
less than
s t a ttor,
o r , rotor,
n d vanes.
1 ~. P
Pump
i'iOT E : Check th0
1-1.
u m p s ttaa ttoo r.
r . NOTE:
the rotor aand
n d stator
s t a t o r c llea
e a rance
r a n c e using a nnarrow
a r r o w feeler gauge,
Inse t E
F:.. The
ho uld not
no t eexceed
xceed .007",
.007".
Inset
T h e clearancE'
c l e a r a n c e sshould
~ O'fE : :Ylar
tor aand
nd rotor with aan
n indelible m ar
whe n disasspmbli
ng pump
NOTE:
Miirkk th('
the sta
>tator
a r kking
i n g pencil when
disassembling
(or
proper
location
w
he
n
a
ssembling
pump.
for
when assembling
1:1
tor sea
l. Lubricate
ge of the seal
tall onto t hhee s tator
15.. Ro
Rotor
seal.
Lubricate th0
the ed
odge
seal and
a n d ins
install
t a t o r (14
( 1 4).) .
16.
Sea l rretainer.
et a iner. 1ns
tall oonto
nto the
rh0 seal (15).
16.Seal
Install
(15).
17. End c o
o,vcr.
pped face
roto r.
e r . Install ont
ontoo the
t h e ppump
u m p body (26)
(26) with the la
lapped
f a c e towards the rotor.
18.
T orque 18-22
IS. PPump
u m p body bolts. Torque
1s-22 ft.
f t . lbs.
lbs.
19.
19. Silaft
Shaft scal.
seal.
20 . Back-up
Bac k-up ring,
ri ng .
20.
l retainer.
r e tai ne r.
21. Sea
Se.11
p ring.
ring . Install
Ins ta ll the
t he sea
r ing (20)
(20 ) a n
ndd retainer (211
(26)
22. Sna
Snap
s e a l (1~),
( l g ! , back-up ring
(21) into the ppump
u m p body (26)
h to
allo w the s na
r ing toengage
to (,ngage theretainingslot
the re ta ining s lot in the ppump
body .
oonly
nl y ffaa r enoug
enough
toallow
n a p ring
u m p body.
2~ . Felt
F e lt SE'aling
23.
scaling was
w a s her.
her,
2-1.
Wa ter s e a ll..
2-1. Water
25.. Wheel nu
nut.t.
2~
26. Pump
P u m p body.

INSET C

i:n)
~(b NJ

15

/.l__
~
~
/"'~I '

. ~U
;,A ~

13

250"

MINiMUM

@1'lI
i!l.'(,

~
~

14

WORN FLAT
/ALONG THIS
EDGE

2" lESS

.00
THA N ROTOR WIDTH

~@

~~~ ~

13
.007" MAXI M UM C LE ARANC E

@}if

,/

,/
,/
,/
,/

v f l

~I
..

AI

Q:

INSET 0

14

13

~oc-

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

POWER STE
ERIN G PU
TEERING
P MP
(Refer to Figure 3)
NOTE
ir shell,
E:: Before removing
removing the reservo
reservoir
shell, mark both the shell and pump body to insure
roper relocation when assembling
assembling.. This will insu
proper
insure a good
leve l reading
ood seal and correct oil level
on dipstick.
dipstick.
1.
Permat(>x ''a.. 3 to the bore of pump
pu mp before
be fore installinstall1. Pump body oil seal.
seal. Apply a thi
thinn coat of Permat

ing sea
l. Press oil seal
ide int
into pump body (26)
(26 ) until flush with the body.
seal.
seal with Ihe
the metal sside
2.
Front
bearing
"(y'
rings.
Install
onto
front
bearings
(3)
.
"0" nngb.
bear
2.
.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
replacing.
Tne bearings should all be replaced if one or more need replacing.
1.
Id ler gear. Install
In stal l into pump body (26),
4.Idler
(26). NOTE: Inspect the gears fo
forr cracked or worn
teeth.
teeth. Both gears must be replaced if
it one needs replacing.
replacing.
5.
Drivc n gear.
).
5.Drivcn
gear. Install into pump body (26
(26).
6.
rca r bearings
Insta ll into pump body (26).
(26).
6. Gea
Gearr rear
bearings.. Install
7. Relief valve.
\alve. Install int
intoo pump intermediate cover (10),
( l o ) , so that valve extends through covcr
cover
ap
proximat e ly .4~8",
,43Sr', Inset B.
E.
approxmialely
8. Relief valve
val ve "0"
ring. Install
Ins ta ll iinto
nto relief
va lve (7).
8.Relief
"0"ring.
relief valve
(7).
9.
Inte rmediate cover "0" ri
ng. Install onto pump body (26).
9.Intermediate
ring.
(26).
10.
iate cover.
pu mp body (26).
10 Intermed
Intermediate
cover. Install onto pump
(26).
11.
t. Install
Insta ll onto intermediate cover (10).
11.Rear COver
cover gaske
gasket.
(10).
12. Rear cover. Ins
ta ll onto inte
rmediate cover (10).
Install
intermediate
(lo),
baIts . Torgue
13. CO\'e r bolts.
Torque 9-11
9-11 n.
tt. Ibs.
Ibs.
NOTE :: After torguing
cover bolts, torque the relief
r elief valve cartridge 10-12
lbs. , the
torquingcovver
10-12 ft.
ft. lbs.,
thenn
torque "elief
1~ 20 It.
wit hout turning the relief
relief valve.
relief valve locknut 18-20
t t . Ibs.
lbs. without
14.
Drive gear key.
key. lnstall
dri ven gear shan
(5 ).
14.Drive
Install into the slot on the driven
shaft (5).
jO. Pump drive gear
sta ll onto driven gear sshaft
haft (S)
13
gear,. In
Install
(5) engaging
engaging key (14).
(14).
16.
16. Flat washer.
washer,
17.
Slotted gear nut and co
tter pin.
17.Slotted
cotter
18.
element. lnstall
to rear cover shaft (12).
18.Filter
&.ilter element.
Install on
onto
(12).
19.
El0ment retainer.
re ta ine r.
19. Elomcnt
20
.e taining spring.
In spcct the spring for craiqked
craeked coils
co ils and the followin
ations.
20.. Fl
Retaining
spring-. NOTE: Inspect
followingg specific
specifications.
..... ..... .............. .......... ........... . 8
Active Coils ...............................................
. ......................... _ ..041"
Wire Diameter ......................................
ON"
Free Length .......................................
.... ....... .... .... 2.383"
2,383"
Compressed to 1.:37';"
... ........... 2.22.8
...................
1.375" ...
2.2-2.8 lbs.
lbs.
21.
j am nut until a measureme
nt of 4-15116
tained measuring
m easur ing from
21, Jam
J a m nut. Tighten jam
measurement
4-15/16 inches is ob
obtained
ide of the
th" jam
j am nut to sshell
he ll flange
flange on the pump,
the outs
outside
pump, Inset A.
22.
Reservoir shell "0"
Install onto pump body (26).
22,Reservoir
"0"ring. InstaIl
(26).
23.
all oonto
nto pump body (26)
23. Reservoir shelt.
shell. Inst
Install
(26) aligning location marks.
24. Copper sealing washer.
25.
nut. Torque 20-25
2()-2:i ft.
Ibs.
25. Acorn nut.
ft. lbs.
26. Pump body.
body,

527

MARK
LL A
ND PUMP
M A R K SHE
SHELL
AND
PUMP BODY
BODY

INSET B

INSET A

- 4 . 15 / 16 ,, ----:-- 1

Figure 3
3

t..

Seclion

53
STEE RING CONTROL VALVE

Rae.
Form 9-80671
980671
Rac. Form

532

STEERI NG CONTROL V ALV E

(Refer
efer to
t o Figure
Figure 1)
1)
NOTE
isassembling control valve,
valve , m
mark
NOTE:: Before ddisassembling
a r k the end ccaps
a p s and body for correct alignment
aand
nd location when reassembling,
reassembling,
1.
Control valve ball check,
1,Control
check. Insta
Installll into valve body (8),
(8).

2,
Ball cchock
heck plug "0"
ring, Install
In stall onto plug (3),
2.Ball
"0" ring.
(3).
3,
plug, Install into valve body (8),
(8).
3. Check plug.
washers, Install onto cent
ering screw
sc rew (6)
4,Centering
( 6 ) before and
4.Centering washers.
centering
a n d after the centering spring (,5)
( 5 ),.
NOTE
rew .
NOTE:: Check that the washers rotate freely
freely on the sc
screw.
5,
Cent e ring sprin
g, Install onto centeri
ng screw (6),
Inspec t the spring for crac
ked coils
5 . Centering
spring.
centering
( 6 ) . NOTE: Inspect
cracked
and the followin
g specifications,
following
specifications,

..............................................
Totall Coils ""
Tota
'''''",."''" ' ,,'','',, ... ,, .. '''',.,. ,, 6
Wire Diameter ""'''"''
..................................
,080"
,,'' ''''''',,, .,,'''''' ,080"
I.
D. ""
...................................................
.625"
I, D,
"""""""" " " ",,, ",,'",'',,''' """ ,625"
F r e e Le
Length
......................................
.860"
Free
ng th '"''''''''
"""",, ""." ",,",'" ,860"
......................
1.5-2.5 Ibs,
Ibs,
Compress to .824" """",""
''',,'' '' 1.52,5
6,Spring
rew, Inst
a ll into valve spool (7).
15 ft.
(7). Tighten to approximately 15
ft. lbs,
Ibs. by in
in6.Spring centering sc
screw.
Install
serting a sma
ll rod in the cross drilled hole in the sspool
pool and a small rod in the centeri
ng screw
small
centeringsha
nk,
shank.
7,
Va lve spool.
va lve body (8),
NOTE
body,
E:: Check that the spool oscillates freely in the body.
7. Valve
spool. Install into valve
(8). N
8.
Va lv e body
8. Valve
body.,

q,
End cap
rings, Install
Ins tall into eend
nd caps
c a p s (10).
(10).
9.End
c a p "0" rings.
l a, Valve
Va lve body end caps,
atin g m
marks
nd valve body.
body,
10.
caps. Align
Alig-n the loc
locating
a r k s on the caps aand

11,
bolts, Torque bolts 1417
It. lbs,
11.End cap
c a p retaining bolts.
14-17 ft.
lbs,

53-3

Figure 1

Section

54
STEERING CYLINDERS
AND
ADJUSTMENT

Rae.
rm 9-80621
Rac. Fo
Form
9-80621

j42

STEERING CYLINDERS
((Refer to Figure 1)
1.
la nd " 0"
r ing sea
l. Install into ggland
land (IOJ
1.Inne
Innerr ggland
0 " ring
seal.
(10)..

back u p ring sseal.

ea l. Install
Insta ll into ggland
la nd (10).
22.. Leather back-up
(10).
3. Retaining ring. Install int
nd (1
0) .
intoo gla
gland
(10).
4. Inner seal wiper
\\'ipt' r rretaining
e taini ng rring.
ing . Ins
ta ll into gla
nd (10)
(10) .
Install
gland

.,?.Gland
J. Gla nd sea
iper. Install
Ins ta ll into gland
g land (10)
li p facing
fa cing outward.
o utward.
seall w
wiper.
(10) with lip

6.
per retaining
re ta in ing ri
ng. In
sta ll in
to gland (10)
6 , 0O utt'r
u t e r sE'a
seall wi
wiper
ring,
Install
into
(10)..
7.G
nd wiper reta
ining ring.
ring . Insta
ll into ggland
la nd (10),
s ure it is sealed
. G l la
a nndd seal aand
retaining
Install
seated in the
(101, making sure
reta ining groove
retaining
groove,, In
I nset
st A
A..
H.
nd oute
the r bac
kup ring.
ring. Install onto the gland (10)
8. Cla
Gland
outp-rt lc'a
leather
back-up
(10)..

9.
Gland oouter
uter "0" ring
r ing (1,75"
(1.75" 1.0.
). Install o
nto the gland
g la nd ( 10)
Inse t A ,.
I.D.).
onto
l o ),, Inset
9.Gland

Ill . Sea l gla

ncl. Lubr
ica le
lU.Soal
gldnci.
Lubricate'
pi
s
to
n
rod
(13
).
:-.IO'fE:
piston
fl3'i. NOTE:
en
e n d .-

t hhee bore of the

Slide the gland
"land

sea
g la nd aand
nd
seall ,gland
assem
bly
on
to
assembly onto

sslide
lide the sseal
eal
the pis
ton
r od
piston rod

g la nd
gland
from

assemb
ly
assembly
the
s
ma
t h e smallll

over the
threaded

11.
bly . Install
Insta ll onto iho
the ssmall
mall end of the piston rod (13)
11. Piston assem
assembly.
(13)..
12.
P iston rod se
nu l. Torque
Torq ue loc
Ibs . NOTE:
NOTE : W
Whe
12.Piston
s e lltf locking lock
loch nut.
lockk nut 3035
30-35 ft.
ft. lbs.
h e n USing
using a new
self 10cl<i
ng lock
loc k nut.
"!OT restake
res take the piston
p iston rod.
locking
nut, DO NOT

13.
iston rod (11116"
rica te the piston seal,
land seals and inside
in side of the cy
lind e r
13 P
Piston
i11/16" diameter
d i a m e t e r).) , Lub
Lubricate
seal, ggland
cylinder
tube.
P ress the piston rod assem
bly into tthe
he cylinder
cy linder tube.
cubo. Press
assembly
14
nd retainer
r eta inN ring
t he rring
ing into the ccylinder
ylinder tube,
tube, make
14.. Gla
Gland
riii ., lnslall
Install the
m a k e ssure
u r e it
i t is properly sea ted In
the
r oove, Inset A.
A. .
The rretaini
~ t a i nng
i n gggroove,
IIS.
~.

Cylindt?~~
re..
Cyli
nde r eend
nd plu
plate

b. C
nd picite
plate rf'ta
ining
l16.
End
regaining
with ggland
land assembly

screws (~,,1024
hd. sslotted).
lot ted) . Line
Lin e up the
holes in the end plate
pla te
1 0 - 2 4x" 112"
1 2" pan hd.
t h e hole's
and torque the screws 57
ft.
Ibs
.
3-7 f t . lbs.

17. Cyl
inde r lube
Cylinder
tube,.

18. E nd Clamp
19.. Thread f'vnd
a s s ~ m bly,l y i'crna
lerna
,
El
nd assemb
le.

20. T
hrt'a d ('end
nd assemb
ly, m
ale.
Thread
assembly,
male

54-3

INSET A

Figure 1

344

STEERING CYLINDER ADJUSTMENT

Chl'ck
ee l toe iinn adjustment.
a djustment. It should be 1/4".
ba ll stud
Check thl'
the frollt
trorit wh
wheel
1/4". Loosen the two piston rod ball
l' nd d
c la
mps
a nd turn piston
pi s ton rod
lly into the ball stud ends.
end
am
p s and
rodss fu
fully
Turn the
th e whee
ls to the full ri
g ht hand turn position. Adjust the length of the R.H. cylinder
cy linde r rod
right
wheels
R .H. steering a rrm
aga inst the axle. Adjust the L.H. piston rod so piston
pis to n bottoms
until the R.H.
m is firmly against
r e trac ted position
posi tion at
ax le stop,
a r m is
is against the axle
stop,
in the full
full retracted
a t the sa
s a me
m e time the R.H.
R.H. steering arm
re
fe r to Figu
r e 22..
refer
Figure
Turn tthh e wh
ee ls to the
pos mon, adjust the R.H.
wheels
t h e full left turn position,
R.H. piston rod until it
i t bottoms in the
rretracted
e tra cted position
pOSition at the sa
m e the L.H.
e fer to
s a m ee titime
L.H. steering
steering arm is against the L.I-I.
L . H . axle slOp,
stop, rrefer
Figur0 3. Tighten both
bot h cclamps.
lamps.
Figure

R
.H . STEERING
ARM
R.H.
STEERING A
R M AGAINST STOP

L.H
L . H. CYLINDER PISTON
PISTON BOTTOMED

Fi
gure 2
2
Figure

L.H. STEERING A
ARM
L.H.
R M AGAINST STOP
('

,,

. ......... ..'. ,, " .. .. .

... .. .i
R
.H. CYLINDER PISTON
R.H.
PISTON BOTTOMED

Figure 3

Seclion

55
STEERING AXLE
AND
WHEEL BEARINGS

Ra
e. Form 9-80631
Rac.
9-80631

.. "-

--

- -

---"

05-2

STEERING AXLE
{Refer to Figure 1)
1.
1.Front Axle
2. Front
F r o n t Axle Pivot Bushing - Press
P r e s s in place and
a n d rream
e a m to 1.744" -- 1.746"
;~.
Grease
3. G
r e a s e Fitting
4.
4. Front Pivot Pin
5_
Pivot Pin Snap Ring
5.Pivot
6. Front
WIl",el Spindl
e , Inset A
F r o n t Wheel
Spindle,
s t Washer
7. Spindle Thru
Thrust
8.
8. Spindle Thru5t
Thrust Bearing
Spind le Lower i'ieedle
9. Spindle
Needle Bearing
10.
Need le Bearing
Bearing
10. Spindle Upper Needle
11.
11Spindle Oil Seal
12. Spindle Dust ShiC'ld
Shield
13.
Spindle Shim -- UAR (16,
13-Spindle
(16, 20 or
o r 28 gao)
ga.)
H.
Steering
Arm
R.H.
14. Steering
15.
13. Axle Spindle Washer
16. Spindle Slotted "ut
200-300 St.
ft. lbs.
Ibs.
Nut -- Torque 250-300
17.
/ 4"
17. Cotter
Colter Pin - .3110"
3/'16" x 1-3
1-3/4"
18.
18. Tic
T i e Rod
19.
Tie Rod Lock Nut -- R.H
19.Tie
R.H.. Threads
20.
RH .
20. Tie Rod End -- R.H.
Tie
221.
l.T
i 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
rq ue 65-80
ft. lbs.
Ibs .
2-1,
Nut - To
Torque65-80 St.
25. Cot ter Pin - 1/
8" x 1-1
/4"
25.Cotter
l-'V
1-1/4"
26.
26. Radius Rod
27. Radius Rod Axle Bolt 0"
Ibs.
27.
(1" dia.)
dia.) -- Torque 580 - 696 fft.
t . lbs.
28.1\"le
ia.)1..
28. Axle Bolt Heavy Nut (1"
(1" ddia.
29. Radius Rod Axle Bolt ((33/'4"
4" d
ia.) - Torque 270 - 324 ft.
ft. Ibs.
lbs.
dia.)
:30_:'<xle
/ 4" dia. )1
30. Axle Bolt Nut
Kw (3
(3i.1"
:31.
ront Pivot
31. Radius Rod F
Front
:)2.Front
Bushi ng - Press in place and rream
32.Front Pivot Bushing
e a m to .86:3"
.863" - .8601",
.86-1", Inset B.
:33.
que 150-180
150180 fft.
33. Radius Rod Pivot Bolt - Tor
Torque
t . Ibs.
H.
34. Lock Washer
3;3.
35. ;-';ut
Nut
36. Radius Rod R
Rear
OTE : When removing pin, it must be driven towards the front of the unit.
unit.
e a r Pin. N
NOTE:
:37.
.37. Groove pin
38.
38, Grease Fitting

for toe-in
toe-in aand
n d turning aang
n g le
l e adjustments.
adjustments.
NOTE:: Refer to Section 54 for

55-~~

INSET A

I
I
I

~ -0

-0

~ --CD

,, -0
)
/
/

35-4

WHEEL BEARINGS
Pac king I nterva I ----- -- ----- ---- --- -- -- -- --------------------- ------------ ------ ------------- -- --------- ---- --- -------- -L
1. Lock the bbrak
r a k ees,
s,
tractor front end_
end.

rraise
a i s e aand
nd

block

up

2. Remove the hub cap

c a p (1).
(I),cotter
colter pin (2),
(2),
sslotted
lotted adju
sti ng nut (3)
st washwash( 3 ) and
a n d thru
thrust
adjusting
er ( 4).
4).

3.
he outer b
bearing
nd
3 . Remove
R e m o v e tthe
e a r i n g cone (5)
(5) aand
pull the wheel hub (7)
(7) off the spindle
containing beari
ng cups
bearing
c u p s (6
(6)) and (8),
(81,cone
(9)
( 9 ) and
a n d outer half at
ot seal
s e a l (10).
(10)

500 Hours

Remove
ha lf of seal (11)
(11 ) ffrom
R
e m o v e tbe
the inner ha1
rom
s pindle.
spindle.

4.

5.
Remove
ups
5.R
e m o v e tthe
h e iinne
n n er cone (9),
(91, bearing ccups
(6)
nd outer seal ha
lf (10)
( 10 ) ffrom
( 6 ) aand
n d (8)
(8) aand
half
rom
hub. Inspec
Inspectt the bearing cups aand
n d cones.
Replace ifif worn or dama
d a m a gged.
ed.

6.
Clean the bearings,
bearings , inside
insid e of
&Clean
spindle.

hub and
and

IN SET B

Figure 2
1_
Pack
bea ri ng with No.
!'io. 2 lvhwl
wheel bbearing
7. P
a c k e ach
a c h bearing
earing
t h e sspace
p a c e around each
each
ggrease.
r e a s e . :Vlake
M a k e sure
s u r e the
roller is filled.
filled.
8. lns
tall the bbearing
(6) and
Install
e a r i n g cups
c u p s (6)
a n d (8)
(8) if they
were removed,
r emoved, inner
bearing cone (9)
i n n e r bearing( 9 ) and
and
new oouu ter
hu b until tthe
t e r seal half (10)
(10) into hub
he
aliter
inne r edg
outer seal
seal half
half inner
edgee Js
js 3;) i 16" below
the ' inner hhub
u b face.
face. See Inset A.
9.Install
ha lf (11)
9. Install a new iinner
n n e r seal half
(11) onto tthe
he
spindle with the curved
c u r v e d face inward. See
See
Inset B.
ur fa ces with
B. Lubricate the Seal
seal ssurfaces
No.2
rease .
No. 2 wheel bearing ggrease.
10.
1

Install
II outer cone (5)
(5) into the hub (7)
(7)

and
spindle_
a n d install the hub aassembly
s s e m b l y onto the spindle.
11 . Install
ins tall the thrust washer
wa s her (( 4)
Slo tted
11.
4 ) aand
n d slotted
ad
justing nut ((3).
nul
adjusting
3 ) . Carefully tighten the nut
(3)
agains t the thrust
thrus t washer ( 44)1 until the
(3) against
pressure
noUcea ble
p r e s s u r e of lhe
the nut c auses
a u s ~ s a noticeable?
drag
while
lhe
h
ub
a
nd
wheel
is
turned.
drag
the hub and
Bac
k
off
nut
118
of
a
turn
or
until
the
next
Back
1/8
t u r n or
slot in thc
tho nut lines up with the hole in the
spindle.
e nd pl
a y. If
spindle, Check fo
forr end
play.
If end play is
is
lay is
g(me _
noted, tighten
tighte n until e nndd pplay
noted,
is gone12.
ut (3)
with a !le
W
12. Lock the slotted adjusting-n
adjusting-nut
(3^ wirh
new
cottpr pin (2)
h ub cap (1)
cotter
(2)aand
n d reinstall tthe
h e hub
(1).

Section

&1
TORQUE CONVERTER,
POWER SHUTTLE COUNTER-SHAFT,
CONTROL VALVE AND ADJUSTM ENTS

TABLE OF CONTENTS
Torque conve
rter removal
remova l ."
... "" ... .. " " ............ ......... ................ """ ..... .. ... " ................ "".,, ..... 61-2
612
converter
.......................................................................................................

.........................................................................
61-2
lubrication
Converter and lu
brication oil regulator valve ............................
.. ...... " .. "."."" .... " ." ...... ........ 612
Torque converter .......................................................................................................................
" ................. " ............................................................ " .. ....... .. .. """." ... .. ,, ... 6]4
61-4
e control
con trol va
lve ""
.... . "." .......... " .. ........ ...... .... ..... " ... ... ... ...... ...... .... ... ,, ........ ....... .. 616
....................................................................................................
61-6
Power shuttl
shuttle
valve
Counte
rshaft and gears .......
" ................................................................. ... ................. .... ... ...... 618
Countershaft
...........................................................................................................
61-8
Power sshuttle
huttle removal
r e m ova l . insta
lla tion ......
... ............ .. .. ..... ... .... ........ ...... ... ... .. ..... " .. .. ..... " .......
61 10
installation
................................................................................
........ 61-10
e nts
Power shuttle adjustm
adjustments
Clutch peda
. ....... .. " .............. .......... .. "" .. ... ........ " ......... " ... ........ " .. .. ,, ... .. "" ". 6]]]
pedall linkage .......
..........................................................................................................
61-11
Shuttle spool linkage """"
. " .. ... " ...... " .......... ..... .. .... ... ... ...... .. ................ .... .......... .. ........... 6112
...........................................................................................................
51-12
Control lever linkage ............
............... .... ............. ......... ......... ...... " ... .. ........ ..... .... ...... .. .. .... 6113
..........................................................................................................
61-13

c Form
Form 9
9-80761
Ra
ae.
80761

612

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 ...................... ..... .............. 13/8"

Wire Dia . ..... .. ....... ..... .............. ............. 051"
No of Coils ........................................... 6112
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

614

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)
sea ted in the carrier.

has been

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

616

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 ............................................ 151/2"
Spring Rate ............ 45 lbs. at 111/ 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

'"

""

<>

'"

'"

<>

"

<.'-'

L-

Figure 3

'"

?
<:>

618

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
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
0
~;";""j'!T1I@r->'-':::::~

POWER SHUTT LE

r-~

) ,. .,
Figure 5

61-11

POWER SHUTTLE ADJUSTMENTS

CLUTCH PEDAL LINKAGE

(Refer to Figure 6)
l1\WORTANT: Prior to adjusting the clutch

pedal, make sure the brakes are properly

adjusted.
1. Disconnect the clutch pedal to cam link.

6. Move the cam through a complete cycle

(back and forth) by hand. The movement
should be free. If not, repeat steps 1
thru 5.

2. Loosen the cam pIvot shaft nut. Inset A.

3. Check to make sure the cam follower
bearing is in full contact with the cam track.
4. Position the flow spool so the cam follower bearing is seated in the upper-most
part of the cam track. Tighten the cam
pivot shaft nut securely without turning
the cam pivot shaft. NOTE: From the
center of the cam follower bearing to the
center of the nearest mounting bolt of the
cam follower bearing support should be
3.575".

5. Adjust the cam follower bearing support

so the cam follow er bearing pin moves
freely in the support.

7. Adjust the clutch peda l stop screw so the

brake pedais and clutch pedal contact their
respective stops at the same time. Inset B.
8. Adjust the cam link clevis, so the clevis
pin can be installed into the clutch pedal
without any binding. NOTE: The cam
follower bearing is sealed and "Parco"
lubrlzed. Excess oil or grease on the cam
or cam follower bearing wll! only collect
dirt a nd cause undue wear.

CAM

BRAKE PEDAL STOP

INSET A

u
CUJTCH

M LINK

,,~----~~~-
CAM FOLLOWER """HIN<'; SUPPORT

Figure 6

PEDAL STOP

61 -12

SHUTTLE SPOOL LINKAGE

(Refer to Figure 7)
1. With

the engine not running, move the

s huttle control lever on the steering column
to the forwa rd position_

shuttle spool out by hand until the rear

de tent is felt.

2. Disconnec t the shuttle spool link. Loosen

and back out the spool stop screw.

4. With the spool in the rear de tent, adjus t

the spool s top screw in until it just touches
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
and screws.

tween the fOlw ard a nd

positions.

reverse

detent

2. DIsconnect the baU Joint (1) from the shuttle

lever (2) at the lower end of the shuttle
shift lever (5) .

5. Readjust the ball Joint (1) by turning on or

off the rod (4) so it ca n be Installed Into the
shuttle lever (2) without forc ing Into place.

3. Manually move the shuttle shift lever (5)

to the neutral position. engaging the slot
in the loc k plate (6) located on top the
steering column (7).

6. Reinstall the ball joint retaining nut (9) and

lockwasher (10) . Tighten locknut (.3i on
rod (4).

4. Manually m ove the power shuttle control

valve spool (8) to the neutral detent position.
The neutral detent position is located be-

7. When the shuttle spoOl and lever are

properly adjusted, the hand lever can be
moved slightly ou t of any detent position,
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

INSET B

INSET C

l.--..--------..............-----FigUre

624

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 B

INSET C

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

"

"-,,-

',,-

"-

"-,

"

II

""- )
~

(!)(), rr } iJ

~~ jf

000

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 ... .. .... ..... .............. .. ......... ........... .. .. ................. 634
Forward clutch pack assembly .. ...... .... ................................................... ... .... .... .... ............... .. 636
Clutch hub shims ...... ... .... ............... .... ... ... .... " ..... ... ...... .. .. .. ..... .. ..... ........ .. .. .. ......... ....... .......... 636
Forward-reverse c lutch drums ........ .. .... .... ...... .......... ... .... .......... .............. ..... .. ..... .. ....... .. ........ 638
Rac. Form 9 80701

http://www.ioffer.com/selling/userfriendlycds
http://stores.ebay.com/UserFriendlyCDs

632

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 636 "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 predetermined number of shims and press ca r r ier assembly on
s ha ft. Re fer to Page 634 and 635.

INSET 0

63-3

INSET C

SPECIAL TOOL, __
CLIP A43071

~
ROLL PINS FOR
SPRING TANG
LOCATION

SNAP

INSET A

GROOVE

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 636 "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 632.
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 636 "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

Figure 2

636

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"
Shims required _ _ _ _ _

Min .. 0 09" to .0'29" Max .

It is recommended that an average

between these two figures be _ _ _

used when installing shims,

.0 86"

,019" average

PLATES CLAMPED TOGETHER

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 .......... .. ..... .. ........................................................... .. ........ ....... .. ___ . 642
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

http://www.ioffer.comlsell ing/userfriend Iycds

http://stores.ebay.com/UserFriendlyCDs

64-2

HYDROSTATIC PUMP & INPUT GEAR TRAIN

(Refer to Figure 1)
Removal
Split the tractor between the flywheel
housing and engine, refer to the splitting
Section 92 .
Remove the torque tube front cover (41),
rear cover (39) and front cover (48) with
gaskets .
Remove the link bolts (16), nuts (17), sealing washers (18), links (19), spacers (20),
spring washers (21), backup washers (22),
nylon seals (23) and metal seal retainers
(24) .
Disconnect the make-up pump pressure
tube (6) , hydrostatic pump inlet hose (8) ,
servo va lve tube (1) and suction tube (10)
from the bulkhead fittings (40 ), (42 ) and (43)
inside the torque tube. Remove "0" rings
(4,7 and 9) .
Remove bolt (11) and suction tube clip (12)
at the bottom of the torque tube.

Remove the HE" ring (14) and servo lever

pin (15) to disconnect the servo lever from the
speed control spring box and the neutral cam
spring box.
Support the torque tube from below and
attach an overhead lifting clevice to the fl y wheel housing. Remove t he flywheel housing
to torque tube bolts (47) with lockwasher.
Slowly work the flywheel housing (49) and
hydrostatic pump away from the torque tube
(44), being very careful not to bend t he oil
tube on the hydrostatic pump or the linkage
inside the torque tube.
Remove banjo fitting bolt (29), sealing washer (30), adapter union (.31), backup ring (:32),
"0" ring (33), banjo adapter (35), pump inlet
tube (34) and "0" rings (36) and (37).

Installation
Assemble the inlet tube (34) and banjo
adapter (35) with new "0" ring seals (36 &
37) to the pump. Install backup ring (32) ,
"0" ring (33). sealing washer (30), adapter
union (31) and bolt (29). With the pump swashed
against the stop, line up the banjo adapter 35)
and adapter union (31) as illustrated in Inset
A. Then tighten 14 to 16 ft. lbs.
Install the make-up pump pressure hose (8),
hydrostatic pump inlet tube (6), servo valve
tube (1) and make-up pump suction tube (10)
with new '"0" r ings (4, 7 & 10). Lubricate
a ll the "0" rIngs with lubriplate when reassembling.
Install a new gasket (46) to the front of
torque tube (44) . Guide the flywheel housing
and pump assembly into the torque tube.
Install the flywheel housing to torque tube
bolts (47) with lockwashers and tighten.
Tilt the hydrostatic pump and motor until
the lower link (19) can be installed without
forcing into place.
Assemble into each link seal area spring
washer (21), backup washer (22 ) , inner sea l
(23) and seal retainer (24). Coat these parts
with lubricate as they are installed.

Install the l ower link spacers (20), lower

link (19), sealing washer (18) a nd bolts (16)
from the bottom up. Install the upper link
spacers (20), link (19), sealing washers (18 )
and lock nuts (17). Torque the nuts 70 to 80
ft. Ibs. NOTE : Be sure that the seals are
sea ted properly or damage to the links wiI!
occur. Check to be sure that the pump and
motor swash freely after the link bolts are
torqued properly.
Install the servo lever pin (13) and "E"
ring (14). Install the suction tube c lip (12 ) and
bolt (11).
Apply Perma tex No. 3 to the thrcads of the
bulkhead fittings (40, 42 and 43).
Install the bulkhead fitting (40, 42, and 43)
into torque tube. Screw connec tor (3) into
fitting (42) from inside the torque tube.
Reconnect make-up pump pressure tube (6),
pump inlet hose (8) , servo valve tube (1),
and suction tube (10) to the bulkhead fittings.
Install the torque tube fron cover (41),
rear cover (39) and lower cover (48 ) with
new gaskets .

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64-4

FLYWHEEl. HOUSING, INPUT GEAR TRAIN

AND HYDROSTATIC PUMP
(Refer to Figure 2)
Disassembly
Stand the flywheel housing (1) on its front
flange for disassembly. Remove the "E"
rings (2), servo lever pivot pin (3), servo leve r
(27) and mounting bolts (4) from the hydrostatic pump, Inset A. Remove the hydrostatic
pump input drIve shaft (5 ) and coupling (6) with
snap ring .
Unbolt pump bracket (9) and remove from
flywheel housing (1 ) . Remove the snap ring
(10) that retains the input drive gear shaft
(11) to the r ea r bearing (12 ) a nd remove the
shaft (11 ).
Remove real' bearing i'Qtalnl>r snap rings
(13) and press out the bearings (12 and 17).

Remove the idler gear (14), pump input gear

(15) and thrust washers (16). Remove the needle
bearings (~O) and seal (18) from the flywheel
housing (1) . Press the needle bearing (19) from
the idler sear (14).
If the idler gear shaft (21) is worn and must
be replaced, it will have to be pulled from the
flywheel housing. The idler shaft (21) cannot
be turned as a ball (22) is used in a groove, to
keep the shaft (21) from turning.

Remove the bolts (23) with Iockwashers that

retain the servo cylinder (24) to the bracke t
(9), Remove the cylinder (24 ), gaskets (25) and
servo body (26) from bracket (9) , Inset B.

Assembly
Install new needle be arings (17 and 20) using
drive rs A9817 and G15042 on the numbered
sid e of the be arings, to a depth of .010 to .060
inch into the pump bracket (9 ) and flywhe el
housing (1) . Install needle bearing (19) using
driver GI5042 into the idler ge a r (14) so it is
recessed .010 to .020 inch on both sid es .
Install the idler gear shaft (21) with a new
steel ball (22) into the flywhee l housing (1)
un til it bottoms.
Install a new oil seal (18) with the lip inward. using drive r G15042, into the flywheel
housing (1) until it jus t seats against the
chamfer at the bottom of the bore .
Press in the rear input shaH bearing (12)
and install two inte rnal snap rings (13) into
the bracke t (9). Install the input drive gear
shaft (11) through rear bearing (12) and r etain in place with snap ring (10).
Assemble the pump input gcar (15), idler
gear (14) and thrust washe rs (16) . Grease the
thrust washers to retain them in position,
so the tabs enga ge the recesses in the housing
and bracket.
Grease the servo mounting gaskets (25)

and place on each side of the moun ting bracket

(9). Make sure the four bolt holes and one oil
hole line up. Install the servo body (26) into
the bracket (9 ). iVlake sut'e the holes line up.
Lightly oil the servo piston. Compre ss the
piston ring and slide the cylinder (24) over the
pL<ton . Again make sure the holes line up.
Install the bolts (23 ) with loc kwashers, Inset B.
Tighten in a diagonal sequ ence 18 to 21 ft. Jbs .
Lubricate the seal lip (18) and input sha ft.
Stand the flywhe el housing (1 ) on its front flange.
Assemble the pump bracket (9) to the flywheel
housing, engaging the two dowel pins. Retain
in place with four bolts. Torque 35 to 42 ft.
Ibs. Install the cup plug (7) into the rear bore
of the idler shaft (17) until it just seats.
Install the hydrostatic pump drive coupling
(6) with snap ring and input drive shaft (5).
Lowe r the pump down onto the mounting bracket
while engaging the input shaft Spline and the two
dowel pins. Retain in place wIth four bolts (4).
Torque 80 to 90 ft. Ibs. Reconnect the servo
lever (27) with pin (3) and "E" rings (2).
Lubricate the front spline (11) and the mating
coupling on the flywheel with molydisulfide
grease.

64-~

INSET B

15

INSET A

A9B17

G15042

Figure 2

7'0

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f"1

64-6

HYDROSTATIC MOTOR, MECH . DISCONNECT

AND PINION SHAFT
(Refer to Figure 3)
Removal
Remove the two uppe r pump mounting bolts
(30) and install two 1/2" x 4" studs (29). Re

move the two lower mounting bolts. Install

the locking bolt (31) (3 /8" x 1" Ui\'F hex. hd. )
into the trunnion mounting (32 ) of the motor.
Be sure the locking bolt engages the tilting
head yoke (33) which should be at 0" tilt
angle. Work the motor forward until it is
free from the transmission case.
Remove the snap ring (19) and output gear
sleeve (18) from the motor. Drive out the
roll pin ( !O ) that retains the disconnect yoke
(9) to the shaft. Pull tbe shaft (4 ) s ideways
out of the yoke (9) and remove key (11).

Slide the sleeve (20) forward and remove the

yoke fingers (12). Loosen and remove the
pinion shaft nut (21) and output gear hub (22).
Loosen or remove the right hand brake
cover and differentia l lock so tha t ring gear
and center wheel can be moved to the right.
This will allow the pinion shaft (35) to be
moved rearward enough so that the rear snap
ring (27) on the pinion shaft bearing cup can
be removed_ Remove t.he pinion shaft a nd
bearings forward a nd out the case. Remove
the bearing cones (23 & 28) and cups (25 & 26) if
they are worn or pitted.

Installation
Press !.be rear bearing c one (28) with cup
(26) onto the pinion shaft as far as it will go.
Install this assembly in throug h the front of
!.be case until the rear bearing snap ring (27)
can be installed.
Install the front bearing cone (23) and cup
(25) with snap ring (24) onto the pinion shaft
part way. Ins tall the output hub (22) and pinion
s haft nut (21). Tighten the nut until the bearIng cups and cones have seated properly.
Adju st the nut (21) for a preloa d of 4 to 12
inch. Ibs. of rolling torque on the pinion
shaft. Press the thin section of the nut into
both slots on the pinion sha ft. Install and
tighten the right hand brake cover . Check
the pinion to ring gear backlas h, refe r to
the Transmission Secti on "65" of this service
manual. Install yoke finge rs (12) and sliding
sleeve whlle e ngaging the yoke fingers onto
the output gear hub (2 2). Install shaft (4) with
key (11 ) and line up the hole in the yoke (9)
and sha ft. Insta ll new roll pin (10).

Install the out.put sleeve (18) onto the motor

and r e tain with snap ring (19) . Install a new "0"
ring (34 ) into the groove on the motor mounting.
Lubricate the " 0" ring and leading chamfer
of the motor with lubriplate or e quivalent. Slide
the motor into the case . Coat the threads of
the bolts (30) with permatex and install to retain motor. Remove the pilot studs as the bolts
are installed. Torque the bolts 80 to 96 ft. Ibs_
Remove the locking (31) from the trunnion
pivot.
Check the mecha nical disconnect for pro
per adjustment by moving the control le ver
(4) to the disengage position. The sliding
sleeve (20) must be rearward and completely
free of the m otor output sleeve (18). Loosen
the hand lever detent mounting bolts (1 ) and
move the detent bracket (7) rearward until
the sliding sleeve is free of the motor output
sleeve. Then retighten the deten t brac ket
bolts (1) 17 to 21 ft. Ibs.

01 -7

L:::::~--~FigUre

64-8

EMERGENCY CLUTCH PEDAL LINKAGE

SAFETY START SWITCH

~/

..
i

,
o

I
I
J
<!,

DUMP CONTROL
D
CROSS SHAFT

Figure 4

".,

-_._--

SPEED CONTROL LINKAGE AND NEUTRAL CAM

,,
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6410

ADJUSTMENTS
These a dju stm e nts mu st be m ade in the
ord",r in which they are numbered. The speed
control rod , clu tch peda l rod a nd control rods
for the forward reverse peda ls disconnected,
Figu re 6.

With the hydrostatic housing d ra ined , reo

move the lower cover from the housing. Check
the clearance between the clutch d ump va lve
pad (8) a nd lever (9) , Figure 8.

hCONTROL R,?....)
Isp~ r
'/
CLUTCH PEDAL ROO

r3~~
Figure 8

Figure 6
1. EMERGENCY CLUTCH

PEDAL

LINKAGE

Remove the "E" ring (I ), speed control lever

(2) and key from the left e nd of the speed can
trol shaft (3), Figure 7. Install the adjusting
gauge A43615 over the speed control shaft.
Move the clutch lever (4) upwa rd a bout 15 and
ins tall the adjus ting pin A4 3614 through the
clutch leve r (4) a nd adjus ting gauge . Refer to
P age 6412 for illu s tratio n of adjusting tools .

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.
s tick with Case TCH oil. Install the speed
cont rol lever (2) with key a nd reta in with " B"
ring (1), Refer to Figure 7.
2. NEUTRAL CAM
Jack up tractor so
rear wheels ate off the ground. Sta rt and run
the engine at 1500 RPM. Loosen the cam
mounting bolts (11), Figure 9 and rotate the
ca m (12) clock\vise until the wheels just start
to turn, m a rk the ca m (12) and hous ing.

Figure 9

Figure 7
Adjust the clutc h pedal s top screw (5) so
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.

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 )
wh ile holding cam (12) in thi s position. Sto p
the engine.

64-11

ADJUSTMENTS (Cont'd)
3 . HAN D LEVER SPEE D CO NTROL With the

hand speed control rod disconnE'Cted , adjust the hand lever speed control friction disc
(6), Figure la, remove the inspection cover (7)
on the steering column. Adjust the locknut (8)

clevis (2) on or off the rod (3) until the clevis

pin can be Installed without moving the hand
speed lever or speed control lever (1), Figure
11,tlghtenthelocknut (4).
4. FORWARD-REVERSE PEDA LS The reverse 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 forwardreverse cross shaft, Figure 12.

Figure 12
Figure 10
untIl It takes 10 to 15 Ibs. pull at the end of
the hand lever before the lever moves. Then
tighten jam nut (9) whUe holding the locknut
(8). Install inspection cover (7).

The forward pedal rod (13) should be adjusted

to 10-11116" between the center of the clevis
pin holes. Then connect this forward pedal rod
(13) to the lower lever (14) on the forwardreverse 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 positlon from the neutral cam adjustment. Turn the

6412

ADJUSTMENTS (Cont'd)
6. SAFETY START SWITCH ON CLUTCH
PEDAL LI NKAGE
Jack up the tractor so

the rear wheels are off the ground. Connect

an Ohm meter across the safe ty start switch
(1) te rminals on the hydrostatic housing rear
cover, Figure 13. Start the trac tor and run
in slow forward while lightly pressing brake
pedals. While holding this condition press the
emergency clutCh pedal slowly until the wheels
stop turning, indicating that the Hydros tatic
drive has been dumped . Continue pressing on
the e mergency c lutch pedal until the switch
(I) closes as indicated by the Ohm m e ter.

6. NEUTRAL START SWITCH 0 111 HYD ROSTATIC PUMP

Jack up the tractor so the
rear wheels are off the g round. Connect an Ohm
meter across the neutral start switc h (4) ter
mlnals on the hydrostatic housing front cover,
Figure 14. Start the engine and run a t low idle
speed. Slowly move the hand s peed control into
forward then back to neutral a nd into reverse.
The Ohm meter should indicate when the switch
(4) is closed. At this time the pump should be
in a neutral position and the rear wheels should
not turn.

Figure 14
Figure 13
If the switch (1) closes before the wheels

s top, add s hims (2) be tween the switch (I) and

cover, Figure 13. Rechec k for proper adjust
m ent each time shims are added.
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

If the wheels do turn add sh ims (3) betwee n

the switch (4) and cove r, until the switch is

ope n.
If the switch does not close and the wheels
stop turning , it will require removal of shims
(3) between the switch (4) and cover.

TOOLS

f
3"

1 12'

1 / 2 " DIA .

64-13

PRESSURE CHECKS
A press ure g auge is loca ted in the Instrum ent panel to show the m a ke -up oil p ressure
In forward, neutra l and r ever se _ The gr een
zone of the ga uge r a nges from 75 PSI to 300
PSL When a m or e accurat e pressure check
is r equired or the gauge is in ques tion. Disconnec t the gauge tube a nd fitting from the filter
return tube tee.

nOO

Insta ll the tes t pressu re g auge

PSI), Case
No. A20l72. J a ck up the tractor rea r wheels .
Start the e ng ine a nd run a t low idle speed (650
RPM ) and in neutr al until the hyd r ostatic drive
oil is up to ope rating tempera ture (1l()<J-1400F.)_

F igure 15

Norm a l Ope rating Oil Pressures

H an d

Lever
P osition

The ne utral and r eve rse pressure r eading

s hould show a min im um of 150 PS I.

Engi ne RPM
650

1500

2000

Neutral

225-255 PSI 235-265 PSI 240-270 P SI

F orward

125-1 55 PSI 135-165 PSI 135-165 PSI

Reverse

215-245 PSI

Operate the trac tor in fo r wa r d a nd the press ure reading s hould show a m inim um of 75 PSI.
If th e press ure is low in all three cond itions
it is ver y possible tha t thE' oil filt er elemen t
is sta rting to plug up.

235-265 PSI 235-265 PSI

LOAD CHECK
Load the Hydrostatlc d r ive, firs t in forward
and then in rever se drive by pos itioning the
front, or r ear, wheel s aga inst a s tout obs tacle
a nd applying the brakes a nd c a refully e asing
the speed control out of ne ut ral in the appropria te direction.

The r esult of this s hould be a ri se in ma ln

pressure to the relief va lve se tting, ti re slip
may occur be for e thi s pressu r e is rea ched .
However, the fact th a t m ain pressu re increases
up to the onset of tir e slip is su fficient indica 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 circuits.

Check filter , cooler, tubing

and hoses for leakage.

(b) Low pressure spill valve

or make-up oil pump relief valve stuck open,

Renew the hydrostatic drive

unit.

(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 leakage.

Refer to (4) and (5).

2. Drive continues with emergency clutch pedal depressed.

Clutch pedal linkage and

dump
valve
incorrectly
adjusted.

Check and adjust.

,3. No drive in Forward or

Reverse
and
make-up
pressure correct.

Clutch pedal linkage and

dump
valve
Incorrectly
adjusted.

Check and adjust.

4. Drive fails under load

in one direction only:
possibly accompanied by
a fall in make-up oil
pressure.

Leakage from link seals

on high pressure link.

Renew the four link seal

assem blies on the link tha t
should be at high pressure
in the failed direction of
drive.

5. Drive fails under load

in both directions: possibly
accompanied by a fall in
make-up oil pressure.

Excessive High Pressure

leakage In the hydrostatic
pump or motor unit.

(a) Check that the connecting

link seals are assembled
correctly.

6. Vehicle creeps forward

or rearwards, with speed
controls in the neutral or
zero-speed position.

Servo pilot
neutral.

valve

not

in

Adjust the neutral cam and

speed control linkage.

Section

65
FOUR SPEED TRANSMISS ION
AND FINAL DRIVE
TA BLE OF CONTE N TS
Specifications ............... ...... ... ................ ................................. ................................... .... ........... 652
Speciai torques ............... ................ ...... .. ................. .. .... .. ..... .. ....... ............. .. ........................... 65-2
Power Trains
Eight speed dual range ...................... .......................... ...... .. ................ .. ..................... .. .......
Eight speed shuttle .......................... ... ............. .. .................................. .. ..... .. ........... .. ..........
Four speed shuttle ........................................... .... .................. .............. .. ............... .. .............
Power shuttletorque conve rter ............................................................. .............. .. ...............

653
654
655
656

General Inspection ........................................................... .. .................... .. .......... ............. .. ...... 657

Generai assembiy ......... ............................................... .. ................... .... ... .... .. ........ .. .. .. ............ 657
Shifting Sequence ............................... .. ............. ................................... .. ......... .. ..... .. ............... 657
Transmission housing ........ .................... .. ............................... .. ................................. .. ............ 658
Pinion shaft ................................................................... ........................................................ 6510
Reverse idier gear (not used with shuttle) .................... .. ........... .. ....... .. ................................ 6512
Diiferential ... ................................................ .. ............. ........ .. .................. .. .............. ......... ..... 6514
Main drive shaft ................. .. ........................................ .. .... .. .............................. .. ................. 6518
Flanged axle ......... .. ..... .. ........................ .................................... ... ........... .. ...... .. ....... .. .... ....... 6520
Keyed axle .......................... .. ........................ ........ .. .... ................... .. .............. .. .... .. ......... .. ..... 6522
Gear shift cover ............ .... ....................................... ....................................... .. .................... 6524
Adjustments ....................................... ........................................ .. ...................... .. ... ............... 6530

Rae. Form 980641

652

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 countershaft 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 required,
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,

FORWAR D GEAR SPEEDS

FO RWARD RANG E SPEEDS
TOTAL FO RWARD SPEEDS

REV ERS E GEAR SPEEDS

REV ERS E RANGE SPEEDS
TOTAL REVERSE SPEEDS

WITH
SHUTTLE

WITHOUT
SHUTTLE

x2
8

4
x2
8

x2
8

x2
2

65-8

TRANSMISSION HOUSING
(Refer to Figure 5)
IMPORTANT If equipped with Draft-OMatic housing, Inset A, the plastic or rubber
drain tube will have to be disconnected and
pushed part ways into rear housing before
the Draft-O-Matic housing can be removed .
1. Torque tube

to transmission case bolts

(1) with lockwashers (2), tighten 80 to 132
{t. Ibs.

2. Torque tube to transmission case studs (3)

with lockwashers (4) and nuts (5), tighten
110 to 132 ft. Ibs. Coat internal threads of
stud thru holes with Permatex #3.

INSET A

3_lt equipped with dipstick extension tube (6),

apply Locktite Sealant, Case Part No.
B17068 to threads. Install a new gasket
(7).

4. Transmission case rear covers (8 and 9)

are used without P.T.O.
5. Plug (10) is used without Draft-O-Matic.
6. Front cover to transmission case studs (11)
with lockwashers (12) and nuts (13), tighten
35 to 42 ft. lbs.

r. _

_________

TUBE

65-9

EDAXLE
WITH
CASE USED
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 exceeds .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)

into the transmission case (3) until the s n3p

r ing (2) is sE'ated

Tap both ends of the pinion shaft with a

rawhide or plastic head ha mmer to help
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

bearing c up 15) into the transmission case
(3) un til c up (5 ) sea ts aga ins t the snap ring (4 ).
3.

Heat rear bea rin g cone (6) in ho t o il (20()!lF .)

and slide it down over p inion shaft (7) until
contact is made with the pi nion gear end of
the sh aft (7) .

4.

In sta ll pinion sh aft ( 7) Witll cone (6) into the

transmission case (:J) .

5. From in Side the transm ission case (3), in

sta ll onto the pi nion shaft (T ) the following,
in pro per sequenc e : 1st speed gear (8), spacer
(9) , 2nd speed gear (101. 3rd speed gear (111.
Dll slinge r gear (12 ). reta ini ng washer (131,
spacer 114). 4.th speed gear (151 an d selec tive
space r (16 ) which was predetermined before
assembly was sta rted .
6. Press th e front bearing cone (17) on the

shaft (7 ) a nd install adjusting nut (18). Th e

counters haft bearings should be preloaded
such tlla t a torque of 4 to 12 inc h pounds is
required to turn the pinion shaft assembly ,
Inse t c.

NOTE Do not confuse torque requi red to

turn the co unters ha ft with the torque generally
spec ified to tighte n a nut. In this case , the nut
is tightened to a n arb itrary ti ghtness with an
ordinary socket wrench and the torque wrench
is then a pplied to de term ine th e torque required to turn the shaft. The ordioary socket
ca n then be use d to tlghten or loosen the nut
until a correct reading is obtained when applying the torque wrench.
7. The gears on the countershaft mu st be so
shImmed as to have a n end play of .001" to
.006" as measured by a feeler g auge betwee n

the 2nd speed and 3rd speed gears. This en d

play must exist with the beari ng pre loa d properly set. End play is a d justed by Ibe selective spacer washer insta lle d be twee n the 4th
speed gear and the tapered bearing cone.
8. AftE'r the! countershaft is corrected Insta lled,
the thin section of the adj usting nut should be
peened into both slots on the countershaft to
lock it in place.

6511

INSET C
POU N DSr:lr:lc

TO 12 INCH TU RN SHA FT
~EQUIRED
TO
<::? ~
I')

C
<::?

'l

,;9
I')

&

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
gear assembly ( 2 ) and replace if necessary.

4. Install shaft (3) and gear assembly (1and 2 )

2. Bushing is pressed into position and burnished to -862"-.863" inside diameter. The
notched end of the bushing projects 1/16"
beyond the outside face of the gear. (See
Inset A ! .

5.Install set screw (4) with lockwasher (5) and

locknut (6) into transmission case. Tighten
set screw ( 4 ) and lock securely with locknut
(6).

in proper position in transmission case,

IMPORTANT Note the groove in shaft (3)

3. When installed, the lead of the spirol oil
groove in the bushing must be in the samc
direction a s the gear operates, which is
clockwise when viewed from rear of transmission case.

into which the set screw ( 4 ) fits. This set

screw ( 4 ) , when installed, must seat in the
shaft groove and be securely locked in place
with the jam nut to prevent any movement
of the reverse idler gear shaft ( 3 ) - Considerable damage to the transmission could
be caused by having this shaft ( 3 ) slipping out
of position.

6513

INSET A

Fio'u.'" 7

65-1-1

DIFFERENTIAL
(Refer to Figure 8)

1. Pinions (1) are not provided with bushings,

Inspect bore for out-aI-round and check
surfaces for rough s pots, Replace pinions if
worn, damaged o r pitted,
2,

Insta ll pinions ( 1) and pins (2) and secure

in position with roll pins (3 ) ,

3,

Press differentia l s haft (4) into the center

wheel (5) from the back side of the ring gear.
Shoulder on the shaft (4) should bottom on the
shoulder in the center wheel (5), See Inset A
for proper positioning on all hydrostatic
models and forklifts without hydrostatic,

6, Install the differential shaft (4) and center

wheel (5) with the proper sintered iron thrust
washers (9) and steel shim washers (10) on
each side of the center wheel (5), into the
transmission case, NOTE Coat both ends
of shaft (4) and both faces of washers (9 and
10) with "Molylube",
7. Press new bearings (14) onto side gears (6)
until they bot to m. Install the side gears (6)

onto the differential shaft (4)on each side of

the center wheel (5).
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
into the brake assemblies, If oil leaks are
detected, the plug must be replaced, Install
cup plug (7) as shown in rear counterbore
of side gear (6), Inset B. Coat bore with
Permatex "1. Do not dilute prior to installation of cup plug, Bore must be clean and
oil free prior to sealant application, Make
certain plug (7) bottoms against shoulder of
gear (6),

9. Press new oiI seals (17) into carriers (16)

using driVE'r GI0516, Inset F,

10, Install the same number of shims (18) or

more that were removed onto the carrier

(16), Make sure enough shims are installed
to gIve some ring gear to pinion gear backlash, Carrier "0" ring (19) must be left off
at this time so as to avoid damage during
differential bearing pre-load.

NOTE Tractors equipped with a diffE'rentiallock do not use a plug in the right hand
side gear (8), Insets C and 0,

11, LubrIcate outside of G13503 sleeve, Inset

G, and also the inside of the carrier oil
seal (16) with "Molylube",

NOTE On tractors equipped with differential

lock, insets C & 0, press in bushing (11) until
the outer edge is even with the shoulder or
step in the side gear, Press in two new seals
( 12) with the lips inward until the inner one
just bottoms on the shoulder or stEeP in the
side gear. Be careful not to damage the new
seals when passing over the splined shaft (13),

12, Slide wIde end of sleeve GI3503. Inset G,

over the side gear (6). Slide carrier assem-

5, Install the same size thrust washer (9), shim

washers (10) that were removed and side gear
(6) on the differential shaft (4),
IMPORTANT For differential CE'nter whE'el
to side gear shim adjustmE'nt, refer to Adjustments on Page 65-30, Alter proper backlash
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

bly with s hims over the sleeve G13503 and

onto the side gear and at t he same ti me
pulling sleeve G13503 out through the carrier assembly,
13. Install screw (20) locking bearing carrier

(16) to transmission case. Use existing

brake cover hardware to further secure
bearing carrier (16) to transmission case.
Spacers must be used to adjust for the
missing brake covers. Torque nuts & bolts
70 to 90 ft. Ibs.

As an alternative, 1" long bolts can be

used for securemen t.

G5 15
INSET A

INSET F

~
141{)

:C:y

INSET B

INSET

19

19
NTlAL LOCK
WIT! H DIFFERE

INSET G

G 13503 SLEEVE

WITH DIFFERENTIAL l OCK

Figure 8

6.516

DIFF ERENTIAL (CONT' D.)

(Refer to Figure 9)
14. With the carrier bolts & nuts properly tor
qued, adjust the differential gear bearings
for correct pre load. Refer to Page 6530 for
Differential Bearing Pre Load Adjustment.
15. Adjust the ring gear and countershaft pinion
backlash. NOTE The differential shaft bear
ing and the countershaft bearing pre loads
must be adjusted before the ring gear &
countershaft pinion backlash can be determined .
Refer to Page 6530 for ring gear and
cou nter shaft pinion backlash.

17. Install new "0" ring (19)to each differential

bearing carrier (16).
18. Reinstall differential bearing carrier (16)
using again the s leeve G13503 on the side
gear spline to avoid damage to the oil seal
(17). Work the bearing carrier (16) into
place by hand. Do not pull it into position
using bolts or damage to the "0" ring
(19) could result.
19. Secure bearing carrier (16) to transmission
case using screw (20) .

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

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
drive sha ft the following steps should be observed:
a. Remove the rear oil seal housing feom th e
mainshaft (with P .T.O.) using a suitable
puller or the oiling cup (without P.O.O.),
before removing the mainshafl.
b. Place a G15012 spacer block between cluster
gea rs on the ma inshafl. (See Inset A).
c. Install s tep plate adapter (1" to 1-1/ 4" Owa
to nna :\0. 630-3 against the rear of the main shaft.
d. Place a rod against the end of the step plate
adapter and deliver a sharp blow to the end
of the rod with a lead or rawhide m allet.
This will loosen the rear bearing cone from
the shaft and the front bea r ing cup from the
case. The rear bearing cup is held in position with a snap ring and will I'pmain in case.
Do not remove unless there are indic ations
that replacement Is necessary. Slide the gears
from the shaft as the shaft is removed.

1. If rear bearing cup (1) and s na p ring (2)

were removed, install a new snap ring (2)
into the transmission case (3). Press new
bearing cup (1) into transmission case (3)
until sea ted aga inst snap ring (2).
2. Press front bearing cone (4) on shaft (5).
3. Slide shaft (5) through bore of transmiss ion
case and position gears (6 and 7) and rear
beari ng cone (8) on s haft as the shaft is
moving into position.
4. Press shaft (5) and rear bearing cone (8)
Into position.
.5. Use a GI:l502 drive, Inset E, to install front
bearing cup (9).
6. Place the same number of shims (10) that
were rp.moved onto the front end of the
shaft (5).
7. Install new oil seals (14) in front cover (13)
or aU seal carrier (15) using GI5010 driver,
Inset C.
8. Install pilot collar (11) and a dry new gasket
(12) onto shaft (5) when equipped with torque converter drive. Install cover (13) with
oil seals (14) ontoshait (5) using GI3501 sleeve,
Inset D.
9. In sta ll oil seal carrier (15 ) w ith new oil

seals (14) but without the new "0" ring (16)

when equipped with dry c lutch drive. Install
the dual range housing & a new dry gasket.
Retain oil seal carrier (15) In dual range
housing with snap ring (19) .
10. Tap both ends of the shaft (5) lig htly with a
rawhide hammer. Rotate shaft several times
and check for end play. Refer to Page 65-20
for main drIve shaft adjustments .
11. When adding or subtracting sh ims to obta in proper mainshaft adjustme nt on torque
converter drive, remove fro nt cover (13)
with oil seals (14) and pilot collar (1l) using
sleeve G13501, Inset D.
12. When adding or subtracting shims to obtain proper mainshaft adjustme nt on dry
clutch drive, remove dual range housing
and oil seal carrier (15) using G13501 sleeve,
Inset D.
13. ""'hen proper mainshaft adjustme nt Is reac hed on the dry clutch drive option, Install a
ne w "0" ring (16) onto the oil seal carrier
(15) which was previously omitted when c heckIng for end play.
14. Whe n equipped with P.T.O., insert a new
wear sleeve (18) in Tool A43043, Inset E a nd
heat the tool and sleeve in oil 14()O to 160"
for ten minutes. Install the sleeve (18) onto
the mainshaft (5) by tapping on the tool until
the tool bottoms on the mainshaft.
15. Insta ll needle bearing (19 ), preSSi ng on the
numbe red edge of bearing into oil sea l hous ing (20). Press new oil sea ls (21 & 22) into
the oil seal housing (20). Lubrica te the oil
sea ls (21 and 22) in the mainshatt rear 011
sea l housing (20) with Lubriplate .
16. Coat surface of rear oil seal housing (20).
Inset F, with bearing retainer LocktiteCase No. 345-34. Install the housing assembly into the transmission case llsing Tool
A43044, Inse t E. Install the housing until
It bottoms against the snap ring in the transmIssion case, Inset F.
17. When equipped without P.T.O., install new
cu p plug (23) using Permatex No.2 into shaft
(5) . Refer to Inset G for dimensions.
Press oiling cup (24) into mainshaft bore.
IMPORTANT Insta ll oili ng cup (2.3) such
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

4 SPEED &
POWER SHUTTLE

Figure 10

G150:0 DRIVER

INSET

G13501 SLEEVE

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
front cover (13) or dual r a nge housing are
a ssembled and a ll stud nuts a re torqued to
35-40 ft. lbs. The mainshaft must be rota ted
to seat the ta pe red bearing before checking
for e nd play_ When properly adjusted, there
will be _002" to .005" end pl ay of the m a insh aft.

2. If shaft end play is too great, add shims (10)

between front cover pilot collar (11) or oil
seal carrie r (15) and bearing cup (10), Insets
H and I.
3. If end play is insufficient, remove shims (10)
between front cover pilot collar (11) or oil
seal carrier (15) and bearing cup (10), Insets
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 bearing cup ( 2 ) into axle housing ( 3 ) .
2. Press inner oil seal ( 4 ) into axle housing (3)
using driver G13504, Inset B.
3. Install outer oil seal ( 5 ) on axle shaft (6)
using (215043 sleeve, Inset C,
4. Press outer bearing (7) on axle shaft (6) until
i t bottoms.
5. Slide sleeve G13.5OS, Inset D, over splined
end of axle shaft ( 6 ) . Place axle shift (6)
in housing ( 3 ) and pull out sleeve after
passing through inner oil seal ( 4 ) . Install
inner bearing ( 8 ) , drive gear ( 9 ) , washer
(10) and nut (11).
IMPORTANT Position drive gear (9) so
letters "NUT THIS SIDE" a r e facing towards the adjusting nut (11).
6. Position Case GI3505 Oil Seal Driver a s
shown in Inset E, Hold in place with rubber bands.
7.Tighten nut (11) on axle shaft (6) and draw
outer oil seal ( 5 ) in until i t is flush with
the end of the axle housing ( 3 ) , Inset A.
Remove oil seal driver.
&Tighten the nut (11) to seat the bearings
and cups, loosen the nut until the axle shaft
has slight end play (no bearing preload).
NOTE There a r e two methods that can be
used to check the bearing preload.

Method A is w i ~ hthe axle housing remove

from transmission case.
Method B is with axle housing assembled
to the transmission case.

Method A To check bearing preload when axle

housing is not assembled to transmission case.
Loosen nut (11)so axle has slight end play (no
pre-load on bearings), Check the turning
torque created by the seal drag. Then tighten
the nut (11)until the turning torque is 20 to 30
inch Ibs. more than the seal drag. Mark the
nut in relation to the cotter pin hole and count
the number of threads exposed beyond the
nut.
9. Remove nut (11), washer (10) and drive gear
(9).
10. Install new "0" ring (12) on axle housing
(3) and reinstall flanged axle and axle housing assembly into transmission case far
enough to install final drive gear (9),
washer (10) and adjusting nut (11).
11.Secure axle housing ( 3 ) to transmission
housing with bolts (13) and lockwashers
(14). Torque bolts 150 to 180 ft. Ibs. NOTE
On Forklift models torque bolts 220 to
264 ft. lbs.
12. Retighten nut (11)on axle shaft (6 j to position marked or noted in Method A.
Method B. To check the bearing preload with
the axles, housings, drive gears and differential installed, loosen the nut (11)until their
is slight end play of the axle (no preload on
bearings). Check the turning torque required
to turn the axle and differential. Then tighten
the nut (11) until the turning torque is 20
to 30 inch Ibs. greater the no load turning
torque.
13. Install cotter pin (15) .

65-23

INS ETC

'''~

@-G15043 SLEEVE

---m~0

G\ll",.{'' -

iJ

IN S ET

G 136 03 SLEEVE

INSET

E
3505 DRIVER

BAND

SH

Figure 1 2

KEYED AXLE
(Refer t o Figure 13)
1,Press outer bearing (1) onto axle shaft (2)

until it bottoms, Inset A,

2, Press inner bearing c u p ( 3 ) and outer bearing cup (4) into axle housing (5) until they
bottom.
3. Install axle shaft (2) into axle housing ( 5 ) .
4. Install outer oil seal (6) onto axle shaft
(2) using GI5018 sleeve & GI502 driver,
Insets B & C.
5 . Install inner bearing ( l o ) , final drive g e a r
(11), (lettered side of gear. "NUT THIS
SIDE", must face adjusting nut) spacer
(121, washer (13) and adjusting nut (14).
6. Tighten the nut (14) to seat the bearings
and cups, loosen the nuts until the axle shaft
has slight end play ( n o bearing preload).

NOTE There a r e two methods that can

b e used to check the bearing preload.
Method A is with the axle housing remove
from transmission case. Method B is with
the axle housing assembled to the transmission case.
Method A. To check bearing preload when
axle housing is not assembled to transmission case. Loosen nut (14) so axle has
slight end play ( n o pre-load on bearings).
Check the turning torque created by the
seal drag. Then tighten the nut (14) until
the torque is 20 to 30 inch Ibs. m o r e than
the seal drag. M a r k the nut in relation to
the cotter pin hole and count the number
of threads exposed beyond the nut.
7. Remove nut (14), washer (13), spacer (12)

and final drive g e a r (11).

8.Install housing ( 5 ) with new "0" ring (15)

to transmission c a s e (7) using bolts (8) and
lockwashers (9). Torque bolts 150 to 180
ft. Ibs. NOTE On forklift tractors torque
bolts 220 to 264 ft. lbs.
9. Reinstall final drive g e a r (11), spacer (12),
washer (13) a n d nut (14).
10. Retighten nut (14) on axle shaft ( 2 ) to position marked o r noted in Method A.
Method B. To check the bearing preload with
the axles, housings, drive g e a r s and differentlal installed, loosen the nut (11) until
their is slight end play of the axle (no preload on bearings). Check the turning torque required to turn the axle and differential. Then tighten the nut (14) until the
turning torque is 20 to 30 inch lbs. greater
the no load turning torque.
11.Install cotter pin (16).
12. Install axle key (17) with pin (18) a n d install
wheel and tire.
13. Tighten each hub bolt (19) evenly until only
slight resistance is met. Then torque bolts
equally In three increments (1) 70 to 80 ft.
Ibs,, (2) 150 to 160 ft. Ibs, (3) 270 to 320 ft.Ibs.
keeping the wheel hub c l a m p (20) parallel with
the hub (21), NOTE R e a r wheel hubs must not
be set closer than 1-1/2" from end of axle
housing. If they a r e , the key will extend into the
run-out o r shallow end of the keyway, with the
result that hub c l a m p cannot be clamped
against the axle a t the inner end and the wheel
will not run straight. Hub c l a m p m a y b e
broken and wheel cannot be kept tight.

6525
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
(15,33 & 37)

SUPPORT
SPRING (1)

REVERSE LUG
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

39

INSET E

CEfP
=--=TO

3.75 "

3RD 80 4TH

/
/~

" .m ~1~
o
0

~~

3/ 4"

.
~'@
~
-*

1 -1 / 4 "

2tl

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)_

THE 3/S" STEEL BALLS ARE HELD IN

THE COVER UNDER SPRING TENSION
AND WILL FLY OUT " 'ITH GR.E AT
FORCE WHEN THE SHIFT HAUS ARE
REl\lOVED FROM THE COVER.

NOTE On
tractors
with
mechanical
shuttle transmission, install plunge r (19),
spring (20), nut (21) and cotter pin (22)
Into I'everse shifter lug (23). Then install
lug assembly with 3/ 4" spacer (24) to the
rear and 1-1 / 4" spacer (25) on front side of
lug. Secure with roll pin (26), Install stop
bolt (28) and nut (29).

COVER THE OPENINGS IN COVER WHEN

REMOVING RAILS TO PREVENT INJURY
FROM THE FLYING DETENT BALLS.

9. Before moving reverse shift rod (17) fully

Into position, make certain that s lot for
interlock is turned towar d the center rail

1. Position spring (1) and shlfl lever (2) Into

control cover

(~l),

from the bottom up, Inset C _

2.lf equippe d, insta ll s hift leve r (2), s pacer (49

a nd snap ring (3) into control "over (3) from

the top down, Inset D.
3. Turn dog point ret aining Screw (6) into cover
(3) until it bottoms in the groove and slight
drag is felt when moving shift le\'er (2) . Back
screw (6) out until lever (2) moves freely and
then IightE'n jam nut (7) to s ec ure screw (6 )
Into place,
IJl.lPORTANT Make certain that projecting
ends of support spring (1) do not interfere
with the ac tion of shift lever (2). Make
certain th e two e nd coils of the sup
port s pring have not doubled up thereby
restric tin g the travel of th e shift lever.
Int"rCerence a t thi s po int m ight limit the
movement o( the shift rail SO that the ba ll
would not fall in to the rail detent.

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) .

(30).

NOTE The interlock slots in the two outer

Talis (17 & 31) must be turned toward the
center rail (30).

10. Move reverse shift rail (17) fuJly into position so that the ball (16) rides in the detent.
11. Install the interlock plug (32). Refe r to [nset
E for plug dimensions.
12. Compress center detent spring (33) into
position in cover (3) with ball (34). Retain
in place by install ing 1st to 2nd shift rail
(30) into the cover (3).
15. Compress detent spring (37) into position
in cover (3) with ball (38). Retain in place by
starling 3rd to 4th shift rail (31) into the
cove r (3).
16. Install roll pins (40) into the s hift forks
(14, 35 & 39) and into the shift rails_

65-29
DETENT

INSET~A~~~~fi~~~~~
INTERLOC K PLUGS

INSET

It
~

(7)0

)1

~
~ '"
J. ,

-f2\

'"
"-<D

_~

----;~~

_ _ _ __

.-1 ,"m ,

"~~~
9D 'i
.@--:. ~
t[JJ= ~"
,s66 ..

ro,s74'~ ..

6530

ADJUSTMENTS
(Refer t o Figure 16)
1 . DIFFERENTIAL PIN ION TO SIDE
GEAR BACKLASH
1. With the differential shaft pressed into the
center wheel, the thrust washer, steel shim
washers and side gears installed on the diff
erential shaft, the adjustment can be made.

2. Install a dial indicator, Inset A, so the point

of the indicator is against the pinion gear
tooth. While holding side gear in place with
one hand, rotate the pinion being checked
back and forth by hand to check the backlash.
IMPORTANT Backlash should be .DOS" to
.015". The differential straight bevel gear

backlash adjustment is obtained by using, as

required, the washers or shims. One sintered
iron thrust washer must be used on each side
of the center wheel and, if required, steel
shims may be used to obtain the required
backlash adjustment. If used, the steel shim
shall be placed against the thrust surface of
the center wheel, Inset B. Each differential
side gear should be shimmed to give from
.D05" to .015" backlash. If backlash is not
uniform as the side gear is rota tcd, the
minimum backlash measured shall be used
to determine the correct shim thickness.
NOTE A .005" shim adjustme nt changes
the backlash approximately .0035". The sin
tered iron thrust washers are available in
sizes from .089" to .119". The steel shims
are .010" in size.

3. DIFFERE NTIAL RIN G GEAR TO

COUNTE RSHAFT SHAFT PINION
GEAR BACKLASH
IMPORTANT The backlash between the
differential center wheel ring gear and the
countershaft pinion mus t be adjusted after
the differential shaft bearing pre load is
adjusted.

1. Loca te a dial indica tor on the transmission

case as shown in Inset D. Position the gauge
carefully so that the dial will not skip on
the tooth and so that sufficient pressure is on
the tooth to move the indicator needle .

2. Take up the slack in both gears by holding

the countershaft pinion and rotating the
diffe rential center wheel ring gear as far
as possible in one direction without moving
the countershaft pinion. Set the dial indio
cator to zero.
3. Hold the countershaft pinion and rotate
the differential center wheel ring gear as
far as possible in one direction without
moving the countershaft pinion. Read the
dial indicator for the backlash between
gears. Correct backlash is from .005"
to .009".

4. If backlash is too great, remove shims from

the left hand differential bearing carrier and
add them to the right hand differential bear
ing carrier. Retorque bearing ca r rier nuts
& bolts.

2, DIFFERENTIAL BEARING PRElOAD

1. Install the same number or more shims than
were removed and torque the carrier bolts
and studs 70 to 90 ft. lbs. Make sure enough
shims are installed to give some ring gear
to pinion gear backlash.

2. A special tool can be made from a brake disc,

Inset C, to be used with a torque wrench,
to check the differential bearing pre load.
This is measured as turning torque of 3
to 8 ft. Ibs. on one differential side gear
while the countershaft pinion gear is locked
against rotation. Add or subtract differential
bearing carrier shims to the opposite side
until correct pre load is obtained. Shims are
available in sizes .005", .OOT' and .010".

NOTE The differential must be rotated

to seat the bearings before the backlash ad
justment is measured. A .005" shim changes
this backlash approximately .00.35".
5. If backlash Is insufficient, remove shims
from the right hand differential bearing
carrier and add them to the left hand differential bearing carrier. Retorque bea ring
carrier nuts and bolts.
6. Check the dial indicator after each shim
change.

65-31
1. DiffERENTIAL PINION

INSET A

TO SIDE GEAR
BACKLASH

" .... '"'L

TOOL

SIDE GEAR

DIAL INDICATOR
.005 " TO ,0 15" BAC KLASH

INSET B

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

S / 8"

~EX .

1 . 1I 2 " ~

<..

SPECIAL TOOL

NUT

/~

~6"

"

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
adjusted it may result in e ithe r the tractor
not starting when the gear shift lever is in the
start position or being able to start the tractor

with the gE'ar shift lever in neutral or in gear.

To adjust the safety starting switch, proceed as foHows:
GEAR SHIFT LEVER
IN NEUTRAL POSITION

SAFETY STARTING
SWITCH \
TRANSMISSION
TOP COVER

SHIMS AS
REQUIRED

Figure 11
A.If engine will not start with the gear shift
lever in start posi tion:
1. Move the gear shift lever to neutral,
remove all the shim washers and turn
the safety s tarting switch "i n' by hand
while holding the key switch in the start
position. When safety switch makes contac t the engine will s ta rt. At this point
turn off the engine and add enough shim
washers betwee n the switch and transmission 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.

Figure 18
B. If the engine s tarts with the gear shift
lever In ne utral or in gear:
1. With the gear shift lever in neutr al position, add one shim a t a time be tween the
switch and transm ission cover until the
enginE' will not s tart by turning the key
switch to the "start" position.

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

lever (3) and disconnect linkage ass emb ly (2).

2. Re move the tour bolts (4) w ith loc kwashers
f rom cover.
:3. Tap cover upwa rd ligh tl y to r e move. The
locating dowels (5) a nd (6) will remain in
cover. Remove gas ke t (7).
4. Remove lockwjres a nd setscrews (8). Drive
the s huttle ra il (9) out and remove detent

ba ll ( 10). spring ( 11 ), fork (12). lug (13) and

selective spacer (14).
5. Remove the p ipc plug (15) in top 01 cover
a nd using a punch drive the roll pin (16 )
do wn and o ut o f the cove r .
6. The lower shut tle lever (3) is s plined to the
fork lever ( 17) and can be pulled out of
cov~r.

7. Drive au t lever sea l (1 8) .

Inspection
Inspect the shuttle fork, ra il , fork lever
and detent ball for excessive wear or r oughness .
Inspect the de te nt spring (11 ).
Spring Speclfica tlon s:

Total coils .. ........ ...... .... ..... ......................... 8

Wire diamete r ... .... .... ....... .............. ....... 072 "
1.0. dia meter ........... .. ................... .... 25/64"
Free le ng th ........ ............ ........... ............ . 1"
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.

2. Wh ile holdi ng fork lever (17 ) In a vertical
position inside of cover, Ins ta ll the lower
shuttle lever (3) a t an approx. a ng le of 60".
toward the rear of the cover. This wIll
engage the s plines correctly. NOTE: Be
careful not to damage seal.
3. Drive in the roll pin (16 ) to r etain the lower
s hu ttle lever In the cover. Insta ll pipe plug

is availa ble in thickness of .550", .531"

and .562 ", can be do ne by m oving the
shuttle lever to the fonv a r d position with
the dete nt ba ll seated in r a il.
8. Using a feeler gauge check the clearance
b e tw een spacer a nd housing (In se t A).
9. In s ta ll the longest spacer that w ill s tm
give a c learance of .010". If this is not
done, ove r shifting can result in d am age
to the shuWe unit.
10. Before ins ta lling the cover assembly, move
the dual r ange level' rearward a nd the
lower shu ttle lever (3) fonvard. Move the
dual ra nge shift collar forward a nd the
s huttle collar rearward. Make s ur e forks
engage th e s hifting collars. I nstall cover
with new gaske t (7).
11. Install bolts (4) with lockwas hers and torque
to 35 ft . Ibs.
12. Reconnect linkagE' assembly to shuttle lever
(2) using bolt (1) with lockwasher.

(15) .

Insta ll detent s pring (11), ba l! (10) and

while compressing spring, s tart the shuttle ra il (9 ) into cover.
S. Install the spacer (14 ) and lug (13) while
d r iving Ihe rail (9) into pos it ion.
6. Insta ll shuttle fork (1 2) and r e tain fork
(12) a nd hub (U ) with setsc rews (8) . Make
sure setscrews e ngage r ecess in rail and
torque to 35 It. Ibs. 1 'OTE : Make sure
lod:wire is not wedged betwee n spacer
a nd fork.
4.

66-3

INSET A

(j)
I

I
v

l...... / /

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
(2) a nd breather tube nut (3) if equipped
from cover,
2, R emove the four bolts (4) with lockwashers
from cover,
3. Tap cover upward lightly to remove. The
loca ting dowe ls (5) a nd (6) will remain in
cover. Rem ove gasket (7).
4, Remove lockwires a nd setscrews (8 ). Drive
the shu t tle rail (9) out and remove detent

ball (10), spring (11), fork (12), lug (13 ) a nd

selective spacer (14).
5. Remove the pipe plug (15 ) in top of cover and
using a punch, drive the roll pin (16) down
and out of the cover.
b. The shuttle lever (19) is splined to the
fork lever (17) and ca n be pulled out of
cover.
7. Drive out lever seal (18).

Inspection
Inspect the shuttle fork, rail, fork lever
and detent ball for e xc essive wear or rough
ness.
Inspect the d e tent spring (11),
Spring SpeCifications:

Total coils .................................................. 8

WIre diameter ...................... .. ............... 072 "
I.D. diameter ..................................... 25/ 64"
Free length ...... .. ............ .. ........................ I"
Compression to 13116" ............. 35 to 38 Lbs.

A ssembly and Installation

1. install new oil seal (18) wlth IIp inward ,
unt il it bottoms in cove r .
2. While holding fork lever (17) in a vertical
position inside of c over, ins ta ll shuttle
leve r (19 ) at a pproximately a right angle
to the c over. This will engage the splines
correct ly. NOTE : Be careful no t to damage
the s ea l.
3. Drive in the roli pin (16) to retain the
s huttle lever (19) in the cover. Install
pIpe plug (1~),
4.Insta ll detent spring (11), ball (10) and
while compressing spring, s tart the shuttle r a il (9) into co ver.
,j. Ins tall the spacer (1i) a nd lug (13) while
driving the rail (9 ) into position.
6. Install shuttle fork (12 ) a nd retain fork (12)
and hub (13) with se tscrews (8). l\'l nke sure
setscrews enga ge r ecess in rail a nd to rque
to 35 ft. lbs. NOTE : Ma ke su re lockwire
is not wedged between spacer and fork.

7. Selection of the pro per spacer (H) , which

is available in thicknes s of . .550" , .531"
and .562" can be done by moving the
s huttle lever to the forwa rd pos ition with
the dete nt ball seated in rail.
8. Using a feeler gauge check the clea rance
be tween spacer and housing (Inset A) .
9. In s tall the longest spacer tha t will st ill
give a clearance of .010". If this is not
done, over s hifting can result in damage
to the shuttle unit.
10. Before installing the c over assembly,
move the dual range lever rearward and
the shuttle lever (19) forward. ;Vlove the
dual range shift colla r forward and the
shuttle colla r r en rward . Make sure forks
e ngagE' the s hifting coll a rs. Install cover
wi th new gasket (7) .
11. Insta ll bolts (4) with lockwa shers and torque to 3.5 ft. Ibs.
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
a brass rod and drive the stud (2) from the
C3se (6). Lea ve idler g ea r a ssemb ly (2,3 ,4,5 )
in case until the shuttle gears are re moved.
2. Remove bea ri ng retainer bolts (7) with tockwa shers a nd reta iner (8).
3. Remove the in put shaft (11) Or (39 ).
4. Remove snap ri ng (9) bearing (10) and
needle bearing (12 ) from inpu t shaft (11 )
if they are to be replaced.
5. Rem ove snap ring (13) nuts or bolts that
reta in the shuttle unit to the dual range
or transmission case. While moving the
sh uttle housing (6) forwa rd . remove the
synchronizer unit (14 thru 19 ), thrust collar
(20), outpu t gear (21) and sleeve (22).
6. Remove the pinned thrust collar (23).
7. Remove reverse idler gear assembly

I nspection
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.

(2,3,4,5) from case. Remove s na p r ing (3)

and press bea ring (4) from gear (5) and
shaft (2) .
8. Remove countershaft bushing bolts (28 )
with lockwashers, countershaft lock (29),
countershaft bushing (30) a nd shi ms (31)
from case .
9. Pull countershaft (32) from case and remove
counte rshaft gear (36), thrust bearings (34)
a nd thrust washers (33) and (35).
10. R emove needle bearin gs (37) from countershait gear (36 ) If they are to be replaced .
11. Rem ove e xpans ion plug ( 38) from case if it
has been leaklng .
12. Disassembly of the synchronizer unit can
be done by removing both the blockin g rings
(14 and 19), springs (15 and 17 1 and the shifter
plates (18) fro m the hub-sleeve assembly
(16) .

FRONT

66-7

668

SHU TT LE TRANSMISS ION

(Refer to F igu re 4)
Assembly and Insta llation
J. Install new expansio n plug (38) and start
countershart (32) into casco
2. [nstall needle bearings (37) in to gear (36)
using GI5021 driver. Drive on the numbered
edge of bearing untit it is even with the
chamfer. (Refer to In set A.)
3. Lubricate t he coun tersha ft gea r bearings.
Install countershaft gear (36) on shaft (32)
with a thick .12.5" thrust washer (33) on
each s ide of gear. In sta ll thrust bear
ing \:H ) a nd thin (.031") thrus t washer
(35) on each side of gear. Push s haft
all the way into gear.
~. Insta ll the sa me number of shims (31)
that we re removed, bushing (30), lock (29)
and bolts (28) with loc-kwashe rs. Tighten
bolts 15 to 20 ft. Ibs. torque. Using
feeler gauge between gea r (36 ) and thrust
wa sher (33) c heck for proper end play of
.004" to .009". Remove or add shims (31)
untit proper end play is reached.
5. Press bearing (4) into idle r gear (3) and
insta ll sna p ring (3). Press idler gear and
bearing assembly on to the idler shaft (2)
with the sn ap ring s ide toward threaded
end of shaft . Lay t his idler s haft assembly
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 hubsleeve
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.
gasket
is used be tween shuttle housing and dual

"0

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.

9. Select the proper sna p r ing (13) to give

the synchronizer unit a minimum of e nd
play. This s nap ring is ava ilable in .076"
.080", .08.3", .087" a nd .091" thickness.
Install the proper snap ring (1:3) onto the
sha ft.
10. Press new need le bearing (12) into input
gea r (11 ) using driver G15042. Use tbe
proper end of the dr-i ver and press on the
num bered s ide of the bearing. (Refer to
Inse t B.) The driver will allow the bearing
to stop at a point inside of the input gea r ,
so that the oil hole is open to the bearing
and it will allow for proper lubrication.
11. Press bearing (10) on to inpu t s haft and
retain with sna p ring (9).
12. Install input s haft (11) or (39) , retainer (8),
bolts (7 ) with lockwashers and tighten 35 to
40 fl. Ibs .
13. Position the idler gear shaft assem bly
in its proper opening in case . Install nut
(1) and lig hten secure ly. Stake nut to s hafl.
14. Reassemble the trac tor and fill torque
tube to proper level wit h Case T CH oil.

FRONT

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
lower sh uttle levC'r (2 ) ancl di sconnec t
linkage assembly.
2. Remove the four bolt s (3) with loc kwashe rs
from cove r.
3. Tap cover upward lightly to remove. The
locating d owels (4) and (5) wi ll rem a in in
cover. Remove ga sket (6).

(9), s pr ing (10) and fo rk (11).

5. Remove the pipe plug (12) in top of cover
a nd usi ng a punch drive the roll pin (13)
down and out of the cover .
6. Pull dual range lever (14 ) out of fork
lever (16) , remove key (15 ) and pull range
lever out of c over.
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
lever and deten t ball for excessive wear or
roughness.
Inspect th e dete nt spring (](I ) _
Spring spec ifications:

Total coils .... ........ .... .. ......... ... _............... _ 8

Wire dia meter ........ .... .. _.. .................. .072"
I.D. Dia meter ................................. 25 / &1"
F ree length ........................................... 1"
Compression to n / 16" _........ .. 35 to 38 lbs.

Assembly and Installation

l.lnstall new oil sea l (17) with lip inward
until it bottoms in cover.
2. While holding fork leve r (16 ) in a vertical
position inside of cover, install the dua l
range lever (14) and key (1')).
3. Drive in the roll pin (13 ) to retain the dual
r ange lever in the cover. Ins tall pipe plug
(12 ) .

4. Insta ll detent spring (10 ) ball (9) and while

compressing spring , start th" dual range
rail (8) into cover.
5. Insta ll the dual ra nge fork (11)
driving the rail (8) in to position.

while

6. Retain fork (11 ) with setscrew (7). Make s ure

setscrew engages recess in rail a nd torque

to 35 ft. lbs. NOTE: Make sure the loc kwire
Is ins talled.
7. Before insta iling the cover assembly, move
the dual range lever (14) rearward and the
lower shuttle lever (2) forward. Move the
dua l range s hift collar forward a nd the
s huttle collar r ea rw a rd. iI'lake s ure the
forks engage the shifting collars. Inst a ll
cover with new gasket (6).
8. Install bolts (3) with lockwashers and torque to 35 ft. lbs.
9. Reconnect linkage assemb ly at lower
shuttle lever (2) using bolt (1) with lockwasher.

67-3

-I
CD--o

Figure 1

..."" ---(D

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

(2 ) and breat her tube nut ( 3) if equipped
from cover .

2. Remove the four bolts (4) with loc kw 3shers

from cover.
3. Tap cover upward lightly to Iemove. The

locatlng dow els (5) and (6) will re main in

cover. Remove g askN (7 ).

(10 ), spring (11) and fo rk (12).

5. Remove the pipe plug (13) in top of cover
and using a punc h drive t he roll pin (14)
down and out of the cover.
6_ Pull dual ra nge lever (15 ) out of fork [ever
(17) , remove key (16) and pull range lever
ou t of cover.
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
a nd deten t ball for e xcessive wea r or ro ughness.
Inspect t he deten l sp ring (11).
Spring spec ifica tions:

Total c oils ... _....... __ .... .. .. ...... . _........ .... ... _.. 8
Wire Diam e te r .... ...... _.. .... .. .. ....... .. ..... 072"
I.D. DIameter ...... ..... .... _................. 25/ 64"
Free length ......... _................................. 1"
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
unti l It bottom s in cover.

2. WhUe holding fork lev er (17) in a vertical

posit io n insi de of cove r , in.'ita lJ the d ual
range lever (15) a nd key (16).

.3 . Drive in the r ol l pin (14 ) to retain the du a l

range lever in t he cover. Insta ll pip!' pl ug
11.3) .

se tscrew engages recess in rail a nd torque

to 35 ft. lbs. NOTE : Ma ke sure the lockwire
is ins talled.
7. Be fore installing the cover assem bly, m ove
the dual range lever (15) rearward and the
shuttle lever (20) forward. M ove the dual
range s hift collar forwa rd a nd the shuttle
collar r eanva rd. Make sur e t he forks
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
rail (9 ) into cover.

8. Install bolt s (4) with lockw3shers and torque

to 35 ft. Ibs.

5. In stall the dua l ra nge fork (12 ) while driving

the rail (9) i nto position .

9. Insta ll breat her tu be (2 ) a nd nu t

ped and breather (1).

6. Retain fo rk (12) wit h setscrew. Make sure

( 3)

if equip-

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
Sec tion 66 of the Servic e :'"Ianual.

2. Remove the input shaft

forward.

(1)

to

by pulling

3. Remove bearing (2) with snap ring , a nd

needl e bearing (3) fro m input shaft (1) if
they are to be replaced.
4. Remove snap ring (4) and nuts that retain
housing. While pulling the housing forward
remove the shifting collar (5 ), shift collar
carrie r (6), output gear (7), sleeve (8) a nd
pinned thrust collar (9 ). Remove snap ring (11).
.J. Remove the coun tershaft collar shims
(12) , collar (13) with s haft (14 ) by pulling

Inspection
Thoroughly clean all parts before inspection. 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 excessive or uneven, wear. This would be an ind 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.

on the ro ll pins (15) with a pair of pliers.

Remove the countershaft gear (16 ), thrust
bearings (17) a nd thrus t washers (18) a nd
(19 ) .

6. Remove roll pin (20) and disassem ble

co llar (13 ) from shaft (14). Remove roll
pins (15) from collar (13).
7. Remove need le bea rings (21) from countershaft gear (16) if they are to be re placed.
8. Remove the expansion plug (22) from hou sing if it has been lea king.
9. Remove gasket (23) a nd discard .

FRONT

67-7

''''SET A

~~
~

/l

1 / 4 " RADIUS

OIL GROOVES"'J

''''SET B

Figure 3

CHAMfER "'OT TO

r==1

EXCEED 11 4 " RADIUS

678

DUAL RANGE TRAN SM ISSION

(Refer to Figure 4 )
Assembly and Installation
1. Install new expansion plug (22) in case.
2. Install needle bearings (21) using driver
G15044, press on the numbered edge of
the bearings until they are even with the
chamfer in the countershafl gear (16).
(Refer to Inse t A.)
3. Install the countershaft (14) into collar (13)
and retain with roll pin (20) .
4. Lubricate the countershaft needle bearings.
Install countershafl gear (16) on shaft with
a thick .125" thrust washer (18) on each
side of gear. Install thrust bearings (17) and
the .0:31" thrust washers (19).
5. Ins tall roll pins (15 ) into collar (13). Tap
the countershaft in place. Check the shaft
end play by using a straigh t edge and feeler
ga uge, (Refer to Inset B.) Place the feeler
gauge between the straight edge and the
shims (12). Add shims (12) unUl .004" to
.009" clearance is reached. This will allow
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.

8. Select the proper snap ring (4) to give a

minimum of end play between the shift
collar carrier (6) and snap ring (11). This snap
ring is available in .076", .080", .083"
.087" and .091" thickness. Install the
proper snap ring (4) onto shaft.
9. Press new needle bearings (3) into input
shaft gear (1) using driver G15042. Use the
proper end of the driver and press on the
number edge of needle bearing, (Refer to
Inset C.) The driver wiJ1 allow the bearing
to stop at a point inside of gear, so that
the oil hole is open to the bea r lng and it
wll! allow for proper lubrication.
10. Press bearing (2 ) onto s haft (1) until it
bottoms. Install sha ft assembly in to the
dual range housing.
11. Install shuttle assem bly, refer to Section
66 of this Service Manual.

FRONT

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 ............................................................................................................ 688
TRACTION CLUTCH
Assemblylnstallation ........................................................................ .................................. 68-10
RELEASE LEVER AD.JUSTMENT ....................................................................................... 68-10
CLUTCH LINKAGE ADJUSTME'iT
Suspended Pedal ............................ ........... ....... ..................... ....................... .. .................... 6812
Floormounted Pedal ..................................................................... .. .................................... 6813

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

684

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
ing capsc rews ( 1), washers, cover assembly
and clutch disc assembly.

2. Remove oil seal (2), snap ring (3) and in

spect bearing (4) for smooth free action.
If damaged use suitable puller for removaL

Disassembly
1. Place the clutch cover assembly in a press
(pressure plate down) and apply pressure
to compress the clutch springs. Loosen lock
nuts (5). Remove the adjusting screws (6)
washer and nut (5) . This allows pressure
plate (7) to drop out of bracket.
2. Press spring ring down until there is
approximately .060" to .125" clearance

between top of lever (8) . Push spring ring

(9) away from lever (8) to be removed.
Pull lever (8) free of spring ring (9). Repeat
for remaining levers.
3. Release pressure

from spring ring. Lift

the c lutch cover (10) off the pressure pla te
(7) .

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"
110120 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

from torque tube and drain torque tube _

2. Remove the snap ring (1 ) from the pivot

shaft (2 ) and remove pi vot shaft (2) and
yoke (3).
3. Slide off bearing carrier (4) and throwout bearing (5).

5. Remove capscrews (7), retain er lock (8).

bearIng re tainer (9) and press bearing
(10) and pump drive (11) from the carrier (12).
6. Remove capscl'ews (13) retainer lock (14),
bea ring retainer (15 ), clutch shaft (16) and
bearing (17).
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
for wear or damage. Replac e a ll parts that
are worn or damaged.
Carefully

inspect

bearings

for

smooth

free opera tion. Replace if damaged.

Replace all oil seals and gaskets during
assembly.

68-7

Figure 3

68-8

MAI N DRIVE SHAFT

(Refer to Figu re 4)
Assem bly and I nstallation
1. Press a
carrier
seal lip
to Inset

new oil sea l (19) into the bearing

(12) using tool A38461. Be s ure
is towards rear of carrier (Refer

6_ I! the bearing (17) was removed from the

clutch shaft (16), press the bearing on, until seated against the shoulder.

A).

2. Press a new oil seal (18) in the pump

drive (11), lip towa rds rcar of pump drive.
(Refer to Inset A. ).

7. Insta ll clutch shaft w ith bearing retainer

(15), retainer lock (14 ) and secure with capscrews (13).

8. Install bearing carr ier and pump drive

:3. If the throwou t bearing ca rrier sleeve
(20) is damaged, press in sleeve usi ng
Locktite in beari ng carri er (12 ) until
flu sh with shoulder in hou sing. NOTE ;
The oil holes in the sleeve must be
centered on one of the bearing carrier
mounting holes.
4.lf the bea ring (10) was removed from the
pump drive (11), press bear ing on until
sea ted on pump drive. In sta ll snap ring
(21) .
5. Using Gl ,1501 sleeve , install the pump
drive assembly in th e bea ring carrier (12)
and in sta ll bearing reta ine r (9), retainer
lock (8) a nd sec ure with capscrews (7).

assembly gasket (22) and secure with

lockwashers and capscrews (6). NOTE:
Ma ke sure holes in sleeve (20 ) are downwa rd .
9.

[f the throwout
l)('aring (5) on
grOOve in the
grease hole in
to Inset B.).

bearing was removed, press

bearing carrier (4 ) so the
bearing lines up with the
the bearing carrier. (Refer

10. Install throwout bearing assembly, yoke

(3), pivot shaft (2) and snap ring (1).
11. Connect clutch linkage and install torque
tube front cover or hydraulic cover assembly.

68-9

INSET B

Figure 4

6810

TRACTION CLUTCH
(Refer to Figure 5)
Assembly
L When assembling the clutch apply a small
amount of high melting point grease to all
pivot pins.
2. Place the clutch cover (10) on the pressure
plate (7).

3. Install spring rings (9) on levers (8).

4. Place the pressure plate and clutch cover
assembly in a press. Apply pressure to
compress the springs. Install the washers
and locknuts (5) and adjusting screws (6).

I nsta lIation
L If necessary. press in a new bearing (4)
and install snap ring (3). Press in a new
oil seal (2) (lip in) until flush with fly
wheel.

2. Install the clutch disc assembly and clutch

cover assembly on the fly.vheel using the
capscrews (1) and washers.

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
through the disc assembly and into the
flywheel. Then install the G15048 clutch
adjusting tool in the adjusting gauge with
the 1116" step against the adjusting
gauge.

2. The release lever should just touch the

underside of the G15CH8 tool. If not turn
the adjusting screw until the lever does
touch the tool. Repeat this procedure for
all three release levers.

FLYWHEEL

G15048 TOOL

RELEASE LEVER

6811

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

/
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

692

TABLE OF CONTENTS
PTO ASS F::VIB L Y
Removal and Installation ................ .. , ................................ , ................ .. ..... , ......................... 693
PTO CLCTCH
Disassembly and Inspec tion ,., ....... ' .... ...... .... ... ..... ...... ......... ..... .... ....... ....... .......... ....... ......... 694
PTO CLCTCH
Assembly .. " ..................... , ...... , ................................................ .... ..... , ....... .... ,........................ 696
INPUT SHAFT Ai\ D CLUTCH DRUM
Disassembly Inspection and AssE'mbly ................................................................................. 698
PTO CLCTCH AD.J USTMEi\T .. ,.. ...... .......... .. , ......................... ................. ......... .. ...... ........... . 6910

693

PTO ASSEMBLY
(Refer to Figure 1)
Removal
3. Remove the four retaining nuts and twO
Allen Head capscrews (3).

1. Drain the transmission oil at both the

transmis Ion drain (1) and PTO drain (2).

4. Remove the PTO assembly (6) from the

transmission case.

2, Remove the outer and inner PTO shields

(3 & 4;,

""-I

Figure 1

Installation
(3 & 4),

1, Install the PTO assembly (6) on the trans

mission case.
2, Install the two Allen head capscrews (5)
and four retainer nu tS.
3, Install the outer a nd inner PTO shields

4, Install the transmission drain (1) and PTO

drain (2).
5, Fill thE' transmission with 17 quarts of
clean SAE 90 EP oil.

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

(I ) that holds th p rear hou si ng (2) to the
front hOUSIng (3). Rem ove gasket (4). (Re fer
to Inse t A. ).
2. Re movE' the s nap ring (5) a nd press the
c lutch a nd output shaft assembly out of the
boa ring (6) and rear housing (2).
3. RE'movC' the washer (7). spring (8) and
a dju s ting plate (9).
4. Unscrew th e carrier (10 ) a nd remove
cotter pins (11). pivot p ins (12 ) . lin ks (13),
spacers (14). link pins (15 ) , outer rollers
(16) and inner rollers (17 ) .

s. Remove

roll pin (18). spring (19) and lock

7. Remove sliding sleeve a nd yoke assembly

out of the rear housing (2).
8. Remove the nuts (27), bolts (28) and yoke
halves (29 & 30 ) from the sliding sleeve
(31). If roll pin (32) is not damaged do not
remove.
9. Remove the roll pin (33) and sna p r ing (3'1 ).
Pull out the hand brake lever a nd crosss h aft (35 ), pivot arm (36 ), s pring (:l7),
washer (38) and over center loc k pin (39).
10. Remove the yoke (40 ) and keys (41).
11 . Remove t.he outer snap ring (4 2). bearing
and seal (6) with "0" ring (43 ). Remove
inner s nap ring (44).

pin (20).
6. Remove the pressure pla te (21) driven
plates (22). separator springs (23), drive
plates (24) and backing plate (25) from
the output s haft (26).

12. The needle bearing (45 ) need only be rem oved if worn or damaged.
13. Remove the oil seal (46).

Inspection
With the power take-off clutch complet e ly
disassembled, thoroughl y inspect all parts
for nic ks, burrs. wear and da mage. Any
parts that are excess ively worn or damaged
must be replaced.
DRIVE:; Ai\D DR[VE PLATES Inspect the
plates for excessive \vear, cracks . grooves
and flatness. Replace a ll plates that are
craCked. worn exeessively or wa r ped.
SEPARATOR SPRINGS ReplacE' the s e parator plates anytime the clutch plates are
replaced.

BEARINGS . Inspec t the bea rings for worn

or pitted balls and needles . They should turn
smoot hly in the bearing races. Re place if
worn or damaged.
Replace all "0" rings and oil seals during
assembly. The bearing and oil seal assembly
(6) must also always be replaced every tIme.
All machined surfaced parts having small
nicks or burrs can be removed with a hone
or croc us cloth.

69-5

INSET A

Figure 2

69-6

PTO CLUTCH
(Refer to Figure 3)

Assembly
in u new oil
(Re fer to Inset A. )

1. Press

s eal

(46 ) . lip

in.

are installed on the output shaft (26). Install the pressure plate (21).

2. If needle bea ri ng (4.5 ) lVa s re moved, press

the bearing in as shown in (Inset B.) Press
only against the numbered side of the
bearing .

10. lniflllll the lock pin (20). spr ing (19 ) and
rell Ilin (18) in the carrie r (10).
Ji.In.sUill links (13). space r (H ), pivot pin

(12 ) and cotter pins (11).

3. Install the inner snap ring (44 ). new bearing and seal (6) with new " 0" ring (43),
Install outer s nap ring (42 ) .
4_ In s tall the hand brake leve r (35), yoke
(40 ) keys (41) a ncl roll pin 13.3 ).
5.lnsta ll the pivot arm (36 ), s pring (37 ) ,
washer (21), over c e nte r lock pin (39 )
and snap ring (34).
6. If the roll pin (32 ) wa s r e mo ved, install
roll pin in the sliding slee ve (31) as
shown in ( Inset C.)
7. Install the yoke halves (29 & 30) on the
sliding s leeve (31 ) and secure with bolts
(28) a nd nuts (27).
8. P la ce the sliding sleeve a ssembly in the
rea r housing (2) and yoke ('llil.
9. Install the backing plate (25)' drive plate
(24 ). sepa rator spring (23), and driven
plate (22 ) until eight drive pla tes . eight
sepa rater springs a nd seve n driven plates

12. Install inne r roller (17 ).

(16) and link pins (15).

outer

rollers

13_ Screw the carrier asse mb ly on the out -

put shaft (26). Place the clutch a sse mbly

in a clutch drum out of s toc k and screw
the carrie r down tigh t <noug h to hold the
clutch plat es securely whe n r emove d from
the drum .
14. Install adjusting pia te
and washer (7).

(9 ),

spring

(8).

15. Press the clutc h and output shalt assembly in the bea ring (6) until the snap ring
(5) can be installed. Il\'lPOR'fANT : When
press ing in the shaft make sure the r oll
pin (32) lines up with the slot In the carrier.
16. Insta ll the rear housing (2 ) to thc front
hous ing (3) using a new ga sket (4 ) and
Phillips head sc rews (1) . NOTE: Make
sure the clutch plat.es line up in the drum.

69- 7

INSH B

INSET A

46

SEATED IN

INSET C

HOU~ING

698

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.
(Re fe r to Inset A.).
2. Remove snap ring (5) and pr~s'3 th~ input
shaft assembl y out of the front housing (3).
3. If the bearing (6) is damaged, remove
snap ring (7) and using a suitab le puller

4. [).n lake nuC (8) lind remove .

5. Press tht' clutch drum assembly out of the
bear~ng (9) alld fr ont housing (3).
6. The needle bearing (10)' bearing cone (11 ),
hearing cup (12) and bea r ing c up (13 ) need
only be removed if damaged.

Inspection
Inspect the bea rings for worn or piHed
balls and needl es . They s hould turn smoothly
in the beari ng races. Replace all worn or
damaged beari ngs .

All machined surfaced parts having small

nic ks OF !JUfFS can be removed with a hone
or crocus cloth. Replace all d amaged parts .

Assembly
1. If.the bearing cups (12 & 13) were removed
press in until sea ted aga inst the snap rings
(14 & 15 ) .

2. If the bearing (11 ) was removed . press the

bearing on the c lutc h dr um (16 ) un til seated
agains t the drum.
3. If the need le bearing (10) was removed
press the bearing in the ('Iutc h drum (16)
as shown in (Inset E.) Press only against
the numbe red side of the bearing.
4. If the bearing (6) was removed . press the
bearing on the input s haft (17) and install
snap ring (7). Press the shaft assembly in

cll~ tront housing until the bearing (6) is

sealed against the snap ring (18). Install
snap ring (5).
S.ln&UI1I the clutch dru m assembly and press
on the bearing (9) until there is no e nd
play in the clutch d t'l!Im a nd shaft (16 ).
6. Install thE' nut (8). Tighten nut until :3-7
inch pounds of torque is required to turn
.the shaft lI6) . Stake the nut.
I.Jnstall tne front hOusing (3) to the rear
housing (2) using a new gasket (4) a nd
Phillips headscrews 0).

69-9

Figura 4

6910

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.

((
Figure 5

CAUTION : THE TRACTOR ENGINE MUST

BE STOPP ED WHEN ADJUSTING THE PTO
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 ... ........................................................... .......... ... ... ... ......"... 11/4 to 1.314"
Brake lower rod length (Flanged Axle Only) ................. ......................... ......... .................. }43/ 4"
Maximum pedal free travel (Prior to adjustment) ............ ....... ........................................ ... 21 / 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 ................................ .......... .. ........... ....... ..... .. .. .... ... ....... ..... .. .............. ...... 221 / 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 ......................... ...... ........................................... ............................................... 51 / 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)

from brake rod (3).

2. Remove fasteners (4) and rea r stud (5).
Depress brake pedal. Remove cover (6)
and brake band assembly (items 7 thru
14) from the transmission case,
3. Remove pivot capscrew (13 ), Unhook retractor spri ngs (17) from up per and lower
bands (13 a nd 14), and remove bands, link
and rod assembly from bra ke cover (6)_

Re move expansioll plugs (1'6) and retractor

springs (17). Re move dust seal (23).
4. Unhook disc :spr'ings (18.and 19) with a slotted
screwdriver, as shown i n Inset A.

5. Remove spUned disk (20, and balls (21) from

actuating drum ,(22),
6, Remove cotter pins (10) {rom clevIs pins
(7,8 and 9) a nd disassemble bands (1.3 and
14), Unks (11 .a nd 12) and rod (3) _

Inspection
Thorough ly clean all pa rts before inspection, Replace a ll badly worn or damaged parts.
Check d iscs, bands and linings for -excessive wear , warpage, loose li nings, or -oil
sat uration. Check ba lls for roughness.
Inspect dust seal. Repla ce if cracked or
deter iora ted,
Inspec t disc springs, They should hold the
actuating disc and drum unde r tension whert
assembl ed, and meet the fol lowing specifi

cations:
Disc springs (18, 19):
Wire Dia meter ... ........ ..................... , ,0857"
Total Coils ....................................... 10-114
Free LE'ngth ............. .... .............. .... .. . 1.27"
E xtended t-o 1,37" ....... 22-1 12 to 27-1 / 2 lbs ,
Retractor Spring (17):
WIre Diame ter ............. .. ..... ...... ....... , ,060"
Total CoIls .. ............. .. ............. ..... ...... 5-3/4
Free LE'ngth ..................... .. .......... ...... .66"
Extend to .74" ......................... 9 to 11 lbs.

Asse mbly
1. if new linings are to be installed on discs
(20) a nd (22) and ba nds (13 a nd 14) , remove
old linings and procE'ed as follows:
a. Clean the lining mating s urfaces.
b. Clamp new linings in place , being careful
as not to damage linings.
c. Drive ri vets through holes . from rivet
head with a tubular rivet set.
2. Place four balls (21) in pOSition on actuating
d r um (22), then assemble splined disc (20) in
pOSition over balls with spring holeS in the
disc in line with projec tion ear OIt dru m .

(6) and asse mble dust cover (23) over rod and
into cover, Insert springs (17) thro ug h holes in
cover a nd hook to link ends of upper band s,
Install new expansion plugs (16) .
6. Align pivot e nd of bands (13 and 14) and install pivot capscrew (15) and washer. Tigh ten
pivot capscrE'w secure ly.
7. Slide actuating drum (22) and splined disc
assembly (20) over splines of differential
side g ea r with splined disc (20) next to
transmissIon case.

3. Att ach hook e nd of disc s pring (19) to ear of

act ua ting drum (22) through s plined disc (20).
Hold disc and drum together, turn over , and
attach hook end of disc spring (18 ) to ear of
d isc through act uating drum.

8. Place e nd of brake rod (3) into brake lever

and assemble cover (6) a nd band assembly
over drum (22). Torq ue bolts (4) 70 to 90
fl. lbs . Install rear stud until seated and
install nut (4), Torque the nut 70 to 90 ft.
lbs .

4. Assemble bands, bra ke rod and link (items 3

and 7 thru 14 ),

9. Install adjusting nut (2) and locknut (1) to

brake rod (3),

5. Insert brake rod (3) throug h opening ill <:-over

74-5

INSET A
SLOTTED SCREWDRIVER

I
ij

@)
,
.r

'-

I~
---

,,
(

Figure 2

DIFFERENTIAL LOCK
(Refer to Figure 3)
Disassembly
1. The differential lock assembly can be removed for servicing as an assembly.
2. Remove the differential lock pedal (1) or (2)
in Inset A, or (3) in Inset B, if equipped. Remove grommet (5) from platform.
3. For tractor with Power Shuttle or Hydrostatic only, disconnect the yoke ends (8),
cotter pins (7) and remove the lever (9) witll
washers (10 ). Remove rod (12).

4. Remove pin (15), collar (16), spring (17) and

lever (18) or pedal (4), Inset C, if equipped.
Remove pin (19). Remove the lock assembly
(rom the brake cover. Remove pin (22) from
lever (24) and remove shaft (23) from the cover
(201. Lever (24), spring (26), fingers (25) and
locking collar (21) may be lifted from cover
(20). Remove bushing (27) from cover (20).

Inspection
Replace broken and worn part s . Replace grommet, roll pins and cotter pins. Re place a ll yoke
pins if worn a nd grooved. Clleck the locking
collar splines for wear or damage. Cllec k th e
springs for broken or cracked coils or ends a nd
for the following specifications.
Outer lever spring (17):
Length ............................... .. ........... 2-1 / 16"
J.D. .. ................................... ...... ......... 844"

Wire Dia ............................................ 192"

No. of Coils ....... ..... .. .... ........... ............... 5

Free angle between wire ends ............ 138"

Torque w l ends
al 112" angle ................ 42_1 to 94.7 in. lbs .
Inner lever spring (26):
Length ....................................... ... 1-13/16"
l.D .................................. ... ................ 844"

Wire Dla. .. ......................................... 135"

No. of Coils ...... ................................ . 51 / 2
Free angle between wire ends ............. 81"
To.rque w Ishor! end
at 2<' angle ................. 17.8 to 28.1 in. lbs.

Assembly
1. Press new bushing (27) into cover (20) until
flush with outside edge.
2. Coat the shift collar (21), groove and internal
splines, shaft (23), springs (17) and (26) and
inner walls of lever (18) and foot pedal (4),
Inset C, with Case Anti-Seize Lubricating
Compound or equivalent.
3. Install pin (19) to shaft (23). Instal l fingers (:l5)
to yoke lever (24). With the short end of spring
(26) engaged wit h hole in yoke lever and the
fingers engaged with groove of locking collar
(21), place into cover (20).
4. Install shaft (23) into cover (20), engaging
spring (26) and yoke lever (24). Align boles
and install roll pin (22). Install lever (181 or
lever (14), Inset A or pedal le ver (4), Inset C.
5. Install spring (17) a nd retainer (16) with spring
ends engaged with hole in retainer and groove

In lew I' (18) or peda l lever (4), Inset C, and

hole In retainer (16) a ligning with shaft (23).
Install pin (15). Install grommet (5) into platfOl1ffi. if equipped . Install the differential lock
assembly to the brake housing, engaging the
splines of locking collar (21) with differential
<:l'(lli~ shaft splines. Install retaIning bolts
t() CQv"r (20) and torque 17 to 21 ft. lbs.
6. (nstaU pedal (3) wi th yoke (8) , Inset B, to lever
(Ill) -Or pedal (2), Inset A, to lever (14 ), if e.quipped with pin (6) a nd new cotter pin (7).
'I. For tractors with Power Shuttle or Hvdrostatic, ins ta ll rod (12) with yoke (13) to lever
(is). 1nstall rod (9) and washers (10) with the
twtl drilled holes a t the L. H. bracket. Install
yokes (8) and connect rod (12) with pin (11 ).
Install the pedal (1) to rod (9) . Install new
cotter pins (7).

74 -7

INSET A

INSET 8

t~
e-CD

e~

cor-~~
~

~
-

INSET C

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

th e counte r-clockwise direction. Inset A,
seve ral turns. Remove the cable pins (1 and
2), cotter pin (3) a nd r emove the brake-cable

(6) with washer (7) and remove the cable

pulley (8) from the brake lever bra cket (9).

(4) .

Inspect ion
Check the brake cable (or excessive wear or
fraying and if the clevis pin ilOles are worn and
elonga ted. If these areevicient , replace t oe cable
assembly.
Check the pulley for e xcessive wear or elan
gation in the pin pivot hole . Repla ce the pulley
if these conditions exist.

in the pivot pin holes or oth er damage. Replace

if necessary.
Check the operation of the brake le ver assem
bly. If the handle docs not go into the engage d
or released position with a decided s nap, it is
an indication the linkage is worn. R ep lace the
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

space rs (11 ) to the lever bracket (9 ). Torque

the mounting bo lt s 17 to 20 ft. lbs.
2. Install the brake ca bl e (4) to til e brake lever
linkage (10 ), and bra ke rod pivot lever (12 1
with yoke pins (2) and new colte r pins (H.
3. With the b rake l ever in the down position,
install the cable pulley (8) with brake cable
tothe le ver brake (9) with pin (5) , washe r (7)

and new cotter pin (6).

4. With the brake lever in the downward position,
turn the handle portion cloc kwise seve ral
turns to lncl'ase the te nsion, Inse t A. Pull
the brake hand lever to fuJI upright e ngaged
position and check that the brake applies
fully. Turn the ha ndle counter-clockwise in
the downward pos i tion to dec r ease the tension
if necessary . Repeat the procC'dure it neces sary until the prope r a djustment is reached.

74-9

ENGAGED

, "\

INSET A

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
pedal lower rods (1) (Fla nged Axle Only).
These rods when properly a djusted should
measure 14-3/ 4" from the ce nter of a djusted yoke end hole (2) to the center of the
stationary yoke (3).

2. Bloc k fron t wheels securely and raise !lP

tractor so rear wheels are just clear of the
ground or floor. Check tha t the parking brake
lever (7) is in the di sengaged position (downward).
3. Tighten brake adjusting nut (4), until a slfght
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).

5. Repea t the same adjustment of the other

brake. When brakes are adjusted, test brake
act ion with the interlock (6) holding both
pedals toge ther. Whe n set correc tly with
pedals locked togethe r, both brakes will
apply evenly a nd have 1-1 / 4" to 1-3/4" free
ped a l (ravel.
IMPORTANT Brake pedals must apply
evenly so that both wheels will stop simul(aneously when bra kes are applied.

6. Refer to pages 8 and 9 to ad just the parking

brake.

.. ~ -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

REF .

TO

FROM

WIRE
COLOR

'1

Amm eter Gauge

Alternator {+}

Orange

lA

Ammeter Gauge

Key Switch " BAT"

Orange

Neutral Sta rt Switch

Starter Motor "S"

Yellow

2A

Start Button

Neutral Start Switch

Yellow

2B

Key Switc h " IGN "

Starter Button

Yellow

Alternator Resistor
H
Key Switch " IGN

Alternator " AUX "

Brown

Alternator Resistor

Brown

Engine Temp . Gauge

Engine Temp. Sender

light Switch
Key Switch " 5TH

A u x. Lamp Outlet
Heater Solenoid

White

Light Switch

Headlight Connector

Black

Transmission Temp. Light

Hydrostatic Temp. Sender

Black

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

Neutral Start Switch

Neutral Start Switch

Yellow

Harness Connector

Headlights

Black

Headlight

Ground

Black

3A

4
5
6
7

.8
*9

.15(2}

16
17

Hydrostatic Tractors Only

* Converter

T ractors Only

light Green
Pink

' NG'N' II ...

'NO .

O~

. . . . .. UGO<l

."

~."..

o ......

.....,,,.

. ..... "

C.,....'Clq.

@oo
CD '''''''

""""~US

.......

O""CIO"

I
I
I

'"

I
I

....,.

"

. ...'''''.

~"_H

.......

......,. ".".

...." - --;

'" ':'" " .. . .. vo.

'"

eo
(j). oo

(I'

01 . . . . . " .......

....,_....
, ........
/

/'

I'

-"

.. ... '-

-'"

"

~- ,

....... ",",'''' ---!

..m .. i.~

........",.

............

\
.cO

81-5

SPARK IGNITION BASIC LOADER TRACTOR WIRING AND CODE

TO

FROM

REF .

WIRE
COLOR

Ammeter Gauge

Alternator (+)

Orange

1A

A mmeter Gauge

Key Switch "BAT"

Orange

Neutral Start Switch

Starter Motor "S"

Yellow

2A

Starter Button

Neutral Start Switch

Yellow

2B

Key Switch " IGN "

Starter Button

Yellow

Alternator Resistor

Alternator " AUX "

Brown

3A

Key Switch " IGN "

Alternator Resisto r

Brown

Engine Temp. Gauge

Engine Temp. Sender

Light Switch

Aux . Lamp Outlet

Key Switch " IGN "

Ballast Resistor

White

6A

Ballast Resistor

Ignition Coil (+)

White

Li ght Switch

Headlight Connector

Black

Transmissio n Temp. Light

Transmission Tem p. Light

Hydrostatic Temp . Sender

Black

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

Neutral Start Switch

Neutral Start Switch

17

Harness Connector

Headlights

Black

18

Headlight

Ground

Black

7
.8

*9

.16(2)

Hydrostatic Tractors Only

* Converter

Tractors Only

Light Green
Pink

Red
Yellow

816

ELECTRICAL ACCESSORY WIRING AND CODE

REF.

TO

FROM

WIRE
COLOR

L.H . Warning light

Harness Black Plug

Yellow

R.H. Warnin g light

Harness Red Plug

Yellow

L.H. Flood Light

Harness B lack Plu g

Black

R.H . Flood Light

Harness Red Plug

Black

L.H. Tail light

Harness Black Plug

Green

R.H . Tail Li ght

Harness Red Plug

Green

8
8
21

L.H . Tail Light

Harness Black Plu g

Black/White

R.H . Tail Light

Harness Red Plug

Black/ White

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
2 3C
24

Black Harness Plug

Harness Splice w / 23A

Gray

Red Harness Plug

Harness Splice w /23A

Gray

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

28
29
30
31
32

Direction Signal Switch

Red Harness Plug

Direction Signal Flasher

Directio n Signal Switc h

Direction Signal Switch

Right Tu rn Indicator Light

Direction Signal Switch

Left Turn Indicator light

Warning light Flasher

Direction Signal Flasher

Key Switch " BAT"

Horn Button

Black

Horn Button

Horn

Black

BackUp Alarm

Gro u nd

Black

Back-Up Alarm Switch

BackUp Alarm

Black

Key Switc h " BAT"

Back-Up Alarm Switch

5
5
6
6

34
35

36
37
38

Green
Red
Brown
Red
Green
Red

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
COUN'rERI!iEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3IOLDBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
REkIR ATTkICH&IENT SUPPORT kIR&IS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.

LmINGkUTDPALLETFORKS
ROLLBAR

REAR ATTACHMENT SUPPORT A RMS

instructions.) Connec t hydra ul ic 1ines

tractor and drive tractor away.

To inc rease the versatlltty of the machine, the 35 Backhoe, rear counterweight and
3 point hitch are all attached to the machine
using the same support arms.

on

To Install an attachment. bac k the tractor

Into the attachment and lower it onto the lower
support arms. Install the uppe l' mounting pins
and connect hydraultc line s and wiring as
required. Loosen the lower tension rod nuts
and torque the top tension rod nuts to 140-170
foot-pounds. Then tighten the lower nuts
until snug and r etorque the top nuts to 450-550
foot-pounds.

To remove an attachment, loosen the nut

on top of each tens Ion rod and remove the
upper mounting pins. Disconnect hydraultc
lin es at the quick diSconnect couplings and
wiring as required and lift the a ttachment
from the lower support arms. (Refer to
Series 90 Sections 92, 93. and 97 for detailed

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

AFTER UP PER MOUrniNG PIN S ARE
INSTALLED, LOOSE" Ul',ER NUTS ANO TORQUE
UPPER NUTS TO 1 ~0 -17 D FOOT- PDUNDS. THEN
NOTE 3;

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.

C'~ :f7

TE NS 1011 ROO( 2) _

~_J/4 " - IiC

5 / S" - IIC x 8" (8)

NU T

,RAD E 8-- 00 NOT

SU8 ST ITUTE

rn

~ ",:" I" c ,

""
a

&

5/8" - IiC

I,

N~

SE E 1101 2

(i))

/"/:;.----

~)( ,I

/ 3 / 4"- "C x 6-3 / 4" (2)

/1

/C

./

"

fI" -:/

S/iA P RI NG( 4 ) - - f J/ ;

/1-,)1'1 '
/"

/ eX
LOVER Su PPOR T ARfI ( 2 ) - -

.::;;.--~

I:l:!;tZ

. / >lASHER ( B ) / SNA P R ING(4)/'

//

SEE NOTE I

~""

.,

TENS I ON RO~ Pln ( 2)

rn
0

Ii
/ L

REVERSE THIS BOLT IF EQU IPPED

!,.JITH DIFFERE :HIAL LOCK OUT

Figure 1 - Hear Attachment Support Arm s

BOLTS /lUST BE I I/S TALLO ON

EACH SIDE AS ILLUSTRA TED

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

and remove the upper mounting pins.

2.

Install the upper mounting pins and loosen

the lower tension rod nuts.

3.
3.

Lift the counterweight from the lower

support arms and lower to the floor.

Torque the top nuts to 140-170 [ootpounds and tighten the lower nuts lmW
snug. Then retorque the top nuts to 450550 foot-pounds.

l " - :IF rWT(4)-

~2s:

(~l

<qJ-

uPPER ,,,,aura I riG

KLiK PI N(4)

BR;\CK ET

I
MOUI<T!NG PI N(2P

TH' SION ROO (2)

UP PE R SUPPO RT " R,"(2)

,~

==r1

~~' - 3

(?>--."

/~

~ - J/4"-'iC

"UT

COUNT ERWElG HT

-~

UPPER SU PPORT

ARM PJ N( 2)

7 1C956

Figure 3 - Rear Counterweight

MOLDBOARD
piece can be unbolted and rotated 180' to
present a new edge to the ground. Cutting
edges are also replaceable.

The Model 35 Loader can be switched

from a loader to a dozer by lnstall!ng a moldboard In place of the loader bucket. This can
be done In the field, using the existing loader
frame and mounting pins, or as a fa ctory
Installation.

To replace or rotate the cutting edge

pieces :
1.

Remove the plowbolts, lockwashers, and

hex. nuts used to attach the cutting edges
to the moldboard.

2.

Clean accumulated mud off the moldboard. Install replacement edge(s) with
plowbolts , lockwashers, and hex. nuts.
Tighten securely.

Replacing Culling Edge

The cutting edge consists of t1u'ee pieces

-a 55-7/8" long center section, fl anked by
two s hort end sections 7" long. The pieces
are made of hardened steel and have two
edges so that wben one edge Is worn, the

~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

to install a palle t fork assembly or logging

fork assembly. Both insta ll ations are mounted

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

Figure 6

Pallet and Logging Forks With Grapple

5/8'
SEE

1: TORQUE

MOTE St: TORQUE

TO 160- 180 FOOT- POU.'iOS

TO 250- 290 FOOT- P O U N D S

Figure 6

WARNING! ROLL8AR MOb'NTINL BOLTS ,+RE

GRADE & - D O W T SUBSTITUTE
7,091 5

Roll B a r Installation

SEC TION
92

LOADER

Burl. "orm

.. r'nled In U.S.A.

TABLE OF CONTENTS
HETUHN-TO-DJG ..

Operation . . . .

Adjustment of Bucket P os ition.

ANTI-ROLLBACK ..

Adjustment ...

4
5

STANDARD BUCKET.
Cutting Edge Removal a nd Replacement

Tooth Shank Removal a nd Roplace ment ..

Tooth Replacement

4-IN-l BUCKET . . . ..

Clam Cutting Edge Removal a nd Repl acement ..

Blade Cutting Edge Removal and Replacement . .

. ..... .

. . . . .

. . . . . . ..

REiIIlOVING LOADER FRONI THACTOR . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . ..

Removing Loader to Service Tractor . . . .

. . . . . . . . ..

Removing Loader to Use Tractor as Drawbar Unit

. . . . . ..

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

RETURN-TO-DIG

to rollback. The ro lling bacl< of the bucket

causes moveme nt all along the return-to -dig
linkage , the most important being the for war d
movement of the r e turn - to-d ig latch. When the
bucket is in the desired digg"ing position, the
return-to- dig l atch will have ph'oted forward
far enough to allow the bucket (tilt) s pool to
return to neutral, hold ing the bucket in
position" However , the lift cylinder spool re mains in the flo at pos ition and the bucket
continues its downwa r d movement. The lift
cylinder spool will rem ain in the float position
until manu all y released by the operator.

Operalion

Assume that the operator has the bucket

r a ised and his load du mped. If he now pushes
the control lever to the left and forward as
far as it will go, the control lever wlll be
e ngaged and held by the return-to- dig latch.
The bucket and lift cylinders are now
ac tu ated- -control valve spools are simultaneously in rollback and float positions.
As the 11ft arms lo wer, the bucket starts

Figure 1 - Return-To-Dig Operation

Adjustment 01
Bueket "osilio,",

tOUChing the control valve mounti ng plate.

If the c r ank contacts the mounting plate,
shorten the linkage between the crank
and the control lever.

The return-to-dig linkage is initi ally set

to poSition the bucket level with the ground.
2.

1.

Position the bucke t flat on the floor

(ground). Hold the control lever in the
rollback position and make sure the
anti-rollback c rank, Figure 3, is not

Positio n the control lever In the returnto-d ig position (left and forward). Loosen
the set sc rew in the collar, Fig"ure 2, and
slide the pipe and co ll ar slowly to the
rear unt!! the control lever is rele a sed.
Then tighten the collar set sc rew.

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, reposition 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
positions bucket flat on fl oor(grounc!) -adjus t return-to-dig as required.

Gener al

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.
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 returnto-dig latch pivots forward W1W finally the
ant i-roll back roc! contac ts the anti-rollback
crank whi ch returns the bucket s pool to neutral
and/ or prevents moving the bucket spool Into
the rollbac k positio n.

2.

Roll the bucket back ag'a inst buc ket stops

on 11ft arms and lowe r bucket to the floor.

3.

Lengthen the an ti-rollback roc! W1til it

contacts the anti-rollback cra nk and
tighten the lock nut. Hefer to ngure 4.

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
front of bucket:

rf
is not to be
disconnect the wiring
alter~
nator and voltage regulator. Also block the
bucket in position to prevent lJOr8,)nl,1
CAUTION:

1'PrY1,,,,,,rl

1.

a.

Remove bucket teeth if so equipped.

carbon arc rod or an acetelyne
cutting torch to remove \\elds.

h.

t 1se

Start at one end of the bucket and

weld toward the center until one rod
is used.
Repeat at the center of the bucket.
0:1 8uccee,dirlg center welds work out

from both
2.

Remove all cutting edge welds

bon arc rod. If carbon arc
a "allable an acetclyne cutting torch may

c.

Repeat
bucket.

d.

Continue
the
welded.

of center.
6a at the other end oHhe

be used but care should be taken to

distortion to the minimum.

3.

4.

To aid in
removal. cut
off the wrap around ends of the cut~
Cut through from the inside
corners
the bucket.

""LCU.U"

in this manner until

i::; completely

Teeth

Ramm'e the

edge and
weld (Uld/ot excess metal
to provide a smooth surface for the new

any

5.

Place
edge on bucket.
C
to hold it in position.
a weld rod
A. \V.S. specification
E7018. 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; wJft/\LL VlrifN'jj

,
64

7'" ,

B"CKET

6Lj"

BuCr<r:T

74"

;;_ ' /q'

9- 1fL!."

3-7/8 1 '
9"

710932

Figure 6 - Bucket Teeth Location

3/16"
__--r-fILLET

Tooth Shank Removal

And
lIation

Figure 5 - Cutting Edge Welds

Remove all shank welds

arc rod or an acetelyne

carbon
torch.

2.

Remove shank and grind off any :cemaining

weld on the cutting edge.

3.

Refer to Figures 6 a nd 7 for location

a nd weld s pec ification s. Cse a weld rod
mee ting A. W.S. specification E-7 018 and
weld s hank to cutting edge.

~SS '. ELO~i

TWO P

A'p -C-OR ~ER

Fn '

E~GE

CUTT I NG

#'#
t

3/8 '1 BOTH SIDE S

Tooth Replacement

2.

,r.<L

-------3/8 " FILLET

W~

1.

BUCKE T

TOOTH

Refer to F igure 7. Cse a suitable tool a nd

r a ise the peened portion on each side of
the tooth and remove tooth from shank.
T he pe e ned a r ea may be heated with a
torch to a id in r e mova l.

,,
3/8" FILL ET ~ __ __ J

=rwo
I

,..../CUrTl tlG EDGE

PASS 'JEl D -----.,

____ ...I _..t.' ....... ...--

~I
;~~i~
1_ 2 ~-=.:.::="-i::..:..::.::..:..:~~

Sl ide the new tooth onto the s hank as far

as it will go and peen e ach side into
depression in shank.

Figure 7 - Bucket Too th and

Shank lnstall ation

4-IN-! BUC KET

Clam Culling Edge Removal
And Replacement
CAUTION:
If the bucke t is not to be
removed , disconnec t the wi ring from the
alternator a nd regu lator . Al so block the bucket
in pos ition to prevent per sonal injury .

1.

b.

Repeat at c ente r of bucket. On succeeding welds work out from both

sides of cente r .

c.

Repeat s tep
bucket.

d.

Conti nue we ld ing in thi s manner

until the cutting edge is completely
welded.

5a a t ot her

end o f

Remove a ll cu tting edge welds using

carbo n arc rod. An ac ete lyne cutti ng
torch may be used but c a re s hould be
taken to kee p d istortio n to the mininlum.

Blade Cutti ng Edge Removal

And Replac emenl

2.

Remove the cutting edge. If nece ssa ry.

cut o ff the wrap a round c orner s of the
cutting edge to a id in removal.

CAUTION: If the bucket is not to be removed , di sconnect the wiring from the a lternator and regu la tor . Al so block the bucket
in po si tion to prevent persona l in jur y.

:3.

Grind any re m a in ing weld aU the clam

to provid e a s mooth surfac e for the new
c utting edge .

1.

Remove all cutting edge welds u sing

carbon a rc rod. An acete lyne cutting
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 Ccla mps to hold it in posit ion. Position
cutti ng e dge as s hown in Figure S.

2.

Remove cu tting edge.

3.

Gri nd the remaining weld off the bl ade

to provide a smooth su dace for the new
c utting edge.

4.

Place cutting edge on blade Llsing Ccla mp s to hold it in posi t ion.

5.

Weld c utting edge to blade as s hown in

Figure 8.

5.

We lcl cutting edge to bucket using E- 701S

we lding rod. Refer to Figure 8. To preve nt dis tortion we ld the cutt ing edge a s
fo llows:
a.

Star t at one end o f bucket and we ld

toward ce nter unt il o ne rod is used.

USE ELECTRODE MEETING A.W.S.

E 70'8 OR E 9015 SPECIFICATIOi'lS
ON ALL WELDS.

CLAM ASScMBL v

BLADE ASSEMBL v

CUTTING EDG E

Figure 8 - Cutting Edge Welds

REMOV IN G LOADER FROM TRACTOR

The loader can be removed from the

tr ac tor by either of two means- -as a complete
unit for ease in servicing, or with the radiato r guard left on so the tr actor can be used
as a deawbar unit.

,q

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' .

2.

Drain the hydraul ic reservoirs and rem ove the cros sover tube and the lift
cyl inder cross tub es . Plug' open ings with
cl ean caplug's.

Figure 9 - Reservoir Drains

3.

Remove the grille and disconnect the

he adlight wiring. Then remove capscrews
that secure the hood and side plates to
the radiator guard, 00 not r e move radIator guard to ch assis m ounting bolts at
this time,

UPPR SUPPORT

TE NS I DOl ROD

'-......!....

4.

Olsconnect hydraulic lines at pump and

remove pump. Plug openings with clean
caplugs.

5,

Remove the fuel tank cover retaining capsc rews and remove cover.

6.

Att ach a chain holst to the loader subframe cross tube and take uR s lack.

AR,~

BACKHO E
MOUN T I NG

FRAM E

Figure 10 - Re moving SUppOlt Arms

7.

Remove the floor plates. Then remove

the nuts from the top of each tension rod,
Figure 10, and the mounting pin from
each upper support arm and remove the
support arms.

4.

Remove the short section of pressure llne

tube and remove pressure line tube secured to the right hand reservoir.

5.

Remove suction line from reservoir

sterns and remove sterns from reservoir.

6.

Remove the fuel tank cover retalnJng

capscrews and remove cover. Then attach
a chain holst to the loader subframe cross
tube and take up slack.

7.

Remove the floor plates. Then remove the

nuts from the top of each tension rod,
Figure 10, and the mounting pins from
each upper support arm and remove the
support arms.

10. fie move the nuts, washers and bolts that

secure the radiator guard to the tractor
frame.

8.

Disconnect the hydraulic tubing to the

re ar of the tractor at the loader control
valve and remove the tubing.

11. Make sure everything Is disconnected and

slowly and c arefully llft the loader from
the tractor.

9.

Remove the nuts, washers and bolts from

the front of the lower support arms. Then
remove the nuts and wa shers that secure
the support arms and loader sUbfrarne to
the rear axle and remove the support
arms.

8.

9.

Disconnect the hydraullc tubing to the

rear of the tractor at the loader control
valve and remove the tubing.
Remove the nuts, washers and bolts from
the front of the lower support arms. Then
remove the nuts and washers that secure
the support arms and loader subfrarne to
the rear axle and remove the support
arms .

Ren'lovlng Load e r To
U Tractor A. Ora_bar Unit

1.

Remove the rear mounted attachment.

2.

Drain the hydraullc reservoirs and remove the crossover tube and 11ft cylinder
cross tubes, Figure 9. Plug openings with
clean cap lugs.

3.

10. Make sure everything is disconnected and

slowly and carefully 11ft the loader from
the tractor.
11. Attach the D50285 and D50286 supports
to the rear axle. Use existing nuts and
bolts with an A28084 washer under each
nut.

Remove the grille. Then di s connect hydraullc llnes at pump and remove pump.

12. Install floor plates and fuel tank cover.

EX P LODED VIBWS
3/8' '- l.'C x 4"

<" (4)

3/8" - NC x 2-112"",--ij'

IIASHERX~/

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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

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~/900 PIPE ELBa'"

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,
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Figure 13 - Basic Hydraullcs

12

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HYDRA-L EV El iNG CY lI 'WER S, AN D
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TO CLOS ED EIIO OF Lin , TILT AN D

B HY DRA-L EVELI NG CY LI NDER S,

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Figu re 14 - Lift, Hyd r a-Le ve ling and Tilt Cyli nder Hyd r au lics

13

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/

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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 PROCEDURE 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. . . . . . . . . . . . . . . . . . . ..

COliPLlNG BACKHOE TO TRACTOR . . . . . . . . . . . . . . . . .

.......... 4

SWIl\G TOWEH REMOVAL Ai\D INSTALLATION

.......... 4

DLd"""

THE BACKHOE

......... .

.. .........

ASSEMBLIl'.'G THE BACKHOE. . . . . . . . . . . . . . . . . . . . . . . . . .. 7

DIPPER EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BUCKET CeTTlNG EDGES A\;D TEETH.

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

21

Stabilizer Hydraullcs
Boom Lockout Hydraulics

20

. . . . . .,

.,

. . . . . . . . . . . . ..
~

22

Hydra-Guide Hydraulics

23

Control Tower . . . . . . . . . . . . . . .

24

UNCOUPLING BACKHOE FROM TRACTOR

1.

Park the tractor on a hard level surface

a nd lower the loader bucket to the ground .

5.

Start the engine and raise or lowe r the

boom as requir ed (which tips the mounting frame in Ql' out) to r e move backhoe
weight from the upp er mounting pins and
drive the pins out. It may l)e necessary to
use stabilizers to level the mounting
frame.

2.

Start tlle engine anel use the backhoe

control levers to form a tripod as shown
in Figure 1. Lower the stabilizers Wltil
they just touch the gound.
NOT~

The stabilizers have a two position pivot. The backhoe can be r emoved
with the stabilizers in either pOSition.

6.

With the stabilizers. I'aise the backhoe

until the lowe l' mounting studs are clear
of the lower support a rms.

3.

At the r ear of the tractor there are two

tension rod assemblies. Loosen the nut on
top of each tension roel.

7.

Drive tlle tractor forward about one foot

and disconnec t the pressure and return
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
mowlt ing pins. Disconnect the dipper light
wirc if s o equipped.

8.

Connect the r eturn hose tc the pressure

tub e On the tractor. The tractor is now
r eady to drive away ,

Figure 1 - Forming a Tripod

Figure 2 - Uncoupling The Backhoe

COUPLING BACKHOE TO TRACTOR
1.

Line up tractor with backhoe and back up

close to the backhoe mounting frame.

2.

Stop the engine and reconnect the hydraulic lines. Be sure the couplings are
fully engaged.

3.

Very carefully back the tractor Into the

backhoe. If necessary, raise the backhoe
with the stabilizers. Lower the backhoe
onto the lower support arms.

4.

Ca refully raise or lower the boom (which

tips the mounting frame in or out) to
align the mounting pin holes in the upper

support ar ms and the mounting frame.

Then drive the mounting pins in and install
the klik pins. It may be necess ary to
use the stabilizers to level the mounting
frame.
5.

Make sure the lower nuts on the tension

rods do not contact the upper' mounting
arms, and torque the upper nuts to HO170 foot pounds. Then tighten the lower
nuts until snug and retorque the upper
nuts to 450-550 foot pounds.

6.

Reconnect dipper light wire if so equipped.

SWING TOWER REMOVAL AND I NST ALLATION

Removal
1.

Completely extend the backhoe and rest

the bucket on the floor. Place a suitable
support under the boom and dipper pivot
to help stabilize the backhoe.

2.

Move the boom, dipper and bucket control

levers In both directions to equalize
circuit pres s ure. Then remove the front
cover fr om the control tower.

3.

Number or otherwise identify the control

valve ports and hoses to assure proper
assembly. Then disconnect the bucke t and
dipper hoses from the control valve and
the boom ho ses from tube s from control
valve. Also remove hose clamp fro m
inside the swing tower.

4.

If equipped with an extendable dipper, remove the hose guard on bottom of boom
and disconnect hoses from tubes. Then
free the hoses from the swing tower.

5.

Remove the swing cylinder rod pivot pin

retainer from bottom of swing tower.
Drive the pivot pins out the bottom of the
swing tower.

6.

Remo\'e the boom l atch mechanism from

the swing tower and install a rod (1" dia.
x 18") in the boom latc h pivot pin holes.
Attach a chain to the outer ends of the
rod. Then attach a chain hoist to the chain
and r e move the slack.

7.

Remove the snap rings from the swing

tower pivot pins and remove the pins.

8.

Raise the swing tower to take weight off

bottom pivot. Then slowly and carefully
move the tractor forw a rd.

9.

Provide additiona l support fOJ.' the boom;

use a chain hoist or block up. Remove
the retaining bolts from both boom cylinder pivot pins. Then remove a pivot
pin and lower the boom cylinder (repeat
for the remaining boom cylinder).

10. Remove the reta iner from each boom

pivot pin and r e move the pins. Then
remove swing tower from boom.

Figure 3 - Removing/ Installing Swing Tower

in place with bolt. Repe at for the remaining boom cylinder.

Installation

1.

2.

Attach chain hoist to swing towe r and

position swing tower to boom. Then
install the boom pivot pins. Secure pins
in place with pin retaining ha rdware.
Position a boom cylinder to the swing
tower and install the pivot pin. Coat
one side of a washer with grease and
po s ition on swing towe r. Make sure hole
in pin and cylinder are aligned and drive
pin in until holes are aligned. Secure pin

3.

Back the tractor into position to mount

the swing tower to the mounting frame.
Install the upper and lowe r swing tower
pivot pins and secure in place with snap
rings.

4.

Remove chain hoist and rod from swing

tower.

5.

Align swing cylinde r rod eyes with swing

tower and install pivot pins through bot-

tom of swing tower. Secure pins In place

with pin retainer.
6.

If hoses and ports were not identifiea.

refer to Figures 11 and 13 for proper
COnnections.

Connect hoses to contro l valve and tubes.

7.

Reinstall front cover on control tower.

DISASSEMBLING THE BACKHOE

tubes secured to boom and c lose all

openings with clean c aplugs .

NOTE 1:
This procedure outlines the
complete disassemb ly of the backhoe. There
may be occasions when comp le te disassembly
is not required. therefore use the steps
necess ary to remove the affected component(s). Refer to Section 45 when removing
cylinders for repair.

5.

NOTE 2 : Shims are used a t pivot points

to r educe side play. When disassembling the
backhoe. note the number and location of
these shims for proper parts positioning
during assembly.

If the backhoe is equipped

standard dipper arm:
a.

Attach a chain hoist to the dipper

arm . Move the dipper control lever in
both directions to equalize circuit
pressure.

b.

Place a block of \Vood under the dipper cylinder to provide support when
the rod pin is removed. Then remove
a snap ring and washer from the
dipper cylinder rod pivot pin and remove pivot pin.

c.

Remove a snap ring and washer from

the dipper arm pivot pin and remove
pivot pin.

d.

Lift the dipper away from the boom

and lower the dipper arm to the floor.

Refer to Figures 9 thru 19 to aid in

disassembly.
Buckel Remov al
1.

Lower the bucket with bottom of bucket

flat on the floor.

2.

Remove a snap ring and washer from the

two pivot pins that must be removed. One
attache s the bucket to the dipper arm and
one attache s the linkage to the bucke t
cylinder rod eye.

6.

with the

If the backhoe Is equipped with a hydraulically extendable dipper arm:

Dipper Arm Removal

1.

Remove bucke t a s instructed under Bucke t Removal.

2.

Extend the d ipper arm and lower the boom

until the end of the dipper arm rests on
the floor.

3.

4.

Move the bucket control lever in both

directions to equalize circuit pressure.
Provide support (chain hoist) for the
bucket cyllnder and remove a snap ring
and washer from the cylinder pivot pin.
Then remove pivot pin.
Free the bucket cylinder from the dipper
arm and disconne ct hoses at bucke t cy l inder and lowe r bucket cylinder to the
floor. Then disconnect bucket hoses at

a.

Attach a chain hoist to the dipper

arm . Then push the diversion Ialve
control down a nd move the le ft hand
stabilizer control lever in both directions to equali ze circ uitpressure.

b.

Disconnect hoses to the e"iension cy lind e r at the tuiJe s sec ur ed to the

boom and close op ening's with clean
caplugs.

c.

Place a block of wood under the

dipper cylinder to provide support
when the rod pin is removed. Then
remove a snap ring and wa sher from
dipper cylinder rod pivot pin and
remove pivot pin.

d.

Remove a snap ring and washer from

the dipper arm pivot pin and remove

pivot pin.
e.

disconnect hoses from cylinder. Close

openings with clean caplugs.

Lift the dipper away from the boom

and lower the dipper arm to the floor.

5.

Provide suitable support for the boom

and move the boom control lever in both
directions to equalize circuit pressure.

6.

Disconnect hoses from each boom cylinder as required and close openings
with c le an caplugs. Then remove the
pivot pin retaining bolts from each cylinder and rod pivot.

7.

Attach a chain hoist to a boom cylinder.

Remove the cylinder pivot pin. Then drive
the rod eye pivot pin into the rod eye to
free rod from pin and lower cylinder to
the floor. Repeat for the remaining boom
cylinder.

8.

Attach a chain hoist to the boom and

disconnect the remaining hoses from the
boom.

9.

Remove the boom pivot pin (2) retaining

hardware and remove the pivot pins. Then
lower boom to floor.

Boom Remov al
1.

Remove the bucket and dipper arm as

previously instructed.

2.

Attach a chain hoist to the dipper cylinder.

Then remove the dipper cylinder pivot pin
retaining bolt and pivot pin.

3.

Remove the hose clamp Inside the boom.

Then remove the hose guard from the
bottom of the boom If equipped with an
extendable dipper arm.
NOTE:
As the remaining hoses are
di s connected , number each hose and its
connect ing point to assure proper assembly.

4.

Carefu lly move the dipper cylinder away

from the cylinder mounting bracket and

ASSEMBLING THE BACKHOE

NOTE: Install shims in same location and
quantity as noted during disassembly.

pivot pin. Make sure the bolt hole In the

pin and eye are a ligned and drive pin
Into the rod eye until the holes are
aligned. Secure the pin In place with bolt
and nut.

Refer to Figures 9 thru 14 to a id In assembly.

Boom Installation
1.

Attach a chain hoist to the boom and lift

boom into position to attach to the swing
tower.

2.

Align the boom with the sWing tower and

install the boom pIvot pins. Secure the
pins In place with the pin retaining
hardware, Figure 9.

3.

4.

Position a boom cylinder to the swing

tower and install the pivot pin. Coat
one side of washer with grease a nd place
on swing tower. lVIake sure hole in pin is
aligned with hole in cylinder and drive
pin In until the hole s are aligned . Then
install the pin retaining bolt.
Allgn the cylinder rod eye with the rod

5.

Repeat steps 3 and 4 for the remaining

boom cylinder. Then connect hoses to the
boom cylInders and tubes attached to the
boom. If hoses were not numbered or
otherwise Identified during disassembly,
refer to Figure 11 for proper connections.

6.

The boom can now be raised or lowered

hydraulically. Position the boom In a suitable position, a nd with the aid of a chain
"holst position the dipper cylinder over
the boom.

7.

Connect the hoses to the dipper cylinder

and position cylinder In mounting bracket.
Install pivot pin and secure In place with
bolt and nut.

8.

Install hose c l amp Inside of boom, making

sure hoses are properly positioned.

9.

If equipped with an extendable dipper,

connect hoses to tubes on bottom of boom
and Install hose guard .

Dipper

1.

4.

Coat the sides of the cylinder eye with

grease and place a washer on each side of
the eye. Then carefully move the cylinder
into position and install the pivot pin. Secure the pin in place with washers and
snap rings.

5.

If equipped with an extendable dipper arm,

cOlUlect the extension cylinder hoses to
the tubes secured to the boom.

Ann Installation

Attach a chain hoist to the dipper arm

and position the dipper on the boom. Use
the same number of shims between the
boom and dipper as were removed. Install
the dipper arm pivot pin and secure In
place with washers and snap rings.

Bu cket In s l allatlon

2.

3.

Coat the sides of the dipper cylinder rod

eye with grease and place a washer on
each s ide of the rod eye. Allgn the rod
eye with the dipper arm and Install the
pivot pin. Secure the pin In place with
washers and snap rings.

1.

Pos ition bucket to dipper arm and install

pivot pin. Secure pin in place with
washers and snap rings.

2.

Extend or retract the bucket cylinder to

align the cylinder rod eye with the upper
and lower bucket control links. Coat the
sides of the rod eye with grease and
place a washer on each side of the rod
eye . Align bucket links with rod e ye and
install pivot pin. Secure pivot pin with
washers and snap rings.

Position the boom and dipper arm to a id

in ins talling the bucket cylinder. Attac h a
chain hoist to the bucket cylinder a nd
po s ition cylinder over dipper arm. Connect hoses to bucket cylinder and tube s
attached to the boom.

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.
1.

Remov e bucket as inst r uct ed on page 6.

2.

Make SUl'e dipper extension is full y retracted and pos iti on boom a nd dipper to
facilitate removal of dipper extension.

3.

Remov e s nap rings and was hel's that

secure bucket links to dipper extension
a ncl remove bucket I inks.

Continue pulling the extens ion from the

dipper arm while being alert for an unbalanced condition when the extension is
fr ee of the dip per arm . Low er the e xtension to the floor.
If l' eplacing E'xtension weal'
strips, torque the Weal' s tr ips retaining
screws to 45 inch pounds.

NOTE:

Installati on

Refer to Figure 12.

WA RNING: Keep fingers clear of sliding

collar when completing step 4 as the

collar will drop when the pin is removed.
4.
5.

R emove pin that attaches sliding collar to

dipper exten sion.
The dipp e r e xtension weig hs approximately 230 pounds and is approximately
7 feet long. Pull the dipper extension out

1.

Block up rod end of extension cy linder

In dipper arm about 1 inc h with a
small piece of wood. Also make sure the
rod eye is straight up and down.

2.

Attach a chain hoist to the dipper extension and pu s h the extension Into the dipper
arm about half way. If nec ess a r y , drive
the extension Into the dipper arm.

3.

Start the engine and SLOWLY extend the

extension cylinde r to bring rod eye into
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
sideways to align rod eye with bosses.

the collar into alignme nt with hole in

dipper extension.

WARNING: Use care in moving s liding

collar as the weight of the co llar 11'111

cause it to slide downward on the dippe r
a rm when the pi n end is r a ised.

WARNING; DO NOT put fingers in pin

5.

Install the collar and rod eye retaining

pin. Then install the bucke t links on pin
with I1nks on top of bucke t pivot bosses.
Secure pin with washers and snap rings.

6.

Install bucke t as instructed on page 8 .

hole while extending the extension cy linder.

4.

After the rod ey e is aiigned with the pin

hole, grasp the slid ing collar and move

BUCKET CUTTING EDGES AND TEETH

CAUTION: If bucket is not removed for
repair, disconnect alte rnator leads and unplug
VOltage r egulator.

8.

Wrap Around Culling Edge

Side Culling Edges

Removal And Installation

Removal And Installation

If old tooth shanks a re to be used , remove

any r em a ining weld before reinstalling.

1.

Remove the bucket teeth if so e qu ipped.

Use carbon arc r od or an acetelyne
cutting torch to remove welds.

1.

Remove all cutting edge welds using

carbon arc rod or an acetelyne cutting
torch.

2.

Remove all cutting edge welds using

c arbon arc rod or an ace telyne cutting
torch.

2.

Remove the cutting edge and grind off any

rema ining weld and/or exc ess metal to
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 Cclamps to hold it in position.

4.

Refer to Figure 4 and weld c utting edge to

bucket. Use a weld r od meeting A. \V.S.
specific ation E-7018.

4.

5.

Remove the cutting edge and grind off any

remaining weld and/ or excess metal to
provide a smooth surface for the new
cutting edge.
Place cutting edge on bucket, using
C-clamps to hold it in position. Using a
weld rod meeting A. W. S. specification
E-7018, fill opening made in e ach corner.

Buckel Teeth
Tooth Shank Removal And Installation

6.

Refe r tc Figure 4 and weld cutting edge to

bucket. Use weld rcd speclfled in step 5.

1.

Remove all shank welds using carbon

arc rod 01' an acete lyne cutting torch.

7.

Install bucket t eet h. Hefe l' to Figures 5

and 6 fa I' loc ation and weld sp ec ifications.

2.

Remove shank and grlne! off any remaining

weld on the cutting edge .

2 PJ',SS 'dEL:)

FI LLET - - -

-:'/"~
- !-- I
! lQ

1/4" FILLCT~

HEAvY DUTV TRENCHING .UCKET

3/i6"
F' LLET

\r'----t-.,.-'
i '

"I'"
Q'

,Jl

~-

...- LeT--:.:.

DELLH08 BUCKET

Figure 4 - Cutting

10

Welds

3.

Refer to Figures 5 and 6 for location and

weld specifications. Use a weld rod
meeting A. \V.S. specific ation E-7018 and
weld shank to cutting eelge.

- - CUTT I NG EDGE

BUCKET

--- - ----

)/8 "

F I LLE T

c-OR" ER~

WRA:"'P3/8" BOTH S I DES

T ooth Replacement

\oI E LD ~

]',10 PASS

11

"

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.

3.

Drive pin in place (heavy duty buckets).

A LL BUCKETS EX CEP T 12" BUCK ET

pos I TJ ON TOOTri SHA NK AS CL OS E
AS POSS I BLE TO CUTT I f-lG ED GE
BEN D WH I LE MA IrHA IN I NG THE 1/ 2"
AIl D OVERALL DI MEI1 S ION S.

1111

r-;

IT,' "
./

36"

8u cr~ET

Figure 5 - Bucket Tooth and

Shank Installation

' '' 3
3-1/8"

24 " BOCKET

6-1 /2"

30" BUCKET

9-)N'

36"

__ ~2- 3/4'~

1--'
I
I
I

I
I

I
I

I
I
I

18"

L 1

,;

SU CK ET

36" BUCKET

'-,

t
I

r\

-\
\

r-(--'r

BUC KET

\
I
\

CE~TOOTH -

US ED o r~
12" AND 30" BUCKET S DillY

18-5/8" (J7-IN' OV ERA LL )

30" BUCKET

15-5/8 '1 (3 1-1 / 4" OVERALL )

24" BUCKET

12- 5/8" ( 25-1/4" OVERA LL )

18" BUCKET

9-5/8" ( 19-1 / 4" OVER ALL)

1-6- 1/ 8" (\ 2-1 /4" OV ERALL}12" SUCK ET ~NLY. pas I TIO N

TO OTH SHANK AS CLO SE AS
POSSIB LE: TO CUTT !NG EDGE
BE ND AN O MA INTA I i: 0 1'ERA LL
I

CEilTER l HJE

Figure 6 - Bucket Tooth Location

11

D ',..,ENS I DH.

7 \0929

EXPLODED VIEWS

BOOM ,
LEV ER

BUCKET

DIPPER

CLEV I S "!lPO)

- - - - - CU,V I S (7)

--CLEVI S ROO (j }

SWIN G

-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

7/S"(4) -

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

STABILIZER

FLAT wASHER(2)

BOOM-SW 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)
l / l O " x 1/2"

II

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

II

P ig-u r e 9 - [,; xP1 ortecI Vie w of Backhoe

14

CONNECTOR " ' -

BACKH oe

CONTR~VE__.....,,,,,_,,q O-R I N G : . ~

ro

A~ _9GO
.

BULKHEA D

CO I!N ECTOR
QUICK

.l"~"

O-R I NG

"'''"~~~.~''''J'~,-,"- _-"
FLAT WASH ER

~ A-

HOSE
lO:~ G

' .

~ ~yd 'f ,
~~

C O"NECTOR -~",

I '
'

<>V,

QU I CK _

O ISCO I~IIEC T
90

O- R I NG

ADJ.

El6G~.J

' '\

.C; , . '-; j-STAB IL IZER CONTROL VA LVE

r '
: , '_

~i
-A
.,/' O-R I IiG
"'-.A"
.......0

~ - 90"
,~

ADJ. ELB O"

El8 0''' ----U

HOS E
)6" LO t:G

71 0?49

Figure 10 - Intermediate Hydraulics

15

0 ' PPE R CYL ' iWR

O-R ING ___

/~~
CONNEC TOR

BUCKET CYLI NDcR

INTERME DIATE ,UB E

ROTATED 1eO '

BOol' cn INOlo'--- 1

L. H.

c
E

R. H. S'IVEL
JOINT

"'-! --- )JII"

~~
~ -HOSE
\~ ~
X . /'" \
0

.....

CLMIP

LQKIiASH ER

1/2"-,', [ " I -J/4 " (4)

HOSe: LENGTH , COlrtROl VALVE TO;

DIPPER cn. CLOSED [lID 82"
DIPPER CYL. ROD END 89"
BUCKET cn. IIlTERMED I ATE TuBE 94"
IIITER.'ED IAT E TUBE TO BUCKET cn . jI."

BOOM cn, IWIVE L JO I IlT }8"

800M cn. CROSS OVl'R , CLOSE D END 2, - 3/4"
80DM CYL. C~ O SSO '/ER., ROD END 23"

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~ /~

- .,." . ",,,,

?,f ."''"'' ')

CY L "' DE R P IN
FLAT WASHER (1)-

9'~

'

I~
DIP PER _

.I

(j
I /.:'
SPA CER
I EACH

/.':,

. ._

SlOE-WJ -

OIPPER CYLI ND ER

'

t--<..:: I , ~

......_~I

Prr~

~9'
I
~, / E

IJi1~y(

~UCKfT CY lI NDfR

6",
I

~'W I,
~-t ~

C-

SiiAP R I riG (2)

"SNA
( ) P RING
2

SL I Oli:G COL LAR

____ DIPPER P IVO T PII

'''A

V -

l
S TO P
WEAR STR I P(8) ---

SIIA? R IIIG ( 2)

I (

aol

'- ij~ ,.:'b t~r

'-J
Q1"'--..
I

1/2 " - 1<C x 1- 1/ 4"( 4)

GRAD E 8 -0 0 NOT SUBSTIT UTE

BUSH ING (2)

SPACE R

- - EXTE I:S I 0 ;) CYL I NOE R

(2 )

12-24

x 1/2 "

/"

PH I LLJ PS HEA D
TORQUE TO 45 IN.-L6S .

BUSH IIIG (2)

~(;clJli
~

SPACf R (2)
USED '.... rTH STAN DAR D
BUCKU S ONLY

l'igure 12 - Exploded Vi e w of Extend able Dipper

17

PI:I

711C 03

70" Loue ('-)

\, r

FL AT ' 'ASHER_ "

I
_",0 _
x 1-1/2" '"

3/B"-t.:C x 1- 1/2 "' - _.n.

<~\

900 ADJ .

fLaO>l -

ro" LOCK,'ASHER
I I
_

/~ I 1
.

A",
W

!
EX TENS IOIJ _ _

en INOER

STAalLIZER
CON TROL V,.LVt

\/ .

67" LONe (2)

3/8"- NC x 3- 1/4"

"'

~,.

HOSES TO L.H .

STAB I L I ZER

900 A~J.
ELB{)\I
9 00 ADJ .

ELB"" (2)

Figure 13 - Extendable Dipper Hydraullcs

18

711004

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-

9) AD~.~r\
El BaJ

Figure 1;J

!:)winoo 1-1 ydrauli c s

20

HO SE 20- 1/2"

L O j~G

3 /8"-~~C x I " _~

~- J /8"-"C

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

0_

COVER

)/8"- "C

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

L.H. FOOT

3/8"- ;;C

'to..

QU I CK EOG
)8" LONG

"

CONTROL
TO\IER

I LOCKWASH R ~~.
3/8"- ;!( x 3/4" -

,::--:,'

"

MQU"TING.........-~
I

I
I

" - BR ACKET

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
1.

Locate the m achine on level surface

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 .

arms. Raise the hitch until the

control valve mounting arm clears
the tension rod.

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 coupling is fully engaged. Care full y drive
the tractor away fr om the hitc h.

7.

If the hitch is to be left standing for

an extended period of time, block up
the hitch as s hown in Figure :3 to prevent loss of position.

Figure 1 - Hitch Removal

3.

Lse the lift and pitch control leve rs as

requ ired to remove the we ight of the
hitch from the upper mounting pins.
Then drive the mounting pins out.

4.

Remove the hitch from the lower support

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 mounting 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

UserFriendlyCDs

Figure 3 -

Hitch

Prepared For Storage

1.

2.

3.

Lse the
and pitch control levers as
required and align the mounting frame
with the upper support arms.

Align the tractor with hitch ami raise

the seat high enough to prevent the seat
adjusting lever from catching in the
hoses from the control valve.
Back the tractor into the hitch until
the hitch mounting frame enters the
lowe r support arms. Stop the
and
connect the hydraulic lines to and from
the control valve.
Carefully hack the tractor completely
into the hitch. Then lower the hitch into
the lower mounting [lrms.

5.

Drive the upper mounting pins in and

secure in place with klik

6.

J;l.ake sure the lower tc;n:oion rod nuts

do not contact the uppe,' support arms
and torque the upper nuts to 140170
foot-pounds.

7.

Tighten the lower tension rod nuts until

snug and retol'que the
nuts to
450-550 foot-pounds,

II FT .4R11

LIFT ARM $H4:fi

LJFT CYLIIHlER PI"

SUSHI

TiLT

CYLI~dJER

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

Figure 4 - Exploded View of Three-Point Hitch

P 11,1

(2)

f)I::

450 ADJ. ELB OW () -4)

RESTR ICTE D FLOII
LETT ER ~ STAM PED

HOSE LENGTM S, IJALVE TO :

LIFT CYLINDER CLOSED Efj D - 56"
LIFT CV L I NOER ROO END - 45"
TI LT CY LINO eR CLOS ED END - 66"
TILT CY LINOER ROD 10110 - 54"
PI TCH CYLI NDER CLO SED EIIO - 42"
PITCH CYL I NDR ROD EflO - 45"

HOSE CLAMP

.r,~
"

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

f' l TER MOUtlT I NG BOLTS

l / Z"-IlC x 1-1 /4" .... ,TH
FLAT ~AS H E R AND LOC KwASHER. .
fl LTR

~ 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~ ~. .

::;r::::::::;~~=

' / 2' '- NC flU T

OC~SHER

3/S"IIC NU T

HOSE

36"
110952

Fil,,"ure 6 - Basic Hydraulics for Three- Point Hitch Only

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
PEDAL POSITION

Depressed

SHUTTLE SHIFT
LEVER POSITION

Forward or

CLUTCH
PRESSURE
TEST PORT

"c"

CONVERTER
CHARGING
TEST PORT "B"

POWER SHUTTLE
LU B OIL PRESS.
TEST PORT "0"

30 to 40 PSI

o PSI

170 to 190 PSI

30 to 40 PSI

15 to 40 PSI

150 PSI Min.

15 to 40 PSI

15 to 40 PSI

180 to 200 PSI

30 to 40 PSI

15 to 40 PSI

Reverse

Released

Forward and

Revers.e

Released

Forward and
Reverse

Re leased

Neutral

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 converter 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
TEST PORT " B"

~r.;I1~p~~L,.~Sl;!!f1.~::::::'~-PRESSURE

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

1014

FITTINGS REQUIRE D FOR TESTING POWER SHUTTLE PUMP

OUTPUT AND MAIN RELIEF VALVE

(----------,
(O(~

(iY

f'5\-I.V

REF. PART NO.

NO.
NO.

fl
~-

fl'
L'>19~ , 'Co,<,:q(J~,J!J
~ r "')
JJ)

O"

...

<t~,~

(1) .............

5
6
7
8
9
10

R21817
221-211
221-425
A21568
220128
220145
220-127
220105
A21567
221-93

' I(J

.'

~.
~
~
REQ'~
'" P
i1"
NO;;.P

DESCRIPTION

L~

111(.

1
2
3

,f,

314" Shut off Valve

314" Close Nipple
314" Female Pipe Tee
5/ 8" LD. (-12) Bulk Hose
3/ 4" -14 Male pipe
7/8" -14 JIC 37 Male Flare
112" 16 Male Pipe

1
1
1
2
3
1
1
718" 14 JIC 370 Female Swivell
1/2" LD. (10) Bulk Hose
2
314" to 1/ 2" Pipe Bushing
2

",

HYDRASLEUTH
M20270

60GPM

M20271

30GPM

L I

/.J
~/";

~c~~
TORQUE TUBE DIPSTICK HOLE

HYDRASLEUTH

SHUTOFF VALVE OPEN

I~~=-LOAD
RPM

I .fer

SHUTOFF VALVE

LOAD VALVE

GPM
9.5

2000

Closed

Adjust to 375 10 500 PSI

2250

OOled

Adjust to 200 PSI Minimum

'0

434 for relief valve adjustment.

11.3

VALVE

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
- i ( - ! type'
~ ~ f p u ~ n p .A r e s e r v o i r : i ~ ~ <filti-:-ii
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~!rvnir. 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 :<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- providcs .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,

1513

/--7',

1/

,If

j]
PUMP

I
I

i
~1

J!

CONTROL vAI.VE--
I

/ ' 't

\.

.,\\
\\

\j
\
I
'-. .../
R.H.

CYUNDER-.......,P=--<'~

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 ntro 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!'
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 .
T I1('

eavi tie ~

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
o

POWER PUMP PRE SSU RE

MANUAL PUMP PRES SURE
RETU RN O il
SUMP O IL

L H. CYLI N DER

INTERMEDIATE
COVER " "

" '-

R"'I,ve
FILTER

POWER PUMP

Figure 2

. H . CY LI N DER

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
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(:ess 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-

fl"<lm til l'

11w 1,..Iltgilll'

l'l'~<'n-u il ',

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
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 ,
I'r'--' '; ~llr iz. l'il

Steering Cylinders
( 0 the two cy lind e r s and e xte nds t he L.H. ~ y li nd cr and rathe 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: conll'ol \-"In, a"d r<?turilS 10 Ihe fiill')' uncI )'c s en'o ir.

The [ll' estiur ized oil is di reded

Il' ac ts

LX STEERING CYLINDER

R. H_ STEERING CYLINDER

151-7

STEERING
CONTROL

MANUAL PUMI"'

VALVE

'EAL

MANUAL PUMP

CONTROL VALVE

POWER PUMP PRESSURE

MANUAL PUMP PRE SS URE

RETURN OIL

SUMP Oil

INTERMEDIATE
COVER ~

.:'\:- - ' . H. CYLINDER

FilTER ''', ....,,''

POWER PUM P

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\ssages . 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 ,
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.,

,;<If!:(',; ,

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 ret )':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

to th, inlel port of thL' manua l pum p. ,\ tm osphe ri c pr es"ure in Ihe I'eset' \'oil' \\' i ll
oi l int<1 tilt' mCll1ual pum p l' i reui( to replace any oi l lost t hrough l Citkage in the manual

'-('('11'1\, '(1

fo r C'~

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

o
o

MAN UAL PUMP PIH SSUIlE

RETURN OIL
STATIC OIL

iii .

Figure 5

H. CYLIN DER

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

1622

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 converter,

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

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 torus .

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 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
this oil to the turb in (; .

----

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

Figure 1

turbine to turn. The tur hine is

connected to and turn s the outpu t
sle eve . The oil leaving the turbine
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'~

zed oil to aclUa

to)' [l ressurithf' dut c h

on ,

lutdl h " mulriple

du tc h, hydroulkril l:: ac tu ated
,Old 10c"l('(1 0)1 th l' rear" ,"'d end of
the I nput ,.,h alt , Ilh pl) th," c lutch is

The Re\'('J'se Clut<;h i ~ 'I m Ult ipl e

dis c c lutc h, hycll'auli,'al1y actuHll:cl

(~ng'ag'l:'rt,

the inp ut

d i ~c

[lOci

Llu.' drh'l~ and dl'j n ,..'n plat es

a re squeezed toget he r' by the force

piston hoUSing, The driven pla tes are
s plined to the cl utch drum a nd gea r,
th e drive plates are spliJled to the
clutc h hUb,

10c ,,[<,cI on 111e f'Jl'\\ ;!l' r! end of

"h~r t,

11 11~n

Ih .. c l utch is

pngag -d . t h l..~ drivl;' :Hu l dr i\-en L11es

Clre sq uee zerl together b y the c luteh
p iston , T he d J' i \'''n pl'l! "" are "pli ned
to ihe c lut eh d n l111 ;lllri geal' , the
drive plat es 3 1'e opl ined to tht-c l utch

hub,

Figure 2

1624

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 oNed to fl ow back to the reservoi r by the converte r pressure reg ula tor valve.

,.,

'"'I ,"''''''' .,"'

'""
.. "'

"GH ..... ""

,"<TIO~

'""' .,,"''''
0 CON"'
I " , .. , , " "
ANO

[i)"'U'N Q'

1626

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 manifold 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 mperature.

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

.,,"._,""'

o ...,....."" ,
o
""'" "'"u.,

l U", .. " " ' ' ' .~,

'''''

Fill"". 5

IOOI>J, Ol "'"

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

"u,,~ "" ,,",, .~,,

., ,.,,'

~").""',".'
,",WON

o <ON.""."""U"
00
""
o "."C o:,
w .... ",U"
"'U.~

. .. D

HOW IT WORKS

TORQUE CONVERTER
WITH TWIN DISC POWER SHUTTLE

TABLE OF CONTENTS
Introduction
Torque Converter ........ ........,.........,..................-...... ............................... ........... ... . . ..........,. 163-2
Power Shuttle .......,......... ........ ..... ....................... ............... ........ ... , .... . ...,, , .,., .,... . .......,. ,. ... 163-3
163-4
Neutral .......,,...........................................,.............,,.........,.~............~.~,,,,,...........,..................
Forward .,. ,.,.....,............ . , .,.., ....................................... ...............,..........-.......... ...,,.-.............-.163-6
Reverse ,....... ..... ....., .,...,....,................ ... .............................,..,..,........., . , ......... ...-... ..........., ... m-8
Clutch pedal depressed (dumped) .......,.,..,....,...............,.,..,.................................................163-10
+

.+

. .

Rac. Form 9-80491

1632

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

r ear of the torq ue converter and
driven

by

th e

ro tating

housing,

whic h is con nected to and driven by

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

ves
by means
vanes, changes the direc tion
oil a nd directs the oi l bac k to the
impeller.

The torus is a passage 10ca te d in

the r o tating housing wh ich receives
oil from the impeller a nd direc ts
this oil

The

the torus . The force of the oU a

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 steering column.
The piston carrier assembly is equIpped with two lubrication va lve s pools .
In either forward or reverse clutc h
e ngagem ent, one of the valve spools
moves and direc ts lubrication oil to
the clutch that is being applied.

The forward and reverse cl u tc h

pistons are equipped with dump valves
which allow for positive c lutc h disen 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 pressurized oil to ac tua te the clu tch pistons .

The forward clutch is a multiple

disc clutch. hydraulically actuated
and located on the rearward end of
the input shaft. When the c lutch is
engaged, the drive a nd dri ve n pla tes
a re squeezed toge the r by the c lutch
piston. The s inte red driven plates are
splined to the clutch drum and gear,
the steel drive plates are splined to
the clutch hub.

The reverse clutch is a multiple

d isc c lutch , hyd ra ulical ly ac tuated
a nd located on the fonvanl end of
the input shMt. When the clutc h is
e ngaged , the dri ve and driven p la tes
a re squeezed together by the c lutch
pi ston . The s intered driven plates are
splined to the clutch drum and gear .
the stee l drive plates are splined to
the c lutc h hub.

NEUTRAL
(Refer to Figure 3)
Oil P u m p
Filter
Cooler

Draws oil from the reservoir and supplies the converter power shuttle system.

Filters all the transmission oil in the system.

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 distribution 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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D

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u.,

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" Ie

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 regulates 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 temperature.

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 pressurized 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,

,~,

D "" "AN '"'

I
Figur. 4

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Lul" "'~ "ON ~ "D

CO~V'" . .. . . . US ,
$...cno~

0"'

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 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
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

c
~

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

......... ................................................................-..........-..................

Reverse Drive Condition

..,..,.,........,...................,...........................................................,.....
164-10

Overload Condition in Forward Drive

Unload Condition

Rac. Form 9-80281

164-8

...............................................-,.,............................... 164-12

............,.....,.......................................................................-.,.,...........,..,,.., 164-14

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 hydraulic 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 similar 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 toe 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 tilting 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 inoperati 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
irn"m .""""
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",nn;"" ,

C<lMIOIotIo . "

<1". "

.'rnpllc't~.only ,~,.,.,.

I. "'''''.8 ,""''''' ... OOft".""'''' ....."",.'" til<

Neutral or Ze ro Speed Cond ition

CR.f.r to Figur. 2)

_n_" "',.,,"" <<0<..."", ."" thO . '"'p ""'''f ""00;1 .., .,

,hi.
""'k<
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n ..

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to

I"mo,

by

,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 .,

,h. ",..

Im,m .",,1. 0' 1'>' to ,h.

~"

~1t'll1<:

"""or ,t\o m'ttl'"'' ...'''t>ot''''''

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dtspl.loo"",", i>QlJ',"n, 0;, .... u, '0 , ... p>mp

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h., "'-"<. rl"'-'O<l '0 1" '0 'hO ",I,.

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"'<1 'h""''''' ,h. . link.

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mo'
' ' 'u,"'"" 0""'" '" . , "'''''''om .""",. 'n "" """'''"",, 0'.......1"" .. , ," I ." ' 0 I
I> obtoln....
q!

Rev., Drive Condition

(Refer to Figure 4 )

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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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164 -5

MOTOR

NEUTRAL CONDITIO N
Figure 2

SERVO

/~
I

25

FORWARD D RIVE
Figure 3

REVERSE DRIVE
Figure 4

SERVO

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 preventing contamination of the system. The restriction to flow will be indicated by the transmission 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 protect 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.

lQW ' M. . . _.... """ _ _

.... " .lH' . U... & e . -

. UM' Oil

oo .,,,'" ""
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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 control 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 preventing contamination of the system. The restriction to flow will be indicated by the transmission 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 protect the oil cooler system from high pressure oil.

, . . . . . ~" .. O ~ 0 '1
.,. . . . "., G >C G'

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o

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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 preventing contamination of the system. The restriction to flow will be indicated by the transmission 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 protect the oil cooler system from high pressure oil.

"~V<"SE

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16412

: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 relaxed 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.

Iii-I)

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