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) ã..ã..ã,.......,ã.,,., ...................................... 2250 R P M Rated Engine echanical Shuttle) ...............................,......,,....,.........,............. 1900 RPM Rated Engine Speed (Power Shuttle) ......*............................. .................................. 2100 RPM Engine Idling Speed ................................................................................................ 600-650 RPM 'Valve Tappet Clearance (Exhaust) ................ã.+....... (Hot and Cold) ,014 Inch (0.356mm) (Intake) ........................................(Hot and Cold) .014 Inch (O.356rnm) 'Hot Settings Are Made? After t h e Engine Has Operated At Thermostat Controlled Temperature For At Least Fifteen Minutes.
.............,......................................,,.,.................................,............
-..
...*..
Bac. Form 9-80721
Piston and Connecting Rods
Rings per Piston .....................................................................,.................,...,.,....................... 3 Number of Compression Ring's .................................................................................................... 2
Number of Oil Rings ....................... ............+..........+....................ã...................+...................... ... 1 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 .,................................ ,, ,.,..ã. ......,...................,. 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 .....,,.,,,,Ã.......,......,......,-.--..,.....,....................................... Replaceable Type Fuel Tank Water Trap and Drain ...........................................,..... Located in Base of Fuel Tank Fuel Tank Capacity .......................................................................... 22 U.S. Gallons (83,31liters) Fuel Level Gauge .....................ãã.................................Electric, Located on Instrument Panel, 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)ã,,,.,.. ...-.,-............,,- ....................................,......................... 3-1j2 Inches (SS.Pmmj Stroke .......................................................................-.........,...................... 4-1/8 Inches (104,Smrn) Compression Ratio (188G) ................................................................,................................ 7,5 to 1 (159G) ..................................... .........-,.............,......,.......................... 7,42 to 1 Piston Displacement ........................................................................................... 377 Cubic Inches No Load Governed Speed ( l W G I ............................................................,.......,............. 2250 RPM (159G) ................................ ,,.,...,.,,ã..,...,ãã .......,.ã....,,..ã. 2250 RPM RatM Engine Speed (188G1 .............. .+..... ................................................................. 2100 R P M ( 159G 1 ........................................................................................... 1900 R P M Engine Idling Speed .............................................,...,..................................,....... . ......... 600 RPM ¥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 ..,£Ã
..
..-
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 ..................................ã. ..,.............--............... Pressurized Thcrmosia t Con trolled Impeller Type Pump, Radiator .,........,,,,....,.,.................................. ,..,,..Ã..,.................. Heavy Duty Fin &Ed Tube Type Thermostat .....................................Starts to Open at Approximately 1779F.Fully Open a t 202". Pressure Cap Required ..........................,.,...,.........................,............................................. 4 PSI WtieJi using a proper operating pressure cap, the engine temperature can safely rise to 2,30T'.
Electrical System Type of System - Diesel and Spark Ignition ..,-...................................., 12 Volt Negative Ground Batteries .................................................................... (2) 12 Volt Batteries Connected in Parallel
Parking Brake Type ....................... Cable
Actuated by Orchlin Type Handle
. Adjustable
from Operator's Seat.
Hydraulic Brakes Type ..................................................................Heavy Duty, Disc and Band Differential Brakes Brake Pedals ............Can Be Locked Together for Safe Road Travel or Operated Independently
for Steering Assistance
Clutch Type .............................................................. Foot Opera fed, Spring Loaded, Single Disc. Disc Size ......................,........................ .....,.,-,,ã..È,,..,ã--......,,--,..r.......,..,ã,., 11 Inch {279,4mrn) Throwout Bearing ............................................................................. Ball Thrust wfgrease fitting Transmission ............................................................................................................ 8 Speed Gear Dual Range Shuttle ................................................................Mechanical Actuated Forward and Reverse Clutch P.T.O. .............................................. ,,...................+.ã.,...,.., ......~.,..............,.....,......,... Independent
Power Shuttle Torque Converter ....................................................................................................... Single Stage Power Shuttle .......................................... Hydraulically Actuated Forward and Reverse Clutches Transmission ............................................................................................................4 Speed Gear P,TdO....................................,..,,.,.,,.ã.,.,.,..,,,,.,.-. ............................... ,,,ã,.......... Independent b , , Ã
Hydrostatic Power Steering Relief Valve Pressure ................. ã,............. ,.,ã..................................................1500 to 1700 PSI Pump Capacity at No Load Engine RPM ...................................................... 6.7 GPM (25.41mm) Capacity of Reservoir ....................................................................................... 1 Quart (-95 liter) Capacity of System ã..,,ã .......................................................,..............,... 2.5 Quarts (236 liters) Type of Oil ................................................................. ......................,...................Case TCH Hand Pump Type .......................................................................... Gerotor Bi-Directional Driven By the Steering Wheel. Actuating Cylinders .......................................,.... 2 Way Cylinders Are Integral Part of Steering System.
..
...
...................,....-...
Power Take-Off Type ........................................................................................................................... Independent Rotation .............................................................................................................-........... Clockwise Spline Size ......................................... ,540 RPM at 1750 RPM ...................., 1-318" Dia. (34.9mm)
...................................................................................
Method of Engagement PTO Control Lever Pulley Diameter ..............................................................................-......... 10.25 Inches (260.4mrn) Pulley Face Width ...,......,-.+ ....................... .,......................................... 6.5 Inches (165.1mm) Ratio Engine R P M to Belt Pulley RPM .......................................................................... 1.53 to 1 2.68 Feet (Q.S72m) Per Minute Belt Travel 1 RPM o f Belt Pulley ..+...,.....ã,
................
...............
.
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
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)
0
. . . . . . . . . . . . . . . •. . . . . 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
12·2
Engine Block ~OTE:
All dimensions are given in inches. Specifications apply to all engine's un te'ss not ed. Maximum Limit Including Wear
CYLI:\DER SLEE VE S LD . of sleeve (109G)
.3..5013 to 3.5028
.005
(1 88D)
3.8115 to 3.8125
.005
(188G )
....... ..... ............. ........ ..... 3.8130 to 3.8145
.000
(148G) ..... ...... ................. ..... ..... .. .. .... 3.2745 to 3.3765
.005
Sleeve out·ai·round .... ......................................... ...... ....................... ....... .. .. ........... ..... ....... .. .004
Clearance to bottom of pisto n skirt (1880) ................. 00.35 to .0055 (188G) .................................................. 0025 to .0035 (159G)
.0015 to .0045
(148G )
.0030 to .0035
.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
o
: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 ·of·round .
.O()]
Mai'l bearing line r widt h 1st, (1880, ISSG )
1.276 to l.286
Main bearing liner widt h 1s t, (159G, U8G)
1.870
10
1.8S0
Main bear ing liner width 3rd (1880) .... ..... ................ 1.371 to 1.37:l ................ ..
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"
12·8
Cylinder Head a nd Valves (Continued)
Maximum Li mit Including Wear
EXH.\ L:ST VALVES (Con tinued I Insert Height ................... .. . . . .... ..................... ..................... ..... .247;) " to .2525" 0.0. o f Insf'rt ... ... ... . .. ... ........... ...... ..................... ............ 1.44;JO" to 1.4505" LD. of In se:·t .... .... . ....... . . . ............ ....... ..... ... .... ..... ... .... ......... 1.245" to 1.255"
INTAKE VALVES Tappet Clea rance (Hot and Cold I ................................ .. .............. ...... ... .......... 014" Fa ce Angle . .. ..... ... .... ...................... .. ............. ...... ..................... ................ 44' F a ce Run·Out ... ...... ............. ......................................... ....... .................. ........ ................. 002" 0.0. of Hea d ..... .. .... ............. ........... ........ .......... ........... ..... ... ... 1.599 " to 1.609" 0 .0. of Stem .............. .... ....... ............. ........... .......... .. ................... 3409" to .3419" .... . ..... 002" Length ............ ..... ...... ...... .. ... .... ...... ............................................... 6.339" to 6.364" Sea tAngle .. ...... .. ............. ..... ........... ... .... .... .......... ........ ................ .......... ......... -15' Sea t Run·Out ............ ... .... ...................... .. ........................................................... .. ... .. .... 002" Seat Width ..................... ... ...................................... .. .......... ....... ... 082" to .09.J" EXH AUST VALVE G UiDES Leng th ............. ... ................................. .. ............. ......................... ... .............. 3.125" 0.0 ...... ......... ................. ........ . ... .. ..... ......... .. ............ .... . ... .. ............ 6565" to .6575" 1.0. (I nstalled and Reamed) ........... .. .................................. ... ........ 3429" to .3439" ..... . .... 001" 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 Run·Out ........... ......... ................. . _.............. ...... •. ........... .................... _.................. ....... 002" Insert Height (188 and 201) ........ ... ............................ ................ ..... 247.5" to .25£5" Insert Height (148 and 159) ._ ....... .............. . .... ..... .... .. ......... .............. _198" to .203" 0.0. of Insert (188 and 201) ........ ........... ..................... .... .. ......... 1.4495" to 1. 4.10.5" 0.0. of Insert (148 and }.';9) ... _.................................. . ........ _.... ... 1..176.';" to 1.3775 " I.D. of Insert (188 a nd 201) ......... . ...... ....... ....... ... .•............. ........... 1.245" to 1.255" I.D . of Insert (148 and 159) ...... ....... ...... ..................... . .. ................ 1.074" to 1.084" INTAKE VALVE Tappet Clearance (HOT AND COLD) ............ ... .................... . ......................... 014" Face Angle .............. _.............................. . .... ................. ... __ ................. ... . _......... 29" Face Run-Out .. _...................................... ....... . ........ .... .. ................... .. ... ...................... .. .. . _... 002 " Length (188 and 201) .. .. _....... ....... .... . ......... ........ .. .. .............. .......... 5.796" to :'.81G" Length (148 and 159) ...... .............. ... ............. .... .......... ............... .. .. 5.275 " to 5.300" 0.0. of Stem .................................................................................. 3406" to .3414" 0.0. of Hea d (188 and 201) ........................................................... 1.51-1" to Li24" 0.0. of Head (148 and 1.19 ) ........................................................ _.. 1.410" to 1.420" Sea tAngle .... ... ........... ............................................•............... . ....... ............ ...... 30:1 Seat Run-out ....................................................................................................................... 002" Seat Contact Width (188 and 201) ...................................................... 055" to .070" Sea t Contac t Width (148 and 159) ...................................................... 04.5 " to .060" EXHAUST VALVE GUID E LE'ngth (188 a nd 201) .......... .. ........................................................................ 2. 8.}j" Length (148 a nd 159) .... ............. ...... ..... ................................. _................ .... .. 2.438" 0.0 ................................................................................................. 6565" to .6575" 1.0. ( Insta lled and Reamed) .............. .................................... ... ..... 3422" to .3432" ............ .. oor Protrusio n Abo ve Cyli nd e r Head (188 & 201) ............................................ 1.000" Protrusion Above Cylind e r Head (148 & 159) ...................... .. _.. ...................... 844"
12-10
Cylinder Head and Valves (Continued) :lIaximum Limi t [ncluding Wear I:\TAK£ VALVE GUWr:: Length (188 ancl 2(1) ......... ............ ..... .. ...... . ........ ...... .... .... .. .............. ... ........ 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 ..... .......... .. .. .. .. .......... .... .. ....... .. ...... ..... ... ... ..... ..... ........ ..... ............ 7·3 / 4 Wire Diameter ... , .................. .. .......... ........ ... ..... ...................... . , ............. ... , ... , .162" LD .. , ...... , ................... .... .............. , ...... .... .... .. ................. .... ............... .970" to .990" Compressed to 1.3:12" (Va lve Open ) ..... ... .... .. ....... ... ..... .. .. .. ... .. ........ 110 to 118 lbs. Compressed to 1.686" (Valve Closed) ... .............................................. 53 to .19 Ib s . VALVE SPR ING (Intake Valve ) F ree Length ., ...................... , .... , ... ...... ......... ...... ..... , .... .. .... .. .. ....... ............... 2-3/8" Tota l Coils ., .... .................. , ... .. ... ..... .. ....... ....... ....... .. ... ................................. , 8-114 Wire Diamete r , ............ ..... .................. .. .................. ... ..................................... 162" 1.0 .... .... .......................................... .. ............... ...... ................ .. .... ..... . 958" to .978 " Compressed to 1.521" (Valve Ope n) ...... ... ............. .. ...... ..... ............. 110 to 118 Ibs. Compressed to 1.87.'5" ( Valve Closed) .... .. .. ... ........... ..... ..... ..... ............ 53 to 59 lbs. ROC KER AR;VI ASSE ;VIB L Y 0.0. of shaft .... ..................... ...... .................. .......... ......... .... ..... .. ...... 622" to .623" LD . of Rocker Arm ......................... .......... ....... .... .... .. ...................... 624" to .62,)" (Insta lled and Rea med on 148 and 159) Shaft Spring (188 and 201): F ree Length ................ ........ .. ................ ...... ... , .......................................... 2-1/ 2" LD ....... ...... ......... " ...... ........ .. , ............. , ..... .. ... .... ... .. .. .. , ...... " ..... " ... , ... ,', .. ,. 11116" Wire Diameter .... .. " .. ................... .... .... ' .. .. .... ............................................... 072" Co mpressed to 1-3 / 4" .......... ...... .. .. .. ............... ... .. .. ............ ........... . 7.5 to 8.5 lbs , Shaft Spring (148 and 159): Free Length .............. ....... ................ .. .. ... ..... .... ............ .... ............ ...... .... . 1·3116" Total Coils ..... ................. ... ...... ...... ,., ........... .. .... . , .. ' .......... ... .......... ..... .............. 7 LD .. ....... ... ... , ............... , .. " ............................................ ,........................... ll ilG" Wire Diameter .. ..... ,." ..... ..... .... .......... ' ....... .... ................... .... ........ ............ ... 072" Com pressed to 11116" ....... .. .. .... .. .... .... .... .. ................ ... ............. .... . 7.5 to 8.5 Ibs. Lubrication ................ .. ................. .. .................. ..... E ngine oil, ca mshaCt m e te ring . Sha ft Oil Holes .... .. .................... .............................. Toward valve side of eng ine . Shaft cannot be rotated .
Cooling System Type ........... ....... ............. .. .. .. ... . .... Pressurized thermos tat controlled by-pass fOfced ci rculation Pump Type ,
.............. ...... . Impeller Type - Sea led Pre-Lubricated Bearings.
Fan .... ............ , .. , ... .. , ........ .. .... . , .. , ................. , ....... " .................. ..... .. ................ , ..... .. Suction Type Fan belt adjus tment ................... 60 to 75 P ou nd tension w /belt tension gauge or 112" deflection
12-11
Cooling System (Continued) Cooling System Capacity (l88D a nd 188G) ....... _.... ..... _............ ... ...... . ][i-112 C.S. Qts. (148G a nd 159G ) .......... .... ....... ....... .... ... ....... ........... . .. 14 C.S. Qts. Radia tor c ap ... .. ....... ................... ... ........ ..... ............ ... .... ... . . ..... ...... ...... 4 P SI Thermostat ... ......... ..... .............. ... ..... ... ...... ........ .. ........... .... Start to open at ap pro xi mately 177"F. Fully Open at 202"F . Cold weather coolant ......... ... .... ..... ........ Re putable top brand "High Bo ilding Point" Anti- Fre<'ze Radiato r .. ....... .... .............................. .. ..... ........ ... ........................ Hea vy Du ty Vin and Tu be Type
Engine Oil Filter Type ............ ......... ..... .. ...... ...... .... .......................... ...... ........ ............ .. .
Full Flow s pin on tYPE"
Capaci ty ... ........................... ...... ... .. .. .. ... ...... .... .. .. ... .... ......... ............. ...
.. .. ... ...... 1 C.S. Quart
Filter rep lacement ......... . .. ...... ... .......... .. ... ....... .. ........ .. ..... ... ....... ... ...............
Every 240 hou rs
Air Cleaner Dry type ................................. .. ............................................................... Re placc'3 ble Elemen t Cha nge Interval .................... .. .............................. Every six washings or more oft('n if required. Ele m ent service inte rval ...... ........... When the re d sig nal a ppears in the clea r plastic window of t he restric ti on ind ica tor. Dust cup c heck ........... .. ..... .. ......................................... .... ....... . ... Whc'nevN eleme nt is serviced. PRE·SCREEN ER Se rvice Interval . . " . .......... ... .. .... .. ........... .... .. .. , ............ ... ... . ........ \Vh eneverclcm0nt is serviced. RESTRICTION INDrCATO R Replacement ...................... ..... .. .............. ......... .. .. ....... When the red sig nal do('s not d isappear a fter severa l r esets or dOt'S not m eet the speci fi cation given below. DONALDSON NO .
INCHES OF WATER
I THES OF
:--:0. A59568
RBXOO·2 254
27.7" to 32.3"
2,(14" to 2.37"
CAS E
ME RCCRY
12·12
Fuel System FUEL FILTERS (Spa rk Ignition IOngine) Fuel strainer serv ici ng
................. ....... ... .... ...... ........ ...... .. .... ................. Every 240 Hours
Fuel filter replacement ......... .... .. ........... ... ......................... ........... Every 1000 Hours or e a r li er when loss of e ngine horsepower is indicated . FUEL FILTERS (Diesel E ngine) Filter replacement (Final and Primary)
Every 600 hours Or e arlier when loss of engine horsepowcr is indic ated.
Final stage filter ....... ......... .... .. ................................................................ :lO :vTicron F il tration Primary stage filter .................. ... ........ ... .. ................. ... ............. .. ....... 2 to
.~
;,Tieron F iltra tion
Fuel fil ter element s pr ing: No. of coi ls (active) ................ .... .................. .. .................... .................... .. .. . ................. 5·1 / 2 F r ee le ngth ................... ....... .. .. ....... .. .. ... .. ............... ......... ........... ..... .......... ................... 1.120" Wire diame te r ............................................................................................ ... ........... ........ 060" l. D. of spring
,6.15" to .665"
FUEL TANK Capacity ........ ........... ........ ....... ......... ............ .... ........... ............ .. ... ............. .... .. . . 22 U.S. Ga ll ons Water trap ........................... ... .. ......... .... ........... ... ........ ......... ... ... .. .............. .. ......... . Drain daily FUEL 1NJECTIOi\ PUMP Type ...... ....... .................... ..... ......................................... ..... .. .. .......... Roose iVIaster, Model DB Rotation ...... ... ... ............. .... ... ... ................... ... ... ..... ........... .................... ....... ... Counter· clockwi se N!o un ting ..... .... ...... ...... ........... .. .. ....... ........... .......... .. .......... .. ............... . Left hand side of engine Drive ........................ .. ...... .. ........ .......... .. ....... .... ......... ............. Gear driven at 1/2 cngine speed Lubrication ........................... .... ............................................................... Self lubrica teci by fu e l Governor ........ ........ .. ..... ...... Cen trifuga l type, variable speed, fl ywe ight, integra l part of pump TIMI NG
Timing marks ................. Located on cranksha ft pulley (0 0 to 35" BTDC) and (0'1 to 1.111 ATDC) tim ing pointer loca ted on timing gear cover.
1750 RPM Rated Engine Speed .......... ........... ................ ......... ............... .......... ............. 4" BTDC 1850·1900 RPM Rated F: nginc Speed
8° BTDC
2000·2100 RPi\ll Rated Engine Speed
8' BTDC
12-13
Fuel System (Continued) TLvlI0:G (Continued ) 22(J0-22'50 RPM Rated e ngi ne Speed .... ............... .......... ............... .. ...... .. ...... .......... .. .... . 8" BTOC FUE L [:\.JECTOR Ty pe ...... ...
...... .... _.... _........... ........... ......... .. ................... ..... ........ Roosa Master-Pencil
Opening pressu re (nev.)
2750 to 2850 PSI
(servic ed) ........ ...... .............................................................. .. .............. 2550 to 2650 PSI Ma ximum opening prt'ss ure differt'nce betlVee n cylinders ............................................. 100 PSI Valve lift .................................. .. ........ .. ........................... .. ....... 1/2 turn off valve seat or .009" Spray orifice size ......... ........ .......... .. ................................................ ............. ........... .. ...... .. .011" .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 shut·o~f sOlenoid. Magnetic fue l shut -oli sole noid ................................ ....................................... " ........ ....... 12 Volt Idle Speed adjustment ...................... ...... ...................... ... ......... _......... ................. 600 to 650 RPM Idle mixture adjustme nt ............................................................... Appmximately 1 (urn open Load adjustment ........................................ ,............. .. ................ Approximately 2 turllS opens Floa t ad justment ............ ........ ................ ......... .... ........................... ........ .. 1.156", without gaske t Venturi (at narrow point) (l88G) ........................ .... , ............................................................ 78" Venturi (at nan'ow point) (l59G) ............................ , ....... ..................................................... 74" Main je t (l88G i ......... ........... .......... , ........ ............................. ..................... ....... , ..... ............. 049" Main jet (159G) ..................................................................................... .. ............................ 037" Main discharge jet .................. ......................................... ............. ... ......... .......................... 118" Well vent jet (l88G I .................... .. .................................................................... .... .............. 039" Wetl vent jet (159G) ......................................... , ............. , .............. .............................. , ...... .051 " Idling j et (l88G) . ......... ..... .. ............................ _.. .................................... . .................. .. ......... 025 "
12·14
Fuel System (Continued) C\RBCRr-:TOR (Continued ) Idling jet ( 159G ) ...... ............ .... .... ...... ....... ........... ... . .. .......... ....... ..... ...... .. ...... ..... .. ............... 020" Float val VI' sea t (l88G) ...................... .... .. .... .............. ...... .... .. .......... .. ..... .. .. .. ".".... .. .......... .069" F loa t va lve sea t ( 1~9G) ... .. ................... .. ......... .................. ............ .. .. . " .. .. .. .. .... .. .. . ............. .078" Idle air bleed ( l 8SG) ........ ..... .. .. .. . .. . ...... ...... ". " ................................................................... 055" Idle air bleed ( 159G) ............................................................................................... 059" Choke Lever spring: Number of coils ............... ..... .......... .... 18 Wire diameter ................ ........ .......... .031" Free le ngth ..................................... . 1.000"
Idle adjusting need le spring: Number of coils ............................... 4·1/2 Wire diameter ................................... 040" Free length .......... .. ...... ...... .......... .... .469"
CARBURETOR (148G) Type ..............................
.. ............. ... ................. Marvel·Schebler Updraft, Single Ven turi with shut ·off sole noid. ylagnetic fuel shu t·off solenoid ......... .. .. .. ............ .... ....................................... .. ................ 12 Volt Idle Speed adjustmen t ..... .................... ... ... ....... ... ..................... .. .................... 600 to 650 RPM Idle mixture adjustment "''''''''''''''' '''''' '''' '''''''' ''''''' '''''''' '''' ' ''''''''''' Approximately 1 t urn open Load ad justm ent ......... .... ...... .......... .. .............. ..... ........ ................... Approximately 2 turns open Float
.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 ............. ..... ..... 4·112 to 5 1. D. . .. " .... "" " ...... ",, .. ".................... .165" Free le ngth .......... ........................... .281"
Brakes Type flui d
......... ..... .............. ..... .................................... .......... .... .. .............. ... .. .......... Case TCH
Free pedal
........................... .... .......... .. ...... ...... ..................... 1·1/4" to 1·3/4"
Brake Pedal Return Spri ng: Free Length .................................................................................................. " .. ... .... ....... 4.625" Wire Diameter .............. ....... ........................................................................ ........................ 135" :\0. of Coils
... .. ................ .. .................................... ....... .............. .. ........ .. .. ...... .. ........... 22·1/ 4
12 -1:;
Brakes (Continued) Disc Spring: Free Length
................... _............ . ...... _...... ................ ........ .. ......... ............ ... ......... 1.27"
Wire Diamete r ... _... . ......... ... ................................................................................. .. ....... .. .0857" No. of Coils ............... ..... ..... .. _.............. . _................ ... .. ... .. ..
10·114
Expand to 1.37"
22-1 /2 to 27-1/2 lbs.
Retractor Spring: Free Length ............ _............ ..... .. . _..... ............. .... . ... .......... .............. _............... .. .. ............... .. 66" Wire Diameter ... _................ ................. ... .. .... _.. ..... ............. .. ..................... _... ... .. .. ...... ....... _ .060" No. of Coils ..... ......... .. .. ........ ... .. ............ _...... .. .......... ....... .. .................. ............... .......... .... .. 5-3/ 4 Expand to .74" ........ ........ ........ .. ...... -........ .. .... .......... ....... .. ........ ...... ......... . ............. . 9 to 11 lbs.
Power Train S HUTILE TRACTORS Reverse id ler gear bu s hing 1.0. (burnished) .. ................. ........ .............. ............. .. .. .862" 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 ..................... .. ................ ..... ..................... ..... . .. .... ......... ............... ........ ........ 1·911 6" Wire Diameter ...... ................ ...... .. ... ............. .......... .... .. . .. .. ................ .. ... . ........ ...... .............. 056" No. of Coil s ................. ..... ............. ............ ....... .......... .......... ....... ................... ... .. .. . ..... ........... 11 Compress to 1.2;;0" .............................................. .... ...................... .. . ..... ........ ..... ..... ... 19-112 Ibs.
12·16
Power Train (Continued) HYDROSTAT1 C TRACTORS Forward· Reverse peda ls free travel ..... .... ........ ... ...... .. " ... . " ..... .................................. 1/4" to 112" P ini()n shaft bea r ing preload
" ."""""." " ... " ." .. """.".",, ..... ,,"" 4 to 12 in . lbs. rolling torque
Dump valve pad to lever clearance """" ..... . " .. "" .... . " ..... .. ................... "" ............... .. " .. ,, .... . 045"
Steering STEERING HAND PUMP Steering sh a ft 10 body clearance
.006" Max.
Rotor to stator clearance .................. ....................... .. " ... .......... ..... " .... . " .. " ....... " .. " .. 005" Max.
STEERING CONTROL VALVE Centering Spring: No. of Coils .... " ................. .... ........................ " .. " ... ................ " .......................... " .................. 6 Free Length ............. " ...... .. .... ... .. .......................... " ................................... ... .. ........ ..........860" Wire Diameter .................... ....... ................... ... .......... ...................... ................................. 080" 1.0. of Spring ......................... ......................... ................ ........ ........... " ............. ................ 625" Compressed to .824" ................................................ " .. ............................................ 1.5·2.5 lbs. STEERING AXLE Front wheel toe·in ........... ...... ....... ....................... ............ ...... ............. .............. ... .. .............. 1/ 4" Front pivot pin bushing, insta lled and removed 1.0 ........................................... 1.744" to 1.746" Rear pivot pin bushing, installed and remove d 1.0 ...... .. ................................. " ..... 863" to .864"
12-17
GENERAL TORQUE SPECIFICATION TABLE ( Rev i sed 6 - 67) USE THE FOlLOWING TORQ UES WHEN SPECIA L TORQ UES ARE NOT GI VEN NOTE: These val ues apply to fastene rs as r e ce ived fr om s upplier, d ry , or Id len lub r icitte d with 1100'm a l engine oil. T he y do 11 0t " pply i f s pcc i;!1 g- r" l'il ite ct or moly- di sulphi (le gre3ses or other extre me press ure luh r ic.mts" re used. Thi s " ppl ies to both UK F anel U:\C t hreads. 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 1·2 916 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 9·80761
Rat. Form 9-80741
SECTION 13 MAINTE
ANCE
AND LUBRICATION FOR LOADER AND BACKHOE
Burl. Form 9·720815 KHCa O
Printed i n
U .S .A.
L UBRICAT ION 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~
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.
2
Section
22 CYLI N DER HEAD AND VALV ES 188 DIESEL ENGINES
SPEC IFICATIONS Maximum Limit CY LINDER HEAD Including Wear Warpage .......... ....... ...... ........ ...... ...... .. ............ ....... .. .... .... ........ .... ... ... ......... ............... .. ........ 006" EXHAUST VALVES Tappe t Cleara nce (Hot and Cold ) .... ................ ....... ....... .. ................... .. .......... 0)4" Face Angle ..... ............... ............ ........... ... ........ .... .... .. .... .... ..... .......................... 44" Face Run·Out ........ ................... ........ ....... ....... .. .............. .................................................... 002" 0.0. of Head .. ......................................... .......... .. .. .............. ... ....... 1.398" to 1.408" 0.0. of Stem .. ... ..................... .... .. ................. ........................ ......... 3399" to .3409" ....... .... . .002" Le ngth ........................................................................................... 6.339 " to 6.364" Insert Seat Angle ........ .. ..... .................. ................ ..... ...... ... .. .. ............... ............ 45" Sea t Face Width ......... ................. ........ ...... ............... ........................... ........ .0415 " Seat Run·Out ......................................... ....... ..................... .. .......... .... ..................... ............. 002" Insert Height ........... .... ......... ........... ... .......................................... .2475" to .2525" O.D. of Insert ............................................................................. 1,4450" to 1.4505 " 1.0. or Insert ................................................................................ 1.245" to 1.255" INTAKE VALVES Tappet Clearance (Hot and Cold ) ................................................................... 014" F ace Angle .... ....... ........... ............ ............. ........ ................. .. ..................... ........ 4411 Face Run-Out .......................................... ........................................................................... 002 " O.D . of Head ...... ........... ......... .............................................. ......... 1.599" to 1.609" O.D. of Stem .................................................................................. :3409" 10 .3419" ............. 002" Length ........................................................................................... 6.339" to 6.364" Sea tAngle ........................................................................................................ 45" Seat Run-Out ............................................................................... ... ............... ....... .. ...... ....... 002" Seat Width .......... .. .. ........ .... ... .. ... ............................... .......... ...... ...... .082" to .094 " Rae. Form 9-80471
22·2
SPECIFICATIONS (Continued)
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 CÈuirU%I" Protrusion Above Cy lincler Head ............ ...... ............... ...... ....... .. ....................,875" 875" Cylinder ................................................................... 1 Â¥
F Ã
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
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 mc·t 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 leak·off 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
1
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 25·30 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
22-5
®---
, .'
-
@I-- -
\-
~
,
e., •
I I
o --® INSET A
TIGH TEN IN G SEOU ENC E
22·6 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 970·7), 970-7), cla clamp NOTE : cylinder sleeve in place, Figure 7. NOTE: The plate OTC 970-7 970·7 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
1
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
1
CYLINDER SLEEVE PROTRUSION R BLOCK CYLINDER
Figure 6
A40682 BAR A4 0 682 CLAMPING B ", A", R_.?!
aTe 9 70 · 7 PLATE
B
A . 0. C AND 0.'" AT POINTS A.
J
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
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
22·12
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
1
1
1
,.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
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 perrOt·ma nce. This fine pitting Is c aused by a norma l oxid ation process and can happen on any engine eluring the r un- in peri od. It Is not necessa ry to grind val 'es 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 -
1
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).
22·13
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.
r
.010"
EXHAUST VALVE
I .01 0"
/Â
-
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
o
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-
\ \
•
c
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
E
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 & 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 ..... ..... ..... .. ................ ...... _.................................. .... ... ... _.... ........ 2·3/8" Tota l Coils .. .............. ..._........... ........ .... _...... _....... _.... _..................... _............... 8-1/4 Wire Diameter ............. .... _.. ......................... ... ....... ......................................... 162" J. D . ... ............. .. .. .............. ................ ....... ..... ................. ..... ..... .......... 958 " to .978" Compressed to 1.521" (Valve Open) ............ . _......... .... .. ..... ........ _..... 110 to 118 Ibs. Compressed to 1.875" (Valve Closed) ... ......... ..... ..... .......... ....... ....... ... 53 to 59 Ibs. ROCKER ARM ASSEr.mLY 0.0. of shaft .... _.. , ..... _.. , __............. ,... .......... . , ..... ...... .............. ... " .. ...... 622" to .623" l. D . of Rocker Arm .... _... ............... _................................ .............. .624" to .625"'
(Installed and ReamE'd on 148 and 159) Shaft Spri ng (188 and 201): Free Len gth .......... _................... .... ........ ......................... ........ .. ......... .. .... _ 2-112" 1.0 ........................................................ __ ..... _._ ........... _........ _......... .......... _ 11/16" Wire Diameter ........ __........ __..... __ ...... __ .... _.. ..... _..... . _..... . _.. _........ .. .................. 072" Compressed to 1-3/4" ................... _... .. ............... ..... ............... ........ 7.5 to 8.5 Ibs . Shaft Spring (148 and 1. .09): Free Length ..... ... .... .. ... ................... _...... ....... _... ............................. .... . ...... 1-3/ 16"' Total Coils ..... .... ... _...... . _.. ... .. ........... ....... ......... _...... ................. .... ............. .. ... .. . 7 r.D .... ... ..... . ... ......... ............................ ...... ... ........ ..... ............ .. ........ _.......... 11 , 16" Wire Diameter .... ............ _....... _.. .................................................................. 072" Compressed to 11116" ..... ......... .. •...•...... ............................... .. __ ...... 7.5 (0 8.5 lbs. Lubrication .............. .. ..................... _........ ..... .. ....... Engine oil, camshaft metering . Shaft Oil Holes ..... ..... .. _...... ........... .... ...... _............... Toward valve side of engin.e . Shaft c annot be r otated .
SPECIAL TORQUES Cylinder Head Flanged Nuts (188 and 201) ................... ...................... .. ...... ..... .... 9lJ to 100 it. Ibs. Cylinder Head S tud Nuts (148 and 159) ............ .......... _...... ........ .... ...... ... ... ......... 9,1 10 105 ft. Ibs. fn take a nd Exhaust Manifold Stud Nuts .................. ............................ ..... ... ....... 2.5 to 30 ft. Ibs. Rocker Arm Bracket Stud Nuts and Bolts ........................... .......... ... ................ . .. 25 to 30 ft. Ibs . Valve Cover Stud Nuts " ......................................................... _.. ... ................. . ... ..... 5 to 8 fUbs_ Water P ump Stud Nuts .. _.................. .. ............ .... .. _..... . ........ ..... . __ ... ........... _... . .... 20 to 25 ft. Ibs. Spark P lugs ............... ........................................... .. ....... _... .......... ... ... .... .......... ..... . 32 to 35 ft. Ibs.
22-4
CHECKING COMPRESSION PRESSURE 1. Clean the engine thoroughly , preferably by 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).
i
lN"imA-- - - - - - INSET A
1'0 11
10
OS
Figure 5
22-9
22·10
CYLINDER HEAD AND COMPONENTS (Continued) 188 AND 201 (Refer to Figure 6) Disassembly Remove the muffler a nd hood from the vehicle. Steam clea n the enti re engine area where ser vice wOl'k is to be pe rform ed. Disconnect and remove the a ir cleaner system . L Drain the cooli ng system. CAUTION: If 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
o
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 brackr·ts 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:'
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
2:1·18
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
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
I
.844"
"
"
-'-
INSET C
.0312 "
INTAKE VALVE A SSE MBLY
,
EXH AU AS SSE™ VALVE SLY
22·20
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
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e
! INTAKE VALVE ASSEMBLY
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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 fE·felTing 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
I
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
22·2i
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.
I
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G AI NOING~A~ N~ G:.I:.LE~ ~~=~~=~=
IN TAKE VA LV E AN D VALV E SEAT"
1
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
A
B
.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 .............. .... ............. . 1·3+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
D
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·
c
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~
. .. ... . ", ...... ...... .... ........ ...... .. " ....... ...... .. ....... .... ..... _............... ... ......... ... 23·2 10 23-7
Spcda l Torqlle~ .. , .. ... ......... _.. __ . " .' ........ .... _... ... , ... .... .. .. ..... , ...... ..... .............. . _......... ,_ .. ............ 23·i Engi ne Lu br lc.:lt ion .. . .. .......... ... ..... " ....... ...... .... ..... . .. , ..... _.. " ... _." .... .......... . __ " ,., ... ... " ... " .. . 23·&, 23·9 Flyw~l, Oil Pa n. seal R ('ta~ ne r and Oil F'ille r .... __..... .. ........ __." , .. .. " .... . ..... "" ... ... 2~ - HI to 23- 13 Dil':lcl Tim Ing Gear COH'r , Gears and Wa ter Pump ........... ............ . ... ... ..... ............. 23- 1-1 10 23·}7 Spa r k Igni tio n T iming r. ell!" Cover, GM r ana W." c r Pump ... ..... ..... ................ ... .... 23·,81023-2 1 C;un s ha fl , Bus hings and Li fre rs ........ ... _.. ........... .............. ........ .... ........ ........ _ ... , .... . , 23·22 10 23·25 P isTons . Rings, Sk'cl-'es a nd ConnecTing Rods - Dis a sseml)ly . inspeCT ion ____ .... .... .... ... ~ 3·2.(j , :13-27 Cy li nde r Sleev('s . Inspco:.'t lon . .. ...... ... ... _. ..... .. ...... ... ............ .. ... .. .. .. .. ..... ....... .... .. ..... ..... .. ... _, .. 2.1·28 Cyllns . Dt'gla zi ng . .. ____ .. , ... .. . , .. __ _.... __ ... , __ .. ... ... ..... .. .... .. ... .. ... ... __ .. ............ _______ .. .. 23-29 Cyll ndcr Sleeves· Hon inv. .. ..... ... .... ... .. . .... ............. .... ....... ..... .. ....................... _ ... ... ..... ....... _ 23-.1(1 Pi s tons a nd Cy lin der Sleev(,s . Inspc<:llon ...... .............. .......... .. ................... .. .......... __ , .... ..... . 2,l·31 P IsTons. Ri ngs, Sleeves and Co nn ecl!n g Rods · AsS("m bly .... __ . .. ...... .. ..... __ .. .. ..... ...... 23 · ,1~ to 23·35 Cra nkshaft , Bear ings, Linc n and Oil f'wn p .. " ... ....... .. .. " .... " ..... " ... ... ... .... ..... ..... .. :!3-3G to 23·39 0 11 Pum p ... ....... ..... .. ...... ..... ......... " " ', .......... . ..... ... .. ,_.... ..... ... .. .. .. .. .... ........ . .. ......... _... 23· ~O. 23·4; Thermos ta t and F .ltl Bell , .................. .... ..... " ... .. ... .. .. .... .......... ___ .. ............ _ . .. . _... __ ... 23- 12.2J·1:I Loea llng: Top o.~a d CenTe r ..... .. ... ..... .. .. .... .......... ... ..... ......... .... ..... ... ....... " ........... .... ... . _. , ..... .. 23-4-1
R:>e f a.m 9_8043 1
23·2
SPECIFICATIONS :\OTE: All dimensions are given in inches. Specifications apply to all engines unless noted.
Maximu m Limit Including W,,'ar CY U:\OER SLEEVES LO. of sleeve (159G) ............................................. 3 ..5013 to 3.5028 (1880 ) .............................................. 3.8113 to 3.8125
.00;)
....... . .......................... 3.8130 to 3.8145
.OO~
(148G ) .............................................. 3.3745 to 3.3765
.OOS
(188G )
Sleeve out· of·round ............................................................................................................ . .004 Clearance to bottom of piston skirt (l 88D) ................. 0035 to .0055 (188G) ................. .............. ........ ......... 0025 to .0035 (159G)
.0015 to .0043
(148G)
.0030 to .0035 .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
23·4
SPECIFICATIONS (Cont'd) :Vlaximum Limit lncluding Wea r PlSTON PIj\' Type ............ .... .......................................................... Full Floating 0.0. of pin (1880 ) .............................. .. ................... 1.2497 to 1.2198 (188G. 159G) ........................ .................. 9991 to .9992 (148G) .................. ................ ............. 8592 to .8593 Fit in piston (1880) ................................ ..... ............. 0002 to .0006 (188G, 159G) .................. , ...................... 0000 to .0003 (148G ) .......... .... ... .............................. 0000 to .0002 Fit in rod bushing (1880 ) ...................... ..................... 0002 to .0006 (188G .159G ,148G ) ............ ... ..... .. ........... .. 0003 to .0006 C01\NECTl:\G ROD Bushing ..................... " _" ............. _... , ............. .. Replaceable Bronze
Bushing 1.0. insta lled (reamed to size) (188G,159G) ........................... .... ............ 9995 to .9997
.001
(1880) ...................... .. ................ .. ..... 1.2502 to 1.2504
.001
(148GI ............... ................. .. ................ 8596 to .8598
.001
Bushing out·of·round
.0015
Bearing Lin<>rs ............................................... ... .... ...... Replaceable Bearing liner width ..... ....................... ....................... 1.120 to 1.130 Rod width at crank e nd ............................. .. ........... 1..3035 to 1.3005 Journal 1.0. without bea ring liners ......................... 2.1870 to 2.1875 Bearing oil clearance ................................................. 0010 to .0035
..... .......... .................. 006
Undersize bearings for service ............................... 002,.010 •. 020,.030 Side clearance ........................................ .. ...................... 005 to .Oll Cap bolts ................................ .. ........................... Self locking type CRA:\'KSHAFT Type ........................ ... ..... .... ..... . .... .... ..... ........ .... ............. Ba la nced Main bearing liners .......................... ..... ............ ..... .... Re placeable End play , center main bearing cap ............................... 001 to .006 Thrust spacer std. thickness ........................................... 092 to .098 Connecting rod journa l std . 0.0 .............................. 2.0605 to 2.0615 Grind to .010" 0.0. undersize ............... .................. 2.0505 to 2.051.5 .020" 0.0. undersize .......................... 2.0405 to 2.0415 .030" O. O. unders ize .......................... 2.0305 to 2.0315 Connecting rod journal maximum taper ............................. ... ...................................... .... .... 002
23-5
SPECIFICATIONS (Cont' d) Maximwn Limit Including Wear CRANKSHAFT (Continued ) Journa ls out-of-round .. .......... _... ........ .. .. __ .. ... ....... ... .. ..... ..... _..... .. 001 Main bearing liner width 1st , (ISS0, I SSG) _... .. ........ .. 1.276 to 1.286 Ma in bearing liner wid 1h 1st, (159G , 148G) ................ 1.870 to I.SS0 Ma in bearing liner width 3rd (ISS0) .......................... 1.371 10 1.373 Main bearing liner wid th 2nd (I SSG) ................ .. ....... 1.371 to 1.373 Main bearing liner width 2nd and 4th (188D) .. ....... ..... .950 to 1.000 Mai n bearing line r width 5th (1SSD) , (ISSG 3rd.) ...... 1.557 to 1.567 Unders ize main bea ring liners for service ............. 002,.010,.020,.030 Main bearing oi l cleara nce .. ........ ...... ... .... ....... .. ......... .0012 to .0042 Main bearing journa l sid. O.D. (18SG , ISSD) ..... _.. .. 2.8730 to 2.8740 (l59G,148G) ....................................... 2.6230 to 2.6240 Grind to: .010" 0. 0 . unders ize. (ISSG, 1880)
2.8630 to 2.8640
.020" O.D. underS ize , (l88G, 188D )
2.8530 to 2.8540
.030" O. D. unders ize. (ISSG, 1880) .... .... ............... 2.8430 to 2.8440 .010" 0.0. und ers ize. (159G, 14SG ) ....................... 2.6130 to 2.6140 .020" O. D. undersize. (159G, 14SG) .. .... ................. 2.6030 to 2.6040 .030" 0.0. und ers ize, (159G, 148G) .. .... .... ........ .. ... 2.5930 to 2.5940 Mai n Journal bo re I.O. w l o liners (ISSD, 188G) ...... .. . 3.066 to 3.067 (159G,l48G) ...... ................ ...... ...... .. ...... 2.816 to 2.817 Main journal width be tween cheeks : 2nd (159G, 148G) ...... .... .... ................ .... ........ .... ...... 1.499 to 1.502 2nd a nd 4th (1880) ............................................... _.. 1.185 to 1.189 2nd (I SSG) ................................................. -.. .... ... 1.3770 to U740 :lrd (1SS0 ) ........ .. ......... .. ...... ... .............. ....... ......... 1.3740 to L1770 3rd (159G, 148G) ............... ... .... ...... .. ............... .... ...... 1.741 to 1.75 1 5th (ISSD ) ._....................... _.................................... 1.745 to 1.755 Connecting rod journal width betwee n cheeks .. ..... .... 1.3105 to 1.3145 CAMSHAFT Type ....................................................... .. ................. .... .. Parabolic Bu sh ings (188D ) ......... _........ .. .. .. ..... ...... .. .. ........... .... . 5, Replac eable Bushings (ISSG) ................. ..... .... ....... ..... ... , ... .. .. ..... 4, Replaceab le Bushings (159G, 148G) ... ....... _... ..... .. ................... ..... 3, Replacea ble Oil Clearance ... _............................................................. 002 to .00:,
23·6
SPECIFICATIONS (Cont'd) Maximum Limit Including Wear CAMSHAFT (Continued) Bushing lubrication: Front bushing .. ,...... , .. "' ... , .. ,',., ... " .... ', .... ,..... Pressure lubricated from oil pump, Intermediate bushing ................................. Gravity flow lubricated Rear bushing (1880 On ly ) ....................... Pressure lubricate d with rear oil meterIng. Oil clearance ................................................................. ,002 to ,005
............................... ,007
1.0, of bushing installed ........ ... .. ................................ 1.752 to ,1753 Bushing width: 1st (front) (lS9G.H8G) .......... .................................. 1.307 to 1.317 1st (front) (188D.I88G) ........................................... , 1.213 to 1.223 2nd (lS9G.H8G) ...... , ............ ..... , .. ........ , .............. .......... 713 to ,723 2nd. 3rd & 4th (1880) ........................................ ......... .490 to .500 2nd. & 3rd, (l88G) ...................................................... .490 to ,500 3rd (rear) (148G, 1S9G) ........................................... 1.177 to 1.197 4th (rear) (I88G) .................................................... , 1.213 to 1.223 5th (rear) (l 88D) ..................................................... 1.213 to 1.223 0,0, of each bearing surface (159G. 188D ) ............... 1.749 to 1.750
.004
0,0, of each bearing surface (l48G,l88G) ............... 1.749 to 1.750
,004
Thrust plate thickness ................ " ............................... 149 to .147 Camshaft end play ....................... ... ..... Taken up by thrust pIa te Camshaft end clearance ............................................ , .003 to ,007 VALVE PUSH ROD LIFTERS Type ,., "",.".,,', .. ,,', "" ,.. ,"',.,.," "' ..... "' .. ' .. ,' .... ', ...... ", .... ,' Mushroom Body 0.0, std, ...................... ............. ........................ , .5615 to ,5620 J.D, of block bore, std, , .............................................. ,5625 to .5635 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
23·7
SPECIFICATIONS (Cont'd) Maximum Limit Including Wear IDLER GEAR 0,0, of idler gear journal (Diesel) "'"''''''''' '' ''''''''' 1.3740 to 1.3755
""",,"""",,",, ,"""" ,0005
J.D, at idler ge ar w/ bushing (DiesE'l) "'"",,.""" "" "'" 1.376 to 1.377 Thrust washer s hims (Diesel) """, .. " " ""."", ... "". ,005,,006,,007,,009 Idler gea r end play (Di esel) ",. """ """ " """" """"" """""."".""" ""." ". "'''''''"."''''''',,'',, ,003 OIL PUMP FRONT MOUNTE D Positive displaceme nt pump """."""."""""" .. ""." ."." , Gear Type Pump gears to oil pump cover c leara nce "" .. """ .. "" ,0015 to ,0055 Pump gears radial cl eara nce ""."""",,,,,,,,,,,,,,,, ... ,,,,,,,, ,002 to .005 Drive gear to body c lea ra nce (l88G,159G,148G) ,,"'''''''' ,003 to ,006 Drive gear to body c lea rance (1880) .""".""".,, " ,,.,,. ,0035 to ,0065
Relief valve spring: Wi re thickne ss (I88D ) "" """ """"""""" .""" ". """." "." """ ", ,0625 Maximum 0,0 , (188G, 159G, 148G) """.""." ... ". " """.".". " .""." , .469 Maxim urn 0 ,0, (1880 ) " . "." """"" ". "." """""" """,,.,," ". ,,"" .4844 Free length (188G ,159G, 148G) ".""" ."""".""" " .. """" " .. """"""" 2 Free length (1880) '''",,'' "",," "'"'' """. "" "" """ """" """,",," 2·118 Load at 1.:38 inches (188G,159G,148G) " ",," ,, """ " 6·3/ 4 to 7·1 / 4 lbs. Load at 1.44 inc hes (188D ) ""'''''''''''''''''''''''''''''''''''''' 18 to 19 Ibs, Oil pressure (188G,159G,148G ) .".""""."""" .. " .. " "." ". 24 to 32 P SI Oil pressure (1880) """"""""'"'''''''''''''''''''''''''''''''''' 50 to 75 PSI Backlash , crankshaft d rive gear and oil pump gear "'''''' ,002 to ,008
SPECIAL TORQUES Camshaft nut """""""" .. """ ""."."""." "" """ """ """" " """"".".". " .. """""."" 80 to 90 Ft. Ibs, ConnE'cting rod nuts '"'' '' .. ''." .... "" .... " .. " .. "."''" .. " .. '' .. " .. "'' ... ,,'''',, .,,,,''''''''' '',,''' 45 to 55 Ft. Ibs. Cra nksha ft nu t "" "" ""' ''". "'''''' .. ''''''"' .. .. "'''' .. ''"." .. ,,.,,.,,'',,'''''''''''.'',,''.'',,.,,'' 125 to 135 Ft. lbs, Flywheel to crankshaft bolt """.""""""" .. . " ." ""." " .. """ .. "." ."" "". " ."""."""" 65 to 70 Ft. lbs , Main bea ring cap bolts "" "" """ "" """,,,,,.,,,,,, ,,,,,, ,,,,,, ,, ,, ,,.,,. ,, ,,.,, .. ,,,,,,,,.,,,,,,,,,,, 90 to 100 Ft. lbs , Oil pan capscrews (Sta mped steel ) """ "" ""."" " .. " .. "."." ." "". " .. """""""".""" 10 to 12 F t, lbs. Oil pan capscrews (Cast iron ) """""""" "" "'"''' ''''' ''' ' ''''''''' '''''' ''''''''' '''''' '''' '''' '' 24 to 28 Ft. lbs, Oil pa n to seal retainer """ """ .. " " ."" """" " ."."".", .. """ "" ".""" ... "" .. "." .. "" . 15 to 20 Ft. lbs. Oi l pa n drain plug " .... """"""" ." """" "". " .. """ .. " .. ",, ...... ,,""" .. ",," ,, .,,,, .. "",," 18 to 20 Ft. lbs. Oil pump cover capscrews "".""''', .. "''''" .... ".".""." .. ''". ,,'' ,'''',,.,, ,, '',,'''''''''' ... ,,'''' 6 to 8 Ft. lbs, Oil seal r etai ner bolts (Grade 8 bolts) "" ..... " .. "" "" .. . " .. "" .. "" " .. " .. ".""" ..... " ... 12 to 15 Ft. lbs. Fuel pump drive gear nut (Diesel) .""" " .. "". " .... ".""" .... .. " .... "" " .. ,," ,,.,," ",,. ,,, 35 to 40 Ft. lbs.
23-8
ENGINE LUBRICATION
DIESEL ENGINE
-..
ROCKER ARM SHAFT
o
FULL PRESSURE
o
METERED FEED
o o
SUCTION FEED
INSET A Engine 61
k
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
I
Cam shaft G(!ar
t
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
0
0-00 0
a
.s.. O~ 0 0
0
0 Q
0
0
0 O~
... r
")
- ,..
w::~=rl \
~
0
0
- .
000-0
0
Q
o~
""O~:;:;:=l[::~:
-
1
\'---- ----...1:
PRESSU RE Rel i Ef VAL VE ( Set 710 9Ib s. )
PLUGGED Oil FILTER
CLEAN OIL FILTER Figure 3
23·10
FLYWHEEL, OllPAN, SEAL RETAINER AND Oil FilTER (Refer to Figure 4}
Disassembly 1. Remove the oil pan drain plug (1) lVith 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'
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 vc·way 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
4
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
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
0
OIAl IIliD ICATDR
INSET A
.560 "
FA N .
Figure 7
23-18
SPARK IGN ITION TIM I N G GEAR COVER, GEAR AN 0 WATER PU MP (Refer to Figure 8) Disassembly 1. Remove the fan (1) and fan pulley (2) . 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
J
I
I I I
INSET B
-RUN-OUT NOT TO EXCEED .010 "
FACE MUST ....---BE SMOOTH
7
Figure 8
23-20
SPARK IGNITION TIMING GEAR COVER, GEAR AND WATER PUMP (Refer to Figure 9) Assembly l. Install key (24) to camshaft and press on
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
23·22
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'e·center 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"
•
i
~@
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-' '@
I
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
g
I
(~j
-
5 / 16" -
PRE SS flUSH WITH BLOCK
-
CD\---
/
~ REAR
l
T /':\0
cP
REAR
INSET E 188D,188G,159G AND 148G ENGINES
,
0 0 &-0
B1U_'7S/ H312N"G
\
INSET B
\
I
ALIGN OIL HOLE
~~CD~, 1 / 32"~
PRESS FRONT BUSHING WITHIN 1/32" OF FRO NT FACE OF BLOCK
7
---- -
,
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
I
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
a
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
D
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 Run·ln· 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 Run·ln·Procedure 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 run·in 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.
c
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
0
INSET
E
KEYSTONE TYP E
~~---0
,""WJ~~ . 'r~ J'C ft~ ~~ ,0 cb Q)
STAMP ED NU MBER
Ii
~
6
(]) (j)
._ _
--@~101~N-SE=T-:-H;-----:~-:--. 1
TAPER
FAce
ARBOR
INSET C
INSET G
L
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
D
INSET C
Figure 24
F
2.3·36
CRANKSHAFT, BEARINGS, LINERS AND OIL PUMP (Refer to Figure 25) Disassembly 1. Wi t h the oil s linger (1) removed, use a 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 drive·away 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
,
D
INSET C
\
BEARING CAP
..
PLAS TI ~AUGE SCALE
188 DIESEL
V
FEELER GAUGE
PLASTi GAUGE INSET A
IGNITIO~8
188, 159 AND 1 SPARK
INSET
E
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-
O
INSET C (DIESEL) .0035" TO .0065 .. -....J1-I SPARK IGNITION ) .003" TO .006 "
~
- - ---11--
INSET
Figure 27
D
23·42
SAFETY PRECAUTION CAU'fIOJli : Cilre s hould bo exercised whe n servicing components of the pressurized coo ling syste m or d rain ing the syst em. There is a da nger of being sprayed by hot coola nt when opening drains or removing the r a diator cap. Relieve the pressure by turning the radiator cap counter· clockw ise to the FIRST s top. a llowing a gradual reduction in pressure and minim izing coolant loss . Jl.'E VER pour c old coo la n t into a hot e ngine . The engine block or cylinder head m ay crack by th e sudden co ntrac tion caused by th e difference in temperature be tween t he metal and the coolant.
CLEANING THE COOLING SYSTEM It is recomm ended that the cooling system be clea ned at lea s t once a year. In areas where
water con taining sca le form ing mineral s is a ll that is a vailable, c lean the syste m m ore often . Add any nationally know n commerc ial brand clea ner marke ted by a reputable manufacturere r. rOLLOW T HE DIRECTIONS PROVIDED WITH TH E CLEANER. If water is used in the cooling system during the summ er m onth s, always add a reputable brand rust (or corrosion ) inhibitor.
THERMOSTAT AND FAN BELT (Refer to Figure 28) Disassembly 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
D
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).
24·3
I
I
I -'
,/ ,/
SPAR K IGNITION
INSET 8
IN SET A
I N SET C
.-;:::
Figure 1
24-4
RESTRICTION INDICATOR CHECK (Refer to Figure 2) The r estriction indica tor can be c hecked on a Dis tributor Tester that is equipped with a manometer.
1. Remove
the restriction indicator a nd 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~
r
/
I
~®/~
1/
MODEL NO . 'RBXOO
VACUUM TUBE
I
FILTER FITTING CLEAR OR RED SIGNAL
IN S ET B
1
~~~_ _ _- VAC UUM TUBE
o
~
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
fillrr ,. " , .. " .. ,'" .. , .. ... ........... . " .. " , .. ,', ... .......... .... ..... " ...... ........ :l() :>'I Ic:ron
F iltr aTion
s(;Jgc> ! llter ... ... ...... .. ... ........................... . _.. .. " ....... ... .......... .... :.l to :) MiCron
F'il t ral iolL
:-"um bPr 01 coils .. ... .. ... ... ... _..... ............ " .... _.. ,. ........ ........ ... ,' ... .... _.. ...... .. .... ... ... ....... .... ... .. . 5·1 ·2 F' re<> lC' ng l h .. .. , .. .. • " ... .... ,. _.. , .. .. .. .... .. ...... . ... .... ... ... .. , ..... ... ... .. .... ... .. " .. . ", . .. .......... ........ _..... 1.120"
II··If!? d 1
,. , •.•• •• .•. •• •. . ...... . .. . .. . .... " .•. .. ..... .. ... .. .•• •..• . • ... ••.•.• ••.• •.•. • •. ••• •.• _. ••• ••.. ..• ..• •• ... ..... . - . 060"
1.0.01 s pri ng ......... .. ... ........... ..... ............... ...... ................ .... ... ............ . _._... ... __ , .... '
.6~5"
to .665"
.. ..... .. " .. . " .... . " ........... .... , ... . " .. .. , .... , .. . " .. " ... ,', ... " ....... .. F. v(' r)' l
.... .. ..... .... .. .......... ........ .-. - .. .. Every 1000 hours or ea l11t'f wht>r. loss of "
e ngI ne horsl?;JO'o'· ..... l!i In d i(" I! e
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 shut·oft 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
(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
_
\t
t
t
--
TRANSFER PUMP
l
Itirl:. ~~l'~~~?~~~lj VALVE
t
,-I>'f) I '
'-r'(r t ~
~.~~7
I
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
m
---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
n
32 ROOSA MASTER MODEL DB FUE L INJECTION PUMPS 188 SERIES DIESEL ENGINES
TABLE OF CONTENTS Descri ption ..... .... .... .... ........ .... .... ........... ..... ..... ,' ...... , ......... .. , ..... . , ...... ...... ,... ..... ", ... ..... .. ... .1:2.-2 Remov ing the Fuel [ni CClio n Pump .. . " , .. ........... ... ...... .... ... ....... ', .. ... .... ... ,.,_. _._. ,. __ ___ ___ .. _.... 32·3 I n ~tall(ng the Fue l Injt'CtiOfl P l!mp .. .. ,", ......... ........... .... ........... , ....... ... ... ..... .. ...... ' ..... .. ....... .... :32 - ~ 'nmlng the Fllel I nj(,('tion Pump to EngIne ..... ........... ... ..... ..... ... ... _...... .. ... ..... ...... ,..... .... .. .... . n·B E ngi ne Spt>ed ... .. ... .. ... . ..... .... .... ....... .. " . ....... , ... " ........ .......... .... . , .......... ..... ... ... ... .. "', .. ... ..... ..... 32·7 Check ing Engine S(X.'(.'{l . ..... ...... .... .... ........... ....... ......... ...... ............ ...... ...... . . __._._ , ____ ___ ...... __._ 32·7 No Lo;J(] Governed E ng ine Speed . .. .... ...... ........ " ..... " ................ .. ......... ... ...... ...... . ... . , .. 32 -8 Low Idle Speed A dj ustm en t .. ... .... .. .. ," .. ... •...... . , ......... .......• , ....... ..... ...... .. .. _. . .. __ , ______ _____ .. ___ . 32·9
Special Torques H igh pressllre fuel lin e ('onn ec tion screws ... "" , ...... ...• .... .. ", ..•.. . " ........... .. ____ ... ....... ... .. J.' fl. Ib'iO. FlU,,1 inlet f ilter assemlJlv ... ........ ................... , ...... .. ............. , ... ......................... ....... _...... 10 fl Ibs.
R"".
F~ ' m
9 _8 0421
32-2
DESCRIPTION So me Case Diesel E ngi nes a re equipped 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 t·of[ 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
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
I
DRI VE
I
----~
/
I
I
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
.
D
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
(
Y
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 0·12" 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
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
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
I
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 '
65·1 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
I
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~~.~
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. >t --:c
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Figure 10
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,
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)
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 /
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 . Pag·e 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
SCREW
LI FT A D J USTING SC.EW LOCAT I NG PLAH
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-.........,
I,
PI£5IUIE '
~ / II ADJUST I N G
"~CIfW"
'Q
/
~,
/
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/
/ / INHCTOI/ IODY I
II .
,
WASH ER
UPPU
~ " " HAT
SPIING
I
/
----.All
LOCKNUT
l OWEI SlAT
/
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/
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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 .
/
I
VAL VE RETRAnoR
CO MPRESSION/
HAl r. AUON HAL
f
VAlV E
I
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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 . S€cure the wire in the pin vise wi th the end protrudi ng 1 /3 2". A longer lengt h of wire will bott om on the opposite wall of the sa c 1101(' a nd le nds to break easi ly . Figur(' 22.
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
5
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
I
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
~
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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.
~
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!
B All WA5HfI
UPPEI
FITTI NG /
/ / / / /
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VA LV E
/
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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
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 (counter·c loc kwise ) . The fl ow of fuel f ro m t he mai n jet is c oot r ol lE'd by th" si ze of [he weil v en t a nd the size of t he diSC ha rge j et. , 'OTE: Tilt· ma i n jet on thcs~ ca rburetor s are equipped with a magnetiC' solenoid that is electricall y energized wile n Ihe ignition key switch is turned " on", ho ldi ng the main jet off of its sea t at a dL ta nc ", predetCl'mined by the m ai n jet adjusT.ing screw . Wilen Ihe ignition ke " ~'.\' i tc h is turned "o ff" , t he m agne t releases the main j et a'l ld the spl'ing pressu r e holds the j et n eed le finnly aga inst i ts sea t preven ting any fu el from entering Ihe venturi. TIlE' purpose of tile m~gnet ic solenoid on th e m ain jet is to pl'Ov idc a t! l mmedia t an d positive fuc- I shut -off ,,·ithin rhe carbu),pror, w he n the ig ni tion key sw itch i s turned off.
Idle System T he idling system consists of the id ling j et , idling needle and passages . T he id llng j N r eceives th .. fupl from Ihe main j et throug h passage (A) . Th e fuel i s metered through t he id ling jet an d is mixed wilh air \\'h ich i s admitted f r om beh ind the venturi rhroug h passage ( 8) . The id l e adju sting needle c o no-ol~ t he am oun ! o f f u .. ] a nd ai r whic h i s adm itted to I he system a nd (unctions only at iriling and low engine speecls. A t these speed s the t hrott le pl ate i s almos t c losed and causes a v ery stro ng suc lion past th e edge of 1h£' !hrortle plate. This suct ion draws the mixture of (ue l and air from the id ling j et whi ch i s d i scha rg ed in to thl? air s tream through the pl-imary passage .
Choke System The choke' SYS!f'ffi cUI"iSI' of a valve and plate m ounted on a shaft located in the air entrance und operated llIl'ch Jnicall)' by " le ver mounted ex ternally on thE' shaft with a choke c able. The chokr \'~ke is 01 n <'~Oll · aur O nlJli c t"pe, having OJ. poppet \o'Ol l v(>, wh ich is cont roll ed by a spr ing. The> popppt "al ,-o ope>ns automalica lly when the engine sta r ts a. nd imm ediately aci miTs enough a i r 10 avoid ove r choking a nd fl ooding of t he engine.
:35-3
PART NO . STAMPED HERE
Figure 1
THROTTLE PLAT E
FLOAT VALVE ASSEMBLY
CHOKE ASSEMBLY
MAGNETIC SHUT-OFF SOLENOID LOAD ADJUSTMENTSCREW
Figure 2
35 4
CARBURETOR (Refer to Figure 3) Removal and Disassembly NOTE : Make sure the area where the carburetor is to be disassembled , is clea n and well lig hted . 1. Disconnect th(' air c leanE'r tu be a nd fu e l 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 ............ .......... ............ . 4·112 Wire diameter .............. _.. _.. .................. . 040" Free iength .......................................... .469"
:1';·7
Figure 4
35·8
CARBURETOR (Cont'd) (Refer to Figure 5) Assembly and Installation 1.1nstall a new plug (38 ) a nd a new choke 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 ut·out 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 ut·out 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 k·out 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.
35·13
..JW~_-tDLE SPEED ADJUSTMEN T
IDLE MIXTURE ADJUSTMENT
LOAD
ADJUSTMENT~ Figure 7
35 -14
MAGNETIC FUEL SHUT-OFF SOLENOID (Refer to Figure 8) Checking Operation To check th e operat ion of the solenoid for 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 ...... ...... . . ......... .. .... ...... . 6·112
'0
,~
Figure 2
Figure 3
Wire Diameter ........ .... ..... .. ....... .. ...... .092" I. D. Diameter .................................... 813 " Free LengUl .................... , ........ ... ... ... 2.00" Compressed to 1.125" .. _..... _.. _... 27·33 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 .
42·3
HYDRAULIC SYSTEM FILTER - HYDROSTATIC Element Change Interval ",,,,,,,,,,,,,,,.,,,,,,,,,,,,, .. . ,,,, .. ,,,, .. ,,,,,,,,, .. , ... ,,, ..... After the first 20 hours of operation a nd every 240 hours thereafter Type " .. ,'" .. "" .... ,"", .... ", .......... ", .. "" ..................... , .... " ... " ...... " .. , .. , .. " .... , .... 10 :"licron Fi lt ra lion Regular interval replacement of the e lement 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 --
G --
l
I
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
T
L
SHOOTING
ING AND S
Burl. Fonn 9·720815 KHCBO
IC
P,inl.d in U . S .A.
TABLE OF CONTENTS HYDRAULIC D1AGRANIS . .
3
Loader With 4 - In-l Bucket
3
Standard Backhoe . . . .
4
Backhoe With Extendable Dipper.
5
HYDRAULIC SPECIFICA TIONS.
6
HYDRAULIC SYSTENI SERVICE.
6
HYDRA-LEV ELING CIRCUT . .
9 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
2
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
3
'FU!1 ~
.o UTP\JT
2'3 GP.'1. AT 1900 R'PX :'.r l OOO PS I H,;,HJ REL IEF I,ft.LV E SETiu,C flOMER VA L.V£ ) 2200 + 75 PS I AT f Ull THROTTL E SECONDA~ "'-'R El lE F '/AlVr:: 5ETT 1NGS SEE FI GuRE 13 . 1. SWJI,C CUSHIOu REL.IEF VALVE' 39 0 0 + 20Q P~I ':'.T 5 GPIt 2 . R£STRI CTOR / CHECK V~ l VE }. 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
4
_ -
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
5
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
8
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
4
:; 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.
6
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 &
~
"" -
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
7
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.
8
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
9
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 , pag·e 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.
2
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
2
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 2500±100 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
a
0-3000 psi pre ssure gauge .
If the unit is equipp ed with a loader, remove the 1/4" pipe plug from the
a
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.
a
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.
i
SI,i
"/l l"<:)
Pump Relief Valve (Non-Loader Models Only)
TO FIL TER_&l ,I
f
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:
0
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 !I·8 oo0 1
TORQUE CONVERTER HYDRAULIC PUMP (Refer to Figure 1) Disassembly 1. R emove tile adapter plate (2-1 I from th e 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 .5·21'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
2
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.
3
DIAPHRAGM MEAR PL ATE)
.I
~
~I .
\
3/8" - 16 x 3-1/2" (4) FERRY HEAD
_ 3/ 8" - 16 x 3-1/4" (4) f ERRY HEAD 701368
Figur e 2 - Expl oded View of D4 8950 Pmnp
4
Removal
1.
Dra in hydraulic r eser voirs.
2
Remove radiator grille . Then remove dirt and grease from pwnp and surrounding area.
3.
Disconnect suc tion line a t pump and plug with clean caplug.
4.
Disconnect tube at eillow on outlet side of pwnp a nd plug with clean caplug.
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
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.
6
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 .
4
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.
I
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 Fl·ont 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
7
with large s t portholes). This plate fits inside the gear plate when gear plate is s eated on r ear cove r. Figure 16.
Figure 17 - Installing Gears 8. 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.
8
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).
9
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.
5
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
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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44-2
TILT CYLINDER (Refer to Figure 1) L Pis ton r od "C" c up sea l. Ins tall into g land (6) with sea l lip toward pi ston end of rod.
2. Pi s ton rod wiper (outer ). Press into g land (6 ) with wiper lip toward piston rod eye. 3. Gland "0" ring. Inse t A. 4. Gland back-up ri ng . Inst a ll wit h c urved face to ward " 0" ring (3), Inset A. 5. Piston rod wiper (inner). Ins tall in to g land (6) with tapered lip toward piston end of rod , Inset A. 6. Sea l g land . Lubricate the bore' of the sea l gland a nd slide the seal gland assem bly over piston rod. 7. Pi s ton rod (1.25 " diameter ) . 8. Piston ha lf, rod end (1- 114" ci ia meter recess). Se e
o. 10 be low a nd Inset B.
9. Piston hal f. bolt end (1 -.) / 8" diame ter rece ss ). See 1\0. 10 be low and Inse t B. 10. Pi ston "Vee Sea l" packing . In stall ha rd outer packing ring on each piston half. In stall t hree
c hevron r ings on each pis ton half with the "Y" of the c hevron ring toward s the cente r of the pi s ton . See Inse t B. 11. P iston seal bearing ri ng . Ins ta ll between the "Vee Seal" packing. See Inset B. 12. Pi sto n retaining was her. 13. Piston retai ning bolt (gl'ade S, 3/ 4" diame te r). T orque 200-220 ft. Ibs. Clamp r od eye e nd of piston rod in a vise and s upport the piston rod when to rquing the bo lt. 14. Seal g land retaining scr!'w (=8-32 x 1/4" se lf·tapping ) . Lub ricate the pisto n seals and install pi s ton rod with gland into th e cylind er be ing careful not to cut the "0" ring or back·up ring. Torque th e gland 100-200 ft. Ibs. using Case spanner wrench 044111, [nset C. 15. Rod pivo t bu s hing (self a ligning) . 16. Bushing re ta in ing sna p rings_ 17. TU\le pivot bus hings. Press in to place. 18. Cylinder tube. 19. Grease fi tt ing.
.J4-4
LIFT CYLI NDE R (Refer to Figure 2) 1. Piston rod "U" c up seal. Install into gland (6) with sE'al lip toward piston e nd of rod.
2. Piston rod wi pe r (outer). PrE's s into gl a nd (6) with wipE'r lip towa rd piston rod eye. 3. Gland "0" r ing, InsE' t A. 4. Gland ba ck-up ring. Insta ll wit h curved face toward "0" ring (:l) , Inse t A_ ,5. Pisto n rod wi per (i nne r). Install into gla nd (6) with tape red lip towa rd pis ton end of rod, Inset A. 6. SE'a l gland. Lubricate the bore of the sea l g land and s lide the seal g land assem bly over piston rod. 7. Piston rod (LiO" dia me te r). 8. Pi s ton half, rod end (1- 112" d ia m e te r recess). See No. 10 be low a nd Inset B. 9. P iston ha lf, bolt e nd (1-5/8" di am eter recess) . See No. 10 below and Inset B. 10. Piston "Vee SE'a l " pac king . Ins ta ll hard oute r packing ring on ea ch piston half. Install threE' c he vron ri ngs on each piston half wit h the "V" of the chevron ring towa rds the cente r of the pis ton. See Inset B.
11. Piston sea l bearing r ing. Install between the " Vee Seal" packing. See Inset B. 12. Piston r eta ining washer . 13. Pi s ton re ta ining bolt (grade 8, :Ji4" diameter). Torque 200-220 ft. lbs. Clamp rod eye e nd of piston rod in a visc :il1d s upport the piston rod whe n torq uing the bolt. 14. Sea l g land re taining screw (08-32 x 1/ 4" self-ta pping ) . Lubricate the piston seal s and inst all pisto n r od with gland in to the cylinder being careful not to c ut the "0" ring or back-up ring. To rque the gland 100-200 ft. lb s. Us ing Ca se spanne r wrench D44112, Inset C. 15. R od pi vot bushings. Pre ss into plac e. 16. T ube pivot bushings. Press into place. 17. Cylinder tube . 18. Grease fi ttings.
44·5 INSET A
INSET B
PACKING RING
NYLON RING NYLON RING RENE RING NEOP
INSET C
44- 6
PITCH CYLINDER (Refer to Figure 3) L Pis ton rod " U" c up ,ca L Ins tall in to g la nd (6) with seal lip to wa rd piston ('nd of rod.
2. Piston rod wi p('r (outer )_ P res, into g land (6) with wiper lip towa r d pi s ton rod eye.
:3. Gland "0 " ring, Inset 1\. 4. Gland bac k-up r ing _ In sta ll with c ur ved [a ce towa rd "0 " r ing (3), In se t A.
'i_ Pi ston r od wipe r (inne r). Insta ll int o g land ( 6 ) with tapered lip to ward piston end o[ rod, Inset A.
6_Seal g la nd_ Lubricat e thre bore of the seal g la nd a nd slide the sea l gland a ssembly 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
9
,
......
I
I I
I
,
17
INSET C
044111
figure 3
SECTION 44a
LOADER CONTROL VALVE ser
nendly
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Print e d
in U .S . A .
TABLE OF CONTENTS SPECIFICATIONS.
. ........•.....•....•••..••..••....•.. , 3
.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS .
4
GENERAL . . .
5
OP ERATION ..
. .. 6-8
i\Ia!n Relief Valve .
6
on
Flow - Lift Spool Actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
on
Flow - Lift Spool In Float..
8
Float Detent .. . . . . . . . . . . .
8
SERVICING WADER CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-14
Removal . . . . . . . . . . . . . . .
9
Disassembly . . . .
.. . . . . . . . . . . . . . . . . . . . . . . . 9
Lift Spool .. .
.. . . . . . . . . . . . . . . . . . . . . . . . 9
Tilt and Clam Spool . . . . . . . . . . . . . . . . . . . . . . . . • . . .
.. . . . 9
Main Relief Valve . . . . • • . . • . . . . . . . . . . . . . . . • • . . .
10
Secondary Rellef Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 10 Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Assembly . . . . . .
• . . . • . . . . . . . • . • • • . • . • . . . . . . . . . . . . . . . • . . ..
11
Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 Sec ondary ReItef Valves
. . . . . . . . . .. 12
Main Relfef Valve . . . .
. . . . . . . . . . . 12
Tilt and Clam Spool . . .
. . . . . . . . . . .. 13
Lift Spool . . . .
. . . . . . . . . . . . 13
InstaHation . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . .. 14
2
SPECIFICATIONS Case part no. 2 spool val ve 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
0
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
4
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':
3
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
4
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 R£UE F
TILT SPOOL PORTS A Atl D fs ,
CLAM SPOOL PORT 8 ,
BM66 11 ~3
Figure 2 - all Flow - Spools In Neutral
5
OPERATION 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
R£FlAC£ Oil !lED PAST PILOT PlUNGfR
STEPC!) P ~ ES SJJR E
CAUSES PILO T PLUNGEr.
TO UNSEAT
•
•
STATIC Oil
HI GH PRE SSURE Oi l 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
6
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
7
711 0jS
lOW eKt,> ",,
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
OE TEI
SPOOL
C ~. f"1
BALL S (6)
"em,
Figure 6 - Float Dete nt (Spool In Neut ral )
8
SERVICING LOADER CONTROL VALVE Removal
Figure 7 - Control Valve Location 1.
Remove accumu lated dirt and gre ase from contro l valve and surrounding area.
2.
Rest the loader and backhoe buckets on the noor.
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.
9
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'.
W
-
C-rHNG
.
/ /
'
J ./ >::1~
,J
C
_
~)
..J '-
A
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.
A
-'O -R ING
A
~C""TRlOG' &'1 #,1'--
J
_
\
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.
5lE·eVf
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
A
O - O -
1I!!I\©-
. \S)~O-AING
'""
pOP PEr SE..6,T -
~,II
..- ,
."
aACKU9 RING
~~o;-:- 'Sf'l ING t:f .l "/ 7
r
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
7~
,
-
BAC KUP RING
IJ '~
SP.RlNG
't!fJ'/-;- CHE.cKPOPPET
J
/ .. 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. SH£9.
.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.
9
DISASSEi\1BLING THE CONTROL VALVE
9
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
2
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.
3
SE CONDARY
REL IEF VA LVE
01 PPER CYL I NDER
REGENmA T 10,'1 CH ECK VALVE
I "l
~.
.., co
.....
/
/
Ii '---/
I
g "l
~
0
~ I
UJ '0 0 0~
;J> 0 ~
" so
~
(l)
0.
RETURN
REC£IlERATIOll 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.
5
SECONDARY
DIPPER CYL I NOER
REliEF VALVE
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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.
8
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.
9
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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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.
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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 hOl·e. 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 spl·ing 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 spl·ing· 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. """-"~ - - - - - t~OJUST t NG 'SCR.EW
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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 O·rit1g groove:,; In each section to help ho ld the 0 - rings in pl ace. The n pl ace a n a · ring in each groove. InsUllI
the tie rods thr ough the i.nlGt
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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
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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
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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 .
3
GENERAL.
3
OPERATION
3
REMOVAL.
3
DISASS EM B LY
3
ASSEMBLY
4
.
INSTALLA TION .
5
2
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.
3
centering s pring is available for To remove the rod in the spool
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Figure 1 - Exploded View of Control Va lve
4
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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
5
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 .
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Figu re 2 - Contro l Valve Installation
6
SECTION 44d
THREE-POINT HITCH CONTROL VALV
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TABLE OF CONTENTS SPECIFICA TrONS. . . . .
3
OPERATING PRINCIPLES.
4
EXPWDED VIEWS
6
Inlet Section
6
Lift Section.
7
Implement. Pitch. and Tilt Sections.
8
SERVICE . . .
9
Removal .
9
Valve Sections and Spools
9
Inlet Sectio n . . . . . .
9
Pitch. Tilt. and Implement Sections
· 10
Lift Sec tion. . . . .
· 10
Assembling the Valve
.11
Installation
· 12
2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .. 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
3
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).
4
SPOOL ACTUATED
oD'>IM/AR0
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PUMP OI L
_
RETURII 0 I L
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PILOT PnE SSURE OIL
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Figure 4 - Exploded View of Lift Section
7
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t Pitch, and Tilt Sections Figure 5 - Ex-ploded View of Im Plemen,
8
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.
9
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.
3
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 ....
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...
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
45·4
LIFT CYLINDERS (Refe r to Figure 2) 1. Piston rod "C" c up spal. Inst a ll into gland (6) with seal lip toward piston end o f rod. 2. Piston rod wiper 10\1t0r). Press into gland (6) with wiper lip toward piston rod eye.
3. Gland "0 " r ing, Insot iI. 4. Gland bac k·up ring. In stall wiih curved fac e toward "0 " ring, Inset A .
.). Piston rod wipe r (inner) . Ins ta ll into gla nd (6 ) with tapered lip toward piston end of rod, Inset A. 6. Seal g land. Lubricat e the bor(' of th e sea l gland and s lide the seal g land ove'r pis ton rod, 7. Piston r eel 11.:;0" dia mC'te r ).
S. Piston ha lf, reel enel (1 ·1 / 2" dia m ete r recess) , See
0,
10 below a nd Inset B.
9 . Piston half, bolt e nd (1 -5/ 8" diame te r recess). See No. 10 below and Inset 8.
10. Pi s ton "Vee Seal" pac king , In st a ll hard oute r packing r ing on each piston h alf. Ins tall three c he vron ri ngs on eacb piSton ha lf with the " V" of the chevron ring tOIVard s the center of the piston. See Inse t B. 11. Piston seal bearing r ing. Install between the "Vee Sea l" packing . See Inset B, 12. Piston retaining washer .
13. Piston reta ining bolt (graele 8, 3; 4" diame te r), Torque 200-220 ft. Ibs. Clamp rod eye end of pisto n rod in a vise and suppo rt the pis ton rod when torquing the bolt. H. Sea l gland r etaining s cre w (0-32 x 1/ 4" se lf-ta pping). Lu,b rica te the pistOll seals and insta ll pisto n rod with g land in to the cylinder beIng ca re ful not to cut the "0" ring or back -up ring. Torque the gland 100-200 ft. Ibs. using Case s panne r wrench D44112, Inset C. IJ . Roc! pivot bushing. Pres s into place.
16. Cy linder tube. 17. Grea se filt ing.
45- 6
HYDRA LEVELING CYLI NDER (Refer to Figure 3) 1. Piston rod "U" c up seal. Ins ta ll into gland (6) with seal lip toward piston end of rod .
2. Piston rod wiper (outer). Press into g la nd (6) with wiper lip toward pisto n r od eye . 3. Gland "0 " ring, Inset A. 4. Gland back-up ring. Install with curved face toward "0" ring (3), Inse t A. 5. Piston rod wiper (inne r). Ins ta ll into g la nd (6) with tape r ed lip toward piston e nd of rod, Inset A. 6. Sea l g land_ Lubricate the bore of the seal gland and slide the seal gland assemb ly over piston rod. 7. Piston rod (1-3/ 4" diameter) . 8_Piston half, rod end (1-3/4" diameter r ecess ). See No . 10 below and Inset 8. 9. Piston ha lf, bolt end (2" diameter recess). See No. 10 below a nd Inset B. 10. Piston "Vee Seal" packing. In s ta ll hard outer packing ring on each piston ha lf. Ins tall three chevron rings on eac h piston half with the "V" of the chevron ring towards the cente r of the piston. See Inset B. 11. Piston seal bearing ring. Install between the "Vee Seal" packing. See Inset B. 12. Piston retai ning washer.
13. Piston retaining bolt (grade 8, I" diameter). Torque 475-525 ft. Ibs. Cla mp rod e ye e nd of piston rod in a vise a nd s upport the pi s ton rod when torq uin g the bolt. 14. Sea l gla nd retaining screw (#8-32 x 1/ 4" self-tapping ). Lubricate the piston seal s and in sta ll piston rod with gland into the cylinder being careful not to cut the "0" ring 01' back-up ring. Torque the gland 100-200 ft. lbs. using Case s pa nner wrenc h 044113, Inset C. 15. Rod pivot bu shi ngs . Press into place. 16. Cy linder tube. 17. Grease fitting.
45·7
INSET A
INSET B
PACKI
RING
-/ r-::::::;-;;--INSET C
044113
I
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:
2
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
3
Section
4& BACKHOE CYLINDERS
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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 back·up ring. In s ta ll with curved face toward "0" ring, In se t A. 5. Sea l g la nd. Lubricate th e bore of the seal gland and slide the sea l gland assembly over piston rod.
6. Pis ton rod (2" diame ter). 7. Piston half, rod e nd (2" diameter recess). See No.9 be low and Inse t B. 8. P iston ha lf , bolt e nd (2-3/ 4" diameter recess). See :-\0. 9 be low and Inse t B. 9. Piston "Vee Sea l" packing. Insta ll hard outer packing ring on each piston half. Install three chevron rings on each p iston half with the " V" of the chevron r ing towards the center of the piston. See Inset B. 10. Piston seal bearing ring. Install betwee n the "Vee Sea l" packing. See Inse t B.
11. Piston re taining washer. 12. Piston retaining bolt (grade 8, 1-1/ 4" dia m e te r). Torque 1000-1200 ft. lb5. Clamp 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
o
46-6
BOOM CYLINDER (Refer to Figure 3) 1. Piston rod "U" c up seal. Install into gland (5) with seal lip toward piston end of rod. 2. Piston rod wiper (outer) . Press into g land (5) with wiper lip towa rd piston rod eye. 3. Gland "0 " ring, Inset A. 4. Gland back-up ring. Install with curved face toward "0" ring, Inset A. 5. Sea l gland . Lubricate the bor e of the seal gland and slide the seal gland assembly G-;er piston rod. 6. Piston rod (1-3/ 4" diameter). 7. Piston half, rod end (1 -3/ 4" d iameter recess ). 8. Piston "Vee Seal " packing. Install hard outer packing ring and the three chevron rings with th e "V" of the chevron ring towards the center of the pi ston. See Inset B. 9. Piston backing adapter (female ). See Inset B.
10. Piston half, bolt end (2-3 / 4" diameter recess). Install with the recess toward the piston rod eye. See Inset B. 11. Piston wear ring, Inset B. 12. Piston retaining washer. 13. Piston retaining bolt (grade 8, I" diameter). Torque 475-525 ft. lbs. Clamp rod eye end of piston rod in a vise and support the piston rod when torquing the bolt. 14. Seal gla nd retaining screw (;8-32 x 1/ 4" self-tapping) . Lubricate the piston seals and install piston rod with gland into t;,e cylinder being careful not to cut the "0" ring or back-up ring. Torque the gland 100-200 ft. lbs . using Case spanner wrench 044113, Ins et C. 15. Cylinder tube .
46-7
INSET B
INSET A
PACKING RING
INSET C
o l
044113
,
'~~ " (
14
\i 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" self·tapping ). Lubricate the piston sea ls and install piston r od with g land into the cylinde r be ing careful no t to cut the "0" ring or ba ck·up ri ng . Torque the gland 100-200 It. lbs. using Case spa nner wrench DH114, Inset C. H. Rod pivot bushings. Press into place. 1,). Tube pivot bu shing (self aligning). 16. Bushing r e ta ining snap rings . 17. Cylinder tube. 18. G rease fitting .
46-11
18 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 "
"
o
NYLON NEOPRENE RING
RING
2
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
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s
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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
2
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
4
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!,
3
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
I
'-.
- ------~ BOOM CYLINDER 1600 PS I -.n ••
",R
I
I I
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
4
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
•
I
rot,·
•
•
..
I
PRES S~R E
SEN, I NG VALVE PSI POPPET
TO RESERVO I R 1900 PSI POPPET 7 10998
FR OM PUMP
Figure 2 - Diagram of Hydra-Guide Hydraulic System. Models With Dual Boom Cylinders
5
DESCRIPTION
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 .
7
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
8
SELECTOR VALVE IN D IG POSrTlON NOTE: Operating princ iples are identical for circuits with du al boom cylinders, although cODtrol valve and hose connections vary from those shown.
o!..Cl(f
• _ _ _ _ _ _ _ _•
_ _ _ _ _ _ _ _ _. , 5ELEcrOll VOlVE
C'fLlr.QEi\
Il~
DIG POSIfI(j\· · ,QRT j 'PO, to R€SEJ\Y.oIR -
POAT 2 8l 0i KEO
I 0 195>H en I NVEil
RuCf(ETr ~_.-J~~~!l SPOOL CLOSE D 1m~iii
sao. . CYll tlDER BOO.h S.pOOl
CLOS ED
PUMP Oi l
SlATI C OI L
_
A. f TuR Il Ol t TO RE SERVOI :R
CI RCUit TO POPPE1S (SYSTEM PRtSSUR f ) 710892
Figure 6 - Dipper Crowd Circuit Operated, System Pressure Below 1600 psi, All Poppets and Spools Closed
9
-
SELECTOR VALVE IN DIG POSITION 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 R£SER\'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
r
[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
2
800M C'I'L I n08t
12009'SI
I
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 PR€ss.uP. E)
710894
Figure 8 - Dipper Crowd Circuit Operated, System Pressure Above 1900 psi, 1600 and 1900 psi Poppets Open , Bucket and Boom Spools Open, All Three Cylinders Can Operate 11
OPERATING SEQUENC E WITH SELECTOR VALVE IN ' 'TRENCH''
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 $).I IT CHE.:O ON UIl I1"5. 'J ITM DUA L CONTROl... lfV(R S'_~-L-
TO
~ESERVG
3
OPEN
IR
o 1'?,p£R, en INDER.
BOOM CYL IllDeR
I11III I11III I11III
PUMP Oil STATIC Oil
RffUA u Ol~ TO ~[S£~vQIA CI RCUIT
T~ PO~ P( TS
( SrSTEH PRESSuRE ) 710592
Flgul'e 9 - DIpper Crowd Circuit Operated, System Pressure Below 1200 psi, All Poppets and Spools Closed
13
SELECTOR VALVE IN TRENCH POSITION NOTE: Operating principles are identical for circuits with dual boom cylinders, although control valve and hose connections vary from those shown. B\JCK'Ef • _ _ _ _ _ _ _ _. ._ _ _ _ _ _ _ _... CYL.I jjD f.R SElfCTOR VALliE Iti TRENCH P'OSITI()ri--
is 2 ANO ) OPEN TO RiS£RI)O ,R
r
t•
L _________ _
--. I I I
I I I
Ol PPER CYLJ NOER
I I
t•• I
'(WOK CVL I NDER
POPPEr OPE/:
_
PUMP OIL
_
STAT l( Oil
OIL RELIEVED 6¥ 1200 PSI POPPET - -
_
-
~ATH OF REL I EvEO {) I L t o SeLECTOR V':"lVE
RETuftN Oil TO ~£S ERVO IR (IACUll
IlO ft:
to
PDPPET5 (SYSTEM ~RI SSuRE)
SELECTOR VAl VE 'PERMITS ;'U l tfll.U P P'9ET$ 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 PtJPP£l .aPEu
t
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 c·linder. Feather Ule dipper control lever In I'owd positlon , l" ig,ure 14. Watch pressure glluge and c ontinu e to move the l ever to oau se a pressure increase.
Pig,u re 12 - Press ure Gauge [nsta lle d 2.
Pl ace selec to r' valve in Manu al pos ition.
3.
T he hyd "aulic oil s hoUld be ut op e r ating te mpel'lltur e (a t least 120· F.) If r 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
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-
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c - Rr :!G CONIIECTOR
~£STRr CTOR I
f~- CHECK VA LVE ~
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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
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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
-
.... .
,,~
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~
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
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.
a
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
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
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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
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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
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
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.
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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, Fig·LIre 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
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MANUAL
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MA NUAL SELECTO R VALV E
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3j8" NC)( 5"
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Figur e 38 - Expl oded View of Hydra-Guide Controls on 480 and 580
28
/ (
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I
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 3100±200 psi, the reliefvalve opens ,1.ndvents oil to the reservoir.
LOCKOU T VALVE
l
OUT
2 7' ':0 -:P,,\~,l'CIt--.L--'-.L-.J
R:ELiEF\r·- l'lE.
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Figur e 2 - Loc kout Val ve Operat.ion. In Loc k-Position
Figure 1 - Hydraulic Diagram
2
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.
B
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
4
2 3"
La,,,,,; - -
1/4"
a
U
(1)
_CAP USED WITHOUT HYDRA-GUIDE
71 096 1
Fig'ure 5 - Boom Lockout Hydraulics
5
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
/'~
...
\
\.
,
.
:
\
\
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r-~'''~-':?-'=L';:J;:J.-' ___ ._.\__ L ~_ ___ ..!-. .L~ t:::..,.... '. . ------ ------- -- '-r---_
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-.-
. ~.~ - -- -
PUMP £----.~
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---~.~ f \" ', I i') .- I ....--::...,;/ .(I')
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Figure Figure 1 1
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R.I-i . CYLINDER
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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 Â¥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,v·cr. 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';" ... ........... 2.2·2.8 ................... 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,
52·7
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..
1
Seclion
53 STEE RING CONTROL VALVE
Rae. Form 9-80671 9·80671 Rac. Form
53·2
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" """","" ''',,'' '' 1.5·2,5 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 14·17 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
j4·2
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 k·up 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 30·35 30-35 ft. ft. lbs. h e n USing using a new self 10cl
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 (~,,10·24 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 5·7 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
34·4
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_:'
-
-
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
I
© -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 61·2 converter .......................................................................................................
......................................................................... 61-2 lubrication Converter and lu brication oil regulator valve ............................ .. ...... " .. "."."" .... " ." ...... ........ 61·2 Torque converter ....................................................................................................................... " ................. " ............................................................ " .. ....... .. .. """." ... .. ,, ... 6]·4 61-4 e control con trol va lve "" .... . "." .......... " .. ........ ...... .... ..... " ... ... ... ...... ...... .... ... ,, ........ ....... .. 61·6 .................................................................................................... 61-6 Power shuttl shuttle valve Counte rshaft and gears ....... " ................................................................. ... ................. .... ... ...... 61·8 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 """" . " .. ... " ...... " .......... ..... .. .... ... ... ...... .. ................ .... .......... .. ........... 61·12 ........................................................................................................... 51-12 Control lever linkage ............ ............... .... ............. ......... ......... ...... " ... .. ........ ..... .... ...... .. .. .... 61·13 .......................................................................................................... 61-13
.
c Form Form 9 9-80761 Ra ae. · 80761
61·2
TO RQUE CONVERTER (Refer to Figure 1) Rem oval Split the tractor between the e ngine and converter housing, refer to the splitting section of this service manual. Install lifting fixture A20165 with attaching plate A34900 to thE' converter. These tools are available through the Case Service Parts Supply. Remove the torque tube front cover. With a suitable hoist on the lifting fixture, remove the carrier mounting bolts. Work the converter out of the torque tube. Reverse the above procedure for installing the converter.
CONVERTE R AND LUB RICATION OIL REGULATOR VALVE (Refer to Figure 1) I. Regulator valve body. 2. Valve spool · Make sure spool operates smoothly in the housing bore. 3. Regulator valve spring.
Free length ...................... ..... .............. 1·3/8" Wire Dia . ..... .. ....... ..... .............. ............. 051" No of Coils ........................................... 6·112 Spring Rate ............... ..... 10 to 12 lbs. at 314"
4. End plug "0" ring. 5. End plug. 6. Snap ring. 7. Gasket. 8. Mounting bolts with lockwashers. 9. ConNrter oil temperature switch.
61 ·3 1I FTI NG FIXTU R E -......,..".-17)<:::
A34900 ATTACHING PLATE
CARRIER MOUNTING BOLTS
~
TORQUE CONVERTER
POWER SHUTTLE CONTROL VALVE
,/
----
TORQUE TUBE FRONT COVER
61·4
TORQUE CONVERTER (Re fer to Figure 2) 1. Output shalt.
2. Ca rrie r bearing. P res s onto shaft until it seats against the shoulder. 3. Bearing space r . 4. Snap ring, bea ring r eta iner. 5. Hook type sealing rings. Insta ll with end gaps, Inset A, 90 0 apa rt. 6. Snap ring. Used to retain carrier bearing (2) into carrier (10). 7. Pump drive gear. 8. [mpell er w heel. 9. Clamp pla te s a nd impelle r mounting bolts. Torque 19 to 21 ft. lbs. 10. Carrier . [nst all the dri ve gear impell e r wheel assembly onto carrie r. U. Stator. 12. Clamp plat e s. 13. Roll pins. H. F erry head ca pscrew s. Torque 24 to 27 It. lbs . to retain the stator to the ca rrier.
15. Sn ap ring. Used to retain the output s haft in the carrier after the bearing (2) 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
61·6
POWER SHUTTLE CONTROL VALVE (R efer to Fig ure 3) Lubricate the spools with Ca se TCH all as they are installed. 1. Flow cont rol oil seal. Install with sealing lip inward until seal bottoms in bore.
2. Shut tie co ntrol spool oil seal. Install with sealing lip inward until seal bottoms in bore. 3. Flow control spool. 4. Clutch pressure r egulator valve. 5. Clutc h pressure regulator valve spring. Free le ngth ................. .. ....... ........ .. .... .... ....... .... . 2. 04" Wire Dia ..... ...................... .. ........ .. ....... .080" No Coils ............................................ 15·1/2" Spring Rate ............ 45 lbs. at 1·11/ 32" leng th 6. Clutch press ure r egulator shims. Use as required to adjust clutch pressu re. At tes t port it should be 170 to 190 PSI at 9.5 GPM fl ow . The .0209" s him equals S PSI. The .0418" shim e quals 10 PSI. 7. Clutc h pressure reg ul a tor plug with "0" ring. 8. POWN shuttle control s pool. 9. Spool stop. Ins tall with the tab toward flow control spool. 10. Control spoo l snap ring. 11. Plug "0" ri ng.
12. P lug. 13. Plug r e ta iner snap ring.
14. Adapter pl ate. 15. Valve body gasket. 16. Dete nt spring. 17. Detent ba ll. 18. Va lve ret a ining bolts w / loc kwashe rs. Tight en to torque of 35 to 42 ft. lbs. The two rea r bolts m ay be loose ned to 25 It. lbs. if the spools arC' not f ree. 19. Pipe plug, clutch pressure test port.
20. Breather assembly. NOTE: After the val v e is installed, the control linkage will ha ve to be ad justed. Refer to the a djustm e nts in thi s section.
61 -7
1~J
CLUTCH PRESSURE GAlJGE
OIL
'"
""
0
<>
'"
'"
<>
"
<.'-'
L-
Figure 3
~
0
'"
? <:>
61·8
COUNTERSHAFT AND GEARS (Refer to Figure 4) L Needle bea r ing. Press on number side of bearing to a depth of 1/16", into torque tube housing, Inset A. 2. Countershaft rear bearing. Press onto countershaft until it bottoms. 3. Countersha ft. Install through rear bore in torque tube. 4. Snap ring, reverse gear rear. 5. Reverse driven gear, large hub toward rear of shaft. 6. Snap ring, reverse gear front. 7. Snap ri ng , rear bearing. Install into torque tube . Lightly tap shaft a nd bearing assembly into case until rear bearing sca ts aga inst snap ring. 8. Snap ring , rear bearing. 9. Forward driven gear. Install with large hub toward rear of s haft. 10. Retainer washer. 11. !'ylock bolt. Torque 35 to 40 ft. Ibs. 12. Reverse idl er bearing. Press into gear until it bottoms. 13. Reverse idler gear. 14. Bearing r etainer sna p ring. 15. Reverse id ler gear st ud. Press into bearing (12) . Install a ssembly into torque tube and torque 130 to 145 ft. lbs.
61-9
t (1)
Figure 4
61-10
POWER SHUTTLE (Refer to Figure 5) Removal Remove transmission fr ont cover and torque tube rear cover. Aiter the tractor ha s been split between the torque tube a nd transmission, carefully pry the power shuttle unit rearward to remove, Inset A. Refer to Section 63 for servicing the "Twin Disc" Power Shuttle Clutch. Refer to Section 64 for Servicing the "Rockford" Power Shuttle Clutch
Installation Locate the e nd gap of the power shuttle shaft sealing rings 90 0 apart. Lubricate the sealing rings with grease. Carefully install the power shuttle unit into the torque tube. Tap lightly on the rear endof the power shuttle unit to seat the front bearing into the torque tube. Rejoin the torque tube and transmission with new gasket and retain with bolts. nuts and lockwashers . Torque the bolts 80 to 132 ft. Ibs. and the stud nuts no to 132 ft. Ibs. Check the amount of end play between the power shuttle unit a nd the snap ring on the transmiss ion input shaft. Pry the power shuttle unit forward a nd use a feeler gauge to check the clearance. Clea ra nce mus t be a minimum of .025" to a maximum of .045". Add or remove shims on the transmission s hart in front of the s nap ring, Inset B. PRY POWER SHUTTlE UNIT 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
\
0
r-~
) ,. ., Figure 5
0
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
D
INSET C
G
l.--..--------..............-----FigUre
1
62·4
FORWARD AND REVERSE CLUTCH PACKS (Refer to Figure 2) Lubricate parts with Case TC H oil as they are assE'mbled. 1. Clutc h hub assemb ly.
2.Si n tered bronze drive p late \7 used ) :l. Steel driven clutc h plate (6 used) Alternately install one bronze dri ve plate (2) and one steel dri ven plate (3) ont o the c lutc h hub (1) until 7 bro nze plates a nd 6 steel plates have been installe d. 4. Clu'ch backing p late. S.Locati ng dowel · insert in groove in plate (4) a nd hub (1). In se t A. 6. Snap ring. insta ll into groove on c lutch hub (1) . Inset A. 7. Spirol type in ternal snap ri ng. Install into groove in backing plate (4) . Inset A. 8. Force piston, housing and shaft assembly. 9. Forward clutch pack assembly. 10. Snap ring, Inset 8. Install in groove on clutch s haft. 11. Splined spacer . In set C. 12. Snap ring. Inset C. Install in to groove In clutch bac king plate. 13. Revers e cl utc h pack assembly . 14. Snap r ing. Inset 8. Ins tall into groove on clutch shaft . IS. Spl ined spacer, Inset C. 16.Snap ring. Inse t C. Install into groove in clutch backi ng plate.
62-5
FO RWAR D
INSET A
-===-
DOWEL GROOV E
INSET 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
"
"-,,-
',,-
"-
"-,
I
"
®
r
r
,
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 ... .. .... ..... .............. .. ......... ........... .. .. ................. 63·4 Forward clutch pack assembly .. ...... .... ................................................... ... .... .... .... ............... .. 63·6 Clutch hub shims ...... ... .... ............... .... ... ... .... " ..... ... ...... .. .. .. ..... .. ..... ........ .. .. .. ......... ....... .......... 63·6 Forward-reverse c lutch drums ........ .. .... .... ...... .......... ... .... .......... .............. ..... .. ..... .. ....... .. ........ 63·8 Rac. Form 9 · 80701
http://www.ioffer.com/selling/userfriendlycds http://stores.ebay.com/UserFriendlyCDs
63·2
RE V ERSE CLUTCH PACK AND SHA FT ASSE MBLY (Refer to Figure 1) Lubricate the parts with Case TCH 011 as they are assembled. L Snap ring, clutch s haft· In stall into s nap dng groove on ~tiarl (2 ). 2. Clutc h shaft 3. Needle bearing' Press on numbe red end of be aring until it is r ecessed 1116" beyond end of shaft (2). Use Drive r , Case No. G15042 . 4. Clutch hub key. 5. Reverse c lutc h hub . Press onto shaft until it bottoms on the s na p ring (1). NOTE: The r everse c lutch hub has a recess m ac hined for the snap ring . IMPORTANT: At this tim e, te m porarily in s tall fi ve sinte red c lutc h plates a nd five steel clutc h pla tes on the reverse clutch hUb . Then proceed to check the hub protrusion above the plates . Refe r to Pa ge 63·6 "Clutc h Hub Sh ims ". Afte r the hub protru s ion and s him require m ent ha s been determined , remove the ten clutc h plates a nd proceed with th e asse mbly . 6. Clutch pla te wavy s pring (Free height of ,1285" ) . Install the firs t wavy spring so the tan g en· gages the two roll pins (one tooth a pa rt) in the c lutch hub, Inse t A, The c lutc h hub must be mar ked at th is po int, Inse t A, and a lso a t a second point fi ve gea r teeth away . 7. Sintered driven plate. 8. Steel dri ve pla te . 9. Clutc h pla te wavy s pr ing. Ins ta ll the second wavy spring with the ta ng rotated five g ear tee th from the ta ng of the fi rs t wavy spring (6), Inse t B. The second s pring ta ng would then line up with the seco nd m a rk on the hub. Proceed to ins tall one sintered plate, one steel pl a te and s pr ing (a lte rnating the s pring ta ngs be tween c lutc h hub marks ) until a to ta l of five ea c h have been insta lled. Ins tall two cla mps and compress the clutch plates and springs down onto the c lutch fia nge un til four A43071 Special Tool clips ca n be installed. Clips are ava ila ble fr om Cas e Service Pa r ts Supply. The r everse c lutc h pack assembiy is now comple te, Inse t C a nd D. NOTE: The A43071 Special Tool Clips are used to keep the c lutch pl a tes a nd wavy s prings compr essed , while pressing the ca rrier ass embly on to the c lutch sha ft a nd reverse clu tch pack. If the c lips are not used, there is a cha nce of squeezing some c lutc h plates be tween the reverse clutch hub a nd the carrie r assembly s ince the plates have a tendency to ride up over the c lutch hu b. 10. Reverse hub s hims. Install pre·determined number of shims and press ca r r ier assembly on s ha ft. Re fer to Page 63·4 and 63·5.
INSET 0
63-3
INSET C
SPECIAL TOOL, __ CLIP A43071
~ ROLL PINS FOR SPRING TANG LOCATION
SNAP
INSET A
GROOVE
INSET B
MARK FIVE GEAR CLUTCH HUB FIRST MARK TEETH FROM
o
5
Figur e 1
63·.
FORWARD AND REVE RS E PISTONS AND CARRIER ASSEMBLY (Refer to Figure 2) Lubricate the parts with Case TCH oil as they are assembled. 1. Piston Carrier Assembly. 2. Piston ring, (hook type), Inset A. Install in grooves on both sides of carrier (1) . 3. Piston ring seal (5 pieces includes items 4,5 and 6) used in both forward and reverse pistons (14 and 17). 4. Expander, seal ring. Install into both pistons. 5. Step type rings (3 used) Inset B. Install into both pistons . Slide both pistons onto the carrier hub to e xpand the rings. The rings must be expanded to correctly align the rings so the ends do not overlap sideways. Remove both pistons from the carrier and inspect rings for proper alignment. 6. Square end type ring (1 used). Install into both pistons, next to the step type rings and toward the carrier. 7. Dump valve spools, Inset E. 8. Dump valve springs, (Free length 1.32"), Inset E. 9. Pin 1/ 8" x 3/ 4". Compress dump valve spring and insta ll pin so it retains spring in each pi ston (14 and 17), Inset E. 10. Rubber piston seal rings. Install into groove on the pistons (14 and 17). 11. Reverse clutch hub shims. 1~1PORTANT: A t this time the correct numbers of shims for proper piston travel will have to be determined. Refer to Page 63·6 "Clutch Hub Shims". Then install the co rrect number of shims over the shaft and onto the hub. 12. Forward lube oil spring (Free Length 1.71"). Instan into hole in reverse clutch hub, Inset C. 13. Forward lube oil spool. Grease the spool and install into hole in reverse piston, Inset D. 14. Reverse piston. Install into carrier (1). Make sure the carrier key way is aligned. Press carrier onto the shaft until the carrier con ta cts the shims a nd reverse c lutch hub. Then remove special tool clips installed in step 9, page 63·2. 15. Reverse lube oil spool. Insta ll into hole in top of carrier, Inset F. 16. Reverse lube oil spring, Inset G. 17. Forward piston. 18. Forward clutch hub shims . Refer to Page 63·6 "Clutch Hub Shims" for determining the corre ct number of shims to be installed.
INSET 0
INSET F
INSET G
63-5
INSET C
INSET B
INSET
E
Figure 2
63·6
FORWARD CLUTCH PACK ASSE MBLY (Refer to Figure 3) Lubricate the parts with Case TCH oil as they a re as sembled. 1. Forward Clutch HUb. IMPORTANT: At this time, temporarily install fi ve s intered c lutch plates and five steel
clutch plates on the forward clutch hub. Then proceed to check the hub protru s ion above the clutch plates. Refer to "C lutch Hub Shims" below. After the hub protrusion a nd shims r eo quired has been determined, remove the ten clutch plates a nd proceed with the assembly. 2. Clutch pla te wavy spring (Free height of .1285"). Insta ll the first wavy spring so the tang engages the two roll pins (one tooth apa r t) in the clutch hUb. The c lutch hub must be marked at this point and a lso at a second point located five gear teeth away. 3. Sintered driven plate. 4. Steel drive plate. 5. Clutch plate wavy spring. Install the second wavy spring with the tang rotated five gear teeth from the tang of the first wavy spri ng (2). The second spring ta ng would the n line up with the second mark on the hub. Proceed to install one sintered plate, one steel plate a nd one spring (alternating the spring tangs between c lutch hub ma r ks) in this order until a total of fi ve each have been installed. 6. Forward hub shi ms. Install the correc t number of shims as de termined by the hub protrusion explained below. Install two c lamps and compress the clutch plates a nd springs down onto the clutch flange until four A43071 Special Tool clips can be installed, Inset D. Clips are a vailable from Case Service Parts Supply. Proceed to press the forward clutch pack onto the shaft until the for · ward clutch pack contac ts the shims a nd carrie r assembly. Then re move the clips. 8. Locknut, tighten securely. Bend one of the lockwasher tabs into one of the grooves on the locknut.
ICLUTCH HUB SHIMS After the specified number of clutch plates have been installed on the c lutch hub, insta ll two clamps, Inset A. Tighte n the clamps until the plates are firmly compressed. Make sure the clutch plate teeth engage the teet h on the clu tch hub , Inset A. Usi ng a two inch micrometer, measure the height of the clutch hub and fla nge, Inset B. Then measure the compressed height of the clutcb plates and flange, Inset C. Example: Measurement over clutch
hub and flange Inset B
. . . . _ _ _ _ 1.158"
Subtract measurement over compressed dutch plates and flange Inset C _ ,__ 1.07'2'1 The difference in measurement is __ _ _ _
.086"
the amount 'he hub protrudes above the clutch plates. Required clutch piston trovel
(eliminate clutch plate drag) _ _ .095" to .115" Subtract hub protrusion above plates _ _ _ _ _ _ _ _ .086" 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 .......... .. ..... .. ........................................................... .. ........ ....... .. ___ . 64·2 Di sassembly a nd Assembly ........ ... .... ................ ... ........... ..... .. ......... .... ..... .. .................. .... ... 64-4 Hydrostatic ;Vlotor . Mechanica l Disconnec t. Pinion Shaft ..... .. ........ .. ... .. .. ................................ 64-6 Emergency Clutch Pedal Linkage ........... .......... ........................ ... .. ... .... ... ....... ... .. .. .. ... .. .. ........ 64-8 Speed Control Linka ge a nd :->eutral Cam .......... .... ...... .... ...... ........... .. .. .. .. .... .. ...... .... ..... .... ...... 64-9 Adjustments . ___ ........... . _.. .............. ... ..... ... ......... ...... ...... ....... _........ ..... ... ..... ....... ............. ..... .... 64-10 Press ure Checks ..... ............. _... .... ... _..... _....... ... ........................ ....... ............. ................... .... ... 64-13 Troub le Shooting .. _.. ............... ... ............... ... ...... ... ......... ... ..... ................... _... _.......... ... ......... . 64 -14
SPECIFICATION S Hydrostatic Operat ing oi l pressures ......... .. .... .. ...... ............ .... ................. _...... Refer to Page 64-13 Forwa rd-Reverse pedals " Free Pedal" .... .... .. .. .................................... .. .................... 1/ 4" to 112" Pinion s ha ft bearin g preload .......... ..... .. .. .............. ...... ... ............. .... 4 to 12 in . Ibs. rolling torque Dump valve pad to lever clearance .. .... ........ .... ............................ .. ...... .. ........................... _... 045" Ba njo fitting bol t on hydrosta tic pump ..... ...... .. .. ................ _....... .... ...................... 14 to 16 ft. Ibs. Servo moun ti ng bolts .... .. ....... ................ ........ ...................................... .. .... .. ....... ... 18 to 21 ft. tbs. Hydros tatic pump brac ket to housi ng bolts ...... ........................ .. ........................... 35 to 42 ft. Ibs . Hydros ta tic pump mounting bolt s .......................................... ... ... ......... .... .. ....... ... 80 to 90 ft. Ibs. Hydrostati c m otor m ounting bolts .... ..... .. .. ............................................................ 80 to 96 ft. Ibs. Rae . Form 9 -80371
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64-2
HYDROSTATIC PUMP & INPUT GEAR TRAIN (Refer to Figure 1) Removal Split the tractor between the flywheel 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
64-~
INSET B
15
INSET A
A9B17
G15042
Figure 2
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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
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64-8
EMERGENCY CLUTCH PEDAL LINKAGE
SAFETY START SWITCH
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DUMP CONTROL D CROSS SHAFT
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64·10
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
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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 64·12 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
64·12
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
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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.
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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()
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
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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 ............... ...... ... ................ ................................. ................................... .... ........... 65·2 Speciai torques ............... ................ ...... .. ................. .. .... .. ..... .. ....... ............. .. ........................... 65-2 Power Trains Eight speed dual range ...................... .......................... ...... .. ................ .. ..................... .. ....... Eight speed shuttle .......................... ... ............. .. .................................. .. ..... .. ........... .. .......... Four speed shuttle ........................................... .... .................. .............. .. ............... .. ............. Power shuttle·torque conve rter ............................................................. .............. .. ...............
65·3 65·4 65·5 65·6
General Inspection ........................................................... .. .................... .. .......... ............. .. ...... 65·7 Generai assembiy ......... ............................................... .. ................... .... ... .... .. ........ .. .. .. ............ 65·7 Shifting Sequence ............................... .. ............. ................................... .. ......... .. ..... .. ............... 65·7 Transmission housing ........ .................... .. ............................... .. ................................. .. ............ 65·8 Pinion shaft ................................................................... ........................................................ 65·10 Reverse idier gear (not used with shuttle) .................... .. ........... .. ....... .. ................................ 65·12 Diiferential ... ................................................ .. ............. ........ .. .................. .. .............. ......... ..... 65·14 Main drive shaft ................. .. ........................................ .. .... .. .............................. .. ................. 65·18 Flanged axle ......... .. ..... .. ........................ .................................... ... ........... .. ...... .. ....... .. .... ....... 65·20 Keyed axle .......................... .. ........................ ........ .. .... ................... .. .............. .. .... .. ......... .. ..... 65·22 Gear shift cover ............ .... ....................................... ....................................... .. .................... 65·24 Adjustments ....................................... ........................................ .. ...................... .. ... ............... 65·30
Rae. Form 9·80641
65·2
SPECIFICATIONS Pinion shaft, 2nd to 3rd gear hub clearance ., ............................................... " .......... 00l" to .006" Pinion shaft bearing pre-Ioaa (turning torque) ...................... " ............................. 4 to 12 In. Lbs. Reverse Idler gear bushing diameter ................ ,....................................................... 862" to .863" Malnshaft bearing end play ....................................................................................... 002" to .005" Differential pinion to side gear backlash ................................................................... 005" to .015" Differential bearing pre-load (turning torque) ......................................................... 3 to 8 it Ibs. Differential ring gear to counter·shaft pinion backlash ............................................. 005" to .009" Rear axle bearing preload ...... .,., ............. 20 to 30 inch Ibs.rnore than the no load turning torque
Special Transmission to torque tube bolts ........................................ " ............................. 80 to 132 ft. Ibs. Transmission to torque tube nuts ...................... ., ............................................... 110 to 132 it Ibs. Transmission front cover bolts or nuts ................................................................. 35 to 42 ft. Ibs. Brake housing and carrier bolts and nuts .................. ., ......................................... 70 to 90 ft. Ibs. Axle housing mounting bolts or nuts ................................................. ., ............... 150 to 190 ft Ibs. Rear wheel hub clamping bolts .......................................................................... 270 to :i20 ft. Ibs.
EIGHT SPEED DUAL RANGE
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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
4
x2 8
4 x2 8
4
1
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.
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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.
65·11
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.
65·13
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
E
19
19 NTlAL LOCK WIT! H DIFFERE
INSET G
G 13503 SLEEVE
WITH DIFFERENTIAL l OCK
Figure 8
6.5·16
DIFF ERENTIAL (CONT' D.) (Refer to Figure 9) 14. With the carrier bolts & nuts properly tor· qued, adjust the differential gear bearings for correct pre· load. Refer to Page 65·30 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 65·30 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
E
19
INSET G
G 13503 SLEEVE
WITH DI FF ERENTI AL LOCK
Figure 9
65-18
MAIN DRIVE SHAFT (Refer to Figure 10) IIUPORTANT When disassembling the main 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
D
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
7
)
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
J
IN S ET
0
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.
65·25 INSET C
01502 DRIVER
INSEf A,
INSET B
G1 50' 8 SLEEVE
Figure 13
65-26
GEA R SHIFT COVER (Refer to Figure 14) IMPORTANT Each of the three shifter rods, in the control cover, are held in position by means of a steel ball backed by a compression spring. These steel balls, seating in the shifter rod (horizontal notches), provide a "detent" or holding action thus preventing the transmission accidentally jumping out of gear. (See Inset A).
Between the shifter rods, in the control cover body, are two interlock plugs. These plugs seat in the vertical notches in the shifter rods, providing a similar detent holding action on the shifter rods. When anyone rod and fork is shifted, these interlock plugs prevent the movement of the other two rods, thus preventing the transmission from being in two gears at once. (See Inset A) On tractors with Mechanical Shuttle transmission the reverse shift fork Is removed and a reverse shift rail lug and a (5/ 16 X 3" ) bolt is used to restrict movement of shift lever to the reverse position, Inset B. With this arrangement the neutral safety starting switch can perform its function. NOTE Refer to Page 65-32 for neutral safety starting switch adjustments.
SPRIN G SPECIFICATIONS Check the springs for the following specifications: DETENT SPRING (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
D
I
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
D
It ~
j
(7)0
!
t
)1
~ ~ '" · J. ,
-f2\
'" "-
_~
----;~~
_ _ _ __
-
.-1 ,"m ,
"~~~ 9D ·'i .@--:. ~ t[JJ= ~" ,s66 ..
ro,s74'~ ..
I
65·30
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"
/
o
"
3. DiffERENTIAL RING GEAR TO CQUNTERSHAFT SHAfT PINION GEAR 8AC~LASi1
Figure 16
65-32 ADJUSTMENTS(Con~)
SAFETY STARTING SWITCH ADJUSTMENT
(Refer to Figure 17and 1 8 ) If the safety starting switch is not properly 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.
I
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
T
(j) I
I v
©l...... / /
I
I I
Figure 1
&--0
66-4
SHUTTLE CONTROL COVER With D irect Lever (Ref er to Figure 2) The re are two types of control covers used , one for tractors with shuttle only and one for tractors wilh shuttle and dual range. The servicing of the dua l range part of the cover is cove red in Section 67 of this Service Manual.
Removal and Disassembly 1. Remove brpather (I ) , also brea ther tube (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
66·8
SHU TT LE TRANSMISS ION (Refer to F igu re 4) Assembly and Insta llation J. Install new expansio n plug (38) and start 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 hub·sleeve assembly (16). 7. Install thrust collar (23) with pin (24) en· gaging sp line in sha ft. S. In s tall new gasket be tween t he s huttle housing arrel transmi ssion case. 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 I·emove. 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
67·8
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 ............................................................................................................ 68·8 TRACTION CLUTCH Assembly·lnstallation ........................................................................ .................................. 68-10 RELEASE LEVER AD.JUSTMENT ....................................................................................... 68-10 CLUTCH LINKAGE ADJUSTME'iT Suspended Pedal ............................ ........... ....... ..................... ....................... .. .................... 68·12 Floor·mounted Pedal ..................................................................... .. .................................... 68·13
S PECIAL TOOLS The special c lutch adjusting tool G15048 is used with the special splined gauge, with 21 splines.
AJ7966 GAUGE
G1S048 TOOL
This special tool. A38461 , is used to press the seal into the bearing carrier.
AJ8461 TOOL
These tools and the gauge are available through service parts supply, J I Case Co.
68-3
INTRODUCTION The operation of the clutch assembly is basically the same as the operation of any sta nda rd single disc type clutch. The clutch cover is attached to the engine flywheel. The press ure pl ate is driven by means of driving lugs and mating slots in the clutch cover. Depressing the clutch pedal disengages the clutch by forc ing the rel ease bearing into contact with the release leve rs. moving the m toward the eng ine flywheel. This retracts the pressure plate from conta ct with the drive n disc assembly thereby disengaging the clutch . Releasing the clutch pedal engages the clutch by allowing the release bearing and release levers to move away from the eng ine flywheel and the press ure springs to exert pressur e against the release lever, resulting in the disc assembly being g ripped between the fric tion surfaces of the e ngine flywheel and the pressure plate ; thereby completely engaging the clutch.
PRESSURE PLATE ENGINE FLYWHEEL PRESSURE SPRING
RELEASE SEARING
1JIr-o;t-~A-DRIVEN DISC
RELEASE LEVER
68·4
TRACTION CLUTC H (Refer to Figure 2) Removal Prior to removal of the clutch it will first be necessary to split the tractor at the engine and transmission. 1. Remove the clutch covel' assembly mount· 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" 110·120 Lbs. at compressed height of 1.52"
68- 5
Figure 2
68-6
MAIN DRIVE SHAFT (Refer to Figure 3) Removal and Disassembly 1.
Remove front cover or hydraulic assembly 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
68·10
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
68·11
Figure 5
68-12
CLUTCH LINKAGE ADJUSTMENT With Suspended Pedal (Refer to Figure 6) The fo ot clutch pedal will ne~d adjustment occasionally to compensa te for normal wear_ The correct free pedal movement should be 1-3/ 8" to 1-5/ 8"_ As the clutch wears, this free movement decreases _ Adjustment must be made before the free pedal movement becomes 1 inch, NOTE: When the tractor is new , it may be necessary to adjust the linka ge several times during the first 50 to 150 hours of operation until the clutch facin gs have " run-in", After this the clutch will seldom require adjustment.
ul ,,-==y.~!!:r~_, ~lUTCH PEDAL
:1_3/1'" TO '-5 / 8-' FREE MOVEMENT
()
HEX NUT
Figure 6 To ob tain the necessary free pedal movement, loosen the hex nut on the clutch rod and remove the pin from the yoke, Turn the yoke off or on the rod until the 1-3/8" to 1-5/8" free peda l is obtained, Install the yoke and pin, Tighten the hex nut. CAUTION
Clutch slippage will seriously damage the clutch fac ings in a short time, If slippage is noted, stop the tractor immediately and make the adjustment listed above,
68-13
CLUTCH LINKAGE ADJUSTME NT With Floor Mounted Pedal (Refer to Figure 7) The foot clutch will need adjustment occasionally to compensate for normal wea r. The correct free pedal movement should be 7/8" to 1-1 / 8" . As the clutch wears, this free movement decreases, Adjus tment mus t be made before the free pedal movement becomes 1/2 inch. NOTE : When the tractor is new, it may be necessary to adjust the linkage several times during the first 50 to 150 hours of operation until the c lutch facings have "run-in ". After this the clutch will seldom require adjustment. 7 / S" TO l-l / S" FREE MOVEMENT
CLUTCH ROD
HEX NUT
\
j
/ YOKE
Figure 7
To obtain the necessary free pedal movement • loosen the hex nut on the clutch rod a nd remove the pin from the yoke. Turn the yoke off or on the rod until the 7/8" to 1-1/ 8" free pedai is obtained. Install the yoke and pin. Tighten the hex nut. CAUTION
Clutch slippage wiil seriously damage the clutch facings in a short time. If slippage is noted. stop the tractor immediately and make the adjustment listed above.
Seclion
69 IND EPE NDENT POWER TAKE-OFF
Rae . Fo rm 9 · 80811
69·2
TABLE OF CONTENTS PTO ASS F::VIB L Y Removal and Installation ................ .. , ................................ , ................ .. ..... , ......................... 69·3 PTO CLCTCH Disassembly and Inspec tion ,., ....... ' .... ...... .... ... ..... ...... ......... ..... .... ....... ....... .......... ....... ......... 69·4 PTO CLCTCH Assembly .. " ..................... , ...... , ................................................ .... ..... , ....... .... ,........................ 69·6 INPUT SHAFT Ai\ D CLUTCH DRUM Disassembly Inspection and AssE'mbly ................................................................................. 69·8 PTO CLCTCH AD.J USTMEi\T .. ,.. ...... .......... .. , ......................... ................. ......... .. ...... ........... . 69·10
69·3
PTO ASSEMBLY (Refer to Figure 1) Removal 3. Remove the four retaining nuts and twO 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
o
/
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
69·8
INPUT SHAFT AND CLUTCH DRUM ( Refer to Figure 4)
Disassembly 1. Remove the two Phillips hea d c-apscrews
(1) tha t holds the rear housing: (2:1 to 100 front housi ng (3). R('movc g a sk~l (il. (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
69·10
PTO CLUTCH ADJUSTMENT (Refer to Figu re 5) The Independent PTO clutch will need adjustment occasionally to compensate for normal wear. Adjust the clutc h immediately if slippage is noted when a power take-off driven machine is a ttached and started. Failure to make the adjustment will cause excessive wear on the clutch plates resulting in eventual breakdown.
A
(( 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 ... ........................................................... .......... ... ... ... ......"... 1·1/4 to 1·.314" Brake lower rod length (Flanged Axle Only) ................. ......................... ......... .................. }4·3/ 4" Maximum pedal free travel (Prior to adjustment) ............ ....... ........................................ ... 2·1 / 4" P arking brake ten sion a djus tme nt ............ .............. ... Turn handle clock-w ise to increase tension. turn counter- clockwise to release tension. Brake lever return spring: Number of coil s ................................ .......... .. ........... ....... ..... .. .. .... ... ....... ..... .. .............. ...... 22·1 / 4 Free length .......................................................................................................... ............. 4.625 " Wire diameter ... ................................... ........... ... .... ....... ................ ................ ..................... . 135" Outer differential lock lever spring: Length ........................... .... ......................................... ........ ...... ........................ .. ............. 2· 1/ 16" LD ......................... .......... .............. ............................ .... ... ... ...... .. ........................................ 844" Wire diameter ....... ......... ...................... ..... ...... .. .. ............................. ... ...... .. ........................ 192" No. of coils .................................... .. .. ...... .................. ......... .. ............... .. .... ... ........................ .... 5 Free angle between wire ends ................ .......... ... .... ....... .... ........ .. ..... ..... ............... .. ............ 1380 Torque wl ends at 1120 angle ..................... ................ ... .. ............................... 42.1 to 94 .7 in. Ibs. Inner differential lock lever spring: Length ............................... ............ ............. .. ....................... .... ... .. ...... ............ ................ 1· 13/ 16" LD ..... ..... ... ....... ... ...... .. .......... ....... ..... ............ ......................................... ..... .......... .. ............ 844" Wire diameter ........................ .......... ... ... ............................................................ ................. 135" No. of coils ......................... ...... ........................................... ............................................... 5·1 / 2 Free angle between wire e nd s ....................... ............................ ....... ...... .. ............................. 81" Torque w l short end at 24 0 a ngle ................................................................... 17.8 to 28.1 in. lbs.
SPECIAL TORQUE Bra ke cover to transmission bolt ............................................. ............................. 70 to 90 ft. lbs.
Rae . Form 9-80691
74-2
BRAKE PEDA LS AND LINKAGE (Refer to Figure 1) l. Cotter pin, 118 x I " (4), 2. Yoke pin, (4).
3. Pivot rod, brake pedal (2). 4. Snap ring, pedal reta ini ng. 5. Brake pedal, R.H. 6. Equalizer lever (power Shuttle Only), At installation, press onto shaft with key (11) to allow .05" e nd play between L.B. orake pedal aDd steering ~olumn. 7_ Bolt, I ! 2 x 1-1 / 2" N.C. Hex . Hd. 8. Link spacer (POWer Shuttle Only). 9. Equali zer li nk (Power Shuttle Only)_ 10. Roll pin, :3/16" x I ". At installation , install so that protrudes approximately li2" of bottom of the equalizE'r level'. Il. Key, Woodruff ~A. 12. Brake pedal, L.H. 13. Stop stud , brake pedal. 14. Equalizer insert, brake pedal (2) (Power Shuttle Only). 15. Spiral pin, 1 / 8 x 9/ 16" (4). 16. Lube fitting, 1/8" P.T., 90 0 iC2) 16. Lube fitting, 1/8" P. T., 90" (2) . 17. Roll pin, 5116 x 1-1/4" 18. Interlock , brake pedals_ 19. Cotter pin, 1/8 x 1" (4) . 20. Washer, 1/ 8 x I-l i S x 21/32" 1.0. (2)_ 2l. Clevis pin ('1). 22. Lower brake lever rod (2 ) . 23. Rod yoke (2) . 24. ,Jam nut, 1 /2" :-':.F_ hex. (2). 25. Snap ring, pivot level' 26. Brake r od pivot lever, R.H. 27. Brake rod pivot lever, L.H. 28. Lube fitting (1/8" P.T. Straight) (2). 29. Stub shaft, pivot levers. 30. Return spring, lever. Check spring for broken ooil~ ~nd for th e following specific at ions. Number of coils ............... __ .. _........ _................. " .. ............................................... _........... 22-1 / 4 Free length ................... ....... .......... ........ _. ... ...... " ........................................... _........... .... 4.625" Wire diameter ............ ........ ............ ... , ..................................... _........... , ... , ... , ........... 1:35" 3l.Jam nut, 7116" :-':.F. hex. (2). 32. Adjusting nut, iil6" :--:.F. (2). 33. Snap ring, brake pivot shaft (2). 34. Washer, cross sha ft (2 ) , 35. Brake lever, R. H. Outer 36. Brake lever, R.H. inner, Install with key 1I00 a)l(lw .06" clearance between the lever and transmission hOll sing. 37. Brake leve r, L.H. 38, Key, Woodrllff ~15 (2). 39. Spacer, L. H. bra ke lever. 40. Cross shaft, brake. 4l. Lube fitting. 42. Spring Anchor 43. Spring Anchor (Hydros tatic ) 44. Bolt, 3/ 8 x 1-3/4" :--:. c. hex. hd. (2). 45. Loekwasher, 3/8" Std. (2). 46. Nut, 3/ 8" N.C. hex. (2 ) . 47. Bolt, 3/ 8 x 1" N.C. hex. hd . (2) . 4S. Lockwasher, 3/ S" Std. (2).
74 ·3
Figure 1
7~-4
DIFFE RENTIA L BRAKES (Ref er to Figure 2) Disassembly l. Remove locknut (1) and ad ju sti ng nut (2)
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
t
@) , .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 ...... ................................ . 5·1 / 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
I
9
INSET 8
t~ e·-CD
I
,
e~
cor-~~ ~
~ -
I
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
2
Neutral Sta rt Switch
Starter Motor "S"
Yellow
2A
Start Button
Neutral Start Switch
Yellow
2B
Key Switc h " IGN "
Starter Button
Yellow
3
Alternator Resistor 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
."
~."..
o ......
.....,,,.
.
. ..... "
C.,....'Clq.
@oo CD • • '''''''
""""~US
.......
£O""CIO"
(
I
I I I
'"
I I
....,.
"
. ...'''''.
~"_H
.......
......,. ".".
...." - --;
'" ':'" " .. . .. vo.
'"
eo (j). oo
(I'
01 . . . . . " .......
....,_.... , ........ /
(
/'
I'
/
-"
.. ... '-
-'"
"
~
~- ,
....... ",",'''' ---!
I
..m .. i.~
........",.
............
\ .cO
81-5
SPARK IGNITION BASIC LOADER TRACTOR WIRING AND CODE TO
FROM
REF .
WIRE COLOR
1
Ammeter Gauge
Alternator (+)
Orange
1A
A mmeter Gauge
Key Switch "BAT"
Orange
2
Neutral Start Switch
Starter Motor "S"
Yellow
2A
Starter Button
Neutral Start Switch
Yellow
2B
Key Switch " IGN "
Starter Button
Yellow
3
Alternator Resistor
Alternator " AUX "
Brown
3A
Key Switch " IGN "
Alternator Resisto r
Brown
4
Engine Temp. Gauge
Engine Temp. Sender
5
Light Switch
Aux . Lamp Outlet
6
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
81·6
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
7
L.H. Tail light
Harness Black Plug
Green
7
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
Back·Up Alarm
Gro u nd
Black
Back-Up Alarm Switch
Back·Up 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
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a
5/8" - IiC
I,
-
N~
SE E 1101£ 2
(i))
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/ 3 / 4"- "C x 6-3 / 4" (2)
/1
/C
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1
./
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fI" -:/
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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
T
~""
~
.,
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
3
BOLTS /lUST BE I I/S TALL£O 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.
4
l " - :IF rWT(4)- ®
~2s:
(~l
-
uPPER ,,,,aura I riG
/
KLiK PI N(4)
BR;\CK ET
I MOUI
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
5
~c\_"_ '-.. ~~
REPLACEAB LE CUTTING EDGE
BM66 0 744
figu r e 4 - Moldboard Assembly L OGG ING AND PALLET F ORKS
The Model 35 Loader arms can be u sed 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
6
Figure 6
-
Pallet and Logging Forks With Grapple
5/8' SEE
H
1: TORQUE
MOTE St: TORQUE
TO 160- 180 FOOT- POU.'iOS
TO 250- 290 FOOT- P O U N D S
Figure 6
-
A
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 ..
3
Operation . . . .
3
Adjustment of Bucket P os ition.
3
ANTI-ROLLBACK ..
4
Adjustment ...
4 5
STANDARD BUCKET. Cutting Edge Removal a nd Replacement
5
Tooth Shank Removal a nd Roplace ment ..
5
Tooth Replacement
6
4-IN-l BUCKET . . . ..
6
Clam Cutting Edge Removal a nd Repl acement .. Blade Cutting Edge Removal and Replacement . .
6
. ..... .
. . . . .
. . . . . . ..
6
REiIIlOVING LOADER FRONI THACTOR . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . ..
8
Removing Loader to Service Tractor . . . .
. . . . . . . . ..
8
Removing Loader to Use Tractor as Drawbar Unit
. • . • . • . . ..
9
EXPLODED VIEWS . . . . . . . .
. 10
Control Lever Install ation
. 10
Exploded View of Loader
.11
Basic Hydraultcs. . . . ..
. ............ .
. . . . . . . . . 12
Lift, Hydra-Leveling and Tilt Cylinder Hydraulics . . . .
· . . . 13
4-in-l Bucket Hydraulics
· . . . 14
4-in-l Bucket Hydraulics, Loader Frame . • . . • . . . . . . . . . . .
· . . . 15
2
RETURN-TO-DIG
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 Bu·eket "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
3
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 E·7018. flll opening made in each corner. 50S I TI Oil Toe Hi CLOSt ;}::i ?OS S aL£ TO CUH I +!G ,t[ 1m
/
J.'!1ILf:
/
I*iTAINHH; wJ£ft/\LL VlrifN'jj
, 64
j
7'" ,
B"CKET
6Lj"
BuCr
74"
;;_ ' /q' 9- 1fL!."
J
C
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
5
L
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.
-------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
r
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.
6
USE ELECTRODE MEETING A.W.S. E 70'8 OR E 9015 SPECIFICATIOi'lS ON ALL WELDS.
\
CLAM ASScMBL v
BLADE ASSEMBL v
I
CUTTING EDG E
Figure 8 - Cutting Edge Welds
7
REMOV IN G LOADER FROM TRACTOR
The loader can be removed from the tr ac tor by either of two means- -as a complete 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,
UPP£R 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,~
/
I
BACKHO E MOUN T I NG
FRAM E
Figure 10 - Re moving SUppOl·t Arms
8
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.
9
EX P LODED VIBWS 3/8' '- l.'C x 4"
<" (4)
3/8" - NC x 2-112"",--ij'
IIASHERX~/
FLAT
3/8"- NC NU T ..........
1/ 8"
O /
h I'
x
. ."1 D
1-
~~J~~'
K" OB LOCK I NG
(2)
RING
'\..
--.1;
I
.v::l
~.
LOADER CONTRO L
.
L I NKAGE
,- ,..,
.;:-
, "" -
LEVfR
LOCK'-IASHER
J/8 " - tlF
fJ ~ - " ~ MOUNTI NG 'J ~ -
... • /
.
LOAOER CONTRO L LE VER BR'CKET
... 8 It
(4- 6) "
.~
I
~ J--
J/8" - I'I C x I "
,
PLATE
~
ANT I- RO LL BACK CRANK Ail O
~o~ OPTIONA L
V'--~LLf2, f'.~CRAI~:EVIS ~h JOIl10~
-----:: RETURtI- TO- OIG LATCH
x
L EVER SHAFT
LOCKII"SH£ R
J/B" - NC NUT
.........
'J CO NTRO L - - SPOO L LI NK 1 LE V~~ ~ ..-c FLAT WAS HER :~ PIVO~ : AIm - ROLL BAC K
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l.J)
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'!:di2 t
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l OA O£R
H
x 5/8"
"
RO LL P I N (2) 1/8" x I "
COTTE~
PI N
1/ 8
COTTE R Pi li
....
x"'; -0'4"-+1
3/ 8" - Nc
I" " "
LOAOER CONTRO L LE VER P IVOT SHA FT "
K"!lOB
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LOC KIoJASHER ~~')
ROL L PI i:
__
I
-
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/:~L;:.?\l _ _ 2- SPOOL V':"LV E
I
PIN
.c -r ~
' <
Q;''''"'!§iJ:t::;<,
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' " SPACER
~ \'d-.. . ilt _
SPOOL
( 2- 4)
~- 3/8"- >lC
NUT
' \ ..:::::-- 3/8" - ~: F NU T
FLAT \lAS HER OPT! OliA L COllTRO L
LEVER 71 0928
Figu r e 11 - Contro l Lever Ins ta ll ation
10
Figure 12
-
Exploded View of Loader
F I L TER COimjlTlmi GIIUGE BREA CHER (2l
~~~
~/900 PIPE ELBa'"
I
90
0
~~:,'''~
I
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'
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fp
X
,
II I
SE STEM
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,
" .~"'" ~bl~
HOSE
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HYDRAULIC OIL FILTER
CO",' ECTOR
(2)
0
90
x 1-3/4" (2)
LOCKWASHER~ n I E, ~~ , " xl" (2)
LOC K ~A SH ER
1/2"-"C
PC'..JER
/ O-RIIlG
BEYr~~
eROS ,RESERV,OIR' SaVER TUBE
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'.1 c.Q --", 3/8"_~IC 3/4'1~/~ LOCKWASHER I.
A
)/8"-'~"!C.X6 ~ ~ I"
QUICK
~
3/4"-IIC x 3/4"
v .,~d
-............. ~ /a~-<.
90° ELBOW--0
,-.
\
"1,0'
.--:::::
"'" J/ B"" ~NC x
3/4"
33" HOSE--
Figure 13 - Basic Hydraullcs
12
-
, ~/
(I
X
I ~/
SCOliliECT------COUPLI"G
RI
~ ) - l!3.~(
,
I
01
°V a-
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,
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45
0
PIPE TEE
~aSE
STE"
A
TO ROD END OF L IFT , T I LT AND HYDRA-L EV El iNG CY lI 'WER S, AN D CLOS 0 EI/O OF CLAA CYli NDER TO CLOS ED EIIO OF Lin , TILT AN D
B HY DRA-L EVELI NG CY LI NDER S,
AllO
RO D EIIO OF CLAM CYLI NOER
CLAl1
0- R I 1111; ---'~:>~/j
1~
1J ~ .I~" O- R I" G COIltI£[ TOR I
l' _-';,..', l 6"-ac
~~
x I"
LOCKIIASHER
jQADJ TEE'
'
......... Lln
T I LT --
FIG . "A"
/ 7 10955
Figu re 14 - Lift, Hyd r a-Le ve ling and Tilt Cyli nder Hyd r au lics
13
1'/ /
3/8"- :IC
8LJ,OE: CuTT
u,~
EO::iE
~-. / C YLI~mE R
?I:~
7109;3.7
Figure 16 - 4-ln-1 Bucket Hydl'aullcs
14
Section
92 SPLITTING THE 480-580 SERIES B TRACTORS BETWEEN THE TORQUE TUBE AND FINAL DRIVE THE FOLLOWING ILLUSTRATION SHOWS THE SPLITlING OF A HYDRO-STATIC DRIVE TRACTOR BUT THE BASIC SPLITTING 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. . . . • . • . • . . . . • • . • • • • . . . . • . . . . ..
3
COliPLlNG BACKHOE TO TRACTOR . • . • . . . • • . . • . . • . . . . . • . . .
.......... 4
SWIl\G TOWEH REMOVAL Ai\D INSTALLATION
.......... 4
DLd"""
THE BACKHOE
......... .
.. .........
6
ASSEMBLIl'.'G THE BACKHOE. . • . . • • • • • • . . . . . . . . . • • • • • . . . • . . . . . . . . . .. 7 DIPPER EXTENSION . . . . • . • . . . . . • . . . . • • . • . . • . • . . . . . . . . . .
B
BUCKET CeTTlNG EDGES A\;D TEETH.
9
EXPLODED VIEWS . • . . . . . . • . . . . • .
12
Standard Control Levers . . . .
12
Twin Le\·er Controls . . . . . .
. • . . . . . . . . . . . . . . . . ..
13
Backhoe (Boom, Bucket, Dipper) . . . . . . . . . . . . . . . . • • . . . . . . . . . . . . . . ..
14
Intermediate Hydraulics . . • • . • • . . . • • • • • • . . • • • . • . • . . . • • • . . • . . • . .•
15
Boom, Dipper, and Bucket lIydraullcs . . . . . . . . . . . .
16
Extendable Dipper . . . . . . . . . . .
17
Extendahle Dipper Hydraulics .. .
18
::Hounting Frarne .
19 . . . ..
Swing Hydraulics
21
Stabilizer Hydraullcs Boom Lockout Hydraulics
20
. . . . . .,
.,
~
. . . . . . . . . . . . .. ~
~
~
22
Hydra-Guide Hydraulics
23
Control Tower . . . . . . . . . . . . . . .
24
2
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
3
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.
4
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
5
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
6
a.
Attach a chain hoist to the dipper arm . Then push the diversion I·alve 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
7
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:
A
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
8
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.
A
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.
A
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 .
9
\
2 PJ',SS 'dEL:)
FI LLET - - -
j
-:'/"~ - !-- 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
~
"
I
TOOTH
1.
Refer to Figure 5. Use a suitable tool and raise the peened portion on eac h side of the tooth and r emove tooth from shank. The peened area may be heated with a torch to aiel in removal. On heavy duty buckets, drive out pin . .
2.
Sllde the new tooth onto the shank as far as it will go and peen each side into depression in shank.
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
U
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
H
I
I I
I
:
I
I
I I
I I I
18"
L 1
,;
SU CK ET
36" BUCKET
'-,
t I
r\
t
-\ \
\
:
I
r-(--'r
I
BUC KET
\
\ I \
1
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
x
7/S"(4) -
B
S'.oIING PEDAL SHAH (2)
COTTER n ' 1/16" x II '
,'"
CLEV I S P",(2 )
MO Uil T (2) 71 0954
Figure 7 - Exploded View of Standard Control Levers
12
Â
STABILIZER
FLAT wASHER(2)
BOOM-SW 1%
1
JO I HT AND
378"- ¥-,'x I - 1 / 2 " ( 2
CONTROL LEVER BRACK
@flD STAB I L I ZER ROCK WH ASSEMBLY
COHTROL VALVE
MOUNT I NG BRACKET C L E V I S ROD(2)COTTER P I H (6) 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
'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
I
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 ' iW€R
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
?
LQ£KIiASH 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)-
7
9'~
'
I
)
I~ DIP PER _
.I
(j I /.:' SPA CER I EACH
/.':,
. ._
SlOE-WJ -
OIPPER CYLI ND ER
I
'
t£--<..:: I , ~
......_~I
Prr~
~9' I ~, / E
IJi1~y(
I
~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 (
i
aol
I
'- ij~ ,.:'b t~r '-J Q1"'--.. I
1/2 " - 1
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 ~
I
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
I
I
! EX TENS IOIJ _ _
en INOER
STAalLIZER CON TROL V,.LVt
\/ .
67" LONe (2)
3/8"- NC x 3- 1/4"
"'
~,.
HOSES TO L.H .
r
STAB I L I ZER
900 A~J. ELB{)\I 9 00 ADJ .
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
K
1- 1/4"
..."
PLAT E
3/8 "- :IC x 2" (3) __ .-:}P> ~'
.." HOSE (4) 33 " LO;IG
900 ADJ.
co:n~ECTOR
Figure 16 - Stabilizer Hydraulics
21
23" LOii G
-
CAP USED WJTHOUT HYDRA-GU 1DE
71 0961
f'igure 17 - Doom Lockou t Hyclraulics .
22
1TO
CLOSED EllD OF e Vl n lDER
2 TO RO D EIID
OF CVl l NDER
7 10957
Figure 18 _ Hydra-Guide HydrauliCs
23
UPPER
FRO~n
0_
/
COVER
)/8"- "C
x
3/4" (5)
-LOW,/ASHER '''' - - FLAT WASH ER
3/4" (4)
.f' " _ LOII eR FRONT COli ER /_
c'"
tx
QU ICK EDGE
...........24 11 LONG
I
L.H. FOOT
3/8"- ;;C
I
'to..
/
QU I CK EOG£ )8" LONG
"
CONTROL TO\IER
I LOCKWASH £R ~~. 3/8"- ;!( x 3/4" -
,::--:,'
"
t
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 -
2
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.
3
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 140·170 foot-pounds.
7.
Tighten the lower tension rod nuts until snug and retol'que the nuts to 450-550 foot-pounds,
II FT .4R11
I
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
4
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 ND£R ROD EflO - 45"
HOSE CLAMP
I
.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
5
f' l TER MOUtlT I NG BOLTS l / Z"-IlC x 1-1 /4" .... ,TH FLAT ~AS H E R AND LOC KwASHER. . fl LT£R
~ oo
HOS E
) /2" - NC x - 3/4" (2)
~
o- R lHG
COUP U he
REL IEF /
CONNECTOR
/
3/8"- tiC x 2- 1/4"
'"
//
3/'~~~~~:'~l~OGKWASH~ ~. .
::;r::::::::;~~=
' / 2' '- NC flU T
L
/
OC~SHER
3/S"·IIC NU T
HOSE
36" 110952
Fil,,"ure 6 - Basic Hydraulics for Three- Point Hitch Only
6
Sectio n
101 HYDR AULIC TESTING TORQUE CONVERTER-POWER SH UTILE
RAe FORM 9 -80981
101-2
CHECKING OPERATING PRESSURES Engine speed 2000 RPM Converter - Power Shuttle oil tempera ture 1100 to 1300F. Pump output - 9.5 GPM minimum CLUTCH BRAKE PEDAL POSITION
1
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"
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
2
Released
Forward and
Revers.e
3
Released
Forward and Reverse
4
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
101·4
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"
...
,
.
(1) .............
4
5 6 7 8 9 10
R21817 221-211 221-425 A21568 220·128 220·145 220-127 220·105 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
",
HYDRA·SLEUTH M20270
60GPM
M20271
30GPM
L I
/.J ~/";
~c~~ TORQUE TUBE DIPSTICK HOLE
HYDRA·SLEUTH
I
SHUT·OFF VALVE OPEN
I~~=-LOAD RPM
I .fer
SHUT·OFF VALVE
LOAD VALVE
GPM 9.5
2000
Closed
Adjust to 375 10 500 PSI
2250
OOled
Adjust to 200 PSI Minimum
'0
43·4 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 ~ ~ -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,
151·3
/--7',
1/
J
,If
j] PUMP
I I
i ~1
J!
CONTROL vAI.VE--· I
/ ' 't
\.
.,\\ \\
\j \ I '-. .../ R.H.
CYUNDER-.......,P=--<'~
1
1.51-4
RIGHT TURN -ENGINE RUNNING (Refer to Figure 2) Reservoir, Filter and Engine Driven Power Pump \\111ellE' \"C'l' the ('nginp is running the power stee ri ng pu n1p ope r ate s con t inuous ly , fir:1\Qng oil [ m nl Ihl' l't'O",'l "\'oir , The resc'l' voit' h as a l)ui lt- in filter r e li e f ,'al v c , If the filte ,' e le m ent be (,Onlt's p luf\~ecl d u(' la llL'gll'ct th" relie f val ve will open a nd a ll ow wlfi lte red oil to pass in to t h,,' pum p. Tile pump has
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 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' \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"
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
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
D
• • D
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:"
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
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.,
,;
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
162·2
INTRODUCTION Torque Converter Th e 1'Ol''1ue Converte r i s mounted to a nd housed in the to rque tube helw een tbe ngille LInd tr ans m iss ion, The to rque c onverter is splincd to a.nd drive n 11Y the e ng ine Oywhe el . Th e o il supply for the tor que convel't.er is s upplied by fL gear tYllE' ]lump driven by th e tOl'qUO 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 tor·us .
The stalor r ccei ves the o il rom the tu.rbine and by means of cu rved vanes , ch anges the cii r ection of the oil IDld cii rects the o il back to the i mpeller .
The 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 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
162·4
NEUTRAL (Refer to Figure 3) Oil Pump . Draws oil from the rese rvoir and supplies the conver ter / power shut tle system. Filler· Filte rs all the transmission oil in the system. Cooler· Co ntrols transmission oil tempera ture. Flow Spool· Controls the flow of oil to ttle converter and clutch spool. Opera ted by the c lu tch pe dal. Power· Shuttle Control Spool . Di rects the flow of oil to e ither the forwa rd or reverse clutCh. Ope r ated by the left ha nd lever on the stee ring column. Clu tch Pressure Regulator· Regulates the c lutch pressure and converte r flow . Converter Press ure Regulator
[{egu la tes the converter and lubrica tion oil pres sure.
Conve rter· :Vlultiplies engine torque . Forward Clutc h
Delivers torque to the transmission for forward trave l.
Reverse Clutch
Delivers torque to the transmission thru a counters haft for reverse travel.
Shuttle Lever in Neutral When t he e ng ine i s running, the oil pump ope r a tes continuous ly , drawing oi l from the reser· voir. The oi l flows fro m the pump th ro ugh th e to rque tube adapter ho us ing, distribution manifold and out of the cont ro l valve th r ough a tube and hose to the filter. F oreign particles a re removed before the oil e nters the cooler. The oil flows from the cooler through a hose and tube back to the control valve. From the cooler the oil e nters the control valve a nd flows around the flow spool to the cl utch pressure reg ulator valve. This maintains the clutch pressure at the shuttle spool an d tile oil not required is allowed to fl ow throu g h the regulator va lve to the torque converter inle t. Oil from the torque converter out let fl ows to and throug h the fl ow spool a nd into t he c lu tc h c ircu its to supply lubrication oil to the power sh u tt le c lutch. Oil not r eq uired by the converter a nd clutch lubrication is a ll o·Ned to fl ow back to the reservoi r by the converte r pressure reg ula tor valve.
,.,
,
'"'I ,"''''''' .,"' '"" .. "'
•
"GH ..... ""
•
,"
'""' .,,"'''' 0 CON"' I " , .. , , " " ANO
[i)"'U'N Q'
162·6
FORWARD Clutch Engaging (Refer to Figure 4) Wh en the tractor engine is running . the oil pump operates continuously, dra\\'ing oil from the r eservoir. The oil flows from the pump through the torque tub" adapter housing, di st ribution manifold and out of the control valv" through a tube and has" to the filter. From the filt"r the oil then flows to the cooler. The oil flows from the cooler, through a hose and tube back to the cont rol valve.
FLOW CONTROL SPOOL AND CLUTCH PRESSURE REGULATOR VALVE With the control valve fl ow spool in the clutch pedal released position , the oil flows around the flow s pool through a passage to the pressure regulator valve. The pressure regul ator va lve reo gu la tes the pressure and flow of oil to the pow" r shuttle control spool a nd by passes the remainder of the oil to the torque converter.
TORQU E CONVERTER The oil for the converter flows [rom the control valve through the distribution manifold and torque tube adapter housing to a passage in the torque tube to the converte r carrie r. The oil flowing into the converter is picked up by the impeller, which forces the oil through the torus to the turbine. The force of the oil against the turbine turns the turbine and output gleev". The oil that is deflec ted off the turbine does not flow back to the reservoir, but Is direc ted back to the impeller by the stator. The oil returning from the converter flows through a passage in the torque tube and adapter housing to the converter pressure regulator valve. The converter pressure regulator valve is located on the return side of the converter circuit and regu late s the pressure within the converter and for lubrication of the power sh!1ttle . An elec trica l sending unit loca ted on the pressure regulator valve indicates the con verter oil temper a ture.
POWER SHUTTLE When the operator moves the sh uttle control lever forward, the power shuttle spool in the control valve moves inward, directing the flow of oil down through the distribution manifold, to rque tube adapter housing, and torque tube to the front port of the clutch shaft. The pres· surized oil flows from the front port of the clutch shaft through a pa ssage in the c lutch shaft (between the clutch shaH and clutc h shaft tube) to a drilled pa ssage which leads to the accel· erator pIston cavity. Pressurized oil entering the accelerator piston ~avity forces the accelerator piston, disc valve and reinforcing disc against th" separator pla te . The disc valve and r e inforcing disc in turn moves the dowel pin, the opposite disc valve, reinforcing disc and accelerator piston away from the separator plate. Then t he pr essurized oil in the accelerator piston cavity starts to move the force piston housing toward the forward clutch. As the force piston housing cavity on the forw a rd clutch side increases , the torce piston cavity on the reverse clutch side decreases an equal amount. The oil from the force piston cavity on the reverse clutch s ide pushes open the disc valve and enters the force pist on housing cavity on the forward clutch side.
Clutch Modulation Once the force pi ston housing ha s begun engagement of the clutch pla tes agains t the clutch baCking plate, the or ific e in th a ccelerator pIs ton allows the clutch pressure Jil from the supply pump to increase the pressure in the force piston housing cavity on the forward clutch side clOSing the disc valve , thereby bu ilding and maintaining clutch pressure. The oil in the fo rce pi s ton cavity on the reverse clutch side is returned to lube pressure and to reservoir.
Clutch Engaged The tra nsferring of oil through the separator plate accelerates the force piston travel and obtains faster engagement since only a small a mount of oil is re quired from the supply pump, therebyeliminating the tim e lag reqUired in a large volume fill.
ISH
. - ....... I!J" ...... ."•
"
O ·v.. ......... .....
CONVI ......,,"'. ,
0 _."",. . ~-
162-8
REVERSE Clutch Engaging (Refer to Figure 5) When the tractor engine is running, the oil pump operates continuously, drawing oil from the reservoir. The oil flows from the pump through the torque tube adapter hose, distribution 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
. .. 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
163·2
INTRODUCTION Torque Converter The Torque Converter is m ounted to and housed In the torque tube between the eng ine and transmission. The torque converter is splined to and driven by the engine flywh eel. The oil supply for the torque conver ter is supplied by a gear type pump driven by th e to rque can· verter.
The impeller is located at the 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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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,
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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.
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{!'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
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Ho\v it Works
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Neutral o r Zero Speed Condition
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Forward Drive Condition
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Reverse Drive Condition
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Overload Condition in Forward Drive Unload Condition
Rac. Form 9-80281
164-8
...............................................-,.,............................... 164-12
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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.
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REVERSE DRIVE Figure 4
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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.
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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.
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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.
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: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.
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