750/760/860/960/965 LOADER BACKHOE SERVICE MANUAL Table of contents DIVISION/SECTION 1
2
SECTION N°
GENERAL Standard torque specifications and loctite product chart .................................1001 Fluids and lubricants ........................................................................................1002
7-79451GB 7-21280GB
ENGINE Engine and radiator removal and installation ...................................................2000 Specifications details .......................................................................................2401
7-21290GB 7-21310GB
3
FUEL SYSTEM
4
ELECTRICAL Electrical schematic .........................................................................................4001 Battery .............................................................................................................4003 Starter motor ....................................................................................................4004 Removal and installation of electrical components ..........................................4005 Alternator .........................................................................................................4007 Steering, loader and backhoe calibration.........................................................4008
5
6
7
REFERENCE N°
STEERING Removal and installation of steering components............................................5000 Steering specifications, pressure checks and troubleshooting (Models 750/760/860)..................................................................................5001 Steering specifications, pressure checks and troubleshooting (Models 960/965).........................................................................................5001 Steering control valve.......................................................................................5002 Steering cylinder ..............................................................................................5003 Front axle, two wheel drive machine/two wheel steer machine (Model 750) .................................................................................................5005 Front axle, four wheel drive machine/two wheel steer machine (Models 750/760/860)..................................................................................5006 Front axle, four wheel drive machine/four wheel steer machine (Models 960/965).........................................................................................5007
7-21320GB 7-21330GB 7-21340GB 7-21350GB 7-21360GB 7-26530GB 7-21370GB 7-21380GB 7-21900GB 7-21390GB 7-21400GB 7-21880GB 7-21410GB 7-21890GB
POWER TRAIN Removal and installation of power train components.......................................6000 Transmission specifications, pressure checks and troubleshooting .................6002 Wheels and tyres .............................................................................................6003 Rear axle two wheel steer (models 750/760/860)............................................6004 Gear box ..........................................................................................................6007 Rear axle-four whell steer ................................................................................6008
7-21420GB 7-21430GB 7-21440GB 7-21450GB 7-21460GB 7-21600GB
BRAKES Removal and installation of brake components ...............................................7000 Disassembly and assembly of brake components ...........................................7003
7-21470GB 7-21480GB
Case
Cre 7-21271GB
Copyright 1999 Case France Printed in France Issued October 1999
DIVISION/SECTION 8
9
SECTION N°
REFERENCE N°
HYDRAULICS Removal and installation of hydraulic components ..........................................8001 Hydraulic specifications, troubleshooting and pressure checks .......................8002 Cleaning the hydraulic system .........................................................................8003 Hydraulic pump and unloader valve.................................................................8004 Loader control valve.........................................................................................8005 Cylinders ..........................................................................................................8006 Backhoe control valve ......................................................................................8007 Extending dipperstick control valve ..................................................................8008 Priority demand valve ......................................................................................8010
7-21500GB 7-21510GB 7-21520GB 7-21530GB 7-21540GB 7-21620GB 7-21550GB 7-21560GB 7-21570GB
MOUNTED/EQUIPMENT Pedals and levers.............................................................................................9001 Loader..............................................................................................................9006 Cab and Rops ..................................................................................................9007 Backhoe ...........................................................................................................9008 Seat and seat belt ............................................................................................9009 Removal and installation of components .........................................................9011
7-21630GB 7-21650GB 7-21660GB 7-21670GB 7-21680GB 7-21690GB
Cre 7-21271GB
Issued 10-99
1001 Section 1001 STANDARD TORQUE SPECIFICATIONS AND LOCTITE PRODUCT CHART
Case
Cre 7-79451GB
Copyright ï›™ 1999 Case France Printed in U.K. Issued June 1999
1001-2
TABLE OF CONTENTS TORQUE SPECIFICATIONS - DECIMAL HARDWARE ........................................................................................... 2 TORQUE SPECIFICATIONS - METRIC HARDWARE ............................................................................................. 3 TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS ...........................................................................4-5 LOCTITE PRODUCT CHART .................................................................................................................................. 6
TORQUES SPECIFICATIONS (DECIMAL HARDWARE) Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.
Grade 5 Bolts, Nuts and Studs
Grade 8 Bolts, Nuts and Studs
Size
Poundinches
Newton metres
1/4 inch
12 to 15
16 to 20
5/16 inch
24 to 29
33 to 39
3/8 inch
45 to 54
61 to 73
Newton metres
7/16 inch
70 to 84
95 to 114
Size
Poundinches
1/2 inch
110 to 132
149 to 179
1/4 inch
8 to 11
12 to 15
9/16 inch
160 to 192
217 to 260
5/16 inch
17 to 21
23 to 28
5/8 inch
220 to 264
298 to 358
3/8 inch
35 to 42
48 to 57
3/4 inch
380 to 456
515 to 618
7/16 inch
54 to 64
73 to 87
7/8 inch
600 to 720
814 to 976
1/2 inch
80 to 96
109 to 130
1.0 inch
900 to 1080
1220 to 1465
9/16 inch
110 to 132
149 to 179
1-1/8 inchs
1280 to 1440
1736 to 1953
5/8 inch
150 to 180
203 to 244
1-1/4 inchs
1820 to 2000
2468 to 2712
3/4 inch
270 to 324
366 to 439
1-3/8 inchs
2380 to 2720
3227 to 3688
7/8 inch
400 to 480
542 to 651
1-1/2 inchs
3160 to 3560
4285 to 4827
1.0 inch
580 to 696
787 to 944
1-1/8 inchs
800 to 880
1085 to 1193
1-1/4 inchs
1120 to 1240
1519 to 1681
1-3/8 inchs
1460 to 1680
190 to 2278
1-1/2 inchs
1940 to 2200
2631 to 2983
Cre 7-79451GB
NOTE : Use thick nuts with Grade 8 bolts.
Issued 06-99
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1001-3
TORQUE SPECIFICATIONS (METRIC HARDWARE) Use the following torques when specifications are not given.
Grade 10.9 Bolts, Nuts and Studs
These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.
Grade 8.8 Bolts, Nuts and Studs 8.8
10.9 Size
Poundinches
Newton metres
M4
3 to 4
4 to 5
M5
7 to 8
9 to 11
M6
11 to 13
15 to 18
Newton metres
M8
27 to 32
37 to 43
Size
Poundinches
M10
54 to 64
73 to 87
M4
2 to 3
3 to 4
M12
93 to 112
125 to 150
M5
5 to 6
7 to 8
M14
149 to 179
200 to 245
M6
8 to 9
11 to 12
M16
230 to 280
310 to 380
M8
19 to 23
26 to 31
M20
450 to 540
610 to 730
M10
38 to 45
52 to 61
M24
780 to 940
1050 to 1275
M12
66 to 79
90 to 107
M30
1470 to 1770
2000 to 2400
M14
106 to 127
144 to 172
M36
2580 to 3090
3500 to 4200
M16
160 to 200
217 to 271
M20
320 to 380
434 to 515
M24
500 to 600
675 to 815
M30
920 to 1100
1250 to 1500
M36
1600 to 1950
2175 to 2600
Cre 7-79451GB
Grade 12.9 Bolts, Nuts and Studs 12.9 Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.
Issued 06-99
1001-4
TORQUE SPECIFICATIONS (STEEL HYDRAULIC FITTINGS) Tube OD Hose ID
Thread size
Poundinches
Newton metres
Tube OD Hose ID
37 Degree flare fitting
Thread size
Poundinches
Newton metres
Straight threads with O-ring
1/4 inch/ 6.4 mm
7/16-20
6 to 12
8 to 16
1/4 inch/ 6.4 mm
7/16-20
12 to 19
16 to 26
5/16 inch/ 7.9 mm
1/2-20
8 to 16
11 to 22
5/16 inch/ 7.9 mm
1/2-20
16 to 24
22 to 34
3/8 inch/ 9.5 mm
9/16-18
10 to 25
14 to 34
3/8 inch/ 9.5 mm
9/16-18
24 to 40
34 to 54
1/2 inch/ 12.7 mm
3/4-16
15 to 42
20 to 57
1/2 inch/ 12.7 mm
3/4-16
42 to 67
57 to 91
5/8 inch/ 15.9
7/8-14
25 to 58
34 to 79
5/8 inch/ 15.9
7/8-14
58 to 92
79 to 124
3/4 inch/ 19.0 mm
1-1/16-12
40 to 80
54 to 108
3/4 inch/ 19.0 mm
1-1/16-12
80 to 128
108 to 174
7/8 inch/ 22.2 mm
1-3/16-12
60 to 100
81 to 135
7/8 inch/ 22.2 mm
1-3/16-12
100 to 160
136 to 216
1.0 inch/ 25.4 mm
1-5/16-12
75 to 117
102 to 158
1.0 inch/ 25.4 mm
1-5/16-12
117 to 187
159 to 253
1-1/4 inch/ 31.8 mm
1-5/8-12
125 to 165
169 to 223
1-1/4 inch/ 31.8 mm
1-5/8-12
165 to 264
224 to 357
1-1/2 inch/ 38.1 mm
1-7/8-12
210 to 250
285 to 338
1-1/2 inch/ 38.1 mm
1-7/8-12
250 to 400
339 to 542
Split flange mounting screws Size
Poundinches
Newton metres
5/16-18
15 to 20
20 to 27
3/8-16
27 to 40
36 to 53
7/16-14
35 to 45
47 to 61
1/2-13
55 to 65
74 to 88
5/8-11
140 to 150
190 to 203
Cre 7-79451GB
Issued 06-99
1001-5
TORQUE SPECIFICATIONS (STEEL HYDRAULIC FITTINGS) Nom. SAE dash size
Tube OD
Thread size
Poundinches
Newton metres
Thread size
Poundinches
Newton metres
O-ring boss end fitting or lock nut
O-ring face seal end -4
1/4 inch/ 6.4 mm
9/16-18
10 to 12
14 to 16
7/16-20
17 to 20
23 to 27
-6
3/8 inch/ 9.5 mm
11/16-16
18 to 20
24 to 27
9/16-18
25 to 30
34 to 41
-8
1/2 inch/ 12.7 mm
13/16-16
32 to 40
43 to 54
3/4-16
45 to 50
61 to 68
-10
5/8 inch/ 15.9 mm
1-14
46 to 56
62 to 76
7/8-14
60 to 65
81 to 88
-12
3/4 inch/ 19.0 mm
1-3/16-12
65 to 80
90 to 110
1-1/16-12
85 to 90
115 to 122
-14
7/8 inch/ 22.2 mm
1-3/16-12
65 to 80
90 to 110
1-3/16-12
95 to 100
129 to 136
-16
1.0 inch/ 25.4 mm
1-7/16-12
92 to 105
125 to 140
1-5/16-12
115 to 125
156 to 169
-20
1-1/4 inch/ 31.8 mm
1-11/16-12
125 to 140
170 to 190
1-5/8-12
150 to 160
203 to 217
-24
1-1/2 inch/ 38.1 mm
2-12
150 to 180
200 to 254
1-7/8-12
190 to 200
258 to 271
Cre 7-79451GB
Issued 06-99
1001-6
Primer
Dark brown
24 h
764
80
Yellow
Fast
764
123
Clear
-
-
220
Blue
290
0.076
65/164 in lbs
-54 to +122
6 min/24 h
747
221
Purple
222
0.127
86/50 in lbs
-54 to +150
2 min/24 h
747
Low strength threadlocker
222
Purple
0.127
51/28 in lbs
-54 to +150 10 min/24 h
747
Low strength threadlocker (small screws)
225
Brown
0.254
51/28 in lbs
-54 to +150
7 min/24 h
747
Low strength threadlocker
242
Blue
0.127
92/57 in lbs
-54 to +150 10 min/24 h
747
Medium strength threadlocker
262
Red
271
0.127
184/218 in lbs
-54 to +150
5 min/24 h
747
High strength threadlocker
270
Green
271
0.177
184/368 in lbs
-54 to +150
3 min/24 h
747
High strength threadlocker
271
Red
262
0.177
184/368 in lbs
-54 to +150 10 min/24 h
747
High strength threadlocker
272
Red
620
0.254
207/311 in lbs
-54 to +234 30 min/24 h
747
High temperature, high strength
275
Green
277
0.254
241/345 in lbs
-54 to +150
3 min/24 h
747
High strength threadlocker
277
Red
0.254
241/345 in lbs
-54 to +150 60 min/24 h
747
High strength threadlocker
290
Green
0.076
97/403 in lbs
-54 to +150
6 min/24 h
747
Wicking threadlocker
*404
Clear
0.156
224 psi
-54 to +82
30 sec/24 h
-
Instant adhesive
*406
Clear
0.101
224 psi
-54 to +82
15 sec/24 h
-
Surface insensitive adhesive
*409
Clear
0.203
175 psi
-54 to +82
50 sec/24 h
-
Gel instant adhesive
*414
Clear
0.156
175 psi
-54 to +82
30 sec/24 h
-
Instant adhesive
*415
Clear
454
0.254
175 psi
-54 to +82
50 sec/24 h
-
Gap filling instant adhesive (metals)
*416
Clear
454
0.254
175 psi
-54 to +82
50 sec/24 h
-
Gap filling instant adhesive (plastics)
*420
Clear
0.05
175 psi
-54 to +82
15 sec/24 h
-
Wicking instant adhesive
*422
Clear
0.05
196 psi
-54 to +82
60 sec/24 h
-
Gap filling instant adhesive
*430
Clear
0.127
175 psi
-54 to +82
20 sec/24 h
-
Metal bonding adhesive
222
495 454
454
Description
Fixture/full cure (steel/steel) time
Working temperature range-fahrenheit
Strength (steel/steel)
Colour
#3
Gap (inches)
Product
Similar products
LOCTITE PRODUCT CHART
Form a Gasket (works with oil, fuel or greas) Pliable Weatherstrip adhesive Parts cleaner fluid Wicking threadlocker
* Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity. Cre 7-79451GB
Issued 06-99
Gap (inches)
Strength (steel/steel)
Working temperature range-fahrenheit
Fixture/full cure (steel/steel) time
Primer
White/ Black
6.35
140 psi
-54 to +82
5 min/24 h
-
Fast setting 2 part epoxy
*454
Clear
0.254
224 psi
-54 to +82
15 sec/24 h
-
Surface insensitive gel instant adhesive
*495
Clear
0.101
175 psi
-54 to +82
20 sec/24 h
-
General purpose instant adhesive
*496
Clear
0.127
175 psi
-54 to +82
20 sec/24 h
-
Metal bonding adhesive
504
Brt orange
0.076
52 psi
-54 to +150 90 sec/24 h
510
Red
0.05
70 psi
-54 to +206 30 min/24 h
764
High temperature, gasket eliminator
515
Purple
0.254
52 psi
-54 to +150
1 hr/24 h
764
Gasket eliminator 515
518
Red
515
0.076
35 psi
-54 to +150
1 hr/24 h
764
Gasket eliminator 578 for aluminum
542
Brown
569
-
152/106 in lbs
-54 to +150
2 hr/24 h
747
Hydraulic sealant
545
Purple
-
28/23 in lbs
-54 to +150
4 hr/24 h
747
Low strength pneumatic/hydraulic sealant
549
Red
504
0.05
175 psi
-54 to +150
2 hr/24 h
747
Instant seal plastic gasket
554
White
277
0.381
276/240 in lbs
-54 to +150 2 to 4 hr/24 h
764
Refrigerant sealant
567
Orange
592
-
35 psi
-54 to +206
4 hr/24 h
764
Pipe sealant for stainless steel
568
Brown
277
0.381
175 psi
-54 to +150
12 hr/24 h
764
Plastic gasket
569
Brown
545
0.254 28/46 in lbs
-54 to +150
1 hr/24 h
764
Hydraulic sealant
570
Brown
592
-54 to +150
6 hr/24 h
764
Steam sealant
571
White
592
764
Pipe sealant
572
White
578. 575
515
-
28/46 in lbs
0.381 46/23 in lbs -
92/31in lbs
-54 to +150 2 to 4 hr/24 h -54 to +150
24 hr/24 h 4 hr/24 h
Description
Colour
*445
Similar products
Product
1001-7
None Rigid gasket eliminator
None Gasketing
592
Black
-
0.05
35 psi
-54 to +206
593
Green
-
6.35
28 psi
-54 to +206 30 min/24 h
-
601
Green
609
0.127
210 psi
-54 to +150 10 min/24 h
747
Current PIN #609
609
Green
-
0.127
210 psi
-54 to +150 10 min/24 h
747
General purpose retaining compound
620
Green
640
0.381
210 psi
-54 to +234 30 min/24 h
747
High temperature. Retaining coumpound
635
Green
680
0.254
280 psi
-54 to +150
747
High strength retaining compound
638
Green
680
0.381
287 psi
-54 to +150 10 min/24 h
747
High strength retaining compound
640
Green
620
0.177
210 psi
-54 to +206
747
High temperature retaining compound
1 hr/24 h 1 hr/24 h
736
Pipe sealant with teflon RTV silicone
660
Silver
-
0.05
210 psi
-54 to +150 20 min/24 h
764
Quick metal
675
Green
609
0.127
210 psi
-54 to +150 20 min/24 h
747
General purpose retaining compound
680
Green
635
0.381
280 psi
-54 to +150 10 min/24 h
747
High strength retaining compound
706
Clear
755
-
-
-
-
-
Cleaning solvent
707
Amber
-
-
-
-
-
-
Activator for structual adhesives
736
Amber
-
-
-
-
-
-
Primer NF
738
Amber
-
-
-
-
-
-
Depend activator
Cre 7-79451GB
Issued 06-99
Colour
Similar products
Gap (inches)
Strength (steel/steel)
Working temperature range-fahrenheit
Fixture/full cure (steel/steel) time
Primer
747
Yellow
-
-
-
-
-
-
Primer T
751
Clear
-
-
-
-
-
-
Activator for structural adhesives
755
Clear
-
-
-
-
-
-
Cleaning solvent
764
Green
-
-
-
-
-
-
Primer N
767
Silver
-
-
-
-54 to +878
-
-
Anti-seize lubricant
Cre 7-79451GB
Description
Product
1001-8
Issued 06-99
1002
Section 1002 FLUIDS AND LUBRICANTS
Case
Cre 7-21280GB
Copyright ï›™ 1999 Case France Printed in U.K. Issued June 1999
1002-2
TABLE OF CONTENTS CAPACITIES AND LUBRICANTS.............................................................................................................................3 ENGINE OIL RECOMMENDATIONS........................................................................................................................5 Oil viscosity/Oil operating range............................................................................................................................5 FLUIDS AND LUBRICANTS .....................................................................................................................................6 Hydraulic fluid........................................................................................................................................................6 Transmission component oil .................................................................................................................................6 Grease ..................................................................................................................................................................6 Anti-freeze/anti-corrosion ......................................................................................................................................6 Fuel .......................................................................................................................................................................6 Fuel storage ..........................................................................................................................................................6 ENVIRONMENT ........................................................................................................................................................7 PLASTIC AND RESIN PARTS ..................................................................................................................................7
Cre 7-21280GB
Issued 06-99
1002-3
CAPACITIES AND LUBRICANTS Engine Oil Capacity with filter replacement ............................................................................................................. 10.7 litres Type of oil ................................................................................................... refer to “Engine oil recommendations” Engine cooling system Capacity ................................................................................................................................................. 16.5 litres Type of collant solution .......................................................................................... refer to “Fluids and lubricants” Fuel tank Capacity .................................................................................................................................................. 120 litres Type of fuel .............................................................................................................. refer to “Fluids and lubricants" Hydraulic system Total hydraulic system capacity model 750............................................................................................... 90 litres Total hydraulic system capacity model 760................................................................................................ 90 litres Total hydraulic system capacity model 860................................................................................................ 90 litres Total hydraulic system capacity model 960................................................................................................ 90 litres Total hydraulic system capacity model 965................................................................................................ 90 litres Hydraulic reservoir filling capacity with filter replacement ......................................................................... 45 litres Hydraulic reservoir filling capacity without filter replacement .................................................................... 43 litres Type of fluid ............................................................................................................ refer to “Fluids and lubricants” Transmission 2-Wheel drive Total system .......................................................................................................................................... 19 litres Filling with or without filter replacement ................................................................................................ 15 litres Type of oil ....................................................................................................................API cd/se grade 10W30 4-Wheel drive Total system .......................................................................................................................................... 19 litres Filling with or without filter replacement ............................................................................................... 15 litres Type of oil ....................................................................................................................API cd/se grade 10W30 Front Axle 4-Wheel steer Axle centre housing ............................................................................................................................... 8 litres Axle hubs (each) .................................................................................................................................. 4.5 litres Type of oil ..........................................................................................................................HI LOAD GEAR OIL 2-Wheel steer Axle centre housing ............................................................................................................................... 8 litres Axle hubs (each) .................................................................................................................................... 1.1 litre Type of oil ..........................................................................................................................HI LOAD GEAR OIL
Cre 7-21280GB
Issued 06-99
1002-4 Rear axle 4-Wheel steer Axle centre housing ............................................................................................................................... 8 litres Axle hubs (each) .................................................................................................................................. 4.5 litres Type of oil ..........................................................................................................................HI LOAD GEAR OIL 2-Wheel steer Capicity ............................................................................................................................................. 22.5 litres Type of oil ..........................................................................................................................HI LOAD GEAR OIL Brake fluid reservoir ...........................................................................................................................LHM brake fluid
Cre 7-21280GB
Issued 06-99
1002-5
ENGINE OIL RECOMMENDATIONS Temperate climates
The engine oil to be used depends on the ambient temperature.
-5°C to +40°C Oil type SAE 30
Use only oil of the API/CD category. NOTE : Do not put any performance additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out on lubricants.
Hot climates 60°C and + Oil type SAE 40
Cold climates -30°C to + 10°C Oil type SAE 10W30
Oil viscosity/Oil operating range A
B IO36LO
A : FAHRENHEIT TEMPERATURE B : CENTIGRADE TEMPERATURE
Cre 7-21280GB
Issued 06-99
1002-6
FLUIDS AND LUBRICANTS Fluids and lubricants must have the correct properties for each application. WARNING : The conditions of use for individual fluids and lubricants must be respected.
Hydraulic fluid
Anti-freeze/anti-corrosion
Hydraulic fluid is specially designed for the high pressure and the hydraulic system used on machines. The type of fluid to be used depends on the ambient temperature.
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
Temperate climates -5°C to +40°C Fluid type : ISO VG 46
Hot climates 5°C to +55°C Fluid type : ISO VG 68
Cold climates -20°C to +30°C Fluid type : ISO VG 32
Transmission component oil Extreme pressure oil is used for all cased transmission components. Extreme pressure oil type API CD/SE. Grade 10W30 or ISO VG 150
Grease The type of grease to be used depends on the ambient temperature.
Temperate and hot climates -20°C to + 60 °C Extreme pressure grease EP NLGI. Grade 2 with molybdenum disulphide.
Cold climates -40 °C to + 20°C Extreme pressure grease EP NLGI Grade 0
Cre 7-21280GB
For environments with a temperature higher than -36°C, use a mixture of 50% ethylene-glycol based antifreeze. For environments with a temperature lower than -36°C, a mixture of 40% water with 60% anti-freeze is recommended.
Fuel The fuel to be used must be in conformity with the D975 standard of the American Society for Testing and Materials (ASTM). Use No. 2 type fuel. The use of other fuels may cause a loss of engine power and excessive fuel consumption. In cold weather, a mixture of No. 1 fuel and No. 2 fuel is temporarily permitted. Consult your fuel supplier. If the temperature falls below the fuel cloud point (point at which wax appears), wax crystals in the fuel will cause a loss of engine power or make it impossible to start the engine. IMPORTANT : In cold weather, fill the fuel tank after each day’s work, to prevent the formation of condensation.
Fuel storage Prolonged fuel storage causes foreign bodies or condensation water to accumulate in the storage tank. Many engine failures are caused by the presence of water in fuel. The storage tank should be placed outdoors and the fuel should be kept at as low a temperature as possible. Condensation water should be drained off at regular intervals.
Issued 06-99
1002-7
ENVIRONMENT Before carrying out any maintenance operation on the machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never put them in leaky receptacles.
Consult a local recycling or environmental centre, to obtain information on the correct method of disposing of these materials.
PLASTIC AND RESIN PARTS When cleaning plastic windows, the console, the instrument panel, the gauges, etc, avoid the use of petrol, paraffin, paint solvents, etc. Use only water, soap and a soft cloth. The use of petrol, paraffin, paint solvents, etc will cause discoloration, cracks or deformation of these parts.
Cre 7-21280GB
Issued 06-99
Section 2000
Case
Cre 7-21290GB
Copyright ï›™ 1999 Case France Printed in France October 1999
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
2000-2
TABLE OF CONTENTS SPECIFICATIONS..................................................................................................................................................... 3 SPECIAL TORQUE SETTINGS ................................................................................................................................ 3 TOOLS REQUIRED .................................................................................................................................................. 3 RADIATOR REMOVAL .............................................................................................................................................4 PERSPECTIVE VIEW ............................................................................................................................................... 6 ENGINE REMOVAL .................................................................................................................................................. 7 INSTALLATION .......................................................................................................................................................13
!
WARNING : This symbol is used in this manuel to indicate important safety messages. When ever you see this symbol, carefully read the message that follows, as there is a risk of serious injury.
Cre 7-21290GB
Issued 10-99
2000-3
SPECIFICATIONS Cooling System capacity : System capacity ..................................................................................................................................................9.8 L Expansion reservoir capacity..................................................................................................................................1 L Engine/Radiator capacity.....................................................................................................................................6.6 L Coolant solution............................................................................................................................... See section 1002
SPECIAL TORQUE SETTINGS Torque converter mounting bolts ...................................................................................................................... 41 Nm Engine mounting bolts ............................................................................................................................ M16 280 Nm Engine mounting nuts............................................................................................................................... M10 48 Nm Transmission mountings......................................................................................................................... M12 140 Nm M20 395 Nm
TOOLS REQUIRED Engine lifting bracket
Cre 7-21290GB
Issued 10-99
2000-4
RADIATOR REMOVAL Put identification tags on all disconnected hoses and wires. Close disconnected hoses and fittings with caps and plugs.
STEP 1 Park the machine on a level surface. Raise the loader and install the support strut to hold the loader.
STEP 2
STEP 9 Tag and disconnect the wires on the audible warning device.
STEP 10 Tag and disconnect the wires on the hydraulic filter obstruction indicator.
STEP 11
Open the hood.
STEP 3
33 11
Remove the bolts, washers, and nuts from the pivot point on the hood.
STEP 4 Have another person help with the following procedure : A. Remove the retainers from the hood struts and disconnect the hood struts from the stud.
22
B. Remove the hood from the machine. 789M250A
STEP 5 Slowly remove the radiator cap.
!
Release the fluid pipes (1) and electrical connections (2) to the screen wash bottle (3) and tie back to the chassis.
WARNING : Do not remove the cap when the engine is hot. The circuit is still under pressure and you could be scalded.
NOTE : During installation, fill the radiator and coolant reservoir completely. See Section 1002 for coolant specifications. Start and run the engine until the coolant is at operating temperature. Stop the engine and check for leakage. When the coolant is cold, check the coolant reservoir level. Add coolant as required. Never remove the radiator cap to check the coolant level in the radiator.
STEP 6 Depressurize the hydraulic system as follows see section 8002.
STEP 7 Disconnect the hoses from the hydraulic filter.
STEP 8 Remove and fit blaks to the expansion reservoir hoses.
Cre 7-21290GB
Issued 10-99
2000-5
STEP 12
STEP 15 Loosen the clamp and disconnect the lower radiator hose (3).
1
STEP 16 Loosen the clamp and disconnect the air cleaner hose (4).
4
STEP 17 1
3
8
7
6 2 9 3
5
2 CI98G517
CI98G516
Remove the hardwere (1), the retaining pins (2), the washers (3) and support (4).
STEP 13
Position a suitable drainage container beneath the hydraulic hose (5) and disconnect the hose from the oil cooler (9). NOTE : Fit blanks to the hose and the oil cooler connection.
STEP 18 2
Repeat step (5) for the remaining hydraulic hoses (6), (7) and (8).
STEP 19 4
Remove the for radiator retaining screw.
STEP 20 3
Install a suitable sling around the radiator and remove the radiator. NOTE : Installation of the radiator is the reverse of removal.
1 CI98G517
Disconnect the overflow hose (1) from the radiator neck.
STEP 14 Loosen the clamp and disconnect the upper radiator hose (2).
Cre 7-21290GB
Issued 10-99
2000-6
PERSPECTIVE VIEW 9
6
7
2
28 8
1
4
17 16 17 16 19 21
25
12
18
15
2
3
26 13 11 10
27
22
14
23
15 5
25
16
24
26 22 21
20 CI98G505
1.
Hose
15. Washer
2.
Collar
16. Nut
3.
Hose
17. Bracket
4.
Collar
18. Bracket
5.
Seal
19. Collar
6.
Shroud
20. Nut
7.
Radiator
21. Hose
8.
Cap, filler
22. Clamp
9.
Cooler, oil
23. Tank, expansion
10. Bracket
24. Bracket
11. Nut
25. Screw
12. Screw
26. Washer
13. Washer
27. Plug
14. Stanchion
28. Grommet
Cre 7-21290GB
Issued 10-99
2000-7
ENGINE REMOVAL Put identification tags on all disconnected hoses and wires. Close disconnected hoses and fittings with caps and plugs.
STEP 5 66
22
STEP 1 Remove the radiator see page 4.
STEP 2 Disconnect the battery.
STEP 3 5 1
789M257A
4
2 3 2 CI98G518
Remove the hose clip (4) from the air filter hose (5) at the turbocharger inlet.
STEP 4 Support the air filter assembly (1) and remove the three bolts (2) from the cylinder head and two bolts (3) from the exhaust bracket. Remove the air filter assembly. 789M256A
Install the engine lifting bracket (6) using two of the bolts (2) from the air filter bracket. The bracket is part of the machine tool kit.
Cre 7-21290GB
Issued 10-99
2000-8
STEP 6
STEP 10 14 14
2 15 15 1 5 16 16
7 3 6 789M259A
4
Disconnect the throttle cable (15) from the fuel injection pump lever (14) and the bracket (16). CI98G519
Release the spring (1) and remove the exhaust pipe (2).
STEP 11 17 17
STEP 7 Release the clip (3) on the silencer to turbocharger connection and remove the nuts, washers and spacers (4). Remove the silencer (5) from the bracket (6).
18 18
STEP 8 Remove the three bolts and washers (7) from the exhaust bracket and remove the bracket.
19 19
STEP 9 Remove the hydraulic oil pump drive shaft (see section 8004).
789M287A
Release the hose clips (19) on the heater hoses (17) at the thermostat housing (18). Remove the hoses and tie back under the scuttle.
Cre 7-21290GB
Issued 10-99
2000-9
STEP 12
STEP 14 Release the dipstick pipe coupling (25) on the transmission and remove the dipstick assembly.
STEP 15
20 20 21 21 22 22
31 31 789M261A
32 32
Remove the four bolts (20) in the hydraulic pump drive coupling (21) and remove the drive shaft (22).
33 33
STEP 13
789M263A
23 23
Remove the nut (32) from the wiring cover (31) on the starter motor (33) and remove the cover.
24 24
STEP 16 34 34
2525
26 26
27 27 29 30 29, 30
28 28
36 36
35 35
789M262A
789M264A
Release the hose clips (24) on the transmission filler flexible pipe (26), remove the two bolts and nuts (23) and (28) in the support bracket (27) and the nut and bolt (29) and (30) in the dipstick pipe support.
Remove the bolt and nut (36) in the clip (35) for the transmission oil cooler pipe (34), and release the pipe.
Cre 7-21290GB
Issued 10-99
2000-10
STEP 17
STEP 20
Disconnect and tag all wiring connections from the engine. These include the starter motor, the alternator, the water temperature switch, the oil pressure switch, the thermostat unit, the air filter restriction switch and the fuel injection pump stop solenoid.
Remove the six screws (41) from the gear lever tower (40) and slide the tower up the lever (42).
STEP 18
STEP 21 Disconnect the clutch switch wiring connection (44) and remove the spring (46) from the shift lever.
STEP 22
37 37
Remove the bolt and nut (43) and (45) from the shift lever and remove the lever from the transmission.
STEP 23 Put the wiring ties which attach the electrical harness to the support rail at the rear of the engine.
STEP 24 Release the oil cooler hose clamp on the right hand side of the chassis.
STEP 25
39 39
38 38 789M265A
Remove the front floor mat (37) in the cab. Remove the four screws (39) from the centre front floor plate (38) and remove the plate.
48 48 47 47
STEP 19
41 40
42
789M288A
43
Disconnect the fuel inlet and discharge pipe (47) and (48) from the fuel lift pump.
46 45
44 CI98G501
Remove the six screws (41) from the gear lever tower (40) and slide the tower up the lever (42).
Cre 7-21290GB
Issued 10-99
2000-11
STEP 26
STEP 28
565757 56,
49 49
50 50 51 51 52 52
56 57 56,57
789M270A
Remove the four bolts (52) and the two bearing caps (51) from the rear coupling. Lower the propshaft (49). Make sure that the needle roller bearing cups (50) on the rear coupling are taped to the joint.
STEP 27
58 58
53 53
789M272A
Remove the eight flywheel to torque converter bolts (56) and the washers (57) from the flex plate assembly (58).
STEP 29 59 59
55 55
54 54 789M271A
Remove the four bolts (54) and the inspection plate (55) from the bottom of the bell housing (53).
789M273A
Remove all except two of the spacer housing bolts (59). Cre 7-21290GB
Issued 10-99
2000-12
STEP 30
STEP 34
Position a trolley jack under the transmission, next to the front axle drive coupling flange. Raise the jack into contact with the transmission but DO NOT lift the transmission.
STEP 31 Attach the special lifting bracket to the engine.
STEP 32 67 67 66 66
65 65
63 63 64 64 789M256A
789M276A
Using a suitable hoist attached to the lifting bracket, apply tension to the lift chains. DO NOT raise the engine.
Remove the centre bolt (67), the nuts (64) and the washers (63) and (66) from each transmission mounting plate (65).
STEP 33
STEP 35 Remove the rear propshaft.
STEP 36 Using the hoist and trolley jack, raise the engine/ transmission unit sufficient to remove the engine mountings. (approximately 40 mm (1.5 in)).
STEP 37 Lower the engine/transmission unit and move it towards the rear of the machine until the rear propshaft slicing joint is completely closed.
STEP 38 60 60
Remove the two bolts in the spacer housing.
62 62
61 61 789M257A
Loosen the two bolts (62) and the nuts (60) from each engine bracket (61).
Cre 7-21290GB
Issued 10-99
2000-13
STEP 39
3.
Torque tighten attaching parts as follows :
Hold the transmission to the rear, and move the engine forward on the hoist to disengage the torque converters spigot. Make sure that the torque converter does not disengage from the transmission input shaft when the engine moves forward.
Flywheel to torque converter flexible plate bolts.................................. 28 Nm (21 lbf ft)
STEP 40
Starter motor friction nuts ..........36 Nm (26 lbf ft)
Remove the engine from the machine.
Rear coupling bearing cap bolts 37 Nm (27 lbf ft) Coupling flange bolts................. 48 Nm (35 lbf ft) 4.
Before starting the engine, do steps 3 through 8.
5.
Bleed air from fuel system (see section 3410).
Installation
6.
NOTE : Install the engine in the reverse order of the removal but note the following :
Check the transmission oil level (see section 6002).
7.
Check the engine oil level.
1.
8.
Replenish the radiator and header tank with coolant.
9.
Check the hydraulic oil level.
10. Carry out a complete functional test of the machine. Check all connections and joints for leakage. Check all fluid levels with the engine stopped and cold.
68 68
A
69 69 789M277A
Before installation of the engine, make sure that the torque converter is correctly installed in the transmission. The flex plate face (68) must be at least 50 mm (2.0 in) from the transmission flywheel cover face (69) (measurement A). If the measurement A is 40 mm (1.5 in) or less, the torque converter is not correctly installed and must be removed and installed correctly. 2.
During assembly of the engine to the transmission, make sure that the torque converter spigot enters the fly wheel bush correctly. To check, rotate the torque converter as the engine and transmission come together.
Cre 7-21290GB
Issued 10-99
2401
Aftercare Section 2401 ENGINES SPECIFICATIONS AND ADJUSTMENTS
Cre 7-21310GB
Copyright ï›™ 1999 Case France Printed in France October 1999
2401-2
TABLE OF CONTENTS SPECIAL TOOLS ...................................................................................................................................................... 4 Sealants ............................................................................................................................................................ 4 SPECIAL TORQUE TENSIONS................................................................................................................................ 5 750 MACHINE (Engine in the Perkins manual) ......................................................................................................... 7 Specifications....................................................................................................................................................7 Power rating...................................................................................................................................................... 7 Engine speeds .................................................................................................................................................. 7 760 MACHINE (Engine in the Perkins manual) ......................................................................................................... 7 Specifications....................................................................................................................................................7 Power rating...................................................................................................................................................... 7 Engine speeds .................................................................................................................................................. 7 860/960/965 MACHINE (Engine in the Perkins manual) ...........................................................................................8 Specifications....................................................................................................................................................8 Power rating...................................................................................................................................................... 8 Engine speeds .................................................................................................................................................. 8 DATA AND DIMENSIONS......................................................................................................................................... 9 Cylinder head assembly ........................................................................................................................................ 9 Cylinder head....................................................................................................................................................9 Inlet valves ........................................................................................................................................................ 9 Exhaust valves.................................................................................................................................................. 9 Valve guides ...................................................................................................................................................10 Valves springs.................................................................................................................................................10 Tappets ...........................................................................................................................................................10 Rocker shaft....................................................................................................................................................10 Rocker levers and bushes ..............................................................................................................................10 Piston and connecting rod assemblies................................................................................................................11 Pistons ............................................................................................................................................................11 Piston cooling jets ...........................................................................................................................................11 Piston rings .....................................................................................................................................................11 Connecting rods..............................................................................................................................................11 Big end bearings .............................................................................................................................................12 Gudgeon pins..................................................................................................................................................12 Small end bushes ...........................................................................................................................................12 Crankshaft assembly...........................................................................................................................................12 Crankshaft.......................................................................................................................................................12 Crankshaft heat treatment ..............................................................................................................................13 Main bearings .................................................................................................................................................13 Bearing width ..................................................................................................................................................13 Bearing thickness at centre.............................................................................................................................13 Bearing clearance ...........................................................................................................................................13 Crankshaft thrust washers ..............................................................................................................................13 Timing case and drive assembly .........................................................................................................................13 Camshaft.........................................................................................................................................................13 Camshaft thrust washer ..................................................................................................................................13 Camshaft gear ................................................................................................................................................14 Fuel pump gear...............................................................................................................................................14 Crankshaft gear ..............................................................................................................................................14 Idler gear and hub...........................................................................................................................................14 Idler gear and hub for the Bendix compressor................................................................................................14
Cre 7-21310GB
Issued 10-99
2401-3 Cylinder block assembly .....................................................................................................................................14 Cylinder block .................................................................................................................................................14 Camshaft bore diameter .................................................................................................................................14 Cylinder liners .................................................................................................................................................15 Cylinder liner specifications.................................................................................................................................15 Partially finished liner ......................................................................................................................................15 Surface finish of the preliminary bore .............................................................................................................15 Surface finish of the diamond hone ................................................................................................................15 Surface finish of the silicone carbide base hone.............................................................................................15 Surface finish of the silicone carbide plateau hone.........................................................................................15 Lubrication system ..............................................................................................................................................15 Lubricating oil pump - four cylinder engines ...................................................................................................15 Idler gear for lubricating oil pump....................................................................................................................16 Oil pressure relief valve (standard) .................................................................................................................16 Oil filter............................................................................................................................................................16 Fuel system .........................................................................................................................................................16 Lucas fuel injection pump ...............................................................................................................................16 Fuel lift pump - four cylinder engines ..............................................................................................................16 Fuel filter .........................................................................................................................................................16 Cooling system....................................................................................................................................................17 Coolant pump, belt driven ...............................................................................................................................17 Thermostat......................................................................................................................................................17 Fan drive housing ...........................................................................................................................................17
Cre 7-21310GB
Issued 10-99
2401-4
SPECIAL TOOLS Tools required for a complete engine overhaul MS.73
Adjustable valve seat cutters
PD.145D
Crankshaft rear oil seal drift (to be used with MS 550 handle)
PD.150B
Cylinder liner remover/replacer (main tool)
PD.150B-17
Adaptor for cylinder bores of 100 mm (3.937 inch) diameter. To be used with PD.150B main tool
PD.1556
Water pump/Camshaft adaptor (imperial) for PD.155C
PD.155B-5
Fuel pump/camshaft adaptor (metric) for PD.155C
PD.155C
Puller, camshaft gear
6118B
Valve spring compressor
PD.6118-7
Adaptor for 611 8B
PD.6118-8
Adaptor for 611 8B
PD.162
Timing case cover centralising tool
MS.550
Drift handle (To be used with PD.145D)
PD.170
Timing case seal installer
PD,17-6
Timing case seal installer
Sealants Hylomar Loctite 242 Loctite 575 Loctite Q Activator
Cre 7-21310GB
Issued 10-99
2401-5
SPECIAL TORQUE TENSIONS Fasteners, rocker shaft brackets Aluminium brackets .......................................................................................................................................... 40 Nm Cast iron and sintered steel brackets ............................................................................................................... 75 Nm Cap nuts, composite plastic rocker cover ......................................................................................................... 20 Nm Cap nuts, aluminium rocker cover .................................................................................................................... 30 Nm Setscrews, inlet manifold to cylinder head........................................................................................................ 44 Nm Nuts (Cadnium plated), exhaust manifold to cylinder head .............................................................................. 33 Nm Setscrews, engine lift bracket ........................................................................................................................... 44 Nm
Piston and connecting rod assemblies Nuts, connecting rods ..................................................................................................................................... 125 Nm Setscrews, connecting rods............................................................................................................................ 155 Nm Banjo bolts, piston cooling jets ......................................................................................................................... 27 Nm
Crankshaft assembly Setscrews, main bearings (4 cylinder engines) .............................................................................................. 250 Nm Setscrews, crankshaft pulley .......................................................................................................................... 115 Nm Setscrews, viscous damper to crankshaft pulley .............................................................................................. 75 Nm Cap screws, crankshaft damper to crankshaft pulley ....................................................................................... 35 Nm Cap screws, crankshaft bonded damper to crankshaft pulley .......................................................................... 35 Nm Setscrews, rear oil seal housing to cylinder block ............................................................................................ 22 Nm Cap screws, bridge piece to cylinder block....................................................................................................... 16 Nm Cap screws, rear oil seal housing to bridge piece ............................................................................................ 13 Nm Torx screw, rear oil seal housing to bridge piece .............................................................................................. 18 Nm
Timing case and drive assembly Setscrews, timing case to cylinder block .......................................................................................................... 22 Nm Setscrews, timing case to cylinder block .......................................................................................................... 44 Nm Setscrews, hub of idler gear ............................................................................................................................. 44 Nm Setscrews, camshaft gear ................................................................................................................................ 95 Nm Setscrews, timing case cover to timing case .................................................................................................... 22 Nm Nuts, timing case cover to timing case ............................................................................................................. 22 Nm
Cylinder block Setscrews, fitted instead of piston cooling jets ................................................................................................. 27 Nm
Cre 7-21310GB
Issued 10-99
2401-6
Fuel system Nuts, high-pressure fuel pipes.......................................................................................................................... 22 Nm Bolt banjo, leak-off connection............................................................................................................................ 9 Nm Gland nut, atomiser body ................................................................................................................................. 30 Nm Setscrews, for the gear of the fuel injection pump............................................................................................ 28 Nm Torx screws, for timing plate ............................................................................................................................... 9 Nm Setscrews, fuel lift pump................................................................................................................................... 22 Nm Nuts for flange of fuel injection pump ............................................................................................................... 28 Nm Locking screw of Bosch VE fuel injection pump ............................................................................................... 27 Nm Locking screw of DP 200 fuel injection pump ................................................................................................... 10 Nm
Lubrication system Plug, lubricating oil sump.................................................................................................................................. 34 Nm Setscrews, oil pump to front bearing cap ......................................................................................................... 22 Nm Setscrews, cover for oil pump........................................................................................................................... 28 Nm Fasteners, lubricating oil sump ......................................................................................................................... 22 Nm
Cooling system Setscrews, fan drive housing to timing case..................................................................................................... 44 Nm Setscrews, fan drive pulley to hub ........................................................................................................ 22 and 44 Nm Setscrews, fan .................................................................................................................................................. 22 Nm Connector, oil cooler to oil filter head ............................................................................................................... 58 Nm Setscrews, coolant pump to timing case .......................................................................................................... 22 Nm Screw, cassette type cooler to oil filter head .................................................................................................... 37 Nm
Flywheel and housing Setscrews, flywheel to crankshaft................................................................................................................... 105 Nm Setscrews, cast iron flywheel housing to cylinder block ................................................................................... 44 Nm Head stamped 8.8........................................................................................................................................ 75 Nm Head stamped 10.9...................................................................................................................................... 63 Nm Head stamped 10.9.................................................................................................................................... 115 Nm Setscrews, aluminium flywheel housing to cylinder block ................................................................................ 70 Nm Setscrews, flywheel housing to cylinder block (paper joint).............................................................................. 70 Nm
Aspiration system Nuts, turbocharger to manifold ......................................................................................................................... 44 Nm
Auxiliary equipment Nut, compressor drive gear to compressor crankshaft................................................................................... 120 Nm Nut, (30 A/F) compressor gears ..................................................................................................................... 130 Nm Cap screw, bracket to idler hub ........................................................................................................................ 60 Nm Cap screw, bracket to timing case .................................................................................................................... 35 Nm
Cre 7-21310GB
Issued 10-99
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