CASE 580C Loader Backhoe Service Repair Manual Instant Download

1
SERVICE MANUAL LOADER BACKHOE
SERVICE MANUAL LOADER BACKHOE
580C
580C
I
I
9-66018
9-66018

1. Trim along dashed line.
2. Slide into pocket on Binder Spine.

1. Trim along dashed line.
2. Slide into pocket on Binder Spine.

Pr -4
TYPE 1-4
SERVICE MANUAL LOADER BACKHOE
SERVICE MANUAL LOADER BACKHOE
580C
580C
I
I
9-66018
9-66018

1. Trim along dashed line.
2. Slide into pocket on Binder Spine.

1. Trim along dashed line.
2. Slide into pocket on Binder Spine.

Pr -4
TYPE 1-4
2
580C LOADER BACKHOE TABLE OF CONTENTS AND SERVICE
MANUAL INTRODUCTION SERIES/SECTION SECTION NO.
FORM NO.
10 GENERAL General Engine Specification 207
Diesel Engine ....................................
.... 1010 Detailed Engine Specifications
9-79315
207 Diesel Engine ........................................ 1026 Maintenance and Lubrication ............................... 1050 9-786g5 9-66015
Torque Charts ............................................. 1051 8-42200
Noise Control .............................................. 1052 9-66015
20 ENGINES Engine Diagnosis ........................................... 2001 9-78875
Engine Tune Up ............................................ 2002 9-78825
Cylinder Head, Valve Train and Camshaft .................... 2015 9-78836
Crankshaft, Bearings, Flywheel and Oil Seals ................. 2035 9-78866
Oil Pump .................................................. 2045 9-78885
Stall Checks, Engine Removal and Installation, and Radiator ............................................. 2050 9-66015
Air Cleaner and Spark Arresting Muffler ...................... 2051 9-66015
Ether Injection ............................................. 2053 9-66015
Cooling System ............................................ 2055 9-78816
Cylinder Block, Sleeves, Pistons and Rods ................... 2125 9-78845
Engine Lubrication ......................................... 2555 9-78985
30 FUEL SYSTEM Fuel Filters ................................................. 3010 9-78785
Fuel Injectlon Pump ........................................ 3012 9-78795
Fuel lnjectors .............................................. 3013 9-78807
Enoine Controls. Fuel Lines and Fuel Tank ................... 3052 9-66015
40 HYDRAULICS
Hydraulic Diagrams, Maintenance, Troubleshooting and Pressure Checks ..................................... 4002 9-66015
Hydraulic Pump ............................................ 4005 9-66015
Loader Control Valve ....................................... 4007 9-66015
Three-Point Hitch Control Valve ............................. 4034 9-66015
Loader, Backhoe and Three-Point Hitch Cylinders ............ 4090 9-66015
Backhoe Control Valve ..................................... 4107 9-66015
Stabilizer Control Valve ..................................... 4109 9-66015
Boom Lock System ......................................... 4121 9-66015
50 STEERING
Hydraulic Diagram, Troubleshooting and Pressure Check .......................................... 5002 9-66015
Steering Pump ............................................. 5005 9-66015
Steering Control Valve ...................................... 5007 9-66015
Steering Cylinders .......................................... 5010 9-66015
Front Axle ................................................. 5021 9-66016
Printed in U.S.A. April 1978 Rev/Rpt April
1981 Reprinted October 1986
9-66018
CASE CORPORATION
eprinted
3
SERIES/SECTION SECTION NO.
FORM NO.
60 POWER TRAIN Power Shuttle Operation, Oil Flow
Diagrams, Troubleshooting and Maintenance
......................... 6202 Power Shuttle and
Torque Converter ........................
6210 Shuttle Controls (Power and Mechanical)
.................... 6211 Transaxle Removal and
Installation ..........................
6212 Transaxle and Differential Lock
............................. 6214 Drive Shaft
.................................................
6222 Wheels and Tires ............................
............... 6229 Clutch and Pressure Plate
................................... 6406 Two
Speed Mechanical Shuttle .........................
..... 6410 70 BRAKES Brakes (Pedals to Transaxle)
................................ 7106 Self
Adjusting Differential Brakes ....................
........ 7122
9-66015 9-66016 9-66015 9-66015 9-79237 9-66015 9-
66015 9-66015 9-79117
9-66016 9-79246
80 ELECTRICAL Troubleshooting ...................
........................ 8002 Wiring Diagrams
...........................................
8003 Instrument Panel and Instrument Cluster
..................... 8004 Battery
..................................................
.. 8005 Starter and Starter Solenoid
.................................
8006 Nippondenso Starter ........................
..............8006A Alternator ...................
............................... 8007 Electrical
Accessories .....................................
. 8015
9-66015 9-66015 9-66015 9-66015 9-66015 9-66015 9-
66015 9-66016
90
MOUNTED EQUIPMENT Loader .........................
............................ 9010 Three-Point
Hitch ..........................................
9033 ROPS Cab and Canopy .........................
............ 9061 Backhoe ........................
........................... 9100
9-66015 9-66015 9-66015 9-66016
4
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Sectioc
1010
GENERAL ENGINE SPECIFICATIONS 580C TRACTORS
THE MODEL AND ENGINE SERIAL NUM- BER IS STAMPED
ON A PLATE LOCATED ON THE RIGHT SIDE OF THE
ENGINE BE- LOW THE CRANKING MOTOR.
DIESEL ENGINES
General Type .....................................
...... Case Open Chamber, 4 Cylinder, 4 Stroke
Cycle, Valve-in-Head Firing Order
..................................................
..................................................
.................... 1-3-4-2 Bore
..................................................
..................................................
............................. 4 Inches Stroke
..................................................
..................................................
..................... 4-1/8 Inches Piston
Displacement ...................................
..................................................
...... 207 Cubic Inches Compression Ratio
..................................................
..................................................
....... 16. 5 to l No Load Governed Speed
..................................................
................................ 2230 to 2270
RPM Rated Engine Speed .......................
..................................................
............................. 2100 RPM Engine
Idling Speed ...................................
..................................................
........ 700 to 750 RPM Valve Tappet
Clearance (Exhaust) ............................
.......................... (Hot and Cold) .014
Inch (Intake) ...................................
........................ (Hot and Cold) .012
Inch "Hot Settings Are Made After the Engine Has
Operated At Thermostat Controlled Temperature For
At Least Fifteen Minutes. Piston and Connecting
Rods Rings per Piston ..........................
..................................................
............................................. 3
Number of Compression Rings ... . .
... .. . .. .. . 2 Numberof Oil Rings
. . . ... . . .. . . ... .. . 1 Type Pins
..................................................
..................................................
..... Full Floating Type Type Bearing ...........
Replaceable Precision, Steel Back, Copper-Lead or
Aluminum Alloy Liners Main Bearings Number of
Bearings ......................... . . ........ .
..................................................
................... 5 Type Bearings ..........
Replaceable Precision Steel Back, Copper-Lead or
Aluminum Alloy Liners Engine Lubricating System
Crankcase Capacity (Without Filter) .........
. . .......................................... 6
Quarts
(With Filter Change) ............................
........................................... 7
Quarts Oil Pressure ............. 50 to 70 Pounds
with Engine Warm and Operating at Rated Engine
Speed Type System ................................
................................................
Pressure and Spray Circulation Oil Pump
..................................................
..................................................
.................. Gear Type Oil Filter
..................................................
...............................................
Full Flow Spin on Type Fuel System Fuel
Injection Pump ...............................
..................................................
............... Roosa-Master Pump
Timing . . .. . 8 Degrees Before Top Dead Center
Fuel Injectors .................................
.............................. Pencil Type
(Opening Pressure 2800 PSI) Fuel Transfer Pump
................................................
Vane Type, Integral Part of Injection Pump
Governor ............ Variable Speed, Fly-Weight
Centrifugal Type, Integral Part of Injection Pump
Fuel Filters ...................................
..................................................
........ Full Flow Spin on Type
CASE CORPORATION
Rac. 9-79315
PRINTED IN U.S.A.
6
Section
MAINTENANCE AND LUBRICATION
C. E. Dlv. 9-6601 5 February 1976
7
10502
FLUIDS AND LUBRICANTS
COMPONENTS CAPACITY U.S. Metric CAPACITY U.S. Metric SPECIFICATIONS
Fuel tank 22 gallons 83 liters Refer to Operator' s Manual.
Engine crankcase Without filter change With filter change 6 quarts 7 quarts 5. 7 liters 6.6 liters Case HDM oil Engine oil, class CD, Above 32 F (0 C) ....... SA30 10-50 F (12-10 C) ... SAE 20W Below 32 F (0 C) . ... . . SAE 10W
Hydraulic system (approx.) Loader/backhoe Loader only Loader/three point hitch Reservoir refill 30 gallons 21 gallons 25 gallons 17 gallons 113 liters 79 liters 94 liters 64 liters Case TCH Fluid Alternate oll Engine oil, SD or CA Above 32 F (0 C) .... SA10WE Below 32 F (0 C) ..... SA5W Type C-2 transmission/hydraulic fluid such as Tenneco Hymans Fluid.
Power shuttle and converter 8 quarts 7. 6 liters Case TCH Fluid.
Power steering system Reservoir refill 3 quarts 1 quart 2. 8 liters 0. 9 liter Case TCH Fluid.
Mechanical shuttle 2 quarts 1. 9 liters Case TCH Fluid.
Transaxle 20 quarts 19 liters Case FDL gear lubricant or lubri- cant meeting API-GL-4, specification Above 0 F (-18 C) ...... SA90 Below 0 F (-18 C) ...... SA80
Grease fittings As required As required No. 2 moly disulflde grease.
Front wheel bearings As required As required No. 2 moly disulfide grease.
Cooling system 21 quarts 19. 8 liters Mix ethylene glycol type antifreeze and water for lowest anticipated temperature.
Battery As required As required Add colorless, odorless drinking water.
Brake master cylinders As required As required DOT 3 brake fluid.
E
E
E E
8
1050-3 MAINTENANCE CHART yew This chart is based
on maximum service intervals. If operating in
severe working conditions, service more often.
INTERVAL SERVICE INSTRUCTIONS
Run-in period. Every two hours until stable Torque front and rear wheel bolts to 115-130 foot-pounds (157-176 N m). Torque transaxle mounting bolts to 250-300 foot-pounds (339-407 N m). Torque swing cylinder trunnion plate mount ing bolts to 520-640 foot-pounds (732-867 N m). Torque drive shaft cap screws to 20-24 foot- pounds (27-32 N m).
Run-in period after first 20 hours Change engine oil and ftlter. Change hydraulic oil filter. Check fan belt tension. Section 4002 Section 8007
Every 10 hours of operation or daily, whichever occurs first Grease loader pivot polnts. Grease backhoe pivot points. Grease extendable dipper, if so equipped. Grease three point hitch, if so equipped. Grease front axle pivot. Grease front axle king pins. Grease power shuttle bellcrank. Check englne oil level. Check hydraulic oil level. Gheck radiator coolant level. Clean air cleaner dust cup. Check power shuttle oil level (if so equipped). Gheck the machine and the ground under it for signsofleaks. Check injection pump sediment bowl for water. If bowl has water, drain fuel tank, first stage fuel filter and sediment bowl. Section 2051 Section 6202
9
1050-4
INTERVAL SERVICE INSTRUCTIONS
Every 100 hour s of operation Ghange engine oil. Grease rear axle bearings. Grease seat post. Grease brake pedals and shaft bearings on power shuttle machines. Grease brake pedals and clutch shaft on mechanical shuttle machines. Check tire condition and pressure. Check battery fluid level. Theck transaxle oil level. Theck mechanical shuttle oil level. Theck power steering oil level. Clean spark arresting muffles if so equipped. Section 6229 Section 8005 Section 2051
Every200lDurs ofoperaton Thange engine oil filter. Theck fan belt tension. Section 2555 Section 8007
Every 500 hours of operation Grease universal Joints. Lubricate hydraulic pump shaft. Replace fuel filters. Section 4005 Section 3010
Check brake master cylinder fluid level.
Repack front wheel bearings. Section 5021
Inspect Roll-Over Protection Structure. Change hydraulic oil filter. Section 9061 Section 4002
Clean hydraulic reservoir breather. Section 4002
EYery 1000 hours of operation or once a year, whichever occurs first Change hydraulic oil. Thange power shuttle oil, IN so equipped. Replace power steering oil filter. Section 4002 Section 6202 Section 5005
Thange mechanical shuttle oil, if so equipped.
Thange transaxle oil.
Clean transaxle breather.
10
1050-5
INTERVAL SERVICE INSTRUCTIONS
Every 2000 hours o1 operation or once a year, whichever occurs first Drain, flush and refill cooling system. Section 2050
As required After a wheel has been removed and installed, check bolt torque every two hours until stable. Service air filter element whenever restric- tion warning light remains on with engine running at full throttle. Change hydraulic oil filter whenever restric- tion warning light remains lit. Section 2051 Section 4002
11
TORQUE CHARTS
TABLE OF CONTENTS Torque Specifications - U.S.
Hardware .........................................
................ 1051-2 Torque Specifications -
Steel Hydraulic Fittings ........................
........................ 1051-3
Written In C/ear And Simple English
Printed in U.S.A. Issued February 1984
8M2200
CASE CORPORATION
12
1051-2
TORQUE SPECIFICATIONS - U.S. HARDWARE Use the
torques in this chart when special tor- ques are
not given. Thèse torques apply to fasten- ers
with both UNC and UNF threads as received from
suppliers, dry, or when lubricated with engine
oil. Not applicable if special graphites,
moly-disul- fide greases, or other extreme
pressure lubricants are used.
Grade 8 Bolts, Nuts, and Studs Grade 8 Bolts, Nuts, and Studs Grade 8 Bolts, Nuts, and Studs Grade 8 Bolts, Nuts, and Studs
Size Pound- Feet Newton metres Kilogram metres
1/4 in 6.4 mm 12-15 16-20 1.7-2.1
5/16 in 7.9 mm 24-29 33-39 3.3-4.0
3/8 in 9.5 mm 45-54 61-73 6.2-7.5
7/16 in 11.1 mm 70-84 95-114 9.7-11.6
1/2 in 12.7 mm 110-132 149-179 15.2-18.2
9/16 in 14.3 mm 160-192 217-260 22.1-26.5
5/8 in 15.9 mm 220-264 298-358 30.4-36.5
3/4 in 19.0 mm 380-456 515-618 52.5-63.0
7/8 in 22.2 mm 600-720 814-976 83.0-99.5
1.0 in 25.4 mm 900-1080 1220-1465 124-149
1-1/8 in 28.6 mm 1280-1440 1736-1953 177-199
1-1/4 in 31.8 mm 1820-2000 2468-2712 252-277
1-3/8 in - 34.9 mm 2380-2-720- 3227-3688 329-376
1-1/2 in 38.1 mm 3160-3560 4285-4827 437-492
Grade 5 Bolts, Nuts, and Studs Grade 5 Bolts, Nuts, and Studs Grade 5 Bolts, Nuts, and Studs Grade 5 Bolts, Nuts, and Studs
Size Pound- Feet Newton metres Kilogram metres
1/4 in 9-11 12-15 1.2-1.5
6.4 mm
5/16 in 17-21 23-28 2.4-2.9
7.9 mm
3/8 in 35-42 48-57 4.8-5.8
9.5 mm
7/16 in 54-64 73-87 7.5-8.8
11.1 mm
1/2 in 80-96 109-130 11.1-13.3
12.7 mm
9/16 in 110-132 149-179 15.2-18.2
14.3 mm
5/8 in 150-180 203-244 20.8-24.9
15.9 mm
3/4 in 270-324 366-439 57.3-44.8
19.0 mm
7/8 in 400-480 542-651 55.3-66.4
22.2 mm
1.0 in 580-696 787-944 80.2-96.2
25.4 mm
1-1/8 in 800-880 1085-1193 111-122
28.6 mm
1-1/4 in 1120-124Ô 1519-1681 155-171
31.8 mm
1-3/8 in 1460-1680 1980-2278 202-232
34.9 mm
1-1/2 in 1940-2200 2631-2983 268-304
38.1 mm
811360A
13
1051-3
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
Tube OD Hose ID Thread Size Pound- Feet Newton metres Kilogram metres
37 Degree Flare Fittings 1/4 in 7/16-20 6-12 8-16 0.8-1.7 6.4 mm 5/16 in 1/2-20 8-16 11-21 1.1-2.2 7.9 mm 3/8 in 9/16-18 10-25 14-33 1.4-3.5 9.5 mm 1/2 in 3/4-16 15-42 20-56 2.1-5.8 12.7 mm 5/8 in 7/8-14 25-58 34-78 3.5-8.0 15.9 mm 3/4 in 1-1/16-12 40-80 54-108 5.5-11.1 19.0 mm 7/8 in 1-3/16-12 60-100 81-135 8.3-13.9 22.2 mm 1.0 in 1-5/16-12 75-117 102-158 10.4-16.2 25.4 mm 1-1/4 in 1-5/8-12 125-165 169-223 17.3-22.8 31.8 mm 1-1/2 in 1-7/8-12 210-250 285-338 29.0-34.6 38.1 mm 37 Degree Flare Fittings 1/4 in 7/16-20 6-12 8-16 0.8-1.7 6.4 mm 5/16 in 1/2-20 8-16 11-21 1.1-2.2 7.9 mm 3/8 in 9/16-18 10-25 14-33 1.4-3.5 9.5 mm 1/2 in 3/4-16 15-42 20-56 2.1-5.8 12.7 mm 5/8 in 7/8-14 25-58 34-78 3.5-8.0 15.9 mm 3/4 in 1-1/16-12 40-80 54-108 5.5-11.1 19.0 mm 7/8 in 1-3/16-12 60-100 81-135 8.3-13.9 22.2 mm 1.0 in 1-5/16-12 75-117 102-158 10.4-16.2 25.4 mm 1-1/4 in 1-5/8-12 125-165 169-223 17.3-22.8 31.8 mm 1-1/2 in 1-7/8-12 210-250 285-338 29.0-34.6 38.1 mm 37 Degree Flare Fittings 1/4 in 7/16-20 6-12 8-16 0.8-1.7 6.4 mm 5/16 in 1/2-20 8-16 11-21 1.1-2.2 7.9 mm 3/8 in 9/16-18 10-25 14-33 1.4-3.5 9.5 mm 1/2 in 3/4-16 15-42 20-56 2.1-5.8 12.7 mm 5/8 in 7/8-14 25-58 34-78 3.5-8.0 15.9 mm 3/4 in 1-1/16-12 40-80 54-108 5.5-11.1 19.0 mm 7/8 in 1-3/16-12 60-100 81-135 8.3-13.9 22.2 mm 1.0 in 1-5/16-12 75-117 102-158 10.4-16.2 25.4 mm 1-1/4 in 1-5/8-12 125-165 169-223 17.3-22.8 31.8 mm 1-1/2 in 1-7/8-12 210-250 285-338 29.0-34.6 38.1 mm 37 Degree Flare Fittings 1/4 in 7/16-20 6-12 8-16 0.8-1.7 6.4 mm 5/16 in 1/2-20 8-16 11-21 1.1-2.2 7.9 mm 3/8 in 9/16-18 10-25 14-33 1.4-3.5 9.5 mm 1/2 in 3/4-16 15-42 20-56 2.1-5.8 12.7 mm 5/8 in 7/8-14 25-58 34-78 3.5-8.0 15.9 mm 3/4 in 1-1/16-12 40-80 54-108 5.5-11.1 19.0 mm 7/8 in 1-3/16-12 60-100 81-135 8.3-13.9 22.2 mm 1.0 in 1-5/16-12 75-117 102-158 10.4-16.2 25.4 mm 1-1/4 in 1-5/8-12 125-165 169-223 17.3-22.8 31.8 mm 1-1/2 in 1-7/8-12 210-250 285-338 29.0-34.6 38.1 mm 37 Degree Flare Fittings 1/4 in 7/16-20 6-12 8-16 0.8-1.7 6.4 mm 5/16 in 1/2-20 8-16 11-21 1.1-2.2 7.9 mm 3/8 in 9/16-18 10-25 14-33 1.4-3.5 9.5 mm 1/2 in 3/4-16 15-42 20-56 2.1-5.8 12.7 mm 5/8 in 7/8-14 25-58 34-78 3.5-8.0 15.9 mm 3/4 in 1-1/16-12 40-80 54-108 5.5-11.1 19.0 mm 7/8 in 1-3/16-12 60-100 81-135 8.3-13.9 22.2 mm 1.0 in 1-5/16-12 75-117 102-158 10.4-16.2 25.4 mm 1-1/4 in 1-5/8-12 125-165 169-223 17.3-22.8 31.8 mm 1-1/2 in 1-7/8-12 210-250 285-338 29.0-34.6 38.1 mm
Tube OD Hose ID Thread Size Pound- Feet Newton metres Kilogram metres
Straight Threads with 0-ring Straight Threads with 0-ring Straight Threads with 0-ring Straight Threads with 0-ring Straight Threads with 0-ring
1/4 in 6.4 mm 7/16-20 12-19 16-25 1.7-2.6
5/16 in 7.9 mm 1/2-20 16-25 22-33 2.2-3.5
3/8 in 9.5 mm 9/16-18 25-40 34-54 3.5-5.5
1/2 in 12.7 mm 3/4-16 42-67 57-90 5.8-9.3
5/8 in 15.9 mm 7/8-14 58-92 79-124 8.0-12.7
3/4 in 19.0 mm 1-1/16-12 80-128 108-174 11.1-17.8
7/8 in 22.2 mm 1-3/16-12 100-160 136-216 13.8-22.1
1.0 in 25.4 mm 1-5/16-12 117-187 159-253 16.2-25.9
1-1/4 in 31.8 mm 1-5/8-12 165-264 224-357 22.8-36.5
1-1/2 in 38.1 mm 1-7/8-12 250-400 339-542 34.6-55.3
Split Flange Mounting Bolts Split Flange Mounting Bolts Split Flange Mounting Bolts Split Flange Mounting Bolts
Size Pound- Feet Newton metres Kilogram metres
5/16-18 15-20 20-27 2.1-2.8
3/8-16 20-25 26-33 2.8-3.5
7/16-14 35-45 47-61 4.7-6.2
1/2-13 55-65 74-88 7.6-9.0
5/8-11 140-150 190-203 19.4-20.7
1361A
14
Section
NOISE CONTROL
C. E.Div 9-66015 February l9T6
ævnœv
CASE CORPORaTj ja
15
1052-2
NOISE PROTECTION
J I Case provides noise abatement kits that may
be factory or field installed. Each bit is made
up of an acoustical foam ma- terial. This
material must be kept clean and tntact to
maintain the proper level of noise
protection. Cleaning If the padding becomes
contaminated with surface dust or dirt, hose down
with water. Steam clean parts that have bcome
contami- nated with oil or graas . Squeeze
out the excess water. If the padding is
saturated with oil or grease and does not
clean up, replace the contaminated
part. Replacement
level. Be sure to check with local autiiorl- tles
to determine what the requirements are. Listed
below are checks that must be performd to
insure continuing noise pro- tection.

• Theck that all exterior parts and sheet metal
  fasteners are tight. All rattles close to
  the operator's area must be eliminated.
• Theck that all seallng and barrier ma- tertals
  are wöole and intact. A small hole can admit a
  large amount of noise.
• Theck noise isolators such as engine mounts,
  rubber shock mounts, hydraulic tube isolators,
  etc. Replace If defectlve.
• Theck that the full throttle - no load engine
  speed is checked with an ac- curate tachometer.
  The engtne speed must be within the limits as
  listed in
• CtÎOn 1010.

3.
4.
When Installing padding make sure the metal
surfaces are clean of all oil, grease, excessive
rust and traces of old material. It 1s very
Important ihat the new piece cover the same area
as the old one. Use a brand name contact cement
ac- cording to manufacturer' s instructions
to hold padding in place. Checking Noise
Protection The laws of some cltles, states or
pro- vinces may requlre tîiat your machine
be checked and certJied for a maximum nolse
5. Theck the frill range o1 engine speed for
resonance (loud, undazopened vibra- tion). To
check, Increase the engtne speed from low Idle
to f'ull throttle slow- ly. If excessive
resonance is found, eli- minate the Ubratlon of
the suspected part. movn For your general
information, see the SAE recommended practice on
sound levels and measurements. Refer to SAE
J9l9a, J87 and J88 tn the SAE Handbook.
16
Section
2001
ENGINE DIAGNOSIS 188 and 207 Diesel Engines
CASE CORPORATION
Rac. 9-78875
PRINTED IN U.S.A.
17
2001-2
GENERAL INFORMATION
Before making any repairs or adjustments on
an engine, a mechanic or technician must
properly diagnose the trouble.
COMPRESSION. Compression on an engine is related
to the breathing function. Proper
compression is affected by the air cleaner
condition, muffler restriction, valve
condition and operation including proper
valve adjust- ment, cylinder head gaskets,
condition of sle- eves, rings, pistons,
camshaft, and camshaft timing.
Locating the trouble and repairing it is
only part of the job, a technician must find
and eliminate the cause of the trouble as
well. Too many repairs are made with no thought
to removing the causes that made the repair
necessary.
COMBUSTION. Combustion is the result of ade-
quate compression to develop enough heat in the
air charge on the compression stroke to fire the
fuel being injected into the engine
cylinders. Proper spray pattern and
atomization of the fuel by the injector is
very important. Timing the fuel injection pump
to the engine to a pre- cise degree BTDC is a
vital requirement for proper combustion.
For any engine to start or perform properly.
three main requirements must be present

1. FUEL
2. COMPRESSION
3. COMBUSTION

When any of these requirements are not pre-
sent or limited by some mechanical reason, the
The engine diagnosis contained in the follow- ing
pages covers many trouble symptoms. the causes,
and what will be necessary to repair or
eliminate the problem. Under each symp- tom
are listed the most common and reoccur- ing
problems progessing to the not so com- mon
problems. Locate your problem symp- tom in
the diagnosis chart and refer to the pages
listed for the probable causes and re- medies.
engine will not start and will fail to operate
properly throughout the power range.
FUEL. Fuel system problems can be present
anywhere from the fuel tank, through the fil-
ters and injection pump as well as the injec-
tors. Correct injection pump timing is impor-
tant in the overall fuel system performance.
18
2001-23
INSTALLATION INSTRUCTIONS FOR M20611 TEFLON VALVE
SEAL KIT
Special Tools Required
M2O615 VALVE GUIDE CUTTING TOOL
M2O624 SEAL INSTALLATION TOOL
VALVE SPRING COMPRESSOR
STEP 1
STEP 3
Remove the cylinder head from the engine
block. Refer to section 2O15 for head remov- al.
NOTE This cylinder head requires two M2O611
Kits.
Install a valve spring compressor.
STEP 4
STEP 2




Compress valve spring and remove valve ke-
epers. IMPORTANT Valves and valve kee-
pers should be marked when removed to in- sure
that they will be reinstated in their ori- ginal
location.
Place cylinder head on work bench.
19
2001-24
STEP 5
STEP 8
VALVE STEM SEAL
Remove spring retainer.
Remove valve stem seal.
STEP 9
Remove spring.
Remove valve.
STEP 7
STEP 10
Remove all the valve assemblies.
Remove spring seat.
20
2001-25
STEP 13
STEP 1 1
MINIMUM 1 /16 WIDE FLAT
Wash, clean and inspect head. Use a rotary
brush to clean around and down into valve
ports. Refer to Section 2015 for complete
head reconditioning. STEP 12
Clean valves with a fine power drive wire
brush, removing all carbon and varnish de-
posits. Be careful not to scratch valve stems.
Refer to Section 2O15 for valve inspection.
Check valve guide top surface. There must
be a minimum of a 1/16 wide flat around entire
top surface.
STEP 14
Use M2O615 tool in a electric drill (if required)
to provide necessary flat area on valve guide.
IMPORTANT Do not exceed 450 RPM drill speed
when using valve guide cutting tool.
21
2001-26
STEP 1 8
Dip valve stems into HDM assembly in cylinder
head.
30 oil before
Carefully start valve seal on cap and hold
thumb against white seal insert to avoid dis-
lodging it. Push seal down until seal jacket
touches top of valve guide.
STEP 16
Install spring seat. STEP 17
STEP 2O
PLASTIC CAP
Place plastic installation cap, provided in
kit, on the end of the valve stem. NOTE Cap pre-
vents sharp edges on valve stem grooves from
cutting valve seal.
Use M2O624 tool and press seal down over valve
guide until seal is flush with top of guide.
22
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23
2001-28
STEP 2 8
STEP 26
Remove spring compressor and tap valve stem end
to seat keepers.
Install cylinder head on engine block
follow- ing procedure outlined in Section 2015.
STEP 27
Install teflon seals on the other intake and ex-
haust valves, following the preceeding proced-
ure.
NOTE The Case Corporation reserves the right to
make improvements in design or changes in
specifications at any time without incurring any
obligation to install them on units previously
sold.
24
2902-6
ENGINE TUNE-UP PROCEDURE
STEP 1 Service the air cleaner. Refer to your
Opera- tor s Manual. STEP 2 Adjust the belts.
Refer to your Operator's Manual. STEP 3
Remove breather tube.

• FAN
• Loosen each cylinder head bolt or nut approxi-
  mately 1 /4 turn and then tighten bolt or nut to
  the specified torquing procedure as listed below
  and in sequence as shown above. NOTE Do not lo-
  osen all nuts or bolts simultaneously but loosen
  and tighten each indiv,iduaI bolt and nut in the
  prescribed sequence. The bolt or nut is backed
  off 1 /4 turn to break the set of the threads
  caused by heat, high stress and oxidation. If
  this is not done, a false reading is obtained.
• Nuts w/hardened washers - torque 95-1O5 ft.lbs.
• Grade 8, 12 pt. hd. bolts - torque 11O-115 ft.
  lbs.
• Flanged nuts - torque 90-1OO ft. lbs.

STEP
Remove valve cover mounting nuts and grom- mets.
STEP 5
Torque rocker arm mounting bracket bolts to
insure that the bolts have retained 25 to 3O ft.
lbs. torque.
Remove valve cover and gasket.
25
2002-7
STEP 1O
STEP 7
TIMING POINTER
Crank engine by inserting a screwdriver
into the timing hole in the flywheel housing or
tor- que tube, and by engaging the ring gear
teeth with the screwdriver, align the timing
pointer with the 1O BTDC mark on the flywheel.
Remove the push rod.
STEP 1 1
STEP 8
Compress exhaust valve spring on number one
cylinder by using a screwdriver.
Turn the rocker arm adjusting screw on number one
cylinder intake valve inwards to take pressure
off the push rod.
STEP 1 2
STEP 9
VALVE KEEPERS
Remove the valve keepers.
Push down on the number one cylinder intake valve
spring and at the same time push the rocker
arm assembly rearwards.
26
2002-8
STEP 13
STEP 16
VALVE SEAL
Remove valve spring seat. WOTE Keep valve seal
in place to prevent valve from falling
through valve guide if the piston is moved too
far.
Valve keepers removed.
STEP 14
STEP 17
Remove valve spring retainer.
STEP 15
Install dial indicator on end of valve stem with
valve resting on top of piston.
Remove valve spring.
27
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28
2002-9
STEP 1 8
STEP 2O
VALVE SEAL
Crank engine clockwise until dial indicator
hand stops moving. Reset indicator to zero.
Remove valve stem seal from lower valve stem
groove.
STEP 21
Crank engine clockwise until .OIO shows on the
dial indi- cator. Scribe a mark on the flywheel
in line with timing pointer.
'0
e

SCRIBE MARK Crank engine counter-clock- wise
past zero mark on indi-
C
cator until .O1O shows on the dial indicator.
Again, scribe a mark on the flywheel in line with
timing pointer.
10
STEP 19
Install the spring seat.
Half the distance between these two scribe
marks on the flywheel will be the top dead
center (TDC).
STEP 22

• D
• C

TO CYLINDER HEAD
CLOSED DAMPING COIL END
SCRIBE MARKS
Install the spring with the damping coil end on
top of the cylinder head. See inset above.
29
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