CASE 1845 UNI-LOADER Service Repair Manual Instant Download

1
1
1845 UNL-LOADETRABLE OF CONTENTS AND
SERVICE MANUAL INTRODUCTION Table of
Contents SECTION NO.
SERIES/SECTION 10
FORM NO.
SERIES - GENERAL SERIES - GENERAL
General Englne 8peciftcattons - Dlesel ...... . 1010 General Englne 8peciftcattons - Dlesel ...... . 1010 9-79035
General Engtne Speciflcatlons - 8park Ignitlon . 1011 General Engtne Speciflcatlons - 8park Ignitlon . 1011 9-79045
Decals and Repaintlng ................. .. 1012 Decals and Repaintlng ................. .. 1012 9-73925
Detalled Engtne Specifications - Diesel ..... . 1027 9-78675
Maintenance and Lubrtcatlon............. . 1050 9-73926
Torque Charts . . . . . . . . . . . . . . . . . . . . . . 1051 9-73925
Detailed Engtne Specifications - Spark
Ignition 20 SERIES - ENGINE Engine Diagnosis .
1128
9-79055
2001
9-78875 9-78825 9-80512 9-78836 9-76995 9-78855 9-
78866 9-78885 9-73925 9-73926 9-73926 9-78816 9-78
985
Englne Tune Up
, 2002
. . . . . . . . . . . . . . . .
Cylinder Head and Valves - SparR Ignition
. 2013 2015 . . 2023 2025 2035 2045 2050 2051 20
54 2055 2555
Cylinder Head, Valve Train and Camshaft, Diesel
Englne Block - Spark Ignit,ion . .,.... ......
Cylinder Block, Sleeves, Pistons and Rods
....... Crankshaft, Bearings, Flywheel and Oll
Se,al . . . otl Pump ........................... E
ngine Removal, Installation and Drive Coupling .
Air Cleaner and Spark Arresting Muffles ......
Cooling 5ystem (Radiator) ................ Coolin
g System, . ..............., ... . Engine
Lubrication ......, ... ...........
30 SERIES - FUEL SYSTEM Fuel Filters - Diesel
....................... 3010
9-78785 9-78795 9-78806 9-77015 9-T3926 9-79065
Fuel Injection Pump Fue1 Injectors ....
Carburetor ...... Engine Controls, Fuel Tank and
Fuel Lines . Fuel Filters - Spark Ignition
..........,
301 3013 3033 3052 311G
40
SERIES - HYDRAULIC SYSTEM Hydraulic Diagrams,
Maintenance, Trouble Shooting
and Pressure Checks . and Pressure Checks . and Pressure Checks . and Pressure Checks . and Pressure Checks . 4011 9-73926
Dual Pump (Equipment and Dual Pump (Equipment and Dual Pump (Equipment and Dual Pump (Equipment and Dual Pump (Equipment and 4013 9-73926
Loader Control Valve ......... .. . Loader Control Valve ......... .. . Loader Control Valve ......... .. . Loader Control Valve ......... .. . Loader Control Valve ......... .. . 4021 9-73926
Selector Valves ........., ... ..,.... , ... ... Selector Valves ........., ... ..,.... , ... ... Selector Valves ........., ... ..,.... , ... ... Selector Valves ........., ... ..,.... , ... ... Selector Valves ........., ... ..,.... , ... ... 4027 9-73925
Auxiliary Control Valve . . Auxiliary Control Valve . . Auxiliary Control Valve . . Auxiliary Control Valve . . Auxiliary Control Valve . . 4031 9-73926
Dump Circuit Relief Valve , Dump Circuit Relief Valve , Dump Circuit Relief Valve , Dump Circuit Relief Valve , Dump Circuit Relief Valve , 4042 9-73926
Cylinders ........... Cylinders ........... Cylinders ........... Cylinders ........... Cylinders ........... 4057 9-73926
60 SERIES - POWER TRAIN charge r'uos ..................... . Reten to Section 4013
Drive Chalns, Axles and Cluster Sprockets . .. 6023 9-73926
Wheels and Tires ...... ............ 6024 9-73925
Hydrostatic System Diagrams and Operation Start Up Procedure and Cle aning and Flushing Procedure ....,.... ,.... . 6030 603,1 9-73926 9-73925
C.E. Did. 9-73926 1845 Uni- Loader Rev. Aug. 1976
CASE CORPORATION
eprRi ted
2
2
FORMNO.
SECTION NO.
SERIES/SE CTION
60 SERIES - POWER TRAIN (Cont' d) Hydrostatic
Pump ...........,.... ..........
6032 Hydrostatic Motor . . . .. . . . . . . .. .
. . . . . . . . .. . 6033
9-73926 9-73926 9-73926 9-73925
Hydrostatic Cont,rols . , .. . .,...,., .. ....
.. . 6034
Gear Reducer.,... , . ,.,... .....,....
.,.... 6036
70 SERIES - BRAKES Parking Latch . G ...
R ........ G . G P ...... . .,,
7022
9-73926
80 SERIES - ELECTRICAL SYSTEM 80 SERIES - ELECTRICAL SYSTEM
roooowoo99ooeeuc99ooRoe9A0" roooowoo99ooeeuc99ooRoe9A0" 9-73926
Trouble Shooting .......................... 8012 Trouble Shooting .......................... 8012 9-73926
Ignition System . . ... ..............,. ...,. . 8013 Ignition System . . ... ..............,. ...,. . 8013 9-73925
Battery ................................. 8014 Battery ................................. 8014 9-T3925
Starter and Starter Solen, oid . ,.... ............ 8015 Starter and Starter Solen, oid . ,.... ............ 8015 9-73926
Induction Discharge Electronic Ignition System ............... , 8015 9-T9265
Alternator ............................. ,. 8016 9-73926
90 SERIES - MOUNTED EQUIPMENT
Loader . ................................
9011 Roll-Over Protection Structure ..............
.. 9019
9-73926 9-73926
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Service Manual Introduction Safety Rules
Thts service manual has been prepared with the
latest service information available. Trouble
shooting, removal, disassembly, In- spection
and installation procedures coupled with
complete specifications and tightening
references can be found tn most sections.
Some sections wlll have exploded vlews
without accompanying text due to the simpli- city
of the procedure. This service manual is one of
the most Important tools available to the service
technician. It 1s invaluable aid In properly
performing any phase or service. The terms
rtght-hand and left-hand as used In this
manual Indicate the right and left sides of the
machine as viewed from the operator' s seat for
proper operation of the machine or
attachment. The Information contained In this
manual 1s current at the time of printing. Table
of Contents The preceedlng pages contain a Table
of Contents whlch list the Series number and
title, and the sections contained in each series.
The Individual sections, where required, will
have a Table of Contents on the second page of
that section. Page Numbers All page numbers
consist of two sets of dtglts separated by a
dash, such as 4011-9.
4
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Torque References
The digits preceeding the dash identify the
section. The digtts following the dash repre-
sent the consecutive page number wlthin that
section. Page numbers will be found at the upper
right or left of each page. Text lf this manual
covers more than one machine, or different
models or component parts tplanetary axles,
gear boxes, control valves, etc.) the procedures
will apply to all unless otherwise
noted. Illustrations Where possible,
Illustrations are placed as close as possible
to the accompanying text and should be used as
part of the text. Use of Loctite Products The
Lcctite products refered to through- out this
serUce manual are primarily those used to provide
additional locking of nuts, bolts, cap screws and
studs. They will be refered to by Loctlte number
and color. These products are available through
the parts de- partment refer to the P arts
Counter Catalog. Use Loctlte whenever instructed
to do so In this manual and according to
manufacturer's Instructions on die
container. Serial and Model Numbers When
requisitioning repair or replace- ment parts It
may be necessary to furnish the parts department
with one or both num- bers. Serial and model
numbers will be found In the following
locations. Machine - Plate hastened to instrument
panel. Also stamped on frame at base of fuel
tank HH tube. Engine - Right hand side of block
above oil filter. Smaller component parts - plate
attached to part or number stamped In part.
Essentially two grades of fasteners
(bolts, nuts and screws) are used on Case
machinery. They are grade 5 and grade 8.
Refer to Section 1051 for torque specifica-
tions and means of Identification. The
specifications tn Section 1051 are standard
torque values and should be used on all
fasteners durtng assembly and In- stallation
unless special torque values are noted In a
particular section. Classification of
Lubricants Otls, lubricants, and grease are
classi- fied and graded according to standards
recom- mended by the Society of Automotive Engi-
neers (SAE), the American Petroleum Insti- tute
(API), and the National Lubricating Grease
Institute (NLGI). Engine Oil The SAE number
indicates the viscosity of engine oils, for
example, SAE 30, a single grade oil. Engine
oils are also identified by dual numbers, SAE
l0W-30, a multlgrade oil. The API classification
(MS DS SD CA) defines oil performance In terms
of engine usage. Only oils specified in
Section 1050 should be used. These oils contain
sufficient chemical additives to provide maximum
en- gine protection. Both the SAE grade and API
designation must be found on the container. Gear
Lubricant The SAE grade number also indicates
the Nscoslty of gear lubricants defined by
MIL-L -2105B. An example is SAE 90, a medium
vis- cosity lubricant. Grease Seml-solid
lubricants such as specified for ptvot points
must be that specified In Section l0ii0.
6
Section
1010
GENERAL ENGINE SPECIFICATIONS 1845 UNILOADERS
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 .....................................
..................................................
................................. 3-13/16
Inches Stroke ...................................
..................................................
.................................... 4 1 8 Znches
Piston Displacement ...... .... . .. ............
... . . ... .. .. ..... ...... . . ......... ..
..... . 188 Cubic Inches Compression Ratio
..................................................
..................................................
.... 16-1/2 to 1 No Load Governed Speed
..................................................
................................ 2330 to 2370
RPM Rated Engine Speed ...........................
..................................................
......................... 2200 RPM Engine Idling
Speed ....... ... ..... .... .. . . .. .. . ..
...... . . ............ .... . .. . .. . . 800 to
850 RPM Valve Tappet Clearance (Exhaust)
..................................................
.... (Hot and Cold) .014 Inch tIntake)
..................................................
......... (Hot and ColdI .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 .......................................
..................................................
................................ 4 Number of
Compression Rings . . ....... . . .. .....
......... . ....... ..... ..... ..... .... ..
. ....... 2 Number of oil Rings
..................................................
..................................................
............... 2 Type Pins .....................
..................................................
............................... Full Floating
Types 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)
..................................................
........................................ 4 (With
Filter Change) ...............................
..................................................
.... o Oil Pressure ...........................
........................................ 50 to ?0
Pounds with Engine Warm and Operating at
Rated Engine Speed Type System ...................
..................................................
........... Pressure and Spray Circulatio 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 FuelFilters
..................................................
...................................... Full flow
Spin on Type CASE CORPORATION
Rac 9-79035
PRINTEO IN U S A
7
Section 1011
GENERAL ENGINE SPECIFICATIONS 1845
UNILOADERS s 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.
SPARK IGNITION ENGINES
General
Type ...........................................
Case Open Chamber, 4 Cylinder, 4 Stroke Cycle,
Valve-tn-Head F1rtng Order .......................
..................................................
...............................................
1-3-4 2 Bore ....................................
..................................................
..................................... 3.1/2
Inches Stroke ....................................
..................................................
................................... 4-le8
Inches Piston Displacement ......................
..................................................
................... 159 Cubic Inches Compression
Ratto ............................................
..................................................
............. 7.42 to 1 No Load Governed Speed
..................................................
................................ 2330 to 2370
RPM Rated Englne Speed ...........................
............................................,.....
..................... ... 2200 RPM Engtne Idllng
Speed ............................................
.................................................
825 to 875 RPM Va1ve Tappet Clearance (Exhaust)
..................................................
.... (Hot and Cold) .014 Inch (Intake)
..................................,..........,....
.......... (Hot and Cold) 012 Inch "Hot Settings
Are Made After the Engtne Has Operated
It Thermostat Controlled Temperature For At Least
fifteen Mlnutes. Piston and Connecting Rods Rings
per Ptston ......................................
......................................
............................................
4 Number of Compression Rlngs ....................
..................................................
.............................. 3 Number of Otl
Rlngs ..........................
................................... .........
................. ....................... 1 Type
Pins .............................................
..................................................
......... Full Floating Type Type Bearing
................................................
Replaceable Precision, Steel Back, Copper-Lead or
Aluminum Alloy Llners
Mai.n Bearinga
Number off Bearings ..............................
..................................................
.................................... 3
Type Bearings ....................................
................ Replaceable Precislon, Steel
Back, Copper Lead
Or AluminumAlloy Liners.
Engine Lubricating System
Crankcase Capacity (Without Fllter)
..................................................
........................................ 4 (With
Fllter Change) ...................................
..................................................
5 011 Pressure ..................................
................................. 24 to 32 Pounds
wtth Engine Warm and Operating at Rated Engine
Speed Type System ................................
................................................
Pressure and Spray Circulation oti Pump
..................................................
..................................................
.................. Gear Type Oll Fllter
..................................................
................................................
Full Flow Spin-on Type
Carburetor ..........p................
.. . Zenith No. 267X9-013T83
Distributor Ignton
Contact Point Gap ................................
..................................................
......................... .020 Inch Dwek Angle
..................................................
..................................................
.......................... 42o Spark Plug Gap
t18mm) (Heat Range-8) ...........................
............................................ .025
Inch Engine Timing Static Timing
..,...............................................
..................................................
............ . i nTDc Running Ttming
..................................................
.................................. 320 BTDC at
Rated Speed CASE CORPORATION R 9-79046
8
Section
1012
DECALS AND R EPAINTING
CASE CORPORATION
C.E. Div. 9-73925 October 1976
9
1012-2
GENERAL INFORMATION
1. All decals relating to operation and
move the existing decal first. Use enamel thinner
to aid in decal removal. s. When repainting a
machine or attach- ment use standard procedure
degrease, wash, sand, wipe down, mask as
re- quired and paint. 6. The following pages show
decals as they are Installed and their part
number. Verify p art number in parts catalog
before ordering a decal. The decals are available
individually or in a kit for the complete machine.
servicing of the machine and mounted
equipment must be in such condition that they
can be read without difficulty. Any decal that 1s
damaged or cannot be read must be replaced.
2. All decals that contain a safety message as
Indicated by DANGER, WARNING or CAUTION, must be
In such condition that they can be read without
difficulty. Any dec al that 1s damaged or cannot
be read must be replaced. Whenever a machine
or attachment is being repainted, cover good
decals and remove damaged decals and decals
that cannot be read. Use enamel thinner to aid
in decal removal.
3.
Use the decal illustrated in this section tf
it is different from the one used on your
machine. This section illustrates the most
recent decals used in produc- tion as of the date
on the cover.
Whenever a decal is being replaced, re-
2. 321-3153
1. 321-3156
1. 321-3030
Figure 1
Figure 2
10
1012-3
76649
1. 321-2973 Decal is used on each side Figure 6

1. 321-315T
2. 321-3153

3. 321-3342 See Figure 5
Ftguz 3

• 1. 321-3076
• 321-230 Also see Figures 8 and 9
• 321-1060 See Figure 10
• 321-3061 See Figure 11
• 321-2733 See Figure 12
• Figure 7

766548
1. 321-3030
Figure 4
76655Z
1. 321-3342
1. 321-230
Figure 5
Flgure 8
11
1012-4
66
1. 321-18
1. 321-2733
Figure 9
Figure12
766614
1. 321-1060
1. 321-3386
2. 321-229 Figure 13
Figure 10
766546
1. 321-3061 Figure 11
1. 321-3385
2. 321-3060 Figure 14
12
1012-5
2. 321-3171
1. 321-2620
Figure 15
766557
3. 321-3582 See Figure 19
1. 321-2509 2. 321-2599 See Ftgure 19 Figure 18
66556
1. 321-2506 Figure 16
1. 321-2599
2. 321-3582 Figure 19
3. 321-3172
1. 321-3059 2. 321-3062
Figure 17
13
1012-6
766561
1. 321-3150 Figure 22
1. 321-3174
2. 321-2996
E'tgure 20
1. 321-3150 Figure 21
14
Section
1027
DETAILED SPECIFICATIONS 188 Diesel Engines
FRACTION to DECIMAL to MILLIMETER CONVERSION TABLE
Fraction 1 /64 1/32 3/64 1/16 5/64 3/32 7/64 1 /8 9/64 5/32 1 1/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 Decimal .0156 .0312 .046 8 .0625 .0781 .0937 .1093 .1250 .1406 .1562 .171 8 .1875 .2031 .2187 .2343 .2500 .2656 .2812 .2968 .3125 .32 81 .5437 MM 0.397 0.794 1.191 1.5 87 1.984 2.3 81 2.77 8 3.175 5.572 3.969 4.366 4.762 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.937 8.334 8.731 Fraction 23/64 8 25/64 13/32 27/64 7/16 29/64 15/32 31 /64 1 /2 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 Decimal .3593 .3750 .3906 .4062 .421 8 .4375 .4531 .4687 .4 843 .5000 .5156 .5512 .5468 .5625 .5781 .5937 .6093 .6250 .6406 .6562 .671 8 .6 875 MM 9.12 8 9.525 9.922 10.519 10.716 11.113 11.509 11.906 12.303 12.700 13.097 13.494 13.890 14.287 14.684 15.081 15.478 15.875 16.272 16.669 17.O65 17.462 Fraction 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 Decimal .7031 .7187 .7343 .7500 .7656 .7812 .796 8 . 8125 . 82 81 . 8437 . 8593 .8750 .8906 .9062 .9218 .9375 .9531 .9687 .9843 1.0000 MM 17. 859 18.256 1 8.653 19.050 19.447 19.844 2O.24O 20.637 21.034 21.431 21. 82 8 22.225 22.622 23.O19 23.415 23.812 24.209 24.606 25.OO3 25.400
INCH to MILLIMETER CONVERSION TABLE
Inch MM Inch MM I nch MM Inch MM
1 25.400 6 152.OOO 10 254.000 60 1,524.000
2 50. 800 7 177. 800 20 50 8.000 70 1,778.000
3 76.200 8 203.200 3O 762.OOO 80 2.032.OOO
4 101.600 9 22 8.600 40 1.016.000 90 2,2 86.OOO
5 127.OOO 1O 254.OOO 50 1,270.OOO 1 OO 2,540.000
Rae. 9-78675
PRINTED IN U S A
CASE CORPORATION
15
1027-2 TABLE OF CONTENTS RUN-IN INSTRUCTIONS
..................................................
..................................................
...... 3,4 DETAILED ENGINE SPECIFICATIONS
..................................................
.............................. 5-10 Cylinder
Sleeves ................................. ...
..................................................
............................ 5 Piston
..................................................
..................................................
................................... 5 Piston
Rings ....... ............ .... ...........
.................. ...............................
................................ 5,6 Piston
Pin ..............................................
....................... ..........................
.............................. 6 Connecting Rod
..................................................
..................................................
.................... 6 Crankshaft
..................................................
..................................................
......................... 6,7 Camshaft
...............................
..................................................
................ ...................... ....
7 Valve Push Rod Lifters ........................
..................................................
......... ...................... 7 Gear Train
..................................................
..................................................
........................... 8 Pil
Pump ..........................
..................................................
...............................................
8 Cylinder Head ................ .
......................................... .......
..................................................
8 Intake Valve .....................
............................................... ..
..................................................
8 Exhaust Valve ...............................
..................................................
.........................,...............
9 Intake Valve Guides ..........................
..................................................
..................................... 9 Exhaust
Valve Guides ....................................
..................................................
........................ 9 Valve Spring .....
........ ....... .................................
...... ...........................................
................. 9 Rocker Arm Assembly
..................................................
..................................................
........ 10 SPECIAL TORQUES ......................
..................................................
.......................................... 1l
GENERAL TORQUE SPECIFICATION TABLE
........................... .... .
.................................... 12
16
1027-3
RUN-IN-INSTRUCTIONS Engine Lubrication When the
engine rebuild is complete, fill the engine
crankcase with Case HDM oil and install new
engine oil filter. NOTE If Case HDM oil is not
used, use only a Series 3 DS or CD Service
Classi- fication oil that has the proper
viscosity rating for prevailing air temperature.
Refer to vehicle Op- erators Manual.
After the first 20 hours of operation, change the
engine oil while the engine is hot and replace
the the engine oil filter. DO NOT DRAIN OIL UNTIL
THE ENGINE HAS BEEN OPERATED 20 HOURS. Change the
engine oil and filter at the recommended
intervals thereafter as outlined in the Opera-
tor's Manual. Break-In Procedure for Rebuilt
Engines (With a Dynamometer) The following
procedure must be implemented when using a PTO
dynamometer to break-in the engine. The
dynamometer will insure control of the engine
load at each speed and will eliminate over
stressing new parts during break-in. During the
break-in, continually check the oil pressure,
coolant level, and coolant temperature.
TIME 10 Minutes 10 Minutes 20 Minutes 20
Minutes
ENGINE SPEED 1000 RPM 1800 RPM 1800 RPM 1800 RPM
DYNAMOMETER SCALE LOAD" None None 1/3 1/2

• STEP
• 1
• 2
• 3
• 4
• 30 Minutes 100 RPM below rated speed 3/4
• Retorque the cylinder head bolts using the
  procedure described in Section 2015 of this
  service manual.

Based upon normal dynamometer scale load at
rated speed for the particular vehicle model.
Reduce this scale load as indicated. "The most
ideal break-in procedure would be to constantly
vary the throttle between 750 to 1000 RPM for
the first 10 minutes and from 1000 RPM to 1800
RPM for the next 10 minutes. The purpose of this
changing RPM is to vary the lubrication and
coolant flow. "30 minutes at 3/4 load is a
minimum amount of time the engine should be run.
It is recommended that whenever possible the
engine (especially turbocharged diesels)
should be run for four (4) hours or more at the
above speed and load before checking the full
engine horsepower or before using the engine for
heavy field work. Break-in Procedure for Rebuilt
Engines (Without a Dynamometer)
STEP TIME ENGINE SPEED LOAD
1 10 Minutes 1000 RPM None
2 10 Minutes 1800 RPM None
3 30 Minutes 2/3 Rated RPM Light Load
4 1 Hour Full RPM (not over 2000 RPM) 80 to 90
5
Retorque the cylinder head bolts using the
procedure described in Section 2015 of
this service manual.
If engine must then run at or near full load to
operate the machine - for first hour remove load
and run at high idle for a few minutes at 15
minute intervals.
17
1027-4 Run-in Procedure (Agricultural
Tractors) For the first 8 hours of field
operation stay one gear lower than normal. For
the next 12 hours DO NOT lug the engine.
Prevent lugging by shifting to a lower gear.
The engine must not be lugged below its Rated
Engine RPM during the early hours of
llfe. Run-in Procedure (Construction
Equipment) For the first 8 hours, operate the
engine at full throttle maintaining a normal
load. DO NOT baby the engine, but avoid prolonged
converter or hydraulic stall. Engine must not be
lugged below its Rated Engine RPM (Do not
exceed 10 seconds of stall). Run-in Procedure
(Power Units) For the first 1/2 hour, operate
engine at 2/3 rated RPM with a light load or no
load. For the next (1) hour, run engine at 80 to
90 load at rated RPM (but not over 2000 RPM).
Then full load and rated RPM as required in
application.
18
1027-5
DETAILED ENGINE SPECIFICATIONS
Cylinder Sleeves U.S. Value Type
..................................................
...................... Replaceable Wet Material
..................................................
............................ Cast Iron I.D. of
sleeve ..........................................
.................. 3.8125 to 3.8115 Maximum
Serviceable Limit ................................
................ 3.8165 Sleeve out-of-round
(installed in block) ............................
.001 max. Maximum Serviceable Limit
..................................................
. .004 Taper (installed in block)
..................................................
........ .001 Maximum Serviceable Limit
..................................................
. .004 Clearance to bottom of piston skirt, 90
to piston pin .. .0035 to .0055 Maximum
Serviceable Limit ................................
................. .0100 Sleeve Protrusion above
cylinder block (Max.) ......................
.005 Piston T e ...............................
................................................
FAITH gFolllld Material .........................
..........................................
Aluminum Alloy O.D. at bottom of skirt, 900 to
piston pin .................... 3.807 to 3.808
Minimum Serviceable Limit .......................
.......................... 3.806 I.D. of piston
pin bore including wear ......................
1.2500 to 1.2â08 Width of 2nd ring groove
................................................
.097 to .098" Maximum Serviceable Limit
..................................................
. .100 Width of 3rd ring groove
.............................................
.1885 to .1895 Maximum Serviceable Limit
................................................ .
1915" Piston Rings No. l Compression
..................................................
............... Chrome Grooved Keystone End gap
in 3.8125 I.D. (96.838mm I.D.) sleeve
.............. .015 to .025 Maximum Serviceable
Limit ............................................
.... .035 No. 2 Compression ....................
.............. Rectangular Grooved Back End gap
in 3.8125 I.D. (96.838mm I.D.) sleeve
............ .015 to .025 Maximum Serviceable
Limit ............................................
.... .035 Side Clearance ......................
.................................... .0035 to
.0055 Maximum Serviceable Limit
................................................
.008
Metric Value
96.838 to 96.812mm 96.939mm .025mm .102mm .025mm .
l02mm .090 to .140mm .254mm .l27mm
96.698 to 96.T23mm 96.672mm 31.T50 to
31.T70mm 2.464 to 2.489mzn 2.540mm 4.788 to
4.8l3mm 4.8Mmm
.381 to .635mm .889mm
.381 to .635mm .899mm .090 to .140mm .203mm
19
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102T-6
U.S. Value
Metric Value
Piston Rings (Cont'd)
No. 3 Oil Control Ring ...........................
......................... Three Piece End gap in
3.8125 I.D. (96.838mm I.D.) sleeve
............... .015 to .055 Maximum Serviceable
Limit ............................................
....... .065 Side clearance ....................
............................................ .000
to .008 Maximum Serviceable Limit
................................................
.010
.381 to 1.397mm 1.651mrn .000 to .203mm .254mm
Piston Pin Type ..................................
............................................ Full
Floating O.D. of pin ..........................
...................................... 1.2495 to
1.2498 Fit in piston .........................
........................................ .0002
to .0010 Fit in rod bushing
..................................................
..... .0004 to .0015 Connecting Rod Bushing
.................................................
............. Replaceable Bronze Bushing I.D.
installed (ream to size) .......................
1.2502 to 1.2504 Maximum-Serviceable Limit
................................................
1.2510 Bearing liners ...........................
......................................
Replaceable Rod width at crank end
............................................
1.3035 to 1.3055 Journal I.D. without bearing
liners .......................... 2.1870 to
2.1875 Bearing oil clearance ....................
............................... .0010 to
.0040 Undersizebearings for service
...............................
.002,.010,.020,.030 Side clearance
..................................................
.............. .005 to .011
31.737 to 31.745mm .005 to .025mm .010 to .038mm
31.T55 to 31.760mm 31.T75mm
33.109 to 33.160mm 55.550to55563im .025to.102im .0
51254,.508,762m .27to.2T9ii
Crankshaft Type ..................................
......................... Hardened Steel
Balanced Main bearing liners ....................
....................................
Replaceable End play, center main bearing cap
................................ .001 to .015
Center main bearing thrust surface thickness
.............. .1025 to .1045 Connecting rod
journal std. O.D. ..............................
2.0605 to 2.0615. .002 (.05lmm) O.D. undersize,
grind to ................. 2.0585 to
2.0595 .010 (.254mm) O.D. undersize, grind to
................ 2.0505 to 2.0515 .020 (.508mm)
O.D. undersize, grind to ................ 2.0405
to 2.0415 .030 (.762mm) O.D. undersize, grind
to ................ 2.0305 to 2.0315 Connecting
rod journal maximum taper ........................
............ .001 Journals out-of-round
..................................................
.............. .0005 Undersize main bearing
liners for service ...... .002,.010,.020,.030
Main bearing oil clearance ......................
.................... .0012 to .0042
.025 to .381mm 2.603 to 2.654mm 52.33T to
52.362rnm 52.286 to 52.311mm 52.083 to
52.108mm 51.289 to 51.854mm 51.5T5to
51.60Omm .025mm .0l3mm .051,.254,.508,.T62mm .031
to .10Tmm
21
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