Serv

ice

Man

ual

Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF J.I. CASE OR IT’S SUCCESSORS. J.I. CASE AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

680G Tractor, Loader, Backhoe

Volume 1 of 3

CA-S-680G TLB

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680G LOADER BACKHOE TABLE OF CONTENTS AND SERVICE MANUAL INTRODUCTION

Table of Contents

SERIES/SECTION SECTION NO.

10 SERIES - GENERAL General Engi ne Specification ................................ 1010 Decals and Painting ........................................ 1012 Detailed Engine Specifications .............................. 1023 Maintenance and Lubrication ................................ 1050 Torque Charts .............................................. 1051

20 SERIES - ENGINE Engine Diagnosis ........................................... 2001 Engine Tune-Up ............................................ 2002 Cylinder Head, Valve Train and Camshaft .................... 2015 Cylinder Block, Sleeves, and Pistons and Rods ....•.......... 2025 Camshaft, Main Bearings, Flywheel and Oil Seals ............. 2035 Lubrication System ......................................... 2047 General Information ........................................ 2050 Air Cleaner, Muffler and Spark Arrester ...................... 2051 Ether Injection ..................... ~ ....................... 2053 Cooling System ............................................ 2055

30 SERIES - FUEL SYSTEM Fuel System and Filters ..................................... 3010 Robert Bosch Fuel Injection Pump ... , ....................... 3012 Roosa Master Fuel Injectors ................................. 3013 Engine Controls, Fuel Lines, and Fuel Tank .................. 3052 Electric Fuel Pump ......................................... 3053

40 SERIES - ELECTRICAL SYSTEM Electrical System Spcifications and Troubleshooting ......... .4002 Wiring Diagrams ........................................... 4003 Instrument Cluster .......................................... 4004 Batteries ................................................... 4005 Starter and Starter Solenoid ................................. 4006 Alternator .................................................. 4007 Electrical Accessories ..................................... .4015

50 SERIES - STEERING SYSTEM Hydraulic Diagram, Pressure Check and Troubleshooting ..... 5002 Steering Control Valve and Steering Column ................. 5007 Steeri ng Cyli nders .......................................... 5010 Secondary Relief Valve and Check Valve ..................... 5011 Front Axle ............................ ' ..................... 5021

60 SERIES - POWER TRAIN Transmission Maintenance and Troubleshooting .............. 6202· Power Shuttle Operation .................................... 6203 Power Shuttle and Torque Converter ........................ 6210 Power Shuttle Controls ..................................... 6211 4 Speed Transmission ..................................... ,6213 Drive Shaft ................................................. 6222 Differential and Planetaries .................................. 6226 Wheels and Tires ........................................... 6229

CASE CORPORATION

C E Div. 9-67782 September 1979

FORM NO.

8-21390 9-67781 9-78645 9-67781 9-67781

9-76365 9-76379 9-76166 9-76176 9-76187 9-78667 9-67781 9-67781 9-67781 9-76337

9-75297 9-74937 9-74959 9-67781 9-67781

9-67781 9-67781 9-67781 9-67781 9-67781 9-67781 9-67781

9-67781 9-67781 9-67781 9-67781 9-67781

9-6n81 9-67781 9-67782 9-67781 9-67782 9-67781 9-67781 9-67781

'RINTED IN U.S.A.

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2

SERIES/SECTION SECTION NO.

70 SERIES - BRAKES Troubleshooting and General Information for the

Air System ............................................... 7102' Air Compressor and Governor ............................... 7103 Air Reservoir and Safety Valve ............................... 7104 Brake Valve ................................................ 7105 Brake Actuator ............................................. 7107 Alcohol Evaporator ......................................... 7111 Pressure Reducer Valve, Pressure Protection Valve, Double

Check Valve, Control Valves for Clutch Cutout and , Stoplight Switch .......................................... 7113

Brakes and Brake Adjusters ................................. 7123 Control Valve for Parking Brake and Quick Release Valve ..... 7126

80 SERIES - HYDRAULIC SYSTEM Hydraulic Diagrams, Maintenance, Troubleshooting,

and Pressure Checks ..................................... 8002 Hydraulic Pump ............................................ 8005 Flow Control Valve ......................................... 8006 Loader Control Valve ................................ :, ..... 8007 Cylinders .................................................. 8090 Backhoe Relief Valve ....................................... 8106 Backhoe Control Valve ...................................... 8107 Stabilizer Control Valve ..................................... 8109

90 SERIES - MOUNTED EQUIPMENT Loader ..................................................... 901 0 ROPS Cab and ROPS Canopy ............................... 9061 Backhoe ................................................... 9100

FORM NO.

9-67781 9-67781 9-67781 9-67781 9-67781 9-67781

9-67781 9-67781 9-67781

9-67781 9-67781 9-67781 9-67781 9-67781 9-67781 9-67781 9-67781

9-67781 9-67781 9-67781

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DIESEL ENGINES General Type ....................................................... 4 Cylinder, 4 Stroke Cycle, Valve-In-Head Firing Order .................................•.........•..................................... 1-3-4-2 Bore ........................................................................ 4-5/8 Inches (117.5mm) Stroke ................................................•...•.......................... 5 Inches (127mm) Piston Displacement ..................................................... 336 Cubic Inches (8 259cm3 ) Compression Ratio ......................................... : .... : .......................... 16.5 to 1 No Load Governed Speed .......................................................... 2330 to 2370 RPM Rated Engine Speed ...................................................................... 2200 RPM Engine Idling Speed .................................................................. 700 to 750 RPM ·Valve Tappet Clearance (Exhaust) ........................................ (Cold) .025 Inch (0.635mm)

(Intake) .......................................... (Cold).015 Inch (0.381 mm) ·Settings Must Be After the Engine Has Been Allowed To Cool For A Minimum of 30 Minutes. Thermostat Operating Range .......................................... 1750 F to 2020 F (790 C to 940 C)

Piston and Connecting Rods Rings per Piston .................................................................................. 3 Number of Compression Rings ..................................................................... 2 -Number of 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 Oil Pressure ...... 45 to 60 PSI (310 to 414 kPa) 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 Oil Capacity With Filter ...................................................... 11 U.S. Quarts (10.3 litre)

Without Filter .................................................... 10 U.S. Quarts (9'.5 litre)

Fuel System Fuel Injection Pump ........................................ Robert Bosch, Type PES Multiple Plunger Pump Timing ...................................... 34 Degrees Before Top Dead Center (Port Closing) Fuel Injectors .................................... Pencil Type Opening Pressure 3200 PSI (22063 kPa) Fuel Transfer Pump ..................................... Plunger Type, Integral Part of Injection Pump Governor .................. Variable Speed, Fly-Weight Centrifugal Type, Integral Part of Injection Pump 1 st Stage Fuel Filter .......................................................... Full Flow Spin on Type 2nd Stage Fuel Filter .......................................................... Full Flow Spin on Type Hand Primer Pump ............................................... Located Top of Fuel Transfer Pump Preliminary .Fuel Filter ......................................... Located Bottom of Fuel Transfer Pump

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1. 321-4461 2. 321-4425

1. 321-4145

, 1.' 321-5041 2. 321-4632

Figure 1

Figure 2

Figure 3

1012-3

1. 321-4633 2. 321-2613 3. L57683

Figure 4

1. 321-4146 2. 321-2720, Three Spool Valve, See Figure 6 3. 321-2722, Two Spool Valve

Figure 5

CLAM BUCKET LIFT ARM

FLOAT! OPEN

I DUMP I LOWER

HOLD NEUT. NEUT.

CLOSE ROLLBACK RAISE

781627

1. 321-2720, See Figure 5 for Location

Figure 6

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1012-4

1. 321-3209 2. 321-3705

Figure 7

1. 321-2721 2. 321-4999 3. 321-5000, Foot Swing With Extendahoe 4. 321-5270, Foot Swing Without Extendahoe,

See Figure 9

Figure 8

781628

1. 321-5270, See Figure 8 for Location

Figure 9

781629

1. 321-5001, Hand Swing With Extendahoe Figure 10

781630

1. 321-5271, Hand Swing Without Extendahoe

Figure 11

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