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.

850 Crawler

Volume 1 of 2

CA-S-850 CRWLR

850 CRAWLER TABLE OF CONTENTS

SERIES/SECTION SECTION NO.

10 SERIES - GENERAL Maintenance and Lubrication ............................... 1050 Torque Chart .............................................. 1051 Crawlers Before SIN 7073469 - Specifications for

Case A301 Diesel Engine .................................... C Crawlers with SIN 7083469 and After

General Engine Specifications .............................. 11 Detailed Engine Specifications - 301 BD Engine ............. 1024

20 SERIES - ENGINES Engine Removal/Installation, Adjusting Throttle Linkage,

Stall Checks ............................................. 2050 Air Cleaner ................................................ 2051 Cooling System Troubleshooting, Radiator Removal/Installation,

Backhoe Oil Cooler ... ~ ................................... 2054 Crawlers Before SIN 7073469

Cylinder Head and Valve System ............................. K Engine Block .................................................. M Engine Counter Balancer .................................... MM Water Pump .................................................. 3M Crawlers with SIN 7073469 and After

Engine Diagnosis ......................................... 2001 Engine Tune-Up .......................................... 2002 Cylinder Head, Valve Train and Camshaft .................. 2015 Cylinder Block, Sleeves, Pistons and Rods ................. 2025 Crankshaft, Main Bearings, Flywheel and Oil

Seal Replacement ...................................... 2035 Lubrication System ....................................... 2047 Coc;>ling System .......................................... 2055.

30 SERIES - FUEL SYSTEM Crawlers Before SIN 7073469

Fuel Injectors ................................................ I Crawlers with SIN 7073469 and After

Fuel System and Filters ..........................•........ 3010 Robert Bosch Fuel Injection Pumps ........................ 3012 Roosa Master Fuel Injectors ............................... 3013 Fuel Lines, Bleeding the Fuel System ...................... 3052

40 SERIES - HYDRAULICS Troubleshooting, Hydraulic Diagrams, Pressure Checks ...... 4011' Equipment Pumps R42531 and R30316 ....................... 4013 Loader, Dozer, Backhoe Control Valves (Commercial

Shearing A-35 Series) ....•............................... 4021 Hydraulic Cylinders ........................................ 4057·

I Reprinted I

CASE CORPORATION C.E. Div. 9-68172 February 1981 Reprinted July 1986

1

FORM NO.

9-72942 9-72942

9-78442

9-79521 9-78655

9-72942 9-72942

9-72942

9-76972 9-75222 9-76731 9-76741

9-76365 9-76379 9-76166 9-/6176

9-76187 ~-78667 9··76337

9-75421

9-75297 9-74937 9·74959 9-72942

9-12942 9-72942

9-72942 9-72942

Printed in U.S.A.

2

SERIESISECTION SECTION NO.

50 SERIES - TRACK AND SUSPENSION Track System .............................................. 5010' Suspension System ......................................... 5019 I ntertrac Rollers ............................................ 5505,

60 SERIES - POWER TRAIN Troubleshooting the Transmission/Torque Converter

Hydraulic System with a Flowmeter ........................ 6012 Transmission and Final Drives (Prior to Tractor SIN

7074053 and Transmission SIN 2697154), Transmission Removal/Installation (All Models), Transmission Controls (All Models) .............................................. 6014

Transmission, Final Drives and Brakes - Starting with Transmission SIN 2697154 ................................ 6014

Torque Converter .......................................... 6016 Charging Pump ............................................ 6017 Clutch Cutout Control (Declutch Lockout) ................... 6019 Drive Shaft ................................................. 6022

70 SERIES - BRAKES Adjusting and Bleeding Brakes, Master Cylinders ............. 7010

NOTE: Also See Section 6014.

80 SERIES - ELECTICAL Wiring Diagrams ........................................... 8011 Troubleshooting and Adjustments ........................... 8012 Batteries ................................................... 8014 Starter and Starter Solenoid ................................. 8015 Alternator .................................................. 8016

90 SERIES - MOUNTED EQUIPMENT Counterweights, Drawbars, Engine Frame and Undercarriage

Guards, Seat and Tank Weldment ......................... 9010 Loader ..................................................... 9011 Power Tilt Dozer, Power Angling Dozer ...................... 9013 Power Angle Tilt Dozer .............................. 9013, Sup. 1 Power Angle Tilt Pitch Dozer Before Tractor SIN

7074906, R24819 Diversion Valve ................... 9013, Sup.-2 Angle Tilt Pitch Dozer, SIN 7074906 and After .......... 9013, Sup.3 Model 19 Gearmatic Winch .................................. 9014 Model 19 Gearmatic Winch Ring, Pinion Shaft and

Drum Shaft Assembly and Adjustments, Winch SIN 19-9000 and After ................................. 9014, Sup: 1

Ripper ..................................................... 9015 Roll-Over Protection Structure .............................. 9019 Model 34 Backhoe .......................................... 9026 Model 36 Backhoe .......................................... 9027

FORM NO.

9-72942 9-72942 9-72942

9-72942

9-72942

9-77516 9-72942 9-72942 9-72942 9-72942

9-72942

9-72942 9-72942 9-72942 9-72942 9-72942

9-72942 9-72942 9-72942 9-72942

9-72942 9-72942 9-72942

9-72942 9-72942 9-72942 9-72942 9-72942

ITEM 4 - LUBillCATING PIVOT AXLE

The pivot axle is lubricated by a pres­sure fitting located in the end cap on each si~~. of the crawler. Lubricate until clean

~. -grease can be seen around the pivot axle.

Figure 5 - Pivot Axle Lubrication Point

ITEM 5 - UNIVERSAL JOINT LUBillCATION

Every 120 hours lubricate as follows:

Figure 6 - Vniversal Joint Lubric-ation Points

1. Remove the floor board:

2. TUrn the drives haft until the pressure fittings are in the right position.

3. Lubricate until clean grease appears aroUnd the seals. Do not use a high pressure gun.

1050-5

4. Replace the floor board.

ITEM 6 - BRAKE MASTER CYLINDERS

Brake fluid level in the two master cylinders should be checked after each 120 hours of operation. The master cylinders

- are located under the rear floor plate on the left side of the Crawler. Remove the rear floor plate for access to the master cylinders. Fluid level should be even with the bottom lip of the filler cap opening. Use a brake fluid meeting SAE J1703c specifi­cations.

..... - =--:il- I ~ _ . I i I I

~ I i ;

..L ..... -- // /

-/ / \ __ / c ~ / ~ 86714~1'

Figure 7 - Brake Master Cylinders

ITEM 7 - CHANGING CRANKCASE OIL

Th~ engine crankcase should be drained and refilled with new oil every 120 hours or TWICE A MONTH. Oil speCifications are given on page 1050-10.

If the engine service is severe-frequent stopping and starting, low operating tem­perature-the crankcase should be drained more often to prevent the formation of sludge or harmful deposits in the engine.

When just the crankcase is drained, always refill with 10 measured quarts of oil. Do not refill using the dipstick as a guide. When the crankcase is drained and the 011 filter element replaced, pour in 11 measured quarts, operate the engine for a few minutes to fill the filter body and check for leaks. Then check the oil level with the dipstick. Be sure to allow sufficient time

1050-6 for the oil to run down off the engine parts.

Figure 8 - Crankcase Drain

ITEM 8 - FAN SHAFT BEARING

Figure 9 - Lubricating Fan Shaft Bearing

The fan shaft bearing is lubricated by a grease fitting on the water pump housing. Two strokes of 1\0. 1 Lithium "soap-base" grease from a pressure gun every 120 hours is sufficient. Use 1\0. 1 grease only.

ITE:\l 9 -CHECKING FINAL DRIVES OIL LEVEL

Check the final drives oil level every 120 hours. With the Crawler on level ground,

remove the oil level plug located on each final drive housing, Figure 10. The oil level must be even with the plug.

Figure 10- Location of Final Drives Plugs

If it is necessary to add oil, pour the SAE #90 mild type extreme pressure gear lubricant into the filler opening until the oil is even with the level plug opening. THE OIL MUST BE ADDED SLOWLY TO INSURE THE PROPER OIL LEVEL IS REACHED.

ITEM 10 - ENGINE OIL FILTER

Replace. The engine oil filter should be replaced after the first 20 hours of operation when the special "run-in" oil is drained and every second oil change there­after.

To replace the engine oil filter:

1. Place a container under the filter to catch the oil which is lost.

2. Loosen the hex. head bolt on the filter shell until the shell and filter can be lifted off together.

3. Pull the contaminated element out of shell and flush the shell and base with clean fuel.

4. Install a new Case Filter Element. Be sure the retainer spring and seal are installed first.

5. Position the shell and element on the base and tighten the bolt just enough to form a seal. 00 NOT OVERTIGHTEN.

2015-24

STEP 64

TORQUE THE RETAINING NUTS 40 TO 45 FT LBS

STEP 65

WITH A FEELER GAUGE, CHECK BOTH ENDS OF THE SHAFT FOR END PLAY. A CLEARANCE OF .010" TO 030" MUST BE MAINTAINED AT EACH END OF THE SHAFT ADD OR DELETE SPACER WASHER TO ACHIEVE NECESSARY END PLAY

INSTALL THE FUEL INJECTORS, REFER TO SEC­TION 3013 FOR INJECTOR INSTALLATION.

Locating Top Dead Center

STEP 67

TIMING POINTER

CRANK THE ENGINE UNTIL THE TIMING POINTER IS ALIGNED WITH THE TDC TIMING MARK ON THE CRANKSHAFT PULLEY.

NO 1 PUSH RODS

CHECK THE PUSH RODS ON NO 1 CYLINDER FOR LOOSENESS IF THE PUSH RODS ARE LOOSE, NO. 1 CYLINDER IS AT TDC ON THE COMPRESSION STROKE. IF THE PUSH RODS ARE TIGHT, CRANK THE ENGINE ONE COMPLETE REVOLUTION AND ALIGN THE TIMING POINTER WITH THE TDC MARK ON PULLEY

d. Moving the Powrcel part smoothly and steadily as if you were writing a "Fig­gure 8", clean the lapped surfaces of the cap and body as shown in Figures 1-49 and I-50. The lapped surfaces should be cleaned until all carbon or discoloration is removed and a polished "mirror" surface is obtained.

Figure I-50. Cleaning Powrcel Cap on Lapping Plate

Checking Powrcel Assembly

1. Check the lapped surfaces of the Powrcel Cap and Body for nicks, scratches, pitting or any indications of damage that would cause leakage. Look closely for signs of burning or scoring that would indicate the presence of a leak or "blow-by".

If the lapped surfaces are damaged or if signs of leakage are found, replace the body or cap that is damaged.

2. Inspect the funnel shaped end cavities and the front orifice of the Powrcel Body for burned spots. If burned spots are found or if the contours of the body are changed in any way, install a new Powrcel Body.

IMPDRTANT The condition of the Powrcel Body and Cap

illustrated in Figure I-51 can be caused by the following:

1. The Powrcel Body and Cap were not clean­ed properly creating a leak or "blowby". A proper seal must be formed or scoring, pitting and burning of the Powrcel Body and Cap will develop, Figure 1-51.

2. The Powrcel Clamp Screw was not tight­ened properly. Tighten the Powrcel Clamp Screw to 100 foot pounds. This will insure a proper seal between the Powrcel Body and Cap.

Figure I-51

STE P 3 -- Remove the plug from the timing hole on the pump drive housing, Figure I-58. If the injection pump is properly timed to the engine, the mark on the injectionpumpgear will be aligned with the mark on the pump flange, Figure I-58.

Figure I-58

STEP4-- The injection pump mounting cap­screws can now be taken out and the fuel in­jection pump removed from the engine, Fig­ure I-59.

Figure I-59

CAI/TION

Take care not to bend any of the fuel lines. Cap or plug all openings and lines immed­iately.

1-35

Figure 1-60. EF 8132 Pump Gear Puller

In removing the pump gear, use the special (EF 8132) puller, Figure 1-60.

Figure 1-61

If a replacement pump is being installed be sure to use pump gear, elbows and fitt­ings from the pump that was removed, Fig­ure 1-61.

Installation and Timing

When installing the pump gear, align the mark on the pump gear with the mark on the pump flange, Figure 1-62.

To install the injection pump on the en­gine:

1. Turn the pump gear counter-clockwise, about the width of one tooth from the mark on the injection pump flange. This will allow the two marks to become a­ligned when the pump gear is slipped in­to mesh with the small helical pinion drive gear, in the pump housing, Figure

1-62.

2. Install the injection pump on the engine and reconnect all of the fuel lines and throttle linkage.

Figure 1-62

NIJTE. Do not tighten the pump mounting caps crews until the last step as it may be neces­sary to rotate the pump slightly toward or away from the engine to align the timing marks.

CAUTIIJII

Tighten High Pressure Fuel Lines finger tight (snug) plus 1/8 of a turn.

Tighten Low Pressure Fuel Lines so the nuts seat against the shoulders of the fitting bodies Be sure the rubber grommets seat properly and are not binding or pinched on the fittings.

IMPORTANT

If the engine has been cranked after the pump was removed, repeat steps 2 and 3 on Pages 1-34 and 1-35. The timing adjustments must be exact. As little as one degree off may affect en­gine performance.

Make sure pump mounting caps crews are tight.

After the pump is correctly timed to the engine, bleed the fuel system. Start the engine and carefully check for leaks.

1-36

Style I

GROUP 1 - CASE MANUFACTURED CYLINDERS

Glands

4057-5

_ The style I gland has a V-cup rod seal with backup ring and O'rings around each rod wiper. This gland may be replaced by a style or n or III gland.

Figure 1 - Style I Gland

Sty Ie II

The style II gland has a V-cup rod seal with backup ring and two snap in rod wipers. This gland may be replaced by a style III gland.

SNAP IN ROD WIPER

Figure 2 - Style II Gland

4057-8

Removal

See page 4057-4.

Disassembly

1. Secure cylinder in a vise using care not to distort the tube. Remove the self-tap­ping screw from the gland. Use a spanner wrench and unscrew gland, Figure 6.

2. Carefully pull the piston rod from cy­linder. Pull the rod straight out to pre­vent damage to the cylinder wall.

3. Secure piston rod in a vise as shown in Figure 7 and remove the piston bolt. Bolt torque ranges from 200 to 1200 foot-pounds.

4. Remove piston assembly from piston rod. Then pull piston halves apart and remove the center ring, vee rings and end rings from piston halves.

~ SPANNER WRENCH ..,.,

>

700322

Figure 6 - Removing Gland

5. Remove gland from piston rod. If neces­sary, the gland may be driven off the rod with a soft hammer. Then remove the ~rings, backup rings, rod wipers and

rod seal from the gland. Refer to page 4057-5 to identify gland style and gland parts.

Figure 7 - Removing Piston Bolt

Inspection

1. Wash parts in cleaning solvent and dry with compressed air.

2. Discard piston packing, ~rings, seals, rod wipers and other parts found to be defective

3. Shine a light in the cylinder tube. If it has deep grooves or score marks, or has been severely damaged in any way, it should be replaced .

4. Inspect the piston rod for alignment. Re­place if bent; do not attempt to straighten.

5. Inspect bushings and replace as required.

6. Before reassembling, remove any minor nicks, scratches, etc. on the rod or in the cylinder tube with medium gr it emery cloth. Polish with a rotary motion rather than lengthwise.

7. Scoring, pitting, etc. are signs of possible oil contamination. Check the hydraulic oil for contamination (See Section 4011).

4057-9

PISTON HALF

/ ~ ROD WIPER \00 °iNG

'ACKUP RlNG'0 701343

Figure 8 - Exploded View of Typical Cylinder

BACKUP RING END RING CENTER RING

Figure 9 - Section View of Typical Cylinder

Assembly

1. Refer to page 4057-5 to identify gland style and assemble gland as illustrated.

2. Lubricate the piston rod and gland bore with hydraulic oil and install gland on piston rod. If necessary the gland may be driven onto the rod with a soft hammer.

3. Lubricate the vee rings in hydraulic oil. Position an end ring and three vee rings on each piston half. The vee of the rings must point to the center of the piston.

NOTE: If replacement packing rings are of nylon and neoprene, assemble as shown in Figure 11.

4057-10

CHEVRON RINGS J ~ -' , ' , '\:"--

~ENTERRING Figure 10 - Assembling Piston

END RING

CENTER RING

NYLON

690061

Figure 11 - Vee Ring Installation

; ~ "~ d'" . ' , '

. '~~:

73~04j

4. Position the center ring on one of the assembled piston halves and fit the two halves together. Install this assembly on the piston rod.

5. Assemble the piston on the rod:

a. If assembling a piston which uses a 1-1/4" retaining bolt, apply a light coating of Amojell petroleum jelly (or equivalent) to the follow­ing surfaces: Bolt threads, bolt washer surface, both sides of wash­er, and end of piston rod. All others, assemble dry.

b.

c.

d.

Secure the piston rod eye in a vise and support the piston end, Figure 12 .

Install the assembled piston on the piston rod.

Install the piston bolt and washer. Torque to specification on page 4057-3.

Figure 12 - Torquing Piston Bolt

6. Secure the cylinder tube in a vise and thoroughly lubricate the cylinder wall and piston packing. Install the piston rod straight into the tube. After the piston has started into the smooth portion of the tube, screw the gland into the tube but do not tighten at this time. The piston rod can now be worked farther into the tube with a rod through the piston rod eye or a soft hammer.

7. Torque the gland until the self-tapping screw holes in the gland and cylinder line up. Gland torque should be between 100 and 200 foot-pounds.

NOTE: If a new gland or tube is being used, drill a new hole for the self-tapping screw after the gland has been torqued. Using a No. 26 drill, drill the hole half in gland and half in cylinder approxi­mately 5/16" deep. Do not drill in line with the spanner wrench holes.

Installation

See page 4057-24.