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Servic
e M
an
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.
450B
Crawler
Volume 1 of 3
CA-S-450BCRWLR
SERIES/SECTION
10 SERIES - GENERAL
450B CRAWLER
TABLE OF CONTENTS
SECTION NO.
General Engine Specifications - 207 Engine .................. 1010 Decals and Repainting ...................................... 1012 Detailed Engine Specifications - 207 Engine .................. 1026 Maintenance and Lubrication ............................. > •• 1050 Torque Charts ............................................ ' .. 1051 Noise Control .............................................. 1052
20 SERIES - ENGINES Engine Diagnosis ........................................... 2001 Engine Tune-Up ............................................ 2002 Cylinder Head, Valve Train, and Camshaft .................... 2015 Crankshaft, Bearings, Flywheel, and Oil Seals ................ 2035 Oil Pump .................................................. 2045 General Engine Information ................................. 2050 Air Cleaner ano Mufflers .................................... 2051" Ether Injection System ................................. ~ .... 2053 Cooling system ............................................. 2055 Cylinder Block, Sleeves, Pistons, and Rods ................... 2125 Engine Lubrication ......................................... 2555
30 SERIES - FUEL SYSTEM Fuel Filters ................................................. 3010 Fuel Injection Pump ........................................ 3012 Fuel Injectors ............................................... 3013 Engine Controls, Fuel Lines, and Fuel Tank .................. 3052
40 SERIES - ELECTRICAL SYSTEM Electrical System Specifications and Troubleshooting ....... .4002 Wiring Diagram ............................................ .4003 Gauges .................................................... 4004 Battery .................................................... 4005 Starter and Starter Solenoid ................................ .4006 Alternator and Voltage Regulator ........................... .4007 Electrical Accessories ..................................... .4015
50 SERIES - TRACK AND SUSPENSION Track and Track Frame ..................................... 5506 Idler, Track Adjuster, and Recoil Housing .................... 5508 Sprocket ................................................... 5509 Carrier Rollers ................................. ' ............ 5510 Track Rollers ............................................... 5511
CASE CORPORATION C E Div. 9-67872 December 1980
FORM NO.
9-46301 9-67871 9-78685 9-67871 9-67871 9-67871
9-78875 9-78825 9-78836 9-78866 9-78885 9-67871 9-67871 9-67871 9-78816 9-78845 9-78985
9-78785 9-78795 9-78807 9-67871
9-67871 9-'67871 9-67871 9-67871 9-67871 9-67871 9-67871
9-67871 9-67871 9-67871 9-67871 9-67871
PRINTED IN U.S.A.
I Reprinted I
SER I ES/SECTI ON SECTION NO.
60 SERIES - POWER TRAIN General Transmission Information and Troubleshooting ...... 6002 Transmission Operation .................................... 6003 Charging Pump ............................................ 6005 Transmission Control Valve ................................. 6007 Torque Converter .......................................... 6010 Transmission ............................................... 6016 Final Drives ................................................ 6017 Transmission Controls ...................................... 60t8 Drive Shafts ................................................ 6021
70 SERIES - BRAKES Brakes ..................................................... 7001 Clutch Cutout Valve ........................................ 7007
80 SERIES - HYDRAULIC SYSTEM General Hydraulic System Information ....................... 8002 Hydraulic Pump ............................................ 8005 Equipment Control Valve .................................... 8007 Cylinders .................................................. 8090 Backhoe Control Valve ...................................... 8107 Stabilizer Control Valve ..................................... 8109
90 SERIES - MOUNTED EQUIPMENT Loader ..................................................... 9010 Blades and Frames ......................................... 9020 Ripper ..................................................... 9031 ROPS Canopy .............................................. 9061 Backhoe ................................................... 91 00 Winch ..................................................... 930.0
FORM NO.
9-67871 9-67871 9-67871 9-67871 9-67871 9-67871 9-67871 9-67871 9-67871
9-67871 9-67871
9-67871 9-67871 9-67871 9-67871 9-67871 9-67871
9-67871 9-67871 9-67871 9-67871 9-67871 9-66861
Exhaust Valve U.S. Value Tappet clearance (HOT and COLD) ........................................... 014" Face angle .................................................................................... 440
Face run-out .................................... ... ....... ....................... .002" max.
O.D. of head ................................................................ 1.398 to 1.408"
O.D. of stem ................................................................. 3399 to .3409"
Minimum Serviceable Limit ................................................... 3389"
Length ......................................................................... 6.340 to 6.364"
Insert seat angle ........................................................................... 450
Seat contact width .............................................. ......... .0608 to .0962"
Seat run-out ....................................................................... 002" max.
Insert height ................................................................. 2475 to .2525"
O.D. of insert ............................ ....... ................ ......... 1.4495 to 1.4505"
LD. of insert ..................... ....... ...... ....................... ... .... 1.245 to 1.255"
Intake Valve Guides
Length ...................................................................................... 3.250"
O.D. . ............................................................................. 6565 to .6575"
LD. (installed and reamed) .......................................... 3429 to .3439"
Maximum Serviceable Limit .. ........... ..... .... ................. .......... .3449"
Protrusion above cylinder head ....... ,. ......................................... 875"
Valve stem clearance in guide ........................................ 001 to .003"
Maximum Serviceable Limit . ...... ............. .......................... ..... .004"
Exhaust Valve Guides Length ...................................................................................... 3.125"
O.D. . ............................................................................. 6565 to .6575"
LD. (installed and reamed) .......................................... 3429 to .3439"
Maximum Serviceable Limit .................................................. 3449"
Protrusion above cylinder head .................................................. 875"
Valve stem clearance in guide ........................................ 002 to .004"
Maximum Serviceable Limit " ......... .... ..... .... ...... ........... .... ...... .005"
Valve Spring
Free length ............................................................................... 2.375"
Total coils .................................................................................. 8.25
Wire diameter ............•............................................................... .162"
LD. . ......... .... ..... ...... ....... ........ ........ ...... .... ........ .... ...... ..... .958 to .978"
Compressed to 1.521" (38.633mm) (valve open) ...... 110 to 118 Ibs.
Compressed to 1.875" (47. 625rnm) (valve closed) .... 53 to 59 lbs.
1026-9
Metric Value .356mm
440
.051mm max.
35.509 to 35.763mm
8.634 to 8.659mm
8.608mm
161.036 to 161.646mm
450
1.544 to 2.443mm
.051mm max.
6.286 to 6.413mm
36.817 to 36.843mm
31.623 to 31.877mm
82.550mm
16.675 to 16.7oomm
8.710 to 8.735mm
8.760mm
22.225mm
.025 to .076mm
.102mm
79.375mm
16.675 to 16.702rnm
8.710 to 8.735mm
8.761mm
22.225rnm
.051 to .102mm
.127mm
6O.325mm
4.115mm
24.333 to 24.B41mm
49.90 to 53.52 kg.
24.04 to 26.76 kg.
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 deposits. Be careful not to scratch valve stems. Refer to Section 2015 for valve inspection.
2001-25
STEP 13
MINIMUM 1/16" WIDE FLAT
Check valve guide top surface. There must be a minimum of a 1/16" wide flat around entire top surface.
Use M20615 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.
2002-6
ENGINE TUNE-UP PROCEDURE STEP 1 Service the air cleaner. Refer to your Operator's Manual.
STEP 2 Adjustthebelts. RefertoyourOperator's Manual.
Remove breather tube.
Remove valve cover mounting nuts and grommets.
Remove valve cover and gasket.
FAN t Loosen each cylinder head bolt or nut approximately 1 14 turn and then tighten bolt or nut to the specified torquing procedure as listed below and in sequence as shown above. NOTE: Do not loosen all nuts or bolts simultaneously but loosen and tighten each indi~idual bolt and nut in the prescribed sequence. The bolt or nut is backed off 1 14 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.
1. Nuts w/hardened washers - torque 95-105 ft.lbs.
2. Grade 8,12 pt. hd. bolts - torque 110-115 ft. Ibs.
3. Flanged nuts - torque 90-100 ft. Ibs.
Torque rocker arm mounting bracket bolts to insure that the bolts have retained 25 to 30 ft. Ibs. torque.
Crank engine by inserting a screwdriver into the timing hole in the flywheel housing or torque tube, and by engaging the ring gear teeth with the screwdriver, align the timing pointer with the 10° BTDC mark on the flywheel.
Turn the rocker arm adjusting screw on number one cylinder intake valve inwards to take pressure off the push rod.
Push down on the number one cylinder intake valve spring and at the same time push the rocker arm assembly rearwards.
2002-7
Remove the push rod.
Compress exhaust valve spring on number one cylinder by using a screwdriver.
STEP 12
Remove the valve keepers.
2015-13
Cylinder Head Inspection
Wash, clean and inspect cylinder head. Use rotary wire brush to clean around and down into the valve ports. Clean carefully all machined surface areas with emery cloth, removing all gasket material, carbon and rust from cylinder head.
Lay a straight edge of the cylinder head from corner to corner. Try to get a .006" feeler gauge under the straight edge. The maximum limit for head warpage is .006". If warpage is greater than .006", the cylinder head must be replaced or resurfaced. A minimum head thickness of 3.968" must be maintained if cylinder head is resurfaced.
IMPORT ANT: If the cylinder head has been resurfaced, the valve protrusion must be checked so as to prevent piston and valve contact. Refer to Steps 65 and 66.
IMPORT ANT: If the cylinder head has been resurfaced, the valve recession must be checked also. Refer to Steps 65 and 66.
2015-14
STEP 43
Check valve guides with an expandable bore gauge in three places as illustrated in the inset.
Check bore gauge with a micrometer. If the diameter is greater than .3449" at any point, replace the valve guide. If the inside diameter of the valve guides is less than .3449", proceed to valve and seat inspection. Refer to Step 53.
Valve Guide Replacement
To replace valve guides, place the cylinder head in a hydraulic press. NOTE: Always press guides from the top, through the head.
Valve guides must protrude .875" above the cylinder head. Fabricate a bushing (.688" minimum 1.0. x .875" long) and place over the valve guide. The bushing will aid in obtaining correct guide protrusion.
4005-10
Procedure
1. See Figure 6. Make sure that the level of charge of the battery is at least 75%. If necessary, charge the battery to get this level of charge.
2. If the battery is charged or removed from service only a short time before you do the capacity (load) test, it is necessary to remove the surface charge from the battery. To remove the surface charge, do the following procedure:
a. See Figure 7. Turn the load control knob to the Off position.
b. Select the voltmeter range that will measure 0- 18 volts.
c. Select an ammeter range that will measure 15 amperes.
d. See Figure 7. Connectthe positive voltmeter lead to the positive post on the battery. Connect the negative voltmeter lead to the negative post on the battery. Put the ammeter clamp around the POSITIVE voltmeter lead so that the points of the arrows on the handles of the ammeter clamp are AWAY from the battery.
NOTE: Never apply a load for longer than 15 seconds. After each 15 seconds, put the load control knob in the Off position for at least one minute.
e. Turn the load control knob clockwise until the ammeter indication is 15 amperes. Keep this load for 15 seconds. Turn the load control knob to the Off position.
o
o 0
1 Load ContrOl Knob
Figure 7 - Capacity (Load) Test Connecti.ons
3. Use a thermometer to measure the temperature of the electrolyte in one of the cells of the battery. Make a record of this temperature.
4. See Figure 7. Turn the load control knob to the Off position.
5. Select the voltmeter range that will measure 0 -18 volts.
6. See Figure 7. Connect the positive voltmeter lead to the positive post on the battery. Connect the negative voltmeter lead to the negative post on the battery. Put the ammeter clamp around the POSITIVE voltmeter lead so that the pOints of the arrows on the handles of the ammeter clamp are AWAY from the battery.
7. To get the correct amperage for the capacity (load) test:
a. If you know the ampere hour rating of your battery, multiply the ampere hour rating of the battery by three. Make a record of the result.
Example: If your battery is rated at 60 ampere hours, the correct amperage for the capacity (load) test is 180 amperes.
b. If you do not know the ampere hour rating of your battery, the correct amperage for the capacity (load) test is 200 amperes.
NOTE: Never apply a load for longer than 15 seconds. After each 15 seconds, put the load control knob in the Off position for at least one minute.
8. Select an ammeter range that will measure the amperage specified in step 7.
9. Tum the load control knob clockwise until the ammeter indication is as specified in step 7. Keep this load for 15 seconds. Check the voltage indication on the voltmeter. Tum the load control knob to the Off position.
10. Look under Test Specifications on page 4005-9 to find the minimum voltage specification for the temperature which you measured in step 3.
a. If the voltage indication from step 9 is equal to or above the minimum voltage specification, the battery is in good condition. If necessary, charge the battery before you use the battery again.
b. If the voltage indication from step 9 is less than the minimum voltage specification, discard the battery.
12. Put the starter drive housing in a vise as shown in Figure 39. Put the lock washers and flat washers on the screws that hold the starter drive housing and starter solenoid housing together. Put new O-rings on the screws if necessary. Put a small amount of grease on the O-rings. Then install and tighten the screws that hold the starter drive housing and starter solenoid housing together.
Figure 39
13. Install the armature in the starter solenoid housing.
4006-13
14. Install the field frame housing. Enage the tab on the field frame with the notch in the starter solenoid housing.
Figure 41
15. Install the brush holder on the commutator.
16. Use _~ pair of needle noise pliers to pull a brush spring away from one ofthe brushes in the brush holder. Push the brush down and put the brush spring on top of the brush. Repeat this step for the other brush in the brush holder.
--Figure 43
4006-14
17. Use a screwdriver to hold a brush spring out of the way for one of the brushes connected to the field coil. Put the brush in the brush holder. Then put the brush spring on top of the brush. Repeat this step for the other brush connected to the field coil.
Figure 44
18. Put the frame of the brush holder even with the end of the armature shaft. Put the end cover over the brush holder. Align the small holes in the end cover with the threaded holes in the frame of the brush holder. Then install and tighten the screws that fasten the brush holder to the end cover.
19. Push the end cover against the field frame. Make sure the tab on the field frame is in the notch in the starter solenoid housing. Put the lock washers and flat washers on the cap screws. Put new O-rings on the cap screws if necessary. Install and tighten the cap screws that fasten the end cover and field frame to the starter solenoid housing.
Figure 46
20. Put the cable on the motor terminal. Then install the lock washer and nut on the motor terminal. Tighten the nut. Put the rubber boot overthe motor terminal.
Figure 47
4007-4
4. Start the engine and run the engine at full throttle for one minute.
5. Decrease the engine speed and stop the engine.
6. Put water into the front and rear of the alternator again.
7. The machine is ready for use.
Test Equipment
The alternator and voltage regulator tests can be done using a Sun Electric VAT-33 Starting and Charging System Tester ,or an equivalent tester.
The rectifier diodes, stator, rotor, and brush tests can be done with any good quality ohmmeter.
ALTERNATOR AND VOLTAGE REGULATOR TESTS
Checks To Do Before Alternator and Voltage Regulator Tests
1. Use a voltmeter to make sure that the pressure switch in the charging circuit is working correctly.
a. If the machine is a dozer, remove the cover on top of the instrument panel, Figure 2. If the machine is a loader, remove the instrument panel.
Figure 2
b. Start the engine. Run the engine at approximately 1000 rpm (r/min).
c. Connect the negative (black) voltmeter lead to the machine frame. The contact point must be free of paint, grease, and rust.
Figure 3
d. Connect the positive (red) voltmeter lead to the pressure switch terminal that has two wires connected to the terminal.
Figure 4
e. The voltmeter must indicate electrical system voltage. If the voltmeter did not indicate electrical system voltage, a new pressure switch must be installed.
2. Check the condition of the battery. The specific gravity of the cells in the battery must be at least 1.225. See Specific Gravity Check in Section 4005.
3. Check to make sure all connections in the charging circuit are clean and tight.
4. Check to make sure that the drive belt is adjusted to the correct tension. See instructions in this section.
Alternator Output Test
The Alternator Output Test will indicate if the alternator is producing the minimum rated output.
1. Put the controls of the Sun VAT-33 in the following positions:
a. Make sure the LOAD control is in the OFF position.
