Service Manual 310, 310E, 310F, 310G, 320 & 350 Gas & Diesel

Camshaft .................................................................................................................................. 7 Valve Push Rod Lifters ............................................................................................................ 7 Gear Train .............................................................................................................................. . 8 Pi! 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 ................................................................................•................................. 11 GENERAL TORQUE SPECIFICATION TABLE ........................................................................ 12 1129-3 TABLE OF CONTENTS ENGINE SPECIFICATION DETAILS Cylinder Sleeve ................................................................................. 4 Piston ..............................•........................................................... 4 Piston Rings .................................................................................... 4 Piston Pi n .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 ~ Connecting Rod ...................................................................................5 Crankshaft ...................................................................................... 5 Camshaft ........................................................................................6 Valve Push Rod Lifters ............................................................................6 Gear Train ...................................................................................... 6 Oil Pump ....................................................................................... 6 Cylinder Head .................................................................................. 6 Spark Plug ...................................................................................... 6 Exhaust Valve ................................................................................... 7 Intake Valve ..................................................................................... '7 Exhaust Valve Guide .....................................•.................•.................... 7 Intake Valve Guide ...........................................................•.................. 7 Valve Spring (Exhaust Valve) ..................................................................... 7 Valve Spring (Intake Valve) ........................................................................8 Rocker Arm Assembly ........................................................................... 8 Distributor .............................•.............•......................................•... 8 Governor Shaft ...................................................................................8 SPECIAL TORQUES ..........•................................................................... 9 GENERAL TORQUE SPECIFICATION TABLE ..................................................•.. 10 Rae 9-79086 Printed in U.S.A. Section 2013 CYLINDER HEAD AND VALVES 148, 159, 188 AND 201 SPARK IGNITION ENGINES TABLE OF CONTENTS Specifications ............................................................................................................................ 2,3 Special Torques ........................................................................................................................... 3 Checking Compression Pressure ............................................................................................... 4,5 Cylinder Head and Components (148 and 159) ...................................................................................................................... 6-9 (188 and 201) ................................................................................................................... 10-13 Rocker Arm Assembly (148 and 159) ................................................................................................................... 14,15 (188 and 201) ................................................................................................................... 16,17 Cylinder Head Assembly (148 and 159) ................................................................................................................... 18,19 (188 and 201) .................................................................................................................... 20,21 Inspection of Valves, Guides, Head and Springs ....................................................................22,23 Refacing Intake and Exhaust Valves ......................................................................................... 24 Grinding Intake and Exhaust Valve Seats ................................................................................. 25 Locating Top Dead Center and Tappet Adjustments ................................................................. 26 CASE CORPORATION Rae. 9-80512 PRINTED IN USA 2015-2 TABLE OF CONTENTS SPECIAL TOOLS ...................................................................................................................... 3,4 SPECIFICATIONS FOR TOOLS WHICH MUST BE MADE ........................................................... 5 CYLINDER HEAD Cylinder Head Assembly .................................................................................................... 24,25 Cylinder Head Inspection ................................................................................................... 13,14 Cylinder Head Installation .................................................................................................. 26,27 Cylinder Head Removal ............................................................................................................. 6 Cylinder Head Torquing - Cold or Initial Torque ..................................................................... 27 Cylinder Head Torquing - Hot ................................................................................................. 35 Diagnosis of Various Valve Bluing Patterns ....................................................................... 21-23 Expansion Plug Replacement .................................................................................................. 16 Locating Top Dead Center ...................................................................................................... 33 Manifolds, Water Pump and Fuel Injectors Installation ....................................................... 31-33 Refacing Valves and Valve Seats ............................................................... '" .......................... 20 Rocker Arm Assembly ....................................................................................................... 28-31 Valve Bluing ........................................................................................................................... 20 Valve Guide Replacement .................................................................................................. 14,15 Valve Inspection ................................................................................................................ 17-19 Valve Seat Inspection ........................................................................................................ 17-19 Valve Seat Replacement ......................................................................................................... 19 Valve Tappet Adjustment - Cold Setting ............................................................................ 34-36 Valve Tappet Adjustment - Hot Setting with Engine Stopped ................................................. 37 CAMSHAFT Backlash - Camshaft to Crankshaft ......................................................................................... 53 Backlash - Camshaft to Idler Gear ................................................... : ...................................... 57 Backlash - Idler Gear to Injection Pump ................................................................................. 58 Bushing Replacement - Front ............................................................................................ 45,46 Bushing Replacement - Intermediate .................................................................................. 45-47 Bushing Replacement - Rear ............................................................................................. 47-49 Camshaft - Assembly ........................................................................................................ 51,52 Camshaft - Installation ...................................................................................................... 53-61 Camshaft - Removal .......................................................................................................... 38-44 Idler Gear - Inspection ............................................................................................................ 55 Idler Gear - Installation ...................................................................................................... 56,57 Valve Lifters - Inspection ................................................................................................... 49,50 Valve Lifters - Replacement ............................................................................................... 49,50 Section 2023 ENGINE BLOCK ASSEMBLIES 201 G, 188G, 159G, 148G SPARK IGNITION ENGINES TABLE OF CONTENTS Camshaft, Bushings and Lifters ............................................................................................. 18·21 Crankshaft, Bearings, Liners and Oil Pump .......................................................................... 32·35 Cylinder Sleeves . Deglazing ..................................................................................................... 25 Cylinder Sleeves . Honing .......................................................................................................... 26 Cylinder Sleeves· Inspection ...................................................................: ................................. 24 Engine Lubrication ................................................................................................................... 8,9 Flywheel, Oil Pan, Seal Retainer and Oil Filter ................................................................... 10·13 Locating Top Dead Center ......................................................................................................... 40 Oil Pump .............................................................................................................................. . 36,37 Pistons and Cylinder Sleeves· Inspection ................................................................................. 27 Pistons, Rings, Sleeves and Connecting Rods . Assembly ..................................................... 28·31 Pistons, Rings, Sleeves and Connecting Rods· Disassembly, Inspection ................................... 22 Special Torques ........................................................................................................................... ., Specifications ............................................................................................................................ 2·6 Timing Gear Cover, Gear and Water Pump .......................................................................... 14·17 Thermostat and Fan Belt ...................................................................................................... 38,39 CASE CORPORATION RIIc: 9-76995 PRINTED IN USA SPECIFICATIONS (Cont'd) Crankshaft (Continued) Grind to: .010" O.D. undersize, (201G, 188G) .020" O.D. undersize, (201G, 188(;) .030" O.D. undersize, (201G, 188G) .010" O.D. undersize, (159G, 148G) .020" O.D. undersize, (159G, 148G) .030" O.D. undersize, (159G, 148G) ....................... 2.8630 to 2.8640 ....................... 2.8530 to 2.8540 ....................... 2.8430 to 2.8440 ....................... 2.6130 to 2.6140 ....................... 2.6030 to 2.6040 ....................... 2.5930 to 2.5940 Main journal bore LD. w/o liners (201G, 188G) ......... 3.066 to 3.067 (159G, 148G) ......................................... 2.816 to 2.817 Main journal width between cheeks: 2nd (159G, 148G) ............ ..... .................................... 1.499 to 1.502 2nd (201G, 188G) .................................................. 1.3740 to 1.3770 3rd ........................................................................... 1.745 to 1.755 Connecting rod journal width between cheeks ......... 1.3105 to 1.3145 Camshaft Type ........................: ....................................................... Parabolic Bushings (201G, 188G) ............................................. 4, Replaceable Bushings (159G, 148G) ............................................. 3, Replaceable Bushing lubrication: Front bushing ............................................... Pressure lubricated from oil pump. Intermediate bushing ................................. Gravity flow lubricated 2023-5 Maximum Limit Including Wear Oil clearance .................. ................... ....... ..................... .002 to .005 ......... ....................... .007 LD. of bushing installed .... ....................... .................. 1.752 to 1.753 Bushing width: 1st (front) (159G, 148G) ........................................... 1.307 to 1.317 1st (front) (201G, 188G) ........................................... 1.213 to 1.223 2nd (159G, 148G) ......................................................... 713 to .723 2nd, & 3rd. (201G, 188G) ............................................ .490 to .500 3rd (rear) (148G, 159G) ........................................... 1.177 to 1.197 4th (rear) (201G, 188G) ........................................... 1.213 to 1.223 O.D. of each bearing surface .................................. 1.749 to 1.750 ................................. 004 Thrust plate thickness ................................................. 149 to .147 2025-2 TABLE OF CONTENTS SPECIAL TOOLS ......................................................................................................................... 3 CYLINDER BLOCK, SLEEVES, PISTONS AND RODS Checking Connecting Rod Journals ........................................................................................ 18 Checking Ring Gap ................................................................................................................ 15 Checking Sleeve Protrusion ............................................................................................... 11,12 Connecting Rod Bearing Replacement ............................................................................... 18,19 Connecting Rod Bushing Replacement .................................................................................... 13 Connecting Rod Inspection ..................................................................................................... 13 Cylinder Sleeve Inspection ..................................................................................................... 7,8 Piston Inspection .................................................................................................................... 14 Piston Installation .............................................................................................................. 15-17 Piston Removal ..................................................................................................................... 4-6 Sleeve Deglazing ................................................................................................................. 9,10 Sleeve Installation ............................................................................................................. 10-12 Sleeve Removal ............................................................ ................... ............... .......... ....... ....... 10 2035-2 TABLE OF CONTENTS Special Tools ............................................................................................................................... 3 Front Oil Seal Replacement ................................................................................................. 4 to 6 Rear Oil Seal Replacement .................................................................................................. 7 to 9 Crankshaft and Main Bearings ......................................................................................... 10 to 29 Removal ....................................................................................................................... 10 to 14 Main Bearing Cap Replacement .................................................................................... 14 to 15 Crankshaft Inspection and Installation ........................................................................... 15 to 29 Flywheel .......................................................................................................................... 30 to 31 2045-2 TABLE OF CONTENTS SPECIAL TOOLS ......................................................................................................................... 2 OIL PUMP Oil Pump Removal ................................................................................................................ 3-5 Oil Pump Inspection ............................................................................................................ 5-10 Oil Pump Installation ......................................................................................................... 11-14 SPECIAL TOOLS SPRING TESTER DIAL INDICATOR FOOT POUND TORQUE WRENCH Using a feeler gauge, check pump gears to body radial clearance. If clearance is great- er than .008 inch, the pump must be replaced. Place a piece of plasti gauge on one of the pump gears. Install pump cover and gasket on pump body. 2045-7 STEP 16 Torque pump cover mounting bolts 6 to 8 ft. Ibs. STEP 17 Remove pump cover from pump body. STEP 18 Measure plasti gauge to obtain gear-to- pump cover clearance. If clearance ex- ceeds .008 inch, the pump must be re- placed. 2050-2 TABLE OF CONTENTS Removing Engine and Clutch Assembly •••..••••.•.•..••••.••••••••••• 2050-3 Installing Engine and Clutch Assembly • . • • • • • • • • . • • • • • • • • • • • • • • • • • • • • • 2050-5 View of Engine Controls on Diesel Engine Models •••••••••.••••••••••• 2050-6 View of Engine Controls on Gasoline Engine Models •••••••••••••••••.•• 2050-7 Installing Hoses and Tubes on Crawler •••.••••••.••••••••.•••••••• 2050-8 2051-2 TABLE OF CONTENTS Air Cleaner ... Description Exploded Views Dry Type Air Cleaner, Gasoline Engine Dry Type Air Cleaner, Diesel Engine Dry Type Air Cleaner Operation Service Instructions Cleaning Filter Assembly Oil Bath Air Cleaner Description General Service Exploded View of Oil Bath Type Air Cleaner Removal ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing Oil Cups Servicing Body Assembly Air Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation Trouble Shooting Safety Filter · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . Air Cleaner Cap. Air Pre-Cleaner · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . · . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 2051-3 2051-3 2051-4 2051-5 2051-6 2051-6 2051-6 2051-7 2051-8 2051-8 2051-8 2051-9 2051-10 2051-10 2051-10 2051-11 .2051-11 2051-11 2051-11 2051-12 2051-12 2051-12 2051-12 2054-2 TABLE OF CONTENTS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2054-3 Trouble Shooting Chart . • • . . . . . . . . • . • . • • . • . . . . • • . . . . . . . . . . • • . • . . . 2054-4 Checking a Cooling System that Overheats .. . . . . . . . . . . . . . . . . . . . • . • . . • . . 2054-5 Description ..................•......•..•...........•...•.... 2054-6 Circulation . . . . . . . . . . . • . . . . . . . . . . . . . . . . • . . . . . . . . • . . • • . . . • . 2054-6 Thermostat. . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . 2054-6 Radiator and Radiator Cap. . . . . . . . . • . . . . • . • . . . . . . . . . . • • . . . . . . . . 2054-6 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2054-6 Water Pump ........................•..................... 2054-6 Anti-Freeze ............................................•..•. 2054-8 Draining and Filling the Cooling System ..•........................•... 2054-8 Cleaning the Cooling System .........•............•............... 2054-9 Cleaning Period ...............•.•...•.....•.•......•..•...• 2054-9 Cleaning Procedure ................................•........ 2054-9 Reverse Flushing ..........................•......•........ 2054-9 Cleaning Exterior of Radiator .....•..•..................•..•.. 2054-10 Radiator . . . . . . . . . . . . . . . . • . . . . . . • . . . . . . . . • . . . . . . . . • . • . . . . . . . 2054-11 Removing Radiator ..............•......................... 2054-12 Repair and Installation .......................•.............. 2054-12 Anti-Sandblast Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . • . • . . • . 2054-12 Installation . . . . . • . . . . . • . . . . . . . • • . . • . . . . . . . . . . • . . . • . • . . . •. 2054-12 Checking and Replacing the Thermostat . . . . • . . . . . . . . . . . . . • . • • • . • . . . .. 2054-13 Thermostat Replacement (Gasoline Engine) ................•••...... 2054-13 Thermostat Replacement (Diesel Engine) . . . • • . . . . . . . . . . . . . . • • • . . .. 2054-13 Testing the Thermostat • . . . • • . . • . • • • . . . • . • . • . . . • . • . . • • . • . . • • . 2054-14 Fans ..................................................... 2054-15 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2054-15 Replacement . . . . . • . . . . • • . . . . . . . . . . • • . • • • . . . . . . . . . • • • . . . . . 2054-15 Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2054-15 Adjustment •. . . . . • . • . . . . • . . • . . . . . . . . . . . . . . . . . . . . . • • • . . . . . 2054-15 Replacement . . • . • . . . . . . . . . . . . . . . . . . . . . . . . . • . • . • . . • • • • . . . . 2054-15 Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2054-16 3012-2 TABLE OF CONTENTS SPECIAL TOOLS ......................................................................................................................... 2 SPECIFICATIONS .......................................................................................................................... 3 SPECIAL TORQUES .................................................................................................................... 3 GENERAL INFORMATION ........................................................................................................... 4 FUEL PUMP REMOVAL ............................................................................................................ 5-8 Pump Drive Shaft Removal ................................................................................................. 9.10 Pump Drive Shaft Installation ............................................................................................ 11.12 FUEL PUMP INSTALLATION ................................................................................................ 13-20 Checking Pump Gear Backlash .......................................................................................... 21,22 Replacing Pump Inlet Filter ............................................................................................... 23-25 ENGINE SPEED ........................................................................................................................ 26 Checking Engine Speed .......................................................................................................... 26 ENGINE SPEED ADJUSTMENTS .............................................................................................. 27 No Load Governed Speed ....................................................................................................... 27 Low Idle Speed Adjustment .................................................................................................... 28 FOOT POUND TORQUE WRENCH SPRING TESTER SPECIAL TOOLS FILTER WRENCH A64761 DIAL INDICATOR SEAL COMPRESSION TOOL CD331 3013-2 11.. WARNING When testing or adjusting .. fuel injectors, do not place your hands or arms in front of the injector nozzle. The fuel spray from an injector has sufficient penetrating power to puncture the flesh and destroy tissue. Should the fuel enter the blood stream, it may cause blood poisoning. In the event the skin is punctured from the dis- charge of an injector, apply the following first aid immediately and then have the injury ex- amined by a physician as quickly as possible. Wash the injured part with boric acid solution, support the injured finger or hand with a splint and sling so the injured part will remain ab- solutely at rest until a physician can examine it. TABLE OF CONTENTS General Informa tion .................................................................................................................... 6 Injector Adjustments ............................................................................................................. 22,23 Injector Test Stand .. .......... ........... .... ... ....... ..................... ....... ...... ...... ............ ...... .......... ....... .... 13 Installing Injectors ................................................................................................................. 10-12 Isolating Faulty Injectors ............................................................................................................ 8 Nozzle Identification .................................................................................................................... 5 Opera ting Principles .................................................................................................................... 7 Removing Injectors ................................................................................................................... 8,9 Servicing Injectors ..... ........... ........... ...................... ............ .............. ...... ........... ........... .......... 16-21 Special Tools ............................................................................................................................... 3 Special Torques ..... i •••••••••••••••••••••••••••••••••••••••••••••••• ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 Specifica tions .............................................................................................................................. . 4 Testing Injectors .................................................................................................................... 14,15 3052-2 TABLE OF CONTENTS Adjusting Governor and Throttle Linkage on Diesel Engine Crawlers. . . • . . . • • • . • . • . • • • • • . • • • . . . • • • • • • • • • • 3052-3 Low Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3052-3 High Idle Adjustment ..••••••.••..•••..•....•••..••..••...•.• 3052-4 Foot Pedal Stop Adjustment . . . • • • • . . . . • . • • . • • . . . . • . . • . • • . . • . . . • 3052-4 Hand Throttle Adjustment 3052-4 Friction Disc Adjustment 3052-4 Adjustment Idle Speed and Throttle Linkage on Gasoline Engine Crawlers .••..•.•.•••.••.•.......•....•....• 3052-6 Adjusting Governor Linkage • . . . . . • . • . • • • . . . • • • . . . . . • . • . . . • . • . . • 3052-6 Foot Pedal Stop Adjustment ....•••........•..........•........• 3052-7 Hand Throttle Adjustment 3052-7 Friction Disc Adjustment 3052-7 Fuel Lines .................................................. 3052-9 4011-2 TABLE OF CONTENTS Specifications ............•............•.•.......•.•....•..•.• 4011-3 Pump and Reservoir ..•............•....•..•...•..•.••.....•. 4011-3 Hydraulic Systems Diagrams ..•.........•.•.................•...•• 4011-4 Loader Hydraulic System with Drott 4-In-1 Bucket ..............•.•..• 4011-4 Mechanical Angling Dozer .....................•......•••....•. 4011-5 Power Angling Dozer ...............................•.....•.• 4011-6 Power Tilt Dozer .•............•...•....................•..• 4011-7 Power Angle-Tilt Dozer (Case) ................................• 4011-8 Power Angle-Tilt Dozer (Ormco) .......•........................ 4011-9 Model 26 and 33 Backhoe Hydraulic System ...................•..•. 4011-10 Loader-Backhoe Supply and Return Circuits ........................ 4011-11 Dozer-Backhoe Pump Supply and Return Circuits .................... 4011-12 Ripper Hydraulic System with Diversion Valve .........•...••....... 4011-13 3-Point Hitch Hydraulic System with Diversion Valve . . . . . . . . . . . . . . . . . . 4011-14 Pull Behind Hydraulics with Diversion Valve ...................•.... 4011-15 Flushing the Hydraulic System .........•.••••..................••• 4011-16 Trouble Shooting. . . . . . . . . . . • • • • . • . • . • . • . • . • . • . • . • . . . • . • . • • • . . 4011-16 Identifying Causes of Pump Failure ••.••.•••••...•.•.....•.••••• 4011-16 Problem: Poor Operation of a Single Circuit Only ....••....•.•.••.... 4011-18 Problem: Poor Operation of All Circuits ....•......•...•..•••.••. 4011-22 Trouble Shooting Chart. • • . . . . . • • . • . • • • . • . • . . . . . . . . . . . • • . . . . • . • • 4011-23 Problem: Poor Loader or Dozer Performance .•.....•.....•..•••••• 4011-23 Problem: Poor Backhoe Performance ••..•.•.•.•••.•..••••..••.. 4011,..24 Problem: Failure of Pump, Valves, or Cylinders ...••.•......••..... 4011-25 Testing the Hydraulic System With a Flowmeter ••..•....•.•.....•..•••• 4011-28 Flowmeter Check Sheet .•.•...••.••.••••.•••.••••.•.•.•.•.••. 4011-35 Testing Secondary Relief Valves With a Hand Pump •.....••.•...••.••••.• 4011-36 Pressure Specifications ••••...•.••.••.•••••••.•••...••.••.....• 4011-40 Backhoe Control Valves •...•.••.•..•.•..•........•.....•.•.• 4011-40 Loader Relief Valves •.....•....••.•.•••.••.•..•..•••..••••• 4011-41 Dozer Relief Valves •.•...•.•••••....••••••..••.•..•••....• 4011-41 Testing Relief Valves With a Pressure Gauge •.•......••...•.••••.••.•• 4011-42 Loader Main Relief Valve ...•.....••.•..•••..•••..••.••••••.. 4011-42 Dozer Main Relief Valve ........•....•....•.•.....•.••..•.•.. 4011-43 Adjusting Relief Valves •.....•••......•...••...........•••..•.• 4011-46 4013-2 TABLE OF CONTENTS Exploded Views Cessna Hydraulic Pump (350 After SiN 3046500 and 310G After SiN 3025561) Hydreco Hydraulic Pump (350 Before SiN 3046501) Commercial Shearing Hydraulic Pump (310G Before SiN 3025562) Webster Hydraulic Pump (310G Before SiN 3025562) Specifications Operation Cessna ....•. Removal Disassembly Inspection Assembly Pump Coupling Testing and Installing Pump Hydreco Removal Disassembly Inspection Assembly Pump Coupling Testing and Installing Pump Commercial Shearing . . . . . .. Removal Disassembly by Subassembly Assembly by Subassembly Pump Coupling Testing and Installing Pump Webster Removal Disassembly Inspection Assembly Pump Coupling Testing and Installing Pump 4013-3 4013-3 4013-4 4013-5 4013-6 4013-7 4013-7 4013-8 4013-8 4013-8 4013-9 4013-10 4013-11 4013-11 4013-13 4013-13 4013-13 4013-13 4013-13 4013-14 4013-14 4013-15 4013-15 4013-15 4013-15 4013-17 4013-17 4013-18 4013-18 4013-18 4013-19 4013-19 4013-20 4013-20 4021-2 Trouble Shooting Chart Specifications VDP-22 VDP-12 TABLE OF CONTENTS Exploded Views of VDP-22 Control Valves Exploded Views of VDP-12 Control Valves Servicing Removal Main Relief Valve Dual-Stage Main Relief Valve VDP-22 Secondary Relief Valves VDP-22 Check Valves VDP-12 Secondary Relief Valves .••.• VDP-12 Check Valves Spools Disassembly Inspection Assembly Installation Special Tools Spool Gland Tool Spring Compressor Snap Ring Installing Tool Operating Principles Valve Circuits Valve Spools Valve Ports Oil Flow Spools in Neutral Actuating a Spool Main Relief Valve Dual Stage Main Relief Valve •••••••••••• Power Beyond Float Detent Position Secondary Relief Valves •••••.•..• eheck Valves .••••.. 4021-3 4021-5 4021-5 4021-6 4021-7 4021-10 4021-12 4021-12 4021-13 4021-14 4021-15 4021-17 4021-17 4021-19 4021-22 4021-22 4021-24 4021-24 4021-25 4021-26 4021-26 4021-26 4021-27 4021-27 4021-27 4021-27 4021-28 4021-28 4021-28 4021-29 4021-31 4021-31 4021-32 4021-32 4021-34 4022-2 TABLE OF CONTENTS Specifications . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .• 4022-3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-4 Exploded View ............ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-4 Removing Control Valve . . . . • • . . . . . . . . . . . . . • . • . . . . . . • . . . . • . • .• 4022-5 Special Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-5 Regeneration Check Valve. . . • . . . . . . . . . . . . . • . • . . . • . . . . . . . . . • . •. 4022-5 Regeneration Spool ......................................... 4022-6 Valve Sections and Spools . . . . . • . . . . . . . . • . . . . • . • . . . . . . . • . . . . . •. 4022-6 Load Check Valves .•......•.........•.............•...•• ,.. 4022-8 Secondary Relief Valves . • • . . . . • . . . . . . • . . . . . . • • . . . . . • . • . . • . . •. 4022-8 Crossover Relief Valves . . . . . • • • . . . . . . . . . . . • . . . . . • . . . . . • . . . . .• 4022-9 Assembling Valve Sections ........................•....•...•. 4022-10 Operating Principles .......................................... 4022-12 General Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-12 Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . .. 4022-13 Actuating More Than One Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-13 Main Relief Valve ......................................... 4022-13 Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-13 High Pressure Secondary Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-13 Boom Down Secondary Relief Valves . . . . . . . . . . . . . • . . . . . . . . . . . . . .. 4022-14 Swing Circuit Relief Valves . . . . . . . . . . . . • . . . . . . . . . . . . . . . • . . . . .. 4022-14 Swinging the Boom . . . . . . . . . . . . . . . . . • . . . . . • . . . • . . . . . • . . . . . .. 4022-15 Stopping the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4022-15 4028-2 TABLE OF CONTENTS Pull Behind Hydraulics . • . • • • . • • • • • • • • . • • • • . • • • • • • • . . . . . • . . . . . . . • • 4028-3 Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4028-4 Pull Behind Coupling, Female •••.•••..•..•.••.••••.••..•.•.•.••• 4028-6 Pull Behind Coupling, Male ••.••••.•....•.••••••.•.••••..•.•..• 4028-6 Diversion Valve ................................................ 4028-8 4041-2 TABLE OF CONTENTS Ope ration- •...•.•.. 4041-3 Operation of Lockout Valve .•••..••••••••••••••••..•.•••.•••••.• 4041-4 D49932 Lockout Valve •..•.•....•••.•••......•••..••.•.•••••••••. 4041-4 D46850 Relief Valve . . . . • • . • • • • • . . • • . . . . . • . • • • • • . . • . . • • • . • • • • • • • • 4041-5 4057-2 Torque Specifications Piston Rod Bolts and Nuts Packing Glands .. Hydraulic Fittings Spanner Wrench Kit . TABLE OF CONTENTS Removing Cylinders ...•....•.•....•..••. Procedure ..... Swing Cylinders Dipper Extension Cylinders Group I - Case Manufactured Cylinders without Cushion Device Glands ........... . Removal Disassembly •. Inspection. . Assembly ... Installation. • Group n - Backhoe Boom and Swing Cylinders with Cushion Device Glands .... Removal •.....•.. Disassembly . Inspection Assembly ... Group TIl - Grapple Cylinder D39720 •.. Removal .... Disassembly . Inspection Assembly .......•.. Installation. Group IV - Clam Bucket Cylinders Removal ... Disassembly Inspection . . Assembly .. Installation . . Installing Cylinders Group V - Ormco Power-Angle-Tilt Dozer Cylinders Removal ... Disassembly Inspection • Assembly .......•...••. . 4057-3 .•...•... 4057-3 .4057-3 • .4057-3 .4057-3 .4057-4 · .4057-4 .4057-4 · .4057-4 .4057-5 · .4057-5 .4057-7 • .4057-7 · .4057-7 · .4057-9 .4057-10 .4057-11 . •..•..• 4057-11 . .•.•.. 4057-13 . ........... . 4057-13 · .4057-13 • .•••••• .4057-14 · ..• 4057-17 .4057-17 .4057-17 .4057-17 · .• 4057-17 .4057-18 .4057-19 · ... 4057-19 .......... 4057-19 · •. 4057-19 .4057-19 · .4057-20 .4057-21 · .•• 4057-21 · .4057-21 •...• .4057-21 · .4057-21 · • ,4057-22 5010-2 TABLE OF CONTENTS Assembly of Track Plates and Links .•............................... 5010-3 Track Service and Maintenance .................................... 5010-4 Specifications ............................................. 5010-4 Track Service Kits ......................................... 5010-4 Track Wear Gauge .............. . . . . . . . . . . . . . . . . . . . . . . • . . . .. 5010-4 Turning Pins and Bushings .................................... 5010-5 Replacing Track Links ....................................... 5010-6 Sprockets ............................................... 5010-6 Rotating Track Rollers .................................•....... 5010-7 Rebuilding Idlers and Rollers .................................•.... 5010-8 Track Removal and Installation .........•.......................... 5010-9 Track Adjustments ........................................•.. 5010-12 Track Tension ... . . . . . . . . . . . . . • • . . • . . . . . . . . . . . . . . . . . . . . . .. 5010-12 Carrier Roller Alignment .................................... 5010-12 Rear Track Roller Alignment .......•......................... 5010-12 Idler Adjustments ...................•...........•.....•... 5010 -13 Removal/Installation of Track Frame and Side Plate. . . . . . . . . . . . . . . . . . . . .. 5010-14 (Applies to Models 350 and 310G After SiN 3039619) Removal/Installation of Track Frame and Side Plate ..................... 5010-17 (Applies to Model 310G Before SiN 3039620) Removal/Installation of Track Frame and Suspension .................... 5010-19 (Applies to 36" Gauge Models) Face Seal Assembly .................•......................... 5010-22 Idler ..................................................... 5010-23 Replacing Idler Bracket Wear Plates .............•................. 5010-30 Track Rollers ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5010-31 Track Rollers - Standard and Heavy Duty ............................. 5010-33 Track Rollers - Face Seal Type ................................... 5010-35 Carrier Rollers .............................................. 5010-37 Sprockets ................................................. 5010-42 Track Adjusters ............................................. 5010-43 Recoil Spring Assembly ........................................ 5010-45 Rock Guards (Track Guides) ..................................... 5010-47 (Models 350 and 310G After SiN 3039619) Rock Guards (Track Guides) ..................................... 5010-48 (Model 310G Before SiN 3039620 and Models with 36" Gauge) 5505-2 Specific ations Identification Loctite Special Tools TABLE OF CONTENTS Removal/Installation of Rollers Face Seal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . Track Rollers • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •••• e _ • • • • •• Disassembly Inspection . . . . . . . . . . . . . ................................ . Assembly · 5505-3 · 5505-3 • 5505-3 • 5505-3 · 5505-4 · 5505-4 • 5505-6 • 5505-6 • 5505-8 • 5505-9 6014-2 TABLE OF CONTENTS Specifications 6014-3 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . • . . . • . . . 6014-3 Torque Converter Oil Drain Access Hole ........................... 6014-3 Checking Oil Level .......................................... 6014-3 Drain and Refill ...................•........................ 6014-3 Description .........•.........................•........... 6014-4 Operation ..............•.............................•...•.. 6014-5 Oil Flow - Power Shuttle in Neutral .......•...................... 6014-5 Oil Flow - Power Shuttle in Forward ••.•...•...................... 6014-6 Oil Flow - Power Shuttle in Reverse ••....••..•................... 6014-7 Servicing the Power Shuttle •...•....•...•..•.....•.•.•...••....... 6014-8 Removal ..............................•••.......•....... 6014- 8 Disassembly ................•••....•..•....•....•.••...••• 6014-8 Inspection. . . . . . . . • . • . . . . . . . . . . . . . . . . . . . . . . • . . • • . . . . . . . . . 6014-12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . • . . . . . . • . . . . . . 6014-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . • • . • . • . • . . . . . . 6014-27 OV.lO-Z TABLE OF CONTENTS Description and Operation. • • • • • • • • • • • • • . • • • • • • . • • • . . • • • • • • • . • . . •• 6018-3 Removing Transmission-Differential •••.••.•••••••....•••..•••.••••• 6018-4 Differential and Brakes Disassembly. • . • • . . • . . • • . • . • . . • • . . • . • . . . . • . .• 6018-5 Removal From Housing ..•.•...••••••......•.•...•....•....•.• 6018-5 Disassembly of Differential. • . . . . . • . . • • • . . . . • . • . . . • . . . • . • . • . . •• 6018-8 Transmission Disassembly . . • • • . . . • • • • • . . • • • . . . . . • • • . . • • . . • • •• 6018-9 Removal of Shafts and Gears . • • • . . • • • • . . . • • • . • . . • . . • • • • . • . . • •• 6018-10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6018-11 Assembly of Differential. • . . . . • • • . • • • • • • . • • . • . . • . . • • • . • • . • • •• 6018-11 Assembly of Transmission ••••••..•••••••.••.••...•.••..••.•• 6018-13 Ring Gear Backlash Assembling Brakes 6018-15 6018-15 Installing Cover Plate. • • • . • . • • • • . • • . • • • . . • . • • • • • • . • . • . • • • • •• 6018-16 Brake Adjustment ............................................ 6018-16 Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6018-16 Disassembly ............................................. 6018-16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6018-17 Brake Pedal and Steering Levers . • • • . . . . . • . • • • . • . • • . • • • • • • . . • • • • .. 6018-18 Installing Transmission-Differential . . . • . • . . . • . . . . . . • • . . . • . • • . . • • • .• 6018-19 6021-2 TABLE OF CONTENTS Description .................................................. 6021-3 Specifications ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6021-5 Removal of Clutch, Clutch Shaft, and Flywheel ...•.•••..•••••.•••.••. 6021-5 Disassembly of Clutch. . • . . • . . • . • . . . • • • . • . • . • . . . . . • . • • • . . • . • . • 6021-6 Inspection ................................................ 6021-7 Servicing the Flywheel ..•••..•..•.•..••..••........•...••.•.• 6021-7 Clutch Housing ..•.....•....•.•••.•••.....••..••.•....•.... 6021- 8 Assembly of Clutch ..••...•...•...••••..••.....••••...•.•..• 6021-8 Balancing the Clutch ...........•..•.•.•..•..•.•..•..•.•••...• 6021-8 Adjusting the Release Levers .....•...•...•.•.....•.........•... 6021-8 Installation of Clutch, Clutch Shaft, and Clutch Pedal •.....•......•..•. 6021-11 Clutch Pedal (Free Play) Adjustments ........••..•.......•....... 6021-11 uu""u-"'" Final Drives Disassembly Assembly •• TABLE OF CONTENTS Assembly of Final Drives Face Seals Assembly Servicing Axle Shaft Replacement Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation • 6026-3 • 6026-3 • 6026-6 • 6026-9 • 6026-9 • 6026-9 6026-10 6026-10 6026-10 6028-2 TABLE OF CONTENTS Power Takeoff (Late Production) 0 0 0 0 0 0 0 0 • 0 • 0 ••••••••• 0 • 0 ••••• 0 0 ••• 0 6028-3 Removal ................................................. 6028-3 Disassembly 0 0 ••• 0 •• 0 • 0 0 • 0 • 0 0 0 •• 0 •••• 0 ••• 0 •••• 0 0 • 0 •• 0 0 •• 0 • 6028-3 Assembly 0 ••• 0 0 • 0 0 0 • 0 0 ••••••••••••••••••••••• 0 0 ••••• 0 •••• 6028-3 Installation . 0 • 0 0 • 0 •• 0 0 0 0 •••• 0 ••••••••••••• 0 ••• 0 ••••••••••• 6028-6 Power Takeoff (Early Production) . 0 •••• 0 ••••• 0 •••••••••••••••••••••• 6028-6 Disassembling P. T.O. - Belt Pulley Housing ......... 0 • 0 ••••••••••••• 6028-7 Assembling P. ToO. - Belt Pulley Housing. 0 • 0 ••• 0 •••• 0 ••••••• 0 •••••• 6028-8 B0l1-2 Wiring Diagrams 350 With Alternator 350 With Generator TABLE OF CONTENTS Late Production 310G (Diesel) Late Production 310G (Gas) B0l1-3 B0l1-3 B0l1-4 B0l1-5 B0l1-6 Early Production 310G (Diesel) .....•••...•................•..•• B0l1-7 Early Production 310G (Gas) •.... . • . • . . • . . • . . . • . . . . . • . . . . . . . • .. B011-B Exploded Views .•............•.....••...................•.•.• BOll-9 350 With Alternator B0l1-9 350 With Generator and 310G Diesel B011-10 310G Gas •..•...•.............•.....•................... BOll-II 8012-2 TABLE OF CONTENTS Specifications ................................................ 8012-3 Trouble Shooting Chart ......................................... 8012-4 Spark Ignition Problems (Gasoline Engine Only) ......................... 8012-7 Trouble Shooting The Alternator Charging Circuit ....................... 8012-8 Trouble Shooting The Generator Charging Circuit ....................... 8012-10 Trouble Shooting The Starting Circuit ................................ 8012-11 Manifold Heater Circuit Check .................................... 8012-13 Fuel Shutoff Solenoid ........................................... 8012-14 8013-2 TABLE OF CONTENTS SPECIFICA TIONS 8013-3 TROUBLE SHOOTING THE IGNITION SYSTEM. . • . . . . . . . . • . . . . • . . . . . . • .. 8013-3 DISTRIBUTOR. . . . . . . . . . . . . • . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . • .. 8013-5 Removal and Installation. . . . . . . . . . . . . • . . . . . . . . . . . . • . . . . . . . . . .. 8013-5 BREAKER POINTS AND CONDENSER. . . . . . . . . . . . . • . . . . . . . . • . . . . • • • •. 8013-5 BREAKER POINT GAP ADJUSTMENT ...••.•.....•..•..........•...• 8013-6 BREAKER POINT ALIGNMENT. . • . • • • • . . . . . . • . . . . . . . . . . . . . . . . • . . .. 8013-6 BREAKER POINT SPRING TENSION. . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . .. 8013-6 IGNITION TIMING - STATIC . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . • . . . . .. 8013-7 DISTRIBUTOR CAP . • • . . . . . . . . • . • . . . . . . . . • . . • . . • . . . . . . . . . • . . . .. 8013-7 ROTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8013-7 DISTRIBUTOR SPARK ADVANCE - MECHANICAL . . . • • . . . . • • . . . . . • . . . . •. 8013-7 Checking and Adjusting the Mechanical Advance. . • • . . . . . . . . . . . . . . . • •• 8013-8 HIGH TENSION SPARK PLUG AND COIL WmE .•..•••.•.•......•....... 8013-8 SERVICING THE DISTRIBUTOR. . • . . . • • . . . . . • . . . . • . . • . • • • • • • . . • . . .. 8013-9 Exploded View of Distributor ..•••....•.•....•..•.••••••.••.... 8013-10 IGNITION COIL .....•........••....••••..•..•.•.•.•••........ 8013-11 SPARK PLUGS . . . . . . . . • . . . . . . . . . . . . . . . . • . . • . . . . . . • . . . • . . . . . •. 8013-12 8014-2 TABLE OF CONTENTS Specifications . . . . . . . . . . . . . . . . . . • . . . . . . . . . . • . . . . • . . . • • . . . . . . . . . 8014-3 Care and Maintenance Nonspi11 Battery Caps Battery Te sts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8014-4 8014-5 8014-5 Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . • . . • . . • . . 8014-5 Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . • . . . • . . 8014-6 Individual Battery Ce11 Test .....................•.............. 8014-7 Soft Top Battery or Exposed Ce11 Connectors . . . . . . . . . . . . . . • . . • . . . . 8014-7 Hard Top Battery ............•.....•.......•...••........ 8014-8 Battery Charging .........................••.........•.•••....• 8014-9 Activating Dry Charged Batteries ....•..............••..•••..•.•.•. 8014-10 Battery Charging Guide ......•.....•..•..•........•.••.•...•.... 8014-10 Battery Check Sheet ..•.•..•••.•.••....•...•..••..•..•....•.... 8014-11 8015-2 TABLE OF CONTENTS SPECIFICATIONS •••..••••••••.....•.•.••••...•.......••.•.•.•. 8015-3 NO-LOAD TEST ............................................... 8015-3 SERVICING THE STARTER •....•..•..•.•••...•••.•..•.•.........• 8015-4 Disassembly (Delco-Remy) ••.••..•......•••••....•....•••...... 8015-4 Disassembly (Prestolite) . • . . . . • . . • • . • . • . . • • • • • • • • . • . . • • . . . • • • . 8015- 5 mspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8015-5 Armature Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8015-8 Field Coil Tests •••.••••.••.••.•.•..•.........•..•...•.•..• 8015-8 Assembly (Delco-Remy) ...•••...•.•...•..••..•.••.........••. 8015-9 Assembly (Prestolite) ........................................ 8015-9 Pinion Clearance (Delco-Remy) ••.••••..••...•......•.•.•••••.•• 8015-9 Pinion Position (Prestolite) ••• • . • . . • . • • • • . • • • • • • • • • • • • • • • . • . • • 8015-10 STARTER SOLENOID (DELCo-REMY) .•••..•.•••••...•....•...•...•• 8015-11 Solenoid Tests ............................................ 8015-11 Exploded View of Solenoid ••••••••••••••.•...•.•.•.......•..•• 8015-12 STARTER SOLENOID (PRESTOLITE) .•••..••••.••.•••.••••.••••..•• 8015-12 Solenoid Test ............................................. 8015-12 8016-2 TABLE OF CONTENTS Specifications ................................................ 8016-3 Alternator Charging Circuit •.•.••••..••••••....•••...•••••.•••.••• 8016-3 Charging System Tests .......................................... 8016-4 Test No.1 - Alternator Output ••••••.•.••••.••••••.••••••••••••• 8016-6 Test No. 2 - Voltage Regulator Setting ••••••••••••••.•••••••••..••• 8016-6 Test No. 3 - Oil Pressure Switch Test ••••••••••••••••••••••••••••• 8016-8 Alternator Belt Adjustment ••••••••••••••••••••••••.•••••••••••.•• 8016-8 8017-2 TABLE OF CONTENTS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . Ambient Temperature Generator and Voltage Regulator Tests General Instructions . . . . . . . . . . . . ......................... . Cleaning Contact Points Test Equipment ..... Generator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... Voltage Regulator Tests Servicing the Generator. . . • Delco-Remy Generators Prestolite Generator .. Generator Belt Adjustment 8017-3 8017-5 8017-5 8017-5 8017-6 8017-6 8017-6 8017-7 8017-10 8017-10 8017-15 8017-17 9011-2 TABLE OF CONTENTS Exploded Views ............................................... 9011-3 Loader ........................•....................•..•. 9011-3 Lift Cylinder Hydraulics ...................................... 9011-4 Tilt and Hydra-Level Cylinders Hydraulics ...•...................... 9011-5 Ulrich Multi-Purpose Bucket ...................•............... 9011-6 Drott 4-In-l Bucket ......................................... 9011-7 4-In-1 Bucket ............................................. 9011-8 Logging Fork and Grapple Attachment .....•................•...... 9011-9 Logging Fork, Pallet Fork & Grapple Attachment ...•...........•.... 9011-10 4-In-1 Bucket Cylinder Hydraulics .............................. 9011-11 Drott Bucket Hydraulics with Diversion Valve. . . . . . . . . . . . . . . . . . . . . .. 9011-12 Single Lever Control ..•.....•.......•......................• 9011-13 Dual Lever Control .......••........•....•...•..•.......... 9011-14 Anti- Rollback .... . . . . . . . . . . . . . . • . . • . . . • . . . . . . . • • . . . . . . . . • . . . 9011-15 Description. . • . . . . . . • . . . • . • . . . • . . • . • • . . . . . • . . . . . • . . . . . . .. 9011-15 Operation . . . . . • . . . . . . . . . . . . . . . . • . • . . . • . . . • . . . . . . . . . . . . .• 9011-15 Adjustment . • . . • . . . . . . . . . • . . • . . . • . . . . . . . . . • . • . . . • . . . . . . . . 9011-15 ReplaCing Control Levers ........••••••..........•.•...••..•.•.• 9011-16 Adjustment ...... .; . . • . • . . . . • • . . . . . • . . . • • . . . . . . . . . . . • . • • •• 9011-16 Removing the Loader •...........•............................. 9011-16 Removal as a Complete Unit ...•......•.•............••..•...• 9011-16 Removing Loader Arms and Bucket ............................•..•. 9011-17 Servicing the Loader Frame and Bucket . . . . . . . . . . . . . • . . . . . . • . . . . . . . . . 9011-18 Correcting Bucket Stops ....•..•.....•••.................•... 9011-18 Bucket Cutting Edge . . . . . . . . . . . . . . . . . • . . . . . . . • • . . . . • • • . . . . . . 9011-18 ReplaCing Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • . • . 9011-18 Replacing Leveling Gauge ..............•................•.... 9011-20 Replacing 4-In-1 Bucket Teeth . . . . . . . . . • . . . . • . . . . . . . . . . . . • . . • . . 9011-20 Replacing Clam Cutting Edges .........•....................... 9011-20 Removing Front Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • 9011-20 Removing Wear Plate ...............................•.....•. 9011-20 Installing Cutting Edge and Wear Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9011-21 Replacing Cutting Edge on Blade Assembly. . . . . • . . . . . . . . . . . . . . . • . . . . •. 9011-22 Removal ................................................ 9011-22 Installation .........................................••... 9011-22 ReplaCing Grab Hook ..........................•.........•.. 9011-23 Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . •. 9011-23 9011-15 ANTI-ROLLBACK Description Refer to Figure 13. Late production loaders are equipped with a safety device as standard equipment which prevents the operator from accidentally spil- ling the load back on himself when the bucket is above the tractor. The anti-rollback device consists of a mechanical linkage between the tilt spool of the control valve and the right hand loader tilt link. Operation To roll back the bucket the spool must be moved toward the center of the control valve. The actuating rod is connected to the tilt spool and its movement is limited by the position of the shoulder bolt. The linkage is so designed and adjusted that the stop on the actuating rod bottoms out on the shoulder bolt when the loader is raised above hood level and the side cutting edges are parallel with the ground. At this point the spool can no longer be moved into the valve, preventing any roll- back action. Dumping action is not affected by the anti- rollback device. Adjustment 1. Remove the anti-rollback actuating rod from the control lever linkage. 2. Raise the loader to full height and posi- tion the bucket so that the side cutting edges are parallel with the ground. 3. Position the control lever in the HOLD or NEUTRAL position. 4. Adjust the actuating rod at the yoke so that it can be reinstalled on the conb:ol lever linkage without moving the lever. 5. Start the engine and try to roll back the bucket with the loader fully raised. Read- just if necessary. 6. Tighten j am nut to secure adjustment. Figure 13 - Anti-Rollback Linkage 9013-2 TABLE OF CONTENTS Exploded Views . . • . . . . . . . . . . . . . . . . . . • . . . . . . . . . • . . . . . . . . . . . . . . . 9013-3 Mechanical Angling Dozer . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9013-3 Mechanical Angling Dozer Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9013-4 Power Angling Dozer . . . . . . . . . • . . . • . . . . . . . . • . . • . . . . . . . . . • . . . . 9013-5 Power Angling Dozer Hydraulics ...............•................ 9013-6 Power Tilt Dozer. . . . . . . . • • . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . • . . 9013-7 Power Tilt Dozer Hydraulics . . • . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . • . 9013-8 Power Angle-Tilt Dozer SiN 3047966 and After ....................•.. 9013-9 Power Angle-Tilt Dozer Hydraulics SiN 3047966 & After . . • . . . . . • . . . . .. 9013-10 Power Angle-Tilt Dozer Before SiN 3047966. . . . . . . . . . . . . . . . • . . . . . .. 9013-11 Power Angle-Tilt Dozer Hydraulics Before SiN 3047966 ................ 9013-12 Power Angle-Tilt Dozer (Ormco). . . . . . . . . . • . . . . . . . . . . . . . . . . . . . •. 9013-13 Power Angle-Tilt Dozer Hydraulics (Ormco). . . . . . . . . . . . . . . . . . . . . . .. 9013-14 Replacing Control Levers ............................•.......... 9013-15 Removing the Moldboard . . . . . . . . . . . . . . • . . . . . . • . . . . . . . . . . . . . . . . .. 9013-17 Mechanical Angling Dozer . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . .. 9013-17 Power Angling Dozer .................•..................... 9013-17 Power Tilt Dozer .......................................... 9013-18 Power Angle Tilt Dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9013-18 Removing" CIT Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9013-19 Mechanical Angling Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9013-19 Power Angling Dozer ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9013-19 Power Tilt Dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9013-19 Power Angle-Tilt Dozer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9013-19 Removing Leveling Beam & Trunnion Outer Race on Power Tilt Dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9013-20 Removing Leveling Beam on Power Angle Tilt Dozers ................. 9013-21 Replacing Cutting Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9013-21 Use of End Cap Shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9013-21 Removing Inner Race of Lift Cylinder Trunnion. . . . . . . . . . . . . . . . . . . . .. 9013-21 Installation of Moldboard Counterweight Bosses & Brackets ................ 9013-23 9014-2 TABLE OF CONTENTS Description Power Train . . . . . . . . . . . . . . .. .. .. .. .. .. . . . .. . .. . . . .. . .. .. . .. . .. .. . . . . . . .. . Adapter ...................................................................... .. Master Control Unit . .. . . .. . .. . . .. . . .. .. .. . . . . .. . .. . .. .. .. . .. .. . . .. . .. . .. . .. . . .. Serial Number Location .............•.•......•.....•........•..• Lubrication ............................................................................. .. Draining the Winch .......................................................... .. Filling the Winch . . . . .. . . .. .. .. . .. . .. . .. . . . . . . .. .. .. .. . . . . .. . . . . . . .. . . .. .. .. Fairleads .. . . .. .. .. .. .. . . . .. .. .. .. .. .. .. .. . .. . . . . .. . .. .. .. .. . . .. .. .. . . .. .. . .. . .. .. . .. .. Specifications .. .. .. . .. . .. .. .. . . .. .. .. .. .. . . . .. .. .. . . . . . . .. . .. .. . .. .. . . .. . . . .. . .. .. .. .. .. Trouble Shooting Chart .. . .. .. .. .. .. . .. . .. .. .. . . . .. . . . .. .. .. .. .. . .. .. .. . . . . .. .. .. .. .. . .. .. . Instructions for Installing Model 9 Winch and Master 9014-3 9014-3 9014-3 9014-3 9014-4 9014-4 9014-4 9014-4 9014-4 9014-5 9014-6 Control Unit on 310G and 350 Crawler . • . • . . . • . . . . . • . . • . . . . . • . . • • . . 9014-9 Installing Adapter on Winch ..••.•.•.•••..........•..•..•.•..•.. 9014-9 Installing Master Control Unit on Dozer & Drawbar Models. . . . . . . . . . . • .. 9014-12 Installing Master Control Unit on Loader Models. • • • . • . • . . . • • • . • • . . •. 9014-13 Bleeding Hydraulic System. • . . . . . . • • . • . • . • . . • . • . . • . . • . . • • . • . .. 9014-14 Installing the Cable .•..........••..................•....... 9014-14 Installing Fairlead Assembly (Early Production) . . . . . . . . . . . . . . . . . . . .. 9014-15 Installing Fairlead Assembly (Late Production) . . . . . . . . . . . . . . . . . . . . . . 9014-16 Servicing .................................................. 9014-17 General Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • • . • . . .• 9014-18 Brake Bands and Brake Cylinder. . • • . • . • . . . . . . . • . . . . • . . . . • . . . . •• 9014-18 Clutch and Clutch Cylinder. . . . . . . . . • . • • . . • . . • . . . • . . . . . . • • . • . .• 9014-20 Cable Drum and Brake Drum . . • . . . . . . . • . . . . . . • . . . . • . . . . . . . . . •. 9014-23 Ring Gear and Pinion ....................................... 9014-25 Ring Gear and Pinion Adjustments ......•....•........•..•.•.•.. 9014-27 Master Control Unit . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . • . . . . . . . . 9014-30 Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . • . . . . 9014-32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . .. 9014-32 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9014-32 9014-3 D.SCIlIPTION Figure 1 - Model 9 Winch and Fairlead Assembly Po""er Train The Model 9 Winch is a mechanically driven winch, p::>wered off the tractor PTO (main) shaft through a ring gear and pinion set, Figure 15. The ring gear is rigidly supported by the ring gear carrier and a reinforced gear cover. The cable drum is connected to the ring gear through a self energizing friction clutch. The primary and secondary clutch bands have a large contact area and give a positive clutch effect. The clutch is adjustable to compensate for wear. During towing operations, the cable drum is held by a self-energizing, heavy-duty brake band. When the brake is released, the drum will "free spool" with just enough resistance to prevent the cable drum from unspooling more cable than is required. The clutch and brake compartment is completely sealed from mud and water. Adapter An adapter, Figure 1, is installed be- tween the winch and the transmission. The adapter contains a gear train which is de- signed to suit the PTO shaft speed and ro- tation. Ma.ter Control Unit The winch is hydraulically controlled by a single-lever master control unit. When the control handle is in the neutral position, the brake is spring applied for towing oper- ations. When the control handle is pulled to engage the clutch, the master control unit supplies hydraulic fluid to a slave cylinder in the clutch for the "winching in" opera- tion. The harder the operator pulls on the control handle, the greater will be the clutching effort. When the control handle is moved to its full extent in the brake release direction it will remain in that position, releasing the brake for "free spool- ing". The clutch and brake hydraulic cylin- ders are each connected to an independent 9022-2 TABLE OF CONTENTS Exploded Views ............................................... 9022-3 Crawler to Backhoe Mounting Parts .............................. 9022-3 Mounting Frame and Stabilizers ................................. 9022-4 Control Tower and Standard Controls ............................. 9022-5 Control Tower and Twin Lever Controls ........................... 9022-6 Swing Tower, Boom, Dipper and Bucket ............................ 9022-7 Extendable Dipper and Boom ................................... 9022-8 Seat and Light ............................................. 9022-9 Dipper Light (Standard Dipper) ................................ 9022-10 Dipper Light (Extendable Dipper) ............................... 9022-11 Crawler to Backhoe Hydraulics ................................ 9022-12 Swing and Stabilizer Hydraulics ................................ 9022-13 Boom, Dipper and Bucket Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-14,15 Extendable Dipper Hydraulics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-16,17 Boom :Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-18,19 Removing the Backhoe from the Crawler ............................. 9022-20 Installing the Backhoe on the Crawler ............................... 9022-21 Disassembling the Backhoe ...................................... 9022-21 Bucket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-21 Dipper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-22 Boom Removal ........................................... 9022-22 Swing Tower, Boom, Dipper and Bucket Removal ..................... 9022-22 Assembling the Backhoe ........................................ 9022-23 Swing Tower to Boom Installation . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . 9022-23 Swing Tower to Main Frame Installation .......................... 9022-24 Dipper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-25 BucAet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-25 Dipper Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-27 Inner Dipper Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-27 Inner Dipper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-27 Extension Cylinder Removal .................................. 9022-28 Extension Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-28 Replacing Wear Strips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . 9022-28 ReplaCing Guide Bl9Cks . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . 9022-28 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-29 Assembly Instructions ...................................... 9022-29 Standard Control Tower ................................... 9022-29 Twin Lever Control Tower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-29 Twin Lever Control Linkage ................................ 9022-29 Servicing the Bushings ......................................... 9022-30 Lower Pivot Bushing ....................................... 9022-30 Self-Aligning Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-30 One Piece Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-30 Bushings for Cylinders, Buckets Frames, etc. . ..................... 9022-30 Service Information ..................................... 9022-30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-31 Installation ........................................... 9022-31 Bucket Cutting Edges .......................................... 9022-31 Wrap Around Cutting Edge .................................... 9022-31 Side Cutting Edges ......................................... 9022-32 Bucket Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-33 Replacing the Tooth Shanks ................................... 9022-33 Replacing Peened Type Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-33 Replacing Flex Pin Type Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9022-34 9023-2 TABLE OF CONTENTS E.xploded Views ............................................. 9023-3 Mounting Parts and Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9023-3 Bucket, Dipper, Boom and Swing Tower .........................• 9023-4 Extendable Boom ......................................... 9023-5 Dipper Light ............................................ 9023-6 Control Tower and Seat ..................................... 9023-7 Crawler to Backhoe Hydraulics •..............•................ 9023-8 Swing and Stabilizer Hydraulics ............•.................•. 9023-9 Boom, Dipper and Bucket Hydraulics ........................... 9023-10 Removing the Backhoe from the Crawler .....•.•.....•.....•....... 9023-11 Installing the Backhoe on the Crawler ........•...•........••...•... 9023-12 Disassembling the Backhoe ..•...•.......•...................•. 9023-12 Bucket Removal ......................................... 9023 -12 Dipper Removal ......................................... 9023-12 Boom Removal .......................................... 9023-13 Swing Tower, Boom, Dipper and Bucket Removal . . . . • . . . . • . . . • . . .. 9023-13 Assembling the Backhoe •...........•.....•..........•....•.... 9023-14 Swing Tower to Boom Installation .....................•.•.•... 9023-14 Swing Tower to Main Frame Installation ..........••......•.•.... 9023-14 Dipper Installation ............................•.......... 9023-14 Bucket Installation .......................•••............. 9023-15 Extendable Boom ........................•....•............. 9023-15 Disassembling the Boom ................................•.. 9023-15 Assembling the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .. 9023-15 Checking Slide Plate Clearance ....•.•........................ 9023-16 Servicing the Bushings .................................. See Section 9022 Replacing the Bucket Cutting Edges and Teeth. . . . . . . . . . . . . . . . . .. See Section 9022 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. See Section 1051 9024-2 TABLE OF CONTENTS EXPLODED VIEWS ............................................................................................................... 9024-3 Crawler to Backhoe Mounting Parts ................................................................................... 9024-3 Mounting Frame and Stabilizers ........................................................................................ 9024-4 Swing Tower, Boom, Dipper and Bucket.. ........................................................................ 9024-5, 6 Extendable Dipper and Boom ......................................................................................... 9024-7, 8 Dipper Light. ..................................................................................................................... 9024-9 Control Tower with Standard Controls .......................................................................... 9024-10, 11 Control Tower with Twin Lever Controls ........................................................................... 9024-12 Backhoe Seat .................................................................................................................... 9024-13 Crawler to Backhoe Hydraulics ......................................................................................... 9024-14 Swing and Stabilizer Hydraulics ................................................................................... 9024-15, 16 Boom, Dipper and Bucket Hydraulics ...................................................................... 9024-17, 18, 19 REMOVING/ATTACHING THE BACKHOE ......................................................................... 9024-20 Uncoupling Backhoe from Crawler ............................................................................... 9024-20 Coupling Backhoe to Crawler ....................................................................................... 9024-21 DISASSEMBLING THE BACKHOE ........................................................................................ 9024-21 Bucket Removal ............................................................................................................... 9024-21 Dipper Removal ............................................................................................................... 9024-21 Boom Removal ................................................................................................................. 9024-22 Swing Tower, Boom, Dipper and Bucket Removal ............................................................. 9024-22 ASSEMBLING THE BACKHOE ............................................................................................. 9024-23 Swing Tower to Boom Installation ..................................................................................... 9024-23 Swing Tower to Main Frame Installation ........................................................................... 9024-25 Boom Installation ............................................................................................................. 9024-25 Dipper Arm Installation .................................................................................................... 9024-26 Bucket Installation ........................................................................................................... 9024-26 CONTROLS ............................................................................................................................ 9024-27 Assembly Instructions ...................................................................................................... 9024-27 Standard Control Tower .............................................................................................. 9024-27 Twin Lever Control Tower .......................................................................................... 9024-27 Twin Lever ControL .................................................................................................... 9024-27 EXTENDABLE DIPPER MECHANICAL STOPS .................................................................... 9024-28 SERVICING THE BUSHINGS .................................................................................. See Section 9022 REPLACING THE BUCKET CUTTING EDGES AND TEETH .................................. See Section 9022 TORQUE SPECIFICATIONS .................................................................................... See Section 1051