Case W8 User manual

W8,W9,W10
Loaders
Service Manual
9-9996SRO
IReprinted I

r----------,
Service
Manual
W8, W9, W10
Loader
9-9996SRO
All Binders
4.75
in
r------,
Service
Manual
W8,W9,W10
Loader
9-9996SRO
I~
I
L ________ .J _____ L ____ .J
....... 1-- __ Large Binder __ --1.~
2. 85 in
.- Small Binder --.
1. 63 in

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TABLE OF CONTENTS
W8, 9, 10 SERIES E LOADER
SER IES/SECT/ON
SECTION NO.
10 SERIES ~ GENERAL INFORMATION
Genera/Engine Specifications ..................................... 11
Maintenance and Lubrication ....................................... IX
20 SERIES ~ ENGINE
Cylinder Head and Valves (Diesel Engines) .......................... 22
Cylinder Head and Valves (Gasoline Engines)
....................... 22
EnginifBlock Assemblies .......................................... 23
Water Pump, Pump Housing, Thermostats, Engine Oil Filter
and Heat Exchanger
............................... . ............. 25
Pierce GearDriven Governor
......•................................ 26
30 SERIES ~ FUEL SYSTEM
Fuel System and Filter ............................................. 31
Robert Bosch Fuel Injection Pump .................................. 32
Roosa Master Fuel Injectors
........................................ 33
62 Series Carburetor .
............................................. , 35
40 SERIES -HYDRAULICS
Hydraulic System .................................... . ............. VI
Servicing the 25X Series Gear Type Hydraulic Pump ................. 3B
50 SERIES -STEERING
Servicing the Combined Unit Power Steering Cylinder and Valve,
Steering Linkage and Gear Box .................... .. ....... : ..... Q
Servicing the VTM Vane Type Power Steering Pump ...... .. ......... PP
60 SERIES -POWER TRAIN
Servicing the Single-Reduction Differentials Universal Joints
and Drive Shafts
.....•............................................ T
Supplement
No.1 Servicing the Single-Reduction Differentials ..... .. . T
Servicing the Planetaries and Axles
.................................. U
Servicing the C-270 Series Torque Converter ......................... X
Servicing the 2000 Series Transmission
.............................. Y
70 SERIES -BRAKES
Servicing the Series 01 Hydraulic Brake Cylinder,
Brake Shoes and Drums
...........••............................. W
Supplement No.2 ServiCing the Transmission Cut-out Control Valve
(Lever Operated) ..
................................................ W
Servicing the Hydrovac Brake System .............................. 3W
80 SERIES ~ ELECTRICAL SYSTEM
Electrical System .................................................. 11
90 SERIES ~ MOUNTED EQUIPMENT
Loader ........................................................... VIII
CASE CORPORATION 9-99965
March
1981
FORM NO.
9-79541
9-99965
9-79391
9-79381
9-79361
9-79421
9-79411
9~:79431
9-79452
9-79463
9-79491
9-99965
9-74561
9-1
4563
9-74561
9-74561
9-74561
9-74561
9":74563
9-74563
9-74562
9-74562
9-74563
9-99965
. 9-99965
PRINTED IN U.S.A.

Seclion
11
GENERAL ENGINE SPECIFICATIONS
W8E, W9E and W1 DE Loaders
I
THE MODEL AND ENGINE SERIAL NUMBER ~~~
IS STAMPED ON A PLATE LOCATED ON THE
SIDE OF THE ENGINE ABOVE THE CRANK-
MOTOR.
General
DIESEL ENGINES
Type .......................................................................... 6 Cylinder, 4 Stroke Cycle, Valve-in-Head.
Firing Order ................................................................................................................. 1-5~3-6-2-4
Bore .......................................................................................................................... 4-1/8 Inches
Stroke ............................................................................................................................. 5 Inches
Piston Displacement .......................................................................................... 401 Cubic Inches
Compression Ratio ......................................................................................................... 16.5 ' to 1
No Load Governed Speed ............................................................................................
2150 RPM
Rated Engine Speed .................................................................................................... 2000 RPM
Engine Idling Speed ............................................................................................ 725 to 775 RPM
·Valve Tappet Clearance (Exhaust) ................................. (Hot) .020 Inch ...... (Cold) .025 Inch
(Intake) ....................................................... (Hot and Cold) .015 Inch
·Hot Settings Are Made After the Engine Has Operated At Thermostat Controlled Temperature
For At Least Fifteen Minutes.
Piston and Connecting Rods
Rings per Piston ...... .. ............................................................................................................... 3
Number of Compression Rings .................................................................................................. 2
Number of Oil Rings ................................................................................................................. 1
Type Pins ......................................,............................................................... Full Floating Type
Type Bearing ................... ........... Replaceable Precision, Steel Back, Copper-Lead Alloy Liners
Main Bearings
Number of Bearings .................................................................................................................. 7
Type ............................................ Replaceable Precision Steel Back, Copper-Lead Alloy Liners
Engine Lubricating System
Oil Pressure .......... 45 to 55 Pounds with Engine Warm and Operating at Rated Engine Speed
Type System .............................................................................. Pressure and Spray Circulation
Oil Pump................ .. .. ................................................................................................ Gear Type
Oil Filter ............................................................................................... Full Flow Spin on Type
Fuel System
Fuel Injection Pump ................................................ Robert Bosch, Type PES Multiple Plunger
Pump Timing .............................................. 30 Degrees Before Top Dead Center (Port Closing)
Fuel Injectors ............................................................ Pencil Type (Opening Pressure 2800 PSI)
Fuel Transfer Pump ........................................ Plunger Type, Integral Part of Injection Pump
Governor ......... Variable Speed, Fly-Weight Centrifugal Type, Integral Part of Injection Pump
1st Stage Fuel Filter ............................................................................. Full Flow Spin on Type
2nd Stage Fuel Filter ............................................................................ Full Flow Spin on Type
Rae. Form 9-79541

GENERAL ENGINE SPECIFICATIONS
W8E, W9E and W1 DE Loaders
SPARK IGNITION ENGINES
General
Type ........................................................................... 6 Cylinder, 4 Stroke Cycle, Valve-in-Head
Firing Order ......................................................................... ........................................ 1-5-3-6 - 2-4
Bore ............................................................................................................................... 4 Inches
Stroke ............................................................................................................................. 5 Inches
Compression Ratio ........................................................................................................... 7.5 to 1
Piston Displacement ................................... ....................................... ................ 377 Cubic Inches
No Load Governed Speed ............................................. ............ ................................... 2215 RPM
Rated Engine Speed .................................................................................................... 2000 RPM ,
Engine Idling Speed ............................................................................................ 725 to 775 RPM
"Valve Tappet Clearance (Intake) .................................................... (Hot and Cold) .015 Inches
(Hot) .015 Inches .................................................... (Cold) . 025 Inches
Exhaust Valve Rotators ........................................... .............................................. Positive Type
"Hot Settings Are Made After The Engine Has Operated At Thermostat Controlled Temperature
For At Least Fifteen Minutes.
Piston and Connecting Rods
Rings per Piston ....................................................................................................................... 4
Number of Compression Rings .................................................................................................. 3
Number of Oil Rings .............................................................................. .. ................................. 1
Type Pin ........................................................................................................ Full Floating Type
Type Bearings ............................ Replaceable, Precision Steel Back, Copper Lead Alloy Liners.
Main Bearings
Number of Bearings ....................................................................................... .. ......................... 7
Type Bearings ............................ Replaceable, Precision Steel Back, Copper Lead Alloy Liners .
Engine Lubricating System
Oil Pressure ........... 45 to 55 Pounds with Engine Warm and Operating at Rated Engine Speed
Type
System ......................................... .. .......................................... Pressure Spray Circulation
Oil
Pump .................................................................................................................... Gear Type
Oil Filter ....... .. ...... .. ............................. .. ..... .......................................... Full Flow, Spin on Type
Fuel System
Carburetor .......................................................................................... Zenith wi solenoid shut-off
Distributor Ignition
Contact Point Gap ......................................................................................................... .020 Inch
Dwell Angle . .. ......................................................................................................................... 390
Spark Plugs .......................................................................................................... Prestolite 18 8
Plug Gap ...................................................................... ........................ ......................... .025 Inch
Thread .............................................................................................................................. 18 MM
Shank Length ................................................................................................................. 1/2 Inch
Engine Timing
Static Timing ....................................................................................................................... TDC
Running Timing ...................................................................... 27
0
BTDC at Rated Engine Speed

SECTION
IX
MAINTENANCE
AND
LUBRICATION
Burl. Form 9-99965
MFCAO
Printed in U.S.A.

TABLE OF CONTENTS
SCHEDULEDMAINTENANCE ...................................... .. 3
Lubrication Points ............................................ 4
LUBRICANTS ................................................... 5
DIESEL FUEL .................................................. 6
GASOLINE ..................................................... 7
APPROXIMATE CAPACITIES ........................................ 7
AIR CLEANER SERVICE
.................•.•....... . .............. 8
Dry Air Cleaner ............. . ...................... . ......... 8
Oil Bath Air Cleaner ....................... . ................... 10
TRANSMISSION AND CONVERTER OIL AND FILTER CHANGE ................•. 11
SERVICING THE HYDRAULIC RESERVOIR ................................ 12
POWER STEERING SERVICE ................•.................. . ..... 14
BRAKE SYSTEM SERVICE .......................................... 15
2

MAINTENANCE/LUBRICATION
Scheduled Maintenance
Component
Service
Comments
Every 10 Hours Or Daily
I.
Loader Pivot Points Including Rear
Axle Mounting Pivot Pins, Steering
Cyl inder and Linkage
Grease
Lithium "Soap-Base" Grease
2.
Engine Oil
Check
3.
Rear Wheel Trunnion Sockets
Grease
Lithium "Soap-Base" Gr ease
4.
Oil Bath Air Cleaner
Check and
Air clean er must be serviced
service as
when dirt in oil cup is 1/2
required
inch deep.
Every 60 Hours Or Weekly
5.
Drive Shaft Universal Joints
NOTE: Slip joints, every 1000 hrs.
Grease
Lithium "Soap-Base" Grease
6.
Hydraulic Oil
Check
7.
Differential Oil
Check
8.
Planetary Oil
Check
9.
Transmission Oil
Check
10.
Power Steering Oil
Check
II.
Hydrovac Breather
Clean
12.
Foot Throttle Cross Shaft
Lubricate Engine Oil, A Fe\\' Drops
j
Every 120 Hours Of Operation
13. Engine Oil
Drain and
Refill
Grease
With Filter, 13 quarts
Without Filter, 12 quarts
Lithium "Soap-Base" Greas e 14. Distributor
Every 240 Hours Of Operation
15.
Steering Gear Box
Check
16.
Engine Oil Filter Change
Every 500 Hours Of Operation
17.
Hydrovac Filter
Clean
18.
Hydrovac Cylinder
Lubricate
1 oz. Case TCH Oil
Every ' 1000 Hours Of Operation Or Yearly
19. Differential Oil
Drain and Refill
Ref er to page 5.
20.
Planetary Oil Drain and Refill
Refer to page 5.
21.
Transmission Oil
Drain and Refill
Case TCH Oil
22.
Transmission Oil Filter
Re place
23.
Transmission Oil Strainer
Clean
24.
Transmission Breather
Clean
25.
Hydraulic Oil
Drain and Refill C ~'se TCH Oil
26.
Hydraulic Oil Filter and Breather
Replace
27.
Power Steering Oil Filter
Replace
28.
Hydrovac Filter
Replace
3
i

Lubrication Points
The following points are to be lubricated once every 10 hours of operation or daily.
In severe or abnormal working conditions lubrication should be more often. Clean grease
fittings before applying grease gun.
Figure 1
1. Rear axle mounting pivot pins ................ ....... (2) Front and rear
2. Lift arm pivot . . . . . . . . . .. ..... (2) One each side
3. Leveling link ....................... (4) Two each side
4. Bellcrank.......................... (2) One each side
5. Bellcrank to tilt link . . . . . . . . . . . . . . . . . . (2) One each side
6. Tilt cylinder pivot. . . . . . . . . . . . . . . . . . . . . .. ...... (4) Two each side
7. Pivot link to lift arm . . . . . . . . . . . . . . . . . . "(2) One each side
8. Lift arm to bucket .................. . . . . . (2) One each side
9. Tilt cylinder rod to bucket ........... (2) One each side
10. Lift cylinder ........... . . . . . . . . . . (4) Two each side
11. Tie rod ends ........... . . . . . (2) One each side
12. Intermediate steering lever ............. . ... (1) On pivot
13. Front drag link ......... ". . . . . . . . . . . . . . . . . . . .. (1) Front ball stud
14. Rear drag link ............................ (2) Front and rear ball studs
15. Steering cylinder .................. (3) Front, rear and control valve ball studs
4

LUBRICANTS
Engine Lubricating Oil
Diesel Engine
32° F. and above .. . ·
................ SAE 30 (Service DS, Series 3, Mil-L-45l99)
10° F. to 50° F .. . ·
............... SAE 20W (Service DS, Series 3, Mil-L-45l99)
Below 32° F. . .... . ·
............... SAE lOW (Service DS, Series 3, Mil-L-45l99)
Gas Engine
40° F. and above. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 30 (Service MS)
32°
F. to 90° F. ................................... SAE 20W (Service MS)
-10° F. to 60° F. .................................. SAE lOW (Service MS)
Below _10° F. to 60° F ...................... .... .... SAE 5W-20 (Service MS)
All
temp. above _10° F ............. ~ > •••••••••••••• SAE 10W-30 (Service MS)
NOTE: If the Loader is operated during extremely cold weather, it may then be necessary to
drain the oil while it is still hot and preheat it to approximately 100° F. before pouring it
back into the crankcase just prior to starting.
Transmission, Converter And Povver Steering Oil
[J se Case TCR Oil
Hydraulic System Oil
It is recommended that Case TCR Oil be used. An alternate oil may be used. It must
Je a heavy duty oil that meets American Petroleum Institute Service Designation MS or
DG. For temperatures above 32° F. use SAE lOW. For temperatures below 32° F. use SAE
5W. If SAE 5W is not available, a Dexron type oil may be used.
Differentials And Planetaries
32° F. and above
SAE 90 Multipurpose Gear Lubricant, API-GL-4
Below 32° F.
SAE 80 Multipurpose Gear Lubricant, API-GL-4
The above lubricants are suitable for use in the steering gear housing.
:m COMMENDED LUBRICANTS
3elow 32°
\.bove 32°
Grease Filtings
Multipurpose or No.1 lithium soap-base grease
Multipurpose or No.2 lithium soap-base grease
5

FUEL
Diesel Fuel
Recommended Fuel
Case diesel engines are designed to operate most efficiently with No. 2 diesel fuel.
Most well known refiners and distributors market a good grade of diesel fuel and there should
be no difficulty in obtaining it.
Do not confuse No. 2 diesel fuel with No.2 furnace oil which is similar but does not
always meet specifications for diesel engines.
CAUTION: No. 1 diesel fuel is not recommended for normal operating conditions. This
is a lighter fuel which can result in loss of engine power, increased fuel consumption, and
lessened injection pump life.
Fuel Specifications
There can be considerable variation in diesel fuels marketed as No.2. The American
Society for Testing Materials (ASTM) has established a widely recognized specification,
ASTM Designation D975, which is used in the United States, Canada, and many other areas
of the world. Any fuel purchased for use in a Case engine should meet this ASTM specification.
However, there is no world-wide standardization of diesel fuels and ASTM specifications
are not used everywhere. Following are the most important specifications of an acceptable
diesel fuel:
Pour point, maximum
Cetane number. minimum
Sulphur, by weight, maximum
Water and sediment. by volume, maximum
Ash, by weight, maximum .....
Carbon residue on 10%, maximum
Distillation, 90% point
End point ....... . .... .
Flash point. minimum ....... .
Viscosity, centistokes at 100° F.
Saybolt Universal Seconds at 100e F.
Corrosion, copper strip, 3 hours at 2120 F.
API gravity, minimum ............ 0 ••
6
100 F. below lowest atmospheric temperature
at which engine must start and operate.
. 40 (45-55 for winter or high altitudes).
. . . . . . . .. .50 of 1%
.05 of 1%
.01 of 1%
.20 of 1%
. 5400 -6250
. ... , 6750
125
0
or legal
2.0 - 4.3
. . . . . .. 32 -40
.. No.3 ASTM
• ••• 0 •••••• 30
700312

Gasoline
Case gasoline engines are designed to operate on REGULAR GRADE gasoline having
a minimum Research Method rating of 90.7 Octane.
The average Octane ratings for regular grade gasoline are:
Motor Method ........................ .. ................ . .. 86.2 Octane
Research Method ..................... . ... . ................ 94.2 Octane
These Octane ratings are used to define the anti-knock quality of gasoline. It has become
common practice in the Petroleum Industry to refer to the Research Method rating.
When only one Octane rating is given and the rating method is not specified it can .be
assumed to be the Research Method rating.
WARNING: NEVER FILL THE FUEL TANK WHEN THE ENGINE IS RUNNING OR WHEN
NEAR AN OPEN FLAME. 00 NOT SMOKE WHEN WORKING NEAR FLAMMABLE FUELS.
APPROXIMATE CAPACITIES
U. S. MEASURE
Fuel Tank .. . . . ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50 Gallons
Engine Crankcase
Without Filter Change .................................... 12 Quarts
With Filter Change ........ . ........... ... .............. . 13 Quarts
Differential Housing
Front
22 Pints
Rear ........... . ....... . ............................. 29 Pints
Planetary Housing
Front ............................................. " 3.5 Pints
Rear .............. . ...... . ............................ 5 Pints
Transmission and Torque Converter .............................. 25 Quarts
Cooling System ....... . ...... ... ... .. ...................... 45 Quarts
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14 Gallons
Power Steering System .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 Quarts
Steering Gear Housing ............... ... ............... . ....... 1 Pint
Air Cleaner Oil Cup
Diesel ................................................. 4.5 Pints
Gas . . ................................................. 6 Pints
7

AIR CLEANER SERVICE
Dry Air Cleaner
The air cleaner must be serviced when
the red band is in full view on the air .cleaner
service indicator.
PRIMARY FILTER ELEMENT: Washing is
the preferred method of cleaning the element
as it removes more dust and soot, thus re-
storing the element to an almost new condition.
Wash the filter in Case Filter Element
Cleaner, Part No. A40910. Mix according to
instructions on container. Do not use water
pressure over 40 PSI at the nozzle . Let the
element dry completely before installing. Do
not use air pressure to dry the element.
The element can be cleaned with com-
pressed air although it is not recommended
because it will not remove carbon and soot.
Do not use air pressure in excess of 100 PSI
at the nOzzle. Place the element on a clean
flat surface, then place a cover (wood or metal)
with a small opening over the top of the
element. Place nozzle in opening in cover.
Blow element clean, starting with low air
pressure and gradually increasing it.
Inspect the element after it is clean and
dryas shown in Figure 2.
Figure 2
Rotate the filter around the light and check
for damage and pin holes. Check the gasket
for defects. Inspect the metal covering for
dents . Any dent in the covering is a poten-
8
tial puncture, in that the paper element will
rub the dent and a hole will result. Elements
with holes or indications of fuzz must be re-
placed. Replace gasket if it is found to be
defective. Do not accept a new filter or in-
stall a new or used filter if the metal covering
is dented.
The filter should be replaced after it has
been cleaned six times or once a year (1000
hours), whichever occurs first. When servic-
ing the air cleaner, make sure all connections
are air tight. Air cleaner efficiency is di-
rectly dependent upon air tight connections.
SECONDARY FILTER ELEMENT: Cleaning
the secondary element is not recommended
except in an emergency. If the element is
cleaned it should be replaced as soon as
possible. Check the secondary element for re-
WING NUT----~
COVER-'9~
WASHER-_-.
COVER
SECO NDA_RY __ ~
ELEMENT
Figure 3

placement as follows: Install cleaned or new
primary filter element and start engine. Ob-
serve air cleaner service indicator. If the
9
red signal is still in full view on the service
indicator the secondary iil ter element must be
replaced immediately.

Oil Bath Air Cleaner
Specifications
Oil capacity (Approximate) ... ... .... . .... . .... ... . Gas, 6 Pints, Diesel, 4.5 Pints
Oil used ...... . . . ............ . .. . ... . ....... Same as used in engine.
Service interval ...... . .. Daily or when 1/2" dirt has collected (See "Servicing" below) .
Servicing
INTERVAL
Service interval for this air cleaner
depends on operating conditions. Remove and
inspect oil cups daily. Clean the cups and
element and change the oil whenever the dirt
level reaches 1/2" in the bottom of either
cup. Experience will dictate how often this
occurs.
NOTE: Over-servicing does not utilize the
oil bath feature to the fullest.
OIL CUP SERVICING
1. Detach the oil cup retaining clamp/s
and remove oil cup from air cleaner
body.
GAS
DIESEL
Q- PRE-CLEANER -0
_BODY----
r ./
~ ~ --- ~ : ~ ~
~ -CL A MP ____ I · ~
,,2-8 __ FlLTER ®
~~:.1 INNER OIL CUP-((;)) ·.
2~ :---- W ING NUTS ~
~---OILCUP ..
~ ~69 0 17 9
Figure 4
2.
Remove filter screen from oil cup (diesel
only). On gas engines, remove filter
screen retaining wing nuts and remove
filter from air cleaner body.
10
3. Pour out the oil, remove inner cup (die-
sel only). remove sludge and wipe clean .
4.
Place inner cup in oil cup (diesel only).
Refill oil cup to indicated level with
engine oil speCified on page 5.
NOTE:
Do not overfill or underfill.
ELEMENT ASSEMBLY SERVICING
1. Hold up the element to a strong light.
An even, bright pattern of light through
the element means it is clean.
2. If the element is even partially plugged
with dirt, lint. or chaff, wash thoroughly
with solvent. Then blowout with com-
pressed air.
3. Place filter screen in oil cup (diesel
only). On gas engines, position filter
screen in air cleaner body and secure
with wing nuts.
4. Position oil cup on air cleaner body
and tighten oil cup retaining clamp/s o
BODY ASSEMBLY SERVICING
1. The lower portion of the body assembly
should be inspected each time the air
cleaner is serviced . If there are any
signs of dirt, clean as described below.
2. At least once a year, remove the body
assembly and service as follows:
a. Remove oil cups and element as-
sembly.
b. Check and clean the center tube.
c. Pump solvent through the air outlet
with sufficient force and volume to
produce a hard, even stream out the
body assembly. Reverse flush until
all foreign material is removed.

TRANSMISSION AND CONVERTER OIL AND FILTER CHANGE
The transmission must be servicedafter
every 1000 hours of operation or yearly.
This service consists of changing the trans-
mission oil and oil filter and cleaning the
oil strainer.
1. Remove the drain plug and oil strainer
and gasket. Discard gasket.
2. Clean the oil strainer in cleaning solvent.
NOTE: Do not reinstall drain plug or
strainer until the oil filter has been
serviced . This procedure is recommen-
ded to allow maximum oil drainage.
Figure 5
3.
Loosen the filter cover retaining clamp
Figure 6
11
and remove clamp, filter cover with
relief valve, gasket and filter e lement.
Discard the gasket and filter element.
4. Remove the remaining oil from the filter
case with a hand suction gun. Clean the
inside of the filter case with a lint free
cloth.
5. Place a new filter in the filter case .
Position a new seal on the relief valve
and a new gasket on the filter cover.
6. Position filter cover and clamp on filter
case and tighten clamp bolts.
7. Fill the transmission with 5 gallons of
Case TCH oil. Start the engine and run at
low idle and slowly shift the transmission
through all ranges. With th e engine run-
ning and the transmission in neutral, oil
should run out of the low level valve. Add
oil as necessary to obtain the low oil
level.
8. Run the engine at 1000 RPM with the
transmission in neutral until the oil has
reached operating temperature (180° -
200°). With the engine running at low idle
and the transmission in neutral, oil
should run out the full level valve . Add
oil as necessary to obtain the proper
level. Check for oil leaks.
CAUTION: The oil level must not be
lower than the low level valve nor above
the full level valve.