Case Series C User manual
,----------------------1
SERVICE MANUAL
Loaders
680 CK
SeriesC
9-72595
--------------------~
1.Trim along dashed line. b
2. Slide into pocket on Binder Spine.
TYPE 1-4
,----------------------1
SERVICE MANUAL
Loaders
680 CK
SeriesC
9-72595
--------------------~
1.Trim along dashed line. b
2. Slide into pocket on Binder Spine.
TYPE 1-4
,----------------------1
SERVICE MANUAL
Loaders
680 CK
SeriesC
9-72595
--------------------......,:0
1.Trim along dashed line. b
2. Slide into pocket on Binder Spine.
TYPE 1-4
,----------------------1
SERVICE MANUAL
Loaders
680 CK
SeriesC
9-72595
--------------------......,:0
1.Trim along dashed line. b
2. Slide into pocket on Binder Spine.
TYPE 1-4
TABLE OF CONTENTS
SERIES/SECTION SECTION NO.
10
SERIES - GENERAL
General Engine Specifications • • • • • . • • • . • • • • . • • • • • • • • • • • • • • • . • • • • • .
11
Maintenance and Lubrication • • • • • • . • • • • • • • • • • . • • • • • • • • • • • • • • • • • •
1050
Torqt1e Chart • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1051
20
SERIES - ENGINES
Cylinder Head an.d Valves • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . • 22
Engine Block Assembly • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 23
Water Pump, Thermostats, Oil Cooler, and Filters ••••••••••••••••••••.••
25
Engine Removal and Stall Checks • . • • • • • • • • • • • • . • • • • • • • • • • • • • • • • • •
2050
Air Clean.er • • • • • . • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 205!
30
SERIES - FUEL SYSTEM
Fuel System and Filters • • • • • • • • • • • • • . • • • . . • • • • . • • • • • • • . • • • • • . •
Fuel In.jection Pumps • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Roosa-Master
Fuel
Injectors •••••••••••••••.••..•••.••••••••••••
Electric
Fuel Pump • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Fuel Lines and Throttle Adjustment ••••••••••••.••••••••••••••••••
40
SERIES - HYDRAULICS
Hydraulic Diagrams, Trouble Shooting, Pressure Checks •••••••••••••.•••
Hydraulic Pump • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
I..oad.er Control Valve •••••••••••••••••••••••••••••••••••••••••
Case Backhoe Control Valve ••••••••••••••.•••••••••••••••••••••
Commercial-Shearing Backhoe Control Valve •••••••••••••••••••••••••
ExteDdah.oe
Control Valve ••••••••••••••••••••••••••••••••••.••••
Stabilizer I..ock Valve .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydra-Guide • • • • • • • • • • • • • • • • • • . • • • • • • • • • • • • . • • • • • • • • • • • • . • .
Boom I..ockout Valve and Relief Valve ••••••••••••••••••••.•••••••••
I..oader and Backhoe Cylinders • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •••••
NOTE:
Also see Sections
9011
and
9012
for exploded views of hydraulic system.
50
SERIES - STEERING
Hydraulic Diagram, Trouble Shooting, Pressure Check ••••••••.••••••••••
Steering Pump • • • . • . .••••••••••••••••••••••••••••••••••••••
~teering
Valve and Column •••••••••••••••••••••••••••••••••••••
Steering Cylinders • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • . •
Front Axle ................................................ .
60
SERIES - POWER TRAIN
Transmission/ Converter Hydraulic Diagram, Operation and Description •••••.•
Trouble
Shooting an.dTesting •••••••••••••••••••••••••••••••••••.
Forward-Reverse Transmission (Power Shuttle) •••••••••••••••••••••••
Four Speed Mechanical Transmission • • • • • • • • • • • •••••••••••••••••••
Rear Axle . . .
.. . .
. .
. .
. .
. . . . .
.
. . . . . . .
. . .. .
.
.
. . .
.
. . .
. .
.
. .
.
. .
Drive Shaft • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
30iO
3012
3013
3051
3052·
4011
4013
4021
4022
4023
4029
4030
4040
4041
4057
5011
5012
5013
5015
5017
6011
6012
6014
6018
6020
6022
CASE CORPORATION
Burl. Form
9-72595
Nov.
1980
PRINTED
IN U.S.A.
IReprinted I
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SERIES/SECTION SECTION NO.
70 SERIES - BRAKES
Air System Diagrams, Operation, Pressurizing/Depressurizing
the Air System, and Trouble Shooting ••••••••••.••.•..•••.•••••.• 7011
Foot Brakes and Slack Adjuster ...••••••.••.••••••••••••••••••••.• 7013
Air Compressor, Governor, Reservoir, Moisture Ejection Valve •••••••.....• 7014
Brake Valve ................................................ 7015
Brake Actll.ator .............................................. 7016
Parking Brake Control Valve and Quick Release Valve .••••.•.••••••••••.. 7017
Pressure Reducing Valve, Pressure Protection Valve
Double Check Valve, Clutch Cutout Valve, Stoplight Switch •..••••••••••• 7018
Alcohol Evaporator . ................•.......................... 7020,
~O
SERIES - ELECTRICAL
Wiring Diagrams ............................................. 8011
Trouble Shooting and Adjustments • • • • . • • • • • • • . . ••••••••••••••••••. 8012
Batteries .................................................. 8014
Starter and Starter Solenoid ••••••••••••••••••••••••••••••••••••. 8015
Alternator . ................................................. 8016·
90 SERIES - MOUNTED EQUIPMENT
Loader .................................................... 9011
Backh.oe ......•..................................•...•..•.. 9012
ROPS Cab an.d Can.opy .......................••.•....•.•...••... 9019
Front Floor Plate Assembly •••••••••.••••••••••••••••••••••••••• 9028
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Section
11
·GENERAL ENGINE SPECIFICATIONS
680 CK Series C Loaders
I
THE MODEL AND ENGINE SERIAL NUMBER -----------r:,,_,....
1!::~::3.·
IS STAMPED ON A PLATE LOCATED ON THE_
SIDE OF THE ENGINE ABOVE THE CRANK-
ING MOTOR.
DIESEL ENGINES
General
Type ............................................................................. 4 Cylinder, 4 Stroke Cycle, Valve-in-Head
Firing Order ........................................................................................................................ 1-3-4-2
Bore ........................................................................................................................... 4-3/8 Inches
Stroke .............................................................................................................................. 5 Inches
Piston Displacement ........................ ..... ......... .............. ............................. .......... 301 Cubic Inches
Compression Ratio ........................................................................................................... 16.5 to 1
No Load Governed Speed .............................................................................................. 2360 RPM
Rated Engine Speed ...................................................................................................... 2200 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 .................................................................................................................. 5
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 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 ................................................ 31 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 9-79921
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1050-2
MAINTENANCE CHART
CAUTION: The following chart is based on maximum intervals. If the machine operates
in severe conditions, service more often.
INTERVAL SERVICE INSTRUCTIONS
Run-In: Every Check wheel nut and bolt torque.
Two Hours Front - 170 foot-pounds torque.
Until Stabilized Rear - 220-240 foot-pounds torque.
Check rear axle mounting bolts.
380-460 foot-pounds torque.
Run-In: After Change engine crankcase oil.
First 20 Hours Replace engine oil filter. Section 25.
Check drive belt tension. Section 8016.
Service fuel system. Section 31.
Every 10 Hours Grease loader pivot points.
or Daily - Which-
ever Occurs Grease backhoe pivot points.
First Check engine crankcase oil level.
Check hydraulic oil level.
Check radiator coolant level.
Clean air cleaner dust cup.
Visually inspect transfer pump sedimant
bowl for water.
If
found, drain water from
bowl, first stage filter and fuel tank.
Check machine and ground under it for leaks.
Every 50 Hours Grease front axle pivot.
or Weekly -
Whichever Grease steering cylinders.
Occurs First Grease brake shafts and slack adjusters.
Grease inner Extendahoe dipper.
Check tire pressures.
Every 100 Hours Check battery electrolyte level. Section
8014.
Check drive belt tension. Section 8016.
Every 150 Hours Change engine oil.
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1050-3
INTERVAL SERVICE INSTRUCTIONS
Every 250 Hours Grease driveshaft universals and slip
splines
Grease loader and backhoe control lever
fittings.
Lubricate shuttle control lever.
Check power shuttle/torque converter oil
level.
Check synchromesh transmission oil level.
Check rear axle oil level. Section 6020.
Clean alcohol evaporator filter. Section 7020.
Every 300 Hours Replace engine oil filter. Section 25.
Every 500 Hours Drain deposits from fuel tank.
Change fuel filters. Section 31.
Service electric fuel pump and transfer pump
filters. Section 31.
Repack front wheel bearings.
Check ROPS as indicated. Section 9019.
Every 1000 Change hydraulic reservoir.
Hours or
Yearly, Which- Replace hydraulic oil filter.
ever Occurs
First Clean hydraulic filter by-pass screen.
Change power shuttle/torque converter oil.
Clean power shuttle/torque converter screen.
Change synchromesh transmission oil.
Change rear axle oil. Section 6020.
Clean air compressor cylinder head
(by dealer only).
Every 2000 Disassemble and clean alcohol evaporator.
Hours or (by dealer only). Section 7020,
Yearly, Which-
ever Occurs Lubricate starter motor. Section 8015.
First. Drain, flush and refill cooling system.
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1050-4
INTERVAL SERVICE INSTRUCTIONS
Every 3000 Rebuild or replace air compressor
Hours (by dealer only). Section 7014.
As Required Service air cleaner element when
restriction indicator shows red band. Section 2051.
After wheel has been removed for service
and reinstalled, check wheel nut/bolt torque
every two hours until stabilized.
Replace fire extinguisher shell.
Fill alcohol evaporator with clean
wood alcohol.
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1050-5
FLUIDS AND LUBRICANTS
COMPONENT CAPACITY SPE CIFICA TIONS
U.S. METRIC
Fuel tank 28 gals. 106 liters No. 2 diesel fuel
Engine crankcase oil
With filter change 11 gals. 10,4 liters Engine oil: CD Commercial
class D. (Service DS, Series 3)
MIL-L-45199B
Without filter change Above 32° F. - SAE 30
10° to 50° F. - SAE 20W
Below 40° F. - SAE 1OW
Equipment/ steering
hydraulic system
Approximate
Total System 35 gals. 132,5 liters Case TCH Fluid
Reservoir refill 13. 8 gal. 52,2 liters Alternate oils: Engine oil -
SD-Service class D.
CA-Commercial class A.
(Service MS or DG)
Above
32° F. -
SAE
l0W
Below
32° F. -
SAE 5W
Type C-2 transmission and
hydraulic fluid such as Tenneco
Hytrans Fluid.
Power shuttle/trans-
mission and torque
converter 12 qts. 11,4 liters Case TCH Fluid
Synchromesh 6.4 qts. 6,1 liters Multipurpose gear lubricant
transmission
SAE 90 (APL-GL-4, MIL-L-2105)
Rear axle
Center bowl 27 pts. 12,8 liters Multipurpose gear lubricant
SAE 90 (APL-GL-4, MIL-L-2105)
Planetaries -
each side 3 pts. 1,4 liters
Cooling system 30 qts. 28,4 liters Ethylene glycol and water should
be mixed for prevailing tempera-
tures. Follow antifreeze manufac-
tures specifications.
Alcohol evaporator
1 pt.
0,5 liter Clean wood alcohol
Batteries As required Add colorless, oderless drinking
water.
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1050-6
COMPONENT CAPACITY SPECIFICATIONS
U.S. METRIC
Grease fittings As required Above 32° F. Multipurpose or No.
2 lithium-soap base grease. Below
32° F. Multipurpose or No. 1
lithium-soap base grease.
Wheel bearings As required Number 2 wheel bearing grease
Drive shaft As required Multipurpose - Molydisulfide type
grease.
CASE CORPORATION
Section
1051
TORQUE CHART
Burl. Form 9-72595 Nov. 1973
PRINTED IN U.S.A.
1051-2
U.S. AND METRIC TORQUE SPECIFICATIONS
Torque values for all situations unless special torque is specified.
Grade 5 Bolts, Nuts, Studs (Dry)
Thread Size Torque Thread Size Torque
ft. lbs. m-kg ft. lbs. m-kg
1/4" - 20 NC 5-10 0,7-1,4
0
3/4" - 10 NC 235-285 32-39
1/4" - 28 NF 10-15 1,4-2,1 3/4" - 16 NF 270-330 37-46
5/16" - 18 NC 15-20 2,1-2,8 7/8" - 9 NC 360-440 50-61
5/16" - 24 NF 15-20 2,1-2,8 7/8" - 14 NF 395-490 55-68
3/8" - 16 NC 25-35 3,5-4,8 1" - 8 NC 520-640 72-88
3/8" - 24 NF 30-40 4,1-5,5
(D
1" - 12 NF 575-705 79-97
7/16" - 14 NC 45-55 6,2-7,6 1-1/8" - 7 NC 720-820 99-113
7/16" - 20 NF 50-60 6,9-8,3 1-1/8" - 12 NF 790-970 109-134
1/2" - 13 NC 65-85 9,0-12,0 1-1/4" - 7 NC 1010-1240 139-171
1/2" - 20 NF 80-100 11-14 1-1/4" - 12 NF 1115-1365 154-188
9/16" - 12 NC 100-120 14-17
C9
1-3/8" - 6 NC 1315-1610 181-222
9/16" - 18 NF 110-130 15-18 1-3/8" - 12 NF 1510-1850 208-255
5/8" - 11 NC 135-165 19-23 1-1/2" - 6 NC 1745-2135 241-295
5/8" - 18 NF 160-200 22-28 1-1/2" - 12 NF 1880-2420 259-334
Grade 8 Bolts, Nuts, Studs (Dry)
Thread Size Torque Thread Size Torque
ft. lbs. m-kg ft. lbs. m-kg
1/4" - 20 NC 10-15 1,4-2,1
®
3/4" - 10 NC 340-420 47-58
1/4" - 28 NF 15-20 2,1-2,8 3/4" - 16 NF 380-460 52-63
5/16" - 18 NC 20-30 2,8-4,1 7/8" - 9 NC 540-660 75-91
5/16" - 24 NF 25-30 3,5-4,1 7/8" - 14 NF 595-725 82-100
3/8" - 16 NC 40-50 5,5-6,9 1" - 8 NC 810-990 112-137
3/8" - 24 NF 45-55 6,2-7,6 1" - 12 NF 900-1100 124-152
7/16" - 14 NC 60-80 8,3-11,0
©
1-1/8" - 7 NC 1150-1400 159-193
7/16" - 20 NF 70-90 9,7-12,0 1-1/8" - 12 NF 1295-1585 179-219
'-
1/2" - 13 NC 100-120 14-17 1-1/4" - 7 NC 1640-2000 226-276
1/2" - 20 NF 110-130 15-18 1-1/4" - 12 NF 1800-2200 248-304
9/16" - 12 NC 135-165 19-23 1-3/8" - 6 NC 2140-2620 295-362
9/16" - 18 NF 155-190 21-26
©
1-3/8" - 12 NF 2450-3000 338-414
5/8" - 11 NC 200-240 28-33 1-1/2" - 6 NC 2845-3475 393-480
5/8" - 18 NF 215-265 30-37 1-1/2" - 12 NF 3200-3900 442.-538
Hydraulic Fittings (Steel)
37° Flare Straight Thread
Female Swivel 0-Ring
Dash Tube Thread Torque Torque
Size O.D. Size ft. lbs. m-kg ft. lbs. m-kg
4 1/4" 7/16" - 20 6-12 0,8-1, 7 12-19 1, 7-2,6
5 5/16" 1/2" - 20 8-16 1,1-2,2 16-25 2,2-3,5
6 3/8" 9/16" - 18 10-25 1,4-3,5 25-40 3,5-5,5
8 1/2" 3/4" - 16 15-42 2,1-5,8 42-67 5,8-9,2
10 5/8" 7/8"-14 25-58 3,5-8,0 58-92 8,0-12,7
12 3/4" 1-1/16" - 12 40-80 5,5-11,0 80-128 11-18
14 7/8" 1-3/16" - 12 60-100 8,3-14,0 100-160 14-22
16 1" 1-5/16" - 12 75-117 10-16 117-187 16-26
20 1-1/4" 1-5/8" - 12 125-165 17-23 165-264 23-36
24 1-1/2" 1-7 /8" - 12 210-250 29-35 700926 250-400 35-55
Section
22
CYLINDER HEAD AND VALVES
2678, 301 B, 3368D, 336BDT AND 401 B
DIESEL ENGINES
SPECIFICATIONS
CYLINDER HEAD
Warpage
Maximum Limit
Including Wear
. . . . . . .005"
INT AKE AND EXHAUST VALVE GUIDES
Length • . • • . . . . • . . • • . . • • . • • . . . . . . . • . 3. 219"
O.D. . • • • • • . . • . . • . . . . . . • . • . . . . • • . . . • .7515"to .7510"
I.D. (Installed and reamed) . . . . . • . . . . . . • . . . . .4045" to .4055" . . . . . .001"
Protrusion above cylinder head. . • . . . . . . . • . . . . .953"
EXHAUST VALVE
Tappet clearance (COLD). • . . • . . • . . • • . • . . . • . .025"
Tappet clearance (HOT) • . • . . • . . • . . . • . • . . • • .020"
Face angle . • . . . • . . . . . . . . . • . . . . • . . . . . . 45°
Face run-out. . . . • • • . . . . . . . . . . . . . • . . . • . . . . . • . . . . . . . . • . . .002"
O.D. of head (267B and 401B) . . • • . . . . . . . . • . . . 1.455" to 1.445"
O.D. of head (336BD and 336BDT) . . . . . • . . • . . • . 1.755" to 1.745"
O.D. of head (301B) . . • . . . . • . . • • . . . . . • . . . • 1.567" to 1.557"
O.D. of stem end .402" to .403" . .002"
O.D. of taper 4.26'75i, froin' st;m end. : : : : : : : : : : : .401" to .402" . • • .002"
Length (301B) . • . . . • . . • • . . . • . . . • . . • • . • . 6.4385" to 6.4175"
Length (336BD and 336BDT) . . . • . . . . . • • . • . • • 6.4405" to 6.4195"
Length (267B and 401B) . . • . . . . . • . . . . . • . • . • 6.4235" to 6.4025"
Insert seat angle . . • . • • • . • . . • . . . . . . . . . . . 44°
Seat contact width .0800" to .1000"
. .. . .. . .. . . . . . . . . . . . . .
Seat run-out . • • • .002"
Insert height . : : : : : : : : : : : : : : : : : : : : : : : : : · ."3i6°"'t~ :3i3 11 • • •
O.D. of insert (401B. and 267B) . . . • . . . • . . . . . . 1.635" to 1.634"
O.D. of insert (301B) . . • • . • • • . • • • . • • . . • . . • 1.723" to 1. 722"
O.D. of insert (336BD and 336BDT) • • • • . • . . • . . • 1.9465" to 1.9455"
I.D. of insert (267B and 401B) • • . . • . • . . . . . • . . 1.2676" to 1.2736"
I.D. of insert (301B). . . • . . • • . . . . . • • • • . . . . • 1.409" to 1.403"
I.D. of insert (336BD and 336BDT) • . • • • • . • . • . . • 1.571" to 1.577'·'
Rae. 9-79392
CASE CORPORATION PRINTED IN USA
22-2
SPECIFICATIONS (Continued)
INTAKE VALVE
Tappet clearance (COLD and HOT)
Face angle ........ .
Face run -out . . . . . . .
Length (267B and 401B)..
Length (301B) . . . . . . .
Length (336BD and 336BDT) .
O.D. of stem ......... .
O.D. of head (267B and 401B) .. .
O.D. of head (301B) .......... .
O.D. of head (336BD and 336BDT) ..
Seat angle ....... .
Seat contact width . . . . .
Seat run-out . . . . . . . . .
Insert height (336BDT) . . .
0 .D. of insert (336BDT)
I.D. of insert (336BDT).
VALVE SPRING
Free length ................ .
Total coils . . . . . . . . . . . . . . . . .
Wire diameter . . . . . . . . . . . . . . .
Compressed to 1-31/64" (Valve open) .
Compressed to 1-15/16" (Valve closed) .
ROCKER ARM ASSEMBLY
O.D. of shaft ............... .
I.D. of arm bore . . . . . . . . . . . . . .
Shaft assembly end play (both ends) .
Shaft spring:
Total coils (working coils) . .
Wire diameter . . . . . . .
Compressed to 1-9/16" ...
Lubrication . .
Shaft oil holes . . . . . . • . . . . . .
Maximum Limit
Including Wear
.015"
45°
.
.... . .. . . .... .. ..
6.2845" to 6.2695"
6.4415 to 6.4205"
6.4405" to 6.4195"
.402" to .403" .
1.685" to 1.675"
1.755" to 1.745"
2.005" to 1.995"
44°
.0075" to .0975"
.2775" to .2825"
2.0990" to 2.1000"
1.805" to 1.815"
2.28"
7.75
.1695"
130 to 140 lbs.
41 to 45 lbs.
.872" to .873"
.8745" to .8755"
.010"
to
.030"
4
.080"
8.5 to 10 lbs.
.002"
.002"
.002"
Engine oil, camshaft metering
Toward valve side of engine.
Shaft cannot be rotated.
SPECIAL TORQUES
Cylinder head bolts ..... .
Intake and exhaust manifold stud nut
Cylinder head valve cover stud nut .
Rocker arm bracket stud nut. . • . .
200
to
210 ft. lbs.
25 to 30 ft. lbs.
60 to 70 in. lbs.
40 to 45 ft. lbs.
CHECKING COMPRESSION PRESSURE
1. Clean the engine thoroughly, preferably
by steam cleaning.
2. Before cranking the engine, make sure all
operating controls are in neutral, brakes
are set and the wheels are securely
blocked.
3. There are two methods of checking com-
pression pressure - the cranking method
and the engine running method. NOTE The
engine must be at operating temperature
for either method used.
A. CRANKING METHOD - Close the needle
valve at the fuel tank. Disconnect all high
pressure fuel lines and leak-offlines bet-
ween injectors. Remove all of the injec-
tors. Refer to the chart on Page 3.
22-3
CHECKING COMPRESSION PRESSURE (Continued)
B. RUNNING METHOD - Disconnect the
high pressure fuel line and leak-off lines
from number one injector. Using an
appropriate length of tubing or hose,
route the fuel from these lines back to
the fuel tank or a clean container. Re-
move the number one injector. Refer to
chart below.
4. Clean the injector bores of loose carbon
and residue. Replace the compression
seal in the injector bore of the cylinder to
be checked and install a Bacharach 70-314
(D-558) Compression Gauge Adapter, Fig-
ure 1. Secure with an original injector
clamp assembly and spacer. Figure 1, In-
set A. Tighten bolt to 20 foot pounds.
Connect Case No. CD-504 Compression
Gauge to the adapter, Figure 2.
IMPORTANT It is very important that
all cylinder pressures be approximately
alike. For the allowable compression
pressure variation, refer to chart below.
INSET A
i!:~SEMBLV
~-
LJ SPACER
COMPRESSION ADAPTER
70-314 (D-558)
5. If the compression is greater than the
figure mentioned, carbon deposits are in-
dicated. If the reading is below these fig-
ures, leaking valves or excessive ring
clearance is indicated. NOTE To make
a simple check when a compression leak
ENGINE
' SPEED
is indicated, squirt a small amount (a tea-
spoon) of oil into the cylinder and recheck
the compression. If the pressure rises to
near normal, compression loss is past the
rings. Very little change in compression
indicates leakage past the valves. A low
pressure reading will cause difficulty in
starting particularly at low temperatures.
NOTE Take several compression read-
ings on each cylinder. This is done by
pressing the vent valve button, Figure 2,
to relieve gauge pressure. When the but-
ton is released the gauge will again in-
dicate compression pressure.
COMPRESSION ADAPTER
70-314 (D-558) IGINALCLAMPASSEMBLY
AND SPACER
VENT BUTTON I
I
"CD504 COMP~ESSION GAUGE
Figure 2
IMPORTANT Replace the compression
seal and carbon seal on all injectors at
the time of installation, Figure 3.
CARBON SEAL
L1--- COMPRESSION SEAL
Figure 3
NORMAL ALLOWABLE
COMPRESSION VARIATION
PRESSURE BETWEEN
CYLINDERS
CRANKING Approximately 200 RPM 400 PSI* 25 PSI
RUNNING 800 RPM 480 PSI* 20 PSI
NOTE *A 4% reduction in PSI must be allowed for every 1000 ft. above sea level.
22-4
TURBO CHARGER SYSTEM
Four Cylinder 336BDT Engine
(Refer to Figure 4)
Removal
Remove the muffler and hood from the vehicle. Steam clean the engine thoroughly before
removing any components for service.
1. Disconnect the air cleaner from the
turbo-charger.
2. Disconnect the turbo and intake elbow
hose clamps(l)and remove withhose(2).
3. Disconnect the turbo oil supplyline(3)
and remove. Disconnect hose clamps (4)
and remove the oil drain tube hose (5).
Remove the oil drain tube (6) with gasket
(7). Discard gasket.
4. Remove the intake elbow (8) with gasket
(9). Discard gasket.
5. Remove the turbo-charger (10), gasket
(11) and coupler (12). Discard gasket (11).
6. Remove the bolts from the manifold brace
(17). Remove the exhaust elbow (13) and
spacers (18).
7. Remove the turbo adapter base (14) with
gasket (15). Discard gasket.
8. Remove the oil drain tube elbow (16).
Inspection
Clean the intake and exhaust elbows,
coupler and turbo adapter thoroughly and
check for cracks or other damage. Replace
if necessary.
Flush and clean the oil supply line, oil
drain tube and elbow. Check foranydamage
and replace if necessary.
Replace the hose clamps to assure air
tight and leak proof connections.
Check the hoses for cracks and deter-
ioration. Replace if necessary.
Installation
1. Install the intake elbow (8) with a new
gasket (9) to the intake manifold. Retain
with bolts and nuts and torque 35
to
42
ft. pounds.
2. Install the exhaust elbow (13) and spacers
(18) to the water manifold. Retain with
bolts finger tight.
3. Install the turbo adapter base (14) with a
new gasket (15) to the exhaust manifold.
Retain with bolts and nuts and torque 35
to 42 foot pounds.
4.lnstall a new gasket (11) to the turbo-
adapter base and install the turbo-charger
(10) to the adapter base with the coupler
(12). Retain the turbo-charger with nuts
and bolts finger tight.
IMPORTANT -
Align
the turbo-charger (10), coupler (12) and
and the exhaust elbow (13) so that the
coupler is free to rotate 360°. Torque the
exhaust elbow bolts and the turbo-charger
bolts and nuts 35 to 42 ft. pounds.
NOTE
recheck that the coupler rotates 360°.
5. Install the brace (17) to the exhaust elbow
(13) and retain with bolts. Torque 35 to
42 ft. pounds.
6. Install the turbo oil supply line (3).
7. Install the turbo oil drain tube (6) with a
new gasket (7). Torque the retaining bolts
35
to
42 ft. pounds.
8. Install the drain tube elbow (16), with the
hose end in a vertical angle position. In-
stall new hose clamps (4) and hose (5),
connecting the elbow (16) to the drain tube
(6). Position the clamps and tighten
securely.
9. Install the new hose clamps (1) and hose
(2), connecting the intake elbow (8) and
turbo-charger (10). Position the clamps
and tighten securely.
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Figure 4
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22-5
22-6
CYLINDER HEAD AND COMPONENTS
Four Cylinder, 267B, 301 B, 336BD and 336BDT Engines
(Refer to Figure 5)
Removal
Remove the muffler and hood from vehicle. Disconnect the exhaust system and air cleaner
from the manifolds. Steam clean the entire area where service work is to be performed.
1. Drain the cooling system. CAUTION If
the engine is hot, do not remove the rad-
iator cap until the coolant has had sufficient
time to cool. Loosen the cap to the first
stop carefully to relieve any excess pres-
sure before removing it completely. Re-
move the upper radiator and water pump
hoses.
2. Disconnect the high pressure fuel lines
from the injectors and the leak-off tubes
between the cylinder heads. Cap them to
prevent any foreign particles from enter-
ing. Remove the injectors as described in
Section 33 of the Service Manual.
3. Remove the breather tube (1) and discard
the gaskets (2). Remove the manifold
brace (5) and spacer (6), if equipped.
4. Remove the intake elbow (3) and gasket
(4), if equipped and discarding the gasket.
5. Remove the intake manifold (7) and dis-
card the gaskets (8).
6. Remove the exhaust stack (9) or cover
plate (10) if equipped. Remove the ex-
haust elbow (11) if equipped.
7. Remove the exhaust manifold (12) and dis-
card the gaskets (13).
8. Remove the water manifold (14) and dis-
card the gaskets (15). NOTE If the ther-
mostat is to be serviced, remove the
thermostat housing (28) and refer to
Section 25 of the Service Manual.
9. Remove the valve cover nuts (14), bevel
washers (15), gaskets (16), valve cover
(17) and cover gasket (18). Discard gaskets
(16 and 18).
10. Remove the studs (19), washers (20) and
rocker arm assemblies (21). NOTE Tag
the rocker arm assemblies for proper a-
ssembly. See Page 22-16 for servicing.
Remove the push rods (22) and tag them
for proper assembly.
11. Remove the cylinder head bolts and
washers (23). Remove the cylinder head
assembly (24), fire rings (25) and head
gaskets (26). Discard the fire rings and
head gaskets. See Page 22-18 for servi-
cing of the cylinder head.
27
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Figure 5
22-7
-
13
26
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