Case 385 Diesel, Shop Manual

Page 1: ...e housing INDEX By Starling Paragraph BRAKES At ustment Bleed Master Cylinders R R and Overhaul CLUTCH ENGINE Adjustment Cylinders R R and Overhaul CAB Remove and Reinstall COOLING SYSTEM Pan Radiator...

Page 2: ...Carrier Rear Axles FRONT SYSTEM Two Wheel Drive Axle Main Member Front Support Spindles Tie Rods and Tbe In Wheel Bearings 385 Diesel 116 78 72 74 85 91 34 39 46 51 52 53 54 35 55 61 36 59 58 50 48 4...

Page 3: ...nd Bleeding 21 Oil Cooler 33 Operation 20 Pump 26 Steering Hand Pump 29 POWER TAKE OFF Clutch Shafts and Gears 127 Linkage Adjustment 125 Operating Pressure 126 TRANSMISSION FORWARD REVERSE Operation...

Page 4: ...ification of 0 011 inch 0 279 mm would indicate that the equipment was manufactured using the U S system of measurement and the metric equivalent of 0 011 inch is 0 279 mm CONDENSED SERVICE DATA 385 4...

Page 5: ...meter Camshaft Journal Diameter Piston Pin Diameter Valve Stem Diameter Intake Exhaust Main Bearing Diametral Clearance Rod Bearing Diametral Clearance Piston Skirt Diametral Clearance Crankshaft End...

Page 6: ...ES CONT Transmission Differential and Hydraulics Capacity 36 U S qts 3 34 L Oil Type Hy Tran Plus Front Drive Axle Capacity 4 75 U S qts 4 5 L Oil Type SAE 90 EP Front Drive Axle Hub Each Side 0 8 U S...

Page 7: ...ar ring loosen nut 1 4 turn to align slot in nut with hole in spindle and install cotter pin 8 Install lithium grease in end of hub and in cap 10 and install cap SPINDLES All Models With Adjustable Ax...

Page 8: ...d nuts then move steering arm steering cylinder left side and tie rod Fig 3 Exploded view of straight adjustable front axle used on some tractors 1 Bolt 2 Steering arm 12 Shoulder bolt R H 13 3 Nut 4...

Page 9: ...rom left and right steering arms 2 and 6 Unbolt and remove axle extensions 4 and 5 with spindle assemblies Identify and dis connect steering cylinder hoses at cylinder Cap and plug all openings Remove...

Page 10: ...fer to Fig 6 and loosen jam nuts at each end of tube 8 One nut is left hand thread and the other is right hand thread Rotate tube as required to lengthen or shorten tie rod as sembly Tighten jam nuts...

Page 11: ...els are off the floor Support front of tractor with splitting tool MS2700B under engine oil pan Remove wheel nuts and using a hoist remove front wheels Place a floor jack under axle assembly Unbolt pi...

Page 12: ...rings 8 Pivot bearings 14 front 10 Bearing cap rear Cap screw 12 Washer 13 Cap screw Spring pin dowel Paragraph 10 Cont Remove and discard 0 ring 8 Remove scraper ring 2 and oil seal 3 from hub 6 then...

Page 13: ...all 0 ring 8 in groove on hub 6 Install thrust washer 11 and snap ring 13 Lubricate roller bearing 21 install in planetary gear 20 and secure with angle rings 19 Heat plane tary gear assembly and inst...

Page 14: ...hims 31 are available in thicknesses of 0 008 0 012 0 016 0 024 0 031 0 039 0 055 0 063 0 071 and 0 079 inch 0 2 0 3 0 4 0 6 0 8 1 0 1 4 1 6 1 8 and 2 0 mm Divide total shim thickness and in stall equ...

Page 15: ...NAL Install roll pins 20 and 21 and cap screws 11 Tight en cap screws to a torque of 51 ft lbs 69 N m then press lock plate 10 over bolt heads Heat bearing cones 1 and 26 in a bearing oven to a temper...

Page 16: ...ap screws to a torque of 51 ft lbs 69 N m then press lock plate 10 over bolt heads Heat carrier bearing cones in a bearing oven to a temperature of 250 F 120 C and install on differential assembly WAR...

Page 17: ...ier bearing cup and left axle housing flange cup 26 and install a thicker shim washer 25 to in crease or a thinner shim washer to decrease preload on bearings Reassemble and reinstall right axle hous...

Page 18: ...nstall four cap screws 22 Fig 15 at 90 de gree intervals and tighten them to a torque of 44 52 ft lbs 60 70 N m Rotate pinion shaft several times then working through the drain plug opening use a dial...

Page 19: ...couplers on drive pinion shaft and transfer case output shaft Align cap screw holes with grooves on shafts Install coupler cap screws and tighten to a torque of 130 ft lbs 175 N m Attach and zero a d...

Page 20: ...from both sides of shift fork 30 Drive the four roll pins 35 into shaft 34 and withdraw shaft Remove left le ver 32 detent ball 23 shift fork 30 right lever 36 and its detent ball as shaft is removed...

Page 21: ...and 30 Remove clutch piston 35 by tapping the ends of pressure pins 34 alternately Remove seal rings 36 and 37 from piston and 0 rings 33 from pres sure pins 34 Clean and inspect all parts and renew a...

Page 22: ...models The intemal hydraulic pump 2 Fig 32 pulls oil from the reservoir through a full flow suction filter installed in the outside of the multiple control valve 13 The filtered oil is pres surized b...

Page 23: ...5 kPa is on pressure gage and record the flow Increase the load to 1600 psi 11032 kPa and record the flow Fully close the load valve and record the reading on pressure gage Then fully open the load va...

Page 24: ...itch supply union on the multiple control valve Place outlet hose from flowmeter into trans mission oil fill hole and wire in place Fully open load valve on flowmeter Start engine and operate at a spe...

Page 25: ...m Reinstall hand park brake linkage and pto linkage Then using a new filter ele ment 15 0 rings and gasket install hydraulic fil ter assembly Tighten filter center bolt to a torque of 12 16 ft lbs 16...

Page 26: ...emove seat 6 or check valve 7 as they are not available as replaceable parts Clean and inspect all parts for excessive wear or other damage If housing 9 seat 6 check valve 7 spool 20 sleeve 22 rotor 2...

Page 27: ...ing a fine emery cloth and oil providing a rotary mo tion is used during polishing operation A cylinder tube that is heavily scored or grooved or is out of round should be renewed Check piston rod an...

Page 28: ...tion Renew cylinder if heavily scored or out of round Check piston rod and piston 6 for scoring and straightness Polish out light scoring with fine emery cloth and oil using a rotary motion Renew rod...

Page 29: ...er to inside of rod guide Install right side rod guide and tighten rod guide cap screws to a torque of 52 ft lbs 70 N m Apply Loctite 242 to the first three threads and in stall threaded studs 3 Fig 4...

Page 30: ...ve air conditioning condenser and tie condenser and hoses back out of the way Unbolt and remove lower radiator seal strip Remove wiring har ness from fan shroud and lay rearward Remove radi ator side...

Page 31: ...ng the sequence shown in Fig 44 or 45 Tighten the cap screws to a torque of 30 ft lbs 41 N m in first step 60 ft lbs 81 N m in second step and 110 ft lbs 149 N m in the third step Adjust valve tappet...

Page 32: ...angle 45 Valve seat angle 44 Stem diameter 0 3912 0 3915 in 9 936 9 945 mm SEAUNG SURFACES Paragraph 37 Stem to guide diametral clearance 0 0025 0 0033 in 0 064 0 084 mm Seat width 0 060 0 070 in 1 5...

Page 33: ...1 2 3 4 5 6 7 8 FRONT 1 2 3 4 5 6 7 8 Fig 50 Chart shows vaive tappet adjusting procedure for D 206 D 239 and D 268 four cylinder engines Refer to text Ikppets can be removed after first removing the...

Page 34: ...ank shaft must protrude approximately 5 64 inch 2 0 mm Heat new gear to 400 F 204 C and install it against bearing journal WARNiNG Aiways wear heat protective gioves when handiing heated parts Make ce...

Page 35: ...an inside diameter of 2 2844 2 2856 inches 58 024 58 054 mm Install new bearings so that oil holes in bearing are in register with oil holes in crankcase Normal oper ating clearance of camshaft journa...

Page 36: ...follows Piston pin diameter 1 4172 1 4174 in 35 997 36 002 mm Piston pin diametral clearance in piston 0 0000 0 0001 in tight 0 0001 0 0025 mm tight Maximum allowable 0 0002 in loose 0 0051 mm loose...

Page 37: ...s CASE iNTERNATiONAL ing special tool No 3228341R1 or equivalent install new seal with lip toward inside When installing crankshaft pulley align pulley with timing pin Make certain clamping ring or pr...

Page 38: ...t shafts gear 6 0 ring 3 Driven weight 7 Housing assy 8 Double roll pins extremely important that balancer weights are cor rectly timed to each other and that complete unit is timed to crankshaft Ib r...

Page 39: ...drive gear 2 Fig 53 first remove crankshaft from engine Remove worn or damaged drive gear by using a chisel and hammer and split ting the gear Remove any burrs which migiit be pres ent on gear mountin...

Page 40: ...ance of reassembly is the reverse of dis assembly OiL PAN Aii Modeis 59 REMOVE AND REINSTALL Ib remove the oil pan place a jack under the clutch housing Re move drain plug and drain oil Remove the low...

Page 41: ...and is completely sealed Because of the special equipment needed and skill required of servicing personnel service of iivjection pumps is generally beyond the scope of that which should be attempted...

Page 42: ...hen tum pump drive shaft clockwise viewed from front until dial indi cator shows a reading of 0 039 inch 1 0 mm Evenly tighten the three hub cap screws to a torque of 19 21 ft lbs 25 28 N m Turn crank...

Page 43: ...fter 10 seconds at 300 psi 2068 kPa below opening pressure is permissible Maximum allowable leakage through retum is 10 drops in one minute at 300 psi 2068 kP below opening pressure If nozzle requires...

Page 44: ...erve spray pattem A good spray pattern is cone shaped Dribbling or no spray indicates a blocked spray nozzle or lack of ether pres sure Clean spray nozzle or install new can of ether as required Ib ch...

Page 45: ...and lift out water pump Disassemble the pump as follows Remove plastic screw 13 Fig 61 then using a 1 2 x 2 inch NC cap screw for ajack screw force impeller 12 off rear end of shaft Using two screwdr...

Page 46: ...key switch is in off position If light fails to go out when key is in off position test circuits as outlined in paragraph 75 Normal operation of the warning light is to come on only when key switch i...

Page 47: ...b and Model A127 65 is used on models with cab All alternators are equipped with LUCAS ALTERNATOR TEST HERE Fig 63 View showing test hole for bypassing voltage regulator on typical Lucas aiternator CA...

Page 48: ...windings connect an ohmmeter between slip ring connectors as shown in Fig 65 Ohmmeter should read 3 2 ohms If not renew rotor Ib check insulation of rotor windings connect a 15 watt test light in a 1...

Page 49: ...y check of stator windings using a 36 watt test light and a 12 volt circuit iiOV in mind Note that some type of heat sink should be used between diodes and connections to be resol dered needlenose pli...

Page 50: ...earing 15 Washer 16 Spacer as shown in Fig 72 Ohmmeter reading should be 3 2 ohms If not renew rotor Ib check insulation of ro tor windings connect a 15 watt test light in a 110 volt circuit connected...

Page 51: ...sing brake shoes 25 and springs 24 Remove brushes 23 from brush holder 22 and remove the holder Inspect bmsh springs 21 and renew as needed Remove field housing 18 Re move eccentric pin 1 and remove d...

Page 52: ...thickness of shims 16 between center bearing plate 14 and armature core Pinion clearance is set by connecting a 6 volt bat tery to solenoid on assembled starter to activate sole 15 WATT TEST BULB 110...

Page 53: ...110 volt 15 watt test light as shown in Fig 76 Brushes must not touch field housing and power terminal insulation must not allow voltage to short to housing If test light comes on and brushes are clea...

Page 54: ...dimension Then tighten locknut on push rod Turn stop bolt 2 until it contacts clutch pedal turn bolt clockwise an additional 1 4 turn and tighten locknut Check safety start switch position Loosen lock...

Page 55: ...ll reser voir with Hy Tran Plus MS 1207 fluid to maximum level mark Fully press and release clutch pedal Re peat as required until fluid free of air bubbles flows through the hose Then tighten bleed s...

Page 56: ...used on Modeis 685 and 885 1 Clutch disc 2 Pressure plate 8 Finger 3 Spring seat 9 Cap screw 4 Insulating washer 10 Washer 5 Spring 11 Finger tension 6 Spring cup spring 7 Cover 12 Pin TWO SPEED POWE...

Page 57: ...nlet tube 7 Oil tubes 6 will remain in speed gearbox housing Clean and inspect all parts for excessive wear or other damage and renew as necessary Body 6 Fig 87 spool 7 and plug 9 are not serviced sep...

Page 58: ...rbox assembly in a transmission stand Unbolt and remove bottom core plate 12 Fig 86 and regulator valve 4 assembly then remove oil in let tube 7 Remove clutch release bearing and sleeve Drive roll pin...

Page 59: ...When reassem bling use all new O rings seal rings and oil seals and reverse disassembly procedure keeping the fol lowing points in mind Before installing new friction discs 10 or 35 soak discs in cle...

Page 60: ...are free to rotate and that minimum clearance between re taining ring 8 and back plate 9 is 0 030 0 040 inch 0 762 1 016 mm Place clutch in a press and com press Belleville washers until the direct d...

Page 61: ...ge section Tighten bolts securing speed gearbox to engine and speed gearbox to range section to a torque of 80 ft lbs 108 N m Fig 97 Chart used in seiectlng shim to adjust correct thickness of direct...

Page 62: ...in in speed gearbox Remove plug 1 Fig 100 with O ring 2 shim 3 pin 4 spring 5 and valve 6 Remove plug 9 and O ring 8 Unbolt and remove regulator valve body 7 then remove gasket 11 Fig 99 separa tor pl...

Page 63: ...Forward Reverse lockout mechanism from speed selector cover Place special tool Churchill MS 2700 or equiva lent under tractor See Fig 89A Adjust splitting tool to support tractor under speed gearbox...

Page 64: ...g ring 21 Press shaft from bearing 32 and remove thrust washer 24 Ib disassemble the clutch unit 34 place unit in a press either end up and apply pressure to clutch Fig 107 Expioded view of Forward Re...

Page 65: ...by 2 equally as possible For example if shim measures 0 024 inch 0 61 mm install one 0 014 inch 0 355 mm thick shim on each clutch half Shims are avail able in thicknesses of 0 014 0 024 and 0 036 inc...

Page 66: ...revent foreign material from entering systems Place special tool Churchill MS 2700 or equiva lent under tractor See Fig 89A Adjust splitting tool to support tractor under speed gearbox and rear main f...

Page 67: ...rlock support arm 35 Interlock Remove clutch release bearing and sleeve Drive roll pins from release fork withdraw release shaft and remove fork Unbolt and remove pto driven shaft end cover and metal...

Page 68: ...tch shaft 31 and bearing 30 out through rear of speed gearbox Press bearing from shaft 4 3 1 Snap ring 2 Needle bearing 3 Mainshaft 4 Snap ring 5 Bearing 6 Snap ring 7 Bearing cage 8 Seal rings 9 Spac...

Page 69: ...ction then reconnect speed gearbox to range section Tighten retaining bolts to a torque of 80 ft lbs 108 N m Refill transmission to level on dipstick with new Hy Tran Plus fluid Refer to Condensed Spe...

Page 70: ...e bearings as follows Remove snap ring 7 and press bearings and hous ing from bevel pinion mainshaft InstaU new bearings 2 and 4 and housing 3 and secure with snap ring 7 Ib remove the countershaft 25...

Page 71: ...ly and shims 10 from transmission case Measure and note thickness of shims 10 if the same bevel pin ion mainshaft is to be reinstaUed Using a dial indi cator measure end play of bearing housing 8 on b...

Page 72: ...aft Pump drive gear 29 is located on pto driven shaft and rides in needle bearing 27 If necessary coun tershaft needle bearing and pump gear needle bear ing 27 can now be removed Note position of nee...

Page 73: ...sembly is the reverse of disas sembly procedures TRANSFER LUBE PUMP Aii Models 114 REMOVE AND REINSTALL The transfer lube pump is located below the reverse idler gear in range gearbox The pump furnish...

Page 74: ...r relationship The differential assembly for Models 385 and 485 has two pinions 9 Fig 131 with a single cross shaft 12 Models 585 685 and 885 have four pinions 9 and four stud shafts 10 The differenti...

Page 75: ...cessive wear or other damage If bevel ring gear is to be renewed bevel pinion shaft 5 must also be renewed as they are available only as a matched set Refer to paragraphs 111 112 or 113 for instaUatio...

Page 76: ...ge total number of shims as this will affect bearing preload Shim pack thickness must not be more than 0 071 inch 1 80 mm on either side With bearing preload and backlash adjusted re move bearing hous...

Page 77: ...rning light switch so that the switch plung er is just in contact with park brake handle Move park brake handle fully downward disengaged po CASE iNTERNATiONAL sition Switch plunger should be pushed i...

Page 78: ...ng and washer on each side of gear with washer flats in alignment Tighten nut to a torque of 10 in lbs 1 23 N m while rotating gear Using a micrometer meas ure distance across bearing inner races as s...

Page 79: ...nstaU out er brake disc 12 BRAKES Brakes on all models are self equalizing hydrau lic actuated wet type single disc brakes Brakes are located on the differential output shafts planetary drive shafts a...

Page 80: ...pposite end of hoses into the transmission filler plug hole Loosen both air removal screws one full turn Start engine and operate at low idle speed Make sure brake pedals are latched to gether Press p...

Page 81: ...models with cab Then on all models remove boot 13 Fig 145 Re move snap ring 15 and push rod 14 or 16 Remove gland seal 12 piston 11 spring 10 with retainer wave washer 9 valve stem 8 and seal 7 Unscr...

Page 82: ...adjust Then tighten clamp bolt Total Spool Movement 1 14 1 18 in 29 30 mm Fig 146 Pto control linkage used on models not equipped with cab 1 Control lever 2 Clamp bolt 3 Pin 4 Locknut 5 Acyusting link...

Page 83: ...uld indicate that spool is not fully up or there is wear on the spool lands Move the control lever forward until the pto spool moves downward 0 39 0 43 inch 10 11 mm initial en gagement position Press...

Page 84: ...38 piston back plate 36 and brake ring 35 Remove snap ring 44 thrust washer 42 and clutch hub 43 Bump front of clutch cup 31 on bench top and remove piston 32 with 0 rings 33 and 34 NOTE Standard dut...

Page 85: ...eversing the removal procedure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Shaft cover Bearing se...

Page 86: ...assembly not seating or body assembly loose 3 Hitch lifts very slowly Could be caused by a Unloading valve leaking b Excessive load c Faulty main relief valve d Faulty cushion relief valve e Work cyl...

Page 87: ...ot be less than 90 percent of the first flow reading If second reading is too low check for the following conditions 1 Low oil level 2 Clogged filter 3 Faulty pump Remove the test pilot relief valve U...

Page 88: ...ngle of 15 degrees forward from vertical and tighten locknut Move raise rate lever fully forward so that lower le ver touches the bracket Remove cotter pin and washer then turn adjusting rod until the...

Page 89: ...racket 135 DROP VALVE SCREW Use the adjusting wrench Case special tool No IH9690 to turn the ad justing screw in the draft valve clevis fuUy clockwise See Fig 161 Turn adjusting screw six revolutions...

Page 90: ...10 Free length 0 460 in 11 68 mm Tbst length 0 400 in 10 16 mm Tbst load 3 2 oz 89 gram Flow control spring 14 Free length 1 703 in 43 26 mm Tbst length 1 200 in 30 48 mm Tbst load 11 Ib 49 N Lubricat...

Page 91: ...de down on a work bench Disconnect control linkage from main valve and other linkage Disconnect sensing spring then unbolt and remove cylinder and valve assembly from housing as shown in Fig 163 Disco...

Page 92: ...p cylinder 1 on a block of wood and move piston 2 to open end of cylinder Remove piston 2 with 0 ring 3 and back up ring 4 from cylinder Inspect piston and cylinder bore for Fig 165 Exploded view of t...

Page 93: ...er then reinstall the cyl inder and valve assembly into lift housing 9 Fig 167 Cushion relief safety valve 2 can be installed in cylinder through hole in lift housing Reinstall lift housing as outline...

Page 94: ...hanicai check vaive must be removed first to prevent damaging the valve spooi Tb disassemble the valves refer to Fig 172 and re move fittings from the raise work port Bend both ends of retaining clip...

Page 95: ...al check valve items 26 through 33 and for hydraulic check valve items 1 through 6 are available for repair Valve spool 14 and body 13 are a matched set and are not available separately Use all new se...

Page 96: ...bolt and remove cab floor panel If so equipped disconnect power shift electrical connec tor Remove hood top rear panel and disconnect wir ing harness connectors Drive out roll pin and discon nect hitc...