Case IH 6000 Windrower Service Repair Manual Instant Download

1
Table of Contents 6000 AND 6500
WINDROWERS DESCRIPTION GENERAL Tractor
Specifications .... .......... ... .........
......... Draper Header and Conditioner
Specifications ...... .. .... ....
FORM NUMBER 8-27950 8-27950
SERIES 10
SECTION
1-1 1-2
1-3 Auger Header and Conditioner Specifications .......................... 8-27950
1-4 Tools .... 8-27950
1-5 Torque Chart .................... ................................... 8-27950
1-6 Hydraulic Fitting Chart . ..... ..... .............. .................. 8-27950
1024 Diesel Engine Specifications .......................................... 8-24161
20 ENGINE
2-1 Engine Removal ...................................................... 8-27950
Gasoline
2A-1 General Specifications ..... ... .......... . ........................ 8-27950
2A-2 Tune-Up Specifications .............. ............... ................ 8-27950
2A-3 Engine Removal .. .. ........... ..... . ................. ..... ... 8-27950
2A-4 Basic Engine .................. ...................................... 8-27950
2A-5 Cylinder Head, Valves and Timing Chain ... .. ....... ................ 8-27950
2A-6 Block, Pistons and Connecting Rods ............................... .. 8-27950
2A-7 Crankshaft, Main Journals and Bearings ... 8-27950
2A-8 Lubrication System . .......... ...................................... 8-27950
2A-9 Cooling System .... .. .... . ....... . ... ...... ... 8-27950
2A-10 Air Intake System ...... ....................... ,..................... 8-27950
Diesel
2415 Cylinder Head and Valve Train ............ ... . . ... .. . 8-24171
2425 Cylinder Block, Crankshaft, Pistons, Rods, Bearings and Camshaft . 8-24181
2445 Lubrication System - Oil Pan, Oil Pump, Oil Cooler and Filter Housing 8-24191
2455 Cooling System - Thermostat, Water Pump, Fan Pulley and Belt Tensioner . . 8-24201
30 FUEL SYSTEM - Gasoline Engines
3-1 Fuel Injectors ................ . .. . ............................. 8-27950
3-2 Carburetor ......... 8-27950
3-3 Governor and Throttle Linkage ................... ................. 8-27950
FUEL SYSTEM - Diesel Engines
3-4 System Layout .......... ................ . ...,................. 8-27950
3-5 Throttle Linkage ...... 8-27950
3-6 Troubleshooting 8-27950
3410 Fuel System and Filters . . ... .. ................................. 8-24211
3412 Fuel Injection Pump 8-27080
40 3413 4-1 Fuel Injectors ................. . ................................. ELECTRICAL Component Specifications ......................................... 8-24231 8-27950
4-2 Wiring Diagram 8-27950
4-3 Alternator - Gasoline Engines ...................................... 8-27950
4-4 Neutral Switch Adjustment ......... ... .. ........................ 8-27950
4-5 Circuit Breaker and Gauges ........................................ 8-27950
4-6 Sending Switches ... ............... ... ......................... 8-27950
4-7 Starter Motor - Gasoline Engine .................................... 8-27950
4-8 Ignition System - Gasoline Engine ... ..... ........................ 8-27950
4-9 Sending Switches - Gasoline Engine ................................ 8-27950
4-10 Troubleshooting .......... .... .. ............. ............. ... 8-27950
4006 Starting Motor - Diesel Engine ... ....... ......................... 8-44340
4240 Alternator - Diesel Engine .......................................... 8-25690
JI Case A Tenneco Gompany
Rae 8-28550
Printed in U.S.A. August, 1986
2
Table of Contents 6000 AND 6500 WINDROWERS
SERIES 50 SECTION DESCRIPTION SEERING FORM NUMBER
5 Steering Linkage 8-27950
Ground Speed 8-27950
60 POWER TRAIN
6-1 Tractor . ..... 8-27950
6-2 Draper Header ... 8-27950
6-3 Common Components .......................... 8-27950
6-4 Draper Header - 36 foot ........ . . 8-27950
6-5 Auger Header ............ 8-27950
70 BRAKES
7-2 Brake Shoes ............. 8-27950
7-3 Parking Brake Adjustments 8-27950
80 8-1 HYDRAULIC Tractor . ...... 8-27950
8-2 Draper Header 8-27950
90 8-3 Auger Header ............ CHASSIS 8-27950
9-1 9-2 9-3 9-4 9-0
Tractor . ... ... ..
8-27950 8-27950 8-27950 8-27950 8-27950
Draper Header . .......... ..
DugH 36 foot .........................
ea er
Air Conditioning and 'Heating
..................
Rac 8-28550
Issued 8-86
Printed in U.S.A.
3
TABLE OP CONTENTS
.Page l . . . . . . . . . .Page 2
BCTION
DRSCRIPTION
. . . .2 . . s ELRCTRICAL STSTRMS.. . . . . .
. . . . . . , . . . . . . . .4 STEERING . . . .
. . . . . . . . . . . . . . . . . . . . . .5 . 6
HYDRAULICS. . . . . . . . . . . . . . . . .
4
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5
SAPETY
IMPORTANT SAPRTY NOTICR
Appropriate service and repair procedures are
essential for safe, reliable machine operation
and the safety of individuals doing the
work. There are various tools, techniques and
procedures for serv- icing machines. This manual
cannot possibly anticipate all varia- tions and
provide cautions or warnings as to each. This
product has been designed with built-in safety
features, however one has not been included TRR
INDIVIDUAL'S SAPRTY HABITS.
CAUTION This notation indicates a potential
hazard and will appear whenever a potentially
dangerous procedure ia being described.
6
SAPRTY SAFETY REMINDERS
l. Avoid fire, do not refuel hot or running
engines.
Extinguish all
tobacco products while refueling. Do not start
engine immediate- ly, if fuel has been spilled on
or near it.

• Carry a fire extinguisher and first-aid kit on
  the swather.
• Keep parking brakes, steering linkages and
  hydraulic systems in
• proper ad j us I.men t. .
• De extra careful when operating swather on
  slopes, rough ground or near ditches and
  embankments.
• Reduce speed when driving tractor with header
  removed. Tractor is more difficult to control
  with header removed, as weight is shifted off the
  drive/steering wheels.
• Oil, grease and service equipment before
  starting engine, not while engine is running.
• If removing pressurized radiator cap when engine
  hot, use protec- tion for the hands and turn cap
  to vent stop. Let all steam and pressure escape,
  then completely remove cap.
• When operating or towing on public roads, observe
  all traffic regulations, and identify equipment
  with the S.M.V. symbol.

5.
9. Put all controls in neutral before starting
the engine. Never
attempt to operate the swather unless you are on
the operator's

• platform.
• Never attempt to start engine by by-passing the
  neutral start system. Always use only the
  ignition key on operator's platform to start
  engine.
• Keep all guards and shields in place.
• Reduce speed before making turns. Come to a
  complete stop before applying parking brakes.

lO.

1. Re sure all work areas are well ventilated.
2. Do not attempt to remove or replace belts when
   pulleys motion or engine is running.

are in

1. Do not carry passengers.
2. Do not mount or dismount when swather is in
   motion. 17.

Lower header attachment, and reel, and remove
ignition keys when leaving swather unattended.
18.
Do not attempt to work under equipment unless
adequate blocking
has been pro vi ded, and suppo r L props are
s ecured in pla ce
2
7
SECTION 2
ENGINES
RRV-ISSURD
TABLE OP CONTRNTS
SRCTION
DRSCRIPTION
PAGR
. 1-2
GAS ENGINE 2-2. . . . . . . . .GENERAL
SPECIPICATIONS. . . . . . . . . . 3 2-3. . . . .
. . . .TUNR-UP SPECIPICATIONS. . . . . . . .
3 2-4 ... ....BASZC EEGTNR ....... .... . .
4 4-16
2-5. . . . . . . .
CYLINDER HEAD, VALVES , TZMZEG CHAIN .
2-7. . . . . . . . .BLOCK, PISTONS, CONEBCTING
RODS . . . .19-23 2-8. . . . . . . . .CRANKS APT
MAIN JOURNALS/BRARI GS . . .24-26 2-9. . . . . .
. . .LUBRICATION SYSTRM. . . . . . . .
.27-32 .33-35 36-37 2-1 2 ........g'ROUBLEfSROO'T
'ING ............3a-39
8
SECTION 2
ENGINES
RSV-ISSUBD

• CYLINDER HEAD, VALVES AND TIMING CHAIN
• ROCKER ARM/SHAFT ASSEMBLY
• REMOVAL - PIGURE 3
• Shut off valve at fuel tank.
• Remove fuel line (A).
• Remove PCV hose (!3).
• Remove wiring harness (C), from retaining clips.

1. Remove valve cover (D), by removing 8 capscrews
   (E).
2. Un-fasten 7 capscrews to remove rocker arm/shaft
   assembly.

Fig.3

• INSTALLATION - PIGURR 4
• Position shaft assembly onto cylinder head so
  that the oil holes are on the bottom of the
  shaft.
• Install long retainer in center
  position. Install normal retainers between
  rocker arms so they seat flush on shaft, and
  not on extended bushing of rocxer arm.

TOP
E ROCKER SHAFT REAR BOLT
FRONT
ROCKER ARAA

• Install towards
• Install
• bolts.

rocker shaft rear bolt rear of engine. remaining
rocker shaft
SPACER

RETAINER
Fig.4
NOTR. TO PREVENT BENT PUSH RODS, TIGHTEN ALL
BOLTS SLOWLY AND EVEN- LY TO ALLOW TAPPRTS TO
LEAKDOWN. REPER TO TORQUE CHART.
- 5 -
9
SBC't'ION 2

• CYLINDER HEAD, VALVES AND TIMING CHAIN
• HYDRAULIC TAPPETS
• NOTE Before disassembling engine to correct a
  suspected tappet
• ooise, do the following.
• Using a reliable pressure gauge at the oil
  pressure sending unit,
• check that pressure reads 207/552 kPa (30/80
  psi).
• Check that engine oil level is at the correct
  mark on the dip- stick. Oil level "too high" or
  "too low" can cause noisy tappets.
• TAPPET REMOVAL - 1) Remove cylinder head cover
  and rocker arm/shaft assembly.
• NOTE. Pushrods, tappets, and internal tappet
  components are not interchangeable. It is
  advisable to work on one tappet at a time to
  avoid mixing of parts. If necessary. identify
  each component to ensure proper reassembly.
• 9'IGURfi 5 -

1. Slide tool through opening in cylinder head, and
   seat firmly into head of tappet body. Remove
   tappet assembly.
2. Remove plunger retaining spring clip and
   disassemble internal components from tappet body.

PLUHGER SPRIHG
PLUNGER CHKK RETAINER BALL SPRING CLlp PLUNGER

• CLEAN AND INSPECT
• t) Use a safe solvent to clean all tappet
  components until all carbon and varni sh has
  been
• r emoved.
• Inspect plunger and valve seat on end of plunger
  for wear, pitting, etc.
• If necessary, replace complete tappet assembly.

TAPPO BODY
RETAINER CHECK VALVE SPRING PLUNGER CAP
Fig.5
- 6 -
10
SECTION 2
RNGINBS

• CYLINDER HEAD, VALVES AND TIMING CHAIN
• HYDRAULIC TAPPETS (continued)
• PIGURR 6 - TAPPET LEAK - TEST
• If tappet is not obviously damag- ed, but faulty
  operation is sus- oected, check tappet for
  leakage.
• Remove cap from plunger, and plunger from tappet
  body.
• Fill tappet body with kero-
• sene and install plunger.
• Unseat check valve with a brass rod to permit
  complete installation of plunger. Replace cap.
• Hold tappet upright, and place in leakdown tool
  (A).
• Compress tool handle (B). If
• plunger collapses almost instant-

ly, disassemble tappet, clean, and re-test. 6) If
tappet still does not operate satisfactorily,
install a new tappet assembly.
Fig.8
PLUHGER RETAINER SPRING CLIP PLUHGER

• PIGURR 7 - 1) Reassemble hydraulic tappets as
  shown.
• Lubricate tappet with clean engine oil, and
  install with pushrod into original location.
• Install rocker arm/shaft assembly.

CHKK BALL
TAPPt B D
RETAINER CHECK VALVE SPRIHG PLUHGER CAP
Fig.7
7
11
SECTION 2
ENGINES
RRV-ISSURD
2-5 CYLINDER HEAD, VALVES AND TIMING CHAIN
2-5-2
MECHANICAL TAPPETS
NOTE IP ENGINR IS EQUIPPRD WITH MECHANICAL
TAPPRTS, ADJUST AS SROWN.
PIGURR 8 - TAPPET ADJUSTMENT ROTR To prevent
damage to tappet valve mechanism, DO NOT run
engine above idle speed until all tappets have
filled with oil. 1) Start engine and run at 800
R.P.M. until normal operating temperature is
obtained. Allow engine to run for a further 5
minutes.
2) With engine running, adjust tappets so that
intake valve clearance (A) is 0.25 mm (0.010
ins. and exhaust valve clearance is 0.51 mm.
(0.020 ins.).
Fig.8
8 -
12
SECTION 2
ENGINES
RRV-ISSURD

• CYLINDER MEAD, VALVES AND TIMING CHAIN
• 2 5-3 CYLINDER HEAD REMOVAL
• Drain engine coolant through radiator drain
  valve.
• Shut off valve at fuel tank.
• PIGURE 9 - 3) Remove fuel line (A).
• Remove PCV hose (S.
• Remove air bweather hose (C).
• Remove wiring harness (D) from retaining clips.
• Remove valve cover E) by removing 8 capscrews
  (F).
• 6) Unfasten 7 capscrews to re- move rocker
  arm/shaft assembly.

Fig.9

• DISCONNECT/REMOVE THL FOLLOWING
• All electrical terminals at cylinder hea3.
• Both heater hoses at cylinder
• head.
• Spark plug wires and spark plugs.
• NOTE Pull on plug wire at the connectors, NOT BY
  TRE WIFI
• Choke cable and throttle linkage at carburetor.
• Exhaust pipe.
• MANIFOLD REMOVAL
• PIGURR 10 - 1) Remove the intake/exhaust manifold
  and car- buretor as a complete assen ly by
  removing 13 nuts (A.
• - 9

13
RAGIARS
SBC7IOE 2
2-5 CYLINDER HEAD, VALVES AND TIMING
CHAIN 2-5-3 CYLINDER HEAD REMOVAL (continued)
REMOVAL Pigure 11 - 1) Remove 14 cylinder head
bolts. 2) Separate cylinder head from engine
block. CAUTION CYLINDER RRAD WRIGBS IN RX-
CRSS OP 60 LBS.I USE ADRQDATE
LIPTIEG DRVICE. PAILURR TO DO
so sxx sesozz im essoxxn zxmuRY.
Flg.1 1

• CYLINDER HEAD INSPECTION/CLEANING
• Clean gasket surface with a
• scraper and soffi wire brush .
• Finish cleaning with a safe solvent. DO NOT
  DAMAGR GASKRT SURPACRS.
• Check block and head for cracks .
• 12 -
• Inspect cylinder head (A) and block for flatness
  by laying a straightedge (B) on the gasket
  surfaces. Measure any space that appears between
  the two with a feeler gauge.
• The allowable out of flat- ness tolerance is 0.23
  mm (.009 ins.) for a 305 mm (12 in.) length.
• If out of flat measurement exceeds tolerance,
  replace head or lightly machine the gasket
  surface.

Fig.12
10 -
14
SECTION 2 2-5 CYLINDER HEAD, VALVES AND TIMING
CHAIN
2-5-3 CYLINDER HEAD (continued) COOLANT PASSAGES
INTAKEVALVES
FRONT
OIL FEED HOLE
DOWEL HOLE
TAPER SEAT SPABK PLUG HOLES (6) DOWEL HOLE
COOLANT PASSAGES (6)
EXHAUST VALVES
BY-PASS TU8E

• INSTALLATION
• PIGURR 14 -
• l Carefully place new head gasket and cylinder
  head onto engine block.
• Secure with clean, lubricat-
• ed cylinder Lead bolts.
• Follow illustrated order, and tighten bolts to 47
  N.m (35 lb-ft).
• Repeat tightening sequence, and torque all bolts
  to 95 N.m (70 lb-ft).
• N0TE RRVRRSE ORDER OP CYLINDRR HRAD REMOVAL
  SECTION POR RRINSTALLATION OP ROCKRR
• ARM/SHAPT ASSEMBLY, AND MANIFOLD ASSRMBLY.
• - 11 -

15
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SRCTION 2
RRV-ISSURD

• 2-5 CYLINDER HEAD, VALVES AND TIMING CHAIN
• 2-5-4 VALVES AND SPRINGS
• PIGURR 15 - Cylinder head must be removed to
  perform valve service.
• NOTE REMOVR ANY BURRS FROM VALVE STEM LOCK
  GROOVES TO PRRVRNT DAMAGE WHEN REMOVING
  VALVES. IDENTIPY VALVRS TO RNSURR PROPER
  RAASSRMBLY.
• 1) Using valve spring compres- sion tool (A),
  compress spring and remove retaining locks,
  spring retainers, valve stem cup shields, valves
  and springs.
• VALVE INSPECTION
• Clean valves thoroughly and discard burned,
  valves.
• Measure valve stems for wear.

Fig.15
warped, or cracked
EOTR NRW INTAKR VALVR STEM DIAMETRR
9.448/9.474 mm (0.372/0.373 in.) NRW EXHAUST
VALVE STRM DIAMRTRR 9.423/9.448 mm
in.)

• (0.371/0.372
• IP WKAR EXCRRDS 0.050 mm (0.002 in.) REPLACE
  VALVE.
• VALVE GUIDE INSPECTION
• Remve all carbon and varnish deposits from inside
  valve guides.
• PIGURE 16 - Using a dial- indicator (A), check
  valve stem guide clearance.
• Guide clearance for intake valve 0.025/0.076
  mm (.0Ol/
• .003 in.) MAXIMUM.
• 3) Guide clearance for exhaust valve
  0.051/0.102 mm (.002/
• .004 in) MAXIMUM.
• 4) If dial-indicator reading is excessive, ream
  valve guides for oversized valve stems.
• 12

Fig.16
17
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