Part of the Case Repair Manuals.
Within the hour you may be holding a pressure gauge on the loader control valve inlet, or jacking up a front wheel on a 480D or 480LL. This Case book, form 9-69260, covers the 188BD diesel, power shuttle, transaxle, brakes, steering, hydraulics, loader, three point hitch and backhoe.
Most jobs stall for want of one number. The wheel is back on and nobody knows the bolt torque. The bucket feels lazy and nobody knows what the relief valve should read. Those numbers are here, along with the test procedures behind them.
The table of contents splits the book into 9 numbered divisions, from General through Mounted Equipment/Chassis. Every section carries a 4-digit number such as 8002, so you can go straight to the one you need.
What's Inside This Case 480D, 480LL Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1-28 | Safety Rules, Service Manual Introduction, Torque Specifications, Maintenance Chart and Fluids and Lubricants, General Engine Specifications (188BD Diesel), Detailed Engine Specifications and Special Torques |
| Engine Diagnosis, Tune-Up and Stall Tests | 29-76 | Engine Diagnosis by Symptom (Fuel, External and Internal Problems), Engine Tune-Up, Torque Converter and Hydraulic Stall Tests |
| Engine Removal and Accessories | 77-136 | Engine Removal and Installation, Engine Accessories |
| Engine Overhaul | 137-250 | Cylinder Head, Valve Train and Camshaft; Cylinder Block, Sleeves, Pistons and Rods; Crankshaft, Main Bearings, Flywheel and Oil Seals |
| Oil Pump, Cooling and Lubrication | 251-278 | Oil Pump, Thermostat and Water Pump, Engine Lubrication |
| Fuel System | 279-340 | Fuel Filters, Roosa-Master Fuel Injection Pump, Fuel Injectors, Fuel Lines, Fuel Tank and Engine Controls |
| Electrical Troubleshooting and Wiring Diagrams | 341-368 | Troubleshooting Charts, Charging and Starting Circuit Tests, Wire Lists and Basic Wiring Diagram for Chassis |
| Battery, Starter, Alternator and Instruments | 369-434 | Battery Tests, Starter and Starter Solenoid, Alternator, Instrument Cluster and Instrument Panel |
| Steering | 435-492 | Steering Troubleshooting Chart, Steering Pump, Steering Control Valve, Steering Cylinders |
| Front Axle | 493-526 | Wheel Bearings, Tie Rods, Special Torques |
| Power Shuttle and Torque Converter | 527-610 | Power Shuttle Maintenance, Operation and Troubleshooting, Power Shuttle and Torque Converter Overhaul, Power Shuttle Controls |
| Transaxle and Drive Line | 611-698 | Transaxle Removal and Installation, Transaxle and Differential Lock, Drive Shaft, Wheels and Tires |
| Brakes | 699-734 | Brake Pedals and Linkage, Master Cylinder, Parking Brake, Self-Adjusting Differential Brakes |
| Hydraulic System Information and Tests | 735-804 | Specifications, Hydraulic Circuit Diagrams, Maintenance, Troubleshooting, Main Relief Valve, Neutral Pressure, Secondary Relief Valve Hand Pump Tests, Flowmeter Tests, Portable Filter |
| Hydraulic Pump and Loader Control Valve | 805-910 | Hydraulic Pump, Loader Control Valve, Pump Protection Valve and Quick Disconnect Couplings |
| Three Point Hitch Control Valve | 911-978 | Three Point Hitch Control Valve with 1, 4 or 5 Spools |
| Cylinders | 979-1000 | Hydraulic Cylinders, Loader Lift Cylinder, Loader Bucket Cylinder, Boom Cylinder, Dipper Cylinder, Torque of Steel Hydraulic Fittings |
| Backhoe and Stabilizer Control Valves, Boom Lock | 1001-1068 | Backhoe Control Valve, Stabilizer Control Valve, Boom Lock System |
| Loader and Three Point Hitch | 1069-1106 | Loader, Three Point Hitch, Replacement of Cutting Edge, Replacement of Tooth Shank, Adjustment of Antirollback, Three Point Hitch Frame |
| Cab, Canopy and Seats | 1107-1126 | Cab and ROPS Canopy, Seats, Seat Belts and Seat Supports |
| Backhoe | 1127-1192 | Backhoe Removal, Backhoe Installation, Pivot Bushings and Bearing Washer |
| Decals, Painting and Noise Control | 1193-1200 | Decals and Painting, Noise Control |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine, Case 188BD diesel | 188 Cubic Inches (3 081 cm3), 4 Cylinder, 4 Stroke Cycle, Valve-In-Head | p. 16 |
| Engine speeds (rated / no load governed / idle) | 2100 RPM rated; 2230 to 2270 RPM no load; 700 to 750 RPM idle | p. 16 |
| Valve tappet clearance (cold) | Exhaust 0.014 Inch (0.356 mm); Intake 0.012 Inch (0.305 mm) | p. 16 |
| Injection pump timing | Roosa-Master, 7 Degrees Before Top Center | p. 16 |
| Fuel tank | 23.5 gallons (89 litres) | p. 13 |
| Engine crankcase | 6 quarts (5.7 litres) without filter change; 7 quarts (6.6 litres) with filter change; Case HDM Oil | p. 13 |
| Hydraulic reservoir | 11 gallons (41 litres), Case TCH Fluid | p. 13 |
| Power shuttle transmission | 8 quarts (7.6 litres), Case TCH Fluid | p. 13 |
| Transaxle | 20 quarts (18.9 litres), Case FDL Final Drive Lube | p. 13 |
| Engine cooling system | 18 quarts (17 litres) with heater; 14 quarts (13.2 litres) without heater | p. 13 |
| Hydraulic pump output | 24 gpm at 1800 psi at 2000 rpm (91 L/min at 12 410 kPa at 2000 r/min) | p. 737 |
| Main relief valve | 2150 - 2250 psi (14824 - 15513 kPa) | p. 737 |
| Pump protection valve | 2550 - 2650 psi (17582 - 18271 kPa) | p. 737 |
| Three point hitch relief valve | 1750 - 1850 psi (12066 - 12755 kPa) | p. 737 |
| Torque converter stall speed | 1720 rpm | p. 74 |
| Hydraulic stall speed | 2100 rpm | p. 74 |
| Front wheel bolts | 115 - 130 pound-feet (156 - 176 N m) | p. 495 |
| Tie rod ball joint nuts | 100 - 120 pound-feet (135 - 162 N m) | p. 495 |
| Cylinder head bolts (Gr. 8, 12 pt. hd.) | 105 to 115 ft. lbs. | p. 27 |
| Main bearing cap bolts | 90 to 100 ft. lbs. | p. 27 |
Case 480D, 480LL Common Problems This Manual Covers
Machine will not move in either forward or reverse
Work down the power shuttle troubleshooting chart on page 537. It names a damaged torque converter, a damaged pressure regulator piston in the control valve spool, a broken regulator piston spring, low oil level and a worn charging pump. The shuttle holds 8 quarts (7.6 litres) of Case TCH Fluid.
Manual Section: Power shuttle and torque converter p. 537Hydraulic oil runs too hot during loader or backhoe work
The hydraulic troubleshooting list on page 758 covers this. It starts with the operator not moving the control levers all the way into the power position. Then it goes through neutral pressure, main relief valve setting, the O-ring on the power beyond fitting, secondary relief valve settings, oil contamination and a flowmeter test.
Manual Section: Hydraulic system information and tests p. 758Steering wheel turns hard or the machine will not turn
Use the steering troubleshooting chart on page 438. It lists low oil in the steering pump reservoir, a worn pump, a relief valve that is open, damaged or set too low, and restrictor fittings in the wrong turn ports. It also covers worn cylinder piston packing, low front tire pressure and worn control valve parts.
Manual Section: Steering p. 438Brake pedals still too far apart after adjustment
Pages 710-711 say that if the pedals are still too far apart after adjustment, the problem is probably in the self-adjusting mechanism of the transaxle brakes. The Brakes section covers the pedals and linkage, the master cylinder, the parking brake and the self-adjusting differential brakes, so you can follow the fault from the pedal back to the transaxle.
Manual Section: Brakes p. 710Frequently Asked Questions
What torque do the front wheel bolts take on a 480D or 480LL?
Front wheel bolts go to 115 - 130 pound-feet (156 - 176 N m). That figure is in the front axle special torques on page 495. The same page lists the tie rod ball joint nuts at 100 - 120 pound-feet (135 - 162 N m). The wheel bearing nut takes 75 - 85 pound-feet (101 - 115 N m) with the wheel turning, then you loosen it a maximum of 1/6 turn. p. 495
What pressure should the loader main relief valve read on a Case 480D, 480LL, and how do I check it?
The spec is 2150 - 2250 psi (14 824 - 15 513 kPa), listed on page 737. Put a pressure gauge on the fitting in the inlet of the loader control valve. Bring the oil to operating temperature and run the engine at full throttle. Hold the bucket control lever in Rollback and read the gauge. Pages 761-762 give separate adjustment procedures for Parker Hannifin and Gresen loader control valves. p. 737
The machine will not move, or it pulls weak in both directions. Where does the book point me?
The power shuttle troubleshooting chart on page 537 covers the no-drive case. It lists a damaged torque converter, a damaged pressure regulator piston or broken spring, low oil level and a worn charging pump. For weak drive, the stall tests on page 74 give a torque converter stall speed of 1720 rpm. Page 75 explains the readings: 600 - 700 rpm below spec means the one way clutch in the torque converter, and 200 - 300 rpm below spec means the problem is in the engine. p. 537
The loader and backhoe feel weak. How do I tell if the pump is starved for oil?
Flowmeter Test No. 1 on page 776 answers that. If pump output at 0 psi is 24 gpm (90.8 L/min) or more, there are no restriction problems between the reservoir and the pump. Page 737 rates the pump at 24 gpm at 1800 psi at 2000 rpm (91 L/min at 12 410 kPa at 2000 r/min). Having those flowmeter procedures in hand is reason enough to own the book. p. 776
Can I top up the brake master cylinder with regular brake fluid?
No. Page 13 says DO NOT use brake fluid in the brake system of this machine, because brake fluid will damage the brake system. The master cylinder takes Case TCH Fluid, the same fluid used in the hydraulic reservoir and the power shuttle. p. 13
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