Part of the Case Repair Manuals.
Case issued this book as Rac 8-97121, the factory service manual for the 8840 self propelled windrower, and this Case 8840 service manual PDF reproduces all 850 pages of it. Hydrostatic ground drive gets the deepest coverage: schematics trace oil from the charge pump through the tandem pump to the drive motors, backed by pressure tests and troubleshooting for the two speed control valve. Full electrical schematics support the instrument and troubleshooting sections, while the header lift and flotation valve, guard angle valve, and bypass valve each carry their own teardown and adjustment procedures. Before you condemn the hydrostatic pump, check inductive sensor resistance against the 3.1 to 3.2 k ohm spec, and pull wheel nuts to 200 lb-ft (271 N-m). A down windrower in cutting season stalls on one missing pressure number. This bookmarked, text searchable file rides on your laptop or phone to whichever field the machine quit in.
What's Inside This Case 8840 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 3-38 | Introduction, Safety Rules, General Machine Specifications, And Standard Torque Specifications, Maintenance and Lubrication, Decals, Specification Details |
| Engine | 39-260 | Engine Removal and Installation and Radiator Removal and Installation, Engine Accessories, Cylinder Head and Valve Train, Cylinder Block, Lubrication System, Cooling System |
| Fuel System | 261-316 | Fuel System and Engine Controls, Fuel System and Filters, Fuel Injectors, Bosch Fuel Injection |
| Electrical System | 317-358 | Removal and Installation of Electrical Components, Specifications, Instruments, Schematics, Troubleshooting |
| Steering | 359-386 | Removal and Installation of Steering Components, Steering Control Linkage Troubleshooting and Adjustments |
| Power Train | 387-526 | Ground Drive Hydraulic System Specifications, Charge Pump, Tandem Pump, Drive Motors, Two Speed Control Valve and Two Speed Cylinder, Drive Controls, Drive Shafts, Chain Cases |
| Brakes | 527-534 | Parking Brake |
| Hydraulic System | 535-664 | Hydraulic System Specifications, Cleaning the Hydraulic System, Header Drive Pump, Header Drive Motor, Header Lift and Flotation Valve, Guard Angle Control Valve, And Bypass Valve |
| Chassis | 665-850 | Removal and Installation of Air Conditioning Components, Air Conditioning Troubleshooting and System Checks, Air Conditioning System, Cab, Header |
Every system also includes an index.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Wheel nuts torque | 200 LB-FT (271 N-m) | p. 14 |
| Wheel bolt torque | 110 to 130 LB-FT (149 to 176 N-m) | p. 14 |
| Battery, minimum cranking capacity at 0°F | Two 12 V, 450 amp | p. 14 |
| Voltmeter reading variance | 1/2 volt | p. 354 |
| Inductive sensor resistance | 3.1 to 3.2 k ohms | p. 356 |
| Charge Pump Total Output | 14.5 gpm (54.9 L/min) | p. 416 |
| Spool movement clearance | 3/16 IN (4.8 mm) | p. 611 |
| Main System Relief Pressure | 5000 psi | p. 14 |
| Header Lift Relief Pressure | 2000 psi | p. 15 |
| Engine High Idle | 2500 rpm | p. 14 |
| Wheel Nut Torque (Drive Wheels) | 200 LB-FT | p. 14 |
| Wheel Nut Torque (Rear Caster Wheels) | 110 to 130 LB-FT | p. 14 |
Case 8840 Common Problems This Manual Covers
Case 8840 header will not lower after machine warms up, works fine cold
Check the header lift and flotation valve before replacing sensors. Verify the spool moves its full 3/16 IN (4.8 mm) travel per page 611; a spool that hangs up hot but moves free cold points to varnish or a scored bore. Confirm circuit relief pressure holds 2000 psi (13 790 kPa), then clean or replace the sticking valve section.
Manual Section: Header Lift and Flotation Troubleshooting p. 611Engine cranks slowly and header controls act up when batteries run down
Test both batteries before chasing wiring; the machine needs two 12 volt, 450 amp batteries at 0°F cranking capacity per the specs on page 14. Load test each one separately, clean and tighten the ground cables, then check that the voltmeter reads within 1/2 volt of a known good meter, covered on page 354.
Manual Section: Electrical System Troubleshooting p. 354Hydrostatic drive loses power and runs hot after a few hours mowing
Check charge pressure first; you need 100 psi (1034 kPa) minimum at the tandem pump per the specs on page 549. Test charge pump output next, which should hit 14.5 gpm (54.9 L/min) on page 416. Low flow means a worn charge pump; when reinstalling, torque the cap screws to 54 to 66 LB-FT (73 to 89 N-m).
Manual Section: Ground Drive Hydraulic System Troubleshooting p. 549Header raises slowly or lifts one side first, flotation feels spongy over rough ground
Verify header lift relief pressure at 2000 psi (13 790 kPa), listed on page 15. Check the accumulator next; a spongy or uneven lift usually means the nitrogen charge has bled below its 700 psi (4827 kPa) setting shown on page 549. Recharge or replace the accumulator, then inspect the lift cylinders for internal bypass.
Manual Section: Header Lift and Flotation Troubleshooting p. 15Swaybar pivot loosens up and knocks, header wanders side to side in the field
Inspect the swaybar spacer assembly and pivot plates for wear before anything else. Replace worn spacers, lubricate the pivot bolt threads, and torque the pivot bolt to 200 LB-FT (271 N-m) per page 757. If the pivot plates attach with countersunk cap screws, tighten those to 100 LB-FT (136 N-m) shown on page 761.
Manual Section: Chassis p. 757Frequently Asked Questions
What are the torque specifications for Grade 5 bolts on the Case 8840?
The torque specifications for Grade 5 bolts vary by size and thread type. For example, a 1/4-20 bolt requires 8.4 LB-FT (11 N-m), while a 1/2-13 bolt requires 76 LB-FT (105 N-m). p. 17
What is the correct engine oil capacity for the Case 8840?
The engine oil capacity for the Case 8840 is 12 U.S. quarts (10.4 L). p. 14
What is the procedure for bleeding air from the fuel system on the 4T-390 engine?
To bleed the fuel system, loosen the vent screw on the filter head one to two turns and operate the hand primer pump until fuel with no air flows from around the vent screw. Then, tighten the vent screw and operate the hand primer pump until fuel flows from the banjo fitting on the injection pump. p. 52
What is the correct valve clearance for the intake and exhaust valves on the 4T-390 engine?
The intake valve clearance (cold) is 0.254 mm, and the exhaust valve clearance (cold) is 0.508 mm. p. 34
What is the connecting rod bolt torque spec for the 4T-390 engine in the Case 8840 windrower?
The connecting rod bolts must be tightened to 95 to 100 Nm, and the threads must be lubricated with engine oil. p. 36
What format is this Case 8840 manual in?
This is a 850-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print a copy of this Case 8840 Service Manual for the shop?
Yes, printing is unrestricted: a single page, a chapter, or the lot, on letter or A4.
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