1987 Case IH 1255/1255XL & 1455/1455XL Tractor Workshop Manual (P/N Don 8-59030)

This Case IH workshop manual covers the 1987 1255 and 1455 agricultural tractors, including the 1255XL and 1455XL. It combines five November 1987 service publications, beginning with Basic Engine, reference Don 8-59030.

• Engine repair: Cylinder-head reconditioning, valve-train service, crankshaft and piston/sleeve overhaul, lubrication and cooling-system repair, and engine testing.

• Fuel injection: Bosch EP/VA and VE pump overhaul, static timing, aneroid service, injector testing, and application-specific bench-calibration sheets.

• Turbochargers: AiResearch T-04/T-04B and KKK (Schwitzer) inspection, disassembly, bearing-clearance checks, repair, reassembly, and installation.

• Electrical equipment: Bosch generator, G1/K1 alternator, and JD/JF starter testing, troubleshooting, overhaul, and component circuit diagrams.

• Brakes and chassis: Hydraulic brake controls, front-wheel brake service, rear-brake removal, trailer-brake testing, and axle and propeller-shaft work.

• Clutches and controls: Turbo-clutch and dual-clutch repair, wear checks, release adjustments, and PTO, four-wheel-drive, and differential-lock linkages.

• Standard and XL cabs: Cab removal and installation, mounting alignment, glazing, and model-specific access procedures.

The material is suited to skilled tractor technicians with the precision measuring equipment and workshop facilities required for engine machining and injection-pump calibration.

Engine Overhaul and Diagnostic Testing

The 25-topic Basic Engine publication covers Neuss-built D-series naturally aspirated and DT-series turbocharged engines from D-155 through DT-402. Its four-cylinder balancer chapter is shared engine-family material; the listed tractors use six-cylinder turbocharged engines.

Internal repairs: Procedures include valve lever assembly overhaul, camshaft-bushing line boring, crankcase counterbore resurfacing, cylinder-head rework, and piston-to-cylinder-sleeve fitting. Crankshaft pulley, vibration damper, and flywheel service are covered alongside oil-pump, water-pump, thermostat, and manifold repairs.

Bolt-identification charts link fastener designs and grades to the appropriate torque tables. Dimensional references include the Oversize Valve Seat Insert Counterbore Chart and Valve Dimensional Chart. Longitudinal and cross-section engine views and timing-gear alignment illustrations support assembly checks.

Engine run-in schedules accompany compression, oil-pressure, boost, and crankcase testing. The Crankcase Pressure and Blow-by Chart includes guidance on interpreting readings alongside oil-consumption trends.

The DT-402 instructions flag the controlled-length No. 1 connecting rod: mixing up the rods can cause interference with the oil pump.

Injection-Pump Calibration and Turbocharger Service

Bosch EP/VA hydraulic-governor and VE centrifugal-governor pumps receive internal overhaul and adjustment coverage. The DT-358 tractor sheets identify VE6/12F 1100R 52; DT-402 sheets distinguish VE6/12F 1100R 47 without aneroid from VE6/12F 1100R 102 with aneroid. These separate sheets help match calibration data to the installed pump before bench testing.

Injector sections cover flange- and crab-mounted holders, opening-pressure checks, spray behavior, and nozzle-tip protrusion. Special-tool references include KDEP 2939 for protecting the VE pump shaft seal.

Turbocharger instructions address core overhaul and intake-system contamination after compressor failure. Retained debris can damage a replacement compressor wheel.

Bosch Electrical Diagnosis and Tractor Connections

The electrical publication provides mechanical and electrical test specifications for the covered charging and starting units. Circuit diagrams distinguish integral transistorized and separate mechanical alternator regulators.

Tractor-specific pages add instrument-panel, fuse-box, and central-distributor service with connector-identification tables. Full tractor wiring diagrams are referred to the respective operator's manual.

Clutches, Brakes, and Cab Variants

Brake procedures distinguish standard and XL hydraulic controls and their high-pressure and low-pressure pneumatic trailer-brake systems. Coverage includes bleeding, compressor service, leak testing, and parking-brake linkage.

Turbo-clutch instructions include a stall check, shaft-play measurement, and oil service. Dual-clutch procedures add release-lever adjustment and flywheel rework, supported by service-tool drawings. Tire-combination charts and propeller-shaft troubleshooting support chassis diagnosis.

Standard-cab procedures are in Chassis. The XL Control Center publication identifies these XL tractors as D-family; its B- and C-family cab-tilting and hydraulic procedures apply to other models.

Coverage limits: Transmission, hydrostatic-steering and hydraulic draft-control overhaul, plus internal rear-wheel-brake inspection and repair, are referred to separate publications.

The four-wheel-drive axle overhaul section is listed for later publication and is not included. The 1455 internal clutch-release bearing detail refers to a separate ZF manual.

Follow the manufacturer's support and lifting precautions for tractor splitting and cab removal, and its pressure-release precautions for brake and hydraulic work.

A Preview of Compression Limits and Turbo-Clutch Capacities

These figures are a small selection of the engine-test limits and clutch-fluid specifications in the manual.

For compression testing at engine operating temperature, repair is recommended below 1.8 MPa (255 psi), or when individual cylinder readings differ by more than 0.25 MPa (36 psi).

The turbo-clutch table lists initial fills of 8.8 + 0.1 liters for 1255/1255XL and 9.2 + 0.1 liters for 1455/1455XL, with DEXRON ATF specified.

Section Bookmarks and Diagram Detail

Reading and navigation: Embedded bookmarks link to the cover and five main publications; technical pages do not support PDF text search. Small circuit labels and connector-table entries require zooming. PDF p. 100 has heavy marks across parts of the injection-pump gear timing text.

One printable English-language PDF contains 641 pages total: Basic Engine, 105 pages; Fuel System and Turbochargers, 328; Electric Equipment, 48; XL Control Center, 58; Chassis, 101; and one additional cover page, already included in the total.