JJ..II.. CCaassee Service Manual 188 Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF J.I. CASE OR IT’S SUCCESSORS. J.I. CASE AND IT’S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CA-S-ENG 188D GROUP C - ENGINE AND SYSTEM r SECTION I - SPECIFICATIONS Contents of Engine Group ...... C- 5 General Specifications ...... C- ,6 Torque Wrench Recommendations .. C- 9

SECTION II-SERVICE SUGGESTIONS AND TROUBLE SHOOTING CHART

Trouble Shooting Chart ...... C- 10 Starting Motor Will Not Turn Engine ...... c- 12 Slow Starting Motor Speed ...... C- 13 Low Compression ...... C- 14 Lack of Power...... C- 15 Overheating ...... C- 16 Coolant Loss...... '" ...... C- 16 Excessive Exhaust Smoke ...... C- 18 Sticking Valves ...... C- 18 Burned Valves and Seats ...... C- 19 Excessive Fuel Consumption ...... C- 20 Excessive Oil Consumption ...... C- 21 Low Oil Pressure Gage Reading ...... C- 22 Premature Main and Connecting Rod Bearing Wear ...... •...... C- 22 Dilution, in Crankcase Oil ...... C- 23 Water, Sludge, in Crankcase Oil ...... C..; 23 Ammeter Indicates Continuous Discharge ...... C- 24 Engine Knocks and Noises ...... C- 25 Excessive Engine Vibration...... C~ 25 Detonation or "Pinging" ...... C- 26 : •. J'

,~ . () SECTION III - FUEL FILTERING SYSTEM AND FUEL FILTER

Fuel Flow Diagram ...... ~ ...... C- 27 Locating Fuel Leaks...... C- 28 Locating Air Leaks ...... C- 29 High Pressure Lines ...... C-:' 29 Bleeding Fuel System ...... c- 30 Determining When Fuel Filter is Plugged ...... C- 31 Cleaning Fuel Tank ...... ',", . '. ,: ...... C- 32 Removing Fuel Filter Assembly From Tank ...... '.: .'.... ' .. C- 33 Replacing Fuel Filter Assembly...... C- 34 Instructions for Replacing Fuel Filter Element ...... C": 34

SECTION IV - FUEL INJECTION PUMP AND TIMING ~'f:/ ... Timing Injection Pump to Engine ...... of C- 35 Removing and Replacing Fuel Injection Pump . '.' . . . . .,·f ...... "...... ' C- 38 ,;," Levers on Injection Pump ...... C- 41

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RI·Form 9-92381 Printea'~j,U.S.A. C-l · ,~.

GROUP·C ENGINE AND FUEL INJECTION SYSTEM

SECTION V - FUEL INJECTORS

Operating Principles ...... •....•...... •.•..... ~ ...... C- 42 Isolating Faulty Injector ...... • ...... C- 43 Removing Injectors ...... •...... ,...... C- 43 Installing Injectors...... C- 44 Nozzle Test Stand ...... ;" ...... ; ...... •. C- 45 Testing Injector on Nozzle Test Stand ...... • . • . • ...... • ...... • .. C- 46 Injectors Which Test Satisfactory...... • ...... • • ...... C- 49 Trouble Shooting Chart on Testing and Correction of Faulty Nozzles ...... C- 50 Disassembly of Injector ...... C- 51 Removing Nozzle Assembly and Servicing ...... C- 52 Injectors That Have Been Serviced ...•...... C- 56 Cleaning Nozzle Holder •...... •...... C- 56

S·ECTION VI - CYLINDER HEAD ASSEMBLY

Rocker Arm Disassembly and Inspection • ...... • . • ...... • • . . . . . C- 58 Reassembly and Installation. . . • ...... • ...... C- 59 Valve Cover Removal and Installation ...... •...... C- 60 Removing Nozzle Liners From Cylinder Head ...... , .... . C- 6'1 Installing Nozzle Liners ...... • ...... C- 62 Cylinder Head Removal ...... •...... ••..... , •...... C- 63 Radiator - Exploded View ...... • ...... •. ~{,? • • • • • C- 64 Servicing Valves and Valve Seats ...... C- 6.5 Removing Valves From Cylinder Head ...... •...... C-. 66 i). Measuring Valve Stem ...... _...... C- 67 \" ' ... ;;. Checking Valve Face Runout ...... •...... •...... C- 68 Diagnosing Valve Problems by Observing Valves Removed ...... C- 69 Servicing Valve Seats in Cylinder Head ...... C- 70 Installing Valve Seats ...... ' ... . C- 71 Checking Valve Seat Runout ...... C- 72 Grinding Intake Valve Seats ...... •...... •...... •. C- 73 Valve Springs ..•...... ' ...... •...... •.. C- 74 Servicing Valve Guides .....' ...... •...... •...... •..••.••...... C- 75 Removing and Installing Valve Guides ...... •.....•.•..•...... C- 76 Reaming Valve Guides ...... C- 77 Welch Plugs ...... C- 77 Reassembly of Cylinder Head ...... C- 77 Installing Dowel Rings in Cylinder Head ...... •...... C- 78 Tightening Cylinder Head Nuts •...... •...... ' ....•.....•...... • C- 78 Adjusting Tappets. . ...•...... •.... -•...... C- 79 In.stalling Injectors ...... •..•.•...•...•.•••...... ••••...... C- 80 Intake and Exhaust Manifold - Exploded View ...... • ...... • • ...... C- 80

".~'.

C-2 GROUP C - ENGINE AND FUEL INJECTION ·SYSTEM

~ SECTION VII - ENGINE LUBRICATING SYSTEM . .--;:;;$' Oil Flow Diagram ...... •...... , .. C- 82 Oil Pan Removal & Installation...... • ...... C- 83 Engine Oil Pump ...... ~ ...... • ...... • . . . . • ...... C- 83 Removing Oil Pump ...... '...... " C- 84 Installing Oil Pump ...... • ...... C- 85 Oil Filter ...... C- 86 Crankcase Breather ...... • . • ...... C- 87

SECTION VIII - WATER PUMP AND COOLING SYSTEM

Removing. Water Pump ...... C- 87 Water Pump Re-assembly ...... • . . • ...... C- 88 Radiator - Exploded View ...... • . . . . • ...... C- 90 Cleaning Cooling System ...... C- 90 Pressure Radiator Cap...... C- 90 Thermostat ...... •...... C- 91 Testing Thermostat ...... •...... C- 91 Radiator Anti-freeze ...... •...... C- 92 Fan Belt Adjustment...... C- 92

SECTION IX - ENGINE RUN-IN PROCEDURE

Recommendations on Running Engine In ...... C- 92

SECTION X - CHECKING CYLINDER COMPRESSION

Proceedure on Checking Compression ...... _ ...... C- 93 Determining Where Compression Loss is Occurring ...... C- 94

SECTION XI - CONNECTING RODS, , AND CYLINDER SLEEVES

Piston & Connecting Rod Removal ...... ; ...•.•... d:- 94 Specifications .. , ...... C- 95 Installing Replacement Piston Rings ...... C- 96 Removing & Installing Piston Pins...... • ...... C- 98 . Piston Pin Bushing ...... C-99 Connecting Rods & Bearing Liners ...... C-lOO Cylinder Sleeves - Servicing ...... ; ...... <: ...... C-102 Cylindsr Sleeve Removal & Installation ...... ' .. C-104

.~~ ... C-3 GROUP C - ENGINE AND FUEL INJECTION SYSTEM

SECTION XII - CRANKSHAFT AND MAIN BEARINGS

Removing Bearing Liners ...... C-106 Inspecting Bearing Liners ...... C-I06 Checking Main Bearing Clearance ...... C-108 Crankshaft Assembly - Exploded View...... C-109 Crankshaft Endplay ...... C-IIO Crankshaft Removal ...... C-IIO Pulling Crankshaft Gear ...... C-lll Checking Crankshaft Runout ...... C-lll

SECTION XIII - CAMSHAFT

Camshaft Assembly - Exploded View ...... C-1l3 Pulling Camshaft Gear ...... C-1l3 Removing Camshaft ...... C-114 Camshaft Bushings...... C-115 Installing Camshaft Gear ...... C-1l6

SECTION XIV - TIMING GEAR COVER

Installing Crankshaft Pulley Oil Seal ...... C-117 Installing Timing Gear Cover ...... C-1l7

SECTION XV - TIMING GEAR TRAIN AND INJECTION PUMP DRIVE

Exploded View - Timing Gear Cover & Injection Pump Drive ...... C-1l8 Injection Pump Drive - Idler Gear ...... C-1l9 Installing Drive Gear Journal ...... C-1l9 Checking Timing Gear Backlash ...... C-120

SECTION XVI - CRANKSHAFT PILOT BUSHING AND REAR OIL SEAL

Removing Pilot Bushing ...... , C-12l Installing Crankshaft Rear Oil Seal ...... C-12l

SECTION XVII - AIR CLEANER AND THROTTLE

Servicing Air Cleaner ...... C-122 Foot Throttle Assembly ...... C-123

SECTION XVIII - ELECTRICAL AND HEAT PLUGS

Wiring Diagram...... C-124 Batteries ...... C-125 Heat Plugs ...... ' C-126 Ether Injector ...... C-126 Trouble Shooting Chart - Heat Plugs ...... C-127

SECTION XIX - AUTHORIZED SERVICE STATION DIRECTORY

Authorized C.A. V. Service Stations ...... '...... C-128 Authorized Roosa-Master Sales & Service Stations ...... C-13l

C-4 GROUP C ENGINE AND FUEL INJECTION SYSTEM CONTENTS OF ENGINE GROUP

CASE 188 CU. IN. DIESEL ENGINE

SECTION I GENERAL SECTION 10n SPECIFICATIONS WATER PUMP 8 COOLING SYSTEM SECTION n SERVICE SUGGESTIONS 8 TROUBLE SHOOTING CHART

SECTION m FUEL FILTERING SYSTEM 8 FUEL FILTER

SECTION IX ENGINE RUN-IN PROCEEDURE

SECTION x:sm AIR CLEANER 8 THROTTLE ASSEMBLY

SECTION Dr FUEL INJECTION PUMP 8 TIMING

SECTION n SECTION XlZI TIMING GEAR PRANKSHAFT PILOT BUSHING TRAIN 8 INJECTION 8 REAR OIL SEAL - PUMP DRIVE

SECTION ~ ENGINE LUBRICATING SYSTEM

SECTION XlZm ELECTRICAL 8 HEAT PLUGS

SECTION n - CONNECTING RODS, PISTON; __--- 8 CYLINDER SLEEVES

_ SECTlON-:xnr TIMING GEAR COVER

SECTION xm CAMSHAFT - 8 PUSH ---~ ROD LIFTERS

/ SECTION xn CRANKSHAFT 8 MAIN B~ARINGS

c-s GROUP C ENGINE AND FUEL INJECTION SYSTEM SECTION ,I, GENERAL' ENGINE' SPECIFICATIONS ',. COOLING SYSTEM

Type of System .. : ...... Pressurized, Thermostat Controlled; Forced Circulation (Pump) Type

FUEL SYST~~': Fuel Injection System ';, "':. '.' . '"". Injection Pump...... Roosa-Master , Model DB, Single':ey1in~r, Opposed Plunger, Inlet Metering , Distributor Type. .... ' , -' . . Direction of Pump Rotation . . • . . • • ...... Counte~"Clockwise (as Viewed from Drive End) .. ., .. - Pump Mounting ...... -...... • ...... • . . . . Left Side of Engine Pump Drive...••...... -•...•...• Gear Driven from Pump Drive Idler Gear Injection Pump Drive Lubrication.... . • . _•...... Crankcase Oil, Through Timing Gear. Train Injection Pump Drive Shaft End Play" ...•..• Automatically Taken up by Spring Loaded Thrust Button in Front End of Pump Drive Shaft. Pump Timing to Engine (At end of injection) ...... •...... fP Degrees B.T.D.C. Timing Marks on Engine Flywheel. .•. 4cP B.T.D.q., to uP Past T.D.C. in One Degree IncrelnCfilti3 _

Fuel Injectors...... ' 0 • • 0 0 • • '. 0 • • • • • • • • : • • • • • 0 • C.A. V. Long Stem M:ulti-ho~~ Typ~

Fuel Transfer Pump .•.. ~ .. ; ...•.•.... 0 ••• Vane Type; Integral Part of Injection Pump

GOvernor ...•••.... 0 ••••••••••• 0 Mechanical, 'Fly Weight, Integral Part of Injection Pump'" Fuel Filter" .'

Fuel Tarik Air Breather. 0 •••• 0 • : ••• ; •••••••• 0 ••• 0 •••••• Vented Tank Filler Cap

Fuel.:'·Filter . 0 ••• Replaceable Sealed "Can" Type Filter Equipped with a Transparent Moisture Trap on Bottom of Filter Assembly.' " _

",F~l. T~ _Level Gage ... o •• 0 • : •••••••••• 0 0 ••• 0 •••••• Electric; FI~adng Type Cage .~ . . ",:' ' . .- .. 1· :.' .' . '. .~ . '. . . . '. . .

STARTING AND ~LIGHTING SYSTEM

-TyPe System; .... 0 •••• ~ 0 • '0 ••• 0 ••••• ; 0 ~ ••• 12 Volt Electrical SystemPQsitive Groun!i."';, " Bmeries~' •.. Two 6 Volt Batteries Connecte<;t in Series, Group I - 105 Amp. Hrs, @. 20 Hr. Rate··~ ;.~n.er~t.o.~. ;. .•• '.....•..• , ...... ~ .•• ~~ ..•. ' 12 Volt, 20 ~mI?"~ ~osit~yeGroundg~lar.it¥, '. Voltage' Regulator.•...... ••... ~ .: .•...• 12 Volt, 20 Amp.,·Mounteq 011 ~tee:r'ing'Post , .. ,.-. Starting Motor •••..' ...•. ' •.•• '••.•.. Sealed, 12 Volt '# I.SAE FI~ge Mounti.Dg. Const~~ ," '. Mesh Pinion when Starter SWltch is Engaged' . . ; _Headlights.· •.. ' ••..•••.•.•..•..•• ~' •••.••.•.••..•• 12 Volt, Sealed -Beam Unit 35 Watt , lfe.8:r Light (Q>mbination ~ed &. White)~, ••.•• ,-"",:.,~.;:. ,.:" i2Volt,Se~ed .' ;3S 'Watt i::\.: , ,', . ", "., ... ,." ',' ,- . .' '" '. ,12Volt, ,;J.Rear Light Bulb Size (Red Bulb)' ~ ....••••••.' ~~ .•••• '~ ~ .•• ~ • #1003', . Instrument Panel Light ...•.....•...•.•..• " •..•...• Three Bulbs - 12 . #57) Fuse •..••• .- ••...•...... •. '.•••••...... ••. 20 Amp.~ated on Inst:rument Panel Electrical Outlet Plug... . • ...... •.. • ...... • • . . . . It'V6it Located 4nCier Tool Box Heat Plugs (4) •.•••..•.•.•.•. ' ...•• ';'>"'~~" .. ~ ..• '.' . 450 Watt ea. In ;(p:t~ke Manifold \ .. ~ .' . ... -.'.:

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.. -.- ..... -'.

".. ~ " ...... - .~.:;., -. ". ~ , .- GROUP C ENGINE AND FUEL INJECTION SYSTEM

SECTION III, FUEL FILTERING SYSTEM·· AND. fUEL FIL

Suction or Low Pressure Line ,r If any of the low pressure lines are kinked or,~ system causes an air worn through they must be replaced. 'if normal supply of fuel from The connections on these lines can be repaired. the pump. As a result, the Disconnect the union nut and pull the line out of tl;1e' engipe may not start, or will be difficult to start and fitting body .. Remove the original bushing and insta.ll performance will be rough. Lack of power will usually a new one in the line. Fig. C-7, .~ be' noticeable. . The fuel system must be bleed of air if any of the following have occurred: 1. Engine runs out of fuel, either from no fuel . in. the tank or from neglecting to open fuel tank shut off valve. . 2. '--

Fig. C-7 FiHing and Union Nut Provided on Sudion and Low Pressure Fuel Lilies

Insert the line into the body until it bottoms on fitting shoulder. Fig. C-7. NOTE: When the union nut is tightened, the bushing may squeeze the tubing slightly. The small crease in the tubing will cause no difficulty. Do not discard a line for this reason. If leakage is encountered at any of the fittings, a thin coat of light, clean oil on the threads will aid in tightening and sealing these fittings,

CAUTION

When working on diesel fuel system: 1. Do not smoke or permit open flames near the area in which you are working. 2. If the system is leaking or if you drain any component of the fuel system indoors, catch the fuel in a metal container. Do not permit fuel to drain onto the floor. Diesel fuel will soak into wood or porous floor­ ing and thereby create a fire hazard that will last indefinitely. Fig. C-8 Bleeding Fuel System

C-30 GROUP C - ENGINE AND FUEL INJECTION SYSTEM

SECTION IV, FUEL INJECTION PUMP AND TIMING

Fig. C·24 . Using CD322 Sleeve Tool to I~sta" Seals on Pump Dri~e Shaft

8. After cover is removed pump drive gear and shaft INSTALLING FUEL INJECTION PUMp· may be pulled out the front of housing.

9. Remove jam nut from pump drive shaft and drive 1. Install pump dri.ve shaft into pump drive gear and shaft out of gear. secure with washer and jam nut. Tighten nut 35 to To replace the seals on pump drive shaft; a 40 ft. lbs. torque. Fig. C-26. special tool is provided for this purpose to prevent 2. Insert· shaft and gear into position on engine making damage to seals during assembly. sure punch mark on pump drive gear and camshaft . gear are in alignment with pointer on ·pump drive If pump drive shaft seals leak, there is a possibility of fuel leaking into crankcase, or engine idler gear. Fig. C-26. . oil into pump. The seals on drive shaft must be installed with lip of each seal pointing in opposite direction. Fig. C-25.

Fig. C·25 Seals Correctly Installed

You will note that the special tool is con­ Fig. C-26 Timing Marks on Camshaft Gear and Injection Pump Drive Siderably larger than pump drive shaft. This is to Gear Correctly Aligned aid in installation of the second seal installed on shaft. i~EAS:E PUMP ~.AF:t SEALTHO:ROUGHLY afO~~ lNS.TA:I,:i.:t.",.,' ?~fY1P Shaft must be stripped of all parts to make installation of seals. To install rear seal, with lip turned rear­ ward on shaft, insert front end of shaft into sleeve, then slide seal off sleeve into groove in shaft. Next put sleeve over rear end of shaft and slide seal into place. Fig. C-24. Fig. C·27 Grease on Pump Shaft Seals

C-39 GROUP C - ENGINE AND FUEL INJECTION SYSTEM

SECTION XI, CONNECTING RODS, PISTON AND CYLINDER SLEEVE

6. Before honing or deglazing sleeves plug bottom CYLINDER SLEEVE REMOVAL AND INSTALLATION of sleeves wi~h clean oil soaked rags to prevent abrasives and dirt from entering crankcase and 1. Cylinder sleeve can be easily removed by using dropping on crankshaft, resulting from the honing 3-13/16" adapter plate with sleeve puller as or deglazing operation. shown in Fig. C-200. The "Case" #TlOS sleeve puller fork and TlOSB sleeve puller bolt with a 7. Afterhonihg, or deglazing, wipe· as much ab­ 3-13/16" adapter' plate is being used to pull rasives from cylinder walls as possible, with a sleeve in Fig. C-200. You will notice that it is clean cloth. Next swab each sleeve with a light necessary to grind small amount of material off oil then again wipe completely clean. This is to both forks to the inside to permit clearance for remove· all grit, as this would result in excessive sleeve .. It is advisable to cover crankshaft and wear and damage to cylinder· walls, rings,· bearings to prevent sediment from entering , valves, and all other internal parts of bearings and oil passages. engine. Do not use or kerosene in an attempt to clean cylinder walls as it will not succeesfully clean grit ftom cylinder walls.

TI05 SLEEVE PULL FORK r ELECTRIC_-l.... DRILL

Fig. C·200 Pulling Cylinder Sleeve

2. After removing sleeve, discard the two "0" rings used on bottom of sleeve. Never attempt to use them the second time. 3. Clean inner surfaces of block which contact cyl­ inder sleeves. 4. If sleeve removed is to be replaced clean the out­ side surface thoroughly. Especially if there is any scale deposits on outside of sleeve. Scale acts as an insulator and prevents heat from being Fig. C·199 Deglazing Cylinder Sleeve dissipated from cylinders as intended.

C-104