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Case 188D Engine Service Manual

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Case 188D Engine Service Manual JJ..II.. CCaassee Service Manual 188 Diesel Engine 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 FUEL INJECTION 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 Crankcase Dilution, Diesel Fuel 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 " ..~ c., e-,' ~ .'., " 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, PISTON, AND CYLINDER SLEEVES Piston & Connecting Rod Removal .............................; ...•.•... d:- 94 Piston Ring 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
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