Service Manual. 188 Diesel Engine

J.I. Case 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

r SECTION GROUP C - I - SPECIFICATIONS Contents of Engine Group.... General Specifications.... Torque Wrench Recommendations.. SECTION II-SERVICE SUGGESTIONS AND TROUBLE SHOOTING CHART C- 5 C-,6 C- 9 () SECTION III - Trouble Shooting Chart.............................................. Starting Motor Will Not Turn Engine.... Slow Starting Motor Speed........................................ Low Compression.... Lack of Power.......................... Overheating........ Coolant Loss..... '".... Excessive Exhaust Smoke.... Sticking Valves.... Burned Valves and Seats.... Excessive Fuel Consumption.... Excessive Oil Consumption.... Low Oil Pressure Gage Reading.... Premature Main and Connecting Rod Bearing Wear...... Crankcase Dilution, Diesel Fuel in Crankcase Oil.... Water, Sludge, in Crankcase Oil.... Ammeter Indicates Continuous Discharge.... Engine Knocks and Noises.... Excessive Engine Vibration.......... Detonation or "Pinging".... FUEL FILTERING SYSTEM AND FUEL FILTER Fuel Flow Diagram... ~.... Locating Fuel Leaks.................... Locating Air Leaks............................................ High Pressure Lines.... Bleeding Fuel System.... Determining When Fuel Filter is Plugged.... Cleaning Fuel Tank... ',",. '.,:.... Removing Fuel Filter Assembly From Tank... '.:.'... '.. Replacing Fuel Filter Assembly................................. Instructions for Replacing Fuel Filter Element....,~. C- 10 c- 12 C- 13 C- 14 C- 15 C- 16 C- 16 C- 18 C- 18 C- 19 C- 20 C- 21 C- 22 C- 22 C- 23 C..; 23 C- 24 C- 25 C~ 25 C- 26 C- 27 C- 28 C- 29 C-:' 29 c- 30 C- 31 C- 32 C- 33 C- 34 C": 34 :. J' 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 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............................ Reassembly and Installation........................................ Valve Cover Removal and Installation...... Removing Nozzle Liners From Cylinder Head...,.... Installing Nozzle Liners............................................ Cylinder Head Removal.........,... Radiator - Exploded View................................. ~{,? Servicing Valves and Valve Seats.... Removing Valves From Cylinder Head...... Measuring Valve Stem... _...................... Checking Valve Face Runout......... Diagnosing Valve Problems by Observing Valves Removed.... Servicing Valve Seats in Cylinder Head.... Installing Valve Seats... '.... Checking Valve Seat Runout.... Grinding Intake Valve Seats.......... Valve Springs.....'........ Servicing Valve Guides...'............... Removing and Installing Valve Guides............ Reaming Valve Guides.... Welch Plugs.... Reassembly of Cylinder Head.... Installing Dowel Rings in Cylinder Head...... Tightening Cylinder Head Nuts...... '......... Adjusting Tappets........... -... In.stalling Injectors................... Intake and Exhaust Manifold - Exploded View........................... C- 58 C- 59 C- 60 C- 6'1 C- 62 C- 63 C- 64 C- 6.5 C-. 66 C- 67 C- 68 C- 69 C- 70 C- 71 C- 72 C- 73 C- 74 C- 75 C- 76 C- 77 C- 77 C- 77 C- 78 C- 78 C- 79 C- 80 C- 80 i). \" '... ;;. ".~'. 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 - 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...... Batteries.... Heat Plugs... ' Ether Injector.... Trouble Shooting Chart - Heat Plugs.... C-124 C-125 C-126 C-126 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 CONTENTS OF ENGINE GROUP CASE 188 CU. IN. DIESEL ENGINE SECTION 10n WATER PUMP 8 COOLING SYSTEM SECTION I GENERAL SPECIFICATIONS SECTION n SERVICE SUGGESTIONS 8 TROUBLE SHOOTING CHART SECTION m FUEL FILTERING SYSTEM 8 FUEL FILTER SECTION IX ENGINE RUN-IN PROCEEDURE x:sm SECTION AIR CLEANER 8 THROTTLE ASSEMBLY SECTION Dr FUEL INJECTION PUMP 8 TIMING SECTION n TIMING GEAR TRAIN 8 INJECTION - PUMP DRIVE SECTION XlZI PRANKSHAFT PILOT BUSHING 8 REAR OIL SEAL 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 SECTION,I, GENERAL' ENGINE' SPECIFICATIONS COOLING SYSTEM ',. Type of System.. :... Pressurized, Thermostat Controlled; Forced Circulation (Pump) Type <Hump..,. ",...................'.................... Impeller Vane" Type Radi~tbr'~.......... '... Heavy Duty Fin and Tube Type Teniperature Control... Butterfly Type Thermostat; Starts to Open at 17'P to 182 0 F. Fully Open at 2020'," <. c,,. Cooling System Capacity (Gallons)... ;... <'-. U. S. 4.2 Imperial... 3.5 Hose Specifications, Radiator to Water Pump'.... 2" Inside Diameter, 23/8" Outside Diameter, 47/8" Long Radiator Inlet Hose... "... 1 3/4" I. D. 2 1/8" 9. D. 2 1/2" Long Radiator Fan..... ~........ ~... ;~.. 4 Blades;' 18 Inch Diameter 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 ~ ~ 12 Volt Electrical SystemPQsitive Groun!i."';, 0 '0 0 ; 0 Bmeries~' Connecte<;t @. Rate ~ ".. Two 6 Volt Batteries in Series, Group I - 105 Amp. Hrs, 20 Hr. ;.~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.. ~.'... -.'.:. \ '. ~. "of:.. -.-... -'. ". ~ ".. ~.~.:;., -.,.- "... -

GROUP C SECTION III, FUEL FILTERING SYSTEM AND. fuel FIL Suction or Low Pressure Line,r If any of the low pressure lines are kinked or,~ if worn through they must be replaced. ' The connections on these lines can be repaired. Disconnect the union nut and pull the line out of tl;1e' fitting body.. Remove the original bushing and insta.ll a new one in the line. Fig. C-7,.~ system causes an air normal supply of fuel from the pump. As a result, the engipe may not start, or will be difficult to start and performance will be rough. Lack of power will usually 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. '--<If any component of the fuel systemhas been removed for service or repairs. 3. If engine has been in storage for a considerable period of time. To bleed the fuel.system open the vent screw located just above fuel filter u{:i4er the fuel tank. Fig. C-B. Make sure fuel shut...;of#alve is in the open position, if not, it will make :it impossible to bleed system as no fuel would enter filter forcing air out. NOTE: If the fuel injection pump has been removed it may be necessary to loosen the fuel line at pump inlet until fuel has forced all the air out of the line. 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 flooring and thereby create a fire hazard that will last indefinitely. Fig. C-8 Bleeding Fuel System C-30

GROUP C - 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 may be pulled out the front of housing. 9. Remove jam nut from pump drive shaft and drive shaft out of gear. To replace the seals on pump drive shaft; a special tool is provided for this purpose to prevent damage to seals during assembly. If pump drive shaft seals leak, there is a possibility of fuel leaking into crankcase, or engine oil into pump. The seals on drive shaft must be installed with lip of each seal pointing in opposite direction. Fig. C-25. INSTALLING FUEL INJECTION PUMp 1. Install pump dri.ve shaft into pump drive gear and secure with washer and jam nut. Tighten nut 35 to 40 ft. lbs. torque. Fig. C-26. 2. Insert shaft and gear into position on engine making sure punch mark on pump drive gear and camshaft. gear are in alignment with pointer on pump drive idler gear. Fig. C-26.. Fig. C 25 Seals Correctly Installed You will note that the special tool is con Siderably larger than pump drive shaft. This is to aid in installation of the second seal installed on shaft. Shaft must be stripped of all parts to make installation of seals. To install rear seal, with lip turned rearward 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-26 Timing Marks on Camshaft Gear and Injection Pump Drive Gear Correctly Aligned i~eas:e PUMP ~.AF:t SEALTHO:ROUGHLY afo~~ lns.ta:i,:i.:t.",.,'?~fy1p Fig. C 27 Grease on Pump Shaft Seals C-39

GROUP C - SECTION XI, CONNECTING RODS, PISTON AND CYLINDER SLEEVE 6. 7. Before honing or deglazing sleeves plug bottom of sleeves wi~h clean oil soaked rags to prevent abrasives and dirt from entering crankcase and dropping on crankshaft, resulting from the honing or deglazing operation. Afterhonihg, or deglazing, wipe as much abrasives from cylinder walls as possible, with a clean cloth. Next swab each sleeve with a light oil then again wipe completely clean. This is to remove all grit, as this would result in excessive wear and damage to cylinder walls, rings, pistons, valves, and all other internal parts of engine. Do not use gasoline or kerosene in an attempt to clean cylinder walls as it will not succeesfully clean grit ftom cylinder walls. CYLINDER SLEEVE REMOVAL AND INSTALLATION 1. Cylinder sleeve can be easily removed by using 3-13/16" adapter plate with sleeve puller as shown in Fig. C-200. The "Case" #TlOS sleeve puller fork and TlOSB sleeve puller bolt with a 3-13/16" adapter' plate is being used to pull sleeve in Fig. C-200. You will notice that it is necessary to grind small amount of material off both forks to the inside to permit clearance for sleeve.. It is advisable to cover crankshaft and bearings to prevent sediment from entering bearings and oil passages. r ELECTRIC_-l... DRILL TI05 SLEEVE PULL FORK Fig. C 200 Pulling Cylinder Sleeve Fig. C 199 Deglazing 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 cylinder sleeves. 4. If sleeve removed is to be replaced clean the outside surface thoroughly. Especially if there is any scale deposits on outside of sleeve. Scale acts as an insulator and prevents heat from being dissipated from cylinders as intended. C-104