Case 750 Crawler Section E,h,i 4mm Service Manual

750 Crawler Section E,H, I, 4MM Service Manual 9-72151A

IReprinted I

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THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULL Y READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEA TH. M171B

If Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows: •

DANGER: Indicates an immediate hazardous situation which if not avoided, will result in death or serious injury. The color associated with Danger is RED.

•

WARNING: Indicates an potentially hazardous situation which if not avoided, will result in serious injury. The color associated with Warning is ORANGE .

•

CAUTION: Indicates an potentially hazardous situation which if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

If Safety Decals on this machine are ISO two panel Pictorial , decals are defined as follows: The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW. ' " Prohibition symbols such as and if used, are RED.

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WARNING

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH . BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: •

Is instructed in safe and proper use of the machine.

•

Reads and understands the Manual(s) pertaining to the machine.

•

Reads and understands ALL Safety Decals on the machine.

•

Clears the area of other persons.

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Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow Case Corporation instructions on machine operation and maintenance.

© 2001 Case Corporation

Bur 0-00000 issued November, 1994

CASE and IH are registered trademarks of Case Corporation

SECTION

E SERVICE SUGGESTIONS

BurL Form 9·121!n

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TABLE OF CONTENTS

Engine Will Not Start or is Difficult to Start ------------------------------------------ E-3 thru

E-8

Lack of Power ------------------------------------------------------- E-9 thm E-21 Smoke

From E~ne Exbaust ---------------------------------------- E-22 thruE-28

Excessive Fuel Consumption ----------------------------------------- E-29 tb.lru E-30 Excessive Oil Consumption ------------------------------------------- E-31 thm E-36 Contamination in the Crankcase Oil --------------------------------- E-37 thru E-40 Engine Will Not Stop When Fuel Is Shut ~ ---------------------------------------------------------- E-40 Generator ----------------------------------------------------------------------E-41 Starting Motor --------------------------------------------------- E-4. E-5 Noise,

and E~41

Knocks and Vibration ---------------------------------------- E-42 thru E-47

Oil Leakage ------------------------------------------------------------------- E-47

E-2

ENGINE WILL NOT START Or Is Difficult To Start

Preliminary Diagnosis

Case Powrcel Diesel Engines are noted for their good starting characteristics. If an engine will not start, isolate the source of the difficulty by answering the follOwing questions:

1. ELECTRICAL STARTING SYSTEM

Is starter turning engine over at normal speed? (Engine requires a minimum of 100 RPM cranking speed to start.)

(If not. check electrical system, and engine for "drag.'~

2. CORRECT FUEL Is tank filled with fuel that me.e taCAse specifications?

Is ether starting fluid being used? (If weather is below freezing.)

3. FUEL INJECTION AND FILTERING SYSTEM

Does smoke or fuel vapor come out of exhaust pipe when engine is being cranked by starter?

(If it does not -- it is evident that no fuel is being injected.)

4. COMPRESSION

Does engine "skip over" on one or more cylinders while being cranked with starter?

Is oompression noticeably low on all cylinders?

(If engine can be started, use compression gauge from CD500 or CDSOO Tool Kit to check compression on eaoh cylinder.)

E-3

ENGINE WILL NOT START (Omtimlt!ti)

Engine Turns Over¡ But Will Not Start or is Hard to Start REMEDY

CAUSE 1. Throttle in either "ofr' or idle position. Especially true during cool weather and when engine is cold.)

1. For normal starting, place throttle in 1/2 openposition. During cold weather. place throttle in full open position. Use ether starting fluid if necessary.

2. Decompressor engaged. (if so equip-

2. If decompressor will not disengage,check linkage for damage. Refer to the Section covering ItServicing the Valve System and Cylinder Heads ."

ped) 3. Air intake system plugged or strioted.

re-

4. Refer to "Slow Starting Motor Speed," below.

4. Slow cranking speed.

5. Fuel does not reach chambers.

3. Thoroughly clean the entire air intake system.Make sure the air cleaner oil cup is fUled with the correct viscosity oil exa,ctly to the level mark.

combustion

5. Refer to "Insufficient Fuel or No Fuel Reaches

Combustion Chamber, If Page E-6.

6. Unsuitable fuel.

6. Drain fuel system and refill with recommended diesel fuel.

7. Water in fuel system.

7. Drain fuel tank water trap and filters to remove water.If necessary drain entire fuel system and refill with uncontaminated fuel.

8. Injection pump timed incorrectly.

S. Check the pump timing as described in the Section covering "Fuel Injection System and CasePowrcel.

9, Low compression.

9. Check compression with CD-504 compression gauge. Refer to "Low compression," Page E-S.

Slow Starting Motor Speed REMEDY

CAUSE

1. One or both batteries not fully charged.

1. Check batteries with hydrometer. If a battery will not hold or take a charge, replace the battery.

2. Loose or corroded battery connections or high voltage resistance caused by defective cables.

2. Clean and tighten all connections,including the

3. Starting motor overloaded.

3. Check for heavy crankcase oU. Check for tight engine bearings and tight piStons.

4. Faulty starting motor .

4. Have starting motor servioed by an Authorized Electrical Service Station.

5. Batteries installed incorrectly. (Batteries must be hooked up in series -

5. Reconnect the cables as directed in wiring diagrams in the Operator IS Manual.

not parallel.)

6. Replayement batteries with too small

capaCIty,

ground connections.Check all wiring for voltage loss .

6. Ahyays install batteries that meet Case Specifi-

cations.

E-4

ENGINE WILL NOT START (Conlimm/)

Starting Motor Operates - .. But Engine Does Not Turn Over CAUSE

1. Starting motor drive damaged.

REMEDY

1. Refer to Section covering the Starting and Electrical System. a. Check for burred or broken drive pinion. b. Check for a broken drive spring. c. Check for damaged flywheel ring gear.

Starting Motor Does Not Operate SYMPTOM

CAUSE and REMEDY

1. Headlights are dim when l1ghtswitch is on.

1. One or both batteries weak or discharged. Check for loose battery ground connection.

2. Headlights dim or go out when keyis turned to start position.

2. a. One or more batteries weak or discharged. Check for dirty, corroded or loose connections in battery to starting motor circuit. Check for defective wires or cables. b. Check for overloaded starting motor due to heavy crankcase oil, tight engine bearings or tight pistons. c. Worn startingmotorbaarings causing drag. Have starting motor serviced by an Authorized Electrical Service Station. d. A short in the starting motor or solenoid will cause the starting motor to be inoperative and will rapidly discharge the battery when starter button is pushed.

3. Headlights stay bright when starting key is turned.

3, a. Check for an open battery to starting motor circuit, (Refer to wiring diagrams) • b. Check for a defective solenoid switch. c. Broken or disconnected wiring in starting motor.

Havemotor serviced by Authorized Electrical Service Station.

E-5

ENGINE WILL NOT START (Conti'llll.")

Insufficient or No Fuel Reaches Combustion Chambers NOTE WHILE THE ENGINE IS TURNED OVER AT NORMAL CRANKING SPEED, WHITE OR BLACK EXHAUST SMOKE SHOULDBE OBSERVED. IF NO SMOKE IS OBSERVED AND THE ENGINE WILL NOT START, IT IS AN INDICATION THAT NO FUEL IS BEING DELIVERED TO THE COMBUSTION CHAMBERS. UMfDY

CAUSE 1. Fuel tank shut-off valve closed or tank empty.

1. One valve or fill tank. Bleed system. See the Section covering "Fuel Filtering System."

2. Kinked or broken fuel lines.

2. Replace damaged fuel lines. Refer to the Section covering "Fuel Filtering System!'

3. Leaking high pressure fuel line connections. (Injection pump to injector .)

3. Tighten union nuts or replace fuel line if necessary.

See Sectlon covering ttFuei Filtering System,1t

4. Lea.ldng low pressure fuel line connf.:lctions. (Fuel transfer pump to intake side of injection pump.)

4. Tighten union nuts or replace rubber bushing in union nut. Bleed system. See Section oovering "Fuel Filtering System. ff

5. Air leaking into "Suction" fuel lines causing air lock in fuel system.

(Fuel tank to intake side of transfer pump,)

5. Same as 4.

6. Bleeder by-pass valve partly or full open.

6. Close bleeder by-pass valve for operation.

7. One or more fuel filters plugged.

7. Cheok and service filters as described in the Section covering "Fuel Filtering System."

8. Fuel tank breather filter plugged.

8. Remove and clean filter as described in the Seotion covering HFuel Filtering System,1f

9. Pressure relief (overflow) valve located on outlet side ofseoond stage filter stuck in open or partly open position. Relief valve spring broken.

9. "Free up" valve or replace complete relief valve assembly. Refer to Section covering ItFuel Filtering System.!!

10. Dirt gum and varnish contaminated fuel that plugs filters and damages injection pump.

10.Refer to the Section in Operator's Manual on "Fuel Specifications and Handling."

11. Pour Point rating of fuel too high for prevailing temperatures.

11. Refer to the Section in Operator's Manual on "Fuel SpeCifications ,"

12. Water in the fuel that freezes in 12. Drain fuel system. Inspect and service filter carewater trap, filters or damages infully. Discuss fuel handling procedures with cusjection pump and injector precision tomer. Refer to the Section in Operator's Manual on "Fuel Handl.ing and Storage, If parts.

E-6

ENGINE WILL NOT START (erlntinNed)

CAUSE

REMEDY

13. Throttle in "offt! position.

13. For normal starting pla.ce throttle in 1/2 open position.

14. Throttle control linkage binding or disconnected.

14. Refer to the Section covering "Fuel Injection System and Case Powrcel. II

15. Control rack in PES Injection Pump stuck in part-or full "No Delivery" position.

15. Refer to the Section covering "Injection System and Case Powrcel."

16. Sluggish or inoperative governor.

16. Refer to "Sluggish or Inoperative Governor, "Page E-15.

17. Air in transfer pump on PES External Drive Injection pump.

17. Refer to "Bleeding Fuel System on Dual Head Filters" in the Section covering "Fuel Filtering System."

18. Fuel transfer pump inoperative.

18. Have complete injection pump checked and serviced by a.n Authorized Bosch Service Station.

DO NOT remove transfer pump alone.

19. Fuel injection pump is not delivering fuel.

19.Have injection pump serviced by an Authorized Bosch Service Station.

20. Entire fuel system contaminated with gum or varnish deposits.

20. In these areas where gum and varnish in the fuel presents a problem. discuss with the customer the use of a "Case Diesel Fuel Conditioner" as outlined in the Operator1s Manual and the Section covering "Fuel Filtering System. fT A gum or varnish deposit in the fuel system can also be the result of not preparing the engine for storage as outlined in the Operator's Manual.

When this condition is found, it will be necessary to remove and clean the tank, all fuel1ines,fuel injectors, relief valve, and fuel pump. The pump should be cleaned and serviced by an Authorized Bosch Service Station. It will also be necessary to replace the first (replaceable type) secondand final stage filter elements.

IMPORTANT I Do not remove the fuel injection pump until you have systematically checked the entire fuel system and are certain that the cause of lack of fuel can be attributed to the pump.

E-7

ENGINE WILL NOT START (Continued)

Low Compression REMEDY

CAUSE

L Valve tappet clearance incorrect.

1. Check and adjust clearance. Refer to the Section covering "Servicing the Valve System and Cylinder Heads. f!

2. Valves sticking.

2. Refer to "Sticking Valves, II Section covering "ServiCing the Valve System and Cylinder Heads.

3. Burned val vea and sea ts .

3. Refer to "Burned Valves andSeats," Section covering "Servicing the Valve Sys tem and Cylinder Heads

4. Excessive amount of material ground off valves or off valve seats in cylinder head, This can increase, size of combustion chamber.It will also lower the valve spring tension.

4. Install new valves. Install new exhaust valve seat inserts. If an intake valve seat is worn or excessively ground, replace cylinder head. Refer to the Section covering "Servicing the Valve System and Cylinder Heads. It

5. Valve guides worn.

5. Replace valve guides. Refer to the Section covering lIServicing the Valve System and Cylinder Heads."

6. Valve springs weak or broken.

6. Check and replace valve springs as described in the Section covering tfServicing the Valve System and Cylinder Head. H

7. Cylinder head gasket leaking.

7. Install new head gasket. See the Section covering "Servicing the Valve System and Cylinder Heads. If Inspect cylinder head and block for damage.

8. Valve timing incorrect.

8. Inspect timing pointer alignment. Inspect timing gear marks. Check timing gears for damage,or excess wear (backlash). Check cams on camshaft for wear. Refer to the Section covering "Servicing the Assemblies Contained in the Engine Block."

9. Worn, stuck,or damaged piston rings or pistons. Worn or scored cylinder sleeves that permit compression leak or "blow-by."

9. Replace worn or damaged parts as described in the Section covering "Servicing the Assemblies Contained in the Engine Block." Discuss with the customer the use of Case recommended engine lubricating oils.

Check the air intake system for leaks between the air cleaner and the intake manifold.

Check the crankcase breathers and the valve covers and gaskets. Refer to the Section covering "Servicing the Valve System and Cylinder Heads."

Discuss air cleaner maintenance with customer.

IMPORTANT When 'you che~k con:pression pressure with a CD-504 Compression Gauge, altitude must be taken mto conslderatlon. Refer to table in the Section covering "Servicing the Assemblies COntained in the Engine Block.

E-8

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