CASE 1000 Crawler Dozer Service Repair Manual Instant Download

1
800/1000 Crawler Service Manual
9-72062
2
800 CRAWLER, S/N 7081201 AND AFTER 1000 CRAWLER,
BEFORE S/N 7103000 TABLE OF CONTENTS SECTION NO.
SECLON
FDRM NO. 9-72061
General Specifications ...........................
NOTE Also see Section II ogre ..................
................... II
9-72061
Fuel System .................................. III 9-72061
Torque Converter .............................. IV 9-72061
Transmission ................................. V 9-72061
Final Drive System .. , , . ,, , .. .... ,.... ,.,,..., .. VI 9-72061
Track System ................................. 9-T2061
Electrical System ... , , ,. ..............,. ...
.... VIII
9-72061
.. IX
Hydraulic System , ...
......, ... ..... ,..., ., ..
9-72061
C.E. Division 9-72062 April 1978 (Original
printing December 1959)
CASE CORPORATION
3
GROUP I GENERAL SPECIFICAZIO NS
Page SECTION A - Model 800 Specifications
............ SECTIO N B - Mode1 800 Loader
Specifications ........ ..... I-3 SECTION C -
Model 800 Dozer Specifications , ............
I-4 SEGZIO N D - Mode1 1000 Specifications
............... I-4 SEGTIO N E - Model 1000
Loader Spec Creations ............ I-6 SEGTIO N
F - Model 1000 Dozer Specifications ............
I-7 SECTIO N G - Ripper Specifications
................. I - 8
4
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GENERAL SPEG IFIGATIO NS GROUP I SEGTION A - MO
DEL 800 SPEG IFIGATIO NS CAPACITIES (U.S.)
............ ...............40Gallons
Fuel tank
Gooling ............
. .
7-1/2 Gallons 11-1/2Ga11ons
I'ransmis s ion and Torque Converter .
. .. . . .. . . .. . .
, ,
FinalDrtve(EtCh) Grankcase
............... 8Quarts
Dry Engine (new filter element) 9 Quarts
Wet Engine (old filter element) - 7 Quarts
AirGleaner ........... ................ lQuart
1-l/2Pint 24Gallons 22Gallons
Hydraulic Brake System ...... . .. . . .. . . .. .
..
Hydraulic System - Terraload'r ... Hydraulic
System - Terradozer ...
.............. ............
TRACTOR Engine , G ontinenta 1 Diesel .......,..,
, . , , , , ,
, . HD-277
HP (Gros s) ............................. 80 HP
(Net) .............................. 70 Electrical
System ........................ 24 Volts Cooling
Fan Diameter ........................ 20
In. Ratio - Engine To Fan .......................
.. 14 .
Radiator No . Tube s .........................
5 No . Fins Per Inch ...................... 7
Torque Converter Make ...................... LO
NG
SINGLE STAGE 13 In. 155 0-165 0
Type ..................
Diameter ......,.. ............
.., .., , . ..........
Stall Speed Sta 11 Torque Ratio
..., , , , . ............ 1.92
Transmis s ion M odel ....................... 5
93 Zype ...... , .............. HYDRAULIG
No . Speeds Forward ................... 4 4
No. Speeds Reverse ...................
Battery
...................... Number ....................
.....
Type
GROUP 2E 4
Capacity - 20 Hour Rate ............ 130 Amp. Hrs.
Generator
Make .....................
Delco-Remy 10 Amp.
Gapacity .....................
I - 1
6
DIMENS IO NS AND WE IGHTS
Wide Gauge (Loaders) ....... 114-11/16 In.
Narrow Gauge (Dozers)
Length , Overall Without Drawbar
Height , .. , , , ... , ..
...
71-1/2 In.
, ... Gauge ............. 60 In. .. 75
In. .. , , ,, ., . , , ,
......54 In . . . . . . 69 In.
Width, Overall , , ., , ., ., Ground
Glearance Without Draw bar, Ground Clearance
Under Drawbar .,
. . 16-3/16 In. .
10-15/16 In. . . 14-1/16 In.
Drawbar Height . ., , , , Drawbar Movement ,
Lateral, Track Shoe Width , Sta ndard, Track Shoe
Width , Maximum
. , , . , , , , , , . . , . . . , ., . , . , , .
24 In. , . , , .. , , . , ., , . , ,, . ,
16 In. . . , . 1S In.
20 In .
...., , , ..
, , ..
Number Track Links Per Side ..
....
37 73 In.
Length Of Track O n Ground
... ,
........
6l-/I4n.
Track Pitch , , , , Sprocket 'teeth ... Ground
Gontact Area Height Of Grouser .
., .. ,, , , , 2 7
.............
2190 Sq . In . , 2-1/16 In. In. In.
,, , , , , , , ,, .,
Track Pin Diameter . , ., , , , . , , , , , . 1-1/4
Track Bushing Diameter, , ., ., , , . ., 1- 7/8
Track Bolt Diamete,r . , ., , ., , , ., , . J/2 In.
Track Rollers , No . Per Side ., ., . , ., . , 5
Track Roller Diameter, . . , , , , , , , , , , 7-1/4 In.
Support Rollers , No Per Side . ... ....... 1 (2
O ptional) Ground Pre s s ure .........5 . 3 PS I
. .... 5 . 1 PSI We ight
(Standard Ba s ie) Shippinq l1, 680 Lbs
........... 11 , 20 0 Lbs . ENGINE Gontinental
Model HD-2 77 Die se1 Number of Gylinders
.......................... 4 Bore
............................... 4
In. Stroke ......... , ...................5-1/2
In. Governed RPM (Full Load) ....................
2250 Injection System ...................... Roosa
-Master Firing Order .......................... 13
4,,2 , Valve Tappet Glearance . . . . . . .
. . ., , . ., . , . ..014 Intake (hot) Valve
Tappet Glearance . . . .. . . . . . . . .
. .. .. 014 Exhaust (hot) PERFORMANCE DATA
2ND 2. 9
3 RD 3 . 3
l ST 1.6
Speeds
Forward
5. 9
Reverse
1. 9
3.5
4 . 0
7. 2
I - 2
7
Geared Turn - 7 Foot Radius Pivot Zurn
GounterRotation Fore And Aft Sideways
(Mea s ured From Ge nter Of Ins ide Tra ck)
Steering
38 32
Gradea bility
Drawbar Pul1
2 0, 700 11, 75 0 10, 0 00 5 , 6 60
2ND 3RD 4RD
SEGTIO N B 8 00 LOADER SPEG IFIGATIO NS REAR
HINGE LOADE R
BucketGapacit, y... , . , , , . , . Digging
Depth Below Ground, , , .. , .
........... l.5Gu.Yd.
......... 8-3/4_at_8-1/2
Grading Angle, . , .. , ... , , , . Bucket
RollbackAt Ground Leve1
..............
ils 40
........ ,, ,, ., , , , , ,
At Carry ..
t ...................
3 9-1/2
At Maximum Lift ....., .. ..

• ..... 55

Overall Height At Maximum Lift (Gleara nce Re
quired To Dump Buc ket-) .
162- 3/8 In . - - 98-5/8In. - - - 35-1/16 "_at_4 5
DumpGlearance............
.
Dump Reach At Maximum Lift .........--- - -
At 7 Foot Dump ........--- - - Lifting Time From
Ground Level To Max. Lift .....

• - - - - 45-1/4 In.
• - 7 Sec.
• - - - - 2.4Sec.
• - - - - - - - -
• - - -
• - -
• -

DumpingTime. ........... LoweringTime - ........
.... - -
---- - -
5.0Sec.
Widthof Bucket..............

• 81In.
• - - - - - - - - 75 In.
• - 94In.

Tractor Width ..............- - -
OverallHeight .............

• -

• - - - -

OverallLength ............-
- - - - 185-S/16In. - 20, 970 Lbs .
We ight With Gounterwe ight ..........------- -
Lift Gapacity At Ground .......... -

• - - - - - - 17, 440 Lbs .
• - - -

Fully Raised ..........- - -

• - 8, 150 Lbs .
• 4 "x 23-1/4 "
• - - - - - 5 "x 2 9-1/2 "
• -
• - - - -

Dump Cylinder Size ...........--- Lift Gylinder
Size ...........--- -
Pump Gapacity At Rated RPM .......-. - -
41 Gal. QM in.
Gutting Edge Of Bucket Width ........-..

• 6 In.

Thickn, ess . , ,. ,, . .
- ...
3/4 In.
I- 3
8
SEGTION C DO
ZER SPEG IPICATIO NS
TILT- CROWNDOZER Moldboard Width Moldboard Height
Lift Above Ground Drop Below Ground Hydraulic
Lift Gylinders Hydraulic Tilt Gylinders Lift
Speed Pump Ga pa city Moldboard Grown Adjustment
Moldboard P itch Adjustment Overall Length We ight
96 In . 31- l/2 In . 33 In . 13 In. 3-1/2 x
31-1/2 " 3-1/2 x 2-1/8" 13 In. /Sec . 31 Gal.
QMin. 14 In . 10 15 7-1/2 In . 14, 450 Lbs .
ANGLE DOZER Moldboard Width Moldboard Height Lift
Above Ground Drop Below Ground Hydraulic Lift
Gylinders Hydraulic Anq le Gylinders Pump Ga
pacity Lift Speed Moldboard Angle Adjustment
Moldboard Crown Adjustment Overall Length Total
Weight SE GTIO N D -
112 In. 31-1/2 In . 30In. 13-1/2 In. 3-1/2" x
31-1/2" 3 " x 33-1/4" 31 Gal. /Min. 12 In . /Sec
. 21 12 In. 158 In . IS , 000 Lbs .
MO DEL 100 0 SPE G IFIGATIO NS
GAPAG ITIES (U . S. )
. . 45 Gal. . . . 8-1/2Ga1. . . . . . .
11-l/2Ga1. 8Qts. llQts. 12 Qts . 1-1/2
Pt. 24Ga1. 2 2 Gal.
FuelTank...........
Gooling ...........
. . . . . . . . . ..
Tra nsmis s ion and Torque Gonverte r
Final Drive (Each Side) .. Grankcase. . .. . ...
. .. .......... . . . ............... with filter
i ot.
Air Gleaner ..........
Hydraulic Brake System .....
.
. . .
Hydraulic System - Terra1oad'r , Hydraulic
System - Terradozer .
I - 4
9
TRACTOR
. . D382
E ng ine , G ontine ntal Diesel ............ - -

. . . 100
HP (Gros s) ., ................- - - - - - - -
. . . . 87
HP (Net) ................... - -
24 Volts . . 2 2 In . . . . 1.3
E le ctrical System ., ....., , .. .......
- .. , . , .... ...... - - - -
Gooling P-an Diameter Ratio - Engine to Fa n
Radiator No . Tube s
........ ....... - -
......... .......
No . Fins Per Inch ....... ..........
. . LONG
Torque Converter Make. . . . . . . . . . . . . .
. . . . . .
Type . . . . . . . . . . . . . . . . . .
SIN GLE STAGE
13 In.
Diameter ......, , ......... ...
. 1400-1500
Stall Speed ..... ........ .
Stall Torque Ratio .. , , ......... ....172.
. . . . 593
Tra nsmis s ion Mode1 ......... ........
. Hydraulic
Type .......... ......... - -
, . , 4
No . Speeds Forward ... No . Speeds Reverse ..
........... ,, ........... . ........... .
. . . . 4 . Group 2E . . . . 4
Battery Type ............. Number
............ Gapa city - 2 0 Hour Rate ... ,
........... .
130 Amp . Hrs .
. , ........
DelcoRe my . . l0Anp.
Ge nerator Make .. ...... . ........ - Ga pa
city .......... .........
DIMENSIO NS AND WE IGH TS
Long Track ( Loaders )
Standard Track (Dozers)
114-15/16 In . 72 5 8 In. 60 76In. 16 -3/16
In. 10 - 15/l6In.
Length , Overa11 Without Drawbar . ., , . ,
.
He ight ......... , ,.. ,..., Gauge -
- - - - -
Width , Overa11 .......
. Ground G leara nce Without Draw bar ... Ground
Cleara nce Under Drawbar .
..
...
Drawbar He ight .............. 14 - 1/l6In.
Drawbar Movement , Latera 1 ......... Track Sh oe
Width , Sta ndard ......... Track Shoe Width ,
Maximum .........
16In. l6In. 24 In .
Number of Track Links Per Side ... 39 ....
Length of Tra ck on Ground . . . . . 79 In .. . .
....... 3 7 .. .. 73 In .
Track Pitch ................ 6 - 1/4In. Sprocke t
Teeth ... , .. , , ... , 27
.... 2336 Sq. In,
Ground G onta ct Area . . 25 28 Sq . In
. - , ,
2 - 1/16 In .
Height Of Grous er ........, , ,
Track Pin Diame ter .........., , , Track
Bushing Diameter ..... , .., , . .. ,
1 - 1/4 In . In. In . In .
1 - 7/8 1/2
Track Bolt Diameter ......, , ,
Track Roller Dia me ter - - - - - .....
7 - l/4
I - 5
10
Long Track (Loaders)
Standard Tra ct (Dozers)
Number of 7rack Rollers Per Side, . , . , Number
of Support Rollers Per, Si,de , ,
6............ 5
, 2,
, ..., , ,
1 (2Optional) 5.6PSI 13,090 Lbs.
GroundPress,ure. , , . , , . , , , . Standard
Basic Shipping Weight , , . . .
5.3,PSI , . .
, , ...
.....
13, 290 Lbs
ENGINE Gontinental Mode 1 JD- 38 2 Number of G
ylinder s ..........................
4 Bore .............................4-1/2
In. Stro ke ...............................6
tn. Governed RP M . (Full Load) .................
.....20 00 Inje ction System .....................
. Roo sa - Master Firing Order
...........................I,34 , 2, Valve Ta
ppet G Ie ara nce .................. 014 Inta ke
(Hot) Valve Tappet Gleara nce .................
.014 Exhaust (Hot)
PERFO RMANGE DATA Speeds Forward
IST 1.6
2ND 2 . 9
4TH 5 . 9
3RD 3 . 3
Reverse Reverse 1.9 3. 5 4.0 7. 2
Steering Power Turn 7 Foot Rad ius Pivot Turn Power Turn 7 Foot Rad ius Pivot Turn Power Turn 7 Foot Rad ius Pivot Turn
GounterRotation GounterRotation GounterRotation
Gradea bility Fore a nd Aft S idewa ys Fore a nd Aft S idewa ys Fore a nd Aft S idewa ys 38 32
Drawbar Pu11 IST IST IST 25 , 4 00 Lbs .
2ND 2ND 2ND 14, 4 00 Lbs .
3RD 3RD 3RD 12, 290 Lbs .
4TH 4TH 4TH 6, 770 Lbs .
SEGTIO N E 1000 LOADER SPEG IFIGATIO NS SEGTIO N E 1000 LOADER SPEG IFIGATIO NS SEGTIO N E 1000 LOADER SPEG IFIGATIO NS
REAR HINGE LOADER
. . 2 Gu . Yd .
Bucket Gapa city ......... ..... ..
- Digging Depth Be low Ground ..............
.
9- l1/16 " _at_ 8 1/2
. . 112-1/2
Grading Angle ....................... .
. . . . . 40
Bucket Rollback - At Ground Level .............
42-1 2
At Carry ................. ...
54
At Maximum Lift .........
I- 6
11
Overall He ight At Maximum Lift
(Glearance Required to Dump Bucket) . - - - - -
- - - -
. 174-1/8 In . 100-3/4 In.
...
Dump Clearance ...................
. . 44- 3/8 _at_ 45
Dump Reach At Maximum Lif t ..............
. . 4 2 " _at_ 60
At 7 Foot Dump , .............. .
. . . 6. 6 Sec .
Lifting Time From Ground to Maximum
Lift ......... .
. . . .
2. 7 Sec . . 3. 1 Sec . . , . ..
Dumplng Time . . Lowering Time ..................-
- -
. .
. 81 In. 76In. 94 In. 197 In.
Width of Bucket ........ .. ...
Width of Tractor ..................... ..
Overall Height Overall Length
.................. . . .................. . . .
2 3, 170 Lbs . 18 , 7 00 Lbs . 9, 300 Lbs .
We ight With G ounterwe ight ................ .
Lift Ga pa city At Ground I'-ully Ra is ed
................. ................
Dump Cylinder Size ...................
. 5" x 22-3/16" 5-1/2 " x 30" 56 Ga1. / Min.
Lift Cylinder Size ....... ....... .
Pump Capacity At Rated RPM . ., , , , , , , , , ,
, , , .
Gutting Edge of Bucket Width ............... . .
. . . . 6 In. Thickness . . . . . ., ., . ., . .
. . . 3/4 In.
SEGTION F MO
DEL 10 00 DO ZER SPEG IFIGATIO NS
TILTGROWN DO ZER MoldboardWidth. . . . . .
. .. . . .. . . . . . . .. . . . .
104In. Moldboard Height .......................
31-1/2 In. LiftAboveGround. . . . . . .
.. . . .. . . .. . . . . . . .
. 33In. Drop Below Ground ........................
13 In.
Hydraulic Lift Gylinders .................. Hydrau
lic Tilt Gylinders .................. LiftSpeed
........................
3-1/2"x31-1/2" 3-1/2"x2-1/8" 14In./Sec.
PumpCapacity .......................
3lGal./Min. MoldboardGrownAdjustment..............
...... 14 In. MoldboardPitchAdjustment ...........
.......... 10 Weight .......................... 16
,450Lbs. ANGLE DO ZER , ,
MoldboardWi,dth, . , , . , , . .. , , . ..., . ..., , , . . , . 120In. , , . . , . 120In.
MoldboardHeigh,t. . , , . , . , , , . , . , , . . , , . , . . , . . 31-1/2 In. , . . , . . 31-1/2 In.
LiftAboveGround, , . ..., , , , , , , . , , .. , .. , , , , , , 31-1/2In. , , , , , , 31-1/2In.
Drop BelowGround , , , , .. , , , , .. , , , . , , . .., .. ..13-1/2In. .., .. ..13-1/2In.
Hydrwllc LiftGylinde,rs . , .. Hydraulic Angle Cylind, er, s , , , Hydrwllc LiftGylinde,rs . , .. Hydraulic Angle Cylind, er, s , , , , .. , , .. , , .. , , , . ... , ... , , .. , , , 3-l/2"x31-1/2" . 3"x33-1/4"
,
, , , ..
PumpCapacity ...., .. ....., .. , .. LiftSp,eed
, . , , . .., ., . , . , .. , .
31Ga1./Min. .l4In./Sec.
..., ..
I- 7
12
......20
Moldboard Angle Adjustment .........
...... Moldboard Grown Adjustment .........
....... Overall Length ............... . . . .
.. .12In. . 160In.
Total Weight .............. . ......... 17,025
Lbs. SE GTIO N G - RIPPER SPE CIFIGATIO
NS Tooth Glearance Above Ground ...........
. . . 15-3/4In. Digging Depth Below
Ground, ,, ......... . . . . . . . 16-3/4
In. Hydraulic Gylinder (1)( Double Acting )
........ . . . . . . . . 4"xl3"
Number Of Teeth (Standard) ..... Spacing Of Teeth
(Sta ndard) .... Tooth Shank Thicknes s
. ... . . . . . 3 ... . . . . .
32 Centes l- 1 2 In .
Distance From Ge nter Line Of Sprocket 'to
Back Of Tooth ( Ra is ed) (Approx. ) ... .
. ...... S 2-13/16 In.
We ight Of Ripper ................. .
. . . . . . 1480Lbs.
. . . . . . . . . . 2
Ballast Weights Ava ila b1e . We ight Of Ba11a
st. .
.. ... . ... . ..
..... 860 Lbs . Ea .
I - 8
13
Burl. Form 9-72061 Original Printing Dec.
1959 Reprinted June 1974
CASE CORPORATIGI/a
14
GROUP 11 - ENGINE
Page II - 1
SE C' IO N A - GENERAL INFOR MATIO N AND SPEGI
FIGATIO NS
Engine Specifications ............ ...
.. II - 1 Elementarr Principle s of Diesel
Engine s ..... ....... H - 1 The Diesel Gycle
............... . .. II -
2 SEGTIO N B FUEL AND L UBRIGATIO
N ................ II4
Fue1 Oil Recommendations ............... ..
II - 4 II - 4
Diesel I'-ue1 Oil Specification s
................ ,
Handling and Storage ..... ................ II -
4 Fuel System Precautions ..........., , , ..
, . II - 5 Fue1 Piping Arrangements
.................. .II - 6 Dirt is the Worst
Enemy of a Diesel Engine ........... II-7
Lubrication Recommendations ................
I-I7 Oil Filter . . . . . . . . . . . . . . . . .
. . . . . . . . . II - 9 Oil Ghane P-requency
.................... I-I9 MPump p p t c o
w o o o o o w t R R 6 w o R o R w Air
Gleaner .................. ...... I-I10
II- 10
SEGTIO N G - ENGINE GOO LING ..... ..

Gleaning the Gooling System ............... Radiat
or Pre s sure Gap ................... . Engine
Oil Gool er ..................... . SEGTIO N D
GOLD WEATHER STARTING ............ .
. Maintenance of Equipment in Gold
Weather, ... , . ....
II - 12 II - 12
II- 12
II - 13
SEGTIO N E - ENGINE REPAIR AND OVERHAUL
............. II - 14
Gylinder Head , , , ., , , ., ., , , ., . . Gylinder Head , , , ., , , ., ., , , ., . . , ,, ., , II - 15
Valve Guides .......... .... Valve Guides .......... .... .. II - 17
Valves....... .. . . Valves....... .. . . II - 18
Valve Springs ............ .. .. .. II - .. .. II - 19
Rocker Arms ............... ... - II - ... - II - 19
In stalling Head ....... ..... ... . .. II - . .. II - 2 0
Gylinder Block .............. .. . II - .. . II - 20
Re - Ringing ............... ... . II - ... . II - 2 I
Re - Sleeving Block ..............
..
II - 22
15
Pistons .............-- .. - ..
II - 24
............---
Piston Rings - - .. II - 25
PI ston Pans ..... G ..
. ... ........ ..... JJ - 25
Grankshaft and Main Bearings , , ., ., , , , ,, ,
, . ,, t
- 2 7
Gamshaft ............ ....
II - 30
............---
Timing Gears ..... II - 31
Grankshaft End Play ................. ....
I-I33 Eront Oil Seal ........................II -
34 Rear Crank.shaft Oil Seal ..................
II - 35 Flywheel and Flywheel
Housing . .. . .... . .. .. .. II - 37 SEGTION F
LANGHESTER BALANCER ..... .. - 38 Principle s
of Operation .................. ..II - 38
Removing Lanche ster Balancer From Engine ....,
.. .. . . II - 39 Di sa s sembly Procedure
................. . . II - 41
As sembly Procedure ................... . II - 42
Installation and Timing Instructions ............
. a -45
SEGTION G - REASSEMBLING ENGINE ................
II - 48 SECTION H - TORQUE SPEGI FIGATIO NS
....... - 48 SEGTION I SERVIGE D IAGNO SIS
......... 49 SEGTION J - LIMITS AND CLEARANCE
DATA ........... . . II - 56
Engine Model HD 2 77 . . . . . . . . . . . . . .
. . . . .. Engine Model JD 382
. . . . . . . . .. .
II - 56 - 60
16
DIESE L ENGINES GROUP II SEGTIO N A GENERAL
INFORMA' IO N AND SPEG IFIGATIO NS ENGINE
SPECIFICATIO NS
Model 800 Model 800 Model 1000
Gontinental Diesel HD 277 HD 277 JD 382
NumberofGylinders....... , . 4.. .... - . . 4 NumberofGylinders....... , . 4.. .... - . . 4 NumberofGylinders....... , . 4.. .... - . . 4 NumberofGylinders....... , . 4.. .... - . . 4 NumberofGylinders....... , . 4.. .... - . . 4
Bore...... Bore...... -. -...... 4". ....... 4-1/2"
Stroke... Stroke... -..... .S-1/2" .... 6
DisplacementinGubicInches .... 277.. . .. . . . 382 DisplacementinGubicInches .... 277.. . .. . . . 382 DisplacementinGubicInches .... 277.. . .. . . . 382 DisplacementinGubicInches .... 277.. . .. . . . 382 DisplacementinGubicInches .... 277.. . .. . . . 382
........
15.01.. ...... IS.01
GompressionRatio
Injection System - ...
Roosa Master ........ Roosa Master
FiringOrder ....- ..... 1-3-4-2... .......1-3-4-2
ELEMENTARY PRING IPLES OF DIESEL ENG INES In
order to dis pe1 any mystery there may be with
regard to the die se1 enq ine and how it operate
s , compare the die se1 enqine with its ga soline
counterpart . Me chanica lly, the two are alike
. Both have pistons moving up and down in
cylinders with connecttng rods attached to a
crankshaft. Both convert the re- ciprocating
motion of the pistons into a rotary motion. Both
have valves in the cylinder heads operated by a
camshaft and push rods . An intake valve
admits air into the cylinder, and an exhaust
valve permits the dis pos ition of the burned
gases . The camshaft is driven through a train
of timing gears so that the open- ing and clos
ing of the exhaust and intake valve s are
properly timed with the stroke of the piston
and crankshaft. The engine s are so much a like
in exterior appeara nce that the only way most
people are able to distinguish betwee n them is
to look for the carburetor and the distributor
on the gas oline eng ine or the injection pump on
the die s e1. Both operate on mixtures of liquid
fuel and air ins ide the combustion cham- bers .
The ignition of the se mixtures under pressure ,
and the subsequent ex- pansion I urnishe s the
power to drive the piston downward on its power
stroke . The one big differe nce between the two
type s of e ng ine 1ie s in the way the. fuel is
handled and combustion brouqh t about . In a ga
s oline enqine des ired proportions of fue 1 and
air are mixed in the car- buretor before entering
the cylinder through the intake valve . In a die
sel en- gine , air is drawn into the cylinde r
through the intake valve and is compre ssed . At
the proper time a measured quantity of fuel is
injected into this air thus form- ing a combu s
tible mixture which is self- ignited by the high
temperature of the compre s sed air. II 1
17
In a ga soline engine the suction or downward
stroke of the piston draws in a combu stible
mixture of air a nd qas oline which is compre s
sed in the upward s troke and ignited by an e
lectric spark , whereupon the expans ion of this
compre s sed mixture force s the piston down on
the power s troke . In the die set eng ine , the
piston on the down s troke draws in clea n , pure
a ir , which is compre ssed on the upward stroke
. At the proper instant, fuel is in jected into
this compre s sed air which then ignite s from
the hecat of ompre s sion , cau sing the exp a us
ion of the mixture and forcing the piston down on
the power stroke . The compre ss ion ratio of
die se1 enq ines is twice that of gasoline e n-
gine s , and it is the heat ge nerated by the
comparative ly rapid compre ss ion of the air
which ignite s the fuel as it is sprayed in under
high pre s sure . It is a we11 known fact that
the te nde ncy in ga soline engine s des ign is
to in- crease compre s sion ratios in order to
obtain more power and qreate r eff iciency out
of the engine without increasing the bore and s
troke . G ompre s sion ratios are however limite
d by the octane number of fue 1s ava ilable and
the de s ire to keep combu s ion chamber
temperature s down to prevent pre- iqnition . A
diesel enq ine is not controlled by the se
conditions , con seque ntly , compre ssion
ratios in the ne ighborh ood of 15 to 1 can be
used with e ntire sati sfa ction s ince there is
no pos s ibility of the air in this engine iq
niting until inj ection of the fuel pro- vides a
combustible mixture . This high compres sion
in a diesel causes the temperature of the air
to rise under c ompre ss ion to approximate 1y
900 Fahre n he it , far above the iq nition
point of the fue 1, thu s iqni ting the m ixture
. To summarize , both engines are heat
engine s of the internal combustion type ,
the power in each ca se be inq deve loped from
the exp ans ion of the mixture of air and fuel
after ignition occurs . Since the expans ion is
directly re lated to the compre ss ion , the die
set is able to delive r a qrea ter amount of work
using a given quantity of fuel . This is bas
ically the reason for its superior efficiency ,
which re sult s in it s saving in fue1
cost. THE DIESEL CYG LE Intake Air only is
drawn into the cylinder through the open
intake valve by the suction created by
the Downward movinq piston . Figure 1 .
Figure l
II 2
18
Gompres s ion The intake valve is now clo sed a
nd the air in the cylinde r is highly compre s
sed by the Upward Mov ing piston . This high
compres sion of the air raises the temperature to
betwe en 900 and 1 00 0 F . Fig ure 2 .
Figure 2 Inje ction and Combustion At a
definite point, shortly before the piston
reache s the top of its stroke , fuel is
injected into the cylinder by the spray noz z1e
. The fuel is iqnite d by the he at of the highly
compre ssed a ir . Figure 3 . F iq ure 3 Power
The exp a ns ion of the qa se s re su
ltinq from the burning of tfie fuel exerts pre s
sure on top of the pis- ton , driving it Downward
. F iqure 4.
Figure 4 Exhaust As the piston pa sses the
bottom of its stroke the exhaust valve opens and
the burnt qase s are ex- pelled by the now
Upward moving piston . The in- take valve opens
about the time the pis ton rea che s
the top of its stroke , and a similar
sequence of events , ofte n referred to as the
cycle , repeats it- self. Figure 5.
F iqure 5
II- 3
19
Compression The intake valve is now c1o sed a nd
the air in the cylinder is highly compre s sed by
the Upward Mov ing piston . This high compres
sion of the air raise s the temperature to betwe
en 900 and 1 000 F . Fiq ure 2 .
Figure 2 Inje ction and Combustion At a
definite point, shortly before the piston
reache s the top of its stroke , fuel is
injected into the cylinder by the spray nozzle .
The fuel is iqnite d by the he at of the high 1y
compre s sed a ir . F iqure 3 . F iq ure
3 Power The expans ion of the gase s
resulting from the burning of the fuel exerts
pre ss ure on top of the pis- ton , driving it
Downward . F iqure 4.
Figure 4 Exhaust As the piston pa sses the
bottom of its strove the exhaust valve open s and
the burnt qase s are ex pelled by the now
Upward moving piston . The in take valve opens
about the time the pis ton rea che s
the top of its stroke , and a s imilar sequence
of eve nts , ofte n referred to as the cycle ,
repeats it self. Figure 5.
F iqure 5
11-3
20
98
Dis tlllation Recovery
Lower recovery indi- cate s heavy oi1
fractions to cause smoke and poor combustion .
Sulphurou s acids corrode and increase engine
wear.
. S Maximum
Total Sulphur
Discoloration or pitting on polished copper
strip shows same effect on en- gine parts .
Pas s Test
Oorros ion(Gopper)3 hours _at_ 212 F .
Pour Point
Fuel O i1 must be in fluid state to prevent
clogging due to congealing wax.
10 F. be low lowe st an- ticipated operating
tern- perature .

• Warning Grade 4 2 Diesel Fuel Oil should not
  be confused with 9 2 Furnace Oil, which has no
  definite lim its on ash content, sulphur
  content, and Cetane Value .
• HANDLING AND STORAGE
• Fue1 should alw ays be strained or filtered
  before being put into the supply tank , as it
  is ea sier and cheaper to remove dirt from the
  fuel BEFORE it finds its way into the engine fuel
  system .
• A storage tank should be constructed for fuel oil
  with provision for removal of accumulated sludge
  and water. This should be done at regular 10-day
  intervals .
• In addition , the fuel should be filtered
  between the storage tank and the dis- pensing
  pump . Double f iltering is preferable , and the
  filter equipment should be maintained as
  recommended by the manufacturer.
• The open ends of the dispenser funne1s , measure
  s , and containers should be covered , when not
  in use , to prevent the entrance of dirt or
  moisture , and they should be kept scrupulously
  clean at all time s .
• FUEL SYSTEM PREGAUTIO NS
• Fill the fuel tank at the end of each day to keep
  condensation to a minimum . When emptying the
  drum of fuel oil, agitate it as little as
  possible , and leave about 1" of fuel , which
  may contain sediment or water , in the bottom
  of the drum .
• Shut off fuel supply valve at fuel tank when
  dis con nectinq line s -- to save needles s
  waste of fuel .
• II- 5

21

• Drain first stage fuel filter da ily . This will
  also prevent ice damage to the filtering eIeme
  nt where free zing temperature s are encountered
  .
• DO NOT USE WASTE 0 R LINTY RAGS AROUND FUEL GO
  NTAINERS OR FUEL INJEGTIO N EQUIPMENT.
• Use of cle an fuel and daily care of the firs
  t- staqe f ilter will prolong the life of the
  final- stage f ilter. For further de tails see
  Section on I'-ue1 Injection .
• FUEL PIPING ARRANGEMENTS
• 'I'he fuel supply arrangement is with the fuel
  tank mounted higher than the in- jection pump and
  filters . This provides gravity feed to the f
  ilter s and pump.
• The fuel supply line s should be 3/8 " copper
  tubinq minimum under 1 0 feet and 1/2 " copper
  tubing for lines over 10 feet. The return lines
  should be S/ 16 min- imum tubing. Return line s
  must also be piped to the tank and never back to
  the inlet , as its fuel flow cools , lubricate s
  , and purge s air from the tank .

F iqure 6 - Schematic of Fue1 Filtering System
II-6
22

• DIRT IS THE WORST ENEMY OF A DIESEL ENGINE
• Eliminate pos s ible damage to die se1 engine s
  by preventing the e ntry of dirt
• Use clean fuel , keeping all funnels and measures
  in dustproof cases .
• Keep fuel system clean while servicing . Gap
  lines that must be broken, and wipe cle an all
  openings before closing .
• Clean and refill oil bath air cleaner at regular
  intervals .
• Replace oil f ilter at every oil change .
• Hose nozzle s , filler flange s , and caps must
  be thoroughly cleaned before
• using .
• Avoid us ing linty or dirty rags wh en work inq
  on die se1 engines .
• Keep outside of engine clean for maximum cooling
  .
• Dirt and water in the fuel cause scored and stick
  inq plungers in the injection pump and may cause
  serious damage .

iEEP DIESE L FUEL G LEAN !
LUBRIGATIO N REGOM MENDATIO NS Die sel enq ine
s operate with much higher pres sure s in the
combu s tion cham- bers than the ir gas oline
counterparts . Die se1 fue 1s have much hiqhe r
e nd points , that is , heavier ends of fuel
which do not vaporize readily and burn comp lete
ly . 7his re sults in a te nde ncy to form depos
its in the combustion area as well as in the
ring groove s which could cause clogging of e
nergy ce lls , ring s s tick inq in the groove
s and poor preformance in general with re s
ultant rapid wear and in- creased maintenance
expense . To counteract these conditions , the
choice of fuels and lubricating oils must be made
according to the specifications . Oi1 used in the
lubrication system mu st have certain qualitie
s to provide a satisfactory oil film on
friction surfaces to minimize wear , to protect
bearing s from corrosion , and to keep engines
free from harmful deposits . Lubricating oils for
die sel engines are compounded with additive s to
provide this protection. They are better able to
res ist oxidation re suiting from the higher
operating pre s sure s found in the diesel and at
the same time , hold combustion by-products in
suspension until removed when the oi1 is drained.
Die sel e n- 11-7
23
gine s are qe nera11y used in heavy duty
operation . The American Petroleum Ins- titute
has classif ied oils for three types of service
General Service DG , Mod erate Service- DM ,
and Severe Service- DS , depending on the type of
operation . For Service DG Diesel Genera1) As
the name indicate s , this DG oil is for use in
Ge nera1 or O rd inary service where die se1 fuel
oil with le s s than . 4 sulphur is used with
norma1 e ng ine operation and maintenance
. I'-or Service DM (Diese1 Moderate) This oil
is to be used in die se1 engine s operating Ande
r severe conditions , or us ing fuel which te nds
to promote depos its , but where de s ign
characteristics or operating conditions make the
engine e ither ie s s sensitive to fuel effects
or more s ens itive to res idue s from the
lubrica ting oil. For Service DS (Diesel Severe)
this oil is to be used when the die se1 fuel oil
ha s over . 4 s ulphur content coupled with
severe operating conditions under heavy load s
and high tempera ture conditions , or very ligh
t or intermittent operation at low temperatures
. While oils in this category are , by no means
, a safeguard aqa ins t failure to follow proper
mainte nance procedures , they are abs olute ly
ne ce s sary whe n op- erating conditions
approach those outlined in the preceding paragraph
. We re- commend using motor oils meeting DS
specifications .
OPERATING GO NDITIO NS . SEVERE
TEMPERATURE
S.A.E. NUMBER
SW-20 l0W-30 40 50
0 or Below 0 to 35 F. 35 tol00 F. 100 or Over
Service DS Service DS Service DS Service DG
As in other inte rna1 combustion e ng ine s ,
oils mu st be s ele cted as to S.A. E . number
grade s in accordance with the atmospheric
temperature where the enq ine is to be opera ted
. Except for the .break- in period , de s ignated
elsewhere in this ma nua1 as the first 50 hours ,
select the grade of oil as shown in the preceding
chart. Gontinental Die sel Engines have full
pre s sure lubrication through drilled pas sage s
in the cylinder block and era nd shaft to all
main and connecting rod bea ring s as well as to
the timing gears and overhead valve rocker arms ,
the over flow from which lubricate s the tappets
. The oil pres sure is automatica fly regu- lated
by a spring Ioaded relief valve . II-8
24
OIL FILTER A full flow type oil f ilter is
provided to remove dirt and fore ign eleme nts
from the oi1. The remova1 of grit , s ludge and
fore ign particle s cause s f ilter elements to
clog and become ineffective unles s they are
replaced at regular interva1s . O i 1 f i I t e r
elements o r cartridges should be replaced at
every oil change or a p p r o x i m a t e 1 y
every 5 0 h o u r s operation.
Figure 7 - O i1 Filter
OIL CHANGE FREOUENGY
Engine oi1 does not "wearout". H o w- ever,
heavy-duty detergents in diesel engines become
contaminated from by- products of combustion ,
dirt, water , and unburned fuel entering the
crankcase and the detergents holding the carbon
part- icles ln suspension in the crankcase . In n
o r m a 1 industrial o p e r a t i o n engine s
should have the oil and the oil filter element
changed after every 5 0 hours of operation
. Zhe oil should be drained when t h e engine
i s a t normal operating temperature .
Figure 8 - Lubrication Diagrarri (The cams hat
t has been moved up in order to s implify the s
chematic drawing . )
O IL PUMP The oi1 pump is mounted on the rear of
the Lanchester Ba lancer . It is a gear type
pump driven by the timing gear on the
crankshaft. The normal oil pressure is 30 to 40
lbs . At idling speed it should not fall below 7
1bs . If the pressure fluctuates or falls
below these limits , STOP THE ENGINE
IMMEDIATELY, and find the cause to the
trouble . Refer to engine overhaul for
repairing .
II - 9
25
AIR CLEANER Die se1 enqine s , when operating ,
consume sev eral thousand cubic feet of air per
hour. Since dusty air is fuI1 of abrasive
matter, the enq ine would soon wear exce ss ively
if it was not prote cted by the a ir cle aner
colle cting du st in an oil cup . Air
cleaners are not 1 00 efficient, and their
efficie ncy is DEGREASE D by the lack of proper
servicing . Proper servicing means cleaning
thoroughly , refilling with new oi1, and main-
taining air tight connections between the air
cleaner and the intake manif old so that all air
entering the enq ine is filtered . The number of
hours an enq ine may be permitted to run before
the air c lea ner is serviced depend s e ntirely
on operating conditions , and no definite
interval can be e stablished . In extremely dusty
operations this might be once or twice a day ,
while in dust free areas the air cle aner s
houId be serviced when changing the Sil . Dirt
and fore ign particles , removed from the air ,
settle to the bottom of the air cleaner oi1
sump. This deposit must not be permitted to
build up to any quantity. The speed at which
this builds up indicate s how often the air
cleaner should be serviced . IT REQ UIRES O NLYA
GO MPARATIVE- LY SMALL QUANTITY OF ABRASIVE DUST
TO WEAR OUT AN ENGINE . A planned air clea ner
s ervicing program will in- crea se the life of
the e ng ine . Figure 9 - Air G le aner SECTIO N
G ENGINE COO LING The function of the cooling
system is to preve nt temperatures , some as
high as 35 00 F . in the combustion chamber ,
from damaging the e ngine . Ma inta ining the
coo ling sys tern efficiency is importa nt , as
engine temperatures must be ma inta ined within a
specific satisf actory ra nge for efficient
operation . Yet overhea ting must not ta ke pla
ce , in order to preve nt damage to valves ,
pistons , a nd bearings .
II - 10
26
Gontine ntal Die se1 Engine s operate most elf
iciently with water temperature s of 165 - 185 F
. A thermostat and by-pas s system is used to
control the se temperatures . The normal
operating temperature when a pres surized cooling
system is used is 175 - 210 F . The thermostat
valve remains closed and only allows the water to
recirculate within the engine its e1f unti1
normal operating temperature s are reached . This
provides for both rapid and even temperature
increase of all enq ine parts during the warm up
period. Whe n the de s ired te m- perature is
reached , the thermostat valve opens a nd allow s
the water to circu late th rough both e nq ine
and radiator . The cooling water is circulated by
a water pump loca ted at the front of the
engine block . The radiator cooled water enters
the pump at the lower or suction ope ning and is
directed through integ ra1 distribution pa s
sage s cast in the cy- linder head to areas in
and around the valve seats and combustion
chambers . This method provide s the coole st
water at the parts in the e ng ine s
ubjected to the highe st temperature s . The
cylinder walls , in turn , are cooled by
convection currents only , which keep the
cylinder barre ls at a more uniform temperature ,
there by qre atly reduc- ing crankcase oil
dilution and s ludge formation . Upon leaving
the cylinder head , water e nters the thermostat
hou s inq through a by-pas s type thermostat,
which controls the openinq to the
radiator. RADIATOR The radiator consists of tube
s through which the coo ling water is c irculated
. In standard radiator de sign fins are
connected to the tubes to give an exte nded
surface through which heat can be dissipated .
It is important that the se tubes be kept clean
on the ins ide and the f ins free of d irt on the
outs ide so that max- imum heat transfer can
take place in the radiator. Keep the cooling
surface s of the core free of d irt and other
fore ign particle s . Each 250 hours of
operation the radiator and cooling sys tern
is to be well cleaned and flu shed with clean
water. Wherever pos s ible , use only soft clean
water in the cooling system . Hard water will
cause scale to form in the radiator and the e ng
ine water jackets a nd cause poor heat transfer.
Where the use of hard water cannot be avoided , u
se an approved anti-rust and water pump lubricant
. GLEANING THE GOO LING SYSTEM Depos its of
sludge , scale , and rust on the cooling surf ace
s prevent norma1 heat transfer and in time render
the cooling system ineffective . The appearance
of rust in the radiator or coolant is a warning
that the corros ion inhibitor has lost its
effective ne s s , a nd the radiator is to be
clean.ed before adding fre sh coolant . II- 1 l
27
Use de penda b1e cleaning compounds . Follow
the precedure recommended by the supplier. This
is of prime importance because different cleaners
vary in concentration and chemical compos ition .
After cleaning and flu shing , fill the system
with an approved anti-free ze compound
containing a rust and corrosion inhabitor or
water with a corros ion inhibitor. RADIATOR
PRESSURE CV The practice of operating the
cooling system under pres sure is used because
of the reduction in evaporation los se s ,
because of the increase in engine operating
temperature s pos sible without overflow los s
from boiling , and beca use of a des ire to
increase the radiator coo ling capacity . 'I'his
is poss ible because the increased pre s sure
within the system raises the boiling point of the
coola nt . The Case Model 800 and 10 00 Grawlers
use 7 pound pres sure caps, which have spring
loaded valves that close the outlet to the
overflow pipe of the radiator and thus seal
the system until 7 pounds of pressure is built
up. To prevent the collapse of hoses which have
no interna I support , a second valve in the
radiator cap opens under vacuum when the system
cools . The boiling point of the cooling water
at 7 pounds of pre s s ure is 232 F a t sea
level. When a pres sure cap is used , an air
tight cooling system is nece s sary , and
particular attention must be pa id to insure
tight connections . ENGINE 0 IL GOO LER The Mode
Is 800 a n d 1000 employ heat exchangers to cool
the engine lubricating o i 1. Figure 1 0 .
Located on the right side of the engine block , t
h e cooler i s de s igned s o t h a t oi1 passes
through tubing surrounded by the coola nt. The
oil is cooled and thus helps to reduce engine
heat. Figure 10 - Engine O i1 Cooler SEGTIO N D
CO LD WEATHE R STARTING AND MAINTE NANCE CO LD
WEATHER STARTING - Be1ow 32 The requirements
for satisfactory cold weather operation of diesel
enq ines differ somewhat from those of gasoline
engines . This is brought about , to a large
extent by a difference in methods of ignition.
II- 12
28
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• the die se1 engine depe nds on the heat from the
  air compres sed in the combustion chamber to
  ignite the fuel when it is injected into this
  air. It require s a temperature of approximately
  900 F . in the combustion chamber to
  institute this combustion proces s .
• With engines standing out in temperatures below
  freezing , difficulty may be expected in ra is
  ing the temperature of the air in the combustion
  chamber to the point where it will ignite f
  ue1,even though compress ion pre s sure s do meet
  the required minimum of 325 pounds per s quare
  inch , and the starter will turn the e nq ine
  over at a des irable m inimum of 15 0 RPM .
• ETHER BOMB STARTING
• An ether s pray bomb is provided with the 800 and
  10 00 Grawler s to insure cold weather starts .
  The bomb is used as f ollow s
• 1 Make sure both track speed controls are in
  neutra 1 pos ition.
• Open shut-off cock in the fuel line beneath tank.
• Us ing the ether s pray bomb , direct spray into
  scree n mes h of a ir clea ner ca p . At the same
  time crank the e ng ine with the starter.
  Repeat until engine has fired . Figure 11.
• Under extremely windy conditions , it is
  advisable to remove the air clea ner cap and s
  pray directly into the opening . 8e careful,
  however not to saturate air with ether.
• GAUTION
• U s e every pre caution aga inst igniting or
  exce ssively inha ling ether fume s .

Figure 11 - Ether Spray Bomb MAINTENANCE OF
EQUIPMENT DURING GO LD WEATHER Gertain
maintenance operations must be checked more
carefully in cold weather , than during summer
operation. For instance , the thermostat and
water temperature control must be maintained so
that the e ng ine is warmed up a s quic kly as
pos sible to 185 F . and remains at this minimum
or above during operation .
II- 13
30
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