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Case 580CK Model B Backhoe • Loader • Tractor Service Manual v 8 .0 http://stores.ebay.com/UserFriendlyCDs

Case 580CK Model B

Backhoe • Loader • Tractor

Service Manual

v 8.0

B Backhoe • Loader • Tractor Service Manual v 8 .0 http://stores.ebay.com/UserFriendlyCDs

© 2006, 2009 UserFriendlyCDs

TABLE OF CONTENTS

SERIES/ SECTION

SECTION NO.

10

SERIES - GENERAL

General Specifications, 580B Tractors

11

Detailed Specifications, 580B Tractors

12

Lubrication, Shuttle Tractors

13

Lubrication, Hydrostatic Tractors

13

Lubrication, Loader & Backhoe

13

20

SERIES - ENGINE

Cylinder Head & Valves, Diesel

22

Cylinder Head & Valves, Spark Ignition

22

Engine Block Assemblies

23

Air Cleaner System

24

30

SERIES - FUEL SYSTEM

Fuel System & Filters

31

Roosa Master Model DB Fuel Injection Pump

32

Roosa Master Fuel Injectors

33

Model 267 Carburetor

35

40

SERIES - HYDRAULICS

Hydraulic Diagrams, Trouble Shooting, Testing, & Service

42

Hydraulic System & Power Steering Oil Filters

42

Torque Converter - Power Shuttle Hydraulic Pump

43

Equipment Pump

43

Three-Point Hitch Cylinders

44

Loader Control Valve

44a

Backhoe Control Valve

44b

Stabilizer Control Valve

44c

Three-Point Hitch Control Valve

44d

Cylinder Removal/Installation

45

Loader Cylinders

45

Backhoe Cylinder

46

Auxiliary Cylinder

47

Hydra-Guide Hydraulics Guidance System

47

Boom Lockout System

49

50

SERIES - STEERING

Power Steering Pump & Hand Pump

52

Steering Control Valve

53

Steering Cylinders & Adjustment

54

Steering Axle & Wheel Bearings

55

60

SERIES - POWER TRAIN

Torque Converter, Power Shuttle Countershaft, Control Valves, & Adjustment

61

Power Shuttle Clutch Pack, Rockford Clutch

62

Power Shuttle Clutch Pack, Twin Disc

63

Hydrostatic Drive, Gear Train, Control Linkage

64

Four-Speed Transmission & Final Drive

65

Mechanical Shuttle

66

Duel Range Assembly

67

11-Inch Traction Clutch

68

Independent Power Take-Off

69

NOTE: The following sections also relate to the Power Train:

70

SERIES - BRAKES

 

Differential Brakes, Differential Lock, and Parking Brakes.

74

80

SERIES - ELECTRICAL

Wiring Diagram, Tractor

81

Wiring Diagram Fork Lift Tractor

81

90

SERIES - MOUNTED EQUIPMENT

Miscellaneous Equipment (Includes Rear Attachment Support Arms, Counterweights, Moldboard, Logging & Pallet Forks, & Rollbar)

91

Loader

92

Backhoe

93

Three-Point Hitch

97

100

SERIES - HOW IT WORKS - TROUBLE SHOOTING

Hydraulic Testing - Torque Converter - Power Shuttle

101

How It Works - Hydrostatic Power Steering.

151

How It Works - Torque Converter with Rockford Power Shuttle.

162

How It Works - Torque Converter with Twin Disc Power Shuttle

163

How It Works - Hydrostatic Transmission.

164

NOTE: Also refer to sections in the 40 Series, Hydraulics, for troubleshooting and how it works information relating to the equipment hydraulics system.

Figure 1

Figure 2

DIESEL ENGINES

Type

Firing Order

Him

Stroke

,

"Case"

Open Chamber Combustion 4 Cylinder, 4 Stroke Cycle, VaIve-in-Head.

,,.,

1-3-4-2

3+13(16I~Ic~~s(96.81~m)

,

4-1;

Inches ( lO4.Smm)

Piston Displacement

Compression Ratio

Cylinder Sleeves

No Load Govern

No

188 Cubic Inches (3

,

Removable

,,

,

,

17.5

to

1

,

ã,

,

Wet Type

2060

2250

1900

2100 RPM

RPM

RPM

RPM

RPM

d

d

(Mechanical Shuttle)

(Power Shuttle) ã

ã

,ã.,,.,

,

-

(Hot

(Hot

Load

Gave

Rated

Engine

echanical Shuttle)

Rated

Engine

Speed

(Power Shuttle)

Engine Idling Speed

'Valve Tappet Clearance (Exhaust)

'Hot

(Intake)

Settings

*

* ã.+

600-650

and Cold) ,014 Inch (0.356mm)

and Cold) .014 Inch

(O.356rnm)

Are Made? After the Engine Has Operated At Thermostat Controlled Temperature

For At Least Fifteen Minutes.

Piston and Connecting Rods

Rings per Piston Number of Compression Ring's

Number of Oil Rings Type Pins Type Bearing

+

Replaceable

Number of Bearings

Type Bearings

,

+ Replaceable

Engine Lubricating System

+

ã

,

,

,.,

3

 

2

 

+

1

- Full Floating Type

Precision, Steel Back, Copper-Lead Alloy Liners,

5

-.-

Precision, Steel Back, Copper-Lead Alloy Liners.

-

Oil Pressure

50 to 70 Pounds (3.5 to 4.9 kgicrn2)with Engine Warm and Operating

Type System ,

at Rated Engine Speed. and Spray Circulation

Pressure

Oil Pump

Oil Filter

,

Fuel System

fuel Injection Pump

Pump Timing

Fuel Injectors

Fuel Transfer Pump .,

,

,

Governor 1st Stage Fuel Filter 2nd Stage Fuel Filter

,-,

,,.,,,,Ã

,

Fuel Tank Water Trap and Drain

Fuel Tank Capacity

Fuel Level Gauge

ãã

,

,,

,.,

*

ã

Mechanical,

,

,-.--

,.,

Full

Gear Type

Flow Spin OH Type

Roosa-Master

,

,.

8 Degrees Before Top Dead Center

Pencil

Type

(Opening Pressure 2800 PSI).

Vane Type, Integral Part of

Injection Pump.

Injection Pump. Replaceable Type

Type

,

,.

Fly-Weight, Integral Part of

,

,

Replaceable

,

Located

in Base of Fuel Tank

Electric,

22 U.S. Gallons (83,31liters)

Located on Instrument Panel,

General

Type

Firing Order

,

,

Bore (188G)

Stroke

(159G)ã,,,.,

,

-,

-.,-

,,-

--,

,

4 Cylinder, 4 Stroke Cycle, Valve-in-Head

 

1-3 4-2

,.,

3-13/16Inches

(96Amtn)

-

,

,

3-1j2Inches

4-1/8

(SS.Pmmj

Inches (104,Smrn)

Compression Ratio (188G)

(159G)

Piston Displacement

No Load Governed Speed ( lWG I

(159G)

RatM Engine Speed

Engine Idling Speed ¥ValvTappet Clearance (Intake)

(188G1

(

159G1

(Exhaust)

 

,

7,5

to

1

-,

,

,

7,42

to 1

.+

,

,,.,

, ,

,

,

,.,,ã

,

,ãã

,

,.ã

,

377 Cubic Inches

RPM

RPM

RPM

RPM

2250

ã.2250

2100

1900

,,

(Hot

+

, 600 RPM and Cold) ,014 Inches (0,356mm)

,.(Cold)

,020 Inches (Oh50Smrn)

(Hot) ,014 Inches (0.356mrn)

Exhaust Valve Rotators

Â¥HoSettings Arc Made After The Engine Has Operated At Thermostat Controlic-d Temperature

For At Least Fifteen Minutes.

Positive

Type

Piston and Connecting Rods

Rings per Piston

 

4

Number of Compression Rings

3

Number of Oil Rings

3

Type P'm

 

,,

Full

Floating Tyw

,

Type

Bearings ,

, Replaceable,

Precision Steel Back, Copper Lead Alloy Liners.

Main Bearings

Number of Bearings

Type Bearings

,

Replaceable,

Engine Lubricating System

3

Precision Steel Back, Copper Lead Alloy Liners.

-

,

Oil Pressure

24 to 32 Pounds (1.7 to 2.3 kg/cm2) with Engine Warm and Operating

at Rated Engine Speed

~

Type System , Pressure Spray Circulation Oil Pump , , , , , ,.Gear Type
Type System
,
Pressure
Spray Circulation
Oil Pump
,
,
,
,
,
,.Gear
Type
Oil Filter
Full
Flow, Spin on Type
Fuel System
Fuel Tank Capacity
,
,
,£Ã
Carburetor
,
Zenith
22 U.S. Gallons (83.3 liters)
(wfsolenoid shu t-off) 1-1/4 Inch SAK Flange (31,7rnm)
,
,
Fuel Strainer
In
Sediment Bowl Under Fuel Tank
Fuel
Filter
,
I
-
Mounted on Fuel Strainer Head
Distributor Ignition
Contact Point Gap
Dwell Angle
-020Inch
,
,,.
700
Spark Plugs
,
,,
Prestolite
18 8
Plug Gap
,
,
,.,
025
Inch
,
Thread
18
MM
,
Shank Length
3/2
Inch
Engine Timing
,
Static Timing UWG)
TDC
x
(159G)
-
,,
3QATDC
Running Timing (18SG)
34"
BTDC at Rated Speed
,
,-,
,
,
(mG)
;JOifBTDCat
Rated Speed
-,

GENERAL SPECIFICATIONS

Cooling System

Capacity (188D & 188G)

Type of System

Radiator

.,

(159G)

,,,,

,.,

Thermostat

Pressure Cap Required

16-1'2

U.S. Quarts (15.6 liters)

ã

,

,

,,

Ã

--

,

-

14 U,S. Quarts (13.3 liters)

Pressurized

Thcrmosia t Controlled

Impeller Type Pump,

Heavy Duty Fin &Ed Tube Type

Starts

to Open at Approximately 1779F.Fully Open at 202".

,.,

,

,

4

PSI

Electrical System

Type of System - Diesel and Spark Ignition Batteries

Parking Brake

Type

,-

Volt Negative Ground

12 Volt Batteries Connected in Parallel

,12

(2)

Cable Actuated by Orchlin Type Handle . Adjustable from Operator's Seat.

Hydraulic Brakes

Type

Brake Pedals

Can

Duty, Disc and Band Differential Brakes

Be Locked Together for Safe Road Travel or Operated Independently

for Steering Assistance

Heavy

Clutch Type

Disc Size

Throwout Bearing

Transmission

Dual Range Shuttle

Foot Operafed, Spring Loaded, Single Disc.

,

,,

,.,-,,ã È,, ,ã--

+.ã.,

,

,,--, r

, ,ã,.,

11 Inch {279,4mrn)

Ball

Thrust wfgrease fitting

Mechanical

Speed Gear

Actuated Forward and

Reverse Clutch

8

,

~.,

,

,

,

Independent

Power Shuttle

Torque Converter

Power Shuttle

Transmission

P,TdO

Hydraulically

,

,,.,.,,.ã.,.,.,

,,,,.,.-.b,,Ã

Hydrostatic Power Steering

Relief Valve Pressure

ã,

Pump Capacity at No Load Engine RPM Capacity of Reservoir

Capacity of System ã

Type of Oil

Hand Pump Type

Actuating Cylinders

,,ã

Power Take-Off

,.,ã

,

Single

Stage

Actuated Forward and Reverse Clutches

,

,

-

,,,ã,

4

Speed Gear

Independent

1500 to 1700 PSI

2.5

,

,

6.7 GPM (25.41mm)

1 Quart (-95 liter)

Quarts (236 liters)

TCH

Case

Bi-Directional Driven

By the Steering Wheel.

2 Way Cylinders Are Integral Part of Steering System.

Gerotor

Type

Independent

Rotation

-

Clockwise

Spline Size

,540

RPM at 1750 RPM

,1-318"

Dia. (34.9mm)

Method of Engagement

Pulley Diameter

Pulley Face Width

Ratio Engine RPM to Belt Pulley RPM

,

,-.+

1 RPM of Belt Pulley

+

,

.,

ã,

-

PTO

Control Lever

10.25 Inches (260.4mrn)

6.5

Inches (165.1mm)

1.53

to

1

2.68 Feet (Q.S72m) Per Minute Belt Travel

(W15-24 Integral Rim)

,.,

+

(W12-24 Integral

Rim, 1.81 offset)

. 79 Inches (2 007mm)

122.5 Inches (3 112mm)

*

.

1/4 Inch (6.35rnm)

57 Inches (1 448rnrn)

 

54

Inches

(1 372mm)

62

Inches

(1 575rnmj

- ,.+

62

Inches

(1 575rnrn)

L

4.a

,.

Dished

Out

Only - 66 Inches (1 676mm)

Rear Wheel Tread (W12-24 Demountable Rim) Wheel dished in and lugs inside - 60 Inches (1 524mm),

Wheel dished out and lugs outside - 64 Inches (1 626mrn),68 Inches (1 727mm), 72 Inches (1 829mrn),

76 Inches (1 930rnrn),

Rear Wheel Tread (W15L-24and WEL-28 Demountable Rim) Wheel dished out only and lugs inside -

ATE TRAVEL SPEEDS

WITH 14.8-24 TIRES

LOW

1

1 DIRECT

NOTE: Listed above are the approximate speeds obtained under full load conditions. Normal transport speeds are approximately 10% higher than those listed above.

11-8

FUEL SPECIFICATIONS

CAUTION

"EVEl,

FILL

THE

[" U EL

TANK

WHEN

THE ENG INE IS IWN NI:\G on WHE"

WORKll'W NEAR ["LAMlvI ABLE ["UELS.

:\E.\fl

,\A- OPE"

["L'-\~[E. DO

:\OT S MOKE

WHEN

GASOLINE

Case G,,~oline Engines are ciesigned to operate on R e gular Grade gaso lin e having a m inimum

ra.ling of 90.7 Octane . This will give full power and economy toge ther with

reseal'ch

method

long engine life and low n1uinlenance cos t.

The a verage Oct~ne :-lumber I\a tings for Ile gular

:\[otOI' Ile se n rch

Hescarch

:'I'Jelliod

Grade g aso line are:

,86.2 Octane Number 94.2 Octane Number

Thesc

two

Octane

becom e COmmo n pract

flatings

are

used

to

define

the anti-knock quality of gasoline. It h as

ice in the Petr ol e u m Indu str

y to r e f e r to only the R es ear c h ~'1ethod R ati ng.

Wh en

on ly o n e Octa ne nating is giv e n for gaso lin e and the rating method is not s p ec ified, it

can be assumed to be the Hesea rch Method r ating.

11-9

D IESEL

Case di e sel e ngin es

F ue l. Most well known

s h o uld be no di ffi c ulty i n obtaining it.

ar e design ed to ope rate most e ffi c i e ntl y when us ing a !\umber 2 Di e se l

good gTad e of Dies e l Fue l and there

re fin e rs and distributors marke t a

Do not

co nfus e

number

2

Diese l

Fuel with Number 2 Furnace Oil, as thi s

m eet the fu el s pe c ific a ti ons fo r diesel e ngines .

does not always

Specifications for a Su itable

A. P.1.

P our Po int (iVlaximum)

Gravity

(iVlinimum)

DL'lTILLATION

Number 2

Diesel Fuel

30

100F ahrenh e it be low ambie nt ope r a ting' te mperature.

90~6 Point

End

Point.

.

.

.

.

.

.

.

.

.

.

.

.

.

540 0 - 625 0 Fnhrenhe it 67 5 0 Fahrenheit

.

.

FL AS H

POINT

(iVIi n imum)

 

.

125 0 F ahr enhe it or

legal

Kine mati c Viscos ity ,

centis tokes @ 100 0 Fahr e nhe it.

.

.

.

.

.

.

.

.

.

.

.

2.0-4 .3 Seoond s*

Cetane No. (Minimum)

 

.

.

40

(45 -55 fOl'

win te r or hi gh a lti t ude

use)

Wa ter

a nd

Sed ime nt

Vo l.

(Maximum)

.05%

As h, wt . (i'Vlax imum)

 

.

.

.01%

Sulphur

wt.

(Maximum)

 

.5%

Ca rb o n R es idue o n 10 % (M aximum) Cor r osion, Copper Strip,

3

hrs .

@ 212 0 F ahre nhe it

(* 3 2-4 0 Sa yb o lt Univer sa l Seoo nd s )

NOTt The

use

of ,,"umb e r

1

Dies e l

F ue l,

which is a lighte r

e ngine po we r and a l s o inc r eased fu e l c o ns umpti o n b e cau se it h as

viscos ity than Numbe r 2 Diese l Fue l.

fuel,

m ay

r e s ult

in

a

l e ss

hea t c on t e nt a nd

.2%

1\0 .

:3

lo s s

of

a l o\\'e r

The

life

of the

injection

pump

may

also be affe cted becaus e

of the lack of lubr ic ant in the

lighte r

1\ umb e r

1

D i e s e l

F uel.

 

11-10

FUEL CONDITIONER

Cnse Die se l Fuel COl1c1itionflJ~ is re co mn1ended for use in all Case Di esel e ngine fu e l sy stenl.

reconlln e nded for

Cnse Lullr~ -

Gas

Conditioner

is

use in all Case Gas olin e e ngine fu e l

:-ivs te nls.

, Th ese fu e l

condit ion l' ],"; shoul d be used us dil' e cted on th e contain e r,

CASE

Diesel Fuel Conditioner :~:~~~~~" ~ -". -'''-'"- --- _-.-- ---- ---
Diesel
Fuel
Conditioner
:~:~~~~~"
~
-". -'''-'"-
--- _-.--
----
---

DIESEl FUEL COND IT IONER

Prevents gLlmmy deposits

from fOl'ming

in t he fuel sy stem,

I mpro v e d l ub ri c ation to th e Up)l8 1' p ;l l' ts of the engine,

int ema l

Elimin ates

fo u ling

v alves and nW.nifolcls.

of

injector no zz les ,

He lps kee p co nden sa ti o n susp e nd ed

in the

fu e l,

a ll o wing it to be bUl'ned with the fu e l.

degree of fuel com-

bustion and engine pel' formaIl CE' frorn fu e l

l\Iaintnins

a highe r

t h e

e ngi ne UU l'll S .

lubra -Gas Condition er M20426 UserFriendlyCDs
lubra -Gas
Condition er
M20426
UserFriendlyCDs

CA SE LU 8RA-GAS CONDIT I ONER

Improved

lubri cation. to uppe ,' int.ern al

parts of the engine,

Reduces

cylinder

proved compress ion,

and

ring

we ar , im-

reduced cor r oSion of

the int ernal. en gine parts,

Reduces cra nkcase 0!1 dilution_ H elps k eep condensation suspend ed i n the

fu el,

allowing it to be burn ed with. the fuel.

Maintains

a higher

engin e performance

fl'OM {!.leI the engine bu rn s .

Section

12

DETAILED SPECIFICATIONS

TABLE OF CONTENTS

ENGINE BLOCK

2

CYLI NDER HEA D AKO VAL VES

7

COOL IN G SYST EM

10

ENGINE OIL FILT ER

11

AIR CLE ANE R

11

F UE L SYSTEM

12

BRA KE S

11

PO WER TRAli':

15

STEE R ING

16

G ENE RAL TOR QUE TABLE

.

17

SPECIAL TORQ UES

17

12·2

~OTE:

All

dimensions

are

given

CYLI:\DER SLEE VES

Engine Block

in

inches.

Specifications

apply

to

all

engine's

un te'ss

not ed.

Maximum Limit Including Wear

LD . of sleeve

(109G)

.3

5013

to 3.5028

.005

(1

88D)

3.8115 to 3.8125

.005

(188G )

3.8130 to 3.8145

.000

(148G)

3.2745 to 3.3765

.005

Sleeve out·ai·round

 

.004

Clearance to

bottom of pisto n skirt

(1880)

00.35

to .0055

(188G)

0025

to .0035

(159G)

.0015 to .0045

 

(148G )

.0030 to .0035

Tape)"

.001

PISTON

Type

Cam

Ground

:Vlaterial

Aluminum Alloy

 

0.0 . at

bottom of skirt : 90" to piston pin

(l88G)

3.8090 to 3.8105

 

(1880)

3.8070 to 3.8080

 

(159G

)

3.4983 to 3.4998

 

( 148(; )

 

3.3735 to 3.3750

1.0.

of p is ton

p

in bore

(188 0)

1.2500 to 1.2503

.001

 

(l8RG, 159G )

9992

to .9994

.001

(148G)

8592

to .8594

.001

Width

of

1st ring groove i188 D )

Keyston e Ty pe

 

(188G. 159G. 148G)

0965 to .0975

\\' idlh

of

2n d

ring g

roove (18SD )

097 to .098

 

(148G . logG . 188C;)

0955

to .0965

Wid th

of

3rd

ri ng groove

(188D)

.1 895

to .1885

 

(188G, 159G, 148(; )

 

.0955 to .0965

Wid t h

01

4th rin g groove (l&QG,

159G . 148 B)

250 to .251

PISTO:\

RI:\GS

:-';0. 1 Compres si

on

(1880)

Chrome Grooved

Keystone

Wi dlll (1880)

(J 88G,

(188G,

159.

159G.

148(; )

148(;\

Fac e

Not measur ea ble

0930 to .0935

Tapered

12-3

Engine Block (Continued)

PI STON RINGS (Continued)

:Vla xim um

Limit

Including Wear

En d

gap in 3.812 I.O . sle eve (1880)

 

.015

to .025

3.375

I.D.

s leeve

(1 48G )

'

"

' ,

,

.010 to

.020

3

500

l.0.

sl eev e

(1 59G)

.010 to

.020

3.812

I.O . s leeve

(188G)

.010 to .020

Si d e

cleara n ce (1880 )

 

Not

measureable

(188G, 1;;9G, 148G)

No.2 Co mpr es s io n ( l88G. 159G, 148G)

Width

(188D ) (188G. 159G. 148G )

(1880)

0030 to .0045

Tapered Fac e

Groove d .0930 to .0935

.0925 to .093')

End Gap in 3.812 s l eeve (188 0 )

015

to .02')

,1.375 sleeve

(148G)

.010 to

.020

3. 500

sleeve

(159G)

.010

to .020

3,

81 2 s lee ve>

(188 (; )

.010 to

.020

No.2 Compression

Side clea ran ce

(1 880)

.0035 to ,0055

 

(l 88G,159(;.148G )

.0020 to

.0035

':\0 . 3 Co mpress io n (188(; ,159(; ,14 8G)

Tapered

Face

Wid th

.0930 to

.0935

Ene! g ap

in :1 .812 sleeve

(188 G )

010 t o

.020

3.3 75

s leeve

(148G)

.010 to .020

3. 500

sleev e

( 159G)

.01 0

to .020

Side c lea ran ce

.0020

to

.0035

OIL Rl:\GS

Width

(188 0 )

.1 82;')

to

.1 888

 

(188G.159G.14 8G)

 

248 .5 to

.2 49 0

Side c lea rance (1880)

 

000 to

.007

 

(188G. 1;J9G.148G)

 

0010

to .0015

End ga p in 3.812 1. 0

.

s leev e

( 188G)

.010

to .018

.3.375

1. 0.

sleeve

( 148(;)

 

010

to .018

3.500

I.O . sleeve

( 159(; )

.010 to

.018

Rail end gap

in

3.8 12 I.O.

sle eve

(1 88 0)

015 to

.050

12· ·)

Engine Block (Continued)

1-' ISTO" 1-']~:

Typt>

0.0. of pin 1181101

F

i t

in

pi ston

i188G . 1:;9(; ) IH8G )

( I SS D) OSSC,

159(;)

F l oa ting

1.2497 to 1.2498

Pu ll

.9991 to

.8592 to

.Q992

.8593

.0002 to .0006 .0000 to .(J003

ilila x imum Ll mi I Incl udi ng Wear

 

( 1·)8(;)

.0000 to

.0002

F'i t

in

r od bu shi ng

(I88 D )

.0002

to

.0006

 

(188G ,lJ9C.1 4HC )

.000.3 to

. 0006

CO, ' J IXTl J ' C Bu shing

ROD

Repl acea bl e Bronze

Bushing LD. in s talled (rca rn t'd 10 s ize' )

 

(188G ,159G)

 

9995 to .9997

.001

1188D )

1.2502 to 1.2504

.001

t1~8G )

8590 to

.8 598

.001

Hushing

oul ·or·round

 

0015

Rearin g Lin e rs

 

Repla cea ble

Hearin g li ner

wid th

1.1 20

to

1.1 30

Rod

,Journa l

width

c LO. withoUI bearing liners

at

c r a nk

nel

1.303.5 to 1.3055

2.1875

2,1870 t o

 

Bearing

oil clearance

 

"

.0010

to .0035

006

Cnd ers ize be ari ngs ror ,crvice

.002,.010 ,. 020, .030

Side clearance

.005

to

.fil l

Ca p baits

Self locking

type

CRA l"KSHAFT Typc o

Balanced

:Vl ai n bea rin g li ners

R ep lac ea bl e

EIle] play , ce nter m a in beari ng cap

.0111

to

.006

Thr us t s pace r s td.

t hic kness

.092

to

.098

Conn ect in g ro el

G rind

to

.0 10"

j ournal st d . a.D.

0.0.

u nd ers i ze

2. 0605 to 2'(J613

2.D:105 to 2.051 :;

.020"

O.D.

unde rs ize

2.0405

to 2.0415

.O;lll"

U.D.

unc! Ns ize

2.030') to 2.0315

Co nlH.'0 ling rod journa i maxi

rnu rn tapC'!'

,

'

.002

Engine Block (Continued)

CR.-\:\KSHAF T

(Continued)

. line r widt h

.J ournals out ·of·round

Mai'l bearin g

Main bearin g li ner widt h 1s t , (159G, U8G)

Main bear ing liner width 3rd (1880)

1st,

(1880,

ISSG )

.O()]

1.276 to l.286

1. 870 10 1.8S0

1.371 to 1.37:l

Maxim um Limit

In c luding \\"car

:l1alll

bearing

li ne r wi dth

2nd (lSS G)

1.371 to

U 7.J

Main b earing Iin c'!' w id th 2nd a nd 4th

(1 88 D)

.9 50

to 1.000

:Vlain

bc'aring

li ner

w idt h

5 th (1 88 0),

(l 88G 3rd.)

1.557

to 1.567

l;nders izc' main bear in g

lin e r s for service

002 ,. 010 ,.020 ,.0:,0

Main

b eari ng

oi l c learan ce

.0012 to .0042

;Vl

a in

bea ring

jou rnal std. 0 .0.

(lSSG, 188 D)

2.8730

to 2.8/40

 

(159G.14 8C )

2.62 30

10

2.62 40

G rin d to:

.010"

0. 0.

u nd ersize , (188(;, 188D)

.,

.020"

0.0.

unders ize , (188(;.

1880)

.0:)0"

0.0.

u nd efSiz('.

(I 88G , 1880 )

 

.010"

0.0 . undersiz(>,

(10';9(;,

14 8GI

'

"

- .

,

unders ize, und er siz e.

Ma in journ a l bore LD.

.020"

.0.30"

O .D.

0.0.

(lo9 G, 148(; ) (159G, 148G )

w l o li ners

,

(1880, 188G )

(l59G,USG)

ivl ai n

journJl w id th be iween c heek ":

2n d

2nd an d 4t h (1880)

(];,j9(;.

U8C)

,

"

 

2. 86 30

to 2.8610

2.8530

to 2.8.'>40

2.8430

to 2.8440

2.6130

to 2.6140

2.6030

to 2.6040

."

.

2.3930

to 2.59'10

 

:3. 06 6

to 3.067

2.8 16

to

2.8 17

1.499

to

1

')(12

1.183

to 1.189

2nd

(188G)

Ll770 to 1.3740

3rd

(188D )

L

J740

to

1. 3770

3rd

tl.S9 G , 148G )

1. t o 1.7 ') 1

74 1

5t h (1&30)

1

745

1. to

1.7 51

Connec tin g r od journal width be twee n cheeks

3105

to 1.3145

CA :vrSHAF T

Ty pp

'.,_, ,,"

P a r abolic

Bushings

(188D)

5, R ep l a cea ble

Bllshings

(l8RG)

4 . Rep lacea

b l('

Bu s hings

(159G , 148(; I

3, Replaeea bl e

Oil

CiC'a ranc e

002 to .00"

12-6

Engine Block IContinued)

CAMSHAFT (Continued)

Bushing lubrica tion:

Fro n t bushing

Pressur e lub r i ca ted

Maximum

Including Weal'

Limit

 

born oil pump.

Inter mediate bushing

Gravity

[low lubrica ted

Rear bushing

(1880 Only)

Pressure lubricated with

 

rear oi l metering.

Oil clear ance

.002 to .005

007

l.D. of bushing installed

Bushing width:

1st (front)

(front)

1st

(l59G.148G)

(1880. 188G )

2nd (159G,l.j8G)

2nd.

2nel.

3rd

4th

5th

O.D.

0.0.

Thrust plate' thick n ess

3rel &

& 3rd.

(rear)

(rear)

(rea r)

4th

(1880)

(lfSSG)

(148G.

(188(; ) .,

(1880 ) ,

159G)

,',

of

each

bearing

s urface

of

each

hearing

sur face

Camshaft

e nd

play

Camsh a ft

e nd

c leara nce

V.-\LVE

PCSH

ROD LIFTERS

Type

Body 0.0. std.

 

1.0. of hloc k bore.

, td .

GI::AR TRAI:\

Backlash:

,

, .,

,

,

,

,

1.752

to .1753

1.307

to

l. 317

1.213

to 1.223

.713

to .723

j90

to .500

.490 to .500

l.l77 to l.l97

1.213 to 1.223

1.213 to 1.223

(159G. 1880)

1. 749

to

l. 750

.004

(148(;,188G)

1.749

to 1.750

.004

_149 to .147

 

Taken up hy thrust plate

 

003 to .0(17

 

,

Mushroom

 

.5615 to .5620

.5625 to

.5633

.0015

Crankshaft gear to camsha ft gear

0002

to .000

Camsh aft gear to

ieller gear

IDiesel)

0004

to .006

[ellpr gear to fuel

pump gear

[Diesel)

,0005 to .007

Crankshaft

ge ar to

oi l pump gear

"

002

to .008

Crankshaft

gear 10

fuel

pump gear

(D iesel)

!';Iaximum

.019

12-7

IDLER GEAR

Engine Block (Continued)

Maximum Limit Including Wear

0_0. of idler gear journal

(Diesel)

 

1.3740 to 1.3705

.0005

l.D. of idler gear w / bu shi ng ( Di ese

l)

1.376 to 1.377

Thrust washer

shims ( Diesel)

005,.006,.007,.009

Idler gear end

play (D iese l)

003

OIL PUMP FRONT MOCNTED

 

Positive displacement pump

 

Gear Type'

Pump gears to oil pump cover clearance

0015 to .0055

Pump gears radial clearance

.002

to .005

Drive gear

to

body

clearance

(I 88G,159G,148G)

003

to .006

Drive gear

to

body

clearance

(1880)

J)035 to .0065

Relief valve spring:

 

Wire thickn ess

(1880)

0625

Maximum

0.0.

(l88G,109G,148G)

 

.469

Maximum

O.D.

(l88D )

.4844

Free

lengt h

(188G, 159G ,148G)

 

2

Free length

(188D)

2-1 /8

Load

a t 1.38 inches

(I88G,159G,148G)

6-3/ 4 to

7-1 / 4 lbs.

Load

a

t 1.44

i nches

(188 0)

18

to

19

lbs.

Oil

pr ess ure

(lS8G, l5 9G, H 8G)

24

to

32

PSI

Oil

pressure

(1880)

50

to

75

PSI

Ba c klash , crankshaft drive gear and oil pump gear

_002 to

.008

Cylinder Head and Valves

Diesel Engines

CYLIND ER HEAD Warp age

 

_006"

EX HAUST VALVES

 

Tappet Clearance

(Hot a nd Cold)

0l4"

Fac e

An g le

-14"

Face

Run-Out

.002"

0.0.

of

Head

1:l9W'

to H08"

 

0.0.

of

Stem

:l:J99"

to

.3409"

.OW "

Length

-

 

6.:139"

to

6. 364 "

In sert Seat Angle

-

45('

Sea t Face Width

0415"

Seat Run -Out

 

002"

12·8

Cylinder Head and Valves (Continued)

Maximum Li mit Including Wear

EXH.\ L:ST VALVES (Con tinued I I nsert Heig ht

.247;) " to .2 525"

0.0. o f Insf'rt

 

1.44;JO"

to 1.4505"

 

LD. of In se:·t

 

.

1.245" to 1.255"

INTAKE VALVES

 

Cle a rance

(Hot and Cold I

 

014 "

Tappet Fa ce

Angle

Run·Out

.

44'

F a ce

 

002"

0.0.

o f He a d

1.599 "

to

1.609"

0 .0.

of

Stem

3409"

to

.3419 "

002"

Length

 

6.339"

to

6.3 64"

Sea tAngle

 

-15'

Sea t Run·Out

 

002"

Seat Width

 

082" to .09.J"

EXH AUST VALVE GUiDES Leng th

 

3.125 "

0.0

6565"

to .6575"

1.0.

(I nstalled and

Reamed)

 

3429"

to . 3439"

001"

V al v e SteIn Clearance in

Gui dE'

"

,

,002/1

to .004 11

Pro t rusi on Ab ove Cylind er Head

 

875 "

INTAKE

VALV!': GU IDES

 

L engt h

 

3.250"

0. 0.

.6565"

to .6575"

 

LD.

( In stalled and Reamed)

 

34 29"

to

.:3439 "

001"

Valve Ste m

Clcdra nee in Guid e

 

001 " to .003"

Pro trusion Ab ove Cylind er Head

 

875"

VALVE SPRI1\C Free Lengt h

2. 375"

Tota l Coils

8.25

Wire Diame ter

102"

LD

958"

to .978"

ComprE'ssed to 1.521 "

(Va lv e

Op e n)

110 to

118

l bs .

Compre s s e d t o 1.8 75 "

(Va lv E'

Cl o s e d)

53

to

59

l bs .

RO CKER

ARM ASSEMBL Y

0.0. of

Sh aft

.622 "

to .623"

1.0 . of Arm

Fre e

Bore

 

.02'1"

to

.625"

Shaft Sp ring

 

--

-

-

2.5 / '

Wi re

Lengt h Di amete r

,

072 "

Compres sed to 1.70 "

7.5 to 8. 5 lbs .

Lubri ca lion Shaft Oi l Holes

Engine oil, cam shaft m etE-ring T oward valve s ide of e ngine , shaft cannot be rotate d.

12-9

Cylinder Head and Valves (Continued)

Spark Ignition Engines