Link Product / Engine
Product Market Product Engine MAXXUM CVT 1 North America F4DFE413C*A MAXXUM CVT 120 North America F4DFE413B*A MAXXUM CVT 130 North America F4DFE413A*A MAXXUM 1 North America F4DFE413E*A MAXXUM 1 Multicontroller North America F4DFE413C*A MAXXUM 1 North America F4DFE613F*A MAXXUM 1 Multicontroller North America F4DFE613F*A MAXXUM 120 North America F4DFE413D*A MAXXUM 120 Multicontroller North America F4DFE413B*A MAXXUM 125 North America F4DFE613E*A MAXXUM 125 Multicontroller North America F4DFE613E*A MAXXUM 130 North America F4DFE413C*A MAXXUM 130 Multicontroller North America F4DFE413A*A MAXXUM 140 North America F4DFE6132*A MAXXUM 140 Multicontroller North America F4DFE6132*A 47665854 27/03/2014
Contents INTRODUCTION Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 T urbocharger and lines [10.254] Intake and
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.310] Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12] Slip clutch flywheel damper T ransmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [21.1 12] Power shuttle transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.1 1 Semi-Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 [21.133] Semi-Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 [21.103] Semi-Powershift transmission lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6 [21.152] Semi-Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7 [21.504] Continuously V ariable T ransmission (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 Continuously V ariable T ransmission (CVT) external controls Continuously V ariable T ransmission (CVT) lubrication system Continuously V ariable T ransmission (CVT) internal components 1 Creeper 47665854 27/03/2014
exhaust manifolds and muf fler
front axle
Front bevel gear set and dif ferential
Final drive steering and shafts
Axle suspension control
Rear axle system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [23.202]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.314] Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2
axle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overdrive Four-Wheel Drive (4WD) system
Electro-hydraulic control
Front
system
Powered
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [27.100]
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and dif ferential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 Power T ake-Of f (PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear control 14] T rear Power T f (PT [31.1 16] Three-speed rear Power T ake-Of f (PT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 [31.142] Front Power T ake-Of f (PT control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4 Front Power T f (PT Brakes and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.1 10] Parking
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.204] Front
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3 T railer brake hydraulic control T railer brake pneumatic control Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [35.000] Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 47665854 27/03/2014
Powered rear axle
brake parking lock
axle brake
Charge
Regulated/Low
Remote
Auxiliary
14] hitch
[35.1 16] hitch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.10 [35.160] Front hitch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 1 Hitches,
couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and ballasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering control T rods [41.200] Hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.5 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [44.51 Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 Rear wheels Cab climate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.104] V entilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3 Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47665854 27/03/2014
Reservoir , cooler , and filters Fixed displacement pump V ariable displacement pump
pump
pressure system
control valves
hydraulic pump and lines
control valve
controls and lines
drawbars, and implement
Rear hitch linkage Frames
Electrical system Harnesses and connectors Engine control system Alternator Battery Fuel tank system Selective Catalytic Reduction (SCR) electrical system Engine cooling system Electronic modules Cab transmission controls T ransmission control system 1 T ransmission speed sensors T ransmission pressure sensors [55.022] T ransmission temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14 [55.023] T ransmission position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15 [55.610] Ground speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16 [55.048] Rear Power T ake-Of f (PT control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17 [55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18 [55.035] Remote control valve electric control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.19 [55.051] Cab Heating, V entilation, and Air-Conditioning (HV AC) controls . . . . . . . . . . . . . . . . . 55.20 V and (HV AC) control system Steering control system Rear hitch electronic control system Global Positioning System (GPS) External lighting switches and relays Cab platform harnesses and connectors W arning and instruments [55.DTC] F AUL T CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.28 47665854 27/03/2014
cab, and decals [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 Engine hood and panels 47665854 27/03/2014
47665854 27/03/2014
INTRODUCTION 47665854 27/03/2014 1
Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Foreword - How use and navigate through this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Foreword Ecology and the Environment 9 Safety rules T orque Basic instructions Conversion factors Consumables Lubrications and Coolants Capacities 47665854 27/03/2014 2
Foreword
IMPORT ANT INFORMA TION
All repair and maintenance works listed this manual must carried out only staf f belonging the CASE Service network, strictly complying with the instructions given and using, whenever required, the special tools.
Anyone who carries out the above operations without complying with the prescriptions shall responsible for the subsequent damages.
The manufacturer and all the organizations its distribution including - without limitation - regional local dealers, reject any responsibility for damages due the anomalous behavior parts and / components not approved the manufacturer including those used for the servicing repair the product manufactured marketed the Manufacturer any warranty given attributed the product manufactured marketed the Manufacturer case damages due anomalous behavior parts and / components not approved the Manufacturer
reproduction, though partial text and illustrations allowed.
INTRODUCTION
27/03/2014 3
47665854
Foreword - How use and navigate through this manual
This new system designed deliver technical information electronically through web delivery and paper A coding system called SAP has been developed link the technical information other Product Support functions, e.g., W arranty .
This manual has been produced a new technical information
T
echnical information written support the maintenance and service the functions systems a When a customer has a concern their machine usually because a function system their chine not working not working ficiently , not responding correctly their When you refer the technical information this manual resolve that you will find all the information classified using the SAP coding, according the functions systems that machine. Once you have located the technical information for that function you will then find all the electrical hydraulic and sub assemblies for that function Y will also find all the types information that have been written for that function system: the technical data the functional data (how the diagnostic data (fault codes and and the service data install integrating SAP coding into technical you will able search and retrieve just the right piece technical information you need resolve that concern his This made possible attaching 3 categories each piece technical information during the authoring process.
The first category the the second category the Information T ype and the third category the Product:
• LOCA TION - the component function the machine, that the piece technical information going describe Fuel
• INFORMA TION TYPE - the piece technical information that has been written for a particular component tion the machine Capacity would a type T echnical Data describing the amount fuel held the fuel
• PRODUCT - the model for which the piece technical information
written.
Every piece technical information will have those three categories attached Y will able use any nation those categories find the right piece technical information you need resolve that concern their
That information could be:
• the procedure for how remove the cylinder head
• a table specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool 47665854
INTRODUCTION
4
27/03/2014
Manual content
This manual divided into Sections. Each Section then divided into Chapters. Contents pages are included the beginning the then inside every Section and inside every Chapter alphabetical Index included the end each Chapter Page number references are included for every piece technical information listed the Chapter Contents Chapter
Each Chapter divided into four Information types:
• T echnical Data (specifications) for all the electrical hydraulic assemblies sub -
• Functional Data (how works) for all the mechanical, electrical hydraulic devices, components, assemblies sub -
• Diagnostic Data (fault electrical and hydraulic troubleshooting) for all the electrical hydraulic assemblies sub -
• Service Data (remove install) for all the electrical hydraulic assemblies sub -
Sections
Sections are grouped according the main functions a systems the Each Section identified a number The Sections included the manual will depend the type and function the machine that the manual written for . Each Section has a Contents page listed alphabetic / numeric order . This table illustrates which Sections could included a manual for a particular
INTRODUCTION
T ractors V ehicles with working arms: skid forage Seeding, planting, floating, spraying SECTION Mounted equipment and - Maintenance X X X X X - Machine completion and equipment X X X X X - Engine X X X X - Main gearbox and drive X X X X - Clutch X X X - T ransmission X X X X - Four wheel drive (4WD) system X X X X - Front axle system X X X X - Rear axle system X X X X - Hydrostatic drive X X X X - Power T ake - f (PT X X - Brakes and controls X X X X - Hydraulic systems X X X X - Pneumatic system X X X X - drawbars and implement couplings X X X - Frames and ballasting X X X X X - Steering X X X X - Wheels X X X X - Steering clutches - T racks and track suspension X X X - Cab climate control X X X X - Electrical systems X X X X X - Grape harvester shaking - Attachments / headers X - Product feeding X 47665854 27/03/2014 5
PRODUCT
INTRODUCTION - Metering system X - Pressing - Bale formation X - Chemical applicators X - Chopping X - Threshing X - T ying / W rapping / T wisting X - Bale wagons - Ejection X - Lubrication system X X X X X - Separation X - Residue handling X - Cleaning X - Soil preparation / Finishing - Secondary cleaning / Destemmer - Seeding X - Spraying X - Planting X - Crop storage / Unloading X - Front loader and bucket X X - T elescopic single arm X X - dippers and buckets X X - Dozer blade and arm X X - Accessories X X X X X - T ools X X X X X - bodywork and decals X X X X 47665854 27/03/2014 6
Chapters
Each Chapter identified a number e.g. Engine - Engine and crankcase10.001. The first number identical the Section number Chapter inside Section The second number representative the Chapter contained within the CONTENTS
The Chapter Contents lists all the technical data functional data (how diagnostic data (fault codes and troubleshooting), and service data (remove, install, adjust, etc.), that have been written that Chapter for that function system the
The Chapter Index lists alphabetical order all the types information (called information units) that have been written that Chapter for that function system the
INTRODUCTION
Contents ENGINE ENGINE - Engine and crankcase –TECHNICAL T A ENGINE - Engine and crankcase - General specification - 4 FUNCTIONAL T A ENGINE - Engine and crankcase - Dynamic description - 6 SER VICE ENGINE - Engine and crankcase - Remove - F 8 DIAGNOSTIC ENGINE - Engine and crankcase - T roubleshootingINDEX
Index ENGINEENGINE ENGINE - Engine and crankcase - Dynamic description - 6 ENGINE - Engine and crankcase - General specification (10.001D.40.A.10) 4 ENGINE - Engine and crankcase - Remove - F 8 ENGINE - Engine and crankcase - T roubleshooting47665854 27/03/2014 7
Information units and information search
Each chapter composed information units. Each information unit has the SAP code shown parentheses. This indicates the function and type information that information Each information unit has a page reference within that Chapter The information units provide a quick and easy way find just the right piece technical information you are looking for Example information unit Engine block cover - Front – Remove - F Information Unit SAP code 102 F 10.A.10 SAP code classification Engine Pan and covers Engine block cover Front Service data Remove
Navigate the correct information unit you are searching for identifying the function and information type from the SAP
• (1) Location and (2) Information type.
• (A) corresponds the sections the service
(B) corresponds the chapters the service manual. After (B) there may some additional information. this case shows “.01”, which represents the block cover These options may front / rear , left / hydraulic / mechanical
(C) corresponds the type information listed the chapter contents: T echnical Functional
(A) and (B) are also shown the page numbering the page footer . THE REST THE CODING NOT LISTED ALPHANUMERIC ORDER THIS
• Y will find a table contents the beginning and end each section and chapter Y will find alphabetical index the end each chapter
• referring (A) , (B) and (C) the you can follow the contents index (page numbers) and quickly find the information you are looking for .
Page header and footer
The page header will contain the following references:
• Section and Chapter description
The page footer will contain the following references:
• Publication number for that
• V ersion reference for that publication.
• Publication date
• Section, chapter , and page reference e.g. 10.102 / 9
INTRODUCTION
NHIL12GEN0070A 1
47665854 27/03/2014 8
Foreword Ecology and the Environment
When legislation does not yet rule the treatment some the substances which are required advanced technology , common sense should govern the use and disposal products a chemical and petrochemical nature.
air , and water are vital factors agriculture and life
NOTICE: The following are recommendations which may
assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable your country
• Where legislation exists, obtain information from suppliers oils, filters, batteries, fuels, antifreeze, cleaning with regard their fect man and nature and how safely use and dispose these sub-
• Agricultural consultants many able help you
HELPFUL HINTS
• A void filling tanks using cans inappropriate pressurized fuel delivery systems which may cause considerable
• avoid skin contact with all
Most them contain substances which may harmful your
• Modern oils contain additives. not burn contaminated fuels and waste oils ordinary heating systems.
• A void spillage when draining f used engine coolant gearbox and hydraulic brake not mix drained brake fluids fuels with lubricants. Store them safely until they can disposed a proper way comply with local legislation and available
• Modern coolant antifreeze and other should replaced every two They should not allowed get into the soil but should collected and disposed properly
• not open the air - conditioning system contains gases which should not released into the phere. Y our CASE dealer air conditioning specialist has a special extractor for this purpose and will have recharge the system properly
• Repair any leaks defects the engine cooling hydraulic system immediately .
• not increase the pressure a pressurized circuit this may lead a component
• Protect hoses during welding penetrating weld splatter may burn a hole weaken allowing the loss
INTRODUCTION
47665854 27/03/2014 9
Safety rules
INTRODUCTION
PRECAUTIONAR Y A TEMENTS
Personal Safety
This the safety alert used alert you potential personal injury Obey all safety messages that follow this symbol avoid possible injury death.
Throughout this manual , you will find the signal words W and CAUTION followed special These precautions are intended for the personal safety you and those working with
Read and understand all the safety messages this manual before you operate service the
DANGER indicates a hazardous situation which, not avoided, will result death serious injury .
W
ARNING indicates a hazardous situation not could result death serious injury
used with the safety alert indicates a hazardous situation not could result minor moderate injury
F AILURE T O FOLLOW DANGER, W ARNING, AND CAUTION MESSAGES COULD RESUL T DEA SERIOUS INJUR Y .
NOTICE: Install new decals the old decals are lost painted over cannot When parts are replaced that have decals make sure you install a new decal with each new part.
MACHINE SAFETY
NOTICE: Notice indicates a situation not could result machine property
Throughout this manual you will find the signal word Notice followed special instructions prevent machine property The word Notice used address practices not related personal safety
INFORMA TION
NOTE: Note indicates additional information which clarifies steps, procedures, other information this manual.
Throughout this manual you will find the word Note followed additional information about a other information the manual. The word Note not intended address personal safety property damage. 47665854 27/03/2014
ACCIDENT PREVENTION W ARNING
A void injury! Always the following before lubricating, maintaining, servicing the machine.
Disengage all drives.
Engage parking
Lower all attachments the ground, raise and engage all safety locks.
Shut off
Remove key from key switch.
Switch off battery key , installed.
W ait for all machine movement
Failure comply could result death serious injury . W0047A
Most accidents injuries that occur workshops are the result non compliance simple and fundamental safety principles. For this reason, MOST CASES THESE ACCIDENTS CAN A VOIDED applying the fundamental safety acting with the necessary caution and
Accidents may occur with all types regardless how well the machine question was designed and
SAFETY REQUIREMENTS FOR FLUID POWER SYSTEMS AND COMPONENTS -DRAULICS (EUROPEAN ANDARD EN982)
• Flexible hose assemblies must not constructed from hoses which have been previously used part a hose assembly
• not weld hydraulic pipes: when flexible hoses piping are replace them immediately
• forbidden modify a hydraulic accumulator welding any other way
• Before removing hydraulic accumulators for the liquid pressure the accumulators must reduced
• Pressure check hydraulic accumulators must carried out a method recommended the accumulator manufacturer .
• T ake care not exceed the maximum allowed pressure the accumulator After any check check for leakages gas the hoses
SAFETY RULES
General guidelines
• Carefully follow specified repair and maintenance
• When use P (Personal Protective Equipment)
• not wear jewellery , unbuttoned loose articles clothing such as: torn open jackets shirts with open zips that may remain entangled moving advised wear approved safety clothing, e.g.: non - slip footwear , gloves, safety goggles, helmets, etc.
• not carry out repair operations with someone sitting the unless the person a trained technician who assisting with the operation question.
• not operate the machine use any the implements from dif ferent other than the
• not carry out operations the machine with the engine unless specifically
• Bring all hydraulic cylinders the home positions before engine shut
• Stop the engine and check that the hydraulic circuits are pressure - free before removing
• All repair and maintenance operations must carried out using extreme care and
• Service steps and platforms used the workshop elsewhere should built according the applicable dards and
• Disconnect the power take f and label the controls indicate that the machine being Any parts that are raises must locked position.
INTRODUCTION
47665854 27/03/2014 1 1
• Brakes are inoperative when manually released for repair maintenance Use blocks similar devices secure the machine these
• Only use specified towing points for towing the Connect parts carefully Make sure that all pins and / locks are secured position before applying Never remain near the towing cables chains that are operating under load.
• When loading unloading the machine from the trailer (or other means select a flat area capable sustaining the trailer truck wheels. Firmly secure the machine the truck trailer and lock the wheels the position used the carrier
• Electric battery - chargers and similar equipment must only powered auxiliary power supplies with ficient ground insulation avoid electrical shock
• Always use suitable hoisting lifting devices when raising moving heavy
• Keep bystanders away
• Never use diesel oil other inflammable liquids cleaning Use non - non toxic commercially available solvents.
• W ear safety goggles with side guards when cleaning parts with compressed air
• not run the engine enclosed spaces without suitable ventilation exhaust extraction.
• Never use open flames for lighting when working the machine checking for
• All movements must carried out carefully when working under , near the W ear personal protective equipment goggles and special footwear
• When carrying out checks with the engine request the assistance operator the The operator must maintain visual contact with the service technician all
• operating outside the position the machine a flat surface and lock working a lock the machine position. Move a flat area soon safely possible.
• Damaged bent chains cables are not use them for lifting Always use suitable tective gloves when handling chains
• Chains should always safely Make sure that the hitch - point capable sustaining the load Keep the area near the hitch - chains cables free all
• Maintenance and repair operations must carried out a CLEAN and Y Clean any water oil spillage immediately
• not create piles oil grease - soaked rags they represent a serious fire hazard. Always store rags a closed metal container
• Before engaging the make sure that there are persons within the machine implement range
• Empty your pockets all objects that may fall accidentally unobserved into the machine inner
• When metal parts are sticking use protective goggles goggles with side special footwear and
• When use protective safety devices: tinted safety special gloves and footwear All persons present the area where welding taking place must wear tinted goggles. NEVER LOOK DIRECTL Y
A T THE WELDING ARC WITHOUT SUIT ABLE EYE
• Always disconnect battery ground terminal when welding.
• Metal cables tend fray with repeated Always use suitable protective devices when handling
47665854 27/03/2014
INTRODUCTION
Machine start -
• Never run the engine confined spaces that are not equipped with adequate ventilation for exhaust gas
• Never place the body , hands fingers near rotating and moving
Hydraulic systems and fuel injection systems
• A liquid leaking from a tiny hole may almost invisible the same powerful enough penetrate the NEVER USE HANDS T O CHECK FOR LEAKS but use a piece cardboard paper for this any liquid penetrates skin call for medical aid immediately Failure treat this condition with correct medical procedure may result serious infection
• order check the pressure the system use suitable instruments.
Wheels and T ires
• Make sure that the tires are correctly inflated the pressure specified the manufacturer . Periodically check the rims and tires for
• Stand away from (at the side of) the tire when checking inflation pressure.
• not use parts recovered wheels incorrect welding brazing heating may weaken and eventually cause damage the
• Never cut weld a rim mounted with inflated
• Deflate the tire before removing any objects that may jammed the tire
• Never inflate tires using inflammable gases, this may result explosions and injury
Removal and - fitting
• Lift and handle all heavy parts using suitable hoisting Make sure that parts are sustained appropriate hooks and Use the hoisting eyebolts for lifting Extra care should taken persons are present near the load lifted.
• Handle all parts carefully not put your hands fingers between W ear suitable safety clothing - safety gloves and
• A void twisting chains metal Always wear safety gloves when handling cables
INTRODUCTION
47665854 27/03/2014
INTRODUCTION
T orque
Minimum hardware tightening torques (in N m / ft) for normal assembly applications unless otherwise stated
NOTICE: Shown below the suggested initial torque tightening sequences for general tighten quence from item 1 through the last item the
The minimum hardware tightening torque specifications have priority The applicable CNH Standard
DF5019 - 1 1 Metric hardware Class 8.8 N m (lb ft) Class 10.9 N m (lb ft) Nominal Size Plated nut Lock nut Hardened nut Plated nut Lock nut Hardened nut 1.3 ( 1 ) 0.7 ( ) 1.2 ( ) 1.8 ( ) 0.9 ( ) 1.6 ( ) N·m ( 25.7 ) N·m ( 14.2 ) N·m ( 23.0 ) N·m ( 37.2 ) N·m ( 20.4 ) N·m ( 32.7 ) N·m ( 52.2 ) N·m ( 28.3 ) N·m ( 46.9 ) N·m ( 75.2 ) N·m ( 40.7 ) N·m ( 67.3 ) 10.1 N·m ( 89.4 ) 5.5 N·m ( 48.7 ) 9.1 N·m ( 80.5 ) 14.5 N·m ( 10.7 ) 7.9 N·m ( 69.9 ) N·m ( 9.6 ) 24.5 ( ) 13.5 ( ) ( ) 35.1 ( ) 19.3 ( ) 31.5 ( ) M10 48.7 ( 35.9 ) 26.8 ( 19.8 ) 43.8 ( 32.3 ) 69.5 ( 51.3 ) 38.2 ( 28.2 ) 62.5 ( 46.1 ) M12 N·m ( 62.7 ) N·m ( 34.4 ) N·m ( 56.4 ) 121 N·m ( 89.2 ) N·m ( 49.0 ) N·m ( 80.3 ) M14 135 N·m ( 99.6 ) 74.2 N·m ( 54.7 ) 121.5 N·m ( 89.6 ) 193 N·m ( 142.3 ) 106.1 N·m ( 78.3 ) 173.7 N·m ( 128.1 ) M16 210 ( ) 1 15.5 ( ) 189 ( ) 301 ( 222 ) 165.5 ( ) 270.9 ( ) M18 299 ( ) 164.4 ( ) 269.1 ( ) 414 ( ) 227.7 ( ) 372.6 ( ) M20 425 N·m ( 313.5 ) N·m ( 172.4 ) N·m ( 282.1 ) 587 N·m ( 432.9 ) N·m ( 238.1 ) N·m ( 389.7 ) M22 579 N·m ( 427 ) 318.4 N·m ( 234.8 ) 521.1 N·m ( 384.3 ) 801 N·m ( 590.8 ) 440.5 N·m ( 324.9 ) 720.9 N·m ( 531.7 ) M24 735 N·m ( ) 404.2 N·m ( ) 661.5 N·m ( ) 1016 N·m ( ) 558.8 N·m ( ) 914.4 N·m ( ) M27 1073 ( ) 590.1 ( ) 967.5 ( ) 1486 ( 1096 ) 817.3 ( ) 1337 ( ) M30 1461 N·m ( 1077.6 ) N·m ( 592.6 ) 1315 N·m ( 969.9 ) 2020 N·m ( 1489.9 ) 1 1 1 1 N·m ( 819.4 ) 1818 N·m ( 1340.9 ) 47665854 27/03/2014
INTRODUCTION ZEIL06CS0136F0A 2 ZEIL06CS0135F0A 3 47665854 27/03/2014
Basic instructions SHIMMING
For each adjustment select adjusting shims and measure individually using a micrometer , then add the recorded values. not rely measuring the entire shimming set, which may incorrect, the rated value indicated each
ROT A TING SHAFT SEALS
For correct rotating shaft seal proceed follows:
• before assembly , allow the seal soak the oil will sealing for least thirty minutes
• thoroughly clean the shaft and check that the working surface the shaft not damaged
• position the sealing lip facing the fluid; with hydrodynamic take into consideration the shaft rotation direction and position the grooves that they will deviate the fluid towards the inner side the seal
• coat the sealing lip with a thin layer lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip double lip seals with grease
• insert the seal its seat and press down using a flat not tap the seal with a hammer mallet
• whilst inserting the seal, check that perpendicular the seat; once settled, make sure that makes contact with the thrust required
• prevent damaging the seal lip the shaft, position a protective guard during installation operations
O - RING SEALS
Lubricate the O - RING seals before inserting them the seats, this will prevent them from overturning and twisting, which would jeopardize sealing ficiency
SEALING COMPOUNDS
Only use the sealants which are recommended this manual! Before applying the sealing prepare the surfaces follows:
• remove any incrustations using a metal brush;
• thoroughly - grease the surfaces using one the following cleaning agents: petrol a water and soda solution.
COTTER PINS
When fitting split cotter pins, ensure that the pin notch positioned the direction the force required stress the Spiral cotter pins not require special
INTRODUCTION
47665854 27/03/2014
INTRODUCTION
Sulphur fuel
The engine oil and filter change period are shown the Lubrication and Maintenance the operators manual. ever , locally available fuel may have a high sulphur which case the engine oil and filter change period should adjusted follows:
Coolants W ARNING
Hazardous chemicals!
Chemical agent may harmful.
- A void contact with and prolonged / repeated skin
- W ear protective goggles when handling.
- Eye contact: Flush with water for Seek immediate medical
- W ash skin with soap and water after handling.
- Keep out reach children.
Failure comply could result death serious injury
T o reduce the amount deposits and the water used the cooling system must comply with the following values.
Using plain water you reside a country where antifreeze not use clean water premixed with 5 % chemical inhibitor The inhibitor available from your authorized dealer
Sulphur content Oil change period Below 5 / ppm) Normal From 5 - / - ppm) Half the normal Above / (10 ppm) One quarter normal
W0370A
Property Maximum value T otal solids 340 / (340 ppm) T otal hardness 9.5°dH (170 ppm) Chloride (cl) / (40 ppm) Sulfate (SO4) 100 / (100 ppm) Acidity 5.5 9.0
47665854 27/03/2014
Lubrications
NOTE: When changing the conventional engine coolant the
LIFE COOLANT vice follow the cooling system – Basic the operator
INTRODUCTION
and Coolant Specifications Recommended fluids and applications CNH specification International specification Recommended engine oil CASE AKCELA UNITEK NO. SBL
SAE 10WCASE AKCELA UNITEK SSL
SAET 3521 API - ACEA Alternative engine oil CASE AKCELA NO. ENGINE
SAE 15WCASE AKCELA NO. ENGINE OIL
SAE 10WT 3522 API - ACEA T ransmission
(axle
oil CASE AKCELA - TRAN® TRACTION T 3540 n / a Conventional engine coolant CNH XHD
(has
T 3620 Ethylene Glycol T engine coolant CASE AKCELA
COOLANT (If
% water) T 3624 ASTM D 6210 Fully organic technology Brake oil CASE AKCELA LHM FLUID T 3630 ISO 7308 Air - conditioning compressor oil P - E13 Low V iscosity Oil SP10 n / a ISO100 V iscosity Grease fittings and bearings CASE AKCELA 251H MUL - PURPOSE GREASE T 3550 NLGI 2 Regarding filling quantity
see Capacities
- 4
- 4
OIL - 4
- 4
rear axle hydraulic system front axle
and hubs) and front O gearbox
H EAVY D UTY C OOLANT / A NTI - FREEZE
mixed with 50% water)
ACTIFULL OT® EXTENDED LIFE
a premixed coolant not mix the concentrate with
-
CASE AKCELA
EXTENDED
47665854 27/03/2014
ACTIFULL OT®
INTRODUCTION
Capacities
MAXXUM Efficient Power UNIT 1 120 130 1 125 140 FUEL T ANK 175 l ( gal ) 227 l ( gal ) DEF / AdBlue® T ANK l ( gal ) COOLING SYSTEM l ( gal ) l ( gal ) ENGINE (including filter) l ( gal ) l ( gal ) TRANSMISSION / REAR AXLE / HYDRAULICS 16x16 l ( gal ) 24x24 65.5 l ( 17.3 gal ) 4WD FRONT AXLE - DIFFERENTIAL 9 l ( 2.38 gal ) 4WD FRONT HUBS (Class 3 Axle - less brakes) 1.25 l ( 0.33 gal ) 4WD FRONT HUBS (Class 3 Axle - with brakes) 3.0 l ( 0.79 gal ) 4WD FRONT HUBS (Class 4 Axle - less brakes) not applicable 3.6 l ( 0.95 gal ) 4WD FRONT HUBS (Class 4 Axle - with brakes) not applicable 4.0 l ( 1.06 gal ) FRONT PT O 0.5 l ( 0.13 gal ) MAXXUM Multicontroller Efficient Power UNIT 1 120 130 1 125 140 FUEL T ANK 175 l ( 46.2 gal ) 227 l ( 60.0 gal ) DEF / AdBlue® T ANK l ( 9.8 gal ) COOLING SYSTEM l ( 5.5 gal ) l ( 6.6 gal ) ENGINE (including filter) l ( 2.64 gal ) l ( 3.96 gal ) TRANSMISSION / REAR AXLE / HYDRAULICS l ( gal ) 4WD FRONT AXLE - DIFFERENTIAL 9 l ( 2.38 gal ) 4WD FRONT HUBS (Class 3 Axle - less brakes) 1.25 l ( 0.33 gal ) 4WD FRONT HUBS (Class 3 Axle - with brakes) l ( gal ) 4WD FRONT HUBS (Class 4 Axle - less brakes) not applicable l ( gal ) 4WD FRONT HUBS (Class 4 Axle - with brakes) not applicable l ( gal ) FRONT PT O l ( gal ) MAXXUM CVT Efficient Power UNIT 1 CVT 120 CVT 130 CVT FUEL T ANK 175 l ( 46.2 gal ) DEF / AdBlue® T ANK l ( 9.8 gal ) COOLING SYSTEM l ( 5.5 gal ) ENGINE (including filter) l ( gal ) TRANSMISSION / REAR AXLE / HYDRAULICS l ( 16.4 gal ) 4WD FRONT AXLE - DIFFERENTIAL 9 l ( 2.38 gal ) 4WD FRONT HUBS (Class 3 Axle - less brakes) 1.25 l ( 0.33 gal ) 4WD FRONT HUBS (Class 3 Axle - with brakes) 3.0 l ( 0.79 gal ) 4WD FRONT HUBS (Class 4 Axle - less brakes) 3.6 l ( 0.95 gal ) 4WD FRONT HUBS (Class 4 Axle - with brakes) 4.0 l ( 1.06 gal ) 47665854 27/03/2014
INTRODUCTION MAXXUM CVT Efficient Power UNIT 1 CVT 120 CVT 130 CVT FRONT PT O 0.5 l ( 0.13 gal ) 47665854 27/03/2014
INTRODUCTION 47665854 27/03/2014
SERVICEMANUAL Engine MAXXUM110EP,MAXXUM110MulticontrollerEP,MAXXUM115EP ,MAXXUM115MulticontrollerEP,MAXXUM120EP,MAXXUM120 MulticontrollerEP,MAXXUM125EP,MAXXUM125MulticontrollerEP, MAXXUM130EP,MAXXUM130MulticontrollerEP,MAXXUM140EP, MAXXUM140MulticontrollerEP,MAXXUMCVT110,MAXXUMCVT120, MAXXUMCVT130 4766585427/03/2014
Contents Engine[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 Fuel tanks Fuel injection system [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 T urbocharger and lines Intake and exhaust manifolds and muf fler [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 Fan and drive [10.310] Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 47665854 27/03/2014
Engine
Engine
MAXXUM
, MAXXUM
Multicontroller
, MAXXUM 1 , MAXXUM 1 Multicontroller
, MAXXUM
, MAXXUM
Multicontroller , MAXXUM
, MAXXUM
Multicontroller , MAXXUM
, MAXXUM
Multicontroller
, MAXXUM
, MAXXUM
Multicontroller
MAXXUM
1 , MAXXUM
, MAXXUM
47665854 27/03/2014 10.1 [10.001] / 1
-
and crankcase - 001
1
1
EP
EP
120 EP
120
125
125
130
130
EP
140
140
,
CVT
CVT 120
CVT 130
TECHNICAL T A
Contents
Engine -
Engine and crankcase - 001
Engine T orque 3 MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 120 - - - MAXXUM 120 Multicontroller - - - MAXXUM 125 - - - MAXXUM 125 Multicontroller - - - MAXXUM 130 - - - MAXXUM 130 Multicontroller - - - MAXXUM 140 - -MAXXUM 140 Multicontroller - -SER VICE Engine Disconnect MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 125 - - - MAXXUM 125 Multicontroller - - - MAXXUM 140 - - - MAXXUM 140 Multicontroller - -Connect MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 125 - - - MAXXUM 125 Multicontroller - - - MAXXUM 140 - - - MAXXUM 140 Multicontroller - -Remove MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 125 - - - MAXXUM 125 Multicontroller - - - MAXXUM 140 - - - MAXXUM 140 Multicontroller - -Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 125 - - - MAXXUM 125 Multicontroller - - - MAXXUM 140 - - - MAXXUM 140 Multicontroller - -Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 120 - - - MAXXUM 120 Multicontroller - - - MAXXUM 130 - - - MAXXUM 130 Multicontroller - - - MAXXUM CVT 1 - - - MAXXUM CVT 120 - - - MAXXUM CVT 130 - -Install MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 120 - - - MAXXUM 120 Multicontroller - - - MAXXUM 130 - - - MAXXUM 130 Multicontroller - - - MAXXUM CVT 1 - - - MAXXUM CVT 120 - - - MAXXUM CVT 130 - -Disconnect MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 120 - - - MAXXUM 120 Multicontroller - - - MAXXUM 130 - - - MAXXUM 130 Multicontroller - - - MAXXUM CVT 1 - - - MAXXUM CVT 120 - - - MAXXUM CVT 130 - -Connect 108 MAXXUM 1 - - - MAXXUM 1 Multicontroller - - - MAXXUM 120 - - - MAXXUM 120 Multicontroller - - - MAXXUM 130 - - - MAXXUM 130 Multicontroller - - - MAXXUM CVT 1 - - - MAXXUM CVT 120 - - - MAXXUM CVT 130 - -47665854 27/03/2014 10.1 [10.001] / 2
Engine - Engine and crankcase
Engine - T orque
MAXXUM
MAXXUM 1 Multicontroller MAXXUM 1 MAXXUM 1 Multicontroller MAXXUM 120 MAXXUM 120 Multicontroller MAXXUM 125 MAXXUM 125 Multicontroller MAXXUM 130 MAXXUM 130 Multicontroller MAXXUM 140 MAXXUM 140 Multicontroller P ART T ORQUE (lb ft) Bolts securing connecting rod caps: 1st phase + / - 3 + /2nd phase + / - 5 + /Angle closed 3rd phase ° + / - 5 ° Nuts securing engine cover cylinder engines refer figure 3 4 cylinder engines refer figure 4 ) 125 ± 5 ± Bolts securing engine flywheel: 1st phase + / - 4 + /2nd phase ° + / - 5 ° Bolts securing pulley and damper: 1st phase ± 5 (36.8781 ± 3.6878) + 2nd phase ° + / - 5 ° Cooling nozzles (mechanical engines only) ± 3(1 1 ± Bolts securing injectors cylinder head: 1 ± 5 ± Nut securing P gear: 105 ± 7 (77.4440 ± 5.1629) Nut securing compressor gear: 125 ± ± Bolts securing timing gear: ± 4 ± Unions securing piston lubrication nozzles: ± 3 ± Bolts securing timing system casing ± 4 ± M10 ± 5 (34.6654 ± 3.6878) Bolts securing front cover M10 ± 4 ± Bolts securing main bearing caps with angle closed M12 1.50 12.9 1st phase + / - 6 + /2nd phase + / - 6 + /Angle closed 3rd phase + ° + / - 5 ° V iti fissaggio Ladder Frame: M10 ± 5 ± Bolts securing lifting brackets: M12 7 ± ± M10 ± 5 ± Bolts securing cooler (refer figure 7 ) ± 5 ± ± 5 (18.4391 ± 3.6878) M12 Connector ± 5 ± Bolts securing valve cover Nuts ± 4 (17.7015 ± 2.9502) Engine V ent Fastener (Ccv) ± 4 ± 47665854 27/03/2014 10.1 [10.001] / 3
1
Engine - Engine and crankcase P ART T ORQUE (lb ft) ± 4 ± Bolts securing oil sump 6 cylinder engines (refer figure 8 ) ♦ T ightening Bolts & M10 ± 5 ± T ightening Bolts 4 - 14; - 27; - M10 ± 5 ± T ightening Bolts 1 - - M10 ± 5 ± T ightening Bolts - M10 15x190 ± 5 ± Bolts securing oil sump 4 cylinder engines (refer figure 9 ) ♦ T ightening Bolts & M10 ± 5 ± T ightening Bolts 3 - 10; - 20; - M10 ± 5 (51.6293 ± 3.6878) T ightening Bolts 1 - - M10 1.5x125 ± 5 ± T ightening Bolts 1 1 - M10 15x190 ± 5 ± Bolts / Plugs Head 1 / 2 Nptf ± 4 (17.7015 ± 2.9502) 3 / 4 Nptf ± 5 ± 1 / 4 Nptf ± 2 ± ♦ Lubricate
Engine Oil
Assembly
T ORQUE WRENCH SETTINGS T ORQUE P T (lb ft) Bolts securing 6 cylinder head (refer figure 1 ) ♦ Step T ightening bolts 1 - 2 - 7 - 8 - 9 - - - - - - -- M12 Step +90 ° Step +90 ° Step T ightening bolts 3 - 4 - 5 - 6 - 1 1 - - - - - -M12 Step +90 ° Step +90 ° Bolts securing 6 cylinder head (refer
♦ Step T ightening bolts 1 - 2 - 7 - 8 - 9 - - - - - M12 1.75x150 Step +90 ° Step +90 ° Step T ightening bolts 3 - 4 - 5 - 6 - 1 1 - - - M12 Step +90 ° Step +90 ° Bolts securing heater grille: ± 2 ± Bolts securing intake manifold: 1.25x25 ± 5 ± ± 5 ± Bolts securing exhaust manifold 6 cylinder head: (refer
5 ) M12 ± 5 ± Bolts securing exhaust manifold 4 cylinder head:
6 ) ± 5 ± ± 5 (18.4391 ± 3.6878) Bolts securing connecting rod caps cylinder engines): 1 Flg 1st phase + / - 3 + /2nd phase + / - 5 + /47665854 27/03/2014 10.1 [10.001] / 4
With
Before
(continued)
figure 2 )
figure
(refer figure
T orque / Angle 3rd phase +60 ° + / - 5 ° Bolts securing connecting rod caps cylinder engines): M10 Flg 1st phase + / - 3 + /2nd phase + / - 5 + /T orque / Angle 3rd phase +60 ° + / - 5 ° Bolts securing flywheel M12 ± ± M10 ± 5 ± Bolts securing camshaft thrust plate: Flg ± 4 ± Bolts securing camshaft gear: Flg ± 4 ± Bolts securing rocker arms: ± 5 ± Bolts securing rocker arm adjusters: 3 / 8 Unf Hex Nut ± 4 ± Bolts securing rocker arm casing: ± 4 ± Bolts securing phonic wheel: M12 Flg Hex 1st phase ± 5 ± 2nd phase + ° + / - 5 ° Fuel connector fastener head side ± 5 ± Fuel connector fastener Common Rail side ± 2 ± Common Rail fastener Flg Hex ± 4 ± Flg Hex ± 4 (17.7015 ± 2.9502) 1.25x90 9.8 Flg Hex ± 4 ± Fastener for high - pressure pipes from Common Rail cylinder head M14 ± 2 ± Fastener for fuel filter mounting crankcase M12 1.75x25 9.8 Fig Hex ± 8 ± T urbo / exhaust manifold fastener (refer figure ) ± 5 ± Oil delivery / return pipe fastener M12 1.5 ± 5 ± Oil dipstick pipe fastener: ± 4 ± ♦ Lubricate With Engine Oil Before Assembly (continued) T ORQUE
SETTINGS T ORQUE P T (lb ft) Bolts securing oil pump: 1.25x30 8.8 Hex 1st phase 8 ± 1 (5.9005 ± 0.7376) 2nd phase ± 4 ± Main oil delivery bolts (plugs) M10 1 6 ± 1 ± M14 1.5 1 1 ± 2 132 ± Oil cooler / oil filter assembly fastener: ± 4 ± Coolant pump / crankcase fastener: Hex 1st phase ± 4 ± 2nd phase ± 6 (31.7152 ± 4.4254) T ightener fastener M10 FigFan mounting fastener 47665854 27/03/2014 10.1 [10.001] / 5
Engine - Engine and crankcase
WRENCH
ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!
Maintenance
Engine Control System
Mechanical
Fuel Service Specifications
Emission Control
Intake Exhaust Cooling
Lube
Ignition Starting Charging
Auto Transmission Clutch
Manual Transmission
Transfer Propeller Shaft
Drive Shaft
Differential
Axle Suspension
Tire & Wheel
Brake Control
Brake
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Parking Brake
Steering Column
Power Steering
Air Condition
Suppl Restraint System
Seat Belt
Engine Immobilizer
Cruise Control
Wiper & Washer
Door Lock
Meter
Horn
Audio/Visual
Windshield/Glass Mirror
Instrument Panel
Seat
Engine Hood/ Door
Exterior & Interior
Electrical
Multiplex/ Can Communication
And much more...
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