SECTION00--GENERAL--CHAPTER1 1 SECTION00--GENERAL Chapter1--General CONTENTS SectionDescription Page GeneralInstructions2 ............................................................ ImportantNotice2 Battery ....................................................................2 Shimming 2 RotatingShaftSeals2 O--RingSeals2 SealingCompounds2 Bearings 2 SpringPins 3 SpareParts 3 NotesforEquipment3 ImportantNotes3 MovingtheTractorwiththeBatteryRemoved3 SafetyRegulations4 ............................................................. SafetySymbols4 ToPreventAccidents4 ........................................................ GeneralGuidelines4 StartUp ...................................................................6 Engine 6 ElectricalSystems6 .......................................................... HydraulicSystems6 WheelsandTires6 ........................................................... RemovalandInstallation6 TractorRefuelling ..............................................................7
GENERALINSTRUCTIONS
IMPORTANTNOTICE
AllmaintenanceandrepairworkdescribedinthismanualmustbeperformedexclusivelybyCASEIHservice technicians,instrictaccordancewiththeinstructionsgivenandusinganyspecifictoolsnecessary.
Anyoneperformingtheoperationsdescribedhereinwithoutstrictlyfollowingtheinstructionsispersonallyresponsibleforanyeventualinjuryordamagetoproperty.
BATTERY
Beforecarryingoutanykindofserviceoperationdisconnectandisolatethebatterynegativelead,unlessotherwiserequestedforspecificoperations(e.g:operationsthatrequiretheenginerunning).Oncethespecificoperationhasbeencompleted,disconnecttheleadinordertocompletetheoperation.
SHIMMING
Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenadd uptherecordervalues:Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortherated valueindicatedforeachonshim.
ROTATINGSHAFTSEALS
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
--beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes;
--thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged;
--positionthesealinglipfacingthefluid;withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirectionandpositionthegroovessothattheywilldeviatethefluidtowardstheinnersideoftheseal;
--smearthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andfillthegapbetweenthe sealinglipandthedustlipondoublelipsealswithgrease;
--insertthesealinitsseatandpressdownusingaflatpunch;donottapthesealwithahammerormallet;
--whilstinsertingtheseal,checkthattheitisperpendiculartotheseat;oncesettled,makesurethatitmakes contactwiththethrustelement,ifrequired;
--topreventdamagingtheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.
O--RINGSEALS
LubricatetheO--RINGsealsbeforeinsertingthemintheseats,thiswillpreventthemfromoverturningandtwisting,whichwouldjeopardizesealingefficiency.
SEALINGCOMPOUNDS
ApplyoneofthefollowingsealingcompoundsonthematingsurfacesmarkedwithanX:LOCTITE518,LOCTITE 5205,SUPERBOND559MASCHERPAorBETABLOCKA272MGURITESSEX.
Beforeapplyingthesealingcompound,preparethesurfacesasfollows:
--removeanyincrustationsusingawirebrush;
--thoroughlyde--greasethesurfacesusingoneofthefollowingcleaningagents:trichlorethylene,petrolora waterandsodasolution.
BEARINGS
Wheninstallingbearingsitisadvisedto:
--heatthebearingsto80to90 °Cbeforefittingontheshafts;
--allowthebearingstocoolbeforeinstallingthemfromtheoutside.
2 SECTION00--GENERAL--CHAPTER1
SPRINGPINS
Whenfittingsplitsocketelasticpins,ensurethatthepinnotchispositionedinthedirectionoftheforcerequired tostressthepin.
Spiralspringpinsdonotrequirespecialpositioning.
SPAREPARTS
Usegenuinepartsonly.
Onlygenuinesparepartsguaranteethesamequality,durationandsafetyastheyarethesamepartsthatare assembledduringproduction.
Only genuineparts canofferthisguarantee.
Whenorderingspareparts,alwaysprovidethefollowinginformation:
--tractormodel(commercialname)andframenumber;
--enginetypeandnumber;
--partnumberoftheorderedpart,whichcanbefoundintheìSparePartsCatalogueîusedfororderprocessing.
NOTESFOREQUIPMENT
ThetoolsthatCASEIHproposeandillustrateinthismanualare:
--specificallyresearchedanddesignedforusewithCASEIHvehicles;
--necessarytomakereliablerepair;
--accuratelybuiltandstrictlytestedtoofferefficientandlong--lastingworkingmeans.
Byusingthesetools,repairpersonnelwillbenefitfrom:
--operatinginoptimaltechnicalconditions;
--obtainingthebestresults;
--savingtimeandeffort;
--workinginsafeconditions.
IMPORTANTNOTES
Wearlimitvaluesindicatedforcertainpartsarerecommended,butnotbinding.Thetermsìfrontî,ìrearî,ìright-handîandìleft--handî(whenreferredtodifferentparts)areintendedasseenfromthedrivingpositionwiththe tractorinthenormaldirectionofmovement.
MOVINGTHETRACTORWITHTHEBATTERYREMOVED
Externalpowersupplycablesshouldonlybeconnectedtotherespectivepositiveandnegativecableterminals, usingefficientclampsthatguaranteeadequateandsecurecontact.
Disconnectallservices(lights,windshieldwipers,etc.)beforestartingthevehicle.
Ifthevehicleelectricalsystemrequireschecking,carryoutoperationswiththepowersupplyconnected;Once checkingiscompleted,disconnectallservicesandswitchoffthepowersupplybeforedisconnectingthecables.
SECTION00--GENERAL--CHAPTER1 3
SAFETYREGULATIONS
SAFETYSYMBOLS
Thefollowingkeywordswithregardstosafetyare usedthroughoutthismanual:
DANGER, usedwiththesafetyalertsymbol(figure1)indicatesahazardoussituationwhich,ifnot avoided,willresultindeathorseriousinjury.ThecolorassociatedwithDangerisRED.M1169A
WARNING, usedwiththesafetyalertsymbol(figure1),indicatesahazardoussituationwhich,ifnot avoided,couldresultindeathorseriousinjury.The colorassociatedwithWarningisORANGE.M1170A
CAUTION, usedwiththesafetyalertsymbol(figure1),indicatesahazardoussituationwhich,ifnot avoided,couldresultinminorormoderateinjury.The colorassociatedwithCautionisYELLOW.M1171A
TOPREVENTACCIDENTS
Mostaccidentsorinjuriesthatoccurinworkshops aretheresultofnon--observanceofsimpleandfundamentalsafetyregulations.Forthisreason,IN
MOSTCASESTHESEACCIDENTSCANBE
AVOIDED:byforeseeingpossiblecausesandconsequentlyactingwiththenecessarycautionand care.
Accidentsmayoccurwithalltypesofvehicle,regardlessofhowwellitwasdesignedandbuilt.
Acarefulandjudiciousservicetechnicianisthebest guaranteeagainstaccidents.
Preciseobservanceofthemostbasicsafetyruleis normallysufficienttoavoidmanyseriousaccidents.
DANGER. Nevercarryoutanycleaning,lubrication ormaintenanceoperationswhentheengineisrunning.
GENERALGUIDELINES
--Carefullyfollowspecifiedrepairandmaintenanceprocedures.
--Donotwearrings,wristwatches,jewelry,unbuttonedorloosearticlesofclothingsuchas:ties, tornclothing,scarves,openjacketsorshirtswith openzipsthatmayremainentangledinmoving parts.Itisadvisedtowearapprovedsafetyclothing,e.g:non--slipfootwear,gloves,safety goggles,helmets,etc.
1
--Donotcarryoutrepairoperationswithsomeone sittinginthedriverísseat,unlessthepersonisa trainedtechnicianwhoisassistingwiththeoperationinquestion.
--Donotoperatethevehicleoruseanyoftheimplementsfromdifferentpositions,otherthanthe driverísseat.
--Donotcarryoutoperationsonthevehiclewith theenginerunning,unlessspecificallyindicated.
--Stoptheengineandensurethatallpressureis relievedfromhydrauliccircuitsbeforeremoving caps,covers,valves,etc.
--Allrepairandmaintenanceoperationsmustbe carriedoutusingextremecareandattention.
--Servicestepsandplatformsusedinaworkshop orinthefieldshouldbebuiltincompliancewith thesafetyrulesinforce.
--Disconnectthebatteriesandlabelallcontrolsto indicatethatthevehicleisbeingserviced.Block themachineandallequipmentwhichshouldbe raised.
--Donotcheckorfillfueltanks,accumulatorbatteries,norusestartingliquidwhensmokingornear nakedflames,asthesefluidsareinflammable.
--Brakesareinoperativewhenmanuallyreleased forrepairormaintenancepurposes:useblocks orsimilardevicestocontrolthemachineinthese conditions.
4 SECTION00--GENERAL--CHAPTER1
--Thefuelnozzleshouldalwaysbeincontactwith thefillingaperture:maintainthiscontactuntilthe fuelstopsflowingintothetanktoavoidpossible sparksduetostaticelectricitybuild--up.
--Onlyusespecifiedtowingpointsfortowingthe vehicle.Connectpartscarefully:makesurethat allpinsand/orlocksaresecuredinpositionbeforeapplyingtraction.Neverremainnearthe towingbars,cablesorchainsthatareoperating underload.
--Transportvehiclesthatcannotbedrivenusinga traileroralow--loadingplatformtrolley,ifavailable.
--Whenloadingorunloadingthevehiclefromthe trailer(orothermeansoftransport),selectaflat areacapableofsustainingthetrailerortruck wheels.Firmlysecurethevehicletothetruckor trailerandlockthewheelsinthepositionusedby thecarrier.
--Electricheaters,battery--chargersandsimilar equipmentmustonlybepoweredbyauxiliary powersupplieswithefficientgroundinsulationto avoidelectricalshockhazards.
--Alwaysusesuitablehoistingorliftingdevices whenraisingormovingheavyparts.
--Takeextracareifbystandersarepresent.
--Neverpourpetrolordieseloilintoopen,wideor lowcontainers.
--Neverusegasoline,dieseloilorotherinflammableliquidsascleaningagents:usenon--inflammable,nontoxiccommerciallyavailablesolvents.
--Wearsafetygoggleswithsideguardswhen cleaningpartswithcompressedair.
--Limittheairpressuretoamaximumof2.1bar, accordingtolocalregulations.
--Donotruntheengineinconfinedspaceswithout suitableventilation.
--Donotsmoke,usenakedflames,orcause sparksintheareawhenfuelfillingorhandling highlyinflammableliquids.
--Neverusenakedflamesforlightingwhenworkingonthemachineorcheckingforleaks.
--Allmovementsmustbecarriedoutcarefully whenworkingunder,onornearthevehicle.
Wearprotectiveequipment:helmets,goggles andspecialfootwear.
--Whencarryingoutcheckswiththeenginerunning,requesttheassistanceofanoperatorinthe driverísseat.Theoperatormustmaintainvisual contactwiththeservicetechnicianatalltimes.
--Ifoperatingoutsidetheworkshop,positionthe vehicleonaflatsurfaceandlockinposition.If workingonaslope,lockthevehicleinposition. Movetoaflatareaassoonasissafelypossible.
--Damagedorbentchainsorcablesareunreliable: donotusethemforliftingortowing.Alwaysuse suitableprotectivegloveswhenhandlingchains orcables.
--Chainsshouldalwaysbesafelysecured:make surethatthehitch--uppointiscapableofsustainingtheloadinquestion.Keeptheareanearthe hitch--uppoint,chainsorcablesfreeofallbystanders.
--MaintenanceandrepairoperationsmustbecarriedoutinaCLEANandDRYarea.Eliminateany wateroroilspillageimmediately.
--Donotcreatepilesofoilorgrease--soakedrags: astheyrepresentaseriousfirehazard.Always storeragsinaclosedmetalcontainer. Beforestartingthetractororitsattachments, check,adjustandblocktheoperatorísseat.Also checkthattherearenopersonswithinthevehicle orimplementrangeofaction.
--Emptypocketsofallobjectsthatmayfallunobservedintothevehicleparts.
--Inthepresenceofprotrudingmetalparts,use protectivegogglesorgoggleswithsideguards, helmets,specialfootwearandgloves.
--Whenwelding,useprotectivesafetydevices: tintedsafetygoggles,helmets,specialoveralls, glovesandfootwear.Allpersonspresentinthe areawhereweldingistakingplacemustwear tintedgoggles.NEVERLOOKDIRECTLYAT THEWELDINGARCWITHOUTSUITABLEEYE PROTECTION.
--Metalcablestendtofraywithrepeateduse:alwaysusesuitableprotectivedevices(gloves, goggles,etc.)whenhandlingcables.
--Handleallpartswithgreatcare.Donotputyour handsorfingersbetweenmovingparts.Always wearsuitablesafetyclothing--safetygoggles, glovesandshoes.
SECTION00--GENERAL--CHAPTER1 5
SECTION10--ENGINE--CHAPTER1 1 SECTION10--ENGINE Chapter1--Engine(Model95N) CONTENTS SectionDescription Page Specifications 4 Torque 12 SpecialTools 14 SectionalViews 15 DescriptionandOperation19 ..................................................... ExhaustGasRecirculationSystem(EGR)19 Troubleshooting ..............................................................20 Overhaul 24 Engine ..................................................................24 Removal24 Installation28 ............................................................ Disassembly30 RemovingtheCrankshaftFrontSeal32 ..................................... RemovingtheCrankshaftRearSeal35 Assembly41 ............................................................ FittingtheConnectingRod--PistonAssembly46 FittingthePistonConnectingRodAssembliesIntheCylinderLiners47 BigEndCapAssembly48 FittingtheThermostatValve49 FittingtheCylinderHead49 ................................................... FittingtheInjectors51 FittingtheRockerArmAssembly51 ............................................ FittingtheTimingGear52 FittingtheInjectionPump54 .................................................. FittingtheAdditionalCounterweights54 FittingtheHydraulicPumpDriveGear55 ....................................... FittingtheTimingGearCasing56 FittingtheCrankshaftRearSeal56 ............................................ FittingtheFlywheel56 FittingtheOilPump57 ....................................................... FittingtheOilSump58
FittingtheCrankshaftFrontSeal58
FittingtheCrankshaftFrontPulley58
FittingtheCoolingSystemUnion58
FittingtheCoolantPump59
FittingtheFan--alternatorPulley59
FittingtheAuxiliaryMemberDriveBelt61
FittingtheExhaustManifold--Turbine61
FittingtheInjectorFeedPipes61
FittingtheFuelPump--FeedPipes61
2 SECTION10--ENGINE--CHAPTER1 SectionDescription Page
............................................
............................................
............................................
.......................................
FittingthePipesBetweentheFuelSupplyandInjectionPumps, Pre-heatingSystemandTappetCover62 FittingtheStarterMotor62 .................................................... Checks,MeasurementsandRepairs63 Crankcase,CylinderLiners63 ................................................. Crankshaft 66 ConnectingRods68 ......................................................... Bushings68 CheckingConnectingRods69 ............................................. CheckingTwisting69 CheckingBending69 ..................................................... Pistons 70 NormalDimensions(mm)PistonData70 MeasuringthePistonDiameter71 PistonPins71 ConditionsforCorrectPin--PistonCoupling72 PistonRings72 ValvesandCamshaft74 Dimensions(mm)ofValvesandValveGuides74 Decarbonizing,CheckingandGrindingValves74 ValveSprings76 Tappets ..............................................................76 Camshaft77 CylinderHead78 ............................................................ CheckingtheCylinderHeadMatingSurface78 CylinderHeadThickness78 ............................................... CylinderHeadHydraulicSealCheck78
SECTION10--ENGINE--CHAPTER1 3 SectionDescription Page LowOilPressureIndicator79 ................................................. FunctionalChecks79 OilFilter .................................................................79 Replacement79 CoolingSystem80 ........................................................... Radiator 80 FlushingandChecks80 ................................................... CoolantThermometer80 Check 80 ThermostatValve80 Replacement80 Crankshaft--FrontSeal81 ................................................... Disassembly81 Assembly82 ............................................................ Crankshaft--RearSeal83 Disassembly83 .......................................................... Assembly84 AdjustingValve/RockerArmClearance86 ...................................... Injectors 88 Removal88 ............................................................. Installation90 BoschInjectionPump91 ..................................................... Removal91 Installation93 ............................................................ Timing 94 FuelCircuitAirBleeding96 CoolantPump97 Removal97 Installation98 4-CylinderCoolantPumpandGeneratorDriveBelt99 TensionAdjustment99
SECTIONALVIEWS
SECTION10--ENGINE--CHAPTER1 15
MIF1096A 1 Engineview
Enginelubricationdiagram
Forced--circulationlubricationisaccomplishedby thefollowingcomponents:
--oilpump,housedatthefrontofthecrankcase, drivenbythegroovedbushingkeyedontothe shankofthecrankshaft;
--water/oilcooler,housedinthecrankcase;
--oilpressurecontrolvalveincorporatedinthe coolerassembly;
--by--passvalvetocutoffcloggedoilfilter, incorporatedinthecoolerassembly;
--cartridgeoilfilter.
16 SECTION10--ENGINE--CHAPTER1 MIF1098A Oilpathunderpressure Oilreturnpathundergravity 2
Coolingdiagram
--acentrifugalcoolantpumphousedatthefrontof thecrankcase;
--athermostatvalvegoverningcoolantcirculation.
SECTION10--ENGINE--CHAPTER1 17 MIF1099A Coolantrecirculatingintheengine Coolantenteringthepump 3
Theforcedcirculation,closed--circuitenginecooling systemiscomposedofthefollowingcomponents: --alubricatingoilcooler;
18 SECTION10--ENGINE--CHAPTER1 MIF1102A 4 Additionalcounterweightdiagram 1. Retainingbolts 2. Support 3. Retainingbolts 4. Gear 5. Balancingweight 6. Halfbearings 7. Counter--shaft 8. Gear 9. Ring 10. O--ring
DESCRIPTIONANDOPERATION
EXHAUSTGASRECIRCULATIONSYSTEM (EGR)
OntheTIER3version,theexhaustcamprofilehas beenmodifiedtopermitpartialopeningoftherelated valveduringtheinletphase(exhaustgasrecirculationEGR)withtheconsequentre--introductionof someoftheexhaustgasesintotheenginecylinders.
Theexhaustgasescanbepartiallyredirectedinto thecylindersinordertoreducethemaximum combustiontemperaturevalueswhichareresponsiblefortheproductionofnitrogenoxide(NOx).
Theexhaustgasrecirculationsystem(EGR), reducingthetemperatureofcombustionby decreasingtheconcentrationofoxygeninthe combustionchamber,isthereforeaneffective systemtocontrolemissionsofNOx.
TheinternalEGRsystemisnotprovidedwithany electronicallycontrolledelements:thesystemis alwayson.
Itsconfigurationneedsnoadditionalelementssuch ascontrolvalves,pipesorheatexchangers.
Theexhaustcam(B)inadditiontothemainlobehas anotherlobe(seesect.A--A,fig.5)withrespecttothe configurationwithoutEGR.
Theadditionallobe,duringtheinletphaseofthe cylinderunderexamination,permitsbrieflyopening theexhaustvalvegeneratingrecirculationduetothe exhaustgasesreturningcausedbythelower pressurecreatedintheinletphaseinsidethe cylinder.
SECTION10--ENGINE--CHAPTER1 19
5 Camshaftview A. Inletvalvecam. B. Exhaustvalvecam.
OVERHAUL
Operation1000110
ENGINE Removal DANGER
Liftandhandleallheavypartsusingsuitable liftingequipment.
Makesurethatassembliesorpartsare supportedbymeansofsuitableslingsand hooks.Ensurethatno--oneisinthevicinityofthe loadtobelifted.
CAUTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.
1.Removethecabasdescribedinoperation 9015010
2.Extractthefixingpinandremovetheballast(1); unscrewtheretainingscrewsandretrievethe ballastsupport(2).
3.Carryoutoperation 2310126 Propellershafts andguard,onlyremoval(seeSect.23).
4.Unscrewthepluganddrainthefronttransmissioncasing(prescribedquantity:44liters). 25628
5.Disconnectthepipes(1and2)ofthe transmissionoilcoolerandofthefrontaxle differentiallock.
24 SECTION10--ENGINE--CHAPTER1
6
7
8
6.Disconnect:thetransmissionoilcoolerpipes(1) andthefrontaxledifferentiallockpipe(2).
7.Unscrew:theretainingboltsofthepipe(1) deliveringoiltothepumpandtheboltsretaining thepipe(2)tothefiltersupport.
8.Loosentherelatedclampsandremovethe sleeve(2)fromthepipe(1)andremovethe transmissionoilinletpipetogetherwiththe above--mentionedsleeve.
9.Unscrewthefixingclampsanddisconnectthe pipes(1and2)fromthecooler,thesleeve(4) betweentheairfilterandtheturbochargerand theoilvaporrecirculationpipe(3).
SECTION10--ENGINE--CHAPTER1 25
9
10
11
12
10.Disconnectthesecondarytankfuellevel connection(1)andthecloggedairfilterpressure switchconnection.
11.Disconnectthesteeringhydrauliccylinder controlpipes(1).
12.Unscrewthefixingclampsanddetachtheupper (1)andlower(2)sleevesfromtheengine radiator.
13.Unhookthecatchandextractthetransmissionoil radiator(1).
26 SECTION10--ENGINE--CHAPTER1
13
14
15
16
14.Disconnectthepipes(1)oftheair--conditioning systemfromtherelatedcondenser.
15.Unscrewthefixingscrews,loosentherelated clampanddetachthepipe(1)joiningthetanks: maintosecondary.
16.Unscrewthefixingscrewanddetachthebracket (1)lockingtheengineradiator.
17.Positionafixedstandunderthetransmission-clutchcasing.
18.Connecttheenginetothehoistusingachainand makeittakeupthestrain.
19.Unscrewthebolts(1)securingtheenginetothe transmission--clutchcasinganddetachthe engineassemblyandfrontaxle.
SECTION10--ENGINE--CHAPTER1 27
17
18
19
20
20.Setuptwofixedstands:oneundertheaxle supportattherearandtheotherunderthefront side.
21.Unscrewthebolts(1)onbothsidesandseparate theenginefromtheaxle--supportassemblywith theradiators.
22.Resttheengineonanadequatesupport.
Installation
Toinstalltheengine,proceedasfollows:
CAUTION
Usesuitabletoolstoaligntheholes.NEVERUSE FINGERSORHANDS.
1.Respectthetighteningtorquesprescribedon page12.
2.Connecttheengine,withchains,tothehoist.
3.Refittheenginetothefrontaxle--support assemblywiththeradiatorandcooler.
4.Beforerefittingtheenginetotheclutchbox carefullycleanthematingsurfacesandapply sealingcompound(2mmdiameter),according tothediagramshownSection21,Chapter1, page34.
5.Positiontheengineontheclutchcasingand secureitwiththespecificbolts.
6.Positionandsecuretheretainingbracket betweentheradiatorandengine.
7.Securethepipejoiningthemaintanktothe secondaryone.
8.Positionandsecuretheguardbetweenthe radiatorandengine.
9.Connecttheair--conditioningsystempipestothe condenser.
10.Insertthetransmissionoilradiatorintoitsseat andsecureit.
11.Connectandsecurethetopandbottomsleeves totheengineradiator.
12.Connectthesteeringcylindercontrolpiping.
28 SECTION10--ENGINE--CHAPTER1
21
13.Connecttheelectricalconnectionsofthe secondarytankfuellevelandcloggedairfilter.
14.Positionandsecuretheconnectingpipesofthe cooler,turbocharger,airfilterandoilvapor recirculation.
15.Positionandconnectthetransmissionoilinlet pipe.
16.Positionandsecurethepipesofthetransmission oilfiltersupport.
17.Connectthetransmissionoilcoolerandfront axledifferentiallockpipes.
18.Carryoutoperation 2310126 Propellershafts andguard,onlyinstallation(seeSect.23).
19.Connectthecoolerandfrontaxledifferentiallock pipes.
20.Formodelsfittedwithbrakesonthefrontaxleit isnecessarytofilltherelevanttank(seesect.00, page6fortheprescribedproductandquantity) andbleedthebrakingsystem(seesect.33).
21.Screwtheplugonthereartransmissioncasing andfillupwithoil(seesect.00,page6forthe prescribedproductandquantity).
22.Positionandsecuretheballastsupport.
23.Positionandsecuretheballast.
24.Installthecabasdescribedinoperation 9015010.
SECTION10--ENGINE--CHAPTER1 29
Operation1000154
Disassembly
ThefiguresrefertotheF4CE9484M*J602versions of71kW(97hp)mod.95Vand95N.
WARNING
Handleallpartswithgreatcaution.Donotput yourhandsorfingersbetweenparts.Wearthe prescribedsafetyclothing,includinggoggles, glovesandsafetyfootwear.
1.Removetheengineasdescribedinoperation 1000110,proceedasfollows.
2.Drainofftheengineoilbyremovingtheplugfrom thesumpandtheoilfillerplug.
3.Detachthefanunitfromthefanpulley.
4.Tobeabletofitthebracket 380000661 (forfixing theenginetotheoverhaulstand)tothe crankcase,itisnecessarytoremovethewiring (1)fromtheleft--handsideoftheengine.
5.Tobeabletofitthebracket 380000661 tothe crankcaseontheright--handside,removethe startermotor(5),oilfilter(3),clamp(4),and turbineoilreturnpipe(1).
6.Fixthegearboxtotherotatingstand 380000301 Detachtheoildeliverypipe(2).
MIF1103A
30 SECTION10--ENGINE--CHAPTER1
22
MIF1104A 23
7.Removetheintakemanifold(2).
8.Disconnecttheengineoilvaporrecoverypipe fromtheblow--by(3).
9.Removethetappetcovers(1).
10.Removethepipeswiththequick--fitcoupling(6) and(8).
11.RemovethepipingfromtheLDAsystem(5).
12.Removethefuelfilter(7).
13.Removetheheater(4).
14.Removethecontrolunitfortheheater(10).
15.Removethefuelfiltersupport(9).
16.Removetheinjectorfeedpipe(4)fromthe injectionpump(3).
17.Removethebracketsonthecylinderheadofthe pipeassembly(1),(2)and(6).
18.Replacefuelsupplypump(5).
MIF1105A
MIF1107A
19.Detachthefuelpipeassembly(1)fromthe injectors.
20.Removethefueloutletpipe(2)fromtheinjectors removingthescrew(3)andtheseal(4).
MIF1108A
SECTION10--ENGINE--CHAPTER1 31
24
25
26
21.Removethescrews(2)andtheturbine(1).
22.Removetheexhaustmanifold(3).
23.Removethebelt(3,fig.28)oftheauxiliary membersbylooseningthetightener.
24.Removethealternator(6),fanpulley(2)andthe tightener(8).Removethesupport(1)ofthe pulley(2)andtheoilcooler(7).
25.Removethecoolantpump(5).
26.Removetheenginecoolingsystemfitting(4) fromthecrankcase.
NOTE: Thecoolantpump(5)cannotbeoverhauled. Itmustbereplacedifthereisanyirregularoperation.
MIF1110A
27.Locktheflywheeltostopitturning,removethe fixingscrews(1)fromthepulley(2).
MIF1111A
Removingthecrankshaftfrontseal
28.Applytool 380000665 (4)onthefronttang(2)of thecrankshaft.
29.Perforatetheinnerseal(1)withadrillbit (∅ 3.5mm)throughtheguideholesofthetool (4),foradepthof5mm.
30.Securethetool 380000665 (4)totheseal(1)with thescrews(3)provided.
31.Extracttheseal(1)byscrewingdownthescrew (5).
MIF0916A
MIF1109A
32 SECTION10--ENGINE--CHAPTER1
27
28
29
(Op.28.to32.)
30
32.Fitthetierod(3)ofthetool 380000669 tothe outerseal(1)asshowninthefigure31andwith thelever(4),extractitfromthefrontcover(2).
MIF0917A
33.Turntheengineover,takeoutthescrews(2)and removetheoilsump(1).
34.Takeoutthescrews(2)andremovetheoilpump (1).
NOTE: Theoilpump(1)cannotbeoverhauled. Itmustbereplacedifthereisanyirregularoperation.
MIF1112A
35.Usingthepin(1),locktheadditionalcounterweights(2)attheT.D.C. Unscrewtheretainingbolts(3)andremovethe additionalcounterweights(2).
MIF1113A
MIF1117A
SECTION10--ENGINE--CHAPTER1 33
31
32
33
34
36.Beforeremovingtheinjectionpump,dothe timingandlocktheengineflywheelwithcylinder no.1atT.D.C.asindicatedonpage10,using tools 380000988 and 380000732.Thenloosen thebolt(2),removetheìLîspacer(1)andlock thescrew(2)inordertokeepthepumpintime withtheengineflywheel.
NOTE: KeeptheìLîspacerwiththepumpcasing.
MIF0920A
37.Removethethreenuts(2)(3)(5)securingthe injectionpump(1)tothecrankcase(4)and extractitfromitshousing.
MIF0922A
38.Removethescrews(2)fixingtheengineflywheel (1)tothecrankshaft.
MIF1115A
39.Screwtwopins(2)oftheappropriatelengthinto theholesinthecrankshaft(3).
40.Extracttheengineflywheel(1)soitcanbeslung withtheliftandputitawayinaspecificcontainer.
MIF1116A
34 SECTION10--ENGINE--CHAPTER1
35
36
37
38
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Removingthecrankshaftrearseal (Op.41.to44.)
41.Extracttheseal,fittingthetool 380000663 (3)on therearshank(1)ofthecrankshaft.
42.Perforatetheinnerseal(5)withadrillbit (∅ 3.5mm)throughtheguideholesofthetool (3),foradepthof5mm.
43.Securethetool 380000663 (3)totheseal(5)by screwingdownthescrews(2)supplied.
44.Extracttheseal(5)byscrewingdownthescrew (4).
45.Takeoutthescrews(2)andremovethetiming gearbox(1),retrievingtheinjectionpumpgear.
NOTE: Notedowntheassemblypositionofthe screws(2)astheyhavedifferentsizes.
MIF0927A
MIF1125A
46.Takeoutthescrews(1)andremovethegears(3) and(4)fromthecamshaft(2).
MIF1118A
47.Takeoutthebolts(1)andremovethehydraulic pumpdrivegear(2).
MIF1119A
SECTION10--ENGINE--CHAPTER1 35
39
40
41
42
48.Foreachcylinder,removetherockerarm assembly(1)loosentheadjusternuts(3), unscrewtheadjusters(4)andtakeoutthe screws(2).
MIF0933A
49.Extracttheinjectors(2)withtool 380000671 (1).
50.Takeoutthescrews(1)fixingtheheadtothe crankcase.
MIF0934A
1
MIF1120A
51.Afterfittingthebrackets(1)and(2)hookthe metalcablesanddetachthecylinderheadfrom thecrankcasewiththehoist.
NOTE: Afterremovingthecylinderhead,removethe brackets(1)and(2).
36 SECTION10--ENGINE--CHAPTER1 MIF1121A
43
44
45
46
52.Valvesareremovedwithtool 380000302 (1), applyingpressureonthecap(3)sothat,by compressingthesprings(4),itispossibleto removethecotters(2).Thenremove:theplate (3),springs(4).
Repeatthisoperationonallvalves(5).
MIF1122A
53.Removetheintakemanifoldcoverandextract theoilseals(1)fittedonthevalvestems. Toremovethevalves,turntheheadover.
NOTE: Marktheinletandexhaustvalvesbefore removingthem.
NOTE: Theinletvalvesdifferfromtheexhaustvalves inthesizeoftheheadandtherebeinganadditional referencemark(1)onthestem.
A= Inletvalve.
B= Exhaustvalve.
MIF0948A
54.Removethethermostatvalve(2)fromthe governorbody(1)takingoutthescrews(3).
MIF1124A
MIF1123A
SECTION10--ENGINE--CHAPTER1 37
47
48
49
50
55.Takeoutthescrews(1)securingtheconnecting rodcaps(2)andremovethem.
56.Extractthepistonstogetherwiththeconnecting rodsfromthetopofthecrankcase.
NOTE: Keepthehalfbearingsintheirrespective housingssince,iftheyareused,theymustbe mountedinthepositionfoundupondisassembly.
57.Removetherings(1)fromthepiston(3)withthe pliers 380000221 (2).
58.Thepistonpin(1)retainingsnaprings(2)should beremovedusingamarkingtool(3).
59.Takeoutthescrews(1)andremovethemain bearingcaps(2).
MIF1126A
MIF0938A
MIF0950A
MIF0951A
38 SECTION10--ENGINE--CHAPTER1
51
52
53
54
60.Thepenultimatemainbearingcap(1)andthe relatedmountinghavethehalfbearing(2) equippedwithashoulder.Removethepistons withtheconnectingrods.
NOTE: Notedowntheassemblypositionofthetop andbottomhalfbearingssince,iftheyarereused, theymustbemountedinthepositionfoundupon disassembly.
61.Usingtool 380000362 (1)andahoist,removethe crankshaft(2)fromthecrankcase.
62.Removethemainhalfbearings(1).
63.Takeoutthescrews(2)andremovetheoil nozzles(3).
64.Takeoutthescrews(1)andremovetheplate(3) retainingthecamshaft(2).
NOTE: Notedowntheassemblypositionoftheplate (3).
MIF1128A
MIF0940A
MIF1127A
MIF0942A
SECTION10--ENGINE--CHAPTER1 39
55
56
57
58
