Case 580K Super 580 K Backhoe Loader Service Repair Manual PDF Download

Case 580 Super K

Backhoe • Loader • Tractor

Service Manual

9

P.I.N. JJG0160001 and after v .0

http://BestManuals.net Best.Manuals @yahoo.com

580 Super K Loader Backhoe P.I.N. JJG0160001 and after Service Manual

Table of Contents General Loctite Product Chart Section Index -General Torque Specifications Fluids & Lubricants

Description

Section No Tabl 10001 10002

Engines Section Index -Engine Engine Removal & Installation Stall Tests Detailed Engine Specifications Cylinder Head & Valve Train Cylinder Block Lubrication System Cooling System Turbocharger Turbocharger Failure Analysis

Tab 2

Fuel System Section Index -Fuel System Fuel System & Filters Fuel Inj ectors CAV Injection Pump (4-390) Bosch Injection Pump (4T-390)

Tab 3

Electrical Section Index -Electrical Removal & Installation of Electrical Components Specifications, Troubleshooting & Schematics Batteries Starter & Starter Selenoid 95 Ampere Alternator 65 Ampere Alternator Instrument Cluster Steering Section Index -Steering Removal & Installation of Steering Component Specifications, Schematics & Troubleshooting Steering Control Valve -Eaton Steering Control Valve -Danfoss Steering Cylinder Front Axle -Two Wheel Drive Front Axle -Four Wheel Drive

2001 2002 2402 2415 2425 2445 2455 2465 2565

3410 3413 3414 3415

Form No 8-98900 8-17141 8-71600 8-12271 8-17161 8-17560 8-12301 8-24163 8-24173 8-24183 8-24193 8-24203 8-25550 9-78235

8-17190 8-24212 8-24233 7-37131 7-37141

Tab 4 4001 4002 4003 4004 4006 4007 4008 Tab 5 5001 5002 5004 5005 5006 5007 5008

8-17200 8-17210 8-17220 8-12350 8-11370 8-12381 8-15670 8-17230

8-17250 8-17260 8-17270 8-12440 8-12450 8-17280 8-12471 8-17300

Description

Power Train Section Index -Power Train Removal & Installation of Components Transmission Specifications & Schematic Wheels & Tires PTO Rear Axles & Planetaries Transfer Gearbox Differential & Differential Lock ForwardlReverse Valve Torque Converter Charging Pump, Output Shaft & Converter Housing Transmi ssi on Brakes Section Index -Brakes Parking Brake Disc Brakes Removal & Installation of Brake Components Master Cylinder Hydraulics Section Index -Hydraulics Removal & Installation of Hydraulic Components Schematics, Specifications & Troubleshooting Cleaning the Hydraulic System Hydraulic Pump Loader Control Valve Cylinder Backhoe Control Valve Swing Sequence Valve Three Point Hitch Control Valve Double Selector Valve Mounted Equipment Section Index -Mounted Equipment Pedals & Levers Air Conditioning Troubleshooting & Pressure Checks Air Conditioning System Loader ROBS Cab & ROPS Canopy Backhoe Three Point Hitch Seat & Seat Belts Suspension Seat

Section No Tab 6

Form No

6001 6002 6003 6019 6201 6202 6203 6204

8-17570 8-12501 8-12512 8-12521 7-37060 7-36980 7-36990 7-37000 7-37010

6205 6206

7-37020 7-37030

Tab 7 7000 7001 7002 7003

TabS 8001 8002 8003 8004 8005 8006 8007 8008 8009 8011

8-17350 7-37040 7-37050 8-12540 8-12570

8-12580 8-17580 8-17530 8-67390 8-17400 8-17410 8-17591 8-17430 8-12650 8-67421 8-12670

Tab 9 9001

8-12680 8-17540

9002 9003 9004 9005 9006 9008 9009 9010

8-12700 8-12711 8-17630 8-17470 8-12741 8-12761 8-12770 8-12781

SECTION INDEX -GENERAL

Section Title

Section Number

Standard Torque Specifications ...............................................................................................................................1 001 Fluids and Lubricants ..............................................................................................................................................1 0 02 Detailed Engi ne Specifications ................................................................................................................................1 024

CASE CORPORATION

Bur 8-16230

Printed in U.S.A. Issued August 1990

2

o o

Ol CO Ol

cb

s

a:

1001 STANDARD TORQUE SPECIFICATIONS TABLE OF CONTENTS Torque Specifications Hardware

- Decimal

Torque Specifications

- Metric Hardware

CASE CORPORATION

1001-2 ... 1001-3

Torque Specifications Fittings

- Steel Hydraullc

Torque Specifications Seal Fittings.....

- O-ring Face ....................1001-5

Bur 8-71600

1001-4

Printed in U.S.A. Issued May 1988

1001-2

TORQUE SPECIFICATIONS

- DECIMAL HARDWARE

Use the torques in this chart when special torques are not given. These torques apply to fastenars with both UNC and UNF threads as received from suppliers. dry. or when lubricated with engine oil Not applicable if special graphites, rnotydisulfide greases. or other extreme pressure lubricants are used.

8113608

1001-3

TORQUE SPECIFICATIONS

- METRIC HARDWARE

Use the following toques when special torques are not given.

These values apply to fasteners with coarse threads as received from supplier. plated or unplated. or when lubricated with engine oil. These values do not apply if graphite or molydisulfide grease or oil if used.

811359A

1001-4

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS Tube OD Hose ID

Threa d Size

Pound - Feet

Newto n metres

Tube OD Hose ID

Threa d Size

Pound - Feet

Newto n metres

Straight Threads with O-ring

37 Degree Flare Fittings 1/4 in 6.4 mm

7/16-20

6-12

8-16

1/4 in 6.4 mm

7/16-20

12-19

16-25

5/16 in 7.9 mm

1/2-20

8-16

11-21

5/16 in 7.9 mm

1/2-20

16-25

22-23

3/8 in 9.5 mm

9/16-18

10-25

14-33

3/8 in 9.5 mm

9/16-18

25-40

34-54

3/4-16

15-42

20-56

1/2 in 12.7 mm

3/4-16

42-67

57-90

15.9 mm

7/8-14

25-58

34-78

7/8-14

58-92

79-124

3/4 in 19.0 mm

1-1/16-12

40-80

54-108

1-1/16-12

80-128

108-174

1-3/16-12

100-160

136-216

1-5/16-12

117-187

159-253

1-5/8-12

165-264

224-357

1-7/8-12

250-400

339-542

1/2 in 12.7 mm 5/8 in

1-1/4 in 31.8 mm 1-1/2 in 38.1 mm

19.0 mm 7/8 in

1-3/16-12

60-100

81-135

1.0 in 25.4 mm

15.9 mm 3/4 in

l/8.in 22.2 mm

5/8 in

1-5/16-12

75-117

102-158

22.2 mm 1.0 in 25.4 mm 1-1/4 in

1-5/8-12

125-165

169-223

1-7/8-12

210-250

285-338

31.8 mm 1-1/2 in 38.1 mm

Split Flange Mounting Bolts Size

PoundFeet

Newton metres

5/16-18

15-20

20-27

3/8-16

20-25

26-33

7/16-14

35-45

47-61

1/2-13

55-65

74-88

5/8-11

140-150

190-203 8113618

1001-5

TORQUE SPECIFICATIONS Nom . SAE Dash Size

Threa d Size

Tube 00

Pound - Feet

O-ring Face Seal End

- O-RING FACE SEAL FITTING

Newto n Metres

Threa d Size

Pound - Feet

Newto n Metres

O-ring Boss End Fitting or Locknut

-4

1/4 In 6.4 mm

9/16-18

10-12

14-16

7/16-20

17-20

23-27

-6

3/8 in

11/16-16

18-20

24-27

9/16-18

25-30

33-40

95mm -8

1/2 in 12.7 mm

13/16-16

32-40

43-54

3/4-16

45-50

61-68

-10

5/8 in 15.9 mm

1-14

46-56

60-75

7/8-14

60-65

81-88

3/4 in 19.0 mm

1-3/16-12

65-80

90-110

1-1/16-12

85-90

115-122

1-3/16-12

65-80

90-110

1-3/16-12

95-100

129-136

1-7/16-12

92-105

125-140

1-5/16-12

115-125

156-169

1-11/16-12

125-140

170-190

1-5/8-12

150-160

203-217

2-12

150-180

200-254

1-7/8-12

190-200

258-271

I

I -12

-14

7/8 in 22.2 mm

-16

1.0 in 25.4 mm

I

I

1-1/4 in -20

31.8 mm 1-1/2 in

-24

38.1 mm

8871553

Section

1002 FLUIDS AND LUBRICANTS

CASE CORPORATION

Bur 8-12271

Printed inU.S.A. Issued March 1991

1002-2

TABLE OF CONTENTS ....................................... 2

CAPACITIES AND LUBRICANTS ...

ENGINE OIL RECOMMENDATIONS

3

.

.

DIESELFUEL .

..

.4

CAPACITIES AND LUBRICANTS Engine Oil Capacity with Filter Change Type of oil.

11.6 U.S. quarts (11 litres) See Engine Oil Recommendations on page 3

Engine Cooling System Capacity without heater Capacity with heater..

Type of coolant.

17.2 U.S. quarts (16.3 litres) ...17.9 U.S quarts (16.9 litres) Ethylene glycol and water mixed for lowest ambient temperature At least SO/50 mix

Fuel Tank Capacity Capacity with auxiliary tank..................................

Type of fuel Hydraulic System Hydraulic reservoir refill capacity Type of oil

.

See Diesel

25 U.S. gallons (94.6 litres) 33 U.S. gallons (124.9 litres) fuel specifications on page 4

21.5 US.

gallons (81.4 litres) Case TCH Fluid

Transmission Capacity Total System Capacity Type of oiL.............

47.6 U.S. quarts (45 litres) 57.1 U.S. quarts (54 litres) Case Hy-Trans Plus (MS 1207)

Front Axle - Four Wheel Drive Capacity of center bowl Capacity of planetary (each) Typeofoil..... ..

7.4 quarts (7 Iitres) 1.1 U.S. quarts (1 litre) CaselH 135-H EP gear lube

Brake Reservoir Type of fluid

Case TCH Fluid

Conversion Formulas Imperial quart = litres x 0.879877 Imperial gallon = litres x 0.219969

Bur 8-12271

Issued 3-91

Printed in U.S.A.

1002-3

ENGINE OIL RECOMMENDATIONS Case IH No.1 Engine Oil is recommended for use inyour Case IH Engine. Case IH Engine Oil will lubricate your engine correctly under all operating conditions. IfCase IH No.1 Multi-Viscosity Engine Oil is not available, Case IH No.1 Single Grade Engine Oil can be used If Case IH No.1 Multi-Viscosity or Single Grade Engine Oil is not available, use only oil meeting API engine oil service catergory CE.

654L9

viscosity at ambient air temperature

See the chart below for recommended NOTE: Do crankcase. lubricants.

ranges.

not put Performance Additives or other oil additive products in the engine The oil intervals given in this manual are according to tests with Case IH

RANGES

AMBIENT AIR TEMPERATURE Temperature Fahrenheit

, I I I

I

I

I I I •

I

I

MUL TI-GRADE OIL I

I

.I

I

I

•

•

.I• •• I

I

SINGLE GRADE OIL I

• I

-34' _29' -23' -18'

I

-7"

I

_1'

I

4'

Temperature

Bur 8-12271

I

.•

I

• •

•

I

737L9

I

-12'

I

•

I

••

I 10'

I 16" 21'

I

I 27" 32'

I

I 38'

I 43'

-49'

Celsius

Issued 3-91

Printed in U.S.A.

1002-4

DIESEL FUEL Use NO.2 diesel fuel in the engine of this machine. The use of other fuels can cause the loss of engine power and high fuel consumption.

Invery cold temperatures, a mixture of NO.1and NO.2 diesel fuels is temporarily permitted. See the following Note.

NOTE: See

your fuel dealer for winter fuel requirements in your area. If the temperature of the fuel is below the cloud point (waxappearance point), wax crystals in the fuel will cause the engine to lose power or not start.

Fuel Storage Ifyou keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank. Many engine problems are caused by water in the fuel.

Keep the fuel storage tank outside and keep the fuel as cool as possible.

Remove water from the storage container at regular periods of time.

The diesel fuel used in this machine must meet the specifications in the chart below or Specification 0975-81 of the American Society for Testing and Materials.

Specifications for Acceptable NO.2 Diesel Fuel API gravity, minimum

..34

Flash point, minimum.

.. 140°F(60°C)

Cloud point (wax appearance point), maximum

..

-5°F (-20°C) See Note above

Pour point. maximum

-15°F (-26°C) See Note above

Distillation temperature. 90% point...

540 to 640°F (282 to 338°C)

Viscosity, at 100°F (88°C) Centistokes Saybolt Seconds Universal.................

Cetane number, minimum Water and sediment, by volume, maximum...........................

Sulfur, by weight, maximum...............

Copper strips corrosion, maximum Ash, by weight, maximum.................

Bur 8-12271

. ..

2.0 to 43 32 to 40 43 (45 to 55 for winter or high altitudes) ..0.05 of 1% .. 0.5of1% .. No.2 .. 0.01of1%

Issued 3-91

Printed in U.S.A.

Section

1024 SPECIFICATION DETAILS

IMPORTANT: This engine was made using the metric measurement system. All measurements and checks must be made with metric tools to make sure of an accurate reading when inspecting parts.

CASE CORPORATION

Rae 8-24162

Copyright © 1991 JICase Company Printed in U.S.A. June, 1983 (Revised January, 1991)

1024-2

TABLE OF CONTENTS RUN-IN INSTRUCTIONS. .

3

IDENTIFICATION MARKS Crankshaft Cylinder Block.... ..

Cylinder Head.....

4 .4 ..4

.

ENGINE SPECIFICATION DETAILS Cylinder Block... .

.4

Service Cylinder Sleeve..... .

5

Piston.......

5

.

Piston Pin

5

Piston Rings

6

Cylinder Head.

Lifters ..

................... 6

..

...6

Connecting Rod .

Crankshaft.

8

Camshaft

9

Turbocharger

9

Gear Train

9

Rocker Arm Assembly.

.............. 10

Intake Valve...

Exhaust Valve

10 ..

10

Valve Springs..........

.11

Valve Seat Installation Dimensions

11

SPECIAL TORQUES .. ,

Rae 8-24162

7

11-13

Revised 1-91

Printed in U.S.A.

1024-3

RUN-IN INSTRUCTIONS Engine Lubrication Fill the engine crankcase with CO or CE service classification oil that has the correct viscosity rating for the ambient air temperature. Install new oil filters, after the engine has been rebuilt.

Run-In Procedure

for Rebuilt Engine

Step 1

Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start Crank the engine for 30 seconds until there is oil pressure, then reconnect the wire.

Step 2

Remove the air from the cooling system at the temperature sending unit.

Step 3

Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks

Step 4

During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.

Run-In Procedure

for Rebuilt Engines (With a Dynamometer)

The following procedure must be followed when using a PTOdynamometer to Run-In the engine. The dynamometer will control the engine load at each speed and will remove stress on new parts during Run-In. During the Run-In, continue to check the oil pressure, coolant level and coolant temperature.

STEP TIME ENGINESPEED DYNAMOMETERSCALELOAD

15Minutes 1000RPM 50 25Minutes 1100RPM 1/2 35Minutes 2200RPM Full

Run-In Procedure STEP 1

2 3

for Rebuilt Engines (Without a Dynamometer)

TIME 5 Minutes 5 Minutes 5 Minutes

Run-In Procedure

ENGINE SPEED 1000 RPM 1100 RPM 2200 RPM

LOAD No Load Light Load Light Load

(Agriculture Tractors)

For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours 00 NOT "lug" the engine.

Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the rated engine RPM during early hours of life.

Run-In Procedure

(Construction Equipment)

For the first 8 hours, operate the engine at full throttle maintaining a normal load. Avoid converter or hydraulic stall. The engine must not be "lugged" below the Rated Engine RPM (00 not stall the engine more than 10 seconds).

Rae 8-24162

Revised 1-91

Printed in USA

1024-4

Crankshaft Letter N =

IDENTIFICATION MARKS

Nitroc Hardened, crankshaft must be rehardened to a minimum hardness of 450 HV 0.2 rockwell any time the crankshaft has been reconditioned.

Cylinder Block (DNa

LetterX = The cylinder block has been retaced and up to 0.25 mm has been removed. Use a thicker head gasket notches).

Letter XX = The cylinder block has been refaced and up to 0.50 mm has been removed Use a thicker head gasket (three notches).

Cylinder Head

Letter G = Thermostat passage in cylinder did not need to be machined Letter M = Thermostat passage in cylinder head was machined.

Letter V = Valve seats have been machined.

LetterX = The cylinders inthe cylinder block have been bored oversize. Use a head gasket with oversize cy (one notch)

LetterXX = The cylinder block has been refaced and up to 0.25 mm has been removed use athicker head gasket (DNa notches) .

LetterXXX = The cylinder block has been refaced and up to 0.50 mm has been removed. Use a thicker hea (three notches).

Numbers = RH rear corner of cylinder head indicates the amount of material removed from the cylinder head.

Cylinder Block

ENGINE SPECIFICATION DETAILS Metric Value Non-Sleeved

Type.. .

Cast Iron

Material

102.00 to 102.04 mm

10ofCylinder... .

Maximum Service Limit

102.116 mm

.

Cylinder Out of Round (Maximum)

0.038 mm

Cylinder Taper (Maximum)

0.076 mm

0.5 mm Oversize Piston Machine Cylinder Bore to Hone to (Finished Diameter) 1.00 mm Oversize Piston Machine Cylinder Bore to Hone to (Finished Diameter) Warpage

(Maximum)..................................................................

102.40 to 102.44 mm 102.50 to 102.54 mm 102.90 to 102.94 mm 103.00 to 103.04 mm 0.075 mm

Maximum Material Removal

Rae 8-24162

0.50 mm

Revised 1-91

Printed in U.SA

1024-5

Service Cylinder Sleeve Dry, Can Be Replaced

Type

Cast Iron

Material Machine Cylinder Block Bore to Installation..................

104485 .

to 104.515 mm Press Fit

.

Machine Sleeve Bore to: Standard Size Piston (Finished Diameter)

................................10200

to 102.04 mm

0.5 mm Oversize Piston Machine Cylinder Bore to

10240 to 10244 mm

Hone to (Finished Diameter) 1.0 mm Oversize Piston

102.50 to 102.54 mm

Machine Cylinder Boreto.. ..

102.90 to 102.94 mm

Hone to (Finished Diameter)

..

103.00 to 103.04 mm

Piston Type

Cam Ground

Material...................

...Aluminum alloy

OD at 12 mm From the Bottom, 90 Degrees Piston Pin Standard Size Piston

101.873 to 101.887 mm

Minimum Service Limit.

101.823 mm

0.5 mm Oversize Piston

102.373 to 102.387 mm

Minimum Service Limit.

101.323 mm

1.0 mm Oversize Piston Minimum Service Limit

102.873 to 102.887 mm

ID of Piston Pin Bore

40.006 to 40.012 mm

102.823 mm

Maximum Service Limit

40.025 mm

Width of 1st Ring Groove (Top)

.2465 to 2.485 mm

Width of 2nd Ring Groove (Intermediate)

2.425 to 2445 mm

Width of 3rd Ring Groove (Oil Ring)

4.040 to 4.060 mm

Protrusion Above Cylinder Block (Maximum)

0.660 mm

Piston Pin Type OD of Pin

Full Float 39.997 to 40.003 mm

Minimum Service Limit

Rae 8-24162

39.990 mm

Revised 1-91

Printed in U.S.A.

1024-6

Piston Rings NO.1 Compression 4T-390 Engine

Key Stone Type (Barrel Face)

EndGapin102.0210.... ..

0.4 to 0.70 mm

No.1. Compression 4-390 Engine

Rectangular Type (Barrel Face)

End Gap in 102.02 10..................

. 0.25to0.55mm

Maximum Service l.irnit..

0.806 mm

Side Clearance

0.075 to 0.120 mm

Maximum Service Limit...

0.15 mm

NO.2 Compression.

Rectangular Type (Tapper Face)

End Gap in 102.02 10.

................0.25 to0.55mm

Maximum Service Limit

0.806 mm

Side Clearance

0.075 to 0.120 mm

Maximum Service Limit

0.15 mm

.

NO.3 Oil Control Rings..

Two Piece

End Gap in 102.02 10

0.25 to 0.55 mm

Maximum Service Limit...............................................

. 0.806 mm

Side Clearance.

. 0130mm

Cylinder Head Warpage (Maximum)

0.20 mm .

Maximum Material Removal..........................

9375 mm

..

Minimum Head Height

1.00 mm

Engines Manufactured in U.S.A.: Injectior Nozzle 9 mm

Prior to Engine Serial Number 45511034

Injectior Nozzle 7 mm

Engine Serial Number 45511034 and After Engines Manufactured in Darlington England: Prior to Engine Serial Number 21092870

Injectior Nozzle 9 mm

Engine Serial Number 21092870 and After

.

Injector Nozzle 7 mm

Engines Manufactured in Neuss Germany: Prior to Engine Serial Number 52107489

Injector Nozzle 9 mm

Engine Serial Number 52107489 and After

Injector Nozzle 7 mm

Lifters Material

Hardened Iron 15.961 to 15.977 mm

00 of Lifter Minimum Service Limit. .

15.960 mm

..

Bore Diameter in Block

16.000 to 16.030 mm

Maximum Service Limit.

16.055 mm

Rae 8-24162

Revised 1-91

Printed in USA.

1024-7

Connecting Rod Bushing .Steel Backed Leaded Bronze Bushing 10 Installed (Ream to Size)........................................................... ..40.053 to 40.067 mm Maximum Service Limit 40.092 mm Bearing Liners...................... . Replaceable Journal 10 Without Bearing Liners 72.987 to 73.013 mm BearingOilClearance. 0.038to0.116mm Maximum Service Limit..... . 0129 mm Side Clearance...................................... . 0.100 to 0.300 mm Maximum Service Limit ...0330 mm Connecting Rod Bend (Maximum) Without Bushing. . . . 0.200 mm With Bushing . 0150 mm Connecting Rod Twist (Maximum) Without Bushing. . ,.. . 0.500 mm With Bushing . . 0.300 mm

Rae 8-24162

Revised 1-91

Printed in U.SA

1024-8

Crankshaft Type

Hardened Steel, Balanced . Replaceable

Main Bearing Liners...... ..

0.13 to 0.25 mm

End Clearance, Center Main Bearing Cap

2.50 mm

Center Main Bearing Thrust Surface Thickness......... ..

Connecting Rod Journal 00, Standard

. 68.987 to 69.013 mm

Maximum Service Lirnit..

0.25 mm 00 Undersize, Grind to

. 68.962 mm 68.737 to 68.763 mm

Maximum Service Limit........................................................... ..

68.712 mm

0.50 mm 00 Undersize, Grind to......................................

. 68.487 to 68.513 mm

Maximum Service Limit..

0.75 mm 00 Undersize, Grind to

68.462 mm 68.237 to 68.263 mm

Maximum Service Limit............ .

1.00mm00Undersize,Grindto....................... ...67.98

. 68.212 mm to 68.013 mm

Maximum Service Limit.....................................

. 67.962 mm

Connecting Rod Journal Maximum Taper

0.013 mm

Journals Out of Round Maximum.......................................

. 0050 mm

Undersize Main Bearing Liners For Service .

0.25,0.50,0.75 and 1.00 mm

Main Bearing Oil Clearance

0.041 to 0.119 mm

Maximum Service Limit

0 140 mm

Main Bearing Journal 00, Standard Maximum Service. Limit..... .

0.25 mm 00 Undersize, Grind to .

Maximum Service Limit.

0.50 mm 00 Undersize, Grind to Maximum Service Limit

82.987 to 83.013 mm 82.962 mm 82.737 to 82.763 mm 82.712 mm 82.487 to 82.513 mm 82.462 mm

0.75 mm 00 Undersize, Grind to .......................................................................82.237

to 82.263 mm

Maximum Service Limit.

1.00 mm 00 Undersize, Grind to Maximum Service Limit..

Main Bearing Journal Bore 10 No Liners Maximum Service Limit .

82.212 mm 81.987 to 82.013 mm 81.962 mm 87.982 to 88.018 mm 88.031 mm

Main Journal Width: 1st, 2nd, 3rd, 5th ..

4th

37.424 to 37.576 mm

Connect Rod Journals Width

37.475 to 37.525 mm 38.950 to 39.050 mm

Rae 8-24162

Revised 1-91

Printed in U.S.A.

1024-9

Camshaft Type

Hardened

Bushing (Front Only)

1, Replaceable

Bushing Lubrication: Front Bushing

Pressure Lubricated

Intermediate.

Pressure Lubricated

Rear

Pressure Lubricated

Oil Clearance

0.076 to 0.152 mm

ID of NO.1 Bushing, Installed Maximum Service Limit ID of NO.1 Oversize (57.24 mm 00) Service Bushing Maximum Service Limit 10 of NO.2, 3, 4 and 5 Service Bushing Maximum Service Limit

Iron

54.107 to 54.133 mm ..

54.146 mm 54.089 to 54.139 mm 54.146 mm 54.089 to 54.139 mm 54.146 mm

Width of No 1 Bushing

25.15 to 25.65 mm

Width of No.2, 3, 4 and 5 Service Bushing

1775 to 18.25 mm

Camshaft Bushing Journal OD Camshaft Bore Diameter in Block NO.1 Bushing NO.1. Oversize Bushing, Machine to No.2, 3,4 and 5, Less Bushings NO.2, 3,4 and 5 Oversize for Bushings, Machine to Camshaft Thrust Thickness

53.987 to 54.013 mm 57.222 to 57.258 mm 57.722 to 57.758 mm 54.089 to 54139 mm 57.222 to 57.258 mm 9.42 to 9.58 mm

Minimum Service Limit

9.34 mm

Camshaft Thrust Clearance

0.130 to 0.340 mm

Maximum Service Limit

0.470 mm

Camshaft Lobes: Minimum Diameter at Peak Intake

47.265 mm

Minimum Diameter at Peak Exhaust

46.994 mm

Turbocharger Horizontal Travel of Turbine Shaft

0.10 to 0.16 mm

Gear Train Backlash: 0.08 to 0.33 mm

Crankshaft Gear to Camshaft Gear Crankshaft Gear to Idler Gear

0.08 to 0.33 mm

Camshaft to Fuel Pump Gear

0.08 to 0.33 mm

Idler Gear to Oil Pump

0.08 to 0.33 mm

Camshaft to Auxiliary

0.08 to 0.33 mm 0.45 mm

Maximum Service Limit (All Gears)

Rae 8-24162

Revised 1-91

Printed in U.S.A.

1024-10

Rocker Arm Assembly ODofShaft. .

18.963 to 18.975 mm

Minimum Service Limit..............

. 18.938mm

ID of Arm Bore..............................

19.000 to 19.026 mm

..

Maximum Service Limit

19.051 mm

Lubrication.. .

Pressure From Oil Gallery

Shaft Oil Holes

. Down

Intake Valve Tappet Clearance (Cold)

0.254 mm

Face Angle

29 Degrees

Face Run-Out.................

0.038 mm

..

Valve Head Edge Thickness, Minimum...........................

1.50 mm

.

Length

128.84 to 129.46 mm

OD of Stem

7.960 to 7.980 mm

.

Minimum Service Limit

7.940 mm

.

OD of Head

44870 to 45.130 mm

Seat Angle................................

. 30Degrees

Seat Contact Width

1.32 to 1.92 mm

Seat Run-Out.......

. 0.10mm

Insert Height.....................

OD of Insert.........................

ID of Insert.....................

6.84 to 6.96 mm

.. ..

.47.063 to 47.089 mm Tapered

Valve Recession Below Head Surface

0.99 to 1.52 mm

MaximumServiceLimit. ..

1.52 mm

ID of Valve Guide Bore

8.019 to 8.039 mm

Maximum Service Limit

8.089 mm

Exhaust Valve TappetClearance(Cold) 0.508mm FaceAngle 44Degrees FaceRun-Out. 0.038mm ValveHeadEdgeThickness,Minimum......................................................................................................150 mm ODofHead .41.870to42.130mm ODofStem.. 7.960to7.980mm MinimumServiceLimit 7.940mm Length 128.74to129.36mm InsertSeatAngle.... .45Degrees SeatContactWidth.. 1.47to2.07mm SeatRun-Out. 0.10mm InsertHeigh!....... 6.65to6.77mm ODofInsert......... 43713to43.739mm

IDofInsert.... Tapered ValveRecessionBelowHeadSurface 0.99to1.52mm MaximumServiceLimit 1.52mm IDofValveGuideBore 8.019to8.039mm MaximumServiceLimit 8.089mm Rae 8·24162

Revised 1-91

Printed in U.S.A.

1024-11

Valve Springs Free Length

55.63 mm

TotalCoils. ..

7.25

Wire Diameter.......... ..

.

4.830 to 4.930 mm

Compressed to 38.53 mm

(Valve Open) 785 to 839 N

Maximum Service Limit

765N

.

Compressed to 49.25 mm

(Valve Closed)

Minimum Service Limit

Valve Seat

285 to 321 N 270N

Installation Dimensions

Exhaust Seat .43.713 to 43.73 mm

Diameter of Insert MachineInsertBoreto...... .

.....43.647 to43663 mm

..

..........1010 to.092mm

Depth of Bore.

..0.05 to 0 102 mm

Press Fit...

Intake Seat Diameter of Insert

47.063 to 47.089 mm

Machine Bore to

..46.987 to 47.013 mm

Depth of Bore

..

10.30 to 10.50 mm

Press Fit.......................

'''_

0.05 to 0.102 mm

14 mm Valve Guide Installation Dimensions Guide Diameter

14.026 to 14.038 mm

Machine Guide Bore to

13.987 to 14013 mm

Press Fit..

013 to .051 mm

Installed Height (above top of valve guide boss on head)

11.25 to 11.75 mm

Guide Installed ID

819 to 8.39 mm

SPECIAL TORQUES Aftercooler Bolts......

Metric Value 21 to 27 Nm

Alternator Bracket Bolts (Lower)

21 to 27 Nm

Alternator Bracket Bolts (Upper)

21 to 27 Nm

Alternator Retaining Bolt

21 to 27 Nm

Balancer Counter Weight Bolts....................

..21 to 27 Nm

Balancer Mounting Bolts

167 to 183 Nm

BalancerIdlerGear .. Belt Tensioner Bracket

52 to 62 Nm

Bolts

21 to 27 Nm

Belt Tensioner Retaining Bolt.

39 to 47 Nm

Block Heater

11 to 13 Nm

Rae 8-24162

Revised 1-91

Printed in U.S.A.

1024-12

SPECIAL TORQUES

(Cont'd)

Camshaft Retaining Bolts

Metric Valve 21 to 27 Nm

Coolant Inlet Bolts

39 to 47 Nm

Connecting Rod Bolts.....................

(Lubricate Threads with Engine Oil)

95 to 100 Nm

Cylinder Head Bolts

120 to 132 Nm

Engine Lift Bracket Bolts (Rear)

71 to 83 Nm

Exhaust Manifold Bolts

39 to 47 Nm

Fan Pulley Bracket Bolts ..

23 to 26 Nm

..

FanPulleyBolts8.8........

37to43Nm

FanPulleyBolts10.9...

52to62Nm

Flywheel Housing Bolts .

54 to 66 Nm

Flywheel Retaining Bolts

130 to 144 Nm

FlywheelHousingCoverBolts

21to27Nm

Fuel Filter Inlet Bolt

29 to 35 Nm

Fuel Air Removal Bolt........ ..

5to7Nm

Fuel Filter Inlet NuL.......

29 to 35 Nm

Fuel Line Fitting (High Pressure)

22 to 28 Nm

Fuel Line Fitting (Low Pressure)

22 to 28 Nm

Fuel Shutoff Solenoid..

15Nm

Front Cover Bolts....

..

21 to 27 Nm

Front Housing Bolts

21 to 27 Nm

Injection Pump Drive Gear Nut

59 to 71 Nm

Injection Pump Lock Bolt (Lock Position)

8Nm

Injection Pump Lock Bolt (Unlock Position)

20Nm

Injection Pump Retaining Nuts

21 to 27 Nm

Injection Pump Bracket Bolts

21 to 27 Nm

Injector Leak Off Bolt. ...

.. 5 to 7 Nm

Injector Retaining NuL...

55 to 65 Nm ..

Rae 8-24162

Revised 1-91

Printed in U.S.A

1024-13

SPECIAL TORQUES (Cont'd) Metric Valve

IntakeManifoldBolts.. 21to27Nm IntakeManifoldPlug 115to135Nm LifterCoverBolts.. 21to27Nm MainBearingBolts 165to180Nm (Lubricate the Thread with Engine Oil) OilFillTubeBolts 39to47Nm OilPanDrainPlug 68to82Nm OilPanHeaterPlug 108to132Nm OilPanRetainingBolts 21to27Nm OilPumpRetainingBolts. 21to27Nm OilInletTubeBolts. 18to30Nm OilInletTubeBrace.. ..21to27Nm OilFilterHousingBolts 21to27Nm OilReliefValvePlug 1 08to132Nm PrimerPump21to27Nm RearSealRetainingBolts 8to10Nm RockerArmBolts 21to27Nm StarterRetainingBolts 39to47Nm TachometerDriveRetainingBolts.. 2to4Nm ThermostatHousingBolts 21to27Nm TimingPinRetainingBolts 4to6Nm ThrustBearingScrews(TorxHead) ..4to6Nm TurbochargerMountingBolts 30to34Nm TurbochargerDrainTubeBolts 21to27Nm TurbineHousingBolts 9to13Nm CenterHousingtoBackPlateBolts 5to7Nm CompressorHousingBolts 5to7Nm CompressorLockNut... 13to1.5Nm WaterPumpMountingBolts 21to27Nm ValveCoverBolts.......................... 21to27Nm

Rae8-24162

Revised 1-91

Printed in U.S.A.

1024-14

NOTE: The J ICase Company reserves the right to make improvements in design or

changes in specifications at any time without incurring any obligation to install them on units previously sold.

Rac 8-24162

Revised 1-91

Printed in U.S.A.

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