CASE IH FARMALL 95N Tractor Service Repair Manual Instant Download

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SECTION 00 - - GENERAL - - CHAPTER 1 1 SECTION 00 - - GENERAL Chapter 1 - - General CONTENTS Section Description Page General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Important Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rotating Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 O--Ring Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Sealing Compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Spring Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Notes for Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Important Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Moving the Tractor with the Battery Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 To Prevent Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tractor Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 00 - - GENERAL - - CHAPTER 1 2 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair work described in this manual must be performed exclusively by CASE IH service technicians, in strict accordance with the instructions given and using any specific tools necessary. Anyone performing the operations described herein without strictly following the instructions is personally re- sponsible for any eventual injury or damage to property. BATTERY Before carrying out any kind of service operation disconnect and isolate the battery negative lead, unless other- wise requested for specific operations (e.g: operationsthat requirethe enginerunning). Oncethe specificopera- tion has been completed, disconnect the lead in order to complete the operation. SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorder values: Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each on shim. ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: -- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes; -- thoroughly clean the shaft and check that the working surface on the shaft is not damaged; -- positionthesealinglipfacingthefluid;withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirec- tion and position the grooves so that they will deviate the fluid towards the inner side of the seal; -- smear the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease; -- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet; -- whilst inserting the seal, check that the it is perpendicular to the seat; once settled, make sure that it makes contact with the thrust element, if required; -- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations. O- -RING SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist- ing, which would jeopardize sealing efficiency. SEALING COMPOUNDS ApplyoneofthefollowingsealingcompoundsonthematingsurfacesmarkedwithanX:LOCTITE518,LOCTITE 5205, SUPERBOND 559 MASCHERPA or BETABLOCK A272M GURIT ESSEX. Before applying the sealing compound, prepare the surfaces as follows: -- remove any incrustations using a wire brush; -- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a water and soda solution. BEARINGS When installing bearings it is advised to: -- heat the bearings to 80 to 90 C before fitting on the shafts; -- allow the bearings to cool before installing them from the outside.

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SECTION 00 - - GENERAL - - CHAPTER 1 3 SPRING PINS When fitting split socket elastic pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning. SPARE PARTS Use genuine parts only. Only genuine spare parts guarantee the same quality, duration and safety as they are the same parts that are assembled during production. Only genuine parts can offer this guarantee. When ordering spare parts, always provide the following information: -- tractor model (commercial name) and frame number; -- engine type and number; -- part number of the ordered part, which can be found in the Spare Parts Catalogue used for order process- ing. NOTES FOR EQUIPMENT The tools that CASE IH propose and illustrate in this manual are: -- specifically researched and designed for use with CASE IH vehicles; -- necessary to make reliable repair; -- accurately built and strictly tested to offer efficient and long--lasting working means. By using these tools, repair personnel will benefit from: -- operating in optimal technical conditions; -- obtaining the best results; -- saving time and effort; -- working in safe conditions. IMPORTANT NOTES Wear limit values indicated for certain parts are recommended, but not binding. The terms front , rear , right-- hand and left--hand (when referred to different parts) are intended as seen from the driving position with the tractor in the normal direction of movement. MOVING THE TRACTOR WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle. If the vehicle electrical system requires checking, carry out operations with the power supply connected; Once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.

SECTION 00 - - GENERAL - - CHAPTER 1 4 SAFETY REGULATIONS SAFETY SYMBOLS The following keywords with regards to safety are used throughout this manual: DANGER, used with the safety alert symbol (fig- ure 1) indicates a hazardous situation which, if not avoided, willresult in death or serious injury. The col- or associated with Danger is RED. M1169A WARNING, used with the safety alert symbol (fig- ure 1), indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. M1170A CAUTION, used with the safety alert symbol (fig- ure 1), indicates a hazardous situation which, if not avoided,couldresultinminorormoderateinjury.The color associated with Caution is YELLOW. M1171A 1 -- Do not carry out repair operations with someone sitting in the driver s seat, unless the person is a trained technician who is assisting with the op- eration in question. TO PREVENT ACCIDENTS Most accidents or injuries that occur in workshops are the result of non--observance of simple and fun- damental safety regulations. For this reason, IN MOST CASES THESE ACCIDENTS CAN BE AVOIDED: by foreseeing possible causes and con- sequently acting with the necessary caution and care. Accidentsmayoccurwithalltypesofvehicle,regard- less of how well it was designed and built. A careful and judicious service technician is the best guarantee against accidents. Precise observance of the most basic safety rule is normally sufficient to avoid many serious accidents. DANGER. Never carry out any cleaning, lubrication or maintenance operations when the engine is run- ning. -- Do not operate the vehicle or use any of the im- plements from different positions, other than the driver s seat. -- Do not carry out operations on the vehicle with the engine running, unless specifically indicated. -- Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. -- All repair and maintenance operations must be carried out using extreme care and attention. -- Service steps and platforms used in a workshop or in the field should be built in compliance with the safety rules in force. GENERAL GUIDELINES -- Disconnect the batteries and label all controls to indicate that the vehicle is being serviced. Block the machine and all equipment which should be raised. -- Carefully follow specified repair and mainte- nance procedures. -- Do not wear rings, wristwatches, jewelry, unbut- toned or loose articles of clothing such as: ties, torn clothing, scarves, open jackets or shirts with open zips that may remain entangled in moving parts.Itisadvisedtowearapprovedsafetycloth- ing, e.g: non--slip footwear, gloves, safety goggles, helmets, etc. -- Donotcheckorfillfueltanks,accumulatorbatter- ies, nor use starting liquid when smoking or near naked flames, as these fluids are inflammable. -- Brakes are inoperative when manually released for repair or maintenance purposes: use blocks or similar devices to control the machine in these conditions.

SECTION 00 - - GENERAL - - CHAPTER 1 5 Wear protective equipment: helmets, goggles and special footwear. -- The fuel nozzle should always be in contact with the filling aperture: maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build--up. -- When carrying out checks with the engine run- ning, request the assistance of an operator inthe driver s seat. The operator must maintain visual contact with the service technician at all times. -- Only use specified towing points for towing the vehicle. Connect parts carefully: make sure that all pins and/or locks are secured in position be- fore applying traction. Never remain near the towing bars, cables or chains that are operating under load. -- If operating outside the workshop, position the vehicle on a flat surface and lock in position. If working on a slope, lock the vehicle in position. Move to a flat area as soon as is safely possible. -- Transport vehicles that cannot be driven using a trailer or a low--loading platform trolley, if avail- able. -- Damagedorbentchainsorcablesareunreliable: do not use them for lifting or towing. Always use suitable protective gloves when handling chains or cables. -- When loading or unloading the vehicle from the trailer (or other means of transport), select a flat area capable of sustaining the trailer or truck wheels. Firmly secure the vehicle to the truck or trailer and lock the wheelsin theposition usedby the carrier. -- Chains should always be safely secured: make surethatthe hitch--uppoint iscapable ofsustain- ing the load in question. Keep the area near the hitch--up point, chains or cables free of all by- standers. -- Electric heaters, battery--chargers and similar equipment must only be powered by auxiliary power supplies with efficient ground insulation to avoid electrical shock hazards. -- Maintenance and repair operations must be car- riedoutinaCLEANandDRYarea.Eliminateany water or oil spillage immediately. -- Do not create piles of oil or grease--soaked rags: as they represent a serious fire hazard. Always store rags in a closed metal container. Before starting the tractor or its attachments, check, adjust and block the operator s seat. Also checkthattherearenopersonswithinthevehicle or implement range of action. -- Always use suitable hoisting or lifting devices when raising or moving heavy parts. -- Take extra care if bystanders are present. -- Never pour petrol or diesel oil into open, wide or low containers. -- Never use gasoline, diesel oil or other inflam- mable liquids as cleaning agents: use non--in- flammable, non toxic commercially available sol- vents. -- Empty pockets of all objects that may fall unob- served into the vehicle parts. -- In the presence of protruding metal parts, use protective goggles or goggles with side guards, helmets, special footwear and gloves. -- Wear safety goggles with side guards when cleaning parts with compressed air. -- When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and footwear. All persons present in the area where welding is taking place must wear tinted goggles. NEVER LOOK DIRECTLY AT THEWELDINGARCWITHOUTSUITABLEEYE PROTECTION. -- Limit the air pressure to a maximum of 2.1 bar, according to local regulations. -- Do not run the engine in confined spaces without suitable ventilation. -- Do not smoke, use naked flames, or cause sparks in the area when fuel filling or handling highly inflammable liquids. -- Metal cables tend to fray with repeated use: al- ways use suitable protective devices (gloves, goggles, etc.) when handling cables. -- Never use naked flames for lighting when work- ing on the machine or checking for leaks. -- Handle all parts with great care. Do not put your hands or fingers between moving parts. Always wear suitable safety clothing -- safety goggles, gloves and shoes. -- All movements must be carried out carefully when working under, on or near the vehicle.

SECTION 10 - - ENGINE - - CHAPTER 1 1 SECTION 10 - - ENGINE Chapter 1 - - Engine (Model 95N) CONTENTS Section Description Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Exhaust Gas Recirculation System (EGR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Removing the Crankshaft Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Removing the Crankshaft Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Fitting the Connecting Rod--Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Fitting the Piston Connecting Rod Assemblies In the Cylinder Liners . . . . . . . . . . . . . 47 Big End Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Fitting the Thermostat Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Fitting the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Fitting the Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fitting the Rocker Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fitting the Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Fitting the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Fitting the Additional Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Fitting the Hydraulic Pump Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Fitting the Timing Gear Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fitting the Crankshaft Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fitting the Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Fitting the Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Fitting the Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

SECTION 10 - - ENGINE - - CHAPTER 1 2 Section Description Page Fitting the Crankshaft Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Fitting the Crankshaft Front Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Fitting the Cooling System Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Fitting the Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Fitting the Fan--alternator Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Fitting the Auxiliary Member Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fitting the Exhaust Manifold -- Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fitting the Injector Feed Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fitting the Fuel Pump -- Feed Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fitting the Pipes Between the Fuel Supply and Injection Pumps, Pre-heating System and Tappet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Fitting the Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Checks, Measurements and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Crankcase, Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Checking Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Checking Twisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Checking Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Normal Dimensions (mm) Piston Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Measuring the Piston Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Piston Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Conditions for Correct Pin--Piston Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Valves and Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Dimensions (mm) of Valves and Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Decarbonizing, Checking and Grinding Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Checking the Cylinder Head Mating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cylinder Head Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Cylinder Head Hydraulic Seal Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

SECTION 10 - - ENGINE - - CHAPTER 1 3 Section Description Page Low Oil Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Flushing and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Coolant Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Thermostat Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Crankshaft -- Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Crankshaft -- Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Adjusting Valve/Rocker Arm Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Bosch Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Fuel Circuit Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 4-Cylinder Coolant Pump and Generator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

SECTION 10 - - ENGINE - - CHAPTER 1 15 SECTIONAL VIEWS MIF1096A 1 Engine view

SECTION 10 - - ENGINE - - CHAPTER 1 16 Oil path under pressure Oil return path under gravity MIF1098A 2 Engine lubrication diagram Forced--circulation lubrication is accomplished by the following components: -- oil pressure control valve incorporated in the cooler assembly; -- by--pass valve to cut off clogged oil filter, incorporated in the cooler assembly; -- oil pump, housed at the front of the crankcase, driven by the grooved bushing keyed onto the shank of the crankshaft; -- cartridge oil filter. -- water / oil cooler, housed in the crankcase;

SECTION 10 - - ENGINE - - CHAPTER 1 17 Coolant recirculating in the engine Coolant entering the pump MIF1099A 3 Cooling diagram The forced circulation, closed--circuit engine cooling system is composed of the following components: -- a centrifugal coolant pump housed at the front of the crankcase; -- a thermostat valve governing coolant circulation. -- a lubricating oil cooler;

SECTION 10 - - ENGINE - - CHAPTER 1 18 MIF1102A 4 Additional counterweight diagram 1. Retaining bolts 6. Half bearings 2. Support 7. Counter--shaft 3. Retaining bolts 8. Gear 4. Gear 9. Ring 5. Balancing weight 10. O--ring

SECTION 10 - - ENGINE - - CHAPTER 1 19 DESCRIPTION AND OPERATION EXHAUST GAS RECIRCULATION SYSTEM (EGR) On the TIER 3 version, the exhaust cam profile has been modified to permit partial opening of the related valve during the inlet phase (exhaust gas recircula- tion EGR) with the consequent re--introduction of some of the exhaust gases into the engine cylinders. The internal EGR system is not provided with any electronically controlled elements: the system is always on. Its configuration needs no additional elements such as control valves, pipes or heat exchangers. The exhaust cam (B) in addition to the main lobe has anotherlobe(seesect.A--A,fig. 5)withrespecttothe configuration without EGR. The exhaust gases can be partially redirected into the cylinders in order to reduce the maximum combustion temperature values which are responsi- ble for the production of nitrogen oxide (NOx). The additional lobe, during the inlet phase of the cylinder under examination, permits briefly opening the exhaust valve generating recirculation due to the exhaust gases returning caused by the lower pressure created in the inlet phase inside the cylinder. The exhaust gas recirculation system (EGR), reducing the temperature decreasing the concentration of oxygen in the combustion chamber, is therefore an effective system to control emissions of NOx. of combustion by 5 Camshaft view A. Inlet valve cam. B. Exhaust valve cam.

SECTION 10 - - ENGINE - - CHAPTER 1 24 OVERHAUL Operation 10 001 10 ENGINE Removal DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies supported by means of suitable slings and hooks.Ensurethatno- -oneisinthevicinityofthe load to be lifted. CAUTION Use suitabletools toalign theholes. NEVERUSE FINGERS OR HANDS. or parts are 1. Remove the cab as described in opera- tion 90 150 10. 2. Extract the fixing pin and remove the ballast (1); unscrew the retaining screws and retrieve the ballast support (2). 3. Carry out operation 23 101 26 Propeller shafts and guard, only removal (see Sect. 23). 6 4. Unscrew the plug and drain the front transmis- sion casing (prescribed quantity: 44 liters). 25628 7 5. Disconnect transmission oil cooler and of the front axle differential lock. the pipes (1 and 2) of the 8

SECTION 10 - - ENGINE - - CHAPTER 1 25 6. Disconnect: the transmission oil cooler pipes (1) and the front axle differential lock pipe (2). 9 7. Unscrew: the retaining bolts of the pipe (1) delivering oil to the pump and the bolts retaining the pipe (2) to the filter support. 10 8. Loosen the related clamps and remove the sleeve (2) from the pipe (1) and remove the transmission oil inlet pipe together with the above--mentioned sleeve. 11 9. Unscrew the fixing clamps and disconnect the pipes (1 and 2) from the cooler, the sleeve (4) between the air filter and the turbocharger and the oil vapor recirculation pipe (3). 12

SECTION 10 - - ENGINE - - CHAPTER 1 secondary tank fuel level 26 10. Disconnect connection (1) and the clogged air filter pressure switch connection. the 13 11. Disconnect control pipes (1). the steering hydraulic cylinder 14 12. Unscrew the fixing clamps and detach the upper (1) and lower (2) sleeves from the engine radiator. 15 13. Unhookthecatchandextractthetransmissionoil radiator (1). 16

SECTION 10 - - ENGINE - - CHAPTER 1 27 14. Disconnect the pipes (1) of the air--conditioning system from the related condenser. 17 15. Unscrew the fixing screws, loosen the related clamp and detach the pipe (1) joining the tanks: main to secondary. 18 16. Unscrew the fixing screw and detach the bracket (1) locking the engine radiator. 19 17. Position a fixed stand under the transmission-- clutch casing. 18. Connecttheenginetothehoistusingachainand make it take up the strain. 19. Unscrew the bolts (1) securing the engine to the transmission--clutch casing and detach the engine assembly and front axle. 20

SECTION 10 - - ENGINE - - CHAPTER 1 28 20. Set up two fixed stands: one under the axle support at the rear and the other under the front side. 21. Unscrewthebolts(1)onbothsidesandseparate the engine from the axle--support assembly with the radiators. 22. Rest the engine on an adequate support. Installation To install the engine, proceed as follows: CAUTION Use suitabletools toalign theholes. NEVERUSE FINGERS OR HANDS. 21 1. Respect the tightening torques prescribed on page 12. 2. Connect the engine, with chains, to the hoist. 3. Refit the engine to the front axle--support assembly with the radiator and cooler. 4. Before refitting the engine to the clutch box carefully clean the mating surfaces and apply sealing compound (2 mm diameter), according to the diagram shown Section 21, Chapter 1, page 34. 5. Position the engine on the clutch casing and secure it with the specific bolts. 6. Position and secure the retaining bracket between the radiator and engine. 7. Secure the pipe joining the main tank to the secondary one. 8. Position and secure the guard between the radiator and engine. 9. Connect theair--conditioning systempipes tothe condenser. 10. Insert the transmission oil radiator into its seat and secure it. 11. Connect and secure the top and bottom sleeves to the engine radiator. 12. Connect the steering cylinder control piping.

SECTION 10 - - ENGINE - - CHAPTER 1 29 13. Connect the electrical connections of the secondary tank fuel level and clogged air filter. 14. Position and secure the connecting pipes of the cooler, turbocharger, air filter and oil vapor recirculation. 15. Position and connect the transmission oil inlet pipe. 16. Positionandsecurethepipesofthetransmission oil filter support. 17. Connect the transmission oil cooler and front axle differential lock pipes. 18. Carry out operation 23 101 26 Propeller shafts and guard, only installation (see Sect. 23). 19. Connectthecoolerand frontaxle differentiallock pipes. 20. For models fitted with brakes on the front axle it isnecessarytofilltherelevanttank(seesect.00, page 6 for the prescribed product and quantity) and bleed the braking system (see sect. 33). 21. Screw the plug on the rear transmission casing and fill up with oil (see sect. 00, page 6 for the prescribed product and quantity). 22. Position and secure the ballast support. 23. Position and secure the ballast. 24. Install tion 90 150 10. the cab as described in opera-

SECTION 10 - - ENGINE - - CHAPTER 1 30 Operation 10 001 54 Disassembly The figures refer to the F4CE9484M*J602 versions of 71 kW (97 hp) mod. 95V and 95N. WARNING Handle all parts with great caution. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Remove the engine as described in opera- tion 10 001 10, proceed as follows. 2. Drainoff theengine oilby removingthe plugfrom the sump and the oil filler plug. 3. Detach the fan unit from the fan pulley. 4. To be able to fit the bracket 380000661 (for fixing the engine to the overhaul stand) to the crankcase, it is necessary to remove the wiring (1) from the left--hand side of the engine. MIF1103A 22 5. To be able to fit the bracket 380000661 to the crankcase on the right--hand side, remove the starter motor (5), oil filter (3), clamp (4), and turbine oil return pipe (1). 6. Fix the gearbox to the rotating stand 380000301. Detach the oil delivery pipe (2). MIF1104A 23

SECTION 10 - - ENGINE - - CHAPTER 1 31 7. Remove the intake manifold (2). 8. Disconnect the engine oil vapor recovery pipe from the blow--by (3). 9. Remove the tappet covers (1). 10. Remove the pipes with the quick--fit coupling (6) and (8). 11. Remove the piping from the LDA system (5). 12. Remove the fuel filter (7). 13. Remove the heater (4). 14. Remove the control unit for the heater (10). MIF1105A 24 15. Remove the fuel filter support (9). 16. Remove the injector feed pipe (4) from the injection pump (3). 17. Remove the brackets on the cylinder head of the pipe assembly (1), (2) and (6). 18. Replace fuel supply pump (5). MIF1107A 25 19. Detach the fuel pipe assembly (1) from the injectors. 20. Remove the fuel outlet pipe (2) from the injectors removing the screw (3) and the seal (4). MIF1108A 26

SECTION 10 - - ENGINE - - CHAPTER 1 32 21. Remove the screws (2) and the turbine (1). 22. Remove the exhaust manifold (3). 23. Remove the belt (3, fig. 28) of the auxiliary members by loosening the tightener. MIF1109A 27 24. Remove the alternator (6), fan pulley (2) and the tightener (8). Remove the support (1) of the pulley (2) and the oil cooler (7). 25. Remove the coolant pump (5). 26. Remove the engine cooling system fitting (4) from the crankcase. NOTE: The coolant pump (5) cannot be overhauled. It must be replaced if there is any irregular operation. MIF1110A 28 27. Lock the flywheel to stop it turning, remove the fixing screws (1) from the pulley (2). MIF1111A 29 Removing the crankshaft front seal (Op. 28. to 32.) 28. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 29. Perforate the inner seal (1) with a drill bit ( 3.5 mm) through the guide holes of the tool (4), for a depth of 5 mm. 30. Securethetool380000665(4)totheseal(1)with the screws (3) provided. 31. Extract the seal (1) by screwing down the screw (5). MIF0916A 30

SECTION 10 - - ENGINE - - CHAPTER 1 33 32. Fit the tie rod (3) of the tool 380000669 to the outer seal (1) as shown in the figure 31 and with the lever (4), extract it from the front cover (2). MIF0917A 31 33. Turn the engine over, takeout thescrews (2)and remove the oil sump (1). MIF1117A 32 34. Take out the screws (2) and remove the oilpump (1). NOTE: The oil pump (1) cannot be overhauled. It must be replaced if there is any irregular operation. MIF1112A 33 35. Using the pin (1), lock the additional counter- weights (2) at the T.D.C. Unscrew the retaining bolts (3) and remove the additional counterweights (2). MIF1113A 34

SECTION 10 - - ENGINE - - CHAPTER 1 34 36. Before removing the injection pump, do the timing and lock the engine flywheel with cylinder no.1 at T.D.C. as indicated on page 10, using tools 380000988 and 380000732. Then loosen the bolt (2), remove the L spacer (1) and lock the screw (2) in order to keep the pump in time with the engine flywheel. NOTE: Keep the L spacer with the pump casing. MIF0920A 35 37. Remove the three nuts (2) (3) (5) securing the injection pump (1) to the crankcase (4) and extract it from its housing. MIF0922A 36 38. Removethescrews(2)fixingtheengineflywheel (1) to the crankshaft. MIF1115A 37 39. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). 40. Extract the engine flywheel (1) so it can be slung with the lift and put it away in a specific container. MIF1116A 38

SECTION 10 - - ENGINE - - CHAPTER 1 35 Removing the crankshaft rear seal (Op. 41. to 44.) 41. Extract the seal, fitting the tool 380000663 (3) on the rear shank (1) of the crankshaft. 42. Perforate the inner seal (5) with a drill bit ( 3.5 mm) through the guide holes of the tool (3), for a depth of 5 mm. 43. Secure the tool 380000663 (3) to the seal (5) by screwing down the screws (2) supplied. 44. Extract the seal (5) by screwing down the screw (4). MIF0927A 39 45. Take out the screws (2) and remove the timing gear box (1), retrieving the injection pump gear. NOTE: Note down the assembly position of the screws (2) as they have different sizes. MIF1125A 40 46. Takeoutthescrews(1)andremovethegears(3) and (4) from the camshaft (2). MIF1118A 41 47. Take out the bolts (1) and remove the hydraulic pump drive gear (2). MIF1119A 42

SECTION 10 - - ENGINE - - CHAPTER 1 36 48. For each cylinder, remove the rocker arm assembly (1) loosen the adjuster nuts (3), unscrew the adjusters (4) and take out the screws (2). MIF0933A 43 49. Extract the injectors (2) with tool 380000671 (1). MIF0934A 44 50. Take out the screws (1) fixing the head to the crankcase. 1 MIF1120A 45 51. After fitting the brackets (1) and (2) hook the metal cables and detach the cylinder head from the crankcase with the hoist. NOTE:After removingthe cylinderhead, removethe brackets (1) and (2). MIF1121A 46

SECTION 10 - - ENGINE - - CHAPTER 1 37 52. Valves are removed with tool 380000302 (1), applying pressure on the cap (3) so that, by compressing the springs (4), it is possible to remove the cotters (2). Then remove: the plate (3), springs (4). Repeat this operation on all valves (5). MIF1122A 47 53. Remove the intake manifold cover and extract the oil seals (1) fitted on the valve stems. To remove the valves, turn the head over. NOTE: Mark the inlet and exhaust valves before removing them. MIF1123A 48 NOTE:Theinletvalvesdifferfromtheexhaustvalves in the size of the head and there being an additional reference mark (1) on the stem. A = Inlet valve. B = Exhaust valve. MIF0948A 49 54. Remove the thermostat valve (2) from the governor body (1) taking out the screws (3). MIF1124A 50

SECTION 10 - - ENGINE - - CHAPTER 1 38 55. Take out the screws (1) securing the connecting rod caps (2) and remove them. 56. Extract the pistons together with the connecting rods from the top of the crankcase. NOTE: Keep the half bearings in their respective housings since, if they are used, they must be mounted in the position found upon disassembly. MIF0938A 51 57. Remove the rings (1) from the piston (3) with the pliers 380000221 (2). MIF0950A 52 58. The piston pin (1) retaining snap rings (2) should be removed using a marking tool (3). MIF0951A 53 59. Take out the screws (1) and remove the main bearing caps (2). MIF1126A 54

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SECTION 10 - - ENGINE - - CHAPTER 1 39 60. The penultimate main bearing cap (1) and the related mounting have the half bearing (2) equipped with a shoulder. Remove the pistons with the connecting rods. NOTE: Note down the assembly position of the top and bottom half bearings since, if they are reused, they must be mounted in the position found upon disassembly. MIF0940A 55 61. Usingtool380000362(1)andahoist,removethe crankshaft (2) from the crankcase. MIF1127A 56 62. Remove the main half bearings (1). 63. Take out the screws (2) and remove the oil nozzles (3). MIF0942A 57 64. Take out the screws (1) and remove the plate (3) retaining the camshaft (2). NOTE: Note down the assembly position of the plate (3). MIF1128A 58

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