CASE IH JX1100U Tractor Service Repair Manual Instant Download

JX1080U, JX1090U, JX1100U REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SECTION 18 - CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SECTION 21 - TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SECTION 23 - MFD TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SECTION 25 - MFD AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SECTION 27 - REAR AXLE MECHANICAL TRANSMISSION . . . . . . . . . . . . . 11 SECTION 31 - POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION 33 - BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SECTION 35 - HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SECTION 41 - STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 SECTION 44 - AXLES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SECTION 50 - AUXILIARY UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SECTION 55 - ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SECTION 90 - CAB, PLATFORM AND BODYWORK . . . . . . . . . . . . . . . . . . . . 35 The following pages are the collation of the contents pages from each section and chapter of the JX1080U, JX1090U, JX1100U Repair manual. Complete Repair part # 87054727. ThesectionsusedthroughoutallCaseIHproductRepairmanualsmaynotbeusedfor eachproduct. EachRepair manual will be made upofone or several books. Eachbook willbelabeledastowhichsectionsareintheoverallRepairmanualandwhichsections are in each book. The sections listedabove are thesections utilizedfor theJX1080U, JX1090U,JX1100U Tractors. 2004 CNH America LLC Printed In U.S.A. 87054735 10/04

SECTION 00 - - GENERAL - - CHAPTER 1 1 SECTION 00 - GENERAL Chapter 1 - General CONTENTS Section Description Page General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ecology and the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Federal Emissions Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 California Emission Control Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Filling and Topping-Up Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 00 - - GENERAL - - CHAPTER 1 2 WARNING WARNING All maintenance and repair work described in this manual must be performed exclusively by CASEIHservicetechniciansin strictaccordance with the instructions given and using any specific tools necessary. The Manufacturer and all organizations belong- ing to the Manufacturer s distribution network, including but not restricted to national, regional orlocaldistributors,willacceptnoresponsibility forpersonalinjuryordamagetopropertycaused by abnormal function of parts and/or compo- nents not approved including those used for maintenance and/or repair of the product manufactured or marketed by the Manufacturer. In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer. by the Manufacturer, WARNING Anyone who performs the operations described herein without strictly following the instructions is personally responsible for resulting injury or damage to property.

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SECTION 00 - - GENERAL - - CHAPTER 1 3 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by the authorised workshops. All instructions detailed should be carefully observed and special equipment indicated should be used if necessary. Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled,ensurethatitcontactsthethrustelement, if required; To prevent damaging the sealing lip against the shaft, place a suitable installation. protection during Everyone who carries out describedwithoutcarefullyobservingtheseprescrip- tions will be directly damages. service operations O RINGS Lubricate the O rings before inserting them into their seats. This will prevent the O rings from roll over and twisting during mounting, which will jeopardize sealing. responsible of deriving SHIMMING Ateachadjustment,selectadjustingshims,measure them individually using a micrometer and then sum up recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on the rated value indicated for each shim. SEALERS Apply silicone/gasket eliminator over the mating surfaces marked with an X. Before applying the sealer, prepare the surface as follows: ROTATING SHAFT SEALS To correctly install rotating shaft seals, observe the following instructions: remove possible scales using a metal brush; thoroughly degrease the surfaces using one of the following cleaning agents: trichlorethylene, diesel fuel or a water and soda solution. Let the seal soak into the same oil as it will seal for at least half an hour before mounting; Thoroughly clean the shaft and ensure that the shaft working surface is not damaged; BEARINGS It is advisable to heat the bearings to 80 to 90 C (176 to 194 F) before mounting them on their shafts and cool them down before inserting them into their seats with external tapping. Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and orient grooves in order that they deviate the fluid towards the inner side of the seal; SPRING PINS When mounting split socket spring pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin. Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill the gap between the sealing lip and the dust lip of double lip seals with grease; Spiral spring pins should not be oriented during installation. Insert the seal into its seat and press it down using a flat punch. Do not tap the seal with a hammer or a drift;

SECTION 00 - - GENERAL - - CHAPTER 1 4 GENERAL INSTRUCTIONS PRECAUTIONARY NOTICE Only authorized workshops should carry out maintenance and repair operations on the tractor, or tractor compo- nents. Carefully observe all instructions, safety precautions, and the use of equipment such as special tools, as detailed in this manual. Damage to the tractor, or injury to personnel is the direct responsibility of anyone who fails to observe these precautions. EQUIPMENT NOTICE The equipment proposed in this manual is: Designed and studied expressly for use on Case IH tractors Necessary for adequate and reliable repair of the tractor Strictly tested for the efficient and long lasting life cycle of the tractor SPARE PARTS NOTICE Genuine CASE IH spare parts guarantee the same quality, safety and life cycle as original components. These parts bear the logo. GENERAL NOTICES In this manual, the description FRONT , REAR , RIGHT--HAND and LEFT--HAND refer to the view seen by the operator while in the operator s seat, looking in the direction in which the tractor normally moves. Wear limits detailed in this manual, although advised, are not binding.

SECTION 00 - - GENERAL - - CHAPTER 1 5 HEALTH AND SAFETY CONTENTS Description Page HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ADHESIVES AND SEALERS -- see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . . . . . . . . . . . . . . . 6 ARC WELDING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BATTERY ACIDS -- see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BRAZING -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CHEMICAL MATERIALS -- GENERAL -- see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DO S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CORROSION PROTECTION MATERIALS -- see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIBRE INSULATION -- see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIRE -- see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FOAMS -- Polyurethane -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FUELS -- see Fire, Legal Aspects, Chemicals -- General, Solvents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GAS CYLINDERS -- see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PAINTS -- see Solvents and Chemical Materials -- General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SOLDER -- see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SOLVENTS -- see Chemical Materials -- General Fuels (Kerosene), Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WELDING -- see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 HEALTH AND SAFETY PRECAUTIONS Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This section lists, alphabeti- cally, some of these hazardous operations and the materials and equipment associated with them. The precautions necessary to avoid these hazards are identified. The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with health and safety in mind.

SECTION 00 - - GENERAL - - CHAPTER 1 6 ACIDS AND ALKALIS -- see Battery acids, e.g. caustic soda, sulfuric acid. Used in batteries and cleaning materials. Provide adequate ventilation and avoid skin and eye contact. Follow manufacturers instructions. Anaerobic, Cyanoacrylate and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin. Some are eye irritants. Irritant and corrosive to the skin, eyes, nose and throat. Causes burns. Avoid splashes to the skin, eyes and clothing. Wear suitable protective gloves and goggles. Can destroy ordinary protective clothing. Do not breathe mists. Skin and eye contact should be avoided and the manufacturers instructions followed. Ensure access to water and soap is readily available for splashing accidents. Cyanoacrylate adhesives (super--glues) must not contact the skin or eyes. If skin or eye tissue is bondedcoverwithacleanmoistpadand getmedical attention. do not attempt to pull tissue apart. Use in well ventilated areas as vapours can cause irritation of the nose and eyes. ADHESIVES AND SEALERS -- see Fire Highly Flammable, Flammable, combustible. Generally should be stored in No Smoking areas; cleanliness and tidiness in use should be observed, e.g. disposable paper covering benches; should be dispensed from applicators where possible; contain- ers, including secondary containers, should be labelled. For two--pack systems see Resin based adhesives/ sealers. Isocyanate Sealers -- see Resin based Adhesives. Individuals suffering from asthma or respiratory allergiesshouldnotworkwithornearthesematerials as sensitivity reactions can occur. (Polyurethane) Adhesives/ Solvent based Adhesives/Sealers -- SeeSolvents. Follow manufacturers instructions. Any spraying should preferably be carried out in exhaust ventilated booths removing vapours and spray droplets from the breathing zone. Individuals working with spray applications supplied air respirators. Water based Adhesives/Sealers Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmfulchemicals. Skin and eye contact should be avoided and adequate ventilation provided during use. should wear ANTIFREEZE -- see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. Follow manufacturers instructions. Highly Flammable, Flammable, Combustible. Resin based Adhesives/Sealers -- e.g. epoxide and formaldehyde resin based. Used in vehicle coolant systems, brake air pressure systems, screenwash solutions. Mixing should only be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released. Vapours given off from coolant antifreeze (glycol) arise only when heated. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze if swallowed is fatal and medical attention must be found immediately. Skin contact with uncured resins and hardeners can result in irritation; dermatitis and absorption of toxic orharmfulchemicalsthroughtheskin. Splashescan damage the eyes.

SECTION 00 - - GENERAL - - CHAPTER 1 7 ARC WELDING -- see Welding. The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life--expectancy. BATTERY ACIDS -- see Acids and Alkalis. Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries. DO S Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned. BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) -- see Fire. Combustible. carefully read and observe hazard and Do precaution warnings given on material containers (labels) and in any accompanying leaflets, poster or other instructions. Material health and safety data sheets can be obtained from Manufacturers. Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation of vapour hazards do not arise at ambient temperatures because of the very low vapour pressure. Doorganiseworkpracticesandprotectiveclothingto avoid soiling of the skin and eyes; breathing vapours/aerosols/dusts/fumes; inadequate contain- er labelling; fire and explosion hazards. BRAZING -- see Welding. CHEMICAL MATERIALS - - GENERAL -- see Legal Aspects. Do wash before job breaks; before eating, smoking, drinking or using toilet facilities when handling chemical materials. Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly inflammable and give rise to hazardous fumes and dusts. Do keep work areas clean, uncluttered and free of spills. Do store according to national and local regulations. Do keep chemical materials out of reach of children.

1 SECTION 10 - - ENGINE - - CHAPTER 1 SECTION 10 - - ENGINE Chapter 1 - - Engine CONTENTS Operation Description Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Torque Settings with Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 10 001 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Checks, Measurements and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Cylinder Block Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Camshaft and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Oil Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Crankshaft Front Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Crankshaft Rear Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 10 102 74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Valve Tappet and Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 10 106 12 Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

2 SECTION 10 - - ENGINE - - CHAPTER 1 Operation Description Page Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 10 218 30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Bosch Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 10 246 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Fuel Circuit Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Turbocharged Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Coolant Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 10 402 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Thermostart Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 10 402 30 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 10 406 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Coolant Pump and Alternator Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 10 414 10 Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3 SECTION 10 - - ENGINE - - CHAPTER 1 SPECIFICATIONS 4 Cylinders Engine, type: -- model JX1080U -- Naturally Aspirated . . . . . . . . . . . . . . . . . . -- model JX1090U -- Turbocharged . . . . . . . . . . . . . . . . . . . . . . -- model JX1100U -- Turbocharged . . . . . . . . . . . . . . . . . . . . . . F4CE0404C*D681 F4CE0454E*D681 F4CE0454D*D681 Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston diameter (bore) -- model JX1080U -- JX1090U -- JX1100U . . . . . . . . . . . . . . . . Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total displacement: -- model JX1080U -- JX1090U -- JX1100U . . . . . . . . . . . . . . . . Compression ratio for Models JX1080U -- JX1090U -- JX1100U Maximum power: -- model JX1080U -- F4CE0404C*D681 . . . . . . . . . . . . . . . . . . -- model JX1090U -- F4CE0454E*D681 . . . . . . . . . . . . . . . . . . -- model JX1100U -- F4CE0454D*D681 . . . . . . . . . . . . . . . . . . Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4--stroke direct 4 4.0944 in. (104 mm) 5.1968 in. (132 mm) 273.67 in3. (4.5L) 17.5:1 60 kW (80 HP) 67 kW (90 HP) 73.5 kW (98 HP) 2500 rev/min Maximum Torque @ 1400 rev/min -- Maximum torque: model JX1080U -- F4CE0404C*D681 . . -- Maximum torque: model JX1090U -- F4CE0454E*D681 . . -- Maximum torque: model JX1100U -- F4CE0454D*D681 . . Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Nm (236 lb.-ft.) 350 Nm (258 lb.-ft.) 370 Nm (272 lb.-ft.) 5 structural, cast iron (continued)

4 SECTION 10 - - ENGINE - - CHAPTER 1 (cont) 4 Cylinders Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with lobe pump Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . 1:1 Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and filtering cartridge on delivery line Normal oil pressure with motor warmed--up at slow idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 psi (1.2 bar) at fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 psi (3.8 bar) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation Radiator on Models JX1080U -- JX1090U -- JX1100U . . . . . . . . 4 rows of vertical pipes with copper fins Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . intake, in plastic with 11 blades Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane--type Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: -- Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Middle green section (normal working conditions) . . . . . . . . . -- Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.977 colored scale divided into 3 sections 104 to 140 F (40 to 60 C) 140 to 230 F (60 to 110 C) 230 to 248 F (110 to 120 C) Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via thermostat valve -- initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.0 35.6 F (81 2 C) Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight--tooth gears Intake: -- start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 30 10 30 -- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust: -- start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 -- end: after T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Valve--rocker arm clearance (with engine cold): -- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01 0.001 in (0.30 0.05 mm) 0.02 0.001in (0.55 0.05 mm) -- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For further timing system technical data . . . . . . . . . . . . . . . . . . . see page 9 (continued)

5 SECTION 10 - - ENGINE - - CHAPTER 1 (cont) 4 Cylinders Fuel system Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged filter indicator with centrifugal pre--filter and automatic dust ejector Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with double diaphragm Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm . . 33.7 g/h (127.6 l/h) Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine timing BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor type All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic For further fuel system technical data: Fixed advance (pump setting for start of delivery before TDC) -- Pressure setting -- Injection order, and other information re- garding the BOSCH pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to the data for the relevant engine type in the table on page 3

15 SECTION 10 - - ENGINE - - CHAPTER 1 DESCRIPTION AND OPERATION SECTIONAL VIEWS MIF1096A 1 View of JX1080U of 60 kW (80 HP)

16 SECTION 10 - - ENGINE - - CHAPTER 1 model JX1090U MIF1097A 2 View of JX1090U tractor engines of 67 kW (90 HP) and JX1100U of 73.5 kW (98 HP)

17 SECTION 10 - - ENGINE - - CHAPTER 1 Oil path under pressure Oil return path under gravity MIF1098A 3 Lubrication diagram for engines mod. JX1090U and JX1100U The pressurized lubrication system contains the fol- lowing components: -- oil pump, housed at the front of the crankcase, driven by the grooved bushing keyed onto the shank of the crankshaft; -- water / oil cooler, housed in the crankcase; -- pressure regulator incorporated in the cooler as- sembly; -- by--pass valve to cut off clogged oil filter, incorpo- rated in the cooler assembly; cartridge oil filter. -- NOTE:EnginesonJX1080Umodelsarenaturallyas- pirated, therefore will not contain a turbocharger lu- brication circuit.

18 SECTION 10 - - ENGINE - - CHAPTER 1 Coolant recirculating in the engine Coolant entering the pump MIF1099A 4 Cooling system diagram The pressurized, closed--circuit engine cooling sys- tem contains the following components: -- lubricating oil cooler; -- centrifugal coolant pump housed at the front of the crankcase; thermostat valve to govern coolant circulation. --

19 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1100A 5 Detail of cylinder head with valve seats installed in engine model JX1080U 1. Exhaust manifold 2. Intake manifold 3. Air heater 4. Valve seats 5. Thermostat valve 6. Injector

20 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1101A 6 Detail of cylinder head with valve seats installed in engine models JX1090U and JX1100U 1. Exhaust manifold 2. Intake manifold 3. Air heater 4. Valve seats 5. Thermostat valve 6. Injector

21 SECTION 10 - - ENGINE - - CHAPTER 1 MIF1102A 7 Detail of Counterweights and Balancer 1. Retaining bolts 2. Support 3. Retaining bolts 4. Gear 5. Balancing weight 6. Half bearings 7. Counter--shaft 8. Gear 9. Ring 10. O--Ring

26 SECTION 10 - - ENGINE - - CHAPTER 1 OVERHAUL Op. 10 001 10 ENGINE Removal DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted. CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. NOTE: Certain steps described in the removal - - installation of the engine are specific to models with MFD or models with cab. 1. Remove the hood (1) as described in operation 9010022. 2. Disconnect the battery negative lead. 3. Drain the oil from the transmission--gearbox housing. 8 4. Remove the three retaining bolts (1) and the guard (2) on the right--hand side of the fan. 9 5. Disconnectthereturnhosefitting(1)from thecab heater radiator connected, located on the under- side of the coolant pump (2), and drain off the en- gine coolant into a suitable container. 10

27 SECTION 10 - - ENGINE - - CHAPTER 1 6. Remove the catch (2) and detach the toolbox (1). 11 7. Remove the split pins, retaining pin (3) and front ballast (2) together with the support (1). 12 8. On MFD model, remove the center and rear re- taining bolts of the front drive shaft guard, and re- move the guard (1). 1 25038 13 9. On MFD models, remove the circlip (2) and move the front sleeve (1) in the direction indicated by the arrow, until clearing the groove on the front axle. 2 1 25039 14

28 10. On MFD models, remove the circlip (2) and move therearsleeve(1)inthedirectionindicatedbythe arrow until it is released from the groove on the drive. SECTION 10 - - ENGINE - - CHAPTER 1 1 2 25040 15 11. On MFD models, remove the drive shaft central support (1) retaining bolts and extract the shaft together with the support. 1 25041 16 12. Remove the lift pump supply pipe retaining bolts (1) and remove pipe (2). 17 13. Remove the power steering/MFD return pipe fit- ting (1) on the left-hand side of the engine. 18

29 SECTION 10 - - ENGINE - - CHAPTER 1 14. Detach the power steering/MFD return pipe on the right--hand side of the engine. 19 15. Remove the bolt (1) retaining the bracket and the power steering/MFD return pipe on the right-- hand side of the engine (2). 20 16. Remove the transmission--to--hydraulic pump oil supply pipe (1) with clamps (2). 21 17. Remove the steering pump oil supply pipe fitting (1) located on the right-hand side of the engine. 22

30 SECTION 10 - - ENGINE - - CHAPTER 1 18. Remove the retaining bolts (2) that secure the lift pump supply pipe (1) to the lift pump. 23 19. Extract the plastic fasteners (2) and detach the diesel recovery pipe (3) and delivery pipe (4) to the diesel pump (1). 24 20. On models with cab, disconnect the electrical connections (1) and (2) between the cab and the engine. 25 21. On models with cab, disconnect the electrical connection (1) between the cab and the engine. 26

31 SECTION 10 - - ENGINE - - CHAPTER 1 22. Disconnect the two power steering oil delivery and return hoses (1). 1 24879 27 23. Remove the four knobs (1) and take off the two right-- and left--hand control panel guards (2). 1 2 MDD2562A 28 24. On models with a mechanicaldifferential lock, re- move the differential lock pedal retaining pin from thedriveshaft(1),andremovethepedalandfoot- board (2). 2 1 25043 29 25. Remove the four plugs (1) to gain access to the engine upper retaining bolts. 30

32 26. Remove the retaining clips (1) and detach the flexiblecablesgoverningthehandthrottle (5)and pedal throttle (4). 27. Remove the retaining clip (3) and detach the throttle control tie--rod (2) connected to the injec- tion pump. SECTION 10 - - ENGINE - - CHAPTER 1 31 28. Detach the fitting (2) and the hose (1) delivering power steering oil to the hydraulic steering cylinders. 32 29. Onmodelswithcab,detachtheclamp(1)andthe cab heater delivery pipe (2). 33 30. Onmodelswithcab,detachtheclamp(2)andthe cab heater return pipe (1). 34

33 SECTION 10 - - ENGINE - - CHAPTER 1 31. Take out the three exhaust muffler rear retaining bolts (1). 35 32. Remove the clamp (1), the air filter dust ejector pipe (2) and the four nuts (3) securing the muf- fler to the exhaust manifold. 36 33. Remove the muffler (2) together with the exhaust pipe (1). 37 34. Remove the four rear retaining bolts (1) of the hood support (2). 38

34 SECTION 10 - - ENGINE - - CHAPTER 1 35. Remove the three front retaining bolts (1) of the hood support (2). 39 36. Remove the two clips (2) retaining the brake fluid reservoir (1) to the support (3). 40 37. Remove the two retaining bolts (1) and the sup- port (2) together with the relays (3). 41 38. Remove the two retaining bolts (1) and the sup- port together with the fuse box (2). 42

35 SECTION 10 - - ENGINE - - CHAPTER 1 39. Remove the hood support (1). 43 40. On models with cab, remove the two retaining bolts (2) and detach the support (3) together with the dryer filter (1) and pipes. 1 3 2 44 41. Onmodelswithcab,unhookthebottompin(1)re- taining the condenser. 45 42. On models with cab, turn the steering wheel fully to the right, then remove the two retaining bolts (1) and the top guide of the condenser (2). 46

36 SECTION 10 - - ENGINE - - CHAPTER 1 43. On models with cab, extract the condenser radia- tor (1) from the right--hand side of the tractor. 47 44. On models with cab, remove the compressor (1) as described in operation 50.200.26 without de- taching pipes (2) and (3) to prevent recovery, evacuation and charging of the gas in the air con- ditioning system. 48 45. On models with cab, remove the condenser ra- diator (1), the dryer filter (2) with its support and the compressor (3), resting them alongside the right--hand rear wheel with the associated piping. 49 46. Remove the two retaining bolts (1) and the brake piping support (2). 50

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37 SECTION 10 - - ENGINE - - CHAPTER 1 47. Remove the retainingbolt (1)of thebracket ofthe power steering return pipe (2). 51 48. Remove the electricalconnections (1) connected to the pressure switch (2) and free the power steering pipe (3) from the engine. 52 49. Remove the electrical connections (2) from the brake fluid reservoir (1). 53 50. Remove the electrical connections (2) installed on the brake pumps (1). 54

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