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Case 445/M2 Service Manual Download Page 158

32620

16552

32619

18857

41104

Figure 45

Figure 46

Figure 47

Figure 48

Figure 49

To measure the piston pin (1) diameter use the micrometer
(2).

Conditions for proper pin

−

piston coupling

Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.

Use a micrometer (1) to check split ring (2) thickness.

Check the clearance between the sealing rings (3) of the 2

nd

and 3

rd

slot and the relevant housings on the piston (2), using

a feeler gauge (1).

DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE

TRAPEZOIDAL RING

Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
make the piston (1) protrude from the engine block so that
the ring (2) protrudes half

−

way from the cylinder barrel (3).

In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.

Piston pins

Split rings

SECTION 4

−

OVERHAUL AND TECHNICAL SPECIFICATIONS

24 

 E NG I NE S 

ED. FEBUARY 2003

Summary of Contents for 445/M2

Page 1: ...CASE ENGINES 445 M2 445T M2 668T M2 SERVICE MANUAL Part Number 6 74500...

Page 2: ...Issued December 2003 6 74500 Bur Copyright 2003 Case LLC All Rights Reserved...

Page 3: ...e and direct instructions to identify the cause of the major inconve niences Sections 4 and 5 illustrate the overhaul operations of the engi ne overhaul on stand and the necessary equipment to execute...

Page 4: ...ENGINES 2 ED FEBUARY 2003...

Page 5: ...clearer and more immediate illustration of the subject being dealt with see next page instead of giving descriptions of some operations or procedures Example 1 housing for connecting rod small end bu...

Page 6: ...ation Adjustment Rotation Warning Note Angle Angular value Visual inspection Fitting position check Preload Measurement Value to find Check Number of revolutions Equipment Temperature Surface for mach...

Page 7: ...ENGINES 5 ED FEBUARY 2003 UPDATING SECTION DESCRIPTION PAGE DATE OF REVISION...

Page 8: ...ENGINES 6 ED FEBUARY 2003...

Page 9: ...nes comply not only with the anti pollution Euro 3 regulations and the relevant prescriptions for noise limit allowed but will also meet the prescriptions of the future more severe specifications with...

Page 10: ...ENGINES 8 ED FEBUARY 2003...

Page 11: ...ERAL SPECIFICATIONS 1 ED FEBUARY 2003 SECTION 1 General Specifications Page ENGINE ID CODE 3 SPECIFIC ENGINE CODE 4 LUBRICATING CIRCUIT 5 OIL VAPOUR RECIRCULATING SYSTEM 7 COOLING CIRCUIT SYSTEM 9 BOO...

Page 12: ...ENGINES 2 ED FEBUARY 2003 SECTION 1 GENERAL SPECIFICATIONS...

Page 13: ...I TCA Model No within D B F 4 8 4 0 E B 4 D F X Y Y Y Y Y Y Y Y X 6 Injection rotary pump 2 valves X 4 Injection in line pump 2 valves ENGINES SECTION 1 GENERAL SPECIFICA TIONS 3 ED FEBRUARY 2003 ENGI...

Page 14: ...truct C Euro3 E E NRMM U EPA USA G Gas M Marine Y XX Y Y Y Y XX XX Power A Not superch S Supercharging T Supercharging with aftercooler Engineering code EXAMPLES N40ENT C N Engine 40 4 liters E Electr...

Page 15: ...OUT 4 cyl engines Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil Lubrication involves the heat exchanger 2 3 as well the supercharged through pipe 1 and the...

Page 16: ...of oil under pressure Routing of oil return by gravity to sump Introduction of oil 1 Lubrication oil pipe to supercharger 2 Heat exchanger body 3 Heat exchanger 4 Oil rotary expansion pump 5 Oil filt...

Page 17: ...ondense oil vapour inducing these to fall down because of gravity to the Tappet cap underneath The remaining non condensed vapours shall be properly conveyed through the breather pipe 2 by suction as...

Page 18: ...ENGINES 8 ED FEBUARY 2003 SECTION 1 GENERAL SPECIFICATIONS...

Page 19: ...e duty to increase the heat dissipating power of the radiator This component as well will be specifically equipped based on the engine s development COOLING SYSTEM LAYOUT 4 cyl engines Water coming ou...

Page 20: ...e 5 COOLING SYSTEM LAYOUT 6 cyl engines Water coming out from thermostat Water recirculating in engine Water coming into pump TO RADIATOR FROM RADIATOR ENGINES 10 ED FEBUARY 2003 SECTION 1 GENERAL SPE...

Page 21: ...r and flown through the piston induction collector The turbocharger is equipped with a transforming valve to regulate the pressure that is located on the exhaust collector before the turbine and conne...

Page 22: ...ENGINES 12 ED FEBUARY 2003 SECTION 1 GENERAL SPECIFICATIONS...

Page 23: ...TION 2 FEED 1 ED FEBUARY 2003 SECTION 2 Page INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP 3 FEED PUMP 5 PRIMING PUMP 6 FUEL FILTER 7 INJECTION FEED SYSTEM BY MECHANICAL PUMP UNIT 9 FEED PUMP 11 FUE...

Page 24: ...ENGINES 2 SECTION 2 FEED ED FEBUARY 2003...

Page 25: ...system is composed by Fuel tank placed on the machine Fuel delivery and back flow to tank Fuel pre filter if available it is usually placed close to the engine on the machine frame Priming pump assemb...

Page 26: ...o be equipped in cold climate areas the fuel filter is provided with heater Transfer pump is placed inside the feed pump and is bladed ty pe its duty is to increase fuel pressure in correspondence wit...

Page 27: ...lic head 13 Drive plate 14 Gauge pin 15 Counteracting spring FEED PUMP VE 4 12 1150L rotary type pump is driven by a gear mating the camshaft s one Identification V Distribution rotary plunger E Pump...

Page 28: ...k and convey it to the feed pump inlet It is assembled to the engine basement and driven by the camshaft The picture here following shows the pump 1 and the position that the pump drive lever assumes...

Page 29: ...de barrier to the impurities and separa tion of water from fuel On the filter cartridge base 4 there is a water dump screw throughout which it is possible to provide regular drainage on the bearing 1...

Page 30: ...ENGINES 8 SECTION 2 FEED ED FEBUARY 2003...

Page 31: ...ion Fuel feed system is composed by Fuel tank placed on the machine Fuel delivery and back flow to tank Fuel pre filter if available it is usually placed close to the engine on the machine frame Primi...

Page 32: ...ump For applications to be equipped in cold climate areas the fuel filter is provided with heater Transfer pump is placed inside the feed pump and is bladed ty pe its duty is to increase fuel pressure...

Page 33: ...ction of rotary Left Definition of dir of rotation Left means anticlockwise when looking from the drive end The low pressure system must be bleed Ambient temperature from 40 to 120 C Oil fill quantity...

Page 34: ...c duty to provide barrier to the impurities and separa tion of water from fuel On the filter cartridge base 4 there is a water dump screw throughout which it is possible to provide regular drainage on...

Page 35: ...plication components 19 Completion of the engine 33 Rotary feed pump disassembly and assembly procedure 35 Feed system bleed procedure 38 Power take off disassembly and assembly procedure 38 Check and...

Page 36: ...feed pump 81 Oil pressure switch 81 Fuel filters 81 Pre post heating resistor 82 Alternator 82 Pagina PART THREE TROUBLESHOOTING 83 PART FOUR MAINTENANCE PLANNING 91 MAINTENANCE PLANNING 93 Recovery...

Page 37: ...cylinder heads gearbox of the timing system and of the front part cover electrical directory describing the connections of the different components of the pre post heating gearbox only for some versio...

Page 38: ...HP rpm 60 81 2300 74 100 2300 94 128 2300 Max torque Nm kgm rpm 398 39 8 1400 Loadless engine idling rpm 850 850 850 Loadless engine peak rpm 2300 2300 2300 SUPERCHARGING Turbocharger type with interc...

Page 39: ...output kW HP rpm 81 129 110 2500 2300 Max torque Nm kgm rpm 700 70 0 1400 Loadless engine idling rpm 850 Loadless engine peak rpm rpm 2500 SUPERCHARGING Turbocharger type with intercooler HOLSET HX35W...

Page 40: ...SECTION 3 DUTY INDUSTRIAL APPLICATION 6 ENGINES ED FEBUARY 2003...

Page 41: ...PART ONE MECHANICAL COMPONENTS SECTION 3 DUTY INDUSTRIAL APPLICATION MOTORI 7 ED FEBUARY 2003 DIAGNOSI...

Page 42: ...SECTION 3 DUTY INDUSTRIAL APPLICATION 8 MOTORI ED FEBUARY 2003 DIAGNOSI...

Page 43: ...sassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required The following information relate to the engine ove...

Page 44: ...t the engine using the rocker arm and put it on the turning stand Drain the oil through the cap underneath the plug Warning the oil filter contains inside aprx 1 kg of engine oil Provide tank with suf...

Page 45: ...in lock position as shown in Picture A to avoid any possible deformation of the fastener itself 75675 Disassembly of application components 1 1 2 3 4 75676 Place a container under the fuel filter and...

Page 46: ...ixing brackets of such pipelines 1 6 and 7 Figure 11 pipe the pipeline ends Disassemble the injectors and remove them from their slot remove the gaskets Figure 13 75678 Loosen the two fixing screws an...

Page 47: ...ng withdraw tappet rods Repeat the operation for all the remaining rocker arm bearings Disassemble water temperature transmitter 1 In the picture the front cap has already been removed On the central...

Page 48: ...nsmission pulley 1 Loosen the four screws 2 and disassemble the pulley 3 from the bearing underneath Proceed disassembling the bearing 75685 1 2 3 4 5 1 2 75686 1 Loosen the screws 2 and withdraw the...

Page 49: ...shaft Figure 25 Remove the engine drive shaft fixing ring from the front cover Use the tool 380000665 4 to operate on the front tang 2 of the engine drive shaft Throughout the tool guide ports drill t...

Page 50: ...orts where the withdrawal pins shall be introduced see picture following Loosen remaining flywheel fixing screws 3 to the engine drive shaft 4 Remove the flywheel block tool 2 Loosen the screws 1 and...

Page 51: ...rovided 4 Proceed with drawing the ring 1 tightening the screw 2 Use acceptable tools 3 4 and withdraw the external holding ring of the flywheel cover box Loosen the screws 2 and remove the flywheel c...

Page 52: ...stiffening plate 4 Loosen the screws 1 and disassemble the gear from the camshaft 2 Figure 37 Loosen the screws 2 and disassemble the timing gearbox 1 70155 70156 70157 Take note of the screw 2 assemb...

Page 53: ...ss to seal the joint Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages After having completed seal application the joints must be immediately assemble...

Page 54: ...assages After having completed seal application the joints must be immediately assembled 10 20 minutes time Tighten the screws 1 fixing the gear to the camshaft 3 and lock them to the prescribed coupl...

Page 55: ...out to maintain rated engine flywheel thickness which is 49 6 0 13 mm Check the conditions of the rim tooth 2 Whether tooth break or excessive wear is detected disassemble the rim from the engine flyw...

Page 56: ...hten fixing screws 2 and lock them to the prescribed couple Apply to the water pump 1 a new fixing ring 2 Figure 52 1 2 75695 Angle dwell shall always be performed using acceptable tool Before assembl...

Page 57: ...engine drive shaft front tang 6 the detail 4 of the tool 380000666 fix it with the screws 5 and key the new holding ring on it 7 Place the detail 2 on the detail 4 screw up the threaded nut until carr...

Page 58: ...rive shaft and the distance ring 3 Tighten the fixing screws 2 and lock them to the 68 7 Nm couple Figure 61 The pictures illustrating the pan and of the rose pipe may not correspond to the ones of yo...

Page 59: ...block s upper surface Place a new fixing ring on the block housing 6 Figure 65 76113 In some applications the bearing of the exchanger shall be assembled to a screw threaded union connected to the fil...

Page 60: ...g and shaft no evidence of excessive wear shall be detected or damages Replace if necessary Carry out the assembly of the rocker arms after previous check of the components Figure 69 If the valves hav...

Page 61: ...ion and exhaust valves are identical and therefore interchangeable Figure 73 Adjust the slack between rocker arms and valves using socket wrench 1 point wrench 3 and feeler gauge 2 Correct working sla...

Page 62: ...he screws fixing them to the prescribed couple Figure 78 Assemble exhaust manifold 1 providing new gaskets 2 Assemble thermostat unit 2 including thermostat 5 and gasket 4 Tighten the screws to the pr...

Page 63: ...igure 80 In case the same belt priory removed is assembled again proceed examining it carefully to check there Assemble the driving belt 4 tighten the screw 1 without locking it in order to let it sli...

Page 64: ...also assemble components 3 and 4 Also assemble the brackets 1 fixing the fuel pipelines to the injectors use the same screws 2 fixing the manifold plate as shown in the picture Figure 83 Assemble pri...

Page 65: ...s previously assembled Figure 86 Fix the LDA pipeline 1 to the engine head and to the feed pump 7 6 5 1 2 3 4 1 Rear bracket fixing screw on suction collector plate 2 Fuel recovery pipeline to pump 3...

Page 66: ...e pipe Connect it to the upper part of the heat exchanger To complete engine assembly it is necessary to remove it from the turning stand Using acceptable tools hold the engine and loosen the screws f...

Page 67: ...from underneath the turbocharger tighten the two screws 2 tighten the screw 3 fixing the pipeline to the block throughout the fixing collar 4 to the block finally tighten the union 5 to the block Fig...

Page 68: ...not directly assembled to the exchanger tighten the screws 3 assembling the bracket 4 including filter bearing 5 Use acceptable tools to install the oil filter Assemble oil level rod together with gui...

Page 69: ...ll be necessary to pr set it while it is still assembled to the engine and disassemble it only afterwards The following procedure analyses this second hypothesis since it is the more complex Figure 95...

Page 70: ...ump and loosen completely the fixing nuts Withdraw the pump from the studs together with the gasket Figure 98 From timing side remove the cover 2 loosening the screws 1 in order to have access to the...

Page 71: ...wheel rotation place the starter in its housing Connect all pipelines from pumping elements to injectors bleeding recovery pipes from injectors to pump LDA pipeline and feed provided by priming pump C...

Page 72: ...withdraw the power take off 2 The two gaskets 4 shall be replaced in phase of reassemble Power take off disassembly and assembly procedure 75720 1 2 3 4 Checks and controls There is no water bleeding...

Page 73: ...overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required The following information relate to the engine overhaul operations only for what...

Page 74: ...ools and put it on the turning stand Drain the oil through the cap underneath the plug Warning the oil filter contains inside aprx 1 kg of engine oil Provide tank with sufficient capacity to contain t...

Page 75: ...ture B After having disconnected the pipeline reset the locking fastener 1 in lock position as shown in Picture A to avoid any possible deformation of the fastener itself 76143 Disassembly of applicat...

Page 76: ...mp and injectors screw out the nuts fixing the pipes to the pumping elements loosen the fuel recovery pipe collar on the injection pump operate on the nuts assembled to the injectors and loosen the sc...

Page 77: ...ring withdraw tappet rods Repeat the operation for all the remaining rocker arm bearings Disassemble water temperature transmitter 1 On the central cap there is a blow by valve for the lubrication oil...

Page 78: ...the screws 2 and withdraw the alternator bearing 1 70141 Loosen the screws 4 and disassemble the oil pressure temperature sensor 3 if fitted Loosen the screws 1 and disassemble the oil filter heat exc...

Page 79: ...e internal holding ring 1 using 3 5 mm drill for a 5mm depth Fix the tool to the ring tightening the 6 screws specially provided Proceed withdrawing the ring 1 tightening the screw 3 Remove the screws...

Page 80: ...ports where the withdrawal pins shall be introduced see picture following Loosen remaining flywheel fixing screws 3 to the engine drive shaft 4 Remove the flywheel block tool 2 Loosen the screws 1 and...

Page 81: ...rovided 4 Proceed with drawing the ring 1 tightening the screw 2 Use acceptable tools 3 4 and withdraw the external holding ring of the flywheel cover box Loosen the screws 2 and remove the flywheel c...

Page 82: ...stiffening plate 4 Loosen the screws 1 and disassemble the gear from the camshaft 2 Figure 142 Loosen the screws 2 and disassemble the timing gearbox 1 70155 70156 70157 Take note of the screw 2 asse...

Page 83: ...ss to seal the joint Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages After having completed seal application the joints must be immediately assemble...

Page 84: ...assages After having completed seal application the joints must be immediately assembled 10 20 minutes time Tighten the screws 1 fixing the gear to the camshaft 3 and lock them to the prescribed coupl...

Page 85: ...out to maintain rated engine flywheel thickness which is 49 6 0 13 mm Check the conditions of the rim tooth 2 Whether tooth break or excessive wear is detected disassemble the rim from the engine fly...

Page 86: ...hten fixing screws 2 and lock them to the prescribed couple Apply to the water pump 1 a new fixing ring 2 Figure 157 1 2 75695 Angle dwell shall always be performed using acceptable tools Before assem...

Page 87: ...engine drive shaft front tang 6 the detail 4 of the tool 380000666 fix it with the screws 5 and key the new holding ring on it 7 Place the detail 2 on the detail 4 screw up the threaded nut until carr...

Page 88: ...procedures described are applicable anyway 70154 Before assembly always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt Before assembly always check th...

Page 89: ...nst the engine block Tighten the screws 2 and lock them to the prescribed couple Figure 170 Place a new fixing ring on the block housing 6 Figure 171 76113 In some applications the bearing of the exch...

Page 90: ...belt tensioner 2 to fit the belt 1 on pulleys and guide rollers Assemble alternator safety guard In case the same belt priory removed is assembled again proceed examining it carefully to check there P...

Page 91: ...0 19 026 19 000 19 026 1 19 00 16 00 75702 ROCKER ARM ADJUSTMENT SCREW If unscrewed check adjustment quota Tighten the screw threaded nut 1 to the i 0 25 0 75 Nm couple 32655 Before executing assembly...

Page 92: ...working slack is suction valves 0 30 0 05 mm exhaust valves 0 55 0 05 mm Figure 182 D1 D2 75703 Insert the tappet driving rods and the Rocker Arm unit Before using the fixing screws again measure the...

Page 93: ...n the screws 1 fixing them to the prescribed couple Figure 186 Assemble exhaust manifold 1 providing new gaskets 2 Assemble thermostat unit 2 including thermostat 5 and gasket 4 Tighten the screws to...

Page 94: ...lso assemble the brackets 1 fixing the fuel pipelines to the injectors use the same screws 2 fixing the manifold plate as shown in the picture Also assemble feed pump see specific procedure and the po...

Page 95: ...d and to the feed pump Fix the pipes to the injectors throughout the brackets previously assembled fixing screw 1 Figure 190 and 2 Figure 191 76148 Assemble lubrication pipes to feed pump 76132 Figure...

Page 96: ...hanger Assemble the turbocharger lubrication exhaust pipe by tightening the screws 3 connect the end to the engine block To complete engine assembly it is necessary to remove it from the turning stand...

Page 97: ...from underneath the turbocharger tighten the two screws 2 tighten the screw 3 fixing the pipeline to the block throughout the fixing collar 4 to the block finally tighten the union 5 to the block Fig...

Page 98: ...filter not directly assembled to the exchanger tighten the screws 3 assembling the bracket 4 including filter bearing 5 Use acceptable tools to install oil filter Assemble oil level rod together with...

Page 99: ...case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr set it while it is still assembled to the engine and disassemble it only afterwards The...

Page 100: ...termined within N 6 cylinder Flywheel rotation shall be carried out with extreme caution The pin charged by excessive shearing stress may get damaged 76135 Plugh the previously removed pin into the ga...

Page 101: ...engine it isnecessary to meet the P M S requirements for the N I cylinder Use the 380000988 tool 2 on the flywheel box I to carry out flywheel rotation and operate using the pin as previously describ...

Page 102: ...p Figure 211 Figure 212 1 2 3 4 75715 On the timing side throughout the specially appointed port fit the washer and screw up the fixing nut 3 to the pump shaft Lock the nut to the 90 95 Nm couple In c...

Page 103: ...ly provided extractor withdraw The power take off 2 The two gaskets 4 shall be replaced in phase of reassemble 76137 Checks and controls There is no water bleeding from the manifolds connecting engine...

Page 104: ...SECTION 3 DUTY INDUSTRIAL APPLICATION 70 ENGINES ED FEBUARY 2003 zs...

Page 105: ...25x25 M18x1 50 24 4 60 9 2 4 0 4 6 0 0 9 Set timing pin 5 1 0 5 0 1 Fuel pump assembly M8 screw M6 screw M6 nut 24 4 10 1 10 1 2 4 0 4 1 0 0 1 1 0 0 1 M10x1 5 flange head nuts pre torque 10 15 50 55 1...

Page 106: ...24 4 2 4 0 4 Fuel injectors 60 5 6 0 0 5 Fuel lift pump 24 4 2 4 0 4 Turbocharger to exhaust manifold M10 43 6 4 3 0 6 Oil feed to oil filter head 24 4 2 4 0 4 Oil feed to turbocharger M12x1 5 35 5 3...

Page 107: ...PART TWO ELECTRICAL EQUIPMENT SECTION 3 DUTY INDUSTRIAL APPLICATION ENGINES 73 ED FEBUARY 2003 DIAGNOSI...

Page 108: ...SECTION 3 DUTY INDUSTRIAL APPLICATION 74 ENGINES ED FEBUARY 2003 DIAGNOSI...

Page 109: ...r temperature sensor 4 Electromagnets assembled to feed pump A on hydraulic head unit B on KKSB 5 Fuel heater 6 Oil pressure switch 7 Resistor for cold start whether specifically designed 8 Alternator...

Page 110: ...driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele switch assembled to the starter itself Specifications BOSCH 3 kW 12V Figure 218 75719 75717 Cooling l...

Page 111: ...4a 1 Hydraulic head Electro magnet 2 KKSB Electro magnet 75722 It is assembled to the block on the engine s left hand side Spe cifications Working tensions 12 24 V Contact closure upon lower pressure...

Page 112: ...Working tensions 12 V Maximum possible Air flow 2 cc min pressure 138 kPa Figure 223 Pre post heating resistor Alternator 75723 75725 It is place front view on the right hand side of the engine and is...

Page 113: ...ter 3 KSB Water temperature sensor 4 Resistor for cold start whether specifically designed 5 Engine stop assembled to feed pump 6 Fuel heater 7 Oil pressure switch 8 Engine oil lever transmitted 9 Alt...

Page 114: ...driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele switch assembled to the starter itself Specifications BOSCH 4 kW 24V Figure 227 75719 75717 Cooling l...

Page 115: ...cifications Working tensions 12 24 V Contact closure upon lower pressure 0 2 bar Contact opening upon higher pressure 0 9 bar 76210 Engine stop assembled to feed pump Fuel filters Oil pressure switch...

Page 116: ...Working tensions 24 V Maximum possible Air flow 2 cc min pressure 138 kPa Figure 232 Pre post heating resistor Alternator 75723 75725 It is place front view on the right hand side of the engine and is...

Page 117: ...PART THREE TROUBLESHOOTING SECTION 3 DUTY INDUSTRIAL APPLICATION MOTORI 83 ED FEBUARY 2003 DIAGNOSI...

Page 118: ...SECTION 3 DUTY INDUSTRIAL APPLICATION 84 MOTORI ED FEBUARY 2003 DIAGNOSI...

Page 119: ...k and correctly time the injection pump See your dealer Deposits or water in the fuel tank Disconnect the hoses and clean them using a jet of compressed air Dismantle and clean the injection pump Re m...

Page 120: ...er Impurities or water in the fuel lines Disconnect the hoses and clean them using a jet of compressed air Dismantle and clean the injection pump Remove water from fuel tank and refuel Drain feed syst...

Page 121: ...k corret worching of such device Coolant level too low Top up radiator with coolant Incorrect engine timing Check timing and tune correctly Incorrect calibration of injection pump Correct the delivery...

Page 122: ...aulty operation of L D A device Check that the diaphragm is not perforated that the counter spring is suitable and that it has the correct loading check on test bench Check that there is adequate air...

Page 123: ...to excessive play of piston hubs and in the rod bushing Loose bushings in the rod seatings Replace the piston journal and or the piston and rod bushing Replace with new bushings Noisy timing Adjust th...

Page 124: ...rts Unsuitable injectors different types of injec tors or incorrectly calibrated Replace or calibrate the injectors Injection hoses with an unsuitable internal diameter end of hoses pinched due to re...

Page 125: ...PART FOUR MAINTENANCE PLANNING SECTION 3 DUTY INDUSTRIAL APPLICATION ENGINES 91 ED FEBUARY 2003 DIAGNOSI...

Page 126: ...SECTION 3 DUTY INDUSTRIAL APPLICATION 92 ENGINES ED FEBUARY 2003 DIAGNOSI...

Page 127: ...anning of controls and periodical intervention Controls and periodical intervention Visual check of engine Check presence of water in fuel filter or pre filter Check of belt wear status Check and sett...

Page 128: ...ine working Verify using the vehicle devices the prescribed pressure temperature and other parameters Visual check of fumes colour of exhaust emissions Visual check of cooling liquid level in the expa...

Page 129: ...check The check must be executed both when the engine discon nected and when it is running Check the pipelines from the engine to the radiator from the expansion tank and vice versa Find out any blow...

Page 130: ...sk as shown in the table Rotate the drive shaft of 360 deg balance cylinder 4 valves and adjust the valves marked by the asterisk as shown in the table cylinder n intake exhaust 1 2 3 4 cylinder n int...

Page 131: ...a tions The filter is composed by a support and a filteringcartridge For the cartridge replacement use acceptable tools Warning the oil filter contains inside a quantity of oil of about 1 kg Place pro...

Page 132: ...uan tity can change However the following operations are valid for all applications Drain the fuel inside the filter by operating the water re lease screw Collect the fuel in a container without impu...

Page 133: ...he returns pumps Replace the worn belt with a new part Place the belt on the pulleys and the guide rollers Place the automatic tightener in order to key the belt in the functioning position Further ad...

Page 134: ...SECTION 3 DUTY INDUSTRIAL APPLICATION 100 ENGINES ED FEBUARY 2003...

Page 135: ...unit 13 TIMING SYSTEM 13 Camshaft 13 Checking cam lift and pin alignment 14 BUSHES 14 Bush replacement 16 Tappets 16 Fitting tappets camshaft 16 OUTPUT SHAFT 17 Measuring journals and crankpins 17 Rep...

Page 136: ...n clearance 28 Checking piston protrusion 29 CYLINDER HEAD 30 Removing the valves 30 Checking cylinder head wet seal 31 Checking cylinder head supporting surface 31 Pagina VALVES 32 Removing carbon de...

Page 137: ...4 in line 6 in line Bore mm 104 Stroke mm 132 Total displacement cm3 4485 6728 TIMING start before T D C A end after B D C B start before B D C D end after T D C C X Checking timing mm X mm Checking...

Page 138: ...rels outside diameter 2 length L Cylinder barrels housings on engine block interference Outside diameter 2 3 X Cylinder barrels inside diameter 2 1 X 2 Spare pistons type Size X Outside diameter 1 Pin...

Page 139: ...70 to 3 990 1 Split rings slots 2 3 0 245 to 0 265 0 100 to 0 110 0 004 to 0 080 Split rings 0 5 X1 3 2 X X Split ring end opening in cylinder barrel X 1 X 2 X 3 0 30 to 0 40 0 25 to 0 55 0 25 to 0 55...

Page 140: ...S 1 Big end half bearings S 2 provided as spare part 2 456 to 2 464 1 955 to 1 968 3 Main bearings No 1 5 3 No 2 3 4 3 87 982 to 88 008 87 977 to 88 013 Half bearings Journals No 1 5 1 7 No 2 3 4 2 3...

Page 141: ...guides and seats on head Valve guides 4 Valves 4 4 7 963 to 7 943 60 7 963 to 7 943 45 Valve stem and guide 0 052 to 0 092 1 Housing on head for valve seat 1 1 46 987 to 47 013 43 637 to 43 663 2 Valv...

Page 142: ...oad equal to 329 N H1 641 N H2 63 05 49 02 38 20 X Injector protrusion X 1 2 3 4 5 Camshaft bush housings No 1 5 Camshaft housings No 2 3 4 59 222 to 59 248 54 089 to 54 139 1 2 3 Camshaft journals 1...

Page 143: ...NDERS CYLINDER HEAD TIMING SYSTEM mm 1 Tappet cap housing on block 1 2 3 2 Tappet cap outside diameter 2 3 15 924 to 15 954 15 965 to 15 930 Between tappets and housings 0 025 to 0 070 Tappets 1 Rocke...

Page 144: ...SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS 10 ENGINES ED FEBUARY 2003...

Page 145: ...them Withdraw the pistons including the connecting rods from the top of the engine block Remove the screws 1 and the main bearing caps 2 The second last main bearing cap 1 and the relevant support are...

Page 146: ...dial gauge I fitted with the dial gauge previously set to zero on the ring gauge 2 of the cylinder barrel diameter Measurements shall be performed on each cylinder at three different heights in the b...

Page 147: ...king head supporting surface on cylinder unit TIMING SYSTEM Camshaft CAMSHAFT MAIN DATA 4 CYL Specified data refer to pin standard diameter Check main bearing housings as follows fit the main bearings...

Page 148: ...wear Use bore dial gauge 3 to measure camshaft front and rear bush 2 and intermediate housing 1 diameter Measurements shall be performed on two perpendicular axes BUSHES Checking cam lift and pin alig...

Page 149: ...Value to be obtained after driving the bushes Sec A A Figure 17 70513 MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS Height to be obtained after driving the bushes sec A A SECTION 4 OVERHAUL AND...

Page 150: ...fit the camshaft 1 taking care not to damage the bushes or the housings Set camshaft 3 retaining plate 1 with the slot facing the top of the engine block and the marking facing the operator then tigh...

Page 151: ...is recommended to insert the found values in the proper table See Figure 26 Undersize classes are Journals and crankpins shall always be ground to the same undersize class Journals and crankpins under...

Page 152: ...rnals SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS 18 ENGINES ED FEBUARY 2003 TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL SHAPE Roundness SHAPE Cilindricity Parallelism DIRECTION Verticality...

Page 153: ...JOURNAL AND CRANKPIN MEASURED VALUES Rated value Figure 29 MAIN OUTPUT SHAFT TOLERANCES Measured on a radius greater than 45 5 mm 0 500 between adjacent main journals 70577 K SECTION 4 OVERHAUL AND TE...

Page 154: ...FICATIONS 20 ENGINES ED FEBUARY 2003 TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL SHAPE Roundness SHAPE Cilindricity Parallelism DIRECTION Verticality Straightness POSITION Concentricity or coax...

Page 155: ...ameter Clean accurately the main half bearings 1 having the lubricating hole and fit them into their housings The second last main half bearing 1 is fitted with shoulder half rings Check that gear too...

Page 156: ...found by comparing the width of the calibrated wire 2 at the narrowest point with the scale on the envelope 1 containing the calibrated wire The numbers on the scale indicate the backlash in mm Replac...

Page 157: ...he clearance between the piston and the cylinder barrel can be checked also with a feeler gauge 1 as shown in the figure The diameter shall be measured at 12 mm from the piston skirt MAIN DA TA CONCER...

Page 158: ...gs 3 of the 2nd and 3rd slot and the relevant housings on the piston 2 using a feeler gauge 1 DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the fir...

Page 159: ...cting rod is marked as follows On body and cap with a number showing their coupling and the corresponding cylinder In case of replacement it is therefore necessary to mark the new connecting rod with...

Page 160: ...ending by comparing two points C and D of the pin 3 on the vertical plane of the connecting rod axis Position the vertical support 1 of the dial gauge 2 to rest the latter on pin 3 point C Move the co...

Page 161: ...and their openings shall be displaced with each other by 120 Fit half bearings 1 on connecting rod and cap Lubricate accurately the pistons including the split rings and the cylinder barrel inside Use...

Page 162: ...Finding crankpin clearance To measure the clearance proceed as follows clean the parts accurately and remove any trace of oil set a piece of calibrated wire 2 on the output shaft pins 1 fit the conne...

Page 163: ...ton 3 protrusion at T D C with respect to the top of the engine of the engine block Protrusion shall be 0 28 to 0 42 mm Before the final fitting of the connecting rod cap fastening screws check that t...

Page 164: ...nd pressing the cap 3 so that when compressing the springs 4 the cotters 2 can be removed Then remove the cap 3 and the springs 4 Repeat this operation for all the valves Overturn the cylinder head an...

Page 165: ...t Checking cylinder head supporting surface Distortion found along the whole cylinder head shall not exceed 0 20 mm If higher values are found grind the cylinder head according to values and indicatio...

Page 166: ...as possible Check the valve stem 1 using a micrometer 2 it shall be 6 960 to 6 980 Use a magnetic base dial gauge 1 set as shown in the figure the assembling clearance shall be 0 052 0 092 mm Turn th...

Page 167: ...GUIDE 1 2 36 5 37 5 60 29 5 30 5 4 06 4 32 4 64 4 38 59 5 60 5 45 74 5 75 5 Should valve seats be not reset just by regrinding replace them with the spare ones Use acceptable tools Figure 79 to remove...

Page 168: ...the position marked at removal Fit the sealing rings 2 and 3 on the valve guide Position on the cylinder head the spring 4 the upper cap 3 use acceptable tools I to compress the spring 4 and lock the...

Page 169: ...ing N of component 1 facing the head The arrow shows the point where the gasket thickness is given 70335 Figure 85 Refitting the cylinder head Before re utilising the fixing screws for the cylinder he...

Page 170: ...3 1 5 0 3 Screw M12 for fastening output shaft caps 1st stage 2nd stage d 50 6 80 6 5 0 6 8 0 6 2 stage 3rd stage 90 5 Screw M8 for fastening camshaft longitudinal retaining plate 24 4 2 4 0 4 Screw...

Page 171: ...SECTION 5 TOOLS ENGINES 1 ED FEBUARY 2003 Tools SECTION 5 TOOLS 3 Page...

Page 172: ...SECTION 5 TOOLS ENGINES 2 ED FEBUARY 2003...

Page 173: ...DEFINITION 380000663 380000988 Crankshaft Rear Seal Puller Tool for Rotating the Engine Flywheel 380000664 Crankshaft Rear Seal Installer Crankshaft Front Seal Puller Injector Puller Injector Pump Pul...

Page 174: ...SECTION 5 TOOLS ENGINES 4 ED FEBUARY 2003...

Page 175: ...APPENDIX ENGINES 1 ED FEBUARY 2003 HYDRAULIC SYSTEM BRAKES APPENDIX Pagina SAFETY PRESCRIPTIONS 3...

Page 176: ...APPENDIX 2 ENGINES ED FEBUARY 2003...

Page 177: ...f provided with elastics at the ends Use protection cream for hands Change wet cloths as soon as possible In presence of current tension exceeding 48 60 V verify efficiency of earth and mass electrica...

Page 178: ...gearbox driving the engine Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration Re...

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