Abstract image of a woman sitting on books and studying on a laptop

Case ih dx55 tractor service repair manual

F
fusjejfjskekme

This document is the repair manual for Case IH DX48 and DX55 tractors. It contains sections covering the engine, transmission, driveline, axles, brakes, hydraulics, steering, wheels/tires, electrical system, and platform. Safety precautions and general information are provided, such as lubrication guidelines, specifications, and dimensions. The manual instructs technicians on properly servicing and repairing components according to OEM specifications.

Automotive
1 of 28
Download to read offline
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Most read
23
24
Most read
25
Most read
26
27
28
87367137 8/05© 2005 CNH America LLC Printed In U.S.A. DX48, DX55 REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 - ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 18 - CLUTCH 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 21 - TRANSMISSION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 23 - FWD DRIVELINE 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 25 - FWD FRONT AXLE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 27 - DIFFERENTIAL, REAR AXLE 21. . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 31 - POWER TAKE-OFF (PTO) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 33 - BRAKES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 35 - HYDRAULIC SYSTEM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 41 - STEERING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 44 - WHEELS AND TIRES 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 55 - ELECTRICAL SYSTEM 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 90 - PLATFORM 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The following pages are the collation of the contents pages from each section and chapter of the DX48, DX55 Repair manual. Complete Repair part # 87367132. The sections used through out all Case IH product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books. Each book will be labeled as to which sections are in the overall Repair manual and which sections are in each book. The sections listed above are the sections utilized for the DX48, DX55 Tractors.
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-1 SECTION 00 - GENERAL INFORMATION Chapter 1 - General Information CONTENTS Section Description Page Precautionary Statements 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruction Decals 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decal Placement Guide 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ecology and the Environment 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Symbols 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Hardware Tightening Torques 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Lubricants 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication and Maintenance Chart 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Fittings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Fuel 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Speeds 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Tread Settings 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle (2WD) Adjustable 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Ballast 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Pressure 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Tire Liquid 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-3 SAFETY PRECAUTIONARY STATEMENTS A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help prevent accidents, read the following precautions before operating this equipment. Equipment should be oper- ated only by those who are responsible and instructed to do so. Carefully review the procedures given in this manual with all operators. It is important that all operators be familiar with and follow safety precautions. THE TRACTOR 1. Read the Operator’s Manual carefully before using the tractor. Lack of operating knowledge can lead to accidents. 2. Use an approved roll bar and seat belt for safe operation. Overturning a tractor without a roll bar can result in death or injury. If your tractor is not equipped with a roll bar and seat belt, see your Case IH Dealer. 3. Always use the seat belt. The only instance when the seat belt should not be used is if the roll bar has been removed from the tractor or folding ROPS is in down position. 4. If a front end loader is to be installed, always use a FOPS (Falling Object Protective Structure) canopy to avoid injury from falling objects. 5. Use the handholds and step plates when getting on and off the tractor to prevent falls. Keep steps and platform cleared of mud and debris. 6. Do not permit anyone but the operator to ride on the tractor. There is no safe place for extra riders. 7. Keep all safety decals clean of dirt and grime, and replace all missing, illegible, or damaged safety decals. See the list of decals in the Decal section of this manual. SERVICING THE TRACTOR 1. The cooling system operates under pressure which is controlled by the radiator cap. It is dangerous to remove the cap while the system is hot. Always turn the cap slowly to the first stop and allow pressure to escape before removing the cap entirely. 2. Keep any type of open flame away from the tractor and do not smoke while refueling. Wait for the engine to cool before refueling. 3. Keep the tractor and equipment, particularly brakes and steering, maintained in a reliable and satisfactory condition to ensure your safety and comply with legal requirements. 4. Keep open flame or cold weather starting aids away from the battery to prevent fires or explosions. Use jumper cables according to instructions to prevent sparks which could cause explosion. Do not use chemical starting aids on glow plug equipped tractors. 5. Stop the engine before performing any service on the tractor. 6. Escaping hydraulic/diesel fluid under pressure can penetrate the skin causing serious injury. If fluid is injected into the skin, obtain medical attention immediately or gangrene may result. • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. • Stop the engine and relieve pressure before connecting or disconnecting lines. • Tighten all connections before starting the engine or pressurizing lines. 7. Do not modify or permit anyone else to modify or alter this tractor or any of its components or functions without first consulting a Case IH Dealer. 8. The fuel oil in the injection system is under high pressure and can penetrate the skin. Unqualified persons should not remove or attempt to adjust a pump, injector, nozzle, or any other part of the fuel injection system. Failure to follow these instructions can result in serious injury. 9. Continuous long-term contact with used engine oil may cause skin cancer. Avoid prolonged contact with used engine oil. Wash skin promptly with soap and water.
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-4 10. Some components of your tractor, such as gaskets and friction surfaces (brake linings, clutch linings, etc.) may contain asbestos. Breathing asbestos dust is dangerous to your health. You are advised to have any mainte- nance or repair on such components carried out by an authorized Case IH Dealer. However, if service operations are to be undertaken on parts that contain asbestos, the essential precautions listed below must be observed: • Work out of doors or in a well ventilated area. • Dust found on the tractor or produced during work on the tractor should be removed by extraction, not by blowing. • Dust waste should be dampened, placed in a sealed container, and marked to ensure safe disposal. • If any cutting, drilling, etc. is attempted on materials containing asbestos, the item should be dampened and only hand tools or low speed power tools used. OPERATING THE TRACTOR 1. Before starting the tractor, apply the parking brake, place the PTO lever in the “OFF” position, the lift control lever in the down position, the remote control valve levers in the neutral position, and the transmission in neutral. 2. Always sit in the tractor seat when starting the engine or operating controls. Do not start the engine or operate controls while standing beside the tractor. 3. Do not bypass the neutral start switches. Consult your Case IH Dealer if your neutral start controls malfunction. Use jumper cables only in the recommended manner. Improper use can result in tractor runaway. 4. Avoid accidental contact with the gear shift lever while the engine is running, as this can cause unexpected tractor movement. 5. Before getting off the tractor, disengage the PTO, turn the engine off, and apply the parking brake. Never get off the tractor while it is in motion. 6. Do not park the tractor on a steep incline. 7. Do not operate the tractor engine in an enclosed building without adequate ventilation. Exhaust fumes can cause death or illness. 8. If the power steering or engine ceases operating, stop the tractor immediately. 9. Pull only from the drawbar or the lower link drawbar in the down position. Use only a drawbar pin that locks in place. Pulling from the tractor rear axle or any point above the axle may cause the tractor to upset. 10. If the front end of the tractor tends to rise when heavy implements are attached to the three- point hitch, install front end weights. Do not operate the tractor with a light front end. 11. Always set the hydraulic selector lever in position control when attaching or transporting equip- ment. Ensure hydraulic couplers are properly mounted and will disconnect safely in case of accidental detachment of implement. 12. Do not leave equipment in the raised position. 13. Use the flasher/turn signal lights and SMV signs when traveling on public roads both day and night (unless prohibited by law). 14. When operating at night, adjust lights to prevent blinding oncoming drivers. DRIVING THE TRACTOR 1. Watch where you are going, especially at row ends, on roads, around trees and low hanging obstacles. 2. To avoid upsets, drive the tractor with care and at a safe speed. Use extra caution when operating over rough ground, when crossing ditches or slopes, and when turning corners. 3. To provide two-wheel braking, lock tractor brake pedals together when transporting on roads. 4. Do not coast or free wheel down hills. Use the same gear when going downhill as is used when going uphill. 5. Any towed vehicle with a total weight exceeding that of the towing tractor should be equipped with brakes for safe operation. 6. If the tractor becomes stuck or the tires become frozen to the ground, back up the tractor to prevent upset. 7. Always check overhead clearance, especially when transporting the tractor. 8. When operating at night, adjust lights to prevent blinding oncoming drivers.
SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-5 OPERATING THE PTO 1. When operating PTO driven equipment, shut off the engine and wait until the PTO stops before getting off the tractor and disconnecting the equipment. 2. Do not wear loose clothing when operating the power take-off or when near rotating equipment. 3. When operating stationary PTO driven equip- ment, always place range gear shift lever in neutral, apply the tractor parking brake, and block the rear wheels front and back. 4. To avoid injury, do not clean, adjust, unclog, or service PTO driven equipment when the tractor engine is running. 5. Ensure the PTO master shield is installed at all times. Always replace the PTO shield cap when the PTO is not in use. DIESEL FUEL 1. UNDER NO CIRCUMSTANCES should gaso- line, alcohol, or blended fuels be added to diesel fuel. These combinations can create an increased fire or explosive hazard. Such blends are more explosive than pure gasoline in a closed container such as a fuel tank. DO NOT USE THESE BLENDS. 2. Never remove the fuel cap or refuel with the engine running or hot. 3. Do not smoke while refueling or when standing near fuel. 4. Maintain control of the fuel filler pipe nozzle when filling the tank. 5. Do not fill the fuel tank to capacity. Allow room for expansion. 6. Wipe up spilled fuel immediately. 7. Always tighten the fuel tank cap securely. 8. If the original fuel tank cap is lost, replace it with a Case IH approved cap. A non-approved, proprietary cap may not be safe. 9. Keep equipment clean and properly maintained. 10. Do not drive equipment near open fires. 11. Never use fuel for cleaning purposes. 12. Arrange fuel purchases so that winter grade fuels are not held over and used in the spring. SAFETY FRAME (ROPS) Your Case IH tractor is equipped with a safety frame. It must be maintained in a serviceable condition. Be careful when driving through doorways or working in confined spaces with low headroom. UNDER NO CIRCUMSTANCES should you: • modify, drill, or alter the safety frame in any way. Doing so may render you liable to legal prosecution. • attempt to straighten or weld any part of the main frame or retaining brackets which have suffered damage. Doing so may weaken the structure and endanger your safety. • secure any parts on the main frame or attach your safety frame with anything other than the special high tensile bolts and nuts specified. • attach chains or ropes to the main frame for pulling purposes. • take unnecessary risks even though your safety frame affords you the maximum protection possible.
SECTION 10 - ENGINE - CHAPTER 1 10-1 SECTION 10 - ENGINE Chapter 1 - Engine Dismantling Sequence CONTENTS Section Description Page Specifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric Bolt Torque Specifications 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Test and Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Operation -- General Information 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Train Components 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block Assembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan and Pulley 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug and Connector 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle/Holder 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Pipe 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover/Intake Manifold/Exhaust Manifold 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Oil Pipe 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Assembly 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 - ENGINE - CHAPTER 1 10-2 Section Description Page Cylinder Head 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tappets 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Stop Solenoid 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear Cover 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Timing Gears and Camshaft 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front End Plate 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 Oil Sump 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Suction Pipe and Strainer 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 110 Balancer Assembly 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 105 Connecting Rods, Bearings and Pistons, Rings 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Flywheel 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backplate and Oil Seal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearings 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Assembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Timing Gear 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly (see Idler Gear) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 101 Cylinder Head 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 - ENGINE - CHAPTER 1 10-3 Section Description Page Valves 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guides 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Seat 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Push Rods 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Piston Rings 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons, Rings and Connecting Rod 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Crankshaft Main Bearing and Thrust Washer 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Inspection 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Bearing (Bushing) 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Main Bearing 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Block 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Crankshaft and Bearing Holder 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Plate/Flyweel Housing 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Flywheel 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 105 Pistons and Connecting Rods 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 - ENGINE - CHAPTER 1 10-4 Section Description Page 10 110 Balancer Assembly 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Suction Pipe and Suction Strainer 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Sump 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Camshaft and Camshaft Gear 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Idler Gear, Oil Pump and Injection Timing 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 Timing Gear Case 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Oil Seal and Steering Pump Seal 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear Case 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 101 Head Gasket Selection 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Gasket Selection Chart 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Valve Clearance Adjustment 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Cover 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake/Exhaust Manifolds 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Oil Tube 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switch 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator and Temperature Sender Switch 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug and Connector 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle/Holder Assembly 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return Pipe and Injection Pipe 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 - ENGINE - CHAPTER 1 10-5 Section Description Page Hydraulic Oil Pump 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 304 Description of Operation -- Engine Lubrication System 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 206 Oil Filter 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction and Function 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 304 Oil Pump 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and Adjustment 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Pressure Check 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Relief Valve 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Consumption 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 400 Description of Operation -- Cooling System 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Cap 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Thermostat 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Water Pump 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 414 Cooling Fan 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Water Pump 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Thermostat 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 - ENGINE - CHAPTER 1 10-6 SPECIFICATIONS GENERAL DX48 DX55 Engine Model N844L N844L-TC Number of Cylinders 4 4 Bore x Stroke 84 x 100 mm. (3.31 x 3.94in) 84 x 100 mm. (3.31 x 3.94in) Displacement 135.2 cu. In.(2216 cc) 135.2 cu. In.(2216 cc) Compression Ratio 22.5:1 22.5:1 Rated Speed(rpm) 2800 2700 Firing Order 1--3--4--2 1--3--4--2 Low Idle Speed 1000 1000 Maximum No Load Speed 3000 2900 Cylinder Arrangement In--line vertical In--line vertical Valve Arrangement Overhead Overhead Compression Pressure At 200 rpm (cylinder speed) 29.4 ± 3.5 bar (427 ± 50 psi) 29.4 ± 3.5 bar (427 ± 50 psi) CYLINDER BLOCK N844L N844L-TC Bore Standard 84.0 mm (3.3071 in.) 84.0 mm (3.3071 in.) Maximum 84.2 mm (3.315 in.) 84.2 mm (3.315 in.) Head Surface Warp Standard .05 mm (.002 in.) .05 mm (.002 in.) Maximum .12 mm (.005 in.) .12 mm (.005 in.) CYLINDER HEAD N844L N844L-TC Head Warp Standard .05 mm (.002 in.) .05 mm (.002 in.) Maximum .12 mm (.005 in.) .12 mm (.005 in.) Valve seat width Standard 1.7--2.1 mm (0.067--0.082 in.) 1.7--2.1 mm (0.067--0.082 in.) Maximum 1.8 mm (0.071 in.) 1.8 mm (0.071 in.) Valve seat sink N844L N844L-TC Standard (recess) 0.85--1.15mm (0.0334--0.0453 in.) 0.85--1.15mm (0.0334--0.0453 in.) Maximum 1.8 mm (0.071 in.) 1.8 mm (0.071 in.) Valve Angle 45 degrees 45 degrees PISTON N844L N844L-TC Diameter Standard 83.948--83.963 mm (3.30503--3.30562 in.) 83.948--83.963 mm (3.30503--3.30562 in.) Minimum 83.7 mm (3.2953 in.) 83.7 mm (3.2953 in.) BORE CLEARANCE N844L N844L-TC Standard 0.038--0.072 mm (0.0015--0.0028 in.) 0.038--0.072 mm (0.0015--0.0028 in.) Maximum 0.25mm (0.010 in.) 0.25mm (0.010 in.) PISTON PIN BORE N844L N844L-TC Standard 27.996--28.0mm (1.102--1.1023 in.) 27.996--28.0mm (1.102--1.1023 in.) Maximum 27.98 mm (1.102 in.) 27.98 mm (1.102 in.)
SECTION 10 - ENGINE - CHAPTER 1 10-19 MODEL N844L - DX4810044351 10044352 4 MODEL N844L-TC - DX5520035585 5
SECTION 10 - ENGINE - CHAPTER 1 10-20 ENGINE Removal 1. Disconnect the negative (--) battery cable, 1, and positive (+) battery cable, 2, from the battery. 10032806 1 2 6 2. Disconnect the headlight wire harness plug, 1. 3. Remove the clips and pins, 2, from each side of the hood bracket. 4. Remove the support rod, 3, and remove the hood from the tractor. 10032784 1 2 3 7 5. Drain the coolant from radiator, and engine using the petcock valve, 1. Remove radiator cap to assist draining. 6. Remove the radiator (see Radiator Removal in Section 10). 10032808 1 8
SECTION 10 - ENGINE - CHAPTER 1 10-21 7. Loosen and remove the drain plug, 1, from the power steering reservoir, 2, and drain into a suitable container. NOTE: See separating the tractor at the transmis- sion in Section 21 to separate the tractor. 10032804 1 2 9 8. After the tractor has been successfully sepa- rated, support the front axle and the front support frame with jack stands. 9. Remove the firewall from the engine. 10. Remove the muffler and exhaust pipe from the tractor. 11. With the chain and hoist still attached to the engine, remove the mount bolts, 1, from each side of the frame rails. 12. Carefully remove the engine. 20002365 1 1 10 Installation 1. Attach a hoist to the engine, and position it onto the frame. 2. Install the engine mounting bolts on both sides of the frame. Apply Loctite® thread locker 242 to the thread of the bolts. TIghten bolts to the following torques: torques #1 -- 80 N⋅m (60 ft. lbs.) torques #2 -- 80 N⋅m (60 ft. lbs.) torques #3 -- 175 N⋅m (130 ft. lbs.) 3. Install the muffler and exhaust pipe onto the tractor. 4. Install the firewall onto the engine. NOTE: See section 21 for attaching the engine to the transmission. 20034413 3 1 2 11
SECTION 10 - ENGINE - CHAPTER 1 10-22 OVERHAUL ENGINE NOTE: Some procedures discussed in this chapter are shown with the engine in the tractor. Many of the procedures can be done with the engine in or out of the tractor. ALTERNATOR Removal Disconnect the alternator wire harness and wires, 1. Remove the alternator pivot and adjusting bracket, hardware, 2. 12 COOLING FAN AND PULLEY Removal Remove the fan, 1, retaining hardware and spacers. 13 GLOW PLUG AND CONNECTOR Removal Remove the glow plugs, 1, and glow plug connectors, 2. 1 2 14
SECTION 10 - ENGINE - CHAPTER 1 10-23 NOZZLE/HOLDER Removal Remove the nozzle and holder assembly with a socket for the nozzle holder. 15 FUEL INJECTION PIPE Removal 1. Loosen the fuel pipe nuts from the fuel injection pump and injectors, 1. Remove the pipes as an assembly. 2. Remove the spring clamp and fuel return hose, 2. INJECTOR Removal Loosen and remove the securing nuts, 3. Remove the leak-off rail, 4. Remove the aluminum washers and discard. Remove the injectors tagging or marking with the cylinder they were removed from. 16 WATER PUMP Removal Loosen the securing bolts and remove the water pump assembly, 1, and set plate, 2. 17
SECTION 10 - ENGINE - CHAPTER 1 10-24 COVER/INTAKE MANIFOLD/EXHAUST MANIFOLD Removal Remove the intake manifold, 1, spacer, 2, and exhaust manifold, 3. For the N844L-TC turbocharged engine, refer to the turbocharger section of the manual for removal and replacement. 18 Loosen and remove four cap nuts with washers. Remove the head cover assembly, 1. 50051492 1 19 EXTERNAL OIL PIPE Removal 1. Loosen and remove the two banjo bolts, 1, at the cylinder block main oil gallery and cylinder head assembly. 2. Remove the clamp, 2, from the fuel injection pump. 2 20
SECTION 10 - ENGINE - CHAPTER 1 10-25 ROCKER ASSEMBLY Removal 1. Loosen and remove nuts, lock washers, and flat washers from the rocker pillar stud, 1. Lift the rocker assembly, 2. 2. Remove the push rods, 3, and valve stem caps, 4. 21 CYLINDER HEAD Removal Loosen the cylinder head bolts, starting from the center, in a circular pattern, using several steps of equal torque. Remove the head. 22 TAPPETS Removal Pull the tappets from the machined bore in the cylinder block. 23
SECTION 10 - ENGINE - CHAPTER 1 10-26 FUEL STOP SOLENOID Removal Unscrew the stop solenoid, and remove from the engine block. 24 TIMING GEAR COVER Removal 1. Drain the engine crankcase oil. 2. Remove the injection pump mounting nuts and raise the injection pump, 1, enough to remove the spring pin, 2, and separate the governor link from the control rack. Remove the injection pump. 2 1 25 NOTE: Insert a small dowel, 1, through the fuel shut- off solenoid hole and slide the control rack, 2, in to allow enough clearance to the cylinder block, for the pump to be removed. 20002371 1 2 26
SECTION 10 - ENGINE - CHAPTER 1 10-27 3. Loosen the hose clamp, 1, on the suction hose, 2, and remove the suction hose from the steering pump, 3. 4. Remove the pressure tube, 4, from the bottom of the steering pump. 30996355 3 4 2 1 27 5. Remove the through bolts and nuts, 1, and re- move the steering pump from the front cover. Cap the lines and pump openings. NOTE: Two of the power steering pump retaining bolts are not shown. 30996393 1 28 6. Install and tighten two nuts, 1, against each other, onto the retaining studs, 2. Remove the studs, 2, and the hydraulic pump, 3. 20002372 1 2 3 29
SECTION 10 - ENGINE - CHAPTER 1 10-28 7. Remove the retaining nut, 1. Pull crankshaft pulley, 2, off of crankshaft, 3. Remove key, 4, from crankshaft. 20002373 1 2 3 4 30 8. Remove the retaining bolts, 1, and lift the cover, 2, off the locating dowels. 1 2 31 Op. 10 106 TIMING GEARS AND CAMSHAFT Removal 1. Remove retaining ring, 1, and remove the idler gear, 2, and oil pump assembly, 3. 1 3 2 32
SECTION 10 - ENGINE - CHAPTER 1 10-29 2. Remove the two bolts, 1, securing the keeper plate, 2. One must be accessed using the access hole, 3, in the cam gear. 3. Slide the camshaft and gear out of the camshaft bore. 1 3 2 33 FRONT END PLATE Removal Remove the retaining bolts and lift the front plate off its locating dowels. Remove the gasket and discard. 34 Op. 10 102 OIL SUMP Removal 1. Remove the oil sump retainer bolts, 1. 2. Remove the oil sump and discard gasket. 3. Remove steel spacer, 2, from the block. 1 2 10032653 35
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
SECTION 10 - ENGINE - CHAPTER 1 10-30 OIL SUCTION PIPE AND STRAINER Removal 1. Remove the two retaining bolts, 1. 2. Remove the oil strainer, 2, and rotate the oil suc- tion pipe, 3, out of its bore. 2 10032654 31 36 Op. 10 110 BALANCER ASSEMBLY Removal 1. Remove the banjo bolts, 1, and the oil transfer pipe, 2. 2. Loosen and remove the balancer retaining bolts, 3. NOTE: Observe the quantity and thickness of the shims, 4, (if used) for re-installation upon assembly. 3. Remove the balancer assembly, 5, from the en- gine block, 6. 20002374 4 5 2 1 3 4 6 37
SECTION 10 - ENGINE - CHAPTER 1 10-31 Op. 10 105 CONNECTING RODS, BEARINGS AND PISTONS, RINGS Removal 1. Remove the two bolts, 1, retaining the connect- ing rod caps, 2. 2. Remove the connecting rod caps and lower half of connecting rod bearing. 3. If necessary, remove any ridge from the top of the cylinder bores using a suitable ridge reamer. 1 2 38 4. Push the piston and connecting rod out of the cyl- inder block. 5. Replace the connecting rod cap to the piston as- sembly it was removed from. Keep together in cylinder sequence. 39 Op. 10 103 FLYWHEEL Removal 1. Loosen the flywheel retaining bolts. 2. Using a brass drift and hammer, tap the end of the crankshaft, 1, to loosen the flywheel, 2, from the shaft. 1 2 40
SECTION 10 - ENGINE - CHAPTER 1 10-32 BACKPLATE AND OIL SEAL Removal 1. Remove the backplate retaining bolts and re- move the backplate. 2. Remove the rear oil seal, 1. 1 41 CRANKSHAFT AND MAIN BEARINGS Removal 1. Remove the crankshaft bearing holder retaining bolts, 1. 1 42 2. Remove the relief valve assembly, 1. 3. Slide the crankshaft and main bearing assembly through the rear of the engine. 1 43
SECTION 10 - ENGINE - CHAPTER 1 10-33 ROCKER ARM ASSEMBLY Disassembly 1. Thread a 8 mm bolt into the rear end of the rocker shaft and slowly withdraw the rocker shaft, 1, while at the same time removing the rocker arms, 2, springs, 3, and shims, 4. 1 3 2 4 44 Inspection and Repair 1. Wear of Rocker Arm Shaft Using a micrometer, check the outside diameter of the rocker arm shaft. If the rocker arm shaft is worn beyond the allowable limit, replace. Standard dimension Allowable Limit 14.95 mm - 14.97 mm 14.87 mm (0.588″ - 0.589″ (0.585″) 45 2. Rocker Arm-to-Shaft Clearance Measure the inside diameter of the rocker arm. Calculate the clearance at, 1, between the rocker arm, 2, and the rocker arm shaft, 3. If the clearance is excessive, replace. Standard Clearance Allowable Limit 0.030 mm - 0.093 mm 0.2 mm (0.0012″ - .0037″) (0.008″) 3. Wear on valve stem contacts face of the rocker arm. Check the face for step wear or score. Slight wear may be corrected using an oil stone. 19992597 46
SECTION 10 - ENGINE - CHAPTER 1 10-34 Op. 10 106 TIMING GEAR Inspection 1. Check the timing gears for wear and damage on the contact area. Replace if any defect is found. 2. Measure the backlash of gears with a feeler gauge or dial indicator. If the allowable limit is ex- ceeded, replace all timing gears. Standard Allowable Limit 0.08 mm (0.003I) 0.25 mm (0.010I) 47 CAMSHAFT Disassembly 1. Remove the slider, 1, from the camshaft gear. 2. Using a gear puller, remove the gear assembly, 2, spacer, 3, spacers, 4, tachometer gear, 5, bearing, 6, and key, 8, from the camshaft, 7. 8 6 4 5 3 2 9 1 7 48 Inspection 1. Place the camshaft in a set of V-blocks and check the runout using a dial indicator, 1. 2. Replace or straighten the camshaft if the runout is greater than 0.1 mm (0.004I). 3. Using a micrometer, measure the height of the camshaft lobes. 4. Replace the camshaft if any of the cam lobes are worn to less than the following dimensions: Valve Lobe: 34.1 mm (1.3425I) Injection Pump Lobe: 42.8 mm (1.685I) 1 49

More Related Content

DOCX
WAWANCARA PEMETAAN Kepala sekolah SD.docx
jelantamoksa
 
DOCX
Bua ngai cach giai tru bua va phong chong bua ngai
Nguyen Tuan Anh
 
PDF
Luận văn: Tổ chức hoạt động nhóm với sự hỗ trợ của Sơ đồ tư duy
Dịch vụ viết bài trọn gói ZALO: 0936 885 877
 
PPTX
3. AKSI NYATA 1.4. PENERAPAN BUDAYA POSITIF.pptx
zainut071
 
PDF
Luận văn: Bồi dưỡng năng lực tự học cho học sinh qua bài tập có nội dung thực...
Dịch vụ viết thuê Luận Văn - ZALO 0932091562
 
PPTX
Tugas Ruang Kolaborasi - Modul 1.1 Kelompok 1.pptx
DoniApriyanto2
 
DOCX
BÁO CÁO THỰC TẬP NHẬN THỨC ĐẠI HỌC HOA SEN KHOA NHÀ HÀNG - KHÁCH SẠN - FREE T...
Dịch vụ viết bài trọn gói ZALO: 0909232620
 
PDF
New holland tc33 da tractor service repair manual
fdjsuekskefmm
 
WAWANCARA PEMETAAN Kepala sekolah SD.docx
jelantamoksa
 
Bua ngai cach giai tru bua va phong chong bua ngai
Nguyen Tuan Anh
 
Luận văn: Tổ chức hoạt động nhóm với sự hỗ trợ của Sơ đồ tư duy
Dịch vụ viết bài trọn gói ZALO: 0936 885 877
 
3. AKSI NYATA 1.4. PENERAPAN BUDAYA POSITIF.pptx
zainut071
 
Luận văn: Bồi dưỡng năng lực tự học cho học sinh qua bài tập có nội dung thực...
Dịch vụ viết thuê Luận Văn - ZALO 0932091562
 
Tugas Ruang Kolaborasi - Modul 1.1 Kelompok 1.pptx
DoniApriyanto2
 
BÁO CÁO THỰC TẬP NHẬN THỨC ĐẠI HỌC HOA SEN KHOA NHÀ HÀNG - KHÁCH SẠN - FREE T...
Dịch vụ viết bài trọn gói ZALO: 0909232620
 
New holland tc33 da tractor service repair manual
fdjsuekskefmm
 

Similar to Case ih dx55 tractor service repair manual (20)

PDF
New holland tc29 da tractor service repair manual
fdjsuekskefmm
 
PDF
Case ih dx31 tractor service repair manual
fjsjjefskekmem
 
PDF
Case ih dx34 tractor service repair manual
jfdjjskfkksmemm
 
PDF
Case ih dx31 tractor service repair manual
fjjskksekmemm
 
PDF
Case ih dx34 tractor service repair manual
fjsjekksemm
 
PDF
Case ih dx34 tractor service repair manual
fjskekmsemmwe
 
PDF
Case ih dx31 tractor service repair manual
jjskefkskemik
 
PDF
Case ih dx33 tractor service repair manual
jfdjjskfkksmemm
 
PDF
Case ih dx29 tractor service repair manual
fjsjjefskekmem
 
PDF
Case ih dx33 tractor service repair manual
fjjskksekmemm
 
PDF
Case ih dx29 tractor service repair manual
fhsjjefksekme
 
PDF
Case ih dx29 tractor service repair manual
jjskefkskemik
 
PDF
Case ih dx33 tractor service repair manual
fjsjekksemm
 
PDF
New holland tc34 da tractor service repair manual
dfjjkskemsme
 
PDF
New holland tc31 da tractor service repair manual
dfjjkskemsme
 
PDF
Case ih dx26 tractor service repair manual
fjskekmsemmwe
 
PDF
Case ih dx26 tractor service repair manual
fjsjekksemm
 
PDF
Case ih dx23 tractor service repair manual
fjsjekksemm
 
PDF
New Holland TT45A Tractor Service Repair Manual.pdf
udjkskmdm3e
 
PDF
New Holland TT50A Tractor Service Repair Manual.pdf
udjkskmdm3e
 
New holland tc29 da tractor service repair manual
fdjsuekskefmm
 
Case ih dx31 tractor service repair manual
fjsjjefskekmem
 
Case ih dx34 tractor service repair manual
jfdjjskfkksmemm
 
Case ih dx31 tractor service repair manual
fjjskksekmemm
 
Case ih dx34 tractor service repair manual
fjsjekksemm
 
Case ih dx34 tractor service repair manual
fjskekmsemmwe
 
Case ih dx31 tractor service repair manual
jjskefkskemik
 
Case ih dx33 tractor service repair manual
jfdjjskfkksmemm
 
Case ih dx29 tractor service repair manual
fjsjjefskekmem
 
Case ih dx33 tractor service repair manual
fjjskksekmemm
 
Case ih dx29 tractor service repair manual
fhsjjefksekme
 
Case ih dx29 tractor service repair manual
jjskefkskemik
 
Case ih dx33 tractor service repair manual
fjsjekksemm
 
New holland tc34 da tractor service repair manual
dfjjkskemsme
 
New holland tc31 da tractor service repair manual
dfjjkskemsme
 
Case ih dx26 tractor service repair manual
fjskekmsemmwe
 
Case ih dx26 tractor service repair manual
fjsjekksemm
 
Case ih dx23 tractor service repair manual
fjsjekksemm
 
New Holland TT45A Tractor Service Repair Manual.pdf
udjkskmdm3e
 
New Holland TT50A Tractor Service Repair Manual.pdf
udjkskmdm3e
 
Ad

More from fusjejfjskekme (20)

PDF
Yamaha outboard f50 feht service repair manual sn1000001
fusjejfjskekme
 
PDF
Yale b974 gdp50 lx lift truck service repair manual
fusjejfjskekme
 
PDF
Yale (e877) gdp130 ec lift truck service repair manual
fusjejfjskekme
 
PDF
Perkins phaser and 1000 series models ac diesel engine service repair manual
fusjejfjskekme
 
PDF
Perkins peregrine edi and 1300 series edi ws diesel engine service repair manual
fusjejfjskekme
 
PDF
Perkins peregrine edi and 1300 series edi wq diesel engine service repair manual
fusjejfjskekme
 
PDF
Perkins new 1000 series models ar diesel engine service repair manual
fusjejfjskekme
 
PDF
Perkins 2800 series 2806 c e16 diesel engine service repair manual
fusjejfjskekme
 
PDF
Perkins 2000 series 2006 diesel engine(model 2006 twg2)service repair manual
fusjejfjskekme
 
PDF
Perkins 1300 series we diesel engine service repair manual
fusjejfjskekme
 
PDF
Perkins 700 series ua four cylinder diesel engine service repair manual
fusjejfjskekme
 
PDF
Perkins 100 series 102 05 diesel engine service repair manual
fusjejfjskekme
 
PDF
Kubota st alpha-30 tractor service repair manual
fusjejfjskekme
 
PDF
Kubota rck60 r f36 front cut ride on mower service repair manual
fusjejfjskekme
 
PDF
Steyr f4 hfe413x tier 4b (final) engine service repair manual
fusjejfjskekme
 
PDF
Steyr f4 he9684 engine service repair manual
fusjejfjskekme
 
PDF
Steyr f4 he9484 engine service repair manual
fusjejfjskekme
 
PDF
Steyr f4 dfe613m tier 4b (final) engine service repair manual
fusjejfjskekme
 
PDF
Steyr 6195 cvt tractor service repair manual
fusjejfjskekme
 
PDF
New holland e27.2 sr hydraulic excavator service repair manual
fusjejfjskekme
 
Yamaha outboard f50 feht service repair manual sn1000001
fusjejfjskekme
 
Yale b974 gdp50 lx lift truck service repair manual
fusjejfjskekme
 
Yale (e877) gdp130 ec lift truck service repair manual
fusjejfjskekme
 
Perkins phaser and 1000 series models ac diesel engine service repair manual
fusjejfjskekme
 
Perkins peregrine edi and 1300 series edi ws diesel engine service repair manual
fusjejfjskekme
 
Perkins peregrine edi and 1300 series edi wq diesel engine service repair manual
fusjejfjskekme
 
Perkins new 1000 series models ar diesel engine service repair manual
fusjejfjskekme
 
Perkins 2800 series 2806 c e16 diesel engine service repair manual
fusjejfjskekme
 
Perkins 2000 series 2006 diesel engine(model 2006 twg2)service repair manual
fusjejfjskekme
 
Perkins 1300 series we diesel engine service repair manual
fusjejfjskekme
 
Perkins 700 series ua four cylinder diesel engine service repair manual
fusjejfjskekme
 
Perkins 100 series 102 05 diesel engine service repair manual
fusjejfjskekme
 
Kubota st alpha-30 tractor service repair manual
fusjejfjskekme
 
Kubota rck60 r f36 front cut ride on mower service repair manual
fusjejfjskekme
 
Steyr f4 hfe413x tier 4b (final) engine service repair manual
fusjejfjskekme
 
Steyr f4 he9684 engine service repair manual
fusjejfjskekme
 
Steyr f4 he9484 engine service repair manual
fusjejfjskekme
 
Steyr f4 dfe613m tier 4b (final) engine service repair manual
fusjejfjskekme
 
Steyr 6195 cvt tractor service repair manual
fusjejfjskekme
 
New holland e27.2 sr hydraulic excavator service repair manual
fusjejfjskekme
 
Ad

Recently uploaded (20)

PDF
Bobcat tl38.70 telescopic handler service repair manual sn b3 zu11001 and abo...
Service Repair Manual
 
PDF
CASE CX45B Series 2 Mini Excavator Service Repair Manual Instant Download.pdf
zhongxiaqielan90
 
PDF
System Diagrams John Deere 370E 410E 460E Repair Manual.pdf
Service Repair Manual
 
PDF
D6E Engine Volvo EC160C NL Excavator Service Repair Manual.pdf
Service Repair Manual
 
PDF
Bobcat t40180 telescopic handler repair manual sn b33 j11001 and above.pdf
Service Repair Manual
 
PDF
Bobcat t40140 telescopic handler service repair manual sn b33 j11001 and abov...
Service Repair Manual
 
PDF
dozer bulldozer Komatsu d85 px 15e0 Technical manual.pdf
hejifob514
 
PDF
Transmission John Deere 370E 410E 460E Technical Manual.pdf
Service Repair Manual
 
PPTX
Instrument_Cluster_And_Infotainement.pptx
XEEDO
 
PDF
CASE CX55B Mini Excavator Service Repair Manual Instant Download.pdf
zhongxiaqielan90
 
PDF
Engine Volvo EC160B LC EC160BLC Excavator Service Repair Manual.pdf
Service Repair Manual
 
PDF
CASE CX50B Series 2 Mini Excavator Service Repair Manual Instant Download.pdf
zhongxiaqielan90
 
DOC
Bài tập bổ trợ I-learn Smart World 9 HK1 Unit 4 (HS) (1).doc
XunHuyn12
 
PDF
Pistons Volvo EC160C NL EC160CNL Excavator Service Repair Manual.pdf
Service Repair Manual
 
PPTX
Total quality management and I have a great day
vishnuai4568
 
PDF
Designyze – Creative Digital Marketing & Design Agency in India
designyze099
 
PDF
BOBCAT 442 muffler SN 522311001 & Above.pdf
Service Repair Manual
 
PDF
Bnmn8tf8tf8f585x85fitc8tc75f74f75f8tx8tc8tx85
alexcabitocabo2
 
PPTX
DNA Packaging in Eukaryot ic Cells.pptx
AbhijithA57
 
PDF
Presentation KSR EV Product Plan for the year of 2023
galangarrafah1
 
Bobcat tl38.70 telescopic handler service repair manual sn b3 zu11001 and abo...
Service Repair Manual
 
CASE CX45B Series 2 Mini Excavator Service Repair Manual Instant Download.pdf
zhongxiaqielan90
 
System Diagrams John Deere 370E 410E 460E Repair Manual.pdf
Service Repair Manual
 
D6E Engine Volvo EC160C NL Excavator Service Repair Manual.pdf
Service Repair Manual
 
Bobcat t40180 telescopic handler repair manual sn b33 j11001 and above.pdf
Service Repair Manual
 
Bobcat t40140 telescopic handler service repair manual sn b33 j11001 and abov...
Service Repair Manual
 
dozer bulldozer Komatsu d85 px 15e0 Technical manual.pdf
hejifob514
 
Transmission John Deere 370E 410E 460E Technical Manual.pdf
Service Repair Manual
 
Instrument_Cluster_And_Infotainement.pptx
XEEDO
 
CASE CX55B Mini Excavator Service Repair Manual Instant Download.pdf
zhongxiaqielan90
 
Engine Volvo EC160B LC EC160BLC Excavator Service Repair Manual.pdf
Service Repair Manual
 
CASE CX50B Series 2 Mini Excavator Service Repair Manual Instant Download.pdf
zhongxiaqielan90
 
Bài tập bổ trợ I-learn Smart World 9 HK1 Unit 4 (HS) (1).doc
XunHuyn12
 
Pistons Volvo EC160C NL EC160CNL Excavator Service Repair Manual.pdf
Service Repair Manual
 
Total quality management and I have a great day
vishnuai4568
 
Designyze – Creative Digital Marketing & Design Agency in India
designyze099
 
BOBCAT 442 muffler SN 522311001 & Above.pdf
Service Repair Manual
 
Bnmn8tf8tf8f585x85fitc8tc75f74f75f8tx8tc8tx85
alexcabitocabo2
 
DNA Packaging in Eukaryot ic Cells.pptx
AbhijithA57
 
Presentation KSR EV Product Plan for the year of 2023
galangarrafah1
 

Case ih dx55 tractor service repair manual

  • 1. 87367137 8/05© 2005 CNH America LLC Printed In U.S.A. DX48, DX55 REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 - ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 18 - CLUTCH 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 21 - TRANSMISSION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 23 - FWD DRIVELINE 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 25 - FWD FRONT AXLE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 27 - DIFFERENTIAL, REAR AXLE 21. . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 31 - POWER TAKE-OFF (PTO) 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 33 - BRAKES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 35 - HYDRAULIC SYSTEM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 41 - STEERING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 44 - WHEELS AND TIRES 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 55 - ELECTRICAL SYSTEM 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 90 - PLATFORM 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The following pages are the collation of the contents pages from each section and chapter of the DX48, DX55 Repair manual. Complete Repair part # 87367132. The sections used through out all Case IH product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books. Each book will be labeled as to which sections are in the overall Repair manual and which sections are in each book. The sections listed above are the sections utilized for the DX48, DX55 Tractors.
  • 2. SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-1 SECTION 00 - GENERAL INFORMATION Chapter 1 - General Information CONTENTS Section Description Page Precautionary Statements 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Decals 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instruction Decals 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decal Placement Guide 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ecology and the Environment 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Symbols 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Hardware Tightening Torques 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Lubricants 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication and Maintenance Chart 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Fittings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel Fuel 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Speeds 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Dimensions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Tread Settings 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle (2WD) Adjustable 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Ballast 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Pressure 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Tire Liquid 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 3. SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-3 SAFETY PRECAUTIONARY STATEMENTS A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help prevent accidents, read the following precautions before operating this equipment. Equipment should be oper- ated only by those who are responsible and instructed to do so. Carefully review the procedures given in this manual with all operators. It is important that all operators be familiar with and follow safety precautions. THE TRACTOR 1. Read the Operator’s Manual carefully before using the tractor. Lack of operating knowledge can lead to accidents. 2. Use an approved roll bar and seat belt for safe operation. Overturning a tractor without a roll bar can result in death or injury. If your tractor is not equipped with a roll bar and seat belt, see your Case IH Dealer. 3. Always use the seat belt. The only instance when the seat belt should not be used is if the roll bar has been removed from the tractor or folding ROPS is in down position. 4. If a front end loader is to be installed, always use a FOPS (Falling Object Protective Structure) canopy to avoid injury from falling objects. 5. Use the handholds and step plates when getting on and off the tractor to prevent falls. Keep steps and platform cleared of mud and debris. 6. Do not permit anyone but the operator to ride on the tractor. There is no safe place for extra riders. 7. Keep all safety decals clean of dirt and grime, and replace all missing, illegible, or damaged safety decals. See the list of decals in the Decal section of this manual. SERVICING THE TRACTOR 1. The cooling system operates under pressure which is controlled by the radiator cap. It is dangerous to remove the cap while the system is hot. Always turn the cap slowly to the first stop and allow pressure to escape before removing the cap entirely. 2. Keep any type of open flame away from the tractor and do not smoke while refueling. Wait for the engine to cool before refueling. 3. Keep the tractor and equipment, particularly brakes and steering, maintained in a reliable and satisfactory condition to ensure your safety and comply with legal requirements. 4. Keep open flame or cold weather starting aids away from the battery to prevent fires or explosions. Use jumper cables according to instructions to prevent sparks which could cause explosion. Do not use chemical starting aids on glow plug equipped tractors. 5. Stop the engine before performing any service on the tractor. 6. Escaping hydraulic/diesel fluid under pressure can penetrate the skin causing serious injury. If fluid is injected into the skin, obtain medical attention immediately or gangrene may result. • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. • Stop the engine and relieve pressure before connecting or disconnecting lines. • Tighten all connections before starting the engine or pressurizing lines. 7. Do not modify or permit anyone else to modify or alter this tractor or any of its components or functions without first consulting a Case IH Dealer. 8. The fuel oil in the injection system is under high pressure and can penetrate the skin. Unqualified persons should not remove or attempt to adjust a pump, injector, nozzle, or any other part of the fuel injection system. Failure to follow these instructions can result in serious injury. 9. Continuous long-term contact with used engine oil may cause skin cancer. Avoid prolonged contact with used engine oil. Wash skin promptly with soap and water.
  • 4. SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-4 10. Some components of your tractor, such as gaskets and friction surfaces (brake linings, clutch linings, etc.) may contain asbestos. Breathing asbestos dust is dangerous to your health. You are advised to have any mainte- nance or repair on such components carried out by an authorized Case IH Dealer. However, if service operations are to be undertaken on parts that contain asbestos, the essential precautions listed below must be observed: • Work out of doors or in a well ventilated area. • Dust found on the tractor or produced during work on the tractor should be removed by extraction, not by blowing. • Dust waste should be dampened, placed in a sealed container, and marked to ensure safe disposal. • If any cutting, drilling, etc. is attempted on materials containing asbestos, the item should be dampened and only hand tools or low speed power tools used. OPERATING THE TRACTOR 1. Before starting the tractor, apply the parking brake, place the PTO lever in the “OFF” position, the lift control lever in the down position, the remote control valve levers in the neutral position, and the transmission in neutral. 2. Always sit in the tractor seat when starting the engine or operating controls. Do not start the engine or operate controls while standing beside the tractor. 3. Do not bypass the neutral start switches. Consult your Case IH Dealer if your neutral start controls malfunction. Use jumper cables only in the recommended manner. Improper use can result in tractor runaway. 4. Avoid accidental contact with the gear shift lever while the engine is running, as this can cause unexpected tractor movement. 5. Before getting off the tractor, disengage the PTO, turn the engine off, and apply the parking brake. Never get off the tractor while it is in motion. 6. Do not park the tractor on a steep incline. 7. Do not operate the tractor engine in an enclosed building without adequate ventilation. Exhaust fumes can cause death or illness. 8. If the power steering or engine ceases operating, stop the tractor immediately. 9. Pull only from the drawbar or the lower link drawbar in the down position. Use only a drawbar pin that locks in place. Pulling from the tractor rear axle or any point above the axle may cause the tractor to upset. 10. If the front end of the tractor tends to rise when heavy implements are attached to the three- point hitch, install front end weights. Do not operate the tractor with a light front end. 11. Always set the hydraulic selector lever in position control when attaching or transporting equip- ment. Ensure hydraulic couplers are properly mounted and will disconnect safely in case of accidental detachment of implement. 12. Do not leave equipment in the raised position. 13. Use the flasher/turn signal lights and SMV signs when traveling on public roads both day and night (unless prohibited by law). 14. When operating at night, adjust lights to prevent blinding oncoming drivers. DRIVING THE TRACTOR 1. Watch where you are going, especially at row ends, on roads, around trees and low hanging obstacles. 2. To avoid upsets, drive the tractor with care and at a safe speed. Use extra caution when operating over rough ground, when crossing ditches or slopes, and when turning corners. 3. To provide two-wheel braking, lock tractor brake pedals together when transporting on roads. 4. Do not coast or free wheel down hills. Use the same gear when going downhill as is used when going uphill. 5. Any towed vehicle with a total weight exceeding that of the towing tractor should be equipped with brakes for safe operation. 6. If the tractor becomes stuck or the tires become frozen to the ground, back up the tractor to prevent upset. 7. Always check overhead clearance, especially when transporting the tractor. 8. When operating at night, adjust lights to prevent blinding oncoming drivers.
  • 5. SECTION 00 - GENERAL INFORMATION - CHAPTER 1 00-5 OPERATING THE PTO 1. When operating PTO driven equipment, shut off the engine and wait until the PTO stops before getting off the tractor and disconnecting the equipment. 2. Do not wear loose clothing when operating the power take-off or when near rotating equipment. 3. When operating stationary PTO driven equip- ment, always place range gear shift lever in neutral, apply the tractor parking brake, and block the rear wheels front and back. 4. To avoid injury, do not clean, adjust, unclog, or service PTO driven equipment when the tractor engine is running. 5. Ensure the PTO master shield is installed at all times. Always replace the PTO shield cap when the PTO is not in use. DIESEL FUEL 1. UNDER NO CIRCUMSTANCES should gaso- line, alcohol, or blended fuels be added to diesel fuel. These combinations can create an increased fire or explosive hazard. Such blends are more explosive than pure gasoline in a closed container such as a fuel tank. DO NOT USE THESE BLENDS. 2. Never remove the fuel cap or refuel with the engine running or hot. 3. Do not smoke while refueling or when standing near fuel. 4. Maintain control of the fuel filler pipe nozzle when filling the tank. 5. Do not fill the fuel tank to capacity. Allow room for expansion. 6. Wipe up spilled fuel immediately. 7. Always tighten the fuel tank cap securely. 8. If the original fuel tank cap is lost, replace it with a Case IH approved cap. A non-approved, proprietary cap may not be safe. 9. Keep equipment clean and properly maintained. 10. Do not drive equipment near open fires. 11. Never use fuel for cleaning purposes. 12. Arrange fuel purchases so that winter grade fuels are not held over and used in the spring. SAFETY FRAME (ROPS) Your Case IH tractor is equipped with a safety frame. It must be maintained in a serviceable condition. Be careful when driving through doorways or working in confined spaces with low headroom. UNDER NO CIRCUMSTANCES should you: • modify, drill, or alter the safety frame in any way. Doing so may render you liable to legal prosecution. • attempt to straighten or weld any part of the main frame or retaining brackets which have suffered damage. Doing so may weaken the structure and endanger your safety. • secure any parts on the main frame or attach your safety frame with anything other than the special high tensile bolts and nuts specified. • attach chains or ropes to the main frame for pulling purposes. • take unnecessary risks even though your safety frame affords you the maximum protection possible.
  • 6. SECTION 10 - ENGINE - CHAPTER 1 10-1 SECTION 10 - ENGINE Chapter 1 - Engine Dismantling Sequence CONTENTS Section Description Page Specifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric Bolt Torque Specifications 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Test and Tools 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of Operation -- General Information 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Valve Train Components 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block Assembly 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Fan and Pulley 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug and Connector 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle/Holder 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injection Pipe 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injector 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover/Intake Manifold/Exhaust Manifold 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Oil Pipe 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Assembly 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 7. SECTION 10 - ENGINE - CHAPTER 1 10-2 Section Description Page Cylinder Head 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tappets 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Stop Solenoid 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear Cover 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Timing Gears and Camshaft 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front End Plate 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 Oil Sump 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Suction Pipe and Strainer 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 110 Balancer Assembly 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 105 Connecting Rods, Bearings and Pistons, Rings 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Flywheel 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backplate and Oil Seal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearings 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arm Assembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Timing Gear 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly (see Idler Gear) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 101 Cylinder Head 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 8. SECTION 10 - ENGINE - CHAPTER 1 10-3 Section Description Page Valves 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Guides 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Seat 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Springs 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rocker Arms 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Push Rods 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston and Piston Rings 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting Rods 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pistons, Rings and Connecting Rod 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Crankshaft Main Bearing and Thrust Washer 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Inspection 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Bearing (Bushing) 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Main Bearing 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Port Block 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Crankshaft and Bearing Holder 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Plate/Flyweel Housing 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 103 Flywheel 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 105 Pistons and Connecting Rods 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 9. SECTION 10 - ENGINE - CHAPTER 1 10-4 Section Description Page 10 110 Balancer Assembly 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Suction Pipe and Suction Strainer 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Sump 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Camshaft and Camshaft Gear 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Idler Gear, Oil Pump and Injection Timing 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 Timing Gear Case 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Oil Seal and Steering Pump Seal 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Gear Case 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection Pump 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 101 Head Gasket Selection 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Gasket Selection Chart 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 Valve Clearance Adjustment 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Cover 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake/Exhaust Manifolds 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Oil Tube 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Switch 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator and Temperature Sender Switch 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug and Connector 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle/Holder Assembly 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return Pipe and Injection Pipe 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 10. SECTION 10 - ENGINE - CHAPTER 1 10-5 Section Description Page Hydraulic Oil Pump 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 304 Description of Operation -- Engine Lubrication System 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 206 Oil Filter 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction and Function 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 304 Oil Pump 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation and Adjustment 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil Pressure Check 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Relief Valve 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Consumption 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 400 Description of Operation -- Cooling System 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator Cap 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Thermostat 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Water Pump 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 414 Cooling Fan 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Water Pump 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 Thermostat 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Cooler 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
  • 11. SECTION 10 - ENGINE - CHAPTER 1 10-6 SPECIFICATIONS GENERAL DX48 DX55 Engine Model N844L N844L-TC Number of Cylinders 4 4 Bore x Stroke 84 x 100 mm. (3.31 x 3.94in) 84 x 100 mm. (3.31 x 3.94in) Displacement 135.2 cu. In.(2216 cc) 135.2 cu. In.(2216 cc) Compression Ratio 22.5:1 22.5:1 Rated Speed(rpm) 2800 2700 Firing Order 1--3--4--2 1--3--4--2 Low Idle Speed 1000 1000 Maximum No Load Speed 3000 2900 Cylinder Arrangement In--line vertical In--line vertical Valve Arrangement Overhead Overhead Compression Pressure At 200 rpm (cylinder speed) 29.4 ± 3.5 bar (427 ± 50 psi) 29.4 ± 3.5 bar (427 ± 50 psi) CYLINDER BLOCK N844L N844L-TC Bore Standard 84.0 mm (3.3071 in.) 84.0 mm (3.3071 in.) Maximum 84.2 mm (3.315 in.) 84.2 mm (3.315 in.) Head Surface Warp Standard .05 mm (.002 in.) .05 mm (.002 in.) Maximum .12 mm (.005 in.) .12 mm (.005 in.) CYLINDER HEAD N844L N844L-TC Head Warp Standard .05 mm (.002 in.) .05 mm (.002 in.) Maximum .12 mm (.005 in.) .12 mm (.005 in.) Valve seat width Standard 1.7--2.1 mm (0.067--0.082 in.) 1.7--2.1 mm (0.067--0.082 in.) Maximum 1.8 mm (0.071 in.) 1.8 mm (0.071 in.) Valve seat sink N844L N844L-TC Standard (recess) 0.85--1.15mm (0.0334--0.0453 in.) 0.85--1.15mm (0.0334--0.0453 in.) Maximum 1.8 mm (0.071 in.) 1.8 mm (0.071 in.) Valve Angle 45 degrees 45 degrees PISTON N844L N844L-TC Diameter Standard 83.948--83.963 mm (3.30503--3.30562 in.) 83.948--83.963 mm (3.30503--3.30562 in.) Minimum 83.7 mm (3.2953 in.) 83.7 mm (3.2953 in.) BORE CLEARANCE N844L N844L-TC Standard 0.038--0.072 mm (0.0015--0.0028 in.) 0.038--0.072 mm (0.0015--0.0028 in.) Maximum 0.25mm (0.010 in.) 0.25mm (0.010 in.) PISTON PIN BORE N844L N844L-TC Standard 27.996--28.0mm (1.102--1.1023 in.) 27.996--28.0mm (1.102--1.1023 in.) Maximum 27.98 mm (1.102 in.) 27.98 mm (1.102 in.)
  • 12. SECTION 10 - ENGINE - CHAPTER 1 10-19 MODEL N844L - DX4810044351 10044352 4 MODEL N844L-TC - DX5520035585 5
  • 13. SECTION 10 - ENGINE - CHAPTER 1 10-20 ENGINE Removal 1. Disconnect the negative (--) battery cable, 1, and positive (+) battery cable, 2, from the battery. 10032806 1 2 6 2. Disconnect the headlight wire harness plug, 1. 3. Remove the clips and pins, 2, from each side of the hood bracket. 4. Remove the support rod, 3, and remove the hood from the tractor. 10032784 1 2 3 7 5. Drain the coolant from radiator, and engine using the petcock valve, 1. Remove radiator cap to assist draining. 6. Remove the radiator (see Radiator Removal in Section 10). 10032808 1 8
  • 14. SECTION 10 - ENGINE - CHAPTER 1 10-21 7. Loosen and remove the drain plug, 1, from the power steering reservoir, 2, and drain into a suitable container. NOTE: See separating the tractor at the transmis- sion in Section 21 to separate the tractor. 10032804 1 2 9 8. After the tractor has been successfully sepa- rated, support the front axle and the front support frame with jack stands. 9. Remove the firewall from the engine. 10. Remove the muffler and exhaust pipe from the tractor. 11. With the chain and hoist still attached to the engine, remove the mount bolts, 1, from each side of the frame rails. 12. Carefully remove the engine. 20002365 1 1 10 Installation 1. Attach a hoist to the engine, and position it onto the frame. 2. Install the engine mounting bolts on both sides of the frame. Apply Loctite® thread locker 242 to the thread of the bolts. TIghten bolts to the following torques: torques #1 -- 80 N⋅m (60 ft. lbs.) torques #2 -- 80 N⋅m (60 ft. lbs.) torques #3 -- 175 N⋅m (130 ft. lbs.) 3. Install the muffler and exhaust pipe onto the tractor. 4. Install the firewall onto the engine. NOTE: See section 21 for attaching the engine to the transmission. 20034413 3 1 2 11
  • 15. SECTION 10 - ENGINE - CHAPTER 1 10-22 OVERHAUL ENGINE NOTE: Some procedures discussed in this chapter are shown with the engine in the tractor. Many of the procedures can be done with the engine in or out of the tractor. ALTERNATOR Removal Disconnect the alternator wire harness and wires, 1. Remove the alternator pivot and adjusting bracket, hardware, 2. 12 COOLING FAN AND PULLEY Removal Remove the fan, 1, retaining hardware and spacers. 13 GLOW PLUG AND CONNECTOR Removal Remove the glow plugs, 1, and glow plug connectors, 2. 1 2 14
  • 16. SECTION 10 - ENGINE - CHAPTER 1 10-23 NOZZLE/HOLDER Removal Remove the nozzle and holder assembly with a socket for the nozzle holder. 15 FUEL INJECTION PIPE Removal 1. Loosen the fuel pipe nuts from the fuel injection pump and injectors, 1. Remove the pipes as an assembly. 2. Remove the spring clamp and fuel return hose, 2. INJECTOR Removal Loosen and remove the securing nuts, 3. Remove the leak-off rail, 4. Remove the aluminum washers and discard. Remove the injectors tagging or marking with the cylinder they were removed from. 16 WATER PUMP Removal Loosen the securing bolts and remove the water pump assembly, 1, and set plate, 2. 17
  • 17. SECTION 10 - ENGINE - CHAPTER 1 10-24 COVER/INTAKE MANIFOLD/EXHAUST MANIFOLD Removal Remove the intake manifold, 1, spacer, 2, and exhaust manifold, 3. For the N844L-TC turbocharged engine, refer to the turbocharger section of the manual for removal and replacement. 18 Loosen and remove four cap nuts with washers. Remove the head cover assembly, 1. 50051492 1 19 EXTERNAL OIL PIPE Removal 1. Loosen and remove the two banjo bolts, 1, at the cylinder block main oil gallery and cylinder head assembly. 2. Remove the clamp, 2, from the fuel injection pump. 2 20
  • 18. SECTION 10 - ENGINE - CHAPTER 1 10-25 ROCKER ASSEMBLY Removal 1. Loosen and remove nuts, lock washers, and flat washers from the rocker pillar stud, 1. Lift the rocker assembly, 2. 2. Remove the push rods, 3, and valve stem caps, 4. 21 CYLINDER HEAD Removal Loosen the cylinder head bolts, starting from the center, in a circular pattern, using several steps of equal torque. Remove the head. 22 TAPPETS Removal Pull the tappets from the machined bore in the cylinder block. 23
  • 19. SECTION 10 - ENGINE - CHAPTER 1 10-26 FUEL STOP SOLENOID Removal Unscrew the stop solenoid, and remove from the engine block. 24 TIMING GEAR COVER Removal 1. Drain the engine crankcase oil. 2. Remove the injection pump mounting nuts and raise the injection pump, 1, enough to remove the spring pin, 2, and separate the governor link from the control rack. Remove the injection pump. 2 1 25 NOTE: Insert a small dowel, 1, through the fuel shut- off solenoid hole and slide the control rack, 2, in to allow enough clearance to the cylinder block, for the pump to be removed. 20002371 1 2 26
  • 20. SECTION 10 - ENGINE - CHAPTER 1 10-27 3. Loosen the hose clamp, 1, on the suction hose, 2, and remove the suction hose from the steering pump, 3. 4. Remove the pressure tube, 4, from the bottom of the steering pump. 30996355 3 4 2 1 27 5. Remove the through bolts and nuts, 1, and re- move the steering pump from the front cover. Cap the lines and pump openings. NOTE: Two of the power steering pump retaining bolts are not shown. 30996393 1 28 6. Install and tighten two nuts, 1, against each other, onto the retaining studs, 2. Remove the studs, 2, and the hydraulic pump, 3. 20002372 1 2 3 29
  • 21. SECTION 10 - ENGINE - CHAPTER 1 10-28 7. Remove the retaining nut, 1. Pull crankshaft pulley, 2, off of crankshaft, 3. Remove key, 4, from crankshaft. 20002373 1 2 3 4 30 8. Remove the retaining bolts, 1, and lift the cover, 2, off the locating dowels. 1 2 31 Op. 10 106 TIMING GEARS AND CAMSHAFT Removal 1. Remove retaining ring, 1, and remove the idler gear, 2, and oil pump assembly, 3. 1 3 2 32
  • 22. SECTION 10 - ENGINE - CHAPTER 1 10-29 2. Remove the two bolts, 1, securing the keeper plate, 2. One must be accessed using the access hole, 3, in the cam gear. 3. Slide the camshaft and gear out of the camshaft bore. 1 3 2 33 FRONT END PLATE Removal Remove the retaining bolts and lift the front plate off its locating dowels. Remove the gasket and discard. 34 Op. 10 102 OIL SUMP Removal 1. Remove the oil sump retainer bolts, 1. 2. Remove the oil sump and discard gasket. 3. Remove steel spacer, 2, from the block. 1 2 10032653 35
  • 23. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 24. SECTION 10 - ENGINE - CHAPTER 1 10-30 OIL SUCTION PIPE AND STRAINER Removal 1. Remove the two retaining bolts, 1. 2. Remove the oil strainer, 2, and rotate the oil suc- tion pipe, 3, out of its bore. 2 10032654 31 36 Op. 10 110 BALANCER ASSEMBLY Removal 1. Remove the banjo bolts, 1, and the oil transfer pipe, 2. 2. Loosen and remove the balancer retaining bolts, 3. NOTE: Observe the quantity and thickness of the shims, 4, (if used) for re-installation upon assembly. 3. Remove the balancer assembly, 5, from the en- gine block, 6. 20002374 4 5 2 1 3 4 6 37
  • 25. SECTION 10 - ENGINE - CHAPTER 1 10-31 Op. 10 105 CONNECTING RODS, BEARINGS AND PISTONS, RINGS Removal 1. Remove the two bolts, 1, retaining the connect- ing rod caps, 2. 2. Remove the connecting rod caps and lower half of connecting rod bearing. 3. If necessary, remove any ridge from the top of the cylinder bores using a suitable ridge reamer. 1 2 38 4. Push the piston and connecting rod out of the cyl- inder block. 5. Replace the connecting rod cap to the piston as- sembly it was removed from. Keep together in cylinder sequence. 39 Op. 10 103 FLYWHEEL Removal 1. Loosen the flywheel retaining bolts. 2. Using a brass drift and hammer, tap the end of the crankshaft, 1, to loosen the flywheel, 2, from the shaft. 1 2 40
  • 26. SECTION 10 - ENGINE - CHAPTER 1 10-32 BACKPLATE AND OIL SEAL Removal 1. Remove the backplate retaining bolts and re- move the backplate. 2. Remove the rear oil seal, 1. 1 41 CRANKSHAFT AND MAIN BEARINGS Removal 1. Remove the crankshaft bearing holder retaining bolts, 1. 1 42 2. Remove the relief valve assembly, 1. 3. Slide the crankshaft and main bearing assembly through the rear of the engine. 1 43
  • 27. SECTION 10 - ENGINE - CHAPTER 1 10-33 ROCKER ARM ASSEMBLY Disassembly 1. Thread a 8 mm bolt into the rear end of the rocker shaft and slowly withdraw the rocker shaft, 1, while at the same time removing the rocker arms, 2, springs, 3, and shims, 4. 1 3 2 4 44 Inspection and Repair 1. Wear of Rocker Arm Shaft Using a micrometer, check the outside diameter of the rocker arm shaft. If the rocker arm shaft is worn beyond the allowable limit, replace. Standard dimension Allowable Limit 14.95 mm - 14.97 mm 14.87 mm (0.588″ - 0.589″ (0.585″) 45 2. Rocker Arm-to-Shaft Clearance Measure the inside diameter of the rocker arm. Calculate the clearance at, 1, between the rocker arm, 2, and the rocker arm shaft, 3. If the clearance is excessive, replace. Standard Clearance Allowable Limit 0.030 mm - 0.093 mm 0.2 mm (0.0012″ - .0037″) (0.008″) 3. Wear on valve stem contacts face of the rocker arm. Check the face for step wear or score. Slight wear may be corrected using an oil stone. 19992597 46
  • 28. SECTION 10 - ENGINE - CHAPTER 1 10-34 Op. 10 106 TIMING GEAR Inspection 1. Check the timing gears for wear and damage on the contact area. Replace if any defect is found. 2. Measure the backlash of gears with a feeler gauge or dial indicator. If the allowable limit is ex- ceeded, replace all timing gears. Standard Allowable Limit 0.08 mm (0.003I) 0.25 mm (0.010I) 47 CAMSHAFT Disassembly 1. Remove the slider, 1, from the camshaft gear. 2. Using a gear puller, remove the gear assembly, 2, spacer, 3, spacers, 4, tachometer gear, 5, bearing, 6, and key, 8, from the camshaft, 7. 8 6 4 5 3 2 9 1 7 48 Inspection 1. Place the camshaft in a set of V-blocks and check the runout using a dial indicator, 1. 2. Replace or straighten the camshaft if the runout is greater than 0.1 mm (0.004I). 3. Using a micrometer, measure the height of the camshaft lobes. 4. Replace the camshaft if any of the cam lobes are worn to less than the following dimensions: Valve Lobe: 34.1 mm (1.3425I) Injection Pump Lobe: 42.8 mm (1.685I) 1 49