Case ih jx1070 u tractor service repair manual
- 1. TRACTORS JX1070U -- JX1080U -- JX1090U -- JX1100U SERVICE MANUAL SECTIONS GENERAL GUIDELINES 00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE LINES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT MECHANICAL TRANSMISSION 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR MECHANICAL TRANSMISSION 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER TAKE-OFF 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC SYSTEMS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE AND WHEELS 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB AIR CONDITIONING SYSTEM 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATFORM, CAB, BODYWORK 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S E R V I C E
- 2. INTRODUCTION ◊ This manual is divided into sections identified by two--figure numbers and each section has independent page numbering. For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections. ◊ The different sections can easily be found by consulting the table of contents on the following pages. ◊ The document number of the manual and the edition/update dates are given at the bottom of each page. ◊ The information contained in this manual was current on the date printed on each section. As CASE IH con- stantly improves its product range, some information may be out of date subsequent to modifications implem- ented for technical or commercial reasons, or to meet legal requirements in different countries. In the event of conflicting information, consult the CASE IH Sales and Service Departments. IMPORTANT WARNINGS ◊ All maintenance and repair work described in this manual must be performed exclusively by CASE IH service technicians, in strict accordance with the instructions given and using any specific tools necessary. ◊ Anyone performing the operations described herein without strictly following the instructions is personally re- sponsible for any eventual injury or damage to property. ◊ The Manufacturer and all organisations belonging to the Manufacturer’s distribution network, including but not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam- age to property caused by abnormal function of parts and/or components not approved by the Manufacturer, including those used for maintenance and/or repair of the product manufactured or marketed by the Manufac- turer. In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer. TEXT AND ILLUSTRATIONS ARE THE PROPERTY OF CNH ITALIA S.p.A. No part of the text or illustrations may be reproduced PRINTED IN FRANCE CNH ITALIA S.p.A. -- Viale delle Nazioni, 55 -- 41100 MODENA -- Italy Technical Support -- Technical Information Print No. 6--62400 -- 03 -- 2004
- 3. CONTENTS 3 6-62400 -- 03 -- 2004 CONTENTS Page Date 00 -- GENERAL GUIDELINES General instructions . . . . . 1--2 03--04 Safety regulations . . . . . . . 3--4--5 03--04 Consumables . . . . . . . . . . . 6 03--04 10 -- ENGINE Summary . . . . . . . . . . . . . . . 1 03--04 General specifications . . . . 2 to 4 03--04 Fuel system data . . . . . . . . 5 03--04 Crankshaft and engine block data . . . . . . . . . . . . . . 6 03--04 Connecting rod data . . . . . 7 03--04 Piston data . . . . . . . . . . . . . 7--8 03--04 Timing gear data . . . . . . . . 8--9 03--04 Cylinder head data . . . . . . 9--10 03--04 Tightening Torques . . . . . . 11--12 03--04 Tools . . . . . . . . . . . . . . . . . . 13 03--04 View of 4--cylinder engine mod. JX1070U, JX1080U . 14 03--04 View of 4--cylinder engine mod. JX1090U, JX1100U . 15 03--04 Engine cooling and lubrica- tion diagrams . . . . . . . . . . . 16--17 03--04 Component parts of cylin- der head mod. JX1070U e JX1080U . . . . . . . . . . . . . . . 18 03--04 Component parts of cylin- der head mod. JX1090U e JX1100U . . . . . . . . . . . . . . . 19 03--04 Component parts of addi- tional counterweights . . . . 20 03--04 Fault diagnosis . . . . . . . . . . 21 to 24 03--04 Engine Removal -- Installa- tion . . . . . . . . . . . . . . . . . . . . 25 to 44 03--04 Engine Disassembly -- As- sembly . . . . . . . . . . . . . . . . . 45 to 78 03--04 Checks and measure- ments -- cylinder block and liners . . . . . . . . . . . . . . . . . . 79 to 81 03--04 Checks and measure- ments -- crankshaft, bear- ings and flywheel . . . . . . . . 82 to 83 03--04 Checks and measure- ments -- connecting rods . 84 to 85 03--04 Checks and measure- ments -- pistons . . . . . . . . . 86 to 89 03--04 Page Date Checks and measure- ments -- camshaft, tappets and valves . . . . . . . . . . . . . . 90 to 93 03--04 Checks and measure- ments -- cylinder head . . . . 94 03--04 Functional testing on low engine oil pressure indica- tor . . . . . . . . . . . . . . . . . . . . 95 03--04 Checks and measure- ments -- cooling system . . 96 03--04 Replacing crankshaft front seal . . . . . . . . . . . . . . . . . . . 97 to 99 03--04 Replacing crankshaft rear seal . . . . . . . . . . . . . . . . . . . 100 to 102 03--04 Adjusting tappet, valve and rocker arm clearance . . . . 103 to 105 03--04 Removal--Installation -- in- jectors . . . . . . . . . . . . . . . . . 106 to 108 03--04 Removal--Installation -- Bosch injection pump . . . . 109 to 113 03--04 Bosch injection pump -- tim- ing . . . . . . . . . . . . . . . . . . . . 114 03--04 Bosch injection pump -- air bleeding . . . . . . . . . . . . . . . . 116 03--04 Removal--Installation -- coolant pump . . . . . . . . . . . 117--118 03--04 Removal--Installation -- thermostat valve . . . . . . . . . 119--120 03--04 Removal--Installation -- radiator . . . . . . . . . . . . . . . . 121 to 126 03--04 Coolant pump drive belt ad- justment . . . . . . . . . . . . . . . . 127 to 128 03--04 18 -- CLUTCH Data . . . . . . . . . . . . . . . . . . . 2 03--04 Tightening Torques . . . . . . 3 03--04 Tools . . . . . . . . . . . . . . . . . . 3 03--04 Cross--sectional views . . . 4 03--04 Fault diagnosis . . . . . . . . . . 5 03--04 Checks and measure- ments -- clutch . . . . . . . . . . 6--7 03--04 Adjustments -- clutch pedal 8 03--04 Removal--Installation -- clutch . . . . . . . . . . . . . . . . . . 9 to 11 03--04 Clutch Overhaul . . . . . . . . . 12 to 15 03--04 Adjustments -- clutch disen- gagement levers . . . . . . . . 16 03--04
- 4. CONTENTS4 6-62400 -- 03 -- 2004 Page Date 21 -- TRANSMISSION CHAPTER 1 -- Transmission and range gear (12x4) Data . . . . . . . . . . . . . . . . . . . 2 03--04 Tightening Torques . . . . . . 3 03--04 Tools . . . . . . . . . . . . . . . . . . 4--5 03--04 Cross--sectional views . . . 6--7--9 03--04 Description and Operation 8 03--04 Fault diagnosis . . . . . . . . . . 8 03--04 CHAPTER 2 -- Reverser Data . . . . . . . . . . . . . . . . . . . 2 03--04 Tightening Torques . . . . . . 3 03--04 Tools . . . . . . . . . . . . . . . . . . 4 03--04 Cross--sectional views . . . 4--5--11--12 03--04 Description and Operation 6 03--04 Fault diagnosis . . . . . . . . . . 6 03--04 Disassembly--Assembly -- clutch casing--reverser . . . 7 to 10 03--04 CHAPTER 3 -- Dual Command (2 Speed Power Shift) Data . . . . . . . . . . . . . . . . . . . 2--3 03--04 Tightening Torques . . . . . . 4 03--04 Tools . . . . . . . . . . . . . . . . . . 5 03--04 Cross--sectional views . . . 6 to 8--47 03--04 Description and Operation 10 to 15 03--04 Fault diagnosis . . . . . . . . . . 16--17 03--04 Removal--Installation -- clutch casing with Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . 18 to 26 03--04 Disassembly--Assembly -- clutch casing with Dual Command (2 Speed Power Shift) . . . . . . . . . . . . . . . . . . 27 to 35 03--04 Dual Command (2 Speed Power Shift) control rod ad- justments . . . . . . . . . . . . . . . 36 03--04 Removal--Installation -- Dual Command (2 Speed Power Shift) solenoid valve 37 to 40 03--04 Working pressure test . . . . 40 03--04 Removal--Installation -- Dual Command (2 Speed Power Shift) control valve 41 to 44 03--04 Disassembly--Assembly -- Dual Command (2 Speed Power Shift) control valve . 45--46 03--04 Page Date CHAPTER 4 -- Reverser and creeper unit Data . . . . . . . . . . . . . . . . . . . 2 03--04 Tightening torque . . . . . . . . 3 03--04 Tools . . . . . . . . . . . . . . . . . . 4 03--04 Cross--sectional views . . . 6 to 7--15 03--04 Description and Operation 8 03--04 Fault diagnosis . . . . . . . . . . 8 03--04 Replacing clutch casing-- reverser and creeper unit . 9 to 13 03--04 CHAPTER 5 -- Power Shuttle transmission with Dual Command (2 Speed Power Shift) function Data . . . . . . . . . . . . . . . . . . . 2--3 03--04 Tightening torque . . . . . . . . 4--5 03--04 Tools . . . . . . . . . . . . . . . . . . 6--7 03--04 Cross--sectional views . . . 8 to 10 03--04 Description and Operation 11 to 17 03--04 Disassembly--Assembly -- clutch casing with power shuttle and Dual Command (2 Speed Power Shift) . . . . 18 to 24 03--04 Disassembly--Assembly -- clutch (A) . . . . . . . . . . . . . . . 25 to 30 03--04 Disassembly--Assembly -- clutch (B) . . . . . . . . . . . . . . . 30 03--04 23 -- DRIVE LINES Data . . . . . . . . . . . . . . . . . . . 2 03--04 Tightening Torques . . . . . . 3 03--04 Tools . . . . . . . . . . . . . . . . . . 3 03--04 Cross--sectional views . . . 4 03--04 Description and Operation 5 03--04 Fault diagnosis . . . . . . . . . . 6 03--04 Removal--Installation -- ser- vices control valve . . . . . . . 7 to 9 03--04 Disassembly--Assembly -- services control valve . . . . 10 to 11 03--04 Removal--Installation -- drive gear casing . . . . . . . . 12 to 16 03--04 Disassembly--Assembly -- drive gear casing . . . . . . . . 17 to 20 03--04 25 -- FRONT MECHANICAL TRANSMISSION Data . . . . . . . . . . . . . . . . . . . 2 to 4 03--04 Tightening Torques . . . . . . 4--5 03--04 Tools . . . . . . . . . . . . . . . . . . 6 to 8 03--04 Cross--sectional views . . . 9 to 14 03--04 Description and Operation 12--15--16 03--04
- 5. CONTENTS 5 6-62400 -- 03 -- 2004 Page Date Fault diagnosis . . . . . . . . . . 17 03--04 Removal--Installation -- front axle . . . . . . . . . . . . . . . 18 to 21 03--04 Disassembly--Assembly -- front axle . . . . . . . . . . . . . . . 22 to 30 03--04 Overhaul -- front differential 31 03--04 Overhaul -- front axle differ- ential with LIM--SLIP . . . . . 32--33 03--04 Overhaul -- differential lock unit . . . . . . . . . . . . . . . . . . . . 34--35 03--04 Disassembly--Assembly -- front epicyclic final drive without brake . . . . . . . . . . . 36 to 38 03--04 Replacing wheel hub seal without brake. . . . . . . . . . . . 39 03--04 Disassembly--Assembly -- front epicyclic final drive with brake . . . . . . . . . . . . . . 40--41 03--04 Replacing wheel hub seal with brake. . . . . . . . . . . . . . 42 03--04 Replacing steering knuckle pins and bearings . . . . . . . 43 03--04 Stub axle adjustments 44--45 03--04 Adjustments -- bevel drive . . 46 to 52 03--04 27 -- REAR MECHANICAL TRANSMISSION Data . . . . . . . . . . . . . . . . . . . 2--3 03--04 Tightening Torques . . . . . . 3--4 03--04 Tools . . . . . . . . . . . . . . . . . . 5 to 9 03--04 Cross--sectional views . . . 10 to 14 03--04 Description and Operation 15 03--04 Fault diagnosis . . . . . . . . . . 16--17 03--04 Removal--Installation -- transmission--gearbox casing . . . . . . . . . . . . . . . . . 18 to 31 03--04 Disassembly--Assembly -- transmission--gearbox casing . . . . . . . . . . . . . . . . . 32 to 40 03--04 Gearbox driving shaft end float adjustment . . . . . . . . . 40 03--04 Adjustments -- differential lock engagement sleeve position . . . . . . . . . . . . . . . . 41 03--04 Adjustments -- bevel drive . . 49 to 50 03--04 Adjustments -- differential lock control pedal travel . . 51 03--04 Removal--Installation -- side gear casing . . . . . . . . . 52 to 55 03--04 Page Date Disassembly--Assembly -- epicyclic final drive . . . . . . . 55 03--04 Disassembly--Assembly -- drive wheel shaft . . . . . . . . 56--57 03--04 31 -- POWER TAKE--OFF CHAPTER 1 -- Mechanical power take--off Data . . . . . . . . . . . . . . . . . . . 2 to 4 03--04 Tools . . . . . . . . . . . . . . . . . . 5 03--04 Tightening Torques . . . . . . 6 03--04 Cross--sectional views . . . 7 to 9 03--04 Description and Operation 10--11 03--04 Fault diagnosis . . . . . . . . . . 11 03--04 Removal--Installation -- power take--off . . . . . . . . . . 12 to 14 03--04 Disassembly--Assembly -- power take--off . . . . . . . . . . 15 to 17 03--04 CHAPTER 2 -- Electro--hydraulic power take--off Data . . . . . . . . . . . . . . . . . . . 2 to 5 03--04 Tools . . . . . . . . . . . . . . . . . . 5 03--04 Tightening Torques . . . . . . 6 03--04 Cross--sectional views . . . 7 to 12 03--04 Description and Operation 13 to 23 03--04 Fault diagnosis . . . . . . . . . . 24 03--04 Replacing the power take-- off brake . . . . . . . . . . . . . . . 25--26 03--04 Removal--Installation -- power take--off . . . . . . . . . . 27 to 30 03--04 Disassembly--Assembly -- power take--off . . . . . . . . . . 31 to 37 03--04 33 -- BRAKES (*) Data . . . . . . . . . . . . . . . . . . . 1 03--04 Tightening Torques . . . . . . 2 03--04 Cross--sectional views . . . 3--4 03--04 Description and Operation 4 03--04 Hydraulic diagram -- brakes . . . . . . . . . . . . . . . . . 5 03--04 Pilot valve operation . . . . . 6 03--04 Fault diagnosis . . . . . . . . . . 7 03--04 Adjustments -- parking handbrake travel . . . . . . . . 8 03--04 Removal--Installation/Dis- assembly--Assembly park- ing brake casing . . . . . . . . . 9 to 11 03--04
- 6. CONTENTS6 6-62400 -- 03 -- 2004 Page Date Service brake circuit air bleeding . . . . . . . . . . . . . . . . 12 03--04 Removal--Installation -- service brake pump . . . . . . 13--14 03--04 Adjusting the height of the service brake pedals . . . . . 14 03--04 Removal--Installation -- service brake . . . . . . . . . . . 15 to 19 03--04
- 7. SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1 1 6-62400 -- 03--2004 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair work described in this manual must be performed exclusively by CASE IH service technicians, in strict accordance with the instructions given and using any specific tools necessary. Anyone performing the operations described herein without strictly following the instructions is personally re- sponsible for any eventual injury or damage to property. SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each shim. ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: -- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes; -- thoroughly clean the shaft and check that the working surface on the shaft is not damaged; -- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc- tion and position the grooves so that they will deviate the fluid towards the inner side of the seal; -- coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease; -- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet; -- whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes con- tact with the thrust element, if required; -- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations. “O--RING” SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist- ing, which would jeopardise sealing efficiency. SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHO- DORSIL CAF 1 or LOCTITE PLASTIC GASKET. Before applying the sealing compound, prepare the surfaces as follows: -- remove any incrustations using a wire brush; -- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a water and soda solution.
- 8. 2 SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1 6-62400 -- 03--2004 BEARINGS When installing bearings it is advised to: -- heat the bearings to 80 ÷ 90 °C before fitting on the shafts; -- allow the bearings to cool before installing them. SPRING PINS When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning. SPARE PARTS Use solely genuine parts, which guarantee the same quality, duration and safety as the original parts as they are identical to the ones fitted during production. Only genuine parts can offer this guarantee. When ordering spare parts, always provide the following information: -- tractor model (commercial name) and frame number; -- engine type and number; -- part number of the ordered part, which can be found in the “Microfiches” or the “Spare Parts Catalogue”, used for order processing. TOOLS The tools that CASE IH offer and illustrate in this manual are: -- specifically researched and designed for use with CASE IH vehicles; -- essential for reliable repair operations; -- accurately built and rigorously tested so as to offer efficient and long--lasting operation. By using these tools, repair personnel will benefit from: -- operating in optimal technical conditions; -- obtaining the best results; -- saving time and effort; -- working in safe conditions. IMPORTANT NOTES Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, “right-- hand” and “left--hand” (when referred to different parts) are intended as seen from the driving position with the vehicle in the normal direction of movement. MOVING THE TRACTOR WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle. If the vehicle electrical system requires checking, carry out operations with the power supply connected. Once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.
- 9. SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1 3 6-62400 -- 03--2004 SAFETY REGULATIONS PAY ATTENTION TO THIS SYMBOL This warning symbol points out important messages concerning your safety. Carefully read the following safety regulations and observe advised precautions in order to avoid potential hazards and safeguard your health and safety. In this manual the symbol is accompanied by the following key--words: CAUTION -- Warnings concerning unsuitable repair operations that may jeopardise the safety of Service personnel. DANGER -- Specific warnings concerning potential hazards for operator safety or for other persons directly or indirectly involved. ACCIDENT PREVENTION Most accidents or injuries that occur in workshops are the result of non--observance of simple and fun- damental safety regulations. For this reason, IN MOST CASES THESE ACCI- DENTS CAN BE AVOIDED by foreseeing possible causes and consequently acting with the necessary caution and care. Accidents may occur with all types of vehicle, regard- less of how well it was designed and built. A careful and judicious service technician is the best guarantee against accidents. Precise observance of the most basic safety rule is normally sufficient to avoid many serious accidents. DANGER. Never carry out any cleaning, lubrication or maintenance operations when the engine is run- ning. SAFETY REGULATIONS GENERAL GUIDELINES -- Carefully follow specified repair and mainten- ance procedures. -- Do not wear rings, wristwatches, jewellery, un- buttoned or loose articles of clothing such as: ties, torn clothing, scarves, open jackets or shirts with open zips that may remain entangled in moving parts. It is advised to wear approved safety clothing, e.g.: non--slip footwear, gloves, safety goggles, helmets, etc. -- Do not carry out repair operations with someone sitting in the driver’s seat, unless the person is a trained technician who is assisting with the oper- ation in question. -- Operate the vehicle and use the implements ex- clusively from the driver’s seat. -- Do not carry out operations on the vehicle with the engine running, unless specifically indicated. -- Stop the engine and check that the hydraulic cir- cuits are pressure--free before removing caps, covers, valves, etc. -- All repair and maintenance operations must be carried out using extreme care and attention. -- Service steps and platforms used in a workshop or in the field should be built in compliance with the safety rules in force. -- Disconnect the batteries and label all controls to indicate that the vehicle is being serviced. Any parts that are to be raised must be locked in posi- tion. -- Do not check or fill fuel tanks, accumulator bat- teries, nor use starting liquid when smoking or near naked flames, as these fluids are inflam- mable. -- Brakes are inoperative if manually released for repair or maintenance purposes. Use blocks or similar devices to secure the ma- chine in these conditions. -- The fuel nozzle should always be in contact with the filling aperture. Maintain this position until fill- ing operations are completed in order to avoid possible sparks caused by the accumulation of static electricity.
- 10. 4 SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1 6-62400 -- 03--2004 -- Only use specified towing points for towing the tractor, connect parts carefully. Make sure that all pins and/or locks are secured in position before applying traction. Never remain near the towing bars, cables or chains that are operating under load. -- Transport vehicles that cannot be driven using a trailer or a low--loading platform trolley, if avail- able. -- When loading or unloading the vehicle from the trailer (or other means of transport), select a flat area capable of sustaining the trailer or truck wheels, firmly secure the tractor to the truck or trailer and lock the wheels in the position. -- Electric heaters, battery--chargers and similar equipment must only be powered by auxiliary power supplies with efficient ground insulation to avoid electrical shock hazards. -- Always use suitable hoisting or lifting devices when raising or moving heavy parts. -- Take extra care if bystanders are present. -- Never pour gasoline or diesel oil into open, wide and low containers. -- Never use gasoline, diesel oil or other inflam- mable liquids as cleaning agents. Use non--in- flammable, non toxic commercially available sol- vents. -- Wear safety goggles with side guards when cleaning parts with compressed air. -- Limit the air pressure to a maximum of 2.1 bar, according to local regulations. -- Do not run the engine in confined spaces without suitable ventilation. -- Do not smoke, use naked flames, or cause sparks in the area when fuel filling or handling highly inflammable liquids. -- Never use naked flames for lighting when work- ing on the machine or checking for “leaks.” -- All movements must be carried out carefully when working under, on or near the vehicle and wear protective equipment: helmets, goggles and special footwear. -- When carrying out checks with the engine run- ning, request the assistance of an operator in the driver’s seat. The operator must maintain visual contact with the service technician at all times. -- If operating outside the workshop, position the vehicle on a flat surface and lock in position. If working on a slope, lock the vehicle in position and move to a flat area as soon as is safely poss- ible. -- Damaged or bent chains or cables areunreliable. Do not use them for lifting or towing. Always use suitable protective gloves when handling chains or cables. -- Chains should always be safely secured. Make sure that the hitch--up point is capable of sustain- ing the load in question. Keep the area near the hitch--up point, chains or cables free of all bystanders. -- Maintenance and repair operations must be car- ried out in a CLEAN and DRY area, eliminate any water or oil spillage immediately. -- Do not create piles of oil or grease--soaked rags as they represent a serious fire hazard; store them in a closed metal container. Before starting the vehicle or implements, make sure that the driver’s seat is locked in position and always check that the area is free of persons or obstacles. -- Empty pockets of all objects that may fall unob- served into the vehicle parts when disas- sembled. -- In the presence of protruding metal parts, use protective goggles or goggles with side guards, helmets, special footwear and gloves. -- When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and footwear. All persons present in the area where welding is taking place must wear tinted goggles. NEVER LOOK DIRECTLY AT THE WELDING ARC WITHOUT SUITABLE EYE PROTEC- TION. -- Metal cables tend to fray with repeated use. Al- ways use suitable protective devices (gloves, goggles, etc.) when handling cables. -- Handle all parts carefully, do not put your hands or fingers between moving parts, wear suitable safety clothing -- safety goggles, gloves and shoes.
- 11. SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1 5 6-62400 -- 03--2004 START UP -- Never start the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas extraction. -- Never bring your head, body, arms, legs, feet, hands, fingers near fans or rotating belts. ENGINE -- Always loosen the radiator cap slowly before re- moving it to allow any remaining pressure in the system to be discharged. Coolant should only be added when the engine is stopped or idling, if hot. -- Never fill up with fuel when the engine is running, especially if hot, in order to prevent the outbreak of fire as a result of fuel spillage. -- Never check or adjust fan belt tension when the engine is running. Never adjust the fuel injection pump when the ve- hicle is moving. -- Never lubricate the vehicle when the engine is running. ELECTRICAL SYSTEMS -- If it is necessary to use auxiliary batteries, re- member that both ends of the cables must be connected as follows: (+) with (+) and (--) with(--). -- Avoid short--circuiting the terminals. GAS RE- LEASED FROM BATTERIES IS HIGHLY IN- FLAMMABLE. -- During charging, leave the battery compartment uncovered to improve ventilation. -- Never check the battery charge using “jumpers” (metal objects placed on the terminals). -- Avoid sparks or flames near the battery zone to prevent explosion hazards. -- Before servicing operations, check for fuel or current leaks. Eliminate any eventual leaks be- fore starting work. -- Never charge batteries in confined spaces. Make sure that there is adequate ventilation in order to prevent accidental explosion hazards as a result of the accumulation of gases released during charging operations. -- Always disconnect the battery before performing any kind of servicing on the electrical system. HYDRAULIC SYSTEMS -- A liquid leaking from a tiny hole may be almost invisible but, at the same time, be powerful enough to penetrate the skin. Check for leaks using a piece of cardboard, NEVER USE HANDS. -- If any liquid penetrates skin tissue, call for medi- cal aid immediately. -- Serious skin infections may result if medical attention is not given. -- Use the specific tools when checking pressure values on the hydraulic system. WHEELS AND TYRES -- Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check possible damages to the rims and tyres. -- Stand away from (at the side of) the tyre when checking inflation pressure. -- Only check pressure when the tractor is un- loaded and the tyres are cold, to avoid incorrect readings as a result of over--pressure. -- Do not re--use parts of recovered wheels as in- correct welding or brazing may heat the material, causing it to weaken and eventually damage or break the wheel. -- Never cut or weld a rim mounted with an inflated tyre. -- When removing the wheels, lock both the front and rear vehicle wheels. -- Always position support stands when raising the vehicle, in order to conform to current safety re- gulations. -- Deflate the tyre before removing any object caught in the tyre tread. -- Never inflate tyres using inflammable gases; this could cause an explosion and put operator safety at risk. REMOVAL AND INSTALLATION -- Lift and handle all heavy parts using suitable lift- ing equipment and make sure that all slings and hooks are correctly secured. -- Handle all parts carefully during lifting oper- ations, keep an eye on the personnel working near the load to be lifted. Never insert hands or fingers between parts, always wear approved accident prevention clothing (goggles, gloves and work boots). -- Avoid twisting chains or metal cables and always wear safety gloves when handling cables or chains.
- 12. 6 SECTION 00 -- GENERAL GUIDELINES -- CHAPTER 1 6-62400 -- 03--2004 CONSUMABLES COMPONENT TO BE FILLED OR TOPPED UP QUANTITY litres (dm3) RECOMMENDED CASE IH PRODUCT INTERNATIONAL SPECIFICATION Cooling system: without cab: . . . . . . . . . . . . . . . . with cab: . . . . . . . . . . . . . . . . . . . 14 16 Water and antifreeze fluid 50% + 50% AKCELA PREMIUM ANTIFREEZE MS 1710 -- Windscreen washer reservoir . . . . 2 Water and liquid detergent -- Fuel tank models JX1070U, JX1080U . . mod. JX1090U, JX1100U . . . . 105 127 Decanted and filtered diesel fuel -- Engine sump: without filter: . . . . . . . . . . . . . . . with filter: . . . . . . . . . . . . . . . . . . 8,9 9,5 AKCELA fluid No 1 ENGINE OIL MS 1121 SAE 15W--40 or MS 1121 SAE 10W--30 API CH--4 ACEA E5 SAE 15W--40 API CH--4 SAE 10W--30 Brake control circuit (without front brakes) . . . . . . . . . . . . . . . . . . . . . . . 0,4 AKCELA LHM FLUID ISO 7308 Hydrostatic steering circuit . . . . . . . 2,0 Front axle: axle casing: model JX1070U . . . . . . . . . . . . . mod. JX1080U, JX1090U and JX1100U . . . . . . . . . . . . . . . . . . . final drives (each): mod. JX1070U . . . . . . . . . . . . . mod. JX1080U, JX1090U and JX1100U . . . . . . . . . . . . . . . . . . . 4,5 7,0 0,8 1,25 AKCELA NEXPLORE MAT 3525 fluid API GL4 ISO 32/46 SAE 10W--30 Rear axle (bevel drive, final drives and brakes), transmission, hydrau- lic lift, power take--off and hydro- static steering: mod. JX1070U . . . . . . . . . . . . . . . . . mod. JX1080U, JX1090U and JX1100U . . . . . . . . . . . . . . . . . . . 49 55 Front wheel hubs . . . . . . . . . . . . . . . -- AKCELA NLGI 2 Grease fittings . . . . . . . . . . . . . . . . . -- AKCELA MULTI--PURPOSE GREASE 251H EP NLGI 2
- 13. SECTION 10 -- ENGINE -- CHAPTER 1 1 6-62400 -- 03--2004 SECTION 10 -- ENGINE Chapter 1 -- Engine CONTENTS Operation Description Page General specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening torques 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine views 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication diagram 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system diagram 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault diagnosis 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 001 10 Engine R.I. 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 001 53 Engine D.A. Checks, measurements and repairs 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 70 Crankshaft front seal -- Replacement 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 102 74 Crankshaft rear seal -- Replacement 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 106 12 Valve tappet and rocker arm clearance -- Adjustment 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 218 30 Engine injector R.I. 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 246 14 Bosch injection pump R.I. Timing. Air bleed 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 10 Coolant pump R.I. 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 402 30 Thermostat valve R.I. 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 406 10 Radiator R.I. 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 414 10 Coolant pump and generator drive belts. Tension adjustment 127. . . . . . . . . . . . . . . . . . . . . .
- 14. 2 SECTION 10 -- ENGINE -- CHAPTER 1 6-62400 -- 03--2004 GENERAL SPECIFICATIONS 4 Cylinders Engine, technical type: -- model TJX1070U -- type F4CE0404D*D601 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data on page -- model JX1070U -- type F4CE0404D*D681 (BOSCH pump) See data on page -- model JX1080U-- type F4CE0404C*D601 (BOSCH pump) See data on page -- model JX1080U -- type F4CE0404C*D681 (BOSCH pump) See data on page -- model JX1090U -- type F4CE0454E*D601 (BOSCH pump) See data on page -- model JX1090U -- type F4CE0454E*D681 (BOSCH pump) See data on page -- model JX1100U -- type F4CE0454D*D601 (BOSCH pump) -- model JX1100U -- type F4CE0454D*D681 (BOSCH pump) See data on page See data on page Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4--stroke Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston diameter -- model JX1070U -- JX1080U -- JX1090U -- JX1100U . . . . . . 4.0944 in. (104 mm) Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1968 in. (132 mm) Total displacement: -- model JX1070U -- JX1080U -- JX1090U -- JX1100U . . . . . . 273.67 in3. (4485 cm3) Compression ratio for Models JX1070U -- JX1080U -- JX1090U -- JX1100U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1 Maximum power: -- model JX1070U -- type F4CE0404D*D601 . . . . . . . . . . . . . . 53 kW (70 HP) -- model JX1070U -- type F4CE0404D*D681 . . . . . . . . . . . . . . 53 kW (70 HP) -- model JX1080U -- type F4CE0404C*D601 . . . . . . . . . . . . . . 60 kW (80 HP) -- model JX1080U -- type F4CE0404C*D681 . . . . . . . . . . . . . . 60 kW (80 HP) -- model JX1090U -- type F4CE0454E*D601 . . . . . . . . . . . . . . 67 kW (90 HP) -- model JX1090U -- type F4CE0454E*D681 . . . . . . . . . . . . . . 67 kW (90 HP) -- model JX1100U -- type F4CE0454D*D601 . . . . . . . . . . . . . . -- model JX1100U -- type F4CE0454D*D681 . . . . . . . . . . . . . . 73,5 kW (100 HP) 73,5 kW (100 HP) Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 rev/min -- Maximum torque: model JX1070U -- type F4CE0404D*D601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 (Nm) -- Maximum torque: model JX1070U -- type F4CE0404D*D681 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 (Nm) -- Maximum torque: model JX1080U -- type F4CE0404C*D601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 (Nm) -- Maximum torque: model JX1080U -- type F4CE0404C*D681 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 (Nm) -- Maximum torque: model JX1090U -- type F4CE0454E*D601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 (Nm) -- Maximum torque: model JX1090U -- type F4CE0454E*D681 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 (Nm) -- Maximum torque: model JX1100U -- type F4CE0454D*D601 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Maximum torque: model JX1100U -- type F4CE0454D*D681 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 (Nm) 370 (Nm) Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rev/min Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . structural, cast iron (continued)
- 15. SECTION 10 -- ENGINE -- CHAPTER 1 3 6-62400 -- 03--2004 (cont) GENERAL SPECIFICATIONS 4 Cylinders Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with lobe pump Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 1:1 Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and filtering cartridge on delivery line Normal oil pressure with motor warmed--up at slow idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 psi (1.2 bar) at fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 psi (3.8 bar) Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation Radiator on Models JX1070U -- JX1080U -- JX1090U -- JX1100U 4 lines of vertical pipes with copper fins Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . intake, in plastic with 11 blades Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane--type Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: -- Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Middle green section (normal working conditions) . . . . . . . . . -- Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.977 coloured scale divided into 3 sections 104 to 140 °F (40° to 60 °C) 140 to 230 °F (60° to 110 °C) 230 to 248 °F (110° to 120 °C) Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via thermostat valve -- initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.0 ± 35.6 °F (81 ± 2 °C) Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight--tooth gears Intake: -- start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’ -- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’ Exhaust: -- start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64° -- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26° Valve--rocker arm clearance (with engine cold): -- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.30 ± 0.05 mm) -- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.55 ± 0.05 mm) For further timing system technical data . . . . . . . . . . . . . . . . . . . see page 8 (continued)
- 16. 4 SECTION 10 -- ENGINE -- CHAPTER 1 6-62400 -- 03--2004 (cont) GENERAL SPECIFICATIONS 4 Cylinders Fuel system Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged filter indicator with centrifugal pre--filter and automatic dust ejector Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with double diaphragm Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm . 127.6 l/h Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine timing BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor type All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic For further fuel system technical data: Fixed advance (pump setting for start of delivery before TDC) -- Pressure setting -- Injection order, and other information regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to the data for the relevant engine type in the table on page 2
- 17. SECTION 10 -- ENGINE -- CHAPTER 1 5 6-62400 -- 03--2004 FUEL SYSTEM DATA Turbo Charger: -- For versions F4CE0454D*D601 -- F4CE0454D*D681: -- type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB11H/A085BXL -- For versions F4CE0454E*D601 -- F4CE0454E*D681: -- type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB11K/A11CXL Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor with speed governor and advance regulator incorporated BOSCH pump: -- model JX1070U -- type F4CE0404D*D601 . . . . . . . . . . . . . . VE 4/12 F1250 L1023 (S/N 504073609) -- model JX1070U -- type F4CE0404D*D681 . . . . . . . . . . . . . . VE 4/12 F1250 L1023--1 (S/N 504073610) -- model JX1080U -- type F4CE0404C*D601 . . . . . . . . . . . . . . VE 4/12 F1250 L1018 (S/N 504073611) -- model JX1080U -- type F4CE0404C*D681 . . . . . . . . . . . . . . VE 4/12 F1250 L1018--1 (S/N 504073612) -- model JX1090U -- type F4CE0454E*D601 . . . . . . . . . . . . . . VE 4/12 F1250 L1024 (S/N 504073613) -- model JX1090U -- type F4CE0454E*D681 . . . . . . . . . . . . . . VE 4/12 F1250 L1024--1 (S/N 504068397) -- model JX1100U -- type F4CE0454D*D601 . . . . . . . . . . . . . . VE 4/12 F1250 L1013 (S/N 504073614) -- model JX1100U -- type F4CE0454D*D681 . . . . . . . . . . . . . . VE 4/12 F1250 L1013--1 (S/N 504068392) Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . anticlockwise Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3--4--2 (For all models) JX1070U JX1080U JX1090U JX1100U BOSCH--type injectors: -- F4CE0404D*D601 / D681 . . . . . . . . . . . . . . 504073703 DLLA 145 P 1338 -- -- -- -- F4CE0404C*D601 / D681 . . . . . . . . . . . . . . -- 504073703 DLLA 145 P 1338 -- -- -- F4CE0454E*D601 / D681 . . . . . . . . . . . . . . -- -- 500390441 DSLA 145 P 1255 -- -- F4CE0454D*D601 / D681 . . . . . . . . . . . . . . -- -- -- 500390441 DSLA 145 P 1255 Number of nozzle holes . . . . . . . . . . . . . . . . . . . 7 7 6 6 Nozzle hole diameter mm. -- F4CE0404D*D601 / D681 . . . . . . . . . . . . . . 0.162 -- -- -- -- F4CE0404C*D601 / D681 . . . . . . . . . . . . . . -- 0.162 -- -- -- F4CE0454E*D601 / D681 . . . . . . . . . . . . . . -- -- 0.237 -- -- F4CE0454D*D601 / D681 . . . . . . . . . . . . . . -- -- -- 0.237 Calibration pressure bar . . . . . . . . . . . . . . . . . . . 260 to 274 260 to 274 260 to 274 260 to 274
- 18. 6 SECTION 10 -- ENGINE -- CHAPTER 1 6-62400 -- 03--2004 CRANKCASE/CYLINDER BLOCK DATA in. (mm) Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast--iron monobloc with cylinder liners, crankshaft, camshaft and tappets Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.09944 to 4.0954 (104.000 to 104.024) Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1141 to 4.1151 (104.500 to 104.524) Main journal half bearing seat diameter external no. 1--5 3.4638 to 3.4648 (87.982 to 88.008) internalno. 2--3--4 3.4636 to 3.4650 (87.977 to 88.013) Camshaft bushing seat diameter: -- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3315 to 2.3325 (59.222 to 59.248) -- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3315 to 2.3325 (59.222 to 59.248) -- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3315 to 2.3325 (59.222 to 59.248) Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . 0.6299 to 0.6311 (16.000 to 16.030) CRANKSHAFT AND BEARINGS DATA in. (mm) Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . balanced with integral counterweights Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2671 to 3.2682 (82.987 to 83.013) Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098 to 0.0196 (0.250 -- 0.500) Main journal half bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . . 0.0966 to 0.0970 (2.456 to 2.464) Main half bearing undersizes (internal diameter) . . . . . . . . . . . . . . 0.0098 to 0.0196 (0.250 -- 0.500) Clearance between bearings and main journal no. 1--5 0.0016 to 0.0046 (0.041 to 0.119) n. 2--3--4 0.0016 to 0.0040 (0.041 to 0.103) Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7160 to 2.7170 (68.987 to 69.013) Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098 to 0.0196 (0.250 -- 0.500) Standard connecting rod half bearing thickness . . . . . . . . . . . . . . . 0.0769 to 0.0774 (1.955 to 1.968) Connecting rod half bearing undersizes (internal diameter) . . . . . 0.0098 to 0.0196 (0.250 -- 0.500) Bearing to crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012 to 0.0016 (0.033 to 0.041) Standard crankshaft thrust washer width . . . . . . . . . . . . . . . . . . . . 1.4677 to 1.4716 (37.280 to 37.380) Width of main bearing for thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0228 to 1.0425 (25.980 to 26.480) Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . 1.4753 to 1.4783 (37.475 to 37.550) Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0067 to 0.0094 (0.172 to 0.240)
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- 20. SECTION 10 -- ENGINE -- CHAPTER 1 7 6-62400 -- 03--2004 CONNECTING ROD DATA in. (mm) Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . printed in steel, oblique--cut type Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . . 1.6136 to 1.6146 (40.987 to 41.013) Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . . 1.6251 to 1.6359 (41.279 to 41.553) Interference between small end bushing and seat . . . . . . . . . . . . . 0.0104 to 0.0222 (0.266 to 0.566) Inside diameter of small end bushing (measured after fitting) . . . 1.4968 to 1.4973 (38.019 to 38.033) Diameter of big end bearing seats . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8734 to 2.8745 (72.987 to 73.013) Connecting rod--crankpin end float . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 to 0.0129 (0.100 to 0.330) in. (mm) PISTON DATA JX1070U JX1080U JX1090U JX1100U Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . light alloy with three compression rings, including two seal rings and oneincluding two seal rings and one scraper ring Standard piston diameter, measured at 2.4015 in. (61 mm) from skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . . 4.0848 to 4.0857 (103.755 to 103.779) 4.0838 to 4.0845 (103.730 to 103.748) Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0087 to 0.0105 (0.221 to 0.269) 0.0099 to 0.0115 (0.252 to 0.294) Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0196 (0.500) Piston protrusion at T.D.C. from cylinder block face . . . . . . . . . . . 0.0110 to 0.0204 (0.280 to 0.520) Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4958 to 1.4960 (37.994 to 38.000) Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . . 1.4964 to 1.4966 (38.010 to 38.016) Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0003 to 0.0008 (0.010 to 0.022) Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . . 0.0007 to 0.0015 (0.019 to 0.039) Piston ring groove depth: -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1023 to 0.1031 (2.600 to 2.620) 0.1064 to 0.1076 (2.705 to 2.735) -- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1003 to 0.1011 (2.550 to 2.570) 0.0960 to 0.0968 (2.440 to 2.460) -- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1586 to 0.1594 (4.030 to 4.050) Piston ring thickness: -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0972 to 0.0984 (2.470 to 2.500) 0.1007 to 0.1025 (2.560 to 2.605) -- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0975 to 0.0980 (2.478 to 2.490) 0.0925 to 0.0937 (2.350 to 2.380) -- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1565 to 0.1570 (3.977 to 3.990) (continued)
- 21. 8 SECTION 10 -- ENGINE -- CHAPTER 1 6-62400 -- 03--2004 (cont) in. (mm) PISTON DATA JX1070U JX1080U JX1090U JX1100U Piston ring groove clearance (measured vertically):Piston ring groove clearance (measured vertically): -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 to 0.0059 (0.100 to 0.150) 0.0039 to 0.0068 (0.100 to 0.175) -- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0023 to 0.0039 (0.060 to 0.092) 0.0023 to 0.0043 (0.060 to 0.110) -- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015 to 0.0028 (0.040 to 0.073) Assembly clearance between piston ring ends in cylinder sleeves: -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098 to 0.0216 (0.25 to 0.55) 0.0118 to 0.0157 (0.30 to 0.40) -- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 to 0.0216 (0.30 to 0.55) 0.0236 to 0.0314 (0.60 to 0.80) -- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 to 0.0216 (0.30 to 0.55) Spare piston ring oversizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0196 (0.500) VALVE TIMING GEAR DATA in. (mm) Inside diameter of camshaft bearings (fitted and reamed):Inside diameter of camshaft bearings (fitted and reamed): -- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1292 to 2.1317 (54.083 to 54.147) -- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1292 to 2.1317 (54.083 to 54.147) -- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1292 to 2.1317 (54.083 to 54.147) Diameter of camshaft journals: -- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1257 to 2.1277 (53.995 to 54.045) -- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1257 to 2.1277 (53.995 to 54.045) -- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1257 to 2.1277 (53.995 to 54.045) Clearance between camshaft journals and bushings . . . . . . . . . . 0.0014 to 0.0059 (0.038 to 0.152) Camshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0090 ± 0.0051 (0.230 ± 0.130) Crankshaft to camshaft teeth clearance . . . . . . . . . . . . . . . . . . . . . 0.0029 to 0.0110 (0.076 to 0.280) TAPPET DATA in. (mm) Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6299 to 0.6311 (16.000 to 16.030) Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . . 0.6271 to 0.6283 (15.929 to 15.959) Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 to 0.0039 (0.041 to 0.101)
- 22. SECTION 10 -- ENGINE -- CHAPTER 1 9 6-62400 -- 03--2004 ROCKER ARM -- VALVE DATA in. (mm) Rocker--arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7465 to 0.7470 (18.963 to 18.975) Rocker--arm shaft seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7480 to 0.7490 (19.000 to 19.026) Rocker arm bore to shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009 to 0.0024 (0.025 to 0.063) Valve clearance for normal running (engine cold): -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 to 0.0019 (0.300 to 0.050) -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0216 to 0.0019 (0.550 to 0.050) Cam lift: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2379 (6.045) -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2849 (7.239) CYLINDER HEAD DATA in. (mm) Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in cast iron with fitted valve seats and seats for injectors and thermostat valve Maximum face re--grinding depth that can be removed from the cylinder head in the event of reboring . . . . . . . . . . . . . . . . . . . . . . . . . 0.0051 (0.130) Diameter of valve stem seat in cylinder head . . . . . . . . . . . . . . . . . 0.3157 to 0.3164 (8.019 to 8.039) Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3133 to 0.3141 (7.960 to 7.980) Assembly clearance between valve stem and seat . . . . . . . . . . . . 0.0015 to 0.0031 (0.039 to 0.079) Valve seat angle in head: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve face angle: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Diameter on head for fitting valve seat: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8498 to 1.8509 (46.987 to 47.013) -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7178 to 1.7190 (43.637 to 43.663) Valve seat insert outside diameter: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8528 to 1.8538 (47.063 to 47.089) -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7209 to 1.7220 (43.713 to 43.739) Valve stand--in relative to cylinder head face: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0132 to 0.0422 (0.336 to 1.072) -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0434 to 0.0330 (0.104 to 0.840) Interference between valve seat and head: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0019 to 0.0040 (0.050 to 0.102) -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0019 to 0.0040 (0.050 to 0.102) (continued)
- 23. 10 SECTION 10 -- ENGINE -- CHAPTER 1 6-62400 -- 03--2004 (cont) CYLINDER HEAD DATA in. (mm) Valve head diameter:Valve head diameter: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7665 to 1.7767 (44.870 to 45.130) -- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6484 to 1.6586 (41.870 to 42.130) Inlet and exhaust valve springs: -- free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4999 (63.500) -- length under load of 329 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9299 (49.020) -- length under load of 641 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5039 (38.200) Injector protrusion relative to head face: D injectors: BOSCH DLLA 145 P 1338 -- BOSCH DSLA 145 P 1255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not adjustable