CNH Cursor 9 Service Manual
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SERVICE MANUAL Cursor® 9 Tier 4A (interim) and Stage IIIB Engine See the following page for engine model numbers Printed in U.S.A. © 2016 CNH Industrial America LLC. All Rights Reserved. Case, Case IH, New Holland, and Steyr are trademarks registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates. Part number 48076828 1st edition English November 2016 Replaces part numbers 84394558, 84394568, 84394551, 84394547 SERVICE MANUAL F2CFE613A*A, F2CFE613C*A, F2CFE613E*A, F2CFE613F*A, F2CFE613H*A, F2CFE613J*A, F2CFE613L*A026, F2CFE613L*A, F2CFE613N*A, F2CFE613P*A, F2CFE613R*A, F2CFE614A*A, F2CFE614B*A, F2CFE614C*A, F2CFE614D*A, F2CFE614E*A 48076828 09/11/2016 EN Find manuals at https://best-manuals.com Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.120] Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 Electrical systems ....................................................................... 55 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 48076828 09/11/2016 Find manuals at https://best-manuals.com [55.988] Selective Catalytic Reduction (SCR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 48076828 09/11/2016 Find manuals at https://best-manuals.com 48076828 09/11/2016 Find manuals at https://best-manuals.com INTRODUCTION 48076828 09/11/2016 1 Find manuals at https://best-manuals.com Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 48076828 09/11/2016 2 Find manuals at https://best-manuals.com INTRODUCTION Foreword Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances. Your CNH dealer can also provide assistance. Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources. • Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly. • Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere. Your CNH dealer or air-conditioning specialist has a special extractor for this purpose and can recharge the system properly. • Repair any leaks or defects in the engine cooling system or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. CNH strongly recommends that you return all used batteries to a CNH dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement. NHIL14GEN0038AA 1 Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil. Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage. Points of sale are obliged to: • Accept the return of your used batteries 48076828 09/11/2016 3 Find manuals at https://best-manuals.com INTRODUCTION • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling 48076828 09/11/2016 4 Find manuals at https://best-manuals.com INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW. FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety. Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage. 48076828 09/11/2016 5 Find manuals at https://best-manuals.com INTRODUCTION Basic instructions - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your CNH Sales and Service Networks. 48076828 09/11/2016 6 INTRODUCTION Basic instructions - Shop and Assembly 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 on 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 direction 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 or seal installation tool. 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 contact with the thrust element, if required. • to prevent damaging the seal lip on the shaft, position a protective guard during installation operations. O-RING SEALS Lubricate the O-RING seals before inserting them in the seats, this will prevent them from overturning and twisting, which would jeopardise sealing efficiency. SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or LOCTITE RTV 598 or LOCTITE® INSTANT GASKET 587 BLUE. Before applying the sealing compound, prepare the surfaces as directed on product container or as follows: • remove any incrustations using a metal brush. • thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts cleaner. SPARE PARTS Only use "CNH Original Parts" or " CNH Parts". Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same parts that are assembled during standard production. Only "CNH Original Parts" or " CNH Parts" can offer this guarantee. When ordering spare parts, always provide the following information: • machine model (commercial name) and serial number • part number of the ordered part, which can be found in the "Microfiches" or the "Service Parts Catalogue", used for order processing 48076828 09/11/2016 7 INTRODUCTION PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR WELDING To avoid damage to the electronic/electrical systems, always observe the following: 1. Never make or break any of the charging circuit connections, including the battery connections, when the engine is running. 2. Never short any of the charging components to ground. 3. Always disconnect the ground cable from the battery before arc welding on the combine or on any header attached to the combine. • position the welder ground clamp as close to the welding area as possible • if welding in close proximity to a computer module, then the module should be removed from the combine • never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress 4. Always disconnect the negative cable from the battery when charging the battery in the combine with a battery charger. NOTICE: If welding must be performed on the unit, either the combine or the header (if it is attached), the battery ground cable must be disconnected from the combine battery. The electronic monitoring system and charging system will be damaged if this is not done. Remove the battery ground cable. Reconnect the cable when welding is completed. WARNING Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetables oil. Call physician immediately. EYES: flush with water for 15 minutes and get prompt medical attention. 84-110 TOOLS The tools that CNH suggests and illustrate in this manual have been: • specifically researched and designed for use with CNH machines • 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 NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from the rear, facing in the direction of travel of the machine during operation. 48076828 09/11/2016 8 INTRODUCTION Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE M4 M5 M6 M8 CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr 2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in) 3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 lb in) M10 37 N·m (27 lb ft) M12 64 N·m (47 lb ft) M16 M20 M24 158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft) 2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft) 52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft) 4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 lb ft) LOCKNUT CL.8 W/CL8.8 BOLT 2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft) LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft) NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet. 48076828 09/11/2016 9 INTRODUCTION METRIC FLANGED HARDWARE NOM. SIZE CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr UNPLATED M4 M5 M6 M8 2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in) M10 40 N·m (30 lb ft) M12 70 N·m (52 lb ft) M16 M20 M24 174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft) 3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft) CLASS 10.9 BOLT and CLASS 10 NUT UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft) 4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft) Metric Hex head and carriage bolts, classes 5.6 and up 1 1. Manufacturer's Identification 2. Property Class Metric Hex nuts and locknuts, classes 05 and up 20083681 2 48076828 09/11/2016 10 LOCKNUT CL.10 W/CL10.9 BOLT 2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in) 3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) PLATED W/ZnCr IDENTIFICATION 20083680 LOCKNUT CL.8 W/CL8.8 BOLT 37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft) 226 N·m (167 lb ft) 440 N·m (325 lb ft) INTRODUCTION 1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8. INCH NON-FLANGED HARDWARE NOMINAL SIZE SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 SAE GRADE 8 BOLT and NUT UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER LOCKNUT GrB W/ Gr5 BOLT LOCKNUT GrC W/ Gr8 BOLT PLATED W/ZnCr GOLD 12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft) 12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in) 8.5 N·m (75 lb in) 31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft) NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet. 48076828 09/11/2016 11 INTRODUCTION INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE PLATED UNPLATED PLATED UNPLATED W/ZnCr or PLATED W/ZnCr or PLATED GOLD SILVER GOLD SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft) LOCKNUT GrF W/ Gr5 BOLT 12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft) LOCKNUT GrG W/ Gr8 BOLT 12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft) IDENTIFICATION Inch Bolts and free-spinning nuts 20083682 3 Grade Marking Examples 1 2 3 Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120 ° Apart 6 Grade 8 Nut - Marks 60 ° Apart 48076828 09/11/2016 12 INTRODUCTION Inch Lock Nuts, All Metal (Three optional methods) 20090268 4 Grade Identification Grade Grade A Grade B Grade C Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches Flats Marking Method (2) No Mark Letter B Letter C 48076828 09/11/2016 13 Clock Marking Method (3) No Marks Three Marks Six Marks CONSUMABLES INDEX Consumable Loctite RTV 598 Loctite® Instant Gasket 587 Blue Reference Basic instructions - Shop and Assembly Basic instructions - Shop and Assembly 48076828 09/11/2016 14 PAGE 7 7 SERVICE MANUAL Engine F2CFE613A*A, F2CFE613C*A, F2CFE613E*A, F2CFE613F*A, F2CFE613H*A, F2CFE613J*A, F2CFE613L*A026, F2CFE613L*A, F2CFE613N*A, F2CFE613P*A, F2CFE613R*A, F2CFE614A*A, F2CFE614B*A, F2CFE614C*A, F2CFE614D*A, F2CFE614E*A 48076828 09/11/2016 10 Contents Engine - 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.120] Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18 48076828 09/11/2016 10 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 48076828 09/11/2016 10 CONSUMABLES INDEX Consumable Loctite® 5970™ Loctite® 5970™ Loctite® 5970™ Loctite® SI 598™ Black Loctite® SI 598™ Black Loctite® 5970™ Loctite® 5970™ Mobilux® EP 023 Mobilux® EP 023 Molykote® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® DEF/AdBlue® Diesel Exhaust Fluid (DEF)/AdBlue® Loctite® 243™ Loctite® 243™ Reference PAGE Engine oil pan - Install Engine oil pan - Install Engine block cover Front - Install Engine block cover Rear - Install Engine block cover Rear - Install - Narrow gear housing Camshaft - Install High pressure pump - Install Common rail Relief valve - Install Common rail Relief valve - Install Turbocharger - Install Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid Diesel Exhaust Fluid 10.3 / 6 10.3 / 6 10.3 / 10 10.3 / 12 10.3 / 14 10.4 / 11 10.12 / 17 10.12 / 25 10.12 / 25 10.13 / 6 10.15 / 4 10.15 / 4 10.15 / 4 10.15 / 4 10.15 / 4 10.15 / 4 10.15 / 4 10.15 / 5 10.15 / 5 10.15 / 5 10.15 / 5 10.15 / 7 Crankcase ventilation system - Install Crankcase ventilation system - Install 10.18 / 23 10.18 / 23 48076828 09/11/2016 10 Engine - 10 Engine and crankcase - 001 F2CFE613A*A, F2CFE613C*A, F2CFE613E*A, F2CFE613F*A, F2CFE613H*A, F2CFE613J*A, F2CFE613L*A026, F2CFE613L*A, F2CFE613N*A, F2CFE613P*A, F2CFE613R*A, F2CFE614A*A, F2CFE614B*A, F2CFE614C*A, F2CFE614D*A, F2CFE614E*A 48076828 09/11/2016 10.1 [10.001] / 1 Contents Engine - 10 Engine and crankcase - 001 TECHNICAL DATA Engine Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FUNCTIONAL DATA Engine Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SERVICE Engine Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Crankcase Liner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Liner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Liner - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Liner - Measure Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 48076828 09/11/2016 10.1 [10.001] / 2 Engine - Engine and crankcase Engine - Service limits Engine specifications Compression ratio Bore Stroke Cylinder spacing Displacement Turbocharging Lubrication Oil pressure (Warm engine) - Idling - Peak RPM Cooling Water pump control Thermostat (Start of opening) Intake valve timing - Opens before TDC - Closes after BDC Exhaust valve timing - Opens before BDC - Closes after TDC Valve lash setting (when engine is cold) - Intake - Exhaust (with brake and/or camshaft 504326209) - Exhaust (without brake) Firing Order Injection pressure Injector calibration Cylinder block and piston Cylinder liner bore - Upper - Lower Cylinder liner external diameter - Upper - Lower Clearance between the OD of liners and ID of bores - Upper - Lower Cylinder liner - ID A* - ID B* * Selection class - Protrusion Pistons - Measuring dimension - External diameter (supplied as spares) - External diameter (production only) - Pin bore OD of piston - ID of cylinder liner Piston protrusion Piston pin diameter 15.9:1 117 mm (4.6 in) 135 mm (5.3 in) 138 mm (5.4 in) 8710 cm³ Inter-cooled, Direct injection Forced by gear pump, relief valve single action oil filter 4 bar (58 psi) 5 bar (73 psi) Liquid cooled Belt driven 83.5 - 86.5 °C (182.3 - 187.7 °F) 17 ° 31 ° 48 ° 9° 0.4 mm (0.016 in) 0.4 mm (0.016 in) 0.6 mm (0.024 in) 1-4-2-6-3-5 1800 bar (26100 psi) 290 - 302 bar (4205 - 4379 psi) 130.500 - 130.525 mm (5.138 - 5.139 in) 129.510 - 129.535 mm (5.099 - 5.100 in) 130.461 - 130.486 mm (5.136 - 5.137 in) 129.475 - 129.500 mm (5.097 - 5.098 in) 0.014 - 0.064 mm (0.001 - 0.003 in) 0.010 - 0.060 mm (0.0004 - 0.0024 in) 117.000 - 117.012 mm (4.606 - 4.607 in) 117.010 - 117.022 mm (4.607 - 4.607 in) 0.035 - 0.065 mm (0.001 - 0.003 in) 15 mm (0.591 in) 116.894 - 116.906 mm (4.602 - 4.603 in) 116.904 - 116.916 mm (4.603 - 4.603 in) 52.016 - 52.022 mm (2.048 - 2.048 in) 0.094 - 0.118 mm (0.004 - 0.005 in) 0.873 - 1.117 mm (0.034 - 0.044 in) 51.994 - 52.000 mm (2.047 - 2.047 in) 48076828 09/11/2016 10.1 [10.001] / 3 Engine - Engine and crankcase Piston pin OD - pin bore Piston ring grooves - Top - Middle - Bottom Piston rings - Combustion ring - Intermediate ring - Oil control ring Clearance between piston rings and grooves - Combustion ring - Intermediate ring - Oil control ring Piston ring end gap in cylinder liners - Combustion ring - Intermediate ring - Oil control ring Connecting rod Small end bush housing - Nominal Big end bearing housing - Nominal - Class 1 - Class 2 - Class 3 Small end bushing diameter - Outside - Inside Big end bearing shell thickness - Red - Green - Yellow Clearance between small end bush and housing Clearance between piston pin and bushing Connecting rod weight - Class A - Class B - Class C Maximum connecting rod axis misalignment tolerance Crankshaft Main journals - Rated value - Class 1 - Class 2 - Class 3 Crankpins - Rated value - Class 1 - Class 2 - Class 3 Main bearing shells - Red - Green - Yellow 0.016 - 0.028 mm (0.0006 - 0.0011 in) 2.582 - 2.716 mm (0.102 - 0.107 in) 2.550 - 2.570 mm (0.100 - 0.101 in) 4.02 - 4.04 mm (0.158 - 0.159 in) 2.429 - 2.473 mm (0.096 - 0.097 in) 2.470 - 2.500 mm (0.097 - 0.098 in) 3.970 - 3.990 mm (0.156 - 0.157 in) 0.109 - 0.287 mm (0.004 - 0.011 in) 0.050 - 0.100 mm (0.002 - 0.004 in) 0.030 - 0.070 mm (0.001 - 0.003 in) 0.3 - 0.4 mm (0.012 - 0.016 in) 0.60 - 0.75 mm (0.024 - 0.030 in) 0.35 - 0.65 mm (0.014 - 0.026 in) 55.700 - 55.730 mm (2.193 - 2.194 in) 85.987 85.987 85.997 86.006 - 86.013 mm 85.996 mm 86.005 mm 86.013 mm (3.385 (3.385 (3.386 (3.386 - 3.386 in) 3.386 in) 3.386 in) 3.386 in) 55.780 - 55.820 mm (2.196 - 2.198 in) 52.015 - 52.030 mm (2.048 - 2.048 in) 1.994 - 2.002 mm (0.079 - 0.079 in) 2.002 - 2.010 mm (0.079 - 0.079 in) 2.010 - 2.018 mm (0.079 - 0.079 in) 0.05 - 0.12 mm (0.002 - 0.005 in) 0.015 - 0.036 mm (0.001 - 0.001 in) 3308 - 3338 g (116.7 - 117.7 oz) 3339 - 3368 g (117.8 - 118.8 oz) 3369 - 3398 g (118.8 - 119.9 oz) 0.08 mm (0.003 in) 92.970 92.970 92.980 92.990 - 93.000 mm 92.979 mm 92.989 mm 93.000 mm (3.6602 (3.6602 (3.6606 (3.6610 - 81.915 81.915 81.925 81.935 - 81.945 mm 81.924 mm 81.934 mm 81.945 mm (3.225 (3.225 (3.225 (3.226 3.226 in) 3.225 in) 3.226 in) 3.226 in) - 3.6614 in) 3.6606 in) 3.6610 in) 3.6614 in) 2.968 - 2.978 mm (0.117 - 0.117 in) 2.978 - 2.988 mm (0.117 - 0.118 in) 2.988 - 2.998 mm (0.118 - 0.118 in) 48076828 09/11/2016 10.1 [10.001] / 4 Engine - Engine and crankcase Big end bearing shells - Red - Green - Yellow Main bearing housings - Rated value - Class 1 - Class 2 - Class 3 Clearance between bearing shells and main journals Clearance between bearing shells and big ends Main journal, thrust bearing Main bearing housing, thrust bearing Thrust bearing thickness Crankshaft end play Main journals and Crankpins - Alignment - Ovalization - Taper Cylinder head and valve train Valve guide housing in cylinder head Valve guide - Inside diameter - Outside diameter Valve guides - housings in the cylinder head Intake valves - Valve stem diameter - Valve face angle Exhaust valves - Valve stem diameter - Valve face angle Clearance between valve guide and valve stem Valve seat in cylinder head - Intake - Exhaust Outside diameter of valve seat - Intake - Exhaust Valve seat angle - Intake - Exhaust Recessing of the valves - Intake - Exhaust Clearance between valve seat and cylinder head - Intake - Exhaust Valve spring height at No load 437 - 483 N (98 - 109 lb) load 707 - 773 N (159 - 174 lb) load Injector protrusion Camshaft bushing housing in the cylinder head 1.994 - 2.002 mm (0.079 - 0.079 in) 2.002 - 2.010 mm (0.079 - 0.079 in) 2.010 - 2.018 mm (0.079 - 0.079 in) 99.000 - 99.030 mm (3.8976 - 3.8988 in) 99.000 - 99.009 mm (3.8976 - 3.8980 in) 99.010 - 99.019 mm (3.8980 - 3.8984 in) 99.020 - 99.030 mm (3.8984 - 3.8988 in) 0.050 - 0.090 mm (0.0020 - 0.0035 in) 0.040 - 0.080 mm (0.0016 - 0.0031 in) 32.94 - 32.99 mm (1.297 - 1.299 in) 38.94 - 38.99 mm (1.533 - 1.535 in) 3.38 - 3.43 mm (0.133 - 0.135 in) 0.09 - 0.34 mm (0.004 - 0.013 in) 0.04 mm (0.002 in) 12.980 - 12.997 mm (0.511 - 0.512 in) 8.023 - 8.038 mm (0.316 - 0.316 in) 13.012 - 13.025 mm (0.512 - 0.513 in) 0.015 - 0.045 mm (0.0006 - 0.0018 in) 7.970 - 7.985 mm (0.314 - 0.314 in) 60 ° 7.970 - 7.985 mm (0.314 - 0.314 in) 45 ° 0.040 - 0.070 mm (0.0016 - 0.0028 in) 41.985 - 42.020 mm (1.653 - 1.654 in) 40.985 - 41.020 mm (1.614 - 1.615 in) 42.060 - 42.075 mm (1.656 - 1.656 in) 42.060 - 42.075 mm (1.656 - 1.656 in) 60 ° 45 ° 0.5 - 0.8 mm (0.020 - 0.031 in) 1.6 - 1.9 mm (0.063 - 0.075 in) 0.040 - 0.090 mm (0.0016 - 0.0035 in) 0.040 - 0.090 mm (0.0016 - 0.0035 in) 70.77 mm (2.786 in) 51.00 mm (2.008 in) 39.00 mm (1.535 in) 1.2 - 1.5 mm (0.047 - 0.059 in) 69.000 - 69.030 mm (2.717 - 2.718 in) 48076828 09/11/2016 10.1 [10.001] / 5 Engine - Engine and crankcase Camshaft bearing journals O.D. of the camshaft bushings I.D. of the camshaft bushings Clearance between bushings and housings in the cylinder head Clearance between bushings and bearing journals Cam lift - Intake lobe - Exhaust lobe Diameter of the rocker shaft Bushing housing in the rocker arms - Intake - Exhaust Clearance between bushings and housings - Intake - Exhaust - Injector Clearance between bushings of rocker arms and shaft - Intake - Exhaust 64.924 - 64.940 mm (2.556 - 2.557 in) 69.090 - 69.130 mm (2.720 - 2.722 in) 65.080 - 65.116 mm (2.562 - 2.564 in) 0.060 - 0.115 mm (0.002 - 0.005 in) 0.050 - 0.122 mm (0.002 - 0.005 in) 7.4034 mm (0.2915 in) 8.2108 mm (0.3233 in) 31.964 - 31.980 mm (1.258 - 1.259 in) 32.025 - 32.041 mm (1.261 - 1.261 in) 32.025 - 32.041 mm (1.261 - 1.261 in) 0.074 - 0.130 mm (0.0029 - 0.0051 in) 0.081 - 0.140 mm (0.0032 - 0.0055 in) 0.050 - 0.091 mm (0.0020 - 0.0036 in) 0.045 - 0.077 mm (0.002 - 0.003 in) 0.045 - 0.077 mm (0.002 - 0.003 in) 48076828 09/11/2016 10.1 [10.001] / 6 Engine - Engine and crankcase Engine - Detailed view NHIL13ENG1011FA 1 Left-hand side view NHIL13ENG1019FA 2 Right-hand side view 48076828 09/11/2016 10.1 [10.001] / 7 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com ">

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