This document is a service manual that provides information for servicing and repairing engines that meet Tier 4 (final) and Tier 4B (final) emissions standards. It lists many engine model numbers and components that are covered, and provides sections on the engine, electrical systems, safety procedures, and basic instructions for tasks like shimming and installing seals. The document aims to ensure repairs are performed correctly and safely by qualified technicians.
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This document provides a service manual for various parts of a lift truck, including:
1) The frame, which consists of a main frame and other weldments that support components like the counterweight, overhead guard, hood, and seat.
2) The overhead guard, which fastens to the main frame and cowl to protect the operator from falling objects.
3) Covers for components like the instrument panel and control valve.
It describes the purpose and construction of these parts and provides diagrams to illustrate their assembly. Procedures for removing parts like the traction motor are also included.
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1) A table of contents listing the document sections by part number, section number, revision date.
2) A description of the forklift frame that includes the hydraulic tank, fuel tank, counterweight, overhead guard, hood, and covers. Safety procedures are provided for when putting the forklift on blocks for maintenance.
3) Instructions for removing the hood, seat, and side covers to access components like the engine and transmission.
Yale (d875) glpo060 vx lift truck service repair manualfjskekmsemmwe
The document provides instructions for removing an operator cab from a forklift. Key steps include:
1. Tilting the steering column, sliding the seat forward, opening rear doors/windows, and disconnecting the battery.
2. Disconnecting air filter hoses, radiator hoses, heater hoses, electrical connections, and removing doors.
3. Removing fasteners securing various cab components like the dash, kick panel, and seal plate.
4. Disconnecting remaining electrical and removing panels/covers to access mounting hardware.
5. Using lifting equipment connected through the cab door openings, carefully lifting the cab off the forklift frame.
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Yale (c875) gp60 vx lift truck service repair manualfjskekmsemmwe
The document provides instructions for removing an operator cab from various lift truck models. Key steps include:
1. Tilting the steering column, sliding the seat forward, and opening doors/windows to access components.
2. Disconnecting the air filter hose, radiator cap, and heater hoses from the engine.
3. For models with air conditioning, extracting refrigerant from the system and disconnecting AC lines.
4. Removing fasteners to separate the cab from the lift truck frame. The cab can then be removed as a complete unit for replacement or repair.
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This document provides a service manual for various parts of a lift truck, including:
1) The frame, which consists of a main frame and other weldments that support components like the counterweight, overhead guard, hood, and seat.
2) The overhead guard, which fastens to the main frame and cowl to protect the operator from falling objects.
3) Covers for components like the instrument panel and control valve.
It describes the purpose and construction of these parts and provides diagrams to illustrate their assembly. Procedures for removing parts like the traction motor are also included.
Yale b875 glp060 vx lift truck service repair manualfjskekmsemmwe
This document is a service manual that contains sections on repairing various components of a forklift. It provides:
1) A table of contents listing the document sections by part number, section number, revision date.
2) A description of the forklift frame that includes the hydraulic tank, fuel tank, counterweight, overhead guard, hood, and covers. Safety procedures are provided for when putting the forklift on blocks for maintenance.
3) Instructions for removing the hood, seat, and side covers to access components like the engine and transmission.
Yale (d875) glpo060 vx lift truck service repair manualfjskekmsemmwe
The document provides instructions for removing an operator cab from a forklift. Key steps include:
1. Tilting the steering column, sliding the seat forward, opening rear doors/windows, and disconnecting the battery.
2. Disconnecting air filter hoses, radiator hoses, heater hoses, electrical connections, and removing doors.
3. Removing fasteners securing various cab components like the dash, kick panel, and seal plate.
4. Disconnecting remaining electrical and removing panels/covers to access mounting hardware.
5. Using lifting equipment connected through the cab door openings, carefully lifting the cab off the forklift frame.
Yale (d849) mr25 lift truck service repair manualfjskekmsemmwe
This document provides technical information and guidelines for Yale service centers. It contains sections on product presentation, installation, diagnostics, electrical and hydraulic systems, mechanics, maintenance, and safety. Symbols are defined to identify hazards, important notes, and disposal instructions. General safety rules are outlined regarding personal protective equipment, workplace safety, batteries, welding, lifting, and more. Tables provide torque settings, belt and rope load capacities, and suspension element load capacities. Technicians are instructed to follow procedures carefully to properly service equipment and avoid damage or injury.
Yale (c875) gp60 vx lift truck service repair manualfjskekmsemmwe
The document provides instructions for removing an operator cab from various lift truck models. Key steps include:
1. Tilting the steering column, sliding the seat forward, and opening doors/windows to access components.
2. Disconnecting the air filter hose, radiator cap, and heater hoses from the engine.
3. For models with air conditioning, extracting refrigerant from the system and disconnecting AC lines.
4. Removing fasteners to separate the cab from the lift truck frame. The cab can then be removed as a complete unit for replacement or repair.
Yale (b910) glc050 vx lift truck service repair manualfjskekmsemmwe
This service manual provides information on servicing and repairing various models of GC/GLC lift trucks. The document outlines procedures for removing and installing components like the counterweight, hood, overhead guard, engine, transmission, and covers. It contains sections on the frame description, removing the hood and seat, and replacing side covers. Safety warnings are provided, and diagrams show the locations of parts. Repair sections cover topics such as the cooling system, fuel systems, mast, cylinders, and electrical systems.
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Discover innovative uses of Revit in urban planning and design, enhancing city landscapes with advanced architectural solutions. Understand how architectural firms are using Revit to transform how processes and outcomes within urban planning and design fields look. They are supplementing work and putting in value through speed and imagination that the architects and planners are placing into composing progressive urban areas that are not only colorful but also pragmatic.
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Volvo bl70 b backhoe loader service repair manualfjskekmsemmwe
This document provides information on a Volvo BL70B backhoe loader, including:
- It has a 4-cylinder turbocharged diesel engine meeting EPA Tier 3 standards.
- It has either a mechanical transmission or optional automatic Powershift transmission.
- The electrical system is 12V and monitored by a vehicle electronic control unit.
- Safety instructions warn to always follow the operator's manual and use genuine parts.
Perkins 2300 series 2306 a e14 6 cylinder turbocharged diesel engine service ...fjskekmsemmwe
This document provides a workshop manual for Perkins 2300 Series diesel engines, including models 2306A-E14 and 2306C-E14. It contains specifications, repair and maintenance instructions across 16 chapters covering the engine systems. The manual is intended to assist technicians in servicing and repairing these engine models. It includes detailed instructions, specifications, and torque values for repairing and replacing engine components.
Perkins 400 series 402 d 403d 404d industrial engine (model gg) service repai...fjskekmsemmwe
This document provides instructions for disassembling and assembling various components of Perkins 402D-403D-404D industrial diesel engines, including removal and installation procedures for items like the fuel filter base, fuel transfer pump, fuel lines, fuel injection pump, turbocharger, valves, pistons, bearings, and other parts. Safety warnings are provided to prevent injury when performing maintenance on these engines.
Komatsu d375 a 6 dozer bulldozer service repair manual sn 60001 and upfjskekmsemmwe
This document is a shop manual for a D375A-6 Bulldozer with serial numbers 60001 and up. The manual contains specifications, component diagrams, and maintenance procedures. It includes sections on the engine and cooling system, power train, undercarriage, frame, hydraulic system, and work equipment control. The table of contents lists these sections and their corresponding page numbers for locating information in the manual.
Kioti daedong dx7510 tractor service repair manualfjskekmsemmwe
This document is a workshop manual that provides safety information for servicing DX7510/DX9010/DX100 tractors. It contains 13 chapters covering topics like safety, general information, engines, transmissions, and more. The manual stresses the importance of reading it fully before working on the tractors and outlines many safety precautions to prevent injuries. These include wearing proper protective gear, avoiding fires, being cautious around batteries and high pressure systems, and more. It also identifies safety symbols used in the manual.
Kioti daedong dk651 tractor service repair manualfjskekmsemmwe
This workshop manual provides service information for KIOTI tractors models DK651/751/801/901. The manual is divided into sections on mechanism, servicing, and safety. It contains specifications, maintenance checklists, lubrication charts, and troubleshooting guides to aid servicing personnel in repairing and maintaining the tractors. Safety warnings and precautions are provided throughout to prevent injury and equipment damage.
Jcb vm115 hpd smooth drum roller service repair manualfjskekmsemmwe
This document provides information about service tools and consumables for a JCB machine. It includes a list of common sealing and retaining compounds with their part numbers and intended uses. Torque specifications are also included for fasteners and hydraulic connections on the machine. The document is the service manual for JCB VM range machines, and provides sections covering general information, safety, maintenance, and repair of specific systems like the body, electrics, engine, and more.
Jcb vibromax 455 tandem roller service repair manualfjskekmsemmwe
This service manual provides information on Vibromax 355/365, 455/465 tandem rollers. Section one includes general machine descriptions, safety guidelines, specifications, fluid capacities and maintenance procedures. Section two covers engine removal, installation and overhaul. Section three reviews electrical systems such as starting, charging, instrumentation and controls. Section four details hydraulic propulsion systems and diagnostics.
2013 kawasaki zx1400 ed service repair manualfjskekmsemmwe
This document provides model and frame number information for Kawasaki motorcycles from 2012-2013. It includes a table listing the model years, models, and beginning frame numbers. It also notes that the digit in the frame number marked with "□" changes for each machine. The rest of the document is a service manual for the ZZR1400 ABS motorcycle and includes sections on general information, maintenance, fuel system, engine, and more. It provides instructions and specifications for repairing and servicing the vehicle.
2013 kawasaki zr1000 dd service repair manualfjskekmsemmwe
This service manual provides information to assist mechanics in locating specific topics or procedures for servicing a Z1000 motorcycle. It contains sections on general information, maintenance, fuel and cooling systems, engine, wheels, brakes, suspension, electrical systems and more. Mechanics should use the manual's tabs and tables of contents to navigate efficiently to the appropriate section for the service needed. The manual is designed for use by trained mechanics but also contains basic information for owners to service their own motorcycle.
2012 polaris sportsman 500 ho service repair manualfjskekmsemmwe
This document provides specifications and information for various 2012 Polaris Sportsman vehicles, including the 400 HO, 500 HO, 500 Touring HO, and 500 EFI Tractor. It includes details on the vehicle dimensions, engine, drivetrain, suspension, brakes, electrical system, and jetting recommendations. Identification numbers for the vehicle, engine, and transmission are also outlined. Technical charts with torque specifications, drill sizes, and conversions are presented at the end.
2012 kawasaki zx1000 jc service repair manualfjskekmsemmwe
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2012 kawasaki ninja 1000 zx1000 hc service repair manualfjskekmsemmwe
The document provides a model application guide for various Kawasaki motorcycle models between 2011-2013. It lists the year, model, and beginning frame number for each bike. It also notes that the frame numbers differ by one digit between machines.
2012 kawasaki ex650 ec service repair manualfjskekmsemmwe
This document provides information about motorcycle models and service manuals. It lists the year, model, and frame numbers for 2012 EX650 and ER-6f motorcycles. It also includes sections about tampering prohibitions and lists abbreviations used in service manuals. The summary provides an overview of the content and purpose of the document without copying significant text.
2011 polaris ranger rzr 4 eps atv service repair manualfjskekmsemmwe
This document is a service manual for Polaris Ranger RZR vehicles from 2011. It contains 10 chapters that cover general information, maintenance, the engine, fuel injection, body/steering/suspension, clutching, final drive, transmission, brakes, and electrical systems. The general information chapter includes specifications, component locations, fluid types and capacities, and other technical details about the vehicles.
2009 subaru legacy 4 service repair manualfjskekmsemmwe
- The manuals provide specifications and maintenance information for 2009 Legacy models with 2.5L SOHC, 2.5L DOHC turbo, and 3.0L DOHC engines.
- The documents describe vehicle dimensions, engine specifications, electrical components, transmission types, steering, suspension, brakes, tire sizes, and capacities.
- Symbols are used to indicate replacement parts, tightening torques, lubrication points, and other details for repairs.
2008 polaris 800 dragon rmk snowmobile service repair manualfjskekmsemmwe
The document provides specifications for various 2007-2008 Polaris snowmobile models including the 600 HO IQ, 600 HO Switchback, 700 HO IQ Dragon, and 800 Dragon RMK. It includes details on the engine, carburetor settings, clutch settings, dimensions, capacity, electrical system, track, suspension and other technical details. The specifications are organized by model and include information needed for service and maintenance of these snowmobiles.
2008 kawasaki kvf750 e8fa service repair manualfjskekmsemmwe
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Discover innovative uses of Revit in urban planning and design, enhancing city landscapes with advanced architectural solutions. Understand how architectural firms are using Revit to transform how processes and outcomes within urban planning and design fields look. They are supplementing work and putting in value through speed and imagination that the architects and planners are placing into composing progressive urban areas that are not only colorful but also pragmatic.
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6. INTRODUCTION
Foreword - 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 manu-
facturer, 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 manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CNH Sales and Service Networks.
47606132 25/08/2014
3
7. 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 you will find the signal words DANGER, WARNING, and CAUTION followed by special in-
structions. 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 that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
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 that 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.
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8. INTRODUCTION
Safety rules - Ecology and the environment
Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that may be of assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these
substances.
• Agricultural consultants will, in many cases, be able to help you as well.
Helpful hints
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them 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 draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper
way to comply with 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 will have to recharge the
system properly.
• Repair any leaks or defects in the engine cooling or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of
oils, coolant, etc.
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9. 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
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10. INTRODUCTION
Protecting the electronic/electrical system 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 burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A
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.
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11. INTRODUCTION
Basic instructions - Shop and assembly
Shimming
For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a microm-
eter, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or
the rated value shown on each shim.
Rotating shaft seals
For correct rotating shaft seal installation, proceed as follows:
1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
3. Position the sealing lip facing the fluid.
NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that
they will move the fluid towards the inner side of the seal.
4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
5. 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.
6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that
the seal makes contact with the thrust element, if required.
7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts or CNH Original 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 Original Parts can offer this
guarantee.
When ordering spare parts, always provide the following information:
• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
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12. INTRODUCTION
Protecting the electronic and/or electrical systems during charging and welding
To avoid damage to the electronic and/or electrical systems, always observe the following practices:
1. Never make or break any of the charging circuit connections when the engine is running, including the battery
connections.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine
attachment.
• Position the welder ground clamp as close to the welding area as possible.
• If you weld in close proximity to a computer module, then you should remove the module from the machine.
• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you
weld.
4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery
charger.
NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.
The electronic monitoring system and charging system will be damaged if this is not done.
5. Remove the battery ground cable. Reconnect the cable when you complete welding.
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A
Special tools
The special tools that CNH suggests and illustrate in this manual have been specifically researched and designed for
use with CNH machines. The special tools are essential for reliable repair operations. The special tools are accurately
built and rigorously tested 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
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18. Engine - Engine and crankcase
Engine - General specification
General specifications
Engine type 4 Cylinders 6 Cylinders
Cycle Four-Stroke diesel engine
Power Turbocharged with intercooler
Injection Direct
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total displacement 4485 cm³ 6728 cm³
Timing
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start before B.D.C. 67 °
End after T.D.C. 35 °
Valve clearance
Intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Fuel feed
Injection type Bosch high pressure common rail
Control EDC17 CV41
Injector CRIN 2
Nozzle type DLLA
Injection sequence 1-3-4-2 1-5-3-6-2-4
Injection pressure 250 - 1600 bar (3625 - 23200 psi)
Aspiration
Turbocharging Intercooled
Turbocharger type Honeywell GT25 Holset HX35
Lubrication
Oil pressure @ low idle 0.7 bar (10 psi)
Oil pressure @ fast idle 3.5 bar (51 psi)
Oil pan capacity 15 l (15.85 US qt)
Oil filter capacity 1 l (1.06 US qt)
Cooling
Water pump Belt driven
Thermostat 79 - 83 °C (174 - 181 °F)
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19. Engine - Engine and crankcase
Clearance data
Cylinder block and crankshaft components
Cylinder barrels 104.000 - 104.024 mm (4.094 - 4.095 in)
Oversize 0.4 mm (0.016 in)
Pistons 103.739 - 103.757 mm (4.084 - 4.085 in) (*)
Skirt height 49.5 mm (1.949 in) (*)
Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Piston (oversize) 0.4 mm (0.016 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Piston pin - Pin housing 0.01 - 0.022 mm (0.0004 - 0.001 in)
Piston ring landings
Combustion 2.705 - 2.735 mm (0.106 - 0.108 in)
Intermediate 2.420 - 2.440 mm (0.095 - 0.096 in) (*)
Oil control 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston rings
Combustion 2.560 - 2.605 mm (0.101 - 0.103 in)
Intermediate 2.350 - 2.380 mm (0.093 - 0.094 in)
Oil control 3.970 - 3.990 mm (0.156 - 0.157 in)
Piston ring and ring landing clearance
Combustion 0.100 - 0.175 mm (0.004 - 0.007 in)
Intermediate 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*)
Oil control 0.040 - 0.080 mm (0.002 - 0.003 in)
Piston ring end gap
Combustion 0.30 - 0.40 mm (0.012 - 0.016 in)
Intermediate 0.60 - 0.80 mm (0.024 - 0.031 in)
Oil control 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting rod
Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in)
Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in)
Small end bushing inside
diameter
38.019 - 38.033 mm (1.497 - 1.497 in)
Big end bearing shell
thickness
1.955 - 1.968 mm (0.077 - 0.077 in)
Piston pin and bushing
clearance
0.019 - 0.039 mm (0.001 - 0.002 in)
Oversize big end bearing
shells
0.250 mm (0.010 in) ; 0.500 mm (0.020 in)
Crankshaft
Main journals 82.99 - 83.01 mm (3.267 - 3.268 in)
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
Main bearing shell thickness 2.456 - 2.464 mm (0.097 - 0.098 in)
Big end bearing shell
thickness
1.955 - 1.968 mm (0.077 - 0.078 in)
Main bearing bore
No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
Bearing shell and journal clearance
No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
Bearing shell and crankpin
clearance
0.033 - 0.041 mm (0.001 - 0.002 in)
Thrust journal 37.475 - 37.545 mm (1.475 - 1.478 in)
Thrust bearing bore 32.180 - 32.280 mm (1.267 - 1.271 in)
Thrust bearing 37.28 - 37.38 mm (1.468 - 1.472 in)
Crankshaft end play 0.095 - 0.265 mm (0.004 - 0.010 in)
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20. Engine - Engine and crankcase
Clearance data
Cylinder head and components
Valve guide bore 7.042 - 7.062 mm (0.277 - 0.278 in)
Intake valves
Stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Face angle 59.75 - 60.25 °
Exhaust valves
Stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Face angle 44.75 - 44.25 °
Valve stem and guide clearance 0.052 - 0.092 mm (0.002 - 0.004 in)
Valve seat bore
Intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
Valve seat outside diameter:
Intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve seat angle
Intake 60 °
Exhaust 45 °
Valve sink
Intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Interference between valve seat and cylinder head
Intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve spring height
Free 47.75 mm (1.880 in)
Under a load equal to:
330.8 - 348.8 N (74.4 -
78.4 lb)
35.33 mm (1.391 in)
Under a load equal to:
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft bore
No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in)
No. 2,3,4,5 / 2,3,4,5,6,7 54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in)
Bushing and journal clearance 0.038 - 0.162 mm (0.001 - 0.006 in)
Cam lift
Intake 7.582 mm (0.299 in)
Exhaust 6.045 mm (0.238 in)
Tappet bore 16.000 - 16.030 mm (0.630 - 0.631 in)
Tappet outside diameter
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Middle 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Tappets and bore clearance 0.025 - 0.070 mm (0.001 - 0.003 in)
Rocker shaft 21.965 - 21.977 mm (0.865 - 0.865 in)
Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
Rockers and shaft clearance 0.024 - 0.162 mm (0.001 - 0.006 in)
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22. Engine - Engine and crankcase
F4DECOMPLETE 1
The NEF F4DFE engines are turbocharged, four-stroke diesel engines with four or six cylinders and with four valves
per cylinder.
The NEF F4DFE engines have high-pressure fuel injection (common rail system). The control of the NEF F4DFE
engines is fully electronic in order to optimize the working process. The control of the NEF F4DFE engines also takes
into account the operating characteristics, the limitation of emissions and the fuel consumption as far as possible.
NOTE: Data, performance information and power are only valid if the configuration fully matches the installation guide-
lines that FPT (Fiat Powertrain Technologies) provided.
Furthermore, after an overhaul, the use of the device must correspond to the originally specified power and engine
speed for the engine.
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23. Engine - Engine and crankcase
General specifications
Engine type 4 Cylinders 6 Cylinder
Cycle 4-stroke diesel
Performance Turbocharger with intercooler
Cycle Direct injection type
Number of cylinders 4 6
Bore 104 mm (4 in)
Stroke 132 mm (5 in)
Total displacement 4485 cm³ 6728 cm³
Settings for the engine control times
Start before T.D.C. 18.5 °
End after B.D.C. 29.5 °
Start after B.D.C. 67 °
End after T.D.C. 35 °
Valve clearance
intake 0.20 - 0.30 mm (0.008 - 0.012 in)
Exhaust 0.45 - 0.55 mm (0.018 - 0.022 in)
Fuel feed
Injection type Bosch high-pressure common rail
Aux. EDC7 UC31
Injector CRIN 2
Injection nozzle type DLLA
Injection order: 1-3-4-2 1-5-3-6-2-4
Injector pressure 250 - 1600 bar (3625 - 23200 psi)
Naturally
Turbocharger With intercooler
Turbocharger type Honeywell GT25 Holset HX35
Lubrication
Oil pressure at low idle 0.7 bar (10 psi)
Oil pressure at high idle 3.5 bar (51 psi)
Oil pan capacity 15 l (15.85 US qt)
Oil filter capacity 1 l (1.06 US qt)
Cooling System
Water pump Belt Driven
Thermo stat 79 - 83 °C (174 - 181 °F)
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24. Engine - Engine and crankcase
Information about free play
Components of the cylinder block and components of the crankshaft
Cylinder Barrels 104.000 - 104.024 mm (4.094 - 4.095 in)
Oversize 0.4 mm (0.016 in)
piston 103.739 - 103.757 mm (4.084 - 4.085 in)
Apron height 49.5 mm (1.949 in)
Connector housing 38.010 - 38.016 mm (1.496 - 1.497 in)
Piston (oversize) 0.4 mm (0.016 in)
Protrusion 0.28 - 0.52 mm (0.011 - 0.020 in)
Piston pin 37.994 - 38.000 mm (1.496 - 1.496 in)
Piston pin – piston pin
housing
0.01 - 0.022 mm (0.0004 - 0.001 in)
Piston ring landings
Top ring 2.705 - 2.735 mm (0.106 - 0.108 in)
Mid 2.420 - 2.440 mm (0.095 - 0.096 in)
Strippers 4.030 - 4.050 mm (0.159 - 0.159 in)
Piston Rings
Top ring 2.560 - 2.605 mm (0.101 - 0.103 in)
Mid 2.350 - 2.380 mm (0.093 - 0.094 in)
Strippers 3.970 - 3.990 mm (0.156 - 0.157 in)
Clearance between the piston ring and the ring grooves
Top ring 0.100 - 0.175 mm (0.004 - 0.007 in)
Mid 0.040 - 0.090 mm (0.002 - 0.004 in)
Strippers 0.040 - 0.080 mm (0.002 - 0.003 in)
End Gap
Top ring 0.30 - 0.40 mm (0.012 - 0.016 in)
Mid 0.60 - 0.80 mm (0.024 - 0.031 in)
Strippers 0.30 - 0.55 mm (0.012 - 0.022 in)
Connecting Rods
Housing of the small end of
the connecting rod
40.987 - 41.013 mm (1.614 - 1.615 in)
Housing of the big end of the
connecting rod
72.987 - 73.013 mm (2.874 - 2.875 in)
Internal diameter of the
bushing of the small end of
the connecting rod
38.019 - 38.033 mm (1.497 - 1.497 in)
Thickness of the rod bearing
cup
1.955 - 1.968 mm (0.077 - 0.077 in)
Free play between the piston
pin and the piston bushing
0.019 - 0.039 mm (0.001 - 0.002 in)
Oversize dimension of the
rod bearing cup
0.250 mm (0.010 in); 0.500 mm (0.020 in)
Crankshaft
Main Journals 82.99 - 83.01 mm (3.267 - 3.268 in)
Crankpins 68.987 - 69.013 mm (2.716 - 2.717 in)
Thickness of the main
bearing cup
2.456 - 2.464 mm (0.097 - 0.098 in)
Thickness of the rod bearing
cup
1.955 - 1.968 mm (0.077 - 0.078 in)
Main bearing bore
Decal No. 1,5 / 1,7 87.982 - 88.008 mm (3.464 - 3.465 in)
Decal No. 2,3,4 / 2,3,4,5,6 87.977 - 88.013 mm (3.464 - 3.465 in)
Free play between the bearings and the journals
Decal No. 1,5 / 1,7 0.041 - 0.119 mm (0.002 - 0.005 in)
Decal No. 2,3,4 / 2,3,4,5,6 0.041 - 0.103 mm (0.002 - 0.004 in)
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25. Engine - Engine and crankcase
Information about free play
Free play between the bearings
and the crankpins
0.033 - 0.041 mm (0.001 - 0.002 in)
Main Journals 37.475 - 37.545 mm (1.475 - 1.478 in)
Main bearing bore 32.180 - 32.280 mm (1.267 - 1.271 in)
Main bearings on the start-up
side
37.28 - 37.38 mm (1.468 - 1.472 in)
Crankshaft end play 0.095 - 0.265 mm (0.004 - 0.010 in)
Cylinder head and components
Valve guide bore 7.042 - 7.062 mm (0.277 - 0.278 in)
Intake valves
Valve stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Seat angle 59.75 - 60.25 °
Exhaust valves
Valve stem diameter 6.970 - 6.990 mm (0.274 - 0.275 in)
Seat angle 44.75 - 44.25 °
Free play between the valve
stem and the valve seat
0.052 - 0.092 mm (0.002 - 0.004 in)
Valve seat bore
intake 34.837 - 34.863 mm (1.372 - 1.373 in)
Exhaust 34.837 - 34.863 mm (1.372 - 1.373 in)
External diameter of the valve seat:
intake 34.917 - 34.931 mm (1.375 - 1.375 in)
Exhaust 34.917 - 34.931 mm (1.375 - 1.375 in)
Valve seat angle
intake 60 °
Exhaust 45 °
Recessing of valve
intake 0.59 - 1.11 mm (0.023 - 0.044 in)
Exhaust 0.96 - 1.48 mm (0.038 - 0.058 in)
Clearance between the valve seat ring and the cylinder head
intake 0.054 - 0.094 mm (0.002 - 0.004 in)
Exhaust 0.054 - 0.094 mm (0.002 - 0.004 in)
Valve spring length
With the spring free 47.75 mm (1.880 in)
Under a preload of:
330.8 - 348.8 N (74.4 -
78.4 lb)
35.33 mm (1.391 in)
Under a preload of:
702 - 780 N (157.8 - 175.4 lb) 25.2 mm (0.992 in)
Camshaft bore
Number 1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in)
Decal No. 2,3,4,5 /
2,3,4,5,6,7
54.089 - 54.139 mm (2.129 - 2.131 in)
Camshaft journals
1-5 / 1-7 53.995 - 54.045 mm (2.126 - 2.128 in)
Internal diameter of the bearing
bushing
54.083 - 54.147 mm (2.129 - 2.132 in)
Free play between the bushing
and the bearing
0.038 - 0.162 mm (0.001 - 0.006 in)
Cam Lift
intake 7.582 mm (0.299 in)
Exhaust 6.045 mm (0.238 in)
Tappet bore 16.000 - 16.030 mm (0.630 - 0.631 in)
External diameter of the plunger
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26. Engine - Engine and crankcase
Information about free play
Top 15.924 - 15.954 mm (0.627 - 0.628 in)
Mid 15.960 - 15.975 mm (0.628 - 0.629 in)
Bottom 15.924 - 15.954 mm (0.627 - 0.628 in)
Free play between the plunger
and the bore
0.025 - 0.070 mm (0.001 - 0.003 in)
Rocker shaft 21.965 - 21.977 mm (0.865 - 0.865 in)
Rockers 22.001 - 22.027 mm (0.866 - 0.867 in)
Clearance between rocker arm
and shaft
0.024 - 0.162 mm (0.001 - 0.006 in)
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27. Engine - Engine and crankcase
Engine - Dynamic description
NHIL13ENG0290FA 1
The NEF F4HFA engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4
valves per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by Fiat Power Train (FPT).
Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for
which the engine has been designed.
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28. Engine - Engine and crankcase
Engine - Component localisation
Location of main electrical components
CRIL04D081G01 1
(1) Coolant temperature sensor (8) Fuel temperature sensor
(2) Electro injector (9) EDC17 CV41
(3) Rail pressure sensor (10) Crankshaft sensor
(4) Air temperature/Pressure sensor (11) Oil level sensor
(5) Engine starter (12) Engine oil temperature/Pressure sensor
(6) Timing sensor (13) Heating element for pre-post heating
(7) Solenoid valve for pressure regulator
The NEF F4HFE engines are fully driven by the electronic engine control module, which is assembled directly to the
engine by means of a heat exchanger enabling it's cooling, utilizing rubber buffers to reduce vibration originated by
the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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30. Engine - Engine and crankcase
Engine - Dynamic description
NHIL13ENG0291FA 1
The NEF F4DFE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4
valves per cylinder.
They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the
working process in accordance to the operation, limiting pollution emissions and consumption as much as possible.
NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions
provided by Fiat Power Train (FPT).
Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for
which the engine has been designed.
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31. Engine - Engine and crankcase
Engine - Component localisation
Location of main electrical components
NHIL13ENG0294GA 1
(1) Coolant temperature sensor (7) fuel temperature sensor
(2) Electro-injector (8) EDC17 CV41 electronic control module
(3) Starter (9) Crankshaft speed sensor
(4) Fuel pressure sensor (10) Engine oil pressure/temperature sensor
(5) Air pressure/temperature sensor (11) Pre-post heating resistor
(6) Timing sensor
The NEF F4DFE engines are fully driven by the electronic engine control module, which is mounted remotely on the
unit utilizing rubber buffers to reduce vibration originated by the engine.
Through the engine control module it is possible to verify the correct working of the engine.
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32. Engine - Engine and crankcase
Engine - Service instruction Maintenance procedures
WARNING
Chemical hazard!
When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.
Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect
fluids in proper containers. Obey all local and environmental regulations when disposing of chemi-
cals.
Failure to comply could result in death or serious injury.
W0371A
WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
Failure to comply could result in death or serious injury.
W0178A
CAUTION
Burn hazard!
Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has
cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.
Failure to comply could result in minor or moderate injury.
C0043A
WARNING
Rotating parts!
The engine is running. Keep clear of rotating fans and belts.
Failure to comply could result in death or serious injury.
W0275A
Engine oil level check
The check can be made using the dipstick (1) placed on
the right hand side of the Engine Control Unit (ECU).
NOTICE: The check must be executed when the engine is
off and possibly cool.
Draw off the rod from it's slot and check that the level is
within the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, pro-
ceed cleaning the rod using a clean cloth with no contami-
nation and put it back in it's slot. Draw it off again and check
the level.
In case the level results being close to the tag showing min-
imum level, provide filling lubrication of the engines com-
ponents.
Add oil through the upper top or through the lateral top (2).
During filling operation, the tops must be removed as well
as the rod in order to make the oil flow easier.
NHIL13ENG1373AA 1
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33. Engine - Engine and crankcase
Combustion system inspection
The check must be executed both when the engine off and
when it is running.
The check operation consists in examining the fuel
pipelines running from the tank to the pre-filter (if provided
in the specific equipment), to the filter, to the high pressure
pump and to the rail diffuser and from this last one to the
head.
Special attention must be paid to the connections on the
high pressure pipelines.
Cooling system inspection
The check must be executed both when the engine is off
and when it is running.
Check the pipelines from the engine to the radiator, from
the expansion tank and vice-versa. Find out any blow-by,
verify the status of the pipes specially close to the holding
strips.
Verify that the radiator is clean, the correct working of the
fan flywheels, the presence of any leakage from the con-
nectors, from the manifold and from the radiating unit.
The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any
case every two years.
NOTE: In case of new filling, proceed bleeding the system,
through the bleeds on the engine.
If bleeding of the system is not carried out, serious inconve-
nience might be caused to the engine due to the presence
of air pockets in the engine's head.
Lubricating system inspection
The check must be executed both when the engine is off
and when it is running.
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan or from the heat exchanger.
Inspection of water presence within the fuel
filter or pre-filter
The components of the common rail system can be dam-
aged very quickly in presence of water or impurity within
the fuel.
Timely proceed operating on the pre-filter (not available on
the engine block) to carry out the drainage of the water
within the feed circuit.
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34. Engine - Engine and crankcase
Inspection / replacement of blow-by filter
The filter in subject has been developed and equipped for
the collection , filtering and condense of the lubricating oil
vapors.
Within the valve cover (1) is a filter (2).
Remove the cover and check the filtering element.
93110965 2
Inspection of drive belt tensioning
The drive belt tensioning control is made using an au-
tomatic tensioning device therefore no intervention is
required apart from checking the wear status of the belt
itself.
Inspection and setting of tappet clearance
Adjust clearance between rockers and valves using
setscrew wrench (1), box wrench (2) and feeler gauge (3).
Valve clearance
• Intake - 0.20 - 0.30 mm (0.008 - 0.012 in)
• Exhaust - 0.45 - 0.55 mm (0.018 - 0.022 in)
NHIL13ENG0312AA 3
Engine oil and filter replacement
Due to the several applications, the pan shape and the
oil quantity can change slightly. However, the following
operations are valid for all applications.
We recommend to carry out the oil drainage when the en-
gine is hot.
Place a proper container for the oil collecting under the pan
connected with drain plug.
Unscrew the plug and then take out the control dipstick and
the inserting plug to ease the downflow of the lubrication oil.
After the complete drainage, screw the plug and carry out
the clean oil filling.
NOTICE: Use only recommended oil or oil having the re-
quested features for the correct engine functioning. In case
of topping up, don't mix oils having different features. If you
don't comply with these rules, the service warranty is no
more valid.
Check the level through the dipstick until when the filling is
next to the maximum level notch indicated on the dipstick.
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