General safety guidelines and maintenance instructions for agricultural equipment

SECTION 00 -- GENERAL -- CHAPTER 1 1
SECTION 00 -- GENERAL
Chapter 1 -- General
CONTENTS
Section Description Page
General Instructions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Notice 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shimming 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating Shaft Seals 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O--Ring Seals 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sealing Compounds 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring Pins 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spare Parts 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes for Equipment 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Notes 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving the Tractor with the Battery Removed 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Regulations 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Symbols 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Prevent Accidents 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Guidelines 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Systems 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Systems 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels and Tires 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and Installation 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tractor Refuelling 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 00 -- GENERAL -- CHAPTER 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair work described in this manual must be performed exclusively by CASE IH service
technicians, in strict accordance with the instructions given and using any specific tools necessary.
Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.
BATTERY
Before carrying out any kind of service operation disconnect and isolate the battery negative lead, unless other-
wise requested for specific operations (e.g: operations that require the engine running). Once the specific opera-
tion has been completed, disconnect the lead in order to complete the operation.
SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add
up the recorder values: Do not rely on measuring the entire shimming set, which may be incorrect, or the rated
value indicated for each on shim.
ROTATING SHAFT SEALS
For correct rotating shaft seal installation, proceed as follows:
-- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes;
-- thoroughly clean the shaft and check that the working surface on the shaft is not damaged;
-- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc-
tion and position the grooves so that they will deviate the fluid towards the inner side of the seal;
-- smear the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the
sealing lip and the dust lip on double lip seals with grease;
-- insert the seal in its seat and press down using a flat punch; do not tap the seal with a hammer or mallet;
-- whilst inserting the seal, check that the 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 twist-
ing, which would jeopardize sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces marked with an X: LOCTITE 518, LOCTITE
5205, SUPERBOND 559 MASCHERPA or BETABLOCK A272M GURIT ESSEX.
Before applying the sealing compound, prepare the surfaces as follows:
-- remove any incrustations using a wire brush;
-- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a
water and soda solution.
BEARINGS
When installing bearings it is advised to:
-- heat the bearings to 80 to 90 °C before fitting on the shafts;
-- allow the bearings to cool before installing them from the outside.

SPRING PINS
When fitting split socket elastic pins, ensure that the pin notch is positioned in the direction of the force required
to stress the pin.
Spiral spring pins do not require special positioning.
SPARE PARTS
Use genuine parts only.
Only genuine spare parts guarantee the same quality, duration and safety as they are the same parts that are
assembled during production.
Only genuine parts can offer this guarantee.
When ordering spare parts, always provide the following information:
-- tractor model (commercial name) and frame number;
-- engine type and number;
-- part number of the ordered part, which can be found in the “Spare Parts Catalogue” used for order process-
ing.
NOTES FOR EQUIPMENT
The tools that CASE IH propose and illustrate in this manual are:
-- specifically researched and designed for use with CASE IH vehicles;
-- necessary to make reliable repair;
-- accurately built and strictly tested to offer efficient and long--lasting working means.
By using these tools, repair personnel will benefit from:
-- operating in optimal technical conditions;
-- obtaining the best results;
-- saving time and effort;
-- working in safe conditions.
IMPORTANT NOTES
Wear limit values indicated for certain parts are recommended, but not binding. The terms “front”, “rear”, “right--
hand” and “left--hand” (when referred to different parts) are intended as seen from the driving position with the
tractor in the normal direction of movement.
MOVING THE TRACTOR WITH THE BATTERY REMOVED
External power supply cables should only be connected to the respective positive and negative cable terminals,
using efficient clamps that guarantee adequate and secure contact.
Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle.
If the vehicle electrical system requires checking, carry out operations with the power supply connected; Once
checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.

4 SECTION 00 -- GENERAL -- CHAPTER 1
SAFETY REGULATIONS
SAFETY SYMBOLS
The following keywords with regards to safety are
used throughout this manual:
DANGER, used with the safety alert symbol (fig-
ure 1) indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The col-
or associated with Danger is RED. M1169A
WARNING, used with the safety alert symbol (fig-
ure 1), indicates a hazardous situation which, if not
avoided, could result in death or serious injury. The
color associated with Warning is ORANGE. M1170A
CAUTION, used with the safety alert symbol (fig-
ure 1), indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury. The
color associated with Caution is YELLOW. M1171A
TO PREVENT ACCIDENTS
Most accidents or injuries that occur in workshops
are the result of non--observance of simple and fun-
damental safety regulations. For this reason, IN
MOST CASES THESE ACCIDENTS CAN BE
AVOIDED: by foreseeing possible causes and con-
sequently acting with the necessary caution and
care.
Accidents may occur with all types of vehicle, regard-
less of how well it was designed and built.
A careful and judicious service technician is the best
guarantee against accidents.
Precise observance of the most basic safety rule is
normally sufficient to avoid many serious accidents.
DANGER. Never carry out any cleaning, lubrication
or maintenance operations when the engine is run-
ning.
GENERAL GUIDELINES
-- Carefully follow specified repair and mainte-
nance procedures.
-- Do not wear rings, wristwatches, jewelry, unbut-
toned or loose articles of clothing such as: ties,
torn clothing, scarves, open jackets or shirts with
open zips that may remain entangled in moving
parts. It is advised to wear approved safety cloth-
ing, e.g: non--slip footwear, gloves, safety
goggles, helmets, etc.
1
-- Do not carry out repair operations with someone
sitting in the driver’s seat, unless the person is a
trained technician who is assisting with the op-
eration in question.
-- Do not operate the vehicle or use any of the im-
plements from different positions, other than the
driver’s seat.
-- Do not carry out operations on the vehicle with
the engine running, unless specifically indicated.
-- Stop the engine and ensure that all pressure is
relieved from hydraulic circuits before removing
caps, covers, valves, etc.
-- All repair and maintenance operations must be
carried out using extreme care and attention.
-- Service steps and platforms used in a workshop
or in the field should be built in compliance with
the safety rules in force.
-- Disconnect the batteries and label all controls to
indicate that the vehicle is being serviced. Block
the machine and all equipment which should be
raised.
-- Do not check or fill fuel tanks, accumulator batter-
ies, nor use starting liquid when smoking or near
naked flames, as these fluids are inflammable.
-- Brakes are inoperative when manually released
for repair or maintenance purposes: use blocks
or similar devices to control the machine in these
conditions.

-- The fuel nozzle should always be in contact with
the filling aperture: maintain this contact until the
fuel stops flowing into the tank to avoid possible
sparks due to static electricity build--up.
-- Only use specified towing points for towing the
vehicle. Connect parts carefully: make sure that
all pins and/or locks are secured in position be-
fore applying traction. Never remain near the
towing bars, cables or chains that are operating
under load.
-- Transport vehicles that cannot be driven using a
trailer or a low--loading platform trolley, if avail-
able.
-- When loading or unloading the vehicle from the
trailer (or other means of transport), select a flat
area capable of sustaining the trailer or truck
wheels. Firmly secure the vehicle to the truck or
trailer and lock the wheels in the position used by
the carrier.
-- Electric heaters, battery--chargers and similar
equipment must only be powered by auxiliary
power supplies with efficient ground insulation to
avoid electrical shock hazards.
-- Always use suitable hoisting or lifting devices
when raising or moving heavy parts.
-- Take extra care if bystanders are present.
-- Never pour petrol or diesel oil into open, wide or
low containers.
-- Never use gasoline, diesel oil or other inflam-
mable liquids as cleaning agents: use non--in-
flammable, non toxic commercially available sol-
vents.
-- Wear safety goggles with side guards when
cleaning parts with compressed air.
-- Limit the air pressure to a maximum of 2.1 bar,
according to local regulations.
-- Do not run the engine in confined spaces without
suitable ventilation.
-- Do not smoke, use naked flames, or cause
sparks in the area when fuel filling or handling
highly inflammable liquids.
-- Never use naked flames for lighting when work-
ing on the machine or checking for leaks.
-- All movements must be carried out carefully
when working under, on or near the vehicle.
Wear protective equipment: helmets, goggles
and special footwear.
-- When carrying out checks with the engine run-
ning, request the assistance of an operator in the
driver’s seat. The operator must maintain visual
contact with the service technician at all times.
-- If operating outside the workshop, position the
vehicle on a flat surface and lock in position. If
working on a slope, lock the vehicle in position.
Move to a flat area as soon as is safely possible.
-- Damaged or bent chains or cables are unreliable:
do not use them for lifting or towing. Always use
suitable protective gloves when handling chains
or cables.
-- Chains should always be safely secured: make
sure that the hitch--up point is capable of sustain-
ing the load in question. Keep the area near the
hitch--up point, chains or cables free of all by-
standers.
-- Maintenance and repair operations must be car-
ried out in a CLEAN and DRY area. Eliminate any
water or oil spillage immediately.
-- Do not create piles of oil or grease--soaked rags:
as they represent a serious fire hazard. Always
store rags in a closed metal container.
Before starting the tractor or its attachments,
check, adjust and block the operator’s seat. Also
check that there are no persons within the vehicle
or implement range of action.
-- Empty pockets of all objects that may fall unob-
served into the vehicle parts.
-- In the presence of protruding metal parts, use
protective goggles or goggles with side guards,
helmets, special footwear and gloves.
-- When welding, use protective safety devices:
tinted safety goggles, helmets, special overalls,
gloves and footwear. All persons present in the
area where welding is taking place must wear
tinted goggles. NEVER LOOK DIRECTLY AT
THE WELDING ARC WITHOUT SUITABLE EYE
PROTECTION.
-- Metal cables tend to fray with repeated use: al-
ways use suitable protective devices (gloves,
goggles, etc.) when handling cables.
-- Handle all parts with great care. Do not put your
hands or fingers between moving parts. Always
wear suitable safety clothing -- safety goggles,
gloves and shoes.

SECTION 10 -- ENGINE -- CHAPTER 1 1
SECTION 10 -- ENGINE
Chapter 1 -- Engine (Model 95N)
CONTENTS
Specifications 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sectional Views 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Gas Recirculation System (EGR) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhaul 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Crankshaft Front Seal 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Crankshaft Rear Seal 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Connecting Rod--Piston Assembly 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Piston Connecting Rod Assemblies In the Cylinder Liners 47. . . . . . . . . . . . .
Big End Cap Assembly 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Thermostat Valve 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Cylinder Head 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Injectors 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Rocker Arm Assembly 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Timing Gear 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Injection Pump 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Additional Counterweights 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Hydraulic Pump Drive Gear 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Timing Gear Casing 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Crankshaft Rear Seal 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Flywheel 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Oil Pump 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Oil Sump 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SECTION 10 -- ENGINE -- CHAPTER 1
Fitting the Crankshaft Front Seal 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Crankshaft Front Pulley 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Cooling System Union 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Coolant Pump 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Fan--alternator Pulley 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Auxiliary Member Drive Belt 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Exhaust Manifold -- Turbine 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Injector Feed Pipes 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Fuel Pump -- Feed Pipes 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Pipes Between the Fuel Supply and Injection Pumps,
Pre-heating System and Tappet Cover 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the Starter Motor 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks, Measurements and Repairs 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase, Cylinder Liners 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rods 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushings 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Connecting Rods 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Twisting 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Bending 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Dimensions (mm) Piston Data 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring the Piston Diameter 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Pins 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions for Correct Pin--Piston Coupling 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Rings 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valves and Camshaft 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions (mm) of Valves and Valve Guides 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Decarbonizing, Checking and Grinding Valves 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Springs 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tappets 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camshaft 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Cylinder Head Mating Surface 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Thickness 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Head Hydraulic Seal Check 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Oil Pressure Indicator 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Checks 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Filter 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing and Checks 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Thermometer 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostat Valve 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft -- Front Seal 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft -- Rear Seal 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Valve/Rocker Arm Clearance 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Injectors 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch Injection Pump 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Circuit Air Bleeding 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Pump 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-Cylinder Coolant Pump and Generator Drive Belt 99. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension Adjustment 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTIONAL VIEWS
MIF1096A
1
Engine view

MIF1098A
Oil path under pressure
Oil return path under gravity
2
Engine lubrication diagram
Forced--circulation lubrication is accomplished by
the following components:
-- oil pump, housed at the front of the crankcase,
driven by the grooved bushing keyed onto the
shank of the crankshaft;
-- water / oil cooler, housed in the crankcase;
-- oil pressure control valve incorporated in the
cooler assembly;
-- by--pass valve to cut off clogged oil filter,
incorporated in the cooler assembly;
-- cartridge oil filter.

MIF1099A
Coolant recirculating in the engine
Coolant entering the pump
3
Cooling diagram
The forced circulation, closed--circuit engine cooling
system is composed of the following components:
-- a lubricating oil cooler;
-- a centrifugal coolant pump housed at the front of
the crankcase;
-- a thermostat valve governing coolant circulation.

MIF1102A
4
Additional counterweight diagram
1. Retaining bolts
2. Support
3. Retaining bolts
4. Gear
5. Balancing weight
6. Half bearings
7. Counter--shaft
8. Gear
9. Ring
10. O--ring

DESCRIPTION AND OPERATION
EXHAUST GAS RECIRCULATION SYSTEM
(EGR)
On the TIER 3 version, the exhaust cam profile has
been modified to permit partial opening of the related
valve during the inlet phase (exhaust gas recircula-
tion EGR) with the consequent re--introduction of
some of the exhaust gases into the engine cylinders.
The exhaust gases can be partially redirected into
the cylinders in order to reduce the maximum
combustion temperature values which are responsi-
ble for the production of nitrogen oxide (NOx).
The exhaust gas recirculation system (EGR),
reducing the temperature of combustion by
decreasing the concentration of oxygen in the
combustion chamber, is therefore an effective
system to control emissions of NOx.
The internal EGR system is not provided with any
electronically controlled elements: the system is
always on.
Its configuration needs no additional elements such
as control valves, pipes or heat exchangers.
The exhaust cam (B) in addition to the main lobe has
another lobe (see sect. A--A, fig. 5) with respect to the
configuration without EGR.
The additional lobe, during the inlet phase of the
cylinder under examination, permits briefly opening
the exhaust valve generating recirculation due to the
exhaust gases returning caused by the lower
pressure created in the inlet phase inside the
cylinder.
5
Camshaft view
A. Inlet valve cam. B. Exhaust valve cam.

OVERHAUL
Operation 10 001 10
ENGINE
Removal
DANGER
Lift and handle all heavy parts using suitable
lifting equipment.
Make sure that assemblies or parts are
supported by means of suitable slings and
hooks. Ensure that no--one is in the vicinity of the
load to be lifted.
CAUTION
Use suitable tools to align the holes. NEVER USE
FINGERS OR HANDS.
1. Remove the cab as described in opera-
tion 90 150 10.
2. Extract the fixing pin and remove the ballast (1);
unscrew the retaining screws and retrieve the
ballast support (2).
6
3. Carry out operation 23 101 26 Propeller shafts
and guard, only removal (see Sect. 23).
4. Unscrew the plug and drain the front transmis-
sion casing (prescribed quantity: 44 liters).
25628
7
5. Disconnect the pipes (1 and 2) of the
transmission oil cooler and of the front axle
differential lock.
8

6. Disconnect: the transmission oil cooler pipes (1)
and the front axle differential lock pipe (2).
9
7. Unscrew: the retaining bolts of the pipe (1)
delivering oil to the pump and the bolts retaining
the pipe (2) to the filter support.
10
8. Loosen the related clamps and remove the
sleeve (2) from the pipe (1) and remove the
transmission oil inlet pipe together with the
above--mentioned sleeve.
11
9. Unscrew the fixing clamps and disconnect the
pipes (1 and 2) from the cooler, the sleeve (4)
between the air filter and the turbocharger and
the oil vapor recirculation pipe (3).
12

10. Disconnect the secondary tank fuel level
connection (1) and the clogged air filter pressure
switch connection.
13
11. Disconnect the steering hydraulic cylinder
control pipes (1).
14
12. Unscrew the fixing clamps and detach the upper
(1) and lower (2) sleeves from the engine
radiator.
15
13. Unhook the catch and extract the transmission oil
radiator (1).
16

14. Disconnect the pipes (1) of the air--conditioning
system from the related condenser.
17
15. Unscrew the fixing screws, loosen the related
clamp and detach the pipe (1) joining the tanks:
main to secondary.
18
16. Unscrew the fixing screw and detach the bracket
(1) locking the engine radiator.
19
17. Position a fixed stand under the transmission--
clutch casing.
18. Connect the engine to the hoist using a chain and
make it take up the strain.
19. Unscrew the bolts (1) securing the engine to the
transmission--clutch casing and detach the
engine assembly and front axle.
20

20. Set up two fixed stands: one under the axle
support at the rear and the other under the front
side.
21. Unscrew the bolts (1) on both sides and separate
the engine from the axle--support assembly with
the radiators.
22. Rest the engine on an adequate support.
Installation
To install the engine, proceed as follows:
CAUTION
Use suitable tools to align the holes. NEVER USE
FINGERS OR HANDS.
1. Respect the tightening torques prescribed on
page 12.
2. Connect the engine, with chains, to the hoist.
3. Refit the engine to the front axle--support
assembly with the radiator and cooler.
4. Before refitting the engine to the clutch box
carefully clean the mating surfaces and apply
sealing compound (2 mm diameter), according
to the diagram shown Section 21, Chapter 1,
page 34.
5. Position the engine on the clutch casing and
secure it with the specific bolts.
6. Position and secure the retaining bracket
between the radiator and engine.
7. Secure the pipe joining the main tank to the
secondary one.
8. Position and secure the guard between the
radiator and engine.
9. Connect the air--conditioning system pipes to the
condenser.
10. Insert the transmission oil radiator into its seat
and secure it.
11. Connect and secure the top and bottom sleeves
to the engine radiator.
12. Connect the steering cylinder control piping.
21

13. Connect the electrical connections of the
secondary tank fuel level and clogged air filter.
14. Position and secure the connecting pipes of the
cooler, turbocharger, air filter and oil vapor
recirculation.
15. Position and connect the transmission oil inlet
pipe.
16. Position and secure the pipes of the transmission
oil filter support.
17. Connect the transmission oil cooler and front
axle differential lock pipes.
18. Carry out operation 23 101 26 Propeller shafts
and guard, only installation (see Sect. 23).
19. Connect the cooler and front axle differential lock
pipes.
20. For models fitted with brakes on the front axle it
is necessary to fill the relevant tank (see sect. 00,
page 6 for the prescribed product and quantity)
and bleed the braking system (see sect. 33).
21. Screw the plug on the rear transmission casing
and fill up with oil (see sect. 00, page 6 for the
prescribed product and quantity).
22. Position and secure the ballast support.
23. Position and secure the ballast.
24. Install the cab as described in opera-
tion 90 150 10.

Operation 10 001 54
Disassembly
The figures refer to the F4CE9484M*J602 versions
of 71 kW (97 hp) mod. 95V and 95N.
WARNING
Handle all parts with great caution. Do not put
your hands or fingers between parts. Wear the
prescribed safety clothing, including goggles,
gloves and safety footwear.
1. Remove the engine as described in opera-
tion 10 001 10, proceed as follows.
2. Drain off the engine oil by removing the plug from
the sump and the oil filler plug.
3. Detach the fan unit from the fan pulley.
4. To be able to fit the bracket 380000661 (for fixing
the engine to the overhaul stand) to the
crankcase, it is necessary to remove the wiring
(1) from the left--hand side of the engine.
MIF1103A
22
5. To be able to fit the bracket 380000661 to the
crankcase on the right--hand side, remove the
starter motor (5), oil filter (3), clamp (4), and
turbine oil return pipe (1).
6. Fix the gearbox to the rotating stand 380000301.
Detach the oil delivery pipe (2).
MIF1104A
23

7. Remove the intake manifold (2).
8. Disconnect the engine oil vapor recovery pipe
from the blow--by (3).
9. Remove the tappet covers (1).
10. Remove the pipes with the quick--fit coupling (6)
and (8).
11. Remove the piping from the LDA system (5).
12. Remove the fuel filter (7).
13. Remove the heater (4).
14. Remove the control unit for the heater (10).
15. Remove the fuel filter support (9).
MIF1105A
24
16. Remove the injector feed pipe (4) from the
injection pump (3).
17. Remove the brackets on the cylinder head of the
pipe assembly (1), (2) and (6).
18. Replace fuel supply pump (5).
MIF1107A
25
19. Detach the fuel pipe assembly (1) from the
injectors.
20. Remove the fuel outlet pipe (2) from the injectors
removing the screw (3) and the seal (4).
MIF1108A
26

21. Remove the screws (2) and the turbine (1).
22. Remove the exhaust manifold (3).
23. Remove the belt (3, fig. 28) of the auxiliary
members by loosening the tightener.
MIF1109A
27
24. Remove the alternator (6), fan pulley (2) and the
tightener (8). Remove the support (1) of the
pulley (2) and the oil cooler (7).
25. Remove the coolant pump (5).
26. Remove the engine cooling system fitting (4)
from the crankcase.
NOTE: The coolant pump (5) cannot be overhauled.
It must be replaced if there is any irregular operation.
MIF1110A
28
27. Lock the flywheel to stop it turning, remove the
fixing screws (1) from the pulley (2).
MIF1111A
29
Removing the crankshaft front seal
(Op. 28. to 32.)
28. Apply tool 380000665 (4) on the front tang (2) of
the crankshaft.
29. Perforate the inner seal (1) with a drill bit
(∅ 3.5 mm) through the guide holes of the tool
(4), for a depth of 5 mm.
30. Secure the tool 380000665 (4) to the seal (1) with
the screws (3) provided.
31. Extract the seal (1) by screwing down the screw
(5). MIF0916A
30

32. Fit the tie rod (3) of the tool 380000669 to the
outer seal (1) as shown in the figure 31 and with
the lever (4), extract it from the front cover (2).
MIF0917A
31
33. Turn the engine over, take out the screws (2) and
remove the oil sump (1).
MIF1117A
32
34. Take out the screws (2) and remove the oil pump
(1).
NOTE: The oil pump (1) cannot be overhauled.
It must be replaced if there is any irregular operation.
MIF1112A
33
35. Using the pin (1), lock the additional counter-
weights (2) at the T.D.C.
Unscrew the retaining bolts (3) and remove the
additional counterweights (2).
MIF1113A
34

36. Before removing the injection pump, do the
timing and lock the engine flywheel with cylinder
no.1 at T.D.C. as indicated on page 10, using
tools 380000988 and 380000732. Then loosen
the bolt (2), remove the “L” spacer (1) and lock
the screw (2) in order to keep the pump in time
with the engine flywheel.
NOTE: Keep the “L” spacer with the pump casing.
MIF0920A
35
37. Remove the three nuts (2) (3) (5) securing the
injection pump (1) to the crankcase (4) and
extract it from its housing.
MIF0922A
36
38. Remove the screws (2) fixing the engine flywheel
(1) to the crankshaft.
MIF1115A
37
39. Screw two pins (2) of the appropriate length into
the holes in the crankshaft (3).
40. Extract the engine flywheel (1) so it can be slung
with the lift and put it away in a specific container.
MIF1116A
38

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Removing the crankshaft rear seal
(Op. 41. to 44.)
41. Extract the seal, fitting the tool 380000663 (3) on
the rear shank (1) of the crankshaft.
42. Perforate the inner seal (5) with a drill bit
(∅ 3.5 mm) through the guide holes of the tool
(3), for a depth of 5 mm.
43. Secure the tool 380000663 (3) to the seal (5) by
screwing down the screws (2) supplied.
44. Extract the seal (5) by screwing down the screw
(4).
MIF0927A
39
45. Take out the screws (2) and remove the timing
gear box (1), retrieving the injection pump gear.
NOTE: Note down the assembly position of the
screws (2) as they have different sizes.
MIF1125A
40
46. Take out the screws (1) and remove the gears (3)
and (4) from the camshaft (2).
MIF1118A
41
47. Take out the bolts (1) and remove the hydraulic
pump drive gear (2).
MIF1119A
42

48. For each cylinder, remove the rocker arm
assembly (1) loosen the adjuster nuts (3),
unscrew the adjusters (4) and take out the
screws (2).
MIF0933A
43
49. Extract the injectors (2) with tool 380000671 (1).
MIF0934A
44
50. Take out the screws (1) fixing the head to the
crankcase.
MIF1120A
1
45
51. After fitting the brackets (1) and (2) hook the
metal cables and detach the cylinder head from
the crankcase with the hoist.
NOTE: After removing the cylinder head, remove the
brackets (1) and (2).
MIF1121A
46

52. Valves are removed with tool 380000302 (1),
applying pressure on the cap (3) so that, by
compressing the springs (4), it is possible to
remove the cotters (2). Then remove: the plate
(3), springs (4).
Repeat this operation on all valves (5).
MIF1122A
47
53. Remove the intake manifold cover and extract
the oil seals (1) fitted on the valve stems.
To remove the valves, turn the head over.
NOTE: Mark the inlet and exhaust valves before
removing them.
MIF1123A
48
NOTE: The inlet valves differ from the exhaust valves
in the size of the head and there being an additional
reference mark (1) on the stem.
A = Inlet valve.
B = Exhaust valve.
MIF0948A
49
54. Remove the thermostat valve (2) from the
governor body (1) taking out the screws (3).
MIF1124A
50

55. Take out the screws (1) securing the connecting
rod caps (2) and remove them.
56. Extract the pistons together with the connecting
rods from the top of the crankcase.
NOTE: Keep the half bearings in their respective
housings since, if they are used, they must be
mounted in the position found upon disassembly.
MIF0938A
51
57. Remove the rings (1) from the piston (3) with the
pliers 380000221 (2).
MIF0950A
52
58. The piston pin (1) retaining snap rings (2) should
be removed using a marking tool (3).
MIF0951A
53
59. Take out the screws (1) and remove the main
bearing caps (2).
MIF1126A
54

60. The penultimate main bearing cap (1) and the
related mounting have the half bearing (2)
equipped with a shoulder. Remove the pistons
with the connecting rods.
NOTE: Note down the assembly position of the top
and bottom half bearings since, if they are reused,
they must be mounted in the position found upon
disassembly.
MIF0940A
55
61. Using tool 380000362 (1) and a hoist, remove the
crankshaft (2) from the crankcase.
MIF1127A
56
62. Remove the main half bearings (1).
63. Take out the screws (2) and remove the oil
nozzles (3).
MIF0942A
57
64. Take out the screws (1) and remove the plate (3)
retaining the camshaft (2).
NOTE: Note down the assembly position of the plate
(3).
MIF1128A
58

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