The document is a service manual that provides technical specifications, diagrams, and repair/maintenance procedures for tractor models T7510, T7520, T7530, T7540, and T7550. The manual contains information on the engine, transmission, axles, hydraulics, electrical systems, and other components. Sections cover topics such as the engine and crankcase, valve drive, cylinder heads, fuel injection system, cooling system, and lubrication system. Specifications, component locations, maintenance guidelines, and troubleshooting procedures are provided.
This document is a service manual for CVT6140, CVT6150, CVT6160, CVT6175, and CVT6195 tractors. It contains an introduction and safety information, as well as sections covering the engine, transmission, four-wheel drive system, front and rear axle systems, power take-off, brakes and controls, hydraulic systems, steering, cab climate control, and electrical systems. Each section contains technical data, functional descriptions, diagnostics, and service procedures for the various components.
New holland tvt170 tractor service repair manualjfjjsekdmme
This document provides technical specifications and repair instructions for engines used in Case IH 797 tractors, including the 620.95, 620.96, 620.97, 620.98, and 620.99 engines. It covers specifications and procedures for the cylinder block, cylinder head, valves, crankshaft, pistons, con-rods, flywheel, timing gears, lubrication system, cooling system, intake/exhaust system, and electronic engine control system. The document also lists required special tools and safety regulations.
New holland ts125 a tractor service repair manualjfjjsekdmme
This document is a service manual for New Holland TS100A, TS110A, TS115A, TS125A, TS130A, and TS135A tractors. It provides instructions and specifications for separating the front axle and front support from the engine on these tractor models. The summary includes torque values for fasteners, lists any special tools required, and provides a step-by-step procedure for separating the front axle and support. Health and safety warnings and environmental considerations are also addressed at the beginning.
New holland td70 tractor service repair manualjfjjsekdmme
This document is the service manual for TD60-TD95 straddle mount model tractors. It contains sections on general information, the engine system, clutches, mechanical transmission (12x4), reverser (12x12) and other systems. Each section provides specifications, views, removal and installation instructions, and troubleshooting information for the components covered. The manual is intended to guide service technicians in repairing and maintaining these tractors.
New holland t7550 tractor service repair manualjfjjsekdmme
The document is a service manual that provides technical specifications, diagrams, and repair/maintenance procedures for tractor models T7510, T7520, T7530, T7540, and T7550. The manual contains information on the engine, transmission, axles, hydraulics, brakes, electrical systems, and other components. Sections cover topics such as the engine and crankcase, valve drive, cylinder heads, fuel injection system, cooling system, and lubrication system. Specifications, component locations, maintenance guidelines, and troubleshooting procedures are provided.
New holland ls180.b skid steer loader service repair manualjfjjsekdmme
The document provides repair information for the primary hydraulic power system for LS180.B, LS185.B, and LS190.B models. It includes technical specifications, diagrams of the system, and procedures for maintenance tasks like cleaning, testing, disassembly, and installation of components. The sections cover the hydraulic pump, reservoir, relief valve, filter, and cooler. Troubleshooting information is also provided for sensors in the system.
New holland c232 200 series compact track loader service repair manualjfjjsekdmme
This document is a service manual for New Holland 200 Series skid steer loaders and compact track loaders, covering models C227, C232, C238, L213, L215, L218, L220, L223, L225, and L230. The manual contains sections on hydraulic, pneumatic, electrical and electronic systems, engines and PTO systems, transmissions, axles, brakes, steering, frames, cabs, user controls, positioning, tool attachment, hitching, digging and landscaping functions. Safety warnings and instructions are provided throughout.
Cummins onan generator set with power command 3100 controller model (dqaa ) s...jfjjsekdmme
This document is a service manual that provides information for troubleshooting and servicing generator sets and their PowerCommand 3100 controllers. It includes sections that cover control operation, circuit boards and modules, troubleshooting procedures, control service and calibration, servicing the generator, day tank fuel transfer pumps, optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and provides detailed technical information, component specifications, and repair and maintenance procedures.
This document is a service manual for CVT6140, CVT6150, CVT6160, CVT6175, and CVT6195 tractors. It contains an introduction and safety information, as well as sections covering the engine, transmission, four-wheel drive system, front and rear axle systems, power take-off, brakes and controls, hydraulic systems, steering, cab climate control, and electrical systems. Each section contains technical data, functional descriptions, diagnostics, and service procedures for the various components.
New holland tvt170 tractor service repair manualjfjjsekdmme
This document provides technical specifications and repair instructions for engines used in Case IH 797 tractors, including the 620.95, 620.96, 620.97, 620.98, and 620.99 engines. It covers specifications and procedures for the cylinder block, cylinder head, valves, crankshaft, pistons, con-rods, flywheel, timing gears, lubrication system, cooling system, intake/exhaust system, and electronic engine control system. The document also lists required special tools and safety regulations.
New holland ts125 a tractor service repair manualjfjjsekdmme
This document is a service manual for New Holland TS100A, TS110A, TS115A, TS125A, TS130A, and TS135A tractors. It provides instructions and specifications for separating the front axle and front support from the engine on these tractor models. The summary includes torque values for fasteners, lists any special tools required, and provides a step-by-step procedure for separating the front axle and support. Health and safety warnings and environmental considerations are also addressed at the beginning.
New holland td70 tractor service repair manualjfjjsekdmme
This document is the service manual for TD60-TD95 straddle mount model tractors. It contains sections on general information, the engine system, clutches, mechanical transmission (12x4), reverser (12x12) and other systems. Each section provides specifications, views, removal and installation instructions, and troubleshooting information for the components covered. The manual is intended to guide service technicians in repairing and maintaining these tractors.
New holland t7550 tractor service repair manualjfjjsekdmme
The document is a service manual that provides technical specifications, diagrams, and repair/maintenance procedures for tractor models T7510, T7520, T7530, T7540, and T7550. The manual contains information on the engine, transmission, axles, hydraulics, brakes, electrical systems, and other components. Sections cover topics such as the engine and crankcase, valve drive, cylinder heads, fuel injection system, cooling system, and lubrication system. Specifications, component locations, maintenance guidelines, and troubleshooting procedures are provided.
New holland ls180.b skid steer loader service repair manualjfjjsekdmme
The document provides repair information for the primary hydraulic power system for LS180.B, LS185.B, and LS190.B models. It includes technical specifications, diagrams of the system, and procedures for maintenance tasks like cleaning, testing, disassembly, and installation of components. The sections cover the hydraulic pump, reservoir, relief valve, filter, and cooler. Troubleshooting information is also provided for sensors in the system.
New holland c232 200 series compact track loader service repair manualjfjjsekdmme
This document is a service manual for New Holland 200 Series skid steer loaders and compact track loaders, covering models C227, C232, C238, L213, L215, L218, L220, L223, L225, and L230. The manual contains sections on hydraulic, pneumatic, electrical and electronic systems, engines and PTO systems, transmissions, axles, brakes, steering, frames, cabs, user controls, positioning, tool attachment, hitching, digging and landscaping functions. Safety warnings and instructions are provided throughout.
Cummins onan generator set with power command 3100 controller model (dqaa ) s...jfjjsekdmme
This document is a service manual that provides information for troubleshooting and servicing generator sets and their PowerCommand 3100 controllers. It includes sections that cover control operation, circuit boards and modules, troubleshooting procedures, control service and calibration, servicing the generator, day tank fuel transfer pumps, optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and provides detailed technical information, component specifications, and repair and maintenance procedures.
Cummins onan generator set with power command 3100 controller model (dfbf ) s...jfjjsekdmme
This document is a service manual that provides information for troubleshooting and servicing generator sets and their PowerCommand 3100 controllers. It includes sections that cover control operation, circuit boards and modules, troubleshooting procedures, control service and calibration, servicing the generator, day tank fuel transfer pumps, optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and provides detailed technical information, component specifications, and repair and maintenance procedures.
Cummins onan generator set with power command 3100 controller model (dfbc ) s...jfjjsekdmme
This document is a service manual that provides information for troubleshooting and servicing generator sets and their PowerCommand 3100 controllers. It includes sections on control operation, circuit boards and modules, troubleshooting, control service and calibration, servicing the generator, day tank and optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and details the generator set models and specifications that it covers.
Case tv370 tier 4 b (final) alpha series compact track loader service repair ...jfjjsekdmme
This document is a service manual that contains specifications and repair/maintenance procedures for skid steer loaders and compact track loaders. It includes sections on the engine, power coupling, front/rear axle systems, hydrostatic drive, brakes, hydraulic systems, frames, wheels, tracks, cab climate control, electrical systems, front loader/bucket, platform/cab, and general specifications. Safety procedures and torque specifications are provided. Only qualified dealership personnel should perform repair and maintenance following the instructions strictly.
This document provides repair procedures for various components of a lift truck, including the counterweight, hood, overhead guard, LED lights, and operator restraint system. It describes removing and installing the counterweight, which involves installing eyebolts and a lifting device. The hood repair section notes the gas assist cylinders and wiring harness that need to be disconnected. LED light assemblies must be replaced as a unit rather than repaired. The operator restraint system, including the seat belt, hip restraint, seat, hood and latches, is checked to ensure it is secure and functioning properly.
Case sv340 tier 4b (final) alpha series skid steer loader service repair manu...jfjjsekdmme
This document is a service manual that provides maintenance and repair instructions for SR270/SV340 skid steer loaders and TR340/TV380 compact track loaders with Tier 4B engines. It contains sections on the engine, power coupling, axles, hydrostatic drive, brakes, hydraulics, frames, wheels, tracks, cab climate control, electrical systems, front loader, platform/cab, and introduction/safety information. Repair and maintenance should only be performed by qualified dealership personnel using the proper tools and approved parts.
Case sr240 tier 4 b (final) alpha series skid steer loader service repair manualjfjjsekdmme
This document is a service manual that provides instructions and specifications for servicing Case construction equipment, including skid steer loaders and compact track loaders. It contains sections on the engine, power coupling, front and rear axles, hydrostatic drive, brakes and controls, hydraulic systems, frames and ballasting, wheels, tracks and track suspension, cab climate control, electrical systems, front loader and bucket, and platform, cab, bodywork and decals. The document provides standard torque specifications for hydraulics and minimum tightening torques for normal assembly. It also includes safety rules and notices for working on the equipment.
Case sr130 tier 4 b (final) alpha series skid steer loader service repair manualjfjjsekdmme
This document is a service manual for Case SR130 and SR160 skid steer loaders with Tier 4B engines. It contains introduction sections with safety information, torque specifications, and contamination guidelines. The bulk of the document provides maintenance and repair instructions organized by system, including the engine, hydraulic systems, electrical systems, frames, and other components. Section numbers and titles are provided for each subsystem.
Hyster e114 (e25 z) forklift service repair manualjfjjsekdmme
This document provides specifications and repair information for service of steering components on lift trucks, including:
- The steering system uses a steering control unit mounted to a adjustable steering housing. The housing holds the steering wheel and mounts other controls.
- The steering is hydraulic with no direct mechanical connection between the wheel and axle. A control unit and hydraulic circuit control steering.
- Even if the steering pump fails, limited steering is still possible via a check valve, though difficult without pump operation.
- Specifications and repair procedures are given for the steering housing, control unit, and related hydraulic system components. Additional information can be found in other service manuals.
New holland tt55 tractor service repair manualjfjjsekdmme
This document is a repair manual for New Holland TT55 and TT75 tractors. It provides detailed instructions and specifications for overhauling various engine systems, including the engine, lubrication system, coolant system, and fuel system. The manual contains sections covering the removal and installation of the engine, disassembly and assembly procedures, inspection and repair of engine components, specifications and torque values. It is intended to guide authorized repair technicians in properly servicing and maintaining the tractor engines.
New holland tc29 tractor service repair manualjfjjsekdmme
This document is the contents page for a repair manual covering various tractor models. It lists 12 sections that provide information on different vehicle systems, including the engine, fuel, electrical, transmission and hydraulic systems, as well as steering, axles, wheels and separating the tractor. The document encourages downloading the full repair manual.
New holland tc25 d tractor service repair manualjfjjsekdmme
This document is the contents page for a repair manual covering various tractor models. It lists 12 sections that provide information on different vehicle systems, including the engine, fuel, electrical, transmission and hydraulic systems, as well as steering, axles, wheels and separating the tractor. The document encourages downloading the full repair manual.
New holland mz14 h zero turn lawn mower service repair manualjfjjsekdmme
This repair manual provides information for repairing the MZ14H, MZ16H, and MZ18H zero radius tractors. The manual contains 7 sections that cover general information, the transaxle, chassis, mower decks, and electrical systems. Specifications for each model are provided, including engine details, dimensions, deck sizes, and other mechanical features. Safety warnings are given at the beginning to remind technicians to avoid injuries while servicing equipment.
Massey ferguson 4335 tractor service parts catalogue manual (part number 819...jfjjsekdmme
This document provides parts information for the crankshaft, pistons, and connecting rods for Massey Ferguson 4325 and 4335 tractors. It includes lists of parts with part numbers, quantities, descriptions, and notes. Key components include the crankshaft, connecting rods, pistons, piston rings, bearings, bolts, bushes, and other fasteners. The document separates information for different tractor models and engine serial number ranges.
Massey ferguson 4325 tractor service parts catalogue manual (part number 819...jfjjsekdmme
This document provides parts information for the crankshaft, pistons, and connecting rods for Massey Ferguson 4325 and 4335 tractors. It includes lists of parts with part numbers, quantities, descriptions, and notes. Key components include the crankshaft, connecting rods, pistons, bearings, and fasteners. The document provides parts for different tractor models and engine serial number ranges.
Kubota v3800 tie4 c diesel engine service repair manualjfjjsekdmme
The document provides information on safely servicing and operating diesel engines. It outlines important safety precautions including reading all instructions before starting work, parking the machine securely, disconnecting the battery, and wearing protective equipment. Specific hazards are identified such as hot surfaces that can cause burns, high pressure fuel/hydraulic lines, and ensuring good ventilation when the engine is running due to carbon monoxide.
Doosan d24 nap diesel engine service repair operation maintenance manualjfjjsekdmme
This document is an operation and maintenance manual for the Doosan D24NAP electronically controlled industrial diesel engine. It provides information to customers and technicians on engine management and maintenance techniques. The manual contains detailed specifications, diagrams and drawings to aid in proper maintenance and troubleshooting. It is intended to help ensure high-level maintenance, safety, and optimal engine performance through recommended operation methods and procedures.
Caterpillar cat 322 l excavator (prefix 9 jl) service repair manual (9jl00001...jfjjsekdmme
This document provides instructions for removing and installing a governor from Caterpillar 322 L, 322 LN, and 322 N excavators powered by a 3116 engine. The removal procedure involves disconnecting linkages and tubes, removing mounting bolts and clips, and extracting the governor from the engine. The installation procedure is the reverse of removal and includes cleaning, lubricating, and adjusting components as needed. Special tools are required to remove the governor and reinstall components properly.
This document provides instructions for servicing the air conditioning system on a Caterpillar 322L excavator. It describes safety precautions that must be followed when working on refrigerant systems, which can be hazardous if guidelines are not properly followed. The document outlines procedures for preparing the machine for service, recovering refrigerant, replacing components, adding new refrigerant and oil, and evacuating and charging the system. Technicians are instructed to keep the system clean and plug all openings to prevent contamination.
Caterpillar cat 320 l track type excavator (prefix 9kk) service repair manual...jfjjsekdmme
The document provides instructions for installing a cylinder head on a Caterpillar 3064 or 3066 engine. It describes cleaning the cylinder head and block mating surfaces, installing a new gasket, lifting the cylinder head into place, and torquing the head bolts to the specified sequence and values. It also notes that the 3066 engine has two cylinder heads to install while the 3064 has one.
Caterpillar cat 320 track type excavator (prefix 9 kk) service repair manual ...jfjjsekdmme
The document provides instructions for servicing components of a Caterpillar 320L excavator engine:
1) It describes how to assemble the rocker shaft, including installing bushings, spacers, clips, and shaft components in the correct order.
2) It details installing the rocker shaft and pushrods onto the cylinder head, including tightening bolts to the specified torque.
3) It outlines removing the cylinder head, including removing bolts in the correct sequence, lifting the head off with tools, and removing the gasket.
Cummins onan generator set with power command 3100 controller model (dfbf ) s...jfjjsekdmme
This document is a service manual that provides information for troubleshooting and servicing generator sets and their PowerCommand 3100 controllers. It includes sections that cover control operation, circuit boards and modules, troubleshooting procedures, control service and calibration, servicing the generator, day tank fuel transfer pumps, optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and provides detailed technical information, component specifications, and repair and maintenance procedures.
Cummins onan generator set with power command 3100 controller model (dfbc ) s...jfjjsekdmme
This document is a service manual that provides information for troubleshooting and servicing generator sets and their PowerCommand 3100 controllers. It includes sections on control operation, circuit boards and modules, troubleshooting, control service and calibration, servicing the generator, day tank and optional enclosure fuel tank systems, and wiring diagrams. The manual contains important safety instructions and details the generator set models and specifications that it covers.
Case tv370 tier 4 b (final) alpha series compact track loader service repair ...jfjjsekdmme
This document is a service manual that contains specifications and repair/maintenance procedures for skid steer loaders and compact track loaders. It includes sections on the engine, power coupling, front/rear axle systems, hydrostatic drive, brakes, hydraulic systems, frames, wheels, tracks, cab climate control, electrical systems, front loader/bucket, platform/cab, and general specifications. Safety procedures and torque specifications are provided. Only qualified dealership personnel should perform repair and maintenance following the instructions strictly.
This document provides repair procedures for various components of a lift truck, including the counterweight, hood, overhead guard, LED lights, and operator restraint system. It describes removing and installing the counterweight, which involves installing eyebolts and a lifting device. The hood repair section notes the gas assist cylinders and wiring harness that need to be disconnected. LED light assemblies must be replaced as a unit rather than repaired. The operator restraint system, including the seat belt, hip restraint, seat, hood and latches, is checked to ensure it is secure and functioning properly.
Case sv340 tier 4b (final) alpha series skid steer loader service repair manu...jfjjsekdmme
This document is a service manual that provides maintenance and repair instructions for SR270/SV340 skid steer loaders and TR340/TV380 compact track loaders with Tier 4B engines. It contains sections on the engine, power coupling, axles, hydrostatic drive, brakes, hydraulics, frames, wheels, tracks, cab climate control, electrical systems, front loader, platform/cab, and introduction/safety information. Repair and maintenance should only be performed by qualified dealership personnel using the proper tools and approved parts.
Case sr240 tier 4 b (final) alpha series skid steer loader service repair manualjfjjsekdmme
This document is a service manual that provides instructions and specifications for servicing Case construction equipment, including skid steer loaders and compact track loaders. It contains sections on the engine, power coupling, front and rear axles, hydrostatic drive, brakes and controls, hydraulic systems, frames and ballasting, wheels, tracks and track suspension, cab climate control, electrical systems, front loader and bucket, and platform, cab, bodywork and decals. The document provides standard torque specifications for hydraulics and minimum tightening torques for normal assembly. It also includes safety rules and notices for working on the equipment.
Case sr130 tier 4 b (final) alpha series skid steer loader service repair manualjfjjsekdmme
This document is a service manual for Case SR130 and SR160 skid steer loaders with Tier 4B engines. It contains introduction sections with safety information, torque specifications, and contamination guidelines. The bulk of the document provides maintenance and repair instructions organized by system, including the engine, hydraulic systems, electrical systems, frames, and other components. Section numbers and titles are provided for each subsystem.
Hyster e114 (e25 z) forklift service repair manualjfjjsekdmme
This document provides specifications and repair information for service of steering components on lift trucks, including:
- The steering system uses a steering control unit mounted to a adjustable steering housing. The housing holds the steering wheel and mounts other controls.
- The steering is hydraulic with no direct mechanical connection between the wheel and axle. A control unit and hydraulic circuit control steering.
- Even if the steering pump fails, limited steering is still possible via a check valve, though difficult without pump operation.
- Specifications and repair procedures are given for the steering housing, control unit, and related hydraulic system components. Additional information can be found in other service manuals.
New holland tt55 tractor service repair manualjfjjsekdmme
This document is a repair manual for New Holland TT55 and TT75 tractors. It provides detailed instructions and specifications for overhauling various engine systems, including the engine, lubrication system, coolant system, and fuel system. The manual contains sections covering the removal and installation of the engine, disassembly and assembly procedures, inspection and repair of engine components, specifications and torque values. It is intended to guide authorized repair technicians in properly servicing and maintaining the tractor engines.
New holland tc29 tractor service repair manualjfjjsekdmme
This document is the contents page for a repair manual covering various tractor models. It lists 12 sections that provide information on different vehicle systems, including the engine, fuel, electrical, transmission and hydraulic systems, as well as steering, axles, wheels and separating the tractor. The document encourages downloading the full repair manual.
New holland tc25 d tractor service repair manualjfjjsekdmme
This document is the contents page for a repair manual covering various tractor models. It lists 12 sections that provide information on different vehicle systems, including the engine, fuel, electrical, transmission and hydraulic systems, as well as steering, axles, wheels and separating the tractor. The document encourages downloading the full repair manual.
New holland mz14 h zero turn lawn mower service repair manualjfjjsekdmme
This repair manual provides information for repairing the MZ14H, MZ16H, and MZ18H zero radius tractors. The manual contains 7 sections that cover general information, the transaxle, chassis, mower decks, and electrical systems. Specifications for each model are provided, including engine details, dimensions, deck sizes, and other mechanical features. Safety warnings are given at the beginning to remind technicians to avoid injuries while servicing equipment.
Massey ferguson 4335 tractor service parts catalogue manual (part number 819...jfjjsekdmme
This document provides parts information for the crankshaft, pistons, and connecting rods for Massey Ferguson 4325 and 4335 tractors. It includes lists of parts with part numbers, quantities, descriptions, and notes. Key components include the crankshaft, connecting rods, pistons, piston rings, bearings, bolts, bushes, and other fasteners. The document separates information for different tractor models and engine serial number ranges.
Massey ferguson 4325 tractor service parts catalogue manual (part number 819...jfjjsekdmme
This document provides parts information for the crankshaft, pistons, and connecting rods for Massey Ferguson 4325 and 4335 tractors. It includes lists of parts with part numbers, quantities, descriptions, and notes. Key components include the crankshaft, connecting rods, pistons, bearings, and fasteners. The document provides parts for different tractor models and engine serial number ranges.
Kubota v3800 tie4 c diesel engine service repair manualjfjjsekdmme
The document provides information on safely servicing and operating diesel engines. It outlines important safety precautions including reading all instructions before starting work, parking the machine securely, disconnecting the battery, and wearing protective equipment. Specific hazards are identified such as hot surfaces that can cause burns, high pressure fuel/hydraulic lines, and ensuring good ventilation when the engine is running due to carbon monoxide.
Doosan d24 nap diesel engine service repair operation maintenance manualjfjjsekdmme
This document is an operation and maintenance manual for the Doosan D24NAP electronically controlled industrial diesel engine. It provides information to customers and technicians on engine management and maintenance techniques. The manual contains detailed specifications, diagrams and drawings to aid in proper maintenance and troubleshooting. It is intended to help ensure high-level maintenance, safety, and optimal engine performance through recommended operation methods and procedures.
Caterpillar cat 322 l excavator (prefix 9 jl) service repair manual (9jl00001...jfjjsekdmme
This document provides instructions for removing and installing a governor from Caterpillar 322 L, 322 LN, and 322 N excavators powered by a 3116 engine. The removal procedure involves disconnecting linkages and tubes, removing mounting bolts and clips, and extracting the governor from the engine. The installation procedure is the reverse of removal and includes cleaning, lubricating, and adjusting components as needed. Special tools are required to remove the governor and reinstall components properly.
This document provides instructions for servicing the air conditioning system on a Caterpillar 322L excavator. It describes safety precautions that must be followed when working on refrigerant systems, which can be hazardous if guidelines are not properly followed. The document outlines procedures for preparing the machine for service, recovering refrigerant, replacing components, adding new refrigerant and oil, and evacuating and charging the system. Technicians are instructed to keep the system clean and plug all openings to prevent contamination.
Caterpillar cat 320 l track type excavator (prefix 9kk) service repair manual...jfjjsekdmme
The document provides instructions for installing a cylinder head on a Caterpillar 3064 or 3066 engine. It describes cleaning the cylinder head and block mating surfaces, installing a new gasket, lifting the cylinder head into place, and torquing the head bolts to the specified sequence and values. It also notes that the 3066 engine has two cylinder heads to install while the 3064 has one.
Caterpillar cat 320 track type excavator (prefix 9 kk) service repair manual ...jfjjsekdmme
The document provides instructions for servicing components of a Caterpillar 320L excavator engine:
1) It describes how to assemble the rocker shaft, including installing bushings, spacers, clips, and shaft components in the correct order.
2) It details installing the rocker shaft and pushrods onto the cylinder head, including tightening bolts to the specified torque.
3) It outlines removing the cylinder head, including removing bolts in the correct sequence, lifting the head off with tools, and removing the gasket.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
Custom Solutions: We understand that every project is unique, which is why we offer custom crane solutions tailored to your specific requirements. Whether you need modifications, attachments, or specialized equipment, we can design and implement solutions that meet your needs.
At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
7. Contents
INTRODUCTION
Foreword - Ecology and the environment ...................................................... 3
Foreword - How to use and navigate through this manual ..................................... 4
Safety rules ..................................................................................... 9
Basic instructions - Important notice regarding equipment servicing ......................... 10
Torque - Minimum tightening torques for normal assembly ................................... 11
Torque - Standard torque data for hydraulics ................................................. 16
Consumables (Lubrications and Coolants) ................................................... 18
Capacities ..................................................................................... 20
47505533 11/02/2013
2
8. INTRODUCTION
Foreword - 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.
• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not
be allowed to get into the soil, but should be collected and disposed of properly.
• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.
Your NEW HOLLAND AGRICULTURE 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.
47505533 11/02/2013
3
9. INTRODUCTION
Foreword - How to use and navigate through this manual
This manual has been produced by a new technical information system. This new system is designed to deliver
technical information electronically through web delivery (eTIM), DVD, and paper manuals. A coding system called
SAP has been developed to link the technical information to other Product Support functions, e.g., Warranty.
Technical information is written to support the maintenance and service of the functions or systems on a customer's
machine. When a customer has a concern on their machine it is usually because a function or system on their ma-
chine is not working at all, is not working efficiently, or is not responding correctly to their commands. When you refer
to the technical information in this manual to resolve that customer's concern, you will find all the information classified
using the SAP coding, according to the functions or systems on that machine. Once you have located the technical
information for that function or system, you will then find all the mechanical, electrical or hydraulic devices, compo-
nents, assemblies, and sub assemblies for that function or system. You will also find all the types of information that
have been written for that function or system: the technical data (specifications), the functional data (how it works),
the diagnostic data (fault codes and troubleshooting), and the service data (remove, install adjust, etc.).
By integrating SAP coding into technical information, you will be able to search and retrieve just the right piece of
technical information you need to resolve that customer's concern on his machine. This is made possible by attaching
3 categories to each piece of technical information during the authoring process.
The first category is the Location, the second category is the Information Type and the third category is the Product:
• LOCATION - the component or function on the machine, that the piece of technical information is going to describe
(e.g., Fuel tank).
• INFORMATION TYPE - the piece of technical information that has been written for a particular component or func-
tion on the machine (e.g., Capacity would be a type of Technical Data describing the amount of fuel held by the fuel
tank).
• PRODUCT - the model for which the piece of technical information is written.
Every piece of technical information will have those three categories attached to it. You will be able to use any combi-
nation of those categories to find the right piece of technical information you need to resolve that customer's concern
on their machine.
That information could be:
• the procedure for how to remove the cylinder head
• a table of specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool
47505533 11/02/2013
4
14. Engine - Engine and crankcase
Engine - Torque
Tightening torques
Cylinder head bolts and nuts 80 Nm + 90 ° + 90 °
Cylinder head bolts in the cylinder block 30 Nm
Crankshaft bearing screws 200 Nm
Connecting rod bolts (Torx E18) 40 Nm + 80 Nm + 90 °
Nuts on crankshaft (right-hand thread) 1000 Nm
Pulley screws 30 Nm
Mounting bolts for flywheel 150 Nm
Mounting bolts for flywheel housing:
- inner screws, M10 80 Nm
- outer screws, M12 150 Nm
Retaining screws for idler gear (with plain bearing):
- M10 60 Nm
- M14 200 Nm
Overflow valve - piston cooling nozzle 30 Nm
Nut for lubrication oil pump gear 60 Nm
Retaining screws for lubrication oil pump 60 Nm
Connection part to the engine oil cooler 60 Nm
Nut to the pulley of the cooling water pump 120 Nm
Fastening - Visco fan on Visco hub 30 Nm
Bolts/nuts to the exhaust manifold 50 Nm
Screws to the air intake channel 30 Nm
Nut - driving toothed wheel, high pressure pump 90 Nm
Mounting bolt, injector 40 Nm
High pressure line from high pressure pump to rail 30 Nm
High pressure line from rail to the injectors 25 Nm
Low pressure line to the high pressure pump 25 Nm
NOTE: Use washers for aluminium parts.
Always use for the values in the table below
if no special tightening torques are provided.
Tightness
Thread
8.8 10.9
M8 25 Nm 35 Nm
M10 50 Nm 75 Nm
Screws for the self-supporting oil pan
1 M8 25 Nm
2 M10 90 Nm
3 M14 160 Nm
4 M20 600 Nm
SS99N015 1
47505533 11/02/2013
10.1 [10.001] / 3
15. Engine - Engine and crankcase
Engine - Static description
General information
The diesel engines in the 620 series described in this manual are water-cooled four stroke straight-type engines with
common rail injection systems. All of the models are equipped with wet, replaceable cylinder liners and exhaust
turbochargers and charge air cooling (air/air). The engines are controlled by the EEM3 control unit.
The exhaust regulations according to Level 3A are complied with.
Cylinder block
The rib-braced cylinder block is the main unit of the
engine, on which the other engine components are
affixed.
The wet and replaceable cylinder liners are supported in
the centre, reducing vibrations and feeding most of the
coolant flow to the upper part of the cylinder liners.
The seal between the lower part of the cylinder liner and
the cylinder block is made by three O-rings, which are
inserted in the grooves in the cylinder liner. The upper
part is sealed by the cylinder head gasket.
The camshaft is in the cylinder block. All camshaft
bearings are equipped with replaceable liners.
Guide bearings are integrated on both sides of the
rear main bearing of the crankshaft (crankshaft axial
bearings).
SS05N374 1
Flywheel housing
The flywheel housing is positioned at the rear end of the cylinder block. The gasket for the rear end of the crankshaft
is inserted in a hole in the housing. The point of starter attachment is in the flywheel housing.
The underside of the flywheel housing serves as the sealing surface for the oil pan gasket. This means that the lower
surface of the cylinder block must make a flush seal with the flywheel housing. When installing the flywheel housing,
its position is determined by roll springs.
47505533 11/02/2013
10.1 [10.001] / 14
16. Engine - Engine and crankcase
Cylinder head
The engines have two cylinder heads which can be
interchanged. Each cylinder has its own intake and
exhaust channel in the cylinder head. There is an inlet
valve between the outlet valves to compensate the
thermal load.
The cylinder head bolts are high-strength pre-tensioned
bolts that are tightened to their yield limit following the
principle of angular tightening. Given the high level of
expansion, the tightening forces are kept constant over
the entire usage period which means that tightening is
not needed.
The injection nozzle seats are machined directly in the
cylinder head. The inlet and outlet valve guides are
identical and can be interchanged. In addition to this,
the inlet and outlet valves are equipped with replaceable
valve seat sets.
SS05N284 2
Valve mechanism
The valve mechanism is actuated by the camshaft in the cylinder block. The actuation force is transferred by valve
tappets and tappet rods.
The press-fit camshaft gear sits on the camshaft and is radially fixed with a feather key. The bearings are lubricated
through holes in the engine block with pressurised oil.
Exhaust gas return system (EGR)
Due to a tightening of legal regulations concerning
exhaust emissions (tier 3) it has become necessary to
employ a range of measures to fulfill these requirements.
One of these measures is an internal exhaust gas
recirculation system (EGR). A special camshaft allows
an internal exchange of gases without the need for
additional components.
An additional inlet cam (c) on the camshaft opens the
inlet valve 2 mm during the exhaust stroke. Using this
method a part of the exhaust gas is channelled into the
intake channel and recirculated back to the cylinder
during the intake stroke. Because the cam (c) opens the
inlet valve in every operating condition, it depends on the
boost pressure on the one hand and the exhaust gas
pressure on the other as to how much exhaust gas is
returned and whether any exhaust gas is returned at all.
SS08A124 3
47505533 11/02/2013
10.1 [10.001] / 15
17. Engine - Engine and crankcase
SS08A125 4
(A) Angular degrees for the crankshaft (B) Opening stroke for the valves
(a) Outlet cam (b) Inlet cam
(c) EGR cam
Crank drive
The crankshaft is forged of chrome alloyed steel and is inductively hardened on the bearing and sealing surfaces.
The bearings can be ground four times without the need for rehardening. The press-fit gears sit on the front end of
the crankshaft. They drive the camshaft, the high pressure pump and the oil pump. In addition to this, the front end
of the crankshaft has keyways to take the drive hub. The pulley and rotational vibration absorber (Visco) are fitted on
the hub. The front PTO shaft is also driven by this hub (if present). An oil-repellent ring is fitted between the hub and
gear. One of the crankshaft's crank webs carries the transmitter wheel for the engine's speed sensor.
There is a main bearing for the crankshaft on both sides of each cylinder. It is therefore has seven bearings. The
crankshaft's axial bearings are on both sides of the rearmost main bearing. At the rear end of the crankshaft there is
a flywheel, on which a press-fit sprocket is added.
The forged connecting rods have an I-shaped cross-section. The connecting rod bearing is divided horizontally by
“breaking”. The bearing cover is fastened with two special screws. The upper part has a tapered bearing seat into
which the press-fit piston pin bearing bush is fitted.
The material from which the pistons are made is an eutectic aluminium alloy. There is a combustion cavity in the piston
top. An optimum mix of air and fuel is achieved thanks to the shape of the optimised combustion cavity. The pistons
have two sealing rings and an oil scraper ring. The upper piston ring, coated with molybdenum, has a trapezoid-
shaped cross-section.
The middle piston ring is a tapered compression piston ring (the outer diameter has a conical surface). The oil scraper
ring is suspended and has two chromed stripper edges.
The pistons are ring carrier pistons (for the receptacle for the upper piston ring, a ring carrier made of special cast
iron is poured into the piston). The piston shaft is also coated with graphite on the sliding surface to ensure a perfect
run in. The piston top is cooled from below by additional splash oil as soon as the oil pressure exceeds 3 bar.
47505533 11/02/2013
10.1 [10.001] / 16
18. Engine - Engine and crankcase
Damper (vibration absorber)
SS05N324 5
1. Housing 3. Space for silicone oil
2. Absorber bulk 4. Bearing bush
The damper stops the crankshaft from torsional vibrations and thus ensures that the engine runs smoothly. The
housing is screwed to the front end of the crankshaft together with the hub. It forms a ring-shaped cavity with a
right-angled cross-section. Inside it there is a ring-shaped absorber bulk which is mounted radially on a bearing bush
with little clearance. The free space is filled with semifluid silicone oil with a stable temperature. The housing is tightly
sealed. The damper is maintenance-free.
NOTE: The housing must not be deformed during transport, storage, disassembly and assembly. Dents into the hous-
ing could jam the absorber bulk (which otherwise moves freely) and thereby restrict the absorber's action. Damage
which leads to the absorber unit becoming leaky make the absorber ineffective as the silicone oil is lost. Absorbers
with dents in their housing must not be fitted.
NOTE: If markings need to be made on the absorber housing as an aid to performing certain adjustment work on the
engine, only marker pens or an electric engraver may be used for this purpose. Never make dents for markings.
47505533 11/02/2013
10.1 [10.001] / 17
19. Engine - Engine and crankcase
Timer gears
SS03G080 6
1. Camshaft gear 4. Twin idler gear
2. Idler gear 5. Drive wheel - crankshaft
3. Drive wheel - high pressure fuel pump
The meshings of the engine control unit gears are hardened and helical. The gears are located in the timer gear
housing which is fitted on the front of the engine.
The timer gears drive the camshaft, the high pressure fuel pump and the oil pump. The high pressure fuel pump is
driven by the twin idler gear (4). The idler gear (2) runs in pressure-lubricated plain bearings, as does the camshaft.
The journal is fastened to the front cylinder block surface. The twin idler gear is mounted with two taper roller bearings.
47505533 11/02/2013
10.1 [10.001] / 18
20. Engine - Engine and crankcase
Lubrication system
SS05N286 7
1. Lube oil pump 2. Oil pressure valve
3. Oil filter 4. Turbocharger
5. Main oil duct 6. Oil injection nozzle
7. Sensor
The engine is equipped with a pressure lubrication system whose oil pump (gear pump) is attached to the underside
of the cylinder block. The oil is sucked by the pump through a screener. From the pump, the oil is fed through an oil
line to the oil cooler (heat exchanger) and oil filter. The oil pressure valve is positioned parallel to this. Then the oil is
fed into the main oil duct from which other oil holes branch off. The oil is fed through holes to the main bearings and
through the crankshaft to the connecting rod bearings.
The pressurised oil is fed from the main oil duct to the turbocharger and to the pressurised air compressor (if exist-
ing). In addition, the bearings of the idler gear, the camshaft bearings and the valve mechanism are lubricated with
pressurised oil via the main oil duct.
The piston tops are sprayed with and cooled by oil from below as long as the lube oil pressure is greater than 3 bar.
The oil pressure valve regulates the lube oil pressure such that it is held at a certain range regardless of the engine
speed. Depending on speed, oil viscosity and temperature, the oil pressure is between 2.5 - 5 bar. At engine idling
speed, the oil pressure must be at least 1 bar.
The oil filter is a one-way main flow filter. An overflow valve located on the underside of the filter ensures the engine is
lubricated after a cold start at extremely low outside temperatures and ensures appropriate lubrication in the event of
the filter being blocked. A check valve prevents the filter being completely emptied of oil after the engine is switched
off.
47505533 11/02/2013
10.1 [10.001] / 19
21. Engine - Engine and crankcase
Cooling system
SS05N373 8
1. Coolant pump 2. Thermostats
3. Diversion duct 4. Radiator
5. Expansion tank 6. Oil cooler
7. Sensor, engine temperature
The coolant pump driven by the belt is fitted at the
front end of the cylinder block. The thermostat housing
is located above the pump. The cooling system is
equipped with two thermostats which regulate the flow
of coolant. The thermostats have different opening
temperatures. If the coolant temperature is below the
opening temperature, the coolant (A) flows back to
the coolant pump via the diversion duct. The smaller
single-action thermostat (1) starts to open at 79 °C and
allows some of the coolant (B) to flow into the radiator.
As the temperature in the engine rises, at 83 °C the
dual-circuit thermostat (2) also starts to open. When it
opens, it closes the diversion and directs the entire flow
of coolant (C) into the radiator.
SS05N287 9
47505533 11/02/2013
10.1 [10.001] / 20
22. Engine - Engine and crankcase
Fan
Visco fan with modulating hub (standard equipment) :
With the modulating hub, each incoming air temperature
corresponds to one particular slip.
As long as there is only little or no cooling requirement
the fan turns at low speed (= high slip) but dependent on
the engine speed. The airflow through the cooling set (air
conditioning condenser - charge air cooler - transmission
oil cooler - engine coolant cooler) acts upon the front
of the Visco hub.
At this point there is a bi-metallic spring which constantly
measures the outgoing air temperature after the coolant
cooler. As the outgoing air temperature rises (increasing
tractor load), the control valve reduces the slip and
the fan rotates faster depending on the temperature
until the minimum slip of approx. 5 % is achieved. As
the outgoing air temperature falls (decreasing tractor
load), the control valve increases the slip and the fan
rotates more slowly depending on the temperature. The
advantages of the Visco fan with modulating hub are:
more precise adjustment of cooling output to tractor load,
further reduction in fan's power requirements and lower
noise levels. The Visco fan is maintenance-free.
SS03G024 10
47505533 11/02/2013
10.1 [10.001] / 21
23. Engine - Engine and crankcase
Reverse fan (option):
The blades of the reverse fan are fitted to the hub such that they are able to be twisted. The built-in thermo-elements
allow the angle of the blades to be varied during operation and the degree of cooling by the fan to be adjusted to the
level required. Return springs hold the blades in a secure position.
The following automatic sequence is activated by tipping the “fan reverse” button:
The electronic central control unit (ECCU3) controls a small air compressor, driven by an electric motor, and a solenoid
valve. This control unit is mounted to the left of the engine. Via a pressure line and a special seal, pressurised air
reaches the centering actuators which rotate with the hub and the blades, turning the blades. As a consequence,
a powerful flow of air blows in the opposite direction through the cooler and any material drawn in, such as grass,
flowers, insects etc. is removed by the radiators. After 30 seconds the blades automatically return to the home
position. If the driver undertakes the relevant programming the activation of the fan reverse function can also take
place automatically, e.g. in connection with automated processes involving the rear or front powerlift or the AUX
auxiliary control units.
SS05N282 11
47505533 11/02/2013
10.1 [10.001] / 22
24. Engine - Engine and crankcase
Intake and exhaust system
SS05N357 12
Compared to aspirated engines, engines which are turbocharged react more sensitively to badly maintained air filters
and leaks in the intake and exhaust system.
Therefore the prescribed maintenance and inspection work is to be carried out conscientiously and the maintenance
intervals observed.
Condition of the air filter and the intake system:
The engine’s performance and the life of the engine are also largely dependent on the condition of the air filter and
the intake system.
Too dirty an air filter or a bent intake hose will reduce the engine's performance and result in engine oil being drawn
in through the shaft mounting gasket in the turbocharger.
NOTE: A leaky air filter (damaged air cartridge, damaged or missing seal) or leaks in the intake system between the
air filter and the turbocharger allow larger impurities to enter the turbocharger and subsequently the cylinders of the
engine.
The filter system for the engine's intake air consists of an advance cyclone filter (integrated in the air filter) and a dry
air filter with safety cartridge. The intake air is rotated in the advance cyclone filter. Heavy particles of dirt are thereby
deposited towards the outside and are separated by the advance cyclone filter’s dust removal valve.
Ejector:
The tractor can be equipped with an “ejector system” for use in extremely dusty conditions. An injector, whose hose
connection sucks continuously when the engine is running, is fitted in the exhaust system. The dust particles sepa-
rating in the pre-filter are continuously sucked up via a hose connection and discharged into the atmosphere together
with the exhaust gas.
47505533 11/02/2013
10.1 [10.001] / 23
25. Engine - Engine and crankcase
Design of the filter cartridges:
The dirt particles in the air are collected in the main cartridge which can be cleaned if necessary. The inner safety
cartridge prevents dirt particles penetrating into the engine in the event of a fault or an incorrectly installed main
cartridge. For maintenance of the filter cartridge please see the operating instructions.
Display for filter service:
There is a pressure difference switch in the filter housing. This switch illuminates a monitoring lamp and a symbol on
the ADIC when the air filter has reached a particular level of contamination. The intake system also includes the air
pipes between the air filter and the turbocharger, and between the turbocharger and the charge air cooler, as well as
between the charge air cooler and the intake manifold.
The exhaust manifold is affixed to the cylinder head with special screws without a separate gasket. Retightening the
special screws is not necessary.
The turbocharger is lubricated and cooled with oil from the engine lubrication system.
Charge air cooling:
The intake air compressed by the turbocharger can reach a temperature of up to 150 °C for high degrees of capacity
utilisation. It is cooled to 50 - 60 °C in a charge air cooler which is located in front of the engine radiator (air/air version).
Cooling the charge air lowers the thermal and mechanical load on the engine and reduces the discharge of nitrogen
oxides and sooty particles.
Boost pressure and charged air temperature as parameters for engine control:
A combined sensor is located in the air collector. It continually supplies the electronic engine management (EEM3)
with information about the boost pressure and charged air temperature. In conjunction with the common rail injection
system, fuel injection is optimised and the discharge of nitrogen oxides and sooty particles is significantly reduced.
The charge air cooler is designed to be service-friendly. It can be folded up and can thus be effectively cleaned against
the direction of the outside air blowing against it. The folding charge air cooler also allows easy access to the other
coolers.
47505533 11/02/2013
10.1 [10.001] / 24
26. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
27. Engine - Engine and crankcase
Engine - Service instruction (Lifting the engine)
SS08A116 1
NOTICE: Lift the engine using suitable lifting gear. The load must lie vertically on the towing lugs (A).
47505533 11/02/2013
10.1 [10.001] / 25
28. Engine - Engine and crankcase
Crankcase - Service instruction
Measuring the wear of the cylinder liners
1. Use a micrometer screw or a new cylinder liner,
(starting measurement 108,00 mm) to set dial gauge
to zero.
2. Clean the inner surface of the cylinder liner thor-
oughly before the measurement.
SS05N289 1
3. Take measurements at the upper end, at the lower
end and in the centre of the cylinder liner.
4. Check the display value for max. wear and runout
(compare with nominal values).
Removing the cylinder liner
5. If the cylinder liners are to be used again, they must
be marked so that they can be reused in the same
position.
47505533 11/02/2013
10.1 [10.001] / 26
29. Engine - Engine and crankcase
6. Remove the cylinder liners using the puller
380000011 and 1TSW 510.
SS99N037 2
Checking the cylinder block
7. Clean the cylinder block and all oil lines.
8. Check cooling ducts and to ensure correct engine
cooling, remove scale and dirt deposits from the en-
gine.
9. Check that cup plugs and threaded plugs in cylin-
der block are secure and examine cylinder block and
sealing surfaces to ensure their condition is OK.
10. Measure wear of camshaft bearings (compare with
nominal values).
NOTE: If the upper surface of the cylinder block must
be worked, the pistons must be shortened by the same
amount. Check the valve plate release on the upper
surface of the piston.
Changing the camshaft bearing bush
11. Pull out the bearing bush with an inner removal tool.
When the rear end connecting piece of the camshaft
has been removed, drive out the bearing bush using
a long drift.
12. Clean the bush seat.
13. Press in a new bearing bush. Note the position of
the oil hole. The bearing bush does not need to be
reamed, as a correctly installed bearing bush has a
correct inner diameter.
NOTE: All camshaft bearing points have a separate bear-
ing bush. Observe the different outer diameters when re-
moving and pressing in the bearing bushes.
SS05N361 3
47505533 11/02/2013
10.1 [10.001] / 27
30. Engine - Engine and crankcase
SS05N292 4
The numbering starts at the front end of the engine.
Bore diameter Bore diameter
1. 55,62 - 55,65 mm 4. 55,42 - 55,45 mm
2. 55,42 - 55,45 mm 5. 55,64 - 55,67 mm
3. 55,22 - 55,25 mm
Oversize bearing bushes for the camshaft
If the seat of the camshaft bearing bush (front bearing) is damaged, a bearing bush with an oversize outer diameter
of 0,4 mm can be fitted. The machining dimensions for the seats of the bearing bushes are shown in the figure.
SS05N293 5
Note the position of the oil holes in the bearing bushes. (see sectional drawing A-A)
The bearing bushes must not be reamed after being inserted
Camshaft oversize bearing bushes
Bore diameter Bore diameter
1. 56,02 - 56,05 mm 4. 55,62 - 55,65 mm
2. 55,62 - 55,65 mm 5. 55,84 - 55,87 mm
3. 55,42 - 55,45 mm
Inserting the plug on the rear end of the camshaft
14. Clean the seat for the plug.
15. Apply sealing material (e.g. Loctite 572) on the plug's
contact surface.
47505533 11/02/2013
10.1 [10.001] / 28
31. Engine - Engine and crankcase
16. Press the plug in with the press-in tool 380000004.
NOTE: Do not drive plug in too far because it may other-
wise affect the camshaft's axial clearance.
SS05N295 6
Pressing in an oversize plug on the rear end of the camshaft after inserting an oversize
bearing bush
The standard plug is replaced with an oversize plug with
an O-ring seal after working the bore.
7
Inserting the cylinder liner
17. Clean the cylinder liner and the liner recess in the
cylinder block. The liner must turn freely without an
O-ring in its installed position.
18. Apply a thin layer of marking colour on the bottom
of the cylinder liner flange. Insert the cylinder liner
without O-rings and turn in both directions. Pry out
the cylinder liner and check whether the coating has
deposited over the entire contact face.
19. Clean the contact surfaces.
47505533 11/02/2013
10.1 [10.001] / 29
32. Engine - Engine and crankcase
20. Insert the cylinder liners and fix each liner with two
clamps. Measure the cylinder liner height with a dial
gauge and the holder 380000364. Set the dial gauge
on a flat surface to zero, e.g. the cylinder block sur-
face. Measure each cylinder liner at four places. The
cylinder liner should protrude from the cylinder block
face by between 0,03 - 0,08 mm.
The difference in height between the cylinder liners
under one cylinder head must not exceed 0,02 mm.
In addition no central cylinder liner must lie lower than
one of the outer ones.
SS99N048 8
21. If a cylinder liner is too low, a liner with a higher flange
must be inserted.
SS05N294 9
Height (H) Marking grooves
(number)
9,03 mm (+ 0,02 mm) (standard)
9,08 mm (+ 0,02 mm) 1
9,13 mm (+ 0,02 mm) 2
9,23 mm (+ 0,02 mm) 3
An oversize of the cylinder liner (higher flange) is labelled as
follows on the exterior with one or more marking grooves:
1. Oversize, 0,05 mm = 1 marking groove
2. Oversize, 0,10 mm = 2 marking grooves
3. Oversize, 0,20 mm = 3 marking grooves
47505533 11/02/2013
10.1 [10.001] / 30
33. Engine - Engine and crankcase
22. If the liner height of a cylinder liner is not the same
over the entire circumference, cylinder liner flange
and recess depth of the cylinder block must be
checked. Cylinder liners with deformed flanges must
be replaced. If necessary, work the bush seat in the
cylinder block with a seat cutter.
SS99N050 10
23. Insert O-rings in grooves of bottom cylinder section
and lubricate with liquid soap (not engine oil).
NOTE: When pulling on the cylinder liners, stretch the
O-rings as little as possible. The max. permitted expan-
sion is 6 %.
SS05N291 11
24. Press the cylinder liners into the cylinder block. It
should be possible to press them in easily until they
are in the initial position. Make sure that the cylin-
der liners can no longer move upwards after being
pressed in.
47505533 11/02/2013
10.1 [10.001] / 31