CASE IH JX1095N Tractor Service Repair Manual Instant Download

1
JX1075N - JX1095N REPAIR MANUAL COMPLETE
CONTENTS
SECTION 00 - GENERAL .............................
............... 2 SECTION 10 - ENGINE
..............................................
2 SECTION 18 - CLUTCH ............................
.................. 7 SECTION 21 - TRANSMISSIONS
..................................... 9 SECTION
23 - MFD TRANSFER BOX AND AUTO MFD
................. 10 SECTION 25 - FRONT AXLE
MECHANICAL TRANSMISSION ........... 12 SECTION
27 - REAR AXLE MECHANICAL TRANSMISSION
............. 14 SECTION 31 - MECHANICAL POWER
TAKE-OFF ...................... 15 SECTION 33 -
BRAKES ...........................................
... 16 SECTION 35 - HYDRAULIC SYSTEM
.................................. 17 SECTION 41
- STEERING .......................................
..... 19 SECTION 44 - FRONT AXLE - 2WD
................................... 20 SECTION 50
- CAB CLIMATE CONTROL ............................
.. 21 SECTION 55 - ELECTRICAL SYSTEM
................................. 23 SECTION 90
- CAB, PLATFORM, AND BODYWORK ....................
29 The following pages are the collation of the
contents pages from each section and chapter of
the JX1075N - JX1095N Tractor Repair manual.
Complete Repair part 87352289. The sections
used through out all Case IH product Repair
manuals may not be used for each product. Each
Repair manual will be made up of one or several
books. Each book will be labeled as to which
sections are in the overall Repair manual and
which sections are in each book. The sections
listed above are the sections utilized for the
JX1075N - JX1095N Tractors.
? 2005 CNH America LLC Printed In U.S.A.
87352295 6/05
2
SECTION 00 - GENERAL - CHAPTER 1
1
SECTION 00 - GENERAL Chapter 1 -
General CONTENTS
Description Page General Instructions
..................................................
.......... 3 Health and Safety ...................
...........................................
5 Precautionary Statements .......................
.............................. 15 Safety
..................................................
.................... 16 Ecology and the
Environment ......................................
............ 19 Minimum Hardware Tightening
Torques .........................................
20 Federal Emissions Warranty ...................
................................ 22 California
Emission Control Warranty Statement
.................................. 23
Consumables ......................................
.......................... 25
Section
3
SECTION 00 - GENERAL - CHAPTER 1 WARNING WARNING
2
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.
The Manufacturer and all organizations belong-
ing to the Manufacturers distribution network,
including but not restricted to national,
regional or local distributors, will accept no
responsibility for personal injury or damage to
property caused by abnormal function of parts
and/or compo- nents not approved by the
Manufacturer, including those used for
maintenance and/or repair of the product
manufactured or marketed by the Manufacturer. In
any case, the product manufactured or marketed
by the Manufacturer is covered by no guarantee
of any kind against personal injury or damage to
property caused by abnormal function of parts
and/or components not approved by the
Manufacturer.
WARNING
Anyone who performs the operations described
herein without strictly following the
instructions is personally responsible for
resulting injury or damage to property.
4
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SECTION 00 - GENERAL - CHAPTER 1
3
GENERAL INSTRUCTIONS
IMPORTANT NOTICE All maintenance and repair
operations described in this manual should be
carried out exclusively by the authorised
workshops. All instructions detailed should be
carefully observed and special equipment
indicated should be used if necessary. Everyone
who carries out service operations described
without carefully observing these prescrip-
tions will be directly responsible of deriving
damages.

• Take care to insert the seal perpendicularly to
  its seat while you are pressing it. Once the
  seal is settled, ensure that it contacts the
  thrust element, if required
• To prevent damaging the sealing lip against the
  shaft, place a suitable protection during
  installation.

O RINGS Lubricate the O rings before inserting
them into their seats. This will prevent the O
rings from roll over and twisting during
mounting, which will jeopardize sealing.
SHIMMING At each adjustment, select adjusting
shims, measure them individually using a
micrometer and then sum up recorded values. Do
not rely on measuring the whole shimming set,
which may be incorrect, or on the rated value
indicated for each shim.
SEALERS Apply silicone/gasket eliminator over the
mating surfaces marked with an X. Before
applying the sealer, prepare the surface as
follows
ROTATING SHAFT SEALS To correctly install
rotating shaft seals, observe the following
instructions

• remove possible scales using a metal brush
• thoroughly degrease the surfaces using one of
  the following cleaning agents trichlorethylene,
  diesel fuel or a water and soda solution.

• Let the seal soak into the same oil as it will
  seal for at least half an hour before mounting
• Thoroughly clean the shaft and ensure that the
  shaft working surface is not damaged
• Place the sealing lip towards the fluid. In case
  of a hydrodynamic lip, consider the shaft
  rotation direction and orient grooves in order
  that they deviate the fluid towards the inner
  side of the seal
• Coat the sealing lip with a thin layer of
  lubricant (oil rather than grease) and fill the
  gap between the sealing lip and the dust lip of
  double lip seals with grease
• Insert the seal into its seat and press it down
  using a flat punch. Do not tap the seal with a
  hammer or a drift

BEARINGS It is advisable to heat the bearings to
80? to 90?C (176? to 194?F) before mounting them
on their shafts and cool them down before
inserting them into their seats with external
tapping.
SPRING PINS When mounting split socket spring
pins, ensure that the pin notch is oriented in
the direction of the effort to stress the
pin. Spiral spring pins should not be oriented
during installation.
6
SECTION 00 - GENERAL - CHAPTER 1
4

• GENERAL INSTRUCTIONS
• PRECAUTIONARY NOTICE
• Only authorized workshops should carry out
  maintenance and repair operations on the tractor,
  or tractor compo- nents. Carefully observe all
  instructions, safety precautions, and the use of
  equipment such as special tools, as detailed in
  this manual. Damage to the tractor, or injury to
  personnel is the direct responsibility of anyone
  who fails to observe these precautions.
• EQUIPMENT NOTICE
• The equipment proposed in this manual is
• Designed and studied expressly for use on Case IH
  tractors
• Necessary for adequate and reliable repair of the
  tractor
• Strictly tested for the efficient and long
  lasting life cycle of the tractor
• SPARE PARTS NOTICE
• Genuine CASE IH spare parts guarantee the same
  quality, safety and life cycle as original
  components. These parts bear the logo.
• GENERAL NOTICES
• In this manual, the description FRONT, REAR,
  RIGHT- HAND and LEFT- HAND refer to the view
  seen by the operator while in the operators
  seat, looking in the direction in which the
  tractor normally moves.
• Wear limits detailed in this manual, although
  advised, are not binding.

7
SECTION 00 - GENERAL - CHAPTER 1
5
HEALTH AND SAFETY CONTENTS Description Page HEAL
TH AND SAFETY PRECAUTIONS ........................
................................. 5 ACIDS AND
ALKALIS ..........................................
............................... 6 ADHESIVES AND
SEALERS - see Fire ...............................
.......................... 6 ANTIFREEZE - see
Fire, Solvents e.g. Isopropanol, Ethylene Glycol,
Methanol. ...................... 6 ARC WELDING -
see Welding. .....................................
............................ 7 BATTERY ACIDS -
see Acids and Alkalis. ...........................
............................ 7 BRAKE AND CLUTCH
FLUIDS (Polyalkylene Glycols) - see Fire.
................................... 7 BRAZING -
see Welding. .....................................
................................. 7 CHEMICAL
MATERIALS - GENERAL - see Legal Aspects.
........................................ 7 DOS
..................................................
..................................... 7 DO NOTS
..................................................
................................. 8 CORROSION
PROTECTION MATERIALS - see Solvents, Fire.
.................................... 8 DUSTS
..................................................
................................... 8 ELECTRIC
SHOCK ............................................
............................... 8 EXHAUST FUMES
..................................................
......................... 9 FIBRE INSULATION -
see Dusts. .......................................
....................... 9 FIRE - see Welding,
Foams, Legal Aspects. ............................
......................... 9 FIRST AID
..................................................
................................ 9 FOAMS -
Polyurethane - see Fire. .........................
.................................... 9 FUELS -
see Fire, Legal Aspects, Chemicals - General,
Solvents. ................................ 10
GAS CYLINDERS - see Fire. ........................
........................................
10 GENERAL WORKSHOP TOOLS AND EQUIPMENT
............................................. 11
LEGAL ASPECTS ....................................
.......................................
11 LUBRICANTS AND GREASES ........................
........................................
11 PAINTS - see Solvents and Chemical Materials -
General. .......................................
12 SOLDER - see Welding. ........................
............................................
12 SOLVENTS - see Chemical Materials - General
Fuels (Kerosene), Fire. ..........................
. 13 SUSPENDED LOADS ............................
...........................................
13 WELDING - see Fire, Electric Shock, Gas
Cylinders. .......................................
..... 13
HEALTH AND SAFETY PRECAUTIONS Many of the
procedures associated with vehicle maintenance
and repair involve physical hazards or other
risks to health. This section lists, alphabeti-
cally, some of these hazardous operations and the
materials and equipment associated with them. The
precautions necessary to avoid these hazards are
identified. The list is not exhaustive and all
operations and procedures and the handling of
materials, should be carried out with health and
safety in mind.
8
SECTION 00 - GENERAL - CHAPTER 1
6
ACIDS AND ALKALIS -- see Battery acids, e.g.
caustic soda, sulfuric acid. Used in batteries
and cleaning materials. Irritant and corrosive to
the skin, eyes, nose and throat. Causes
burns. Avoid splashes to the skin, eyes and
clothing. Wear suitable protective gloves and
goggles. Can destroy ordinary protective
clothing. Do not breathe mists. Ensure access to
water and soap is readily available for
splashing accidents.
Provide adequate ventilation and avoid skin and
eye contact. Follow manufacturers instructions.
Anaerobic, Cyanoacrylate and other Acrylic
Adhesives Many are irritant, sensitizing or
harmful to the skin. Some are eye
irritants. Skin and eye contact should be avoided
and the manufacturers instructions
followed. Cyanoacrylate adhesives (super-
glues) must not contact the skin or eyes. If
skin or eye tissue is bonded cover with a clean
moist pad and get medical attention. do not
attempt to pull tissue apart. Use in well
ventilated areas as vapours can cause irritation
of the nose and eyes. For two- pack systems see
Resin based adhesives/ sealers.
ADHESIVES AND SEALERS -- see Fire Highly
Flammable, Flammable, combustible. Generally
should be stored in No Smoking areas
cleanliness and tidiness in use should be
observed, e.g. disposable paper covering benches
should be dispensed from applicators where
possible contain- ers, including secondary
containers, should be labelled. Solvent based
Adhesives/Sealers - See Solvents. Follow
manufacturers instructions. Water based
Adhesives/Sealers Those based on polymer
emulsions and rubber lattices may contain small
amounts of volatile toxic and harmful chemicals.
Skin and eye contact should be avoided and
adequate ventilation provided during use. Follow
manufacturers instructions. Resin based
Adhesives/Sealers - e.g. epoxide and
formaldehyde resin based. Mixing should only be
carried out in well ventilated areas as harmful
or toxic volatile chemicals may be
released. Skin contact with uncured resins and
hardeners can result in irritation dermatitis
and absorption of toxic or harmful chemicals
through the skin. Splashes can damage the eyes.
Isocyanate (Polyurethane) Adhesives/ Sealers --
see Resin based Adhesives.
Individuals suffering from asthma or respiratory
allergies should not work with or near these
materials as sensitivity reactions can
occur. Any spraying should preferably be carried
out in exhaust ventilated booths removing
vapours and spray droplets from the breathing
zone. Individuals working with spray
applications should wear supplied air
respirators.
ANTIFREEZE -- see Fire, Solvents e.g.
Isopropanol, Ethylene Glycol, Methanol. Highly
Flammable, Flammable, Combustible. Used in
vehicle coolant systems, brake air pressure
systems, screenwash solutions. Vapours given off
from coolant antifreeze (glycol) arise only when
heated. Antifreeze may be absorbed through the
skin in toxic or harmful quantities. Antifreeze
if swallowed is fatal and medical attention must
be found immediately.
9
SECTION 00 - GENERAL - CHAPTER 1
7
ARC WELDING -- see Welding.
The effects of excessive exposure to chemicals
may be immediate or delayed briefly experienced
or permanent cumulative superficial life
threatening or may reduce life- expectancy.
BATTERY ACIDS -- see Acids and Alkalis. Gases
released during charging are explosive. Never
use naked flames or allow sparks near charging
or recently charged batteries.
DOS Do remove chemical materials from the skin
and clothing as soon as practicable after
soiling. Change heavily soiled clothing and
have it cleaned. Do carefully read and observe
hazard and precaution warnings given on material
containers (labels) and in any accompanying
leaflets, poster or other instructions. Material
health and safety data sheets can be obtained
from Manufacturers. Do organise work practices
and protective clothing to avoid soiling of the
skin and eyes breathing vapours/aerosols/dusts/f
umes inadequate contain- er labelling fire and
explosion hazards. Do wash before job breaks
before eating, smoking, drinking or using toilet
facilities when handling chemical materials. Do
keep work areas clean, uncluttered and free of
spills. Do store according to national and local
regulations. Do keep chemical materials out of
reach of children.
BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) --
see Fire. Combustible. Splashes to the skin and
eyes are slightly irritating. Avoid skin and eye
contact as far as possible. Inhalation of vapour
hazards do not arise at ambient temperatures
because of the very low vapour pressure.
BRAZING -- see Welding.
CHEMICAL MATERIALS - GENERAL -- see Legal
Aspects. Chemical materials such as solvents,
sealers, adhesives, paints, resin foams, battery
acids, antifreeze, brake fluids, oils and grease
should always be used with caution and stored
and handled with care. They may be toxic,
harmful, corrosive, irritant or highly
inflammable and give rise to hazardous fumes and
dusts.
10
SECTION 10 - ENGINE - CHAPTER 1
1
SECTION 10 - ENGINE Chapter 1 - Engine CONTENTS
Description Page Specifications
..................................................
................ 3 Engine Type ...................
............................................
3 Timing System ..................................
........................... 4 Valve Timing Gears
..................................................
....... 4 Crankcase and Cylinder Block
................................................
5 Crankshaft and Bearings ........................
............................. 6 Connecting Rod
..................................................
.......... 7 Piston ..............................
....................................... 8 Tappet
..................................................
.................. 8 Rocker Arm and Valve
..................................................
..... 9 Rotating Counterweight Dynamic Balancer
..................................... 9 Cylinder
Head .............................................
............... 10 Tightening Torques
..................................................
.......... 11 Special Tools ......................
..........................................
12 Description and Operation .....................
................................ 14 Sectional
Views ............................................
.............. 14 Troubleshooting
..................................................
............ 16 Overhaul .........................
...........................................
20 Engine ........................................
.......................... 20 Removal
..................................................
........... 20 Installation ......................
......................................
26 Compression Test ..............................
....................... 27 Disassembly
..................................................
........ 28 Assembly .............................
............................... 44 Crank, Main
Bearings and Thrust Rings .......................
........ 44 Rear Cover with Seal and Engine
Flywheel ............................
46 Synchronizing the Timing Gears
...................................... 47 Bosch
Injection Pump ...................................
............ 48 Cylinder Head ....................
................................. 48 Valve and
Rocker Arm .......................................
....... 49 Fuel Injectors ........................
.............................. 50
Section
10 001 10
10 001 30 10 001 54
11
2
SECTION 10 - ENGINE - CHAPTER 1
Description Page Cylinder Block
..................................................
.......... 51 Inspection .........................
................................... 51 Crankshaft
and Main Bearings ................................
.............. 53 Crankshaft Inspection
..................................................
53 Main Bearing Inspection ......................
......................... 55 Main Bearing Cap
Bolt Inspection ..................................
...... 55 Crankshaft Front Oil Seal
..................................................
56 Removal ......................................
....................... 56 Installation
..................................................
.......... 57 Engine Flywheel ....................
......................................
58 Refacing ......................................
....................... 58 Flywheel Bolts
..................................................
.......... 58 Inspection .........................
................................... 58 Connecting
Rods .............................................
............ 59 Inspection .......................
..................................... 59 Pistons
with Rings, Pins, Connecting Rods, Big End Caps
and Bearings .......... 60 Inspection
..................................................
.......... 60 Assembly ...........................
................................. 61 Installation
..................................................
.......... 62 Valves, Tappets and Camshaft
..............................................
64 Valves, Grinding ..............................
......................... 64 Dimensions (mm) of
Valves and Valve Guides ..........................
... 64 Valve Timing Check .......................
............................. 65 Tappets
Inspection .......................................
.............. 65 Camshaft Inspection
..................................................
. 66 Cylinder Head ...............................
............................. 67 Inspection
..................................................
.......... 67 Valve Seats, Grinding
..................................................
68 Valve Guides, Replacement ....................
......................... 69 Rotating
Counterweight Dynamic Balancer ...................
................ 72 Assembly ....................
........................................
73 Installation ..................................
.......................... 73 Exhaust Pipe
..................................................
........... 74 Removal ...........................
..................................
74 Installation ..................................
.......................... 74
Section
10 102 70
10 101 53
10 254 44
12
SECTION 10 - ENGINE - CHAPTER 1
3
SPECIFICATIONS
ENGINE TYPE
- Mod. JX1075N .................................................... 8035.25.929
- Mod. JX1095N with cab ............................................ 8045.25C.929
- Mod. JX1095N less cab ............................................ 8045.25S.925
Cycle ............................................................... diesel, 4-stroke
Fuel injection ........................................................ direct
Number of cylinders in line - JX1075N .................................. 3
Number of cylinders in line - JX1095N .................................. 4
Piston diameter
- Mod. JX1075N .................................................... 4.0944 in. (104 mm)
- Mod. JX1095N .................................................... 4.0944 in. (104 mm)
Piston stroke ......................................................... 4.5275 in. (115 mm)
Total displacement
- Mod. JX1075N .................................................... 178.84 in3 (2931 cm3)
- Mod. JX1095N .................................................... 238 in3 (3900 cm3)
Compression ratio for Mod. JX1075N, JX1095N .......................... 16.51 turbocharged
Maximum power
- Mod. JX1075N .................................................... 55.5 kW (76 Hp)
- Mod. JX1095N .................................................... 67.5 kW (92 Hp)
Maximum power speed ................................................ 2300 rpm
Maximum torque speed for Mod. JX1075N ............................... 1400 rev/min
Maximum torque speed for Mod. JX1095N ............................... 1400 rev/min
Number of main bearings - JX1075N .................................... 4
Number of main bearings - JX1095N .................................... 5
Sump ............................................................... structural, cast iron
Rev counter/hourmeter .............................................. incorporated in control panel
Control .............................................................. from gear on camshaft
Hour counter calibrated for engine speed of .............................. 1800 rpm
(continued)
13
14
SECTION 10 - ENGINE - CHAPTER 1
DESCRIPTION AND OPERATION SECTIONAL VIEWS
1 2
7
3
4
5
6
25357
2
Longitudinal section of engine (mod. JX1095N).

1. Rocker shaft pedestal bolts.
2. Cylinder head bolts.
3. Flywheel mounting bolts.
4. Main bearing cap bolts.

1. Connecting rod cap bolts.
2. Fan and alternator pulley bolts.
3. Crankshaft hub retaining nut.

14
SECTION 10 - ENGINE - CHAPTER 1 15
1 25358
Cross-section of engine (mod. JX1095N) 3
15
20
SECTION 10 - ENGINE - CHAPTER 1
OVERHAUL
ENGINE Op. 10 001 10 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.
Check that no one is in the vicinity of the load
to be lifted. WARNING Always use appropriate
tools to align fixing holes. NEVER USE FINGERS
OR HANDS. Proceed as follows. 1. Carry out
operation 90 150 10 Cab with platform unit
removal (see Sect. 90) (models with cab). Ensure
that the bracket 380001613 locking the front
axle in relation to the engine is positioned and
secured between the above.

• Carry out operation 90 110 36 Platform assembly
  removal (see Sect. 90) (models with platform).
• Carry out operation 90 114 20 Front roll bar, re-
  moval (see Sect. 90) (models with platform).
• Unscrew the plug and drain the oil from the rear
  transmission casing (the prescribed quantity is
• 11.09 US gal. (42 liters).

25628
4
5. Disconnect the electrical connections (2)
and re- move the front guard (1) by sliding
forwards.
5
16
SECTION 10 - ENGINE - CHAPTER 1
21

1. If the tractor is not fitted with an extra fuel
   tank, disconnect the piping (1) and drain the
   fuel from the main tank.
2. If the tractor is fitted with a platform the
   coolant must be drained.

6
8. Disconnect the fuel return piping (1).
7
9. Remove the clamp (1) and detach the radiator
sleeve (2), unscrew the radiator retaining
bracket (3).
8
10. Disconnect the connecting pipe (1) between
the main fuel tank and the extra fuel tank.
9
17
22 SECTION 10 - ENGINE - CHAPTER 1 11. Unscrew
the brake control piping (1) on the front axle
(if fitted).
10
12. Disconnect the hydrostatic steering piping
(1).
11
13. Disconnect the steering sensor wire, loosen
the hose and wire retaining clamps (1) on the
radia- tor.
12
14. Loosen the clamp and disconnect the fuel
injec- tion pump hose (1).
13
18
SECTION 10 - ENGINE - CHAPTER 1
23

1. Unscrew the clamp (3) to release the sleeve (2)
   from the turbocharger (if fitted).
2. Disconnect the electrical connections (1) on the
   clogged air filter sensor.

14
17. Unscrew the clamp and remove the sleeve (1)
on the relative rigid pipe (2).
15
18. Loosen the hydraulic pump line piping bolts
(1).
16
19. Loosen the clamps (1, 3 and 4), unscrew the
bracket retaining bolts (2) and remove the hy-
draulic pump line piping (5).
17
19

• 24 SECTION 10 - ENGINE - CHAPTER 1
• Unscrew the filter piping (1 and 2).
• Unscrew the services distributor piping (3, 4 and
  5).

18

1. Disconnect and remove piping (1, 2, 3, 4, 5 and
   6).
2. Carry out operation 10 254 44 Exhaust pipe re-
   moval (see Sect. 10).

19
24. Disconnect the piping (2), unscrew the clamp
(1), the piping/clutch housing retaining bolt,
and re- move piping (1 and 3).
20

1. Remove the guard (2) and disconnect the starter
   motor wires (1), disconnect the pipe (4).
2. Remove the retaining clamp and disconnect the
   engine electrical wires, place the wires (2 and
   3) on the clutch casing.

21
20
SECTION 10 - ENGINE - CHAPTER 1
25

1. Disconnect the brake piping (1) from the block.
2. Carry out operation 23 101 26 Drive shafts and
   guard, removal (see Sect. 23).

22

1. Position an hydraulic jack under the rear axle,
   at- tach the motor to a hoist, using a chain,
   and place a stand under the clutch casing.
2. Unscrew the front axle - engine retaining bolts
   (1).

23
31. Remove the front axle, complete with support,
tanks, radiator and air filter.
24

• Unscrew the bolt (2) accessing the Allen screw
• (on both sides).
• Unscrew all of the clutch casing - engine bolts
  and detach the engine.

25
21
26
SECTION 10 - ENGINE - CHAPTER 1
Installation WARNING Always use appropriate
tools to align fixing holes. NEVER USE FINGERS
OR HANDS. Apply the prescribed tightening
torques. See table of contents.

1. Before refitting the engine to the clutch box
   carefully clean the mating surfaces and apply
   sealing compound (0.0787 in. (2 mm) diameter),
   according to the diagram shown Section 21.
2. Install the engine on the clutch casing.
3. Install the front axle support assembly on the
   engine.
4. Carry out operation 23 101 26 Drive shafts and
   guard, installation (see Sect. 23).
5. Connect the brake piping.
6. Connect the wires to the starter motor and
   position the other wires on the engine.
7. Assemble all hydraulic pipes and hoses.
8. Carry out operation 10 254 44 Exhaust pipe
   installation (see Sect. 10).
9. Assemble the hydraulic pump feed piping,
   complete with the relative support bracket.

26

1. Connect the lower radiator sleeve to the rigid
   pipe.
2. Place the inlet sleeve on the turbocharger and
   secure in position (if fitted).
3. Connect the electrical connections to the
   clogged air filter sensor.
4. Connect the injection pump fuel supply piping.
5. Connect the steering sensor wire.
6. Install the hydrostatic steering piping to the
   radiator.
7. Connect the hydrostatic steering piping.
8. Connect the brake piping on the front axle.
9. Connect and secure the main fuel tank/extra fuel
   tank piping.
10. Connect the upper radiator sleeve.
11. Attach the radiator bracket.
12. Connect the fuel return piping to the fuel tank.
13. Position the front guard and connect the
    headlamps and direction indicator electrical
    connections.
14. Screw the plug on the rear transmission casing
    and fill up with oil (see Sect. 00 for prescribed
    products and quantities).
15. Carry out operation 90 114 20 Removable front
    roll bar re-assembly (see sect. 90) (models with
    platform).

1. Carry out operation 90 110 36 Platform assembly
   installation (see Sect. 90) (models with
   platform).
2. Carry out operation 90 150 10 Cab with platform
   unit installation (see Sect. 90) (models with
   cab).
3. Fill up the engine cooling system (see Sect. 00
   for prescribed products and quantities).
4. Fill up the fuel tank (see Sect. 00 for
   prescribed products and quantities).
5. Bleed the brakes (see Sect. 33).

22
SECTION 10 - ENGINE - CHAPTER 1 27
Op. 10 001 30 Compression Test In case of poor
engine performance, in addition to checking the
fuel injection system (injection nozzles and
injection pump), also test the compression on
each cylinder.

• install the dummy injector 380000617 in place of
  the injector removed previously, inserting the
  copper sealing washer
• connect the compression test instrument
  380000303 and take readings while turning the
  engine over with the starter motor.
• On engines in perfect working order, with the
  sump oil at approx. 104 ?F (40 ?C) at sea level
  (29.9212 in. (760 mm) mercury) and at an engine
  speed of 200 to
• 280 rpm, the compression should be 369.75 to
• 398.75 psi (25.5 to 27.5 bar).
• 8) Test the compression on the other cylinders,
  repeating steps 4- 5- 6- 7, bearing in mind that
• The minimum permissible compression on a used
  engine is 313.2 psi (21.6 bar).
• The maximum permissible compression difference
  between cylinders is 43.5 psi (3 bar).
• Every 328 ft. (100 meters) above sea level
  corresponds to a reduction in compression by
  approx. 1.

DANGER
Do not use matches, lighters, blowtorches or any
form of naked flame as a source of light when
inspecting the engine due to the presence of
flammable fluids and vapor.

• Compression ratio
• The compression ratio is a measure of the
  quantity of air drawn into the cylinder, and
  provides an indication of the efficiency of the
  sealing elements in the cylinder (piston rings
  and valves).
• Uniform compression in all the cylinders ensures
  that they all perform an equal amount of work,
  provided that each cylinder is injected with the
  same quantity of fuel at the right time.
• Low compression not only reduces engine perfor-
  mance, it also causes incomplete fuel combustion
  due to the lack of available combustion air.
• The engine therefore gives poor performance with
  excessive fuel consumption and, consequently,
  exhaust smoke and restriction of the exhaust
  passages.
• As the compression ratio also varies with the
  temperature of the engine (cold engines produce
  lower compression values than hot engines), the
  compression should only be tested when the engine
  is at normal operating temperature.
• Compression should be tested using the compres-
  sion test kit 380000303, as follows
• run the engine until it reaches normal operating
  temperature
• switch off the engine
• disconnect the lead from the engine stop
  electromagnet on the injection pump in order to
  close the valve and block the flow of fuel to
  the injectors
• remove the injector from the cylinder to be
  tested
• turn the engine over a few times with the starter
  motor in order to expel any carbon residue

CONSIDERATIONS Uniform compression Although high
compression is important, it is more important
for smooth engine running that compres- sion is
uniform in all cylinders. Low compression
readings. If extremely low pressure readings are
obtained on one cylinder it is advisable to
repeat the test. Before testing this time, pour
about a spoonful of engine oil into the cylinder
through the injector bore. Turn over the engine a
few times to distribute the oil evenly over the
cylinder walls, and then repeat the test. If the
second test readings are significantly higher,
suspect worn piston rings, out-of-round or
damaged pistons or cylinders. If the second test
readings are not higher, the problem will be the
valves. On the other hand, if the second test
reading shows only a slight improvement, the
problem will be due to both the valves and the
rings.
23
28
SECTION 10 - ENGINE - CHAPTER 1
Op. 10 001 54 Disassembly WARNING Handle all
parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed
safety clothing, including goggles, gloves and
safety footwear. Proceed as follows.

1. Carry out operation 10 001 10 Engine, removal.
2. Remove the alternator and air conditioning com-
   pressor belts (1).
3. Unscrew the retaining bolts and remove the ex-
   haust muffler (1).

27
28
4. Unscrew the retaining bolt (2) and move the
alter- nator (1) outwards.
29
5. Loosen the clamp and remove the turbocharger
sleeve (1) (if fitted).
30
24
SECTION 10 - ENGINE - CHAPTER 1
29

• Disconnect the turbocharger lubrication piping
• (if fitted).
• Unscrew the retaining bolts and remove the ex-
  haust manifold (2) complete with the turbochar-
  ger (1) (if fitted).

31

1. Unscrew the retaining bolt and remove the alter-
   nator.
2. Disconnect and remove the turbocharger (2) lu-
   brication piping (if fitted).

32

1. Unscrew the retaining bolts and remove the lift
   pump (1).
2. Unscrew the hydraulic oil filter (2), the
   relative retaining bolts and remove the filter
   support (3).

33
12. Unscrew the retaining bolts and remove the
ser- vices pump (1).
34
25

• 30 SECTION 10 - ENGINE - CHAPTER 1
• Unscrew the oil filter (3).
• Loosen the clamps (2) and remove the heat ex-
  changer (4) piping (1), unscrew the retaining
  bolts and remove the heat exchanger.

35

1. Unscrew the union (1) and remove the piping (2).
2. Unscrew the retaining bolts and remove the pip-
   ing (3).

36
17. Loosen the clamp (2) and remove the oil vapor
recovery device (1).
37

1. Unscrew the retaining bolts and remove the brake
   fluid reservoir (2).
2. Disconnect the injector delivery piping (1), both
   from the pump and the injectors, and remove.
3. Disconnect the fuel return piping (4) from the
   in- jection pump.
4. Disconnect the thermostarter supply piping (3).

38
26
SECTION 10 - ENGINE - CHAPTER 1
31

• Disconnect the piping on the fuel supply pump
  (3), injection pump (2) and the connecting piping
• between the LDA device to the inlet manifold.
• Remove the piping (5).
• Unscrew the retaining bolts and remove the fuel
  supply pump (4) and support.
• Unscrew the fuel filter (6).
• Make reference marks on the injection pump and
  relative support.

39
27. Remove the injection pump (1). (Refer to
Chap- ter 4).
1
40
28. Unscrew the retaining bolts and remove the
inlet manifold (1).
41
27
32 SECTION 10 - ENGINE - CHAPTER 1 29. Unscrew
the retaining bolts and remove the start- er
motor (1).
42

• Unscrew the retaining bolts and remove the fan
• and relative drive pulley (2).

43
31. Unscrew the retaining bolts and remove the
cool- ant pump (1).
44
28
SECTION 10 - ENGINE - CHAPTER 1
33
32. Unscrew the retaining bolts and remove the
cool- ant pump support (1).
45
33. Unscrew the retaining bolts and remove the
ther- mostat switch (1) and support.
46

1. Using tool 380001760 (1), unscrew the retaining
   bolts and remove the clutch (2).
2. With the aid of the brackets 380000313, secure
   the engine to the rotating stand 380000301.

27785
47
29
34 SECTION 10 - ENGINE - CHAPTER 1

1. Remove the injector mounting nuts, the underly-
   ing spherical washers, then the supports and the
   injectors themselves.
2. Remove the retaining bolts (1), washers and
   seal, then remove the rocker housing cover (2)
   and seal.

1 2 25098
48
38. Remove the rocker shaft retaining bolts (2),
then remove the entire rocker shaft assembly (1).
1
2
25099
49
39. Remove the valve collets (1) and extract the
pushrods (2).
2
1
25100
50
30
SECTION 10 - ENGINE - CHAPTER 1
35

1. Unscrew the cylinder head bolts (1) and remove
   the head using a hoist and lifting hook
   380000216.
2. Remove the cylinder head gasket.

1
25101
51
42. (On 4 cylinder models) turn the rotating
stand through 180, remove the retaining bolts,
the sump cover (1) and seal (2).
1
2
25102
52

1. (On 4 cylinder models) take out the retaining
   bolts and remove the engine lubrication oil inlet
   pipe (1) together with the suction cup and seal.
2. (On 4 cylinder models) remove the retaining bolts
   (2), release the rotating counterweight casing
   (3) and remove the sleeve (4) and the casing (3).

1
4
2
3
25103
53
31
36 SECTION 10 - ENGINE - CHAPTER 1

1. Unscrew the sump pan retaining bolts and re-
   move the sump pan using a hoist, lifting hook
   380000216 and lifting chain with eyeholes.
2. Remove the half-gaskets (1) and (3) between the
   crankcase/sump pan and the gasket (2) between
   the timing gear carrier/sump pan.

1 2 3 25104
54
47. Remove the gasket (1) between the flywheel
car- rier and the sump pan.
1 25105
NOTE When relocating gaskets apply a high heat
RTV silicone Gasket Maker to the mating surfaces.
(See your local Case IH dealer).
55
48. Remove the rotating counterweight oil seal O-
ring (1) installed on the crankcase mating sur-
face.
1 25106
56
32
SECTION 10 - ENGINE - CHAPTER 1
37
49. Unscrew the retaining bolts (1) and remove
the complete oil pump (Naturally aspirated
engines only).
1
25107
57
50. Unscrew the retaining bolts (2) and remove
the fan-alternator drive pulley (1).
1 2 25108
58
51. Straighten the lock tab and remove the nut
(1), securing the crankshaft against rotation.
1
25109
59
33
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34
38 SECTION 10 - ENGINE - CHAPTER 1
52. Pull the pulley hub off the crankshaft using
tool 380000226 (1) and recover the Woodruff key.
1 25110
60
53. Unscrew the retaining bolts (1) and remove
the timing cover and gasket.
1 25111
61
54. Unscrew the retaining bolts and remove the
lift pump drive gear carrier (1).
1 25112
62
35
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