Iveco S8000 Workshop manual

SERVICE MANUAL

8035.05.716 / 8035.25C.313T /

8035.25D.313T / 8045.05.260 /

8045.05.716 / 8045.05R.939T /

8045.25.260 / 8045.25.261 /

8045.25.262 / 8045.25L.939T S8000

Engine

Part number 47454136

1st edition English

November 2013

INTRODUCTION

Engine.......................................................................................10

[10.001]Engineandcrankcase.............................................................10.1

[10.101]Cylinderheads.....................................................................10.2

[10.102]Panandcovers....................................................................10.3

[10.103]Crankshaftandywheel............................................................10.4

[10.105]Connectingrodsandpistons.......................................................10.5

[10.106]Valvedriveandgears..............................................................10.6

[10.114]Pumpdrives........................................................................10.7

[10.206]Fuellters..........................................................................10.8

[10.210]Liftpumpandlines.................................................................10.9

[10.218]Fuelinjectionsystem.............................................................10.10

[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.11

[10.304]Enginelubricationsystem........................................................10.12

[10.400]Enginecoolingsystem...........................................................10.13

[10.414]Fananddrive....................................................................10.14

Electricalsystems.......................................................................55

[55.013]Engineoilsystem..................................................................55.1

[55.201]Enginestartingsystem.............................................................55.2

[55.301]Alternator...........................................................................55.3

4745413625/11/2013

INTRODUCTION

4745413625/11/2013

Contents

INTRODUCTION

Foreword-Ecologyandtheenvironment......................................................3

Safetyrules.....................................................................................4

Basicinstructions-Importantnoticeregardingequipmentservicing...........................5

Basicinstructions-Shopandassembly........................................................6

Torque-Minimumtighteningtorquesfornormalassembly.....................................8

4745413625/11/2013

INTRODUCTION

Foreword-Ecologyandtheenvironment

Soil,air,andwaterarevitalfactorsofagricultureandlifeingeneral.Whenlegislationdoesnotyetrulethetreatment ofsomeofthesubstancesrequiredbyadvancedtechnology,soundjudgmentshouldgoverntheuseanddisposalof productsofachemicalandpetrochemicalnature.

NOTE:Thefollowingarerecommendationsthatmaybeofassistance:

Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyourcountry.

•

Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,antifreeze,cleaning

• agents,etc.,withregardtotheireffectonmanandnatureandhowtosafelystore,use,anddisposeofthese

substances.

Agriculturalconsultantswill,inmanycases,beabletohelpyouaswell.

•

Helpfulhints

Avoidllingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable

• spillage.

Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostofthemcontainsubstancesthatmaybe

• harmfultoyourhealth.

Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.

•

Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,gearboxandhydraulicoils,brakeuids,etc.

• Donotmixdrainedbrakeuidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofinaproper

waytocomplywithlocallegislationandavailableresources.

Moderncoolantmixtures,i.e.antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshouldnot

• beallowedtogetintothesoil,butshouldbecollectedanddisposedofproperly.

Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmosphere.

• YourCNHdealerorairconditioningspecialisthasaspecialextractorforthispurposeandwillhavetorechargethe

systemproperly.

Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.

•

Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.

•

Protecthosesduringweldingaspenetratingweldsplattermayburnaholeorweakenthem,allowingthelossof

• oils,coolant,etc.

4745413625/11/2013

INTRODUCTION

Safetyrules

Personalsafety

Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.

Throughoutthismanualandonmachinedecals,youwillndthesignalwordsDANGER,WARNING,andCAUTION followedbyspecialinstructions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworking withyou.

Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.

DANGERindicatesahazardoussituationwhich,ifnotavoided,willresultindeathorseriousinjury.The

colorassociatedwithDANGERisRED.

WARNINGindicatesahazardoussituationwhich,ifnotavoided,couldresultindeathorseriousinjury.

ThecolorassociatedwithWARNINGisORANGE.

CAUTION,usedwiththesafetyalertsymbol,indicatesahazardoussituationwhich,ifnotavoided,couldresult

inminorormoderateinjury.ThecolorassociatedwithCAUTIONisYELLOW.

FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY .

Machinesafety

NOTICE:Noticeindicatesasituationwhich,ifnotavoided,couldresultinmachineorpropertydamage.Thecolor associatedwithNoticeisBLUE.

ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.

Information

NOTE:Noteindicatesadditionalinformationwhichclariessteps,procedures,orotherinformationinthismanual.

ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.

4745413625/11/2013

INTRODUCTION

Basicinstructions-Importantnoticeregardingequipmentservicing

Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel, strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.

Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein shallberesponsibleforanysubsequentdamages.

Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer. Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.

Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor continuousimprovement.Someinformationcouldnotbeupdatedduetomodicationsofatechnicalorcommercial type,orchangestothelawsandregulationsofdifferentcountries.

Incaseofquestions,refertoyourCNHSalesandServiceNetworks.

4745413625/11/2013

INTRODUCTION

Basicinstructions-Shopandassembly

Shimming

Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenaddup therecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortheratedvalue indicatedoneachshim.

Rotatingshaftseals

Forcorrectrotatingshaftsealinstallation,proceedasfollows:

Beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes.

•

Thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged.

•

Positionthesealinglipfacingtheuid;withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirection

• andpositionthegroovessothattheywilldeviatetheuidtowardstheinnersideoftheseal.

Coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andllthegapbetweenthesealinglip

• andthedustlipondoublelipsealswithgreaseunlessinstructedotherwise.

Insertthesealinitsseatandpressdownusingaatpunchorsealinstallationtool.Donottapthesealwitha

• hammerormallet.

Whileinsertingtheseal,checkthatitisperpendiculartotheseat;oncesettled,makesurethatitmakescontact

• withthethrustelement,ifrequired.

Topreventdamagingtheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.

•

O-ringseals

LubricatetheO-ringsealsbeforeinsertingthemintheseats,thiswillpreventthemfromoverturningandtwisting, whichwouldjeopardizesealingefciency .

Sealingcompounds

Applyoneofthefollowingsealingcompoundsonthematingsurfaceswhenspecied:SILMATE®RTV1473,or LOCTITE®RTV598orLOCTITE®INSTANTGASKET587BLUE.Beforeapplyingthesealingcompound,preparethe surfacesasdirectedonproductcontainerorasfollows:

Removeanyincrustationsusingametalbrush.

•

Thoroughlyde-greasethesurfacesusingalocallyapprovedcleaningagentsuchassafetysolventorbrakeparts

• cleaner.

Spareparts

Onlyuse"CNHOriginalParts"or"CNHParts".

Onlygenuinesparepartsguaranteethesamequality ,durationandsafetyasoriginalparts,astheyarethesame partsthatareassembledduringstandardproduction.Only"CNHOriginalParts"or"CNHParts"canofferthis guarantee. Whenorderingspareparts,alwaysprovidethefollowinginformation:

Machinemodel(commercialname)andserialnumber

•

Partnumberoftheorderedpart,whichcanbefoundinthe"ServicePartsCatalogue",usedfororderprocessing

•

4745413625/11/2013

INTRODUCTION

Protectingtheelectrical/electronicsystemsduringchargingorwelding

WARNING

Batteryacidcausesburns.Batteriescontainsulfuricacid. Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):ush withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklargequantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately. Failuretocomplycouldresultindeathorseriousinjury.

Toavoiddamagetotheelectronic/electricalsystems,alwaysobservethefollowing:

1.Nevermakeorbreakanyofthechargingcircuitconnections,includingthebatteryconnections,whentheengine isrunning.

2.Nevershortanyofthechargingcomponentstoground.

3.Alwaysdisconnectthegroundcablefromthebatterybeforearcweldingonthemachineoronanyattachments onthemachine.

Positiontheweldergroundclampasclosetotheweldingareaaspossible

•

Ifweldingincloseproximitytoacomputermodule,thenthemoduleshouldberemovedfromthemachine

•

Neverallowweldingcablestolayon,nearoracrossanyelectricalwiringorelectroniccomponentwhilewelding

•

isinprogress

4.Alwaysdisconnectthenegativecablefromthebatterywhenchargingthebatteryinthemachinewithabattery charger.

W0111A

NOTICE:Ifweldingmustbeperformedontheunit,thebatterygroundcablemustbedisconnectedfromthemachine battery.Theelectronicmonitoringsystemandchargingsystemwillbedamagedifthisisnotdone.

Removethebatterygroundcable.Reconnectthecablewhenweldingiscompleted.

Tools

ThetoolsthatCNHsuggestsandillustratedinthismanualhavebeen:

SpecicallyresearchedanddesignedforusewithCNHmachines

•

Essentialforreliablerepairoperations

•

Accuratelybuiltandrigorouslytestedsoastoofferefcientandlong-lastingoperation

•

Byusingthesetools,repairpersonnelwillbenetfrom:

Operatinginoptimaltechnicalconditions

•

Obtainingthebestresults

•

Savingtimeandeffort

•

Workinginsafeconditions

•

NOTE:Theterms"front","rear","right-hand"and"left-hand"(whenreferredtodifferentparts)aredeterminedfrom therear,facinginthedirectionoftravelofthemachineduringoperation.

4745413625/11/2013

INTRODUCTION

Torque-Minimumtighteningtorquesfornormalassembly

METRICNON-FLANGEDHARDWARE

NOM.

SIZE

CLASS8.8BOLTand

CLASS8NUT

UNPLATED

M10

M12

M16

M20

M24

2.2N·m(19lb in)

4.5N·m(40lb in)

7.5N·m(66lb in)

18N·m(163lb

in)

37N·m(27lbft)

64N·m(47lbft)

158N·m(116lb

ft)

319N·m(235lb

ft)

551N·m(410lb

ft)

PLATED

W/ZnCr

2.9N·m(26lb in)

5.9N·m(52lb in)

10N·m(89lb

in)

25N·m(217lb

in)

49N·m(36lb

ft)

85N·m(63lb

ft)

210N·m

(155lbft)

425N·m

(313lbft)

735N·m

(500lbft)

CLASS10.9BOLTand

CLASS10NUT

UNPLATED

3.2N·m(28lb in)

6.4N·m(57lb in)

11N·m(96lb

in)

26N·m(234lb

in)

52N·m(38lbft)

91N·m(67lbft)

225N·m(166lb

ft)

440N·m(325lb

ft)

762N·m(560lb

ft)

PLATED

W/ZnCr

4.2N·m(37lb in)

8.5N·m(75lb in)

15N·m(128lb

in)

35N·m(311lb

in)

70N·m(51lb

ft)

121N·m(90lb

ft)

301N·m(222lb

ft)

587N·m(433lb

ft)

1016N·m

(750lbft)

LOCKNUT

CL.8

W/CL8.8

BOLT

2N·m(18lbin)

4N·m(36lbin)

6.8N·m(60lb in)

17N·m(151lb

in)

33N·m(25lb

ft)

58N·m(43lb

ft)

143N·m(106lb

ft)

290N·m(214lb

ft)

501N·m(370lb

ft)

LOCKNUT

CL.10

W/CL10.9

BOLT

2.9N·m(26lb in)

5.8N·m(51lb in)

10N·m(89lb in)

24N·m(212lb in)

48N·m(35lb ft)

83N·m(61lb ft)

205N·m(151lb ft)

400N·m(295lb ft)

693N·m(510lb ft)

NOTE:M4throughM8hardwaretorquespecicationsareshowninpound-inches.M10throughM24hardwaretorque specicationsareshowninpound-feet.

4745413625/11/2013

METRICFLANGEDHARDWARE

INTRODUCTION

NOM.

SIZE

M10

M12

M16

M20

M24

CLASS8.8BOLTand

CLASS8NUT

UNPLATED

2.4N·m(21lb in)

4.9N·m(43lb in)

8.3N·m(73lb in)

20N·m(179lb

in)

40N·m(30lbft)

70N·m(52lbft)

174N·m(128lb

ft)

350N·m(259lb

ft)

607N·m(447lb

ft)

PLATED

W/ZnCr

3.2N·m(28lb in)

6.5N·m(58lb in)

11N·m(96lb

in)

27N·m(240lb

in)

54N·m(40lb

ft)

93N·m(69lb

ft)

231N·m(171lb

ft)

467N·m(345lb

ft)

809N·m(597lb

ft)

CLASS10.9BOLTand

CLASS10NUT

UNPLATED

3.5N·m(31lb in)

7.0N·m(62lb in)

12N·m(105lb

in)

29N·m(257lb

in)

57N·m(42lbft)

100N·m(74lb

ft)

248N·m(183lb

ft)

484N·m(357lb

ft)

838N·m(618lb

ft)

PLATED

W/ZnCr

4.6N·m(41lb in)

9.4N·m(83lb in)

16N·m(141lb

in)

39N·m(343lb

in)

77N·m(56lb

ft)

134N·m(98lb

ft)

331N·m(244lb

ft)

645N·m(476lb

ft)

1118N·m

(824lbft)

LOCKNUT

CL.8

W/CL8.8

BOLT

2.2N·m(19lb in)

4.4N·m(39lb in)

7.5N·m(66lb in)

18N·m(163lb

in)

37N·m(27lbft)53N·m(39lbft)

63N·m(47lbft)91N·m(67lbft)

158N·m(116lb

ft)

318N·m(235lb

ft)

552N·m(407lb

ft)

LOCKNUT

CL.10

W/CL10.9

BOLT

3.1N·m(27lb in)

6.4N·m(57lb in)

11N·m(96lb in)

27N·m(240lb in)

226N·m(167lb ft)

440N·m(325lb ft)

IDENTIFICATION

MetricHexheadandcarriagebolts,classes5.6andup

200836801

1.Manufacturer'sIdentication

2.PropertyClass

MetricHexnutsandlocknuts,classes05andup

4745413625/11/2013

200836812

INTRODUCTION

1.Manufacturer'sIdentication

2.PropertyClass

3.ClockMarkingofPropertyClassandManufacturer'sIdentication(Optional),i.e.marks60°apartindicateClass 10properties,andmarks120°apartindicateClass8.

INCHNON-FLANGEDHARDWARE

NOMINAL

SIZE

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

SAEGRADE5BOLT

andNUT

UN-

PLATED

W/ZnCr

GOLD

SILVER

8N·m(71lb

in)

17N·m

(150lbin)

30N·m(22lb

ft)

48N·m(36lb

ft)

74N·m(54lb

ft)

107N·m (79lbft)

147N·m

(108lbft)

261N·m

(193lbft)

420N·m

(310lbft)

630N·m

(465lbft)

11N·m(97lb

in)

23N·m

(204lbin)

40N·m

(30lbft)

65N·m

(48lbft)

98N·m

(73lbft)

142N·m

(105lbft)

196N·m

(145lbft)

348N·m

(257lbft)

561N·m

(413lbft)

841N·m

(620lbft)

SAEGRADE8BOLT

andNUT

UN-

PLATED

orPLATED

SILVER

12N·m

(106lbin)

24N·m

(212lbin)

43N·m(31lb

ft)

68N·m(50lb

ft)

104N·m (77lbft)

150N·m

(111lbft)

208N·m

(153lbft)

369N·m

(272lbft)

594N·m

(438lbft)

890N·m

(656lbft)

PLATED

W/ZnCr

GOLD

16N·m

(142lbin)

32N·m

(283lbin)

57N·m(42lb

91N·m(67lb

139N·m

(103lbft)

201N·m

(148lbft)

277N·m

(204lbft)

491N·m

(362lbft)

791N·m

(584lbft)

1187N·m

(875lbft)

ft)

LOCKNUT

GrBW/Gr5

BOLT

8.5N·m(75lbin)

17.5N·m(155lb in)

31N·m(23lbft)44N·m(33lbft)

50N·m(37lbft)71N·m(53lbft)

76N·m(56lbft)

111N·m(82lbft)

153N·m(113lb

ft)

271N·m(200lb

ft)

437N·m(323lb

ft)

654N·m(483lb

ft)

LOCKNUT

GrCW/Gr8

BOLT

12.2N·m(109lb in)

25N·m(220lb

in)

108N·m(80lb

ft)

156N·m(115lb

ft)

215N·m(159lb

ft)

383N·m(282lb

ft)

617N·m(455lb

ft)

924N·m(681lb

ft)

NOTE:ForImperialUnits,1/4inand5/16inhardwaretorquespecicationsareshowninpound-inches.3/8in through1inhardwaretorquespecicationsareshowninpound-feet.

4745413625/11/2013

INCHFLANGEDHARDWARE

INTRODUCTION

NOM-

INAL SIZE

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

SAEGRADE5BOL Tand

UNPLATED orPLATED

SILVER

9N·m(80lbin)

19N·m(168lb

in)

33N·m(25lb

ft)

53N·m(39lb

ft)

81N·m(60lb

ft)

117N·m(86lb

ft)

162N·m(119lb

ft)

287N·m(212lb

ft)

462N·m(341lb

ft)

693N·m(512lb

ft)

NUT

12N·m(106lb

25N·m(221lb

44N·m(33lb

71N·m(52lb

108N·m(80lb

PLATED

W/ZnCr

GOLD

in)

ft)

156N·m

(115lbft)

216N·m

(159lbft)

383N·m

(282lbft)

617N·m

(455lbft)

925N·m

(682lbft)

SAEGRADE8BOLTand

NUT

UNPLATED

orPLA TED

SILVER

13N·m(115lb

in)

26N·m(230lb

in)

47N·m(35lb

ft)

75N·m(55lb

ft)

115N·m(85lb

ft)

165N·m

(122lbft)

228N·m

(168lbft)

405N·m

(299lbft)

653N·m

(482lbft)

979N·m

(722lbft)

PLATED

W/ZnCr

GOLD

17N·m(150lb

35N·m(310lb

63N·m(46lb

100N·m(74lb

153N·m

(113lbft)

221N·m

(163lbft)

304N·m

(225lbft)

541N·m

(399lbft)

871N·m

(642lbft) 1305N·m

(963lbft)

in)

ft)

LOCKNUT

GrFW/Gr5

BOLT

8N·m(71lbin)

17N·m(150lb

in)

30N·m(22lbft)43N·m(32lbft)

48N·m(35lbft)68N·m(50lbft)

74N·m(55lbft)

106N·m(78lbft)

147N·m(108lb

ft)

261N·m(193lb

ft)

421N·m(311lb

ft)

631N·m(465lb

ft)

LOCKNUT

GrGW/Gr8

BOLT

12N·m(106lb

in)

24N·m(212lb

in)

104N·m(77lb

ft)

157N·m(116lb

ft)

207N·m(153lb

ft)

369N·m(272lb

ft)

594N·m(438lb

ft)

890N·m(656lb

ft)

IDENTIFICATION

InchBoltsandfree-spinningnuts

1 2 3

Grade2-NoMarks Grade5-ThreeMarks Grade8-FiveMarks

GradeMarkingExamples

SAEGradeIdentication

200836823

4 5 6

Grade2Nut-NoMarks Grade5Nut-Marks120°Apart Grade8Nut-Marks60°Apart

4745413625/11/2013

INTRODUCTION

InchLockNuts,AllMetal(Threeoptionalmethods)

200902684

GradeIdentication

GradeCornerMarkingMethod(1)FlatsMarkingMethod(2)ClockMarkingMethod(3)

GradeA GradeBOneCircumferentialNotch GradeCTwoCircumferentialNotchesLetterCSixMarks

NoNotchesNoMarkNoMarks

LetterBThreeMarks

4745413625/11/2013

SERVICEMANUAL

Engine

8035.05.716,8035.25C.313T,8035.25D.313T,8045.05.260,8045.05.716,

8045.05R.939T,8045.25.260,8045.25.261,8045.25.262,8045.25L.939T

4745413625/11/2013

Contents

Engine-10

[10.001]Engineandcrankcase...............................................................10.1

[10.101]Cylinderheads.......................................................................10.2

[10.102]Panandcovers......................................................................10.3

[10.103]Crankshaftandywheel..............................................................10.4

[10.105]Connectingrodsandpistons.........................................................10.5

[10.106]Valvedriveandgears................................................................10.6

[10.114]Pumpdrives..........................................................................10.7

[10.206]Fuellters............................................................................10.8

[10.210]Liftpumpandlines...................................................................10.9

[10.218]Fuelinjectionsystem...............................................................10.10

[10.254]Intakeandexhaustmanifoldsandmufer.........................................10.11

[10.304]Enginelubricationsystem..........................................................10.12

[10.400]Enginecoolingsystem.............................................................10.13

[10.414]Fananddrive......................................................................10.14

4745413625/11/2013

Engine-10

Engineandcrankcase-001

8035.05.716,8035.25C.313T,8035.25D.313T,8045.05.260,8045.05.716,

8045.05R.939T,8045.25.260,8045.25.261,8045.25.262,8045.25L.939T

4745413625/11/2013

10.1[10.001]/1

TECHNICALDA TA

Engine

Generalspecication(*).....................................................................3

Servicelimits..............................................................................3

FUNCTIONALDA TA

Engine

Sectionalview.............................................................................4

Contents

Engine-10

Engineandcrankcase-001

SERVICE

Crankcase

Liner-Measure............................................................................6

Liner-Rebore.............................................................................7

Liner-Replace............................................................................8

(*)Seecontentforspecicmodels

4745413625/11/2013

10.1[10.001]/2

Engine-Engineandcrankcase

Engine-Generalspecication

8035.25C.313T

Specications

Enginetype4–strokediesel FuelinjectionDirect Numberofcylinders Orientationofcylinders Bore Stroke115mm(4.528in) Displacement Compressionratio Maximumpowerat2300RPM Maximumtorqueat1400RPM Numberofmainbearings OilpanconstructionStructural,Castiron

3 In-line

104mm(4.094in)

2931cm³(178.9in³)

18:1

48kW(65Hp) 261N·m(192.5lbft)

Engine-Generalspecication

8035.25D.313T

Specications

3 In-line

104mm(4.094in)

2931cm³(178.9in³)

18:1

53kW(72Hp) 295N·m(217.6lbft)

Engine-Servicelimits

Specications

Insidediameterofcylinderliners104.000-104.024mm(4.094-4.095in) Outsidediameterofcylinderliners107.020-107.050mm(4.213-4.215in) Diameterofcylinderbores106.850-106.900mm(4.207-4.209in) Interferencetbetweencylinderlinersandbores0.120-0.200mm(0.005-0.008in) Linerinternaldiameteroversizes Linerexternaldiameteroversizes Maximumpermissiblelinerovalityortaperduetowear Diameterofcrankshaftbore84.200-84.230mm(3.315-3.316in) Diameterofcamshaftbore

-Front

-Middle

-Rear Diameteroftappetbore15.000-15.018mm(0.591-0.591in) Sparetappetoversizes0.1mm(0.004in)

0.4-0.8mm(0.016-0.031in)

0.2mm(0.008in)

0.12mm(0.005in)

54.780-54.805mm(2.157-2.158in)

54.280-54.305mm(2.137-2.138in)

53.780-53.805mm(2.117-2.118in)

0.2mm(0.008in)

0.3mm(0.012in)

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Engine-Sectionalview

Engine-Engineandcrankcase

NHIL12ENG0237AA1

(1)Rockershaftpedestalbolts(5)Mainbearingcapbolts (2)Cylinderheadbolts(6)Fanandalternatorpulleybolts (3)Flywheelbolts(7)Crankshafthubbolts (4)Big-endcapbolts

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Engine-Engineandcrankcase

NHIL12ENG0238AA2

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CrankcaseLiner-Measure

Engine-Engineandcrankcase

NHIL12ENG0321AA1

1.Usegure1tomeasurethecylinderliners.

2.Measuretheupperandlowerendsofarea(X)parallel tothecrankshaft(a)andperpendiculartothecrank- shaft(b).

3.Comparethemeasuredvaluestodeterminelinerovalityandtaper.Thevaluesshouldnotexceed0.12mm (0.005in).

4.Measurearea(Z)paralleltothecrankshaft(a)andper- pendiculartothecrankshaft(b).

5.Comparethemeasuredvaluewiththediameterof thepiston.Thecalculatedvalueshouldnotexceed

0.3mm(0.012in).

6.Borethecylindersorreplacethelinersifanyofthe valuesaboveareexceeded.

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Engine-Engineandcrankcase

CrankcaseLiner-Rebore

1.Determineifboringthecylinderlinerisnecessary

byfollowingstepsinCrankcaseLiner-Measure (10.001).

NOTICE:Ifonelinerrequiresboring,allofthelinersinthe enginemustbeboredtothesameoversizeandmatched withapistonofthesamesize.

2.Borethelinersto0.4-0.8mm(0.016-0.031in)over-

size.

3.Restorethe30°chamfer0.5mm(0.020in)intothe

linerasshowninthegure.

4.FollowthestepsinCrankcaseLiner-Measure (10.001)toverifythatthelinersarewithinspecications.

5.Replacethelinersiftheyarestilloutsideoftheacceptableranges.

NHIL12ENG0319AA1

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Engine-Engineandcrankcase

CrankcaseLiner-Replace

1.Pressthelinerfromthebottomsideofthecrankcase.

2.Measuretheovalityoftheboreinthecrankcaseand

reboreifnecessaryto0.22mm(0.009in)oversize.

3.Pressthenewlinerintothetopofthecrankcase.

4.Borethenewlineraccordingtothespecicationsout-

linedinCrankcaseLiner-Rebore(10.001).

NHIL12ENG0320AA1

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Index

Engine-10

Engineandcrankcase-001

CrankcaseLiner-Measure..........................................................................6

CrankcaseLiner-Rebore...........................................................................7

CrankcaseLiner-Replace..........................................................................8

Engine-Generalspecication(*).....................................................................3

Engine-Sectionalview.............................................................................4

Engine-Servicelimits..............................................................................3

(*)Seecontentforspecicmodels

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Engine-10

Cylinderheads-101

8035.05.716,8035.25C.313T,8035.25D.313T,8045.05.260,8045.05.716,

8045.05R.939T,8045.25.260,8045.25.261,8045.25.262,8045.25L.939T

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TECHNICALDA TA

Cylinderheads

Servicelimits..............................................................................3

SERVICE

Valvecover

Remove..................................................................................4

Install.....................................................................................5

Contents

Engine-10

Cylinderheads-101

Cylinderhead

Remove..................................................................................6

Install.....................................................................................7

Injectorcup-Replace......................................................................8

Valves

Remove.................................................................................10

Install....................................................................................1 1

Measure.................................................................................12

Valveguide

Replace..................................................................................13

Valveseat

Resurface................................................................................16

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Engine-Cylinderheads

Cylinderheads-Servicelimits

Specications

Originalheightofcylinderhead92mm(3.622in) Maximumsurfaceregrindingdepth0.5mm(0.02in) Diameterofvalveguidebores13.950-13.983mm(0.549-0.551in) Outsidediameterofvalveguides13.993-14.016mm(0.551-0.552in) Guideinterferencetinbores0.010-0.066mm(0.0004-0.003in) Insidediameterofvalveguide(installedinhead)8.023-8.043mm(0.316-0.317in) Valvestemdiameter Assemblyclearancebetweenvalvestemandguide Maximumpermissibleclearance Maximumrun-outofvalvemeasuredfromthevalvehead0.03mm(0.001in) Valveguideoversizes Valveseatangle

-Intakevalve

-Exhaustvalve Valvefaceangle

-Intakevalve

-Exhaustvalve Valveheaddiameter

-Intakevalve

-Exhaustvalve Valverecess Maximumpermissiblevalverecess Valvespringheight

-Freeheight

-Underaloadof256-284N(58-64lb)34mm(1.339in)

-Underaloadof502-544N(113-122lb)23.8mm(0.051in) Injectorprotrusion

7.985-8.000mm(0.314-0.315in)

0.023-0.058mm(0.001-0.002in)

0.13mm(0.005in)

0.2mm(0.008in)

60° 45°

61° 46°

45.300-45.500mm(1.783-1.791in)

37.500-37.750mm(1.476-1.486in)

0.7-1.0mm(0.028-0.039in)

1.3mm(0.051in)

46mm(0.181in)

0.3-1.1mm(0.012-0.043in)

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Valvecover-Remove

1.Removethenuts,washers,andseals.

2.Removethevalvecover(1).

Engine-Cylinderheads

NHIL12ENG0268AA1

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