Case 445/M2 User manual

CASE ENGINES
445/M2 445T/M2 668T/M2
SERVICE MANUAL
PartNumber: 6-74500

Issued December, 2003 • 6-74500 Bur
Copyright © 2003 Case, LLC. AllRights Reserved.

PREFACE TO USER’S GUIDELINE MANUAL
Section 1describes the engine illustrating itsfeatures
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four sepa-
rate parts:
1
11
1.
... Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2
22
2.
... Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3
33
3.
... Maintenance planning and specific overhaul.
4
44
4.
... Troubleshooting part dedicated to the operators who, being
entitled to provide technical assistance, shall have simple and
direct instructions to identify the cause of the major inconve-
niences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
Installation general prescriptions are reported within the ap-
pendix.
Such prescriptions shall be strictly followed by the operators
in−charge of installation to avoid incorrect working as well as
serious failures which may reduce performance and life of the
engine.
Furthermore, the appendix reports general safety prescrip-
tions to be followed by all operators whether being in−charge
of installation or maintenance, in order to avoid serious injury.
CONTENT OF SECTIONS
General information 1
Feed 2
Duty −Industrial applications
Mechanical injection Engines 3
Overhaul and technical specifications 4
Equipment 5
Installation guidelines
Safety instructions Appendix
Section
ENGINES 1
ED.FEBUARY 2003

ENGINES
2ED. FEBUARY 2003

Where possible, the same sequence of procedures has been followed for easy reference.
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.
Example
Ø 1 = housing for connecting rod small end bush
Ø 2 = housing for connecting rod bearings
α
Tighten to torque
Tighten to torque + angular value
1
∅
∅2
ENGINES 3 ED. FEBUARY 2003
SPECIAL REMARKS

ENGINES
4ED. FEBUARY 2003
Graph and symbols
Removal
Disconnection Intake
Refitting
Connection Exhaust
Removal
Disassembly Operation
Fitting in place
Assembly ρCompression ratio
Tighten to torque To l e r a n c e
Weight difference
α
Tighten to torque + angle value Rolling torque
Press or caulk
Regulation
Adjustment Rotation
!Warning
Note
Angle
Angular value
Visual inspection
Fitting position check Preload
Measurement
Value to find
Check
Number of revolutions
Equipment Te m pe r a t u r e
Surface for machining
Machine finish bar Pressure
Interference
Strained assembly
Oversized
Higher than….
Maximum, peak
Thickness
Clearance
Undersized
Less than….
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Te m p e r a t u r e < 0 °C
Cold
Winter
Air bleeding
Te m p e r a t u r e > 0 °C
Hot
Summer

ENGINES 5
ED. FEBUARY 2003
UPDATING
SECTION DESCRIPTION PAG E DATE OF REVISION

ENGINES
6ED. FEBUARY 2003

ENGINES 7
ED. FEBUARY 2003
ENGINES
General information
Thanks to a centenary engine tradition as well as to a continuous research and development process focused on product advan-
cement,E.B.U.is able toensure the highestlevel ofversatilityand efficiency on the market.
The new rangeofengines is the result ofaproject originated bythe partnership among some of the mostimportant
sector manufacturersinthe Worldtomeet the expectations ofthe customer andcomply
with the new European regulations ruling preservation of the environment.
In addition to their better performances in terms of stout, power, efficiency, reliability and life, these engines comply not only with
the anti−pollution Euro 3 regulations and the relevant prescriptions for noise limit allowed but will also meet the prescriptions of
the future more severe specifications with no need of substantial modifications.
The improvement of the above mentioned features has been possible thanks to the utilisation of new materials, new technolo-
gies and technical solutions such as: cylinder head with two−four valves per cylinder, induction and exhaust manifolds improving
the dynamic flow of air as well as of exhaust emissions, and pistons with new shaped combustion chamber.
Furthermore, the reliability and cost reduction has been enhanced reducing the number of components and utilising the same
parts not only for engines destined to road engine applications but also for the most different purposes such as marine and
station engines.

ENGINES
8ED. FEBUARY 2003

ENGINES SECTION 1 −GENERAL SPECIFICATIONS 1
ED. FEBUARY 2003
SECTION 1
General Specifications
Page
ENGINE ID. CODE 3
SPECIFIC ENGINE CODE 4
LUBRICATING CIRCUIT 5
OIL VAPOUR RECIRCULATING SYSTEM 7
COOLING CIRCUIT SYSTEM 9
BOOST FEEDING DIAGRAM 11

ENGINES
2ED. FEBUARY 2003
SECTION 1 −GENERAL SPECIFICATIONS

Engine series
Range evolution
A = Not struct.
B = Not struct.
Engine
Exhaust emiss. level
Homologation power
Duty No.
Feed/Injection
Cylinder No.
Engine cycle – cylinder position
0= 4–stroke,
vertical
4 = 4 cylind.
6 = 6 cylind.
8 = DI. TCA
Model No. within D.B.
F4840EB4DF
*+
X
YY Y
Y
YYY
Y
X = 6 Injection rotary pump 2 valves
X = 4 Injection in line pump 2 valves
+
ENGINES SECTION 1 – GENERAL SPECIFICATIONS 3
ED. FEBRUARY 2003
ENGINE IDENTIFICATION CODE
C = Struct.
0 = Different between the
following specifications
1 = Truck
2 = Bus
3 = Rail road
4 = M.T. Vehicles
and tractors
5 = Gen set
6 = Marine
7 = Industrial and
fork lift truck
8 = Cars and similar
9 = Army

Engine series:
N=Engine
Total displacement or n.
of cylinders
Feed system:
M = Mechanical
E= Electronic
Exhaust emiss. level
Engine block:
N = Not struct.
S= Struct.
C = Euro3.
E= E(NRMM)
U=EPAUSA
G=Gas
M=Marine
YXX YY Y
.Y.
XX XX
Power :
A= Notsuperch.
S= Supercharging
T= Supercharging
with aftercooler
Engineering code
EXAMPLES:
N40ENT.C
N=Engine
40 = 4 liters
E= Electronic
N = Type of Engine block
T = Supercharger with aftercooler
C = Euro3
ENGINES
4ED. FEBUARY 2003
SECTION 1−GENERAL SPECIFICATIONS
SPECIFIC ENGINE CODE

003237t
Figure 1
Lubrication by forced circulation is achieved through oil
rotary expansion pump (4), placed in the front part of the
basement, driven by the straight−tooth gear splined to the
shaft’s bar hold.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
LUBRICATION SYSTEM LAYOUT (4 cyl. engines)
Routing of oil under pressure
Routing of oil return by gravity
to sump
Introduction of oil
Lubrication involves the heat exchanger (2,3) as well, the
supercharged (through pipe 1) and the eventual compressor
for any eventual compressed air system.
All these components may often vary according to the
specific duty.
1
2
34
5
1. Lubrication oil pipe to supercharger −2. Heat exchanger body −3. Heat exchanger −4. Oil rotary expansion pump −
5. Oil filter
ENGINESSECTION 1−GENERAL SPECIFICATIONS 5
ED. FEBUARY 2003
LUBRICATION

76212
Figure 2
LUBRICATION SYSTEM LAYOUT (6 cyl. engines)
Routing of oil under pressure
Routing of oil return by gravity
to sump
Introduction of oil
1. Lubrication oil pipe to supercharger −2. Heat exchanger body −3. Heat exchanger −4. Oil rotary expansion pump −
5. Oil fil
t
e
r
ENGINES
6ED. FEBUARY 2003
SECTION 1−GENERAL SPECIFICATIONS

003240t
Figure 3
OIL VAPOUR RECIRCULATING SYSTEM
1.Valve−2. Breather pipe −3. Tappet Cap
On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity,
to the Tappet cap underneath.
The remaining non−condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example
(connection towards these vapours shall be designed by the Engineer).
1
2
3
ENGINESSECTION 1−GENERAL SPECIFICATIONS 7
ED. FEBUARY 2003

ENGINES
8ED. FEBUARY 2003
SECTION 1−GENERAL SPECIFICATIONS

003241t
Figure 4
The engine cooling system, closed circuit forced circulation
type, generally incorporates the following components:
-Expansion tank; placement, shape and dimensions are
subject to change according to the engine’s equipment.
-Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
-Visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engine’s
development.
COOLING SYSTEM LAYOUT (4 cyl. engines)
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
-Heat exchanger to cool the lubrication oil: even this
component is part of the engine’s specific equipment.
-Centrifugal water pump, placed in the front part of the
engine block.
-Thermostat regulating the circulation of the cooling
liquid.
-The circuit may eventually be extended to the
compressor, if this is included in the equipment.
TO RADIATOR
FROM RADIATOR
ENGINESSECTION 1 −GENERAL SPECIFICATIONS 9
ED. FEBUARY 2003
COOLING SYSTEM

76216
Figure 5
COOLING SYSTEM LAYOUT (6 cyl. engines)
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
TO RADIATOR
FROM RADIATOR
ENGINES
10 ED. FEBUARY 2003
SECTION 1 −GENERAL SPECIFICATIONS