Case F5dfl413a a001 series User manual

PrintedinU.S.A.

CaseisaregisteredtrademarkofCNH America LLC.

Racine Wisconsin 53404 U.S.A.

Part number 84496807

1st edition English

April 2012

SERVICE MANUAL

F5DFL413A*A001 / F5DFL413A*A002 /

F5DFL413B*A006 / F5DFL413C*A003 /

F5DFL413D*A003 / F5DFL413D*A004 /

F5HFL413A*A001 / F5HFL413B*A001 /

F5HFL413B*A002 / F5HFL413C*A001

Tier 4a

Engine

Contents

INTRODUCTION

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

Engineandcrankcase....................................................................10.001

Cylinderheads...........................................................................10.101

Panandcovers...........................................................................10.102

Crankshaftandywheel..................................................................10.103

Connectingrodsandpistons.............................................................10.105

Valvedriveandgears....................................................................10.106

Fuellters................................................................................10.206

Fuelinjectionsystem.....................................................................10.218

Turbochargerandlines...................................................................10.250

Intakeandexhaustmanifoldsandmufer................................................10.254

Enginelubricationsystem................................................................10.304

Enginecoolingsystem...................................................................10.400

Oilcoolerandlines.......................................................................10.408

Fananddrive.............................................................................10.414

ExhaustGasRecirculation(EGR)exhausttreatment....................................10.501

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

Enginecoolingsystem...................................................................55.012

Engineoilsystem.........................................................................55.013

Engineintakeandexhaustsystem.......................................................55.014

Enginecontrolsystem....................................................................55.015

Enginestartingsystem...................................................................55.201

Coldstartaid.............................................................................55.202

Alternator.................................................................................55.301

84496807-22/04/2012

INTRODUCTION

84496807-22/04/2012

Contents

INTRODUCTION

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

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

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

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

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

84496807-22/04/2012

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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.Mostofthemcontainsubstancesthatmay

beharmfultoyourhealth.

•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.

•Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,gearboxandhydraulicoils,brakeuids,

etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofin

aproperwaytocomplywithlocallegislationandavailableresources.

•Moderncoolantmixtures,i.e.antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshould

notbeallowedtogetintothesoil,butshouldbecollectedanddisposedofproperly.

•Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmos-

phere.YourCNHdealerorairconditioningspecialisthasaspecialextractorforthispurposeandwillhaveto

rechargethesystemproperly.

•Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.

•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.

•Protecthosesduringweldingaspenetratingweldsplattermayburnaholeorweakenthem,allowingthelossof

oils,coolant,etc.

84496807-22/04/2012

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.

84496807-22/04/2012

INTRODUCTION

Basicinstructions-Importantnoticeregardingequipmentservicing

Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,

strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.

Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein

shallberesponsibleforanysubsequentdamages.

Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or

localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-

facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.

Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase

ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.

Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor

continuousimprovement.Someinformationcouldnotbeupdatedduetomodicationsofatechnicalorcommercial

type,orchangestothelawsandregulationsofdifferentcountries.

Incaseofquestions,refertoyourCNHSalesandServiceNetworks.

84496807-22/04/2012

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llthegapbetweenthesealing

lipandthedustlipondoublelipsealswithgreaseunlessinstructedotherwise.

•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-greasethesurfacesusingalocallyapprovedcleaningagentsuchassafetysolventorbrake

partscleaner.

Spareparts

Onlyuse"CNHOriginalParts"or"CNHParts".

Onlygenuinesparepartsguaranteethesamequality,durationandsafetyasoriginalparts,astheyarethesame

partsthatareassembledduringstandardproduction.Only"CNHOriginalParts"or"CNHParts"canofferthis

guarantee.

Whenorderingspareparts,alwaysprovidethefollowinginformation:

•Machinemodel(commercialname)andserialnumber

•Partnumberoftheorderedpart,whichcanbefoundinthe"ServicePartsCatalogue",usedfororderprocessing

84496807-22/04/2012

INTRODUCTION

Protectingtheelectrical/electronicsystemsduringchargingorwelding

WARNING

Batteryacidcausesburns.Batteriescontainsulfuricacid.

Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):ush

withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge

quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately.

Failuretocomplycouldresultindeathorseriousinjury.W0111A

Toavoiddamagetotheelectronic/electricalsystems,alwaysobservethefollowing:

1.Nevermakeorbreakanyofthechargingcircuitconnections,includingthebatteryconnections,whentheengine

isrunning.

2.Nevershortanyofthechargingcomponentstoground.

3.Alwaysdisconnectthegroundcablefromthebatterybeforearcweldingonthemachineoronanyattachments

onthemachine.

•Positiontheweldergroundclampasclosetotheweldingareaaspossible

•Ifweldingincloseproximitytoacomputermodule,thenthemoduleshouldberemovedfromthemachine

•Neverallowweldingcablestolayon,nearoracrossanyelectricalwiringorelectroniccomponentwhile

weldingisinprogress

4.Alwaysdisconnectthenegativecablefromthebatterywhenchargingthebatteryinthemachinewithabattery

charger.

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.

84496807-22/04/2012

INTRODUCTION

Torque-Minimumtighteningtorquesfornormalassembly

METRICNON-FLANGEDHARDWARE

NOM.

SIZE

CLASS8.8BOLTand

CLASS8NUT

CLASS10.9BOLTand

CLASS10NUT

LOCKNUT

CL.8

W/CL8.8

BOLT

LOCKNUT

CL.10

W/CL10.9

BOLT

UNPLATEDPLATED

W/ZnCrUNPLATEDPLATED

W/ZnCr

M42.2N·m(19lb

in)

2.9N·m(26lb

in)

3.2N·m(28lb

in)

4.2N·m(37lb

in)2N·m(18lbin)2.9N·m(26lb

in)

M54.5N·m(40lb

in)

5.9N·m(52lb

in)

6.4N·m(57lb

in)

8.5N·m(75lb

in)4N·m(36lbin)5.8N·m(51lb

in)

M67.5N·m(66lb

in)

10N·m(89lb

in)

11N·m(96lb

in)

15N·m(128lb

in)

6.8N·m(60lb

in)

10N·m(89lb

in)

M818N·m(163lb

in)

25N·m(217lb

in)

26N·m(234lb

in)

35N·m(311lb

in)

17N·m(151lb

in)

24N·m(212lb

in)

M1037N·m(27lbft)49N·m(36lb

ft)52N·m(38lbft)70N·m(51lb

ft)

33N·m(25lb

ft)

48N·m(35lb

ft)

M1264N·m(47lbft)85N·m(63lb

ft)91N·m(67lbft)121N·m(90lb

ft)

58N·m(43lb

ft)

83N·m(61lb

ft)

M16158N·m(116lb

ft)

210N·m(155

lbft)

225N·m(166lb

ft)

301N·m(222

lbft)

143N·m(106lb

ft)

205N·m(151lb

ft)

M20319N·m(235lb

ft)

425N·m(313

lbft)

440N·m(325lb

ft)

587N·m(433

lbft)

290N·m(214lb

ft)

400N·m(295lb

ft)

M24551N·m(410lb

ft)

735N·m(500

lbft)

762N·m(560lb

ft)

1016N·m(750

lbft)

501N·m(370lb

ft)

693N·m(510lb

ft)

NOTE:M4throughM8hardwaretorquespecicationsareshowninpound-inches.M10throughM24hardwaretorque

specicationsareshowninpound-feet.

84496807-22/04/2012

INTRODUCTION

METRICFLANGEDHARDWARE

NOM.

SIZE

CLASS8.8BOLTand

CLASS8NUT

CLASS10.9BOLTand

CLASS10NUT

LOCKNUT

CL.8

W/CL8.8

BOLT

LOCKNUT

CL.10

W/CL10.9

BOLT

UNPLATEDPLATED

W/ZnCrUNPLATEDPLATED

W/ZnCr

M42.4N·m(21lb

in)

3.2N·m(28lb

in)

3.5N·m(31lb

in)

4.6N·m(41lb

in)

2.2N·m(19lb

in)

3.1N·m(27lb

in)

M54.9N·m(43lb

in)

6.5N·m(58lb

in)

7.0N·m(62lb

in)

9.4N·m(83lb

in)

4.4N·m(39lb

in)

6.4N·m(57lb

in)

M68.3N·m(73lb

in)

11N·m(96lb

in)

12N·m(105lb

in)

16N·m(141lb

in)

7.5N·m(66lb

in)

11N·m(96lb

in)

M820N·m(179lb

in)

27N·m(240lb

in)

29N·m(257lb

in)

39N·m(343lb

in)

18N·m(163lb

in)

27N·m(240lb

in)

M1040N·m(30lbft)54N·m(40lb

ft)57N·m(42lbft)77N·m(56lb

ft)37N·m(27lbft)53N·m(39lbft)

M1270N·m(52lbft)93N·m(69lb

ft)

100N·m(74lb

ft)

134N·m(98lb

ft)63N·m(47lbft)91N·m(67lbft)

M16174N·m(128lb

ft)

231N·m(171

lbft)

248N·m(183lb

ft)

331N·m(244

lbft)

158N·m(116lb

ft)

226N·m(167lb

ft)

M20350N·m(259lb

ft)

467N·m(345

lbft)

484N·m(357lb

ft)

645N·m(476

lbft)

318N·m(235lb

ft)

440N·m(325lb

ft)

M24607N·m(447lb

ft)

809N·m(597

lbft)

838N·m(618lb

ft)

1118N·m(824

lbft)

552N·m(407lb

ft)

IDENTIFICATION

MetricHexheadandcarriagebolts,classes5.6andup

200836801

1.Manufacturer'sIdentication

2.PropertyClass

MetricHexnutsandlocknuts,classes05andup

200836812

84496807-22/04/2012

INTRODUCTION

1.Manufacturer'sIdentication

2.PropertyClass

3.ClockMarkingofPropertyClassandManufacturer'sIdentication(Optional),i.e.marks60°apartindicate

Class10properties,andmarks120°apartindicateClass8.

INCHNON-FLANGEDHARDWARE

NOMINAL

SIZE

SAEGRADE5BOLT

andNUT

SAEGRADE8BOLT

andNUT

LOCKNUT

GrBW/Gr5

BOLT

LOCKNUT

GrCW/Gr8

BOLT

UN-

PLATED

SILVER

PLATED

W/ZnCr

GOLD

UN-

PLATED

orPLATED

SILVER

PLATED

W/ZnCr

GOLD

1/48N·m(71lb

in)

11N·m(97lb

in)

12N·m(106

lbin)

16N·m(142

lbin)8.5N·m(75lbin)12.2N·m(109lb

in)

5/1617N·m(150

lbin)

23N·m(204

lbin)

24N·m(212

lbin)

32N·m(283

lbin)

17.5N·m(155lb

in)

25N·m(220lb

in)

3/830N·m(22lb

ft)

40N·m(30

lbft)

43N·m(31lb

ft)

57N·m(42lb

ft)31N·m(23lbft)44N·m(33lbft)

7/1648N·m(36lb

ft)

65N·m(48

lbft)

68N·m(50lb

ft)

91N·m(67lb

ft)50N·m(37lbft)71N·m(53lbft)

1/274N·m(54lb

ft)

98N·m(73

lbft)

104N·m(77

lbft)

139N·m(103

lbft)76N·m(56lbft)108N·m(80lbft)

9/16107N·m(79

lbft)

142N·m(105

lbft)

150N·m(111

lbft)

201N·m(148

lbft)111N·m(82lbft)156N·m(115lb

ft)

5/8147N·m(108

lbft)

196N·m(145

lbft)

208N·m(153

lbft)

277N·m(204

lbft)

153N·m(113lb

ft)

215N·m(159lb

ft)

3/4261N·m(193

lbft)

348N·m(257

lbft)

369N·m(272

lbft)

491N·m(362

lbft)

271N·m(200lb

ft)

383N·m(282lb

ft)

7/8420N·m(310

lbft)

561N·m(413

lbft)

594N·m(438

lbft)

791N·m(584

lbft)

437N·m(323lb

ft)

617N·m(455lb

ft)

1630N·m(465

lbft)

841N·m(620

lbft)

890N·m(656

lbft)

1187N·m

(875lbft)

654N·m(483lb

ft)

924N·m(681lb

ft)

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

through1inhardwaretorquespecicationsareshowninpound-feet.

84496807-22/04/2012

INTRODUCTION

INCHFLANGEDHARDWARE

NOM-

INAL

SIZE

SAEGRADE5BOLTand

NUT

SAEGRADE8BOLTand

NUT

LOCKNUT

GrFW/Gr5

BOLT

LOCKNUT

GrGW/Gr8

BOLT

UNPLATED

orPLATED

SILVER

PLATED

W/ZnCr

GOLD

UNPLATED

orPLATED

SILVER

PLATED

W/ZnCr

GOLD

1/49N·m(80lbin)12N·m(106lb

in)

13N·m(115lb

in)

17N·m(150lb

in)8N·m(71lbin)12N·m(106lb

in)

5/1619N·m(168lb

in)

25N·m(221lb

in)

26N·m(230lb

in)

35N·m(310lb

in)

17N·m(150lb

in)

24N·m(212lb

in)

3/833N·m(25lbft)44N·m(33lb

ft)

47N·m(35lb

ft)

63N·m(46lb

ft)30N·m(22lbft)43N·m(32lbft)

7/1653N·m(39lbft)71N·m(52lb

ft)

75N·m(55lb

ft)

100N·m(74lb

ft)48N·m(35lbft)68N·m(50lbft)

1/281N·m(60lbft)108N·m(80lb

ft)

115N·m(85lb

ft)

153N·m(113

lbft)74N·m(55lbft)104N·m(77lb

ft)

9/16117N·m(86lb

ft)

156N·m(115

lbft)

165N·m(122

lbft)

221N·m(163

lbft)106N·m(78lbft)157N·m(116lb

ft)

5/8162N·m(119lb

ft)

216N·m(159

lbft)

228N·m(168

lbft)

304N·m(225

lbft)

147N·m(108lb

ft)

207N·m(153lb

ft)

3/4287N·m(212lb

ft)

383N·m(282

lbft)

405N·m(299

lbft)

541N·m(399

lbft)

261N·m(193lb

ft)

369N·m(272lb

ft)

7/8462N·m(341lb

ft)

617N·m(455

lbft)

653N·m(482

lbft)

871N·m(642

lbft)

421N·m(311lb

ft)

594N·m(438lb

ft)

1693N·m(512lb

ft)

925N·m(682

lbft)

979N·m(722

lbft)

1305N·m(963

lbft)

631N·m(465lb

ft)

890N·m(656lb

ft)

IDENTIFICATION

InchBoltsandfree-spinningnuts

200836823

GradeMarkingExamples

SAEGradeIdentication

1Grade2-NoMarks4Grade2Nut-NoMarks

2Grade5-ThreeMarks5Grade5Nut-Marks120°Apart

3Grade8-FiveMarks6Grade8Nut-Marks60°Apart

84496807-22/04/2012

INTRODUCTION

InchLockNuts,AllMetal(Threeoptionalmethods)

200902684

GradeIdentication

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

GradeANoNotchesNoMarkNoMarks

GradeBOneCircumferentialNotchLetterBThreeMarks

GradeCTwoCircumferentialNotchesLetterCSixMarks

84496807-22/04/2012

SERVICEMANUAL

Engine

F5DFL413A*A001,F5DFL413A*A002,F5DFL413B*A006,F5DFL413C*A003,

F5DFL413D*A003,F5DFL413D*A004,F5HFL413A*A001,F5HFL413B*A001,

F5HFL413B*A002,F5HFL413C*A001

84496807-22/04/2012

Contents

Engine-10

Engineandcrankcase......................................................................10.001

F5DFL413A*A001,F5DFL413A*A002,F5DFL413B*A006,F5DFL413C*A003,F5DFL413D*A003,F5DFL413D*A004,