New Holland F4DE9684B J111 Series User manual

Part number 47597675
1st edition English
October 2013
SERVICE MANUAL
F4CE9484 / F4CE9487A / F4CE9487N /
F4CE9684 / F4DE9484 / F4DE9684B*J111 /
F4DE9684M*J101 / F4DE9684M*J103 /
F4DE9684 / F4DE9687 / F4GE9484C*J601 /
F4GE9484 / F4GE9684 / F4HE0484G*J102 /
F4HE0484G*J109 / F4HE9484C*J102 /
F4HE9484C*J103 / F4HE9484 / F4HE9684 /
F4HE9687G*J100 / F4HE9687
NEF Tier 3
Engine
PrintedinU.S.A.
Copyright © 2013 CNH America LLC. All Rights Reserved. NewHollandisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.

Mechanical fuel injection / Structural engine bloc
k
F4CE9454H*J601 F4CE9484J*J602 F4CE9484M*J603 F4CE9487M*J605 F4CE9684J*J601
F4CE9454H*J605 F4CE9484J*J604 F4CE9484M*J606 F4CE9487N*J601 F4CE9684J*J606
F4CE9484A*J600 F4CE9484L*J600 F4CE9484M*J607 F4CE9487N*J602 F4CE9684J*J607
F4CE9484A*J602 F4CE9484L*J602 F4CE9484M*J608 F4CE9487N*J603 F4CE9684J*J609
F4CE9484C*J600 F4CE9484L*J603 F4CE9484N*J601 F4CE9487N*J605 F4CE9684K*J601
F4CE9484C*J601 F4CE9484L*J604 F4CE9484N*J604 F4CE9487N*J606 F4CE9684K*J606
F4CE9484G*J600 F4CE9484L*J605 F4CE9487A*J600 F4CE9684B*J600 F4CE9684K*J607
F4CE9484G*J604 F4CE9484L*J606 F4CE9487A*J601 F4CE9684C*J600 F4CE9684K*J608
F4CE9484G*J607 F4CE9484M*J601 F4CE9487M*J602 F4CE9684H*J603 F4CE9684L*J600
F4CE9484G*J608 F4CE9484M*J602 F4CE9487M*J603 F4CE9684H*J604 F4CE9684L*J605
Mechanical fuel injection / Non-structural engine bloc
k
F4GE9454C*J601 F4GE9484C*J603 F4GE9484F*J615 F4GE9684C*J602 F4GE9684F*J604
F4GE9454C*J602 F4GE9484C*J605 F4GE9484H*J600 F4GE9684D*J600 F4GE9684G*J600
F4GE9454C*J607 F4GE9484C*J606 F4GE9484J*J600 F4GE9684D*J603 F4GE9684G*J601
F4GE9454C*J608 F4GE9484C*J607 F4GE9484J*J601 F4GE9684D*J604 F4GE9684G*J602
F4GE9454J*J605 F4GE9484D*J600 F4GE9484J*J603 F4GE9684E*J600 F4GE9684G*J603
F4GE9454J*J607 F4GE9484D*J603 F4GE9484J*J604 F4GE9684E*J601 F4GE9684G*J605
F4GE9454K*J602 F4GE9484D*J606 F4GE9484J*J605 F4GE9684E*J603 F4GE9684G*J606
F4GE9454K*J604 F4GE9484D*J607 F4GE9484P*J600 F4GE9684E*J604 F4GE9684H*J600
F4GE9454K*J605 F4GE9484D*J617 F4GE9484P*J601 F4GE9684E*J605 F4GE9684H*J601
F4GE9484A*J602 F4GE9484D*J618 F4GE9684A*J603 F4GE9684E*J606 F4GE9684R*J600
F4GE9484A*J605 F4GE9484D*J619 F4GE9684A*J605 F4GE9684E*J607 F4GE9684R*J601
F4GE9484A*J607 F4GE9484D*J620 F4GE9684B*J601 F4GE9684E*J610 F4GE9684R*J602
F4GE9484A*J608 F4GE9484E*J600 F4GE9684B*J602 F4GE9684E*J611 F4GE9684R*J603
F4GE9484A*J610 F4GE9484E*J601 F4GE9684B*J604 F4GE9684E*J612 F4GE9684R*J605
F4GE9484A*J611 F4GE9484E*J602 F4GE9684B*J605 F4GE9684E*J613 F4GE9684R*J606
F4GE9484A*J612 F4GE9484E*J603 F4GE9684B*J606 F4GE9684E*J615
F4GE9484C*J600 F4GE9484F*J600 F4GE9684B*J607 F4GE9684F*J600
F4GE9484C*J601 F4GE9484F*J610 F4GE9684C*J600 F4GE9684F*J602
F4GE9484C*J602 F4GE9484F*J614 F4GE9684C*J601 F4GE9684F*J603
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Electronic fuel injection / Structural engine block
F4DE0484B*J100 F4DE9684B*J100 F4DE9684J*J101 F4DE9684R*J103 F4DE9687J*J104
F4DE0484C*J100 F4DE9684B*J101 F4DE9684J*J102 F4DE9684R*J104 F4DE9687R*J101
F4DE9484A*J100 F4DE9684B*J102 F4DE9684J*J104 F4DE9684R*J105 F4DE9687U*J100
F4DE9484A*J103 F4DE9684B*J104 F4DE9684J*J105 F4DE9684S*J100 F4DE9687U*J102
F4DE9484A*J104 F4DE9684B*J106 F4DE9684L*J100 F4DE9684S*J103 F4DE9687V*J100
F4DE9484B*J101 F4DE9684B*J107 F4DE9684L*J103 F4DE9684S*J106 F4DE9687V*J101
F4DE9484D*J101 F4DE9684B*J108 F4DE9684L*J106 F4DE9684S*J107 F4DE9687V*J104
F4DE9484E*J100 F4DE9684B*J109 F4DE9684L*J107 F4DE9684U*J100 F4DE9687X*J100
F4DE9484F*J100 F4DE9684B*J110 F4DE9684L*J108 F4DE9684Y*J100 F4DE9687X*J101
F4DE9484F*J101 F4DE9684B*J111 F4DE9684L*J109 F4DE9684Y*J101 F4DE9687X*J102
F4DE9484G*J100 F4DE9684C*J100 F4DE9684M*J100 F4DE9684Y*J102 F4DE9687X*J103
F4DE9484H*J100 F4DE9684D*J100 F4DE9684M*J101 F4DE9684Z*J102 F4DE9687X*J104
F4DE9487A*J103 F4DE9684E*J100 F4DE9684M*J103 F4DE9687A*J100 F4DE9687X*J105
F4DE9487A*J104 F4DE9684F*J100 F4DE9684N*J100 F4DE9687A*J103 F4DE9687X*J106
F4DE9487B*J100 F4DE9684F*J102 F4DE9684N*J104 F4DE9687A*J104 F4DE9687Y*J100
F4DE9487B*J101 F4DE9684G*J100 F4DE9684N*J107 F4DE9687C*J100 F4DE9687Y*J101
F4DE9487C*J100 F4DE9684G*J101 F4DE9684N*J108 F4DE9687J*J100 F4DE9687Y*J102
F4DE9487D*J101 F4DE9684H*J100 F4DE9684R*J100 F4DE9687J*J101
F4DE9487L*J100 F4DE9684J*J100 F4DE9684R*J102 F4DE9687J*J102
Electronic fuel injection / Non-structural engine block
F4HE0454D*J102 F4HE9484F*J105 F4HE9684E*J104 F4HE9684S*J102 F4HE9687L*J100
F4HE0454D*J104 F4HE9484F*J106 F4HE9684E*J106 F4HE9684S*J103 F4HE9687L*J101
F4HE0484A*J101 F4HE9484M*J100 F4HE9684E*J107 F4HE9684T*J100 F4HE9687M*J101
F4HE0484A*J103 F4HE9484M*J101 F4HE9684F*J100 F4HE9684T*J101 F4HE9687M*J103
F4HE0484G*J100 F4HE9684B*J100 F4HE9684F*J102 F4HE9684U*J101 F4HE9687M*J104
F4HE0484G*J101 F4HE9684B*J101 F4HE9684F*J103 F4HE9684U*J103 F4HE9687M*J105
F4HE0484G*J102 F4HE9684B*J103 F4HE9684F*J104 F4HE9684V*J102 F4HE9687N*J101
F4HE0484G*J103 F4HE9684B*J104 F4HE9684F*J105 F4HE9684V*J103 F4HE9687N*J103
F4HE0484G*J105 F4HE9684C*J100 F4HE9684F*J107 F4HE9687C*J100 F4HE9687N*J104
F4HE0484G*J106 F4HE9684C*J101 F4HE9684F*J108 F4HE9687C*J101 F4HE9687P*J101
F4HE0484G*J108 F4HE9684C*J102 F4HE9684F*J109 F4HE9687C*J103 F4HE9687Q*J101
F4HE0484G*J109 F4HE9684C*J104 F4HE9684J*J100 F4HE9687F*J100 F4HE9687Q*J103
F4HE0484G*J110 F4HE9684C*J105 F4HE9684J*J101 F4HE9687F*J101 F4HE9687S*J101
F4HE0684T*J100 F4HE9684C*J106 F4HE9684J*J102 F4HE9687G*J100 F4HE9687S*J103
F4HE0684T*J101 F4HE9684D*J100 F4HE9684J*J104 F4HE9687G*J101 F4HE9687S*J104
F4HE0684T*J103 F4HE9684D*J101 F4HE9684J*J106 F4HE9687G*J102 F4HE9687S*J105
F4HE9484C*J100 F4HE9684D*J102 F4HE9684K*J100 F4HE9687G*J104 F4HE9687T*J101
F4HE9484C*J102 F4HE9684D*J103 F4HE9684K*J102 F4HE9687H*J100 F4HE9687T*J103
F4HE9484C*J103 F4HE9684D*J105 F4HE9684L*J101 F4HE9687H*J101 F4HE9687T*J104
F4HE9484C*J104 F4HE9684D*J106 F4HE9684L*J102 F4HE9687H*J102 F4HE9687W*J100
F4HE9484C*J105 F4HE9684D*J107 F4HE9684M*J100 F4HE9687H*J103 F4HE9687W*J101
F4HE9484C*J106 F4HE9684D*J109 F4HE9684M*J101 F4HE9687K*J100 F4HE9687W*J102
F4HE9484C*J107 F4HE9684E*J100 F4HE9684P*J102 F4HE9687K*J101 F4HE9687Z*J100
F4HE9484C*J108 F4HE9684E*J101 F4HE9684P*J103 F4HE9687K*J102 F4HE9687Z*J101
F4HE9484F*J103 F4HE9684E*J102 F4HE9684S*J100 F4HE9687K*J103
F4HE9484F*J104 F4HE9684E*J103 F4HE9684S*J101 F4HE9687K*J105
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.102]Panandcovers....................................................................10.2
[10.106]Valvedriveandgears..............................................................10.3
[10.101]Cylinderheads.....................................................................10.4
[10.105]Connectingrodsandpistons.......................................................10.5
[10.103]Crankshaftandywheel............................................................10.6
[10.110]Balanceranddamper..............................................................10.7
[10.114]Pumpdrives........................................................................10.8
[10.210]Liftpumpandlines.................................................................10.9
[10.206]Fuellters........................................................................10.10
[10.218]Fuelinjectionsystem.............................................................10.11
[10.250]Turbochargerandlines...........................................................10.12
[10.254]Intakeandexhaustmanifoldsandmufer.......................................10.13
[10.400]Enginecoolingsystem...........................................................10.14
[10.414]Fananddrive....................................................................10.15
[10.304]Enginelubricationsystem........................................................10.16
[10.408]Oilcoolerandlines...............................................................10.17
Electricalsystems.......................................................................55
[55.015]Enginecontrolsystem..............................................................55.1
[55.201]Enginestartingsystem.............................................................55.2
[55.301]Alternator...........................................................................55.3
[55.202]Coldstartaid.......................................................................55.4
[55.010]Fuelinjectionsystem...............................................................55.5
[55.014]Engineintakeandexhaustsystem.................................................55.6
[55.012]Enginecoolingsystem.............................................................55.7
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[55.013]Engineoilsystem..................................................................55.8
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INTRODUCTION
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Contents
INTRODUCTION
Foreword........................................................................................3
Safetyrules.....................................................................................4
Torque..........................................................................................6
F4DE9484,F4HE9484,F4HE0484G*J109,F4HE0484G*J102,F4HE9484C*J102,F4HE9484C*J103,F4DE9684,F4DE9687,
F4HE9684,F4HE9687,F4HE9687G*J100,F4DE9684M*J101,F4DE9684M*J103,F4DE9684B*J111
Torque..........................................................................................9
F4CE9484,F4GE9484,F4CE9487N,F4CE9487A,F4GE9484C*J601,F4CE9684,F4GE9684
Specialtools..................................................................................11
F4DE9484,F4HE9484,F4HE0484G*J109,F4HE0484G*J102,F4HE9484C*J102,F4HE9484C*J103,F4DE9684,F4DE9687,
F4HE9684,F4HE9687,F4HE9687G*J100,F4DE9684M*J101,F4DE9684M*J103,F4DE9684B*J111
Specialtools..................................................................................17
F4CE9484,F4GE9484,F4CE9487N,F4CE9487A,F4GE9484C*J601,F4CE9684,F4GE9684
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INTRODUCTION
Foreword
EngineOverhaul
Partoftheoperationsillustratedwithinthismanualcanbepartiallyexecutedwhiletheengineisassembledonthe
vehicle,dependingontheroomavailableforaccesstotheengineandontheequipmentapplicationaswell.
NOTE:Withregardtotheenginedisassemblyoperations,pleaseapplyforinformationconsultingthespecicmanual.
Thefollowinginformationrelatestotheengineoverhauloperationsonlyforwhatconcernsthedifferentcomponents
customizingtheengine,accordingtoitsspecicduties.
Insection"GeneralOverhaul",alltheoperationsofengineblockoverhaulhavebeencontemplated.Thereforethe
abovementionedsectionistobeconsideredasfollowingthepartherebydescribed.
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INTRODUCTION
Safetyrules
Standardsafetyprescriptions
Particularattentionshallbedrawnonsomeprecautionsthatmustbefollowedabsolutelyinastandardworking
areaandwhosenonfulllmentwillmakeanyothermeasureuselessornotsufcienttoensuresafetytothe
personnelinchargeofmaintenance.
Beinformedandinformpersonnelaswellofthelawsinforceregulatingsafety,providinginformationdocumentation
availableforconsultation.
•Keepworkingareasascleanaspossible,ensuringadequateaeration.
•Ensurethatworkingareasareprovidedwithemergencyboxes,thatmustbeclearlyvisibleandalwaysprovided
withadequatesanitaryequipment.
•Provideforadequatereextinguishingmeans,properlyindicatedandalwayshavingfreeaccess.Theirefciency
mustbecheckedonaregularbasisandthepersonnelmustbetrainedoninterventonmethodsandpriorities.
•Organizeandidentifyspecicexitpointstoevacuatetheareasincaseofanemergency,providingforadequate
indicationsoftheemergencyindicationsoftheemergencyexitlines.
•Smokinginworkingareassubjecttoredangermustbestrictlyprohibited.
•Providewarningsthroughoutadequateboardssignalingdanger,prohibitionsandindicationstoensureeasycom-
prehensionoftheinstructionsevenincaseofanemergency.
Preventionofinjury
•Donotwearunsuitableclothesforwork,withutteringends,norjewelssuchasandchainswhenworkingcloseto
enginesandequipmentinmotion.
•Wearsafetyglovesandgoggleswhenperformingthefollowingoperations:
••llinginhibitorsoranti-frost
•lubricationoiltoppingorreplacement
•utilizationofcompressedairorliquidsunderpressure(pressureallowed<2
bar(29 psi)).
•Wearsafetyhelmetwhenworkingclosetohangingloadsorequipmentworkingatheadheightlevel.
•Alwayswearsafetyshoesandclothesadheringtothebody,betterifprovidedwithelasticsattheends.
•Useprotectioncreamforhands.
•Changewetclothesassoonaspossible.
•Inpresenceofelectricalcurrentexceeding48-60
Vverifyefciencyofearthandmasselectricalconnections.
Ensurethathandsandfeetaredryandexecuteworkingoperationsutilizingisolatingfootboards.Donotcarryout
workingoperationsifnottrainedfor.
•Donotsmokenorlightupamesclosetobatteriesandtoanyfuelmaterial.
•Putthedirtyragswithoil,dieselfuelorsolventsinanti-respeciallyprovidedcontainers.
•Donotexecuteanyinterventionifnotprovidedwithnecessaryinstructions.
•Donotuseanytoolorequipmentforanydifferentoperationfromtheonesthey'vebeendesignedandprovidedfor.
Seriousinjurymayoccur.
•Incaseoftestorcalibrationoperationsrequiringenginerunning,ensurethattheareaissufcientlyventilatedor
utilizespecicvacuumequipmenttoeliminateexhaustgas.Danger:poisoningordeath.
Duringmaintenance
•Neveropenllercapofcoolingsystemwhentheengineishot.Operatingpressurewouldprovokehightemperature
withseriousdangerandriskofburn.Waituntilthetemperaturedecreasesunder50
°C(122 °F).
•Nevertopupanoverheatedenginewithcoolerandutilizeonlyappropriateliquids.
•Alwaysoperatewhentheengineistunedoff;whenparticularcircumstancesrequiremaintenanceinterventionon
runningengine,beawareofallrisksinvolvedwithsuchoperation.
•Beequippedwithadequateandsafecontainersfordrainageoperationofengineliquidsandexhaustoil.
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