TRAINING MANUAL

ENGINE (S8000 Tier-3)

TRAINING CENTER
GREATER NOIDA,
U.P. (INDIA)
 ENGINE
S8000 ENGINE SPECIFICATON

Engine model, HP 76 86 96
Engine Model Code 8045.45.731 8045.45.735 8045.45.740
CNH part no. 84594264 84585200 84602889
Break Horse Power 76 (56kw) 86 (64kw) 96 (72kw)
Emission Bharat (CEV)Stage -III, Bharat (CEV)Stage -III, Bharat (CEV)Stage -III,
Tier-3 Tier-3 Tier-3
No. off cylinder 4 4 4
Type TCA TCA TCA
Bore (mm) 104 104 104
Stroke (mm) 115 115 115
Displacement (cc) 3908 3908 3908
Maximum Torque (Nm) 320 405 420
Maximum Torque RPM 1300 1300 1300
Rated RPM 2200 2200 2200
High Idle RPM 2450+/-50 2450+/-50 2450+/-50
Low Idle RPM 1000+/-50 1000+/-50 1000+/-50
Compresion Ratio 18.1 18.1 18.1
Fuel Injection Pump Rotary Rotary Rotary
FIP comb no. B460 816 909 B460 816 937 to be decided
High Pressure Pipe 1.6x530 1.6x530 1.6x530
Nozzle 6x0.193x145p 6x0.193x145p 6x0.193x145p
Injector Washer (mm) 2 2 2
Nozzle Through Flow 575 575 575
Identification on nozzle 5544 5544 5544
Nozzle Tip Potrusion 3 3 3
Injector Pressure kgf/sq.cm 260+8 260+8 260+8
Camshaft with Tiner with Tiner with Tiner
FIP Timming @ TDC 0.9 mm 1.0 mm 0.9 mm
Turbocharger 5cm2WG-11T, HX25W 5cm2WG-11T, HX25W 5cm2WG-11T, HX25W
Air Cleaner Dry Dry Dry
Oil Capacity, liters 8.5 8.5 8.5
Oil grade 14W40 14W40 14W40

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 ENGINE

SPECIFICATION

ENGINE BLOCK : MM
Cylinder liner seat diameter in engine block 106.850-106.900
Cylinder sleeve O.D 107.020-107.050
Interference between liners and seats in block 0.120-0.200
Liner O.D. oversize 0.2
Cylinder liner inner diameter 104.00-104.024
Maximum ovality and taper due to wear 0.12
Liner inner diameter oversize 0.4 - 0.8

CAMSHAFT BUSH SEAT DIAMETERS :

- front 54.780-54.805
- intermediate 54.280-54.305
- rear 53.780-53.805
Tappet seat bore diameter 15.000-15.018
Tappet oversize 0.1 - 0.2 - 0.3

CYLINDER HEAD :
Valve guide seat bore diameter in head 13.950-13.983
Valve guide oversize 0.2
Valve stand-in 0.7-1.0
- maximum stand-in permitted 1.3
Injector stand-out (N.T.P.) 3.0-3.5
- max. stand-out permitted 1.0
Original cylinder head height 92
Maximum head dressing allowed 0.5

CRANKSHAFT - BEARINGS :
Main journal diameter 79.791-79.810
Main journal undersize 0.254-0.508-0.762-1.016
Main bearing wall thickness 2.168-2.178
Main bearing undersize 0.254-0.508-0.762-1.016
Main journal clearance in bearings 0.034-0.103

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 ENGINE

SPECIFICATION
CRANKSHAFT - BEARINGS : MM
- maximum wear clearance 0.180
Crankpin diameter 63.725-63.744
Crankpin undersize 0.254-0.508-0.762-1.016
Big end bearing wall thickness 1.805-1.815
Big end bearing undersize 0.254-0.508-0.762-1.016
Crankpin clearance in big end bearing 0.033-0.087
- maximum wear clearance 0.180
Crankshaft thrust washer thickness 3.378-3.429
Thrust washer oversize 0.127-0.254-0.508
Crankshaft end float 0.082-0.334
- maximum wear end float 0.40
CONNECTING RODS :
Small end bore diameter 41.846-41.884
Small end bushing outer diameter 41.979-42.017
Bushing interference fit in small end 0.095-0.171
Small end bushing fitted I.D 38.004-38.014
Big end bore diameter 67.407-67.422
Maximum connecting rod weight difference
over a complete set from the same engine 25 grams
PISTONS :
Piston diameter: measured at 57 mm from
base (Thrust side) right angles to pin 103.852-103.870
Piston clearance in liner 0.174-0.212
- max. wear clearance 0.30
Piston stand- out with respect to head at T.D.C 0.430-0.840
Piston pin diameter 38.000-38.006
Piston pin seat bore in piston 37.993-38.000
Piston pin clearance in piston 0.003-0.017
Piston pin clearance in small end bushing 0.010-0.023
- maximum wear clearance 0.06
Maximum weight difference between
pistons on same engine 20 grams

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 ENGINE

SPECIFICATION

Ring clearance in piston groove: MM

- Top 0.090-0.122
- 2nd 0.060-0.092
- 3rd 0.040-0.075
Maximum wear clearance:
- Top 0.50
- 2nd and 3rd 0.20
Piston ring gap:
- Top 0.40-0.65
- 2nd 0.30-0.55
- 3rd 0.30-0.60
Maximum wear gap 1.20

VALVE TIMING GEARS :

Timing gear backlash 0.160

Idler gear jack shaft diameter 36.975-37.000

Idler gear bushing (fitted) I.D. after reaming 37.050-37.075

Jack shaft journal clearance in bushing 0.050-0.100

- max. wear clearance 0.15

Bushing interference fit in idler gear 0.063-0.140

Shaft clearance in bushing 0.050-0.100

Bushing interference fit in housing 0.063-0.140

Pump drive gear thrust washer thickness 1.45-1.50

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 ENGINE

SPECIFICATION
CAMSHAFT : MM
Camshaft bushing O.D.:
- front 54.875-54.930
- intermediate 54.375-54.430
- rear 53.875-53.930
Bushing interference fit in housing 0.070-0.150
CAMSHAFT BUSHING FITTED I.D. AFTER REAMING:
- front 51.080-51.130
- intermediate 50.580-50.630
- rear 50.080-50.130
CAMSHAFT JOURNAL DIAMETER:
- front 50.970-51.000
- intermediate 50.470-50.500
- rear 49.970-50.000
Camshaft journal clearance in bushing 0.080-0.160
Maximum wear clearance 0.20
Camshaft end float (thrust plate to associated seat in camshaft) 0.070-0.220
TAPPETS :
Tappet O.D 14.950-14.970
Tappet clearance in housing on engine block 0.030-0.068
- maximum wear clearance 0.15
Tappet oversize 0.1-0.2-0.3
ROCKERS :
Rocker bushing O.D 21.006-21.031
Rocker bore diameter 20.939-20.972
Bushing interference fit in rocker 0.034-0.092
Rocker bracket bore diameter 18.016-18.034
Rocker shaft diameter 17.982-18.000
Rocker shaft clearance in bracket 0.016-0.052
maximum wear clearance 0.15
ROCKER SPACER SPRING LENGTH:
- free 59.5
- under load (4.7-5.3 kg) 44

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 ENGINE

SPECIFICATION
MM
Valve head diameter :
Inlet 43.300-45.500
exhaust 37.500-37.750
Valve stem diameter 7.985-8.000
Valve face angle :
- inlet 60° 30' ± 7'
- exhaust 45° 30' ± 7'
- timing check 0.45
Valve clearance:
- inlet 0.30
- (warm or cold) exhaust 0.30
Cam lift :
- inlet 5.8885
- exhaust 6.1277
Valve lift:
- inlet 10.4437
- exhaust 10.8679
Valve guide O.D 13.933-14.016
Valve guide oversize 0.2
Valve guide interference fit in housing on cylinder head 0.005-0.050
Valve guide fitted I.D. after reaming 8.023-8.043
Valve stem clearance in guide 0.023-0.058
- maximum wear clearance 0.13
Inlet and exhaust valve spring length:
- free 44.6
- with load of 26.1-28.9 kg 34
- with load of 51.2-56.5 kg 23.8

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 ENGINE

SPECIFICATION
LUBRICATION SYSTEM :

Oil pump Gear, crankshaft

Oil pressure, warm at governed speed (kg/cm²) 3-4

Relief valve crack-off setting (kg/cm²) 3.6

m.m.

Shaft clearance in bushing 0.016-0.055

Shaft clearance in driven gear 0.033-0.066

Gear backlash 0.100

Gear clearance in pump body 0.060-0.170

Drive and driven gear width 40.961-41.000

Gear housing depth in pump body 41.025-41.087

Drive and driven gear end float 0.025-0.126

Relief valve spring length :

- free 45

- loaded: 9-9.6 kg 30.5

Oil filter Mesh on suction

and cartridge on delivery

COOLING SYSTEM :

Water pump Centrifugal, vane type

Water pump drive ratio 1.403 : 1

Shaft interference fit in impeller 0.017-0.059

Shaft interference fit in fan hub 0.024-0.058

Face sealing bushing interference fit in impeller 0.012-0.058

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 ENGINE

TIGHTENING TORQUE

ENGINE Nm kgm Angle

Capscrew, cylinder head 40 4 130° + 140°

Capscrew, main bearing cap 80 8.2 90°

Capscrew, connecting rod cap 40 4.1 60°

Capscrew, flywheel 40 4.1 60°

Capscrew, rocker shaft bracket 24.5 2.5

Nut, crankshaft pulley hub 294 30

Retaining screws, Balancer (S 8000) 110 11.2

Sheetmetal oil pan 35 3.5

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 ENGINE

TECHNICAL TERMINOLOGY :
1. Torque :
Twisting moment or a moment causing twist or rotational effect about a point is called
torque. Metric unit of torque is also Kg-m & S.I. unit is N-m.

Engine torque is the torque available at the flywheel of an engine.

2. Work :
It is the product of force applied to an object and the displacement of the object from its
initial position caused due to application of the force. Metric unit of work is Kg-m & S.I. unit
is N-m.

3. Power :
Power is rate of doing work or work done per unit time. Metric unit of power is Kg-m/s. &
S.I. unit is Watt (Nm/s).

4. Horse Power :
The rate at which the engine can do work is measured in horsepower. One horsepower is
equivalent to 736 watts or 4500 kg m per min.

BHP :- H.P available at the flywheel is called Brake horsepower (bhp). It is measured by
using brake dynamometer.

Drawbar horsepower (dbhp): Is the power available at the tractor drawbar and so is of
main importance as this is what is available for pulling of implements.
For four stroke engines.

5. Compression Ratio:
It is the ratio of gas volumes in the combustion chamber when the piston is at BDC and
when it is at TDC.

6. Stroke : Travel of piston from TDC to BDC.

7. Bore : Internal diameter of cylinder.

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 ENGINE
PISTON, PIN, CONNECTING ROD - INSPECTION

3a 3b 3c

z Measure the pistons at dimension L (Thrust side) 50 mm. Pic. 3a.

z Check the Piston ring clearance in groove (Land clearance) and piston ring gap
Pic. 3b/3c.
Ring clearance in groove Max.wear Piston ring gap Max.wear
1st 0.090 - 0.122 mm 0.50 mm 0.35 - 0.55 mm 1.20 mm
2nd 0.060 - 0.092 mm 0.20 mm 0.30 - 0.45 mm 1.20 mm
3rd 0.040 - 0.075 mm 0.20 mm 0.25 - 0.40 mm 1.20 mm
z Connecting rod hole for pressure lubrication to gudgeon pin bush. Pic. 2.
z Maximum weight difference between pistons on same engine is 20 grams and con-
necting rod is 25 grams, check bend and twist of con.rod as per specification.

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 ENGINE
CRANK SHAFT

S 8000

Crankshaft with integrated weights MM

z Crankshaft end float 0.082-0.334

z Crankshaft maximum wear end float 0.40

z Main journal clearance in bearings 0.034-0.103

z Main journal max. wear clearance 0.180

z Crank pin clearance in big end bearing 0.033-0.087

z Crank pin max. wear clearance 0.180

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 ENGINE
CAM SHAFT

S 8000

z To inspect,place the camshaft over V-block and check,using a suitable dial gauge
that journal eccentricity does not exceed 0.02 mm.

z Camshaft end float(thrust plate to associated seat in camshaft) is 0.070-0.220 mm

z Integral gear of camshaft drives engine oil pump

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 ENGINE

LUBRICATION CIRCUIT

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 ENGINE

GEAR TIMING

Engine Timing :
Match 1-1, 2-2, 3-3 & 4-4 while assembling on PMS 1(TDC), as marked on flywheel

54 Teeths
Camshaft
gear
54 Teeths
Fuel Injection
pump gear

56 Teeths
27 Teeths
Idler gear
Crankshaft
25 Teeths gear
Hydrolics pump
gear 49 Teeths
Idler gear

Injector and valve inspection :

B1: Checking injector stand out - (3.0-3.5)
B2 : Checking valve stand in - (0.7mm to 1mm)

B1 B2

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 ENGINE

Disassembly Disassembly Assembly

(293784) (293784) (293861)

Dressing Cutting Cutter

(293746+293747) (293746+293790) (293790)

z Insert sleeve puller (293784), on to the injector sleeve.

z Tighten the nut(C), so that tool grips the sleeve.
z Fix plate(B) of sleeve puller on to the nuts(E) of injector holding studs, so as to pull out
sleeve by tightening nut (D).
z Insert new sleeve assembled with ‘O’ rings, fit in housing, ensure that lower part
contacts seat in cylinder head and install with installer (293861) Injector sleeve .
z Insert in new sleeve & fit guide for dresser and cutter(293746), in injector sleeve,
turning ring-nut (H) clockwise, insert dresser (1) 293747 in bushing and dress sleeve
lower part.
z Disassemble dresser (1) and unscrew ring-nut (H) by about 10 mm to remove tool.
z Press by hand, or tap the rod lightly with plastic head hammer to release inside body
of bushing of guide for dresser and cutter (293746)

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 ENGINE

CYLINDER HEAD TORQUING

B - 292248

S 8000

z Position the cylinder head gasket with the word “ALTO” on top,

z Cylinder Head : bolt tightening sequence as shown above.

z B. Tool 292248 for angular torquing

Stage ——> 1 2 3
40 NM Turn through Turn through
(4.1 kgm) 130º 140º
(With torque wrench) (With angular torquing tool)

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 ENGINE
Pump Timing - S 8000
z Give supply to KSB direct from the battery or heat the engine up to 40 degree to
activate KSB.
z Wait for approximate 3 minutes to fully open the KSB.
z Bring first piston at PMS1 (TDC) mark by rotating the engine in clockwise direction
(from pulley end) in compression stroke.
z Fit adopter SST - No. 9971500.
z Insert dial gauge fully and see total travel.
z Pre load the dial gauge.
z Set needle at 0 and move the flywheel anticlockwise(from pulley end) till needle stops.
z Set needle at 0 mark & rotate engine clockwise (from pulley end) till PMS1 (TDC)
mark aligns with pointer.
z At that time needle should travel and stop at 0.90 mm mark.
z Any deviation in this specification required pump timing adjustments.
z Adjust timing by loosening three FIP mounting bolts.
z Move pump up for advance & down for retard.

KSB

- +

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 ENGINE
Adjustment of Valve Tappet Clearance

1. S8000 Turbo Super : Tappet setting can be done as per following figure.

2. Firing order of S8000 Turbo Super engine (1-3-4-2)

z Rotate the engine anticlockwise from flywheel side and Match the flywheel on PMS1
compression stroke and adjust 1st & 2nd valve tappet clearance (0.30 mm)

z Rotate the flywheel further anticlockwise 180° and adjust the 5th & 6th valve tappet
clearance

z Rotate the flywheel further anticlockwise 180° and adjust the 7th & 8th valve tappet
clearance

z Rotate the flywheel further anticlockwise 180° and adjust the 3rd & 4th valve tappet
clearance

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 ENGINE
What is Turbo Charge
Important ratio in engine – Fuel / Air Ratio
Piston makes almost 21 suction strokes in one second , so very very little time for air to get
in. Usually Fuel unburnt – Black smoke, due to lack of available air for burning.
So turbocharger helps pushing the intake air, so better volumetric efficiency, full utilisation
of fuel.
Benefits – More torque & more power. Reduced fuel consumption and emissions.

FIP with KSB & LDA

LDA

KSB

z KSB (Kaltstartbeschleuniger) Cold starting timing advance system is used to advance

the timing in cold starting and at low speed cold running. A lever is pulled which turns
cam that pushes timing piston to provide about 5.5 degree advance at no load.
z LDA (Laden Druck Angleichung) controls the injected fuel quatity at middle and high
engine speeds in relation to boost from the turbocharger.

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 ENGINE

Manifold Pressure Compensator (LDA)

IMPORTANT : The LDA is adjusted and set by Bosch.

If the LDA requires any type of adjustment, the injection
pump with the LDA must be brought to an authorized
Bosch specialist.

1. Governor spring
2. Governor cover
3. Reverse lever
4. Guide pin
5. Adjusting nut
6. Diaphragm
7. Compression spring
8. Sliding pin
9. Control cone
10. Full-load adjusting screw
11. Adjuster lever
12. Tensioning lever
13. Starting lever
14. Connection for the charge air
15. Vent bore

The LDA reacts to charge pressure entering at (14) from the exhaust gas generated by the
turbocharger and adapts the full-load delivery to the charge air pressure. The LDA functions
by means of a pipe from the engine inlet manifold that allows boost pressure to push on a
diaphragm acting against spring . As the diaphragm moves it influences the action of
governor to allow more fuelling The air acts against the diaphragm (6) compressing spring
(7). The control cone (9) acts against the guide pin (4) causing the reverse lever (3) to pivot
about M1 which in turn acts against the tensioning lever (12) resulting in the control collar
moving towards the full load position.

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 ENGINE
HP Application
Sl. Tool no. Description Tool
no. 76 86 96

1. 292248 Angular torquing gauge • • •

2. 290090 Engine stand • • •

3. 293860 Support (old) • • •

4. 291050 Cylinder head valve spring • • •

compressor.

Special Tools Application Manual 1

 ENGINE
HP Application
Sl. Tool no. Description Tool
no. 76 86 96

5. 82834300 Puller F.I. Pump gear & crank • • •

shaft pully hub

6. 291525 Sump locating pin (set of two) • • •

7. 9971500 Adoptor fuel injection pump timing - A • • • A

Assembled condition - B • • •

Note : To be used with dial guage

Special Tools Application Manual 2

 ENGINE
HP Application
Sl. Tool no. Description Tool
no. 76 86 96

8. 291883 Tappet adjusting screw driver • • •

9. 293329 Installer, crankshaft front seal In • • • A

sparate cover - A

Assembled condition -B

10. 9971367 Oil pressure gauge with adapter • • •

11. 291328 Oil pressure testing adapter (B) • • •

(Part of hydraulic pressure A
testing kit - 292870)

Special Tools Application Manual 3

 ENGINE
HP Application
Sl. Tool no. Description Tool
no. 76 86 96

12. 290284 Nozzle tester • • •

13. 293299 Installer, main oil seal • • •

14. 292927 Sliding hammer, injector / final • • •

drive bearing remover

Special Tools Application Manual 4

 ENGINE
HP Application
Sl. Tool no. Description Tool
no. 76 86 96

15. 9971387 Remover, Filters • • •

16. 9971389 Wrench to remove solenoid Switch • • •

17. 9971388 Remover, FI pump nut • • •

Special Tools Application Manual 5