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Workshop Manual.....................................................................................................2002 6-51250
Workshop Manual (TVT 195) ...................................................................................2002A 6-93080

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Functional description Injection System ...................................................................3001 6-51300
Functional description Injection System - Common Rail System (TVT 195) ............3001A 6-93150

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Functional description CAN Bus (Basics).................................................................4002 6-51350
Functional description and Troubleshooting – ADIC ................................................4003 6-91700
Function diagrams - Electrics ...................................................................................4008 6-92771
Function diagrams - Electrics (TVT 195) ..................................................................4008A 6-93221
Connectors, Wiring Harnesses, Electrical and Electronic Components ...................4009 6-92970
Connectors, Wiring Harnesses, Electrical and Electronic Components (TVT 195)..4009A 6-93290
Circuit diagram .........................................................................................................4010 6-51402
Circuit diagram (TVT 195) ........................................................................................4010A 6-93360

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Fault codes ...............................................................................................................4011 6-52632

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Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.25S.....................................................5001 6-51450
Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.29S.....................................................5002 6-51500
Workshop Manual - Front Axle - Carraro 20.25, 20.25 FR.......................................5005 6-51550
Workshop Manual - Independently Suspended Front Axle 20.25S and 20.25SI FR5006 6-51600
Workshop Manual - Independently Suspended Front Axle 20.29SI / FR .................5007 6-51651

 75$160,66,21
Functional description Transmission ........................................................................6001 6-51700
Troubleshooting - System hydraulics .......................................................................6002 6-51750
Cartridge - Removing and Fitting..............................................................................6005 6-51800
Cartridge - Disassembling and Assembling..............................................................6006 6-51850
Rear Axle - Removing and Fitting.............................................................................6007 6-51900
Rear Axle - Disassembling and Assembling.............................................................6008 6-51950
Parking Interlock, 4-wheel Drive Clutch and Bevel Pinion (Rear Module)................6009 6-52000

&1+gVWHUUHLFK*PE+ Copyright © 2006 CNH Österreich GmbH


Sva 6-92333
July 2006
 +<'5$8/,&6<67(0
Functional description CC-LS Hydraulic System (Closed Center-Load Sensing).... 8001 6-52051
Functional description and troubleshooting
High Pressure Hydraulic Circuit ............................................................................... 8002 6-92610
Functional description and troubleshooting
(Electronic 3-point hitch control system EDC) ......................................................... 8005 6-52100
Fault codes and fault description, EHS Auxiliary Control Units ............................... 8006 6-52150

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Functional description and troubleshooting Air Conditioning ................................... 9002 6-92840

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Fault codes .............................................................................................................. 4011 6-52632

Sva 6-92333 July 2006


Sva 6-92333 July 2006
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Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.25S.................................................... 5001 6-51450
Functional description, Troubleshooting and Settings
Front Axle with Independent Suspension 20.29S.................................................... 5002 6-51500
Workshop Manual - Front Axle - Carraro 20.25, 20.25 FR ...................................... 5005 6-51550
Workshop Manual - Independently Suspended Front Axle 20.25S and 20.25SI FR5006 6-51600
Workshop Manual - Independently Suspended Front Axle 20.29SI / FR ................ 5007 6-51651

 75$160,66,21
Functional description Transmission ....................................................................... 6001 6-51700
Troubleshooting - System hydraulics....................................................................... 6002 6-51750
Cartridge - Removing and Fitting............................................................................. 6005 6-51800
Cartridge - Disassembling and Assembling............................................................. 6006 6-51850
Rear Axle - Removing and Fitting............................................................................ 6007 6-51900
Rear Axle - Disassembling and Assembling............................................................ 6008 6-51950
Parking Interlock, 4-wheel Drive Clutch and Bevel Pinion (Rear Module)............... 6009 6-52000

 +<'5$8/,&6<67(0
Functional description CC-LS Hydraulic System (Closed Center-Load Sensing) ... 8001 6-52051
Functional description and troubleshooting
High Pressure Hydraulic Circuit............................................................................... 8002 6-92610
Functional description and troubleshooting
(Electronic 3-point hitch control system EDC) ......................................................... 8005 6-52100
Fault codes and fault description, EHS Auxiliary Control Units ............................... 8006 6-52150

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Functional description and troubleshooting Air Conditioning................................... 9002 6-92840
TVT 195

Sva 6-92333 July 2006


Sva 6-92333 July 2006
Chapter
2002

2002
ENGINE WORKSHOP MANUAL

CNH Österreich GmbH Sva 6-51250 EN © 2003 CNH Österreich GmbH


Technical Documentation July 2003
A – 4300 St. Valentin, Steyrer Straße 32
2002-2
TABLE OF CONTENTS

SPECIAL TOOLS .....................................................................................................................5

FOR THE USER ......................................................................................................................7


Engine code and serial number ...........................................................................................7

SAFETY REGULATIONS ........................................................................................................8

ENGINE DATA .........................................................................................................................9


Lifting the engine .................................................................................................................9

TECHNICAL DATA ................................................................................................................10


Conformance with exhaust standards ...............................................................................10
Cylinder block ....................................................................................................................10
Cylinder liners ....................................................................................................................10
Cylinder head .....................................................................................................................10
Valves, rocker arms and push rods ...................................................................................11
Camshaft ...........................................................................................................................12
Crankshaft .........................................................................................................................12
Flywheel .............................................................................................................................13
Gear drive, camshaft and injection pump ..........................................................................13
Con-rods ............................................................................................................................13
Pistons, piston rings and piston pins .................................................................................14
Lubrication system .............................................................................................................14
Lubrication oil pump ...........................................................................................................15
Thermostat .........................................................................................................................15
Coolant temperature indication and monitoring (signal from sensor B22) .........................15
Coolant pump ....................................................................................................................15
Schwitzer turbocharger S200 ............................................................................................15
Tightening torques .............................................................................................................16

CONSTRUCTION ..................................................................................................................17
General ..............................................................................................................................17
Cylinder block ....................................................................................................................17
Flywheel casing .................................................................................................................17
Cylinder head .....................................................................................................................18
Valve mechanism ..............................................................................................................18
Crankshaft drive .................................................................................................................20
Timing gears ......................................................................................................................21
Lubrication system .............................................................................................................22
Cooling system ..................................................................................................................23
Fan .....................................................................................................................................24
Intake/exhaust system .......................................................................................................25

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2002-3
ELECTRONIC ENGINE CONTROL SYSTEM – EEM2 .........................................................26
Layout ................................................................................................................................27
Signals ...............................................................................................................................28
Function .............................................................................................................................28

JOB INSTRUCTIONS ............................................................................................................29


1. Cylinder block ................................................................................................................29
A. Measuring the cylinder liner wear ..............................................................................29
B. Removing the cylinder liner .......................................................................................29
C. Checking the cylinder block ......................................................................................29
D. Replacing the camshaft bearing bush .......................................................................29
E. Oversize bearing bushes for the camshaft ................................................................30
F. Fitting the plug at the rear camshaft end ...................................................................31
G. Fitting the plug at the rear camshaft end after inserting an oversize bearing bush ..31
H. Installing the oil dipstick tube ....................................................................................31
I. Fitting the cylinder liner ...............................................................................................31
2. Flywheel casing .............................................................................................................33
A. Fitting the flywheel casing .........................................................................................33
B. Replacing the rear crankshaft sealing ring ................................................................33
3. Cylinder head .................................................................................................................34
A. Removing the cylinder head ......................................................................................34
B. Removing the valves .................................................................................................34
C. Checking the cylinder head .......................................................................................34
D. Replacing the valve guides .......................................................................................35
E. Machining the valve seat ...........................................................................................36
F. Replacing the valve seat rings ...................................................................................36
G. Grinding the valves ...................................................................................................36
H. Fitting the valves .......................................................................................................37
I. Fitting the cylinder head ..............................................................................................37
4. Valve mechanism ...........................................................................................................38
A. Maintenance of the rocker arm system .....................................................................38
B. Replacing the camshaft/camshaft gear wheel ...........................................................38
C. Checking and adjusting the valve clearance .............................................................39
5. Crankshaft ......................................................................................................................40
A. Removing the crankshaft ...........................................................................................40
B. Checking the crankshaft ............................................................................................40
C. Replacing the crankshaft gear wheels ......................................................................40
D. Fitting the crankshaft .................................................................................................41
E. Crankshaft hub ..........................................................................................................41
F. Replacing the crankshaft belt pulley and the vibration damper .................................42
G. Checking the rubber element in the vibration damper ..............................................42
6. Pistons and con-rods .....................................................................................................43
A. Removing the pistons together with the con-rods .....................................................43
B. Checking and replacing the con-rod bearings ...........................................................43
C. Checking the con-rod ................................................................................................43
D. Checking and replacing the piston rings ...................................................................44
E. Checking the pistons .................................................................................................45
F. Fitting the piston pin ..................................................................................................45
G. Fitting the pistons and con-rods ................................................................................45

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2002-4
7. Flywheel .........................................................................................................................46
A. Replacing the starter ring gear on the flywheel .........................................................46
B. Fitting the flywheel ....................................................................................................46
8. Timing mechanism .........................................................................................................47
A. Removing the timing gear case .................................................................................47
B. Replacing the intermediate gear wheel bearing bush ...............................................47
C. Fitting the timing gear case .......................................................................................48
9. Lubrication system .........................................................................................................50
A. Checking the oil pressure valve ................................................................................50
B. Removing and checking the oil pump .......................................................................50
C. Assembling and fitting the oil pump ..........................................................................50
D. Fitting the sump ........................................................................................................51
E. Oil cooler ...................................................................................................................51
F. Piston cooling nozzles ...............................................................................................52
G. Recommended lubrication oils ..................................................................................52
10. Cooling system ............................................................................................................53
A. Thermostat ................................................................................................................53
B. Repairing the coolant pump ......................................................................................53
C. Coolant quality requirements ....................................................................................54
11. Intake/exhaust system .................................................................................................55
A. Checking the air filter ................................................................................................55
B. Checking the intake/exhaust system .........................................................................55
C. Checking the boost pressure ....................................................................................55
D. Checking the turbocharger ........................................................................................56
E. Fitting the turbocharger .............................................................................................57

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2002-5
SPECIAL TOOLS
Pressing tool for the front crankshaft Assembly pin for the water pump seal
dust seal

SS00B068
SS00B064
1 x 380000005 (1TSW 523)
1 x 380000010 (1TSW 519)
Universal pin
Pressing tool for the front crankshaft
shaft sealing ring

SS00B077
1 x 1TSW 18390 M24

SS00B065
Pressing tool for valve guides
1 x 380000002 (1TSW 520)

Pressing tool for the rear crankshaft


shaft seal

SS00B069
1 x 380000007 (1TSW 524)

Valve spring tensioning lever


SS00B066
1 x 380000003 (1TSW 521)

Pressing tool for


cam shaft cover

SS00B071
1 x 380000008 (1TSW 014)

SS00B067
1 x 380000004 (1TSW 522)
Sva 6-51250 EN Edition 07/2003
2002-6
Extractor Mini-measuring connection

SS98J031
1 x 380001915 M12x1,5
SS00B070
1 x 1TSW 662 (available from your dealer)
Mini-measuring line
Cylinder liner extractor

SS98J030
1 x 380001127 (1TSW 635)

Pressure gauge and connection

SS00B072
1 x 1TSW 510 (available from your dealer)

SS00B076
Extraction plate
1 x 380001129 (1TSW 645) Connection
1 x 380001121 (1TSW 5002) Pressure gauge

Injection pump installation pin

SS00B073
1 x 380000011 (1TSW 508)

Dial test indicator and holder

SS03D046
380001487

SS00B075
1 x 380000364 (1TSW 5610) Holder
1 x 380000228 (1TSW 17049-6) Dial test indicator

Sva 6-51250 EN Edition 07/2003


2002-7

FOR THE USER


The purpose of this manual is to provide basic information required to service and repair CNH diesel engines.
The engines are of the same design. Differences which have an influence on repair work are therefore listed in
the technical data and repair instructions. All dimensions are specified in millimetres and apply at a temperature
of +20 °C, if not specified otherwise.
Before starting repair work, make sure all necessary special tools, spare parts and accessories are available. It is
not absolutely necessary to have all the special tools mentioned in this manual. However, having them does
make it quicker and easier to carry out any repairs necessary. After a repair, the engine must be run in just like a
new engine.
If any questions arise, which cannot be clarified with the aid of this manual, please contact Customer Service at
CNH Österreich GmbH in St. Valentin or the respective importer.
IMPORTANT: When making any queries, please specify the following engine data and the current operating
hours count.
EEM2 = Electronic Engine Management
PCU = Pump Control Unit

Engine code and serial number

Engine Engine
type output
620.95 135 PS
620.96 145 PS
620.97 155 PS
620.98 170 PS

Manufacturer
620.99 190 PS
SISU Diesel Inc.
FIN-37240 Linnavuori
e17*97/68EA*97/68EA*0016*00

FINLAND
Type XXXX XXXXX 620.99
regulations large nonroad compression

Power 180 PS 2100 rpm


This engine conforms to199 U.S EPA

Engine number
Serial nr M19858 5.05.2003
Valve
0,35 mm
(serial number)
clearance
Timing
TDC 30 degrees
Low idle 850 rpm
ignition engines

Cust.
Part nr 620.99.00.0001
EU
Family D20AEE
EPA
Family 3SIDL7.4G4A
Displacement: 6.6 l Fuel: 2-D fuel oil

Assembled by:

This label is affixed to the right-hand


M07575
side of the engine.

SC03G005

Sva 6-51250 EN Edition 07/2003


2002-8

SAFETY REGULATIONS
There is always a risk of getting  Naked flames and smoking are not permitted in the
injured when performing serv- vicinity of fuel tanks or batteries. Electrical sparks
ice and repair work. Before com- should be avoided. (Particularly when charging the
mencing work, the following batteries. Explosion hazard!)
safety regulations and instruc-
tions must be read.
 Disconnect the cable at the negative battery pole
before carrying out service or repair work on the
 Never start repair work which you do not fully electrical system.
understand.
 If the engine gets excessively hot (over 300 °C), for
 Make sure that it is possible to work safely at the example, if it catches fire, the viton seals (e.g.
location and in the vicinity. bottom O-ring on the cylinder liner or the O-ring on
 Make sure the location is clean and in a good
the oil pressure valve) release highly caustic HF
acid. Never touch viton seals, which have been
state.
subjected to unusually high temperatures, with
 Never use wrong or unsuitable tools. bare hands. Always wear neoprene gloves or thick
 Remove all rings, chains and watches before
work gloves and safety goggles when removing
these harmful substances. Wash the seals and
commencing work.
contaminated surfaces with a 10 % hydroxide
 Use state of the art safety equipment. For solution or another alkaline solution. Collect the
example, wear goggles when using compressed material in air-tight sealed plastic bags and bring
air for cleaning, grinding, hammering or similar them to an authorised collecting depot.
work.
,03257$17Viton seals may never be burned!
 Use a lifting device for lifting or transporting heavy
 Fuel, lubrication oil and coolant can cause skin
(over 20 kg) parts. Make sure the hooks and
irritations, if contact is made over a longer period.
chains are in a good condition and sit firmly.
 Never work below an engine hanging from a lifting
 Avoid running the engine in idle unnecessarily.
device or raised by a jack. Always secure the  When carrying out service work, take measures to
engine with strong supports before commencing prevent fuel or other fluids from entering the
work. ground or drains.
 Only use original CNH spare parts.  All seals are asbestos-free.
 Only start the engine from the cab, using the  Be careful when washing the engine using a
ignition key. washing facility with a high water pressure. Do not
wash, for example, the electrical and fuel systems
 Never start the engine with the protective covers
under high pressure as they can easily be
removed.
damaged.
:$51,1* It is difficult to see the radiator fan when
the engine is running! Loose fitting clothes and long
hair can get caught in rotating engine parts!
 If the engine is started in a confined space,
sufficient ventilation must be provided.
 Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
 Ear muffs must be worn when testing the engine or
working close to the engine.
 Always switch the engine OFF before carrying out
repair work.
 Avoid touching the exhaust manifold, turbocharger
and other hot engine parts.
 When the engine is hot and the coolant is
pressurised, be careful on opening the radiator
sealing cover. Coolant and lubrication oil out of the
hot engine can cause severe injuries if contact is
made with the skin.
Sva 6-51250 EN Edition 07/2003
2002-9

ENGINE DATA
Engine type 620.95 620.96 620.97 620.98 620.99
Number of cylinders 6
3
Capacity (dm ) 6,6
Bore (mm) 108
Stroke (mm) 120
Rated power in PS at 2100 rpm 135 145 155 170 190
acc. to ISO 14396
Delivery start mark on the
30
V-belt pulley (° before UDC)
Compression ratio 18,5 : 1 18,5 : 1
Method of combustion direct injection
Injection sequence 1-5-3-6-2-4
Compression pressure1 (bar) 24
2
Charge-air pressure (bar) 0,94 1,03 1,12 1,24 1,45
3
Weight (kg) 510
Direction of rotation of the Clockwise
crankshaft

1
) Minimum value at operating temperature and starter speed.
Highest permissible difference between the cylinders is 3 bar (max.)
2
) Measured behind the charge-air cooler (measuring point: see section entitled "Checking the boost pressure"
page 55), at full load, nominal engine speed and top fan speed
3
) Without flywheel and electrical equipment.
,03257$17After certain repairs to the engine, the fuel system must be bled before starting for the first time (for
details, refer to Chapter 3001, Injection system).
127( The plug-in connection on the PCU must be released and disconnected before performing any arc
welding work. Do not touch the plug-in contacts!

Lifting the engine

The engine is lifted safely by means of a lifting device,


on which the lifting force acts vertically on the lifting eyes.

A = Engine lifting eyes


A A

SS99N013

Sva 6-51250 EN Edition 07/2003


2002-10

TECHNICAL DATA
Conformance with exhaust standards
Europe: 97/68 EC Level 2
America: Tier 2

Cylinder block
Guide pin bore holes ...................................................................................................... 13.250 - 13.320 mm
Diameter of the crankshaft bearing base bore hole ....................................................... 91.000 - 91.025 mm
Diameter of the crankshaft bearing base bore hole (oversize) ...................................... 92.000 - 92.025 mm
Bore hole diameter of the cylinder liner:
– top ........................................................................................................................... 124.514 - 124.554 mm
– bottom ..................................................................................................................... 123.000 - 123.040 mm
Diameter of the camshaft bearing bush (fitted) .............................................................. 50.010 - 50.070 mm
Construction height of the cylinder block ................................................................... 428.170 - 428.430 mm

Cylinder liners
Liner height above the cylinder block................................................................................. 0.030 - 0.080 mm
Highest permissible height difference between cylinder liners......................................................... 0.02 mm
Diameter of the cylinder liner bore holes in the engine block:
– top end of liner ........................................................................................................ 124.475 - 124.500 mm
– bottom end of liner .................................................................................................. 122.961 - 122.986 mm
Cylinder liner bore hole .............................................................................................. 108.010 - 108.032 mm
Height, cylinder liner flange.................................................................................................... 9.03 - 9.05 mm
Height, cylinder liner flange, 1st oversize............................................................................... 9.08 - 9.10 mm
Height, cylinder liner flange, 2nd oversize ............................................................................. 9.13 - 9.15 mm
Height, cylinder liner flange, 3rd oversize .............................................................................. 9.23 - 9.25 mm
Outer diameter of the cylinder liner flange ................................................................. 131.700 - 131.800 mm

Cylinder head
Construction height of the cylinder head.................................................................... 104.800 - 105.000 mm
Minimum height of the cylinder head after surface grinding....................................................... 104.000 mm
Inner diameter of the valve guide (when not fitted) ............................................................ 9.000 - 9.015 mm
Outer diameter of the valve guide .................................................................................. 16.028 - 16.039 mm
Diameter of the bore hole for the valve guide in the cylinder head ................................ 16.000 - 16.018 mm
Projection of the valve guide over the cylinder head face................................................................... 21 mm
Depth, valve head below cylinder head surface:
– Inlet valve ................................................................................................... 0.7 ± 0.05 mm (max. 2,20 mm)
– Outlet valve ................................................................................................ 0.6 ± 0.05 mm (max. 2,20 mm)
Valve seat angle:
– Inlet valve ......................................................................................................................................... 35°+20’
– Outlet valve ...................................................................................................................................... 45°+20’
Valve seat width:
– Inlet valve ................................................................................................................................ 2.9 - 3.7 mm
– Outlet valve ............................................................................................................................. 1.3 - 2.3 mm
Diameter, outlet valve seat insert (standard).................................................................. 44.070 - 44.132 mm
Bore hole in cylinder head for outlet valve seat insert (standard) .................................. 44.000 - 44.025 mm
Diameter, outlet valve seat insert (oversize) .................................................................. 44.270 - 44.332 mm
Bore hole in cylinder head for outlet valve seat insert (oversize) ................................... 44.200 - 44.225 mm
Diameter, inlet valve seat insert (standard).................................................................... 48.570 - 48.632 mm
Bore hole in cylinder head for inlet valve seat insert (standard) .................................... 48.500 - 48.525 mm
Diameter, inlet valve seat insert (oversize) .................................................................... 48.770 - 48.832 mm
Bore hole in cylinder head for inlet valve seat insert (oversize) ..................................... 48.700 - 48.725 mm

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2002-11
Valves, rocker arms and push rods
Valve control times at a valve play of 1.0 mm:
– Inlet valve opens ............................................................................................................0° ±2° before TDC
– Inlet valve closes.............................................................................................................16° ±2° after BDC
– Outlet valve opens .......................................................................................................39° ±2° before BDC
– Outlet valve closes............................................................................................................1° ±2° after TDC
Valve play when engine is cold/hot:
– Inlet valve...................................................................................................................................... 0.35 mm
– Outlet valve ................................................................................................................................... 0.35 mm
Valve head angle:
– Inlet valve.......................................................................................................................................... 35°-20’
– Outlet valve ....................................................................................................................................... 45°-20’
Valve head diameter:
– Inlet valve......................................................................................................................................... 48 mm
– Outlet valve ...................................................................................................................................... 41 mm
Maximum opening lift of the valves:
– Inlet valve...................................................................................................................................... 10,9 mm
– Outlet valve ................................................................................................................................... 12.1 mm
Diameter, inlet valve stem.................................................................................................. 8.960 - 8.975 mm
Diameter, outlet valve stem................................................................................................ 8.925 - 8.940 mm
Clearance, inlet valve stem (guide fitted in cylinder head)................................................. 0.025 - 0.055 mm
Wear limit (inlet valve stem) ............................................................................................................. 0.30 mm
Clearance, outlet valve stem (guide fitted in cylinder head) .............................................. 0.060 - 0.090 mm
Wear limit (outlet valve stem)........................................................................................................... 0.35 mm
Inner diameter of the valve guide (when not fitted)............................................................ 9.000 - 9.015 mm
Outer diameter of the valve guide.................................................................................. 16.028 - 16.039 mm
Diameter of the bore hole for the valve guide in the cylinder head................................ 16.000 - 16.018 mm
Projection of the valve guide over the cylinder head face................................................................... 21 mm
Depth, valve head below cylinder head surface:
– Inlet valve................................................................................................... 0.7 ± 0.05 mm (max. 2.20 mm)
– Outlet valve ................................................................................................ 0.6 ± 0.05 mm (max. 2.20 mm)
Length of the valve spring, relaxed .................................................................................................. 69.8 mm
Force of the valve spring compressed to a length of:
– 48,6 mm .....................................................................................................................................327 ± 17 N
– 37.4 mm .....................................................................................................................................500 ± 23 N
Diameter, rocker arm shaft............................................................................................. 22.970 - 22.990 mm
Diameter of rocker arm bore hole .................................................................................. 23.000 - 23.021 mm
Permissible radial deflection of the push rod (free)............................................................................ 0.4 mm
Length of the rocker arm spring, relaxed ............................................................................................ 80 mm
Force of the valve spring compressed to a length of 58 mm .........................................................80 - 100 N
Outer diameter of the tappet .......................................................................................... 29.939 - 29.960 mm
Diameter of the tappet bore holes in the cylinder block ................................................. 30.000 - 30.043 mm

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2002-12
Camshaft
Diameter, camshaft bearing journal No. 1 (front) ................................................................ 49.925 - 49.950 mm
Diameter, camshaft bearing journals No. 2, 3 and 4 ........................................................... 49.865 - 49.890 mm
Diameter, camshaft bearing journal No. 5........................................................................... 49.885 - 49.910 mm
Diameter, camshaft bearing No. 1 (bearing bush fitted)...................................................... 50.010 - 50.070 mm
Diameter of the other camshaft bearings (bearing bushes fitted) ....................................... 50.000 - 50.025 mm
Play, camshaft bearing No. 1 ................................................................................................. 0.060 - 0.145 mm
Play of camshaft bearings No. 2, 3 and 4 ...............................................................................0.110 - 0.160 mm
Play, camshaft bearing No. 5 .................................................................................................. 0.090 - 0.140 mm
Overlap of the bearing seats (press fit) in the cylinder block .................................................. 0.025 - 0.080 mm
Diameter of the bearing seat bore holes in the cylinder block ............................................ 55.620 - 55.650 mm
Axial play of the camshaft (with a 0.5 mm seal between the cylinder block and
timing case and between the timing case and timing case cover ................................................... 0.5 - 1.0 mm
Cam height (dimension between cam base circle and cam lobe):
– Inlet valve ......................................................................................................................... 41.180 - 41.430 mm
– Outlet valve ...................................................................................................................... 40.080 - 40.330 mm
Cam stroke:
– Inlet valve ............................................................................................................................................7.38 mm
– Outlet valve .........................................................................................................................................8.28 mm
Max. permissible radial deflection of the camshaft ................................................................................0.03 mm

Crankshaft
Diameter of the con-rod bearing journals:
– Standard dimension ......................................................................................................... 67.981 - 68.000 mm
– 1st. repair level 0.25 mm.................................................................................................. 67.731 - 67.750 mm
– 2nd. repair level 0.50 mm................................................................................................. 67.481 - 67.500 mm
– 3rd. repair level 1.00 mm ................................................................................................. 66.981 - 67.000 mm
– 4th. repair level 1.50 mm.................................................................................................. 66.481 - 66.500 mm
Width of the con-rod bearing journal ................................................................................... 40.000 - 40.160 mm
Diameter of the crankshaft journals:
– Standard dimension ......................................................................................................... 84.985 - 85.020 mm
– 1st. repair level 0.25 mm.................................................................................................. 84.735 - 84.770 mm
– 2nd. repair level 0.50 mm................................................................................................. 84.485 - 84.520 mm
– 3rd. repair level 1.00 mm ................................................................................................. 83.985 - 84.020 mm
– 4th. repair level 1.50 mm.................................................................................................. 83.485 - 83.520 mm
Diameter, crankshaft bearing casing................................................................................... 91.000 - 91.025 mm
Thickness of the main bearing shells
– Standard dimension ........................................................................................................ 2.955 - 2.965 mm
– 1st. repair level 0.25 mm................................................................................................. 3.080 - 3.090 mm
– 2nd. repair level 0.50 mm................................................................................................ 3.205 - 3.215 mm
– 3rd. repair level 1.00 mm ................................................................................................ 3.455 - 3.465 mm
– 4th. repair level 1.50 mm................................................................................................. 3.705 - 3.715 mm
Crankshaft bearing play ..................................................................................................... 0.050 - 0.127 mm
Width of the journal at the thrust bearing (crankshaft bearing at flywheel):
– Standard dimension (2 standard thrust washers) ....................................................... 45.000 - 45.080 mm
– 1st. repair level (one standard thrust washer and one with an oversize of 0.1 mm) ... 45.100 - 45.180 mm
– 2nd. repair level (one standard thrust washer and one with an oversize of 0.2 mm) .. 45.200 - 45.280 mm
– 3rd. repair level (one 0.1 mm thrust washer and one with an oversize of 0.2 mm)..... 45.300 - 45.380 mm
– 4th. repair level (two thrust washers with an oversize of 0.2 mm) .............................. 45.400 - 45.480 mm
Other crankshaft bearing journals must not be ground wider.
Axial play of the crankshaft ................................................................................................ 0.100 - 0.380 mm
Max. permissible out-of-true of the crankshaft or con-rod bearing journals ..................................... 0.03 mm
Max. permissible imbalance of the crankshaft .................................................................................1.0 Ncm.

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2002-13
Flywheel
Overlap of the starter ring gear on the flywheel ................................................................. 0.425 - 0.600 mm
Before pressing the starter ring gear onto the flywheel, the
ring gear must be heated up to a temperature of....................................................................... 150 - 200 °C
Max. permissible imbalance at the flywheel...................................................................................... 1.0 Ncm
Max. permissible warpage of the clutch surface measured at the inner
edge of the clutch surface (diameter 200mm) ................................................................................. 0.06 mm

Gear drive, camshaft and injection pump


Tooth flank play:
Intermediate gear wheel – crankshaft.................................................................................... 0.05 - 0.25 mm
Intermediate gear wheel – camshaft...................................................................................... 0.05 - 0.25 mm
Intermediate gear wheel – injection pump ............................................................................. 0.05 - 0.25 mm
Max. permissible lateral runout of the wheels.................................................................................. 0.05 mm
Intermediate gear wheel (with friction bearing):
– Inner diameter, intermediate gear wheel bearing bush (fitted).................................... 55.000 - 55.030 mm
– Diameter, bearing journal for intermediate gear wheel ............................................... 54.951 - 54.970 mm
Inner diameter, camshaft gear wheel............................................................................. 32.000 - 32.025 mm
Diameter, front end of the camshaft............................................................................... 32.043 - 32.059 mm
Timing marks:
The alignment of the timing marks on the gear wheels correspond to the
top dead centre of the piston in the 1st cylinder, between the compression stroke and firing stroke.
On the crankshaft gear wheel ...........................................................................................2 dots on the teeth
On the intermediate gear wheel:
– opposite the crankshaft gear wheel ..........................................................................."0" mark on the tooth
– opposite the camshaft gear wheel .................................................................................. 1 dot on the tooth
– opposite the injection pump gear wheel.................................................................... 1 dot at the tooth gap
On the camshaft gear wheel ........................................................................................ 1 dot at the tooth gap
On the injection pump gear wheel ..................................................................................... 1 dot on the tooth

Con-rods
Inner diameter, piston-pin bush
(bearing bush pressed into the con-rod) ........................................................................ 40.025 - 40.040 mm
Outer diameter of the piston-pin bush............................................................................ 44.082 - 44.120 mm
Overlap of the bearing seat (press fit) in the con-rod......................................................... 0.057 - 0.120 mm
Bore, seat for piston-pin bush ........................................................................................ 44.000 - 44.025 mm
Bore, con-rod bearing end ............................................................................................. 71.730 - 71.749 mm
Thickness of the con-rod bearing shells:
– Standard ......................................................................................................................... 1.835 - 1.842 mm
– 1st. repair level 0.25 mm................................................................................................. 1.960 - 1.967 mm
– 2nd. repair level 0.50 mm ............................................................................................... 2.085 - 2.092 mm
– 3rd. repair level 1.00 mm ................................................................................................ 2.335 - 2.342 mm
– 4th. repair level 1.50 mm ................................................................................................ 2.585 - 2.592 mm
Con-rod bearing play ......................................................................................................... 0.046 - 0.098 mm
Con-rod bearing axial play ................................................................................................. 0.200 - 0.410 mm
Alignment of the con-rod bearing bore to the piston-pin bearing bore................................... within 0.15:100
Parallelism of the con-rod bearing bore to the piston-pin bearing bore ................................. within 0.05:100
The weight markings are punched in the bottom end of the con-rods
(on the camshaft side)
Max. permissible weight difference between con-rods in the same engine ............................................ 20 g

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2002-14
Pistons, piston rings and piston pins
Smallest gap between the piston and cylinder head (measured
through the bore for the nozzle holder seat using lead wire) ............................................. 0.900 - 1.150 mm
Piston diameter (measured 17 mm above
the lower edge of the piston ....................................................................................... 107.873 - 107.887 mm
Diameter, piston pin bore hole in the piston ................................................................... 40.003 - 40.009 mm
Diameter, piston pin ....................................................................................................... 39.991 - 40.000 mm
Width of the piston ring grooves:
– 1st. groove (rectangular compression ring)..................................................................... 2.560 - 2.580 mm
– 2nd. groove ..................................................................................................................... 2.520 - 2.540 mm
– 3rd. groove ...................................................................................................................... 4.040 - 4.060 mm
Vertical play of the piston rings in their grooves:
– 1st. groove (rectangular compression ring)....................................................................... 0.07 - 0.102 mm
– 2nd. groove ....................................................................................................................... 0.03 - 0.062 mm
– 3rd. groove ........................................................................................................................ 0.05 - 0.082 mm
– Wear limit ...................................................................................................................................... 0.15 mm
Piston ring height (in direction of cylinder):
– 1st. groove (rectangular compression ring)..................................................................... 2.478 - 2.490 mm
– 2nd. groove ..................................................................................................................... 2.478 - 2.490 mm
– 3rd. groove ...................................................................................................................... 3.975 - 3.990 mm
End play of piston rings (with piston fitted):
– 1st. groove (wedge-type compression ring) ........................................................................ 0.40 - 0.55 mm
– 1st. groove (rectangular compression ring)......................................................................... 0.30 - 0.45 mm
– 2nd. groove ......................................................................................................................... 0.60 - 0.80 mm
– 3rd. groove .......................................................................................................................... 0.30 - 0.60 mm
– Wear limit, rings 1 and 3 ................................................................................................................. 1.0 mm
– Wear limit, ring 2 ............................................................................................................................. 1.5 mm
Max. permissible weight difference between pistons in the same engine............................................... 25 g
127(When fitting the pistons, make sure the piston recess is on the same side as the nozzle holders.

Lubrication system
Oil pressure at normal operating temperature:
– idling ................................................................................................................................... at least 1.0 bar
– at operational speed....................................................................................................................2.5 - 5 bar
Lubrication oil filter overflow valve opens at a differential pressure of ........................................... 2 ±0,5 bar
Oil pressure switch opens at .........................................................................................................p > 0.5 bar
Engine types 620.95 and 620.96:
Spring in oil pressure valve: length, relaxed .................................................................................... 49.5 mm
Spring length and force (with oil pressure valve fitted) ........................................................... 28.5 mm/76 N
Engine types 620.97, 620.98 and 620.99:
Spring in oil pressure valve: length, relaxed .................................................................................... 49.8 mm
Spring length and force (with oil pressure valve fitted) ......................................................... 28.5 mm/127 N
Oil pressure alarm at.....................................................................................................................p < 0.5 bar
Fault code EEM99 ............................................................................................................ Indicated on ADIC
Optical and acoustic warning, automatic
engine shutoff after ......................................................................................................................30 seconds
Overflow valves for the piston cooling nozzles: Opening pressure ...............................................3 ±0.25 bar

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2002-15
Lubrication oil pump
Tooth flank play when the crankshaft lies firmly against the under side of the bearing
– between the crankshaft gear wheel and oil pump gear wheel .......................................... 0.05 - 0.025 mm
– between the oil pump gear wheels .................................................................................... 0.16 - 0.26 mm
Diameter of the drive shaft in the housing and cover..................................................... 17.966 - 17.984 mm
Diameter of the drive shaft bearing bores...................................................................... 18.000 - 18.018 mm
Diameter of the fixed shaft near the pump gear wheel .................................................. 17.966 - 17.984 mm
Diameter of the bearing bore in the pump gear wheel................................................... 18.000 - 18.018 mm
Diameter of the fixed shaft in the pump housing............................................................ 20.035 - 20.048 mm
Depth of the drive shaft end below the housing surface ............................................................ 0.5 - 1.0 mm
Thickness of the housing seal................................................................................................ 0.06 - 0.08 mm
Outer diameter of the gear wheels................................................................................. 55.824 - 55.870 mm
Housing diameter........................................................................................................... 56.000 - 56.120 mm
Width of the gear wheels ............................................................................................... 32.000 - 32.027 mm
Axial play of the gear wheels ................................................................................................. 0.03 - 0.11 mm
Housing depth................................................................................................................ 32.000 - 32.043 mm
Number of teeth on the drive gear wheel................................................................................................... 46

Thermostat
Type, version .......................................................................................................................... ∅ 54 mm/single circuit
Starts opening at................................................................................................................................ 79 °C±2
Fully open at ......................................................................................................................................... 94 °C
Max. stroke ........................................................................................................................................ 7.5 mm
Type, version .....................................................................................................................................∅ 67/dual-circuit
Starts opening at................................................................................................................................ 83 °C±2
Fully open at ......................................................................................................................................... 95 °C
Max. stroke ........................................................................................................................................... 8 mm

Coolant temperature indication and monitoring (signal from sensor B22)


Display on ADIC...................................................................................................................................analog
Warning at ADIC when temperature ........................................................................................... > 106± 3 °C
Fault code EEM112 (test values for sensor: see Service Tool)
Acoustic alarm (additionally) when temperature .......................................................................... > 113± 3 °C
Fault code EEM113 (test values for sensor: see Service Tool)

Coolant pump
Bearing outer diameter ....................................................................................................................... 52 mm
Bearing housing diameter .............................................................................................. 51.979 - 52.009 mm
Shaft diameter at bearing............................................................................................... 19.980 - 19.993 mm
Shaft diameter at impeller .............................................................................................. 15.907 - 15.920 mm
Diameter of impeller bore hole....................................................................................... 15.876 - 15.894 mm
Clearance between impeller and rear side of housing............................................................... 0.8 - 1.2 mm
(must be observed when pressed on)
Permissible imbalance of the fan ..................................................................... max. 0.3 Ncm max (30 pcm)
V-belt tension, when pressed in between the two pulleys,
amount of give ............................................................................................................................. 10 - 15 mm

Schwitzer turbocharger S200


Axial play of the shaft...............................................................................................................max. 0.10 mm
Radial play of the shaft (compressor end) ...............................................................................max. 0.88 mm
Tightening torque for the compressor housing bolts .......................................................................13.60 Nm
Tightening torque for the turbine housing bolts...............................................................................21.00 Nm
Tightening torque for the shaft nut (compressor end) .....................................................................13.60 Nm

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2002-16
Tightening torques
Cylinder head nuts and bolts
(up to engine number N 8956) ................................80 Nm+90°+90° (+60° at coolant temperature of 75 °C)
Cylinder head nuts and bolts
(from engine number N 8957) .............................................................................................. 80 Nm+90°+90°
Cylinder head bolts in the cylinder block..............................................................................................30 Nm
Crankshaft bearing bolts ....................................................................................................................200 Nm
Con-rod bolts (Torx E18) ............................................................................................................ 40 Nm + 90°
Nut on crankshaft (face)...................................................................................................................1000 Nm
Belt pulley bolts ....................................................................................................................................30 Nm
Securing bolts for flywheel .................................................................................................................150 Nm
Securing bolts for flywheel casing:
– internal M10 bolts..............................................................................................................................80 Nm
– external M12 bolts...........................................................................................................................150 Nm
Retaining screws for intermediate gear wheel (with friction bearing):
– M10 ...................................................................................................................................................60 Nm
– M14 .................................................................................................................................................200 Nm
Overflow valve, piston cooling nozzle (620.97, 620.98, 620.99)..........................................................30 Nm
Nut for lubrication oil pump gear wheel................................................................................................60 Nm
Retaining screws for lubrication oil pump.............................................................................................60 Nm
Connecting part for (engine) oil cooler .................................................................................................60 Nm
Nut for belt pulley on coolant pump....................................................................................................120 Nm
Fastening, Visco fan on Visco hub .......................................................................................................30 Nm
Nuts/bolts for exhaust manifold............................................................................................................50 Nm
Bolts for air intake channel...................................................................................................................30 Nm
Nut for injection pump gear wheel........................................................................................................90 Nm
Retaining nuts, nozzle holder (for bolts)...............................................................................................15 Nm
Injection nozzle union nut.....................................................................................................................60 Nm
Injection line union nut .........................................................................................................................25 Nm

127(Use washers for aluminium parts.

If no particular tightening torques are specified,


always use the values specified in the table below.

M8 M10
±5
Cast iron 35 Nm 70±5 Nm
Aluminium 25±5 Nm 50±5 Nm

Bolts for the self-supporting oil sump


1 M8 25 Nm
3
2 M10 90 Nm
3 M14 160 Nm
4 M20 600 Nm 4 2
1 SS99N015

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2002-17

CONSTRUCTION
General
The 620 series CNH diesel engines are water-
cooled, four stroke, in-line engines with direct
injection. All models are equipped with wet,
replaceable cylinder liners, an exhaust turbocharger
and charge-air cooling (air/air). As the engines are
equipped with an electronic diesel control system in
conjunction with an electronic engine control system
(CAN network including solenoid valve-controlled
distributor injection pump VP30), all models comply
with the exhaust-gas regulations in accordance with
Tier 2.

Cylinder block
The rib-reinforced cylinder block forms the main
engine unit, onto which other engine components are
mounted.
The wet, replaceable cylinder liners are supported in
the middle, thus reducing vibration and the coolant
flow is mainly directed to the upper section of the
cylinder liners.
The bottom part of the cylinder liner and the cylinder
block are sealed by three O-rings, which are inserted
in the grooves in the cylinder liner. The upper part is
sealed by the cylinder head gasket.
The camshaft is located in the cylinder block.
All camshaft bearings are equipped with replaceable
SS00F035
cylinder liners.
Guide bearings are fitted on both sides of the rear
crankshaft bearings (crankshaft – axial bearings).

Flywheel casing
The flywheel casing is fitted at the rear end of the
cylinder block. The seal for the rear end of the
crankshaft is fitted in a bore hole in the casing. The
flange for the starter is located in the flywheel casing.
The underside of the flywheel casing is used as a
sealing surface for the oil sump seal. This means that
the underside of the cylinder block must be flush with
the flywheel casing. When the flywheel casing is
fitted, its position is determined by sprung dowel
pins.

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2002-18
Valve mechanism
The valve mechanism is operated by the camshaft in
the cylinder block. The drive power is transferred via
valve tappets and push rods. The camshaft gear
wheel is force fitted on the camshaft and fixed
(radially) by a feather key. The bearings are
lubricated with pressure oil through bore holes in the
engine block.

SS99N017

Cylinder head
The engines are equipped with two interchangeable
cylinder heads. Each cylinder has its own intake and
outlet channels in the cylinder head. To compensate
for thermal stress, an inlet valve is fitted between the
outlet valves
The cylinder head bolts are high-tensile pre-
tensioned bolts, which are tightened to their
elongation limit in accordance with the angular
tightening principle. Due to the high degree of
elongation, the retaining power is kept constant
throughout the entire service life, and the bolts do not
therefore have to be check tightened.
The injection nozzle seats are integrated into the
cylinder head. The inlet and outlet valve guides are
identical and can be interchanged. Furthermore, the
in/outlet valves are fitted with replaceable valve seat
inserts.

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2002-19

BLANK PAGE

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2002-20
Crankshaft drive The pistons are equipped with two compression rings
and an oil scraper ring. In the case of engine types
The crankshaft is made from forged chrome alloy 620.95 and 620.96, the top molybdenum-coated
special steel and the bearing and sealing surfaces piston ring has a rectangular cross-section. Engine
are inductively tempered. The bearing points can be types 620.97, 620.98 and 620.99 have a top piston
re-ground four times without having to be re- ring with a trapezoidal cross-section.
tempered. The gear wheels are force fitted at the
front end of the crankshaft. They are used to drive The middle piston ring is a taper face ring (the outer
the camshaft, injection pump and oil pump. In diameter has a conical surface).
addition, the front end of the crankshaft has key-ways The oil scraper ring is sprung and has two chrome-
for seating the drive hub. The V-belt pulley and the plated scraping edges.
torsional vibration damper (with rubber element) are
fitted on the hub. The front PTO shaft (if fitted) is also The pistons are ring carrier pistons (the piston has a
driven via this hub. An oil deflector ring is fitted special cast iron ring carrier cast into it to seat the top
between the hub and gear wheel and a dust seal is piston ring). The friction surface of the piston skirt
fitted on the hub to protect the crankshaft sealing also has a graphite coating to ensure optimal
ring. The transmitter wheel for the engine speed running-in.
sensor is fitted on a crankshaft web. In the case of engine types 620.97, 620.98 and
A crankshaft bearing is located on both sides of each 620.99, the piston head is cooled from below by
cylinder. There are thus seven crankshaft bearings. additional oil spray as soon as the oil pressure
The crankshaft axial bearings are located on both exceeds 3 bar.
sides of the rearmost crankshaft bearing. The
flywheel is mounted at the rear end of the crankshaft
and carries a force fitted crown gear.
The forged con-rods have an I-shaped cross-section.
The con-rod bearing is split horizontally. The bearing
cover is secured by means of two special bolts. The
upper part has a wedge-shaped bearing seat in
which the small end bearing bush is force fitted.
The piston is made of an eutectic aluminium alloy.
There is a combustion space in the piston head. The
shape of the optimised combustion space ensures
an optimal carburetion of air and fuel. The pistons
have different types of piston rings depending on the
engine type (see next paragraph).

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2002-21

SS03G080

Timing gears
The engine control gear wheels are hardened in the area of contact and have a helical gearing.
The gear wheels are located in the timing gear case, which is fitted at the front of the engine.
The timing gears drive the camshaft, the fuel injection pump and the oil pump.
The intermediate wheel runs in pressure-lubricated friction bearings (like the camshaft).
The bearing journal is fixed to the front surface of the cylinder block.

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2002-22

7
6

5
Lubrication system
1. Lubrication oil pump
2. Oil pressure valve
3. Oil filter
4. Turbocharger
1 5. Main oil duct
6. Oil spray nozzles
7. Oil pressure switch
SS99N019

Lubrication system
The engine is equipped with a pressure lubrication The oil pressure valve regulates the lubrication oil
system, in which the oil pump (gear pump) is fixed to pressure so that a constant value is maintained
the lower part of the cylinder block. The pump sucks independent of the engine speed. Depending upon the
the oil in via an intake sieve. From the pump, the oil is grade of oil, the engine speed and temperature, the oil
fed through an oil line to the oil cooler (heat pressure lies between 2.5 - 5 bar.
exchanger) and to the oil filter. The oil pressure valve The oil pressure must be at least 1.0 bar at idling
is located parallel. The oil is then fed into the main oil speed.
duct, from which other oil bores branch off. The oil
The oil filter is a one-way main stream filter. An
flows through the oil bores to the crankshaft bearings
overflow valve, on the underside of the filter, ensures
and through the crankshaft to the con-rod bearings.
reliable engine lubrication after cold starting at
The pressure oil flows from the main oil duct to the extremely low outside temperatures and sufficient
turbocharger and to the air compressor (if fitted). In lubrication in the event of a filter blockage. A non-
addition, the intermediate gear wheel bearings, return valve prevents the filter being completely
camshaft bearings and valve mechanism are drained of oil after switching off the engine.
lubricated with pressure oil via the main oil duct. The oil pressure switch opens at a pressure of
> 0.5 bar.
In the case of engines 620.97, 620.98 and 620.99, the
piston heads are sprayed with oil from below and
cooled as long as the lubrication oil pressure is higher
than 3 bar.

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2002-23

5 7

7
6

SS03G023

Cooling system
1. Coolant pump 5. Expansion chamber
2. Thermostat 6. Oil cooler
3. Bypass channel 7. Engine temperature sensor
4. Radiator

Cooling system
The belt-driven coolant pump is located at the front
end of the cylinder block. The thermostat housing
is situated above the pump. The cooling system is
equipped with two thermostats, which control the
coolant flow. The thermostats have different C
opening temperatures. If the coolant temperature
lies below the opening temperature, the coolant (A)
circulates back to the coolant pump via the bypass
channel. The smaller, single-action thermostat (1)
starts to open at 79 °C and lets some of the B
coolant (B) flow into the radiator. When the engine 1
temperature increases, the dual-circuit
thermostat (2) also starts to open at 83 °C. It
closes the bypass when it opens and allows all the 2
coolant (C) to flow into the radiator. A

SS00F031

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2002-24
Fan
VISCO FAN REVERSIBLE FAN

SS03G024

SC03G004

Visco fan with modulating hub (standard equipment)


In the case of the modulating hub, every flow air temperature corresponds to a certain slip.
As long as there is little or no requirement for cooling, the fan rotates at low speed (= high slip), but dependent on
the engine speed. The air flow through the cooler/radiator assembly (air conditioning condenser, charge-air
cooler, transmission oil cooler, radiator for engine coolant) acts on the front of the Visco hub. A bimetal spring
located here continuously measures the discharge temperature behind the radiator (coolant). As the discharge
temperature increases (loading on the tractor increases), the control valve reduces the slip and the fan rotates
faster according to the temperature until the minimum slip of approx. 5 % is reached. When the discharge
temperature decreases (loading on the tractor decreases), the control valve increases the slip and the fan rotates
slower according to the temperature.
The Visco fan with a modulating hub has the following advantages: More exact adaptation of the cooling
performance to the tractor load, reduction of the fan’s power consumption and noise level.
The Visco fan is maintenance-free.
Reversible fan (optional equipment)
The blades on the reversible fan can be rotated on the hub. Integrated thermoelements vary the angle of the
blades during operation and the cooling performance of the fan is adapted to the cooling requirements. Return
springs hold the blades securely in position.
The following automatic process is activated on pressing the "Fan reversal" button:
The electronic central control unit (ECCU2) controls a small electric motor-operated air compressor and a
solenoid valve. This control unit is fitted on the left-hand side of the engine. Compressed air is supplied via a
pressure line and a special seal to the control cylinders (that rotate with the hub and blades) and turn the blades.
A powerful stream of air then blows in the opposite direction through the radiator/coolers and any grass,
blossoms, insects, etc., which have been sucked in are removed from the radiator/coolers. The blades
automatically return to their original position after 30 seconds. The fan reversal function can also be activated
automatically when programmed accordingly by the driver, i.e. in conjunction with automatic processes
concerning the front or rear hitch or EHS auxiliary valves.

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2002-25

SC03G006

Intake/exhaust system
The filter system for the engine intake air comprises a The turbocharger is lubricated and cooled by oil from
pre-cyclone filter (integrated into the air filter) and a the engine lubrication system.
dry air filter with safety cartridge. The intake air is
Charge-air cooling
rotated in the pre-cyclone filter. This removes heavy
dirt particles, which are then discharged via the pre- The intake air compressed by the turbocharger can
cyclone filter’s dust discharge valve. reach a temperature of up to 150 °C under extreme
conditions. It is cooled down to 50 - 60 °C in a charge-
Ejector
air cooler (air/air version) located in front of the
The tractor can be equipped with an ejector system for radiator. The cooling of the charge-air reduces the
use in extremely dusty conditions. The exhaust pipe is thermal and mechanical strain on the engine and
fitted with an injector and there is a permanent suction reduces the discharge of nitrogen oxides and soot
effect at its hose connection when the engine is particles.
running. The dust particles separated in the pre-filter
Charge-air pressure/temperature
are continuously sucked in via a hose connection and
as engine control variables
discharged together with the exhaust gases.
A combined sensor is located in the air collector. It
Filter cartridges
continuously supplies information about the charge-air
The dirt particles in the air are collected in the main pressure/temperature to the electronic engine
cartridge, which can be cleaned as required. The management (EEM2). Fuel injection is optimised in
internal safety cartridge stops dirt particles getting into conjunction with the electronic injection control
the engine in the event of the main cartridge breaking system, thus substantially reducing the discharge of
or being fitted incorrectly. nitrogen oxides and soot particles.
Filter service indication The charge-air cooler is easy to service. It can be
folded up and can thus be effectively cleaned against
A differential pressure switch is located in the filter
the direction of the flow of outside air. By folding up
housing. This switch makes an indicator lamp on the
the charge-air cooler, the other coolers are easier to
ADIC light up when the air filter reaches a certain
access.
degree of soiling. The intake system also comprises
the air lines between the air filter and the
turbocharger, between the turbocharger and the
charge-air cooler and between the charge-air cooler
and the inlet manifold.
The exhaust manifold is fixed to the cylinder head by
means of special bolts, without a separate seal.
The special bolts do not have to be re-tightened.

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2002-26

ELECTRONIC ENGINE CONTROL SYSTEM – EEM2


The electronic engine control system comprises the electronic engine control unit (EEM2), several sensors and
control switches, the electronic injection pump control unit (PCU) and the necessary cabling, including the
CAN connection between the EEM2 and PCU.

6 7

3
5

8 4

10

SC03G007

11

1. Engine control unit (EEM2) 7. Charge-air pressure/temperature sensor (B29)


2. Injection pump control unit PCU (A2/2) 8. Engine temperature sensor (B22)
3. Oil pressure switch (S6) 9. Test switch, fuel delivery pressure (B21)
4. Speed sensor (B20) 10. Fuel delivery pump (M13)
5. Heater flange (E10/1) 11. Optional equipment, sensor B23
6. Power relay (K8/2) "Water in fuel"

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2002-27
Layout

DZG = Signal, crankshaft position


A2/2
(top dead centre)
PCU
MAB =Signal, emergency engine
shut-down

CAN H

CAN L

MAB
DZG
Switch S6
A2
Oil pressure

Sensor B29
Charge-air pressure
Charge-air
Starting aid E10/1
temperature
(heating flange)

Sensor B22
Coolant temperature
EEM 2
M13 Fuel
Test switch B21 feed pump
Fuel delivery pressure

Switch S22
Sensor B23 Coolant level
"Water in
fuel"
Sensor B2/1
Fuel level
Sensor B20
Engine speed and
crankshaft position

Limp home
A1
ADIC
Sensor B28
Man. oper.
accelerator slider
CAN H

CAN L

DISPLAY Warning
Fuel
level
too low
ARU

Warning Warning
Fuel
Coolant level feed pressure
too low
R8 sensors A4
Accelerator pedal FMGR Warning
Water in fuel
(optional extra)

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2002-28
Signals
The EEM2 receives values for various parameters which are important for controlling the engine.

Analog signals (voltage) Digital signal (level)


 Coolant temperature (from sensor B22)  Fuel delivery pressure
 Charge-air temperature (from sensor B29)
(from test switch B21)

 Charge-air pressure (from sensor B29)


 Engine oil pressure (from test switch S6)

 Water in fuel (from sensor B23)


Digital signal (CAN messages)

 Engine setpoint speed for Limp home


 Drive commands (from FMGR)
(from accelerator pedal sensor R8) Â Injection pump speed (from PCU)
Digital signal (Frequency) Â Actual start of delivery (from PCU)
 Engine speed (from sensor B20)  Spray adjustment angle (from PCU)
Digital signal (coding) Â Fuel temperature (from PCU)
 Crankshaft position (from sensor B20)

Function
The EEM2 always has continuously updated values for various parameters which are important for controlling the
engine at its disposal. The EEM2 electronics evaluate this data and send corresponding control commands in the
form of CAN messages to the electronic control unit for the injection pump. Control variables such as the
maximum injection volume or start of delivery are continuously adjusted (in real-time). This ensures an optimum
engine power curve and torque increase, high economy and conformance with the more stringent emission
standards which are now valid. For Europe: 97/68 EC Level 2. For America: Tier 2.
Control variables which influence the dynamic delivery start
 Engine speed
 Engine load
 Coolant temperature
Control variables which influence the maximum injection volume
 Torque characteristics
 Coolant temperature
 Charge-air pressure
 Certain faults which occur (e.g. incorrect injection pump Serial No. in the EEM2 software, fault code 175).
Idling speed
The idling speed and final idling speed are electronically controlled and cannot be changed. Readjustment is not
necessary.
Engine protection when exceeding limit values
If limit values are exceeded, the engine control system intervenes to protect the engine. The engine power/speed
is reduced and the fuel injection is stopped as required, thus shutting down the engine.
Fault Detection
If a fault occurs, a fault warning appears on the ADIC and the corresponding EEM2 fault code is shown on the
display on the A column.
The fault can be localised and remedied by means of the CNH Service Tool. Also refer to Chapter 4011, Fault
codes.
127( Function, fitting and removing the injection pump, checking the delivery pressure, checking the injection
nozzles: see Chapter 3001 – Functional description of the injection system.

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JOB INSTRUCTIONS
1. Cylinder block
A. Measuring the cylinder liner wear
1. Set the dial test indicator to zero by means of a
micrometer screw or using a new cylinder liner (initial
dimension 108.00 mm). 1TSW 510
2. Thoroughly clean the inner surface of the cylinder
liner before the measurement.

380000011
SS99N037

C. Checking the cylinder block


1. Clean the cylinder block and all oil lines.
2. Check the cooling channels and remove scale and
dirt deposits in order to ensure correct engine
cooling.
3. Check the tightness of the shell plugs and screw
plugs in the cylinder block and make sure the
cylinder block and sealing surfaces are in good
condition.

SS99N036
4. Measure the wear on the camshaft bearings
(compare with nominal values).
3. Measure cross-wise at the top end, bottom end 127( If the surface of the cylinder block has to be
and in the middle of the cylinder liner. re-ground, the pistons must be shortened by a
corresponding amount. Pay attention to the valve
4. Check the displayed value for max. wear and head clearance at the top surface of the piston.
ovality (compare with nominal values).
D. Replacing the camshaft bearing bush
B. Removing the cylinder liner
1. Pull the bearing bush out using an internal
1. If the cylinder liners are to be re-used, they must extractor. After removing the rear camshaft end
be marked so they can be re-fitted in the same support piece, the bearing bush can be driven out
positions. using a long drift.
2. Remove the cylinder liners using the 380000011 2. Clean the bush seating.
and 1TSW 510 extraction tools.

0.1 - 0.4 mm

SS99N038

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3. Press fit a new bearing bush. Pay attention to the position of the oil bore hole. The bearing bush does not have
to be reamed as it has the correct inner diameter if it is fitted correctly.
127( All camshaft bearing points are fitted with a separate bearing bush. Pay attention to the different outer
diameters when removing and fitting the bearing bushes.

5 4 3 2 1

SS99N039

The numbering starts at the front end of the engine.


Bore hole diameter
1. 55.62 - 55.65
2. 55.42 - 55.45
3. 55.22 - 55.25
4. 55.42 - 55.45
5. 55.64 - 55.67

E. Oversize bearing bushes for the camshaft


If the seat of the camshaft bearing bush (front bearing) is damaged, a bearing bush with an oversize outer
diameter of 0.4 mm can be fitted. The machining dimensions for the bearing bush seats are shown in the figure.
:$51,1*Observe the position of the bearing bush oil bore holes. (see section A-A)
The bearing bushes do not have to be reamed after being fitted.

266 mm
272 mm
134 mm
A-A 7,2...8,0 mm
A

0,1...0,4 mm

5 4 3 2 1

A SC03G008

Camshaft oversize bearing bushes


Bore hole diameter
1. 56.02 - 56.05
2. 55.62 - 55.65
3. 55.42 - 55.45
4. 55.62 - 55.65
5. 55.84 - 55.87

The numbering starts at the front end of the engine.

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F. Fitting the plug at the rear camshaft
end

max. 1,0 mm

111 mm

SC03G009 SS99N045

1. Clean the plug seating. 127( The position of the tube influences the
measured engine oil level.
2. Apply sealant (e.g. Loctite 572) to the contact
surface of the plug. I. Fitting the cylinder liner
3. Drive the plug in using pressing tool 380000004.
1. Clean the cylinder liner and liner recess in the
127( Do not drive the plug in too far, as it could cylinder block. Without the O-ring, it must be easy to
impair the axial play of the camshaft. turn the liner to its installation position.
2. Apply a thin coat of marking paint to the underside
G. Fitting the plug at the rear camshaft of the cylinder liner flange. Fit the cylinder liner
end after inserting an oversize bearing without O-rings and turn it back and forth. Remove
bush the cylinder liner and check whether there is paint
over the entire contact surface.
O-ring 3. Clean the contact surfaces.

0.03 - 0.08 mm

Plug
SS00F003
SS99N048

Upon completion, the rear camshaft end plug is 4. Fit the cylinder liners and secure each liner using
replaced by the plug and the O-ring. two clamps. Measure the cylinder liner height using a
dial test indicator and the holder (380000364). Set
H. Installing the oil dipstick tube the dial test indicator to zero on a flat surface, e.g.
the cylinder block. Measure each cylinder liner at four
1. Clean the tube seating.
points. The cylinder liner should protrude from the
2. Apply locking fluid (e.g. Loctite 601) to the bottom top of the cylinder block by 0.03 - 0.08 mm.
end of the tube.
3. Drive the guide tube into the cylinder block to the
dimension shown in the figure.

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The difference in height between the cylinder liners 7. Insert the O-rings in the grooves in the lower
below a cylinder head must not exceed 0.02 mm. In cylinder section and lubricate them with liquid soap
addition, a middle cylinder liner must not be lower (not with oil).
than one of the outer ones.
127( Stretch the O-rings as little as possible when
5. If the cylinder liner height is insufficient, a liner with pulling them onto the cylinder liners.
a higher flange must be fitted. The max. permissible elongation is 6 %.

SS99N049

Height Marking
(H) grooves
(quantity)

9.03+0.02 (standard)

9.08+0.02 1 SS99N051

9.13+0.02 2
8. Press the cylinder liners into the cylinder block. It
9.23+0.02 3 should be easy to press them into their initial
position. Make sure the cylinder liners do not move
An oversize of the cylinder liner (higher flange) is upwards once they have been fitted.
marked as follows on the outer circumference by
means of one or more marking grooves:
1. oversize, 0.05 mm = 1 marking groove
2. oversize, 0.10 mm = 2 marking grooves
3. oversize, 0.20 mm = 3 marking grooves
6. If the height of a cylinder liner is not the same over
the entire circumference, the cylinder liner flange and
recess depth must be checked. Cylinder liners with
warped flanges must be replaced. If necessary, ream
the liner seating in the cylinder block.

BLACK

GREEN

SS99N050

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2002-33
2. Flywheel casing
Spacer ring
A. Fitting the flywheel casing
The flywheel casing is centred on the cylinder block
by means of two sprung dowel pins. The flywheel
casings, which are also available as a spare part, are
supplied with the bore holes for the pins.
1. Clean the sealing surfaces between the cylinder
block and flywheel housing.

SS99N054

127( If the crankshaft is worn at the sealing ring


seat, a 2 mm spacer ring (available as a spare part)
can be fitted between the flywheel casing and the
crankshaft sealing ring.
5. Carefully press the sealing ring in down to the
bottom of the flywheel casing using the 380000003
and 1TSW 662 fitting tools.

1TSW 662
SC03G010

2. Apply sealant (e.g. silicone) to the points shown in


the figure.
3. Lift the flywheel casing to the correct position and
insert all the bolts.
4. Centre the casing and fit the sprung dowel pins
using a mandrel.
380000003 SS99N056
5. Tighten the inner ring bolts to a torque of 80 Nm
and the outer ring bolts to a torque of 150 Nm. 127( Assembly of the sealing ring must be carried
out in a dry and oil-free state.
B. Replacing the rear crankshaft sealing
ring
1. Separate the tractor between the engine and
power unit.
2. Remove the flywheel.
3. Remove the sealing ring without damaging the
crankshaft.
4. Clean the sealing ring seat and grind away any
burrs.

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2002-34
3. Cylinder head
A. Removing the cylinder head
1. Clean the outside of the engine.

Drain plug

SS99N057

1. Screw a nut on a grub screw for the rocker arm


mechanism. There is no grub screw for the valves for
the middle cylinders. A screw of an appropriate
length should be used instead.
2. Compress the valve springs by means of lever
SS99B056 380000008. Remove the valve spring seat retainers,
the spring guide and the spring. Remove the valves.
Drain the coolant at the engine drain plug and the
drain cock on the underside of the radiator.
Disconnect the coolant hoses from the cylinder head
C. Checking the cylinder head
and the thermostat housing. 1. Remove carbon deposits in the outlet channels,
clean the sealing surfaces and wash the cylinder
2. Remove the intake lines between the exhaust
head.
turbocharger and the air filter and the charge-air lines
from the turbocharger and the intake manifold. 2. Check the cylinder head for cracks and any other
damage.
3. Remove the oil lines from the exhaust
turbocharger.
4. Remove the injection lines and leak oil collectors.
Remove the nozzle holders. Fit all open connections
with sealing caps.
5. Remove the intake and exhaust manifolds as well
as the thermostat housing.
127(It is also possible to remove the cylinder head
even when these parts are still fitted.
6. Remove the valve cover and air bleed hose.
SS99N058
7. Remove the rocker arm mechanism and the push
rods. 3. Check the evenness of the cylinder head using a
8. Loosen all cylinder head bolts by a ¼ of a straightedge. An uneven or bent surface must
revolution and then unscrew them. Remove the undergo surface grinding. After being ground, the
cylinder head. height of the cylinder head may not be less than
104.00 mm. The valve disk depth from the surface of
the cylinder head must be 0.60 mm for outlet valves
B. Removing the valves
and 0.70 mm for inlet valves.
Make sure that those valves which are to be re-used
are marked accordingly, so that they can be re-
inserted in their original seating.

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2002-35
D. Replacing the valve guides

SS99N059

4. If necessary, clean the nozzle holder contact


surface in the cylinder head using a reamer.

SS99N061

1. Press or drive the old guides out using a mandrel.


Clean the valve guide seats.
2. Fit the new guides using pressing tool 380000007,
thus ensuring the correct installation height (21 mm
above the end face of the spring).

380000007

SS99N060

5. Measure the clearance between the valve stem


and guide by means of a dial test indicator. Lift the
valve so that the valve disk juts out of the surface of
the cylinder head by 15 mm mm and measure the
clearance. In the case of inlet valves, it may not
exceed 0.30 mm and 0.35 mm for outlet valves. To 21 mm
determine whether the valve guide is worn, a new
valve must be used for the measurement.

SS99N062

3. The same guides are used for inlet and outlet


valves. Make sure the steepest chamfer on the guide
points towards the valve spring. Also make sure the
valves do not stick in the guides.

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2002-36
E. Machining the valve seat Inlet valve
11±0,1 mm

48,500...48,525 mm

SC03G030

3. Clean the valve seat. Cool the new valve seat ring
in dry ice of liquid nitrogen.
4. Fit the valve seat ring using a suitable pressing
SS99N063
tool. Re-work the seat.
A damaged valve seat must be machined using a
milling cutter. If the width of the seat exceeds 2.3 mm G. Grinding the valves
in the case of an outlet valve and 3.7 mm in the case In order to ensure that a sufficient sealing effect is
of an inlet valve, then it has to be reduced at the attained around the valves, there are different sealing
outer edge, in particular. surface angles. Thus, there is a particularly narrow
The valve seat angle is 45°+20’ for outlet valves and sealing surface, which ensures an effective sealing
35°+20’ for inlet valves. effect even after prolonged operation.

F. Replacing the valve seat rings


The outlet valves are equipped with separate valve
seat rings. If the sealing surface is so badly damaged B
that it cannot be repaired, then the valve seat rings
have to be replaced. A

1. Grind the valve disk on a disused valve so that it C


fits snugly in the valve seat. Fit the valve and weld it
to the seat in the regular way. Cool it with water.
2. Turn the cylinder head round and drive the valve
out together with the seat. SC03G011

Outlet valve
A B C (mm)
10,1 mm -20’ +20’
INLET 35° 35° 0.7
-20’ +20’
OUTLET 45° 45° 0.6

1. Grind the damaged valve disk using a valve


grinding tool. Adjust the angle to 45°-20’ for outlet
valves and 35°-20’ for inlet valves.
44,000...44,025 mm
2. If the height of the edge of the valve disk is less
than 1.5 mm after grinding or the valve stem is bent,
the valve must be replaced.
SC03G029 3. Grind in the valves using grinding paste and check
the contact surface with marking dye.
4. Clean the grinding paste off the cylinder head and
valves.

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2002-37
H. Fitting the valves 127( From engine serial no. N 8957 (see Engine
code and serial number, page 7), steps 6 to 8 can be
1. Use a spring tester to check the straightness, skipped (modified cylinder head gasket).
length and tension of the valve springs. Compare
these values with the technical data. 1. Pre-tension of 80 Nm

2. Lubricate the valve stems and insert the valves in 2. Tighten by 90°.
the cylinder in the correct order. 3. Tighten by 90°.
3. Fit the valve springs, valve disks and valve spring 4. Adjust the valve clearance (see page 39).
seat retainers in the cylinder head with the aid of
lever 380000008. 5. Fit the other engine parts, add coolant and
engine oil.
4. After inserting the valves, tap the ends of the valve
stems, e.g. with a plastic hammer, to make sure the 6. Let the engine run at low load until it reaches a
valve spring seat retainers are sitting correctly. coolant temperature of 75 °C.
7. Tighten by 60°.
I. Fitting the cylinder head
8. Adjust the valve clearance.
1. Measure the length of the cylinder head bolts. The
length should lie within the limit values specified in 127( The cylinder head bolts do not have to be
tightened again after this procedure.
the figure. If this is not the case, the bolt must be
replaced.

max. 142 mm

50 Nm

max. 188.5 mm

SS99N066

2. Screw the cylinder head grub screws into the SC03G012


cylinder head and a tighten them to a torque of
30 Nm. Insert the push rods, if they have been Tighten the exhaust manifold securing bolts/nuts to a
removed. torque of 50 Nm.
3. Make sure the sealing surfaces are clean and fit
the cylinder head gasket. Use a ruler to make sure
the cylinder heads are parallel to each other. Clean,
oil and insert the bolts.

SS99N067

4. The figure shows the bolt tightening sequence.


The correct sequence is also cast into the cylinder
heads.
5. Tighten the bolts in phases as follows:

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2002-38
4. Valve mechanism
60°
A. Maintenance of the rocker arm system
1. Check the valve tappets, particularly the guide
surface on the camshaft. Replace worn and bent
valve tappets.

SS99N073

5. Fix a flange seal on one end of the rocker arm


shaft. Lubricate the shaft and assemble the parts in
the correct order. Make sure the shaft and the
bearing retainers are in the right position. The split
side of the retainers and the oil bore holes in the
shaft must be on the valve side, as shown in the
SS99N070 figure. Fix the other flange seal

2. Check the straightness of the push rod. Also check


the condition of the spherical faces at the ends of the
push rod.
3. Dismantle the rocker arm mechanism and clean
the components. Check the rocker arm shaft for wear
and the condition of the oil lines.

SC03G014

23,000...23,021
SC03G013 B. Replacing the camshaft/camshaft gear
wheel
4. If the pressure surface of the rocker arm is worn,
grind it until it has the right shape. Do not grind off 1. Remove the suction pipe between the
more than necessary as the pressure surface is turbocharger and the intake manifold. Remove the
hardened. cover for the valve mechanism and the bleed pipe.
Remove the rocker arm mechanism.
2. Remove the cooler/radiator assembly, fan,
alternator and the V-belts.
3. Loosen the crankshaft nut. Remove the V-belt
pulley with the hub (loosen the belt pulley first).
4. Remove the control box cover.
SS99N072

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2002-39
C. Checking and adjusting the valve
clearance

0,35

SS99N075

5. Lock the valve tappets so that they do not fall down


on removing the camshaft and impair the installation SC03G015
of the camshaft. Raise two adjacent valve push rods
by tilting them towards each other. Clamp adjacent The inlet and outlet valves have a clearance of
push rods together to form a pair (e.g. using an 0.35 mm. It can be checked when the engine is hot
O-ring) so they are under slight tension and the or cold. Check and adjust the valve clearances of a
tappets remain in the top position. cylinder whilst the piston is at top dead centre of the
compression stroke. Proceed according to the
:$51,1* Excessive tensioning of the push rods
causes deformation. injection sequence of the engine.

6. Turn the crankshaft, so the positioning marks on If the valve clearance deviates from the specified
the camshaft gear wheel and intermediate gear value, loosen the locking nut and adjust it to the
wheel coincide. Pull the camshaft out. correct value via the adjusting screw. A 0.35 mm
feeler gauge must fit tightly between the rocker arm
7. Loosen the camshaft gear wheel using a suitable and the end of the valve stem.
mandrel.
8. If the used camshaft or camshaft gear wheel is
going to be re-fitted, clean them before assembly.
9. Push the feather key into the corresponding
groove in the camshaft. Heat the camshaft gear E A E A E A E A E A E A
wheel up to 200 °C and fit it in the corresponding
position.
SC03G016
10. Grease the bearing surfaces and press the shaft I = INLET
into the cylinder block, paying attention to the
position marks on the camshaft gear wheel. O = OUTLET

11. Fit the control box cover and the belt pulley with
the hub. – turn the crankshaft in the direction of rotation until
the valves of cylinder 6 overlap. (Outlet valve closes,
12. Release the push rods and fit the rocker arm inlet valve opens). Check the valves of the first
mechanism. Adjust the valves. Then screw the valve cylinder.
cover and air bleed hose onto the cylinder head. Also
fit the suction pipe between the turbocharger and – turn the crankshaft 1/3 of a revolution in the
intake manifold. direction of rotation so that the valves of the 2nd
cylinder overlap. Check the valves of the 5th cylinder.
13. Fit the alternator and V-belts. Tension the V-belts
accordingly. Fit the cooler/radiator assembly. – continue work in the sequence of injection:

Injection sequence: 1 5 3 6 2 4

Valve overlap: 6 2 4 1 5 3

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2002-40
5. Crankshaft For the correct undersize and corresponding
bearings, refer to the technical data. Make sure the
A. Removing the crankshaft radii do not change during the grinding process.

1. Unscrew the sump


2. Unscrew the securing bolts for the lubrication oil
pump pressure line in the cylinder block. Remove the
oil pump and the intake/pressure lines.
3. Remove the flywheel casing.
4. Remove the belt pulley/hub from the front end of
the crankshaft (also refer to the instructions
concerning the timing gears page 47).
5. Remove the con-rod bearing covers and push the
con-rods up so they are not in the way when SS99N079
removing the crankshaft.
6. Remove the crankshaft bearing covers and lift the
crankshaft out. 127( In the event of the crankshaft bearing base
bore holes being damaged or worn as a result of
bearing damage, crankshaft bearings are also
B. Checking the crankshaft available as a spare part with an oversize of 1.0 mm
(outside dimension) and an undersize of 0.5 mm
(inside dimension). The cylinder block must now be
machined to a dimension of 92.000 - 92.025 mm.
The crankshaft must be machined to a dimension of
84.485 - 84.520 mm. The bearing shell with a groove
and oil bore hole is fitted in the cylinder block and the
bearing shell without an oil bore hole in the bearing
cap.

C. Replacing the crankshaft gear wheels

1TSW 662

SS99N078

1. Clean the crankshaft. Do not forget to clean the oil


bore holes.
2. Measure the wear on the crankshaft bearing
journals at different points. Ovality, conicity or other
wear must not exceed 0.03 mm.
SS99N080
3. Insert the bearing caps with new bearing shells
and tighten them to the correct torque. Measure the 1. Attach an extractor to the crankshaft gear wheels
inner diameter with a dial test indicator, which has and pull off both gear wheels.
been reset to zero according to the dimensions
2. Clean the seat on the crankshaft using a wire
measured under item 2. The indicator thus displays
brush, for example.
the actual bearing play. If the bearing housing which
shows signs of wear is not round, take 3. Heat up the new gear wheels to 200 °C. Drive the
measurements at several points. gear wheels onto the shaft using a suitable sleeve or
soft mandrel. Pay attention to the position of the
4. If the bearing play exceeds 0.18 mm for the
feather key and make sure the alignment marks on
crankshaft bearings or 0.14 mm for con-rod bearings
the front gear wheel are visible. Allow the parts to
with new bearing shells, the bearing journals on the
cool down.
crankshaft must be ground.

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2002-41
D. Fitting the crankshaft 4. Insert the crankshaft bearing covers according to
their numbering, with axial bearings at the rear,
1. Clean the oil lines, bearing shells and seats. Make which have got joggles. Lubricate the bolts and
sure the crankshaft is clean. tighten them to a torque of 200 Nm.

0,10...0,38 mm

B
A

SC03G018

5. Make sure the crankshaft turns freely and without


SS99N082 sticking. Check the axial play using a dial test
indicator. The correct axial play is approx.
2. Fit a bearing shell (A) with an oil bore hole and oil 0.10 - 0.35 mm. If there is excessive axial play,
groove in the cylinder block and a bearing shell (B) oversized axial bearings must be fitted.
without an oil bore hole in the bearing cover. Make
sure the bearing shell joggles engage in the 127( The bearing shells may never be reamed or
corresponding notches and that the shells to be fitted machined and the sides of the bearing covers may
in the cylinder block have an oil bore hole which not be filed.
aligns with the oil bore hole in the cylinder block.
E. Crankshaft hub
3. Lubricate the bearing surfaces and fit the
crankshaft.
127( Check the transmitter wheel for the speed
sensor and do not damage it when fitting the
crankshaft!
Insert the axial bearings for the crankshaft so that the
lubrication grooves point towards the crankshaft.

200 Nm

SS99N085
7

When fitting the hub at the front end of the


crankshaft, make sure it is in the correct position
(injection mark on the vibration damper). The hub
has an installation marking: -- both lines on the hub
must lie adjacent to the dot marking • on a crankshaft
6

tooth.

SC03G017

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2002-42
F. Replacing the crankshaft belt pulley G. Checking the rubber element in the
and the vibration damper vibration damper

A
1.5 mm

SS00E039
SS99N087
1. Loosen the alternator securing bolts and remove
the V-belt. 1. If the lines (A) are misaligned by more than
1.5 mm, the vibration damper must be replaced.
2. Unscrew the bolts holding the belt pulley and
vibration damper and remove the parts. The belt OK
pulley and vibration damper are pinned together with
the crankshaft hub (injection mark on the vibration
damper).
3. Fix a new vibration damper or belt pulley onto the
crankshaft. Drive the dowel pins in and tighten the
securing bolts to a torque of 30 Nm.
127(Vibration dampers (belt pulleys) supplied as a
spare part do not have an injection marking. New
OK
vibration dampers must be marked after being fitted.
4. Turn the crankshaft until the piston of the first
cylinder is at top dead centre (TDC). Let the valve fall
against the cylinder head. Mount the dial test
indicator at the top of the valve stem and set it to zero
when the piston is at top dead centre. Then turn the
crankshaft against the direction of rotation until the OK
dial test indicator reads approx. 15 mm below TDC.
Then slowly turn the crankshaft in the direction of SS99N088
rotation until the dial test indicator shows the value
which corresponds to the injection marking (see table 2. Also check the condition of the rubber element. If
below). pieces of rubber are missing or the rubber part is
more than 3.5 mm below the surface, or if a forward
127( The setting value is 30° before TDC for all
motion of the inertial component (outer ring) is
engines.
discernible, the vibration damper must be replaced.
5. Inscribe the injection marking by means of an
electric engraving pen (do not punch it in).
127( Make sure the pointer is not loose or bent
before making the mark.

Piston stroke to top dead centre


in comparison to crankshaft angle
Degrees mm
30 10.213

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2002-43
6. Pistons and con-rods 3. If the small end bearing bush is worn, it must be
driven out using a suitable mandrel.
A. Removing the pistons together with
the con-rods
1. Unscrew the sump and the lubrication oil pressure
and suction lines.
5
2. Unscrew the cylinder head.
40.025 -
3. Scratch the carbon ridge off the cylinder liner. 40.040
If necessary, scrape off the sharp abrasion edge at
the reversal point of the piston ring.
4. Remove the con-rod bearing covers and bearing
shells. If the bearing shells are to be re-used, their
order must be marked.
5. Push the piston and con-rod up by using the shaft
of a hammer or some similar object.
6. Remove the piston pin circlips. Push the piston pin
SS99N091
out.
127( If the piston pin does not move on applying 4. Press the new bush in. The oil channel in the bush
finger pressure, the piston must be gradually heated must coincide with the corresponding channel in the
up to 100 °C. con-rod. After fitting it, drill a hole with a ∅ 5 mm.
Use a reamer to ream the bush to the correct
B. Checking and replacing the con-rod diameter.
bearings
C. Checking the con-rod
1. Clean the con-rod and bearing shells. Fit the
bearing shells and tighten the old bolts to a torque of Clamp the con-rod in a suitable test device and
40 Nm + 90°. check it. (Test values: see Technical Data, page 13)
127(The con-rod bolts must not be re-used. The con-rods are split into weight groups of 20 g.
A letter designates the weight group. It is marked on
the side of the con-rod. All con-rods in an engine
must belong to the same weight group, which means
the permissible weight difference is 20 g.

SS99N090

2. Measure the inner diameter with a plug gauge,


which has been zeroed at the diameter of the
applicable bearing journal. If new bearing shells have
a clearance of more than 0.14 mm, the con-rod Torx E18
bearing journals must be ground and the next 40 Nm + 90°
bearing shell undersize fitted (repair level). SC03G019

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2002-44
The letter stands for the following weights: 3. Insert the piston ring in the cylinder and measure
Weight: the distance between the ring ends. The distance
measured for the 1st and 3rd rings must not exceed
F 1935 - 1954 g
1 mm and 1.5 mm for the 2nd ring.
V 1955 - 1974 g
4. Re-insert the piston rings with the aid of the piston
X 1975 - 1994 g ring pliers. Make sure the rings are fitted in the right
Y 1995 - 2014 g place and the letters TOP or the manufacturer’s
identification mark on the rings point(s) upwards.
W 2015 - 2034 g
Z 2035 - 2054 g
620.97
G 2055 - 2074 g 620.98
620.99 DS
D. Checking and replacing the piston
rings
1. Release the piston rings using piston ring pliers.
Do not expand the rings more than necessary. If the
same rings are to be re-used, then they should be
kept in the correct order.

620.95
620.96 D

SC03G020

SS99N098

2. Carefully clean the piston ring groove and then


measure the piston ring play in the groove. The play
must not exceed 0.15 mm. Check whether the play is
due to wear in the ring groove. The rings and/or the
pistons must then be replaced accordingly.

SS99N099

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2002-45
E. Checking the pistons G. Fitting the pistons and con-rods
Inspect the pistons and piston pins by performing a 1. Insert the bearing shells in the con-rods. Make
visual check. Pay particular attention to possible sure the contact surfaces are clean and the bearing
cracks at the edge of the combustion chamber or at shells sit correctly.
the upper part of the piston pin bore hole. Measure
2. Lubricate the piston, piston rings and cylinder with
the diameter of the piston at the point indicated in the
engine oil. Turn the piston ring gaps to different sides
figure and compare the result with the specified
of the piston.
value. Replace the piston, if necessary.

∅107.873 -
107.887

17 mm
SS99N101

F. Fitting the piston pin


1. Insert the con-rod in the piston and push the
piston pin to its position.

SS99N103

3. Use a piston ring clamp or tapered installation tool


for fitting. Insert the piston and con-rod so that the
combustion space in the piston and the nozzle holder
in the cylinder head are on the same side (the arrow
on the piston must point forwards).
4. Oil the con-rod bearing journals and bearing shells
and push the piston down. Mount the bearing cover
so that the joggles on the bearing shells are on the
same side. Then tighten the bolts to a torque of
40 Nm+90°.
5. Check whether the lower con-rod bearing has
sufficient axial play on the crank journal.

SC03G021

:$51,1* The combustion chamber in the piston


and the letter for marking the weight class of the con-
rod are on the side.
2. Then fit the circlips for the piston pin. The ends of
the circlips must point upwards.

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2002-46
7. Flywheel
A. Replacing the starter ring gear on the B. Fitting the flywheel
flywheel 1. Clean the contact surfaces on the rear crankshaft
The ring gear cannot be re-finished because the flange and on the flywheel.
teeth on the side of the starter are chamfered and 2. Bolt the flywheel onto the crankshaft. Two M12
hardened. grub screws, which fit into the securing holes in the
1. Free the old ring gear by hitting it with a mandrel. flywheel, should be used as guide pins.
Clean the ring gear seat on the flywheel using a wire 3. Tighten the flywheel bolts evenly to a torque of
brush. 150 Nm.

SC03G022

2. Heat up the new ring gear to 150 - 200 °C. Mount


the ring gear. The chamfered inner edge must point
towards the flywheel and the tooth chamfer towards
the starter.
,03257$17 Allow the ring gear to cool down. Do
not use coolant.

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2002-47
8. Timing mechanism
A. Removing the timing gear case B. Replacing the intermediate gear wheel
The timing gear case acts as a seal for the sump. bearing bush
127( The timing gear case can only be removed If the intermediate gear wheel bearing bush is to be
after removing the sump. replaced, press in a new bearing bush so that its rear
edge lies within the rear gear wheel edge by
1. Drain the engine oil and remove the sump. 0.1 - 0.25 mm (see fig.).
2. Remove the fan, alternator, belt pulley
and the V-belt. If the tractor is equipped with an 1
air-conditioning system or compressed air system,
the compressor must also be removed. 2
,03257$17 Do not disconnect the refrigerant
lines! Only swivel the air conditioning compressor
with the lines connected (suspend it so that there is
no strain on the lines).
3. Remove the V-belt pulley.
4. Loosen the crankshaft nut.
5. Remove the timing gear case cover and remove
the oil deflector ring from the crankshaft.
6. Remove the injection pump (see Chapter 3001).
127( If the timing gear case is not going to be
replaced, the injection pump can remain in place. In SS99N109
1. Lathe chuck
this case, disconnect all lines and pipes from the
2. Roller ø = 5 mm
pump. Fit all openings on the injection pump with
sealing caps. After fitting, machine the inner diameter of the
7. Unscrew the intermediate gear wheel bolts. intermediate gear wheel bearing bush to the correct
Remove the flange, gear wheel and bearing journal. size. Centre the intermediate gear wheel according
to the above figure so the tooth play is kept even.
8. Pull out the camshaft.
127(If the cylinder head and valve mechanism are
not removed, the valve tappets must be secured
against falling down (refer to instructions in
Chapter 4 B, page 38).
9. Unscrew the bolts on the timing gear case and
remove the timing gear case. If a soft wedge has to
be driven in between the engine block and timing
gear case, make sure the sealing surfaces are not
damaged.
10. Take the front crankshaft sealing ring off the 0.10 - 0.25
timing gear case and clean all parts which have been
removed. 55.00 -
55.03
30 SS99N118

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2002-48
C. Fitting the timing gear case
The position of the timing gear case and the cover is
determined by two sprung dowel pins. It therefore
does not have to be centred for the assembly
process. However, the clearance between various
gear wheels must be checked. The timing gear case
and cover supplied as spares already have bore
holes for the sprung dowel pins.
1. Fit the timing gear case on the cylinder block using
a new seal. Drive the sprung dowel pins in by means
of a mandrel. Tighten the nuts and bolts.
2. Install the injection pump and the injection pump
gear wheel (if removed) (see Chapter 3001).
SS99N112
3. Oil the camshaft bearings and fit the shaft in the
cylinder block. Release the push rods and valve 5. Check the tooth play.
tappets, if they have been suspended. It should be between 0.05 - 0.25 mm.

200 Nm

60 Nm 35 Nm
SS99N113

6. Mount the oil deflector ring on the crankshaft and


fit the timing gear case cover using a new seal. Drive
the sprung dowel pins in, by means of a mandrel
(mate the hollow pin with the grub screw). Tighten
the nuts and bolts to the specified torque.

SC03G023

4. Fit the intermediate gear wheel with the shaft grub


screw and make sure the marks are aligned correctly.
Insert the washer and tighten the bolts to the
specified torque.
127( Remove the assembly pin used for installing
the injection pump.

SS99N114

7. Insert the guard ring correctly in the sealing ring


seat (see sectional drawing) and insert the front
crankshaft sealing ring so that it is seated correctly
using special tool 380000002.

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2002-49
11. Push the hub onto the profile on the crankshaft.
12. Apply a little oil to the thread on crankshaft nut.
Tighten the bolt to a torque of 1000 Nm.
13. Fit the vibration damper and V-belt pulley on the
hub. Tighten the bolts to the specified torque.
14. Re-fit the other parts which have been removed.

SS99N115

8. If it has been removed, re-fit the dust cap on the


V-belt pulley hub on the crankshaft. To do so, use
pressing tool 380000010.

1000 Nm
SC03G024

9. Lubricate the sealing surfaces on the sealing ring


and crankshaft as well as the profile for seating the
hub.
10. Align the mark on the hub with the mark on the
crankshaft (see graphic).

SS99N085

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2002-50
9. Lubrication system 5. Clamp the pump, at the pump gear wheel, in a vice
with protected jaws and unscrew the nut on the drive
A. Checking the oil pressure valve gear wheel. Use a plastic hammer to drive the pump
drive shaft off the gear wheel. Pull the drive shaft
Check whether the oil pressure valve is functioning if gear wheel out of the pump body.
the engine oil pressure is not sufficient or fluctuates
6. Wash the parts and check the wear. Compare the
noticeably. However, first check whether there is
actual dimensions with the specified values,
enough oil in the engine.
page 15, section entitled "Lubrication oil pump".
Replace worn parts and all gaskets.

Gear wheel

25 Nm

Loctite
638
SS00B054

127( Two different valve springs are used,


depending on the engine type. Although the length
(relaxed) of both springs is almost identical, the force 60 Nm 0 Nm
of the tensioned spring is much greater for engine +Loctite 243
types 620.97, 620.98 and 620.99.
1. Remove the cover on the oil pressure valve and
the spring located underneath. Pull the valve cone
out of the cylinder block.
2. Clean the parts. Check that the valve cone moves
SC03G025
freely in the valve insert. If the valve cone sticks,
clean out any particles of dirt. If necessary, grind the 7. The oil pump bearing points are fitted with
parts with fine abrasive wool or use new parts. Clean separate bearing bushes. On replacing the bearing
the sealing surfaces between the cylinder block and bushes, machine them to the dimension
the cover. 18.000 - 18.018 mm after fitting them.
3. Apply Loctite 638 to the outer diameter of the
cylindrical part of the valve insert. Drive the valve C. Assembling and fitting the oil pump
insert into the engine block using a suitable insertion 1. Insert the gear wheels in the recess in the pump
tool. Insert the valve cone in the valve insert. Fit the body. Fit a new seal between the pump body and
cover and spring using a new cover seal. cover (as required). Tighten the securing bolts a little.
127( The spring must be fitted with the larger Turn the shaft and tap the cover laterally into the
diameter towards the cover. position, in which it rotates most easily. Tighten the
cover securing bolts and check that the shaft still
B. Removing and checking the oil pump rotates easily.

1. Drain the engine oil and remove the sump. 2. Mount the drive gear wheel on the pump shaft. Put
screw locking fluid Loctite 243 on the nut thread. Fit
2. Disconnect the intake and pressure lines on the oil the washer and the nut. Tighten the nut to a torque of
pump. 60 Nm.
3. Remove the oil pump and any adjusting disks
between the pump housing and the cylinder block.
4. Release the pump cover and the seal. Remove the
gear wheel fitted on the axle.

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2002-51
D. Fitting the sump
Fit the sump seal with the silicone strips pointing
towards the cylinder block.

TOP

SS99N126

3. Clamp the pump at the mounting base in a vice


with protected jaws. Check the axial play of the gear SC03G026
wheel (0.03 - 0.11 mm) with a dial test indicator.
Change the number of seals between the cover and
pump body as required. E. Oil cooler
All engine types are equipped with an oil cooler,
which lies between the engine oil filter and the
cylinder block.
1. The coolant must be drained out of the oil cooler
before removing it.

SS99N127

4. Secure the pump in its position below the cylinder


block and use a dial test indicator to check the tooth
play between the crankshaft and pump gear wheels. SS99N129
(0.05 - 0.25 mm). Change the number of shim rings
2. Fit new seals. Mount the oil cooler so that the drain
between the pump base and the cylinder block as
connection points downwards. Secure the coolant
required (shim ring graduation: 0.2 mm). The
hoses in a regular manner.
insertion or removal of a shim ring alters the tooth
play by approx. 0.07 mm. 3. Put some screw locking fluid (e.g. Loctite 243) on
the thread on the engine end of the mounting pipe
127( When measuring the tooth play, the engine
must be in its operating position (cylinders upwards) and tighten it to a torque of 60 Nm.
as the crankshaft bearing play has an effect on the
tooth play.
5. Fix the pump intake and pressure lines, replace
the seals on the mounting flange.
6. Fit the sump and fill the engine with oil.

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2002-52
F. Piston cooling nozzles G. Recommended lubrication oils
The piston cooling nozzles (engine types 620.97, – For engines with a turbocharger
620.98 and 620.99) can be taken out after removing
the sump. The nozzle is equipped with a ball valve. It API CG-4 and CH-4
has an opening pressure of 3±0.25 bar. ACEA E3-96, E4-98, E5-99

°C
40

30

20

SAE 30
10

SAE 20W-20

SAE 20W-40
SAE 15W-40
0

SAE 10W-40
SAE 10W-30
SS99N130
-10
1. Change the valve as required. Unscrew the valve

SAE 5W-30

SAE 5W-40
from the engine and remove the nozzle pipe. Insert
the new valve. -20

-30

-40
SC03G027

SS99N131

2. On assembling the valve, fix the nozzle pipe, as


shown in the figure, at an angle of 90° to the
longitudinal axis of the engine. Tighten the valve to a
torque of 30 Nm. After assembly, check that the
nozzle pipe does not touch the piston or con-rod
when the engine is running.

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2002-53
10. Cooling system
A. Thermostat
The opening temperature of the smaller, single-
action thermostat is 79 °C.
The opening temperature of the bigger, double-action
thermostat is 83 °C.
If you have doubts about the functionality of the
thermostat, check it as follows:
– place the thermostat in boiling water without it
touching the sides of the vessel.
SS99N140
– the thermostat must start to open within
20 seconds. 4. Pull the impeller off using the 1TSW 662 extractor.

– the thermostat must be fully open after no longer 5. Remove the circlip from the pump body. Use a
than 50 seconds. Compare the measured values with hydraulic press, for example, to press the shaft with
those specified in the technical data. the bearing out of the pump body towards the fan.
Clamp the pump body so that the shaft bearing can
be taken out.
6. Remove the axial and shaft seals from the pump
body by means of a mandrel. Clean the parts and
check their condition. Replace worn or faulty parts.
127(If the pump bearings have to be replaced, it is
better to fit the pump repair kit, which also comprises
all seals required for the repair (refer to spare parts
catalogue).

SS00F032

B. Repairing the coolant pump


1. Drain the coolant. Unscrew the thermostat
housing, fan and V-belts.
2. Remove the coolant pump. Take the back plate off
the pump and clean the sealing surfaces.
3. Unscrew the securing nut for the V-belt pulley and
remove the belt pulley. Use the 1TSW 662 extractor,
if required.

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2002-54

1TSW 18390

380000005

SS99N143

SS99N138 10. Fix the back plate using a new seal. To fit the
back plate, use guide pins with a diameter of 8.5 mm
7. Use mandrel 380000005 to drive the shaft seal for the bore holes shown in the figure.
into the pump body. Mount the bearings and
intermediate sleeves on the shaft. Grease the C. Coolant quality requirements
bearings with plenty of heat-resistant ball bearing
grease. Fit the shaft and bearings in their place so – the coolant must conform with quality standard
that the forces produced by pressing do not act on ASTM D 3306 or BS 6580:1992.
the bearing balls. Fit the bearing circlip in its place. – if there are no frost resistance requirements, a
mixture ratio of 40 % is enough to ensure sufficient
corrosion protection.
– check the coolant (anti-freeze) mixture ratio at
certain intervals. Replace the coolant every two
0,8...1,2
years.
– the water used must be clean and soft, i.e. it must
not contain any metals and their salts.
,03257$17Never use only water as a coolant.

120 Nm

SC03G028

8. Fit the impeller whilst supporting the other end of


the coolant pump shaft. The clearance (X) between
the pump housing and the impeller is 0.8 - 1.2 mm.
Check that the coolant pump shaft rotates freely.
9. Fix the belt pulley on the shaft and tighten the
securing nut to a torque of 120 Nm.

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2002-55
11. Intake/exhaust system 5. Remove the manifold, if necessary. Clean the
sealing surfaces and remove any carbon deposits.
An engine equipped with a turbocharger is far more Make sure the sealing surfaces are level. If the
sensitive to faults and contamination in the intake/ mounting flanges are twisted or the sealing surfaces
exhaust system than conventional engines. Particular scratched, machine the flange or replace the exhaust
attention must therefore be paid to the intake/exhaust manifold.
system.
6. Make sure no loose objects or dirt particles have
A. Checking the air filter ingressed into the exhaust pipe or silencer. Such
loose objects or dirt particles can increase the back-
The engine performance and service life are largely pressure for the exhaust gases from the turbine
dependent on the condition of the air filter. A faulty air wheel.
filter lets dirt particles through, which in the long run
will cause damage to the turbocharger and engine. C. Checking the boost pressure
A blocked air filter reduces engine performance and
also causes oil leakage through the sealing ring on The boost pressure should be checked before
the turbocharger shaft. removing the turbocharger.

:$51,1* The safety filter located in the main filter


does not have to be cleaned, but must be replaced
as required (refer to operator’s manual).

B. Checking the intake/exhaust system


,03257$17 Leakages in the intake or exhaust
system impair the effect of the turbocharger. Due to
the pressure, even small leaks in the manifold or
turbine inlet flange quickly get bigger. Leakages must
therefore be eliminated without delay.
1. Check the pipes and sealing surfaces between the
air filter and exhaust turbocharger, between the A
exhaust turbocharger and charge-air cooler and
between the charge-air cooler and exhaust manifold.
SC03G033
If the intake manifold is dusty on the inner side, then
there is a leakage in the air filter or in the suction
pipes. Eliminate the leakage. To check the boost pressure, the mini-measuring
connection (380001915) is screwed into the intake
127( Check the condition and tightness of the
manifold instead of screw (A). This applies to all
flexible connection of the charge-air lines to and from
engines. In addition, a mini-measuring line
the charge-air cooler (pivot point) at different pivoting
angles. (380001127) and pressure gauge (380001121) have
to be used.
2. Clean the sealing surface of the intake manifold. Boost pressures see "Engine data", page 9.
Use a straightedge to make sure the sealing surface
is level. If the sealing surface is not level or is
scratched, machine or replace the intake manifold.
Make sure the cylinder heads are parallel to each
other.
3. Insert a new seal and secure the intake manifold.
Tighten the intake manifold securing bolts to a torque
of 30 Nm. Secure the air pipes.
4. Make sure the exhaust manifold does not leak.
Tighten the nuts/bolts to a torque of 50 Nm and
check for damage (cracks, deformation, corrosion,
etc.). Also check the connection between the
turbocharger and exhaust manifold.

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2002-56
D. Checking the turbocharger If the engine does not run properly even though the
turbocharger is not faulty and does not show
If it is assumed that the turbocharger is faulty, the excessive wear, the fault could have one of the
fault can be determined as follows: following causes:
1. Carry out a visual check on the turbine and – a blocked air filter
compressor wheels. The wings may not show any – a leakage in the intake or exhaust system; a
signs of damage, deformation or wear caused by leaking flange seal
foreign bodies. – a faulty or maladjusted injection pump
2. Check whether oil leaks through the sealing rings – faulty or maladjusted injection nozzles
on the shaft in the turbine/compressor housing. – insufficient fuel pressure (e.g. caused by a blocked
fuel filter)
:$51,1* A small amount of oil always comes out – weak compression, incorrect valve clearance
on the compressor side at low idling speeds.
However, there is no need to worry about this unless
a lot of oil is lost.

SS99N144

3. Check the running play of the turbine shaft. Hold


the probe of a dial test indicator against the shaft and
move the shaft sideways. Also refer to the play
specified under Technical Data.

SS99N145

4. Check the axial play of the shaft. Hold the probe of


the dial test indicator against the end of the shaft
move the shaft axially. Also refer to the play specified
under Technical Data.
If a fault or wear is confirmed, the turbocharger must
be overhauled.

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2002-57

4
3

1 5

SS99N146

Schwitzer turbocharger S200


1. Compressor housing 5. Bearing bushes
2. Lock nut 6. Turbine housing
3. Compressor wheel 7. Shaft and turbine wheel
4. Bearing housing

E. Fitting the turbocharger 3. Connect the intake/silencer pipe to the


turbocharger.
First, the cause of possible turbocharger damage must
be clarified and eliminated before a new turbocharger 4. Pour clean engine oil into the bearing housing via
is fitted. the oil filler in order to ensure lubrication of the
turbocharger bearings after switching the engine on.
For perfect operation of the turbocharger, it is
important that the engine lubrication oil is changed in 5. Secure the pressure and oil return pipes. Make sure
accordance with the relevant instructions and that the the turbocharger is held completely by the mounting
correct quality class is used. The maintenance flange and that the pipes do not put any strain on the
specifications for the oil and air filters must also be turbocharger.
adhered to. 6. Start the engine and check the line connections for
The injection pump setting, which must correspond the turbocharger lubrication system for leakage.
with the manufacturer’s specifications, has a major
influence on turbocharger operation.
1. Check the fastening and tightness of the exhaust
and intake manifolds. Make sure there are no loose
carbon particles, rust or other foreign bodies on the
exhaust or intake manifolds.
2. Fix the turbocharger onto the exhaust manifold by
means of the flange. Always use new seals.

Sva 6-51250 EN Edition 07/2003


Chapter
2002A

2002A
ENGINE WORKSHOP MANUAL

with Common Rail Fuel Injection System

CNH Österreich GmbH Sva 6-93080 EN © 2006 CNH Österreich GmbH


Technical Documentation July, 2006
A - 4300 St. Valentin, Steyrer Strasse 32
2002A-3

CONTENTS
SPECIAL TOOLS .................................................................................................................................................. 7

TO THE USER ...................................................................................................................................................... 9


Engine code and serial number ......................................................................................................................... 9

SAFETY REGULATIONS ................................................................................................................................... 10

ENGINE DATA .................................................................................................................................................... 11


Jumper lead starting and electrowelding ......................................................................................................... 11
Lifting the engine .............................................................................................................................................. 11

TECHNICAL DATA ............................................................................................................................................. 12


Compliance with exhaust standards ................................................................................................................ 12
Cylinder block .................................................................................................................................................. 12
Cylinder liners .................................................................................................................................................. 12
Cylinder head ................................................................................................................................................... 12
Valves, rocker arms and push rods ................................................................................................................. 13
Camshaft .......................................................................................................................................................... 14
Crankshaft ........................................................................................................................................................ 14
Flywheel ........................................................................................................................................................... 15
Gear drive - camshaft and high-pressure pump .............................................................................................. 15
Con-rods .......................................................................................................................................................... 15
Pistons, piston rings and piston pins ................................................................................................................ 16
Lubrication system ........................................................................................................................................... 16
Lubricating oil pump ......................................................................................................................................... 17
Thermostat ....................................................................................................................................................... 17
Coolant temperature - display and monitoring (signal from sensor B22) ......................................................... 17
Coolant pump ................................................................................................................................................... 17
Schwitzer turbocharger S200 ........................................................................................................................... 17
Tightening torques ........................................................................................................................................... 18

CONSTRUCTION ............................................................................................................................................... 19
GENERAL INFORMATION .............................................................................................................................. 19
Cylinder block .................................................................................................................................................. 19
Flywheel casing ............................................................................................................................................... 19
Cylinder head ................................................................................................................................................... 20
Valve mechanism ............................................................................................................................................. 20
Crank drive ....................................................................................................................................................... 21
Vibration absorber ............................................................................................................................................ 22
Timing gears .................................................................................................................................................... 23
Lubrication system ........................................................................................................................................... 24
Cooling system ................................................................................................................................................ 25
Fan ................................................................................................................................................................... 26
Intake / exhaust system ................................................................................................................................... 27

ELECTRONIC ENGINE CONTROL - EEM3 ....................................................................................................... 29


Layout .............................................................................................................................................................. 30
Function ........................................................................................................................................................... 31
Signals ............................................................................................................................................................. 31

Sva 6-93080 EN Edition 07-2006


2002A-4
EEM3 in conjunction with the service tool ........................................................................................................ 32
Error codes ....................................................................................................................................................... 32
Replacing the EEM3 box .................................................................................................................................. 36

WORK INSTRUCTIONS ..................................................................................................................................... 37


1. Cylinder block ............................................................................................................................................... 37
A. Measuring wear on cylinder liners ............................................................................................................. 37
B. Removing the cylinder liners ...................................................................................................................... 37
C. Checking the cylinder block ....................................................................................................................... 37
D. Replacing the camshaft bearing bush ....................................................................................................... 38
E. Oversize bearing bushes for the camshaft ................................................................................................ 38
F. Adjusting the plug on rear end
of camshaft ..................................................................................................................................................... 39
G. Adjusting the plug on the rear end of the camshaft after fitting an oversize bearing bush ........................ 39
H. Adjusting the cylinder liner ......................................................................................................................... 39
2. Flywheel casing ............................................................................................................................................ 41
A. Fitting the flywheel casing .......................................................................................................................... 41
B. Replacing the rear crankshaft sealing ring ................................................................................................ 41
3. Cylinder head ............................................................................................................................................... 42
A. Removing the cylinder head ...................................................................................................................... 42
B. Removing the valves ................................................................................................................................. 42
C. Checking the cylinder head ....................................................................................................................... 42
D. Replacing the valve guides ........................................................................................................................ 43
E. Machining the valve seat ........................................................................................................................... 44
F. Replacing the valve seat rings ................................................................................................................... 44
G. Grinding the valves .................................................................................................................................... 44
H. Fitting the valves ........................................................................................................................................ 45
I. Fitting the cylinder head .............................................................................................................................. 45
4. Valve mechanism ......................................................................................................................................... 46
A. Maintenance of the rocker arm system ...................................................................................................... 46
B. Replacing the camshaft / the camshaft gear ............................................................................................. 46
C. Checking and adjusting valve clearance ................................................................................................... 47
5. Crankshaft .................................................................................................................................................... 48
A. Removing the crankshaft ........................................................................................................................... 48
g. Checking the crankshaft ............................................................................................................................. 48
C. Replacing the crankshaft gears ................................................................................................................. 48
D. Fitting the crankshaft ................................................................................................................................. 49
E. Crankshaft hub .......................................................................................................................................... 49
6. Connecting rods and pistons ........................................................................................................................ 50
A. Removing the pistons together with the connecting rods .......................................................................... 50
B. Checking and replacing the connecting rod bearings ................................................................................ 50
C. Checking the connecting rod ..................................................................................................................... 50
D. Checking and replacing the piston rings .................................................................................................... 51
E. Checking the piston ................................................................................................................................... 52
F. Fitting the piston pin ................................................................................................................................... 52
G. Fitting pistons and connecting rods ........................................................................................................... 52
7. Flywheel ....................................................................................................................................................... 53
A. Replacing the starter ring gear on the flywheel ......................................................................................... 53
B. Fitting the flywheel ..................................................................................................................................... 53
8. Control mechanism ...................................................................................................................................... 54
A. Removing the timing gear case ................................................................................................................. 54
B. Replacing the intermediate gear
Sva 6-93080 EN Edition 07-2006
2002A-5
bearing bush .................................................................................................................................................. 54
C. Fitting the timing gear case ....................................................................................................................... 55
9. Lubrication system ....................................................................................................................................... 57
A. Checking the oil pressure valve ................................................................................................................. 57
B. Removing and checking the oil pump ........................................................................................................ 57
C. Assembling and fitting the oil pump ........................................................................................................... 57
D. Assembly of the oil sump .......................................................................................................................... 58
E. Oil cooler ................................................................................................................................................... 58
F. Piston cooling nozzles ............................................................................................................................... 59
G. Recommended lubricants ......................................................................................................................... 59
10. Cooling system .......................................................................................................................................... 60
A. Thermostat ................................................................................................................................................ 60
B. Repairs to coolant pump ............................................................................................................................ 60
C. Coolant quality requirements ..................................................................................................................... 61
11. Air intake and exhaust system ................................................................................................................... 62
A. Checking the air filter ................................................................................................................................. 62
B. Checking the air intake system and exhaust system ................................................................................. 62
D. Checking the turbocharger ........................................................................................................................ 63
E. Assembly of the turbocharger .................................................................................................................... 64

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2002A-6

BLANK PAGE

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2002A-7
SPECIAL TOOLS
Pressing tool for the front crankshaft Universal pin
shaft sealing ring

SS00B077
1 x 1TSW 18390 M24

SS00B065 Pressing tool for valve guides


1 x 380000002 (1TSW 520)

Pressing tool for the rear crankshaft shaft


sealing ring

SS00B069
1 x 380000007 (1TSW 524)

SS00B066 Valve spring tensioning lever


1 x 380000003 (1TSW 521)

Pressing tool for


camshaft cover

SS00B071
1 x 380000008 (1TSW 014)
SS00B067
1 x 380000004 (1TSW 522) Extractor

Assembly pin for the water pump seal

SS00B070
1 x 1TSW 662 (available from stockists)

SS00B068
1 x 380000005 (1TSW 523)

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2002A-8
Cylinder liner extractor Three-armed puller

SS05N371
1 x 380000329

Key for crankshaft nut


SS00B072
1 x 1TSW 510 (available from stockists)

Extraction plate

SS05N0372
1 x 380002658

Key for Visco fan


SS00B073
1 x 380000011 (1TSW 508)

Dial gauge and holder

SS05N395
1 x 380001791

SS00B075
Key for reverse fan
1 x 380000364 (1TSW 5610) Holder
1 x 380000228 (1TSW 17049-6) Dial gauge

SS05N396
1 x 380002657

Sva 6-93080 EN Edition 07-2006


2002A-9

TO THE USER
The purpose of this manual is to provide basic information required to service and repair CNH diesel engines.
The engines are of the same design. Differences which have an influence on repair work are therefore listed in the
technical data and repair instructions. All dimensions are specified in millimetres and apply at a temperature of +20°C,
unless otherwise specified.
Before starting repair work, make sure all necessary special tools, spare parts and accessories are available. It is not
absolutely necessary to have all the special tools mentioned in this manual. However, they do make it quicker and
easier to carry out the necessary repairs. After carrying out any repair work you must run in the engine as you would
a new engine.
Should any problems arise which are not covered in this manual, please contact the customer service team at CNH
Österreich GmbH in St. Valentin or through the relevant importer.
IMPORTANT: When making any queries, please specify the following engine data and the current operat-
ing hours count.
EEM3 = Electronic Engine Management.

Engine code and serial number

Engine number
(serial number)

SS05N359

NOTE: This label is affixed to the right-hand side of the engine.

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2002A-10

SAFETY REGULATIONS
There is always a risk of injury · Avoid touching the exhaust manifold, turbo charg-
when carrying out maintenance er and other hot engine parts.
and repair work. Read the · When the engine is hot and the coolant is pressu-
following safety regulations and rised, be careful when opening the radiator cap.
information before starting work. Coolant and lubrication oil out of the hot engine
· Never start repair work which you do not fully un- can cause severe injuries if contact is made with
derstand. the skin.
· Make sure that it is possible to work safely at the · Naked flames and smoking are not permitted in
location and in the vicinity. the vicinity of fuel tanks or batteries. Electrical
· Make sure that the repair area is clean and well- sparks should be avoided. (Particularly when
maintained. charging the batteries. Explosion hazard!)

· Never use incorrect or unsuitable tools. · Disconnect the cable at the negative battery pole
before carrying out service or repair work on the
· Remove all rings, chains and watches before electrical system.
starting work.
· If the engine gets excessively hot (over 300°C),
· Use modern safety equipment when working. For for example if it catches fire, the viton seals (e.g.
example, protect your eyes when using com- bottom O-ring on the cylinder liner or the O-ring on
pressed air for cleaning, grinding, hammering or the oil pressure valve) release highly caustic HF
similar tasks. acid. Never touch viton seals which have been
· When lifting or transporting heavy parts (over 20 subjected to unusually high temperatures, with
kg), use lifting equipment. Make sure that hooks bare hands. Always wear neoprene gloves or thick
and chains are in good condition and are firmly at- working gloves and protective glasses when re-
tached. moving these harmful materials. Wash the seals
· Never work underneath an engine that is freely and soiled surfaces using a 10% hydroxide solu-
suspended from a lifting apparatus or has been tion or other alkaline solution. Collect the material
raised by a jack. Always secure the engine with in air-tight sealed plastic bags and take it to an au-
strong supports before starting work. thorised collecting depot.

· Only use genuine CNH spare parts. IMPORTANT: Viton seals must never be burned!
· Only start the engine from the cab using the igni- · Extended contact with the fuel, lubricant and cool-
tion key. ant can irritate the skin.
· Never start the engine when any protective covers · Avoid idling the engine unnecessarily.
are removed. · When carrying out service work, take measures to
CAUTION: The cooling fan is difficult to see when the prevent fuel or other fluids from entering the
engine is running. Loose clothing and long hair may ground or drains.
become caught in rotating engine parts. · All seals are free of asbestos.
· If starting the engine in an enclosed space, make · Be careful when washing the engine using a
sure there is sufficient ventilation. washing facility with a high water pressure. For
· Never use aerosol-based starting fuels while the example, the electrical systems, fuel system and
thermal auxiliary ignition system is operating (risk cooler must not be washed at high pressure be-
of explosion). cause this could easily cause damage.

· Ear muffs must be worn when testing the engine


or working close to the engine to avoid hearing
damage.
· Always switch off the engine before performing
maintenance or repair work.
CAUTION: Never open the connections of high-pres-
sure lines while the engine is running. Always wait at
least 30 seconds after switching the engine off before
opening it. A high-pressure jet of fuel (up to 1100 bar)
can penetrate the skin and cause serious injury. If such
an event occurs, medical attention must be sought im-
mediately.

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2002A-11

ENGINE DATA
Engine type 620.64
Number of cylinders 6
3
Cubic capacity (dm ) 6.6
Bore (mm) 108
Height of stroke (mm) 120
Nominal power output in kW at 2100 144
rpm in line with ISO 14396
Marker for start of fuel delivery on
set automatically
V-belt disc (° before TDC)
Compression ratio 18.5 : 1
Combustion process direct injection
Injection sequence 1-5-3-6-2-4
1
Compression pressure (bar) 24
Charge-air pressure 2 (bar) 1.45
3
Weight (kg) 515
Direction of rotation of the crank- Clockwise
shaft

1)
Minimum values at operating temperature and starter speed.
Maximum permissible difference between cylinders max. 3 bar.
2)
measured using Service Tool at full load, rated engine speed and maximum fan speed
3)
Without flywheel and electrical equipment.

Jumper lead starting and electrowelding


• Jumper lead starting may only be used with 12V batteries connected in parallel.
• Before performing any welding work, turn the start switch to the „0“ position.
IMPORTANT: Attach the earth terminal of the welding device close to the area to be welded (max. 1m apart).
IMPORTANT: After repairing the fuel system, the system must be vented before attempting to start for the first time
(see Chapter 3001A - Venting the fuel system).

Lifting the engine


The engine can be safely raised using a lifting device where the lifting force acts vertically on the lifting eyes.
(Prepare lifting eyes yourself at the site where repairs are being undertaken)
A = Engine lifting eyes

A A

SS05N281

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2002A-12

TECHNICAL DATA
Compliance with exhaust standards
The engine complies with emissions requirement EU97/68/EC Level 3A.

Cylinder block
Guide pin bores ................................................................................................................. 13.250 - 13.320 mm
Diameter of crankshaft bearing ground bore ...................................................................... 91.000 - 91.025 mm
Diameter of crankshaft bearing ground bore (oversize) ...................................................... 92.000 - 92.025 mm
Bore diameter of cylinder liner:
- top ............................................................................................................................... 124.514 - 124.554 mm
- bottom ......................................................................................................................... 123.000 - 123.040 mm
Diameter of camshaft bearing bush, no. 1 (assembled) ...................................................... 50.040 - 50.060 mm
Diameter of camshaft bearing bush, nos. 2 - 5 (assembled) ............................................... 50.010 - 50.070 mm
Height of cylinder block .................................................................................................. 428.170 - 428.430 mm

Cylinder liners
Height of liners above cylinder block ...................................................................................... 0.030 - 0.080 mm
Max. permissible height difference between cylinder liners (below same head) ................................... 0.02 mm
Diameter of cylinder liner bores in engine block:
- top end of liner ............................................................................................................ 124.475 - 124.500 mm
- bottom end of liner ....................................................................................................... 122.961 - 122.986 mm
Cylinder liner bore ......................................................................................................... 108.010 - 108.032 mm
Height, cylinder liner flange (standard) ....................................................................................... 9.03 - 9.05 mm
Height, cylinder liner flange, oversize 1 ...................................................................................... 9.08 - 9.10 mm
Height, cylinder liner flange, oversize 2 ...................................................................................... 9.13 - 9.15 mm
Height, cylinder liner flange, oversize 3 ...................................................................................... 9.23 - 9.25 mm
Outer diameter of cylinder liner flange ........................................................................... 131.700 - 131.800 mm

Cylinder head
Height of cylinder head .................................................................................................. 104.800 - 105.000 mm
Minimum height of cylinder head after surface grinding (minimum) ................................................ 104.000 mm
Inner diameter of valve guide (not fitted) ................................................................................ 9.000 - 9.015 mm
Outer diameter of valve guide ............................................................................................ 16.028 - 16.039 mm
Diameter of bore for valve guide in cylinder head .............................................................. 16.000 - 16.018 mm
Projection of valve guide above cylinder head surface ............................................................................21 mm
Depth, valve head below cylinder head surface:
- Inlet valve ........................................................................................................0.7 ± 0.05 mm (max. 2.20 mm)
- Outlet valve .....................................................................................................0.6 ± 0.05 mm (max. 2.20 mm)
Valve seat angle:
- Inlet valve ............................................................................................................................................ 35° +20'
- Outlet valve .........................................................................................................................................45° +20'
Valve seat width:
- Inlet valve ....................................................................................................................................2.9 - 3.7 mm
- Outlet valve .................................................................................................................................1.3 - 2.3 mm
Diameter, outlet valve seat ring (standard) ......................................................................... 44.070 - 44.132 mm
Bore in cylinder head for outlet valve seat ring (standard) .................................................. 44.000 - 44.025 mm
Diameter, outlet valve seat ring (oversize) ......................................................................... 44.270 - 44.332 mm
Bore in cylinder head for outlet valve seat ring (oversize) .................................................. 44.200 - 44.225 mm
Diameter, inlet valve seat ring (standard) ........................................................................... 48.570 - 48.632 mm
Bore in cylinder head for inlet valve seat ring (standard) .................................................... 48.500 - 48.525 mm
Diameter, inlet valve seat ring (oversize) ........................................................................... 48.770 - 48.832 mm
Bore in cylinder head for inlet valve seat ring (oversize) .................................................... 48.700 - 48.725 mm

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2002A-13

Valves, rocker arms and push rods


Valve control times at a valve play of 1.0 mm:
- Inlet valve opens ................................................................................................................ 0° ±2° before TDC
- Inlet valve closes ................................................................................................................ 16° ±2° after BDC
- Outlet valve opens ........................................................................................................... 39° ±2° before BDC
- Outlet valve closes ................................................................................................................ 1° ±2° after TDC
Valve play when engine is cold/hot:
- Inlet valve ......................................................................................................................................... 0.35 mm
- Outlet valve ....................................................................................................................................... 0.35 mm
Valve head angle:
- Inlet valve ............................................................................................................................................ 35° -20'
- Outlet valve .......................................................................................................................................... 45° -20'
Valve head diameter:
- Inlet valve ............................................................................................................................................ 48 mm
- Outlet valve .......................................................................................................................................... 41 mm
Maximum opening travel of valves (with valve play of 0.35 mm):
- Inlet valve ......................................................................................................................................... 10.9 mm
- Outlet valve ....................................................................................................................................... 12.1 mm
Diameter, inlet valve stem ..................................................................................................... 8.960 - 8.975 mm
Diameter, outlet valve stem ................................................................................................... 8.925 - 8.940 mm
Clearance, inlet valve stem (guide fitted in cylinder head) ..................................................... 0.025 - 0.055 mm
Wear limit (inlet valve stem) ................................................................................................................ 0.30 mm
Clearance, outlet valve stem (guide fitted in cylinder head) ................................................... 0.060 - 0.090 mm
Wear limit (outlet valve stem) .............................................................................................................. 0.35 mm
Inner diameter of valve guide (not fitted) ............................................................................... 9.000 - 9.015 mm
Outer diameter of valve guide ............................................................................................16.028 - 16.039 mm
Diameter of bore for valve guide in cylinder head ...............................................................16.000 - 16.018 mm
Projection of valve guide above cylinder head surface ........................................................................... 21 mm
Depth, valve head below cylinder head surface:
- Inlet valve ....................................................................................................... 0.7 ± 0.05 mm (max. 2.20 mm)
- Outlet valve ..................................................................................................... 0.6 ± 0.05 mm (max. 2.20 mm)
Free length of valve spring .................................................................................................................. 69.8 mm
Force of valve spring with pressed length of:
- 48.6 mm ......................................................................................................................................... 327 ± 17 N
- 37.4 mm ......................................................................................................................................... 500 ± 23 N
Diameter, rocker arm shaft .................................................................................................22.970 - 22.990 mm
Diameter of rocker arm bore ...............................................................................................23.000 - 23.021 mm
Permissible radial runout of push rod (free) ........................................................................................... 0.4 mm
Free length of rocker arm spring ............................................................................................................. 80 mm
Force of rocker arm spring with pressed length of 58 mm ................................................................... 70 - 90 N
Outer diameter of pusher ...................................................................................................29.939 - 29.960 mm
Diameter of pusher bores in cylinder block .........................................................................30.000 - 30.043 mm
Length of push rod .........................................................................................................237.000 - 238.300 mm

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2002A-14

Camshaft
Diameter, camshaft bearing journal no. 1 (front) ................................................................ 49.875 - 49.900 mm
Diameter, camshaft bearing journals nos. 2, 3 and 4 .......................................................... 49.865 - 49.890 mm
Diameter, camshaft bearing journal no. 5 ........................................................................... 49.885 - 49.910 mm
Clearance, camshaft bearing no. 1 ........................................................................................ 0.140 - 0.185 mm
Clearance of camshaft bearings nos. 2, 3 and 4 .................................................................... 0.110 - 0.160 mm
Clearance, camshaft bearing no. 5 ........................................................................................ 0.100 - 0.185 mm
Axial play of camshaft (seal 0.5 mm - between cylinder block and
steering housing and between steering housing and cover ............................................................0.5 - 1.0 mm
Cam height (distance between base circle and elevation of cam):
- Inlet valve ........................................................................................................................ 41.987 - 41.487 mm
- Outlet valve ..................................................................................................................... 39.883 - 40.383 mm
Cam stroke:
- Inlet valve .......................................................................................................................................... 7.38 mm
- Outlet valve ....................................................................................................................................... 8.28 mm
Max. permissible radial runout of camshaft .......................................................................................... 0.03 mm

Crankshaft
Diameter of the con-rod bearing journals:
- Standard dimension ......................................................................................................... 67.981 - 68.000 mm
- 1st repair level 0.25 mm .................................................................................................. 67.731 - 67.750 mm
- 2nd repair level 0.50 mm ................................................................................................. 67.481 - 67.500 mm
- 3rd repair level 1.00 mm .................................................................................................. 66.981 - 67.000 mm
- 4th repair level 1.50 mm .................................................................................................. 66.481 - 66.500 mm
Width of con-rod bearing journal ........................................................................................ 40.000 - 40.160 mm
Diameter of the main bearing journals:
- Standard dimension ......................................................................................................... 84.985 - 85.020 mm
- 1st repair level 0.25 mm .................................................................................................. 84.735 - 84.770 mm
- 2nd repair level 0.50 mm ................................................................................................. 84.485 - 84.520 mm
- 3rd repair level 1.00 mm .................................................................................................. 83.985 - 84.020 mm
- 4th repair level 1.50 mm .................................................................................................. 83.485 - 83.520 mm
Diameter, main bearing housing ......................................................................................... 91.000 - 91.025 mm
Thickness of the main bearing shells:
- Standard dimension ............................................................................................................. 2.955 - 2.965 mm
- 1st repair level 0.25 mm ...................................................................................................... 3.080 - 3.090 mm
- 2nd repair level 0.50 mm ..................................................................................................... 3.205 - 3.215 mm
- 3rd repair level 1.00 mm ...................................................................................................... 3.455 - 3.465 mm
- 4th repair level 1.50 mm ...................................................................................................... 3.705 - 3.715 mm
Clearance of main bearings ................................................................................................... 0.050 - 0.127 mm
Width of the journal at the thrust bearing (main bearing at flywheel):
- Standard dimension (2 standard thrust washers) ............................................................. 45.000 - 45.080 mm
- 1st repair level(one standard thrust washer and one with 0.1 mm oversize) ..................... 45.100 - 45.180 mm
- 2nd repair level (one standard thrust washer and one with 0.2 mm oversize) ................... 45.200 - 45.280 mm
- 3rd repair level (one thrust washer of 0.1 mm and one of 0.2 mm oversize) ..................... 45.300 - 45.380 mm
- 4th repair level (two thrust washers with 0.2 mm oversize) .............................................. 45.400 - 45.480 mm
Other crankshaft bearing journals may not be ground wider.
Crankshaft axial play ............................................................................................................. 0.100 - 0.380 mm
Max. permissible ovality of main bearing or con-rod bearing journals ................................................... 0.03 mm
Max. permissible imbalance of crankshaft .................................................................................... 1.0 Ncm max.

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2002A-15

Flywheel
Cover, starter gear ring on flywheel ....................................................................................... 0.425 - 0.600 mm
Before pressing the starter gear ring on the flywheel, heat up the
gear ring to a temperature of .......................................................................................................... 150 - 200°C
Max. permissible imbalance on flywheel ...................................................................................... 1.0 Ncm max.
max. permissible runout of coupling face, measured on inner edge
of coupling face (diameter 200mm) ..................................................................................................... 0.06 mm

Gear drive - camshaft and high-pressure pump


Tooth flank play:
Crankshaft - intermediate gear .................................................................................................. 0.05 - 0.25 mm
Intermediate gear - camshaft ..................................................................................................... 0.05 - 0.25 mm
Double intermediate gear - high-pressure pump ........................................................................ 0.05 - 0.25 mm
Max. permissible lateral runout of gears .............................................................................................. 0.05 mm
Intermediate gear (with plain bearing, 50.7 mm long):
- Inner diameter, intermediate gear bearing bush (fitted) ....................................................55.200 - 55.230 mm
- Diameter, bearing journal for intermediate gear ................................................................55.151 - 55.170 mm
Inner diameter, intermediate gear .......................................................................................60.000 - 60.030 mm
Timing marks:
The orientation of the timing marks on the gears corresponds to
the upper dead centre of the piston in the first cylinder between the compression stroke and working stroke.
On the crankshaft gear ...................................................................................................... 2 points on the teeth
On the intermediate gear:
- to crankshaft gear ...................................................................................................................1 point on tooth
- to camshaft gear .....................................................................................................................1 point on tooth
On camshaft gear ......................................................................................................... 1 point on the tooth gap

Con-rods
Inner diameter, piston pin bearing bush
(bearing bush pressed into con-rod) ...................................................................................40.025 - 40.040 mm
Outer diameter of piston pin bearing bush (standard) .........................................................44.080 - 44.120 mm
Outer diameter of piston pin bearing bush (oversize) ..........................................................44.580 - 44.620 mm
Cover for bearing seat (press fit) in the con-rod ..................................................................... 0.057 - 0.120 mm
Bore, seat for piston pin bearing bush ................................................................................44.000 - 44.025 mm
Bore, seat for piston pin bearing bush (oversize bush) .......................................................44.500 - 44.525 mm
Bore, con-rod side ..............................................................................................................71.730 - 71.749 mm
Thickness of the con-rod bearing shells:
- Standard ............................................................................................................................. 1.835 - 1.842 mm
- 1st repair level 0.25 mm ...................................................................................................... 1.960 - 1.967 mm
- 2nd repair level 0.50 mm ..................................................................................................... 2.085 - 2.092 mm
- 3rd repair level 1.00 mm ..................................................................................................... 2.335 - 2.342 mm
- 4th repair level 1.50 mm ...................................................................................................... 2.585 - 2.592 mm
Clearance of con-rod bearing ................................................................................................ 0.046 - 0.098 mm
Axial play of con-rod bearing ................................................................................................. 0.200 - 0.410 mm
Alignment of con-rod bearing to bore piston pin bearing ............................................................ within 0.15:100
Parallelism of con-rod bearing bore to bore piston pin bearing .................................................. within 0.05:100
The weight markers are engraved on the lower end of the con-rods
(on the camshaft side)
Max. permissible weight difference between con-rods in same engine ....................................................... 20 g

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2002A-16

Pistons, piston rings and piston pins


Piston diameter (measured 17 mm above
the piston's lower edge .................................................................................................. 107.883 - 107.897 mm
Diameter, piston pin bore in piston ..................................................................................... 40.003 - 40.009 mm
Diameter, piston pin ........................................................................................................... 39.991 - 40.000 mm
Width of the piston ring grooves:
- 1st groove ..................................................................................................................................keystone ring
- 2nd groove .......................................................................................................................... 2.520 - 2.540 mm
- 3rd groove ........................................................................................................................... 4.040 - 4.060 mm
Vertical play of the piston rings in their grooves:
- 1st groove ..................................................................................................................................keystone ring
- 2nd groove ............................................................................................................................ 0.03 - 0.062 mm
- 3rd groove ............................................................................................................................. 0.05 - 0.082 mm
- wear limit ........................................................................................................................................... 0.15 mm
Piston ring height (in direction of cylinder):
- 1st groove ..................................................................................................................................keystone ring
- 2nd groove .......................................................................................................................... 2.478 - 2.490 mm
- 3rd groove ........................................................................................................................... 3.975 - 3.990 mm
End play of piston rings (with piston fitted):
- 1st groove ............................................................................................................................... 0.40 - 0.55 mm
- 2nd groove .............................................................................................................................. 0.60 - 0.80 mm
- 3rd groove ............................................................................................................................... 0.30 - 0.60 mm
- wear limit - rings 1 and 3 .....................................................................................................................1.0 mm
- wear limit - ring 2 .................................................................................................................................1.5 mm
Maximum weight difference between pistons in same engine ......................................................................25 g
NOTE: To assemble the piston pins, heat up the pistons to 100°C!
NOTE: When fitting the pistons, ensure that the piston bowls are on the side of the injectors.

Lubrication system
Oil pressure at normal operating temperature:
- when idling ................................................................................................................................... min. 1.0 bar
- at operating speed ....................................................................................................................... 2.5 - 5.0 bar
Lubricating oil filter - overflow valve opens at pressure difference of .................................................. 2 ±0.5 bar
Oil pressure monitoring .............................................................................................. using oil pressure sensor
Switching pressures for oil pressure sensor .......................................... Speed-dependent from 900 - 2300 rpm
at 900 rpm ........................................................................................................................................... 1.15 bar
at 2300 rpm ......................................................................................................................................... 1.92 bar
Spring in oil pressure valve: free length (identification = yellow point) ........................................ 49.3 - 50.8 mm
Spring length and spring force (with fitted oil pressure valve) ................................................... 28.5 mm / 127 N
±0.25
Overflow valves for the piston cooling nozzles: Opening pressure .................................................... 3 bar

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2002A-17

Lubricating oil pump


Backlash when the crankshaft is positioned almost against the lower face of the bearing
- between crankshaft gear and oil pump gear .......................................................................... 0.05 - 0.025 mm
- between gears of oil pump ...................................................................................................... 0.16 - 0.26 mm
Diameter of driveshaft in housing and cover .......................................................................17.966 - 17.984 mm
Diameter of bearing bores of driveshaft ..............................................................................18.000 - 18.018 mm
Diameter of fixed shaft in pump gear area ..........................................................................17.966 - 17.984 mm
Diameter of bearing bore in pump gear ..............................................................................18.000 - 18.018 mm
Diameter of fixed shaft in pump housing .............................................................................20.035 - 20.048 mm
Depth of end of driveshaft below surface of housing .............................................................................. 0.5 mm
Thickness of housing seal ......................................................................................................... 0.06 - 0.08 mm
Outer diameter of gears .....................................................................................................55.824 - 55.870 mm
Diameter of housing ...........................................................................................................56.000 - 56.120 mm
Width of gears ....................................................................................................................32.000 - 32.027 mm
Axial play of gears ......................................................................................................................0.03 - 0.11 mm
Depth of housing ................................................................................................................32.000 - 32.043 mm

Thermostat
Type, version ............................................................................................................................ ∅ 54 mm / single-circuit
Starts opening at ................................................................................................................................... 79°C ±2
Fully open at ............................................................................................................................................. 94°C
Max stroke ............................................................................................................................................. 7.5 mm
Type, version ....................................................................................................................................... ∅ 67 / two-circuit
Starts opening at ................................................................................................................................... 83°C ±2
Fully open at ............................................................................................................................................. 95°C
Max stroke ................................................................................................................................................ 8 mm

Coolant temperature - display and monitoring (signal from sensor B22)


Display on ADIC ..................................................................................................................................analogue
Warning on ADIC when temperature ............................................................................................... > 106 ± 3° C
error code EEM112
Acoustic alarm (additional) when temperature ................................................................................. > 113 ± 3° C
error code EEM113

Coolant pump
Outer diameter of bearing ...................................................................................................................... 72 mm
Diameter of bearing housing ..............................................................................................71.961 - 71.991 mm
Diameter for insertion of seal in housing .............................................................................39.981 - 40.019 mm
Diameter of shaft with bearing ............................................................................................30.002 - 30.015 mm
Diameter of shaft with impeller ...........................................................................................15.907 - 15.920 mm
Diameter of impeller bore ...................................................................................................15.876 - 15.894 mm
Gap between impeller and rear face of housing ..................................................................................... 0.7 mm
(must be complied with even when pressing)
Permissible imbalance of fan................................................................................. max. 0.3 Ncm max (30 pcm)

Schwitzer turbocharger S200


Axial play of shaft ........................................................................................................................ max. 0.10 mm
Radial play of shaft (compressor side) ......................................................................................... max. 0.88 mm
Tightening torque of compressor housing screws ............................................................................... 13.60 Nm
Tightening torque of turbine housing screws .......................................................................................21.00 Nm
Tightening torque of nuts on shaft (compressor side) .........................................................................13.60 Nm

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Tightening torques
Cylinder head screws and nuts .................................................................................................80 Nm+90°+90°
Cylinder head pins in the cylinder block .................................................................................................. 30 Nm
Crankshaft bearing screws .................................................................................................................... 200 Nm
Connecting rod bolts (Torx E18) ..................................................................................................... 40 Nm + 90°
Nuts on crankshaft (front face) ............................................................................................................ 1000 Nm
Pulley screws .......................................................................................................................................... 30 Nm
Retaining bolts for flywheel ................................................................................................................... 150 Nm
Retaining bolts for flywheel casing:
- inner bolts M10 ..................................................................................................................................... 80 Nm
- outer bolts M12 ................................................................................................................................... 150 Nm
Retaining screws for intermediate gear (with plain bearing):
- M10 ...................................................................................................................................................... 60 Nm
- M14 .................................................................................................................................................... 200 Nm
Overflow valve - piston cooling nozzle .................................................................................................... 30 Nm
Nuts for lubricating oil pump gear ........................................................................................................... 60 Nm
Retaining screws for lubricating oil pump ................................................................................................ 60 Nm
Connecting part to engine oil cooler ........................................................................................................ 60 Nm
Nuts for coolant pump pulley ................................................................................................................. 120 Nm
Attachment - Visco fan to Visco hub ........................................................................................................ 30 Nm
Screws/nuts on exhaust manifold ............................................................................................................ 50 Nm
Screws on air intake port ........................................................................................................................ 30 Nm
Nuts - Drive gear, high-pressure pump .................................................................................................... 90 Nm
Retaining bolt, injector ............................................................................................................................ 40 Nm
High-pressure line from high-pressure pump to rail ................................................................................. 30 Nm
High-pressure line from rail to injectors ................................................................................................... 25 Nm
Low-pressure line to high-pressure pump ............................................................................................... 25 Nm

NOTE: Use washers for aluminium parts.

If no special tightening torques are given,


always use the values in the table below.

Tightness
Thread size
8.8 10.9
M8 25 Nm 35 Nm
M10 50 Nm 75 Nm

Bolts for the self-supporting oil pan


1 M8 25 Nm
3
2 M10 90 Nm
3 M14 160 Nm
4 M20 600 Nm 4 2
1 SS99N015

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CONSTRUCTION
GENERAL INFORMATION
The 620-series diesel engines described in this manual
are water-cooled four-stroke in-line engines with a
common rail fuel injection system. All models are
equipped with wet, replaceable cylinder liners, an ex-
haust turbocharger and charge-air cooling (air/air). The
engine is controlled by the EEM3 control unit. The en-
gine meets the requirements of the Level 3A exhaust
regulations.

Cylinder block
The rib-reinforced cylinder block forms the main engine
unit, onto which other engine components are mount-
ed.
The wet and interchangeable cylinder liners are sup-
ported in the middle, which has the effect of reducing vi-
bration and making sure that most of the coolant flows
to the upper part of the cylinder liners.
The seal between the lower part of the cylinder liner
and the cylinder block is provided by three O-rings fitted
into the grooves in the cylinder liner. The upper part is
sealed by the cylinder head gasket.
The camshaft is located in the cylinder block. All cam-
shaft bearings are fitted with interchangeable bearing
bushes.
Guide bearings are fitted on both sides of the rear main
bearing of the crankshaft
(crankshaft axial bearings).

Flywheel casing
The flywheel casing is fitted at the rear end of the cylin-
SS05N374
der block. The seal for the rear end of the crankshaft is
inserted in a bore in the casing. The attachment for the
starter is housed in the flywheel casing.
The underside of the flywheel casing serves as a seal-
ing face for the oil sump seal. This means that the lower
face of the cylinder block must stop flush with the fly-
wheel casing. When the flywheel casing is fitted, its po-
sition is determined by sprung dowel pins.

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Valve mechanism
The valve mechanism is activated by the camshaft lo-
cated in the cylinder block. The drive force is trans-
ferred by valve tappets and push rods. The camshaft
wheel is force-fitted on to the camshaft and is radially
fixed with a feather key. The bearings are lubricated
with compressed oil through oil bores in the engine
block.

SS05N284

Cylinder head
The engines have two interchangeable cylinder heads.
Each cylinder has its own intake and outlet duct in the
cylinder head. Between the outlet valves is an inlet
valve to balance out the thermal load.
The cylinder head bolts are high-strength pre-loaded
bolts that are tightened to yield point in line with the
principle of tightening by angle. Due to the high degree
of elongation, the retaining power is kept constant
throughout the entire service life, and the bolts do not
therefore have to be re-tightened.
The injector seats are integrated into the cylinder head
itself. The inlet and outlet valve guides are identical and
can be interchanged. Furthermore, the inlet/outlet
valves are fitted with replaceable valve seat inserts.

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Crank drive The pistons have two compression rings and one oil
The crankshaft is forged from special chrome alloy scraper ring. The upper piston ring, coated with molyb-
steel and the bearing surfaces and sealing faces are in- denum, has a trapezoidal cross-section.
ductively hardened. The bearing points can be re- The middle piston ring is shown as a 'minute ring' (the
ground four times without having to be rehardened. The surface of the outer diameter is conical).
gear wheels are force-fitted at the front end of the The oil scraper ring is sprung and has two chrome-plat-
crankshaft. These serve to drive the camshaft, the high- ed scraping edges.
pressure pump and the oil pump. The front end of the The pistons are ring carrier pistons (the piston has a
crankshaft is also fitted with keyways to hold the drive special cast iron ring carrier cast into it to seat the top
hub. The pulley and rotary vibration absorber (viscous) piston ring). The friction surface of the piston skirt also
are mounted on the hub. The front PTO shaft (if fitted) has a graphite coating to ensure optimal running-in.
is also driven via this hub. An oil repellent ring is insert- The piston base is cooled from below by extra splash
ed between the hub and the gear. The crankshaft car- oil as soon as the oil pressure exceeds 3 bar.
ries the sensor wheel for the engine speed sensor on a
crankweb.
There is a main bearing for the crankshaft on both sides
of each cylinder. Is it therefore supported in seven main
bearings. The crankshaft axial bearings are located on
both sides of the rearmost crankshaft bearing. The fly-
wheel is mounted at the rear end of the crankshaft and
carries a force-fitted crown gear.
The forged con-rods have an I-shaped cross-section.
The con-rod bearing is divided horizontally by 'breaks'.
The bearing cover is held in place by two special
screws. The upper part is fitted with a wedge-shaped
bearing seat in which the piston pin bearing bush is
press-fitted.
The pistons are made of a eutectic aluminium alloy.
There is a combustion space in the piston base. The
shape of the optimised combustion space ensures an
optimal carburetion of air and fuel.

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Vibration absorber
NOTE: When transporting, storing, dismantling or as-
sembling, you must take care to avoid deforming the
3 casing. Any dents made in the casing could trap the
2 otherwise free-moving absorber mass and thus ham-
per the absorber's effectiveness. Damage which re-
sults in the absorber unit becoming non-airtight will
render the absorber ineffective, because the silicon oil
4 will escape. Absorbers with a dented casing must not
be fitted.
NOTE: If indicating marks have to be made on the ab-
sorber casing for certain adjustments, only use a mark-
er pen or an electric engraver. Never make marks
which cause impact on the casing.

1 SS05N324

1. Casing 3. Space for silicon oil


2. Absorber mass 4. Bearing bush

The absorber eliminates rotary vibrations from the


crankshaft, making the engine run more quietly. The
casing is screwed on to the front end of the crankshaft
with the hub. It forms a ring-shaped cavity with a rectan-
gular cross-section. In this cavity is a ring-shaped ab-
sorber mass radially mounted on a bearing bush with
low mounting clearance. The empty space is filled with
viscous, temperature-stable silicon oil. The casing is
hermetically sealed. The absorber requires no mainte-
nance.

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SS03G080

Timing gears
1. Camshaft gear 4. Double intermediate gear
2. Intermediate gear 5. Crankshaft drive gear
3. High-pressure fuel pump drive gear

Timing gears
The gears of the engine control unit are hardened and bevel-toothed when engaged. The gears are located in the
timing gear housing, which is fitted on the front face of the engine.
The timing gears drive the camshaft, high-pressure fuel pump and the oil pump. The high-pressure fuel pump is driven
by the double intermediate gear (4). Like the camshaft, the intermediate gear (2) operates in pressure-lubricated plain
bearings. The bearing journal is attached to the front face of the cylinder block. The double intermediate gear is
mounted with two inclined ball bearings.

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Lubrication system
7 1. Lubricating oil pump
2. Oil pressure valve
3. Oil filter
1 4. Turbocharger
5. Main oil duct
6. Oil spray nozzles
7. Oil pressure sensor
SS05N286

Lubrication system
The engine features a lubrication system for which the sure so that a constant value is maintained regardless of
oil pump (gear pump) is fitted on the lower face of the engine speed. Depending on speed, oil type and tem-
cylinder block. Oil is drawn in by the pump through a perature, the oil pressure will be between 2.5 - 5bar.
suction filter. From the pump, the oil is conveyed through When the engine is at idling speed, the oil pressure must
an oil line to the oil cooler (heat exchanger) and to the oil be at least 1.0 bar.
filter. The oil pressure valve is fitted in parallel to this. The oil filter is a one-way main stream filter. An overflow
The oil is then conveyed into the main oil duct, from valve located on the underside of the filter ensures lubri-
which other oil bores branch off. The oil is conveyed cation of the engine after a cold start at extremely low
through these bores to the main bearings and through outside temperatures and also ensures appropriate lu-
the crankshaft to the connecting rods. brication should the filter become blocked. A non-return
From the main oil duct, the compressed oil is then chan- valve prevents the filter being completely drained of oil
nelled to the turbocharger and the air compressor (if fit- when the engine is switched off.
ted). The bearing of the intermediate gear, the camshaft
bearings and the valve mechanism are also lubricated
with compressed oil.
The piston bases are sprayed and cooled with oil from
below for as long as the lubricating oil pressure is above
3 bar.
The oil pressure valve regulates the lubrication oil pres-

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4 1

Cooling system
1. Coolant pump 5. Expansion tank
2. Thermostats 6. Oil cooler
3. Bypass duct 7. Engine temperature sensor
4. Cooler 05N373

Cooling system
The coolant pump, which is driven by the belt, is fit-
ted at the front end of the cylinder block. The ther-
mostat casing is located above the pump. The
cooling system features two thermostats which reg-
ulate the flow of coolant. The thermostats have dif- C
ferent opening temperatures. If the coolant
temperature is below the opening temperature, the
coolant (A) will circulate back to the coolant pump
via the bypass duct. The smaller, single-action ther-
mostat (1) starts opening at 79°C and allows a quan-
tity of the coolant (B) to flow into the cooler. When B
the temperature inside the engine rises and reaches 1
83°C, the two-circuit thermostat (2) also starts to
open. This closes when the bypass is opened and
conducts the entire flow of coolant (C) into the cool- 2
er.
A

SS05N287

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Fan

VISCO FAN REVERSIBLE FAN

SS03G024 SS05N282

Viscous fan with modulating hub (standard equipment)


For the modulating hub, each incoming air temperature corresponds to a particular slip.
When no cooling or a low level of cooling is required, the fan runs at low speed (= high slip), but the speed is depend-
ent on the engine speed. The flow of air through the cooler pack (air conditioning condenser - charge-air cooler - trans-
mission oil cooler - engine coolant cooler) acts on the front face of the Visco hub. Here there is a bimetallic spring that
continuously measures the discharge air temperature downstream of the coolant cooler. As the discharge tempera-
ture rises (causing an increasing load on the tractor), the control valve reduces the slip and the fan rotates faster ac-
cording to the temperature until the minimum slip of approx. 5% is reached. As the discharge temperature falls
(decreasing load on the tractor), the control valve increases the slip and the fan run more slowly according to the tem-
perature.
The advantages of the Visco fan with modulating hub are: Cooling rating adjusted more accurately to load on tractor,
fan rating required further reduced and reduced noise level.
The Visco fan requires no maintenance.

Reverse fan (optional equipment)


The blades of the reverse fan are arranged on the hub such that they can be twisted. Installed thermo-elements vary
the angle of the blades while the fan is operating and adjust the cooling rating of the fan to suit the cooling require-
ment. Recoil springs hold the blades securely in position.
Touching the 'Reverse fan' button activates the following automated process:
The Electronic Central Control Unit (ECCU2) controls a small air compressor operated by an electric motor and a
solenoid valve. This control unit is fitted on the left of the engine. Compressed air travels via a pressure line and a
special seal to the actuator cylinders, which rotate with the hub and the blades and turn the blades. This causes a
strong current of air to blow in the opposite direction through the coolers and any material which has been sucked in,
such as grass, flowers, insects etc. is removed from the coolers. After 30 seconds the fan blades automatically move
back to their starting position. The driver can also program the fan to reverse automatically, e.g. in conjunction with
automated processes relating to the front or rear power lifts or the AUX additional remote control valves.

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SS05N357

Intake / exhaust system


Compared with aspirated engines, engines with turbo- Ejector
chargers are more sensitive to poorly serviced air filters If the tractor is being used in areas where there is a lot of
and leaks in the intake and exhaust system. dust, it can be fitted with an 'ejector system'. The ejector
You should therefore carry out the specified mainte- system features an injector with a hose connection,
nance and inspection tasks diligently and observe the where there is a constant suction effect while the engine
maintenance intervals. is running. The dust particles eliminated by the pre-filter
are continually drawn in through a hose connector and
Condition of air filter and intake system conveyed to the open air together with the exhaust gas-
To a large extent, the performance and lifetime of the en- es.
gine are dependent on the condition of the air filter and
intake system. Design of filter cartridges
A very dirty air filter or a buckled intake hose will reduce Dirt particles in the air are collected in the main cartridge,
the engine's performance and cause engine oil to be which can be cleaned when required. The safety car-
sucked in by the seal on the shaft bearing of the turbo- tridge inside prevents dirt particles from entering the en-
charger. gine in the event of a leak or if the main cartridge is
incorrectly installed. To service the filter cartridges, refer
NOTE: A leaky air filter (caused by a damaged filter to the operating instructions.
cartridge or damaged/missing seal) or leaks in the in-
take system between the air filter and turbocharger al- Filter service indication
lows larger foreign bodies to enter the turbocharger and A pressure difference switch is located in the filter hous-
from there the engine cylinder. ing. This switch turns on an indicator light on the ADIC
The filter system for the engine intake air consists of an when the air filter has reached a certain level of soiling.
upstream cyclonic filter (integrated in the air filter) and a The air intake system also contains the air lines between
dry air filter with a safety cartridge. In the upstream cy- the air filter and the turbocharger, between the turbo-
clonic filter, the intake air is induced to rotate. This caus- charger and the charge-air cooler and between the
es heavy dirt particles to be separated out before being charge-air cooler and the intake manifold.
removed by the dust discharge valve of the upstream cy- The exhaust manifold is attached to the cylinder head by
clonic filter. special screws without a separate seal. There is no need
to retighten these special screws.
The turbocharger is lubricated and cooled by oil from the
engine lubrication system.

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Charge-air cooling
The intake air compressed by the turbocharger can The charge-air cooler is designed for straightforward
reach temperatures of up to 150°C during high utilisa- servicing. It can be folded upwards for effective clean-
tion. It is cooled to 50 - 60°C in a charge-air cooler (air/ ing against the direction of incoming outside air. By
air design) located upstream of the engine cooler. folding up the charge-air cooler, the other coolers are
Cooling of the charge air reduces the thermal and me- easier to access.
chanical stress on the engine and reduces emissions
of nitrogen oxides and soot particles.
Charge-air and charge-air temperature as pa-
rameters for engine control
There is a combined sensor in the air accumulator. It
continually sends information on charge-air pressure
and temperature to the Electronic Engine Management
unit (EEM3). In conjunction with the common rail fuel
injection system, fuel injection is optimised and the dis-
charge of nitrogen oxides and soot particles is signifi-
cantly reduced.

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ELECTRONIC ENGINE CONTROL - EEM3

6 11

12
14

10
7
5

15

8 3

16
13

1
2
SS05N290

1. EEM3 engine control unit (A3) 9. Coolant temperature sensor (B22)


2. Oil pressure sensor (B37) 10. Fuel delivery pump (M13)
3. Engine speed sensor (B20) 11. Power relay (K8/2)
4. Camshaft position sensor (B40) 12. Heating flange (E10/1)
5. Rail pressure sensor (B38) 13. ID module (A7)
6. Charge-air pressure / temperature sensor (B29) 14. Injector, 1st cylinder (Y21)
7. Fuel temperature sensor (B36) 15. Solenoid valve, high-pressure pump (Y20)
8. Fuel delivery pressure sensor (B39) 16. 'Water in fuel' sensor (B23)

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Layout

A7 ID MODULE

CAN H CAN L
Sensor B29
Charge-air pressure A3 Y21 - Injector 1
Charge-air
temperature Y22 - Injector 2

Sensor B40 Y23 - Injector 3


Camshaft position
Y24 - Injector 4
Sensor B39
Fuel delivery pressure Y25 - Injector 5

Y26 - Injector 6
Sensor B36
Fuel temperature
Heating flange E10/1
EEM3 (Jumper lead starting)
Sensor B38
Rail pressure
M13 Fuel
Sensor B23 delivery pump
'Water in
fuel' Solenoid valve Y20
High-pressure pump
Sensor B37
Oil pressure Switch S22
Coolant level
Sensor B22
Coolant temperature Sensor B2/1
Fuel level
Sensor B20
Engine speed
A1
ADIC

Limp home

Warning
Sensor B28 Fuel level
Manual accelerator too low
CAN H

CAN L

ICU Warning
Water in fuel
(optional feature)

ARU
Warning
Coolant level

Indicator
Oil pressure
Potentiometer R8 A4
Accelerator pedal FMGR
Indicator
Cold start aid

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Function
The basic function of the EEM3 engine management system is to continually record and control the engine speed
and fuel injection volume. These two parameters are used to continually calculate the load on the engine.
The central unit of the engine management system receives continuous information (as electronic signals) from var-
ious sensors on physical parameters such as engine speed, coolant temperature, intake air and fuel, charge-air pres-
sure, fuel delivery pressure and engine lubricating oil pressure. The central unit of the engine management system
receives continuous information on the power and speed requirements of the FMGR via the CAN bus (depending on
the position of certain controls in the driver's cab).
The central unit of the engine management system receives the engine identification from the ID module. The EEM3
has an important diagnostic capacity. Errors in the EEM3 system are displayed using codes.

Signals
The EEM3 also receives data in different ways about various parameters which are important to the management of
the engine.

Analogue signals (voltage) Digital signal (Frequency)


· Coolant temperature (from sensor B22) · Engine speed (from sensor B20)
· Charge-air temperature (from sensor B29) Digital signal (coding)
· Charge-air pressure (from sensor B29) · Crankshaft position (from sensor B20)
· Rail pressure (from sensor B38) · Camshaft position (from sensor B40)
· Water in fuel (from sensor B23)
Digital signal (CAN messages)
· Nominal engine speed for limp home
(from accelerator pedal sensor R8) · Drive commands (from FMGR)

· Fuel delivery pressure (from sensor B39)


· Fuel temperature (from sensor B36)
· Engine oil pressure (from sensor B37)

Control parameters (which affect fuel injection volumes)


· Torque map
· Coolant temperature
· Charge-air pressure
· Certain errors (e.g. ID module not recognised, error code 453).

Idling speed
The idling speed and final idling speed are electronically regulated and cannot be changed. There is no need to re-
adjust.
Engine protection when limit values are exceeded
If any limit values are exceeded, the engine control system will be activated as a protective measure. The engine pow-
er and/or speed are reduced and if necessary fuel injection is stopped, shutting off the engine.

Fault detection
If an error occurs, an error warning message appears on the ADIC and the corresponding EEM3 error code is shown
on the A-column display.
The error can be pinpointed using the EST (Service Tool) and then remedied. (See Error codes Page 32)
NOTE: Function, removing and fitting the high-pressure pump, checking the delivery pressure: see Chap-
ter 3001A - Mode of operation: Fuel injection system.

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EEM3 in conjunction with the service tool


The following functions are performed with the aid of the service tool:
• Functional test on high-pressure pump
• Functional test on injectors
• Software download
• Software update
• Adjusting engine speed (idling speed and rated speed)
• Correcting current engine operating hours count (only one addition possible)
• Calibrating accelerator pedal sensor
• Calibrating hand throttle
• Analysing errors
• Localising errors
• Show how often a particular error was active
• Read and delete running and shutdown memory (error code)
• Read motor identification and operation memory from ID module

Error codes
Fuel / speed
Error codes

reduction

Error description

Engine sensors
110 FL1 Coolant temperature sensor, signal voltage too low
111 FL1 Coolant temperature sensor, signal voltage too high
112 FLm Coolant temperature too high
113 FLm Coolant temperature alarm
109 FL1 Coolant temperature sensor, no signal
251 FL1 Fuel temperature sensor signal voltage too low
252 FL1 Fuel temperature sensor signal voltage too high
253 FL1 Fuel temperature too high
261 FL1 Fuel temperature sensor, no signal
114 FL1 Charge air temperature sensor, signal voltage too low
115 FL1 Charge air temperature sensor, signal voltage too high
116 FL1 Charge air temperature, value too high
117 FL1 Charge air temperature sensor, no signal
96 FL1 Oil pressure sensor, signal voltage too low
97 FL1 Oil pressure sensor, signal voltage too high
92 FL1/SL1 Oil pressure too high
98 Oil pressure too low
99 Oil pressure too low, alarm
95 FL1 Oil pressure sensor is faulty
93 FL1 Oil pressure sensor, no signal
100 FL1 Boost pressure sensor, signal voltage too low
101 FL1 Boost pressure sensor signal voltage too high
102 FL1/SL1 Charge presure too low
276 Pressure drop in intake system too high during engine start-up
103 FL1/SL1 Boost pressure too high
104 FL1 Boost pressure, no signal
263 FL2/SL2 Rail pressure sensor - signal voltage too low
264 FL2/SL2 Rail pressure sensor - signal voltage too high
265 FL2/SL2 Rail pressure too high

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266 FL2/SL2 Rail pressure, no signal


94 FC Overspeed
269 FL1/SL1 Engine speed, signals faulty
271 FL1/SL1 Engine speed sensor signal faulty
272 FL1/SL1 Faulty engine speed sensor signal
273 FL1/SL1 Engine speed sensor connections reversed
281 FL1/SL1 Faulty camshaft position sensor signal
282 FL1/SL1 Faulty camshaft position sensor signal
283 FL1/SL1 Camshaft position sensor connections reversed
284 FL1/SL1 Camshaft position sensor signal not plausible
121 FL1/SL1 Water in fuel
291 FL1 Fuel delivery pressure sensor, signal voltage too low
292 FL1 Fuel delivery pressure sensor, signal voltage too high
293 FL1 Fuel delivery pressure sensor, no signal
EEM3 diagnosis
22 Temperature sensor in the engine controller, signal voltage too high
20 FL1 Temperature in engine controller too high
21 Temperature sensor in the engine controller, signal voltage too low
23 Temperature sensor in the engine controller, no signal
471 Air pressure sensor in engine controller, signal voltage too low
472 Air pressure sensor in the engine controller, signal voltage too high
473 Air pressure too high
474 Air pressure sensor in the engine controller, no signal
211 FL1 Supply voltage 1 too low
212 FL1 Supply voltage 1 too high
215 FL1 Supply voltage 3 too low
216 FL1 Supply voltage 3 too high
141 A CAN Bus OFF (vehicle bus)
143 CAN bus OFF (ID modules - EEM3)
10 FL2/SL2 EEPROM error
221 FL2/SL2 Engine electronics self-test, internal error 1
222 FL2/SL2 Engine electronics self-test, internal error 2
223 FL2/SL2 Engine electronics self-test, internal error 3
231 Engine controller does not switch off
233 Engine controller switch-off did not function the last time
235 Final stage 1, short-circuit to ground
237 Final stage 3, short-circuit to ground
241 Final stage 1, short-circuit to battery +
245 Engine controller switches off briefly while operating and then functions again
246 Engine controller switches off briefly 3 times while operating and then functions again
248 Water in fuel sensor - supply voltage too low
249 Water in fuel sensor - supply voltage too high
172 Upgrade protective error
EEM3 function monitoring
17 Battery voltage is much too low
18 Battery voltage is much too high
19 Battery voltage, no signal
371 Battery voltage is too low
372 Battery voltage is too high
80 IDLE Accelerator pedal potentiometer, signal voltage too low
81 IDLE Accelerator pedal potentiometer, signal voltage too high
146 A Speed setting through FMGR too low
147 A Speed setting through FMGR too high
381 FL2/SL2 Rail pressure too low
382 Rail pressure too high
383 FL2/SL2 Rail pressure is lower than expected

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384 FL2/SL2 Rail pressure is higher than expected


385 FL2/SL2 Rail pressure, leakage at no-load speed
386 FL2/SL2 Rail pressure, leakage
387 FL2/SL2 Rail pressure signal, leaks during overspeed
391 FL2/SL2 Pressure relief valve open
392 FL2/SL2 Pressure relief valve is stuck
441 Fuel delivery pressure, value fluctuates
442 Fuel delivery pressure sensor, drop-out
445 Fuel delivery pressure, too high
446 FL1/SL1 Fuel delivery pressure, too low
421 High-pressure pump solenoid valve, short-circuit to ground
422 High-pressure pump solenoid valve, short-circuit to +supply
423 High-pressure pump solenoid valve open circuit
424 High-pressure pump solenoid valve, driving circuit overtemperature
Injector function monitoring
311 FL2/SL2 Injector 1 - solenoid valve short circuit to ground
312 FL2/SL2 Injector 1 - solenoid valve short-circuit on +supply
313 FL2/SL2 Injector 1 - solenoid valve open circuit
314 FL2/SL2 Injector 1 - solenoid valve is open too long
315 FL2/SL2 Injector 1 - solenoid valve error
321 FL2/SL2 Injector 2 - solenoid valve short circuit to ground
322 FL2/SL2 Injector 2 - solenoid valve short circuit on +supply
323 FL2/SL2 Injector 2 - solenoid valve open circuit
324 FL2/SL2 Injector 2 - solenoid valve is open too long
325 FL2/SL2 Injector 2 - solenoid valve error
331 FL2/SL2 Injector 3 - solenoid valve short circuit to ground
332 FL2/SL2 Injector 3 - solenoid valve short-circuit on +supply
333 FL2/SL2 Injector 3 - solenoid valve open circuit
334 FL2/SL2 Injector 3 - solenoid valve is open too long
335 FL2/SL2 Injector 3 - solenoid valve error
341 FL2/SL2 Injector 4 - solenoid valve short-circuit to ground
342 FL2/SL2 Injector 4 - solenoid valve short-circuit on +supply
343 FL2/SL2 Injector 4 - solenoid valve open circuit
344 FL2/SL2 Injector 4 - solenoid valve is open too long
345 FL2/SL2 Injector 4 - solenoid valve error
351 FL2/SL2 Injector 5 - solenoid valve short-circuit to ground
352 FL2/SL2 Injector 5 - solenoid valve short-circuit at +supply
353 FL2/SL2 Injector 5 - solenoid valve open circuit
354 FL2/SL2 Injector 5 - solenoid valve is open too long
355 FL2/SL2 Injector 5 - solenoid valve error
361 FL2/SL2 Injector 6 - solenoid valve short-circuit to ground
362 FL2/SL2 Injector 6 - solenoid valve short-circuit on +supply
363 FL2/SL2 Injector 6 - solenoid valve open circuit
364 FL2/SL2 Injector 6 - solenoid valve is open too long
365 FL2/SL2 Injector 6 - solenoid valve error
ID module
451 FLf/SLf Incorrect engine specification
452 FLf/SLf Incorrect serial number
453 FLf/SLf ID module, no communication
454 FLf/SLf ID module, not compatible
455 FLf/SLf ID module, memory 1 faulty
456 ID module, supply voltage too high
457 ID module, supply voltage too low
458 ID module, temperature too high
459 ID module, memory 2 faulty
461 ID module, internal error 1

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2002A-35

462 ID module, start error


463 FLf/SLf Missing engine specification
464 FLf/SLf Missing serial number
465 Missing ID module, by pass function activated
466 Missing ID module, by pass function deactivated
467 Missing ID module, by pass function time expired

Abbreviations:
FL1 ..................................................................... Fuel injection limit 1 (75% of volume at nominal output)
FL2 ..................................................................... Fuel injection limit 2 (50% of volume at nominal output)
FLm .................................................................... Fuel injection limit through parameters in ignition map
FLf ...................................................................... Fuel injection limit fixed at 50 mg
FC ...................................................................... Fuel injection set to zero
SL1 ..................................................................... Speed limit 1 (max. 1800 rpm)
SL2, SLf ............................................................. Speed limit 2 (max. 1500 rpm)
SLp ..................................................................... Speed limit through parameters in ignition map
A ......................................................................... Analogue speed query is active
SDd .................................................................... Delayed engine shut-off
SDi ..................................................................... Immediate engine shut-off
SNA .................................................................... Starting is not possible

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Replacing the EEM3 box


NOTE: The allocation specification and engine serial number are always given on the type plate of the EEM3 box.
Both of these numbers must be quoted when ordering an EEM3 box.
The EEM3 box is located on the left-hand side of the engine. It is mounted on a bracket fitted with a vibration absorber.
1. Turn the ignition switch to the OFF position. Turn the
main battery switch (if present) to the OFF position.
2. Remove the outer plastic cover. Disconnect the plug
connection. Remove the inner plastic cover.
IMPORTANT: You must not touch the contacts on the open
plug connection.
3. Remove the box from the bracket. Check the condition
of the rubber absorbers on the bracket. Replace the rub-
ber absorbers if necessary. The tightening torque of the
retaining bolts is 30 Nm.

4. Put the new EEM3 box in position.


Tightening torque ............................................. 10 Nm
NOTE: Tighten the retaining bolts in the sequence given
(see diagram).
5. Fit the inner plastic cover. Connect the plug connection. SS05N363

Fit the outer plastic cover.


6. Link up the Service Tool and the current software and transfer the memory data file in the ID module to the new
EEM3 box.

SS05N362

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2002A-37

WORK INSTRUCTIONS
1. Cylinder block
A. Measuring wear on cylinder liners B. Removing the cylinder liners
1. Set the dial gauge to zero using a micrometer 1. If the cylinder liners are to be re-used, they must be
screw or a new cylinder liner, (initial dimension marked so they can be re-fitted in the same posi-
108.00 mm). tions.
2. Thoroughly clean the inner surface of the cylinder 2. Remove the cylinder liners using the 380000011
liner before the measurement. and 1TSW 510 extraction tools.

1TSW 510

380000011
SS99N037

C. Checking the cylinder block


1. Clean the cylinder block and all oil lines.
2. Check the coolant ducts and remove any scale and
SS05N289 deposits of dirt from the engine to make sure the
engine cooling system functions correctly.
3. Measure cross-wise at the top end, bottom end and 3. Check that the shell plugs and thread plugs in the
in the middle of the cylinder liner. cylinder block are secure and examine the cylinder
4. Check the indicated value for maximum wear and block and sealing faces to make sure they are in
ovality (compare with nominal values). serviceable condition.
4. Measure the wear on the camshaft bearings (com-
paring it with the nominal values).
NOTE: If the upper face of the cylinder block needs to
be machined, the pistons must be shortened by the
same amount. Pay attention to the valve disk clear-
ance at the top surface of the piston.

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D. Replacing the camshaft bearing bush
1. Pull out the bearing bush with an inner extraction tool.
Once the rear end connection of the camshaft is re-
moved, push out the bearing bush with a long mandrel.
2. Clean the bush seat.
3. Press in a new bearing bush. Pay attention to the posi-
0.1 - 0.4 mm tion of the oil bore. The bearing bush does not need to
be worn down because if it is correctly fitted it will have
the correct inner diameter.
SS05N361

NOTE: All camshaft bearing points have a separate bearing bush. Observe the various outer diameters when re-
moving and adjusting bearing bushes.

SS05N292

The numbering starts at the front end of the engine.


Bore diameter Bore diameter
1. 55.62 - 55.65 4. 55.42 - 55.45
2. 55.42 - 55.45 5. 55.64 - 55.67
3. 55.22 - 55.25

E. Oversize bearing bushes for the camshaft


If the seat of the camshaft bearing bush (front bearing) is damaged, a bearing bush with an oversize outer diameter
of 0.4 mm can be adjusted. The machining dimensions for the seats of the bearing bushes are shown in the illustra-
tion.
CAUTION: Pay attention to the position of the bearing bush oil bores. (see step A-A)
After adjusting, the bearing bushes do not need to be worn down.

SS05N293

Camshaft oversize bearing bushes


Bore diameter Bore diameter
1. 56.02 - 56.05 4. 55.62 - 55.65
2. 55.62 - 55.65 5. 55.84 - 55.87
3. 55.42 - 55.45

The numbering starts at the front end of the engine.

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2002A-39
F. Adjusting the plug on rear end H. Adjusting the cylinder liner
of camshaft 1. Clean the cylinder liner and the liner recess in the
cylinder block. Once fitted the liner must be able to
rotate freely without the O-ring.
2. Apply a thin coat of marker paint to the underside
of the cylinder liner flange. Fit the cylinder liner
without the O-rings and rotate backwards and for-
wards. Remove the cylinder liner and check that
the paint has been transferred to the whole of the
contact surface.
3. Clean the contact surfaces.

0.03 - 0.08 mm

SS05N295

1. Clean the plug seating.


2. Apply sealant (e.g. Loctite 572) to the contact sur-
face of the plug.
3. Drive in the plug with pressing tool
380000004.
NOTE: Do not drive the plug in too far, because this
could affect the axial play of the camshaft.

G. Adjusting the plug on the rear end of SS99N048

the camshaft after fitting an oversize bear-


ing bush 4. Fit the cylinder liners and attach each liner with two
clamping devices. Measure the height of the cylin-
der liners using a dial test indicator and holder
O - ring 380000364. Set the dial gauge to zero on a flat sur-
face, e.g. the cylinder block. Measure each cylinder
liner at four points. The projection of the cylinder
liner above the surface of the cylinder block should
be between 0.03 - 0.08 mm.
The height difference between the cylinder liners
below a cylinder head must not exceed 0.02 mm.
In addition, a middle cylinder liner must not be low-
er than one of the outer ones.

Plug
SS00F003

Upon completion, the rear camshaft end plug is re-


placed by the plug and the O-ring.

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2002A-40
5. If the height of one cylinder liner is too low, one liner
must be fitted with a higher flange.

BLACK

GREEN

SS05N294
SS99N050

7. Fit the O-rings in the grooves on the lower part of


Height Marker the cylinder and lubricate with liquid soap (not with
(H) grooves engine oil).
(number) NOTE: When tightening on to the cylinder liners,
9.03 +0.02
(standard) stretch the O-rings as little as possible.
The maximum permissible elongation is 6%.
9.08+0.02 1

9.13+0.02 2

9.23+0.02 3
The oversize of the cylinder liner (higher flange) is indi-
cated on the outer circumference by one or more mark-
er grooves as follows:

1st oversize, 0.05 mm = 1 marker groove

2nd oversize, 0.10 mm = 2 marker grooves

3rd oversize, 0.20 mm = 3 marker grooves


6. If the height of a cylinder liner is not even across the
whole breadth, you must check the cylinder liner
flange and the depth of the recess in the cylinder
block. Replace any cylinder liners with misshapen
flanges. If necessary, machine the bush seat in the
cylinder block with a reamer.

SS05N291

8. Press the cylinder liners into the cylinder block. You


should be able to press them in to their starting po-
sition without difficulty. Ensure that the cylinder lin-
ers no longer move upwards after being fitted.

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2. Flywheel casing
A. Fitting the flywheel casing
The flywheel casing is centred on the cylinder block us-
ing two dowel pins. The casings for the flywheel, which Spacer ring
are available as spare parts, feature ready-made bores
for the dowel pins.
1. Clean the sealing faces between the cylinder block
and the flywheel casing.

SS05N297

NOTE: If the crankshaft shows signs of wear on the


seal seating, a 2 mm spacer ring (available as a spare
part) can be fitted between the flywheel casing and the
crankshaft sealing ring.
5. Carefully press in the sealing ring using installation
tool 380000003 and 1TSW 662 until it reaches the
base of the flywheel casing.

1TSW 662
SS05N296

2. Apply the sealant (e.g. silicone) to the areas shown


in the illustration.
3. Lift the flywheel casing into the correct position and
fit all screws.
4. Centre the casing and adjust the dowel pins with a
mandrel.
5. Tighten the screws on the inner ring to a tightening 380000003
SS99N056
torque of 80 Nm and the screws on the outer ring
to a tightening torque of 150 Nm.
NOTE: The sealing ring must be fitted dry and free of
oil.
B. Replacing the rear crankshaft sealing
ring
1. Separate the tractor between the engine and power
unit.
2. Remove the flywheel.
3. Remove the sealing ring, making sure you do not
damage the crankshaft.
4. Clean the seal seat and grind down any burrs.

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3. Cylinder head
A. Removing the cylinder head B. Removing the valves
1. Clean the engine on the outside. Ensure that valves which are to be reused are marked
appropriately so that they can be replaced in their orig-
inal position.

SS99N057

Drain plug
1. Screw a nut on to a stud bolt for the rocker arm
mechanism. There is no stud bolt for the valves on
the central cylinder. Instead, use a bolt of the ap-
SS05N360
propriate length.
2. Press together the valve springs with lever
Drain off the coolant at the engine drain plug and the 380000008. Remove the valve spring seat retain-
drain cock on the lower side of the cooler. Disconnect ers, the spring guide and the spring. Remove the
the coolant hoses from the cylinder head and the ther- valves.
mostat housing.
2. Remove the intake lines between the exhaust tur- C. Checking the cylinder head
bocharger and the air filter and the charge-air lines 1. Remove carbon deposits from the outlet ducts,
from the turbocharger and the intake manifold. clean the seal surfaces and wash the cylinder
3. Remove the oil lines from the exhaust turbocharg- head.
er. 2. Check the cylinder head for cracks and any other
4. Unscrew the screw connections on the electrical damage.
wires from the injectors.
5. Remove the high-pressure lines and oil leakage
lines. Remove the injectors. Fit seal caps on all
open connections.
6. Remove the intake and exhaust manifolds and the
thermostat housing.
7. Remove the valve cover and the vent hose.
8. Remove the rocker arm mechanism and the push
rods.
9. First loosen all the cylinder head screws by a quar-
ter-turn and then unscrew them. Remove the cylin-
der head.

SS05N299

3. Check the evenness of the cylinder head using a


straight edge. An uneven or bent surface must un-
dergo surface grinding. After grinding, the height of
the cylinder head must not be less than 104.00
mm. The depth of the valve disk below the cylinder
head surface must be 0.60 mm for outlet valves
and 0.70 mm for inlet valves.

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D. Replacing the valve guides

SS99N061

SS05N300
1. Press or force out the old guides using a mandrel.
Clean the valve guide seats.
4. If necessary, clean the bearing surface of the injec-
2. Fit the new guides using pressing tool 380000007,
tor in the cylinder head using a reamer.
which is used to ensure the right installation height
(21 mm above the plane face of the spring).

380000007

SS05N304

SS05N301
3. The same guides are used for both inlet and outlet
valves. Ensure that the steepest chamfer on the
5. Measure the amount of play between the valve
guide points towards the valve spring. Ensure that
stem and the valve guide with a dial gauge. Lift the
the valves do not jam in the guides.
valve so that the valve disk juts out of the surface
of the cylinder head by 15 mm and measure the
clearance. For the inlet valves, this must not ex-
ceed 0.30 mm and for the outlet valves, must not
exceed 0.35 mm. To determine whether the valve
guide is worn, a new valve must be used for the
measurement.

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2002A-44
E. Machining the valve seat Inlet valve

SS05N306

3. Clean the valve seat. Cool the new valve seat ring
in dry ice or liquid nitrogen.
4. Fit the valve seat ring with a suitable pressing tool.
Machine the seat.
NOTE: If required, the valve seat rings can be re-
SS05N302
placed by oversize valve seat rings. If this is the case,
A damaged valve seat must be machined using a mill- the cylinder head will need to be reworked. (see Tech-
ing cutter. If the width of the seat exceeds 2.3 mm at the nical Data Page 12)
outlet valve or
3.7 mm at the inlet valve, it must be reduced, particu- G. Grinding the valves
larly at the outer edge. To ensure there is an adequate seal around the valves,
The angle of the valve seat is 45° +20' at the outlet there is a difference between the angles of the sealing
valve and 35°+20'at the inlet valve. faces. There is an especially narrow sealing face that
guarantees an effective seal even after extended peri-
ods of use.
F. Replacing the valve seat rings
The outlet valves have separate valve seat rings. If the
sealing face is so heavily soiled that it cannot be re-
paired by machining, the valve seat rings must be re-
placed.
1. Grind the valve disk on a discarded valve so that it
fits snugly in the valve seat. Fit the valve and weld
correctly on to its seat. Cool with water.
2. Rotate the cylinder head and knock out the valve
together with the seat.

Outlet valve

SS05N307

A B C [mm]
INLET 35° -20'
35° 0.7 ±0.05
+20'
(max. 2.20)
OUTLET 45° -20'
45° 0.6 ±0.05
+20'
(max. 2.20)
1. Machine the damaged valve disk with a valve
SS05N305 grinder. Adjust the angle for the outlet valves to 45°-
20'
and for the inlet valves to 35°-20'.
2. If the height of the edge of the valve disk is less
than 1.5 mm after grinding, or if the valve stem is
bent, the valve will need to be replaced.
3. Grind the valves using a grinding paste and exam-
ine the contact surface using marker paint.

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2002A-45
4. Clean the grinding paste off the cylinder head and 5. Tighten the screws in phases as follows:
valves.
1. Pre-tension of 80 Nm
H. Fitting the valves 2. Tighten by 90°
1. Use a spring tester to check that the valve springs 3. Tighten by 90°
show the correct straightness, length and tension. 4. Adjust valve clearance (see Page 47).
Compare the measured values with the technical 5. Sub-assemble the engine and fill up the coolant
data. and
2. Oil the valve stems and fit the valves in the cylin- engine oil.
ders in the correct sequence.
NOTE: The cylinder head screws do not need to be
3. Fit the valve springs, spring disks and valve spring
retightened after this procedure has been carried out.
seat retainers in the cylinder head using lever
380000008.
4. After inserting the valves, tap the ends of the valve
stems, e.g. with a plastic hammer, to make sure the
valve spring seat retainers are sitting correctly.

I. Fitting the cylinder head


1. Measure the length of the cylinder head screws.
The length should lie within the limit values shown
in the diagram. Replace any screws which vary
from these limit values.

SS05N310

Tighten the retaining bolts / nuts on the exhaust mani-


fold to a tightening torque of 50 Nm.
IMPORTANT: Do not over-tighten the nuts.

SS05N308

2. Screw the cylinder head stud bolts into the cylinder


head with a tightening torque of 30 Nm. Fit any
valve tappets which were removed.
3. Ensure that the sealing faces are clean and fit the
cylinder head seal. Use a ruler to check that the cyl-
inder heads are parallel to each other. Clean, oil
and fit the screws.

SS05N309

4. The illustration shows the order in which the screws


should be tightened. The correct sequence is also
cast on the cylinder heads.

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2002A-46
4. Valve mechanism
A. Maintenance of the rocker arm system
1. Examine the valve tappets, particularly the guide
face on the camshaft. Replace any worn or twisted
valve tappets.

SS05N313

5. Attach a flange fastening to one end of the rocker


arm shaft. Apply oil to the shaft and assemble the
parts in the correct sequence. Pay attention to the
SS05N311 correct position of the bearing holders and the
shaft. The divided side of the holder and the oil
2. Examine the push rod to make sure it is straight. Al- bores in the shaft must point towards the valve face
so check the condition of the spherical surfaces on as shown in the illustration. Attach the other flange
the end of the push rod. fastening.
3. Dismantle the rocker arm mechanism and clean
the individual parts. Check the level of wear on the
rocker arm shaft and the condition of the oil lines.

SS05N312

4. Check the diameter of the bore in the rocker arm


SS05N314
(23.000 - 23.021) and replace if necessary. If the
pressure face of the rocker arm is worn, grind it to
the correct shape. Do not grind down more than B. Replacing the camshaft / the camshaft
necessary, because the pressure surface is sur- gear
face-hardened. 1. Remove the intake pipe between the turbocharger
and the intake manifold. Remove the cover of the
valve mechanism and the venting pipe. Remove
the rocker arm mechanism.
2. Remove the cooler unit, the fan, the generator and
the belt.
3. Remove the pulley and the vibration absorber.
4. Undo the crankshaft nut and remove the hub.
5. Remove the cover from the timing gear case.

SS99N072

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2002A-47
C. Checking and adjusting valve
clearance

SS05N315

SS05N314
6. Lock the valve tappets so that they do not come off
when the camshaft is removed and do not hinder The clearance of the inlet and outlet valves is 0.35
installation of the camshaft. Raise the valve tappet mm. You can carry out this check when the engine is
push rods by bending two at a time slightly to- hot or cold. Check and adjust the the valve clearance
wards each other, working with pairs positioned of one cylinder while the piston is positioned at the up-
alongside each other. Clamp the push rods to- per dead point of the compression stroke. Proceed fol-
gether (e.g. with an O-ring), working with pairs po- lowing the engine's fuel injection sequence.
sitioned alongside each other, so that they are
If the valve clearance deviates from the specified val-
slightly tensioned, keeping the tappets in the up-
ue, loosen the lock nut and adjust the valve clearance
per position.
using the adjustment screw. The 0.35 mm thickness
CAUTION: Applying too much tension to the push gauge must fit snugly between the rocker arm and
rods will cause them to distort. the end of the valve stem.
7. Rotate the crankshaft until the position markers on
the camshaft gear and intermediate gear are
aligned with each other. Pull out the camshaft.
8. Remove the camshaft gear wheel from the cam-
shaft.
9. If you will be refitting the used camshaft or cam- E A E A E A E A E A
E A
shaft gear later, clean the parts before assembling
them.
10. Slide the feather key into the appropriate groove
on the camshaft and fit the camshaft gear wheel. I = INLET
Tighten the nut to 200 Nm. O = OUTLET SS05N317
11. Lubricate the bearing faces and slide the shaft into
the cylinder block, noting the position marks on - Turn the crankshaft in running direction until the
the camshaft gear. valves of the 6th cylinder overlap. (Outlet valve is
12. Fit the cover of the timing gear case and the pulley closed, inlet valve is opened). Check the valves on the
with the hub. (see Page 49) first cylinder.
13. Lower the push rods and fit the rocker arm mech- - Rotate the crankshaft by 1/3 of a turn in running di-
anism. Adjust the valves. Then screw the valve rection until the valves of the 2nd cylinder overlap.
cover and venting hose on to the cylinder head. Check the valves on the 5th cylinder.
Also fit the intake pipe that goes between the tur- - Continue working, following the fuel injection se-
bocharger and intake manifold. quence:
14. Fit the generator and the belt. Tension the belt to
the correct level of tension. Fit the cooler unit.
Fuel injection sequence: 153624

Valve overlap: 624153

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2002A-48
5. Crankshaft
A. Removing the crankshaft If a bearing housing which exhibits wear is not
1. Unscrew the oil sump. round, take the measurements at several different
2. Remove the retaining bolts of the lubricating oil points.
pump pressure line from the cylinder block. Re- 4. If the bearing play exceeds 0.18 mm on the main
move the oil sump, suction lines and pressure bearings or 0.14 mm on the con-rod bearings with
lines. new bearing shells, the bearing journals on the
3. Remove the flywheel casing. crankshaft must be ground.
4. Remove the pulley, vibration absorber and hub Refer to the Technical Data for the correct under-
from the front end of the crankshaft (see Page 54). size and corresponding bearings. Ensure that the
5. Remove the con-rod bearing covers and push the radii do not change when ground.
con-rods up so they are not in the way when re- NOTE: If the ground bores of the crankshaft bear-
moving the crankshaft. ing are damaged or worn as a result of damage
6. Remove the crankshaft bearing covers and lift the to a bearing, main bearings with an oversize of
crankshaft out. 1.0 mm (external) and an undersize of 0.5 mm
(internal) are also supplied as spares. The cylin-
g. Checking the crankshaft der block must now be machined down to a di-
mension of 92.000 - 92.025 mm. The crankshaft
must be machined down to a dimension of 84.485
- 84.520 mm. The bearing shell with a groove
and an oil bore is fitted in the cylinder block, and
the bearing shell without an oil bore is fitted in
the bearing cap.

C. Replacing the crankshaft gears

380000329

SS05N318

1. Clean the crankshaft. Don't forget to clean the oil


bores as well.
2. Measure the amount of wear at different points on
the crankshaft bearing journal. Ovality, conicity or
other forms of wear must not exceed 0.03 mm.

SS05N320

1. Use the extractor tool for the crankshaft gears and


remove both gears.
2. Clean the seat on the crankshaft, e.g. using a wire
brush.
3. Heat up the new gears to 200°C. Knock the gear
wheels on to the shaft using a suitable sleeve or
soft mandrel. Pay attention to the position of the
feather key and ensure that the orientation marks
on the front gear wheel are clearly visible. Allow the
parts to cool down.

SS05N319

3. Refit the bearing caps with new bearing shells and


tighten to the correct tightening torque. Measure
the internal diameter using a dial gauge which has
been zeroed using the values obtained in step 2.
The display will then show the actual bearing play.
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2002A-49
D. Fitting the crankshaft 4. Insert the main bearing covers by number. Behind
1. Clean the oil lines, bearing shells and seats. Make them fit axial bearings with guide lugs. Lubricate
sure the crankshaft is clean. the screws and tighten to a tightening torque of
200 Nm.

SS05N323

SS05N321 5. Ensure that the crankshaft can rotate unhindered


and without jamming. Check the axial play with a
2. Position one bearing shell (A) with an oil bore and dial gauge. The correct axial play is 0.10-0.38 mm.
oil groove into the cylinder block and one bearing If the axial play is too great, you must insert axial
shell (B) without an oil bore into the bearing cover. bearings with oversize.
Ensure that the lugs of the bearing shell engage
with the corresponding notches and that the shells NOTE: Never abrade or machine the bearing shells
to be fitted in the cylinder block have an oil bore that and never file the sides of the bearing covers.
matches the oil bore in the cylinder block.
3. Oil the bearing faces and fit the crankshaft. E. Crankshaft hub
NOTE: When fitting the crankshaft, make sure the
sensor wheel of the speed sensor is not damaged.
Insert the axial bearings of the crankshaft such that the
lubrication grooves point towards the crankshaft.

SS05N325

When mounting the hub at the front end of the crank-


shaft, pay attention to the correct position (injection
marker on vibration damper). The hub features markers
to help with fitting -- the two lines on the hub must be
SS05N322 positioned to the side of the points marked • on a tooth
of the crankshaft.

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2002A-50
6. Connecting rods and pistons
A. Removing the pistons together with the
connecting rods
1. Loosen the oil sump and the pressure and suction
lines for the lubricating oil.
2. Loosen the cylinder head.
3. Scrape off the carbon deposits in the cylinder liner.
If necessary, scrape away the sharp wearing edge
in the reverse point of the piston ring.
4. Remove the con-rod bearing cover and the con-rod
bearing shells. If the bearing shells are to be re-
used, you will need to number them in sequence.
5. Slide the piston and con-rod upwards using the
shaft of a hammer or a similar tool.
6. Remove the circlips from the piston rings. Slide out
the piston rings.
NOTE: If the piston pin cannot be moved by pressing SS05N327

it with a finger, the piston must be heated up evenly to


100°C. 4. Force-fit the new bush. The oil duct in the bush
must match the corresponding duct in the con-rod.
After adjusting, machine the new bush with the
B. Checking and replacing the connecting
reamer to the specified dimensions.
rod bearings
1. Clean the con-rod and bearing shells. Fit the bear- NOTE: If necessary, an oversize bush can be fitted in
ing shells and tighten the 'used' screws to a tighten- the connecting rod. In this case, the ground bore of the
ing torque of 40 Nm + 90°. connecting rod must be reworked (see Technical Da-
ta).
NOTE: The connecting rod bolts must only be used
once.
C. Checking the connecting rod
Clamp the con-rod in a suitable test apparatus and
check it. (For test values, refer to Technical Data
Page 15)
The con-rods are divided into weight groups of
20 g. The weight group is indicated by a letter. This is
marked on the side face of the con-rod. All the con-rods
in an engine must belong to the same weight group, i.e.
the permissible difference in weight is 20 g.

SS99N090

2. Measure the internal diameter with a plug gauge


that has been zeroed to the diameter of the rele-
vant bearing journal. If the clearance of the new
bearing shells is greater than 0.14 mm, the con-rod
bearing journals must be ground and the next un-
dersize (repair level) bearing shell fitted.
3. If the piston pin bush is worn, it must be driven out
using a suitable mandrel.
SS05N328

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2002A-51
The letters represent the following weights: 3. Position the piston ring in the cylinder and measure
Weight [g] the distance between the ends of the ring. For the
1st and 3rd rings the distance must not exceed 1
F 1935 - 1954 mm and for the 2nd ring it must not exceed 1.5
V 1955 - 1974 mm.
X 1975 - 1994 4. Re-insert the piston rings with the aid of the piston
ring pliers. Make sure that the rings are in the cor-
Y 1995 - 2014 rect position and the letters TOP on the rings or the
W 2015 - 2034 manufacturer's name point upwards.
Z 2035 - 2054
G 2055 - 2074

D. Checking and replacing the piston


rings
1. Loosen the piston rings using piston ring grippers.
Do not stretch the rings any more than is necessary
to loosen them. If the same rings are to be fitted
back in the pistons, set them aside in their correct
sequence.

SS05N331

SS05N329

2. Clean the piston ring groove carefully and then


measure the play of the piston ring in the groove.
The play must be less than 0.15 mm. Check wheth-
er the play was created by wear in the ring groove.
Then replace either the rings or the pistons as ap-
propriate.

SS05N330

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E. Checking the piston G. Fitting pistons and connecting rods
Visually examine the pistons and piston pins. In partic- 1. Insert the bearing shells into the con-rods. Make
ular, look out for any cracks on the edge of the combus- sure that the fitting surfaces are clean and the bear-
tion chamber or the upper part of the piston pin bore. ing shells are sitting correctly.
Measure the diameter of the piston at the point shown 2. Grease the piston, piston rings and cylinder with
in the diagram and compare the result with the given engine oil. Rotate the piston ring gap on different
value. If necessary, replace the piston. sides of the piston.

∅ 107.883 -
107.897
17 mm
SS05N332

F. Fitting the piston pin


1. Insert the con-rod into the piston and slide the pis-
ton pin into place.

SS05N334

3. When fitting, use a piston ring tension band or in-


sertion cone. Insert the piston and the con-rod such
that the combustion space of the piston and the in-
jector in the cylinder head are on the same side
(the arrow on the piston must point forwards).
4. Grease the con-rod journals and bearing shells
with oil and slide the pistons downwards. Fit the
bearing cover such that the guide lugs of the bear-
ing shells are on the same side. Then tighten the
screws to a tightening torque of 40 Nm+90°.
5. Check that the lower con-rod bearing has sufficient
axial play on the crank pin.

SS05N333

CAUTION: The combustion chamber in the piston and


the letter indicating the weight class of the con-rod can
be found on the side.
2. Then fit the circlips of the piston pin, making sure
that the ends of the circlips point upwards.

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7. Flywheel
A. Replacing the starter ring gear on the B. Fitting the flywheel
flywheel 1. Clean the contact surfaces on the rear crankshaft
The ring gear cannot be reworked because the teeth on flange and the flywheel.
the starter side are bevelled and hardened. 2. Bolt the flywheel on to the crankshaft. Two M12
1. Release the old ring gear by tapping with a man- grub screws, which fit into the securing holes in the
drel. Clean the ring gear seat on the flywheel with flywheel, should be used as guide pins.
a steel wire brush. 3. Tighten the screws on the flywheel evenly to a tight-
ening torque of 150 Nm.

SS05N335

2. Heat up the new ring gear to 150 - 200°C. Fit the


ring gear, making sure the bevelled inner edge fac-
ing the flywheel and the bevelled teeth point to-
wards the starter.
IMPORTANT: Allow the ring gear to cool in the air.
Do not use coolant.

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2002A-54
8. Control mechanism
A. Removing the timing gear case B. Replacing the intermediate gear
The timing gear case acts as a seal to the sump. bearing bush
NOTE: The timing gear case can only be removed If the intermediate gear bearing bush is to be replaced,
once the oil sump has been removed. force-fit a new bearing bush
such that 0.1 - 0.25 mm of its rear edge is inside the
1. Drain off the engine oil and remove the sump. rear
2. Remove the fan, generator, pulley and belt. If the edge of the gear wheel (see illustration).
tractor has air conditioning or a compressed air
system, the compressor must also be removed.
Key for Visco fan ....................................... 380001791 1
Key for reverse fan .................................... 380002598 2
IMPORTANT: Do not disconnect coolant lines!
Just pivot the compressor backwards with the
lines connected and suspend to relieve strain on
the lines.
3. Remove the pulley and vibration absorber.
4. Remove the crankshaft nut using key 380002658.
5. Remove the retaining bolt on the double intermedi-
ate gear bearing.
6. Take the cover off the timing gear case and remove
the oil repellent ring from the crankshaft.
7. Remove the high-pressure fuel pump (see Chapter
3001A).
8. Remove the double intermediate gear.
9. Unscrew the intermediate gear bolts. Remove the 1. Lathe chuck
flange, gear wheel and bearing journal. 2. Roller ø=5 mm SS05N336
10. Pull out the camshaft.
NOTE: If the cylinder head and valve mechanism are After fitting, machine the inner diameter of the interme-
not dismantled, the valve tappets must be prevented diate gear bearing bush to the correct dimension. Cen-
from falling off (see Page 46). tre the intermediate gear as shown in the diagram
above such that the tooth play stays uniform.
11. Unscrew the bolts on the timing gear case and re-
move the case. If a soft wedge needs to be driven
between the engine block and the wheel arch,
make sure you do not damage the sealing faces in
the process!
12. Loosen the front crankshaft sealing ring from the
wheel arch and clean all dismantled parts.

SS05N337

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C. Fitting the timing gear case
The position of the timing gear case and cover is deter-
mined by two sprung dowel pins. For this reason, cen-
tring should not be done as part of the fitting process.
However, the play between the different gear teeth
must be checked. The timing gear case and cover sup-
plied as spare parts also feature holes already ma-
chined for the dowel pins.
1. Use a 2-dimensional sealing compound to seal the
timing gear case and fit on cylinder block. Drive in
the dowel pins with a mandrel. Tighten the screws
and nuts.
2. Oil the camshaft bearing and insert the shaft in the
cylinder block. If the push rods and valve tappets SS05N338
are still attached, remove them.
5. Check the tooth play.
It must be 0.05 - 0.25 mm.

SS05N339

6. Attach the oil repellent ring to the crankshaft and fit


the wheel arch cover using a new seal. Drive in the
SS05N365 dowel pins using a mandrel (connect the pipe pin
around the stud bolt). Tighten the bolts and nuts to
3. Fit the intermediate gear with the shaft stud bolt the correct tightening torque.
and ensure that the markers are correctly aligned.
Insert the washer and tighten the bolts to the cor-
rect tightening torque.

SS05N364
SS99N114

4. Pre-fit the angled ball bearings in the double inter- 7. Insert the protective ring correctly into the seal seat
mediate gear. Fit the intermediate gear in the timing (see sectional drawing) and use special tool
gear case using the retaining bolt. 380000002 to insert the front crankshaft sealing
NOTE: Use new O-rings! ring fully home.

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SS05N340 SS05N325

8. Oil the sealing faces on the sealing ring and crank- 10. Slide the hub on to the crankshaft profile.
shaft and the profile for holding the hub. 11. Apply a thin coat of oil to the thread of the crank-
9. Line up the marker on the hub with the marker on shaft nut. Fit the nuts and tighten with key
the crankshaft (see diagram). 380002658.
Tightening torque .......................................... 1000 Nm
12. Fit the vibration damper and the V-belt pulley on the
hub. Tighten the bolts to the correct tightening
torque.
13. Refit the other dismantled parts.

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9. Lubrication system
A. Checking the oil pressure valve 5. Clamp the pump on the pump gear wheel into a
Check the function of the oil pressure valve if the en- vice with protective jaws and release the nuts on
gine's oil pressure is insufficient or if it fluctuates notice- the drive gear. Drive out the pump driveshaft from
ably. First make sure, however, that there is enough oil the gear wheel using a plastic hammer. Pull the
in the engine. driveshaft gear wheel out of the pump body.
6. Wash the parts and check the level of wear. Com-
pare the actual measurements with the given di-
mensions in the Page 17'Lubricating oil pump'
section. Replace any worn parts and all the seals.

25 Nm

Loctite 638
SS05N341

1. Remove the cover from the oil pressure valve and


the spring underneath it. Pull the valve cone out of 60 Nm
the cylinder block. +Loctite 243
2. Clean the parts. Check that the valve cone can
move easily in the valve insert. If the valve cone
sticks, remove any dirt which has accumulated. If
necessary, rub down the parts using fine sanding
wool or else use new parts. Clean the sealing sur- SS05N342

faces between the cylinder block and the cover.


3. Apply Loctite 638 to the outer circumference of the 7. The bearing points on the oil pump are fitted with
cylindrical part of the valve insert. Drive the valve separate bearing bushes. If the bearing bushes are
insert into the engine block using a suitable tool. In- replaced, machine them after installation to a di-
sert the valve cone into the valve insert. Fit the mension of 18.000 - 18.018 mm.
spring and the cover, using a new seal for the cov-
er. C. Assembling and fitting the oil pump
1. Fit the gear wheels in the recess located in the
NOTE: The spring must be fitted with the largest di-
pump body. Position a new seal (if required) be-
ameter facing the cover.
tween the pump body and the cover. Tighten the re-
taining bolts slightly. Rotate the shaft and tap the
B. Removing and checking the oil pump cover laterally into the position in which the shaft
1. Drain off the engine oil and remove the sump. rotates most easily. Firmly tighten the retaining
2. Release the intake and pressure line from the oil bolts on the cover and check that the shaft can still
pump. turn slightly.
3. Remove the oil pump and any regulating washers 2. Fit the drive gear on to the pump shaft. Apply Loc-
between the pump housing and the cylinder block. tite 243 screw locking fluid into the nut thread. Fit
4. Release the pump cover and seal. Remove the the washer and nut. Tighten the nuts to a tightening
gear wheel on the axle. torque of 60 Nm.

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2002A-58
D. Assembly of the oil sump
Fit the seal for the sump using silicone strips facing the
cylinder block.

SS05N343

3. Clamp the pump on the mounting bracket into a


vice with protective jaws. Use the dial gauge to
SS05N345
check the axial play of the gear wheel (0.03 - 0.11
mm). If necessary, change the number of seals be-
tween the cover and the pump body. E. Oil cooler
All engine types are fitted with an engine oil cooler that
is housed between the engine oil filter and the cylinder
block.
1. Before removing the oil cooler, drain off the coolant.

SS05N344

4. Fix the pump in place below the cylinder block and


use the dial gauge to check the tooth play between
the gears of the crankshaft and the pump. (0.05 -
0.25mm). If necessary, change the number of com- SS05N346
pensation washers between the pump base and
the cylinder block (the compensation washers are 2. Fit new seals. Fit the oil cooler such that the drain
graded in steps of 0.2mm). Inserting / removing a nozzle points downwards. Attach the coolant hoses
compensation washer alters the tooth play by correctly.
around 0.07 mm. 3. Put some screw locking fluid (e.g. Loctite 243) on
NOTE: When measuring the tooth play, the engine the thread on the engine end of the retaining tube
must be in operating position (cylinder pointing up- and tighten it to a tightening torque of 60 Nm.
wards) because the tooth play is affected by the bear-
ing play of the crankshaft.
5. Attach the intake and pressure line of the pump and
replace the seals on the retaining flange.
6. Fit the oil sump and fill with engine oil.

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F. Piston cooling nozzles G. Recommended lubricants
The piston cooling nozzles can be removed after taking
out the oil sump. The nozzle is equipped with a ball - For engines with a turbocharger
valve. This has an opening pressure of 3±0.25 bar. API CI-4

ACEA E7

SS05N347

1. If necessary, replace the valve. Remove the valve


from the engine and remove the nozzle pipe. Fit the
new valve.

SS05N349

SS05N347

2. When assembling the valve, attach the nozzle pipe


to at an angle of 90 ° to the longitudinal axis of the
engine as shown in the illustration. Fix the valve in
place with a tightening torque of 30 Nm. After as-
sembling, check that the nozzle pipe does not
touch either the piston or the con-rod when the en-
gine is running.

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10. Cooling system
A. Thermostat
The opening temperature of the smaller, single-action
thermostat is 79 ° C.
The opening temperature of the larger, double-action
thermostat is 83 ° C.
If you have any doubts as to whether the thermostat is
functioning correctly, inspect it as follows:
· Place the thermostat in boiling water, making sure
it does not touch the sides of the container.
· The thermostat must start opening within 20 sec-
onds.
· It must be fully open within 50 seconds. Compare
the measurements obtained with the specifica- SS99N140

tions in the Technical Data.


4. Pull out the impeller with the aid of extraction tool
1TSW 662.
5. Remove the circlip from the pump body. Press the
shaft out of the pump body together with the bear-
ing, for example using a hydraulic press, pressing
towards the fan. Clamp the pump body such that
the shaft bearing can be taken out.
6. Use a mandrel to remove the axial and shaft seals
from the pump body. Clean the parts and check
their condition. Replace any worn or defective parts
with new ones.
NOTE: If the pump bearings need to be replaced, it is
more cost-effective to fit the pump repair kit, which al-
so includes all the seals needed for repairs (see spare
parts catalogue).

SS05N350

B. Repairs to coolant pump


1. Drain the coolant. Unfasten the thermostat casing,
fan and belt.
2. Remove the coolant pump. Remove the rear plate
of the pump and clean the sealing faces.
3. Release the retaining nuts of the pulley and remove
the pulley. Use an extraction tool if required.

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380000005

SS05N353

10. Attach the rear plate using a new seal. To fit the
SS05N351 rear plate for the bores shown in the diagram, use
guide lugs with a diameter of 8.5 mm.
7. Use mandrel 380000005 to tap the shaft seal into
the pump body. Fit the bearings and the intermedi- C. Coolant quality requirements
ate sleeves on the shaft. Lubricate the bearings · The coolant must fulfil quality standard
with plenty of heat-resistant ball bearing grease. ASTM D 3306 or BS 6580:1992.
Mount the shaft and bearing in position such that
the force created when they are pressed does not · If no frost resistance requirements are specified, a
affect the bearing balls. Fit the bearing circlip in its mixture ratio of 40% is sufficient to protect against
place. corrosion.
· Check the coolant (anti-freeze) mixture ratio at
certain intervals. Replace the coolant every two
years.
· The water used must be clean and soft, i.e. it must
contain no metals or their salts.
IMPORTANT: Never use water on its own as a
coolant.

SS05N352

8. Fit the impeller, supporting the other end of the


coolant pump shaft. The clearance between the
pump housing and impeller is 0.8 - 1.2 mm. Check
that the coolant pump shaft can rotate freely.
9. Attach the pulley to the shaft and tighten the retain-
ing nuts to a tightening torque of 120 Nm.

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2002A-62
11. Air intake and exhaust system
An engine fitted with a turbocharger is much more sen- 5. If necessary, remove the manifold. Clean the seal-
sitive to malfunctions and contamination in the intake ing faces and remove any carbon deposits. Ensure
and exhaust system than a conventional aspirated en- that the sealing faces are even. If the retaining
gine. You should therefore be particularly careful when flanges are twisted or there are scratches on the
working with the intake and exhaust system. sealing faces, machine the flanges or replace the
exhaust manifold.
A. Checking the air filter 6. Ensure that no loose objects or dirt particles have
Engine performance and service life are highly depend- made their way into the exhaust pipe or silencer.
ent on the condition of the air filter. A defective air filter Any such loose objects or particles may increase
allows in dirt particles that cause lasting damage to the the counter-pressure for exhaust gases from the
turbocharger and the engine. A blocked air filter im- turbine wheel.
pedes the engine's performance and may also allow oil
to escape through the sealing ring on the shaft of the
exhaust turbocharger.
CAUTION: The safety filter located inside the main fil-
ter does not require cleaning, but must be replaced
when necessary (see operating instructions).

B. Checking the air intake system and ex-


haust system
IMPORTANT: Any leaks which develop in the in-
take or exhaust system seriously affect the effec-
tiveness of the turbocharger. Because of the
pressure levels present, even small leaks in the
manifold or turbine inlet flange become bigger
very quickly. You must therefore repair any leaks
as soon as you discover them.
1. Examine the pipes and sealing faces between the
air filter and the exhaust turbocharger, the exhaust
turbocharger and the charge-air cooler, and the
charge-air cooler and the intake manifold. If the in-
side of the intake manifold is dusty, there is a leak
either in the air filter or in the intake pipes. Repair
the leak.
NOTE: You should check the condition of the flexible
connection on the charge-air lines to and from the
charge-air cooler (swivel point) for leaks at different
swivel angles.
2. Clean the sealing face of the intake manifold. Use
a straight edge to make sure the sealing surface is
level. If the sealing face is uneven or scratched, ei-
ther machine the intake manifold or replace it. En-
sure that the cylinder heads lie parallel to one
another.
3. Fit a new seal and secure the intake manifold.
Tighten the retaining bolts on the intake manifold to
a tightening torque of 30 Nm. Secure the air pipes.
4. Make sure the exhaust manifold does not leak.
Tighten the screws / nuts to a tightening torque of
50 Nm and check for damage (cracks, deformation,
corrosion etc.). Also check the connection between
the turbocharger and the exhaust manifold.

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D. Checking the turbocharger
If you believe there is a malfunction in the turbocharger,
you can identity it as follows:
1. Carry out as visual inspection of the turbine and
compressor wheels. The blades should exhibit no
damage, deformation or wear caused by foreign
particles.
2. Check whether any oil is escaping through the
sealing rings on the shaft in the turbine and com-
pressor casing.
CAUTION: At low idling speed, some oil will always
escape on the compressor side. This should not give
rise to undue concern unless a great deal of oil is be-
ing lost.

SS05N355

4. Check the axial play of the shaft. Hold the sensor of


the dial gauge at the end of the shaft and move the
shaft in an axial direction. Refer to the play speci-
fied in the Technical Data.
If you discover a defect or worn-out part, the turbo-
charger will need to be overhauled.
If the engine's performance and response are not sat-
isfactory even though there are no apparent faults with
the turbocharger, the reason may lie in the following
faults:
· Air filter too heavily soiled
· Leak in intake and/or exhaust system, leaky
flange seals
· Fuel delivery pressure too low
SS05N354
· Unsuitable fuel type (e.g. summer diesel instead
3. Check the running play of the turbine shaft. Hold of winter diesel when the weather is cold)
the probe of a dial gauge against the shaft and · Injector(s) defective or incorrectly adjusted
move the shaft sideways. Refer to the play speci- · High-pressure pump malfunction
fied in the Technical Data.
· EEM3 engine control unit malfunction
· ID modules malfunction
· Compression pressure of one or all cylinders too
low (wear on piston rings, cylinder bushes, pis-
tons, leaking valves, valve stroke too narrow be-
cause of worn cam on camshaft)

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SS99N146

E. Assembly of the turbocharger


Pinpoint the cause of the malfunction in the turbocharg- 4. If using a new seal, fit the waste pipe for the turbo-
er. If the cause is outside the turbocharger, remedy the charger lubricant to the turbocharger. Avoid creating
problem before fitting a new or repaired turbocharger. To torsion on the fitted pipe, or remedy it if it does oc-
make sure the turbocharger operates satisfactorily, you cur.
must use the engine oil specified by the manufacturer. 5. Add approx. 0.1 litres of pure engine oil to the bear-
The air filter and engine oil filter must be serviced or re- ing casing of the turbocharger through the connec-
placed regularly (see operating manual). The fuel injec- tion opening of the pump-fed lubrication system.
tion system must be in perfect working order if the This is the only way to ensure that the turbocharger
turbocharger is to function well. The fuel injection sys- is sufficiently lubricated the first time the engine is
tem must be correctly calibrated (see Service Tool). started.
1. Check the attachment of the intake and exhaust 6. If using a new seal, connect the line for the pump-
manifold. Check that screws and nuts are tightened fed lubricant to the turbocharger. Avoid creating tor-
to the specified tightening torque. Ensure that there sion on the fitted pipe, or remedy it if it does occur.
are no rust particles or other loose foreign bodies in 7. Start the engine. Check the lubrication, intake and
the intake or exhaust manifold. Remove any loose exhaust systems for leaks.
soot from the exhaust manifold.
2. If using a new flange seal, mount the turbocharger
on the exhaust manifold.
3. Connect up the intake line, line to the charge-air
cooler and the exhaust pipe. Avoid creating torsion
on the fitted pipe, or remedy it if it does occur.

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3001
Section
3001

FUNCTIONAL DESCRIPTION INJECTION SYSTEM

CNH Österreich GmbH Sva 6-51300 EN © 2003 CNH Österreich GmbH


Technische Dokumentation April, 2003
A – 4300 St. Valentin, Steyrer Straße 32
3001-3

TABEL OF CONTENS

SPECIAL TOOLS .................................................................................................................................................. 5


GENERAL INFORMATION ................................................................................................................................... 7
SAFETY REGULATIONS ..................................................................................................................................... 7
TECHNICAL DATA ............................................................................................................................................... 8
Injection pump ............................................................................................................................................. 8
Type of pump ( related to engine type) ....................................................................................................... 8
Sequence of injection .................................................................................................................................. 8
Fuel supply .................................................................................................................................................. 8
Fuel filters ................................................................................................................................................... 8
Injectors and Nozzles .................................................................................................................................. 8
Tightening torques ...................................................................................................................................... 8
FUEL SYSTEM ..................................................................................................................................................... 9
Function .................................................................................................................................................... 10
Safety measures ....................................................................................................................................... 10
Electronically controlled fuel injection system ................................................................................................ 11
Solenoid-Valve-Controlled Axial-Piston Distributor Pump ............................................................................ 12
General ..................................................................................................................................................... 13
Parameters affecting the injection timing .................................................................................................. 13
Parameters affecting the maximum quantity of fuel injected .................................................................... 13
Emergency operation and emergency engine stop .................................................................................. 13
Signal „engine speed“ faulty: .................................................................................................................... 13
Idle speed ................................................................................................................................................. 13
Electronic control ...................................................................................................................................... 14
Injection Pump - Operating Principle ............................................................................................................. 15
Operating Principle ................................................................................................................................... 16
IAT Sensor - Commencement of Delivery and Pump Speed ......................................................................... 17
Bleeding the fuel system ................................................................................................................................ 18
General ..................................................................................................................................................... 18
Automatic bleeding during operation ........................................................................................................ 18
Bleeding after changing the fuel filter ........................................................................................................ 18
Bleeding after fuel has been used up ....................................................................................................... 18
Bleeding after a new or an overhauled injection pump has been fitted .................................................... 18
Fuel feed pressure ......................................................................................................................................... 19
Testing the fuel feed pressure .................................................................................................................. 19
Removal of the fuel injection pump ................................................................................................................ 20
Fitting the fuel injection pump ........................................................................................................................ 21
Static pump timing .................................................................................................................................... 21
Updating pump serial numbering in EEM ................................................................................................. 21
Final jobs ................................................................................................................................................... 21
Injectors and nozzles ..................................................................................................................................... 22
Removing the injectors ............................................................................................................................. 22
Checking the nozzles ................................................................................................................................ 22
Overhauling injectors ................................................................................................................................ 23
Fitting the injectors .................................................................................................................................... 23
Assembly of the injection lines .................................................................................................................. 23
Fuel quality requirements ............................................................................................................................... 24
Directives to run on biological fuel (RME)
(RME = Rape oil-Methyl-Ester Bio - Fuel) ................................................................................................ 24
Service intervals ........................................................................................................................................ 24

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3001-4

EMPTY PAGE

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3001-5

SPECIAL TOOLS

Timing pin Mini-measuring line

SS03D046 SS98J030

1 off 380001487 1 off 380001127 (1TSW 635)

Pressure gauge and connection Mini-measuring connection

SS00B076 SS98J031

1 off 380001129 (1TSW 645) Connection 1 off 380001486 (1TSW 641) M14x1,5
1 off 380001121 (1TSW 5002) Pressure gauge

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3001-6

EMPTY PAGE

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3001-7

GENERAL INFORMATION
This manual only contains general instructions for repairing and servicing the injection system. This applies to the
injection pump in particular, as specially trained personnel with special tools and measuring instruments are required
to repair it. All service and repair work on the injection system requires particular care and cleanliness.
Boost start and arc-welding
• Only 12V Batteries must be connected in parallel. As soon as the supply voltage will raise > 17V, the EEM
will interrupt the electrical supply to the PCU. The engine will not start (zero delivery).
• Prior to arc-welding turn the starter key to position "0". At the PCU, the connector must get unlocked and
disconnected. Do not touch the pins of either side.
IMPORTANT: In the case of fuel systems with Bosch VP 30 injection pump, it is important that the fuel system is
bled of air before starting the engine for the first time (see page 19 , bleeding the fuel system).
ATTENTION: Never wash the area of the injection pump with high pressure (electrical connection)

PCU = Pump Control Unit


EEM = Electronic Engine Management

SAFETY REGULATIONS
There is always a risk of getting injured working close to the engine.
when performing service and repair
•) Always switch the engine OFF before carrying out
work. Before commencing work,
repair work.
the following safety regulations
and instructions must be read. •) Naked flames and smoking are not permitted in the
vicinity of fuel tanks or batteries. Electric sparks
•) Never start repair work which you do not fully
should be avoided.
understand.
•) Disconnect the cable at the negative battery pole
•) Make sure that it is possible to work safely at the (–) before carrying out service or repair work on the
location and in the vicinity. electrical system.
•) Make sure the location is clean and in a good state.
•) When checking the injection nozzles, never touch
•) Never use wrong or unsuitable tools. the fuel, which is ejected under high pressure. The
jet will penetrate the skin and cause serious
•) Remove all rings, chains and watches before
poisoning. If contact is made with the skin, consult
commencing work.
a doctor without delay!
•) Use state of the art safety equipment. For example,
wear goggles when using compressed air for •) Fuel and lubrication oil can cause skin irritations if
cleaning. contact is made over a longer period.
•) Avoid running the engine in idle unnecessarily.
•) Only use original CNH spare parts.
•) When carrying out service work, take measures to
•) Only start the engine from the cab, using the
prevent fuel or other fluids from entering the ground
ignition key.
or drains.
•) Never start the engine with the protective covers
removed. •) Be careful when washing the engine using a
washing facility with a high water pressure. Do not
•) It is difficult to see the radiator fan when the engine wash, for example, the electrical and fuel systems
is running! Baggy clothes and long hair can get under high pressure as they can easily be
caught in rotating engine parts! damaged.
•) If the engine is started in a confined space, •) Never wash the area around the injection pump
sufficient ventilation must be provided. when the engine is running.
•) Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
•) Ear muffs must be worn when testing the engine or

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3001-8

TECHNICAL DATA
Injection pump
Manufacturer and series.......................................................................................................................Bosch VP 30
Design ..............................................................................Solenoid-valve-Controlled Axial Piston Distributor Pump
Pump control ..................................................................................electronically by PCU (in connection with EEM)
Control of fuel quantity ........................................................................................... solenoid valve (PCU controlled)
Injection timing (dynamic)...............................................................................electronic/hydraulic/mechanic control
Speed control ............................................................................................electronically by the EEM (via CAN bus)
Electrical supply to PCU (from EEM) ..................................................................................................12V (min. 7V)
Current draw of the PCU (constant) ............................................................................................................ max. 8A
Direction of rotation (to be seen from pump drive) .................................................................................... clockwise
Pump setting (static)...........................................................................................................................with timing pin

Type of pump ( related to engine type)


620.95 to 620.99 .......................................................................................................................VP30 0470 006 004

Sequence of injection
620.95 to 620.99 ...........................................................................................................................1 - 5 - 3 - 6 - 2 - 4

Fuel supply
Fuel feed by.............................................................................................................................. electrical feed pump
Position of fuel feed pump..................................................... in the head of the sedimenter/primary filter assembly
Electrical supply (Fuse F29, 7,5A, +15/2) .......................................................................................................... 12V
Current draw................................................................................................................................................ max. 6A
Feed pressure - at low idle speed (past the fuel filter) ........................................................................ 1,0 to 1,3 bar
Feed pressure - at rated power (past the fuel filter) ............................................................................ 1,0 to 1,1 bar
Control of feed pressure (past the fuel filter) ................................................... pressure control switch and warning
Feed pressure warning activated when pressure......................................................................... < 0,05 bis 0,2 bar

Fuel filters
Sedimenter/primary filter (with water drain plug)................................................................................................ 30µ
Fuel filter (with water drain plug) .......................................................................................................................... 5µ
Indicator „water in fuel“ (standard) ................................................................................ sedimenter on primary filter
Indicator „water in fuel“ (option)............................................................ sensor in sedimenter and warning on ADIC

Injectors and Nozzles


With the engines 620.95 to 620.99, producer, type and opening pressure of the nozzles is equal.
Producer, type ...............................................................................................................Stanadyne M - Typ M35927
Number of spray holes ............................................................................................................................................5
Opening pressure.............................................................................................................................270 bis 280 bar
Pressure setting ...............................................................................................................................270 bis 280 bar
System of pressure adjustment....................................................................................................................... shims
Graduation of the adjusting shims...............................................................................................................0.05 mm
Change in opening pressure per graduation ............................................................................................... 5.00 bar
Range of adjusting shims (refer to spare parts catalogue)..............................................................1.00 to 1.90 mm
Periode for nozzle check or re-adjustment..............................................................................................2000 hours

Tightening torques
Pump retaining nuts (M8) ............................................................................................................................... 30 Nm
Pump drive gear retaining screws .................................................................................................................. 40 Nm
Banjo bolt with overflow orifice (pump-fuel return line)................................................................................... 27 Nm
Injection pipe union nut .................................................................................................................................. 25 Nm
Bracket for retaining the injector (retaining nut) ............................................................................................. 15 Nm
Injector nozzle sleeve..................................................................................................................................... 60 Nm

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3001-9

FUEL SYSTEM

19
18

17
7

17
13 3
14

15
5

12 9
10 8

4
6

11
16

17

SS03D002

SS03D002

1. Fuel tank 11. Injection pump


2. Fuel gauge 12. Pump Control Unit (PCU)
3. Gravity valve (tank vent) 13. Delivery line
4. Suction line 14. Injector (with nozzle)
5. Sedimenter/primary filter assembly 15. Overflow valve (fitted into filter housing)
6. Sensor "water in fuel" 16. Overflow valve (screw-mounted)
7. Electrical feed pump 17. Overflow line
8. Fuel filter (with water drain) 18. EEM (Electronic Engine Management)
9. Feed pressure - control switch 19. ADIC (Analog Digital Instrument Cluster)
10. Feed line

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3001-10

Function
The electrical fuel feed pump (7) draws fuel from the tank (1) through the sedimenter/primary filter assembly (5) and
passes fuel through the fuel filter (8) to the injection pump (11).
NOTE: The electrical fuel feed pump starts operating at the moment the starter key is turned to position "1". If the
engine is not started within one minute, the EEM will cut out the feed pump. As soon as the engine will be started,
the EEM will cut in the feed pump.
The injection pump forces the fuel into the injector (14) that feeds the fuel into the combustion space via the nozzle
in a fine spray. An overflow line (17) leads from the fuel filter to the tank, passing-by the injectors (14) and the injection
pump (11). At the fuel filter (8), an overflow valve with a throttle (15), located in the filter housing, allows a constant
bleed of the filters. At the injectors, the leak-off will join the overflow line (17) and finally, the overflow valve (16) allows
a certain overflow for the purpose of pump bleeding and pump cooling. The injection pump is lubricated by the fuel
only. As an option, the prefilter (5) can carry a transparent sedimenter equipped with a sensor (6) that triggers an
alarm on the ADIC (19) if a certain amount of water has collected in the bowl.
The quantity of fuel to be injected is controlled by the PCU (12) and metered by the fuel-quantity solenoid valve inside
the injection pump (11). When the engine is in operation, a number of parameters are fed continuously to the EEM
(Electronic Engine Management) (18) from different sensors. Concerning the quantity of fuel to be injected and the
timing advance, the EEM (18) constantly gives the needed information to the PCU (12) via CAN Bus.

Safety measures
Fuel level in the tank below minimum
If the fuel level in the tank is going below a certain limit, an alarm will be activated on the ADIC (19).
Fuel feed pressure to low
If the fuel feed pressure will drop below 0,05 to 0,2 bar between fuel filter and injection pump, the control switch (9)
will trigger an alarm on the ADIC (19). Additionally, fault code EEM 122 will be stored and displayed. Possible causes
for low feed pressure see page 20, „testing the fuel feed pressure“.
NOTE: When the fault code 122 is active, the EEM does not apply any active restrictions on engine operation.

Reasons for fuel cut off (to stop running engine)


• Low engine oil pressure: fuel cut off after 30 seconds delay.
Fault code EEM 99 will be stored and displayed.
• Engine overheating : fuel cut off after 30 seconds delay.
Fault code EEM 113 will be stored and displayed.
• Engine overspeed (> 3000 rpm): fuel cut off immediately.
Engine operation returns to normal as soon as engine speed is < 2700 rpm.
Fault code EEM 94 will be stored and displayed.
• Upgrade protection:
Fault code EEM 172
• Power "on" - self test:
Fault code EEM 10
• Pump map defect:
Fault code EEM 33
• PCU - internal CAN bus defect:
Fault code EEM 34
• Wrong pump CAN interface configuration:
Fault code EEM 37
• Solenoid valve final defect:
Fault code EEM 40
• Injection control pulse width defect:
Fault code EEM 5
• Pump speed deviation:
Fault code EEM 55
• Pump supply voltage too high (>17,0V):
Fault code EEM 57
Reason for reduced quantity of fuel injected (reduction of engine power)
Injection pump - serial number mismatch
Fault code 175

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3001-11

Electronically controlled fuel injection system

Solenoid valve
IAT Sensor A2/2
Fuel quantity
Timing advance PCU
Commencement
Solenoid valve
of delivery
Timing device
Pump speed
(proportional)

CAN H

CAN L
DZG
Signal
Engine
emergency stop
Switch S6
A2
Engine oil pressure
DZG = Signal, crankshaft position
(top dead centre)
Sensor B29
Boost pressure
Sensor B29
Starting aid E10/1
Boost air-temperature
(Grid heater)

Sensor B22
Coolant temperature

EEM M13
Control switch B21 Fuel feed pump
Fuel feed pressure

Sensor B23
"Water
in fuel"
Sensor B2/1
Fuel level
Sensor B20
Engine speed and
crankshaft position

Limp home
A1
(engine speed)
ADIC

Sensor B28
Hand throttle
CAN H

CAN L

Warning
Fuel
level
too low
ARU
P8
Warning
DISPLAY Fuel feed
pressure
too low
Sensors R8 A4
Drive pedal FMGR Warning
Water
in fuel

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3001-12

Solenoid-Valve-Controlled Axial-Piston Distributor Pump

10

17

11

16

13

SS03D037
12
15 5 6 7 14 8 9

1. Drive shaft 10. PCU (Pump Control Unit)


2. Housing 11. IAT sensor
3. Vane pump 12. incremental wheel
4. Bearing ring 13. Fuel-quantity solenoid valve
5. Roller ring 14. Proportional solenoid valve (timing device)
6. Lift disc 15. Timing device
7. Axial piston 16. Connector
8. Delivery valve 17. Conductive foil
9. Delivery port

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3001-13

General
The injection system consist of a mechanical distributor pump with electro-hydraulic actuators. Further an electronic
Pump Control Unit (PCU) (10), which communicates with the Electronic Engine Management (EEM) via CAN Bus.
The fuel supply is done by an electrical feed pump. A warning is activated on the ADIC if the feed pressure drops
below 0,05 - 0,2 bar, or the feed pump ceases.
• The EEM gets supplied with 12V (Fuse F30, 5A, +15/2) and ground. The PCU gets supply (12V and ground)
by the EEM only.
• The PCU (10) controls the actuators responsible for commencement of delivery and quantity of fuel injected.
• High pressure and delivery is performed by a mechanical pump with a concentrically arranged piston (7).
The piston simultaneously moves axialy to deliver fuel with high pressure and rotates to distribute the fuel to
the delivery valves (8) and delivery ports (9) of the very cylinders.
• To control the timing advance dynamically, a hydraulically controlled piston in the timing device (15) positi-
ons the bearing ring (4) together with the roller ring (5). The required pressure is delivered by an internal
vane pump (3) and gets controlled by means of a proportional pressure control valve (14).
• Engine-related parameters get changed into electrical signals by sensors. The signals are fed to the EEM.
The electronic makes use of the value of the signals.
• The IAT sensor (11) (Incremental Advance Time System), which is fixed to the bearing ring (4) inside the
injection pump, delivers the "incremental angle/time" signal to the PCU (10) by means of the conductive foil
(17). The electronic is drawing three different informations out of this signal. Details see page 14 (Electronic
control).

Parameters affecting the injection timing


• Engine speed
• Engine load
• Engine coolant temperature

Parameters affecting the maximum quantity of fuel injected


• Torque map
• Engine coolant temperatue
• Boost pressure
• Certain fault conditions (e.g. fault code 175, injection pump - serial number mismatch)

Emergency operation and emergency engine stop


CAN failure between EEM and PCU:
The additional signal line „emergency engine stop“ will be activated by the EEM. Immediately, the PCU will cease to
energise the fuel-quantity solenoid valve. As a result, fuel injection will be interrupted and the engine will stop. In cer-
tain cases, the EEM will even interrupt the electrical supply to the PCU. Again, there is no fuel injection and the engine
will stop.

Signal „engine speed“ faulty:


Via CAN bus communication, the EEM permanently receives information of the current speed of the injection pump
from the PCU. Thus, the electronic will calculate the engine speed. For the moment, there is no reason to stop the
engine. Fault code EEM 66 will be stored and displayed.

Idle speed
The low idle speed as well as the high idle speed are controlled electronically and cannot be altered.
There is no re-adjustment necessary.

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3001-14

Electronic control
• No mechanical connection (rod or cable) exists between the engine and the controls in the cabine. The para-
meters supplied by the electronic drive pedal or the electronic hand throttle are conducted as electrical
signals to control units like FMGR (Vehicle Control Unit) and ARU (Arm Rest Unit). There, these signals get
converted into CAN messages, thus being transmitted to the EEM too.
• Messages related to engine and fuel injection are transmitted between EEM and PCU by CAN Bus.
• Taking in account the coming-in parameters and the momentary engine requirements, the EEM determines
CAN messages to control injection timing and the quantity of fuel to be injected.
• The PCU (10) controls the proportional solenoid valve (14) of the hydraulic-mechanically controlled timing
device (15) by means of PCC (Pulsed Current Control).
• In the injection pump, at the circumference of the rotating incremental wheel (12), there are six notches (18)
arranged by symetrical division (see page 17). At the moment a notch will pass the IAT sensor (11), the
signal generated will trigger the PCU (10) to energise the solenoid of the fuel-quantity solenoid valve (13).
Thus the valve needle will close a port leading to the barrel. Pressure will build up and fuel, displaced by the
piston(7), gets delivered to the injector (21) via delivery valve (8) and delivery port (9) to the injector.
• By CAN message, the PCU (10) gets informed for how many degrees of rotation of the incremental wheel
(12) and rotating pump drive shaft (1) the pump should deliver to the very injector (this will represent a cer-
tain distance of the effective lift of the pump piston (7). After completing the desired angle, the PCU (10) will
de-energise the fuel-quantity solenoid valve (13). The valve needle will open the port, as a result delivery
will be stopped. The angle run through between closing and opening the valve needle will determine the
quantity of fuel injected.
• The incremental wheel rotating with the crankshaft of the engine is provided with a notch too. The signal
generated at this point by the engine speed sensor serves as an electronic (virtual) reference marking (e.g.
Top Dead Center). In connection with the signal of the IAT sensor (11) in the injection pump, the electronic
will calculate the real timing advance. Additionally, the signal of the PCC (Pulsed Current Control) to control
the solenoid valve of the timing device will be altered if required.

Cam angle
Cam lift of delivery

Effective lift

Control pulse

Lift of valve
needle

IAT-Signal

SS03D036

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3001-15

Injection Pump - Operating Principle

27

28 26
10

23 25

2 17 22
11

3 12 6
24

5
1
13
20

18 7 8 9

15
21
14
SS03D035

1. Drive shaft 14. proportional solenoid valve (timing device)


2. Housing 15. Timing device
3. Vane pump 17. Conductive foil
4. Bearing ring 18. Notch (missing tooth)
5. Roller ring 20. Pressure valve (flow controlled)
6. Lift disc 21. Injector (with nozzle)
7. Axial piston 22. Overflow valve (screw-mounted)
8. Delivery valve 23. Overflow valve (located in fuel filter housing)
9. Delivery port 24. Tank
10. PCU (Pump Control Unit) 25. Sedimenter/Pre-filter
11. IAT sensor 26. Electrical fuel feed pump
12. Incremental wheel 27. Fuel filter
13. Fuel-quantity solenoid valve 28. Feed pressure-control switch

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3001-16

Operating Principle
Latest technology used with the injection pump VP30 results in a compact construction, fulfilling the emission stan-
dards, developing the whole potential of engine power, at the same time ensuring low fuel consumption.
An electrical feed pump (26) supplies fuel to the injection pump. An overflow valve (22) ensures permanent bleeding
and cooling of the injection pump.
High pressure delivery is produced mechanically by means of the cam lobes of the roller ring (5), the lift disc (6) in
connection with the axial piston (7). An integrated vane pump (3) creates a pressure, which, on the one hand ensures
proper feeding of the high pressure element and, on the other hand serves as a control pressure for the hydraulic/
mechanically controlled timing device (15). The injection pump as a whole is lubricated by the fuel only. In connection
with fitting the injection pump to the engine, static timing is part of the procedure (see page 22).
The electronic Pump Control Unit (PCU) (10) is attached to the upper side of the pump. The electrical supply to the
PCU comes from the Electronic Engine Management (EEM). With the exception of an extra line for „emergency en-
gine stop“, all signals and parameters are sent by a series of numeric values by means of CAN communication (Con-
troller Area Network) between the EEM and PCU.
The PCU (10) controls the proportional solenoid valve (14) by means of PCC (Pulsed Current Control). Valve (14)
vary a control pressure. This control pressure moves a piston in the timing device (15), positioning the bearing ring
(4) together with the roller ring (5) dynamically.
The IAT sensor (11), attached to the bearing ring (4) signals the real angle of timing advance as well as the pump
speed and triggers the commencement of delivery. Taking in account various parameters, the EEM determines the
timing advance, transmitting the message to the PCU (10) by CAN Bus. In case the signal of the engine speed sensor
is faulty, the EEM makes use of the pump speed signal to calculate the engine speed.
The fuel-quantity solenoid valve (13) is positioned concentrically around the distributor body. When the PCU (10) en-
ergises the valve, it‘s needle will close a port and delivery commences. As the valve get‘s de-energised, delivery cea-
ses. Within the periode the fuel-quantity solenoid valve (13) is energised the piston (7) moves a certain distance of
its total stroke. This again determines the quantity of fuel delivered to the injector (21). During one revolution of the
pump drive shaft (1), the fuel-quantity solenoid valve (13) runs through six cycles of closing and opening the needle.

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3001-17

IAT Sensor - Commencement of Delivery and Pump Speed


10
10

17

17 11
2 11 5

12
6
3

7
12
19

18 4
SS03D033

15
SS03D034

1. Drive shaft 10. PCU (Pump Control Unit)


2. Housing 11. IAT sensor
3. Vane pump 12. Incremental wheel
4. Bearing ring 15. Timing device
5. Roller ring 17. Conductive foil
6. Lift disc 18. Notch (missing tooth)
7. Axial piston 19. Guide

• The incremental wheel (12) rotates together with the pump drive shaft (1). The IAT sensor (11) moves toge-
ther with the bearing ring(4) and the roller ring (5).
• When in the timing device (15) the timing advance is altered by the proportional solenoid valve , the bearing
ring (4) together with the roller ring (5) and the IAT sensor (11) is moved in the direction „advance“ or „retard“
either.
• At the circumference of the incremental wheel (12), there are six notches (18) (one notch for each cylinder of
the engine), arranged by symetric division. The sequence of teeth and notches is scanned by the IAT sensor
(11).
• The signal is transmitted to the PCU (10) by means of a conductive foil (17). The signal is utilised as follows:
- to determine the present angle position
- to determine the present timing advance in connection with the engine speed signal
- to sense the speed of the pump drive shaft
• The present angle position determines the trigger point for energising the fuel-quantity solenoid valve (13)
by the PCU (10). This will ensure the correct timing for closing and opening of the valve needle (valve lift) in
accordance with the cam lift (see page 14).

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3001-18
Bleeding the fuel system Bleeding after a new or an overhauled
injection pump has been fitted
General • Ensure adequate fuel in the tank.
With this fuel system, bleeding screws are not requi- • Crack the union nuts of the six injection pipes at
red. Due to the configuration of this fuel system, the their connection to the injector open.
procedure of bleeding depends on the very situation.
• Turn starter key to position „1“ (electric fuel
feed pump will run).
Automatic bleeding during operation
This fuel system automatically removes air bubbles
• Keep fuel feed pump running for 30 to 45
seconds.
from the filters and injection pump when the engine is
running. Further, constant bleeding during operation NOTE: If the engine will not be started after one
provides also cooling of the pump. minute, the EEM will cut off the fuel feed pump. As
soon as the engine get‘s started, the fuel feed pump
NOTE: Due to the electric fuel feed pump, will start to operate automatically.
automatic bleeding starts already at the
moment the starter key is turned to position „1“. • Crank the engine for about 5 seconds, until fuel
(engine is not running). comes out from every loosened connection.
Retighten connections with 25 Nm. Clean off
the over flown fuel and start the engine.
Bleeding after changing the fuel filter
NOTE: If no fuel will reach the opened connections
• Ensure adequate fuel in the tank.
of the injection pipes, a faulty gravity valve (tank
• Turn starter key to position „1“ (electric fuel vent, see page 9) may be the reason. To prove this,
feed pump will run). Provisions for overflow on open the tank cover and repeat the bleeding proce-
fine filter and injection pump ensure automatic dure.
bleeding. There are no bleeding screws to be
opened!
• Keep fuel feed pump running for about 30
seconds before you make the first attempt to
start the engine.
NOTE: If the engine will not be started after one
minute, the EEM will cut off the fuel feed pump. As
soon as the engine get‘s started, the fuel feed pump
will start to operate automatically.

Bleeding after fuel has been used up


IMPORTANT: Drivers have to be instructed in
advance to avoid "using fuel up"!
Supposed the engine was stopped in time after signs
of power loss, the engine will run again if you comply
with the following steps:
• Add fuel into the tank.
• Turn starter key to position „1“ (electric fuel
feed pump will run).
• Keep fuel feed pump running for about 30
seconds before you make the first attempt to
start the engine.
NOTE: If the engine will not start, keep to the blee-
ding procedure as you apply after fitting an injection
pump.

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3001-19
Fuel feed pressure Disconnect the wiring at the feed pressure - control
switch. Unscrew the control switch.
At any condition of engine load and engine speed, Fit adapter 380001486 (thread M14 x 1,5), using a
sufficient feed pressure is essential that the injection copper seal . Connect mini-test tube 380001127 and
pump will deliver the demanded quantity of fuel to be pressure gauge 380001121.
injected. Feed pressure and capacity (after fuel filter):
NOTE: If the warning „fuel filter blocked“ is aktiv, the Engine at low idle speed ................... 1,0 to 1,3 bar
function of the electric fuel feed pump is to be chek- Engine at rated power ....................... 1,0 to 1,1 bar
ked prior to a change of the fuel filter or testing the If the pressures demanded are not reached, there can
feed pressure. be various causes:
Supply voltage ................................................. 12V • blocked fuel filter
(at the pump while engine is running)
(Fuse F29, 7,5A, +15/2)
• blocked primary filter
Current draw ............................................. max. 6A • feed pump defective (worn)
• gravity valve defective
• leaking primary filter
• blocked, kinked or leaking suction lines
• wrong diesel fuel (e.g. not suitable for winter)
If the gravity valve will be suspected, the steps of
testing the feed pressure may be repeated with par-
tially opened tank cap.

SS03D001

NOTE: If the electrical supply exists but the pump


cannot be heard running, this indicates that the pump
is sticking. The pump will need replacing.
If there is a fault in the electrical supply, see service
manual chapter 04, wiring diagram.
NOTE: If the engine will not be started after one
minute, the EEM will cut off the fuel feed pump. As
soon as the engine get‘s started, the fuel feed pump
will start to operate automatically.

Testing the fuel feed pressure


Clean the fuel filter outside and the connec-
tions.Make sure that adequate fuel is in the tank.

SS03C027

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3001-20
Removal of the fuel injection pump
Prior to removing the pump, disconnect the battery or
switch OFF the battery master switch (if fitted) in order
to prevent inadvertent starting.

SS03C029

NOTE: Never loosen the retaining nut of the


hub! There is no key to locate the hub to the
pump drive shaft. The hub is accommodated by
the cone of the shaft only. Refitting the hub is
only possible on a pump test bench.

SS00E039

Turn the crankshaft until the beginning of compressi-


on stroke of cylinder No. 1 (front). Gradually turn the
crankshaft in the direction of rotation until the marking
of the belt pulley matches with the reference marking.
Carefully clean the pump and the surrounding com-
ponents. Remove the injection pipes, the supply line
as well as the overflow line. Fit protective caps to the
delivery ports, to the feed- and overflow connection.

SS03C030

Unscrew the three nuts retaining the pump. Take the


pump off the timing housing by keeping the pump
drive gear engaged in the intermediate gear.
ATTENTION: Once the pump has been removed,
the crankshaft must not be turned! The loose gear
SS03C028
could damage the timing drive and (or) the timing
housing.
Pull up the lock () of the connector and disconnect the Clean the sealing surfaces.
connector () on the pump control unit (PCU).
NOTE: The pins of either side of the connector
must not be touched with fingers!
Remove the cover on the engine timing housing to
make the pump drive gear accessible.
Unscrew the four retaining screws of the pump drive
gear. The gear is centered (loose) by the hub.

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3001-21
Fitting the fuel injection pump Tighten the pump retaining nuts finally to 30 Nm.
Fit the cover on the engine timing housing with a new
ATTENTION: The starter of the engine must never seal.
be operated prior to air bleeding after an injection Remove the protective caps and fit the pipes. Tighten
pump was fitted (damage to the injection pump due the union nuts of the injection pipes only at the pump
to lack of lubrication). delivery ports (25 Nm). Use new sealing rings for the
Ensure that the crankshaft is still in the position as it banjo bolts. Tighten the overflow valve at the overflow
was turned to prior to removing the pump. If the mar- port of the pump to 27 Nm.
kings do not match, adjust accordingly. Fit the connector of the harness to the pump control
NOTE: If the crankshaft needs to be turned, the unit and push in the lock.
loose pump drive gear must be supported to avoid NOTE: The pins of either side of the connector
damage. must not be touched with fingers!

Updating pump serial numbering in EEM


• Connect the CNH service tool to the diagnosis
connector.
• Go to the screen
"CONFIGURATION ITEM SELECTION" .
• Select the menu "ENGINE - FUEL INJECTION
PUMP CONFIGURATION".
• Execute updating of pump serial numbering in
the sequence as indicated on this screen.
• Disconnect the CNH service tool.

SS03C030 Final jobs


• Make sure there is adequate fuel in the tank.
Ensure clean contacting surfaces at timing housing, • Perform bleeding according to paragraph
spacer and pump flange. Place new seals to spacer „Bleeding after a new or an overhauled
and pump flange. Push the pump to the correct posi- injection pump has been fitted“ (see
page 19).
tion on the timing housing, at the same time hold the
pump drive gear in position to allow the hub to slip into • Tighten the union nuts of the injection pipes at
the gear. Attach the washers, fit the pump retaining the injector connections to 25 Nm.
nuts and tighten them only hand-tight for the moment. • Clean off spilled fuel. Start the engine, check for
leaks and see the engine performance.
Static pump timing • Take a test ride with the tractor.

380001487 SS03C032

Turn the pump drive shaft clockwise by means of ap-


plying a wrench to the hub retaining nut until the in-
spection holes of gear, hub and pump housing will
match and the timing pin 380001487 will easely enter.
Fit the retaining screws of the pump drive gear by
hand. Remove the timing pin. Tighten the drive gear
retaining screws to 40 Nm.

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3001-22
Injectors and nozzles – opening pressure

– buzzing sound and spray pattern


1 – tightness

1.Fuel inlet
2.Leakage oil port
3. Adjusting shim
4.Pressure spring 3
5.Thrust bolt
6.Nozzle body
4
SS99N147
7.Pressure chamber
5
8. Needle
9.Spray orifice 6
7
Opening pressure
8
To fill the injector, pump the system a few times.
9 Increase the pressure in the injector until the buzzing
SS99N149
is audible. Check the opening pressure. If the opening
pressure deviates from the specified value (see
The injectors are equipped with a five-hole nozzle. page 8), the injector must be dismantled to adjust the
The small amount of leakage fuel used to lubricate the opening pressure.
needle is returned to the fuel tank via the overflow li- An adjustment is made by means of altering the adju-
ne. sting shim. The thickness of the adjusting shims va-
ries between 1.00 and 1.90 mm and they are
Removing the injectors available in graduations of 0.05 mm. A thicker adju-
sting shim increases the opening pressure, a thinner
1. Clean the injectors and the surrounding area. Dis-
one reduces the opening pressure. Changing the
connect the pressure lines and the leakage oil line.
thickness of the shim by 0.05 mm changes the ope-
NOTE: Keep in mind the assignment of the injection ning pressure by approx. 5.0 bar. Because the ope-
lines to the connections at the pump and notice how ning pressure of the nozzle drops slightly after being
the injectors are fitted (direction of leakage oil port). adjusted, it should be set approx. 10 bar higher than
the value specified in the technical data. This value is
2. Unscrew the nuts of the injector retaining brackets.
valid for both new and used nozzles.
Remove the brackets and then the injectors from the
cylinder head. Seal off all connecting points by fitting Buzzing properties
protective caps. Testing by means of the hand pump does not fully cor-
3. Remove the sealing washers from the injectors respond to the conditions that the nozzle is subject to
seating in the cylinder head, if they have not already in the engine. The test results are only reliable for new
been taken out together with the injectors. nozzles. Used nozzles do not buzz at certain pump
speeds, which is due to the design of the nozzle.
Checking the nozzles When pumping quickly, however, the buzz is audible
and/or a fine jet of atomised fuel is visible. The jet is
IMPORTANT: When checking the nozzles on the
thicker and less defined in the buzz-free zone.
test stand, it is not permitted to remain in the vicinity
of the nozzle outlet (e.g. with one’s hands). The fuel Tightness of the nozzle
jet, which is ejected at high pressure, can easily Press the test pump lever slowly, until the pressure
penetrate the skin and cause serious injuries. Brea- increases to approx. 20 bar below the setting value.
thing-in fuel spray is detrimental to health. Maintain this pressure for approx. 10 seconds. If no
1. Clean the injectors using cleaning fluid and a soft drops of fuel form at the tip of the nozzle, the nozzle
brush. The carbon deposits must not be knocked off seals correctly. When the nozzle does not perform as
or removed in such a way that the nozzle can be da- demanded, see page 24, chapter "Overhauling injec-
maged. tors".
2. Mount the injectors on the test stand and check the
following points:
Sva 6-51300 EN Edition 05-2003
3001-23
Overhauling injectors
1. Mount the injector in such a way in a fixture that it
will not be damaged.
2. Unscrew the nozzle tensioning nut. Remove the
nozzle and the parts inside the injector body.
3. Clean the nozzle, both inside and outside, in cle-
aning fluid.
4. Steep blocked spray orifices or clean them using a 1
cleaning needle. 2
5. Check the movement of the needle as follows:

1. Sealing washer
2. Rubber ring
3. Sealing ring

3
SS99N150

2. Fit the injector in its place in the cylinder head. Use


a new sealing washer.
SS99N148

IMPORTANT: The spraying directions of the injec-


Rinse the parts out with fuel or test fluid. Pull the tion nozzle are not symmetrical. It is therefore
needle out off the nozzle body by one third of the slide important that the injector is fitted into the cylinder
face length. The needle must be able to slide into the head correctly.
valve seat by its own weight. Turn the needle a little 3. Fit the bracket and tighten the nuts evenly to a tor-
and repeat the test. The needle must not stick in any que of 15 Nm.
position. If it does, rinse the parts and repeat the test.
4. Connect the leakage oil line and the injection line.
If the needle sticks again, the nozzle must be repla-
Use new seals where required.
ced.
6. Before assembly, all parts must be carefully clea- ATTENTION: Always make sure the correct type of
ned in clean fuel or test fluid. nozzle is used. Incorrect nozzles impair engine ope-
7. Insert the adjusting shim in the injector body. Bear ration and will cause engine damage.
in mind that the opening pressure may require adjust-
ment. Assemble the injector, making sure the thrust Assembly of the injection lines
bolt and intermediate washer are in the correct positi- 1. Check the state of the lines before fitting them. If
on. the lines show signs of kinking, breakage or abrasion,
8. Tighten the nozzle tensioning nut by hand and then or the sealing olive is damaged, replace the line with
to a torque of 60 Nm. a new one.
2. When connecting the line, make sure that the union
Fitting the injectors nut is not cross threaded, otherwise the olive will be
1. Clean the injectors seating in the cylinder head. If damaged.
necessary, smoothen the surface by using a reamer. Tighten the union nut of the line to a torque of 25 Nm.
3. Secure the injection lines by refitting all the holders.

Sva 6-51300 EN Edition 05-2003


3001-24
Fuel quality requirements Service intervals
Reduction of running hours recommended in the ope-
This fuelsystem can be run on diesel fuel which will
rators handbook for periodical change of engine oil
meet the standard ÖNORM EN 590, but also biologi-
and engine oil filter:
cal fuel (RME), standard ÖNORM C 1190, can be
used. • Limited by 50% if engine is low loaded (easy
Running on RME, a reduction of engine output up to work).
7% must be taken in account. • Limited by 25% if engine is high loaded (hard
RME is known by the trade marks „BIO-DIESEL“ and work).
„ÖKO-DIESEL“.
NOTE: In case the engine oil level would raise by
NOTE: For different seasons as summer or winter, more than one inch, the engine oil must be changed.
different diesel fuels are recommended.
For further details about alteration of service intervals
For suitable diesel fuel in the winter season, special
see the „Operator‘s maual“.
info will be available with the fuel dealers.

Directives to run on biological fuel (RME)


(RME = Rape oil-Methyl-Ester Bio - Fuel)
The diesel engines 620.95, 620.96, 620.97, 620.98
and 620.99 can be run on RME fuel without requiring
technical modifications. The only one requirement is
to meet the Austrian standard ”C 1190”.
IMPORTANT: To ensure smooth run on RME, the
operator should obey the following recommendati-
ons.
• To store RME correctly, keep to the recommen-
dations of the fuel supplier. Seal tanks to avoid
entering of air and water, for RME is hygrosco-
pical.
• Do not take fuel from the lowest point of the
tank (danger of water collection).
• When the starting temperature will be < -10 °C,
do not use RME. Other recommendations from
the fuel suppliers are excepted.
• Do not run on RME if longer periodes of vehicle
standstill (> 3 months) will be ahead. Otherwise
there would be danger of a sticking axial plun-
ger and sticking delivery valves in the injection
pump, as well as sticking nozzles.
• Do not run on RME if longer periodes of low
engine load are expected. Since the boiling
point of RME is remarkable higher compared to
diesel fuel, RME which will not combust will
enter the oil sump, thus diluting the engine oil.
Additionally, not combusted RME will exit the
exhaust and will soil the cabine, engine hood,
windscreen and other parts.

Sva 6-51300 EN Edition 05-2003


&KDSWHU
$

$
02'(2)23(5$7,21
)8(/,1-(&7,216<67(0
&RPPRQ5DLO6\VWHP

CNH Österreich GmbH Sva 6-93150 EN © 2006 CNH Österreich GmbH


Tecnical Documentation Januar, 2006
A - 4300 St. Valentin, Steyrer Straße 32
3001A-3

&217(176

SPECIAL TOOLS .................................................................................................................................................. 5

GENERAL ............................................................................................................................................................. 7

SAFETY REGULATIONS ..................................................................................................................................... 7

TECHNICAL DATA ............................................................................................................................................... 8


High-pressure pump ........................................................................................................................................ 8
Injectors ........................................................................................................................................................... 8
Fuel .................................................................................................................................................................. 8
Fuel filter .......................................................................................................................................................... 8
Tightening torques ........................................................................................................................................... 8

JUMPER LEAD STARTING AND ELECTROWELDING ...................................................................................... 8

FUEL SYSTEM ..................................................................................................................................................... 9


Function ......................................................................................................................................................... 10
Safety equipment ........................................................................................................................................... 11
Diagram - Electronically controlled injection system ...................................................................................... 12
Venting the fuel system .................................................................................................................................. 13
Checking the fuel delivery pressure ............................................................................................................... 13
Checking the injectors .................................................................................................................................... 14
Removing the injectors .................................................................................................................................. 14
Assembly of injectors ..................................................................................................................................... 14
High-pressure pump ...................................................................................................................................... 15
Removing the high-pressure pump ........................................................................................................... 15
Assembly of high-pressure pump ............................................................................................................. 16
Final work .................................................................................................................................................. 16
Fuel quality requirements ............................................................................................................................... 17

Sva 6-93150 EN Edition 01-2006


3001A-4

BLANK PAGE

Sva 6-93150 EN Edition 01-2006


3001A-5

63(&,$/722/6
3UHVVXUHJDXJHDQGFRQQHFWLRQ 0LQLPHDVXULQJFRQQHFWLRQ

SS00B076 SS98J031
[ 76: Connection [ 76: 0;
[ 76: Pressure gauge

0LQLPHDVXULQJOLQH

SS98J030
[ 76:

Sva 6-93150 EN Edition 01-2006


3001A-6

BLANK PAGE

Sva 6-93150 EN Edition 01-2006


3001A-7

*(1(5$/,1)250$7,21
The engines are equipped with a FRPPRQUDLO fuel injection system. This system is controlled by the electronic en-
gine management system EEM3. The engines meet Tier 3 emissions standards.
To make sure that the engine continues to meet these emissions standards over its entire service life, the stipulated
periodic service and maintenance work must be carried out with the necessary diligence. Only genuine CNH service
material (filters) may be used.
The stipulated periodic functional check of the injectors should be carried out every 2000 operating hours using the
EST (Service Tool).
Calibration of the fuel injection system should be undertaken using the EST (Service Tool).
Only genuine CNH spare parts may be used to carry out repairs. Maintenance and service work which is not carried
out with due diligence or is not carried out in time and/or the use of any parts which are not genuine spare parts or
service material will result in the manufacturer’s guarantee of the fulfilment of emissions standards becoming void.
127( 7KLVPDQXDOFRQWDLQVLQVWUXFWLRQVRQKRZWRUHSODFHWKHIXHOILOWHUHOHFWULFDOIXHOGHOLYHU\SXPSVKLJKSUHV
VXUHSXPSLQMHFWRUVDQGUDLO
This work may only be undertaken by trained personnel using the required special tools and testing and calibration
equipment.
((0 = Electronic Engine Management. German: Electronic engine management

6$)(7<5(*8/$7,216
7KHUHLVDOZD\VDULVNRILQMXU\ZKHQ •) Always switch the engine off before performing re-
FDUU\LQJRXWPDLQWHQDQFHDQGUHSDLU pair work.
ZRUN5HDGWKHIROORZLQJVDIHW\
$77(17,211HYHURSHQWKHFRQQHFWLRQVRIKLJKSUHV
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VXUHOLQHVZKLOHWKHHQJLQHLVUXQQLQJ$OZD\VZDLWDW
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•) Never start repair work which you do not fully under- RSHQLQJLW$KLJKSUHVVXUHMHWRIIXHO XSWREDU 
stand. FDQSHQHWUDWHWKHVNLQDQGFDXVHVHULRXVLQMXU\,IVXFK
•) Make sure that it is possible to work safely at the lo- DQHYHQWRFFXUVPHGLFDODWWHQWLRQPXVWEHVRXJKWLP
cation and in the vicinity. PHGLDWHO\

•) Make sure the repair area is clean and in good con- •) Naked flames and smoking are not permitted in the
dition. vicinity of fuel tanks or batteries. Electrical sparks
should be avoided.
•) Never use incorrect or unsuitable tools.
•) Disconnect the cable at the negative battery pole (-)
•) Remove all rings, chains and watches before start- before carrying out service or repair work on the
ing work. electrical system.
•) Use modern safety equipment when working. For •) Extended contact with fuel or lubricant
example, protect your eyes when using compressed can irritate the skin.
air for cleaning.
•) Avoid running the engine in idle unnecessarily.
•) Only use JHQXLQH&1+VSDUHSDUWV.
•) When carrying out service work, take measures to
•) Never wash the components of the fuel injection sys- prevent fuel or other fluids from entering the ground
tem while the engine is running. or drains.
•) Only start the engine from the cab using the ignition •) Be careful when washing the engine using a wash-
key. ing facility with a high water pressure. Do not wash,
•) Never start the engine when protective covers are for example, the electrical and fuel systems under
not in place. high pressure as they can easily be damaged.
•) The cooling fan is difficult to see when the engine is •) Never use auxiliary starting fuels on an aerosol basis
running! Loose clothing and long hair may become whilst the pre-glow starting facility is in operation (ex-
caught in rotating engine parts. plosion hazard).
•) If the engine is being started in an enclosed space,
make sure there is sufficient ventilation.
•) Ear muffs must be worn when testing the engine or
working close to the engine to avoid hearing dam-
age.

Sva 6-93150 EN Edition 01-2006


3001A-8

7(&+1,&$/'$7$
+LJKSUHVVXUHSXPS
Type .............................................................................................................................................................. CP 1H
Design .................................................................................................................... Radial piston pump, 3 cylinders
Lubrication .........................................................................................................................................................Fuel
Max. injection pressure ..............................................................................................................................1100 bar
Transmission ratio of drive gears ......................................................................................................................4 : 3
Injection sequence .................................................................................................................................1-5-3-6-2-4

,QMHFWRUV
Type ..................................................................................................................................................... CRIN 2 - 2V
Number of blowholes...............................................................................................................................................5

)XHO
Required fuel quality ......................................................................................................................EN 590 standard
Fuel supply temperature, max. .............................................................................................................. 70° Celsius

)XHOILOWHU
Pre-filter .......................................................................................................................................... 30 µ Stanadyne
Fine filter ........................................................................................................................................... 5 µ Stanadyne
Delivery pump ................................................................................................................. electric, fitted on pre-filter
Supply voltage ....................................................................................................................................... 12 volts DC
Max. current. ............................................................................................................................................6 amperes
Delivery pressure when engine idling, min. ................................................................................................ 0.75 bar

7LJKWHQLQJWRUTXHV
,QMHFWRUV
Retaining bolt ................................................................................................................................................ 40 Nm
Retaining nuts - cable connection ................................................................................................................ 1.5 Nm
+LJKSUHVVXUHSXPS
Retaining nuts - drive gear wheel (M14) ....................................................................................................... 70 Nm
Retaining bolts ............................................................................................................................................... 30 Nm

)XHOOLQHV
High-pressure line from high-pressure pump to rail ...................................................................................... 30 Nm
High-pressure line from rail to injectors ......................................................................................................... 25 Nm
Low-pressure line to high-pressure pump ..................................................................................................... 25 Nm

-XPSHUOHDGVWDUWLQJDQGHOHFWURZHOGLQJ
‡ Jumper lead starting may only be used with 12V batteries connected in parallel.
‡ Before performing any welding work, turn the start switch to the „0“ position.
,03257$17 $WWDFKWKHHDUWKWHUPLQDORIWKHZHOGLQJGHYLFHFORVHWRWKHDUHDWREHZHOGHG PD[PDSDUW 
,03257$17 $IWHUUHSDLULQJWKHIXHOV\VWHPWKHV\VWHPPXVWEHYHQWHGEHIRUHDWWHPSWLQJWRVWDUWWKHHQJLQHIRU
WKHILUVWWLPH VHH6HLWH9HQWLQJWKHIXHOV\VWHP 

Sva 6-93150 EN Edition 01-2006


3001A-9

)8(/6<67(0


  












SS05M991

1. Fuel tank 9. Fuel delivery pressure sensor


2. Level sensor 10. Fuel temperature sensor
3. Gravity valve (tank venting) 11. High-pressure pump
4. Suction line 12. Rail
5. Electric delivery pump 13. Overflow valve
6. Pre-filter 14. Injector
7. ’Water in fuel’ sensor 15. High pressure sensor (pressure in rail)
8. Fuel filter

Sva 6-93150 EN Edition 01-2006


3001A-10

)XQFWLRQ
The electric delivery pump (5) draws fuel from the tank through the pre-filter (6). It conveys the fuel through the fuel
filter (8) to the high-pressure pump (11).
127( 7KHHOHFWULFGHOLYHU\SXPSVWDUWVZRUNLQJDVVRRQDVWKHVWDUWVZLWFKLVVHWWRSRVLWLRQij,IWKHHQJLQHLVQRW
VWDUWHGZLWKLQRQHPLQXWHWKH((0ZLOOVKXWGRZQWKHGHOLYHU\SXPS7KHGHOLYHU\SXPSVWDUWVZRUNLQJDVVRRQDV
WKHHQJLQHLVVWDUWHG
The high-pressure pump pumps fuel into the rail (12) (storage area). When the engine is running, fuel is stored at high
pressure (up to 1100 bar) in the rail and the high-pressure lines, as far as the injectors (14). Electronically controlled
injectors inject the fuel, finely atomised, into the combustion chambers of the cylinders.
The timing of the injection and the volume of fuel injected are controlled by the electronic engine management unit,
the EEM3. The injection volume is determined by both the current pressure in the rail and the time during which an
injector is activated by the EEM3.
The common rail injection system significantly optimises the fuel injection process. This is due to a number of advan-
tages of the common rail injection system:
‡ Fuel is injected at high pressure (up to 1100 bar) through five-hole injector nozzles
‡ The fuel is injected in up to three part-volumes
‡ Key physical parameters are processed by the EEM3 to determine the number, volume and timing of inject-
ed part-volumes:
- Output requirements through FMGR via CAN bus, engine speed
- Engine temperature (coolant), intake air and fuel
- Charge-air pressure, high pressure in rail, fuel delivery pressure, engine oil pressure

7KHUHDUHPDQ\DGYDQWDJHVWRWKLVW\SHRIIXHOLQMHFWLRQ
‡ Reduction in harmful emissions
‡ Reduction in specific fuel consumption
‡ Reduction in engine noise
‡ Automatic venting (starting from driver’s seat) without opening the line system

)XHOUHWXUQHGWRWDQN
‡ by pressure control valves on high-pressure pump
‡ by overflow valve in rail
‡ as leaked oil from the injectors
‡ from the overflow connection on the fuel filter (this also aids automatic venting of the fuel system after a filter
change or when the fuel tank is empty).

Sva 6-93150 EN Edition 01-2006


3001A-11

6DIHW\HTXLSPHQW
)XHOOHYHOLQWDQNEHORZPLQLPXP
If the fuel level falls below the minimum, a warning message is displayed on the ADIC.

)XHOGHOLYHU\SUHVVXUHWRRORZ
If the delivery pressure between the fuel filter and the high-pressure pump is insufficient, the fuel delivery pressure
sensor (9) activates a warning message on the ADIC. For possible causes of low delivery pressure, refer to Seite 13,
’Checking the fuel delivery pressure’.

(QJLQHLVVKXWRIILPPHGLDWHO\
‡ Rail pressure too high:
Error code EEM3 - 382 is stored and displayed.

(QJLQHVKXWVGRZQZLWKGHOD\
‡ Engine oil pressure too low: Zero delivery after 30-second delay.
Error code EEM3 - 99 is stored and displayed.
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‡ Coolant temperature too high: Zero delivery after 30-second delay.
Error code EEM3 - 113 is stored and displayed.

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‡ Engine speed too high (> 3000 rpm): Zero delivery cuts in immediately.
Error code EEM3 - 94 is stored and displayed.

6WDUWLQJLVQRWSRVVLEOH
‡ Upgrade protection error
Error code EEM3 - 172 is stored and displayed.
‡ Self-test for shut-off, hardware error
Error code EEM3 - 221, 222, 223 is stored and displayed.

Sva 6-93150 EN Edition 01-2006


3001A-12

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Sva 6-93150 EN Edition 01-2006


3001A-13

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There is no need to vent the engine specially after changing the fuel filter or if the fuel tank has run empty. It is sufficient
to turn the start switch to the ON position and allow the electric delivery pump to run for at least 30 seconds. Then
activate the starter (max. 10 seconds). If the engine still will not start, activate the electric delivery pump for at least
another 30 seconds and then attempt to start the engine again.

&KHFNLQJWKHIXHOGHOLYHU\SUHVVXUH
1. Clean both filter casings and the line connections.

2. Disconnect the plug connection on the delivery pressure


sensor. Detach the delivery pressure sensor (9) from the fil-
ter head of the fuel filter. Attach measurement connection
with sealing ring (thread M14 x 1.5).
Connect up mini measurement line and pressure
gauge 
127( $IWHUHQJLQHLVVWDUWHGHUURUFRGH((0LVDF

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3. Start the engine and allow to idle. The delivery pressure
should reach 0.75 bar. If this nominal value is not reached, SS05M992
one of the following causes may be responsible:
‡ Too little fuel in tank.
‡ Fuel filter heavily soiled.
‡ Leak between fuel tank and electric delivery pump (air ingress).
‡ Fuel unsuitable for season (e.g. summer diesel in freezing temperatures).
‡ Suction line crimped (clamped), buckled or blocked.
‡ Supply voltage to electric delivery pump too low.
‡ Electric delivery pump malfunction.
If you suspect that a tank venting valve is malfunctioning, you can repeat the steps of the test while the tank lock is
partly open and compare the pressure values.
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If the power supply fails, refer to the workshop manual, chapter 04: Circuit diagram.
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Sva 6-93150 EN Edition 01-2006


3001A-14

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The function of the injectors must be checked every 2000 operating hours using the EST (Service Tool) (’run-up’ test).
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1. Clean the injectors, line connections, lines and immediate surroundings.
2. Disconnect the electrical connection, high-pressure line and oil leakage line.
3. Undo the retaining bolt. Remove the retaining bolt and washer, noting the position in which the washer is fitted.
4. Remove the injector and the bracket. Immediately seal the connection openings on the injector with plastic plugs.
5. Remove the injector seal from its seat in the cylinder head if it was not removed along with the injector.

$VVHPEO\RILQMHFWRUV
1. Clean the bore in the cylinder head and the sealing face. If necessary, clean the seat in the cylinder head with a
reamer.
2. Ensure that the sealing face in the cylinder head is clean. Fit a new sealing ring.
3. Fit the injector. Put the bracket in position, aligning the injector to the bracket.
4. Attach the washer with the spherical surface to the brack-
et. Screw in the retaining bolt.
Anzugsdrehmoment ..................................................40 Nm
5. Connect the high-pressure line to the injector.
Anzugsdrehmoment .................................................. 30 Nm 

6. Connect the oil leakage line to the injector.


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7. Connect the electrical cables to the injector.
Anzugsdrehmoment .................................................1.5 Nm
8. Fit the protective cap.
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1. Electrical connection
2. Washer with spherical surface
3. Bracket
4. Sealing ring

 SS05M993

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3001A-15

+LJKSUHVVXUHSXPS
The high-pressure pump is mounted on the engine control housing on the left-hand side of the engine. It is driven by
gear wheels. The high-pressure pump is a radial piston pump with three cylinders. The high-pressure pump is lubri-
cated by the fuel.
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If necessary the function of the high-pressure pump can be checked using the (67 (Service Tool).

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VXUHSXPS
1. Turn the start switch to the OFF position. Turn the main battery switch (if present) to
the OFF position.
2. Clean the high-pressure pump, the area around it and the line connections.
3. Disconnect the plug connection. Disconnect the fuel lines and immediately seal the connection openings with
plastic plugs.
4. Unscrew the retaining bolts. Remove the high-pressure pump, being careful with the guide ring.
5. Unscrew the retaining nut of the drive gear from the pump shaft, fixing the drive gear using a suitable tool. Use a
suitable extractor to pull the drive gear off the pump shaft.
127( :KHQGRLQJWKLVWKHH[WUDFWRUPXVWEHVXSSRUWHGDJDLQVWWKHSXPSVKDIW
6. Remove the guide ring from the pump flange.

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1. Clean the guide ring (A) and the drive gear (B). Check
the mounting flange on the high-pressure pump you plan 1P
to install. Check the O-ring grooves on the pump flange
and on the guide ring. They must be clean and free from
burrs or foreign material. Check the outer cone of the
pump shaft and the inner cone of the drive gear. They 1P
must be dry, free of oil and grease and must not show
any signs of burrs.
$ 1P
2. Attach an O-ring to both the pump flange and the guide
ring. Apply a thin coat of oil to the O-ring on the pump %
flange. Fit the guide ring. Manually slide the drive gear on
1P
to the pump shaft. Fit the nut. Fix the drive gear in place
with a suitable tool. Tighten the nut.
Anzugsdrehmoment ..................................................70 Nm
SS05M994

3. Clean the flange face and the bore for inserting the high-
pressure pump on the control unit casing. Apply a thin
coat of oil to the O-ring on the guide ring. Hold the high-
pressure pump in its installation position. Align the guide
ring radially on the pump flange such that the bore (see
arrow) is in line with the bore on the control unit casing.
4. Slide the high-pressure pump into the control unit casing
together with the guide ring. Screw on and tighten the re-
taining bolts (with shim).
Anzugsdrehmoment ................................................. 30 Nm
5. Connect the fuel lines to the high-pressure pump and
tighten them.
Anzugsdrehmoment Low-pressure lines .................. 25 Nm
High-pressure line (pump to rail) .............................. 30 Nm SS05M995

6. Connect the plug connection.


127( $IWHUWLJKWHQLQJWKHIXHOOLQHVPXVWEHIUHHRIGLVWRUWLRQ

)LQDOWDVNV
‡ Ensure that the tank contains sufficient fuel.
‡ Vent the fuel system (see Seite 13).
‡ Start the engine, check the fuel system for leaks and observe how the engine runs.
‡ Carry out a test drive.

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3001A-17

)XHOTXDOLW\UHTXLUHPHQWV

5HTXLUHPHQW 7HVWPHWKRG
3
Density at +15 °C 0.82...0.84 kg/dm EN ISO 3675:1998, EN ISO 12185
2
Viscosity at +40 °C 2.0...4.5 mm /s EN ISO 3104
Sulphur content max. 350 mg/kg EN ISO 14596:1998
Cetane rating min. 51 EN ISO 5165:1998
Water content max. 200 mg/kg prEN ISO 12937:1996
Lubricity max. 460 microns ISO 12156-1

The diesel fuel used must satisfy the EN 590 standard.


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'HSHQGHQFHRIHQJLQHRXWSXWRQIXHOTXDOLW\
Various physical parameters relating to fuel quality, such as temperature, density and viscosity, have an impact on
engine output.
The output of the engines is given at a density of 0.84 kg/dm³, a specific heat capacity of 42.7 Mj/kg and a fuel tem-
perature of +15 °C.
The diagrams below show the change in engine output as a percentage when one physical parameter is changed.
'LDJUDP$
Engine output is dependent on the fuel temperature. The refer-
ence temperature is +35 °C (correction factor 0%). The fuel tem-
perature not only depends on the ambient temperature but also
varies according to factors in the fuel system such as the volume
and position of the tank, the return volume, position of the lines
and filter and the material from which the lines are made.

'LDJUDP%
Engine output is dependent on the density of the fuel used. The
standard value is 0.84kg/dm³ at +15 °C.

'LDJUDP&
Engine output is dependent on the viscosity of the fuel used. The
standard value is 3 cSt at +20 °C.
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ZKHQDGLIIHUHQWIXHOLVXVHG7KHVWDQGDUGGHQVLW\DQGYLVFRVLW\
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DEOHIURPWKHPDQXIDFWXUHURUGHDOHU 

'HWHUPLQLQJWKHRYHUDOOFKDQJHLQHQJLQHRXWSXW

Add together the correction values (in %) of diagrams A, B and


C. Correct the manufacturer's specified rated engine output us-
ing the percentage calculated.

SS05M996

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3001A-18

BLANK PAGE

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Chapter
4002

4002
FUNCTIONAL DESCRIPTION OF
THE CAN BUS
(Basics)

CNH Österreich GmbH Sva 6-51350 EN © 2003 CNH Österreich GmbH


Technical Documentation May, 2003
A – 4300 St. Valentin, Steyrer Straße 32
4002-3
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................................... 5

DIGITAL TECHNOLOGY ...................................................................................................................................... 6


Advantage of digital message transmission ..................................................................................................... 6
Ranges for 1 and 0 .......................................................................................................................................... 7
Parallel Data Transmission .............................................................................................................................. 8
Serial Data Transmission ................................................................................................................................. 8

DATA BUS ............................................................................................................................................................ 9


Function ......................................................................................................................................................... 10
Can bus line ................................................................................................................................................... 11
Can high – Can low ........................................................................................................................................ 12
CAN High Speed Signal Level ....................................................................................................................... 13
Topology ........................................................................................................................................................ 14
Data Transmission ......................................................................................................................................... 14

DATA PROTOCOL ............................................................................................................................................. 15


Structure of the CAN Data Frame – Standard Identifier (11 bits) CAN V2.0A ............................................... 15
Structure of the CAN Data Frame – Standard Identifier (29 bits) CAN V2.0B ............................................... 17
Structure of the CAN Remote Frames Identifier ............................................................................................ 19

ERROR DETECTION ......................................................................................................................................... 20


Mechanisms on the Data Frame level ........................................................................................................... 20
Mechanisms of the Bit Level .......................................................................................................................... 20

TROUBLESHOOTING ........................................................................................................................................ 21
Interrupting the Transmission ........................................................................................................................ 21
Resumption of the Transmission ................................................................................................................... 21
Realtime Transmission .................................................................................................................................. 21

TRANSMISSION SPEED .................................................................................................................................... 22

TELEGRAM LENGTH ......................................................................................................................................... 23

CENTRAL GATEWAY ........................................................................................................................................ 25

SERVICE TOOL .................................................................................................................................................. 25

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BLANK PAGE

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4002-5

INTRODUCTION
There is a clear trend in automobile and farm implement technology towards an increasing replacement of mechanical
components by electronic components.
This thereby allows the maker to provide the customer with more comfort and more safety inside the vehicle.
However, this also means that vehicle electronics are becoming ever more complex and are equipped with a growing
number of sensors and actuators.
In the future, these increased requirments can no longer be implemented by autonomous control devices.
The solution to the problem lies in the networking of various electronic modules with a data bus.
The simple motto is: "Less hardware, and more software".
This provides many advantages, which will be described in detail in this document.

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DIGITAL TECHNOLOGY
There are only two conditions in digital technology (lat. digitus >finger<). Both of these conditions are defined exactly.
They are termed logical zero and logical one.

Lamp lights Lamp does not light

Both conditions (logical one and logical zero) are mutually exclusive, i.e. both conditions can never be present
simultaneously.
There are no intermediate values (e.g. lamp lights weakly).
One single such condition is termed within digital technology as a bit (BInary digiT ).
Therefore, using one bit (Bi = 2), exactly two different conditions can be described (e.g. switch closed or switch
open).

Condition Electrical Magnetic Light

Logical zero No current Not magnetized Dark

Logical one Current present Magnetized Bright

One BIT therefore represents the smallest amount of information.


In control units, a voltage of 3.5 volts is defined with logical one.

Advantage of digital message transmission


The great advantage is that the "quality" of a single bit is insignificant. The only fact that is decisive is whether or not
a bit is set (logical one) or not (logical zero).
If the requirements for the correct type and installation of the lines are met and the limit values for the line length and
transmission speed (see page 22) are observed, then there are no losses of quality during data transmission by
means of digital technology.
127( Repairs to CAN bus lines must be carried out in such a way that the EMC* requirements are met again
(screening and transposition must be restored).
* EMC = electro-magnetic compatibility

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Ranges for 1 and 0


Voltage


Time

Assigned areas that are defined by one and zero.


1 Bit = 2 possible states
.

State of the bits PTO state State of the seat switch

0 0 OFF OPEN

1 0 ON OPEN

0 1 OFF CLOSED

1 1 ON CLOSED

This information could be used, e.g. in FMGR control units for recognising the working mode or at the seat switch for
safety conditions.
Possibilities in relation to the number of bits
A single bit has a low data content. Several bits are therefore used in practice.

Number of BITs Possibilities

1 2

2 4

3 8

4 16

5 32

6 64

7 128

8 256

The number of possibilities increases exponentially.


Number of possibilities = 2 n (n = number of BITs).
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4002-8
Therefore, using eight BITs, 256 (2 8 = 256) various conditions can be shown.
There are eight BITs to a BYTE (BY eighT).
Using one BYTE, 28 = 256 various conditions can be shown.
Often, one byte (eight bits) is used in the electronic systems of farm implement technology.
In this way, e.g. the engine temperature of -20 °C to +120 °C can be "digitized" to one BYTE. This in turn means that
the temperature difference of 140 °C is divided into 256 steps or levels.
This means that a resolution of 0.546 875 °C per BIT is achieved.
0000 0000 ...................................................................... corresponds to -20 °C
1111 1111 ........................................................................ corresponds to 120 °C
If a higher resolution is required then a (phsical) signal can also be "digitized" with two (or more) bytes. In principle,
there are no limits to this.

Parallel Data Transmission


The transmision of the single bytes can be made in such a way that each bit has its own line.
This means that eight lines are required. This procedure is suitable when large amounts of data have to be
transmitted. The large amount of cable required for this is, however, somewhat disadvantageous.

E\WH

1 1 0 0 0 1 1 0

OLQHV

Serial Data Transmission


If the single bits are transmitted one after the other using just a single line then this procedure is referred to as serial
data transmission. Using this method, however, only relatively short transmission paths can be bridged. The greater
the rate of transmission, the shorter the line length (1 Mbit/s up to 40 m and 50 Kbit/s up to 1000 m).

0 E\WH
1
1
0
0 OLQH
0
1
1

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DATA BUS
The term CAN (= Controller Area Network) originates from computer technology and, when related to tractors,
means the electronic coupling (i.e. networking) of control units.
Within a data bus system, individual control units are linked to each other in a network can therefore exchange data.
As all control units connected to the bus participate in the data exchange, the control units in such a system are
also called bus users.
Note:
‡ The bus users are connected in parallel to the data bus.
‡ Data transmission is effected serially.

EEM

CAN Data Bus

ARU FMGR MONITOR

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4002-10

Function
The CAN data bus is a bi-directional bus.
This means that every control unit which is connected can transmit and receive.
Conditioning an analogue signal
‡ A sensor transmits an analogue signal, e.g. engine coolant temperature (the voltage is the signal value), to an
assigned control unit
‡ In the control unit, the analogue signal is conditioned (digitalised) by an AD converter and converted into
a numeric code
‡ A data telegram is also created in the control unit
‡ The signal value is a part of the data telegram
Conditioning a digital signal
‡ A sensor transmits a digital signal, e.g. engine speed (the frequency is the signal value), to an assigned control
unit
‡ In the control unit, the digital signal is converted into a numeric code by a code converter
‡ A data telegram is also created in the control unit
‡ The signal value is a part of the data telegram
Forwarding the data telegram
The data telegrams are sent to the data bus. Every control unit connected to the data bus can read and process the
signal value in the data telegram as required.

Message-related addressing
This means that every message is assigned one fixed address (identifier) that identifies the contents of the message
(e.g. engine speed).
The CAN protocol can allow up to 2048 messages in the case of an 11-bit identifier and up to 500 million for a 29-bit
identifier. The data capacity per message is up to 8 bytes.
A receiver evaluates only those messages (data telegrams) that are stored in its list of messages to be received
(acceptance test).
Advantages:
‡ Sensor lines must be led to the nearest control unit. This results in much less cable being used with a
concomitant reduction in plug connections and thereby a reduced number of possible error sources.
‡ Improved EMC (= electromagentic compatibility) and therefore less trouble-prone.
‡ Multiple use of signals and thereby less sensors.
‡ Better and more exact diagnosis possibilities using the CNH Service Tool.
‡ Control units can be programmed when assembled in the vehicle (flashing).

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Can bus line


Design
The CAN data bus is a special twisted two-wire line. The users (control units) are connected in parallel to this line.
Data transmission is made redundantly via both lines, whereby the bus levels are mirrored (i.e. if the level at one line
is 0 then the other line transmits level 1, and vice versa).
Dual-line mode
Dual-line mode is used for several reasons:
‡ Bus systems with a higher clock frequency work in dual-line mode (for physical reasons)
‡ In conjunction with the transposition, there is a (partial) compensation of the electro-magnetic interference
caused by the clock mode
‡ As a security concept
‡ For error recognition.
Screening of the CAN line
The screening is run parallel to the two-wire CAN line. The overal line is thus four-wire.
The screening comprises two wires. The ground potential is carried in one. The second wire carries a plus potential
of 12 V. The CAN line is twisted together with the screening. In some cases, the two-wire screening ends directly in
front of the casing of a bus user.
127( When looking for faults in the CAN cabling, bear in mind that in some cases the 12 V potential of the
screening is supplied by its own fuse. For details, refer to Chapter 4010, "Circuit Diagram" / "Diagram of CAN Bus" in
the CNH Service Tool.
Bus user screening
In addition to the integrated protective measures in their electronic circuits, the bus users are protected against
external electro-magnetic interference by a metal casing. Such interference occurs especially when operating radio
equipment, mobile phones, GPS, etc.
The carrier waves of these systems have a high frequency. The closed metal casing forms a "Faraday cage".
127( In the case of certain bus users, e.g. EEM, the metal casing is connected to the ground supply for the
electronics circuit (refer to Chapter 4010, "Circuit Diagram" / "Diagram of CAN Bus" in the CNH Service Tool).
These electrical connections must also be checked when looking for faults in the CAN cabling.

Standardised representation of a twisted line in the circuit diagram

CAN high

CAN low

+12 V

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4002-12

Can high – Can low


One bus line is theoretically enough for bus systems with a low clock frequency. High-speed bus systems must
always have 2 lines as the voltage level will otherwise be too low.
The data is transmitted redundantly via both lines, whereby the signal is mirrored. Data transmission errors are
thereby reliably recognised (e.g. checksum test).
Data signal on the CAN-high line (example)

Bit 3

Bit 4

Bit 5

Bit 7

Bit 8
Bit 2

Bit 6
Bit 1

Logical 1

Logical 0

0 1 1 0 1 0 0 1

Mirrored signal on the CAN-low line


Bit 3

Bit 4

Bit 5

Bit 7

Bit 8
Bit 2

Bit 6
Bit 1

Logical 1

Logical 0

1 0 0 1 0 1 1 0

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4002-13

CAN High Speed Signal Level

Voltage

5
CAN_H

4
CAN_H
CAN_L / CAN_H
3 CAN_H
CAN_L / CAN_H

2 CAN_L
CAN_L / CAN_H
CAN_L
1
CAN_L
0
Time
Recessive Dominant Recessive

min
nom
max

CAN Recessive Dominant


High Speed min nom max min nom max

CAN H 2.0 V 2.5 V 3.0 V 2.75 V 3.5 V 4.5 V

CAN L 2.0 V 2.5 V 3.0 V 0.5 V 1.5 V 2.25 V

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Topology
"Series" system

HI

LO

FMGR EEM ECCU

Data Transmission
Transmission Protocol
All details of a data transmission are regulated in a transmission protocol.
Data telegrams can only be transmitted when the CAN data bus is free (i.e. when, after the last data telegram, there
is a 3 bit space and no control unit starts transmitting). The bus level is thereby logical one.
Arbitration
If several control units start transmitting simultaneously, then a procedure is introduced in which the message with
the highest priority wins through without any time or bit loss ensuing.
Every control unit that looses the arbitration automatically becomes a receiver and repeats its attempt to transmit as
soon as the CAN data bus is free.
Apart from data telegrams, there are also request telegrams for particular messages. Every control unit that is able
to provide the required data telegram then reacts to this request.
If a voltage peak only occurs at one line (e.g. due to EMC problems) then the receivers can recognise this as an
error and ignore the voltage peak.

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4002-15

DATA PROTOCOL
Structure of the CAN Data Frame – Standard Identifier (11 bits) CAN V2.0A

Arbitration

IFS Start Identifier IDE DLC Data CRC ACK EOF IFS
3 Bit 1 Bit 11 Bit 1 Bit 4 Bit 0-8*8 Bit 15 Bit 2 Bit 7 Bit 3 Bit
Bus idle RTR r0 CRC DEL
1 Bit 1 Bit 1 Bit

Start of Frame (1 bit)


Start bit = Low (dominant). The negative flank is used for phase synchronization of the receivers.

Arbitration Field (12 bits)


Identification of the address (ID 0-ID 10)
The smaller the numerical value in the address, the higher the priority. The highet value 7 bits must not all be
recessive.
Remote Transmission Request – RTR (last bit of the Arbitration Field)
RTR = LOW – Telegram contains data
RTR = HIGH – Telegram contains request to send data

Control Field
ldentifier Extension – IDE (1 bit)
IDE = LOW – Standard Identifier – there are no further Identifier bits
r0 = 1 reserved bit for subsequent extensions

Data length Code – DLC (4 bits)


Identifies the number of data bytes in Data Field

Data Field
0 - 8 byte data can be transmitted per Data Frame.

CRC Field (15 bits)


Cyclic Redundancy Code – CRC
‡ The CRC sequence is formed (on the transmission side) from the data flow (without stuff bits) from Start of Frame
+ Arbitration Field + Control Field + Data Field (if available).
‡ The CRC Check recognises up to 5 individual errors per message, up to 15 burst errors per message (errors that
directly follow each other), all errors with an uneven number per message
CRC Delimiter (1 bit – recessive)

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4002-16

Acknowledge Field (2 bits)


‡ 1st. bit (ACK slot) is transmitted recessively by the transmitter. Receivers that have received a valid message
acknowledge receipt with a dominant bit.
‡ 2nd. bit is transmitted recessively as an ACK delimiter.

End of Frame – EOF "Data/Remote Frame" (7 bits – recessive)


A stuff bit is not generated; normally a stuff bit is added after five bits of the same level.

lnter Frame Space – IFS (3 bits – recessive)


Identifies the period of time between a correctly received telegram and transfer into the respective
message buffer.

Bus Idle (recessive)


‡ Bus is not assigned
‡ Every bus user can start the transmission of a new frame by means of a Start bit

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4002-17

Structure of the CAN Data Frame – Standard Identifier (29 bits) CAN V2.0B

Arbitration

IFS Start Identifier Data CRC ACK EOF IFS


IDE Identifier r1 DLC
3 Bit 1 Bit 11 Bit 0-8*8 Bit 15 Bit 2 Bit 7 Bit 3 Bit
1 Bit 18 Bit Bit 4 Bit
Bus idle SRR RTR r0 CRC DEL
1 Bit 1 Bit Bit 1 Bit

Start of Frame
Start bit = Low (dominant). The negative flank is used for for phase synchronization of the receivers.

Arbitration Field
Identification of the address (ID18-ID28)
The smaller the numerical value in the address, the higher the priority. The highet value 7 bits must not all be
recessive.
Substitute Remote Request – SRR (1 bit)
Replacement for the RTR bit from the standard CAN (CAN V2.0A); otherwise meaningless
ldentifier Extension – IDE (1 bit)
IDE = HIGH – there are further 18-bit identifiers in the 2nd. Identifier Field (ID 17-ID 0)
Remote Transmission Request – RTR (last bit of the Arbitration Field)
RTR = LOW – Telegram contains data
RTR = HIGH – Telegram contains request to send data

Control Field
r1 / r0 = 2 reserved bits for subsequent extensions

Data length Code – DLC (4 bits)


Identifies the number of data bytes in Data Field

Data Field
0 - 8 byte data can be transmitted per Data Frame.

CRC Field (15 bits)


Cyclic Redundancy Code – CRC
‡ The CRC sequence is formed (on the transmission side) from the data flow (without stuff bits) from Start of Frame
+ Arbitration Field + Control Field + Data Field (if available).
‡ The CRC Check recognises up to 5 individual errors per message, up to 15 burst errors per message (errors that
directly follow each other), all errors with an uneven number of errors per message
CRC Delimiter (1 bit – recessive)

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4002-18

Acknowledge Field (2 bits)


‡ 1st. bit (ACK slot) is transmitted recessively by the transmitter. Receivers that have received a valid message
acknowledge receipt with a dominant bit.
‡ 2nd. bit is transmitted recessively as an ACK delimiter.

End of Frame – EOF "Data/Remote Frame" (7 bits – recessive)


A stuff bit is not generated; normally a stuff bit is added after five bits of the same level.

lnter Frame Space – IFS (3 bits – recessive)


Identifies the period of time between a correctly received telegram and transfer into the respective message buffer.

Bus Idle (recessive)


‡ Bus is not assigned
‡ Every bus user can start the transmission of a new frame by means of a Start bit

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4002-19

Structure of the CAN Remote Frames Identifier

Data frame (CAN 2.0A with 11-bit identifier)

IFS Start Identifier IDE DLC CRC ACK EOF IFS IDLE/
3 Bit 1 Bit 11 Bit 1 Bit 4 Bit 15 Bit 2 Bit 7 Bit 3 Bit Next telegram
Bus idle RTR r0 CRC DEL
1 Bit 1 Bit
1 Bit

Remote Frame (CAN 2.0B with 29-bit identifier)

IFS Start Identifier CRC ACK EOF IFS


IDE Identifier r1 DLC
3 Bit 1 Bit 11 Bit 15 Bit 2 Bit 7 Bit 3 Bit
1 Bit 18 Bit Bit 4 Bit
Bus idle SRR RTR r0 CRC DEL
1 Bit 1 Bit Bit 1 Bit

CAN Remote Frame


Receivers of a message can:
‡ Wait for a Data Frame triggered by the Transinit job in the corresponding transmitter
‡ Request a transmitter with a Remote Frame to transmit the current data
Independent of the Data Length Code (DLC), a Remote Frame does not contain any data (RTR bit is recessive).
Depending on the priority of the Remote Frame, the answer can be delayed by higher priority telegrams.
All nodes (bus users) at the CAN bus can receive the requested data telegram, whereby data consistency is ensured
in the network.

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ERROR DETECTION
Faults can result in errors during data transmission. Such transmission errors must be detected and rectified. In the
CAN protocol, there are two different error-detection levels:
1 Mechanisms on the Data Frame level
2 Mechanisms on the Bit level

Mechanisms on the Data Frame level


Cyclic Redundancy Check
The transmitter calculates check bits from the message to be transmitted; these check bits are transmitted along
with the message in the "CRC field" of the data telegram. The receiver re-calculates these check bits from the
received message and compares them with the received check bits.
Frame Check
This mechanism checks the structure of the transmitted frame by checking the bit fields with a pre-determined fixed
format as well as the frame lengths. The errors detected by the Frame Check are called format errors.

Mechanisms of the Bit Level


Monitoring
Each station observes the bus level when transmitting and thereby recognises differences between the transmitted
bit and the received bit. This allows global and local bit errors at the transmitter to be reliably detected.
Bit Stuffing
In every data telegram, a maximum of 5 consecutive bits can have the same polarity between "Start of Frame" and
the end of the "CRC Field". After each 5 identical consecutive bits, the transmitter attaches a bit of the opposite
polarity into the bit stream. The receivers remove these bits after receiving the message.

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TROUBLESHOOTING
Interrupting the Transmission
If any station on the CAN bus detects an error then it interrupts the current transmission by transmitting an error
message. The error message consists of 6 dominant bits.
The error message informs all connected control units of a locally occurring error; these then ignore the
subsequently transmitted messages.

Resumption of the Transmission


After a short pause, all control units are then once more able to transmit, whereby the message with the highest
priority once again wins out.
The control unit whose message has caused the error also begins to re-transmit its message (automatic repeat
request).

Realtime Transmission
To be able to process data in realtime, the data must be transmitted quickly. This not only presupposes a fast
physical data transmission path, but also requires a fast allocation on the bus if several control units want to transmit
simultaneously.
To take into account the various levels of urgency of messages that are transmitted via the bus, there are various
priorities for the single messages. The advance angle (hydrostat) has, e.g. very high priority, the oil temperature
value medium priority and the service message low priority.
Example:
If several control units want to transmit simultaneously then the bus access conflict is triggered by the respective
identifier via "bit arbitration".
On transmitting the Arbitration Field, the transmitter checks after every bit whether it is still authorized to transmit or
whether another control unit is transmitting a message of higher priority. When a recessive bit transmitted by the first
transmitter is overwritten by a dominant bit from another transmitter then the first transmitter loses its authorization to
transmit (arbitration) and becomes a receiver.
The first control unit (N2) loses the arbitration with bit 3. The third control unit (N3) loses the arbitration with bit 7. The
first control unit (N1) retains access to the bus and can transmit its message.

User 1
Node 1
High priority

User 2
Node 2
Receive only Low priority

User 3
Node 3
Receive only Medium Priority

CAN Bus CAN Bus


Recessive
Line
Dominant

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4002-22

TRANSMISSION SPEED
Different CAN data busses are used. They are mainly differentiated by their various transmission speeds. If one bit
per second is transmitted on a line then the transmission speed is one baud (Jean Maurice Baudeot – French
lineman)
1 baud (Bd) ........................................................................................................................... 1 bit/sec.
1 kbaud (kBd)..................................................................................................................1024 bits/sec.

Data bus systems currently in use


125 kBd................................................................................................................... Å125,000 bits/sec.
250 kBd......................................................................................................................250,000 bits/sec.
500 kBd......................................................................................................................500,000 bits/sec.
5,785.6 kBd (optical data bus) .................................................................................5,785,600 bits/sec

A maximum of 135 bits (11-bit identifier) and 160 bits (29-bit identifier) are transmitted for a data telegram.
The number of data telegrams that can be transmitted per second can be calculated from these values as follows:

125 kBd (11-bit ID) .............................................................................................. 925 telegrams / sec.


125 kBd (29-bit ID) .............................................................................................. 781 telegrams / sec.
250 kBd (11-bit ID) ............................................................................................ 1851 telegrams / sec.
250 kBd (29-bit ID) ............................................................................................ 1562 telegrams / sec.

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4002-23

TELEGRAM LENGTH
Maximum length of a telegram for standard frames (11-bit identifier) = 135 bits.
The transmission time for a telegram is 540 µs at 250 kBd.
Sections Number of bits
Start ............................................................................................................................................................. 1
Identifier ......................................................................................................................................................11
RTR ............................................................................................................................................................. 1
Contrl ........................................................................................................................................................... 6
Data ........................................................................................................................................................... 64
CRC ........................................................................................................................................................... 15
CRC Dlimiter ................................................................................................................................................ 1
Staff .................................................................................................................................................. max. 24
ACK ............................................................................................................................................................. 2
EOF ............................................................................................................................................................. 7
IFS ............................................................................................................................................................... 3

Maximum length of a telegram for standard frames (29-bit identifier) = 160 bits.
The transmission time for a telegram is 640 µs at 250 kBd.
Sections Number of bits
Start ............................................................................................................................................................. 1
Identifier ......................................................................................................................................................11
SRR ............................................................................................................................................................. 1
IDE ............................................................................................................................................................... 1
Identifier ..................................................................................................................................................... 18
RTR ............................................................................................................................................................. 1
Contrl ........................................................................................................................................................... 6
Data ........................................................................................................................................................... 64
CRC ........................................................................................................................................................... 15
CRC Dlimiter ................................................................................................................................................ 1
Staff .................................................................................................................................................. max. 29
ACK ............................................................................................................................................................. 2
EOF ............................................................................................................................................................. 7
IFS ............................................................................................................................................................... 3

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4002-24

SGR
VP30

Sva 6-51350 EN
Transmision bus
Getriebe Bus
AUX
1
Service

29 bit ID 250 kBaud


Tool FMGR AUX
11 bit ID 500 kBaud
2
AUX
3
EEM ICU FSS
AUX
4
AUX
Vehicle bus
Fahrzeug Bus
5
29 bit ID 250 kBaud

EDC
ADIC KPAD TC ECCU ARU
Gerät
ISO Bus

29 bit ID 250 kBaud ISO


Bus
= Matching resistor Virtual GPS
SC03E068

Edition 05-2003
4002-25

CENTRAL GATEWAY
Efficient data bus systems are used in automotive engineering for the communication between individual control
units. However, it has become apparent that it is not useful to connect all control units to the same (common) data
bus.
Different function areas, such as the gearbox management, operating management and engine management, as
well as the distribution of the data bus load, result in bus systems that work parallel. These differ through the
transmission speed, transmission protocol and transmission medium.
The gateway is the connecting link between the data bus systems located in the vehicle. However, a gateway can
also assume additional tasks of a control unit (e.g. operation).
Gateways: FMGR, ECCU and EEM.

SERVICE TOOL
The existence of a common interface between the various data bus systems allows important functions to be
implemented. For example, the various data bus systems can be accessed via a common diagnostics interface for
the CNH SERVICE TOOL. In addition, in the event of a data bus failure, certain important tests are easily accessible
and can thus be carried out in a short time via the diagnostics interface when looking for the fault in the CAN bus
line.

Sva 6-51350 EN Edition 05-2003


)81&7,21$/'(6&5,37,21$1'
7528%/(6+227,1*±$',&



CNH Österreich GmbH Sva 6-91700 EN © 2004 CNH Österreich GmbH


Technical Documentation March 2004
A – 4300 St. Valentin, Steyrer Straße 32
4003-3

TABLE OF CONTENTS
TABLE OF CONTENTS .........................................................................................................................................3

SPECIAL TOOLS ...................................................................................................................................................5

GENERAL DESCRIPTION ....................................................................................................................................6

GENERAL NOTES ................................................................................................................................................7


Handling plug-in connections ............................................................................................................................7
Regulations for using jumper cables for starting ...............................................................................................7
Regulations for carrying out electro-welding work on the tractor or on an implement ......................................7

ANALOG AND DIGITAL DISPLAYS ......................................................................................................................8

WARNING AND INDICATOR LAMPS ...................................................................................................................9

ANALOG DISPLAY INSTRUMENTS ...................................................................................................................10


Engine speed display ......................................................................................................................................10
Coolant temperature display ...........................................................................................................................10
Fuel level indicator ..........................................................................................................................................10

DIGITAL DISPLAY INSTRUMENTS ....................................................................................................................11


Display 1 .........................................................................................................................................................11
Display 2 .........................................................................................................................................................11
Display 3 .........................................................................................................................................................11

ADJUSTMENT BUTTONS ...................................................................................................................................12

DMD (DOT MATRIX DISPLAY) ...........................................................................................................................13


Warnings .........................................................................................................................................................13
Information ......................................................................................................................................................13
Service ............................................................................................................................................................14

KEYPADS ............................................................................................................................................................15
Service interval key .........................................................................................................................................15
Odometer key .................................................................................................................................................15
Hectare counter key ........................................................................................................................................16
Hectare performance / hour key .....................................................................................................................16
Menu up scroll key ..........................................................................................................................................16
Enter / Save key ..............................................................................................................................................16
Menu down scroll key .....................................................................................................................................16
Escape key without saving ..............................................................................................................................16
Key for displaying 3-point hitch position front / rear ........................................................................................17
Key for displaying PTO shaft speed front / rear ..............................................................................................17
Wheel slip key .................................................................................................................................................17
Battery voltage key .........................................................................................................................................17
Engine operating hours key ............................................................................................................................17
Key for tractor RESET ....................................................................................................................................18
Key for compressed air trailer braking system ................................................................................................18
Changeover key for driving strategy and speed range display .......................................................................18

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4003-4
MENU SETTINGS ............................................................................................................................................... 19
Setup menu 1 ................................................................................................................................................. 19
Setup menu 2 ................................................................................................................................................. 21
Plugs on the ADIC .......................................................................................................................................... 23

TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM ............................................................................ 24

TEST VALUES FOR SPEED DISPLAYS ............................................................................................................ 29

TEST VALUES FOR ANALOG DISPLAYS AND WARNING .............................................................................. 29

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4003-5

SPECIAL TOOLS

SD00C040 SD00D003

MULTIMETER (Fluke 79 or similar) DIAGNOSTIC BOX, 100-POLE


(1TSW 516-1) 380000058 (1TSW 528-1)
380000061 (1TSW 528-44)

SD00C038

SD04A006
MEASURING CABLES (pin diameter - 4 mm)
(1TSW 528-11) "Y" ADAPTER, 26-POLE (ADIC) 38000149226

SD04A002

TEST LAMP (with 21 W bulb)


1TSW 528-2

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GENERAL DESCRIPTION
ADIC = Analog-digital instrument cluster

The ADIC comprises the following components:


Analog display instruments
• Engine speed
• Coolant temperature
• Fuel tank level

Digital display instruments


• Driving speed
• PTO shaft speed front / rear (switchable)
• Lifting height of 3-point hitch front / rear (switchable)
• Wheel slip
• Time

DMD display for graphic symbols


(DOT MATRIX DISPLAY)

Adjustment buttons
• ADIC lighting (dimmer)
• Time (hours, minutes)

Warning and indicator lamps

Acoustic warning facility

Keypad with 16 function keys

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GENERAL NOTES
Handling plug-in connections
• High-pressure cleaning should be avoided in the vicinity of electrical plug-in connections.
• Plug-in connections that connect signal lines from sensors must not be treated with contact or cleaning spray
(e.g. MOS2) as this can cause malfunctions.
NOTE: Plug-in connections must be kept clean and dry.

Regulations for using jumper cables for starting


• Only connect in parallel to another 12 Volt supply (battery or vehicle).
• Do not reverse connect the poles.
• Take care when using starting aid devices – voltage peaks must not exceed 16 V.
• Never remove jumper cables during the starting procedure and ensure that the cable clamps cannot
inadvertently fall off. This will result in voltage peaks.

Regulations for carrying out electro-welding work on the tractor or on an


implement
• Switch the engine off. Ignition switch S1 must be in position ”0”.
• The ADIC must be disconnected. (CN1-CN3)
• Do not disconnect the battery.
• Disconnect the implement from the tractor (if possible) when performing welding work on implements.
• Connect the welding equipment ground to the part to be welded.
• The cables for the welding equipment must not run in the direct vicinity of electronic units, their supply lines,
sensors and their signal lines or cross such lines.
NOTE: Cables for welding equipment carry high currents during the welding process. These currents produce
powerful electromagnetic fields (alternating currents produce alternating fields). Memory modules / microprocessors
could get damaged.

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ANALOG AND DIGITAL DISPLAYS

10
2
1 3

5 4 6 9
7 8

SS04B181

1. ENGINE SPEED 6. PTO SHAFT SPEED / 3-POINT HITCH


POSITION / SLIP DISPLAY
2. COOLANT TEMPERATURE 7. TIME DISPLAY
3. FUEL LEVEL 8. ADJUSTMENT BUTTON – HOURS
4. DRIVING SPEED 9. ADJUSTMENT BUTTON – MINUTES
5. DIMMER ADIC LIGHTING 10. DMD (DOT MATRIX DISPLAY)

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WARNING AND INDICATOR LAMPS

7 8 9 10 11 12 13
6 14
5 15

4 16

3 20
17
21
2 18
22

1 19

28 27 26
25 23
24

SS04B181

1. FUEL CHECK / RESERVE 15. FUEL PRE-HEATING


2. FAST STEER 16. ENGINE OIL PRESSURE
3. DIFFERENTIAL LOCK 17. FRONT PTO SHAFT
4. 4-WHEEL DRIVE 18. REAR PTO SHAFT MANAGEMENT
5. TRAILER TRAFFICATOR, 2ND TRAILER 19. REAR PTO SHAFT
6. TRAILER TRAFFICATOR, 1ST TRAILER 20. FORWARD DRIVING DIRECTION
7. SIDELIGHT 21. N = NEUTRAL POSITION, TRANSMISSION
8. HIGH BEAM 22. REVERSE DRIVING DIRECTION
9. STOP WARNING LAMP 23. TRAFFICATOR INDICATOR, RIGHT
10. ENGINE MANAGEMENT 24. ENGINE SPEED REDUCTION
11. WARNING LAMP, DOT MATRIX DISPLAY 25. TRAFFICATOR INDICATOR, LEFT
12. SPRUNG FRONT AXLE 26. ENGINE BACK PRESSURE BRAKE
13. PARKING BRAKE 27. PRE-GLOWING INDICATOR
14. WARNING LAMP, TRAILER BRAKE 28. CHARGING INDICATOR LAMP

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ANALOG DISPLAY INSTRUMENTS

3 2

1
5

4
SS04B181

Engine speed display


The engine speed (1) is displayed in revs per minute x 100. The red area starts at 2500 rpm.

Coolant temperature display


The coolant temperature display (4) is divided into three areas.
Blue field → Temperature too low
Neutral area → Desired operating temperature
Red field → Temperature too high
If the temperature exceeds 110 °C, the temperature symbol appears on the DMD, the red warning lamp (3) starts
flashing and an acoustic warning signal sounds. (Critical warning!)
NOTE: The engine switches off automatically when the temperature exceeds 110 °C for more than 30 seconds.

Fuel level indicator


The fuel level indicator is divided into the areas EMPTY, RESERVE (red area), HALF FULL and FULL.
If the pointer reaches the red area, the indicator lamp (6) for fuel check (reserve) lights up.
The tank is then approx. 1/6 full.

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DIGITAL DISPLAY INSTRUMENTS

7
8

4 1 2 3 5 6

SS04B182

Display 1
The driving speed is indicated in kilometres per hour in display 1. The display can be switched over to miles per hour
in Setup menu 2.

Display 2
The following values can be called up in display 2 by pressing function keys 7 - 9.
• Lifting height of rear 3-point hitches – Display from approx. 10 - 96 % (press key 7 briefly)
• Lifting height of front 3-point hitches – Display from 0 - 100 % (press key 7 longer)
(front display only possible with front hitch management)
• Rear PTO shaft speed – Display in revs per minute (press key 8 briefly)
• Front PTO shaft speed – Display in revs per minute (press key 8 longer)
• Slip – Display in % (display only possible with radar sensor)

Display 3
The time is displayed in hours and minutes in display 3. The display can be switched over from 12 to 24 hr indication
in Setup menu 1.

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ADJUSTMENT BUTTONS
Dimmer adjustment button for ADIC lighting
The brightness of the display instruments and the function keys can be adjusted with the lighting switched on. The
brightness gradually changes on pressing the button (4) for a brief moment.
When the button is kept depressed, the dimmer runs through the whole setting range from bright to dark.
Hours / minutes adjustment button
Turn the ignition switch to ON and keep the Hours button (5) depressed for approx. 5 seconds. The time is adjusted
by one hour / minute by pressing button 5/6 for a short moment. When button 5/6 is kept depressed, you run through
the hours / minutes display.
After making the setting, wait approx. 5 sec. until the values stop flashing. (The new time setting is stored.)
Operating hours setting
The operating hours setting can be adjusted upwards, if necessary (e.g. a new ADIC is fitted).
• Turn the ignition switch to ON and keep the Hours button (5) and Minutes button (6) depressed for 15 seconds.
The value can be increased by pressing the Hours button.
• To store the value which has been set, keep both buttons (5 and 6) depressed for 15 seconds.
NOTE: The operating hours cannot be corrected downwards.

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DMD (DOT MATRIX DISPLAY)


The display symbols are split into four main groups:
• Warning
• Information
• Service
• System error

Warnings
These symbols refer to a critical fault during operation of the tractor.
Stop the tractor as soon as possible, determine the cause and rectify the
fault. SS02K039
Warnings are also supported acoustically and are split into
”NON-CRITICAL ALARMS” and ”CRITICAL ALARMS”.

NON-CRITICAL ALARM: In conjunction with the yellow warning lamp – Alarm sounds 2 x 1 second

CRITICAL ALARM: In conjunction with the red ”STOP” warning lamp – Alarm sounds periodically

Graphic symbols
1. COOLANT TEMPERATURE TOO HIGH – Red warning lamp
flashes and alarm sounds periodically.

2. RESERVOIR PRESSURE IN TRAILER BRAKE SYSTEM TOO


LOW – Red warning lamp flashes and ”Trailer brake” warning lamp
(item 14, page 9) lights up.
3. ENGINE OIL PRESSURE TOO LOW – Red warning lamp flashes,
alarm sounds periodically and ”Engine oil pressure” warning lamp
(item 16, page 9) lights up.

Information
The information symbols do not actually indicate a fault during operation of the tractor but they should not be ignored.
Take appropriate measures, as required.
1. LC display (LCD)/dot matrix display (DMD) brightness setting.

2. Speed display and PTO shaft operation


dot matrix symbol

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4003-14

Service
These symbols inform the driver that basic tractor functions are impaired, for example: Air filter dirty, Service display,
etc.
1. Engine air filter blocked.
Yellow warning lamp flashes twice (no acoustic alarm)

2. Brake fluid level too low – in conjunction with red warning lamp

3. Engine coolant level too low – in conjunction with yellow warning


lamp

4. Fuel contamination caused by water – in conjunction with yellow


warning lamp (no acoustic alarm)

5. Hydraulic oil filter blocked – in conjunction with yellow warning lamp

6. Fuel filter blocked – in conjunction with yellow warning lamp

7. Small (”light”) service.


Yellow warning lamp flashes twice (no acoustic alarm)

8. Big (”heavy”) service.


Yellow warning lamp flashes twice (no acoustic alarm)

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KEYPADS

1 9

2 10

3 11
4
12
5
13

6
14

7 16 15
8
SS04B183

1. SERVICE INTERVAL 9. CHANGEOVER KEY FOR DISPLAYING


3-POINT HITCH POSITION FRONT / REAR
2. ODOMETER 10. CHANGEOVER KEY FOR DISPLAYING
PTO SHAFT SPEED FRONT / REAR
3. HECTARE COUNTER 11. WHEEL SLIP
4. HECTARE PERFORMANCE / HOUR 12. BATTERY VOLTAGE
5. MENU UP SCROLL KEY 13. ENGINE OPERATING HOURS DISPLAY
6. ENTER / SAVE KEY 14. KEY FOR TRACTOR RESET
7. MENU DOWN SCROLL KEY 15. TRAILER COMPRESSED AIR BRAKE SYSTEM
8. ESCAPE KEY WITHOUT SAVING 16. CHANGEOVER KEY FOR DRIVING STRATEGY
AND SPEED RANGE DISPLAY

Service interval key


The Service interval key (1) is used to call up the remaining driving hours until the next service (LIGHT / HEAVY) is
due.

Odometer key
The odometer key is used to display the distance travelled in km on the
DMD and to save it.
Two displays (”Memory A” and ”Memory B”) are available.
The display ”Memory A” can be used to measure partial distances and
the display ”Memory B” to measure the total distance, for example.
Press the Odometer key (2) once to display Memory A (partial distance)
and once again to display Memory B (total distance).

Display ranges:
0 - 19.999 km → Display: 0.001 km
20 - 199.99 km → Display: 0.01 km
200 - 1,999.9 km → Display: 0.1 km SS02K050

2000 - 19,999 km → Display: 1 km


To delete the stored value, keep the key (2) in the respective display (A or B) depressed for 3 seconds.

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4003-16

Hectare counter key


The working width of the implement used must be stored before
activating the hectare counter.
(see Setup menu 1, page 19)
The key (3) is used to activate the hectare counter / memory. The area
symbol appears on the DMD and the total area that has been covered
is displayed in ha.

Display ranges:
0 - 199.99 ha → Display: 0.01 ha
200 - 1,999.9 ha → Display: 0.1 ha
2000 - 19,999 ha → Display: 1 ha
SS03A018

The following operating modes can be selected by pressing the key (3) several times:
• OFF
The hectare counter is switched off.
• ON
The hectare counter is switched on. The counting function is active as long as the tractor is driven, independent
of the position of the implement.
• A (AUTOMATIC)
The hectare counter is switched on. The counting function is only active as long as the tractor is driven and the
implement is lowered. Raising the implement interrupts the counting function.
To delete the stored values, keep the key (3) depressed in the OFF operating mode for 3 seconds.

Hectare performance / hour key


The working width of the implement used must also be stored before
activating the hectare performance display.
Press key (4) to access the Hectare performance menu.
The symbols for area and time and the probable hectare performance
(ha/h), dependent on the momentary driving speed, appear on the
DMD.
The hectare performance (ha/h) is displayed in steps of 0.01 ha. If the
hectare counter is in operating mode A (Automatic), then the display
reads 0 as long as the implement is raised. (The counting function is not
active.)

Menu up scroll key SS02K051

Menu up key or number entry. Press this key several times to scroll the menu upwards or to change a number.

Enter / Save key


For selecting the setting and programming modes (e.g. for working width adjustment, 12/24 clock adjustment, beeper
on/off).

Menu down scroll key


Menu down key or number entry. Press this key to scroll the menu downwards or to select a number on the dot matrix
display (DMD).

Escape key without saving


Press here to close or abort setting and programming modes without storing them.

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4003-17

Key for displaying 3-point hitch position front / rear


Press briefly to get the lifting height of the rear linkage and longer to get
the lifting height of the front linkage (if fitted).
Here you can read off the position of the 3-point hitch on the display,
starting at approx. 10 % (lowest position) up to approx. 96 % (maximum
lifting height).
In the case of a front hitch with sensor, 0 - 100 is displayed.
NOTE: In the case of a front hitch without a sensor, the lifting height
cannot be displayed and a switchover is not possible.

SS02K037

Key for displaying PTO shaft speed front / rear


Press briefly to get the speed of the rear PTO shaft and longer to get the
speed of the front PTO shaft (if fitted).

Wheel slip key SS02K038

The rear wheel slip is displayed as a single or two-digit percentage


figure (%) (radar version only, otherwise key does not have a function).
The slip value is calculated on the basis of the information from the
transmission speed sensor (theoretical driving speed) and the radar
sensor (actual driving speed).

SS02K036

Battery voltage key


Press this key to display the battery symbol together with the digital display of the battery voltage.

Engine operating hours key


Press this key to display the total operating hours count of the tractor. The counted hours should be used as a guide
for the tractor service intervals.

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4003-18

Key for tractor RESET


Key for tractor reset. If this key is pressed for approx. 10 seconds (until display A emits a short beep), the following
values are reset to the factory setting.
• Oil quantities for lowering for all 5 AUXs to 50 %
• Stored sequences in the headland management menu are deleted.
• The engine speed for engine speed reduction is reset to 1100 rpm.
• The 3-point hitch position (rear) at which the engine speed is raised or lowered and the PTO shaft is switched
on / off in PTO shaft management is reset to 50 %.
• The timers are inhibited and reset to 0.
• The momentary position of the front hitch (with sensor) is stored so that the front hitch does not move if the front
hitch pushbutton on the armrest is accidently pressed.
• In addition, this key is used, after being pressed for 5 seconds, to reset an active fault displayed on the ADIC so
that the driver has the normal ADIC display and can thus finish his work (only the yellow/red warning lamp
remains active). This function is only valid when there is an active fault. This fault is then suppressed. If another
fault occurs, then this is immediately displayed.

Key for compressed air trailer braking system


Press here to display the symbol for the compressed air trailer brake
(if fitted). One bar on the display corresponds to a pressure of approx.
1 bar.

SS04B184

Changeover key for driving strategy and speed range display


Driving strategy, driving range, speed and PTO shaft operation (D). C1,
C2, C3, M1, M2, M3 + km/h and PTO shaft symbol, if the vehicle is in
PTO shaft mode.

SS04B185

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MENU SETTINGS
Setup menu 1
(for the customer)
The following settings can be made in Setup menu 1:
• Switching the beep on/off
• Time display 12 / 24 hour mode changeover
• Setting the working width 6
5
Access:
Turn the ignition switch to the ON position and then keep the Enter
key (6) depressed for 3 seconds.
”SET UP MENU” appears on the DMD.
After 2 seconds, the display automatically switches over to working
7 8
width setting. SS02K033

NOTE: If a fault has occurred (e.g. coolant temperature too high, trailer brake reservoir pressure too low,....), then
the fault must be suppressed by pressing the Tractor reset key (item 14, page 15) for 5 seconds. Otherwise Setup
menu 1 cannot be accessed.

Setting the working width


Example: Working width 4.5 m
• Access Setup menu 1 (see above)
• After 2 seconds, the display automatically switches over to working
width setting

SS03A019

• Press the Enter key (6). A flashing cursor appears at the first place
for entering the working width on the DMD.
• Use the UP scroll key (5) to select the blank space
• Use the DOWN scroll key (7) to shift the cursor to the right to the
next place
• Use the UP scroll key to enter the number 4
• Use the DOWN scroll key to shift the cursor another place to the
right
• Use the UP scroll key to enter the number 5
(if a number is also to be entered at the last place, then proceed in
the same way) SS03A020

• Store the setting by pressing the Enter key (6)

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Setting the beep


A beep sounds on pressing one of the function keys. This beep can be
switched on or off as required.
• Access Setup menu 1 (see page 19)
• Use the scroll bars (5 / 7) to call up the ”BEEP ON/OFF” submenu
• Press the Enter key (6) and set the arrow (X) in the display to ON /
OFF by means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6) once again
X

SS03N025
Switching over the time display
• Access Setup menu 1 (see page 19)
• Use the scroll bars (5 / 7) to call up the ”CLOCK SETTING”
submenu
• Press the Enter key (6) and set the arrow in the display to 12 / 24 by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6) once again

SS03H004

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Setup menu 2
(for the workshops)
The following settings can be made in Setup menu 2:
• Changing the speed display (mph – km/h)
• Programming compressed air sensor available / not available
• Programming the service indicator 6
• Programming the driving speed display 5
(theoretical or via the radar sensor)
Access:
Turn the ignition switch to the ON position and, within 5 seconds, keep
the Enter key (6) and the Escape key (8) depressed (simultaneously) for
3 seconds. 7 8
SS02K033

Programming the compressed air sensor


• Access Setup menu 2 (see above)
• On entering the menu, the display automatically switches over to
the ”AIRBRAKE SENSOR” menu
• Turn the ignition switch ”OFF” and then ”ON” again

SS04A034

• Press the Enter key (6) and set the arrow to ”YES” or ”NO” by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6)

SS04A035

Switching over the speed display


• Access Setup menu 2 (see above)
• Use the scroll keys (5 / 7) to scroll through the menu until the
”MPH / Km/h” menu appears
• Press the Enter key (6) and set the arrow to the required display by
means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6)

SS03N026

Sva 6-91700 EN Edition 03-2004


4003-22

Programming the service indicator


This function can be used to program two service interval displays.
Factory setting:
LIGHT = 250 operating hours
HEAVY = 250 operating hours
• Access Setup menu 2 (see page 21)
• Use the scroll keys (5 / 7) to scroll through the menu until the
”SERVICE INTERVAL” menu appears

SS04A036
• Press the Enter key (6) and select the ”LIGHT” or ”HEAVY” display
by means of the scroll keys (5 / 7)

SS04A037

• Press the Enter key (6) again. A flashing cursor appears at the first
place in the entry field
• Enter the required number by pressing the UP scroll key (5). Jump
to the next place in the entry field by means of the DOWN scroll
key (7).
Use the UP scroll key again to enter the required number. Enter the
third number in the same way.
• Store the setting by pressing the Enter key (6)

SS04B188

NOTE: Enter the hours after which the Service message is to appear (e.g. 250).
Do not enter the operating hours after which the next service is due (e.g. 1250).

Sva 6-91700 EN Edition 03-2004


4003-23

Programming the driving speed display


With this function it is possible to select whether the following information is displayed according to the radar signal
or theoretically via the driving speed sensor.
1. Current driving speed
2. Distance measurement (odometers ”A” and ”B”)
3. Hectare counter
4. Hectare performance / hour

This function can only be activated if the radar sensor is installed correctly.
• Access Setup menu 2 (see page 21)
• Use the scroll keys (5 / 7) to scroll through the menu until the
”WHEEL / RADAR” menu appears

SS04B186

• Press the Enter key (6) and select the ”WHEEL” or ”RADAR”
display by means of the scroll keys (5 / 7)
• Store the setting by pressing the Enter key (6).
The radar symbol appears on the top left-hand side of the DMD.
NOTE: If the ADIC is set to ”Radar” and the radar fails (radar
defective, faulty fuse,...), then the signal from the driving speed sensor
is automatically used for the display and the calculations. The radar
signal is automatically used again as soon as the radar sensor is
operating again.

SS04B187

Plugs on the ADIC

SV03B032

Sva 6-91700 EN Edition 03-2004


4003-24

TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM


NOTE: Correct measurement results are only ensured when the test conditions are met.

Test conditions
Symbol Meaning of symbol

Ignition switch in position ”0”

Ignition switch in position ”1”

Engine is turning over

X.. Plug

Pin Pin

Plug connected

Plug disconnected

Use a 21 W bulb as a load

NOTE: When measuring the voltage drop of a ground supply cable, the selected test lamp (for loading the cable to
be tested) must be connected from the cable’s terminal to a + supply. The measuring instrument (voltmeter) is
connected parallel to the ground cable.

Special tools required


Tool No. Designation Use

380000058 Diagnostic box, 100-pole General

380001492 26 pole ’Y’ adapter ADIC, plugs CN1 – CN3

1TSW 528-11
(available from 2 measuring cables, 1.5 m General
your dealer)

1TSW 528-2
(available from Test lamp, 21 W For loading supply lines
your dealer)

1TSW 516-1
Multimeter
(available from General
(Fluke 79 or similar)
your dealer)

Sva 6-91700 EN Edition 03-2004


PLUG CN1
Measure- Measure from Measured
Designation Pin Cable Requirements CN1 CN1
ment pin to pin value

Sva 6-91700 EN
Supply, permanent + (+30)
26 CN1/26 U 21W 26 23 13 - 14 VDC
from F41 (3 Amps)

Supply
23 CN1/23 U 21W 23 Batt. 0.1 - 0.3 VDC
Ground

Supply, switched + (+15)


24 CN1/24 U 21W 24 23 13 - 14 VDC
from F14 (15 Amps)

Supply
22 CN1/22 U 21W 22 23 approx. 0.1 VDC
internal ground connection

Ignition switch in position ”1”


1.5 - 1.7 VDC
Dynamo positive (D+) 25 CN1/25 U 25 23
Charging indicator lamp has
13.5 - 14 VDC
gone out

”OFF” approx. 0 VDC


Sidelight (58) 15 CN1/15 U 15 23
”ON” 12 - 14 VDC

Trafficator indicator lamp 12 - 14 VDC


6 CN1/6 U flashes 6 23 alternately at
”right” approx. 0 VDC

Trafficator indicator lamp 12 - 14 VDC


5 CN1/5 U flashes 5 23 alternately at
”left” approx. 0 VDC

Suspension switched off 12 - 14 VDC


Indicator, sprung front axle 13 CN1/13 U 13 23
Suspension switched on approx. 0 VDC

Switch S3 open 12 - 14 VDC


Indicator, air filter 11 CN1/11 U 11 23
Switch S3 closed approx. 0 VDC

Indicator, hydraulics Ignition switch in position ”1” approx. 0 VDC


pressure filter
12 CN1/12 U 12 23 12 - 14 VDC
Engine running

Edition 03-2004
4003-25
PLUG CN1 4003-26

Measure- Measure from


Designation Pin Cable Requirements CN1 CN1 Value
ment pin to pin

Sva 6-91700 EN
Fuel ”OFF”
pre-heating
16 CN1/16 U ”ON”
16 23

Coolant level ok 12 - 14 VDC


Indicator, coolant level 17 CN1/17 U 17 23
Coolant level too low approx. 0 VDC

12 - 14 VDC
Brake fluid level ok
Indicator, brake fluid 7 CN1/7 U 7 23
Brake fluid level too low
approx. 0 VDC

Edition 03-2004
Plug CN2
Measure- Measure from
Designation Pin Cable Requirements CN2 Ground Value
ment pin to pin

Sva 6-91700 EN
Position ”Transport”
12 - 14 VDC
rear 3-point hitch 17 CN2/17 U "Control" 17 approx. 0 VDC
standard signal

Speed standard signal PTO shaft rotating


rear PTO shaft ”540” 6 - 7 VDC
PTO shaft does not rotate 12 - 14 VDC
14 CN2/14 U 14
PTO shaft ”540” at
54 Hz
engine speed of 1900 rpm

Speed standard signal PTO shaft rotating


rear PTO shaft ”1000” PTO shaft does not rotate 6 - 7 VDC
12 - 14 VDC
14 CN2/14 U 14
PTO shaft ”1000” at
engine speed of 1900 rpm 100 Hz

Tractor stationary 12 - 14 VDC


Driving speed
Tractor moving 6 - 7 VDC
standard signal
130 impulses/m
16 CN2/16 U 16 or
505 Hz at
14 km/h

Tractor stationary 12 - 14 VDC


Tractor moving 6 - 7 VDC
Radar sensor 130 impulses/m
standard signal
15 CN2/15 U 15 or
505 Hz at
14 km/h

Edition 03-2004
4003-27
Plug CN3 4003-28

Measure- Measure from


Designation Pin Cable Requirements CN3 Ground Value
ment pin to pin

Sva 6-91700 EN
Hydr. trailer brake
”Italy”
12 CN3/12 U 12

Trafficators 12 - 14 VDC
trailer I 16 CN3/16 U flashing 16 alternately at
approx. 0 VDC

Trafficators 12 - 14 VDC
trailer II 13 CN3/13 U flashing 13 alternately at
approx. 0 VDC

Analog display Sensor B2/1,


Test values:
Tank 14 CN3/14 R replace with 14 see page 29
level resistor

Analog display Sensor B3,


Test values:
Compressed air 15 CN3/15 R replace with 15 see page 29
reservoir pressure resistor

High beam OFF approx. 0 VDC


Indicator, high beam 18 CN3/18 U 18
High beam ON 12 - 14 VDC

Edition 03-2004
4003-29

TEST VALUES FOR SPEED DISPLAYS


Rear PTO shaft speed (standard signal from ADIC to standard signal socket)

Speed in rpm Frequency in Hz

540 54

1000 100

TEST VALUES FOR ANALOG DISPLAYS AND WARNING


Fuel level indicator, analog (signal from sensor B2/1)

Level Resistance in Ω Display area Warning

empty 10
red Yellow lamp ”Refuel” lights up
< 1/6 < 30

1/6 30

1/4 38

> 1/4 > 38 neutral

1/2 76 Yellow lamp ”Refuel” does not light up


3/4 113

full 180

Compressed air indicator, analog (signal from sensor B3)

Pressure in bar Resistance in Ω Display area Warning

0 10

2 52 Red lamp ”Trailer brake” flashes


4 88
neutral
< 5.5

6 124

8 155

10 184

Sva 6-91700 EN Edition 03-2004


&KDSWHU


)81&7,21$/6&+(0$7,&',$*5$06
(/(&75,&$/



CNH Österreich GmbH Sva 6-92771 EN © 2006 CNH Österreich GmbH


Technical Documentation June, 2006
A - 4300 St. Valentin, Steyrer Straße 32
4008-3

&217(176

GENERAL DESCRIPTION ....................................................................................................................................5


Abbreviations ....................................................................................................................................................5
Supply voltages .................................................................................................................................................5
General advise: .................................................................................................................................................5
A27 CAN module and A28 Plug module ---> DBD094270 ...............................................................................6
A30 ARU print DBD094271 ---> ........................................................................................................................6

FUNCTIONAL SCHEMATIC DIAGRAM FOR ADIC ..............................................................................................7

FUNCTIONAL SCHEMATIC DIAGRAM FOR EEM2 .............................................................................................9

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR - SGR ...............................................................................11

FUNCTIONAL SCHEMATIC DIAGRAM FOR FMGR REVERSING FACILITY ...................................................15


FUNCTIONAL SCHEMATIC DIAGRAM FOR ECCU2 ........................................................................................17

FUNCTIONAL SCHEMATIC DIAGRAM FOR EDC .............................................................................................21

FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES ...................................................25


FUNCTIONAL SCHEMATIC DIAGRAM FOR REMOTE CONTROL VALVES - ADDITIONAL FUNCTIONS .....27

FUNCTIONAL SCHEMATIC DIAGRAM FOR FRONT AXLE WITH INDEPENDENT SUSPENSION ................29

FUNCTIONAL SCHEMATIC DIAGRAM FOR CAN BUS ....................................................................................31

FUNCTIONAL SCHEMATIC DIAGRAM FOR ISO BUS ......................................................................................33

Sva 6-92771 EN Edition 06-2006


4008-4

BLANK PAGE

Sva 6-92771 EN Edition 06-2006


4008-5

*(1(5$/'(6&5,37,21
The key electric circuits are shown in the functional schematic diagrams, sub-divided into the individual main com-
ponents, e. g. control units, controllers and display instruments. The complete diagram of the individual electric cir-
cuits and/or functions should help the mechanic gain better comprehension. Faster narrowing down of errors is
thereby possible in the future.
The diagrams are structured so that the supply for each component is shown first. As a rule, the inputs are on the left
and the outputs on the right.
When troubleshooting in the wiring, the circuit diagram and/or list of connectors must be used.

$EEUHYLDWLRQV
ADIC............................................................................................................................ Analogue / digital instrument
ARU.............................................................................................................................................................. Armrest
AUX.........................................................................................................................................Remote control valve
DMD ................................................................................................................................... DOT MATRIX DISPLAY
DZG................................................................................................... Crankshaft position signal (upper dead point)
ECCU2 ....................................................................................................................................... Central control unit
EDC.............................................................................................................. Electronic 3-point hitch control system
EEM2 ..........................................................................................................................................Engine control unit
FMGR........................................................................................................... Vehicle/engine/transmission controller
GSV .................................................................................................................................................... Cyclic supply
HTS ............................................................................................. Field end management (headland management)
ICU ..........................................................................................................................................Performance monitor
KEY PADS ........................................................................................ Function keys for analogue/digital instrument
NTC.......................................................................................................................Negative temperature coefficient
PCB.....................................................................................Printed circuit board (relay circuit, terminal resistance)
PCU.......................................................................................................................... Electronic pumps - control unit
PTC ........................................................................................................................ Positive temperature coefficient
SGR .................................................................................................................................... Transmission controller

6XSSO\YROWDJHV
On-board voltage ...................................................................................................................................... 12 V +2.0
GSV1 ........................................................................................................................................................... 3 V ±0.2
GSV2 ........................................................................................................................................................... 3 V ±0.2
GSV3 ........................................................................................................................................................... 3 V ±0.2
GSV4 ........................................................................................................................................................ 6.4 V ±0.4

*HQHUDODGYLVH
7KHFRQQHFWRUPRGXOH$DQGWKHFDQPRGXOH$ZDVILWWHGLQWUDFWRUVXSWRFKDVVLVQXPEHU'%'
)URP'%'WKHWZRPRGXOHVDUHUHSODFHGE\RQHPRGXOH$7KHQHZPRGXOHKDVQRLQIOXHQFHLQIXQFWLRQ
DQGKDVWKHVDPHFRQQHFWRUVOLNHWKHWZRROGPRGXOHV2QWKHQHZPRGXO$WKHWZRFRQQHFWRUV<$DQG<%ZLOO
EHGURSSHG QRPRUHQHHGHG 

Sva 6-92771 EN Edition 06-2006


4008-6

$&$1PRGXOHDQG$3OXJPRGXOH!'%'

SS05F006

$$58SULQW'%'!

SS05F007

Sva 6-92771 EN Edition 06-2006


4008-7

)81&7,21$/6&+(0$7,&',$*5$0)25$',&
$ $
)$ )$ )$
  
$((0 

X20/1 8 X18/1 11 X24/1 16 X24/1 4


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$)0*5 $(&&8
Q

CN1 26 16 24 23
$$',&
6XSSO\
A4/3 17 18 CN1a 15 16
X70 CN3
CAN H 3LORWODPSVDQGGLVSOD\VFRQWUROOHG
18 26
CAN L YLD&$1%86
42 25
X6/11 X6/8 X29
3LORWODPSVDQGGLVSOD\V 5 5 6
CN1 Speed signal
Generator D+ CN2 6 6 7
25 Starter switch position ON = 0.7V transmission 14 km/h = 504 Hz
16 1 1 2
Engine ON = 12V (Light OFF) Radar screen 14 km/h = 504 Hz
$ $ CN3 15 2 2 1
X12/20 X4/45 PTO shaft speed 1000 rpm = 100 Hz
18 High beam ON = 12V 14 3 3 3
11 3 Button transport 12V, button control 0V
17 4 4 4
X24/1 CN1
5 Lighting ON = 12V
15
X4/52 X4/51 2 A1 ADIC
5 Turn signal left
3 4 A2 EEM2
6 A4 FMGR
4 3  6 Turn signal right A4/3 15-pin plug connection
S A12 Central print
A14 Engine print
CN3 A60 ECCU2
16 Turn signal trailer I A61 Electronics, suspended front axle
B2/1 Fuel tank level transmitter, left
6 2 (11) X23/1 13 Turn signal trailer II B3 Compressed air transmitter
1 M CN1 26-pin plug connection
X24/3 CN1 CN1a 26-pin plug connection
1 9 Suspended front axle OFF = 11.7 V, CN2 26-pin plug connection
13 CN3 26-pin plug connection
ACTIVE = 0V (Light ON)
6 2 CN3 S3 Test switch for air filter
S 3 p >10 bar = 0 V S13 Control switch for brake fluid
S22 Control switch for coolant level
- (16) S23 Test switch for charge pressure 1bar
CN1 S50 Pushbutton for trailer brake valve
6 + 7 Brake fluid level OK = 11 V X4/45 4-pin plug connection
S X23/1 12 DMD Feed pump pressure OK (>1 bar) = 12 V X4/51 4-pin plug connection
X4/52 4-pin plug connection
J 11 Air filter OK = 11 V X6/8 6-pin plug connection
1
K 17 Coolant level OK = 12 V X6/10 6-pin plug connection
6 2 X6/11 6-pin plug connection
X24/3 % X24/3 CN3 X12/20 12-pin plug connection
2 G 3 15 Compressed air 8.1 bar = 155 Ω X18/1 18-pin plug connection
X20/1 20-pin plug connection
(11) CN1 X23/1 23-pin plug connection
GND X24/1 24-pin plug connection
22 X24/3 24-pin plug connection
180 Ω X29 Standard signal socket,
X70 70-pin plug connection
95 Ω Fuel tank level (11) Ground point, engine device carrier
X6/10 % X6/10 CN3 (16) Ground point, starter
1 2 1 3 14 10 Ω

Sva 6-92771 EN Edition 06-2006


4008-8

BLANK PAGE

Sva 6-92771 EN Edition 06-2006


4008-9

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$ )$

)$
X20/1 )$
 7 
$505(67 )$ )$
 X1/14
(16) 
$3/8*02'8/( X1/10 )$

X1 X18/4
$35,17$58 X24/2 17 18 2 X5/1
8 10
X3 7 13
% 5V
1
X70 21 48 70 46 69
9 9 CAN H (11)
$
CAN + 18 $((0 A2 _GND
X7 15 CAN L
0.4V to 4.7V CAN - 42
; 2 2 16 6XSSO\
CAN H
3 17
GND 4 CAN L
4 18
X1/21
P8/1 4 3 1 2 3UHJORZLQJDQG


3,&8 P8/2 IXHOGHOLYHU\SXPS X70 X20/1 $ (


*YA1 39 40 25 8 6 33 4 2 3 1 5 7
3 3 12V 4 (11)
4 50 12V 5 SSR1 .
X1/12 30 87
*YB1 39 40 25 8 6 33 4 2 3 1 5 7 

1 2
X20/1 (11)
12V
CN3 17
$&$102'8/( $$',& 12V
26 16
0 (11)
25 (PHUJHQF\VLJQDO
X70
3 M 1
36 0.8 to 4.4 V
$3&8 2
X70 X9/7 (11)
12V
5 X23/2 1 7
GND M13 _GND
4 U 23 6
CAN H
3&8DFWLYDWLRQ 20 2 2.5 V
CAN L
44 1 2.5 V
6 43 5 Emergency shut-down
130 Hz at 900 rpm
% X1/3 S 19 8 DZG
335 Hz at 2300 rpm
1 X70
S 34 GND A1 ADIC X1 14-pin plug connection
A2 EEM2 X1/3 1-pin plug connection
X3/20 55 GND A2/2 PCU X1/10 Plug connection
GND
Q 1 62 A12 Central print X1/12 Plug connection
% 2 39 510 Hz at 900 rpm
1300 Hz at 2300 rpm
A14 Engine print X1/14 Plug connection
I 12V A27 CAN module ---> DBD..... X1/21 Plug connection
3 45 A28 Plug module ---> DBD..... X2/22 2-pin plug connection
6ZLWFKHVDQG A30 Print ARU DBD..... ---> X3 4-pin plug connection
VHQVRUV A50/1 Power module X3/12 3-pin plug connection
W X2/22 B20 Engine speed sensor X3/13 3-pin plug connection
GND
% 1 33 B21 Test switch, fuel delivery pressure X3/20 3-pin plug connection
5 2 PTC 1kΩ to 4.6 kΩ B22 Engine temperature sensor X4/71 4-pin plug connection
9
B23 „Water in fuel“ sensor X5/1 Plug connection
X3/13 X3/12 B28 Manual throttle X7 4-pin plug connection
12V B29 Sensor for charger pressure, X9/7 9-pin plug connection
5 A 1 25
0.7 V at water in fuel charged air temperature X18/4 18-pin plug connection
% B 2 31 9 V no water in fuel CN3 26-pin plug connection X20/1 20-pin plug connection
8 C 3
GND
22 E10/1 Heating flange X23/2 23-pin plug connection
K8/2 Relay, heating flange X24/2 24-pin plug connection
X4/71 M13 Fuel delivery pump X70 70-pin plug connection
GND
SW 1 59 P8 ICU YA1 44-pin plug connection ---> DBD.....
NTC 32 kΩ to 102 Ω P8/1 4-pin plug connection
% 2 12 YB1 44-pin plug connection ---> DBD.....
P8/2 4-pin plug connection (11) Ground point, engine device carrier
85 3 5V
11 R8 Potentiometer, accelerator pedal (16) Ground point, starter
4 35 1 V to approx. 2 V S6 Switch, engine oil pressure

Sva 6-92771 EN Edition 06-2006


4008-10

BLANK PAGE

Sva 6-92771 EN Edition 06-2006


4008-11

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5
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1 1 7 13
6 9 9
13 3 (16) (16) 5
X7 15 A4/3 10 14 13 A4/4 X16/21 13 12 3
CAN - CAN H
6 2 16 1 $)0*5 17 1 $6*5
CAN H CAN L X6/9 E F L M H K B
11 11 3 17 3 18 2
CAN L 6XSSO\ 6XSSO\
4 18 2

GND
11 V
6
10 12 6
X6/3 X24/3 A4/2 1 12 2 11 9 10 3
6 3 10 8 NEUTRAL

0 V or 5 V
9 4 X16/21 /,03+20(FLUFXLW
2 11 7 DEAD MAN GND
GSV2 10
6 4 12 6 12 V
6KXWWOHOHYHU 14 Select 0 V** for FORWARDS
12 5 1 2 2 12 V
8 Select 0 V** for REVERSE
5 1 1 7 11 FORWARDS
*YA1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 $(/(&7521,&6
6 3 3 8 10 REVERSE **) Only if the
X4/59/b (A) and X4/59/c (B) A23 8 5 7 6

X4/59/b
X4/59/a
*YB1 21 17 15 13 11 8 6 4 2 3 1 33 5 7 plug connection is linked.
A21/4
$&$102'8/( 11 X6/1
12 4

CAN H

CAN +
CAN L
X24/3

CAN -
2 19 A21/5 1
$ X14/15 X10/11 $ X10/12 P8 3,&8 P8/1 1 21 3 3
)$
 12 7 6 7 4 3 20 9 2
5 3 X4/59/c
3 2 A24 Hydrostat X5/1 Plug connection
%UDNH
X14/14 4 1 A27 CAN module ---> DBD..... X6/1 4-pin plug connection
X4/14 X24/3 A4/2 A28 Plug module ---> DBD..... X6/3 6-pin plug connection
P8/2 3 4 1 GSV2
6 A30 Print ARU DBD..... ---> X6/9 7-pin plug connection
$ X20/1 X23/1 X10/14 12
)$ (7) 6  Ω A31 Multi controller X7 4-pin plug connection
 8 Q 7 (8) 3 4 14 3 V B17 Angle of rotation sensor, clutch X10/11 10-pin plug connection
6 2 5 13 3 V CN3 26-pin plug connection X10/12 10-pin plug connection
P8 ICU X10/14 10-pin plug connection
P8 10-pin plug connection X11 16-pin plug connection
CN3 X24/3 A4/2 &OXWFK P8/1 4-pin plug connection X14/14 14-pin plug connection
$$',& CAN L GSV2 P8/2 4-pin plug connection X14/15 14-pin plug connection
25 1 12 6
CAN H  Ω R8 Potentiometer, accelerator pedal X16/21 16-pin plug connection
26 6 A4/1 S4/4 Shuttle lever X18/4 18-pin plug connection
2 24 15 3 V S5 Switch for brake light X20/1 20-pin plug connection
S25 Switch for steering brake X21 14-pin plug connection
A4/4 S46 Switch, clutch X23/1 23-pin plug connection
A1 ADIC GND
1 13 4 S60/1 F/R button X23/2 23-pin plug connection
A2 EEM2
CAN H
CAN L

% 5.6V S60/2 Cruise control button X24/2 24-pin plug connection
A4 FMGR 2 14 11
A4/1 18-pin plug connection 8 3 15 12 1.1 to 4 V
S60/3 Speed button +
S60/4 Speed button -
X24/3
X70
24-pin plug connection
70-pin plug connection
A4/2 18-pin plug connection S60/5 HTS button YA1 44-pin plug connection
A4/3 15-pin plug connection X1 14-pin plug connection ---> DBD.....
A4/4 18-pin plug connection X4/70 A4/4 $FFHOHUDWRUSHGDO X4/14 4-pin plug connection YB1 44-pin plug connection
A12 Central print GND ---> DBD.....
1 1 X4/59/a 3-pin plug connection
A13 Roof print
X70 18 42 3 X4/59/b 3-pin plug connection (7) Ground point, roof hood, left
A14 Engine print
$((0 5 6 4.4 to 0.8 V X4/59/c 3-pin plug connection (8) Ground point, roof hood, right
A21 SGR transmission controller 5.8V (16) Ground point, starter
2 10 X4/70 4-pin plug connection
A21/4 12-pin plug connection
A21/5 12-pin plug connection 4 3 0.8 to 4.4 V
A23 Electronics X70 X23/2
A23 12-pin plug connection 36 U

Sva 6-92771 EN Edition 06-2006


4008-12

BLANK PAGE

Sva 6-92771 EN Edition 06-2006


4008-13

$)0*5
A4/2 A21/2 $6*5
GSV3 5V
1 S 1 4
% GND
6 2 7 A21/3 <
X4/61 X4/61 A4/2
8 3 6 0.2 to 3.1 V 6 4V
1
GND
2 1 17 6HDWFRQWDFW A21/2 7
5V
6 S 1 11 2
GND
X4/25 X4/25 A4/2 % 2 8
2 1 16 3DUNLQJEUDNH RSHQ 8 3 5 0.2 to 1.2 V A21/3 <
4V
5 1
6 A21/2 GND
W 8
A4/1 1 3
(QJLQHEDFNSUHVVXUH % PTC 1 kΩ to 4.4 kΩ 2
2 1 3 EUDNH 5 2 10
X5 A21/4 A21/3 <
GND 4V
1 2 9 4 1
$ X14/4 A4/1 GND
8 GSV1
18
6 2 1 3 GND 9
S Opens at a difference in pressure of 2
> 5 bar
1 2 X10/4 6
6SHHGUDQJHV 12 V
1 A21/3 <

X24/5 A4/1 3 4V
1
 23 16 increase "+" < GND
 10
7 5 17 decrease "-" 2
3 6HQVRUVDQG 2
1 A4/3 VROHQRLGYDOYHV
12 V
6 5 1 A21/3 <
%UDNHRLOFRROLQJ < 4V
8 2 1
GND
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21
2 11
X24/5 A4/1 2
A21/7
5 1 8 5 0DQXDOPRGH
1
6
(16) % Q 10 to 6000 Hz
A21/3
4V
<
I 2 1 1
GND
 12

X24/5 A4/1 A21/8

0DQDJHPHQW 2
5 3 1 Q 1
3 DQG % 10 to 6000 Hz
1 4 2 DOOZKHHO I 2

A21/9
X3/23 X24/5 A4/4 1
5.8 V Q
a 1 11 14 3RWHQWLRPHWHU % I 2
10 to 6000 Hz
<
5 b 3 12 15 0 to 5.8 V IRUOLPLWORDG
1
6 c 2 13
GND
5
A21/5
A21/10 10 V
4
Q 1 GND
2))
21 A4/1 % I 2
10 to 6000 Hz 8 2
X24/3 13 3.0 V X17
1 3 18 6ZLWFKIRUSDUNLQJ <
A4/2 A21/6 2
GSV2 LQWHUORFN
1
12 6
% Q 10 to 6000 Hz A21/5
I 2 10 V
A4 FMGR