service repair manual

1. &1+ gVWHUUHLFK *PE+ Copyright © 2006 CNH Österreich GmbH
Sva 6-52245
July 2006
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Workshop Manual.....................................................................................................2002 6-51250
Workshop Manual (6195 CVT).................................................................................2002A 6-93080
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Functional description Injection System ...................................................................3001 6-51300
Functional description Injection System - Common Rail System (6195 CVT)..........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 (6195 CVT)................................................................4008A 6-93221
Connectors, Wiring Harnesses, Electrical and Electronic Components ...................4009 6-92970
Connectors, Wiring Harnesses, Electrical and Electronic Components (6195 CVT)4009A 6-93290
Circuit diagram .........................................................................................................4010 6-51402
Circuit diagram (6195 CVT)......................................................................................4010A 6-93360
7$%/( 2) 217(176 92/80(
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Fault codes...............................................................................................................4011 6-52632
7$%/( 2) 217(176 92/80(
67((5,1* 667(0
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

2. Sva 6-52245 July 2006
+'5$8/, 667(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

3. Sva 6-52245 July 2006
97 97 97 97 97 97 7UDFWRUV
6HUYLFH 0DQXDO 6YD
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Fault codes .............................................................................................................. 4011 6-52632

4. Sva 6-52245 July 2006
97 97 97 97 97 97 7UDFWRUV
6HUYLFH 0DQXDO 6YD
7$%/( 2) 217(176 92/80(
67((5,1* 667(0
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/, 667(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

5. Chapter
2002
2002
CNH Österreich GmbH
Technical Documentation
A – 4300 St. Valentin, Steyrer Straße 32
Sva 6-51250 EN © 2003 CNH Österreich GmbH
July 2003
ENGINE WORKSHOP MANUAL

6. 2002-2
Sva 6-51250 EN Edition 07/2003
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
TABLE OF CONTENTS

7. 2002-3
Sva 6-51250 EN Edition 07/2003
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

8. 2002-4
Sva 6-51250 EN Edition 07/2003
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

9. 2002-17
Sva 6-51250 EN Edition 07/2003
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
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.
SS00F035
CONSTRUCTION

10. 2002-18
Sva 6-51250 EN Edition 07/2003
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.
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

11. 2002-20
Sva 6-51250 EN Edition 07/2003
Crankshaft drive
The crankshaft is made from forged chrome alloy
special steel and the bearing and sealing surfaces
are inductively tempered. The bearing points can be
re-ground four times without having to be re-
tempered. The gear wheels are force fitted at the
front end of the crankshaft. They are used to drive
the camshaft, injection pump and oil pump. In
addition, the front end of the crankshaft has key-ways
for seating the drive hub. The V-belt pulley and the
torsional vibration damper (with rubber element) are
fitted on the hub. The front PTO shaft (if fitted) is also
driven via this hub. An oil deflector ring is fitted
between the hub and gear wheel and a dust seal is
fitted on the hub to protect the crankshaft sealing
ring. The transmitter wheel for the engine speed
sensor is fitted on a crankshaft web.
A crankshaft bearing is located on both sides of each
cylinder. There are thus seven crankshaft bearings.
The crankshaft axial bearings are located on both
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).
The pistons are equipped with two compression rings
and an oil scraper ring. In the case of engine types
620.95 and 620.96, the top molybdenum-coated
piston ring has a rectangular cross-section. Engine
types 620.97, 620.98 and 620.99 have a top piston
ring with a trapezoidal cross-section.
The middle piston ring is a taper face ring (the outer
diameter has a conical surface).
The oil scraper ring is sprung and has two chrome-
plated scraping edges.
The pistons are ring carrier pistons (the piston has a
special cast iron ring carrier cast into it to seat the top
piston ring). The friction surface of the piston skirt
also has a graphite coating to ensure optimal
running-in.
In the case of engine types 620.97, 620.98 and
620.99, the piston head is cooled from below by
additional oil spray as soon as the oil pressure
exceeds 3 bar.

12. 2002-21
Sva 6-51250 EN Edition 07/2003
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.
SS03G080

13. 2002-22
Sva 6-51250 EN Edition 07/2003
Lubrication system
Lubrication system
1. Lubrication oil pump
2. Oil pressure valve
3. Oil filter
4. Turbocharger
5. Main oil duct
6. Oil spray nozzles
7. Oil pressure switch
4
3
2
1
5
SS99N019
6
7
The engine is equipped with a pressure lubrication
system, in which the oil pump (gear pump) is fixed to
the lower part of the cylinder block. The pump sucks
the oil in via an intake sieve. From the pump, the oil is
fed through an oil line to the oil cooler (heat
exchanger) and to the oil filter. The oil pressure valve
is located parallel. The oil is then fed into the main oil
duct, from which other oil bores branch off. The oil
flows through the oil bores to the crankshaft bearings
and through the crankshaft to the con-rod bearings.
The pressure oil flows from the main oil duct to the
turbocharger and to the air compressor (if fitted). In
addition, the intermediate gear wheel bearings,
camshaft bearings and valve mechanism are
lubricated with pressure oil via the main oil duct.
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.
The oil pressure valve regulates the lubrication oil
pressure so that a constant value is maintained
independent of the engine speed. Depending upon the
grade of oil, the engine speed and temperature, the oil
pressure lies between 2.5 - 5 bar.
The oil pressure must be at least 1.0 bar at idling
speed.
The oil filter is a one-way main stream filter. An
overflow valve, on the underside of the filter, ensures
reliable engine lubrication after cold starting at
extremely low outside temperatures and sufficient
lubrication in the event of a filter blockage. A non-
return valve prevents the filter being completely
drained of oil after switching off the engine.
The oil pressure switch opens at a pressure of
0.5 bar.

14. 2002-23
Sva 6-51250 EN Edition 07/2003
Cooling system
SS03G023
5
2
7
3
1
4
6
Cooling system
1. Coolant pump
2. Thermostat
3. Bypass channel
4. Radiator
5. Expansion chamber
6. Oil cooler
7. Engine temperature sensor
7
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
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
coolant (B) flow into the radiator. When the engine
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
coolant (C) to flow into the radiator.
C
A
B
1
2
SS00F031

15. 2002-24
Sva 6-51250 EN Edition 07/2003
Fan
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.
SC03G004
SS03G024
VISCO FAN REVERSIBLE FAN

16. 2002-25
Sva 6-51250 EN Edition 07/2003
Intake/exhaust system
SC03G006
The filter system for the engine intake air comprises a
pre-cyclone filter (integrated into the air filter) and a
dry air filter with safety cartridge. The intake air is
rotated in the pre-cyclone filter. This removes heavy
dirt particles, which are then discharged via the pre-
cyclone filter’s dust discharge valve.
Ejector
The tractor can be equipped with an ejector system for
use in extremely dusty conditions. The exhaust pipe is
fitted with an injector and there is a permanent suction
effect at its hose connection when the engine is
running. The dust particles separated in the pre-filter
are continuously sucked in via a hose connection and
discharged together with the exhaust gases.
Filter cartridges
The dirt particles in the air are collected in the main
cartridge, which can be cleaned as required. The
internal safety cartridge stops dirt particles getting into
the engine in the event of the main cartridge breaking
or being fitted incorrectly.
Filter service indication
A differential pressure switch is located in the filter
housing. This switch makes an indicator lamp on the
ADIC light up when the air filter reaches a certain
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.
The turbocharger is lubricated and cooled by oil from
the engine lubrication system.
Charge-air cooling
The intake air compressed by the turbocharger can
reach a temperature of up to 150 °C under extreme
conditions. It is cooled down to 50 - 60 °C in a charge-
air cooler (air/air version) located in front of the
radiator. The cooling of the charge-air reduces the
thermal and mechanical strain on the engine and
reduces the discharge of nitrogen oxides and soot
particles.
Charge-air pressure/temperature
as engine control variables
A combined sensor is located in the air collector. It
continuously supplies information about the charge-air
pressure/temperature to the electronic engine
management (EEM2). Fuel injection is optimised in
conjunction with the electronic injection control
system, thus substantially reducing the discharge of
nitrogen oxides and soot particles.
The charge-air cooler is easy to service. It can be
folded up and can thus be effectively cleaned against
the direction of the flow of outside air. By folding up
the charge-air cooler, the other coolers are easier to
access.

17. 2002-26
Sva 6-51250 EN Edition 07/2003
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.
1. Engine control unit (EEM2)
2. Injection pump control unit PCU (A2/2)
3. Oil pressure switch (S6)
4. Speed sensor (B20)
5. Heater flange (E10/1)
6. Power relay (K8/2)
7. Charge-air pressure/temperature sensor (B29)
8. Engine temperature sensor (B22)
9. Test switch, fuel delivery pressure (B21)
10. Fuel delivery pump (M13)
11. Optional equipment, sensor B23
Water in fuel
SC03G007
5
8
3
6
4
7
2
9
10
11
1

18. 2002-27
Sva 6-51250 EN Edition 07/2003
Layout
Sensor B28
Man. oper.
accelerator slider
Starting aid E10/1
(heating flange)
Sensor B23
Water in
fuel
R8 sensors
Accelerator pedal
ARU
FMGR
Test switch B21
Fuel delivery pressure
Sensor B29
Charge-air pressure
Charge-air
temperature
Sensor B22
Coolant temperature
EEM 2
PCU
ADIC
Sensor B2/1
Fuel level
Sensor B20
Engine speed and
crankshaft position
Limp home
CANL
CANHCANL
CANH
A4
A2
A2/2
A1
Switch S6
Oil pressure
Warning
Water in fuel
(optional extra)
Warning
Fuel
feed pressure
too low
Warning
Fuel
level
too low
M13 Fuel
feed pump
DISPLAY
Warning
Coolant level
Switch S22
Coolant level
DZG
MAB
DZG = Signal, crankshaft position
(top dead centre)
MAB =Signal, emergency engine
shut-down

19. 2002-28
Sva 6-51250 EN Edition 07/2003
Signals
The EEM2 receives values for various parameters which are important for controlling the engine.
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.
Analog signals (voltage)
 Coolant temperature (from sensor B22)
 Charge-air temperature (from sensor B29)
 Charge-air pressure (from sensor B29)
 Water in fuel (from sensor B23)
 Engine setpoint speed for Limp home
(from accelerator pedal sensor R8)
Digital signal (Frequency)
 Engine speed (from sensor B20)
Digital signal (coding)
 Crankshaft position (from sensor B20)
Digital signal (level)
 Fuel delivery pressure
(from test switch B21)
 Engine oil pressure (from test switch S6)
Digital signal (CAN messages)
 Drive commands (from FMGR)
 Injection pump speed (from PCU)
 Actual start of delivery (from PCU)
 Spray adjustment angle (from PCU)
 Fuel temperature (from PCU)

20. 2002-29
Sva 6-51250 EN Edition 07/2003
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).
2. Thoroughly clean the inner surface of the cylinder
liner before the measurement.
3. Measure cross-wise at the top end, bottom end
and in the middle of the cylinder liner.
4. Check the displayed value for max. wear and
ovality (compare with nominal values).
B. Removing the cylinder liner
1. If the cylinder liners are to be re-used, they must
be marked so they can be re-fitted in the same
positions.
2. Remove the cylinder liners using the 380000011
and 1TSW 510 extraction tools.
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.
4. Measure the wear on the camshaft bearings
(compare with nominal values).
127( If the surface of the cylinder block has to be
re-ground, the pistons must be shortened by a
corresponding amount. Pay attention to the valve
head clearance at the top surface of the piston.
D. Replacing the camshaft bearing bush
1. Pull the bearing bush out using an internal
extractor. After removing the rear camshaft end
support piece, the bearing bush can be driven out
using a long drift.
2. Clean the bush seating.
SS99N036
SS99N037
1TSW 510
380000011
0.1 - 0.4 mm
SS99N038
JOB INSTRUCTIONS

21. 2002-30
Sva 6-51250 EN Edition 07/2003
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.
The numbering starts at the front end of the engine.
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.
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
5 4 3 2 1
SS99N039
45 123
272 mm
266 mm
134 mm
7,2...8,0 mm
0,1...0,4 mm
A
A
A-A
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
SC03G008

22. 2002-31
Sva 6-51250 EN Edition 07/2003
F. Fitting the plug at the rear camshaft
end
1. Clean the plug seating.
2. Apply sealant (e.g. Loctite 572) to the contact
surface of the plug.
3. Drive the plug in using pressing tool 380000004.
127( Do not drive the plug in too far, as it could
impair the axial play of the camshaft.
G.Fitting the plug at the rear camshaft
end after inserting an oversize bearing
bush
Upon completion, the rear camshaft end plug is
replaced by the plug and the O-ring.
H. Installing the oil dipstick tube
1. Clean the tube seating.
2. Apply locking fluid (e.g. Loctite 601) to the bottom
end of the tube.
3. Drive the guide tube into the cylinder block to the
dimension shown in the figure.
127( The position of the tube influences the
measured engine oil level.
I. Fitting the cylinder liner
1. Clean the cylinder liner and liner recess in the
cylinder block. Without the O-ring, it must be easy to
turn the liner to its installation position.
2. Apply a thin coat of marking paint to the underside
of the cylinder liner flange. Fit the cylinder liner
without O-rings and turn it back and forth. Remove
the cylinder liner and check whether there is paint
over the entire contact surface.
3. Clean the contact surfaces.
4. Fit the cylinder liners and secure each liner using
two clamps. Measure the cylinder liner height using a
dial test indicator and the holder (380000364). Set
the dial test indicator to zero on a flat surface, e.g.
the cylinder block. Measure each cylinder liner at four
points. The cylinder liner should protrude from the
top of the cylinder block by 0.03 - 0.08 mm.
max. 1,0 mm
SC03G009
SS00F003
O-ring
Plug
SS99N045
111 mm
SS99N048
0.03 - 0.08 mm

23. 2002-32
Sva 6-51250 EN Edition 07/2003
The difference in height between the cylinder liners
below a cylinder head must not exceed 0.02 mm. In
addition, a middle cylinder liner must not be lower
than one of the outer ones.
5. If the cylinder liner height is insufficient, a liner with
a higher flange must be fitted.
An oversize of the cylinder liner (higher flange) is
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.
7. Insert the O-rings in the grooves in the lower
cylinder section and lubricate them with liquid soap
(not with oil).
127( Stretch the O-rings as little as possible when
pulling them onto the cylinder liners.
The max. permissible elongation is 6 %.
8. Press the cylinder liners into the cylinder block. It
should be easy to press them into their initial
position. Make sure the cylinder liners do not move
upwards once they have been fitted.
Height
(H)
Marking
grooves
(quantity)
9.03+0.02
(standard)
9.08+0.02
1
9.13+0.02
2
9.23+0.02
3
H
SS99N049
BLACK
GREEN
SS99N050
SS99N051

24. 2002-33
Sva 6-51250 EN Edition 07/2003
2. Flywheel casing
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.
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.
5. Tighten the inner ring bolts to a torque of 80 Nm
and the outer ring bolts to a torque of 150 Nm.
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.
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.
127( Assembly of the sealing ring must be carried
out in a dry and oil-free state.
SC03G010
SS99N054
Spacer ring
SS99N056
1TSW 662
380000003

25. 2002-34
Sva 6-51250 EN Edition 07/2003
3. Cylinder head
A. Removing the cylinder head
1. Clean the outside of the engine.
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
and the thermostat housing.
2. Remove the intake lines between the exhaust
turbocharger and the air filter and the charge-air lines
from the turbocharger and the intake manifold.
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.
7. Remove the rocker arm mechanism and the push
rods.
8. Loosen all cylinder head bolts by a ¼ of a
revolution and then unscrew them. Remove the
cylinder head.
B. Removing the 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.
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
380000008. Remove the valve spring seat retainers,
the spring guide and the spring. Remove the valves.
C. Checking the cylinder head
1. Remove carbon deposits in the outlet channels,
clean the sealing surfaces and wash the cylinder
head.
2. Check the cylinder head for cracks and any other
damage.
3. Check the evenness of the cylinder head using a
straightedge. An uneven or bent surface must
undergo surface grinding. After being ground, the
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
and 0.70 mm for inlet valves.
SS99B056
Drain plug
SS99N057
SS99N058

26. 2002-35
Sva 6-51250 EN Edition 07/2003
4. If necessary, clean the nozzle holder contact
surface in the cylinder head using a reamer.
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
determine whether the valve guide is worn, a new
valve must be used for the measurement.
D. Replacing the valve guides
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).
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.
SS99N059
SS99N060
SS99N061
21 mm
SS99N062
380000007

27. 2002-36
Sva 6-51250 EN Edition 07/2003
E. Machining the valve seat
A damaged valve seat must be machined using a
milling cutter. If the width of the seat exceeds 2.3 mm
in the case of an outlet valve and 3.7 mm in the case
of an inlet valve, then it has to be reduced at the
outer edge, in particular.
The valve seat angle is 45°+20’
for outlet valves and
35°+20’
for inlet valves.
F. Replacing the valve seat rings
The outlet valves are equipped with separate valve
seat rings. If the sealing surface is so badly damaged
that it cannot be repaired, then the valve seat rings
have to be replaced.
1. Grind the valve disk on a disused valve so that it
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.
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
tool. Re-work the seat.
G. Grinding the valves
In order to ensure that a sufficient sealing effect is
attained around the valves, there are different sealing
surface angles. Thus, there is a particularly narrow
sealing surface, which ensures an effective sealing
effect even after prolonged operation.
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.
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.
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.
SS99N063
44,000...44,025 mm
10,1 mm
SC03G029
Outlet valve
48,500...48,525 mm
11±0,1
mm
SC03G030
Inlet valve
A
B
C
A B C (mm)
INLET 35°-20’
35°+20’
0.7
OUTLET 45°-20’
45°+20’
0.6
SC03G011

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29. 2002-37
Sva 6-51250 EN Edition 07/2003
H. Fitting the valves
1. Use a spring tester to check the straightness,
length and tension of the valve springs. Compare
these values with the technical data.
2. Lubricate the valve stems and insert the valves in
the cylinder in the correct order.
3. Fit the valve springs, valve disks and valve spring
seat retainers in the cylinder head with the aid of
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 bolts. The
length should lie within the limit values specified in
the figure. If this is not the case, the bolt must be
replaced.
2. Screw the cylinder head grub screws into the
cylinder head and a tighten them to a torque of
30 Nm. Insert the push rods, if they have been
removed.
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.
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:
127( From engine serial no. N 8957 (see Engine
code and serial number, page 7), steps 6 to 8 can be
skipped (modified cylinder head gasket).
1. Pre-tension of 80 Nm
2. Tighten by 90°.
3. Tighten by 90°.
4. Adjust the valve clearance (see page 39).
5. Fit the other engine parts, add coolant and
engine oil.
6. Let the engine run at low load until it reaches a
coolant temperature of 75 °C.
7. Tighten by 60°.
8. Adjust the valve clearance.
127( The cylinder head bolts do not have to be
tightened again after this procedure.
Tighten the exhaust manifold securing bolts/nuts to a
torque of 50 Nm.
max. 142 mm
max. 188.5 mm
SS99N066
SS99N067
50 Nm
SC03G012

30. 2002-38
Sva 6-51250 EN Edition 07/2003
4. Valve mechanism
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.
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.
4. If the pressure surface of the rocker arm is worn,
grind it until it has the right shape. Do not grind off
more than necessary as the pressure surface is
hardened.
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
figure. Fix the other flange seal
B. Replacing the camshaft/camshaft gear
wheel
1. Remove the suction pipe between the
turbocharger and the intake manifold. Remove the
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.
SS99N070
23,000...23,021
SC03G013
SS99N072
SS99N073
60°
SC03G014

31. 2002-39
Sva 6-51250 EN Edition 07/2003
5. Lock the valve tappets so that they do not fall down
on removing the camshaft and impair the installation
of the camshaft. Raise two adjacent valve push rods
by tilting them towards each other. Clamp adjacent
push rods together to form a pair (e.g. using an
O-ring) so they are under slight tension and the
tappets remain in the top position.
:$51,1* Excessive tensioning of the push rods
causes deformation.
6. Turn the crankshaft, so the positioning marks on
the camshaft gear wheel and intermediate gear
wheel coincide. Pull the camshaft out.
7. Loosen the camshaft gear wheel using a suitable
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
wheel up to 200 °C and fit it in the corresponding
position.
10. Grease the bearing surfaces and press the shaft
into the cylinder block, paying attention to the
position marks on the camshaft gear wheel.
11. Fit the control box cover and the belt pulley with
the hub.
12. Release the push rods and fit the rocker arm
mechanism. Adjust the valves. Then screw the valve
cover and air bleed hose onto the cylinder head. Also
fit the suction pipe between the turbocharger and
intake manifold.
13. Fit the alternator and V-belts. Tension the V-belts
accordingly. Fit the cooler/radiator assembly.
C. Checking and adjusting the valve
clearance
The inlet and outlet valves have a clearance of
0.35 mm. It can be checked when the engine is hot
or cold. Check and adjust the valve clearances of a
cylinder whilst the piston is at top dead centre of the
compression stroke. Proceed according to the
injection sequence of the engine.
If the valve clearance deviates from the specified
value, loosen the locking nut and adjust it to the
correct value via the adjusting screw. A 0.35 mm
feeler gauge must fit tightly between the rocker arm
and the end of the valve stem.
– turn the crankshaft in the direction of rotation until
the valves of cylinder 6 overlap. (Outlet valve closes,
inlet valve opens). Check the valves of the first
cylinder.
– turn the crankshaft 1/3 of a revolution in the
direction of rotation so that the valves of the 2nd
cylinder overlap. Check the valves of the 5th cylinder.
– continue work in the sequence of injection:
SS99N075
Injection sequence: 1 5 3 6 2 4
Valve overlap: 6 2 4 1 5 3
0,35
SC03G015
I = INLET
O= OUTLET
E A
SC03G016
E A E A E A E A E A

32. 2002-40
Sva 6-51250 EN Edition 07/2003
5. Crankshaft
A. Removing the crankshaft
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
removing the crankshaft.
6. Remove the crankshaft bearing covers and lift the
crankshaft out.
B. Checking the crankshaft
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.
3. Insert the bearing caps with new bearing shells
and tighten them to the correct torque. Measure the
inner diameter with a dial test indicator, which has
been reset to zero according to the dimensions
measured under item 2. The indicator thus displays
the actual bearing play. If the bearing housing which
shows signs of wear is not round, take
measurements at several points.
4. If the bearing play exceeds 0.18 mm for the
crankshaft bearings or 0.14 mm for con-rod bearings
with new bearing shells, the bearing journals on the
crankshaft must be ground.
For the correct undersize and corresponding
bearings, refer to the technical data. Make sure the
radii do not change during the grinding process.
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
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
1. Attach an extractor to the crankshaft gear wheels
and pull off both gear wheels.
2. Clean the seat on the crankshaft using a wire
brush, for example.
3. Heat up the new gear wheels to 200 °C. Drive the
gear wheels onto the shaft using a suitable sleeve or
soft mandrel. Pay attention to the position of the
feather key and make sure the alignment marks on
the front gear wheel are visible. Allow the parts to
cool down.
SS99N078
SS99N079
SS99N080
1TSW 662

33. 2002-41
Sva 6-51250 EN Edition 07/2003
D. Fitting the crankshaft
1. Clean the oil lines, bearing shells and seats. Make
sure the crankshaft is clean.
2. Fit a bearing shell (A) with an oil bore hole and oil
groove in the cylinder block and a bearing shell (B)
without an oil bore hole in the bearing cover. Make
sure the bearing shell joggles engage in the
corresponding notches and that the shells to be fitted
in the cylinder block have an oil bore hole which
aligns with the oil bore hole in the cylinder block.
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.
4. Insert the crankshaft bearing covers according to
their numbering, with axial bearings at the rear,
which have got joggles. Lubricate the bolts and
tighten them to a torque of 200 Nm.
5. Make sure the crankshaft turns freely and without
sticking. Check the axial play using a dial test
indicator. The correct axial play is approx.
0.10 - 0.35 mm. If there is excessive axial play,
oversized axial bearings must be fitted.
127( The bearing shells may never be reamed or
machined and the sides of the bearing covers may
not be filed.
E. Crankshaft hub
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
tooth.
B
A
SS99N082
200 Nm
76
SC03G017
0,10...0,38 mm
SC03G018
SS99N085