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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
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$8/,&6<67(0
Functional description CC-LS Hydraulic System (Closed Center-Load Sensing).... 8001 6-52051
Functional description and troubleshooting
High Pressure Hydraulic Circuit ............................................................................... 8002 6-92610
(Electronic 3-point hitch control system EDC) ......................................................... 8005 6-52100
Fault codes and fault description, EHS Auxiliary Control Units ............................... 8006 6-52150
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Functional description and troubleshooting Air Conditioning ................................... 9002 6-92840
Sva 6-92333 July 2006
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7977977977977977977UDFWRUV
6HUYLFH0DQXDO6YD
7$%/(2)&217(17692/80(
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Fault codes .............................................................................................................. 4011 6-52632
Sva 6-92333 July 2006

Sva 6-92333 July 2006

7977977977977977977UDFWRUV
6HUYLFH0DQXDO6YD
7$%/(2)&217(17692/80(
67((5,1*6<67(0
Front Axle with Independent Suspension 20.25S.................................................... 5001 6-51450
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
High Pressure Hydraulic Circuit............................................................................... 8002 6-92610
(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
Sva 6-51250 EN Edition 07/2003

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

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

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)
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

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

2002-8
SAFETY REGULATIONS
There is always a risk of getting Â 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.
Â Disconnect the cable at the negative battery pole
before carrying out service or repair work on the
Â Never start repair work which you do not fully electrical system.
understand.
Â If the engine gets excessively hot (over 300 °C), for
Â 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
Â 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
Â Never use wrong or unsuitable tools. bare hands. Always wear neoprene gloves or thick
Â 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
Â 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!
Â Use a lifting device for lifting or transporting heavy
Â 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.
Â Never work below an engine hanging from a lifting
Â Avoid running the engine in idle unnecessarily.
device or raised by a jack. Always secure the Â 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.
Â Only use original CNH spare parts. Â All seals are asbestos-free.
Â Only start the engine from the cab, using the Â 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
Â 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!
Â If the engine is started in a confined space,
sufficient ventilation must be provided.
Â Never use auxiliary starting fuels on an aerosol
basis whilst the pre-glow starting facility is in
operation (explosion hazard).
Â Ear muffs must be worn when testing the engine or
working close to the engine.
Â Always switch the engine OFF before carrying out
repair work.
Â Avoid touching the exhaust manifold, turbocharger
and other hot engine parts.
Â 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.
2002-9
ENGINE DATA
Engine type 620.95 620.96 620.97 620.98 620.99
Number of cylinders 6
Capacity (dm3 ) 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
Charge-air pressure2 (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

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

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

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.

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

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

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

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

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.

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.

2002-19
BLANK PAGE

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).

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.

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.

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

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.

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.

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"

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)

2002-28
Signals
The EEM2 receives values for various parameters which are important for controlling the engine.
Analog signals (voltage) Digital signal (level)

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

Â Engine oil pressure (from test switch S6)
Â Water in fuel (from sensor B23)

Digital signal (CAN messages)
Â Engine setpoint speed for Limp home

Â 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)
Â Engine speed (from sensor B20) Â Spray adjustment angle (from PCU)
Digital signal (coding) Â Fuel temperature (from PCU)
Â 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
Â Engine speed
Â Engine load
Â Coolant temperature
Control variables which influence the maximum injection volume
Â Torque characteristics
Â Coolant temperature
Â Charge-air pressure
Â 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.

2002-29
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

2002-30
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.

2002-31
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.

2002-32
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

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.

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.

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.

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
INLET 35°-20’ +20’
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.

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:

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

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

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.

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

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

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

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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7977977977977977977UDFWRUV

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

Sva 6-92333 July 2006

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Sva 6-92333 July 2006

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Find manuals at https://best-manuals.com

Sva 6-92333 July 2006

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

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

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

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

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

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

Sva 6-51250 EN Edition 07/2003

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

Sva 6-51250 EN Edition 07/2003

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Sva 6-51250 EN Edition 07/2003

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Pressing tool for the rear crankshaft

Valve spring tensioning lever

Pressing tool for

Pressure gauge and connection

Injection pump installation pin

Dial test indicator and holder

Sva 6-51250 EN Edition 07/2003

FOR THE USER

Engine code and serial number

Power 180 PS 2100 rpm

This label is affixed to the right-hand

Sva 6-51250 EN Edition 07/2003

Lifting the engine

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

A = Engine lifting eyes

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Gear drive, camshaft and injection pump

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Coolant temperature indication and monitoring (signal from sensor B22)

Schwitzer turbocharger S200

Sva 6-51250 EN Edition 07/2003

127(Use washers for aluminium parts.

If no particular tightening torques are specified,

Bolts for the self-supporting oil sump

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

Sva 6-51250 EN Edition 07/2003

7977977977977977977UDFWRUV

127(Use washers for aluminium parts.

127( If the crankshaft is worn at the sealing ring