New Holland T7510 Tractor Service Repair Manual Instant Download

1
SERVICE MANUAL
T7510 / T7520 / T7530 T7540 / T7550 Tractor
Part number 47505533 English February 2013
Copyright 2013 CNH Europe Holding S.A. All
Rights Reserved.
2
Contents INTRODUCTION Engine......................
..................................................
............... 10 10.001 Engine and crankcase
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10.1 10.106 Valve drive
and gears . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 10.2 10.101
Cylinder heads . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 10.3 10.105 Connecting rods and pistons. .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10.4 10.103 Crankshaft and flywheel. . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 10.5 10.218 Fuel injection system
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 10.6 10.250
Turbocharger and lines. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10.7 10.254 Intake and exhaust manifolds and
muffler . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 10.8
10.400 Engine cooling system . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 10.9 10.414 Fan and drive . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 10.10 10.304 Engine
lubrication system . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
10.11 Transmission................................
..............................................
21 21.504 Continuously Variable Transmission
(CVT) . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 21.1 21.505
Continuously Variable Transmission (CVT) external
controls . . . . . . . . . . . . . . . . . . . .
. . 21.2 21.506 Continuously Variable
Transmission (CVT) lubrication system . . . . . .
. . . . . . . . . . . . . . 21.3 21.507
Continuously Variable Transmission (CVT) internal
components. . . . . . . . . . . . . . . . . .
21.4 Four-Wheel Drive (4WD) system
..................................................
23 23.202 Electro-hydraulic control . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 23.1 23.314 Drive shaft. . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 23.2 Front axle
system ...........................................
............................ 25 25.100
Powered front axle . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
25.1 25.102 Front bevel gear set and
differential . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 25.2 25.108 Final drive hub, steering
knuckles, and shafts . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
25.3 25.122 Axle suspension control . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 25.4
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Rear axle system................................
........................................
27 27.100 Powered rear axle. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 27.1 27.106 Rear bevel gear set and
differential . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 27.2 27.120 Planetary and final
drives . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 27.3 Power Take-Off
(PTO) ............................................
..................... 31 31.104 Rear
electro-hydraulic control . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 31.1 31.119
Four-speed rear Power Take-Off (PTO) . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 31.2 31.142 Front
Power Take-Off (PTO) control . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 31.3 31.146 Front Power
Take-Off (PTO) . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 31.4 Brakes and
controls .........................................
........................... 33 33.202
Hydraulic service brakes . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
33.1 33.110 Parking brake or parking lock . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 33.2 33.220 Trailer brake hydraulic control.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 33.3 33.204 Front axle brake . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 33.4 33.200 Brake
cooling. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
33.5 Hydraulic systems...........................
............................................
35 35.000 Hydraulic systems. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.1 35.106 Variable displacement
pump . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 35.2 35.359 Main control valve
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 35.3 35.204
Remote control valves . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
35.4 35.114 Three-point hitch control valve . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 35.5 35.116 Three-point hitch cylinder . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 35.6 Steering...........................
..................................................
........ 41 41.200 Hydraulic control
components. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 41.1 41.216 Cylinders . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
41.2 41.432 Autoguidance steering . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 41.3 Cab climate control
..................................................
................... 50 50.104 Ventilation . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 50.1
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5
50.200 Air conditioning . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 50.2 Electrical systems............
..................................................
......... 55 55.000 Electrical system . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 55.1 55.100
Harnesses and connectors. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
55.2 55.525 Cab engine controls . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 55.3 55.015 Engine control system.
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 55.4 55.301 Alternator .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
55.5 55.302 Battery. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 55.6 55.202 Cold
start aid . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 55.7 55.011 Fuel tank system . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 55.8 55.010 Fuel injection
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 55.9 55.014
Engine intake and exhaust system. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 55.10 55.012 Engine
cooling system . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 55.11 55.013
Engine oil system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
55.12 55.640 Electronic modules . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 55.13 55.513 Cab transmission
controls. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 55.14 55.024 Transmission
control system . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 55.15
55.020 Transmission speed sensors. . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. 55.021 Transmission pressure sensors . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. 55.022 Transmission temperature sensors . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 55.023
Transmission position sensors . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 55.045 Front
axle control system . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
55.16 55.17 55.18 55.19 55.20
55.048 Rear Power Take-Off (PTO) control system
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 55.049 Front Power
Take-Off (PTO) control system . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. .
55.21 55.22
55.051 Cab Heating, Ventilation, and
Air-Conditioning (HVAC) controls. . . . . . . . .
. . . . . . . .
55.23
55.050 Heating, Ventilation, and
Air-Conditioning (HVAC) control system. . . . . .
. . . . . . . . .
55.24
55.519 Cab brake controls . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. .
55.25
55.030 Service brake electrical system . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
55.26
55.032 Trailer brake electrical system . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
55.27
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55.512 Cab controls. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 55.035 Remote control valve
electric control . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . .
55.28 55.29
55.036 Hydraulic system control . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
55.30
55.047 Steering control system . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
55.31
55.523 Cab hitch controls . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 55.130 Rear three-point hitch electronic
control system . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
55.32 55.33
55.160 Front hitch electronic control system .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 55.680
Autopilot/Autoguidance . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 55.510
Cab or platform harnesses and connectors . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 55.408 Warning indicators,
alarms, and instruments . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
55.34 55.35 55.36 55.37
55.DTC FAULT CODES. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
.
55.38
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INTRODUCTION
47505533 11/02/2013 1
8
Contents INTRODUCTION
Foreword - Ecology and the environment . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 3
Foreword - How to use and navigate through this
manual . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 4 Safety rules .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 9 Basic instructions -
Important notice regarding equipment servicing .
. . . . . . . . . . . . . . . . . . . . . . . .
10 Torque - Minimum tightening torques for normal
assembly . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 11 Torque -
Standard torque data for hydraulics . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 16 Consumables
(Lubrications and Coolants) . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 18 Capacities . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 20
47505533 11/02/2013 2
9

• INTRODUCTION
• Foreword - Ecology and the environment
• Soil, air, and water are vital factors of
  agriculture and life in general. When legislation
  does not yet rule the treatment of some of the
  substances required by advanced technology, sound
  judgment should govern the use and disposal of
  products of a chemical and petrochemical nature.
• NOTE The following are recommendations that may
  be of assistance
• Become acquainted with and ensure that you
  understand the relative legislation applicable to
  your country.
• Where no legislation exists, obtain information
  from suppliers of oils, filters, batteries,
  fuels, antifreeze, cleaning agents, etc., with
  regard to their effect on man and nature and how
  to safely store, use, and dispose of these
  substances.
• Agricultural consultants will, in many cases, be
  able to help you as well.
• Helpful hints
• Avoid filling tanks using cans or inappropriate
  pressurized fuel delivery systems that may cause
  considerable spillage.
• In general, avoid skin contact with all fuels,
  oils, acids, solvents, etc. Most of them contain
  substances that may be harmful to your health.
• Modern oils contain additives. Do not burn
  contaminated fuels and or waste oils in ordinary
  heating systems.
• Avoid spillage when draining off used engine
  coolant mixtures, engine, gearbox and hydraulic
  oils, brake fluids, etc. Do not mix drained
  brake fluids or fuels with lubricants. Store them
  safely until they can be disposed of in a proper
  way to comply with local legislation and
  available resources.
• Modern coolant mixtures, i.e. antifreeze and
  other additives, should be replaced every two
  years. They should not be allowed to get into
  the soil, but should be collected and disposed of
  properly.
• Do not open the air-conditioning system yourself.
  It contains gases that should not be released
  into the atmosphere. Your NEW HOLLAND
  AGRICULTURE dealer or air conditioning specialist
  has a special extractor for this purpose and
  will have to recharge the system properly.
• Repair any leaks or defects in the engine cooling
  or hydraulic system immediately.
• Do not increase the pressure in a pressurized
  circuit as this may lead to a component failure.

47505533 11/02/2013 3
10

• INTRODUCTION
• Foreword - How to use and navigate through this
  manual
• This manual has been produced by a new technical
  information system. This new system is designed
  to deliver technical information electronically
  through web delivery (eTIM), DVD, and paper
  manuals. A coding system called SAP has been
  developed to link the technical information to
  other Product Support functions, e.g., Warranty.
• Technical information is written to support the
  maintenance and service of the functions or
  systems on a customer's machine. When a customer
  has a concern on their machine it is usually
  because a function or system on their ma- chine
  is not working at all, is not working
  efficiently, or is not responding correctly to
  their commands. When you refer to the technical
  information in this manual to resolve that
  customer's concern, you will find all the
  information classified using the SAP coding,
  according to the functions or systems on that
  machine. Once you have located the technical
  information for that function or system, you will
  then find all the mechanical, electrical or
  hydraulic devices, compo- nents, assemblies, and
  sub assemblies for that function or system. You
  will also find all the types of information that
  have been written for that function or system
  the technical data (specifications), the
  functional data (how it works), the diagnostic
  data (fault codes and troubleshooting), and the
  service data (remove, install adjust, etc.).
• By integrating SAP coding into technical
  information, you will be able to search and
  retrieve just the right piece of technical
  information you need to resolve that customer's
  concern on his machine. This is made possible by
  attaching 3 categories to each piece of technical
  information during the authoring process.
• The first category is the Location, the second
  category is the Information Type and the third
  category is the Product
• LOCATION - the component or function on the
  machine, that the piece of technical information
  is going to describe (e.g., Fuel tank).
• INFORMATION TYPE - the piece of technical
  information that has been written for a
  particular component or func- tion on the
  machine (e.g., Capacity would be a type of
  Technical Data describing the amount of fuel held
  by the fuel tank).
• PRODUCT - the model for which the piece of
  technical information is written.
• Every piece of technical information will have
  those three categories attached to it. You will
  be able to use any combi- nation of those
  categories to find the right piece of technical
  information you need to resolve that customer's
  concern on their machine.
• That information could be
• the procedure for how to remove the cylinder head
• a table of specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool

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SERVICE MANUAL Engine
T7510 T7520 T7530 T7540 T7550
47505533 11/02/2013 10
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Contents Engine - 10
10.001 Engine and crankcase . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10.1 T7510 , T7520 , T7530 , T7540 ,
T7550 10.106 Valve drive and gears . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 10.2 T7510 , T7520 , T7530 ,
T7540 , T7550 10.101 Cylinder heads . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.3 T7510 ,
T7520 , T7530 , T7540 , T7550 10.105
Connecting rods and pistons. . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
10.4 T7510 , T7520 , T7530 , T7540 ,
T7550 10.103 Crankshaft and flywheel. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 10.5 T7510 , T7520 , T7530 , T7540
, T7550 10.218 Fuel injection system . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10.6 T7510 , T7520 , T7530
, T7540 , T7550 10.250 Turbocharger and
lines. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.7 T7510 ,
T7520 , T7530 , T7540 , T7550 10.254 Intake
and exhaust manifolds and muffler . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 10.8 T7510 , T7520 , T7530 ,
T7540 , T7550 10.400 Engine cooling system .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 10.9 T7510 , T7520 ,
T7530 , T7540 , T7550 10.414 Fan and drive .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
10.10 T7510 , T7520 , T7530 , T7540 ,
T7550 10.304 Engine lubrication system . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 10.11 T7510 , T7520 , T7530 , T7540 ,
T7550
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Engine - 10 Engine and crankcase - 001
T7510 T7520 T7530 T7540 T7550
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14
Contents Engine - 10 Engine and crankcase -
001 TECHNICAL DATA Engine Torque . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 3 Special tools . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 4 General specification
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
6 Crankcase Service limits . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 8 FUNCTIONAL
DATA Engine and crankcase Overview . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
9 Functional diagram . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 10 Dynamic description . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 11 Dynamic
description Automatic engine shutdown . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 13 Engine Static
description . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 14 SERVICE Engine Service instruction
(Lifting the engine) . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
25 Crankcase Service instruction . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 26
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Engine - Engine and crankcase
Engine - Torque Tightening torques
Cylinder head bolts and nuts Cylinder head bolts in the cylinder block 80 Nm 90 90 30 Nm
Crankshaft bearing screws Connecting rod bolts (Torx E18) Nuts on crankshaft (right-hand thread) 200 Nm 40 Nm 80 Nm 90 1000 Nm
Pulley screws 30 Nm
Mounting bolts for flywheel Mounting bolts for flywheel housing inner screws, M10 outer screws, M12 150 Nm 80 Nm 150 Nm
Retaining screws for idler gear (with plain bearing) - M10 - M14 60 Nm 200 Nm
Overflow valve - piston cooling nozzle 30 Nm
Nut for lubrication oil pump gear 60 Nm
Retaining screws for lubrication oil pump 60 Nm
Connection part to the engine oil cooler 60 Nm
Nut to the pulley of the cooling water pump 120 Nm
Fastening - Visco fan on Visco hub 30 Nm
Bolts/nuts to the exhaust manifold 50 Nm
Screws to the air intake channel 30 Nm
Nut - driving toothed wheel, high pressure pump 90 Nm
Mounting bolt, injector High pressure line from high pressure pump to rail High pressure line from rail to the injectors Low pressure line to the high pressure pump 40 Nm 30 Nm 25 Nm 25 Nm
NOTE Use washers for aluminium parts. Always use
for the values in the table below if no special
tightening torques are provided.
Thread Tightness Tightness
Thread 8.8 10.9
M8 25 Nm 35 Nm
M10 50 Nm 75 Nm
Screws for the self-supporting oil pan Screws for the self-supporting oil pan Screws for the self-supporting oil pan
1 M8 25 Nm
2 M10 90 Nm
3 M14 160 Nm
4 M20 600 Nm
SS99N015 1
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Engine - Engine and crankcase Engine - Static
description General information The diesel
engines in the 620 series described in this
manual are water-cooled four stroke straight-type
engines with common rail injection systems. All
of the models are equipped with wet, replaceable
cylinder liners and exhaust turbochargers and
charge air cooling (air/air). The engines are
controlled by the EEM3 control unit. The exhaust
regulations according to Level 3A are complied
with. Cylinder block The rib-braced cylinder
block is the main unit of the engine, on which
the other engine components are affixed. The wet
and replaceable cylinder liners are supported
in the centre, reducing vibrations and feeding
most of the coolant flow to the upper part of the
cylinder liners. The seal between the lower part
of the cylinder liner and the cylinder block is
made 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 in the cylinder block. All camshaft bearings
are equipped with replaceable liners. Guide
bearings are integrated on both sides of the rear
main bearing of the crankshaft (crankshaft axial
bearings).
SS05N374 1
Flywheel housing The flywheel housing is
positioned at the rear end of the cylinder block.
The gasket for the rear end of the crankshaft is
inserted in a hole in the housing. The point of
starter attachment is in the flywheel
housing. The underside of the flywheel housing
serves as the sealing surface for the oil pan
gasket. This means that the lower surface of the
cylinder block must make a flush seal with the
flywheel housing. When installing the flywheel
housing, its position is determined by roll
springs.
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17
Engine - Engine and crankcase Cylinder head The
engines have two cylinder heads which can be
interchanged. Each cylinder has its own intake
and exhaust channel in the cylinder head. There
is an inlet valve between the outlet valves to
compensate the thermal load. The cylinder head
bolts are high-strength pre-tensioned bolts that
are tightened to their yield limit following the
principle of angular tightening. Given the high
level of expansion, the tightening forces are
kept constant over the entire usage period which
means that tightening is not needed. The
injection nozzle seats are machined directly in
the cylinder head. The inlet and outlet valve
guides are identical and can be interchanged. In
addition to this, the inlet and outlet valves are
equipped with replaceable valve seat sets.
SS05N284 2
Valve mechanism The valve mechanism is actuated
by the camshaft in the cylinder block. The
actuation force is transferred by valve tappets
and tappet rods. The press-fit camshaft gear sits
on the camshaft and is radially fixed with a
feather key. The bearings are lubricated through
holes in the engine block with pressurised oil.
Exhaust gas return system (EGR) Due to a
tightening of legal regulations concerning
exhaust emissions (tier 3) it has become
necessary to employ a range of measures to
fulfill these requirements. One of these measures
is an internal exhaust gas recirculation system
(EGR). A special camshaft allows an internal
exchange of gases without the need for additional
components. An additional inlet cam (c) on the
camshaft opens the inlet valve 2 mm during the
exhaust stroke. Using this method a part of the
exhaust gas is channelled into the intake channel
and recirculated back to the cylinder during the
intake stroke. Because the cam (c) opens the
inlet valve in every operating condition, it
depends on the boost pressure on the one hand and
the exhaust gas pressure on the other as to how
much exhaust gas is returned and whether any
exhaust gas is returned at all.
SS08A124 3
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Engine - Engine and crankcase
SS08A125 4
(A) Angular degrees for the crankshaft (B) Opening stroke for the valves
(a) (c) Outlet cam EGR cam (b) Inlet cam
Crank drive The crankshaft is forged of chrome
alloyed steel and is inductively hardened on the
bearing and sealing surfaces. The bearings can be
ground four times without the need for
rehardening. The press-fit gears sit on the front
end of the crankshaft. They drive the camshaft,
the high pressure pump and the oil pump. In
addition to this, the front end of the crankshaft
has keyways to take the drive hub. The pulley and
rotational vibration absorber (Visco) are fitted
on the hub. The front PTO shaft is also driven by
this hub (if present). An oil-repellent ring is
fitted between the hub and gear. One of the
crankshaft's crank webs carries the transmitter
wheel for the engine's speed sensor. There is a
main bearing for the crankshaft on both sides of
each cylinder. It is therefore has seven
bearings. The crankshaft's axial bearings are on
both sides of the rearmost main bearing. At the
rear end of the crankshaft there is a flywheel,
on which a press-fit sprocket is added. The
forged connecting rods have an I-shaped
cross-section. The connecting rod bearing is
divided horizontally by breaking. The bearing
cover is fastened with two special screws. The
upper part has a tapered bearing seat into which
the press-fit piston pin bearing bush is
fitted. The material from which the pistons are
made is an eutectic aluminium alloy. There is a
combustion cavity in the piston top. An optimum
mix of air and fuel is achieved thanks to the
shape of the optimised combustion cavity. The
pistons have two sealing rings and an oil scraper
ring. The upper piston ring, coated with
molybdenum, has a trapezoid- shaped
cross-section. The middle piston ring is a
tapered compression piston ring (the outer
diameter has a conical surface). The oil
scraper ring is suspended and has two chromed
stripper edges. The pistons are ring carrier
pistons (for the receptacle for the upper piston
ring, a ring carrier made of special cast iron is
poured into the piston). The piston shaft is also
coated with graphite on the sliding surface to
ensure a perfect run in. The piston top is cooled
from below by additional splash oil as soon as
the oil pressure exceeds 3 bar.
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