New Holland 87515682 Operating instructions

87515684 2/06
SERVICE
REPAIR
MANUAL
NEW HOLLAND
8.3 & 9.0L 6 Cylinder, 24 Valve
CNH Engine with High Pressure
Common Rail Fuel System

CNH ENGINE
REPAIR MANUAL
8.3L, 9.0L, 6 Cyl, 24 Vlv.
High Pressure Common
Rail Fuel System
87515682
CNH ENGINE
REPAIR MANUAL
8.3L, 9.0L, 6 Cyl, 24 Vlv.
High Pressure Common
Rail Fuel System
87515682
CNH ENGINE
REPAIR MANUAL
8.3L, 9.0L, 6 Cyl, 24 Vlv.
High Pressure Common
Rail Fuel System
87515682
CNH ENGINE
REPAIR MANUAL
8.3L, 9.0L, 6 Cyl, 24 Vlv.
High Pressure Common
Rail Fuel System
87515682
Please cut where indicated and place the label on the spine of the binder.
87515683
Find manuals at https://best-manuals.com

390 ©2006 CNH America LLC
Repair Manual Number 87515682
POWER PRODUCTION - B
87515684
Introduction
Engine - B.10.A
87515685
Fuel and Injection System - B.20.A
87515686
Air Intake System - B.30.A
Exhaust System - B.40.A
Engine Coolant System - B.50.A
Lubrication System - B.60.A
Starting System - B.80.A
You can order Repair Manual Books separately (see publication
numbers above) or you can order a complete Engine Repair Manual
(Publication Number 87515682).
Find manuals at https://best-manuals.com

REPAIR MANUAL
TG215 , TG245 , TG275 , TG305 , TJ280 , TJ330
87515682 4 18/01/2006
Find manuals at https://best-manuals.com

Contents
INTRODUCTION
POWER PRODUCTION B
ENGINE B.10.A
FUEL AND INJECTION SYSTEM B.20.A
AIR INTAKE SYSTEM B.30.A
EXHAUST SYSTEM B.40.A
ENGINE COOLANT SYSTEM B.50.A
LUBRICATION SYSTEM B.60.A
STARTING SYSTEM B.80.A
87515682 4 18/01/2006
Find manuals at https://best-manuals.com

INTRODUCTION
87515682 4 18/01/2006
1
Find manuals at https://best-manuals.com

Contents
INTRODUCTION
Foreword – How to use this manual ( - A.10.A.40) 3
Safety rules ( - A.50.A.10) 10
Basic instructions ( - A.90.A.05) 11
Torque ( - A.90.A.10) 14
Definition ( - A.92.A.15) 17
Conversion factors ( - A.92.A.21) 20
Product identification ( - A.80.A.10) 21
87515682 4 18/01/2006
2
Find manuals at https://best-manuals.com

INTRODUCTION
Foreword – How to use this manual ( - A.10.A.40)
The information in this manual is organized using the Integrated Coding Environment (ICE). ICE is a shorthand
system for pointing to Sections, Chapters and sub-Chapters in the manual without using the words. ICE also
identifies the type of information at that location.
A search for information on an engine component will
likely begin at the Table of Contents (TOC) or the Index:
for example, a search for information on the rear seal
of the crankshaft. When you locate “crankshaft - rear
seal” in the TOC with the indicated page number, this
Foreword explains:
•how to proceed to the correct location in the manual
based on the ICE code,
•how to identify the type of information you may
expect at that location.
RCPH05CDC414ABA 1
NOTE: Due to differences in languages and models, the page number indicated in the illustration may not applicable
to your manual. Refer to the table of contents in your repair manual.
Location
The first half of an ICE code describes the location of
the information.
(The ICE code has two parts separated by a hyphen.
The first part describes the location. The periods break
up the ICE code into its parts.)
RCPH05CDC476ABA 2
The first letter identifies the section.
Sections are arranged alphabetically in a manual. This
engine repair manual is contained within one section –
the Power Production Section – signified by the letter
“B,” and all ICE references in the manual begin with the
letter “B.”
Do NOT confuse a section with a bound book. Because
of its size, a section may require more than one bound
book, sometimes a book for each chapter within a
section.
This repair manual, although contained within one
section, requires more than one bound book. The book
cover always lists both the section(s) and chapter(s)
contained inside the bound book.
RCPH05CDC476ABA 3
87515682 4 18/01/2006
3
Find manuals at https://best-manuals.com

INTRODUCTION
The second number and letter identify the chapter within
the section.
Chapters are arranged numerically within the section.
The chapters used in this manual are listed below:
ENGINE (B.10.A)
FUEL AND INJECTION SYSTEM (B.20.A)
AIR INTAKE SYSTEM (B.30.A)
EXHAUST SYSTEM (B.40.A)
ENGINE COOLANT SYSTEM (B.50.A)
LUBRICATION SYSTEM (B.60.A)
STARTING SYSTEM (B.70.A)
The coding indicates that the rear seal is located in
Chapter 10.A (Engine), of Section B (Power Production).
RCPH05CDC483ABA 4
The section and chapter titles (A) are displayed at the
top of each page in the body of the manual.
The ICE code for the section, chapter and page number
(for example, B.10.A/149) (B) are displayed at the bottom
of each page in the body of the manual.
RCPH05CDC407ABA 5
The last two positions in the location code always form
the title of the document – in this example, crankshaft -
rear seal.
The third number identifies a sub-chapter within the
chapter.
The number “43” represents the crankshaft and indicates
that rear seal information is located under crankshaft in
Chapter 10.A of Section B.
RCPH05CDC490ABA 6
87515682 4 18/01/2006
4
Find manuals at https://best-manuals.com

INTRODUCTION
The fourth number identifies the rear seal itself, a
sub-topic (or sub-sub-chapter) of crankshaft. This is not
any rear seal; this is the rear seal for the crankshaft.
The page numbers for rear seal information within
Chapter 10.A are also given.
RCPH05CDC497ABA 7
Ifthesameloc
ation is viewed as part of a manual outline,
the uniqueness of the location is apparent. Rear seal
information is the only information that will be found at
B.10.A.43.02 within the entire manual.
RCPH05CDC506ABA 8
When you locate the information at the given page
number, the page heading confirms the location.
RCPH05CDC393ABA 9
Information type (Infotype)
The information in each chapter, and therefore the table
of contents, is separated into four broad categories:
•Techni c al Data
•Functional Data
•ServiceData
•Diagnostic Data
NOTE: The information in the Index for a chapter is organized alphabetically. The locations are listed alphabetically,
and then information from the different categories is listed alphabetically for the location.
87515682 4 18/01/2006
5
Find manuals at https://best-manuals.com

INTRODUCTION
This is the order of the information in the chapter and the
table of contents. These are the exact headings used in
the table of contents to separate the information.
There may be information on any component, like the
rear seal of the crankshaft, in any of the four categories.
Thelocationisthesame–B.A.10.43.02forallfour
categories. The second part of the code which identifies
the type of information, or infotype, is different.
RCPH05CDC421ABA 10
In fact, there are only two types of information offered on
the crankshaft rear seal in this manual:
•technical data which describes a special tool
needed for installation (A),
•and service data, which describes seal removal,
inspection and installation (B).
The first grouping in the illustration is located under the
Technical Data heading in the TOC. The second grouping
is located under the Service Data heading in the TOC.
RCPH05CDC406ABA 11
The coding for technical information always begins with
the letter “D.” The coding for the service information
always begins with the letter “F.”
The first letter of the infotype code always explains the
category of the information:
D = technical data,
C = functional data,
F = service data,
G = diagnostic data.
RCPH05CDC406ABA 12
87515682 4 18/01/2006
6

INTRODUCTION
Techni c a l d a ta may be:
•aspecification for the engine, the fuel system, the
air intake system, etc.,
•a special tool, whether recommended or required,
to perform a service procedure on the component,
•a torque value for installing a component,
•a service limit criterion, for determining when
a component must be replaced or the pass/fail
criterion for a test.
RCPH05CDC422ABA 13
Functional data may be:
•a dynamic description of how a system or
sub-system works during operation,
•a static description of a system component,
•an identification illustration to show the location
of components – sensor locations, fuel system
components, lubrication system components, etc.
RCPH05CDC429ABA 14
Service data may be:
•a basic service action like remove, disassemble,
assemble or install,
•an inspection or testing procedure,
•an adjusting or measuring procedure.
RCPH05CDC436ABA 15
87515682 4 18/01/2006
7

INTRODUCTION
Diagnostic data may be:
•guided troubleshooting to correct a problem,
•symptom-based troubleshooting to locate the
source of a problem.
RCPH05CDC443ABA 16
When searching for information in the table of contents
or the index, pay attention to the first letter of the infotype
and its title (special tool, dynamic description, remove,
problem-solving) so you find the type of information you
are seeking.
Applicability – Does the information apply to my model?
If an entry in the table of contents or the index has no
models listed immediately beneath it, the information
applies to all models listed on the repair manual, section
or chapter cover.
The information shown is applicable to all models.
RCPH05CDC414ABA 17
When an entry in the TOC or index has models listed
below it, the information applies only to those models.
Although the location code, infotype code and title of the
entry are exactly the same, the model names inform you
that the content varies by model.
Go to the page number listed for your model. When you
locate the information in the manual, the same models
are listed below the title to confirm that you are at the
right location.
RCPH05CDC503ABA 18
87515682 4 18/01/2006
8

INTRODUCTION
Prior Operation and Next Operation
This manual makes extensive use of “Prior operation”
and “Next operation” lists to avoid repetition.
A“Prioroperati
on” list always occurs at the beginning of
document and points to procedures which must precede
the current procedure.
A “Next operation” list always occurs at the end of a
document and points to procedures which must follow
the current procedure in order to restore the engine to
active service.
RCPH05CDC466ABA 19
Prior and Next operations usually contain an ICE code
reference which follows the same format as previously
explained. For example, installation of the lower main
bearings and bearing caps is the first operation listed
after the crankshaft is installed. The ICE code given is
(B.10.A.43.15 - F.10.A.15) with the title, Crankshaft Main
Bearing - Install.
The location code points to the sub-topic main bearings
(4), in the sub-chapter on the crankshaft (3), in Chapter
10.A (2),ofSectionB(1).
The infotype code points to a service procedure because
of the initial letter “F” that is located under Service Data
in the table of contents. RCPH05CDC473ABA 20
87515682 4 18/01/2006
9

INTRODUCTION
Safety rules ( - A.50.A.10)
Read and understand all of the safety precautions and warnings before performing any repair. This list contains
the general safety precautions that must be followed for your personal safety. Additional safety precautions are
included in the procedures where they apply.
General safety precautions
•The work area around the engine must be dry, well lit, ventilated, free from clutter, ignition sources and
hazardous substances.
•Always wear protective glasses and protective shoes when working.
•Stay clear of rotating parts which can cut, mutilate or strangle.
•Do NOT wear loose-fitting or torn clothing. Remove all jewelry when working.
•Disconnect the battery [negative (-) cable first] and discharge any capacitors before beginning any repair work.
Put a “Do NOT Operate” tag in the cab or on the controls.
•Only use proper engine barring techniques when rotating the engine manually. Do NOT attempt to rotate the
crankshaft by pulling or prying on the fan. This practice may cause serious personal injury, property damage,
fan damage or premature fan failure.
•When coolant is hot from engine operation, allow the engine to cool before slowly loosening the pressure cap
to relieve pressure in the cooling system.
•ALWAYS use blocks or the proper engine stand to support the engine before performing any repair work. Do
NOT work on an engine which is only supported by floor jacks or a hoist.
•Relieve all pressure in the air, oil and cooling systems before any lines, fittings or related items are removed or
disconnected. Be alert for possible pressure when disconnecting any component from a system that uses
pressure. Do NOT check for leaks with your hand. High pressure oil or fuel can cause personal injury.
•To reduce the possibility of personal injury, use a hoist or an assistant when lifting components that weigh 23
kg (50 lb) or more. Make sure all lifting equipment – such as chains, hooks or slings – is in good condition and
of the correct capacity. Make sure all lift hooks are positioned correctly. ALWAYS use a spreader bar when
necessary; lifting hooks must NOT be side-loaded.
•Corrosion inhibitor, a component of coolant additives and lubricating oil, contains alkali. Do NOT get the
substance in eyes. Avoid prolonged or repeated contact with skin. Do NOT swallow internally. In case of
contact, immediately wash skin with soap and water. In case of contact, immediately flood eyes with large
amounts of water for a minimum of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF THE
REACH OF CHILDREN.
•Naptha and Methy Ethyl Ketone (MEK) are flammable materials and MUST be used with caution. Follow the
manufacturer’s instructions when using these materials. KEEP OUT OF THE REACH OF CHILDREN.
•To prevent burns, be aware of heated parts and hot fuel in lines, tubes and compartments on recently
operated engines.
•ALWAYS use tools that are in good condition. Understand the correct use of the tool before performing repair
work. Use ONLY genuine CNH replacement parts.
•ALWAYS use the same fastener part number (or equivalent) when replacing fasteners. Do NOT use a fastener
of lesser quality when replacing components.
•Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
•Some government agencies have determined that used engine oil can be carcinogenic and can cause
reproductive toxicity. Avoid inhalation of vapors, ingestion and prolonged contact with used engine oil.
•Coolant is toxic. If NOT reused, follow local environmental regulations for proper disposal.
87515682 4 18/01/2006
10

INTRODUCTION
Basic instructions ( - A.90.A.05)
Definition of “clean”
Parts must be free of debris that can contaminate any engine system. This does not mean that cleaned parts
have to appear to be new.
Abrasive pads and abrasive paper
Thereisnopartof an engine designed to withstand abrasion. All engine components are designed to lock together
or slide across each other. Abrasives and dirt particles will degrade both functions.
CNH does NOT recommend the use of emery cloth or sand paper on any part of an ASSEMBLED engine or
component, especially for removing the carbon ridge from cylinder liners or to clean block decks or counterbores.
Use abrasive products with great care when cleaning engine parts, particularly on partially assembled engines.
These cleaning products come in many forms and sizes. All contain aluminum oxide particles, silicon carbide, sand
or some other similar hard material. These materials are harder than most parts of the engine. When pressed
against a softer material, they will either damage the material or become embedded in it.
Once embedded in a part, the abrasive particle will abrade the other part it contacts until contact is no longer
made between the two parts. If the damage sufficiently degrades the oil film, the two parts may fail prematurely
from ineffective lubrication.
In addition, particles fall off of the holding material as the abrasive product is being used.
Gasket surface
The object in cleaning gasket surfaces is to remove gasket material, not to refinish the gasket surface on the part.
CNH does NOT recommend any specific brand of liquid gasket remover. If a liquid gasket remover is used, check
the manufacturer’s directions to make sure the part being cleaned will not be damaged.
Air powered gasket scrapers can save time, but the surface cannot be damaged in the process.
All old gasket material must be removed from the gasket mating surfaces. However, it is not necessary to clean
and polish the gasket surface until the machining marks are erased. Excessive sanding or buffing can damage the
gasket sealing surface. Surface finish and flatness tolerances must be maintained to form a quality sealing surface.
Solvents and acid cleaning
Solvents and acid-type cleaner can be used to clean disassembled engine parts (with the exception of pistons). The
best results are obtained with a cleaner that can be heated to 90-95°C(180-200°F). CNH does NOT recommend
any specific brand of cleaner. Always follow the manufacturer’s instructions when using cleaning solutions.
WARNING
When using solvents, acids or alkaline materials for cleaning, follow the manufacturer’s recommendations
for use. Wear goggles and protective clothing to reduce the possibility of personal injury. M995
Kerosene emulsion based cleaners work the best for cleaning pistons. These cleaners should NOT be heated to
temperatures in excess of 82 °C (180 °F). The cleaners begin to break down at temperatures in excess of 82 °C
(180 °F) and will be less effective.
Do NOT use solutions composed primarily of chlorinated hydrocarbons with cresols, phenols and/or cresylic
components. These solutions often do NOT clean well and are costly to dispose of properly.
Solutions with a pH above 7.0 are considered alkaline and those below 7.0 are acidic. The solutions become highly
alkaline or highly acidic the further they move from the neutral 7.0. Solutions with a pH above approximately 9.5
cause aluminum to turn black; highly alkaline solutions must NOT be used.
A cleaning tank that provides a constant mixing and filtering of the cleaning solution will yield the best results.
87515682 4 18/01/2006
11

INTRODUCTION
•Remove all gasket material, O-rings and sludge or carbon deposits with a wire brush or scraper before putting
the parts in the cleaning tank.
•When possible, use high pressure water or steam clean the parts before submerging them in the tank.
Removing the heaviest dirt before tank cleaning will allow the cleaner to work more effectively.
•Rinse all parts in hot water after cleaning. Dry completely with clean shop air. Use air to remove the rinse
water from all cap screw holes and the oil drillings.
•If the parts are NOT to be used immediately after cleaning, dip them in a suitable rust proofing compound.
This compound MUST be removed from the parts before assembly or installation on the engine.
Steam cleaning
Steam cleaning can be used to remove all types of dirt that may contaminate the cleaning tank. Steam cleaning is
an excellent method for cleaning oil drillings and coolant passages.
WARNING
Always wear protective clothing, safety glasses or a face shield when using a steam cleaner or power
washer. Failure to wear protective equipment can cause serious injury. M927
The following components should NEVER be steam cleaned:
– electrical components – belts and hoses
– wiring harnesses – bearings (ball or tapper roller)
–injectors – electronic control module (ECM)
– fuel pump – ECM connectors
Plastic bead cleaning
CNH recommends using ONLY plastic bead media on any engine part.
CNH does NOT recommend the use of glass bead blast or walnut shell media on ANY engine part. NEVER use
sand as a blast media on any engine part. Glass and walnut shell media can cause excess dust and can embed in
engine parts, which can result in premature component failure from abrasive wear.
Plastic beading can be used on many engine components to remove carbon deposits. The cleaning process is
controlled by the use of plastic beads, the operating pressure and the cleaning time.
CAUTION
Do not use thebeadblastingcleaningmethodonaluminumpistonskirtsorborepinsinanypiston,piston
skirt or piston crown. Small particles of the media will embed in the aluminum or other soft metal and result
in premature wear of the cylinder liner, piston rings, pins and pin bores. Valves, turbocharger shafts, etc.
canalsobedamaged. Follow the cleaning methods specified in the procedure. M1064
CAUTION
Do not contaminate wash tanks and tank type solvent cleaners with foreign material and plastic beads.
Remove the foreign material and plastic beads with compressed air, hot high pressure water or steam before
placing them in tanks and cleaners. The foreign material and plastic beads can contaminate the tank and any
other engine parts cleaned in the tank. Contaminated parts may cause failures from abrasive wear. M1065
Plastic bead material (U.S. size 16-20) can be used to clean piston ring grooves. Do NOT use bead blasting
media on piston pin bores or aluminum skirts. Bead blasting is best used on stubborn dirt or carbon build-up that
has NOT been removed by steam or high pressure washing, followed by cleaning in a heated wash tank. This
is particularly true of pistons: steam and soak the pistons first and then use the plastic bead method to safely
remove the carbon remaining in the grooves.
Follow the equipment manufacturer’s cleaning instructions. Adjust the air pressure in the blasting machine to
the manufacturer’s recommendation. Use these guidelines when plastic bead blasting recommendations are
not available:
87515682 4 18/01/2006
12

INTRODUCTION
•Use plastic bead size 16-20 (U.S. size) or equivalent.
•Use an operating pressure of 270 kPa (40 psi) for piston cleaning. Pressure should not cause the beads to
break.
•Steam clean or wash the parts with solvent to remove all foreign material and plastic beads after cleaning.
Rinsewithhotw
ater. Dry with compressed air.
CAUTION
Bead blasting must not disturb the metal surface of the component. If the metal surface is disturbed,
the engine can be damaged due to increased parts clearance or inadequate surface finish on parts that
move against other parts. M1066
•When cleaning pistons, it is NOT necessary to remove all the dark stain from the piston. Removing the carbon
on the rim and from the ring grooves IS necessary. Direct the blast across the part rather than straight at the
part. If machining marks are disturbed by the blasting process, the pressure is too high or the blast is being
held on one spot too long. The blast operation must not disturb the metal surface.
•Always direct the bead blast nozzle across rather than at the part. This allows the beading to get under the
unwanted material. Keep the nozzle moving, rather than held in one spot, to prevent surface damage.
•Never bead blast valve stems. Tape or use a sleeve to protect the stems during bead blasting. Direct the
nozzle across the seat surface and radius rather then straight at them.
87515682 4 18/01/2006
13

INTRODUCTION
Torque ( - A.90.A.10)
IMPORTANT: When replacing cap screws, always use a cap screw of the same measurement and strength as
the cap screw being replaced.
Metric cap screws and nuts are identified by the grade number stamped on the head of the cap screw or on the
surface of the nuts. U.S. customary cap screws are identified by radial lines stamped on the head of the cap screw.
Cap screw marking and torque value – Metric
Commercial steel class
8.8 10.9 12.9
Cap screw head marking
rh04h178 1rh04h179 2rh04h180 3
Dia. Cast iron Aluminum Cast iron Aluminum Cast iron Aluminum
mm Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb Nm ft lb
69 5741310
7414974
714 9 11 718 14 11 723 18 11 7
8 231718143325181440291814
10 45 33 30 25 65 50 30 25 70 50 30 25
12 80 60 55 40 115 85 55 40 125 95 55 40
14 125 90 90 65 180 133 90 65 195 145 90 65
16 195 140 140 100 280 200 140 100 290 210 140 100
18 280 200 180 135 390 285 180 135 400 290 180 135
20 400 290 ––550 400 ––––––
NOTES
1. Always use the torque values listed in the above table when specific torque values are not supplied in a
procedure.
2. Do NOT use these torque values in place of specified torque values in a procedure.
3. The values in the table are based on lubricated threads.
87515682 4 18/01/2006
14

INTRODUCTION
Cap screw marking and torque value – U.S. Customary
Cap screw head marking
SAE Grade 5 SAE Grade 8
rh04h175 4rh04h176 5
Cast iron Aluminum Cast iron Aluminum
Body size Nm ft lb Nm ft lb Nm ft lb Nm ft lb
1/4 - 20 9786151186
1/4 - 28 12 9 9 718 13 9 7
5/16 - 18 20 15 16 12 30 22 16 12
5/16 - 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
3/8 - 24 40 30 35 25 60 45 35 25
7/16 - 14 60 45 45 35 90 65 45 35
7/16 - 20 65 50 55 40 95 70 55 40
1/2 - 13 95 70 75 55 130 95 75 55
1/2 - 20 100 75 80 60 150 110 80 60
9/16 - 12 135 100 110 80 190 140 110 80
9/16 - 18 150 110 115 85 210 155 115 85
5/8 - 11 180 135 150 110 255 190 150 110
5/8 - 18 210 155 160 120 290 215 160 120
3/4 - 10 325 240 255 190 460 340 255 190
3/4 - 16 365 270 285 210 515 380 285 210
7/8 - 9 490 360 380 280 745 550 380 280
7/8 - 14 530 390 420 310 825 610 420 310
1 - 8 720 530 570 420 1100 820 570 420
1 - 14 800 590 650 480 1200 890 650 480
NOTES
1. Always use the torque values listed in the above table when specific torque values are not supplied in a
procedure.
2. Do NOT use these torque values in place of specified torque values in a procedure.
3. The values in the table are based on lubricated threads.
4. When a ft-lb value is less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb wrench.
Pipe plug torque values
Size Torque
Thread Actual thread OD In aluminum housing In cast iron or steel housing
in in Nm ft-lb Nm ft-lb
1/16 0.32 545 lb in 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
11.32604595
75
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100
87515682 4 18/01/2006
15