New Holland 87515682 Repair Manual Download

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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

Summary of Contents for 87515682

Page 1: ...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 ...

Page 2: ...essure 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 ...

Page 3: ... 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 ...

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

Page 5: ...ON 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 ...

Page 6: ...INTRODUCTION 87515682 4 18 01 2006 1 Find manuals at https best manuals com ...

Page 7: ...anual 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 ...

Page 8: ...cated 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...

Page 9: ...DC483ABA 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 ...

Page 10: ... 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 Technical Data Functional Data Service Data Diagnostic Data NOTE The information in the Inde...

Page 11: ...ed 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 techn...

Page 12: ...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 disas...

Page 13: ...ts 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 exactl...

Page 14: ...6ABA 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 be...

Page 15: ...gh 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 ...

Page 16: ...ng 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 toleran...

Page 17: ... 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 the bead blasting cleaning method on aluminum piston skirts or bore pins in any piston piston skirt or piston crown Small particles...

Page 18: ... 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...

Page 19: ...inum 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 6 9 5 7 4 13 10 7 4 14 9 7 4 7 14 9 11 7 18 14 11 7 23 18 11 7 8 23 17 18 14 33 25 18 14 40 29 18 14 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 2...

Page 20: ...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 val...

Page 21: ... 80 59 180 133 10 89 lb in 85 63 185 136 11 97 lb in 90 66 190 140 12 106 lb in 95 70 195 144 14 124 lb in 100 74 200 148 15 133 lb in 105 77 205 151 16 142 lb in 110 81 210 155 18 159 lb in 115 85 215 159 20 15 lb ft 120 89 220 162 25 18 lb ft 125 92 225 165 30 22 lb ft 130 96 230 170 35 26 lb ft 135 100 235 173 40 30 lb ft 140 103 240 177 45 33 lb ft 145 107 245 180 50 37 lb ft 150 111 250 184 8...

Page 22: ...ression left in the surface by a piece of foreign material that is trapped between two parts A dent has a relatively smooth shiny bottom and does NOT have rough or sharp edges RCPH05CDC004AAA 2 Frosted bands Frosted bands are created by high density micro denting The bands are frosted or white in appearance Frosted bands are not detectable with a fingernail RCPH05CDC005AAA 3 87515682 4 18 01 2006 ...

Page 23: ...ft lobe The extent of the galling determines whether the part must be replaced RCPH05CDC006AAA 4 Surface distress conditional reuse RCPH05CDC007AAA 5 Major surface distress no reuse Pitting Pitting is the loss of material from a part resulting in a hole that is visible to the naked eye Pits typically have rough dark bottoms and sharp edges and usually occur in heavily loaded areas on the part RCPH...

Page 24: ...NTRODUCTION Macro Spalling Macro spalling is the loss of large material from the surface of a part This amount of damage will affect the operation of the engine RCPH05CDC009AAA 7 87515682 4 18 01 2006 19 ...

Page 25: ... kPa inch of mercury in Hg 0 29613 3 3769 kilopascal kPa inch of water in H2O 4 019299 0 2488 millimeter of mercury mm Hg inch of mercury in Hg 0 039370 25 40 millimeter of water mm H2O inch of water in H2O 0 039370 25 40 kilopascal kPa bar bar 0 00999 100 001 Pressure millimeter of mercury mm Hg bar bar 0 001333 750 06 Temperature centigrade C fahrenheit F 1 8 x C 32 F 32 1 8 Newton meter N m pou...

Page 26: ...INTRODUCTION Product identification A 80 A 10 RCPH05CDC183ABA 1 Data plate locations A Engine data plate B Fuel injection pump data plate C Engine control module ECM data plate 87515682 4 18 01 2006 21 ...

Page 27: ...4 4 Horsepower and RPM rating The engine data plate is located on top of the timing gear housing The engine data plate contains specific information about your engine The engine serial number ESN and part number are used when ordering service parts The data plate MUST not be changed unless approved by CNH 87515682 4 18 01 2006 22 ...

Page 28: ...not readable the engine serial number is also stamped into the top of the oil cooler housing RCIL05CDC007AAA 4 Fuel injection pump data plate 1 Part number 2 Pump serial number 3 Factory code The fuel pump data plate is located on the side of the injection pump 87515682 4 18 01 2006 23 ...

Page 29: ...ial number ECM CODE Software programming code The engine control module data plate is located above the module connectors on the left hand side of the engine The data plate contains hardware and software programming information about the control module as well as the engine serial number ESN 87515682 4 18 01 2006 24 ...

Page 30: ...REPAIR MANUAL POWER PRODUCTION TG215 TG245 TG275 TG305 TJ280 TJ330 87515682 4 18 01 2006 B ...

Page 31: ...30 B 20 A AIR INTAKE SYSTEM TG215 TG245 TG275 TG305 TJ280 TJ330 B 30 A EXHAUST SYSTEM TG215 TG245 TG275 TG305 TJ280 TJ330 B 40 A ENGINE COOLANT SYSTEM TG215 TG245 TG275 TG305 TJ280 TJ330 B 50 A LUBRICATION SYSTEM TG215 TG245 TG275 TG305 TJ280 TJ330 B 60 A STARTING SYSTEM TG215 TG245 TG275 TG305 TJ280 TJ330 B 80 A 87515682 4 18 01 2006 B ...

Page 32: ...POWER PRODUCTION B ENGINE 10 A TG215 TG245 TG275 TG305 TJ280 TJ330 87515682 4 18 01 2006 B 10 A 1 ...

Page 33: ...44 30 D 20 A 40 19 Camshaft Journal Service limits B 10 A 40 44 35 D 20 A 20 19 Camshaft Lobe Service limits B 10 A 40 44 40 D 20 A 20 20 Valve assembly Valve Service limits B 10 A 40 46 10 D 20 A 20 23 Valve assembly Valve Special tools B 10 A 40 46 10 D 20 A 40 23 Valve assembly Spring Service limits B 10 A 40 46 15 D 20 A 20 24 Valve assembly Spring Special tools B 10 A 40 46 15 D 20 A 40 25 Cr...

Page 34: ...e limits B 10 A 70 15 D 20 A 20 45 Cylinder block Liner Special tools B 10 A 70 15 D 20 A 40 47 Cylinder head Cylinder head Torque B 10 A 72 D 20 A 10 50 Cylinder head Service limits B 10 A 72 D 20 A 20 50 Cylinder head Special tools B 10 A 72 D 20 A 40 52 Cylinder head Valve seat Service limits B 10 A 72 10 D 20 A 20 56 Cylinder head Valve guide Service limits B 10 A 72 15 D 20 A 20 56 Valve cove...

Page 35: ...A 10 97 Valve drive Camshaft Visual inspection B 10 A 40 44 F 40 A 10 99 Valve drive Camshaft Measure B 10 A 40 44 F 40 A 16 100 Valve drive Camshaft Install B 10 A 40 44 F 10 A 15 102 Valve drive Camshaft End play B 10 A 40 44 F 40 E 10 104 Valve drive Camshaft Backlash B 10 A 40 44 F 40 E 15 105 Camshaft Gear Remove B 10 A 40 44 10 F 10 A 10 106 Camshaft Gear Visual inspection B 10 A 40 44 10 F ...

Page 36: ... A 43 10 F 40 A 10 171 Crankshaft Gear Measure B 10 A 43 10 F 40 A 16 172 Crankshaft Gear Install B 10 A 43 10 F 10 A 15 173 Crankshaft Main bearing Remove B 10 A 43 15 F 10 A 10 175 Crankshaft Main bearing Visual inspection B 10 A 43 15 F 40 A 10 179 Crankshaft Main bearing Measure B 10 A 43 15 F 40 A 16 180 Crankshaft Main bearing Install B 10 A 43 15 F 10 A 15 181 Crankshaft End play B 10 A 43 ...

Page 37: ...emove B 10 A 47 15 05 F 10 A 10 247 Piston Ring Measure B 10 A 47 15 05 F 40 A 16 248 Piston Ring Install B 10 A 47 15 05 F 10 A 15 249 Piston Pin Measure B 10 A 47 15 10 F 40 A 16 251 Flywheel Flywheel Remove B 10 A 50 F 10 A 10 252 Flywheel Visual inspection B 10 A 50 F 40 A 10 254 Flywheel Install B 10 A 50 F 10 A 15 256 Flywheel Measure B 10 A 50 F 40 A 16 259 Vibration damper Vibration damper...

Page 38: ...8 Front cover Visual inspection B 10 A 75 F 40 A 10 319 Front cover Install B 10 A 75 F 10 A 15 320 Rear cover Rear cover Remove B 10 A 76 F 10 A 10 323 Rear cover Install B 10 A 76 F 10 A 15 325 Wiring harness Wiring harness Disconnect B 10 A 88 F 10 A 11 326 Wiring harness Connect B 10 A 88 F 10 A 16 327 Electronic control Electronic control Check B 10 A 92 F 40 A 11 328 Electronic control Contr...

Page 39: ...ENGINE Testing B 10 A G 40 A 20 347 ENGINE Problem solving B 10 A G 40 A 30 350 87515682 4 18 01 2006 B 10 A 8 ...

Page 40: ... 2 722 kg 6000 lb RCSC05CDC137AAA 1 Universal engine adapter OEM205061 SPX This assembly included with OEM4137 is required to add engine mounting plates to The Revolver RCPH05CDC996AAC 2 Engine mounting plate OEM218099 SPX This plate is bolted to the CNH C Series engines so the engine can be installed on The Revolver engine repair stand OEM4137 RCPH05CDC121AAA 3 87515682 4 18 01 2006 B 10 A 9 ...

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