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CURSOR SERIES

Base - 03/2015

Print P4D32C006 E

Removal
Disconnect

Intake

Refitting
Connect

Exhaust

Disassembly
Dismantling

Operation

Assembly
Assemble

Compression ratio

Tighten to the specified torque

Tolerance
Weight difference

Tighten to the specified angle value

Rolling torque

Press or caulk

Rotation

Registration
Adjustment

Angle
Angle value

Visual check
Fitting position check

Preload

Measuring
Value to be found
Check

Revolutions per time unit

Tools

Temperature

Surface for machining
Finished workpiece

bar

Pressure

Interference
Forced assembly

Oversized
Oversized by no more than .....
Max.

Clearance
Shim

Undersized
Undersized by no more than.....
Min.

Lubricate
Moisten
Grease

Selection
of oversizing

class

Coolant
Sealant

Temperature < 0

Cold
Winter

Bleeding air

Temperature > 0

Hot
Summer

Содержание CR13 TE 6W

Страница 1: ...CURSOR 13 NON EMISSIONS CERTIFIED Power generation CR13 TE 7W F3HFA615A D001 CR13 TE 6W F3HFA615B D001 Technical repair manual...

Страница 2: ...nce and operators safety Each repair intervention must be finalised to the recovery of functionality efficiency and safety conditions that are provided by Iveco Each intervention on the vehicle that i...

Страница 3: ...LS 3 Warnings 3 Service operations 3 GENERAL WARNINGS 5 GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM 7 Grounding and screening 8 CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIO...

Страница 4: ...2 CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 5: ...ng stand Section 7 provides the technical specifications of the engine such as data fitting clearance and tightening torques Section 8 deals with the equipment required for carrying out the operations...

Страница 6: ...aulk Rotation Registration Adjustment Angle Angle value Visual check Fitting position check Preload Measuring Value to be found Check Revolutions per time unit Tools Temperature Surface for machining...

Страница 7: ...on it Scrupulously observe all safety warnings on the assembly Do not leave the assembly in motion unattended during repair work When working on an assembly off the ground make sure that it is restin...

Страница 8: ...ap and water Wait approximately 15 minutes before proceeding with welding Use suitable fire resistant protections to protect hoses or other components in which fluids or other flammable materials flow...

Страница 9: ...sconnect the batteries from the circuit disconnecting the chassis earth cable first of all from the negative terminal of the battery Before connecting the batteries to the system make sure the latter...

Страница 10: ...o the negative terminal of the battery or batteries Even if not connected to the circuit ground battery negative terminal analogue ground sensors should have optimal insulation Consequently particular...

Страница 11: ...0 1047 rad s 1 rad s 9 55 rpm Pressure 1 bar 1 02 kg cm2 1 kg cm2 0 981 bar 1 bar 105 Pa Temperature 0 C 273 15 K 0 F 255 37 K 0 C 32 F the conversion factor between Celsius and Fahrenheit is 1 1 8 T...

Страница 12: ...ype of engine Section title Page number Number of printed copies Language of Publication Basic edition referring to closing phase of drafting month year When present a month year update Revi to the ba...

Страница 13: ...CURSOR SERIES TIER 4B Section General information 1 Operating diagrams 2 Electricl equipment 3 Scheduled Maintenance 4 Removal Refitting of the main engine components 5 General mechanical overhaul 6 T...

Страница 14: ...2 CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 15: ...3 CURSOR SERIES Print P4D32C006 E Base 03 2015 UPDATE DATA Section Section name Description of modification Page Revision date...

Страница 16: ...4 CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 17: ...S Print P4D32C006 E Base 03 2015 SECTION 1 General information Page IDENTIFICATION DATA 3 CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES 4 PRODUCT TECHNICAL CODE 5 VPRODUCT COMMERCIAL COD...

Страница 18: ...2 SECTION 1 GENERAL INFORMATION CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 19: ...F3HFA615B D001 225053 Figure 1 A Serial number B Month and year construction date C Engine type D Engine family name E FPT Engine P N 1 Bar code The Bar code contains Serial number Manufacturing date...

Страница 20: ...NCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES 4 SECTION 1 GENERAL INFORMATION CURSOR SERIES Base 03 2015 Print P4D32C006 E Technical codes Commercial Codes F3HFA615A D001 CR13 TE 7W F3HFA615B D001...

Страница 21: ...erise the application and the corresponding level of power output It is stamped on one side of the crankcase near the oil filter F ENGINE FAMILY IDENTIFICATION PROJECT EVOLUTION ENGINE CYLINDER CONFIG...

Страница 22: ...inging together engines of different families origin and applications for which they are to be used The commercial acronym is not used for any technical purpose to recognise the parts which make up th...

Страница 23: ...Turbocharger exhaust gas outlet LATERAL VIEW INTAKE SIDE 1 Alternator protective grille 2 Radiator support bracket 3 Oil sump drain plug 4 Engine cold air inlet pipe 5 Fuel filter 6 Electric starter m...

Страница 24: ...radiator 5 Turbocharger 6 Pipe for intake of external air to turbocharger 7 Refitting water inlet pipe to crankcase REAR VIEW 1 Oil sump drain plug 2 Engine flywheel 3 Oil filter 4 Air filter 5 Engin...

Страница 25: ...cover 7 Air filter 8 Pipe for intake of external air to turbocharger 9 Turbocharger 10 Hot compressed air outlet pipe from turbocharger to radiator 11 Radiator 12 Water outlet pipe from head ISOMETRIC...

Страница 26: ...FA615A D001 F3HFA615B D001 Cycle Diesel 4 stroke Supply Turbocharged Injection Direct Number of cylinders 6 in line Bore mm 135 Stroke mm 150 Total capacity cm3 12882 Compression ratio 16 5 1 Maximum...

Страница 27: ...filling 5 Use STANDARD fuel which complies with standards ASTM D975 or EN 590 The indications connected to the fuel tank capacity are the responsibility of the vehicle equipment manufacturer since the...

Страница 28: ...12 SECTION 1 GENERAL INFORMATION CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 29: ...miter valve 9 Fuel filter 9 Oil filter tightening torques 10 LUBRICATION 11 Oil pump 12 overpressure valve 12 Oil pressure regulator valve 13 Heat exchanger 13 Filter by pass valve 14 Engine oil filte...

Страница 30: ...2 SECTION 2 OPERATING DIAGRAMS CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 31: ...d accumulates fuel in a common duct for all injectors At the electro injector inlet therefore there is always fuel at the injection pressure calculated by the ECU When an injector solenoid valve is en...

Страница 32: ...ase 03 2015 Print P4D32C006 E Figure 2 210171 A High pressure B Low pressure 1 High pressure pump 2 Fuel filter 3 Tank 4 Fuel prefilter 5 Engine control unit 6 Electric injectors 7 Overpressure valve...

Страница 33: ...m tank 4 Fuel delivery to filter 5 Plug 6 Fuel return to tank Technical data Pump characteristics Transmission ratio 1 1 Number of cam plungers lobes 2 3 Incoming fuel temperature gear pump 40 80 C 90...

Страница 34: ...the high pressure pump operation This function is further enabled by a calibrated hole being set downstream of the high pressure pump Some calibrated holes have been made in the retaining fittings of...

Страница 35: ...ssure fuel intake fitting 4 Injector closing force 5 Spray nozzle 6 Injector nozzle 7 Fuel return hole 8 IQA codes 9 Production code The electro injectors are mounted on the cylinder head and operated...

Страница 36: ...er 10 of the pilot valve is closed Under this condition opening and closing forces are balanced as fuel pressure in the control volume 9 equals that of the pressure chamber 7 2nd Phase Injection start...

Страница 37: ...a value the valve regulates it by releasing part of the fuel to the tank Furthermore in case of failure of the injection pressure control system it allows the engine to function with limited performan...

Страница 38: ...6 E Oil filter tightening torques PART TORQUE Nm kgm 1 Fitting for bleeding 17 5 2 5 1 75 0 25 2 Fuel filter 32 5 2 5 3 25 0 25 3 Fuel filter support 24 5 2 5 2 45 0 25 4 Drain valve 1 5 0 5 0 15 0 05...

Страница 39: ...3 2015 LUBRICATION The engine is lubricated by gear pump driven via gears by the crankshaft A heat exchanger regulates the temperature of the lubricating oil It houses the oil filter indicator sensors...

Страница 40: ...shall not be overhauled If you find any da mage replace the entire oil pump To change the gearing 2 of the crankshaft see the relevant section overpressure valve Figure 12 73540 MAIN DATA TO CHECK TH...

Страница 41: ...ure 15 161269 A Opening Start B Opening End MAIN DATA TO CHECK THE PRESSURE RELIEF VALVE SPRING Heat exchanger 180296 Figure 16 1 By pass valve 2 Heat exchanger 3 Oil filter support seat TECHNICAL DAT...

Страница 42: ...5 The valve quickly opens at a pressure of 3 4 0 3 bar Engine oil filter Figure 18 180257 1 Oil filter support 2 Cap O Ring 3 Cartridge O Ring 4 Filter element 5 Closing cap 6 Drain plug Technical dat...

Страница 43: ...engine oil filter 6 5 1 5 Nm Valve integrated in piston cooling nozzle The valve allows oil to enter and thus lubrication of pistons only above the pressure value shown below Figure 19 109080 Technica...

Страница 44: ...at the top of the timing system cover and sent into the air intake circuit The device is essentially composed of a rotary filter fitted to the high pressure pump camshaft control shaft and a rear cove...

Страница 45: ...system is a closed circuit forced circula tion system and can be connected to an additional heater if any and to the Intarder heat exchanger It consists mainly of the following components an expansion...

Страница 46: ...lant vent excess pressure into the atmosphere that is caused by high temperature of the coolant The function of the inlet valve is to permit the transfer of coo lant from the expansion tank to the rad...

Страница 47: ...he cylinders The intercooler is composed of a radiator applied on the engine coolant radiator and it is used for lowering the tempe rature of the air coming out from the turbocharger to send it to the...

Страница 48: ...outlet detail B sending a portion of the exhaust gas directly into the exhaust pipe when the turbo charging pressure down from the turbocharger reaches a calibrated value 221065 Figure 26 Figure 27 tu...

Страница 49: ...and the centrifugal move ment is imparted at high speed by the wings aimed at the filter The larger particles of dust and dirt are separated from the air and collected in the condensate discharge val...

Страница 50: ...22 SECTION 2 OPERATING DIAGRAMS CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 51: ...96 PIN CONTROL UNIT EDC 17 HP 41 6 CRIN INJECTOR 3 3 9 Rail pressure sensor RSD 4 9 Pressure sensor inside engine crankcase 10 Crankshaft sensor 11 Camshaft sensor 12 Fuel temperature sensor 13 Coola...

Страница 52: ...2 SECTION 3 ELECTRIC EQUIPMENT CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 53: ...th pressure and temperature sensor 7 Fuel pump with flow rate regulator 8 Starter motor 9 Rpm sensor 10 Oil high pressure and temperature sensor 11 Timing sensor 12 Electro injectors 13 Rail with fuel...

Страница 54: ...emperature sensor 4 Oil high pressure and temperature sensor 5 Turbocharging air pressure and temperature sensor 6 Fuel pre filter clogged sensor 7 Fuel filter clogged sensor 8 Pressure sensor inside...

Страница 55: ...pm sensor 3 Fuel filter clogged sensor 4 Fuel temperature sensor 5 EDC connector 96 way 6 Fuel pre filter clogged sensor 7 Turbocharging air pressure and temperature sensor 8 Engine pressure sensor in...

Страница 56: ...ower supply A12 Fuel temperature sensor signal A13 Oil pressure and temperature sensor temperature signal A14 A15 A16 A17 A18 A19 Fuel pre filter clogged sensor ground A20 A21 A22 A23 A24 A25 Cylinder...

Страница 57: ...ing unit power supply A59 Common ground fuel temperature sensor coolant temperature sensor A60 Rail pressure sensor ground A61 Crankshaft pressure sensor signal A62 Fuel pre filter clogged sensor sign...

Страница 58: ...3 ELECTRIC EQUIPMENT CURSOR SERIES Base 03 2015 Print P4D32C006 E Pin Signal A84 A85 A86 Air pressure temperature sensor signal A87 A88 A89 A90 Air temperature and pressure sensor ground A91 A92 A93 A...

Страница 59: ...th power the coil moves up the shut ter The fuel in the control volume flows back towards the return duct resulting in a pressure drop in control volume At the same time the fuel pressure in the press...

Страница 60: ...e crankshaft pressure sensor is used to measure the pres sure inside the engine 10 SECTION 3 ELECTRIC EQUIPMENT CURSOR SERIES Base 03 2015 Print P4D32C006 E Pin Description ECU pin 1 Power supply EDC1...

Страница 61: ...sections on 58 of which there is a hole The sensor reads the signal generated by these holes The EDC 17 uses this signal to recognise the position of the pistons during normal run ning determine the...

Страница 62: ...nsor generates signals obtained from the magnetic flow lines which come towards the teeth of the phonic wheel fitted on the shaft number of teeth 7 WARNING The sensor gap is not adjustable S 12 SECTIO...

Страница 63: ...elivery Common ground Coolant temperature sensor It is an N T C type sensor and is located on the fuel filter It detects the fuel temperature thus enabling the electronic control unit to determine the...

Страница 64: ...measure the absolute pressure on the intake manifold and the supply air flow temperature The engine oil temperature is only used by the EDC 17 control unit and is not sent to the instru ment panel 1...

Страница 65: ...o doors P SECTION 3 ELECTRIC EQUIPMENT 15 CURSOR SERIES Print P4D32C006 E Base 03 2015 Pin Description ECU pin 1 Ground EDC17 pin A 78 2 Signal EDC17 pin A 79 Specifications Measurement Conditions Rat...

Страница 66: ...rnator start up S battery voltage sensor Alternator wiring diagram 106282 Figure 26 Alternator current delivery curve 16 SECTION 3 ELECTRIC EQUIPMENT CURSOR SERIES Base 03 2015 Print P4D32C006 E Suppl...

Страница 67: ...SERIES Print P4D32C006 E Base 03 2015 Voltage Nominal power Rotation direction control side Pinion number of teeth Supplier Weight Tightening torque on terminal 30 Tightening torque on terminal 50 24...

Страница 68: ...tor wiring diagrams Electric starter motor characteristics 18 SECTION 3 ELECTRIC EQUIPMENT CURSOR SERIES Base 03 2015 Print P4D32C006 E Ref Description Measurement unit T C O V S Torque Current streng...

Страница 69: ...rter motor characteristics 215787 Figure 29 WIRING DIAGRAM 1 Main current contactor 2 Control solenoid 3 Electric engine 4 Battery ies SECTION 3 ELECTRIC EQUIPMENT 19 CURSOR SERIES Print P4D32C006 E B...

Страница 70: ...20 SECTION 3 ELECTRIC EQUIPMENT CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 71: ...cillary belt 7 Exhaust gas pipes s condition check 7 PERIODIC MAINTENANCE HOW TO PROCEED 7 Draining the water from the fuel prefilter if any 7 Condensed water drainage from fuel tank 7 Change engine l...

Страница 72: ...2 SECTION 4 SCHEDULED MAINTENANCE CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 73: ...nths Exhaust gas pipes s condition check 6 months Periodical maintenance Frequency Draining the water from the fuel prefilter if any 150 hours 6 months Condensed water drainage from fuel tank 150 hour...

Страница 74: ...ts electrical wiring After all maintenance operations that require disconnecting the batteries make sure that the terminals have been well secu red on the poles Do not use a battery charger to start t...

Страница 75: ...ipstick Make sure that the dipstick is fully inserted and that the filler plug is tightened fully in theclockwise direction Engine coolant level check example Only proceed when the engine is not turni...

Страница 76: ...oil or grease on the engine repre sents a fire risk Clean the cock tap 1 before performing the operation so as to minimize the risk of contamina ting the system Inspection cleaning of the air filter...

Страница 77: ...duct PERIODIC MAINTENANCE HOW TO PROCEED Draining the water from the fuel prefilter if any Figure 4 221037 In the case of a high risk of refuelling with fuel polluted with foreign agents and water the...

Страница 78: ...the refilling operation through the hole 2 si tuated on the tappet cover using lubricant oil that complies with the international standards as indicated in Section 1 General table General Characterist...

Страница 79: ...Moisten the O ring seal 1 of the new filter with oil Tighten the drain plug 3 and the filter body 4 to the torque indicated in the table Proceed with the refilling operation of the lubricant oil see...

Страница 80: ...tem Dispose of consumable materials and the parts in contact with them for example filters in accor dance with the law Figure 9 221041 Loosen the following bleed connectors connecting them to the desi...

Страница 81: ...32 5 2 5 Nm 4 1 Threaded plug 1 5 0 5 Nm 5 1 Fitting for bleeding 18 2 Nm Figure 11 221041 Loosen the following bleed connectors connecting them to the designated pipes to allow the residue to flow i...

Страница 82: ...e with spacer radiator assembly and protection grilles Replace the belt if it shows signs of abrasion cracks or tears or if it is soiled with oil or fuel When the engine is off but still hot the belt...

Страница 83: ...ry Figure 15 114287 Remove the tappet cover Take the cylinder whose clearance has to be adjusted into the combustion phase the valves of this cylinder are closed as they balance those of the symmetric...

Страница 84: ...ble General Characteristics Do not fill the expansion tank to the brim With the pressure plug 4 open start the engine and idle it for approximately one minute This helps to completely bleed the air co...

Страница 85: ...NG 3 Removal 3 Refitting 4 FAN REMOVAL REFITTING 5 Removal 5 Refitting 6 REMOVAL REFITTING OF THE MAIN ENGINE COMPONENTS 6 ENGINE CABLE REMOVAL REFITTING 6 Removal 6 Refitting 6 REMOVAL REFITTING OF A...

Страница 86: ...al 24 Refitting 24 ENGINE CONTROL UNIT REMOVAL REFITTING 25 Removal 25 Refitting 25 AIR FILTER REMOVAL REFITTING 26 Removal 26 Refitting 26 Page BLOW BY REMOVAL REFITTING 27 Removal 27 Refitting 27 IN...

Страница 87: ...the protection grilles as described in the procedure PROTECTION GRILL REMOVAL REFITTING Removal Figure 3 227824 Only proceed when the engine is not turning and is at low temperature so as not to run t...

Страница 88: ...Figure 5 227754 NOTE Before installing the radiator assembly check the state of wear of the rubber sleeves Replace the sleeves in question if found to be excessively worn Install the radiator assembl...

Страница 89: ...the cooling circuit Stop the engine and top up with more coolant if necessary When the engine is cold make sure that the coolant in the expansion tank is a few centimetres below the filling hole In t...

Страница 90: ...re RADIATOR ASSEMBLY REMOVAL REFITTING Refit the protection grilles as described in the procedure PROTECTION GRILL REMOVAL REFITTING REMOVAL REFITTING OF THE MAIN ENGINE COMPONENTS ENGINE CABLE REMOVA...

Страница 91: ...emove the control belt of the crankshaft electromagnetic coupling water pump alternator A pulley Refitting Figure 11 225040 Using a 1 2 inch square wrench operate on the belt tensioner 1 and position...

Страница 92: ...20 2 3 Screws M8x1 25x20 3 1 Screw M8x1 25x20 Figure 14 227757 With the help of a 1 2 square head wrench act on the belt tensioner 2 and remove the ancillary belt 1 from the alternator pulley Figure 1...

Страница 93: ...03 2015 Figure 17 227757 With the help of a 1 2 square head wrench act on the belt tensioner 2 and fit the ancillary belt 1 on the alternator pulley Figure 18 150675 ASSEMBLY DIAGRAM OF THE PULLEY WA...

Страница 94: ...Nm WATER PUMP REMOVAL REFITTING Removal Remove the protection grilles as described in the procedure PROTECTION GRILL REMOVAL REFITTING Remove the radiator assembly as described in the procedure RADIA...

Страница 95: ...square wrench operate on the belt tensioner 1 and position the control belt of the crankshaft electromagnetic coupling water pump alternator A pulley Refit the fan as described in the procedure FAN R...

Страница 96: ...e 25 225040 Using a 1 2 inch square wrench operate on the belt tensioner 1 and remove the control belt of the crankshaft electromagnetic coupling water pump alternator A pulley Figure 26 225046 Unscre...

Страница 97: ...wrench operate on the belt tensioner 1 and position the control belt of the crankshaft electromagnetic coupling water pump alternator A pulley Refit the fan as described in the procedure FAN REMOVAL...

Страница 98: ...ly pipe to the radiator assembly Unscrew the screws 1 2 and remove the thermostat box 3 thermostat and relative gaskets Ref No Description 1 5 Screws M8 X 1 25 X 100 2 2 Screws M8 X 1 25 X 50 Refittin...

Страница 99: ...scription Tightening torques 1 5 Screws M8x1 25x20 18 4 Nm 2 6 Screws M8x1 25x20 18 4 Nm 3 1 Screw M8x1 25x20 18 4 Nm STARTER MOTOR REMOVAL REFITTING Removal Figure 37 227759 Remove the nuts 1 from th...

Страница 100: ...he bracket 1 and fitting 2 and remove the oil supply pipe to the turbocharger 3 Undo the screws 4 6 and remove the oil return pipe from the turbocharger 5 with its gaskets Ref No Description 1 1 M10 s...

Страница 101: ...he turbocharger 5 with the new gaskets and tighten the screws 4 6 to the torque indicated in the table Ref No Description Tightening torques 1 1 M10 screw 10 1 Nm 2 1 Fitting M16 X 1 5 X 12 42 5 2 5Nm...

Страница 102: ...ng 2 and remove the oil supply pipe to the turbocharger 3 Undo the screws 4 6 and remove the oil return pipe from the turbocharger 5 with its gaskets Ref No Description 1 1 M10 screw 2 1 Fitting M16 X...

Страница 103: ...rn pipe from the turbocharger 5 with the new gaskets and tighten the screws 4 6 to the torque indicated in the table Ref No Description Tightening torques 1 1 M10 screw 10 1 Nm 2 1 Fitting M16 X 1 5 X...

Страница 104: ...able container to collect the oil Avoid skin contact with the engine oil in case of contact wash thoroughly with water The engine oil is highly pollutant it must be disposed of according to applicable...

Страница 105: ...ter 2 and gasket Ref No Description 1 4 Screws M8 X 1 25 X 65 The oil filter contains approximately 2 kg of engine oil inside Position a suitable container to collect the oil Avoid skin contact with t...

Страница 106: ...the table Ref No Description Tightening torques 1 2 M8x1 25 screws 24 5 2 5 Nm 5 2 M8x1 25 screws 24 5 2 5 Nm Figure 61 225031 Tighten the fastening screws following the sequence indicated in the figu...

Страница 107: ...1 5 screws Refitting Figure 65 227765 Arrange the gasket on the oil sump 1 position the spacer 3 and fit the sump on crankcase screwing in the screws 2 to the torque as in the table Ref No Descriptio...

Страница 108: ...ement 3 by unscrewing the relative bell shaped support 5 remove the O ring 2 Refitting Figure 68 227766 Replace the filtering element 3 and the O ring seal 2 inside the bell housing support 5 Grease t...

Страница 109: ...Ref No Description 1 4 2 Fittings M22 X 1 5 2 2 Screws M8 X 1 25 X 60 3 1 Screws M8 X 1 25 X 45 5 2 Screws M6 X 1 X 25 Refitting Figure 70 227767 Fit the engine control unit 6 and tighten the screws...

Страница 110: ...rew 8 and remove the bracket 7 Ref No Description 1 1 M10 screw 2 1 M8 screw 3 1 M6 screw 4 1 M10 screw 6 1 M18 screw 8 1 M18 screw Refitting Figure 72 227768 Mount the bracket 7 and tighten the screw...

Страница 111: ...lters in accordance with the law Refitting NOTE Carefully clean the seating of the filter and the cover Figure 74 221043 Fit the new blow by filtering element 1 into its seat and tighten the screws 2...

Страница 112: ...X 100 1 2 Screws M10 X 1 5 X 130 1 1 Screws M10 X 1 5 X 150 Refitting Figure 77 227769 Fit the intake manifold 2 together with the engine preheating resistor 3 and its gasket and tighten screws 1 to...

Страница 113: ...heel to 36 before TDC of the first cylinder NOTE This position can be obtained by turning the engine flywheel in the direction opposite of the operating direction to the 30 position marked by THREE no...

Страница 114: ...9 12 4 Fittings M18 X 1 5 Undo the fitting 10 bracket retainer screws 6 8 and move the LP fuel pipe from control unit to pump off to the side Ref No Description 6 8 2 Screws M8 X 1 25 X 16 10 1 Fittin...

Страница 115: ...e screws 4 5 to torque shown in the table Ref No Description Tightening torques 1 2 Screws M10 X 1 5 X 20 37 5 5 Nm 2 3 Screws M8 X 1 25 X 20 24 5 2 5 Nm 4 2 Screw M12 X 1 75 X 30 32 5 2 5 Nm 5 4 Scre...

Страница 116: ...a and tighten fittings 5 9 12 to the torque shown in the table close springs 4 Ref No Description Tightening torques 5 9 12 4 Fittings M18 X 1 5 37 3 Nm Fit the new fuel return pipe 7 11 and tighten t...

Страница 117: ...following the sequence indicated in the figure Refit the air filter as described in the procedure AIR FILTER REMOVAL REFITTING TAPPET COVER REMOVAL REFITTING Removal Figure 91 227771 Disconnect the e...

Страница 118: ...019 Unscrew the fittings 8 on rail and head side screw on bracket 12 and remove the high pressure fuel supply pipes Unscrew the fittings from the rail side and detach the high pressure fuel pipes 1 2...

Страница 119: ...1 5 42 5 2 Nm Connect the high pressure fuel supply pipes 8 and tighten the fittings to the torque indicated in the table Ref No Description Tightening torques 8 4 Fittings M16 X 1 5 42 5 2 Nm Fix the...

Страница 120: ...emove all the wiring Refitting Figure 99 225049 Position the wiring and secure it appropriately with clamps Connect the elctrical connections 2 to the injectors and tighten the nuts to the torque indi...

Страница 121: ...th the gasket Ref No Description 2 24 M6 x 1 screws Figure 102 227745 Release the retainer springs of the engine brake 1 Unscrew the screws 2 securing the rocker arm shaft Ref No Description 2 7 Screw...

Страница 122: ...ng clearance indicated in the table Data and assembly clearance in SECTION 7 Technical specifications Use a suitable wrench to screw or unscrew rocker arm 2 adjusting screw Check that the thickness ga...

Страница 123: ...ne brake 1 Unscrew the screws 2 securing the rocker arm shaft Ref No Description 2 7 Screws M16 X 1 5 X 76 Figure 110 224083 Use the specified tool 99360553 1 on the rocker arm shaft 2 and remove the...

Страница 124: ...M8 X 1 25 X 45 Figure 114 169826 Position the specified tool 99342157 1 and extract the injectors 2 from the head Refitting Figure 115 169828 Fit the sealing gasket 2 on the injectors 1 Figure 116 22...

Страница 125: ...iption Tightening torques 6 Screws M8 X 1 25 X 45 35 2 Nm Complete assembly of the high pressure fuel pipes 1 2 3 6 5 4 by first tightening the injector side fittings and then those on the rail side t...

Страница 126: ...hickness gauge blade 3 can slide with a slight friction Lock the nut 1 holding the adjustment screw still To carry out the adjustments stated above the sequence shown in the table is mandatory Start a...

Страница 127: ...p and collar and remove the combustion air intake pipe 1 to the aftercooler Undo the screws 2 of the oil deliver pipe to turbocharger Ref No Description 2 2 M8 x 1 25 screws Slacken the clamps and rem...

Страница 128: ...M8 X 1 25 X 50 Figure 128 221043 Unscrew the screws 3 and remove the blow by cover 4 Unscrew the screws 2 and remove the blow by filter element 1 Ref No Description 2 3 Screws M6 X 1 X 40 3 6 Screws...

Страница 129: ...plugs undo the fittings 1 3 and remove the HP fuel pipes Ref No Description 1 3 4 Fittings M16 X 1 5 2 2 Nuts M6 X 1 The HP pipes that are disassembled cannot be used again and must always be replace...

Страница 130: ...1 5 X 20 2 2 Screws M8 X 1 25 X 20 4 2 Screws M12 X 1 75 X 30 5 4 Screws M12 X 1 5 Figure 134 227772 Unscrew the fastening screws 1 and remove the head cover 2 together with the gasket Ref No Descript...

Страница 131: ...0351 to lock the mounted engine flywheel 3 unscrew the retaining screws 1 then remove the tool 3 and remove the engine flywheel 2 Ref No Description 1 8 Screws M18 X 1 5 X 72 4 1 M6 x 12 screw Figure...

Страница 132: ...ylinder head Figure 143 225019 Unscrew the fittings 8 the screw of the bracket 12 and remove the high pressure fuel supply pipes 8 Unscrew the fittings from the rail and the injectors and remove the h...

Страница 133: ...2 Refitting Figure 145 227750 Check that the pistons 1 and 6 are exactly at the T D C Put the sealing gasket 2 on the crankcase Place the cylinder head 1 on the crankcase Figure 146 225061 Tighten th...

Страница 134: ...he designated tool 1 as indicated in the figure NOTE Fit the flywheel housing within 10 minutes of applying the sealant Figure 150 225008 Use a torque wrench to tighten the screws to the torque shown...

Страница 135: ...shaft lubricatethethread of the screws 2 with engine oil and screw them down Block rotation using the tool used to fasten the engine flywheel housing 99360351 3 Using the torque wrench 4 tighten the s...

Страница 136: ...o notches 5 on the engine flywheel 1 can be seen through the small inspection window 2 Figure 157 71774 Check that the tool for positioning the T D C 99360612 1 through the seat 2 of the engine speed...

Страница 137: ...ition of the connecting rod 3 for the transmission gear tighten the screw 2 to the torque specified in the table Ref No Description Tightening torques 2 1 Screws M8 X 1 25 X 16 24 5 2 5 Nm Figure 161...

Страница 138: ...tighten the fastening screws 9 to the torque shown in the table Ref No Description Tightening torques 9 3 Screws M8 X 1 25 X 55 24 5 2 5 Nm Connect the high pressure fuel pipes and tighten the fitting...

Страница 139: ...ure 167 185253 Carefully clean the surface of the head on which the rocker arm cover rests Using the magnetic support 99370400 2 as shown in the figure arrange the dial gauge 0 30mm 99395606 1 with th...

Страница 140: ...with the base radius of the cam profile This occurs when the flywheel is turned in the opposite direction of the operating direction approx 1 and 1 4 rotations Figure 169 185524 Camshaft rotation ang...

Страница 141: ...cated while keeping the cam lift value unchanged Lock the screws 2 and repeat timing check as described above NOTE While performing this operation recover the clearance between the camshaft gears Tigh...

Страница 142: ...m Figure 174 185254 Turn the crankshaft bringing cylinder piston no 1 in compression stage to TDC turn the flywheel by approximately 1 4 turn in the opposite direction to the normal direction of rotat...

Страница 143: ...y 6 If the engine flywheel does not have 3 notches to identify the reference hole simply turn the flywheel in the opposite direction to the operating direction until reaching the position marked with...

Страница 144: ...le Data and assembly clearance in SECTION 7 Technical specifications Use a suitable wrench to screw or unscrew rocker arm 2 adjusting screw Check that the thickness gauge blade 3 can slide with a slig...

Страница 145: ...he table close springs 4 Ref No Description Tightening torques 5 9 12 4 Fittings M18 X 1 5 37 3 Nm Fit the new fuel return pipe 7 11 and tighten the fittings to the torque indicated in the table Ref N...

Страница 146: ...X 1 X 40 Step 1 5 Nm Step 2 15 1 5 Nm NOTE Apply Loctite 243 to the screws 2 Position the blow by cover 4 and tighten the screws 3 to the torque indicated in the table Ref No Description Tightening to...

Страница 147: ...e oil return pipe from the turbocharger 5 with the new gaskets and tighten the screws 4 6 to the torque indicated in the table Ref No Description Tightening torques 1 1 M10 screw 24 5 2 5 Nm 2 1 Fitti...

Страница 148: ...64 SECTION 5 REMOVAL REFITTING OF THE MAIN ENGINE COMPONENTS CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 149: ...r removal 9 Alternator support removal 10 Electromagnetic coupling pulley removal 10 Assembly of auxiliary parts 10 Thermostat case removal 10 Crankshaft front gasket removal 11 DISASSEMBLY OF ENGINE...

Страница 150: ...IDE 21 Connecting rod removal 21 Lower crankcase removal 22 Page Crankshaft removal 22 Main bearings and oil nipples removal 22 CRANKCASE ASSEMBLY CHECKS 23 Crankcase checks 23 Cylinder liners Removal...

Страница 151: ...product characteristics 57 Camshaft bushings check 58 Replacing camshaft bushings using beater 59 Page Rocker shaft check 60 Exhaust valve rocker arm check 61 Intake valve rocker arms check 61 ENGINE...

Страница 152: ...AKE SIDE 86 Fuel filter assembly 86 Inlet manifold assembly 87 Starter motor assembly 88 ASSEMBLY OF ENGINE AT BENCH COMPONENTS AT THE REAR PART 2 88 Page Timing gear assembly cover mounting 88 Blow b...

Страница 153: ...ING Section 5 Removal of radiator assembly pipes from engine Figure 1 227773 Slacken the clamp and from the engine remove the combustion air intake pipe 1 to the aftercooler Slacken the clamps and fro...

Страница 154: ...sure and temperature sensor together with the O ring Ref No Description 1 2 Screws M6 Unscrew the screws 3 and remove the oil pressure regulator valve Unscrew the screws 4 and 6 and remove the turboch...

Страница 155: ...Screws M8 X 1 25 X 65 5 3 M8 x 1 25 screws The oil filter contains approximately 2 kg of engine oil inside Position a suitable container to collect the oil Avoid skin contact with the engine oil in c...

Страница 156: ...oil by removing the plug from the oil sump Ref No Description 1 Plug M22 X 1 5 The engine oil is highly pollutant and noxious In case of contact with skin wash thoroughly with water and detergent Suit...

Страница 157: ...per flywheel 2 by acting on the screws 1 Ref No Description 1 6 M14 x 2 screws Coolant pump alternator drive belt disassembly Figure 13 166728 Using a 1 2 inch square wrench 1 act in the direction of...

Страница 158: ...ription 1 1 M12 x 1 75 screw 3 5 Screws M12 X 1 75 Assembly of auxiliary parts Figure 17 225016 Unscrew the screw 5 and remove the automatic belt ten sioner 6 Unscrew the screws 3 and remove the crank...

Страница 159: ...No Description 3 8 Screws M8 X 1 25 X 16 DISASSEMBLY OF ENGINE AT BENCH COMPONENTS AT EXHAUST SIDE Turbocharger and exhaust manifold removal Figure 20 225021 Unscrew and remove the coolant temperatur...

Страница 160: ...asket Ref No Description 2 1 Screws M8 X 1 25 X 55 3 17 Screws M8 X 1 25 X 40 4 4 Screws M8 X 1 25 X 45 DISASSEMBLY OF ENGINE AT BENCH COMPONENTS AT THE INTAKE SIDE PART 1 Disassembly of the starter m...

Страница 161: ...he bracket 4 and remove the engine control unit 6 Ref No Description 1 1 Fitting M22 X 1 5 2 2 Screws M8 X 1 25 X 60 3 1 Screws M8 X 1 25 X 45 4 2 Screws M8 X 1 25 X 16 5 2 Screws M6 X 1 X 25 DISASSEM...

Страница 162: ...r 3 Ref No Description 1 1 M10 X 1 2 24 M6 X 1 DISASSEMBLY OF ENGINE AT BENCH COMPONENTS AT THE INTAKE SIDE PART 2 Fuel filter removal Figure 31 225014 Unlock the cable ties 6 Unscrew the fittings dsc...

Страница 163: ...isconnect the collars and remove the LP fuel pipe 4 Unscrew the fittings and remove the fuel return pipe 6 Ref No Description 5 2 Screws M8 X 1 25 X 16 6 2 Fittings M18 X 1 5 7 1 Fitting M18 X 1 5 Fig...

Страница 164: ...screw the screws 2 and remove the thrust plate 1 and the sheet gasket Ref No Description 2 5 Screws M8 X 1 25 X 25 Figure 38 221107 Unscrew the screws 2 and remove the idle gear 1 Ref No Description 2...

Страница 165: ...e cover 2 complete with O ring Ref No Description 1 3 Screws M8 X 1 25 X 20 4 8 M16 x 2 screws Flywheel case removal Figure 42 225018 Unscrew the screws 1 and remove the flywheel case 2 Ref No Descrip...

Страница 166: ...e the oil pump 2 Ref No Description 1 1 Screws M8 X 1 25 X 35 1 3 Screws M8 X 1 25 X 70 DISASSEMBLY OF ENGINE AT BENCH COMPONENTS AT THE TOP PART 2 Rocker arm shaft removal Figure 46 227745 Release th...

Страница 167: ...fuel pipes must be replaced at each disassembly Disconnect the electric connection from pressure sensor 11 Unscrew the fastening screws 9 and remove the rail 10 Ref No Description 1 6 12 Fittings M16...

Страница 168: ...ake cylinders 2 Figure 52 227748 Ref No Description 1 12 Screws M8 X 1 25 X 20 Camshaft removal Figure 53 60514 Mount suitable plugs inside electro injector seats 1 Remove the camshaft 2 Cylinder head...

Страница 169: ...uction strainer 1 Ref No Description 2 3 6 M8 X 1 25 DISASSEMBLY OF ENGINE AT BENCH CRANKCASE COMPONENTS SIDE Connecting rod removal Figure 57 47574 Turn the crankcase 1 into vertical position Figure...

Страница 170: ...g them they will need to be fitted in the position found upon removal Crankshaft removal Figure 60 47570 Using the tool for lifting the crankshaft 99360500 1 remove the crankshaft 2 Main bearings and...

Страница 171: ...diameter 135 mm NOTE If the 135 mm ring gauge is not available use a micrometer Figure 63 60596 1 1st measurement 2 2nd measurement 3 3rd measurement Measurements should be carried out for every sing...

Страница 172: ...IES Base 03 2015 Print P4D32C006 E Figure 66 60598 Cylinder liners can be removed and fitted several times into different seats if needed Figure 67 221075 During checks make sure that the main data fo...

Страница 173: ...bricate the lower part of the liner and install it in the cylinder assembly using the proper tool NOTE The adjustment ring 1 is supplied as spare parts in the following thicknesses 0 08 mm 0 10 mm 0 1...

Страница 174: ...nder liners 1 at the crankcase 2 with stud bolts 99360703 3 Crankshaft measurements Figure 73 38 700 39 000 47 95 48 00 131 122 131 147 3 380 3 430 47 785 47 800 47 785 47 800 95 970 96 000 38 700 39...

Страница 175: ...asis of the undersizing of the half bearings the final diameter to which the pins are to be ground NOTE It is advisable to enter readings in a table NOTE For a more accurate reading take different mea...

Страница 176: ...be ground NOTE For a more accurate reading take different mea surements on more than one point of the shaft and calculate the average value Figure 78 224077 Y Crankpin fitting detail During the grindi...

Страница 177: ...C006 E Base 03 2015 Defining the diameter class of the seats for half bearings on the crankcase Figure 80 190208 To identify the diameter class of the seats for the main half bearings look at the fron...

Страница 178: ...of seven digits refers to the crankpin more specifically The isolated digit indicates the state of the pins 1 STD 2 0 127 The six digits taken individually represent the diameter class of each crankp...

Страница 179: ...ominal diameter In order to identify the diameter class of the main journals identify the three sets of figures marked on the front of the crankshaft Figure 82 CLASS STATUS OF MAIN JOURNAL CLASS RATED...

Страница 180: ...rankpins nominal diameter In order to identify the diameter class of the crankpins identify the three sets of figures marked on the front of the crankshaft Figure 84 CLASS STATUS OF MAIN JOURNAL CLASS...

Страница 181: ...specifications of the main bearings available as spare parts in the standard sizes STD and in the permissible oversizes 0 127 0 254 0 508 Main half bearing thickness Figure 86 210304 1 Coloured markin...

Страница 182: ...27 0 254 0 508 Red 1 960 1 970 2 087 2 097 2 214 2 224 Red Black 2 023 2 033 Green 1 970 1 980 2 097 2 107 2 224 2 234 Green Black 2 033 2 043 Yellow 1 980 1 990 Yellow Black 2 043 2 053 Not supplied...

Страница 183: ...106 300 106 307 2 106 308 106 315 3 106 316 106 323 4 106 324 106 330 210307 1 99 970 99 977 Green Yellow Yellow Black Yellow Yellow Black Black 2 99 978 99 985 Green Green Yellow Yellow Green Yellow...

Страница 184: ...324 106 330 210307 1 99 843 99 850 Green Black Yellow Black Yellow Black Black Black Yellow Black Yellow Black Black Black Black Black 2 99 851 99 858 Green Black Green Black Yellow Black Yellow Blac...

Страница 185: ...d Red Red 4 99 746 Red Red Red Red NOTE If using main half bearings of a different thickness fit the thicker bearings at the bottom plate side 210306 0 508 CLASS 1 106 300 106 307 2 106 308 106 315 3...

Страница 186: ...body in the indicated position NOTE The number indicating the diameter class of the seat for half bearings can be 1 2 or 3 1 Serial No 2 Letter indicating the weight class A 5502 5535 g B 5536 5569 g...

Страница 187: ...00 010 2 100 011 100 020 3 100 021 100 030 210310 1 95 990 96 000 Red Red Green Red Green Green 2 95 980 95 989 Red Green Green Green Green Yellow 3 95 970 95 979 Green Green Yellow Green Yellow Yello...

Страница 188: ...bearing shells identified with the relevant table 210309 210312 0 127 CLASS 1 100 000 100 010 2 100 011 100 020 3 100 021 100 030 210310 1 95 863 95 873 Red Black Red Black Green Black Red Black Gree...

Страница 189: ...726 95 735 Red Green Green Red Green Green NOTE If using big end half bearings of a different thickness fit the thicker bearing at the bottom 210309 210312 0 508 CLASS 1 100 000 100 010 2 100 011 100...

Страница 190: ...ged nor worn if it is take it out with an appropriate extractor and repla ce it When fitting the gear 1 on the crankshaft 2 heat it for no longer than 2 hours in an oven at the temperature indicated b...

Страница 191: ...gure 90 155940 1 Connecting rod body 2 Half bearings 3 Connecting rod cap 4 Cap fastening screw 5 Circlip 6 Slotted oil scraper ring with spiral spring 7 Claw seal ring 8 Trapezoidal seal ring 9 Pisto...

Страница 192: ...tons are grouped into classes A and B depending on diameter Piston removal Figure 92 155942 Remove the piston pin circlips 2 using the round tipped calipers 1 Figure 93 155943 Remove the piston pin 1...

Страница 193: ...he pin and piston is the same as that indicated in Figure 96 Lubricate the pin 1 and the relevant housings on the internal piston hubs with engine oil the pin must be inserted in the piston with a lig...

Страница 194: ...liner 3 If the distance between ends is lower or higher than the value required replace the circlips Connecting rod checks Figure 102 155939 1 Standard numbers 2 Letter indicating the weight class A 5...

Страница 195: ...L 47 CURSOR SERIES Print P4D32C006 E Base 03 2015 Figure 103 181695 Values to be obtained after fitting the bush During checks make sure that the main data of the bushing connecting rod pin and half b...

Страница 196: ...the V prisms resting the connecting rod 1 on the stop bar 2 Torsion check Figure 105 61694 Check the torsion of the connecting rod 5 by comparing two points A and B of the pin 3 on the horizontal plan...

Страница 197: ...in 3 The difference between points C and D must not exceed 0 08 mm Connecting rod small end bush check Figure 107 073535 Check that the bushing in the small end has not come loose and shows no sign of...

Страница 198: ...der head it is supplied as a spare part with a threaded plug which must be removed during assembly NOTE In case of plugs removal replacement when assembling apply sealant Loctite 121078 on the plugs V...

Страница 199: ...g and injector protrusion Valve descale and check Figure 113 204301 Remove all carbon deposits from the valves using a wire brush Figure 114 A B 155953 Value to be obtained after driving in the valve...

Страница 200: ...y need to be replaced using the same tool and taking care not to accidentally damage the cylinder head remove as much material as possible from the valve seats until it is possible to extract them fro...

Страница 201: ...linder head so they protrude by a value equal to the one given below Technical data Valve guide standout 30 80 31 2 mm After driving in the valve guides smooth their holes with sleeker 99390330 Checki...

Страница 202: ...the centre of the poppet valve Figure 123 86290 Fit the springs 6 the upper plate 5 Fit tool 99360263 2 and secure it with the bracket 4 screw down with device 99360259 1 so the cotters 3 can be fitte...

Страница 203: ...0 085 mm Replacement of the dual idle gear bushes Figure 126 225001 1 Camshaft 2 Bushing 3 Pin 4 Connecting rod 5 Camshaft l control gear 6 Transmission gear 7 Double transmission gear 8 Crankshaft d...

Страница 204: ...sing a dial gauge 2 comparing the values with those specified below Technical data Intake valve control cam lift 9 231 mm Exhaust valve control cam lift 9 5607 mm Figure 129 47507 Still with the camsh...

Страница 205: ...the camshaft Figure 131 225004 The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth whereas if they show any signs of seizing or scoring the shaft and the re...

Страница 206: ...ore meter and replace them if the value measured exceeds the tolerance value Figure 133 107217 A Drift with seat for bushings to insert extract B Dowel pin for positioning bushings C Reference mark to...

Страница 207: ...is necessary however to use the extension and the guide bushings Assembly To insert the bushes 1 2 3 4 5 proceed as follows Figure 135 107217 Assemble the drift 99360499 together with the extension P...

Страница 208: ...ws Unscrew the grip l and the extension N Refit the guide G from the inside as shown in the figure Position the bush on the drift A and bring it close to the seat making the bush hole coincide with th...

Страница 209: ...e the engine crankcase to the rotating stand 99322230 with brackets 99361036 Oil sprayer assembly Figure 141 225064 Fit the oil spray nozzles 1 making the dowel 2 match the hole 3 on the crankcase and...

Страница 210: ...the half bearings 1 on the main bearing supports in the lower crankcase 2 Figure 145 60559 Fit the lower crankcase by means of a suitable hoist and hooks 1 Figure 146 47579 Using a torque wrench 3 tig...

Страница 211: ...mparing the width of the calibrated wire 1 at the point subjected to the greatest crushing forces with the graduated scale on the casing containing the calibrated wire The numbers on the scale indicat...

Страница 212: ...1 14 Lower crankcase inner tightening screws Step 1 160 Nm Step 2 60 Step 3 60 NOTE Always use new screws each time you fit the lower part of the crankcase Figure 152 47581 Using a torque wrench 99395...

Страница 213: ...ING SCREWS FRONT SIDE 60593 First step inner screws preliminary tightening 160 Nm FRONT SIDE 60593 Second step internal bolt angle tightening 60 FRONT SIDE 60593 Third step internal bolt angle tighten...

Страница 214: ...bearings as described in the chapter Defining the diameter class of the main journals and crankpins NOTE Do not try to adapt the half bearings Assembling connecting rod piston assemblies in the cylind...

Страница 215: ...nkpin fitting clearance check Figure 156 47594 Connect the connecting rods to the relevant journals of the crankshaft placing a length of calibrated wire on the journals mounttheconnectingrodcaps 1 to...

Страница 216: ...OF ENGINE AT BENCH COMPONENTS AT THE BOTTOM Suction strainer installation Figure 158 221114 Turn the engine and position the oil suction strainer 1 Tighten the screws 3 and secure the flange Tighten...

Страница 217: ...ine on the rotating stand ASSEMBLY OF ENGINE AT BENCH COMPONENTS AT THE TOP PART 1 Cylinder head assembly Figure 161 60515 Check that the pistons 1 and 6 are exactly at the T D C Put the sealing gaske...

Страница 218: ...f No Description Tightening torques 20 M18x2x196 6 M18x2x175 Step 1 90 Step 2 90 ASSEMBLY OF ENGINE AT BENCH COMPONENTS AT THE REAR PART 1 Installing the oil pump Figure 165 221113 Fit the oil pump 2...

Страница 219: ...esignated tool 1 as indicated in the figure NOTE Fit the flywheel housing within 10 minutes of applying the sealant Figure 169 225008 Use a torque wrench to tighten the screws to the specific tighteni...

Страница 220: ...the screws 4 to the torque indicated in the table Ref No Description Tightening torques 1 3 Screws M8 X 1 25 X 20 20 5 2 5 Nm 4 8 M16 x 2 screws Step 1 120 Nm Step 2 55 Engine flywheel assembly Figur...

Страница 221: ...176 225006 Fit the high pressure pump support flange 2 and tighten the fastening screws 1 without locking in place Figure 177 227749 Apply the gauge 99395226 1 to correctly position the high pressure...

Страница 222: ...can be seen through the small inspection window 2 Figure 180 71774 Check that the tool for positioning the T D C 99360612 1 through the seat 2 of the engine speed sensor enters the hole 3 in the engin...

Страница 223: ...e connecting rod 3 for the transmission gear tighten the screw 2 to the torque specified in the table Ref No Description Tightening torques 2 1 Screws M8 X 1 25 X 16 24 5 2 5 Nm Figure 183 221107 Fit...

Страница 224: ...e screws 4 securing the transmission gear 3 Loosen the connecting rod fixing screw move the connecting rod in order to obtain the required clearance Lock the screw securing the connecting rod and the...

Страница 225: ...ws 9 to the torque shown in the table Ref No Description Tightening torques 9 4 Screws M8 X 1 25 X 55 24 5 2 5 Nm Connect the high pressure fuel pipes and tighten the fittings by hand in the sequence...

Страница 226: ...torques 7 2 Fittings M16 X 1 5 42 5 2 Nm Fitting rocker shaft assembly NOTE Use torque wrench 99389833 to tighten fittings of the HP fuel pipes Figure 189 1 225035 Apply the tool 99360553 1 to the ro...

Страница 227: ...during the engine overhaul phase the allowed tolerance of the mea surement is between 0 05 0 12 mm The allowed measurement tolerance during OVERHAUL is 0 05 mm Figure 193 177714 Using the specific to...

Страница 228: ...tru sions A B and B C on the cam profile connec ted to the engine brake operation This condition occurs when the flywheel is turned in the opposite direction of the operating direction by approx 1 and...

Страница 229: ...the table Ref No Description Tightening torques 2 4 Screws M14 X 4 X 60 Step 1 60 3 Nm Step 2 60 NOTE Lubricate the screws with engine oil When adjustment via the slots is not sufficient for recoveri...

Страница 230: ...tions Technical data Cam timing dial gauge value 5 95 0 05 mm Remove tool 99360612 1 Phonic wheel timing Figure 199 185254 Turn the crankshaft bringing cylinder piston no 1 in compres sion stage to TD...

Страница 231: ...position marked by THREE notches 4 and continuing to turn the flywheel in the same direction until reaching the next hole by 6 If the engine flywheel does not have 3 notches to identify the reference...

Страница 232: ...sure pipe 4 and tighten the fittings and collars 5 to the torque indicated in the table Fit the fuel return pipe 6 and tighten the fittings to the torque indicated in the table Ref No Description Tigh...

Страница 233: ...nding to the TDC of pistons 1 6 B Hole on flywheel with reference mark corresponding to the TDC of pistons 2 5 C Hole on flywheel with reference mark corresponding to the TDC of pistons 3 4 D Flywheel...

Страница 234: ...R 1 4 2 6 3 5 Start and rotation in the engine direction Balancing cylinder valves no Adjust valve clearance for cylinder no 1 and 6 at T D C 6 1 120 degree of angle 3 4 120 degree of angle 5 2 120 de...

Страница 235: ...p and tighten fitting 1 to the torque indicated in the table Ref No Description Tightening torques 1 1 Fitting M22 X 1 5 50 5 Nm 2 2 Screws M8 X 1 25 X 60 24 5 2 5 Nm 3 1 Screws M8 X 1 25 X 45 24 5 2...

Страница 236: ...R PART 2 Timing gear assembly cover mounting Figure 213 221124 Mount timing gear cover 2 complete with gasket 3 Tighten the screws 1 to the prescribed torque Ref No Description Tightening torques 1 21...

Страница 237: ...n the flywheel case and tighten screws to the torque shown in the table Ref No Description Tightening torques 2 M6 x 12 screws 8 2 Nm ASSEMBLY OF ENGINE AT BENCH COMPONENTS AT THE EXHAUST SIDE Heat ex...

Страница 238: ...225062 Tighten the screws securing the turbocharger to the prescri bed torque following the sequence indicated in the figure NOTE Lubricate the screws with graphite oil Exhaust manifold assembly Figu...

Страница 239: ...and tighten the fastening screws 1 2 to the prescribed torque according to the sequence indicated in the next figure Ref No Description Tightening torques 1 2 5 Screws M8 X 1 25 X 100 2 Screws M8 X 1...

Страница 240: ...gasket and tighten the screws 1 to the torque indicated in the table Ref No Description Tightening torques 1 4 Screws M8 X 1 25 X 20 25 2 5 Nm 3 6 M14 x 2 screws Step 1 70 Nm Step 2 50 5 1 M10 x 1 5...

Страница 241: ...t tensioner 1 in the direction indicated by the arrow in the fi gure NOTE Belt tensioner is of automatic type therefore further adjusting is not provided after mounting Figure 234 108844 1 Alternator...

Страница 242: ...M12 X 1 75 74 8 Nm Assembly of the oil filter with relative support and water inlet pipe to crankcase Figure 237 224061 Fit the water inlet pipe to the crankcase 4 together with the new gasket and tig...

Страница 243: ...the turbocharger to the torque indicated in the table Ref No Description Tightening torques 1 2 M8 x 1 25 screws 24 5 2 5 Nm Figure 240 224054 Screw the fitting 2 of the oil intake pipe to the turboc...

Страница 244: ...and amount specified Use only engine oil with recommended specifications Failure to observe this requirement may void the warranty Check oil level using the dipstick the level must be around the MAX...

Страница 245: ...be performed after mounting the engine onto the vehicle Start the engine leave running at an rpm slightly greater than the idle speed and wait for the coolant to heat sufficiently to open thermostat O...

Страница 246: ...98 SECTION 6 GENERAL MECHANICAL OVERHAUL CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 247: ...SECTION 7 TECHNICAL SPECIFICATIONS 1 CURSOR SERIES Print P4D32C006 E Base 03 2015 SECTION 7 Technical specifications Page MAIN FEATURES 3 DATA INSTALLATION CLEARANCES 5 TIGHTENING TORQUES 11...

Страница 248: ...2 SECTION 7 TECHNICAL SPECIFICATIONS CURSOR SERIES Base 03 2015 Print P4D32C006 E...

Страница 249: ...mpression ratio 16 5 1 Maximum power prime engine kWm HP revs min Hz 415 564 1500 50 428 582 1800 60 371 504 1500 50 400 544 1800 60 Maximum power engine in stand by kWm HP revs min Hz 459 624 1500 50...

Страница 250: ...sure fuel supply system is managed by the BOSCH EDC 17 It consists of the CPN 5 22 2 high pressure pump electro injectors hydraulic accumulator rail EDC 17 control unit and pressure and temperature se...

Страница 251: ...ameter 2 upper 153 461 153 486 lower 151 890 151 915 length L 252 2 Cylinder liners crankcase seat upper 0 014 0 039 lower 0 085 0 135 Outer diameter 2 3 X Cylinder liners Inner diameter 3 135 000 135...

Страница 252: ...r X1 0 35 0 45 X2 0 65 0 80 X3 0 40 0 75 1 2 Connecting rod small end bush seat 1 63 000 63 030 Connecting rod bearing seat 2 100 000 100 030 Classes 1 100 000 100 010 2 100 011 100 020 3 100 021 100...

Страница 253: ...n half bearings YES Red colour 3 115 3 122 Green colour 3 123 3 130 Yellow colour 3 131 3 138 Black colour 3 139 3 146 Connecting rod half bearings S2 Red colour 1 960 1 970 Green colour 1 970 1 980 Y...

Страница 254: ...1 Valve guide housing on cylinder head 1 15 980 15 997 2 3 Valve guides 2 10 015 10 030 3 16 012 16 025 Valve guides and seats on the head 0 015 0 045 Valve guides 4 Valves 4 9 960 9 975 60 30 7 30 4...

Страница 255: ...under a load of 504 N mm2 H1 59 887 N mm2 H2 46 Camshaft bush housing fitted in the cylinder head 1 7 88 000 88 030 1 2 3 Camshaft journals 1 7 82 950 82 968 Camshaft bushing outer diameter 88 153 88...

Страница 256: ...SOR SERIES Base 03 2015 Print P4D32C006 E Type F3HFA615A D001 F3HFA615B D001 mm Rocker arm bush outer diameter 59 070 59 110 Rocker arm bush inner diameter 56 045 56 064 Bushes and housing 0 051 0 110...

Страница 257: ...flywheel case to headL M10x1 5x30 45 5 4 5 4 55 0 45 Timing flywheel cover fastening screws M6x1x25 10 1 1 0 1 Screw fixing cylinder head L M18x2x175 196 1st Phase pre tightening 75 7 5 2nd Phase pre...

Страница 258: ...od for idle gear M8x1 25x16 24 5 2 5 2 4 0 25 Double gear fastening screws M12x1 75x90 1st Phase 30 1 5 3 0 15 2nd Phase 90 Screws fixing the oil pump M8x1 25x35 70 25 2 5 2 5 0 2 Screw fixing cranksh...

Страница 259: ...pipes brackets running from pump to head M8x1 25x16 24 5 2 5 2 45 0 25 Nuts fastening to head the HP fuel pipes brackets running from pump to head M6x1 8 2 0 8 0 02 Screws securing the high pressure p...

Страница 260: ...ure and temperature fastening screws M6 8 2 0 8 0 2 Oil pressure and temperature fastening screws M6 11 5 1 15 Screws fastening oil pressure regulating valve M8x1 25x20 25 5 2 5 2 55 0 2 Pressure sens...

Страница 261: ...SECTION 8 TOOLS 1 CURSOR SERIES Print P2D32C006 E Base 03 2015 SECTION 8 Tools Page TOOLS 3...

Страница 262: ...2 SECTION 8 TOOLS CURSOR SERIES Base 03 2015 Print P2D32C006 E...

Страница 263: ...telescopic stand range 2000 daN torque 375 daNm 99340053 Extraction tool for crankshaft front ring seal 99342157 Extraction tool for injectors 99346250 Key to fit crankshaft front gasket 99346260 Key...

Страница 264: ...99360184 Pliers for removing refitting piston rings 105 160 mm 99360259 Tool to remove and refit engine valves to be used with special plates 99360263 Plate to remove and refit engine valves to be use...

Страница 265: ...360321 99360329 Adjuster for gasket assembly on valve guide 99360334 Cylinder liner protrusion gauge to be used with 99370415 99395603 and special plates 99360336 Spacer to be used with 99360334 99360...

Страница 266: ...o take down and fit back camshaft bushes 99360500 Tool for lifting the crankshaft 99360553 Tool for assembling and installing rocker arm shaft 99360585 Arm for removing and installing engine 99360603...

Страница 267: ...g of phonic wheel on camshaft 99360703 Check tool for cylinder liners 99360706 Tool to extract cylinder liners use with specific rings 99360728 Ring 135 mm 141mm to be used with 99360706 99361036 Brac...

Страница 268: ...6 99370415 Stand for dial gauge for checking cylinder liner protrusion to be used with 99395603 99389813 Torque wrench 20 120 Nm with 1 2 square head 99389829 9X12 coupling torque wrench 5 60 Nm 99389...

Страница 269: ...e 99395216 Pair of gauges for angular tightening with 1 2 and 3 4 square heads 99395225 Gauge for defining the distance between the centres of cam shaft and transfer case gear 99395226 Gauge to determ...

Страница 270: ...10 SECTION 8 TOOLS CURSOR SERIES Base 03 2015 Print P2D32C006 E TOOLS TOOL No NAME 99396035 Centering ring of crankshaft front gasket cover...

Страница 271: ...APPENDIX 1 CURSOR SERIES Print P2D32C006 E Base 03 2015 Appendix Page SAFETY REGULATIONS 3 Standard safety precautions 3 Accident prevention 3 During maintenance 3 Protection of the environment 4...

Страница 272: ...2 APPENDIX CURSOR SERIES Base 03 2015 Print P2D32C006 E...

Страница 273: ...as possible In the presence of voltage higher than 48 60V check the effectiveness of the ground electric connections Make sure your hands and feet are dry and perform the work standing on insulating p...

Страница 274: ...y be damaged also seriously thus prejudicing their life cycle Avoid draughts from fuel tanks in copper alloy and or pi pes without filters Do not apply changes to the cabling their length must not be...

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