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CURSOR 13
Page 20
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274 pages
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CORRESPONDEN
CE
BETWEEN
TECHNICAL
CODES
AND
COMM
ERCIAL
CODES
4
SEC
TION
1
-
GENERAL
INFORMATION
CURS
OR
SERIE
S
Ba
s
e
-
03/2015
Prin
t
P4D
32C006
E
Technical
codes
Commercial
Codes
F3HF
A615A
*D001
CR13
TE
7W
F3HF
A615B*D001
CR13
TE
6W
19
21
Table of Contents
Main Page
Section 2 Operating Diagrams
29
Table of Contents
29
HP Pump CPN 5 - 22/2
33
Hydraulic Accumulator (Rail)
34
Electro-Injector CRIN
35
Fuel Filter
37
Pressure Limiter Valve
37
Oil Filter Tightening Torques
38
Lubrication
39
Oil Pump
40
Overpressure Valve
40
Oil Pressure Regulator Valve
41
Heat Exchanger
41
Filter By-Pass Valve
42
Engine Oil Filter
42
Valve Integrated in Piston Cooling Nozzle
43
Oil Vapour Recirculation (Blow-By)
44
Cooling
45
Description
45
Operation
46
Water Pump
46
Thermostat
46
Description
47
Turbocharging
47
Turbocharger
48
Air Filter
49
Section 3 Electrical Equipment
51
Engine Side Wiring
54
Engine Side Wiring Diagram
54
Engine Side Wiring Diagram
55
Pin out Connector 1A (96 Pin) - Control Unit Edc 17 Hp 41
56
Crin Injector 3.3
59
Rail Pressure Sensor (RSD 4)
59
Pressure Sensor Inside Engine Crankcase
60
Crankshaft Sensor
61
Camshaft Sensor
62
Fuel Temperature Sensor
63
Coolant Temperature Sensor
63
Oil Pressure and Temperature Sensor
64
Fuel Filter Clogged Sensor
65
Alternator
66
Section 4 Scheduled Maintenance
71
Checks to be Made During Periods of Use
73
How to Proceed
75
Check the Engine Lubricant Oil Level
75
Engine Coolant Level Check (Example)
75
Engine Visual Inspection
76
Inspection Cleaning of the Air Filter and Relative Seat
76
Check Tension and Condition of Ancillary Belt
77
Exhaust Gas Pipes(S) Condition Check
77
Scheduled Maintenance
73
Introduction
73
Periodic Maintenance - How to Proceed
77
Draining the Water from the Fuel Prefilter (if Any)
77
Condensed Water Drainage from Fuel Tank
77
Change Engine Lubricant Oil
78
Change Lubricant Oil Filter
79
Replace Fuel Prefilter (if Fitted) (Example)
80
Replacing Fuel Filter
81
Change Air Filter
82
Replace Auxiliary Member Drive Belt
82
Replacing Blow-By Filter Element
82
Unscheduled Maintenance
83
How to Proceed
83
Visual Turbocharger Inspection
83
Clean the Heat Exchanger (Radiator)
83
Check the Tappet Clearances and Adjusting if Necessary
83
Replace Engine Coolant
84
Section 5 Removal-Refitting of the Main Engine Components
85
Protective Grille Removal - Refitting
87
Removal
87
Refitting
87
Radiator Assembly Removal - Refitting
87
Refitting
88
Fan Removal - Refitting
89
Removal
89
Refitting
90
Engine Cable Removal-Refitting
90
Removal
90
Removal-Refitting of the Main Engine
90
Components
90
Removal-Refitting of Ancillary Belt
91
Removal
91
Refitting
91
Removal
92
Refitting
92
Starter Motor Removal-Refitting
99
Removal
100
Refitting
100
Turbocharger Removal-Refitting
100
Exhaust Manifold Removal-Refitting
102
Removal
102
Refitting
102
Oil Filter and Mount Removal-Refitting
104
Removal
104
Refitting
104
Heat Exchanger Removal-Refitting
105
Removal
105
Refitting
106
Removal
107
Refitting
107
Fuel Filter Removal-Refitting
108
Removal
108
Refitting
108
Engine Control Unit Removal-Refitting
109
Removal
109
Refitting
109
Air Filter Removal - Refitting
110
Removal
110
Refitting
110
Blow-By Removal-Refitting
111
Removal
111
Refitting
111
Intake Manifold Removal-Refitting
112
Removal
112
Refitting
112
Fuel Pump Removal-Refitting
113
Removal
113
Refitting
115
Tappet Cover Removal-Refitting
117
Removal
117
Refitting
117
Common Rail Removal-Refitting
118
Removal
118
Refitting
119
Electro-Injector Removal-Refitting
120
Removal
120
Refitting
120
Rocker Arm Shaft Removal-Refitting
121
Removal
121
Refitting
121
Setting Rocker Free Play
122
Electro - Injectors Removal-Refitting
123
Removal
123
Refitting
124
Setting Rocker Free Play
126
Cylinder Head Removal-Refitting
127
Removal
127
Refitting
133
Section 6 General Mechanical Overhaul
149
Engine Disassembling
153
Disassembly of G-Drive Components
153
Removal of Components Hindering Bracket Assembly
154
Fitting the Engine on the Rotating Stand
156
Disassembly of Engine at Bench (Components at the Front)
157
Damper Flywheel Removal
157
Alternator Support Removal
157
Electromagnetic Coupling Pulley Removal
158
Assembly of Auxiliary Parts
158
Thermostat Case Removal
158
Crankshaft Front Gasket Removal
159
Disassembly of Engine at Bench (Components at Exhaust Side)
159
Turbocharger and Exhaust Manifold Removal
159
Heat Exchanger Removal
160
Disassembly of Engine at Bench (Components at the Intake Side Part 1)
160
Disassembly of the Starter Motor
160
Inlet Manifold Removal
160
Engine Control Unit Removal
161
Disassembly of Engine at Bench (Components at the Rear Side Part 1)
161
Blow-By Case Removal
161
Blow-By Filter Removal
161
Timing Gear Cover Removal
162
Disassembly of Engine at Bench (Components at the Intake Side Part 2)
162
Fuel Filter Removal
162
High Pressure Pump Removal
162
Disassembly of Engine at Bench (Components at the Top Part 1)
162
Removal of Head Cover
162
Disassembly of Engine at Bench (Components at the Rear Side Part 2)
164
Timing Gear Removal
164
Flywheel Removal
164
Crankshaft Rear Gasket Removal
165
Removing Engine Mounts
165
Flywheel Case Removal
165
Double Gear Removal
165
Connecting Rod Removal
166
Disassembling the Oil Pump
166
Disassembly of Engine at Bench (Components at the Top Part 2)
166
Rocker Arm Shaft Removal
166
Rail Removal
167
Injector Removal
167
Removing the Engine Brake Cylinders
168
Camshaft Removal
168
Cylinder Head Removal
168
Disassembly of Engine at Bench (Components at the Bottom)
169
Oil Sump Removal
169
Suction Strainer Removal
169
Disassembly of Engine at Bench (Crankcase Components Side)
169
Connecting Rod Removal
169
Lower Crankcase Removal
170
Crankshaft Removal
170
Main Bearings and Oil Nipples Removal
170
Crankcase Checks
171
Cylinder Liners Removal
173
Cylinder Liner Refitting and Protrusion Check
173
Crankshaft Measurements
174
Measuring Crankpins
176
Defining the Diameter Class of the Seats for Half-Bearings on the Crankcase
177
Defining the Diameter Class of the Main Journals
179
(Nominal Diameter)
180
Defining the Diameter Class of the Crankpins
180
Selection of Main Half-Bearings
181
Main Half-Bearing Thickness
181
Main Half-Bearing Selection (Nominal Diameter)
183
Main Half-Bearings Selection (Rectified Pins)
184
Big-End Half-Bearing Selection
186
Big End Half-Bearings Selection
187
Big End Half-Bearings Selection
188
Checking the Timing and Oil Pump Gear Control
190
Overhauling the Connecting Rod-Piston Assembly
191
Circlips Removal
192
Piston Removal
192
Measuring the Piston Diameter
192
Measuring the Piston Pin Diameter
192
Conditions for Correct Pin-Piston Coupling
193
Connecting Rod Checks
194
Axis Alignment Check
196
Torsion Check
196
Bending Check
197
Connecting Rod Small End Bush Check
197
Piston Assembly
197
Fitting Circlips
198
Cylinder Head Overhaul
198
Main Operation
198
Valve Removal
198
Regrinding - Replacing the Valve Seats
200
Replacing the Valve Guides
201
Checking Protrusion of Injectors
201
Valve Spring Check
201
Valve Assembly
201
Mounting the Oil Seal Ring
202
Timing System Assembly
202
Main Operation
202
Change Transmission Gear Bushing
202
Replacement of the Dual Idle Gear Bushes
203
Tolerance Characteristics
205
Class of Importance Product Characteristics
205
Camshaft Bushings Check
206
Replacing Camshaft Bushings Using Beater
207
Rocker Shaft Check
208
Exhaust Valve Rocker Arm Check
209
Intake Valve Rocker Arms Check
209
Engine Assembly
209
Crankcase Compoennts
209
Oil Sprayer Assembly
209
Main Bearings Assembly
209
Crankshaft Assembly
210
Main Bearings and Pin Clearance Measurement
210
Lower Crankcase Assembly
211
Diagram of Tightening Sequence of Lower Crankcase Fixing Screws
213
Big End Half-Bearing Fitting
214
Assembling Connecting Rod - Piston Assemblies in the Cylinder Liners
214
Crankpin Fitting Clearance Check
215
Checking Crankshaft Shoulder Clearance
216
Assembly of Engine at Bench (Components at the Bottom)
216
Suction Strainer Installation
216
Oil Sump Assembly
216
Assembly of Engine at Bench (Components at the Rear Part 1)
217
Installing the Oil Pump
218
Double Gear Assembly
218
Fitting Flywheel Case
219
Crankshaft Rear Gasket Assembly
220
Engine Support Assembly
220
Engine Flywheel Assembly
220
High Pressure Pump Flange Assembly
221
Fitting Camshaft
222
Assembling the Engine Brake Cylinders
224
Assembly of Engine at Bench (Components at the Top Part 1)
217
Cylinder Head Assembly
217
Assembly of Engine at Bench (Components at the Top Part 2)
225
Injector Assembly
225
Rail Installation
225
Fitting Rocker Shaft Assembly
226
Camshaft Timing
227
Phonic Wheel Timing
230
Assembly of Engine at Bench (Components at the Intake Side)
231
High Pressure Pump Assembly
231
Intake and Exhaust Rocker Arm Clearance Adjustment
233
Assembly of Engine at Bench (Components at the Intake Side)
234
Fuel Filter Assembly
234
Inlet Manifold Assembly
235
Starter Motor Assembly
236
Assembly of Engine at Bench (Components at the Top Part 3)
234
Tappet Cover Assembly
234
Assembly of Engine at Bench (Components at the Rear Part 2)
236
Timing Gear Assembly Cover Mounting
236
Blow-By Filter Fitting
236
Blow-By Case Fitting
237
Assembly of Rpm and Timing Sensor
237
Assembly of Engine at Bench (Components at the Exhaust Side)
237
Heat Exchanger Assembly
237
Turbocharger Assembly
238
Exhaust Manifold Assembly
238
Thermostat Case Assembly
239
Crankshaft Front Gasket Installation
239
Assembly of Auxiliary Parts
240
Electromagnetic Coupling Assembly
240
Alternator Support Assembly
240
Alternator Assembly
241
Alternator/Water Pump Drive Belt Assembly
241
Damper Flywheel Installation
241
Removing the Engine from the Rotating Stand
242
Engine Assembly
242
Asembly of Bracket Interference Components
242
Assembly of G-Drive Components
244
Checks
245
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