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Excavators: Workshop Manual Engine
Excavators: Workshop Manual Engine
All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication.
The right is reserved to make changes at any time without notice.
INTRODUCTION
TO THE READER
• This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information needed found any errors regarding the contents of this
to maintain and repair this machine. manual, please contact:
ADDITIONAL REFERENCES
- Operator’s Manual
- Spare Parts Catalog
- The Technical Manual -Troubleshooting includes • The Service Manual for EX215 Excavator consists
the technical information needed for operational of the following book/print numbers:
INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Section number
T : Technical Manual
W : Excavator Workshop Manual
EW: Engine Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.
UNITS USED
A table for conversion from SI units to other system units is shown below for reference purposes.
To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.039 37 Pressure MPa kgf/cm2 10.197
mm ft 0.003 281 MPa psi 145.0
L US gal 0.264 2 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Weight Kg lb 2.205 Velocity Km/h mph 0.621 4
-1
Force N kgf 0.101 97 min rpm 1.0
N lbf 0.224 8 Flow rate L/min US gpm 0.264 2
Torque N.m Kgf.m 1.0197 ML/rev Cc/rev 1.0
N.m lbf.ft 0.737 5
WORKSHOP MANUAL EX135–EX215
ENGINES
LIST OF SECTIONS
EW–1–1
Section 1 – Diagnostics
EW–2–1
Section 2 – Removing–refitting engine EX135
EW–3–1
Section 3 – Engine EX135 overhaul
EW–4–1
Section 4 – Removing–refitting engine EX215
EW–5–1
Section 5 – Engine EX215 overhaul
EW–6–1
Section 6 – Recharge and start–up EX135–EX215
SECTION 1 EX135 – EX215
DIAGNOSTICS
CONTENTS
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . EW–1–3
EW–1–3
DIAGNOSTICS
Battery terminals efficient Clean, check and tighten the nuts of the ter-
NO minals or replace them.
YES
Batteries efficient Carry out the checks described in the repair man-
NO ual ” Electrical System ”.
YES
Starter mtor working Carry out the checks described in the repair man-
NO
ual ” Electrical System ”.
YES
YES
Injection pump delivering Check the entire set up as described in the ap-
NO propriate chapter.
(to be continued)
EW–1–4
DIAGNOSTICS
YES
No air bubbles in the fuel pipes or injection pump. Check and bleed.
NO
YES
No traces of water in the fuel pipes or the fuel Check and clean the fuel feed circuit, including
pump NO the tank.
YES
Compression ratio correct Check the engine or carry out only the essential
NO
checks (valves, split rings, etc...).
YES
YES
Automatic spark lead governor and engine Check and replace the necessary parts.
STOP device efficient NO
EW–1–5
DIAGNOSTICS
Coolant level correct Check for leakage and top up the level.
NO
YES
Water pump and ventilator working correctly Check and register the tension, if necessary re-
NO place the parts.
YES
YES
YES
YES
(to be continued)
EW–1–6
DIAGNOSTICS
Injection pump adjusted correctly Check the setting as described in the appropriate
NO paragraph.
YES
YES
YES
Fuel feed circuit efficient Check and carry out the necessary repairs.
NO
YES
YES
(to be continued)
EW–1–7
DIAGNOSTICS
YES
Injection pump timing correct Check the registration as described in the corre-
NO sponding paragraph.
YES
Injection pump regulated correctly Check and calibrate the injection pump in the
NO workshop.
YES
Compression ratio correct Check using tool 75301463 Motometer and carry
NO out necessary repairs.
YES
YES
DIAGNOSTICS
YES
YES
YES
YES
YES
YES
Injection pump settings correct Check and calibrate the injection pump in the
NO
workshop.
(to be continued)
EW–1–9
DIAGNOSTICS
Compression ratio correct Check using tool 75301430 Motometer and carry
NO out necessary repairs.
YES
Fuel of good quality Clean the tank and replace the fuel filters.
NO
YES
YES
Injection pump adjusted correctly Check the settings as described in the relative
NO paragraph.
YES
Coolant level correct Probable leakage of the coolant into the combus-
NO
tion chamber; replace the cylinder head gasket
or overhaul the engine.
YES
Fuel of good quality Clean the tank and replace the diesel filters.
NO
EW–1–10
DIAGNOSTICS
Knocking located in the drive shaft Check for: excessive clearance in one or more
YES big end bearings; loose fixings in the headblock
and flywheel; oil pressure. Replace the damaged
parts or overhaul the engine.
NO
Knocking located in the tie rods Check for: excessive clearance or misshaping in
YES the crankpins; loose fixings in the connecting
rod; misalignment of the connecting rods. Re-
place the damaged parts or overhaul the engine.
NO
Knocking located in the pistons Check clearance of the pistons – piston barrels;
YES split rings; piston pins – piston hubs. Replace
damaged parts or overhaul the engine.
NO
Knocking located in the cylinder head Check the equalisers and the valves; injection
YES pump settings, valve train settings. Calibrate.
NO
Kocking located in the valve train Check and if necessary replace the gears.
YES
(to be continued)
EW–1–11
DIAGNOSTICS
Knocking located in the injectors Check and calibrate them according to S.I. 1094
YES or replace.
YES
YES
YES
YES
Injection pumps set correctly Check the flow rate in the workshop.
NO
YES
Injection pump controls working properly Replace damaged parts and calibrate.
NO
EW–1–12
DIAGNOSTICS
YES
Oil pump and supply pipes efficient Check and replace if necessary.
NO
YES
YES
Viscosity of SAE motor oil correct Replace the engine oil with oil of correct viscosity.
NO
EW–1–13
DIAGNOSTICS
Tank and fuel pipes efficient Eliminate any leakage and replace the worn out
NO parts.
YES
YES
YES
YES
YES
Injection pump adjusted correctly Check static fit of the injection pump.
NO
SECTION 2 EX135
INDEX
Engine/Pumps Assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . EW–2–1
Engine/Pumps Assembly
Installation . . . . . . . . . . . . . . . . . . . . . EW–2–6
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . EW–2–7
EW–2– 1
ENGINE/PUMPS ASSEMBLY
REMOVAL
! CAUTION
Keep people not involved in the maintenance
work outside the working area. Wear adequate
personal clothes and glasses with side shields as
a protection against flying debris. 1
! WARNING
The hydraulic oil reservoir is under pressure. 2
Press the pressure relieve button (1) on the filler
plug to relieve pressure before maintenance.
Danger of personal injuries.
!
3
CAUTION
The engine reaches high working temperatures. 4
Therefore, it is necessary to let the machine cool
down prior to carrying out this operation.
! CAUTION 6
Always disconnect the negative (–) ground ter-
minal first and reconnect it last.
! CAUTION
— Pressure fluid. Turn the cap slowly (7) before
removing it completely to relieve pressure. Do
not loosen the radiator cap when the engine is 8 7
hot to avoid burn hazard.
— Do not perform this operation when the ma-
chine is still hot. Contact with engine coolant at
working temperature may cause burns and
personal injuries.
10
EW–2– 3
12 11
13
15
EW–2– 4
AIR CONDITIONER
! CAUTION
The air conditioning system hoses contain re-
frigerant gas under pressure. Wear adeguate pro-
tective clothes, gloves and glanes with side
shields, prior to operate on the system.
ELECTRICAL CONNECTIONS
HYDRAULIC PUMPS
! CAUTION
Check that the hoist ropes are securely anchored
and that the anchor point is sufficiently strong to
sustain the load to be lifted. Keep any person
away from ropes or chains anchor point.
21
ENGINE/PUMPS ASSEMBLY
INSTALLATION
For the engine/pumps assembly installation
make reference to the procedures previously de-
scribed for the removal, but proceeding step by
step in opposite way.
TIGHTENING TORQUES
FILLING
Attachment hydraulic
120 HI–TECH 46 QFH 583/HD – –
system
EW–2– 8
2
EW–2– 9
4
EW–2–10
Install cover (1) ensuring that the filter and rod as-
sembly is correctly positioned. Tighten the bolts
to the torque of 50 Nm (37 lbf.ft).
Reinstall plugs.
CONTENTS
Type 8045.25.282
Turbocharged
turbocharged with aftercooler
∅
Diameter mm 104
Stroke mm 115
66
Max. output KW (90)
CEE 80/1269 (HP)
2200
rpm
Max. torque Nm
365.9
(Kgm)
(37.3)
rpm
1600
Min. permissible
T.D.C. pressure * bar ≥ 19
bar
Engine motoring over
speed rpm ≈ 260
(*) The pressure value is measured by rotating the enging by the starter only, with oil temperature at 40o – 50o C and
injection pump at shut–off.
EW–3–4
B
C
Timing check
0.45
mm
X 0.45
X mm
α
Pump setting 7o ± 0,5o
X
Beginning of delivery mm 1
Injection order
bar
LUBRICATION SYSTEM Forced feed by gear pump, relief valve, dual action
oil filters
– max. opening
OIL FILLING
Quantity at periodical
replacements:
– engine sump
litres 9.1
Kg 8.2
L Cylinder sleeve:
106.94 ÷ 106.97
Outer diameter ∅2
∅ Length L
198.00 ÷ 198.50
2
Cylinder sleeve – crankcase
0.04 ÷ 0.12
housing
∅3
Cylinder sleeve
X
Inner diameter ∅3 104.000 ÷ 104.024
Sleeve protrusion X
Pistons:
∅1
X Oversize dimension X 12
X
Piston protrusion X 0.64÷0.97
X1
X1 3.20÷3.23
X2 Piston ring grooves X2
2.55÷2.57
X3 X3
4.03÷4.05
EW–3–7
S1 S1 2.932 ÷ 2.963
S2
Piston rings S2 2.478 ÷ 2.490
S3
S3 3.970 ÷ 3.990
1 0.537 ÷ 0.598
3 0.040 ÷ 0.075
∅4
Small end bushing
∅3 Outer dia. ∅4 41.979 ÷ 42.017
X
125
Measuring dimension X
X2
X3 Thrust washer
3.378 ÷ 3.429
thickness X3
1 2 1 ≤ 0.10
Alignment
2 0.03
Ovalization 1–2 0.015
∅2
∅2 8.023 ÷ 8.043
Valve guide
∅3 13.993 ÷ 14.016
∅3
∅4 Valves:
∅4 7.985 ÷ 8.000
α 60o 30’ ± 7’
∅4 7.985 ÷ 8.000
45o 30’ ± 7’
α α
Valve stem and guide 0.023 ÷ 0.058
∅1 –
∅1 39.000 ÷ 39.025
∅1
∅2 –
60o ± 5’
α
∅2
α 39.136 ÷ 39.161
α 45o ± 5’
H H1 Under a load of N.
H2 270 ± 14 H1 34
528 ± 26 H2 23.8
∅1
∅2 54.780 ÷ 54.805
∅ ∅ ∅ ∅3 54.280 ÷ 54.305
1 2 3 53.780 ÷ 53.805
∅ 5
Camshaft journal diameter
∅4
50.970 ÷ 51.000
∅5
50.470 ÷ 50.500
∅6
49.970 ÷ 50.000
∅ 4 ∅ 6
Camshaft bushing
∅1 outer diameter:
∅2
front ∅1 54.875 ÷ 54.930
∅3 ∅2
intermediate 54.375 ÷ 54.430
rear ∅3 53.875 ÷ 53.930
Camshaft bushing
∅1 inner diameter:
∅2 51.080 ÷ 51.130
∅1 50.580 ÷ 50.630
∅3 front
intermediate ∅2 50.080 ÷ 50.130
rear ∅3
Bushing and housing in
0.07 ÷ 0.15
engine block
Cam lift:
H H
5.97
H
6.25
EW–3–11
8045.25.282
mm
∅1
Tappet washer bore ∅1
15.000 ÷ 15.018
∅2 ∅3
14.950 ÷ 14.970
∅ 1
Valve lifter diameter ∅1 17.982 ÷ 18.000
79
72
65
58
51
44
37
30
23
EW–3–13
Removal
Intake
Disconnect
Re–fit in place
Exhaust
Connect
Removal
Operation
Disassembly
Fitting in place
Assembly r Compression ratio
Tolerance
Driving torque
Weight difference
Replacement
Caulk
Original spare parts
Regulation
Rotation
Adjustment
Caution Angle
! Note Angular value
Visual check
Pre–load
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Oversizing
Interference
Greater than...
Strained assembly
Maximum
Undersizing
Thickness
Smaller than...
Clearance
Minimum
Lubricate Selection
Damp Classes
Grease Oversizing
Temperature < 0o C
Sealant Cold
Winter
Temperature > 0o C
Air vent Hot
Summer
EW–3–14
STRIPPING DOWN THE ENGINE IN THE - Disconnect the check rod sleeve (3);
WORKSHOP - Put the engine on the revolving stand 75301124,
Using a suitable lift (capacity greater than 500 kg) fixing it to the brackets 75301426.
and some ropes, keep the engine suspended, then
apply brackets 75301426 after the operations de-
scribed below: When handling the engine, keep at a safe
! distance in compliance with the accident–
- Remove the supports (1); prevention standards.
- Drain oil from the engine;
- Remove the heat exchanger (2);
Figure 1
1 47277
Figure 2
1 9
2 10
11
3 12
13
8
14
Figure 3
47279
15
18
19
16
17
47278
1. Air pipeline – 2. Air intake manifold – 3. Fuel filter – 4. Accelerator tie rod – 5. Filter –
6. Starter motor – 7. Fuel pump – 8. Tightener – 9. Fuel pipes – 10. Injection pump – 11. Fuel return piping –
12. Pulley support – 13. Fan – 14. Belts – 15. Turbocharger – 16. Alternator – 17. Oil filter – 18. Exhaust
manifold – 19. Equaliser cover
EW–3–19
- Remove the fuel pump (7). Prevent the flywheel from rotating by tool 75301432
- Remove the starter motor (6) from its housing. (2), then loosen the screws (1).
- On the front side, loosen the relevant screws
and remove the fan (13), through the holes of the Figure 5
fan driving pulley loosen the water–pump pulley
screws.
- Loosen the belt tightener (8), loosen the water–
pump alternator driving belt by unscrewing the
screw on the relevant slotted bracket.
- Then extract the two belts (14) from the pulleys.
47285
NOTE – The fan driving belt is self–ventilated. After having definitely removed the pulley on the
water pump, remove the tightener (3), the pipe (2)
NOTE – Where present, loosen the conditioner and the alternator bracket (1).
compressor fixing device to extract the belt, then Figure 6
unscrew the screws completely and remove the
compressor.
(17). Remove the pulley (2) and the flywheel damper (1)
- Remove the equaliser cover. removing the perimeter screws.
EW–3–20
Figure 7 Figure 10
47287 32567
Remove the thermostat unit (1) from the head, and Remove the entire valve lifter shaft (1).
the water pump from the crankcase.
Figure 8 Figure 11
32568
Straighten the locking plate (2) and unscrew the hub Put aside valve lifter control rods (1) and covers (2)
locking nut (1) using a suitable wrench. on valve spindle.
Figure 9 Figure 12
47289
32569
Apply tool 75301437 (2) and pull off the hub (1).
Extract the retaining screws (1) of cylinder head (2)
and remove the cylinder head; keep its gasket.
EW–3–21
Figure 13 Figure 16
47292 47293
Turn engine by 180° and, using a wrench, extract the Remove the timing gear cover (3).
screws and remove the oil sump (1) keeping its Remove the intake pipes (1) and the delivery pipes
gasket. (2); remove the oil sump (4).
Figure 14 Figure 17
47290 47294
Unscrew the flywheel fixing screws (2), which had Loosen the screws (1) and remove the connecting
been already loosen, and extract the flywheel (1). rod covers (2).
Figure 15 Figure 18
47291 32573
Loosen the flywheel cover fixing screws (1) and re- Pull the piston/connecting rod assemblies (1) out of
move the cover. the upper part of crankcase.
EW–3–22
Figure 19 Figure 21
47295 32577
Figure 22
Figure 20
32578
REPAIRS Figure 24
CYLINDER BLOCK
CHECKS AND MEASUREMENTS 1. MEASURING
3. MEASURING
Figure 23
20581
Figure 25
32579
32580
- go on pressing in and, at 30 mm before finishing, Check support surfaces (3) of the cylinder head for
check that the load is between 10,000 and unevenness by means of a calibrated ruler (1) and
40,000 N; a feeler gauge (2).
- when pressing is completed, stop for 5” with a Surface–grind the support surface by means of a
press–in load above 50,000 N; grinding machine removing as little material as
possible after determination of the unevenness. Re-
- by restriking, check whether the liner edige is member that, after surface–grinding, the piston
well–set in the crankcase. must project by 0.64 0.97 mm over the cylinder
If the driving load is outside the above limits, the cyl- block.
inder liner must be extracted and replaced.
After driving, the cylinder liners must be bored and NOTE – Pull out centering pin only if the support sur-
ground. face must be surface–ground.
Figure 26
32581
Figure 28
5619
MAIN DATA OF THE CAMSHAFT
The surfaces of the bearing journals of the shaft and scoring and furrows, the shaft and their correspon-
the cams must be completely smooth; if they have ding bushes must be replaced.
EW–3–26
32583
32586
Clamp camshaft (2) between centers (3) and check In order to check the mounting clearance, measure
the cam pitch (4) by means of a cent indicating caliper the inner diameter of bushes and diameter of cam-
(1). Cam pitches must be: shaft journals (1); the difference represents the
- 5.955 mm for the inlet cam; actual clearance.
For a clearance of more than 0.160 mm, replace the
- 6.027 mm for the outlet cam.
bushes and, if necessary, also the camshaft.
Figure 30
Figure 33
32584
32585
Check that the toothing of the driven toothed wheel
(1) is not excessively worn or damaged, otherwise 32588
replace it. In order to mount the new toothed wheel,
it must be heated up to 180 °C in the furnace for After mounting, grind the bushes completely by
about 10’ and then drawn upon the shaft together means of the mandrel (1) complete with guide
with the plate (2) and the curved washer. bushes (2–3) and milling cutter (4) in order to obtain
the prescribed values.
EW–3–27
Figure 35
5619
32589
32593
Figure 39
32591 Figure 42
Lubricate the valve lifters (1) and mount them into
their crankcase seats.
Figure 40
32594
CRANKSHAFT
Figure 43
21175
MAIN DATA OF THE CRANKSHAFT MAIN AND CONNECTING ROD BEARING JOURNALS
32596
32595
Figure 46 Figure 49
ROLLED
*
32597
ROLLED
32598
21178
This check must be carried out after possible grind-
DETAIL OF THE CONNECTING ROD BEARING ing of the crankshaft journals; for this purpose the
JOURNAL CONNECTIONS shaft (3) must be clamped between centers (2) and
a centi indicating caliper has to be used (1).
Figure 48 - Alignment of main bearing journals: max. toler-
ance > 0.10 mm (total reading at the indicating
caliper).
Figure 51
NORMAL POSITION
LIMIT mm 0,25 LIMIT
POSITION mm POSITION
0,25
ÇÇÇÇ MAIN
ÇÇÇÇ
BEARING
JOURNAL
ÇÇÇÇ CONNECTING
32575
Figure 56
32605
a
32603
32606
Figure 60
32604
47290/
47296
Mount flywheel (1). Apply tool 75301432 (3) and
Insert a new seal ring (1) on the flywheel cover (2). tighten the screws that were previously lubricated
with “LOCTITE HVX 576” to a tightening torque of
40 Nm by means of a torque wrench (2).
Some seal rings are supplied as spare parts
! with the built–in ring, to be removed after the
assembly.
Figure 62
47291
Figure 64
ENGINE FLYWHEEL
REPLACEMENT OF ENGINE FLYWHEEL a
TOOTHED WHEEL
Replace the toothed flywheel ring if the teeth of the
toothed flywheel ring mounted on the engine fly-
wheel to start the engine are very damaged. Before
mounting, the thoothed flywheel ring must be heated
up to a temperature of 80 °C.
32612
32613
32616
32614
Take off locking rings (2) of piston pin (1) by means The clearance between piston and cylinder liner can
of a center punch (3). also be checked by means of a feeler gauge (1) as
shown in the figure.
EW–3–35
Figure 70
47318
MAIN DATA OF THE PISTON, THE PISTON RINGS AND THE PISTON PIN (ENGINE 8045 25.282)
PISTON PINS
The pins are mounted with clearance as well at the
connecting rod eye as at the piston.
Figure 71 Figure 72
32618 32619
Measure the piston pin diameter (1) by a micrometer For mounting the new piston pins (1) check the cor-
(2). rect fit in the piston as follows:
- Lubricate the piston pin and the corresponding
fit at the piston pin hubs with engine oil;
- insert the piston pin vertically in the piston pin
hub;
- it must be possible to insert the piston pin with a
slight pressure;
- the piston pin cannot slip out of the hubs.
EW–3–36
32621
16556
3513
The seal ring (2) of the 1st piston groove has a trap-
ezoidal cross section. The clearance between the
sealing ring and the seat is determined as follows: Connecting rod assembly drawing. 32622
Figure 79 BUSHES
Figure 81
20584
32625
MAIN DATA OF THE CONNECTING ROD, THE
BUSH, THE PISTON AND THE BEARING Dismounting and mounting of the bush (2) are car-
SHELLS ried out with a suitable driving mandrel (1).
Figure 82
36624
32613
To mount the piston rings (1) onto the piston (2) use
pliers 75301434 (3).
32677
The rings must be mounted with lettering “TOP’’ to-
wards the top; furthermore the joints in the rings
NOTE – The piston (2) must be mounted in such a must be aligned in such a way that they are offset by
way that lettering “VALVE LIFTER SIDE” (1) at the top 120° to each other.
is placed opposite to the number (4)on the connecting
rod.
Insert piston pin (3) and mount the spring rings.
Figure 84
Figure 86
32630
Figure 87
NOTE – When mounting the connecting rod – piston
assemblies check that:
– the connecting rod number corresponds to the
cylinder number;
– the lettering “VALVE LIFTER SIDE’’ which is
punched into the piston head must point to the
top, i.e. in the direction of the camshaft;
– the connecting rod numbers point to the side op-
posite to the camshaft;
– the piston ring joints must be offset by 120° to
each other.
Figure 88
32633
In order to adjust the clearance, the following oper-
ations must be carried out:
- clean the parts carefully and remove the oil;
- place a piece of calibration cable (2) at the
crankshaft journals (1);
- mount the connecting rod cover (4) and tighten
the screws with the prescribed tightening
torque;
- dismount the cover and determine the existing
clearance; for this purpose compare the width of
the calibration cable (2) with the scale printed at
the calibration cable wrapping.
32632
32634
Mount connecting rod covers (2) complete with
bearing shells, tighten screws (3) by means of a
torque wrench (1) to a tightening torque of 40 Nm;
the screws must be previously lubricated.
Figure 91
32635
Place tool 75301460 (1) at the socket wrench and
tighten the screws (2) by further 60°.
Check that the connecting rods can be displaced ax- REPLACEMENT OF BUSH FOR TRANS-
ially on the crankshaft journals. MISSION GEAR WHEEL
Figure 92
Figure 93
32636
Figure 94 Figure 96
32638 32640
After mounting, the bush (1) must be bored in order Shrink on the transmission gear wheel (2) and align
to obtain the diameter given in the drawing. it in such a way that the marks 1 - 2 and 3 punched
into it cover the marks on the driving toothed wheel
(1), the camshaft driven toothed wheel (3) and the
injection pump driving toothed wheel (4).
CYLINDER HEAD
Figure 97
Figure 95
32641
Tightness check
32642 32644
Place the cylinder head at the work bench and press The bearing surface of the cylinder head on the cyl-
with tool 75301431 (2) on the upper plate (6, inder block is checked by means of a ruler (1) and a
Figure 99) of the springs (3) in order to pull out the feeler gauge (2).
cone halves (4) and detach the valves; pull out the For values above 0.15 mm on the whole surface, the
upper spring plate (6), the springs (3) and the lower head must be reground by means of a surface grind-
spring plate (5). Repeat this for all valves. Turn the ing machine while removing as less material as pos-
cylinder head and pull out the valves. sible.
VALVES
Removal of incrustration and valve check
Figure 99 Figure 101
32643 18625
32645
valve stem guide. If case clearance is too large, re- After mounting the valve stem guides (2), regrind the
place the valve and, if necessary, the valve stem bore by reamer 75295890 (1).
guide.
EW–3–44
16587
Figure 108
EXHAUST INTAKE
0.7 TO 1 VALVE
SINKING
32642
Mounting is carried out performing the same steps
of the dismounting but in reversed order.
32650
The valve sealing of the cylinder head is checked NOTE – Lubricate the valve spindle with engine oil.
with a suitable tool.
EW–3–45
18929
Before reusing the cylinder head fastening screws (2), 32653
measure by a micrometer screw (1) that the thread di-
ameter of the screws is not lower than 11.5 mm at any - mount the cylinder head (2), insert the previous-
point; otherwise the screws must be replaced. ly–lubricated screws (3) and tighten them ac-
cording to the following data and in the order
Figure 114 given in Figure 115;
- 1st step, by a torque wrench (1), pretighten to a
tightening torque of 70 Nm;
- 2nd step, tighten again to a tightening torque of
70 Nm.
32652
Figure 115
2790
32654
PATTERN OF THE TIGHTENING ORDER OF
THE CYLINDER HEAD FASTENING SCREWS IN - 3rd step, place tool 75301460 (1) on the socket
THE CRANKCASE wrench (2) and tighten with an angle of 180_.
EW–3–46
32655
32656
The control rods of the valve lifters must not be de-
formed. The ball seats which can have contact to the Mount the valve lifter control rods (1) in their seats.
valve lifter adjusting screw and the valve lifter (ar-
rows) must be free from score grooves or wear;
otherwise they must be replaced.
The rods which operate the intake and exhaust
valves are identifical and can be exchanged.
Figure 119
32657
MAIN DATA OF THE BEARINGS OF THE VALVE LIFTER SHAFT AND THE VALVE LIFTER
Figure 120
Check that the sealing surfaces are free from fur-
rows or score grooves; otherwise replace the dam-
aged parts.
Check clearance between valve lifters and valve
lifter shaft, which must be 0.016 ÷ 0.052 and the
clearance between bearing and valve lifter shaft,
which must be 0 ÷ 0.061 mm; replace the parts which
cause larger clearances.
Check the perfect sealing of the plugs mounted at
the shaft end.
32658
Mounting of valve lifter shaft and adjustment of The clearance between valve lifters and valves must
working clearance between valves and valve lifters be adjusted carefully in order to avoid changes of the
prescribed control diagram. This would be the case
Figure 122 if the clearance was smaller or larger than pre-
scribed.
The working clearance is 0.25 ÷ 0.35 mm for both
the intake and the exhaust. Place the cylinder for
which the clearance is to be adjusted in the working
stroke; the valves of this cylinder remain closed,
while the valves of the corresponding cylinder are
adjusted.
The cylinder pairs are 1 - 4 and 2 - 3.
LUBRICATION
32659
Mount cover (1) to the valve spindle. The engine is lubricated by means of a gear pump
(Figure 125) that is mounted in the lower part of the
Figure 123
crankcase at the front bearing; it is driven by toothed
wheels of the crankshaft.
32567
Figure 124
32662
Figure 126
6960
OIL PUMP ASSEMBLY COMPONENTS
1. Screw - 2. Washer - 3. Centering dowel - 4. Bushing - 5. Oil pump gear - 6. Centering dowel - 7. Driving
gear - 8. Seal ring - 9. Valve body - 10. Spring - 11. Valve - 12. Screw - 13. Washer - 14. Locking plate - 15.
Oil pump body - 16. Bushing - 17. Oil pump gear - 18. Bushing - 19. Shaft - 20. Oil pump cover.
Figure 127
32663
32664 32665
Figure 132
32666
Figure 131 NOTE – Check that pump body is not cracked or that
thre are no water leaks; otherwise replace the entire
pump.
THERMOSTAT
When the engine is cold, water flows from the top
part of the cylinder head and enters a filler pipe
where the thermostat inhibiting water circulation in
the radiator is located.
In this way, water will circulate between pump and
engine only, thus allowing fast heating of the water.
Thermostat valve starts opening at 80°C, allowing
water circulation through the radiator and simulta-
neously inhibiting direct return to the engine. Check
47298
efficiency of thermostat; if in doubt as to its correct
Fit the oil pump (3) and suction (1) and delivery (2) operation, replace it.
pipes.
EW–3–50
47299
- remove the plug (1) on the pump closing screw;
32669
Figure 136
47300
47302 47286
Mount cover (1) for control toothed wheel. Mount the flywheel damper (1) and the driving pulley
(2).
47287/A 47285
Mount the water pump (2) and the thermostat group Mount the belt tensioning device (3), the water pipe
(1). (2) and the generator bracket (1).
Figure 140
Figure 143
47303
47304
Mount tool 75301432 on the engine flywheel in order
to lock it.
Mount the pulley (3) of the water pump; mount the
Mount hub (1) with the locking plate; tighten nut by
generator (1), the fan pulley support and the driving
means of torque wrench (2) to a tightening torque of
belts.
295 Nm, bend the locking plate (3).
EW–3–52
47292
Figure 146
47278/
Figure 147
47279/
EW–3–54
Lift the engine from the revolving stand for overhaul engine oil exchanger (2) following the connections
by means of an appropriate hoist and, on the fly- with the pipes, remount the sleeve for the oil level-
wheel side, if necessary, remove the flywheel clamp, gauge (3) and the engine supports (1). Then fill oil
then remove the brackets 75301426; remount the according to the indicated quantities.
Figure 148
47277
EW–3–55
Figure 149
8862
33676
DISMOUNTING
Figure 151
Figure 153
8865
32677
NOTE – In case of dismounting and remounting of the
turbocharger parts, the work bench must be carefully Fix the shaft end (3) in the vice and detach the self–
cleaned. locking nut (2) by means of a suitable wrench (1).
EW–3–57
33584
33678
Pull off the thrust bearing (1) together with the
Pull off the compressor impeller (1). bracket for the spring ring (2) from the rear central
part (3).
Figure 155
33679
Pull off the central part (1) and the seal ring (2). Figure 158
Figure 156
33585
33680
Remove the spring ring (2) by round pliers (1) and
Mark the mounting position of the rear bearing (1) of extract the bearing (3) from the central part; repeat
the central part; unscrew the screws and remove the the same operation on the opposite side of the cen-
bracket (1) from the central part. tral part with the other bearing.
EW–3–58
Figure 159
33588
Figure 162
33586
Figure 163
33587
- the turbine wheel shaft is free from score - the compressor housing and the turbine housing
grooves or furrows and that it is centered; other- must be free from furrows or wear in the seats of
wise replace the shaft; the rotating parts indicated by the arrows.
EW–3–59
33594
33592
Clamp the shaft/turbine wheel assembly (1), after
On the central part (3), mount the inner spring rings mounting the sealing ring (4) in the vice.
(2) in their seats by means of round pliers (1). Mount the sealing ring (2) and the central piece (3),
taking care not to damage the ring (4).
33593
Mount the bearings (1) and the outer spring rings. 33595
NOTE – Mount the seal ring. Mount sealing ring on the bearing (2), and insert the
The bearings must be lubricated with engine oil before thrust bearing (3) on the support; then mount these
mounting. to the impeller shaft: the positioning pins (4) must
cover the bores in the thrust bearing.
Mount the sealing ring (1).
Mount the spring at the rear bearing.
EW–3–60
33596 33597
Mount the rear bearing (1) on the central part (2): the Mount the central part at the locking device (3) of the
reference marks applied during dismounting must impeller.
cover each other; mount the locking plates, fix the Mount the compressor wheel (2), lubricate the self–
screws and bend the locking plates. locking nut slightly and tighten it to a tightening
torque of 0.23 kgm by means of a torque wrench (1);
tighten by a further quarter turn and check the pro-
jection of the shaft over the self–locking nut which
should be 0.140 ÷ 0.165 mm.
Check the axial play of the rotary unit.
Mount the compressor and turbine housings and
take care that the reference marks applied during
dismounting cover each other. Mount the locking
plates, tighten the screws and bend the locking
plates.
Lubricate the inner parts of the turbocharger with en-
gine oil after mounting.
EW–3–61
19195
Figure 172
19282
30454
MODE OF OPERATION
NOTE – The parts listd in the text refer to Figure 176.
Feed step
Figure 175 The distributor piston (5) is lifted under the infuence
of the cam disk to the T.D.C. and rotates at the same
time around its own axis. By means of these two
movements, the fuel intake pipe (1) is closed and the
fuel in the compression chamber (2) is simulta-
neously compressed. The inner pipe (3) of the dis-
tributor piston is connected to pipe (4) thus making
it possible to feed the injection valves (6) with fuel.
19198
The distributor piston (6) is placed at the B.D.C. and Figure 177
the slive valve (8) closes the bore for fuel cut–off (7).
The fuel is fed into the compression chamber (4) via
feed pipe (1) that is kept open by the solenoid valve
(2).
Delivery
Figure 176
19200
19201
6726
Figure 179
18588
Figure 181
6723
Figure 182
7148
Figure 183
30434
Description
The load–dependent adjustment of the feed start - Pump housing with a hole that is closed from
(LFB) enables a “smoother” engine operation (with outside by means of a ball that is connected to
reduced noise). the feed chamber.
The LFB device is realized by means of the following
changes: NOTE – The LFB device is calibrated only on the test
- Governor collar with an additional bore to the bench.
antipump bore.
- Controller shaft with a longitudinal hole and two
cross holes.
EW–3–67
30455
Figure 188
19202
Mode of operation
The L.D.A. device adjusts the fuel throughput irre-
spective of the air pressure in the suction manifold.
This air pressure acts upon the membrane (1) which
is rigidly connected to the controller pin (4). The
lower part of the controller pin (4) is provided with a
conical mounting (5) with a feeler pin (6).
By means of the axial displacement of the controller 26340
pin (4) the feeler pin (6) is also displaced and acts Detect the position of the reference notches be-
upon the stop lever (7). The stop lever rotates on its tween shaft (2) and lever (4).
own axis (8) and acts upon the controller disk in such Unscrew nut (3) and pull off lever (4) together with
a way the the fuel throughput is adjusted to the air plate (5) and controller lever (1) from the shaft.
quantity fed into the cylinders.
Figure 186
26341
19203
Remove: spring plate (2), spring (3) and spring plate
Attach the injection pump (1) to the plate (2) of the (4).
adjustable bracket 75290239. Remove the fastening screws and dismount the
L.D.A. cover (1).
EW–3–69
26342
19210
Remove the sealing plug (2), and the vent screw (1);
19207
detach the fixing screws (3) of the cover to the pump
Turn and pull off the membrane (1) together with the housing.
adjustment pin (2).
Figure 192 Figure 195
19208
19211
Remove the pressure spring (1) of the membrane Dismount the cover (1) and extract the driving shaft
and the distance bush (2). (2) by means of pressing the bottom (arrow).
Remove the cover seal.
EW–3–70
19215
19212
Measure the distance between the upper bush end
Pull off the guide pin by means of a center punch and (1) and the cover surface. Detach nut (3), remove
pull off the stop lever (1). locking pin (2) and detach the guide bush (1) for the
controller pin.
Figure 197 Figure 200
19213 26345
Pull out the feeler pin (1) by means of suitable pliers. For removing the driving shaft (1) and the governor
lever, unhook the spring (4) out of the pin (3) to which
the spring plate and the idling spring are mounted
Figure 198 (2).
Figure 201
19214
Detach the hub nut (1) from the cover (5); then pull 26346
off the seal ring (2), the guide bush (3) and the seal Dismount the pressure increase control valve by
(4) by means of a suitable pulling–off device. means of wrench 75301451 (1).
EW–3–71
19220
19218
Take off the locking nut and the plane washer; screw Take off solenoid valve (1) and valve (2) with inner
off the governor shaft (1) by means of a hexagon spring.
socket wrench.
Figure 206
Figure 203
19221
Figure 204
30341
26348
The speed governor (1) consists of the governor col- PARTS OF THE FEED PIPE CONNECTIONS
lar (4) with adjustment plug and locking clamp, collar 1. Pipe connection - 2. Spring support - 3.
disk (3) and governor weights (2). Adjustment disks - 4. Spring - 5. Valve seat - 6.
Ball - 7. Spring support with calibrated bore - 8.
Spring - 9. Valve housing.
EW–3–72
19223 19226
By means of wrench (1) screw off the fastening Take out the distributor piston (1) together with the
screws (2) of the hydraulic head. return springs (2), the slider (3), the spring plate (4),
and the condensating washers.
Figure 209
Figure 212
19224
Act upon the distributor piston (3) and pull out the hy-
19227
draulic head (1); the guide pins (4) and the pressure
springs (2) of the governor disk must remain in the By means of wrench 75291912 (1) screw off and pull
hydraulic head. out the fastening screws of the governor disk (2) and
extract it.
Figure 210 Figure 213
30343
19228
On the lower part of the hydraulic head, take out the Pull off the cam disk (2) together with the adjusting
spring plates (2) of the pump element return springs, screw (1) for feed start by means of suitable round
the distance washers, the guide pins (1), the pres- pliers.
sure springs (3) and the seal ring (4).
EW–3–73
18609
19229
Pull out coil supporting ring (1) but do not change the
Take out Oldham coupling (1) by means of round position of the coils in their seats.
pliers.
18623 19230
Take off the locking clamp (1) and locking pin (2) of By means of wrench (2) unscrew fastening screw (1)
the connection pin (3). and take off both covers of the injection adjuster.
18608
coil supporting ring (3) to inside. Pull out the whole injection adjuster (1).
EW–3–74
19232
19233 18618
Pull off coupling from pump driving shaft by means Take off the toothed wheel (3) for driving of the speed
of pulling–off device 75297449 (1). controller and buffer (2) from the driving shaft (1).
Figure 222
CHECKS
18611
Figure 225
NOTE – For correct mounting it is necessary to align
the eccentric ring (1, Figure 227), in such a way that
the transition opening (3, Figure 227) for the pressure
increase points to the cover and the bore (2,
Figure 227), which is recognized because the it is lo-
cated at a larger distance from the inner diameter of
the ring, points to the nameplate of the pump.
18614
Figure 226
Figure 228
18615
Figure 227
19235
18617
19236
Take out the driving shaft and fix the fastening disk Mount connection pin into piston (1) and insert it into
(1) by means of the corresponding screws. its seat.
Mount key to driving shaft and insert this assembly
into the pump housing in such a way that the key
locks into its seat in the impeller. NOTE – The spring part of the piston must correspond
to the antipump bore in the pump housing.
Figure 230
Figure 233
18620
seat in the coil supporting ring (1). Press operating pin (2) into the connection pin of the
governor piston.
Figure 231 Figure 234
18623
18621
Insert locking pin (2) and corresponding locking
clamp (1) into connection pin (3).
Mount coil supporting ring (1) in pump housing.
EW–3–77
18624
18625
Mount seal rings (2) and flat cover (5). Arrange a
1–mm adjustment washer in spring seat and mount Place indicating caliper in tool 75301458 (2), and ad-
spring (3). Place adjustment washer (4) in the cover just it to zero on surface plate (1) with a pretension
hollow (1) and mount cover. of 6 mm.
Figure 236
19858
19237
Mount spring journal (5), adjustment washers (4),
Mount Oldham coupling (1) in its seat. spring plates (2) and springs (3) into the hydraulic
Figure 237 head (1).
Figure 240
18629
Place cam disk (1); the stop for pump element (2) 19859
must point to the notch in the driving shaft.
Mount the washer for adjustment of feed start (3). Mount the distributor piston (1) together with spring
plate (4) and collar disks (2 and 3) in hydraulic head.
EW–3–78
18627
26352
Figure 244
Figure 242
19238
Figure 245
23046
19239
Place slider in distributor piston. Lubricating hole Mount controller disk (3) and place operating pin (2)
must be turned towards piston foot. into the fit (1) in the slider.
EW–3–79
23047
26354
18625
If dimension “K” deviates from the prescription, the
Mount the indicating caliper in tool 75301458 (2), adjustment washer (2) below the foot (1) of the dis-
and adjust it to zero on the surface plate (1) with a tributor piston must be replaced.
pretension of 6 mm.
Figure 251
Figure 248
18633
26356
Figure 256
30433
Place in the housing of the controller group (6): the GOVERNOR SHAFT ADJUSTMENT
weights (7), the plain washers (5 and 8) and the ad- A=X3
justing bushing (9). The exact adjustment is carried out subsequently
at the test bench.
Figure 254 Figure 257
19240
19218 Using a feeler gauge (1), test the end play of the con-
Mount the shim (4, Figure 253) and the controller troller group (3). The clearance must be between
group in the pump housing. Screw in the shaft (1) 0.25 ÷ 0.45 mm between journal (2) and controller
about 3 mm. (3), otherwise replace adjusting washer.
EW–3–81
Figure 258
30668 19241
Using tool 75301445 (1) pull out the locking clamp Screw cover (3) provisionally to pump housing,
(1, Figure 259), extract piston (2, Figure 259) and screw down bush (1) in such a way that the distance
spring (3, Figure 259) out of valve housing (5, between the bush end and the cover surface is equal
Figure 259). to the dismounting distance and that the bore (2)
points to the bottom and the feeler pin seat (4).
Figure 259
Figure 262
26359
19242
PRESSURE CONTROL VALVE
1. Elastic locking ring - 2. Piston - 3. Spring - 4. Sealing Mount locking clamp (1).
ring - 5. Valve housing - 6. Sealing ring.
Check that the controller valve parts are not worn,
otherwise they must be replaced. Figure 263
Figure 260
19046
Place adjusting piston at the height of the valve 19243
housing by means of a center punch. Remount pres-
sure increasing controller valve and screw it down Screw down fastening nut and tighten it by means of
into the pump housing. torque wrench at 25 ÷ 30 Nm.
EW–3–82
19244 19246
Screw down adjusting groove nut (1) to bush until Insert indicating caliper (1) in tool 75301458 (2) and
stop. adjust it to zero with a pretension of 10 mm.
19245 19247
Using a feeler gauge (1), measure the distance be- Place indicating caliper (1) at membrane (2);
tween the groove nut (1, Figure 264) and the upper measure and note dimension “C”.
part of the cover; then unscrwe the groove nut (1,
Figure 264) in order to reduce the previously Figure 268
measured distance by 3 mm.
19249
19252
If dimension “F” does not correspond to the prescrip-
Dismount segment cover and membrane once
tion, it must be adjusted at screw (1) by means of a
again and mount subsequently the adjustment
hexagon socket wrench (2).
screw (2) and the spring (1).
Lift adjustment of the L.D.A. device
Figure 273
Figure 270
26360
Figure 274
19251
and adjust to zero. Press governor rod of the mem- Place tool 75301462 (3) at cover (1) with the bent
brane to the bottom and check maximum lift (L.D.A. tool part connecting the lever (2). The exact mount-
lift). Subtract the value that is to be read at the adjust- ing position of the membrane is determined by
ment table from the determined value (L.D.A. lift). means of turning the membrane and noticing a
The difference must be compensated by means of hardening caused by the contact of the conical part
an adjustment washer. of the shaft with the feeler pin.
EW–3–84
19253 19256
Mount cover (1) and fix with its screws. Using a hexagon socket wrench (2) screw down
plug (1).
19254
19257
Place groove nut (2), guide bush (1) together with
sealing ring and copper seal at a suitable tool and in- Take off cover (1) from the pump, mount stop lever
sert them into the pump housing. (3) and fix it to the cover by the guide pin (2).
19255 19258
Mount feeler pin (1) with the top oriented to inside. Screw down screws (1) at the side together with the
corresponding seals by means of a screwdriver.
EW–3–85
26364
26356
Figure 285
26363
19260 26340
Place seal (1) in its fit at the cover. Mount lever (4) together with plate (5) and operating
lever (1), in such a way that the reference notch
covers the one applied to the shaft (2) and fix the
Figure 287 lever by the nut (3).
26367
Mount cover (4), vent valve (1), the min. and max.
speed adjustment screws (2) and the max. throuhg- Figure 290
put adjustment screw (3).
Figure 288
19263
26341 Mount the key, the driving clutch (2), and the plain
washer; using the torque wrench (3) and tool
Mount the lower spring plate (4), the spring (3) and 75296068 (1), tighten the nut at 59 Nm.
the upper spring plate (2) at the shaft.
EW–3–87
2) Follow instructions given in the Iveco Technical Publications and Training no. XXXXXXXXX to carry out cor-
rect pump adjustment at the electrical test bench.
3) Measurements carried out on injection pumps fitted with “KSB” must be taken with KSB unit off.
6) To adjust the starting point (ARF valve) insert a spacer (12.0 mm) in connectino with the 3rd delivery stop.
SECTION 4 EX215
INDEX
Engine/Pumps Assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . EW–4–1
Engine/Pumps Assembly
Installation . . . . . . . . . . . . . . . . . . . . . EW–4–6
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . EW–4–7
EW–4– 1
ENGINE/PUMPS ASSEMBLY
REMOVAL
! CAUTION
Keep people not involved in the maintenance
work outside the working area. Wear adequate
personal clothes and glasses with side shields as
a protection against flying debris. 1
! WARNING
The hydraulic oil reservoir is under pressure. 2
Press the pressure relieve button (1) on the filler
plug to relieve pressure before maintenance.
Danger of personal injuries.
! CAUTION
The engine reaches high working temperatures.
Therefore, it is necessary to let the machine cool 3
down prior to carrying out this operation.
! CAUTION 6
Always disconnect the negative (–) ground ter-
minal first and reconnect it last.
! CAUTION 7
— Pressure fluid. Turn the cap slowly (7) before
removing it completely to relieve pressure. Do
not loosen the radiator cap when the engine is 8
hot to avoid burn hazard.
— Do not perform this operation when the ma-
chine is still hot. Contact with engine coolant at
working temperature may cause burns and
personal injuries.
10
Close the cab heater taps located on the engine,
then disconnect the related hoses from engine
side.
12 11
EW–4– 3
13
AIR CONDITIONER
! CAUTION
The air conditioning system hoses contain re-
frigerant gas under pressure. Wear adeguate pro-
tective clothes, gloves and glanes with side
shields, prior to operate on the system.
ELECTRICAL CONNECTIONS
HYDRAULIC PUMPS
Disconnect the suction pipe (16) from the hy-
draulic main pumps.
! CAUTION
Check that the hoist ropes are securely anchored
and that the anchor point is sufficiently strong to
sustain the load to be lifted. Keep any person
away from ropes or chains anchor point.
ENGINE/PUMPS ASSEMBLY
INSTALLATION
For the engine/pumps assembly installation
make reference to the procedures previously de-
scribed for the removal, but proceeding step by
step in opposite way.
TIGHTENING TORQUES
FILLING
3
4
EW–4–10
Install cover (1) ensuring that the filter and rod as-
sembly is correctly positioned. Tighten the bolts
to the torque of 50 Nm (37 lbf.ft). 1
IMPORTANT: Should the hydraulic pump remain
without oil, it would be damaged in a few seconds
after engine start–up.
Reinstall plugs.
CONTENTS
Specifications and data . . . . . . . . . . . . . EW–5–3 Replacement of engine flywheel
Fitting data . . . . . . . . . . . . . . . . . . . . . . . . EW–5–6 toothed wheel . . . . . . . . . . . . . . . . . . . . . . EW–5–32
Tightening torques . . . . . . . . . . . . . . . . . EW–5–12 Mounting of engine flywheel . . . . . . . . . . EW–5–32
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–15 Connecting rod–piston assembly . . . EW–5–32
Stripping down the engine in the Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–33
workshop . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–17 Piston diameter measurement . . . . . . . . EW–5–33
Repairs Piston pin . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–33
Cylinder block Check of correct fit between
Checks and measurements . . . . . . . . . EW–5–22 piston pin and piston . . . . . . . . . . . . . . . . . EW–5–33
Replacement of cylinder liners . . . . . . EW–5–23 Piston rings . . . . . . . . . . . . . . . . . . . . . . . EW–5–34
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–24 Connecting rods . . . . . . . . . . . . . . . . . . . EW–5–35
Bushes – valve lifters . . . . . . . . . . . . . . . EW–5–24 Check of rectangularity of
Cam pitch and bearing journal connecting rod . . . . . . . . . . . . . . . . . . . . . . EW–5–36
alignment check . . . . . . . . . . . . . . . . . . . EW–5–24 Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–36
Driven toothed wheel Mounting of connecting rod – piston
replacement . . . . . . . . . . . . . . . . . . . . . . . EW–5–24 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–36
Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–25 Connecting rod–piston mating . . . . . . . . EW–5–36
Bush replacement . . . . . . . . . . . . . . . . . . EW–5–25 Mounting of piston rings . . . . . . . . . . . . . . EW–5–37
Valve lifters . . . . . . . . . . . . . . . . . . . . . . . . EW–5–26 Adjustment of the mounting clearance
Replacement of valve lifters . . . . . . . . EW–5–26 of the connecting rod journals . . . . . . EW–5–38
Mounting of valve lifters – Mounting of connecting rod covers . . . . EW–5–38
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–26 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–38
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–27 Check and replacement of the
Main and connecting rod transmission gear wheel . . . . . . . . . . . . EW–5–38
bearing journals . . . . . . . . . . . . . . . . . . . EW–5–28 Replacement of bush for
Check of main bearing journal transmission gear wheel . . . . . . . . . . . . EW–5–39
alignment . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–29 Mounting of the transmission gear wheel
Replacement of driving toothed wheel and adjustment of the steering . . . . . . . . EW–5–39
steering and oil pump . . . . . . . . . . . . . . EW–5–29 Cylinder head . . . . . . . . . . . . . . . . . . . . . . EW–5–40
Mounting of main bearings . . . . . . . . . EW–5–30 Tightness check . . . . . . . . . . . . . . . . . . . . . EW–5–40
Crankshaft end play check . . . . . . . . . . . EW–5–30 Dismounting of valves . . . . . . . . . . . . . . EW–5–40
Rear flywheel cover . . . . . . . . . . . . . . . . EW–5–32 Check of cylinder head bearing surface
Engine flywheel . . . . . . . . . . . . . . . . . . . . EW–5–32 on cylinder block . . . . . . . . . . . . . . . . . . . . EW–5–40
CONTENTS
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–41 Injection pump installation and
timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–49
Removal of incrustration and valve
check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–41 Adjustment of the tension of control
belts: water pump – generator and
Valve grinding . . . . . . . . . . . . . . . . . . . . . . EW–5–41 fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–50
Check of clearance between valve Turbocharger . . . . . . . . . . . . . . . . . . . . . . EW–5–53
spindle and valve stem guide . . . . . . . . . EW–5–41 Description . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–53
Necessary checks before dismounting
Valve stem guide . . . . . . . . . . . . . . . . . . . EW–5–41
the turbocharger from the engine . . . . . . EW–5–53
Boring of inner surfaces Dismounting . . . . . . . . . . . . . . . . . . . . . . . EW–5–54
of valve stem guides . . . . . . . . . . . . . . . . . EW–5–42 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–55
Remounting of valves . . . . . . . . . . . . . . . . EW–5–43 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–57
Fuel system . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
Mounting of cylinder head . . . . . . . . . . . . EW–5–43
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
Mounting of valve lifter shaft and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
adjustment of working clearance
between valves and valve lifters . . . . . . . EW–5–45 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–59
Injection pump with RSV
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . EW–5–46 speed governor . . . . . . . . . . . . . . . . . . . . EW–5–60
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–46 L.D.A. device (delivery adjustment
as a function of load) . . . . . . . . . . . . . . . . EW–5–60
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–48
Pump marking . . . . . . . . . . . . . . . . . . . . . . EW–5–60
Oil pump assembly . . . . . . . . . . . . . . . . . . EW–5–48 Speed governor marking . . . . . . . . . . . . . EW–5–60
Cooling system . . . . . . . . . . . . . . . . . . . . EW–5–48 Speed governor . . . . . . . . . . . . . . . . . . . . . EW–5–60
High–pressure pumping elements . . . . . EW–5–60
Water pump . . . . . . . . . . . . . . . . . . . . . . . . EW–5–48
Delivery valves . . . . . . . . . . . . . . . . . . . . . . EW–5–61
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . EW–5–49 Pressure control valve assembly . . . . . . EW–5–61
Carrying out engine assembly at Fuel injector units . . . . . . . . . . . . . . . . . . . EW–5–61
work bench . . . . . . . . . . . . . . . . . . . . . . . . . EW–5–49 Calibration tables . . . . . . . . . . . . . . . . . . . . EW–5–63
EW–5–3
Type 8065.25.085
Turbocharged
turbocharged with aftercooler
∅
Diameter mm 104
Stroke mm 115
Max. output KW
107
CEE 80/1269 (HP)
(145)
rpm
2150
Max. torque Nm
558.6
(Kgm)
(60)
rpm
1600
B
C
50o
start, before B.D.C. D
16o
finish, after T.D.C. C
D
Timing check
mm 0.45
X
mm 0.45
X
Working clearance (*)
mm 0.25 ÷ 0.35
X
mm 0.25 ÷ 0.35
(*) Further adjustment to be performed when reading is
other than 0.15 to 0.45 mm
FUEL SYSTEM By feed pump – injection pump – filters – injectors –
thermostarter
Type PES6A90D410RS2757
α
Pump setting 18o ± 0.5o
X
Beginning of delivery mm 2.25 ÷ 2.35
DLLA 132S1320
Nozzle type
Injection order
bar
LUBRICATION SYSTEM Forced feed by gear pump, relief valve, dual action
oil filters
– max. opening
OIL FILLING
Quantity at periodical
replacements:
– engine sump
litres 9.3
Kg 10.5
Cylinder sleeve:
L 106.94 ÷ 106.97
Outer diameter ∅2
198.00 ÷ 198.50
Length L
∅
2
Cylinder sleeve – crankcase
0.04 ÷ 0.12
housing
∅3
Cylinder sleeve
X
Inner diameter ∅3 104.000 ÷ 104.060
Sleeve protrusion X
∅1 Pistons:
X Oversize dimension X 12
X
Piston protrusion X 0.64 ÷ 0.97
X1 X1 3.20 ÷ 3.23
X2
Piston ring grooves X2 2.55 ÷ 2.57
X3
X3 4.03 ÷ 4.05
EW–5–7
S1 S1 2.932 ÷ 2.963
S2
Piston rings S2 2.490 ÷ 2.478
S3
S3 3.990 ÷ 3.975
1 0.537 ÷ 0.598
3 0.040 ÷ 0.075
∅4
Small end bushing
∅3 Outer dia. ∅4 41.979 ÷ 42.017
Measuring dimension X
125
Max. connecting rod
axis misalignment
tolerance
0.07
8065.25.085
mm
∅1 ∅2
79.791 ÷ 79.810
Main journal diameter ∅1
63.744 ÷ 63.725
Crankpin diameter ∅2
2.169 ÷ 2.178
Crankshaft bearings S1
S1 S2
1.805 ÷ 1.815
Big end bearing thickness S 2
Main bearings ∅3
∅3 84.200 ÷ 84.230
X2
X3 Thrust washer
3.378 ÷ 3.429
thickness X3
1 2 1 ≤ 0.10
Alignment
2 0.03
Ovalization 1–2 0.015
∅1
∅2
∅2 8.023 ÷ 8.043
Valve guide
∅3 13.993 ÷ 14.016
∅3
∅4 Valves:
∅4 7.985 ÷ 8.000
60o 30’ ± 7’
α
∅4 7.985 ÷ 8.00
45o 30’ ± 7’
α α
Valve stem and guide 0.023 ÷ 0.058
∅1
–
∅1
∅1 39.000 ÷ 39.025
∅2
–
α 60o ± 5’
∅2
α 39.136 ÷ 39.161
α 45o ± 5’
H H1 Under a load of
H2 270 ± 14 N H1 34
528 ± 26 N H2 23.8
∅ 6
Cam shaft journal diameter
51.470 ÷ 51.500
∅5
50.970 ÷ 51.000
∅6
50.470 ÷ 50.500
∅7
49.970 ÷ 50.000
∅ 5 ∅ 7 ∅8
Camshaft bushing
∅1 outer diameter:
∅2 front ∅1 55.375 ÷ 55.430
∅3 front intermediate ∅2 54.875 ÷ 54.930
rear intermediate ∅3 54.375 ÷ 54.430
rear ∅4 53.875 ÷ 53.930
Camshaft bushing
∅1 inner diameter:
∅2 51.580 ÷ 51.630
front ∅1
∅3 front intermediate ∅2 51.080 ÷ 51.130
rear intermediate ∅3 50.580 ÷ 50.630
rear ∅4 50.080 ÷ 50.130
Bushing and housing in
0.07 ÷ 0.15
engine block
Cam lift:
H H
5.97
H
6.25
EW–5–11
8065.25.085
mm
∅1
Tappet washer bore ∅1
15.000 ÷ 15.018
∅2 ∅3
14.950 ÷ 14.970
∅ 1
Valve lifter diameter ∅1 17,982 ÷ 18,000
112
105
98
91
84
77
70
63
56
49
42
EW–5–13
Removal
Intake
Disconnect
Re–fit in place
Exhaust
Connect
Removal
Operation
Disassembly
Fitting in place
Assembly r Compression ratio
Tolerance
Driving torque
Weight difference
Replacement
Caulk
Original spare parts
Regulation
Rotation
Adjustment
Caution Angle
! Note Angular value
Visual check
Pre–load
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Oversizing
Interference
Greater than...
Strained assembly
Maximum
Undersizing
Thickness
Smaller than...
Clearance
Minimum
Lubricate Selection
Damp Classes
Grease Oversizing
Temperature < 0o C
Sealant Cold
Winter
Temperature > 0o C
Air vent Hot
Summer
EW–5–14
STRIPPING DOWN THE ENGINE IN THE - Disconnect the check rod sleeve (3);
WORKSHOP - Put the engine on the revolving stand 75301124,
Using a suitable lift and some ropes, keep the en- fixing it to the brackets 75301426.
gine suspended, then apply brackets 75301426
after the operations described below:
When handling the engine, keep at a safe
- Remove the supports (2); ! distance in compliance with the accident–
- Drain oil from the engine; prevention standards.
- Remove the heat exchanger (1) and its pipes;
Figure 1
47280
Figure 2
Figure 3 47282
47281
1. Air pipeline – 2. Fuel pipes – 3. Intake manifold – 4. Fuel filter – 5. Accelerator tie rod – 6. Starter motor – 7.
Elettric stop device – 8. Fuel pump – 9. Water pump – 10. Belt tightener – 11. Air intake pipe – 12. Pipe fixing
bracket – 13. Fuel return piping – 14. Pulley support – 15. Belts – 16. Fan – 17. Alternator – 18. Turboblower –
19. Oil filters – 20. Exhaust manifold.
EW–5–19
- Loosen the belt tightener (10); On the front side remove the thermostat unit (1) ex-
tracting it from the water pump, then remove the
- Loosen the alternator fixing screws (17, pump (2) after having previously removed: the pipe
Figure 3). from the heat exchanger and the drive pulley (previ-
ously loosened), remove the perimeter screws on
the pulley, then extract the pulley (4) and the fly-
wheel damper (3).
NOTE – The fan driving belt is self–ventilated.
Figure 6
Figure 7 Figure 10
47309 32702
Remove the hub (1) of the flywheel damper using Put aside the valve lifter control rods (1) and covers
tool 75301437 (2). (2) on valve spindle.
Extract the retaining screws (3) of cylinder head (4)
and remove the head keeping its gasket.
Figure 8 Figure 11
32700 47324
Remove the valve lifter cover (1). Turn the engine by 180° and remove the oil sump
(1), keeping its gasket.
Figure 9 Figure 12
32701 47310
Remove the injector (1) and the entire shaft (2). After removing tool 75301432 (Figure 4), loosen the
screws and remove the flywheel, then remove the
cover (1).
EW–5–21
Figure 13 Figure 16
32704 32709
Dismount oil suction pipe (1), the oil feed pipe (2) Detach the fastening screws (1) of the main bearing
and the control toothed wheel cover (3). covers (2) and remove them.
Figure 17
Figure 14
32710
32705
Using tool 75301429 (1) lift and remove the cran-
shaft (2); put aside main bearing shells and shoulder
Using round pliers (2) remove spring ring (3) and pull semi–rings.
off the transmission gear wheel (4). Remove the oil
pump (1). Remove the injection pump driving wheel
(5).
Figure 18
Figure 15
32711
Figure 20
NOTE – Clean carefully all disassembled parts and
check their integrity after stripping down the engine.
On the following pages instructions for the main
1. MEASURING
checks and measuring are given, which have to be
carried out to determine whether the parts can be
used again for mounting.
2. MEASURING
REPAIRS
CYLINDER BLOCK 3. MEASURING
20581
NOTE – Because of its ductility, the cylinder liner must
never be measured inside when dismounted; the inner DIAGRAM FOR CHECK OF CYLINDER LINER
diameter must be measured at a completely mounted DIAMETER
liner.
Figure 19
Each single cylinder must be measured at different
heights of the liner and at two surface planes rec-
tangular to each other; one of these surface planes
is parallel to the longitudinal axis of the engine (A)
and the other is perpendicular to it (B); generally at
the surface plane (B) and at the height of the first
measurement, the cylinder liner is worn most.
Ovalness, conical form or wear can be removed by
regrinding of the liners for a little wear or slide fur-
rows; for deep furrows or marked ovalness the
bored liners must subsequently be surface–ground.
Figure 21
32579
32713
32715
CAMSHAFT
BUSHES – VALVE LIFTERS
Figure 26
1403
MAIN DATA OF THE CAMSHAFT
The surfaces of the bearing journals of the shaft and scoring and furrows, the shaft and their correspon-
the cams must be completely smooth; if they have ding bushes must be replaced.
32718
32719
32717
Check that the toothing of the driven toothed wheel
Always with the camshaft (4) between centers (1), (1) is not excessively worn or damaged, otherwise
check alignment of the bearing journals (3) with a replace it. In order to mount the new toothed wheel,
1/100 gauge (2); this alignment cannot exceed it must be heated up to 180 °C in the furnace for
0.020 mm. If the measured value exceeds 0.020 about 10 minutes and then drawn upon the shaft (4)
mm, replace the shaft. together with the plate (3) and the curved washer
(2).
EW–5–25
BUSHES
The surfaces of the bushes must have no signs of
seizing or scores, otherwise they must be replaced.
Figure 31
1403
MAIN DATA OF THE BUSHES FOR CAMSHAFT AND RELEVANT CRANKSHAFT SEATS
BUSH REPLACEMENT
Figure 32 Figure 33
32720 32587
Figure 34 Figure 36
32721
Figure 37
VALVE LIFTERS
The valve lifters are delivered as normal spare parts
and oversized by 0.10 – 0.20 – 0.30 mm.
Figure 38
32795
are required and the seats (2) must be bored by an Lubricate the camshaft bearings and insert the shaft
appropriate reamer (1). (1) into the crankcase.
EW–5–27
Figure 39
32724
CRANKSHAFT
Figure 40
20400
MAIN DATA OF THE CRANKSHAFT MAIN AND CONNECTING ROD BEARING JOURNALS
EW–5–28
MAIN AND CONNECTING ROD BEARING NOTE – The measurement carried out at the main or
JOURNALS connecting rod bearing journals must be indicated by
Masure shaft journals (2) by means of a micrometer a stamp at the side of the crank web No. 1.
caliper (1) before grinding of journals, and determine For undersized conn. rod b. journals: letter M
by means of the bearing smaller dimension scale (7) For undersized main bearing journals: letter B
which journal diameter must be obtained by grind- For undersized c. rod and main b. j.: letter MB.
ing.
The smaller dimension classes are 0.254 – 0.508
mm. Figure 43
Figure 41 ROLLED
21177
ROLLED
32725
21178
NOTE – All main and connecting rod bearing journals DETAIL OF THE CONNECTING ROD BEARING
must always be ground to the same smaller dimension JOURNAL CONNECTIONS
class in order to avoid out–of–balance of the shaft. Figure 45
Figure 42
ROLLED
21176
32726
Figure 46 Figure 48
ÇÇÇÇ
ÇÇÇÇ
MAIN BEARING JOURNA
32597 2219
Check that plugs (2) of the lubricating circuit are not - Connecting rod bearing journal alignment re-
leaky for an inner pressure of 15 bar, otherwise re- ferred to main bearing journals: the axis of each
place plugs by means of an appropriate driving man- connecting rod bearing journal pair and the axis
drel. of the main bearing journals must be at one
place: max. permissible tolerance perpendicular
to this plane ± 0.25 mm.
- The maximum admitted tolerance for the dis-
tance between the rotation axis of the shaft and
the outer surface of the connecting rod bearing
journals is + 0.10 mm.
32599
32727
32730
Figure 51
Figure 53
NOTE – The screws must be lubricated.
Figure 56
32603
Figure 54 32779
32731
Figure 57
Figure 55
32732 32733
Tighten the fastening screws (2) by means of a Place the indicating caliper (1) with magnetic base
torque wrench (1) to a tightening torque of 80 Nm. and check end play.
EW–5–32
Figure 60
47312
Insert a new seal ring (1) on the flywheel cover (2). 47313
Figure 59
47314
ENGINE FLYWHEEL
Replace the toothed flywheel ring if the teeth of the PARTS OF THE CONNECTING ROD – PISTON
toothed flywheel ring mounted on the engine fly- ASSEMBLY
wheel to start the engine are very damaged. Before 1. Reatining rings – 2. Pin – 3. Piston –
mounting, the thoothed flywheel ring must be heated 4. Piston rings – 5. Screw – 6. Bearing shells –
up to a temperature of 80 °C. 7. Connecting rod – 8. Bush.
EW–5–33
Figure 63 Figure 66
32616
32618
32614
Take off locking rings (2) of piston pin (1) by means Measure the piston pin diameter (1) by a micrometer
of a center punch (3) as shown in the figure. (2).
Check of correct fit between piston pin and
PISTON piston
The pistons are delivered as spare parts with stan-
Figure 68
dard size or oversized by 0.4 – 0.6 – 0.8 mm.
Piston diameter measurement
Figure 65
32619
Figure 69
47318
MAIN DATA OF THE PISTON, THE PISTON RINGS AND THE PISTON PIN (ENGINE 8065.25.085)
* Values are measured on 101–mm ∅.
PISTON RINGS
The piston rings are supplied as spare parts with
standard diameter size or oversized by 0.4 – 0.6 –
0.8 mm for the seal ring and the 2nd oil scraper and
by only 0.6 mm for the 1st oil scraper.
Figure 70 Figure 71
16552 32620
Check the piston ring thickness (2) by means of a Check clearance between piston rings (3) and corre-
micrometer (1). sponding grooves (2) on the piston with a feeler
gauge (1).
EW–5–35
Figure 75
3513
20584
The seal ring (2) of the 1st piston groove has a trap-
ezoidal cross section. The clearance between the
sealing ring and the seat is determined as follows:
arrange piston (1) with the corresponding ring in the
cylinder liner (3) in such a way that the sealing ring
projects from the cylinder liner by a half.
Figure 73
32737
Figure 74 Figure 76
16556
32738
Check that axes of the connecting rods are parallel.
The permissible tolerance is 0.07 mm, measured at
a distance of 125 mm from the longitudinal axis of
the connecting rod.
NOTE – Each connecting rod has to be provided – on
the body and cover – with a number corresponding to 32627
the cylinder on which it must be mounted. Therefore,
in case of replacement, the new connecting rod must
be marked with the same number. NOTE – The piston (2) must be mounted in such a
way that the lettering “VALVE LIFTER SIDE” (1) at
BUSHES the top is placed opposite to the number (4) punched
Figure 78 into the connecting rod.
Insert the piston pin (3) and mount the spring rings.
32625
Figure 79
32628
32631
32613
REPRESENTATION OF THE FIT BETWEEN
Use pliers 75301434 (3) to mount the piston rings (1) CONNECTING ROD AND PISTON FOR
in pistons (2). The rings must be mounted with the MOUNTING THE ASSEMBLY INTO THE CYLINDER
lettering “TOP” to the top; furthermore the joints in 1. Piston - 2. Combustion chamber - 3. Stamp area
the rings must be aligned in such a way that they ae for the number of the cylinder to whcih the
offset by 120° to each other. connecting rod belongs - 4. Camshaft.
The arrow indicates the direction of rotation of the
engine, as viewed from the steering side.
NOTE – The connecting rod screws can be used as
long as the thread diameter measured between 19
and 35 mm from the screw head is not lower than 10.5
mm.
Figure 85
Figure 83
47315
32740
STEERING
REPLACEMENT OF BUSH FOR TRANS- Mounting of the transmission gear wheel and
MISSION GEAR WHEEL adjustment of the steering
Figure 90 Figure 92
47316
32637
Rotate the crankshaft and place the piston of the cyl-
Check the contact surfaces of the bush (1): they inder No. 1 in the compression stage in the T.D.C.
must not have furrows or score grooves; otherwise This position is reached when the pointer (2) points
the bush (1) must be replaced by means of a suitable to the “O” (1) that is punched onto the engine fly-
driving mandrel. wheel.
Figure 93
32742
Figure 91 Shrink on the transmission gear wheel (2) and align
it in such a way that the marks 1 - 2 and 3 punched
into it cover the marks on the driving toothed wheel
(1), the camshaft driven toothed wheel (3) and the
injection pump driving toothed wheel (4).
Figure 94
47320
32638 Mount the cover (3) for steering gear.
Apply tool 75301432 on the engine flywheel to pre-
After mounting, the bush (1) must be bored in order
vent it from rotating.
to obtain the diameter given in the drawing (*).
Mount the hub (1) with the locking plate: tighten the
nut by a torque wrench (2) at 300 Nm, bend the lock-
ing plate (4).
(*) Value to be obtained after mounting of bush.
EW–5–40
CYLINDER HEAD Figure 98) of the springs in order to pull out the cone
halves (4) and detach the valves; pull out the upper
Figure 95 spring plate (6), the springs (3) and the lower spring
plate (5). Repeat this for all valves. Turn the cylinder
head and pull out the valves.
Figure 98
32743
Tightness check
Figure 96
32643
32744
Figure 99
DISMOUNTING OF VALVES
Figure 97
32746
18625
32747
Figure 101
VALVE STEM GUIDE
Figure 103
INTAKE EXHAUST
20397
32748
32647 32749
MOUNTING VALUES OF VALVE STEM GUIDES Using the “Hunger’’ tool 75301453 (1), refinish valve
seats at the cylinder head so that maximum sealing
is obtained.
NOTE – The valve seats on the cylinder head have to
be ground if the valves or valve stem guides are
ground or replaced.
Figure 107
Boring of inner surfaces of valve stem guides
EXHAUST INTAKE
Figure 105
VALVE.
SINKING
20585
32750 32745
The valve sealing of the cylinder head (1) is checked Mounting is carried out performing the same steps
with a suitable tool (2 and 3). of the dismounting but in reversed order.
16587
Before mounting, the elasticity of the valve springs Mounting of cylinder head
is checked by means of tool 75301440; compare the
load data and the elastic deformation data with
those of the new springs that are indicated in the fol- Figure 112
lowing figure.
Figure 110
18929
20398
Before reusing the cylinder head fastening screws
(2), measure by a micrometer screw (1) that the
MAIN DATA FOR CHECKING OF VALVE thread diameter of the screws is not lower than 11.5
SPRINGS mm at any point; otherwise the screws must be re-
placed.
EW–5–44
32754
32752
- 1st step, by means of a torque wrench (1), per-
tighten to a tightening torque of 70 Nm;
For mounting and tightening the cylinder head, ob-
serve the following: - 2nd step, tighten again to a tightening torque of
70 Nm;
- mount seal (1) in the crankcase, with the letter-
ing TOP (2) pointing to the mechanic; - 3rd step, place tool 75301460 (1) on the socket
Figure 114 wrench and tighten with an angle of 180_.
Figure 117
6935
32655
PATTERN OF THE TIGHTENING ORDER OF
THE CYLINDER HEAD FASTENING SCREWS IN The control rods of the valve lifters must not be de-
THE CRANKCASE formed. The ball seats which can have contact to the
valve lifter adjusting screw and the valve lifter (ar-
rows) must be free from score grooves or wear;
otherwise they must be replaced.
Figure 115 The rods which operate the intake and exhaust
valves are identifical and can be exchanged.
Figure 118
47317
Figure 119
32658
Figure 120
32657
MAIN DATA OF THE BEARINGS OF THE VALVE LIFTER SHAFT AND THE VALVE LIFTER
32756
Check the perfect sealing of the plugs mounted at Mount cover (1) to the valve spindle.
the shaft end.
EW–5–46
OIL PUMP
Figure 124
32757
32662
Cylinder No. 1 2 3 4 5 6
Intake * * – * – –
Exhaust * – * – * –
EW–5–47
Figure 125
6960
Figure 126 Check that gear (5 - 17 Figure 125) and gear (7) are
not worn or damaged; otherwise, replace the com-
plete pump.
Check that valve (11, Figure 125) slides freely in its
seat without any scoring or pick–up. Also check
pressure–relief valve spring (10) against those indi-
cated in Figure 128.
Valve opening starts at: 6 bar; valve opening ends at:
11 bar.
32663
Figure 127
32664 32665
47324
Refit the oil sump (1) with a new gasket using an ap-
propriate sealing compound.
COOLING SYSTEM
WATER PUMP
32666
Water pump is of the centrifugal vane type. Pump
OIL FILTER CROSS SECTION bearing is solid with the blowing spindle.
Figure 132
Figure 130
32668
32759
NOTE – Check that pump body is not cracked or that
Fit the oil pump (2) and suction (1) and delivery (3) thre are no water leaks; otherwise replace the entire
pipes. pump.
EW–5–49
47319
Figure 133
Figure 135
47321
Figure 136
PRESSURE UNION
DELIVERY VALVE
SPRING
DELIVERY VALVE
47323
Figure 137
1. Fan – 2. Belt tightener (3) – 3. Fan driving belt –
4. Driving shaft pulley – 5. Water pump – 6.
Generator – 7. Generator driving belt.
Mount the injection valves (2) Figure 140 and the starter motor, (6), the suction manifold (3) the in-
tighten the fastening nuts in two steps: jection pump – injector pipes (2) pipeline (9); re–con-
pretightening at 9.9 Nm – final tightening at 22.5 Nm. nect all the other recovery pipes, always replacing
Mount the valve lifter cover (3), the exhaust manifold the seal washers, re–connect the fuel filter assembly
(1), the turbocharger (4), the oil filters, according to (4), the accelerator tie rod (5); mount the suction
the instructions given at pag. 48. pipe (11) fixing the bracket (10) to the valve lifter
cover; finally, remount the fan (8).
On the opposite side, Figure 141, mount:
Figure 140
47281/A
Figure 141
47282/A
EW–5–52
Lift the engine from the revolving stand for overhaul Remount the exchanger with the related pipeline (1)
by means of an appropriate hoist and some ropes conneting the pipeline to the water pump, then re-
and, on the flywheel side, if necessary, remove the mount the supports (2) and the oil level rod sleeve
flywheel clamp, then remove the brackets (3).
75301426. Then fill with oil according to the indicated quantities.
Figure 142
47280
EW–5–53
Figure 143
8862
Figure 145
33578 33580
The turbocharger has to be carefully cleaned out- Fix the appropriate wheel locking tool (3) in the vice;
side by means of anticorrosion or antirust fluids. Fix place the shaft–wheel assembly end and detach the
the turbocharger in the vice. self–locking nut (1) by a suitable wrench (2).
Using a suitable tool (1) provided with an indicated
caliper, check the axial play of the rotating aggregate
(2) which must be equal to 0.025 ÷ 0.10 mm. Figure 148
Align the locking plates; mark the position of the
compressor housing and the turbine housing re-
ferred to the central part; loosen the screws and re-
move the housings.
Figure 146
33581
Figure 149
33579
33582
Always using a suitable tool (1) with a special exten-
sion, check the radial play of the rotating aggregate Extract the turbine shaft–wheel unit (1) together with
(2) which must be equal to 0.075 ÷ 0.18 mm. the seal ring (2) from the central part (3).
EW–5–55
33583
Figure 154
33584
33585
Figure 155
8863
33588
33592
33589
On the central part (3), mount the inner spring rings
- the bearings are free from score grooves or fur-
(2) in their seats by means of round pliers (1).
rows in the parts indicated by the arrows;
Figure 161
Figure 158
33593
33594
33595
Figure 164
33596
Mount the rear bearing (1) on the central part (2): the
reference marks applied during dismounting must
cover each other; mount the locking plates, fix the
screws and bend the locking plates.
EW–5–59
19195
Figure 168
INJECTORS
Dismantling
Figure 166
16689
19282
On each piston there is a one–way delivery valve The fuel injection unit is used to atomize the fuel to
which allows fuel at the injection pressure to flow allow for correct combustion. The injector must cor-
within high–pressure pipes preventing it from flow- rectly send clean fuel into the combustion chamber
ing back. The valve is also used to rapidly reduce with an optimized jet.
pressure in the injection line after the pressure The nozzle is placed inside a support. To allow the
coming from the piston has ceased. A rapid pres- fuel to enter correctly the combustion chamber,
sure decrease is necessary for the injection valve to centering pins are provided which direct the nozzle
snap in order to avoid any leakage of fuel that may inside its support. A ring bracket directs the support
cause coking to be generated on the injector end. within the engine cylinder head.
Figure 169
47283
EW–5–62
CONTENTS
STARTER MOTOR . . . . . . . . . . . . . . . . . . EW–6–3 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . EW–6–9
Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW–6–3 Quick diagnosis . . . . . . . . . . . . . . . . . . . . . EW–6–9
Magneti Marelli MT67CB–4kW . . . . . . . . EW–6–4 Bosch NL1 28V 10/55A . . . . . . . . . . . . . EW–6–9
Test and checks on the vehicle TEST AND CHECKS ON THE VEHICLE EW–6–11
Current absorption test . . . . . . . . . . . . . . . EW–6–5
Maximum output test . . . . . . . . . . . . . . . . EW–6–11
Voltage drop test on the circuit . . . . . . . . EW–6–5
Pressure drop test on the circuit . . . . . . . EW–6–11
Excessive voltage drop test on the
circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–5 Voltage drop test on the earth
Starter motor earth test . . . . . . . . . . . . . . EW–6–6 circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–12
Voltage drop test on the solenoid Voltage regulator calibration
contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–6 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . EW–6–7 Alternator belt tensioning . . . . . . . . . . . . . EW–6–12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–7 Disassembly and bench test . . . . . . . . . . EW–6–13
Bench test . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . EW–6–13
EW–6–3
MARELLI MT67CB–24V–4Kw
Quick diagnosis
3820 3821
6,5
19
26,8+0,8
43,2 +0,8
21282 3823
CHARACTERISTIC CURVES PINION ADJUSTMENT
1. PINION CONTROL
ELECTROMAGNET
1 2. INDUCTORS
3. DRIVE SIDE SUPPORT
4. STARTER MOTOR
SUPPORT
3 2
5. FRAME
6. BRUSH HOLDER
4 7. COVER
8. MESHING FORK
5 AND PINION
9. ARMATURE
8
9
924
EXPLODED VIEW
EW–6–5
Excessive voltage drop test on the circuit VOLTAGE DROP TEST ON CIRCUIT AND
To carry out the excessive voltage drop test on the CONNECTIONS
circuit proceed as follows: Figure 3
- connect the positive clip of the external volt-
meter cable to the positive terminal of the battery
and the clip of the negative cable to the 30 ter-
minal in the starter motor (Figure 3);
- position the test selector on ”EST” (external);
- prevent the engine from starting and operate the
starter motor.
Check that the voltage read on the digital voltmeter
does not exceed 0.5V. If it does not, the circuit is effi-
cient.
3841
3842
Figure 5
In addition to the above tests, to find a fault in the If a visual inspection shows that the armature mani-
starter motor, it is possible to perform bench tests fold requires grinding, due to eccentricity, use a
with appropriate test equipment. hard–steel tool for turning.
It is necessary to make use of the manufacturer’s If the windings are removed, mark the pole pieces.
data to compare them with the results found. Lightly heat the new windings and assemble them
Disassembly making reference to the marks put during the disas-
sembly operation.
Clamp the starter motor in the vice provided with If you have to carry out checks by a tester, lean the
lead vice caps. Disassemble the motor proceeding pole frame on a working level that is insulated from
as described below. both the bench earth and the ground.
Replace all relays with worn or damaged working
contacts.
Special attention must be paid during the armature
insulation test.
Vibrations in the steel reed on the armature pack
indicate a shorted armature or inaccurate mica re-
NOTE – To facilitate some disassembly operations moval. If the mica removal is accurately carried out,
only use a plastic hammer. a perfect U shape must be obtained.
Assembly
Remove the control relay and put aside the com-
pensation plate. During assembly, make sure that the armature (pro-
vided with brushes) rotates freely.
Remove the brush holder support making sure not
to damage the winding terminals. Check that the brushes correcly slide in their seats
and check the spring pressure on the brushes (1.2
When disassembly is completed, wash the disas- Kg).
sembled parts using only liquids for electrical com-
ponents: benzine, solvents, trichlorethylene. Also check the spring on the engagement bar.
Lubricate the bright parts with anticorrosive oils and
slighly grease the pinion with a specific grease.
22649
Voltage curve. The voltage curve depends on the
BENCH TEST status of the batteries at the bench and is a function
of the current absorbed by the starter motor.
If the values measured at the bench highly differ
from test data, the motor is defective.
When assembly is completed, check that the pinion
runs freely by operating the engagement relay; also Repeat the disassembly sequence and check each
make sure that the armature rotates freely. single part.
Special attention must be paid to the polarity
jumpers of the brushes. Also check the winding ter-
minals with regard to both the brushes and the con-
trol and engagement relays.
Make sure that the winding terminals are not, or run
the risk of being caused by vibrations, to be short cir-
cuited with the pole frame, the armature or the brush
holder.
Bench test
Firmly fix the starter motor (provided with the mani-
fold side protection cover) to the test bench with the
appropriate fastening chains.
Connect the power cables to the corresponding ter-
minals in the starter motor observing their polarity.
If the values highly differ from the data shown on the
characteristic curves, disassemble the starter motor
and check each single part again.
BOSCH NL1–28V–10/55A
2817
Quick diagnosis
Failing to charge 1. Charging circuit cut off Check the connections of the
(warning light, fuse, charging circuit, clean and
connector, etc.) tighten the terminals on alter-
nator and battery
2. Inefficient voltage regulator Replace the component
3. Rotor winding cut off Replace the component
4. Worn brushes Replace the component
2822 3862
2820 2819
20 13. STATOR
14. SCREW WITH WASHER
19 15. RECTIFIER
12 16. BUSHING
14 17. SUPPORT
17 18. GROMMETS
19. NUTS
20. GASKET
15 16 21. CONDENSER
11 22. WASHER
10
13 23. SCREW
24. BRUSH HOLDER REGULATOR
25. SCREW
924
EXPLODED VIEW
EW–6–11
PRESSURE DROP TEST ON THE CHARGING - connect the main cables of the vehicle to the bat-
CIRCUIT teries observing their polarity;
Figure 9 - connect the external voltmeter with the negative
clip to the POSITIVE terminal of the battery and
connect the positive clip to either 30 or B+ on the
alternator;
- position the test selector on EST (external);
- connect the inductive clip to the alternator cable
observing its polarity and the direction of the
arrow;
- accelerate until current output is equal to 10A.
Read the voltmeter value: it must not exceed 0.6V if
the circuit and related connections are efficient.
3868
To carry out the voltage regulator calibration test VOLTAGE REGULATOR CALIBRATION TEST
proceed as follows:
- connect the external voltmeter cables to the bat- Figure 11
tery terminals observing their polarity;
- position the selector on EST (external);
- connect the inductive clip to the alternator cable
observing its polarity and the direction of the
arrow;
- start the motor and accelerate it until the am-
meter value is slightly below 8A.
Check that the voltmeter value corresponds to the
Manufacturer’s value.
Alternator belt tensioning
To put under tension the alternator belt, proceed as
follows:
- loosen the fastening nuts of the alternator sup-
port and tensioning bracket (see Figure 11);
- insert a lever between the alternator and the 3870
motor so that the control belt is appropriately
stretched;
ALTERNATOR BELT TENSIONING
- tighten the 2 alternator fastening nuts, closing
first the nut relevant to the adjustment slot;
- make sure that the belt, which is put under ten-
sion in the medium section, bends by about 10
mm.
EW–6–13