ENGINES 0. Fun 005 1 CONTENT OF SECTIONS Section General nforation 1 Feed 2 Dury —Industsl appliations Mechanical injection Engines 3 ‘Overhaul and technical specications 4 Exuipment 5 Intaltion guidelines Safety instructions Appen PREFACE TO USER'S GUIDELINE MANUAL Section | describes the engine iustrating its features ‘and working in general | Section 2 describes the type of ful feed | Section 3 relatesto the specific duty and isvided in four sepa- rate parts |. Mechanical part, related to the engine overhaul lenited to those components with diferent characteristics based on the relating spec duty, 2. Electrica part, concerning wiring harness, electrical land electronic equipment with diferent characteristics based on the relating specific duty, 3. Maintenance planning and specific overhaul 4.Troubleshooting part dedicatedto the operators who, being entitled to provide technical assistance, shall have simple and rect instructions to identify the cause ofthe major incorwe Sections 4 and 5 illustrate the overhaul operations ofthe eng)- ne overhaul on tandandthe necessary equipmentto exeaute such operations. Inealtion general presriptions are reported within the ap pendix, Such prescriptions shall be strict followed by the operators in-charge of instalation to avoid incorrect working as well as serious falures which may reduce performance and lif ofthe engine Furthermore, the appendix reports general safety prescrip- ions tobe followed by all operators whether beingin-charge ofinstalation or maintenance, in order to avoid serious injury.FD. FEBUARY 200 ENGINES‘Where possible the same sequence of procedures has been followed for easy reference. Diagrams and symbols have been widely used to gve a clearer and more immediate llustation of the subject being dealt with, (ee Feu 2000 SPECIAL REMARKS ‘ext page) instead of ging descriptions of some operations or arocecures. Example © | = housing for connecting rod smal end bush © 2 = housing for connecting rod beaings Tighten to torepie Tighten to torque + angular valveA FD. FEBUARY 200, Beane Graph and symbols Ty] keno! inate IEEg] Disconnection cf " 2 Refitting Exhaust Eq} Comesion es i Ce) money Sorin (ES) fare pee =o mine Stowe [D] Teron eee] Wee dtrence | [GQ] Terertotrge + rte fling tonne Bl) Pres orca FT] Regulation Fy| oh| See, Jj een 7 Warning E ange AR a ‘Angular value P ‘Visual inspection o ( ae TURBOCHARGER > Ly exaust om EERE AIR FILTER al GB must vom] VLESSS | Description “The turbocharger is composed by the folowing main parts: cone turbine, one transforming vale to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine dik wheels rotation. ‘The compressor rotor, being connected by shaft to the turbine dsk wheel, rotates as long a: this last one rotates, compressing the sucked ar through the air fiter “The above mentioned airis then cooled by the radiator and flown through the piston induction collector TURBOCHARGER, The turbocharger is equipped with a transforming vale to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector Its duty isto choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value The cooling process and the lubrication ofthe turbocharger and ofthe bearing: is made by the ol of the engine12. SECTION | ~GENERAL SFECIRCATIONS ‘fo Fenuny 200 ENGINESENGINES .Fenuary 2005, SECTION 2~ SECTION 2 INJECTION FEED SYSTEM BY MECHANICAL, ROTARY PUMP FEED PUMP PRIMING PUMP FUEL FILTER INJECTION FEED SYSTEM BY MECHANICAL, PUMP UNIT FEED PUMP FUEL FILTER ED2 SECTION 2 ~FeE0 Ep, Femua 200 ENGINESBRINE en FEMUR 20 SECTION? -FED 3 | INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP General information Fuel feed system is composed by- 1 Fuel tank (placed on the machine) D1 Fuel delivery and backflow to tank C1 Fuel pre-fiter (ravailable, ti usually placed close to the ngine on the machine frame) G1 Priming pump, assembled to the engine and driven by the camshaft Fuel fier (assembled to the engine in diferent postions according to equipment application and duty) Injector feed pipatine (Form fuel feed pump to injectors) OD Injectors | njector eed pipes ~2. Fuel exhaust pipes fom injectors ~3, Fue feed rotary purnp ~4. Connector for LDA pressure _uge pipe within suction collector ~ 5, KKSB thermal bulb ~ 6, Electro-vale ~7. Injector0, euay 200 ENGIN Figura 2 |. Fuel fiter ~2. Feed pipeline from fer to fuel pump ~3. Feed pipelne from priming pump to fiter ~. Priming pump Description of working principles Fuels sucked from the fue! takby the priming purnp. This last| _| The fuel arrives therefore tothe vahe gauging the pressures ‘one ie placed on the engine basement andis driven by the camn-| | de feed purnp. fee ‘The cstbution puner further increases this pressure and de “Throughout the fiters the felis piped tothe union ting va-| _|lversfuel throughout the delvery pipe iting to the njectors. uur chamber of the transfer pump. For applications t0 be] | the tt raving or 2 a luc drawing from the injectors is recovered and delivered equipped in cod chat areas the fel fer prowded wih] | Teel dawn heater), "Transfer pump is placed inside the eed purnp, andis bladed ty-| sits duty isto increase fuel pressure in correspondence with | {the increase of the number of revolutions,FEED PUMP VE 412 11901 rotary ype pump is driven by a gear mating the cemshalts one. w 1 = Pump dimensions = 4 lindars engine = Distrbution rotary plunger = Distribution plunger in mn, 1150 = Number of pump revolutions per minute = Leftdrection of otaton Figura O.FEBUARY 2002 Diafram 2, Locking nut 3. Pot 9, Advance converter scowone FEED 5. 7 8 Uy) 2 ¢ i O) AES Z TOU ES Li, Low (=e) hoon pun tal seen 4. Drive lever 5, Speed gauge 6. Tanster pump —_7. Drive shaft 8. Cam disk 10, Distribution plunger 11. Delivery pipe fiting 12. Hydraulic head 13. Drive plate 14, Gauge pin 15. Countractng spring,6 SECTION? FEED eo reauary 200 PRIMING PUMP “This pump has the specific duty to prime the fuel avalable in the tank and convey it to the feed purnp inet. is assembled to the engine basement and driven by the carehaf. “The picture here following shows the purnp (I) and the position that the pump dive lever assumes depending on the camshaft rotation (2) and on ite eccentricity Figura 4 qH L| ——s / |. Priming purnp ~2. CanshaftENGINES ED. FEMUARY 20s section? Fem FUEL FILTER ‘The teri assembled cose tothe fed and priming pump and hes the specie duty to provide barrier tothe impurities and separa- ‘tion of water from fuel ‘On the fiter cartridge base () there is a water dump screw, throughout which it possible to provide regular drainage: on the ‘bearing (I) for those equipment applications requiring (cold elmate area) there can beaheater assembled to (2)andatempera- ‘ure sensor (5). Figura S| oO \l TTT |. Fuel ter bearing~2. Heater ~3, Water dump screw—4. iter cartridge — 5, Temperature sensorSECTION? -FEED €,FeBunRy 200 eNGINSSECTION2 FEED | INJECTION FEED SYSTEM BY MECHANICAL PUMP UNIT | General information Fuel fed system compoted by Fil ak aed on the machine) | Go Fuel delnery and backflow o tank | Gi Fuel pre-fiter (iPavailable, iti usually placed close to the engine on the machine frame) 1 Priming pump, assembled to the purnp body 1 Ft erased to he eng in erent posites cording to esupment appation and duty) CO njector ed piptne (rom fe ed pur to nec) O injectors Figura 6 | Injector feed pipes ~2. Fuel exhaust pipes from injectors ~3, Fuel feed pump ~4. Connector for LDA pressure gauge pipe within suction collector ~5, Lubrication pipes 6, Engine stop ~ 7. Injector10 secTion2-FeeD Figura 7 Description of working principles Fuels aicked from the fuel tank by the pring purnp. This lat ‘one is placed on the engine basement andis driven by the cam shaft “Throughout the fterfs, the fuelispipedto the union fitting va- ‘cuum chamber of the transfer purnp. (For applications to be ‘equipped in cold climate areas, the fue! fer is provided with heater) “Transfer pump is placed inside the feed pump, andi bladed ty pe its duty isto increase fal pressure in correspondence with the increase of the number of revolutions fo, rouaRy 200) vanes |. Fuel filter ~2. Feed pipeline from fiter to fuel pump ~3. Feed pipeline ffom priming purnp to fer ~4. Priming purnp Fuels delivered to the pressure gauge valve within feed pump, “Timing plungers further increace the pressure and deliver fuel to the injectors throughout the delvery pipe fitings, Fuel eeding rom the injectors isrecevered and piped backto| the pump.FMR 208 | FEED PUMP “The pump is den by a gear mating the carshals ene. Direction of rotary Left Defnition of dir ofrotation “Left” means anticlockwise when looking from the drive end “The low pressure system must be bleed Ambient temperature from “40° to +120°C ‘Oi fll quantity (0.45 liters engine oil Figura 8 SECTION? -FeED12 secnow2 ~Fe=D €,FepuaRY 200 ENGINES FUEL FILTER “The iter ic assembled close tothe feed and priming purnp andhas the specific duty to provide barrier tothe impurities and separa- {ton of water fom fue. (On the fiter cartridge base (4) there isa water dump screw, throughout which it is possible to provide regular drainage; on the bearing (I) forthove equip appications requiring (cold climate ares), there canbe a heater assembled to (2) andatempera ture sensor (5), Figura 9 |. Fuel fiter bearing ~2, Heater ~3, Bleender vent screw —4. Filter cartridge — 5, Temperature sensor ~6, Water dup screwSECTICNS3 ~DUTY “INDUSTRIAL APPLICATION 0 Franny 200, ENGINES SECTION 3 DUTY - INDUSTRIAL EQUIPMENT. GENERAL INFORMATION 1D Version equipped with mechanical feed pump 1 Clearance data PART ONE = MECHANICAL COMPONENTS (OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL ROTARY FUMP Preface Engine sting operation forthe assembly on turning sand Disassembly of application cornponents Installation of application components Completion of the engine Rotary feed pump disassembly and sob prseaire Feed system bleed procedure Power take-off disassembly and assembly procedure Check and controls oO, ow) ow \oo; oo (OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL IN LINE PUMP Preface Engine sting operations forte ase on turning stan Diasserbly of application components Installation of application components ‘Completion ofthe engine Feed pump unit deasserby and assembly procedure Feed system bleed procedure lo| olo| colo loo] of Power take-off dsasserrbly and assembly procedure ‘Check and controls TIGHTENING TORQUE 19 33 35 38 38 38 39 39 4l 2 e o eoos Trae reat pear cel Pacha Pana PART WO “ELECTRICAL EQUPMENT 72 |_|. paRr THREE -TROUBLESHOOTING 8 | ELECTRICAL COMPONENT LAYAOUT (4 CYL. 7 aca. Conponen uaa ys. |PARTFOUR-MAINTENANCE PLANNING 91 Coot temper swan 76, | MANTENANCERLANNING 98 © sure 76, | Oh Recovery al SB water temperatur sensor ELISE vocertonperaiarsseor! + 8 Planning of control and periodical intervention 93 Checks not inched in maintenance planning ~ Erectromagnets assented to fed pure | | 2 Spt se Sl esteee 77 | MAINTENANCE PROCEDURES ~CHECKS ©) flier 77) | NAMB cons x TD) Pre-past hextng reskanr 768) | GD Enghe ol level check. 94 vise 70 | | C1 creck ore ten %5 HECTHCAL COMPONENT LAYAOUT 6crL |_| CL Cooling sem check %5 ERSNESRITH Pure Unt) » Lubricating tem check % Cooling liquid temperatur sensor 80, eee eta eee ee eee care em Goole Ea coe Check of water presence within fel er O Sater 5 sree 98 158 water terperaur sewer 20 | | check ordre bt ensoning %6 {2 Engine stop assembled to eed pump a1 | | Co check orbs tear and wear stats %6 O. Olpresre sich 81) | checkand setting of tapped dearace %6 O Feel fitters: co Oil motor and filter replacement 7 re-post hewing rior 82) | C foet iter repacerent %8 post heating | y O Alternator 82 2 Alternator belt replacement 98SECTION 3 ~ DUTY ~INDUSTRIAL APPLICATION FD. Fenuny 2003 avons 3 GENERAL INFORMATION ‘Version equipped with mechanical feed pump. Figure | F4BE0484 engineshavebeen designed and developed specifically for transportation by land and farming equipment in general [They are featured by 4 stroke diesel cycle having 4 cylinder boost with 2 valves per cyinder Feed is provided by rotary mechanical pump or en tine according to the equipment application, It clifers from other applications because of the provision of diferent power, power take-of for the diferent collector configuration, priming pump, oil pan and boost turbine. ‘The picture shows application designed for4 cylinders version, 2 vakes per cyinder, having fuel feed mechanical pump. Data, technical specications and performances parted shal be vald only the Setter wil flow and emply with al intaltionpresptons Furthermore, the expanders assembledby the Setter ‘must always comply with couple, power and number ‘of revolutions based on wihich the engine has been designed, “The section herein described is composed or four directories 1 drectory of mechanical overhaul prescribed in axcordance to the engine's specific duty, illustrating all necessary operations to. remove and assembly the ‘external components of the engine, including cylinder heads, gearbox ofthe timing system and ofthe font part LD electrical directory. describing the connections of the diferent components. of the pre-post heating gearbox (nly for some versions) and ofthe sensors assembled to the engine: 1 toubteshooting directory; rectory of preventive and regular” maintenance ‘operations providing instructions forthe execution ofthe ‘main operations4 NEFENGINES ED. FEBRUARY 203, SECTION 3 DUTY - INDUSTRIAL APPLICATION CLEARANCE DATA ~ 4 CYL. Data, Features and performances are valid only if the etter fully complies with al the installation prescriptions. Furthermore, te users assembled by the setter shall always be in conformance to couple, power and numberof tans FAGE04 ine 044"D6 | S4A*D6 84C*D6 Compression ratio ms ‘Max. outpat kW a 4 T 4 ca) 5 10 18 om 230 2300 2300 Max. torge Ni = wR 500 erm) = wx 500 om : vo | 1400 Toadies engine iting rem 890 850 850 Loadless engine peak om 2300 2300 2300 Hore x stoke mm Jos x 132 Displacement em 5 fy 0 SUPERCHARGING with itereooler I einai rs by Be pam, ave sige ston | Ce oil « ) = i pressure (warm engine | @©8 , | lng bar 070 | peak rpm bar 330 | coouso xm pp ein ernse exchanger, inercoler ‘Water pump contol “Through belt ‘Thermostat ~stat of opening °C sie FILLING BL tswosceas enemies 8s engine sump + filter liters 95 based on which the engine has been designedSECTION 3-DUTY INDUSTRIAL APPLICATION >, FEBRUARY 2003 ENGINES (CLEARANCE DATA - 6 CYL. Type | o1nsps sicepe | Compression ratio | 15:1 LTTE w ary) | 110 175, pm 2500 2300 ‘Mx, torque Nm 3 700 kam é 700 om_| 1400 _ Loads engine ialng mm | S 880 Loaaless engine | peak pm pm = 2500 Bore x stoke 1 THX Displacement 6729 SUPERCHARGING ith itercooter “Tabocharger type HOLSET HX35W TUTBRICATION Oil pressure (warm engine) Forced by gear pump, relief valve single action ‘oi iter idling bar 0.70 ~ peak rpm bar 350 COOLING By centrifugal pump, regulating thermal, heat | ‘eachanger intercooler Water pump control | ‘Through belt ‘Thermostat | stat ofopening °C | s22 FILLING Bf svsoacenes tne ann tiers 1s 16 ‘engine sump + titer ters based on which the engine has been designed, ‘Data, features and performances are valid only If the sete fully complies with all the installation prescriptions. Furthermore, the users assembled by the setter shall ways bein conformance to couple, power and number of turnsENGINES ED, FEBUN 2002 SECTION 3 ~DUTY -INDUGTRUAL APPLICATIONSECTION 3 ~ DUTY —INDUGTRAL APPLICATIONS rea 2000 Moron 7 PART ONE - MECHANICAL COMPONENTSED, FeBUARY 2003 SECTION 3 -DUTY -INDUSTRIAL APPLICATION.SECTION 3- DUTY = INDUSTRIAL APPUCAION EDEBIARY200 ENGINES 9 OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface Part of the operations illustrated within this section con be Periially execuied while the engine is assembled on the ‘hicle, depending on the room available lor access 10 the engine and on the equipment application as wel With rogord to the engine disassembly operations, please apply for information consulting the speciic ‘manual. All operations of engine disassembly ‘operations as well os overhaul aperatione must be executed by qualiled engineers provided withthe specific tooling and equipment required, The following information relate 10 the engine overhaul ‘operations only for what concerns thedlferent components cuslomising the engine, according lois specific duties. For speciic application exigencies, some units con be ‘ossembled lo the engine in cllerent positions Within “Gonerol overhaul” section, ell the operations of engine block overhaul hove baen contemplated. Therlore the above mentioned section isto be consideredosfollowing the part hereby described Engine setting operations for the assembly on turning stand In orderto apply the brackes to the engine block to fix it on fo the stand for the overhaul, tis necessary 10 perform the following operations: ‘On the right hond side: 1G disossemble pipes (1) rom the union (2) fing the lubrication oi filler (essembled on the opposite side: Unlock the nuls fing the pipes (1) and remove them from ihe union (2};droin the oil eventually silinsde he pips and elug hem propery in rr 6 ooidimpury shall be disassombled using acceptable tools. Werning: the oil fier contains inside opr. 1 ko. of engine ol. Provide for oil recovery ond disposal in ‘compliance wth the law ond regulations in force, disassemble lubrication il exhaust pipe from the turbo blower: Underneath the turbo - Blower loosen the lwo screws {2), loosen the screw (3) fixing the pipe throughout the slop collr (4 xing the block; finally loosen ond remove the union (5) from the block; plug the pipe ends andthe exhaust of the turbo - blower 1 Disassemble the starter; Properly hold the starier (I) and loosen the wo fing serews (2); assemble the bracke! bearing using the four screw threaded ports (3) |]On the left hand side Disassemble oilfiter (I) and bracket as wel farversions with engine oi fiter not directly assemtled on to the exchanger) Use accoptabl to! to incta i Loosen the screws (3) removing the bracket together with the fter bearing (4 and 5), Warning: the oil flter contain inside api. | hg. of engine oi Prowie tank with sufficient capacity to contain the liquid Waning: avoid contact of engine oll wth the skin: case of skin contamination rnze in running water Engine ols highly pollutant provide for disposal in compliance with the law and regulations in force, Ci Remove the oil evel rod together with guide pipe (2); (loosen the guide pipe disassembling from the block) properly pipe the screw-threaded port to avoid inlet of Foreign matters 0, FEBUARY m2 SECTION 3 -DUTY ~INDUSTRIAL APPUCATION, O Assemble the second bracket throughout the. serew-threaded ports (1), 1 Lift the engine using the rocker arm and put {Won the turning stand, Drain the ol through the cap underneath the plug. ‘Warning: avoid contact af engine oil wth the akin: in x ne om ‘ase of skin contamination, rinse in running water Engin oils highly pollutant: provide for disposal in compliance with the law and regulations in force.SECTION 3 -DUTY “INDUSTRIAL APPLICATION, ED FesUARY 2002 eGNe 1 Disassembly of application components Proceed dlzasserbiing the supercharger: 1D toosen the fixing nut (1) and remove the hibrication pipe from the supercharger Analogously carry out the sarme ‘operation on the other end of the pipe and remove ft fom the upper part ofthe heat exchanger Loosen the serew nuts fixing the supercharger on the exhaust manifold Hold up the supercharger and ar Ring remove the soket Figure 8 BF K @ Place a container under the fue! fiter and serew out the condense drain faucet underneath said fiter Carry out complete drainage of the fuel contained therein. screw out completely the faucet and, using accoplabe toa, remove the ol itr (, C1 Disconnect fuel pipelines (2 and 3) respectively from priming purnp to fiter bearng and from ths last one to the feed pur, Remove the fue fit bearing (4) from the bracket fixed to the engine head “To disconnect fuel pipelines (2 and 3, picture 8), in /'\\ ow pressure from the relating pipe fitings, i is Necessary to press the locking fastener (I) at shown in picture B. After having disconnected the pipeline, reet the locking fastener (|) in lock postion as’ shown i, Ficture A, to avoid any possible deformation of the fastener itself DD Disconnect the LDA pipe (1) fom the head and from the feed pump Pipe the ends ofthe pipelines as well as the feed pump and the engine head,0 FeaunRv 200 SECTION 3 ~DUTY ~INDUSTRIAL APPUCATION C1 Disconnect the pipeines (1) and (2) that provide feed and fuel recovery betvieen pump and injectors screw fut the nut fang the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws Sing the fuel recovery pipeline; loosen the screws holding the fixing brackets of such pipelines (1.6, and 7, Figure |); pipe the pipeline ends, Disassemble the injectors and remove them from their slot: remove the gnekets, |. Rear bracket fing screw (on suction collector plate) ~ 2. Fuel recovery pipeline to pump ~3. Rotary feed pump ~4 ‘Connection nut to pumping elements =5. Injector ~ 6, Bracket fixing screvé to injection pump side 7. Front bracket fing screw (on suction collector plate) Di Loosen the two fixing serews and disassemble priming pump,SECTION 3 -DUTY ~INDUSTRIAL APPLICATION D.Feauney 200 DD Remove tappet caps Loosen the four fing screws (I) and it the caps (2): remove the gaskets i In the picture, the front cap has already been (On the central cap there is a blow-by valve forthe Lrication oil vapours. ‘All the gaskets shall ays be replaced during assemby = Da Disassemble rocker arm bearings: loosen the two fing screws (2)andremove the completerockerarmbeanng, withdraw tappet rods. Repeat the operation fora the remaining rocker arm bears. Dr Disassemble water temperature transriter (I) C1 Disassemble suction and exhaust manifolds: loosen the 8 screws (I) fixing the suction manifold plate to the cylinder head (two of them have already been screwed-out since firing the pipe brackets to the Injectors) from the exhaust manifold sie; loosen the eight (2) fixing screws; remove the gaskets Dr Loosen the screw (I) on the altemator belt tensioning banger and by loosening the lock nut, loosen the screw as well (3) in. order to sack the bett (4) unt enabling ‘withdrawal ofthe driven and guide pulleys. Disassemble alternator bet tensioning hanger (5)e | Disassemble thermostat unit; loosen the three fixing screws (I) and disassemble the thermostat unit (2) together with the bracket (3); remove the gasket (4) and she thermostat (5) Assemble the bracketin the orginal postion fixing it wth ‘he screws ofthe thermostat unt. Figure 19) |e Property hold the alternator (I) separating it fromm its bearing by loosening the screw (2) remove screw nut and washer: 1D Loosen the screws (2) and withdraw the altemator beating (I) ep. 2000 SECTION 3 -DUTY ~INDUSTRIAL APPLICATION TD Loosen the screws (4) and diassemble the ol! pressurekerperature sensor (3) (fed) Th Loosen the screws (I) and disassemble the ol iterheat exchanger bearng (2), interlayer plate (6) and relating paket, Dy Disassemble oil evel sensor (5) (whether provided). Dr Disassemble injection pump (See specific procedure) and the power take-off undem D From the front, disassemble transmission pulley (I). CD Loocen the four serews (2) and dzasserble the pulley (0) from the bearing undemeath Proceed slsassembiing the bearing,SECTION3 -DUTY “INDUSTRIAL APPLICATION, Eo. FERUARY 2002 ENGINES a 1 Disassemble cyinder head, loozen the crews I) and (2) fing thecyfinder head (3) hhook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block, Figure 24 oF @) Gi Use the 380000988 too! (2) to operate on the thywheol cover box (I) in order to block flywheel rotation (3). (Utlise starter holding down studs and fing screw ruts). | Loosen the flywheel fixing screws (4) to engine drive shat Ci Loosen the screws (1) and withdraw water pump (2) 1D) Loosen the screws (3) and disassemble the pulley (4. Remove the engine drive shat fing rng rom the front over. Use the to! 220000065 (4) opera onthe Honk tang 2) of the engine crve sha, Throughout the tool guide ports drilthe intemal holding rng (I) using © 35 fren dil for Simm depth. Fix the tool tthe ring tignening the 6 srewe special provided Proceed withdrawing the ing (1) tering the screw ©0, FeaunRy 2a SECTION 3 DUTY ~INDUSTRIA APPLICATION. Use acceptable tools (8) (4) and withdraw the extemal holding ting (2 trom the front cover () i Loosen the screws (I) and remove the font cover (2). R “Take note of the screw (I) assembly poston, since the screws have diferent length Cr Lcosen the screws (1) and remove oil pump (2. C._Screw out the opposite screws (I) from the ports where ‘the withdrawal pins shall be introduced (see pecture folowing) Loosen remaining flywheel fing screws (3) to the engine drive shat (4). Rerove the tywheel block tool (2)SECTION 3 ~DUTY “INDUSTRIAL APPLICATION eo Feauny 200 INGNES 17 1D) Screw up two medium length screws in the ports (4) t0 sling the flywheel with a hoist. “Throughout two guide pins (2) previously screwed up into the engine dive shaft ports (3) control the engine | flywheel withdrawal by means of a hoist IWS Remove the fyvhee cover box fing ringusing the tool “HOOIOE62 (3) to operate on the Back tang (8) ofthe engine drive shat Throughout the tool guide ports ei theintemalholdngring using @ 35 erm cl fora Siren epth Fax the too! 380000663 (3). to the ring (1) tightening the 6 screws specially provided (4). Proceed with craving the rng) tightening the screw @ Use accopable too (8) (4 and witha the extemal holding rng ofthe yhoo cover box. a Qa 1 Loosen the screws (2) and remove the fywheel cover box (1) “Take note of the screw (|) assembly position since the screws have diffrent length, Tum the engine upside-down, 1D Loosen the screws (2) disassemble the plate (3) and remove the oll pan (1. iN “The shapeand dimensions ofthe pan and ofthe rose pipe may vary according to the engine application, ‘The relating lustrations provide general guidelines ‘of the operation to be performed. The procedures described are applicable anyway.18 exanes |) igure’3s Loosen the screws (1) and disassemble the ail suction rose pipe (3). Cr Loosen the screws (2) and remove the stifling plate @ 1 Loosen the screws (I) and disassemble the gear fromthe camshaft (2) ED, Fenun 2009 SECTION 3 -DUTY ~INDUSTRUAL APPLICATION. Ch Loosen the screws (2) and disassemble the timing gearbox (1), J. Tike note ofthe screw (2) assembly position, since WX, the screws have different length.SECTION 3 ~DUTY “INDUSTRIAL APPLICATION 0, runny 28 Installation of application components DXAGRAM SHOWING SEALING LOCTITE 5205 'AFPLICATION WITHIN GEARBOX AREAS Ch Accurately clean the timing gearbox (I) and the engine block Its necessary and essential to clean the surface to bee sealed in order to achieve excellent tight seal, Apply sealing LOCTITE 5205 on the boxin order to forma kerbstone ofa few mm. Diameter: It must be uniform (no crumb), with no air ister, ‘thinner or irregular zones, ‘Any eventual imperfection shall be correct as soon a possible, ‘Avoid using material n excess to seal the joint Too ‘much sealing matenal would drop out on both sides fof the joint and obstruct hibricant paseages. ‘After having completed seal application, the joints must be immediately assembled (10-20 minutes time), DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX | Reassemble to box (1) to the engine block ID Tiehten the fing screws in the same positon as found ‘ut during disassembly and fix the screws to the locking couples sted here below, folowing the order as shown, in the picture screws ra 65+ ONm | Sacws 8 peri | acws 0 22 StNm | [| Before assembly. ahvays check thatthe threads ofthe portsand ofthe serewshaveno evidence of tear and ‘wear nor drt 0 With a penmarkerrmarkthe tooth (I) ofthe driving gear assembled to the engine drive shaft with (2) (+) timing Screw up two pins to facltate operation of engine “dive shat rotation.1 Ovientengine dive shaft (4) and camshaft (2) taking care ‘that in phase of assembly ofthe driving gear (2) to the camshaf, the notches marked on the gears (I and 3) shal match, Cr Tighten the screws (1) sing the gearto the camshaft (3) and lock them to the prescribes couple. Figure 43 DIAGRAM SHOWING SEALING LOCTITE 5205 ‘APPLICATION. FD FEBUARY 2001 SECTION 3 -DUTY ~INOUSTRIAL APPLICATION. fa asa osmcs sare 7 Apply sealing LOCTITE 5205 on the box in orderto. women eee soa etary te mlb et Ee eee eae aren a DIAGRAM SHOWING SCREW TIGHTENING TO FX FLYWHEEL COVER BOX. C1 Reassemible the box (I) to the engine block, tighten the fang screws in the same postion as found out during dtassemby and foc the screws t0 the locking couples led here below, following the order as shown inthe picture, Screws M12 75 + 95Nm Screws M10 44 = 53Nm enveer meer srer emer 7 EeSECTION 3 ~DUTY “INDUSTRIAL APFUCATION a ic Dr Apply to engine drive shaft rear tang (6), the detail (5) fof tho tool 380000866, fi tighoning tho serows.(@) and keey the new holding ring on (3) Place detail (1) on detail (5), tighten the screw nut 2) Lunt complete assembly of the fixing ring (3) into the Aywheel cover box (7). Figure 46 [ea , Fuse ona mNGINS 21 Screw up two hooks or trail rings in the fywheel (1) ‘threaded ports (4) for handling Usingahoist handle the wheel to place tin ts housing inside the fywheel cover box. Screw up to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine flywheel (I) properly placing inside the fyhee! cover box. In case of engine coupling with mechanical gears in /\,) presence of fiction, very surface status of the (E> fywhee and eventually workitoutto maintain rated engine fywheel thickness, which is 49,6 + 0,13. mm, Check the conditions of the rim tooth (2). Whether ‘tooth break or excessive wear is detected, disasserrble ‘the rim from the engine fywheel using a common willow and replace with a new one, previously heated to 150° C degrees for 15° +20; seconds; beveling must bbe made towards engine flywheel direction, Di Tighten the screws (4) fxing the engine fhwhee (3) to the engine shait, Use 380000088 10) (2) to ‘the fywheel cover box (I) to block engine rotation,Tighten the engine fywheel (I) fing screws (2) in two | phases | Cd Istphasetightening by means of dynamometric wrench ‘to couple 30 + 40 Nm Dr 2nd phase, 6 ++ 5* angle dwell [AQ] Angle ave shall always be performed using ‘acceptable tool Before assembly always check thatthe threads ofthe portsandof the screwshaveno evidence of tear and ‘wear nor dirt | Figures | Assemble oil pump (1) DF Tighten fixing crews (2) andlockthemto theprescribed couple. ep Feu 2a SECTION 3 -DUTY “INDUSTRIAL APPUCATION (D Aseemble the water pur (1). Tighten the screws (2) and lock them to the prescribed 1 Femove the fixing ring (2) from the front cover (1), sccurately lean the plug surfacesorta scence Sana facta | Figure 56 easy —, I] 7 a— | z Se, | a i ! 2 7) ; a4 Li i : = [Accurately clean the contact surface of engine blockand ply sealing OCTITE 5205 cn it x rer to form 3 Uniform and continuous kerbstone with no crumb, G Assemble the front cover(2)tothe blockandtighten the sere (1) fang ther to the prescribed couple Apply on engine drive zhaft front tang (6) the deta (4) ‘ofthe toot 160000866, fi it with the serews (5) and key the new holding ring on ® (7) Place the detail (2) on the detail (4), screw-up the ‘threaded nut until carrying out the complete assembly of the holding ring (7) %0 the front cover Aczemible the plate (I), the rose pipe 2), tighten the fing screws (3) and fic them tothe prescribed couple.24 ENGINES Figure 58 D Provide fornew gasket replacement (I) ofthe cil pan (2). pictures ilustrating the pan and ofthe rose pipe may not correspond to the ones of your model However the procedures described are applicable anyway. Cd Assemnbe cil pan (1), apply the plate over it (2) Tighten the screws (2) and lock thern to the prescribed couple. ED, FeBUNRY on8 eee A ee wear nor dirt SECTION 3 -DUTY INDUSTRIAL APPLICATION. [2 Asiemble the pulley (I) to the engine drive shaft, and the distance rng (3). [A Tiehten the xing screw (2) andlockthemto the 68 + 7 Nim couple C) Asemble the folowing elements to the block: new gasket (I) heat exchanger (2). new gasket (3), ol er Bearing), Tien the screws (5) and lock them to the preserbed couple Before assembly aways checkthat the threads oftheSECTION 3 DUTY “INDUSTRIAL APPUCATION Fauna oma GINS 25: Lubricate the fixing rng (2) using engine oil and place it on the oil flter (3). 1D Manually start the oil ltr (3) on the bearing union (I) Until counter-borng, further screw up the oil iter (3) by 314 tur, 1D Appl, GF needed) new fing rng on the oll ‘emperature/pressure sensor (4) and assemble it to the beating (I) tightening the fxing screws ta the prescribed couple In some applications, the bearing ofthe exchanger ‘\\] shall be assembled to a screw threaded union [5 connected to the fiter on the opposite side of the engine, throughout two pipelines (see picture 2) D1 Place a new faxing ring on the block housing (6) Figure 63 &) ® Before assembly, aways check thatthe threads ofthe portsandof the screws have no evidence oftearand wear nor dirt 1 Reassemble the alternator (I) OD Tighten the screw (2) and lock i to the prescribed couple. Cr Pace the gasket (1) over the block, “The choice of the gaskets thickness shall be made in consideration ofthe cylinder protrusion measured with respect to the block’ upper surface. 1D Assemble the alternator bearing (1) ensuring that the pins (3 and 4) are against the engine block. Tighten the screws (2) and lock them to the prescribed couple. Verify thatthe engine block stand is lean Donotgrease the gasket Its recommended tokeep the gusket inside packaging unt assembly to the cylinder head Gasket assembly shall be made following the 0.1 mm the screw rust be replaced Ep. Feaunny aoa GING 27 | Aiur the sk between rockerarmsandvalesusing socket ‘wrench (I), point wrench (3) and feer gauge 2). Correct working slack = "Tucion valves 030 + 005 rm = exhaust valves 055 + 005 mm aN In order carry out a quicker adustment of the working slack between rocker arms and valves, proceed a: folowing Rotate the engine drive shaf. balance the valves of ‘jlinder | and adjust the vahes identifed by star _ymbol, a incicated in the following table Gfindern [2 3s Te Suction © T-[-[- Exhaust =bet* t= Rotate the engine civ shaft of 360 deg, balance the valves of einer 4 and adjust the valves identified by star symbol, a5 dicated i the following table: Gylindern® [Ts a Suction ~[+[. [= Exhaust =[=l=Ts28 ENGINES Assemble injectors after having replaced the sealing ase (1). J |] Daring aserby oF njectors, very that te jetor /\| sphere is correctly postioned onthe head hous, aareree fA (2) D1 Assemiie cylinder covers (2) with the respective gaskets; C1 Fit the seal nods and tighten the screws fixing them to the prescribed couple. ep Fenny 2000 SECTION 3 -DUTY “INDUSTRIAL APPLICATION. [A | Always replace the gaskets using new ones, ZY, cheartettventsottne ing srensther sabe po otdene of wo ovat Sapa Seal nods shall have no visible deformation In such case provide for replacement with new nods. DP Gt ree Eee Ie Ee © 1 Assemble thermostat unit (2) including thermostat (5) and gasket (4), Di Tehten the screws to the prescribed couple, “The serews (I) have been have been utilised to fx the bracket (3) Disassemble the bracket and reassemble components from | to 5 as shown inthe picture. “The gasket must be new.SECTION3 -DUTY ~INDUGTRIA APPUCATION ro Feuney 200 1D Assemble the driving belt (4) tighten the screw (1) ‘without locking in orderto tt sie within thebracket hole (5). Adjust belt tensioning by tightening the screw (3). After ‘having set correct tensioning blockthe checknut (2)and the screw (I) Dr Assemble the pulley fan bearing tightening the screws to the preserbed couple. 1 Assemble the altemator tensioning bracket Assemble the tivo pulleys (3) and fcthem tightening the screws (2) ofthe bearnig. Assemble the tranrizsion pulley (1), Incase the same belt priory removed is assembled agan, proceed examinng it carefully to check there (KDr Apply on the surface joining the suction manifold plate (i) a aufcient coat of Loctite 5999 and provide, fing, the screws to the prescribed couple, C1 Irth pipe (6) ofthe suction manifold plate (1) has been removed reassemble it after having ft anew gasket (5). Tighten the serews (7) to the prescribed couple. For the versions provided with heater also assemble ‘components (3) and (4), FD, FEBUARY a3 SECTION 3-DUTY ~INDUSTRIAL APPLICATION Abo assemble the brackets (I) fxing the fuel pipelines ‘© the injectors: use the same screws ‘manifold plate ac shown in the picture @) fang the Cr Assemble priming pump (I) providing new gasket and ‘iiten the screws (2) to the prescribed couple. Cr Also assemble feed pump (see specific procedure) and the power take-off underneath Pump assembly requires. specific procedure as reported at the end of the hereby sectionep. Frauany 208 SECTION 3 DUTY “INDUSTRIAL APPUCATION | Rear bracket fing screw (on suction collector plate) ~2 Fuel recovery pipeline to purnp ~3. Rotary feed pump —4 Connection nut to purnping elements ~5, Injector ~ 6. Braet fing sre to injection purnp side 7, Front bracket fing screw (on suction collector plate) ite Peureias Se8 O Ficthe LDA pipeline (I) to the engine head and to the feed pure, le the pipes (I) and (2) providing ful feed and 5 between pump and injectors ip the long nuts and Uphten the screws fing the injectors ied the fuel recovery manifold othe pipes to throughout the brackets previously assem32 ENGINES FD. FEBUARY 008 SECTION 3 -DUTY —INDUSTRIAL APPUCATION Gh Assemble the fu! fit bearing (4) to the bracket xed ‘to the engine head Ca Connect the fue pipelines (2 and 3) respectively from priming pump to iter bearing and rom this lst one to feed pump. C1 Using acceptable tools assemble tue! titer (I). “The fter shal be prior filed with fuel to fcitate {ee system bleed operations WN “To connect fuel ppelines (2 and 3, Figure 87) in ow pressure from the relating connection unions it is necessary to press the locking fastener (I) as shown inpicure 8 ‘After having connected the pipeline, reset the fastener (I) into block postion as shown i picture a Proceed assembling the turbocharger: D1 Hold the turbocharger and place it on the exhaust ‘manifold after having interposed the gasket, 1D Screw up the fixing nuts of the turbocharger to the ‘edraust manifold tightening them to the prescribed couple, D1 Tighter the lubrication pipe fxng ring. Operate in the same way on the other end of the pipe. Connect it to ‘the upper part ofthe heat exchanger “To complete engine assembly itis necessary to remove it from the turning stand C1 Using acceptable tools hold the engine and loosen the screws fixing the brackets tothe turing stand C1 Disassemble the brackets from the engine after having roperly put it on a wooden bearing.SECTION 3 DUTY — INDUSTRIAL APPUCATION. . Fesuagy zon ENGINES 33 Completion of the engine Figure 90 ‘On the ight hond side: reassemble the pipes (1) from the union (2) 10 the lubrication al iter (placed on he opposite side) ighien the pie rings (1) and connec them to the union rectly placed on shell be assembled In some coses, the il fir (3) the heot exchonger:in this cos sing accopabletocs. Q Reossomble the lubrication cil exhoust pipeline (1) rom the turbocharger: from underneath the turbocharger lighten the two screws (2); tighten the serew (3) lxing ‘the pipolino o the block throughout the fixing collar (4) to the block; finaly ighten he union (5) fo the block.34 ENGINES 0, Feauay 2003 SECTION 3 -DUTY INDUSTRIAL APPLICATION. 1 Reassemblethe starter; properiyholdthestarter(I)and_ | [On the lefthand side: tugiten the fixing screws (2) to the prescribed couple, Assemble ol fiter (I) together with bracket (for the ‘arsions with engine ol fiter not directly assembled to ‘the exchanger); tighten the screws (3) assembling the bracket (4) nchudingfiter bearing (5) Use acceptable tols to install the ol iter Assemble cillevel odtogether with guide pipe 2). Fllup engine of TD testa the engine on the archine (for instalation ‘operations please apply to specie isue).SECTION 3 -DUTY “INDUSTRIAL APPLICATION Rotary feed pump disassembly e assembly procedure “This procedure prescribes that: C1 The fuel pipelines (rom pumping elements to Injectors bleeding recovery pipes rominjectors ‘to pump, LDA pipeine and feed provided by ppoiming purmp) sal all be cssesernbled 1D Electrical connection to feed pump shall be disconnected, Oi Accelerator cable shall be disconnected, Incase feed pump replacement is necessary, this shall be supplied pre-set aeady as spare part. (On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while itis sil assembled to the engine and dsazcemble only afterwards ‘The following procedure analyses this second hypothesis since its the more complex. Figure 95 1 Rotate with caution the fee following its own rotation seve to annul the gar sacks and tthe same time keep the (~) pin presied unt when thi ast one isting into the port ofthe camshaft gear This way the PMS. shall be determined within Ni. ojinder FD, Fea 208 None 35 (Cr Dizacsemble the starter from the fywheel box (1) and | so the 880000988 tool (2) orotate the fywhoel. bea rotation shall be cared outwith Cauton Thepmchargedby exes shea aes may get damaged36 ENGINES Partially loosen the lateral screw (2) locking the pump shaft and remove the sip washer (2). Absolutely keep ‘the sip washer (it isrecommended to fit with stripe ‘or wire to the purp). Tighten the lateral sere (I) blocking rotation of the pump shat. CD From tiring side, remove the cover (2) loosening the screws (I) inorder to have access to the union fixing rst @) to the pump crving gear Loosen the fxingnut (3)and remove the relating washer: ep Fes 2008 ‘SECTION 3 -DUTY INDUSTRIAL APPUCATION. Fromm the pump side, loosen the focng nuts (|) without removing them in order to enable moving the pump backward using 380000079 extractor. 1D Assemble to 380000879 extractor throughout the two threaded ports (4, Figure 97) and withdraw the gear ‘fom the pump shaft Dr Property hold the feed pump and loosen completely the ‘ing nuts, DD Withdraw the pump from the studs, together with the ket ‘When assembling the eed pumptothe engine itisnecessary to meet the PMS, requirements forthe NI. cylinder C1 Use the 380000088 too! (2) on the flywheel box () to carry out flywheel rotation and operate using the pin 3s previously described. Al Hold the pump driving gearto avoid interference or crawling during timing gear rotation.SECTION “DUTY ~INDUSTRIN. APPLICATION Cr Assemble the pump pre-setin its housing onthe engine, fitting the shaf into the gear port (not provided with wrench) Gi Tighten the fixing nuts (1) locking the pump fange inthe slot centre JA The ese removed crng pump desesemtly shall ZN) not be tied again 1 Aways use ongnal pare pats Gy On the timing side, throughout the specially appointed port, ft the washer and screw up the fixing nut (3) tothe pump shaft Lock the nut to the 90-95 Nin couple. ro Femunky om D1 Partially loosen the screw (2) locking the pump shaft rotation and fit the sip washer (1). Tighten the screw fixing above said washer: this way the feed pump shaft is free to rotate 1D Assemble the cover (2,Figure 101) inching gasket and tighten the screws (1, Figure 101). Oath pin outwards setting the camshaft gear fee. Dr Disassernble the $00000868 tool locking fywheel rotation; place the starter in its housing, Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump). 1D Connect electrical connections to electro-magnets on ‘the hydraulic head and on KKSE, Incase pump removalhas been carried out while the A nrcerecrmalmtomearatog tee38 ENGINES ep. Feauy 2002 SECTION 3 -DUTY “INDUSTRIAL APPLICATION, Feed system bleed procedure In case any operation hasbeen executedon the components ofthe feed circuit ti necessary to execute bleeding of ai ‘within the system, Cy Loosen the bieeder vent screw (3) on the fuel ster (1) and keep working on the bleed lever of the priming pump (2) Da Continue executing this operation unti when ful drains ‘fom the bleeder vent screw. Tighten the tieeder vent screw () Power take-off disassembly and assembly procedure, Figure’ (04 Where designed, there isa power take-off able to transmit motion to different aunilary parts, Disassembly of such mechanism shall be executed as allowing Cr Loosen the two screws (3)and atterhaving removedthe cover (I) with a specially provided extractor withdraw the power take-off 2). The two gaskets (4) shall be replaced in phase of reassemble Ci Vary out the assembly fitting the power take-off ints hauting, providing nev gasket and checking the sprocket gearmeshing (Assemble cover and gasket and tighten the serewstothe preserbed couple, ‘Checks and controls “he following tests shall be made after engine assembly 10 the vehicle Preventively check that the liquid levels have been correctly restored, IS) sete erase ni a vin ern (Gay Sa RAE ae Sg i en ei “be ake ord ‘thermostat opening, then check that [There is no water bleeding from the manifolds connecting engine cooing. circut pipelines and cabin irternal heating, eventually providing to further tighten the locking rings. i Garetuly check the fuel connection pipes to the respective unions, 1 There's no cil leakage fromthe lubrication circuit ofthe ‘various pipelines connecting cover and. Di Cylinder head, oil pan and bearing, oll fiter and heat cerchanger az well as relating housings There is no fuel leakage from fuel pipelines. DD There sno blow-by from pneumatic pipes (provided). DD Verify correct working of the lighting leds of the dushboard containing the tools as well as of the equipment that was disconnected during engine connection, Cr Check and blow by with care the engine cooling stern, carrying out frequent drainageSECTION 3- DUTY ~ INDUSTRIAL APPLICATION ED TeBuARY 203 ENGINES 39 OVERHAUL OF ENGINE PROVIDED WITH MECHANICAL IN LINE PUMP. |Preface | | Port ofthe operations illustrated within this section con be [portly execvied while the engine is assembled on the |fehicle, depending on the room evlale lor aczes othe bngine and on tho equipment application os wel TA] With regard fo the engine disassembly operations, please apply for inlormation coneuling the speciic manual. All operations of engine disassembly ‘operations os well os overhaul operations must be ‘executed by qualified engineers provided wih the | specific fooling ond equipment required The following information relate to the engine overhaul operations anlyforwhatcancernsthe diferent components customising the engine, eccording oil specific duis. For speci opplication exigances, some unis con be ‘essembled lo the engine in eileen! positions Within "Generel overhau!" section, all the operations of tengine block overhoul have been contemplated. Therelore The above mentioned section isto be considered asfollowing the port heceby described Engine setting operations for the assembly on turning stand Figure 105 eZ In order to apply the brackots tothe engine biook io fix it on to the stond for the overhaul, itis ‘necessary lo perform the following operations: (On the right hand side 1D disossemble pipes (1) from the union (2) fing the lubrication ol filler fossembled on the oppesi sd): unlock the nuts fring the pines (1) and remove them fromthe union (2) drain he ofl eventually sil inside he pipes and pug hem propery inorder io vadimpuriy For some versions, the oil fier (3) is directly ‘orsembled on fo the heat exchanger: in such cose i ‘shall bo disassembled using acceptable tools. Warning: the ol filer contain inside apex 1 kg. of ‘engine oil. Provide for cil recovery and disposal in ‘compliance with the law and regulotions in force D disossemble lubricotion oll exhoust pipe trom the turbo blower: Underneath the trbo- blower loosen the Iwo scress {2), loosen the screw (3) fixing the pipe throughout the siop collor (4 xing he bloc; finaly loosen and remove ‘the union (5) rom he block; plug he pipe ends ond he ‘ephous! ol the turbo: blower 1 Disossomble the siarter; Properly hold the starer (1) ond loosen the two fixing screws (2)ED. FERUARY 2002 SECTION 3 - DUTY ~INDUSTRIAL APPLICATION. (On the left hand sie: D1 Disassemble oil fiter (I) and bracket aswel (forversions. with engine ol iter not directly assembled on to the exchanger) Use acceptable tools to remove the ol iter Loosen the screws (3) removing the bracket (4) ‘together with the flter bearing (5). Manteo Reresemn see oe WN ts ee es liquid. \Warning:avoid contact of engine cl wth the skin: in case of sk contamination rinse in running water Engine oll is highly pollutant: provide for cisposal in compliance with the law and regulations in force 1D Remove the oil level rod together with guide pipe (2); (loosen the guide pipe disassembling from the block); properly pipe the serewthreaded port to avoid inlet of foreign matters, Figure 110 o 1D Assemble the second bracket throughout the ‘crew-threaded ports (I). C1 Litthe engine using acceptable tools and put it on the {turning stand, Drain the oi through the cap undemeath the plug ‘Waring: avoid contact of engine cil with the skin: in case of skin contamination, rinse in running water, Engine ols highly pollutant: provide for disposal in ‘compliance with the law and regulations in force.‘SECTION 3- DUTY ~ INDUSTRIAL APPUCATION, | Disassembly of application components Figure 117 Proceed disassembling the superchorger: [D loosen the fixing nut (1) and remove the lubrication pipe from the superchorgec Anclogously carry ou! the some ‘operation on the other and of the pipe ond remove it from the upper part ofthe heot exchangec D1 Loosen the fixing screw (3) ond remove the exaust lubrication pipe from the superchargec [1 Loosen the screw nuts fixing the supercharger on the chavs! monial C1 Hold up the supercharger and ater iting it remove the gasket 1D Ploce 0 container under the fuel filer and screw out the condense drain faucsl underneath said flier Carry out complete droinage of the {vel contoined therein screw out completly th faucot and use acceptable tools to disassemble oll fiers (), Disconnect {vel pipelines (2 ond 3) respectively from priming pump tiller bearing and from this lost one 10 the feed pump. Gi Remove the {vel filler bearing from the bracket fixed 10 the engine head. FFEBIAReoD2 ENoIes 41 Figuie 113 {1} low pressure from the relating pipe litings, itis Fu] To disconnect ful pipelines (2 ond 3, picture 8) in Disconnect the LDA pipe (1) Irom the heod and from Necessary to press the locking fastener (1) os shown in picture B. Aller hoving disconnected the pipeline, reset the locking fastener {1) in lock postion os’ shown in Picture A, to avoid ony possible deformation of the fastener ill. the feed pump. Pipe the ends ofthe pipelines as wall as the feed pump and the engine head.,FeauaRy2o0a SECTION 3 -DUTY INDUSTRIAL APPUCATION. D1 Disconnect the pipelines (1) and (2) that provide feed and fuel recovery between pump and injectors; screw fut the nuts fixing the pipes to the pumping elements loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors {and loosen the serene fixing the fuel recovery pipeline Figure 116 D1 Loosen the screws (I, Figure 116) and (1, Fgure 117) holding the fing brackets of such pipelines; pipe the pipeline enc. Figure 118) | 2 Disconnect kibrication pipes (1) from feed pump. D1 Disassemble the injectors and remove ther from thei dot: remove the gaskets,SECTION 3 -DUTY ~NOUSTRIAL APPUCATION .FenunRy 200 evans 43 Remove tappet caps: Loosen the fixing Screws (1) and lit the caps (2); remove the gaskets. A] On the central cap there is a blow-by valve forthe /\\| lubrication oil vapours. SI A the gaskets shall avays be replaced during assembly, Dr Disassemble suction and exhaust manifolds: loosen the screws (I) fing the suction manifold plate to the cylinder head (Some of them have already been screwed-out since fixing the Injectors); from the exhaust manifold side loosen the ‘eight Q) feng screws; remove the gaskets pipe brackets to the Figure (21 Cr Disassemble rocker arm bearings loosen the two fixing screws (2) and remove the complete rocker armbearing: ‘withdraw tappet rods. Repeat the operation forall the remaining rocker arm bearings ) Disacsemble water temperature transmitter (I) | Unloose the screws fixing the altemator’s protection to the support and remove f 1 Workon the drive belttensor (I) and extractthe belt (3) from the belt pulleys, from the water pump ones and from the bet rebound pulleys. 1D Disassemble the bett tensor Unloose the screw fixing the alternator to the upper bracket.44 acne ED, FEBUAR 208 SECTION 3 -DUTY ~ INDUSTRIAL. APPLICATION, Figo 23 as 1 Disassemble thermostat nit; loosen the three fixing screws (I) and Gsasserise the thermostat unit (2) together withthe bracket (3); remove the gasket (4) and | the thermostat 6). | Assemble thebracketinthe orinapostionfxingitwith | the screws ofthe thermostat nt Figure 124 f=.) Gi Property hold the alternator () separating it from its beating by loosening the screw (2): remove screw rast and washer: D1 Loosen the screws (2) and withdraw the alternator bearing (1). Figure 126 Loosen the screws (4) and disassemble the il pressure/temperature sensor 3) (fitted) | Loosen the screws (|) and disassemble the ol fitersheat ‘exchanger bearing (2), interlayer plate (6) and relating atkets 1D Disassemibie oil level sensor (5) (whether provided), 1 Disassemble injection pump (see specific procedure) | and the power take-off undemeath, Figure 127 | | 0 Okassentie cinder head bosen the scree) and(2) feng the nderhead 3) | Roak'he beaches wth meta ropes ae trough host where eynder head for the lockSECTION 3 ~DUTY ~ INDUSTRIAL APPLICATION Dy Use the 280000888 too! (2) to operate on the fywrhea! cover box (1) order to block fwheel rotation (3. (Uillse starter holding down studs and fixing screw ut). Loosen the Mywheel fing screws (4) to engine drive shaft Figure 129 aS Di Unloose the screws (3) and disassemble the damping ‘iywheel (2) andthe pulley (1), err rare 7 esessas eee tego eed ZN seri fo. rrauary 20 euch 45 Figure 130 | Remove the screws (1) and disconnect the water pump a Remove the screw (3) and the roller (4) Oy Remove the screw (5) and disconnect the engine speed sensor (6) Figure 131 em @ = C1 Remove the engine driveshaft fing ring from the front, ‘over Use the tool 380000665 (4) to operate on the rent tang (2) of the engne dive shat, Throughout the tool guide ports, dilthe internal holding rng (I) using © 35 ‘mn drill for a Simm depth. Fix the tool to the ring tightening the 6 screws specialy provided, FRoced when he (tng the wreED. FeBUARY 008 SECTION 3 DUTY ~INDUSTRIAL APPLICATION. C1 Use acceptable tools (3) (4) and withdraw the extemal holding ring (2) ftom the trent cover () Dr Loosen the screws (I) and remove the front cover (2). “Take note of the screw (I) assembly position, since A th the screws have dflerent lengt Loosen the screws (1) and remove oil pur (2). Figure 135) | S:rew outshe opposite screws (I) from the ports where the withdrawal pins shall be Iroduced (see picture following), CD Loosen remaining fywhesl fing screws (3) to the engine drive shaft (4). Remove the fywheel block too! (2)SECTION -DUTY ~INDUSTRIAL APPUCATION ep Fenny 2a ENGIN 47 Figure 136 1D Screw up wo medium length screws in the ports (4) to sing the Mwheel with a hot. “Throughout two guide pins (2) previously screwed up into the engine drive shat ports (3) control the engine Aywheel wihdraval by means of & hoist Remove the fywheel cover box fing rng using the too! 380000663 (3) to operate onthe back tag (5) ofthe engine drive shaft. Throughout the tool guide ports, dil the internal holding ring usng @ 3,5 mm drilfora Smm depth G1 Fix the toot 380000669 (3) othe tng (I) tightening the 6 screws specially provided (4). Gi Proceed with drawing the ring (1) tightening the screw @. 1 Use acceptable tools (3) () and withdraw the external holding ring of the tlywheol cover box Cr Loosen the screws (2) and remove the fywheel cover box (1) “Take note of the screw () assembly position, since the screws have ferent length Tum the engine upside-down, i Loosen the screws (2), disassemble the plate (3) and Al “The shape and dimensions ofthe pan and ofthe rose [a remove the of pan (1, pipe ray vary according to the engine application. “The relating illustrations provide general guidelines lof the operation to be performed. The procedures described are applicable anywayIC Loosen the screws (|) and disassemble the oil suction rose pipe (3). IC Loosen the screws (2) and remove the stifening plate a Figure (41 oF D1 Loosen the screws (I) and disassemble the gear fromthe camhaft [Loosen the screws (2) and disassemble the timing gearbox (I) J | Take note of the screw (2) assembly position, since Z| the sevens have dierent lengthSECTION3 -DUTY “INDUSTRIAL APFUCATION Installation of application components Figure 143 DIAGRAM SHOWING SEALING LOCTITE 5205 "APPLICATION WITHIN GEARBOX AREAS CD Accurately clean the timing gearbox (I) and the engine bbeck Itis necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal ‘Apply sealing LOCTITE 5205 cn the boxin orderto forma kerbstone ofa few rm. Diameter Itmust be uniform (no crumbs), with no air bisters, ‘thinner or irregular zones. 1X Any eventual imperfection shal be correct as soon a: possible, ‘Avoid using material in excess to seal the joint Too ‘much sealing material would drop out on bath sides (ofthe joint and obstruct hibricant passages, After having competed seal aplication, the joints must be immediately assembled (10-20 minutes time). enone; 49 DIAGRAM SHOWING SCREW TIGHTENING TO FX REAR GEARBOX IC Reassemble to box (I) to the engine block ICD Tighten the fing screws in the same position as found cout during disassembly and fix the screws to the locking couples sted here below. folowing the order as shown in the picture. Screws M2 65 = 89 Nm Screws Me 20 + 28Nm [Screws M10 42 + 52Nm portsandof the screws haveno evidence of tearand [| Before assembly akvays check thatthe threads ofthe 7N\ ‘wear nor dit | Figure 145) (=e (2) With pen marker mark the tooth (1) ofthe diving gear assembled to the engine drive shat with (2) (-») tring notch Screw up two pins to faciitate operation of engine chive shaft rotation,C1 Orient engine dive shat (4) and camshaft (2) takingcare that n phase of assembly of the drive, gear (2) 10 the camshaf, the notches marked on the gears (I and 3) shall mate Figure 147, Tighten the screws (1) fixing the gearto the camshaft (3) and lock them to the prescribed couple. i ey Na DIAGRAM SHOWING SEALING LOCTITE 5205, AFPLICATION, 0. Feu 2008 SECTION3 - DUTY “INDUSTRIAL APPLICATION. Its necessary and essential to clean the surface to be sealed in order to achieve excellent tight sel ‘Apply sealing LOCTITE 5205 onthe boxin oderto forma kerbatone ofa few mm. Diameter must be tuniform (no crumbs), with ne air blisters, thinner or irregular zones, Any eventual imperfection shall be correct as soon 2s possible. ‘Avoid using material in excess to seal the jai, Too ‘much sealing material would drop out on both sides Of the joint and obstruct lubricant passages. ‘After having completed seal application, the joints must be enmediately azzernblec! (10-20 minutes tine). DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX 1D Reasserble the box (I) to the engine Bock, tighten the fing screws inthe same postion as found out during disassembly and fix the screws to the locking couples liked neve below, fllowng the order as shown nthe paure Screws M12 Screws M10 75 + 95Nm 44-2 53Nm Before assembly always check thatthe threads ofthe portsandof the screwshaveno evidence oftearandSECTION -DUTY “INDUSTRIAL APPLICATION. eo.FEURy 208 ecines 51 Figure 152 G Screw up two hooks or tall rings in the fhwhee! (1) ‘threaded ports (4) for handling D1 Usrigahoist handle te fywhee to place itinitshousing inside the fywhnee! cover box. ofthe too 380000666. thi ignoring the screws (a)and || 2 Seer eee “han puis, lee fn i key the new holding ang on t (3), engine flywheel (1) properly placing inside the fywheel 1 Prace detail (1) on detail (5), tighten the serew nut (2) cover box Until complete assembly of the fang ring (3) into the Aywiheel cover box (7) oH Di Apply to engine drive shaft rear tang (6), the deta (5) Figure 151 Fr In case of engine coupling with mechanical gears in ZN) presence of fiction, verify surface status of the [= ywheel and eventually workit outto maintain rated engine flywheel thickness, which is 49,6 + 0,13 mm, | check: the candions of the im tooth (2). Whether toa rea or acenie wear acoced dswemble the rim from the engine fywhee usinga cornmonvillow and replace with a new one, previously heated 10 150°C degrees for I5' + 20: seconds; beveling rust bbe made towards engine flywheel direction, Tighten the screws (4) fing the engine tywheel (3) to the engine shaft, Use 380000908 tool (2) to eperato on. the Sjwheel caver box (I) to block engine fywheel retation,52. ENGINES 0, Feauney 2003 Figure 156 Ea een te ene Bye! (1) fg ere) 9 | IO pop tothe ater p ()anew ing re OI stphacetghtening by means of dnamometrc wrench 40 couple 30 + 40 Nin Faure 157, 1D 2nd phase, 60° + SP angle dell 7 Anele dwell shal avays be performed using, AA accotabie toi Before assembiy alvayscheckthat te threads ofthe portsandofthescrewshveno.adence fear at Sear nor Dy Assemble the water pump (1). Dr Tighten the screws (2) and lock themto the prescribed couple, Figure (55 | Fate 158) Assemble ol pump (1). O Tytenbinesrere@andtakthentetepreciied | JC) famove the fing ng For the font comr (I, accurately clean the plug surface.Figure 159 C Accurately clean the contact surface ofengine blockand apply sealing LOCTITE $205 on it in orcer to form a Uriform and continuous kerbstone with no crumbs ‘Assemble the front cover (2)to theblockandtighten the screws (|) fxing ther to the prescribed couple €.Fousey 2003 |) Flgire 161 INGINES 53, B 7 a OE [= 1D Apply on engine drive shaft front tang (6) the detail (4) ‘ofthe too! ABO000606, cit with the serowes (6) andl Key the new holding ring on it (7). CO Place the detail (2) on the detail (), screw-up the ‘headed nut unti carrying out the complete assernbly of the holding ring (7) to the front cover Dh Assemble the plate (1), the rose pipe (2), tighten the fixing screws (3) and fx them to the prescribed couple54 ENGINES |. Provide for new gosket replacement) ofthe ol pan (2). ‘The pictures ilustrating the pan and ofthe rose pipe ‘may not correspond to the ones of your model. However the procedures described are applicable anyway. C1 Assemble oi pan (1), apply the plate ove it (2). Tighten the screws (2) and lock them to the prescribed couple, Before assembly always check thatthe threads ofthe portsandofthe screwshaveno evidence of tearand DFA 2000 SECTION 3 - DUTY “INDUSTRIAL APPLICATION. DD Assemble the pulley (I) and the dumping fywheel (2) to ‘the dewving shaft Tighten the fxing screws (3) and clamp them to the couple 68 = 7 Nm. Figure 166 O. Fita new seating ring on the speed sensor (3) (i ted). D1 Fit the speed senzor (3) on the front cover (I) and sighten the screw (2) to the specied torque (ited). | Fue 167 i Assemble the following elements to the blode new gasket (I), heat exchanger (2), new gasket (3), ol flter bearing 4). “Tiehten the screws (5) and lock them to the prescribed couple. A Before assembly aways check thatthe threads ofthe portsand ofthe srewshaveno evidence oftearand ‘wear nor ditN13 -OUTY ~INDUSTRAL APPLICATION Figure 168 Ci Lubricate the fing rng (2) using engine oil and place it fon the ol iter (3) Manual start the ol iter) on the bearing union (1) Until counter-borng, further screw up the ol fer (3) by 34 turn. Cl Apply. (iF needed) new fing ring on the oll ‘emperature/pressure sensor (4) and assemble itto the beating (I) tightening the xing screws to the prescribed couple. Gh Tiehten the screw (5) and lock it to the prescribed couple In some applications the bearing of the exchanger all be assembled to a screw threaded union connected to the fiter on the opposite side of the “engine, throughout twa pipelines (zee Figure 105), 1D Prace a new fing rng on the block housing (6) DD Assemble the alternator bearing (I) enauring that the pins (3 and 4) are against the engine block. Tighten the screws (2) and lock therm to the prescribed couple. ep Femuany om mNGNES 55 Before assem. abvayscheck that the threads ofthe ports and ofthe screws havena evidence oftearand ‘wear nor drt. Oy Reassemble the alternator (I). Tighten the serew (2) and lock it to the prescribed couple. Figure I71 Ret the atemator (I) 1 Tighten the screw (2) to the specified torque