Tigercat FPT C87 T2 ENGINE Service & Repair Manual - PDF DOWNLOAD

Tigercat FPT C87 T2 ENGINE

SERVICE AND REPAIR MANUAL

PRELIMINARY ISSUE 1.0, FEBRUARY 2016 Tigercat Industries Inc.

60214AENG

P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

I

Print notes Product: Language:

CURSOR 9 Tigercat Tier II R96 Construction ENG

Name:

P2D32C015E0116 ENG

Publication status:

26.02.2016

FPT Industrial S.p.A. Via Puglia 15 10156 Torino Italy Figures and words: FPT Industrial S.p.A. 2016 All rights reserved. www.fptindustrial.com

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Contents

Technical repair manual

1

General information

2

Operating diagrams

3

Electric/electronic system

4

Scheduled maintenance

5

Removal-refitting of the main engine components

6

General mechanical overhaul

7

Technical specifications

8

Equipment

9

Safety regulations

10

II

III

Contents

CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual Contents

Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . .

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1

CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual 2

Contents

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual INTRODUCTION Contents

Contents SYMBOLS - WARNINGS

. . . . . . . . . . . . . . . . . . .

5

SYMBOLS - SERVICE OPERATIONS . . . . . . . . . . . .

6

GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . .

7

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . .

8

Grounding and screening . . . . . . . . . . . . . . . . . . . .

9

Optional electrical and mechanical parts installations . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Conversions between the main units of measurement of the international system and the most commonly used derived sizes . . . . . . . . . . . . . . . . . . . . . . .

11

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Revolutions per time unit . . . . . . . . . . . . . . . .

11

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Temperature . . . . . . . . . . . . . . . . . . . . . . . .

11

update data . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual 4

INTRODUCTION

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual INTRODUCTION

5

SYMBOLS - WARNINGS

INTRODUCTION This document provides data, specifications, instructions and methods to perform repair interventions on the assembly and its components.

Anyhow, this document is addressed to qualified and specialised personnel.

Before performing any intervention, check that the document relating to the vehicle model on which the intervention is being performed is available and also make sure that all accident prevention devices, including but not limited to, goggles, helmet, gloves, shoes, as well as work equipment, lifting and transport equipment, etc., are available and efficient, and also make sure that the unit is in safety conditions for intervention.

Carrying out interventions which fully comply with the indications given here, as well as the use of the specific equipment indicated, ensures repair interventions are carried out correctly, timings are respected and the operator's safety is safeguarded.

Each repair intervention must be finalised to the recovery of functionality, efficiency and safety conditions that are provided by FPT. Each intervention on the unit aimed at a modification, alteration or other which has not been authorised by FPT relieves FPT of any liability, and, in particular, where the assembly is covered by a warranty, each intervention will immediately invalidate the warranty.

FPT declines any liability for repair work.

FPT is available to provide any information necessary for the execution of the interventions and to provide instructions for any cases and situations not covered in this publication.

The data contained in this issue may not be up-to-date due to possible modifications made by the Manufacturer for technical or commercial reasons, or to adaptations required by laws in force in different countries.

In the event of discordance between the information in this publication and the actual assembly, please contact the FPT network before performing any interventions.

The complete or partial reproduction of the text or illustrations herein is forbidden.

Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents.

Sections with mechanical contents include technical data, tightening torque tables, tool lists, assembly/component connections disconnections, overhauls at the bench and scheduled maintenance.

In the electrical/electronic system section there are the descriptions of the electric network and the electronic systems of the assembly, wiring diagrams, electrical characteristics of components and the component codes.

The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians, must comply with to prevent any serious injury.

The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of symbols has been defined to classify warnings, while another set has been specified for service operations.

SYMBOLS - WARNINGS Danger for persons Failure to comply with these prescriptions can result in the risk of serious injury.

Risk of serious damage to the assembly The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify the warranty.

General danger Includes the dangers of both above described signals.

Environmental protection Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.

NOTE

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Indicates an additional explanation for a piece of information.

CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual 6

INTRODUCTION SYMBOLS - SERVICE OPERATIONS

SYMBOLS - SERVICE OPERATIONS Removal Disconnect

Intake

Refitting Connect

Exhaust

Disassembly Disassembly

Operation

Assembly Composition

Compression ratio

Tighten to the specified torque

Tolerance Weight difference

Tighten to the specified torque + angle value

Rolling torque

Press or caulk

Rotation

Adjustment regulation

Angle Angle value

Visual inspection Assembly position check

Preload

Measurement Value to be measured Check

Revolutions per time unit

Tools

Temperature

Surface for machining Machined finished product

Pressure

Interference Forced assembly

Oversized Greater than ...

Maximum

Thickness Clearance

Undersized Lesser than ...

Minimum

Lubricate Dampen Grease

Selection Classes Oversizes

Sealant Glue

Temperature < 0 °C Cold Winter

Bleeding air

Temperature > 0 °C Hot Summer

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual INTRODUCTION

7

GENERAL WARNINGS

GENERAL WARNINGS The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors should be contacted whenever a dangerous situation that has not been described occurs.

Use the specific and general equipment according to that prescribed in the respective use and maintenance handbooks. Check the working condition and suitability of tools not subject to periodic review.

Manual handling of loads must be previously appraised regarding the weight, size and path.

Handling with mechanical equipment must be done using appropriate lifts and hoists, in terms of weight, shape and volume. Hoisters, ropes and hooks used must show clear indications regarding maximum acceptable carrying capacity. The use of such tools is strictly permitted by authorised personnel only. Stay at a safe distance from the load and never below it.

In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out from accidentally striking workshop personnel.

Workshop activities carried out in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator resulting from a lack of visibility or his/her incorrect position.

Keep any personnel not assigned to the operations clear of working area.

Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it.

Scrupulously observe all safety warnings on the assembly.

Do not leave the assembly in motion unattended during repair work.

When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands and that the manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp.

When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe all the specific safety regulations provided.

Remove the expansion tank cap only when the engine is cold, unscrewing it carefully to allow the residual pressure in the system to escape.

Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point cards of harmful materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks, in order to prevent sudden fires/explosions. Suitably store flammable, corrosive and pollutant fluids and liquids in accordance with current regulations. Strictly avoid using containers for food to store harmful liquids. Avoid drilling or burning pressurised containers and discard cloths impregnated with inflammable substances into suitable containers.

Worn out, damaged or consumable parts must be replaced with original spare parts.

During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and stains of liquids and oils. Electric sockets and electrical equipment necessary to perform repair operations must meet safety rules.

Wear, where required by the operation, garments and protection provided for by accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc.

Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside.

Do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas. Wear an appropriate respirator in the presence of paint dust.

Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid direct contact with liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact occurs.

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual 8

INTRODUCTION GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM

Before overhauling, clean the assemblies and make sure they are intact and complete. Place in an orderly fashion and in appropriate containers the parts removed or disassembled with their respective fixing elements (screws, nuts, etc.).

Check for the integrity of the parts which prevent screws from being unscrewed: spring lockwashers, copper pins, retaining clips, etc.

Nylon insert locknuts must always be replaced.

Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.

Before pressure washing mechanical parts, protect electrical connectors and any control units.

The tightening of screws and nuts should always be carried out according to directions. FPT's sales and assistance network is available to provide any clarifications necessary to carry out any repair work not covered by this document.

Before welding: ● ● ● ●

Disconnect all electronic control units and unplug the power cable from the battery's positive terminal (connecting it to the chassis ground) and connectors.

Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.

Wait approximately 15 minutes before proceeding with welding.

Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable materials flow when welding.

Should the vehicle be subjected to temperatures exceeding 80 °C (dryer ovens), remove the electronic control units.

The disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the chassis ground cable first of all from the negative terminal of the battery.

Before connecting the batteries to the system, make sure that the system is suitably insulated.

Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from the battery terminals.

Do not cause sparks to verify the presence of voltage in a circuit.

Do not use a test lamp to verify circuit continuity, but proper control equipment only.

Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding, grounding, etc.) conform with the FPT system and that they are carefully restored after repair or maintenance work.

Measurements on ECUs, on plug-connectors as well as on electrical connections can be made only on suitable testing lines, by means of special plugs and plug-type bushes. Never use improvised equipment like metal wires, screwdrivers, pins or similar. In addition to the risk of causing a short circuit, this might damage plug-type connections and this would then give rise to contact problems.

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual INTRODUCTION

9

Grounding and screening

Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or special truck.

Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of batteries) may lead to their destruction.

Disconnect the batteries from the system before recharging them by means of an external unit. on connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening torque.

Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.

Do not directly supply current to components served by electronic control units with nominal vehicle voltage.

The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.

Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.

Key programming procedures can be affected by electromagnetic disturbances (mobile phones, etc.). Therefore when key programming: 1.

2.

Note

Make sure there are no sources of disturbance near the keys or in the cab.

Keys not inserted in the panel must be at least 1 metre away.

The connectors are viewed from the cable side. Connector views contained in the manual are representative of cable side.

For fuse identification and rating, comply with the indications present in the vehicle, since their identification or rating may be subject to changes.

Grounding and screening

185272

Figure 1

The negative conductors connected to a system grounding point must be as short as possible and connected in a "star pattern", as well as being tightened down correctly and as specified ref. (M).

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual 10

INTRODUCTION Optional electrical and mechanical parts installations

d

C

d

C

88039

Figure 2

The following precautions must be observed regarding the electronic components: ● ● ● ● ● ●

electronic control units must be connected to the system ground when equipped with metal housings.

Electronic control unit negative cables must be connected to a system ground point, such as the dashboard compartment ground (avoiding "serial" or "chain" connections), as well as to the negative terminal of the battery/is.

Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal insulation. Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.

The metal braid of the shielded circuits must be in contact only at the control unit side to which the signal is to be sent.

In the case of junction connectors the unshielded section (d), near to the latter, must be as short as possible.

The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.

Optional electrical and mechanical parts installations Accessory installation, additions and changes on the vehicle must be carried out in compliance with the FPT assembly directives. it is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional) sockets in order to simplify and normalise the electrical intervention by bodybuilders.

Any exception to the assembly directives must be authorized by FPT. lack of observance of above described prescriptions involves guarantee lapse. ▶

It is strictly forbidden to carry out any modifications or connections to the electric control unit wiring. In particular, the data line between the control units (CAN line) is to be considered untouchable.

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual INTRODUCTION

11

Conversions between the main units of measurement of the international system and the most commonly

Conversions between the main units of measurement of the international system and the most commonly used derived sizes Power 1 kW = 1.36 CV 1 kW = 1.34 hp 1 CV = 0.735 kW 1 CV = 0.986 hp 1 hp = 0.746 kW 1 hp = 1.014 CV Note The CV unit is converted into hp for simplicity according to a ratio of 1:1 1 hp = 1 CV Torque 1 Nm = 0.102 kgm 1 kgm = 9.81 Nm Note Unless there is a specific need for accuracy, the unit Nm is converted into kgm for simplicity according to a ratio of 10:1, or rather: 1 kgm = 10 Nm. Revolutions per time unit 1 rpm = 0.1047 rad/s 1 rad/s = 9.55 rpm Pressure 1 bar = 1.02 kg/cm2 1 kg/cm2 = 0.981 bar 1 bar = 10 5 Pa Note The unit bar is converted into kg/cm² for simplicity according to a ratio of 1:1 1 kg/cm² = 1 bar.

Temperature 0 °C = 273.15 K 0 °F = 255.37 K 0 °C = 32 °F (the conversion factor between Celsius and Fahrenheit is 1:1.8)

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CURSOR 9 Tigercat Tier II R96 ‒ Technical repair manual 12

INTRODUCTION update data

update data section

Description

page

revision date

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CURSOR 9 Tigercat Tier II R96 ‒ General information Contents

Contents General information . . . . . . . . . . . . . . . . . . . . . . .

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CURSOR 9 Tigercat Tier II R96 ‒ General information 2

Contents

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CURSOR 9 Tigercat Tier II R96 ‒ General information General information Contents

Contents IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . .

5

Identification plate . . . . . . . . . . . . . . . . . . . . . .

5

CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES . . . . . . . . . . .

5

CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES . . . . . . . . .

5

TECHNICAL CODES . . . . . . . . . . . . . . . . . . . . . .

5

TECHNICAL CODES . . . . . . . . . . . . . . . . . . .

5

COMMERCIAL CODES . . . . . . . . . . . . . . . . . . . .

6

COMMERCIAL CODES . . . . . . . . . . . . . . . . . .

6

ISOMETRIC VIEW . . . . . . . . . . . . . . . . . . . . . . . .

7

ISO VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

CHARACTERISTIC CURVES . . . . . . . . . . . . . . . . .

9

CHARACTERISTIC CURVES F2CFA613T . . . . . . .

9

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . .

10

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . .

10

GENERAL CHARACTERISTICS . . . . . . . . . . . . . .

13

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CURSOR 9 Tigercat Tier II R96 ‒ General information 4

General information

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CURSOR 9 Tigercat Tier II R96 ‒ General information General information

5

IDENTIFICATION PLATE

General information IDENTIFICATION PLATE Identification plate

237481

1.

2.

Engine name.

Engine serial No.

3.

4.

Figure 1

Date of manufacture.

Type-approval.

CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES 54

CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES Technical codes

Commercial Codes

F2CFA613T*E026

C87 ENT R W

TECHNICAL CODES 54

TECHNICAL CODES

The technical code is assigned during production; it is used to identify the main characteristics, characterise the application and the corresponding level of power output.

F2CFA613T*E026

●

F2CFA613T*E026- ENGINE FAMILY IDENTIFICATION

●

F2CFA613T*E026 - CRANKCASE: C = STRUCTURAL (OFF ROAD)

●

F2CFA613T*E026 - MANAGEMENT: F = ENGINE WITH HW

●

F2CFA613T*E026 - CYLINDER CONFIGURATION: E = 4 STROKE VERTICAL

●

F2CFA613T*E026 - NUMBER OF CYLINDERS

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CURSOR 9 Tigercat Tier II R96 ‒ General information 6

General information COMMERCIAL CODES

●

F2CFA613T*E026 - MAIN ENGINE CHARACTERISTICS: 1 = DIRECT INJECTION TURBOCHARGED WITH INTERCOOLER

●

F2CFA613T*E026 - APPLICATION

●

F2CFA613T*E026 - ENGINE POWER

●

F2CFA613T*E026 - EMISSION LEVEL: E = Not emissioned)

●

F2CFE613T*B025 VARIANTS TO THE BASIC ENGINE: the first number refers to the injection system (0 = 4-valve Common Rail) whereas the other numbers refer to the engine configuration.

COMMERCIAL CODES 54

COMMERCIAL CODES

The purpose of the commercial name is to make the information regarding engine characteristics easy to understand, by joining engines from different families, origins and applications for which they are intended. The commercial code cannot be used for technical purposes in order to completely identify the parts that make up the engine, referring to the “serial number” otherwise indicated as ”ENGINE S/N”, as the identification.

C87 ENT R W

●

C87 ENT 6 R W- ENGINE FAMILY IDENTIFICATION: C = CURSOR

●

C87ENT 6 R W- DISPLACEMENT (LITRES x 10) - THE FIRST DIGIT ALSO IDENTIFIES THE NUMBER OF CYLINDERS

●

C87EENT R W- TYPE OF INJECTION: E = ELECTRONIC

●

C87ENT R W- CRANKCASE: N = NON STRUCTURAL

●

C87ENT R W- INTAKE: T = TURBOCHARGED WITH INTERCOOLER

●

C87ENT RW - USE = CONSTRUCTION EQUIPMENT.

●

C87ENT RW - CONTROL UNIT = EDC 17

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CURSOR 9 Tigercat Tier II R96 ‒ General information General information ISOMETRIC VIEW

ISOMETRIC VIEW 540110

ISO VIEW

237410

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Figure 2

7

CURSOR 9 Tigercat Tier II R96 ‒ General information 8

General information ISOMETRIC VIEW

237411

Figure 3

F2CFA613 is an in-line 6-cylinder turbo engine with intercooler and 4 valves per cylinder. It is part of CURSOR series and operates according to a 4-stroke diesel cycle.

The engine's fuel system is electronically controlled and based on the direct injection of the fuel in the combustion chamber by means of a high pressure pump and the common rail.

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CURSOR 9 Tigercat Tier II R96 ‒ General information General information CHARACTERISTIC CURVES

CHARACTERISTIC CURVES 5401

CHARACTERISTIC CURVES F2CFA613T

237468

A

Power

Technical data Max POWER 285 kW (387 HP) at 2000 rpm Technical data Max. TORQUE 1550 Nm (159 kgm) at 1500 rpm

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B

Torque

Figure 4

9

CURSOR 9 Tigercat Tier II R96 ‒ General information 10

General information ENGINE VIEWS

ENGINE VIEWS 5401

ENGINE VIEWS

FRONT VIEW

237412

1 2 3 4

Blow-by engine vent Turbocharger Water pump drive water pump water inlet pipe (from radiator)

5 6 7 8

Figure 5

Damper flywheel Automatic belt tensioner Guide pulley Turbocharger lubrication delivery pipe

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CURSOR 9 Tigercat Tier II R96 ‒ General information General information ENGINE VIEWS

REAR VIEW

237413

1 2 3

Waste-Gate valve Incremental speed sensor (camshaft) Timing / Blow-by filter cover

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4 5 6

Oil sump Oil drainage plug Flywheel

Figure 6

11

CURSOR 9 Tigercat Tier II R96 ‒ General information 12

General information ENGINE VIEWS

LEFT SIDE VIEW

237414

1 2 3

Head cover Exhaust manifold Oil filter support

4 5 6

Figure 7

Oil filter Oil refilling plug Heat exchanger

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CURSOR 9 Tigercat Tier II R96 ‒ General information General information GENERAL CHARACTERISTICS

RIGHT SIDE VIEW

Figure 8

237415

1 2 3

Fuel filter Intake manifold Engine cable

4 5 6

ECU Starter motor High pressure fuel pump

GENERAL CHARACTERISTICS (*)

It is prohibited to mix fluids of different brands.

type

F2CFA613T*E026 Diesel 4-stroke

Cycle Power supply Injection

Turbocharged with aftercooler Direct

Number of cylinders

Bore

– P2D32C015E0116

6 in line

mm

117

13

CURSOR 9 Tigercat Tier II R96 ‒ General information 14

General information GENERAL CHARACTERISTICS

type

F2CFA613T*E026

Stroke

mm

135

Total displacement

cm3

8710

Compression ratio

16:1

Max. power

kW (HP) rpm.

285 (387) 2000

maximum torque

Nm (kgm) rpm.

1550 (1590) 1500

Idle speed with no load

rpm.

900 ± 50

Maximum engine idle speed

rpm.

2290 ± 50

DISTRIBUTION start before T.D.C.

A = 17°

end after B.D.C.

B = 31°

start before B.D.C.

D = 48°

End after T.D.C.

C= 9°

For timing check X

mm

0.40 ±0.05

mm

0.40 ±0.05 The high pressure fuel supply system is managed by the BOSCH EDC 17. It consists of the CP 3.3 high-pressure pump, electro-injectors, hydraulic accumulator (rail), EDC 17 ECU and pressure and temperature sensors.

POWER SUPPLY

Injection Bosch

CRIN 3

1–4–2–6–3–5

Firing order

Injection pressure Calibration

bar bar

1800

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CURSOR 9 Tigercat Tier II R96 ‒ General information General information GENERAL CHARACTERISTICS

type

F2CFA613T*E026

TURBOCHARGING Turbocharger type:

Honeywell (HTT)

LUBRICATION

Forced by gear pump, pressure relief valve, oil filter

Oil pressure with hot engine (100 °C ± 5 °C):

Forced by gear pump, pressure relief valve, oil filter.

at idle speed at max speed

bar bar

0.6 3.5 By means of a centrifugal pump, thermostat for regulation, fan, radiator, heat exchanger.

COOLING Water pump drive:

Belt driven

Thermostat initial opening maximum opening

°C

85 ± 1.5

°C

95

REFILLING Cooling circuit

.

litres

14

litres (kg)

30 (27)

engine sump min level.

litres (kg)

19 (17.1)

engine sump max level.

litres (kg)

28 (25.2)

(*)

Total capacity of 1st filling

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.

(*)

15

CURSOR 9 Tigercat Tier II R96 ‒ General information 16

General information

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams Contents

Contents OPERATING DIAGRAMS. . . . . . . . . . . . . . . . . . . .

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 2

Contents

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. Contents

Contents FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

FUEL SUPPLY COMPONENTS

7

. . . . . . . . . . . . .

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . .

16

lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .

16

LUBRICATION CIRCUIT COMPONENTS . . . . .

17

OIL VAPOURS

. . . . . . . . . . . . . . . . . . . . . . . .

24

Oil vapour recirculation (Blow-by) . . . . . . . . . . .

24

COOLANT CIRCUIT

. . . . . . . . . . . . . . . . . . . .

25

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

COOLING CIRCUIT COMPONENTS . . . . . . . .

27

TURBOCHARGING . . . . . . . . . . . . . . . . . . . . .

27

Turbocharging . . . . . . . . . . . . . . . . . . . . . . .

27

Honeywell waste-gate turbocharger . . . . . . . . . .

29

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3

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 4

OPERATING DIAGRAMS.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS.

5

FUEL SUPPLY

OPERATING DIAGRAMS. FUEL SUPPLY 5420

Supply

237473

A

Fuel supply system

B

Figure 1

Tank return circuit

The Common Rail fuel system has a special pump that continuously keeps fuel at high pressure, independently from the stroke and the cylinder which is to receive the injection and accumulates fuel in a common duct for all injectors.

At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit.

When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from the rail takes place in the corresponding cylinder.

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 6

OPERATING DIAGRAMS. FUEL SUPPLY

ENGINE FUEL SUPPLY DIAGRAM

204474

A

High pressure

B

Low pressure

1 2 3 4 5

High-pressure pump Fuel filter Tank Fuel pre-filter E.C.U. (Electronic Control Unit)

6 7 8 9

Electro-injectors overpressure valve Common rail Pressure sensor

Figure 2

Caution! ▶

After having fitted the high pressure pipes, check the oil level frequently in the next 20 hours (IT MUST NOT FALL).

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS.

7

FUEL SUPPLY

FUEL SUPPLY COMPONENTS 773010

Mechanical supply pump

Gear pump, mounted on the rear part of the high pressure pump, has the function of supplying it. It is controlled by the high pressure pump shaft.

Normal operating condition

72592

Figure 3

A

Fuel inlet from tank

B

Fuel outlet to filter

1

By-pass valves in closed position

2

By-pass valves in closed position

Output overpressure condition

72593

Figure 4

The by-pass valve(1) operates in output(B) and generates an overpressure. This pressure, overcoming the elastic resistance of the valve spring (1), connects the output with the entrance through the duct (2).

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 8

OPERATING DIAGRAMS. FUEL SUPPLY

Air bleeding conditions

72594

Figure 5

The by-pass valve (2) cuts in when, with engine off, the fuel system is to be filled through the priming pump. In this situation the bypass valve (1) stays closed and the by-pass valve (2) opens due to the inlet pressure and fuel flows through the outlet (B).

Note The mechanical supply pump cannot be replaced individually, so it must not be removed from the high pressure pump.

771010

High pressure pump CP 3.3

Pump with 3 radial plungers, controlled by distribution gears, requires no timing. The mechanical supply pump controlled by the high pressure pump shaft is mounted on the rear side of the high pressure pump.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. FUEL SUPPLY

144822_2

1 2 3 4 5

High-pressure pump Fuel delivery union to rail Fuel inlet from control unit heat exchanger fitting Fuel inlet fitting from filter Pressure regulator

– P2D32C015E0116

6 7 8

Figure 6 6. Connection between fuel outlet from mechanical pump and filter Connection between fuel outlet and rail Mechanical supply pump.

9

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 10

OPERATING DIAGRAMS. FUEL SUPPLY

High-pressure pump internal structure

70498

Upper figure LH sec. B - B 1 2 3 4

Cylinder Three lobe element Cap intake valve Ball delivery valve

Figure 7

Lower figure LH sec. C - C 5 6 7 8

Piston Pump shaft Low pressure fuel inlet Fuel canals to power plungers

Each pump unit consists of: ● ● ●

a piston (5) actuated by a three lobe element (2) floating on the pump shaft (6). The element (2), floating on an offset part of the shaft (6), does not rotate with the shaft during the shaft's rotation, but is only moved in a circular movement on a wider range, alternatively activating the three plungers; cap intake valve (3); ball delivery valve (4).

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. FUEL SUPPLY

Operating principle

72597

Upper figure sec. B - B 1 2 3 4

Connection between fuel outlet and rail Delivery valve to rail Plunger Pump shaft

– P2D32C015E0116

Figure 8

Lower figure sec. D - D 5 6 7

Pumping element supply duct Pressure regulator supply duct Flow regulator

11

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 12

OPERATING DIAGRAMS. FUEL SUPPLY

The pumping element (3) is oriented to the pump shaft cam (4). During the operation phase, the plunger is powered through the power supply duct (5).

The pressure regulator modulates the amount of fuel sent to the high-pressure circuit (7). The load regulator, based on the PWM command from the control unit, shuts the flow of fuel to the plunger. During the fuel pump compression phase, once a pressure is reached that will open the delivery valve to the common rail (2), it powers it through the outlet (1). sec C - C

72598

1 2 3 4 5

Plunger inlet Ducts for pump lubrication Plunger inlet Main pumping element supply duct Flow regulator

6 7 8 9

Figure 9 Plunger inlet Regulator discharge duct 5 bar relief valve Fuel discharge from regulator inlet.

The figure shows the low-pressure fuel paths inside the pump; it also shows the main supply duct of the plungers (4), the supply ducts of plungers (1)-(3)-(6), the ducts used to lubricate the pump (2), the load regulator (5), the 5 bar relief valve (8) and the fuel discharger (7). The pump shaft is lubricated by the fuel through the delivery and return ducts (2). The load regulator (5) sets the quantity of fuel with which the plungers must be supplied; the excess fuel flows through the duct (9). The 5 bar relief valve, in addition to functioning as a collector for fuel discharge, has the function of keeping the pressure constant at 5 bar at the entrance of the regulator.

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS.

13

FUEL SUPPLY

Sec. A-A

Figure 10

72601

1 2

Fuel outlet duct Fuel outlet duct

3

Pump fuel outlet with coupling for high pressure pipe for the common rail

The figure shows the high pressure fuel flow through the plunger outlet ducts. operation The cylinder is filled through the plate intake valve only if the supply pressure can open the delivery valves on the plungers (approx.

2 bar).

The quantity of fuel that powers the high pressure pump is dosed by the load regulator on the low pressure system; the load regulator is controlled by the EDC17 control unit through a single PWM. If the fuel is sent to the plunger, its piston is moving down (intake stroke). When the piston stroke inverts, the intake valve closes and the fuel remaining in the plunger chamber, which cannot exit, is compressed beyond the existing supply pressure in the rail.

The pressure generated this way causes the discharge valve to open and the compressed fuel reaches the high pressure circuit.

The plunger compresses the fuel till the top dead centre (delivery stroke) is reached. Then the pressure decreases so that the discharge valve closes.

The plunger piston returns to the bottom dead centre and the residual fuel is decompressed.

When the pressure in the plunger chamber is lower than the supply pressure, the intake valve opens again and the cycle is repeated.

The delivery valves must always be free in their movement, with no impurities or oxidation.

The pressure delivered to the rail is modulated by the electronic unit by means of the pressure regulator solenoid valve.

The pump is lubricated and cooled by the same fuel. The removal - refitting time of the radialjet pump on the engine is significantly reduced compared to traditional injection pumps because no timing is necessary.

In the event of removal - refitting of the fuel filter pipe and high pressure pump, make sure hands and components are as clean as possible.

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 14

OPERATING DIAGRAMS. FUEL SUPPLY

774510

Rail (pressure accumulator)

114254

1 2 3

Rail Fuel return Pipes to injectors

4 5 6

Figure 11 Fuel inlet from high-pressure pump Pressure sensor Overpressure valve

The rail volume is of reduced size to allow a quick pressurisation at start-up, at idle and in case of high flow-rates.

It anyway has enough volume as to minimise pulsations caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.

A fuel pressure sensor (5) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. FUEL SUPPLY

542010

Fuel filter

Figure 12

191090

1 2 3

Fuel filter Fuel temperature sensor Clogged filter sensor

4 5

Fitting for bleeding Drain valve

Technical data Maximum load

500 ℓ/h

Nominal pressure

< 13 bar

operating temperature

−40 ℃ to120 ℃

Pressure drop with new filter

<0,45 bar

Pressure drop with filter at end of life

>1.5 bar

Tightening torques DETAIL

TORQUE Nm

kgm

1

Fuel filter

32.5 ± 2.5

3.25 ± 0.25

2

Fuel temperature sensor

30 ± 2

3 ± 0.2

3

Clogged filter sensor

30 ± 2

3 ± 0.2

4

Fitting for bleeding

18 ± 2

1.8 ± 0.2

5

Drain valve

1.5 ± 0.5

0.15 ± 0.05

– P2D32C015E0116

15

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 16

OPERATING DIAGRAMS. LUBRICATION

LUBRICATION 5430

lubrication

Lubrication circuit

237472

A

Return oil transmission due to gravity

B

Figure 13

Oil transmission under pressure

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. LUBRICATION

LUBRICATION CIRCUIT COMPONENTS 543010

Oil pump

The oil (1) pump cannot be overhauled.

If you find any damage, replace the entire oil pump.

To change the gearing (2) of the crankshaft, see the relevant chapter.

114245

Oil pump cross-section

112327

Technical data Initial opening pressure - Overpressure safety valve

– P2D32C015E0116

10.1 ±0.7 bar

Figure 15

Figure 14

17

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 18

OPERATING DIAGRAMS. LUBRICATION

543076

Overpressure valve

Main data to check the overpressure valve spring

117716

543075

Figure 16

Oil pressure regulator valve

The oil pressure relief valve is located on the left-hand side of the crankcase.

Technical data Start of opening pressure

5 bar

73542

Figure 17

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. LUBRICATION

Main data to check the oil pressure adjustment valve spring

168 ± 9

36,4

51

63

308 ± 15

88819

– P2D32C015E0116

Figure 18

19

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 20

OPERATING DIAGRAMS. LUBRICATION

543070

Engine oil filter

Engine oil filter components

114247

1 2 3 4 5 6

Closing cap.

Filter cartridge.

Spring.

Filter support O-ring.

Cap O-ring.

Washer.

7 8 9 10 11

Figure 19

Washer.

Oil filter support.

Plug M14x1,5.

Plug M38x1,5.

By-pass valve 3.4 bar.

Technical data Maximum operating pressure

13 bar

Operating temperature

−30 ℃ to120 ℃

By-pass valve opening pressure

3.4 ±0.3 bar

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. LUBRICATION

Tightening torques Technical data Cap (1) : 60±5 Nm Drain plug (9) : 30 ± 5 Nm By-pass valve plug(10) : 90±5 Nm

543077

Filter by-pass valve

The valve quickly opens at the pressure shown below.

Technical data Valve opening pressure

3 bar

073545

543070

Disassembly

Remove the plug (2).

Unscrew the body (1) of the filter a couple of full turns and wait a few minutes.

In this way, the remaining oil in the body starts to leak and then flow regularly out Unscrew the body completely and replace the cartridge.

144826 - Copia

– P2D32C015E0116

Figure 21

Figure 20

21

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 22

OPERATING DIAGRAMS. LUBRICATION

Insert the cartridge into the body and fit the centring flanges (2) on the top cap (1) with the relative seats.

The cartridge is pushed into the container until overcoming the action of the clasping system located at the bottom of the body.

At the same time, the flaps on the top plate slide in their seats.

115877

Figure 22

Bring the top part of the body thread next to the first bottom thread of the support (the stub of the cartridge cover fits into the oil outlet on the support).

Screw in the body cartridge-body assembly (2) onto the support (1).

145899

Figure 23

Tightening torque Oil filter Ufi Filter

60 ±5 N⋅m

Screw in the protection cap (1) onto the filter body.

144827

Figure 24

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. LUBRICATION

543110

Heat exchanger

Heat exchanger

180296

1 2

By-pass valve (opening pressure 2.5 ± 0.3 bar) Heat exchanger

– P2D32C015E0116

3

Oil filter support seat

Figure 25

23

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 24

OPERATING DIAGRAMS. OIL VAPOURS

OIL VAPOURS 540480

Oil vapour recirculation (Blow-by)

237471

A B

Gas with oil content above 10 g/h Gas with oil content of ≈ 0.2 g/h

C

Figure 26

Condensed oil that returns to the oil sump

Part of the gas produced by combustion leaks out of the piston gaskets into the sump and mixes with the oil vapour it contains.

This mixture is conveyed upwards and is partially separated from the oil by a rotating filter (1) located at the top of the timing gear cover and splined on the camshaft.

After passing through the rotating filter, the residual oil vapours pass inside the cable camshaft and are returned to the air intake circuit through the membrane valve (3) located on the front cover (2).

A pressure sensor that detects the clogging of the Blow-by filter is located on the rocker arm cover.

By measuring the pressure under the rocker arm cover, it is also able to detect the presence of fuel in oil.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS.

25

COOLANT CIRCUIT

COOLANT CIRCUIT 5432

Cooling

Description The engine cooling system is a closed circuit forced circulation system and can be connected to an additional heater (if any) and to the Intarder heat exchanger.

It consists mainly of the following components: ● ● ● ●

An expansion tank whose plug has two valves, one exhaust and one inlet which together adjust the system pressure.

A heat exchanger to cool the lubricating oil.

A centrifugal water pump incorporated in the crankcase.

A 3-way thermostat regulating the circulation of the coolant.

operation The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the cylinder head.

When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid is channelled from here to the radiator and cooled by the fan.

The pressure inside the system depending on the temperature variation is controlled by the discharge and charge valves incorporated in the expansion reservoir filling plug.

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 26

OPERATING DIAGRAMS. COOLANT CIRCUIT

Coolant diagram

237470

A B

Water entering the thermostat Water circulating in the engine

C

Figure 27

Pump outlet water

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS. TURBOCHARGING

COOLING CIRCUIT COMPONENTS 543210

Water pump

Section on water pump

44915

Figure 28

The water pump is composed of: rotor, bearing, gasket and drive pulley.

Note Make sure that the pump body is free of cracks and water leaks; otherwise replace the entire water pump.

TURBOCHARGING 5424

Turbocharging

The turbocharging system is composed of: ● ● ●

an air filter; a fixed geometry turbocharger equipped with a WG (waste-gate) pressure relief valve; an intercooler radiator.

– P2D32C015E0116

27

CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 28

OPERATING DIAGRAMS. TURBOCHARGING

Turbocharging diagram

237469

A B

Exhaust gas Hot compressed air

C

Figure 29

Air intake

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams OPERATING DIAGRAMS.

29

TURBOCHARGING

542410

Honeywell waste-gate turbocharger

189008

1.

2.

3.

Gasket Exhaust gas inlet Waste-Gate valve

4.

5.

Figure 30 Compressed air outlet Air intake

The turbocharger is of the type with a pressure relief valve. It consists mainly of: ● ● ●

a central body which incorporates a shaft supported by bushings at the opposite ends of which the turbine impeller and the compressor rotor are fitted; a turbine casing and a compressor casing mounted on the end of the central body; an overpressure relief valve applied on the turbine casing. The function of this valve is to choke the exhaust gas outlet, by conveying part of the gas directly into the exhaust pipe, when the turbocharging pressure downstream of the compressor reaches the calibration value.

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CURSOR 9 Tigercat Tier II R96 ‒ Operating diagrams 30

OPERATING DIAGRAMS.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system Contents

Contents ELECTRIC/ELECTRONIC SYSTEM . . . . . . . . . . . . .

– P2D32C015E0116

3

1

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 2

Contents

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM Contents

Contents ENGINE CABLE . . . . . . . . . . . . . . . . . . . . . . . . .

5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

WIRE DIAGRAM

. . . . . . . . . . . . . . . . . . . . . . . .

8

ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

EDC17CV41 electronic control unit

. . . . . . . . . .

9

EDC system operation . . . . . . . . . . . . . . . . . .

10

Engine side pin out . . . . . . . . . . . . . . . . . . . .

14

EDC (ECM) SYSTEM . . . . . . . . . . . . . . . . . . . . .

16

Electro-injectors . . . . . . . . . . . . . . . . . . . . . .

17

Fuel metering valve . . . . . . . . . . . . . . . . . . . .

18

Rail pressure sensor (RPS) . . . . . . . . . . . . . . . .

19

CPS pressure sensor . . . . . . . . . . . . . . . . . . .

21

Flywheel pulse transmitter . . . . . . . . . . . . . . . .

21

Timing system pulse transmitter . . . . . . . . . . . .

23

Fuel temperature sensor . . . . . . . . . . . . . . . . .

25

Fuel filter clogged sensor . . . . . . . . . . . . . . . . .

28

Engine coolant temperature / engine fan sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

Oil pressure and temperature sensor . . . . . . . . .

30

Air temperature and pressure sensor . . . . . . . . .

33

Pre/post heating element . . . . . . . . . . . . . . . . .

36

STARTER MOTOR "NIPPONDENSO" 24V 5.5KW STARTER MOTOR - [08000] . . . . . . . . .

38

– P2D32C015E0116

3

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 4

ELECTRIC/ELECTRONIC SYSTEM

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM ENGINE CABLE

ELECTRIC/ELECTRONIC SYSTEM 5401

ENGINE CABLE

Electrical components.

237479

1.

2.

3.

4.

Electroinjector Rail Fuel filter support sensors Water temperature sensor.

– P2D32C015E0116

5.

6.

7.

8.

Figure 1

Crankcase pressure sensor.

Starter device.

Air pressure and temperature sensor.

Oil pressure and temperature sensor.

5

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 6

ELECTRIC/ELECTRONIC SYSTEM ENGINE CABLE

237479

9.

10.

11.

EDC control unit.

Electric starter motor.

High-pressure pump.

12.

13.

Figure 1

Crankshaft incremental speed sensor.

Camshaft incremental speed sensor

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

7

ENGINE CABLE

Cable on engine

237474

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Electro-injector (cylinder 6).

Electro-injector (cylinder 5).

Electro-injector (cylinder 4).

Electro-injector (cylinder 3).

Electro-injector (cylinder 2).

Rail pressure sensor.

Electro-injector (cylinder 1) Connector.

Engine crankcase pressure sensor.

Coolant temperature sensor.

EDC connector 96 pin engine side.

– P2D32C015E0116

12.

13.

14.

15.

16.

17.

18.

19.

20.

Figure 2

In-line connector 6 pin.

Engine oil temperature and pressure sensor.

Air temperature and turbocharging pressure sensor Camshaft incremental speed sensor.

High pressure fuel pump dosing unit.

Fuel filter clogged sensor.

Fuel temperature sensor.

Flywheel incremental speed sensor.

Motorised throttle valve actuator connector (exhaust valve).

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 8

ELECTRIC/ELECTRONIC SYSTEM WIRE DIAGRAM

76

WIRE DIAGRAM

237475

Figure 3

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

9

ECU

1.

2.

3.

4.

5.

6.

7.

96 pin engine EDC connector.

Fuel temperature sensor.

Coolant temperature sensor.

Engine oil temperature and pressure sensor.

Air pressure and temperature sensor.

Fuel filter clogged sensor.

Motorised throttle valve actuator connector (exhaust valve).

In-line connector.

Crankcase pressure sensor.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Camshaft incremental speed sensor.

Crankshaft incremental speed sensor.

High pressure fuel pump dosing unit.

Rail pressure sensor.

Electro-injector (cylinder 6).

Electro-injector (cylinder 5).

Electro-injector (cylinder 4).

Electro-injector (cylinder 3).

Electro-injector (cylinder 2).

Electro-injector (cylinder 1).

ECU 766161

EDC17CV41 electronic control unit

The control unit is a flash e.p.r.o.m which can be reprogrammed externally without the need to intervene on the hardware.

The ECU processes the signals from the sensors by applying software algorithms and controls the actuators (especially the electroinjectors and pressure regulator).

It records, in the non-volatile memory area, the information on the engine parameters originally set or acquired during engine operation.

The control unit is fitted on the left-hand side of the engine and is connected to two connectors: 1.

2.

one connector for the engine cable (electro-injector and sensor connector); one connector for the chassis cable.

To reduce the number of connections, the length of the connection cables with the injectors and, as a result, disturbances in the transmitted signal, the control unit is mounted directly on the engine by means of a heat exchanger that cools it, using elastic dowels which reduce the vibrations transmitted by the engine.

Internally, there is an ambient pressure sensor that is used to further improve injection system management.

It is also equipped with a very advanced self-diagnosis system and it is capable of recognizing and memorizing, in function of the environmental conditions, the possible anomalies, even of an intermittent type, that occurred on the system during operation, ensuring a more correct and reliable repair action with the help of the FPT diagnostic instruments.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 10

ELECTRIC/ELECTRONIC SYSTEM ECU

EDC17CV41 control unit

178240

1

Chassis side connector (connector 1)

766161

2

Figure 4

Engine side connector (connector 2)

EDC system operation

The electronic control unit EDC17 CV41 manages the following main functions: ● ● ● ● ●

Fuel injection Turbine geometry variation Exhaust brake engagement Self-diagnostics Recovery

Also permits:

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

11

ECU

● ●

Interfacing with other on-board electronic systems (where present) Diagnosis

Fuel dosing The fuel metering is calculated in relation to: ● ● ●

position of the accelerator pedal by the VCM (Vehicle Control Module); engine speed; the amount of air introduced.

The outcome may be corrected in relation to: ● ●

water temperature; fuel temperature (DIESEL DENSITY).

Or to avoid: ● ● ●

overloading; overheating; turbine over-revving.

The delivery can be modified in the case of: ● ● ● ●

the engine brake or brake pedal being activated (signals via CAN); a limiting device cutting in (ASR, speed limiter, etc.) (signals via CAN); activation of the ANTIPOLLUTION devices: ∆p sensor, NOx sensor, NH3 sensor. serious trouble decreasing the load or stopping the engine.

Once the control unit has determined the mass of the introduced air and measured its pressure and temperature, it calculates the corresponding fuel load needed to inject into the cylinder (mg. per delivery). It also takes diesel temperature into account (density).

The fuel load calculated in this way is converted into crank degrees i.e. injection advance and duration.

Correcting flow rate according to water temperature When cold, the engine encounters greater resistance in operating: there is greater mechanical friction, the oil is still very viscous, the various clearances are not yet optimised.

In addition to this, injected fuel tends to condense on the still cold metallic surfaces.

The fuel supply for a cold engine is therefore greater than for a warm one.

De-rating In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in proportion to the temperature reached by the coolant. The control unit considers the oil temperature in case of a water temperature sensor failure.

Turbine speed Turbine speed is adjusted continuously and corrected if needed through geometry variation.

Closed loop injection pressure management Based on engine load, determined by the processing of signals coming from the various sensors, the control unit controls the pressure regulator to always ensure an optimal pressure (TARGET PRESSURE). The control unit controls the result (INJECTION PRESSURE) using the sensor on the COMMON RAIL. Injection advance electronic control

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 12

ELECTRIC/ELECTRONIC SYSTEM ECU

The advance (starting moment, expressed in degrees) may be different from one injection to the next, and in a differentiated manner from one cylinder to another, and is calculated, similarly to the flow rate, on the basis of engine load (accelerator pedal position, engine speed and introduced air).

The advance is appropriately corrected: ● ●

in acceleration steps; according to the coolant temperature;

and also to obtain: ● ●

lower emissions, noise and overloading; better vehicle acceleration.

When starting the engine, a high degree of advance is used based on water temperature. the feedback from the start of delivery is supplied by the change in impedance of the injector solenoid valve.

Engine speed limiter The control unit controls the engine speed at all rev ranges and in particular: ● ●

at idle; at top speed.

Starting the engine During the initial driven engine revolutions, the timing and recognition signals are synchronised for cylinder no.1 (flywheel sensor and camshaft sensor). Upon ignition, the signal of the accelerator pedal that arrives via CAN is ignored. The delivery of the diesel upon ignition is set exclusively based on the temperature of the water by means of a specific map. When the control unit detects a number of revolutions as well as a flywheel acceleration such to consider the engine as started and no longer driven by the starter motor, it re-enables the accelerator pedal signal.

Cold starting Pre-post heating is activated when just one of the three sensors (water, air or fuel) registers a temperature lower than 10 °C. Upon activation of the key contact, the pre-heating warning light turns on the electronic dashboard (cluster display) and remains on for a variable amount of time depending on the temperature (while the heating element at the intake manifold heats the air), then it flashes. At this point the engine can be started.

When the engine is running, the warning lamp goes out but the heater element continues working for a certain (variable) period of time for post-heating.

If, with the warning lamp blinking, the engine is not started within 20–25 seconds (absence time) the operation is cancelled in order not to discharge the batteries.

The pre-heating curve is also variable in relation to the battery voltage.

Warm starting When the ignition key is inserted and the reference temperature exceeds 10°C, a warning light turns on for approximately 2 seconds as a short test, then goes out. At this point the engine can be started.

Run Up When the key makes contact, the control unit transfers the information stored in memory when the engine was last stopped into the main memory (see After Run) and makes a diagnosis of the system.

After run Each time the engine is turned off with the key, the control unit continues to operate for a few seconds thanks to the internal MAIN RELAY.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

13

ECU

This permits the microprocessor to transfer some data from the main memory (volatile) to a non volatile, erasable and rewritable memory (EEPROM), to make it available for the next start (see: Run Up).

The data mainly consists of: ● ● ●

various settings (engine idling, etc.); calibration of certain components; faults memory.

This procedure lasts a few seconds, typically from 40 to 120 (depending on the quantity of data to save), after which the ECU deactivates the main power supply.

Note This procedure should never be interrupted, for instance by switching off the engine with the battery isolator or disconnecting the battery isolator before at least 10 seconds have passed after the engine is switched off.

If this happens, system functionality remains guaranteed until the fifth time it is turned off incorrectly (also non consecutively) after which an error is stored in the faults memory and upon the following engine start-up, the engine will function with reduced performance while the EDC warning light remains on.

Repeated interruptions of the procedure could in fact lead to damage to the control unit.

Cut - off This function cuts off fuel feed during deceleration and during engine braking etc.

Cylinder Balancing This function permits individual, customised control over the delivery of fuel and the start of delivery for each cylinder, which can even differ from one cylinder to another, to compensate for the hydraulic tolerances of the injector.

The difference in fuel feed to each cylinder is not signalled by the ECU but by an FPT instrument.

Synchronisation Search If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.

If this takes place when the engine is already running, the fuel flow is already acquired as a result of which the ECU continues with the sequence already synchronized.

If this takes place when the engine is stopped, the control unit excites only one solenoid valve. Within a maximum of 2 revolutions of the crankshaft, injection will take place in that cylinder. This means that the control unit simply needs to synchronise with the firing sequence and start the engine.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 14

ELECTRIC/ELECTRONIC SYSTEM ECU

76

Engine side pin out

189005

Figure 5

Pin Out ( ➠ Page 14) Pin Out Pin.

Component

01.

”Low” signal injector 1, bank 2, cylinder 4.

02.

”Low” signal injector 2, bank 2, cylinder 6.

03.

”Low” signal injector 3, bank 2, cylinder 5.

04.

Spare.

05.

Spare.

06.

Engine oil pressure and temperature sensor: ground for frequency input 3.

07.

Air temperature and boost pressure sensor.

08.

Spare.

09.

Spare.

10.

Spare.

11.

Rail pressure sensor.

12.

Fuel temperature sensor.

13.

Engine oil temperature sensor.

14.

Spare.

15.

Spare.

16.

Exhaust gas pressure sensor (P3): pressure signal.

17.

Motorised throttle valve actuator connector (exhaust valve): Controller Area Network 2 high (CAN H).

18.

Motorised throttle valve actuator connector (exhaust valve): Controller Area Network 2 low (CAN H).

19.

Exhaust gas pressure sensor (P3): ground signal.

20.

Spare.

21.

Spare.

22.

Spare.

23.

Spare.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM ECU

Pin.

Component

24.

Spare.

25.

”High” signal injector 1, bank 2, cylinder 4

26.

”High” signal injector 2, bank 2, cylinder 6.

27.

”High” signal injector 3, bank 2, cylinder 5.

28.

Spare.

29.

Spare.

30.

Spare.

31.

Engine oil temperature and pressure sensor:

32.

Crankcase pressure sensor: supply +5V.

33.

Exhaust gas pressure sensor: supply +5V.

34.

Spare.

35.

Engine oil pressure signal.

36.

Rail fuel pressure signal.

37.

Boost air temperature signal.

38.

Spare.

39.

Coolant temperature signal.

40.

Spare.

41.

Spare.

42.

Crankcase pressure sensor.

43.

Spare.

44.

Spare.

45.

Spare.

46.

Spare.

47.

Spare.

48.

Spare.

49.

”High” signal injector 1, bank 1, cylinder 1.

50.

”High” signal injector 2, bank 1, cylinder 2.

51.

”High” signal injector 3, bank 1, cylinder 3.

52.

Spare.

53.

Spare.

54.

Spare.

55.

Spare.

56.

Spare.

57.

Spare.

58.

High pressure fuel pump dosing unit: supply.

59.

Coolant/fuel temperature sensor: analogue input shared ground 18.

60.

Rail fuel pressure sensor: ground.

61.

Crankcase pressure sensor: pressure signal.

62.

Spare.

63.

Spare.

64.

Spare.

65.

Crankshaft speed increase speed sensor: negative signal.

– P2D32C015E0116

15

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 16

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Pin.

Component

66.

Crankshaft speed increase speed sensor: positive signal.

67.

Camshaft timing segment speed sensor: negative signal.

68.

Camshaft timing segment speed sensor: positive signal.

69.

Ref (speed sensor).

70.

Spare.

71.

Spare.

72.

Spare.

73.

”Low” signal injector 1, bank 1, cylinder 1.

74.

”Low” signal injector 2, bank 1, cylinder 2.

75.

”Low” signal injector 3, bank 1, cylinder 3.

76.

Spare.

77.

Spare.

78.

Fuel filter clogged sensor: ground.

79.

Fuel filter clogged sensor: pressure drop

80.

Spare.

81.

Spare

82.

Spare.

83.

High pressure fuel pump dosing unit.

84.

Spare.

85.

Spare.

86.

Air temperature and boost pressure signal.

87.

Spare.

88.

Spare.

89.

Spare.

90.

Analogue input 5 ground.

91.

Spare.

92.

Spare.

93.

Spare.

94.

Spare.

95.

Spare.

96..

Spare.

76

EDC (ECM) SYSTEM

System components

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

17

EDC (ECM) SYSTEM

775010

Electro-injectors

178241

1

Electrical connections

2

Figure 6

Electromagnet assembly

Characteristics Technical data Maximum working pressure

1,800 bar

Minimum working pressure

250 bar

Tightening torque Electrical connection M4 nut

1.5 ±0.25 N⋅m

operation This is an N.O. solenoid valve.

They are connected to the EDC ECU on connector 2.

The resistance of the coil of each individual injector is 0.56 - 0.57 Ohm. The electro-injector essentially consists of two parts: ● ●

actuator - spray nozzle consisting of a pressure rod, a needle and a jet control solenoid valve made up of coil and pilot valve

The solenoid valve checks the lift of the nozzle needle.

BEGINNING OF INJECTION Upon being supplied with power, the coil moves up the shutter. The fuel in the control volume flows back towards the return duct resulting in a pressure drop in control volume.

At the same time, the fuel pressure in the pressure chamber moves up the needle resulting into the fuel being injected into the cylinder.

END OF INJECTION

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 18

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

When power to the coil is cut off, the shutter closes again so as to re-create an equilibrium which moves the needle back into its closed position and stops the injection process.

771034

Fuel metering valve

144822_2

A B C D

Fuel inlet coupling from rail Connection for fuel inlet from control unit heat exchanger Connection for fuel inlet from fuel filter Connection between fuel outlet from feed pump and filter

E 1 2 3

Figure 7 Connection between fuel outlet and rail High-pressure pump Feed pump Pressure regulator (NO solenoid valve regulated by the control unit by means of PWM signal).

Pump with 3 radial pistons controlled by the timing gears, requiring no timing adjustment, with rotor type feed pump fitted to the back.

Situated at the inlet of the high pressure pump, on the low pressure system, this device adjusts the quantity of fuel reaching the high pressure pump in accordance with the commands received from the control unit.

It mainly consists of the following parts: ●

tapered shutter

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

19

EDC (ECM) SYSTEM

● ● ●

valve control pin Pre-load spring Coil

In the absence of a control signal, the pressure regulator is normally open, and thus the high pressure pump is in maximum delivery mode.

The control unit regulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying fuel to the high pressure pump.

This component cannot be replaced individually and thus should not be dismantled.

The amount of fuel feeding the high pressure pump is metered by a proportional valve on the low pressure system that is managed by the EDC. The delivery pressure to the rail is regulate between 250 and 1400 bar by the control unit acting on the flow regulator solenoid valve.

It is a N.O. solenoid valve.

Its resistance is approximately ~ 3.2 Ω Technical data Supply voltage

0.25 V Note

Complete operation

Technical data Power supply frequency

1 Hz Note

check for frequency MLI or intensity for ramp pressure

Technical data Delivery pressure

250 bar to1,400 bar

Pin - out Pressure regulator pin

Function

1

Power supply pin 58 of the EDC control unit.

2

Ground pin 83 of the EDC control unit.

774511

Rail pressure sensor (RPS)

The value of injection pressure is used to keep the pressure level under control and to determine the time duration of the injection electronic command.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 20

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

196904

A B

Technical view Perspective view

C

Figure 8

Recommended assembly position

Technical specifications Supplier: BOSCH Technical data Pressure range

0 bar to2,400 bar

Technical data Supply voltage.

0.5 V to4.5 V

Tightening torque RPS sensor

140 N⋅m

Pin-out Pin

Function

Engine cable pin out

1

Pressure sensor power supply on rail (+5V)

2/60

2

Pressure signal on rail

2/36

3

Ground

2/11

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

21

EDC (ECM) SYSTEM

7642

CPS pressure sensor

178245

Figure 9

It is a pressure sensor fit on the engine head.

Technical specifications Supplier: KAVLICO Technical data Storage temperature

−40 to125

Power supply frequency

120 Hz

Sensor power supply

5V

Pin-out Pin

Function

Engine cable pin out

1

Air supply

2/32

2

Ground

2/42

3

Pressure signal

2/61

764263

Flywheel pulse transmitter

This sensor is an inductive one and is located on the flywheel.

It generates signals obtained from the magnetic flow lines, which close through the holes obtained on the flywheel.

The electronic control unit uses this signal to detect the various engine ratings and to control the electronic rev counter.

If this signal fails the rev counter will not work.

The sensor gap is NOT ADJUSTABLE.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 22

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Sensor

191894

A B

Technical view Perspective view

C D

Figure 10

Wiring Diagram Connector

Characteristics: Supplier: BOSCH Tightening torque Tightening torque

8 ±2 N⋅m

Technical data Resistance

860 Ω ±10 % Note

Inductance

Temperature 20 °C

370 ±60 mH

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

23

EDC (ECM) SYSTEM

Technical data Frequency for speed ratio

58 Hz Note

Engine speed

Pin-out Pin

Function

Engine cable pin out

1

Engine speed signal on flywheel

2/67

2

Ground

2/68

764264

Timing system pulse transmitter

This inductive sensor is located on the camshaft.

It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the phonic wheel fitted to the crankshaft.

The signal generated by this sensor is used by the control unit as the injection timing signal.

The sensor gap is NOT ADJUSTABLE.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 24

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Sensor

191894

A B

Technical view Perspective view

C D

Figure 11

Wiring Diagram Connector

Characteristics Supplier: BOSCH Tightening torque Tightening torque

8 ±2 N⋅m

Technical data Resistance

860 Ω ±10 % Note

Inductance

Temperature 20 °C

370 ±60 mH

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

25

EDC (ECM) SYSTEM

Technical data Frequency for speed ratio

58 Hz Note

Engine speed

Pin-out Pin

Function

Engine cable pin out

1

Engine speed signal on timing.

2/66

2

Ground.

2/65

772656

Fuel temperature sensor

It is a N.T.C. sensor located on the fuel filter at the engine left side.

It detects the fuel temperature thus enabling the ECU to determine the fuel density and volume and adjust the delivery.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 26

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Sensor

196902

A B

Technical view Perspective view

C

Figure 12

Wiring Diagram

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

27

EDC (ECM) SYSTEM

Technical specifications Supplier: BOSCH Technical data 2.5 kΩ ±6 %

Resistance

Note

20 °C

Technical data 5 ±0.15 V

Voltage Tightening torque maximum tightening torque

25 N⋅m

Pin-out Pin

Engine cable pin out

Function

1

Fuel temperature signal

2/12

2

Ground

2/55

1

2 190515

– P2D32C015E0116

Figure 13

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 28

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

542019

Fuel filter clogged sensor

This is a normally closed electric sensor, which identifies fuel filter clogging, measuring the difference in pressure between the two doors and checking that a certain threshold is not exceeded.

1

2 190523

Figure 14

Technical specifications Technical data Rated voltage

12 V

Differential opening pressure

150 ±10 kPa

Maximum working pressure

500 kPa

Operating temperature

−40 ℃ to120 ℃

Tightening torque 1 sensor M12X1.5

30 ±2 N⋅m

P

190524

Figure 15

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

29

EDC (ECM) SYSTEM

764274

Engine coolant temperature / engine fan sensor

It is a N.T.C. sensor located on the head water output manifold on the engine left side.

It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies the need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.

The coolant temperature signal is used to be displayed on the Cluster and to control the fan.

Sensor

196902

A B

Technical view Perspective view

– P2D32C015E0116

C

Wiring Diagram

Figure 16

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 30

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Technical specifications Supplier: BOSCH Tightening torque maximum tightening torque

25 N⋅m

Technical data Temperature range

40 ℃ to150 ℃

Resistance

2.5 kΩ ±6 % Note

Temperature 20 °C

Pin-out Pin

Function

Pin out

1

Fuel temperature signal.

2/12

2

Ground.

2/59

764251

Oil pressure and temperature sensor

This component incorporates a temperature sensor and a pressure sensor.

The output voltage is proportional to the pressure (or temperature) measured by the sensor.

The values sent are transmitted to the EDC control unit which, in turn, governs the indicator on the dashboard (indicator/low pressure warning light).

The engine oil temperature is used by the EDC control unit only.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Sensor

196906

A B C

Technical view Perspective view Recommended assembly position

– P2D32C015E0116

D E

Wiring Diagram Connector

Figure 17

31

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 32

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Technical specifications Supplier: BOSCH Technical data Sensor power supply

5V

Operating range

50 kPa to600 kPa

Pin-out Pin

Engine cable pin out

Function

1

Ground

2/6

2

Oil temperature signal

2/13

3

Sensor power supply (+5V)

2/31

4

Oil pressure signal

2/35

Temperature and pressure sensor resistance ( ➠ Page 32) 1) Capacity of diagnosis with minimum values that do not guarantee 2) valid only for a measuring voltage < 0.5 V Resistance for temperature or voltage for temperature ( ➠ Page 32) Temperature and pressure sensor resistance Parameter

Value [kPa]

Symbol Min Rpull-up

Nom

Max

Rpull-down

5 10

Ground outlet resistance ² , Us open

Rio

2.4

4.7

8.2

Us outlet resistance ² , ground open

Rhi

3.4

5.3

8.2

Load Us or ground resistance ¹

Resistance for temperature or voltage for temperature Temperature

Resistance R in Ω

Tolerance

Tolerance test with T ± 1K

T in °C

Rated

Minimum

maximum

in K

Minimum

-40

45303

43076

47529

± 0.9

40730

50314

-35

34273

32643

35902

± 0.9

30908

37953

-30

26108

24907

27309

± 0.9

23603

28829

-25

19999

19108

20889

± 0.9

18142

22023

-20

15458

14792

16124

± 0.8

14055

16970

-15

12000

11499

12501

± 0.8

10945

13144

-10

9395

9015

9775

± 0.8

8595

10261

-5

7413

7123

7704

± 0.8

6801

8074

0

5895

5671

6118

± 0.8

5420

6403

5

4711

4537

4884

± 0.8

4343

5106

10

3791

3656

3927

± 0.8

3504

4100

15

3068

2962

3174

± 0.8

2842

3310

20

2499

2416

2583

± 0.8

2323

2690

maximum

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

33

EDC (ECM) SYSTEM

Temperature

Resistance R in Ω

Tolerance

Tolerance test with T ± 1K

T in °C

Rated

Minimum

maximum

in K

Minimum

25

2056

1990

2123

± 0.8

1916

2207

30

1706

1653

1760

± 0.8

1591

1827

35

1411

1368

1455

± 0.8

1318

1510

40

1174

1139

1209

± 0.8

1100

1254

45

987.4

959.0

1016

± 0.8

927.0

1051

50

833.8

810.5

857.0

± 0.8

783.1

886.3

55

702.7

683.7

721.7

± 0.8

661.2

746.6

60

595.4

579.7

611.0

± 0.8

561.6

631.4

65

508.2

495.3

521.1

± 0.8

480.2

537.8

70

435.6

424.9

446.4

± 0.8

412.1

460.3

75

374.1

365.2

383.1

± 0.8

354.4

394.9

80

322.5

315.0

329.9

± 0.8

306.0

339.8

85

279.5

273.2

285.8

± 0.8

265.7

294.0

90

243.1

237.8

248.4

± 0.8

231.5

255.4

95

212.6

208.1

217.1

± 0.8

202.7

223.0

100

186.6

182.9

190.3

± 0.8

178.0

195.4

105

163.8

160.3

167.2

± 0.8

156.2

171.6

110

144.2

141.0

147.3

± 0.9

137.5

151.0

115

127.3

124.4

130.1

± 0.9

121.4

133.4

120

112.7

110.1

115.2

± 1.0

107.5

118.0

125

100.2

97.81

102.5

± 1.0

95.55

104.9

130

89.28

87.13

91.43

± 1.1

85.13

93.52

540752

maximum

Air temperature and pressure sensor

This component incorporates a temperature sensor and a pressure sensor.

It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible to determine the exact amount of fuel to be injected at each cycle.

The output voltage is proportional to the pressure (or temperature) measured by the sensor.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 34

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Sensor

196905

A B C

Technical view Perspective view Recommended assembly position

D E

Figure 18

Wiring Diagram Connector

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM

35

EDC (ECM) SYSTEM

Technical specifications Supplier: BOSCH Technical data Sensor power supply

5V

Output signal at 95 kPa

1.014 ±0.52 V

Output signal at 350 kPa

3.929 ±0.052 V

Storage temperature

−40 to130

Pin-out Pin

Engine cable pin out

Function

1

Ground

2/90

2

Air temperature signal

2/37

3

Sensor power supply (+5V)

2/07

4

Air pressure signal

2/86

Temperature and pressure sensor resistance ( ➠ Page 35) Resistance for temperature or voltage for temperature ( ➠ Page 35) Temperature and pressure sensor resistance Parameter

Value [kΩ]

Symbol Min Rpull-up

Nom

Max

Rpull-down

5 10

Ground outlet resistance², Us open

Rio

2.4

4.7

8.2

Us outlet resistance², ground open

Rhi

3.4

5.3

8.2

Load Us or ground resistance ¹

Resistance for temperature or voltage for temperature Temperature

Resistance R in Ω

Tolerance

Tolerance test with T ± 1K

T in °C

Rated

Minimum

maximum

in K

Minimum

-40

45303

43076

47529

± 0.9

40730

-35

34273

32643

35902

± 0.9

30908

37953

-30

26108

24907

27309

± 0.9

23603

28829

-25

19999

19108

20889

± 0.9

18142

22023

-20

15458

14792

16124

± 0.8

14055

16970

-15

12000

11499

12501

± 0.8

10945

13144

-10

9395

9015

9775

± 0.8

8595

10261

-5

7413

7123

7704

± 0.8

6801

8074

0

5895

5671

6118

± 0.8

5420

6403

5

4711

4537

4884

± 0.8

4343

5106

10

3791

3656

3927

± 0.8

3504

4100

15

3068

2962

3174

± 0.8

2842

3310

20

2499

2416

2583

± 0.8

2323

2690

– P2D32C015E0116

maximum 50314

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 36

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Temperature

Resistance R in Ω

Tolerance

Tolerance test with T ± 1K

T in °C

Rated

Minimum

maximum

in K

Minimum

maximum

25

2056

1990

2123

± 0.8

1916

2207

30

1706

1653

1760

± 0.8

1591

1827

35

1411

1368

1455

± 0.8

1318

1510

40

1174

1139

1209

± 0.8

1100

1254

45

987.4

959.0

1016

± 0.8

927.0

1051

50

833.8

810.5

857.0

± 0.8

783.1

886.3

55

702.7

683.7

721.7

± 0.8

661.2

746.6

60

595.4

579.7

611.0

± 0.8

561.6

631.4

65

508.2

495.3

521.1

± 0.8

480.2

537.8

70

435.6

424.9

446.4

± 0.8

412.1

460.3

75

374.1

365.2

383.1

± 0.8

354.4

394.9

80

322.5

315.0

329.9

± 0.8

306.0

339.8

85

279.5

273.2

285.8

± 0.8

265.7

294.0

90

243.1

237.8

248.4

± 0.8

231.5

255.4

95

212.6

208.1

217.1

± 0.8

202.7

223.0

100

186.6

182.9

190.3

± 0.8

178.0

195.4

105

163.8

160.3

167.2

± 0.8

156.2

171.6

110

144.2

141.0

147.3

± 0.9

137.5

151.0

115

127.3

124.4

130.1

± 0.9

121.4

133.4

120

112.7

110.1

115.2

± 1.0

107.5

118.0

125

100.2

97.81

102.5

± 1.0

95.55

104.9

89.28

87.13

91.43

± 1.1

85.13

93.52

77.67

81.59

±1.1

75.93

83.45

130 135

79.63

140

71.18

69.39

72.97

±1.2

67.88

74.60

145

63.85

62.21

65.48

±1.2

60.88

66.91

150

57.39

55.89

58.89

±1.3

54.75

60.15

766123

Pre/post heating element

The resistance is located between the cylinder head and the intake manifold used to heat the air in pre - post heating operations.

When the key switch is actuated, if even only one of the temperature sensors (water, air, diesel) detects less than 10 °C, the electronic control unit activates pre/post-heating and turns on the relevant dashboard warning light for a time depending on the temperature.

Once this time expires, the warning light starts flashing, thus telling the driver that he can now start the engine.

The warning light goes off after engine start while the resistance continues to be supplied for a variable period of time performing post - heating.

If the engine is not started within 20 to 25 seconds after the warning light starts flashing, the operation is cancelled so as to prevent battery discharge.

When reference temperature is above 10°C, actuating the ignition key makes the warning light go on for approximately 2 seconds to complete the test and then turns it off to indicate the engine can be started.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

resistance

196907

A

Technical view

B

Perspective view

Technical specifications Supplier: BERU Technical data Rated voltage

12 V

Pick-up current

180 A to280 A

Constant current

120 A to150 A

Insulating resistance

1 MΩ

Loss of load

2 kPa

– P2D32C015E0116

Figure 19

37

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 38

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

760810

STARTER MOTOR "NIPPONDENSO" 24V - 5.5KW STARTER MOTOR - [08000]

Technical view

4956

Figure 20

Characteristic curves

137660

Figure 21

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Wiring Diagram

4958

– P2D32C015E0116

Figure 22

39

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 40

ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Perspective view with matching electrical connections

6658

Figure 23

technical specifications Characteristics Nominal power Rated voltage Coupling system Adjusted time Direction of rotation Operating voltage Weight

Version 5.5 kW 5.5 kW 24 V Positive approach control 30 s Clockwise seen from pinion end 16 V MAX ≈ 10.5 kg

Tightening torque for terminal +30

17.6 N⋅m to24.5 N⋅m (M10X1.5)

Tightening torque for terminal +50

2.6 N⋅m to4.6 N⋅m (M5X0.8)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system ELECTRIC/ELECTRONIC SYSTEM EDC (ECM) SYSTEM

Specific power Version 5.5 kW

Load Test conditions

Characteristics

23 V

120 A MAX (3,100 rpm)

Load

16 V (49 N⋅m)

690 A MAX (900 rpm)

Stall

6V

1,260 A MAX (73.5 N⋅m)

No load

– P2D32C015E0116

41

CURSOR 9 Tigercat Tier II R96 ‒ Electric/electronic system 42

ELECTRIC/ELECTRONIC SYSTEM

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance Contents

Contents SCHEDULED MAINTENANCE

– P2D32C015E0116

. . . . . . . . . . . . . . .

3

1

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 2

Contents

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance SCHEDULED MAINTENANCE Contents

Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Checks not included in the daily checks-maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

MAINTENANCE PROCEDURES . . . . . . . . . . . . . . .

6

Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Check engine lubricant oil level . . . . . . . . . . . . . .

8

Checking the engine coolant level . . . . . . . . . . . .

9

SCHEDULED MAINTENANCE

. . . . . . . . . . . . . . .

9

Ancillary belt replacement . . . . . . . . . . . . . . . . .

9

Change engine lubricant oil . . . . . . . . . . . . . . .

10

Replacing the oil filter . . . . . . . . . . . . . . . . . . .

11

Change blow-by filter . . . . . . . . . . . . . . . . . . .

12

Replacing fuel filter . . . . . . . . . . . . . . . . . . . .

12

Replacing the fuel prefilter . . . . . . . . . . . . . . . .

13

SPECIAL MAINTENANCE . . . . . . . . . . . . . . . . . .

14

Replacement of the coolant . . . . . . . . . . . . . . .

14

Adjustment of valve/rocker arm clearance . . . . . .

14

– P2D32C015E0116

3

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 4

SCHEDULED MAINTENANCE

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance SCHEDULED MAINTENANCE

5

Introduction

SCHEDULED MAINTENANCE M

Introduction

To ensure the best performance, the interventions of revision, checks and adjustment operations to be performed on the engine at the scheduled times are indicated on the following pages.

The frequency of the maintenance operations is approximate, considering that engine use is the factor that has the greatest impact on determining and assessing replacement and control operations.

It is not only permitted, but it is also recommended for maintenance personnel to perform maintenance and control operations even if they are not included below in the list, but can be suggested based on good sense and the specific engine operating conditions.

Intervene immediately in the case of a malfunction of the engine, such as excessive exhaust gas, high coolant temperature or low oil pressure, to find the causes. Please keep in mind that all maintenance operations, even the most simple ones, must be carried out in accordance with the standards regarding accident prevention for the safety of maintenance personnel.

Checks and scheduled maintenance program

Checks (during periods of use)

Frequency

Engine visual inspection

50 hours

Check engine lubricant oil level

At every start-up

Checking the engine coolant level

At every start-up

Water drainage from fuel prefilter

150 hours

Ancillary belt condition inspection

300 hours

Exhaust manifold check

6 months

Check using the electronic control unit

In the event of a fault

Periodical maintenance

Frequency

Change engine lubricant oil

600 hours(2)

Replace engine oil filter

600 hours

(2) (3) (4)

Fuel pre-filter change

600 hours

(5) (1)

Fuel filter replacement

600 hours

(1) (2) (4)

Auxiliary belt replacement

1200 hours

Turbocharger visual inspection

1200 hours

Change blow-by filter

1800 hours

Unscheduled maintenance

Frequency

Adjustment of valve/rocker arm clearance

2400 hours

Coolant change

3000 hours

1.

2.

3.

(1)

.

(3)

.

. .

.

(2)

.

(5)

Maximum period relative to the use of high quality fuel (ASTM D975 or EN 590 specifications). This is reduced based on fuel contamination and alarm signals caused by clogging of the filter and/or the presence of water in the prefilter. The filter clogged signal means the filter must be replaced. If the signal of water present in the prefilter does not deactivate after draining it, the filter must be replaced.

To be performed every year even if the specified operating hours interval has not been reached.

The frequencies apply to lubricants which comply with international standards API CJ-4 / ACEA E7 as specified in the REFILLING table.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 6

SCHEDULED MAINTENANCE MAINTENANCE PROCEDURES

4.

5.

Only use filters with the following specifications: ■ degree of filtering < 12 μm ■ filtering efficiency 99.5% (ß > 200).

To be performed every two years even if the specified operating hours interval has not been reached.

Note The frequency of the maintenance operations is approximate, considering that engine use is the factor that has the greatest impact on determining and assessing replacement and control operations.

The maintenance interventions are only valid if all the installation indications provided by FPT have been respected.

Furthermore, the devices fitted by the installer must be compliant with the torque, power and rpm for which the engine was designed.

Note Diesel fuel for low temperaturesThe standard EN590 defines the different classes of diesel fuel, identifying the most suitable characteristics for use in low ambient temperatures.

Respecting the standards in terms of fuel distribution suitable for the climatic and geographic conditions of the country, is the sole responsibility of the fuel companies.

Checks not included in the daily checks-maintenance schedule It is good practice, before starting the engine, to carry out a simple set of checks which can prove to be a valuable tool in avoiding problems, even serious, during operation. These checks are usually the responsibility of the operators and drivers of the vehicle. ● ●

Checking the levels and checking for any leaks from the fuel, cooling and lubrication circuits.

Notify the maintenance department of any anomalies or refills needed.

After starting the engine and with the engine running, perform the following checks and inspections: ● ● ● ● ●

check for any leaks from the fuel, coolant and lubricant circuits.

Make sure that there are no unusual noises or clinks while the engine is running.

Check the pressure and temperature, along with other parameters, using the vehicle devices.

Visually check the exhaust smoke (colour of the exhaust emissions) Visually check the coolant level in the expansion tank.

MAINTENANCE PROCEDURES Checks (in periods of use) M

Checks

Check lubrication system Carry out the check with the engine running and with the engine off.

Check for oil leaks or blow-by from the head, the sump or heat exchanger.

Caution! ▶ ▶

The engine oil is highly pollutant and noxious.

In case of contact with skin, wash thoroughly with water and detergent.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance SCHEDULED MAINTENANCE

7

MAINTENANCE PROCEDURES

Caution! ▶ ▶

Protect your eyes and skin and work in full accordance with safety regulations.

Waste disposal must be carried out in full compliance with the law and regulations in force.

Fuel system inspection Carry out the check with the engine running and with the engine off.

This check involves inspecting the fuel pipes which go from the tank to the prefilter (if present in the specific device), to the filter, to the high pressure pump and to the rail diffuser and from here, to the head.

Caution! ▶ ▶

Because of high pressure in the pipes which go from the high pressure pump to the rail diffuser rail and from here to the electro-injectors, pay careful attention to check for any leaks or blow-by.

Protect your eyes and skin from any high-pressure jets as they can penetrate deep under the skin causing serious poisoning.

Check for water in the fuel filter or pre-filter.

Note The components of the common rail system will be quickly damaged if the fuel contains water or other impurities.

Act promptly on the pre-filter (not available on the engine block) to drain the water in the supply circuit.

Checking belt tension The belt tension check is carried out using an automatic tensioning device, therefore no intervention is needed apart from checking the state of wear of the belt itself.

Checking for any tears and the state of wear of the belt Check the surface of the belt carefully for any cuts, broken areas, excessive wear at the toothing. Check the end of the belt and the smoothing of the surface.

Caution! ▶ ▶

Danger: if the engine is off but still hot, the belt could move unexpectedly.

As a precautionary measure in order to prevent any serious injury, wait for the engine temperature to fall.

Cooling system inspection Carry out the check with the engine running and with the engine off.

Check the pipes from the engine to the radiator, from the expansion tank and vice versa. Find any blow-by present, check the state of the pips, especially near the retaining clamps.

Check that the radiator is clean, that the fan flywheels work correctly, check for any leaks from the connectors, the manifold and the radiating unit.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 8

SCHEDULED MAINTENANCE MAINTENANCE PROCEDURES

Caution! ▶ ▶

Because of the high temperatures reached by the system, do not operate immediately after the engine has stopped but wait for it to cool down.

Protect eyes and skin from any unexpected high pressure jets of coolant.

The density of the coolant must however be checked every year before the winter and in any case, be changed every two years.

Note In the case of a new fill, bleed the system through the engine exhausts.

If the system is not bled, the engine can be seriously damaged due to the presence of air pockets in the engine head.

M

Check engine lubricant oil level

Check the engine when it is not running and preferably cold. ● ● ● ●

●

Make sure that the vehicle is on a level surface.

Use the dipstick (not supplied by FPT) to check that the lubricant oil is between the ”Min” and ”Max” reference points.

If it is difficult to perform the measurement, clean the oil dipstick using a clean cloth without any loose threads, and re-fit the dipstick into its housing. Remove it again and check the level.

If the level is too low, top-up with lubricant oil compliant with international standards API CJ-4 / ACEA E7, as specified in the REFILLING table. Remove the lubricant oil filler plug (1) and introduce the engine lubricant oil through the filler hole.

Use the dipstick to check that the level of lubricant oil does not exceed the "Max" limit.

Caution! ▶ ▶ ▶

Always make sure that the oil used has the same properties as the oil already in the sump.

Mixing oil is not permitted as it would not ensure the correct lubrication of the internal parts of the engine.

Make sure that the dipstick is inserted completely and that the oil filler cap is completely tightened in a clockwise direction.

218529

Figure 1

Caution! ▶ ▶

The engine oil is highly pollutant and noxious.

In case of contact with skin, wash thoroughly with water and detergent.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance SCHEDULED MAINTENANCE

9

SCHEDULED MAINTENANCE

Caution!

Protect your eyes and skin and work in full accordance with safety regulations.

Waste disposal must be carried out in full compliance with the law and regulations in force.

▶ ▶

M

Checking the engine coolant level

Only proceed when the engine is not turning, and is at low temperature, so as not to run the risk of burns. ● ● ● ●

Remove the pressurization cap from the expansion tank.

Visually check that the coolant in the expansion tank is above the minimum level.

As required, top-up the expansion tank with a mix of 50% water and Actifull OT, as indicated in the REFILLING table. Do not completely fill the expansion tank.

When the engine is cold, make sure that the coolant in the expansion tank is a few centimetres below the filling hole.

In the event of an externally located level indicator as regards the heat exchangers, proceed with the top up operation by making sure that the coolant does not overfill the internal volume of the exchanger in order to allow the expansion of coolant volume during increases in temperature.

SCHEDULED MAINTENANCE M

Ancillary belt replacement

Act on the automatic belt tensioner (5) and remove the auxiliary device drive belt from the water pump pulley, from the crankshaft pulley with damper and from the guide pulleys.

218010

– P2D32C015E0116

Figure 2

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 10

SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE

M

Change engine lubricant oil

Remember to drain the oil when the engine is hot.

Caution! ▶

▶

● ●

Caution: It is recommended that you wear suitable protections due to the high temperatures reached while the engine is operating.

Engine oil reaches extremely high temperatures. Always wear protective gloves.

Place a suitable container for catching the oil beneath the sump connected to the drain plug (5).

Unscrew the plug (5) and remove the dipstick (2), unscrew the filler plug (1 e 3) to allow the lubricant oil to flow more easily.

Caution!

218529

▶ ▶

Figure 3

The engine oil is highly pollutant and noxious.

In case of contact with skin, wash thoroughly with water and detergent.

Caution! ▶ ▶

● ●

Protect your eyes and skin and work in full accordance with safety regulations.

Waste disposal must be carried out in full compliance with the law and regulations in force.

Wait for the oil sump (4) to be fully drained, then screw on the lubricant oil drain plug (5) below the oil sump (4).

Fill the engine lubricant through the hole (1) located on the tappet cover or the pipe (3) connected to the crankcase. Add the quantity of lubricant oil compliant with international standards ACEA E7, as specified in the REFILLING table.

Note Only use recommended oils or oils with the properties required for proper engine operation.

If topping up, do not mix oils with different properties.

Failure to observe these regulations will invalidate the maintenance warranty. ●

Check the level with the dipstick until the oil level is near the maximum level notch shown on the dipstick.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE

M

Replacing the oil filter

Note Caution: the oil filter contains approximately 1kg of oil.

Arrange a suitable container for collecting the oil.

Caution! ▶ ▶

The engine oil is highly pollutant and noxious.

In case of contact with skin, wash thoroughly with water and detergent.

Caution! ▶ ▶

Protect your eyes and skin and work in full accordance with safety regulations.

Waste disposal must be carried out in full compliance with the law and regulations in force.

Note Before refitting the new cartridge, moisten the gasket with engine oil.

Unscrew and remove the filter(4) from the relative support (1) using a suitable tool.

Replace the filtering element(3) and the sealing gasket (2) contained inside the filter (4).

Carefully clean the surfaces of the support (1) in contact with the sealing gasket (2).

Moisten the sealing ring (2) of the new filter (4) with a thin layer of oil.

Manually tighten the new filter (4) on the support (1) until it fits up against the gasket (2). Tighten further using a specific tool to a torque of 60 ± 5 Nm..

Operate the engine for a few minutes and then recheck the level using the dipstick. Top up if necessary to compensate for the oil used for filling the filtering cartridge.

– P2D32C015E0116

223486

Figure 4

11

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 12

SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE

M

Change blow-by filter

Unscrew the fastening screws (4) and remove the timing cover (3).

Unscrew the fastening screws (2) and remove the blow-by filter (1).

Replace and fit the centrifugal filter (1) on the timing gear (5) and tighten the fastening screws (2).

Insert the timing cover (3) and tighten the fastening screws (4).

219644

M

Figure 5

Replacing fuel filter Caution! ▶ ▶

Do not smoke or use naked flames during this operation.

Do not inhale fumes from the filter.

Caution! ▶

After replacing the filter, de-aerate the supply device.

Position a container to collect the diesel below the filter mount (2).

Drain the fuel from the fuel filter (5) loosening the drain screw (6).

223487

Figure 6

Remove the filter (5) unscrewing it from the relative support (2).

Replace the filtering element (4) and the O-ring seal (3) inside the filter body (5).

Carefully clean the surfaces of the support (2) in contact with the O-ring seal (3).

Apply oil to the O-ring seal (3) of the new filter.

Manually tighten the new filter (5) on the support (2) until it fits up against the gasket (3).

Tighten further using a specific tool to a torque of 32.5 ± 2.5 Nm. Caution! ▶ ▶

When replacing the filter cartridge (5) do NOT fill it.

This operation is prohibited to prevent impurities from entering the circuit, which would damage the injector/pump system components.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE

M

Fuel bleeding

After replacing the fuel filter (5) there may be air bubbles in the supply circuit.

Bleed the residual air from the fuel filter (5) by loosening the breather plug (1) and connecting it to a suitable container with a transparent flexible pipe.

With the hand pump (2) of the fuel pre-filter (1) pump until fuel completely free of air bubbles flows from the bleed screw.

After the operation, tighten the bleed screw.

Start the engine and let it run idle for a few minutes to remove any residual air.

145887

M

Figure 7

Replacing the fuel prefilter

Proceed with the engine off.

Remove the pre-filter by unscrewing it.

Check that the new filter has performance levels which meet the engine requirements (for example, comparing it with the one which has been removed).

Lubricate the new filter gasket with diesel or engine oil.

Screw in the new filter by hand until the sealing gasket touches the support, then lock it be turning it a further 3/4 of a turn.

Place the water sensor in its seat making sure that the wires are connected correctly.

227104

Caution!

Environment pollution Risk of groundwater pollution ▶

– P2D32C015E0116

The disposal of all liquids and fluids must be in full compliance with current legislation.

Figure 8

13

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 14

SCHEDULED MAINTENANCE SPECIAL MAINTENANCE

Loosen the bleed screw (1) on the pre-filter support and activate the pump manually until the supply circuit is full. Make sure that the fuel which comes out is not dispersed into the environment.

Tighten the bleed screw to torque.

Start engine and let it run idle for a few minutes to remove any residual air.

SPECIAL MAINTENANCE M

Replacement of the coolant

Carry out he procedure only while engine is OFF and at low temperature in order to prevent risk of burns. ● ● ● ● ● ● M

Arrange suitable containers to ensure that the coolant is not dispersed into the environment.

Loosen the fastening elements and remove the sleeves connecting the engine circuit to the heat exchanger and wait for it to drain completely. When it is empty, repair the circuit making sure that the sleeves are perfectly sealed.

Refill the circuit.

Refill the engine and the heat exchanger completely.

With the filler plug open, start the engine and let it idle for approx. one minute. This will make it easier to bleed the air in the coolant fluid.

Stop the engine and top up again.

Adjustment of valve/rocker arm clearance

Undo the screws (2).

Remove the cylinder head cover (1) and its gasket.

Threaded parts Tappet cover (20 screws M6x1x50)

193948

Figure 9

The adjustment of clearance between the rocker arms and intake and exhaust valve control bridges must be done very carefully. Bring the cylinder to be adjusted to the detonation stage. The valves of this cylinder are closed while the symmetric valves of the cylinder are balanced.

Symmetric cylinders are 1-6, 2-5 and 3-4.

To carry out these operations carefully, refer to the procedure and table below. ● ● ● ●

Use a box wrench to release the locking nut (1) of the rocker arm adjustment screw 2).

Introduce the shim (3) with the same operating clearance value as indicated in the table "Characteristics and data".

Use a special wrench to tighten/loosen the adjustment screw.

Check that the shim (3) slides with a small level friction.

114287

Figure 10

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance SCHEDULED MAINTENANCE SPECIAL MAINTENANCE

●

Tighten the adjustment screw fastening nut (1).

Respect the ignition order indicated in the table.

FIRING ORDER 1-4-2-6-3-5 FIRING ORDER 1-4-2-6-3-5 ( ➠ Page 15) Note To carry out the aforementioned adjustments correctly, it is mandatory to follow the sequence indicated in the table, checking the exact positioning at each stage using the pin 99360612.

Fit the valve cover (1) with the relative gasket and insert all the screws (2).

Tighten the fastening screws (2) to the specified torque in the order and manner indicated in the following figure.

193948

Figure 11

FIRING ORDER 1-4-2-6-3-5 Start and rotation in the engine direction

Balancing cylinder valves no.

Adjust clearance of cylinder valve no.

1 and 6 at T.D.C.

6

1

120 Angle grade [°]

3

4

120 Angle grade [°]

5

2

120 Angle grade [°]

1

6

120 Angle grade [°]

4

3

120 Angle grade [°]

2

5

– P2D32C015E0116

15

CURSOR 9 Tigercat Tier II R96 ‒ Scheduled maintenance 16

SCHEDULED MAINTENANCE

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Contents

Contents Removal - refitting of main components . . . . . . . . . . .

– P2D32C015E0116

3

1

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 2

Contents

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Contents

Contents Removal-refitting of ancillary belt

. . . . . . . . . . . . . .

5

Alternator removal-refitting . . . . . . . . . . . . . . . . . .

6

Removal - Refitting the thermostat cover . . . . . . . . . .

6

Water pump removal-refitting

. . . . . . . . . . . . . . . .

8

Engine cable removal-refitting . . . . . . . . . . . . . . . . .

9

Removal - refitting of the EDC 17 control unit . . . . .

10

Fuel filter removal-refitting . . . . . . . . . . . . . . . . . .

11

Removal - Refitting vehicle fuel filter mount . . . . . . .

12

Turbocharger removal-refitting . . . . . . . . . . . . . . .

14

Exhaust manifold removal-refitting . . . . . . . . . . . . .

16

Intake manifold removal-refitting . . . . . . . . . . . . . .

17

Engine oil filter removal - refitting . . . . . . . . . . . . .

18

Heat exchanger removal-refitting . . . . . . . . . . . . . .

19

Starter motor removal-refitting . . . . . . . . . . . . . . .

22

Removal - refitting of the fuel pipes . . . . . . . . . . . .

22

Removal - refitting of the high pressure pump . . . . . .

25

Removal - Refitting of air compressor seat cover . . . .

26

Oil sump removal-refitting . . . . . . . . . . . . . . . . . .

26

Tappet cover removal-refitting . . . . . . . . . . . . . . .

28

Removal - refitting of the rocker arm unit . . . . . . . .

29

Common rail removal-refitting . . . . . . . . . . . . . . .

31

Removal - refitting of the electro-injectors . . . . . . . .

33

Cylinder head removal-refitting . . . . . . . . . . . . . . .

35

Removal - refitting of the damper flywheel . . . . . . . .

37

Change blow-by filter . . . . . . . . . . . . . . . . . . . . .

38

– P2D32C015E0116

3

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 4

Removal - refitting of main components

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal-refitting of ancillary belt

Removal - refitting of main components .543411. Removal-refitting of ancillary belt

Main activity .543411. Removal (the following figure is provided for demonstration purposes only) 1. Act on the automatic belt tensioner (5) with the designated tool (4) and remove the auxiliary device drive belt from the water pump pulley(1), from the crankshaft pulley (3) with damper and from the guide pulleys (2).

218010

Figure 1

.543411. Refitting (the following figure is provided for demonstration purposes only) 2. Using a suitable tool (4) work on the automatic belt tensioner (5) and fit the new auxiliary device drive belt.

3. Make sure the belt is correctly inserted in the water pump drive pulley (1), the crankshaft pulley (3)with damper and the guide pulleys (2).

4. No further adjustments are required. The belt tension is adjusted automatically via the calibrated spring in the automatic belt tensioner (1).

5. Fully rotate the crankshaft twice to ensure that the new ancillary belt (3) has settled.

218010

– P2D32C015E0116

Figure 2

5

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 6

Removal - refitting of main components Alternator removal-refitting

.7603.

Alternator removal-refitting

Main activity .7603. Removal (the following figure is provided for demonstration purposes only) 1. Remove the screws (1, 3) and remove the alternator (2).

2. Unscrew the fastening screws and remove the supports (4) from the crankcase.

169282

Figure 3

169282

Figure 4

.7603. Refitting (the following figure is provided for demonstration purposes only) 3. Position the alternator support (4) on the engine crankcase and tighten the fastening screws to the specified torque.

4. Position the alternator (2) on the support (4) and tighten the screws (1, 3) to the specified torque.

.543253. Removal - Refitting the thermostat cover

Tightening torques Thermostat cover (5 screws M8x1.25x70)

25 ±2 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal - Refitting the thermostat cover

Main activity .543253. removal 1. Disconnect the engine cable (4) from the temperature sensor (3).

2. Unscrew the fastening screws (5) and remove the thermostat cover (1).

Threaded parts Thermostat cover (5 screws M8x1.25x70) (5)

3.

4.

Take off the gasket (2).

237440

Figure 5

237441

Figure 6

237441

Figure 7

Remove the thermostat (1) from the seat on the cylinder head (2) .

.543253. refitting 5. Insert the thermostat (1) into the designated seat on the cylinder head (2) .

– P2D32C015E0116

7

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 8

Removal - refitting of main components Water pump removal-refitting

6.

Position the gasket (2), fit the thermostat cover (1) and tighten the fastening screws (5) to a torque of: Tightening torque Thermostat cover (5 screws M8x1.25x70) (5)

7.

25 ±2 N⋅m

Connect the engine cable (4) to the temperature sensor (3).

237440

Figure 8

.543210. Water pump removal-refitting

Tightening torques Water pump (4 screws M8x1.25x25)

25 ±2 N⋅m

Water pump (4 screws M8x1.25x25)

24.5 ±2.5 N⋅m

Preparatory operation ▶ Remove the ancillary belt. ( ➠ Page 5) Main activity .543210. removal 1. Position a suitable container to collect any coolant which may leak out.

2. Drain the coolant.

3. Unscrew the screws (2) and remove the water pump (3) recovering the relative gasket.

Threaded parts Water pump (4 screws M8x1.25x25) (2)

237442

Figure 9

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Engine cable removal-refitting

.543210. refitting 4. Apply a new sealing ring to the water pump (3).

5. Position the water pump (1) in its seat (3), tighten the fastening screws (2) to a torque of: Tightening torque Water pump (4 screws M8x1.25x25) (2)

24.5 ±2.5 N⋅m

Note Do not damage the new sealing ring while tightening.

237442

Figure 10

237480

Figure 11

Subsequent operation ▶ Refit the ancillary belt. ( ➠ Page 5)

.769140. Engine cable removal-refitting

Main activity .769140. removal 1. Open the clips securing the engine cable to the crankcase.

2. Disconnect the engine cable connector (1) from the control unit (2).

3. Disconnect the engine cable (3) from all the sensors fitted on the engine.

4. Remove the cable.

– P2D32C015E0116

9

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 10

Removal - refitting of main components Removal - refitting of the EDC 17 control unit

.769140. refitting 5. Arrange the engine cable in the correct position on the engine.

6. Connect the engine cable connector (1) to the control unit connector (2).

7. Connect the engine cable (3) to all the sensors fitted on the engine.

8. Close the clips fastening the engine cable to the crankcase.

237480

Figure 12

.766161. Removal - refitting of the EDC 17 control unit

Tightening torques Fitting (1 M16x1.5)

30 ±5 N⋅m

Control unit with crankcase (3 screws M8x1.25)

19 ±3 N⋅m

Preparatory operation 1. Remove the engine cable. ( ➠ Page 9) 2. Position a suitable container to collect the fuel.

Main activity .766161. removal 1. Act on the fitting (4) and disconnect the low pressure fuel pipe which connects the engine management control unit (1) to the mechanical pump.

Threaded parts Fitting (1 M16x1.5) (4)

2.

Unscrew the fastening screws (2) and remove the engine management control unit (1) together with the heat exchanger.

Threaded parts Control unit with crankcase (3 screws M8x1.25) (2)

3.

Act on the fitting and disconnect the pipe which connects the tank to the control unit.

237451

Figure 13

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Fuel filter removal-refitting

.766161. refitting 4. Fit the engine control unit including the heat exchanger, on the crankcase and tighten the fastening screws (2) to a torque of: Tightening torque Control unit with crankcase (3 screws M8x1.25) (2)

5.

19 ±3 N⋅m

Act on the fitting (4) and connect the low pressure fuel pipe which connects the engine management control unit (1) to the mechanical pump.

Tightening torque Fitting (1 M16x1.5) (4)

6.

30 ±5 N⋅m

Act on the fitting and connect the low pressure fuel pipe which connects the tank to the engine management control unit (1).

237451

Figure 14

Subsequent operation ▶ Refit the engine cable. ( ➠ Page 10)

.542010. Fuel filter removal-refitting

Tightening torques Fuel filter (1 fitting)

30 ±5 N⋅m

Main activity .542010. removal 1. Position a container to collect the diesel below the filter mount (3).

2. Use a suitable tool to unscrew and remove the fuel filter (4) and the relative gasket from the support (3).

237446

– P2D32C015E0116

Figure 15

11

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 12

Removal - refitting of main components Removal - Refitting vehicle fuel filter mount

.542010. refitting 3. Moisten the gasket of the fuel filter with a thin layer of oil.

4. Manually tighten the fuel filter (4) on the mount (3) until it fits up against the gasket .

5. Using a suitable tool, tighten the fuel filter (4) further to a torque of: Tightening torque Fuel filter (1 fitting) (4)

30 ±5 N⋅m

Note Do not damage the new sealing ring while tightening.

237446

Figure 16

.542014. Removal - Refitting vehicle fuel filter mount

Tightening torques Fuel pipes (2 fittings M16x1.5)

40 ±5 N⋅m

Fuel temperature sensor (1 fitting M12x1.5)

30 ±2 N⋅m

Fuel filter clogged sensor (1 fitting M14x1.5)

30 ±2 N⋅m

Fuel filter mount (4 M8x1.25x60 screws)

24.5 ±2.5 N⋅m

Preparatory operation 1. Remove the engine cable. ( ➠ Page 9) 2. Remove the fuel filter. ( ➠ Page 11) Main activity .542014. removal 1. Unscrew the fittings (5, 6) of the delivery pipes to the fuel filter and the delivery pipe to the high pressure pump from the filter support (3).

Threaded parts Fuel pipes (2 fittings M16x1.5) (5, 6)

2.

Unscrew the temperature sensor (2)from the fuel filter support.

Threaded parts Fuel temperature sensor (1 fitting M12x1.5)

3.

Unscrew the filter clogged sensor (1) from the fuel filter support.

237446

Figure 17

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal - Refitting vehicle fuel filter mount

Threaded parts Fuel filter clogged sensor (1 fitting M14x1.5)

4.

Unscrew the fastening screws (2) and remove the fuel filter support (3) (1)from the engine crankcase.

Threaded parts Fuel filter mount (4 M8x1.25x60 screws) (2)

237447

Figure 18

237447

Figure 19

237446

Figure 20

.542014. refitting 5. Fit the fuel filter support (3) on the crankcase (1) and tighten the fastening screws (2) to a torque of: Tightening torque Fuel filter mount (4 M8x1.25x60 screws) (2)

6.

24.5 ±2.5 N⋅m

Screw the temperature sensor to the fuel filter support (2).

Tightening torque Fuel temperature sensor (1 fitting M12x1.5) (2)

7.

30 ±2 N⋅m

Screw the pressure sensor to the fuel filter support (1).

Tightening torque Fuel filter clogged sensor (1 fitting M14x1.5) (1)

8.

30 ±2 N⋅m

Screw the fittings (5, 6) of the delivery pipes to the fuel filter and the delivery pipe to the high pressure pump onto the filter support (3).

Tightening torque Fuel pipes (2 fittings M16x1.5) (5, 6)

– P2D32C015E0116

40 ±5 N⋅m

13

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 14

Removal - refitting of main components Turbocharger removal-refitting

Subsequent operation 1. Refitting the vehicle fuel filter. ( ➠ Page 12) 2. Refit the engine cable. ( ➠ Page 10)

.542410. Turbocharger removal-refitting

Tightening torques Pipe delivering air from the turbocharger to the intercooler (1 M6x1x50 screw)

8 ±0.5 N⋅m

Turbocharger oil delivery pipe screws ( 1 nut M18x1.5x)

50 ±5 N⋅m

Turbocharger on exhaust manifold (4 nuts M10x1.5)

1.

Step 1

2.

Step 2

35 ±5 N⋅m 46 ±2 N⋅m

Blower turbo oil return pipe screws ( 2 screws M8x1.25x25)

20 ±2 N⋅m

Lubricant oil delivery pipe to turbocharger (2 fittings M14x1.5)

35 ±5 N⋅m

Main activity .542410. removal 1. Unscrew the screw (3), loosen the clip (2) and remove the pipe (1) from the turbocharger.

Threaded parts Pipe delivering air from the turbocharger to the intercooler (1 M6x1x50 screw) (3)

2.

3.

237417

Figure 21

237416

Figure 22

Position a suitable container to collect the oil.

Unscrew the fitting (4) and remove the lubricant oil delivery pipe which connects the top part of the turbocharger oil filter support (1) .

Threaded parts Turbocharger oil delivery pipe screws ( 1 nut M18x1.5x) (4)

4.

Unscrew the screws (2) securing the lubricant oil return pipe (3) from the lower part of the turbocharger (1) and recover the relative gasket.

Threaded parts Turbocharger oil delivery pipe screws ( 1 nut M18x1.5x) (2)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Turbocharger removal-refitting

5.

Unscrew the fastening nuts (1), remove the turbocharger (4) and recover the relative gasket (3) .

Threaded parts Turbocharger on exhaust manifold (4 nuts M10x1.5) (1)

6.

1.

Step 1

2.

Step 2

If necessary, unscrew the studs (2) from the exhaust manifold and from the turbocharger(4).

237419

Figure 23

237419

Figure 24

237416

Figure 25

.542410. refitting 7. If removed, screw the studs (2) onto the exhaust manifold and the turbocharger(4).

8. Fit the turbocharger (4) with a new gasket (3) on the exhaust manifold .

9. Tighten the fastening nuts (1) to a torque of: Tightening torque Turbocharger on exhaust manifold (4 nuts M10x1.5) (1)

1.

Step 1 35 ±5 N⋅m

2.

Step 2 46 ±2 N⋅m

10. Fit the lubricant oil drain pipe (3), positioning the relative gasket and tighten the screws (2) on the turbocharger.

Tightening torque Blower turbo oil return pipe screws ( 2 screws M8x1.25x25) (2)

20 ±2 N⋅m

11. Fit the lubricant oil delivery pipe and tighten the fitting (4) to a torque of: Tightening torque Lubricant oil delivery pipe to turbocharger (2 fittings M14x1.5) (4)

– P2D32C015E0116

35 ±5 N⋅m

15

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 16

Removal - refitting of main components Exhaust manifold removal-refitting

12. Fit the pipe (1) on the turbocharger and tighten the screw (3) of the clip (2) to a torque of: Tightening torque 8 ±0.5 N⋅m

Pipe delivering air from the turbocharger to the intercooler (1 M6x1x50 screw) (3)

237417

Figure 26

.540720. Exhaust manifold removal-refitting

Tightening torques Exhaust manifold (24 screws M10x1.5x38)

1.

Step I

30 ±5 N⋅m

2.

Step II

60 ±5 N⋅m

Preparatory operation ▶ Remove the turbocharger. ( ➠ Page 14) Main activity .540720. removal 1. Unscrew the screws (2) and remove the exhaust manifold(3) from the cylinder head (4) recovering the relative gaskets (1).

Threaded parts Exhaust manifold (24 screws M10x1.5x38) (2)

1.

Step I

2.

Step II

237466

Figure 27

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Intake manifold removal-refitting

.540720. refitting 2. Fit the exhaust manifold (3) in position with the new gaskets (1) on the cylinder head (4) and tighten the fastening screws (2) to the specified torque.

Tightening torque Exhaust manifold (24 screws M10x1.5x38) (2)

1.

Step I 30 ±5 N⋅m

2.

Step II 60 ±5 N⋅m

Note Always replace the gaskets with new spare parts. Check the thread of the fastening screws: it must not show signs of wear or deposits of dirt.

237466

171168

3.

diagram of tightening sequence for exhaust manifold fastening screws.

Subsequent operation ▶ Refit the turbocharger. ( ➠ Page 15)

.540710. Intake manifold removal-refitting

Tightening torques Air pressure and temperature sensor

(1 M6x1x18 screw)

5 ±0.5 N⋅m

Intake manifold

1.

(2 M10x1.5x110 screw)

50 ±5 N⋅m

2.

(2 M10x1.5x100 screw)

50 ±5 N⋅m

3.

(2 M10x1.5x150 screw)

50 ±5 N⋅m

– P2D32C015E0116

Figure 28

Figure 29

17

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 18

Removal - refitting of main components Engine oil filter removal - refitting

Main activity .540710. removal 1. Remove the collar (4) and remove the air inlet pipe (1).

2. Unscrew the screw (6) and remove the air pressure and temperature sensor (3).

Threaded parts Air pressure and temperature sensor (6)

3.

(1 M6x1x18 screw)

Unscrew the screws (2) and remove the intake manifold (5).

Threaded parts Intake manifold (2)

4.

1.

(2 M10x1.5x110 screw)

2.

(2 M10x1.5x100 screw)

3.

(2 M10x1.5x150 screw)

Remove the starter device.

237425

Figure 30

237425

Figure 31

.540710. refitting 5. Fit the starter device.

6. Position the intake manifold (5) and tighten the fastening screws (2) to a torque of: Tightening torque Intake manifold (2)

1.

(2 M10x1.5x110 screw) 50 ±5 N⋅m

2.

(2 M10x1.5x100 screw) 50 ±5 N⋅m

3.

(2 M10x1.5x150 screw) 50 ±5 N⋅m

7.

Fit the air pressure and temperature sensor (3) in place, then tighten the fastening screw (6) to a torque of: Tightening torque Air pressure and temperature sensor (6)

8.

(1 M6x1x18 screw) 5 ±0.5 N⋅m

Position the air inlet pipe (1) and secure it to the intake manifold with the collar (4) tightening the relative fastening screw to the specified torque.

.543070. Engine oil filter removal - refitting

Tightening torques Oil filter (1 fitting)

60 ±5 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Heat exchanger removal-refitting

Main activity .543070. removal 1. Position a container to collect the used oil below the heat exchanger .

2. Unscrew and remove the oil filter (1) and the sealing gasket (2) from the support (3).

Threaded parts Oil filter (1 fitting) (1)

237438

Figure 32

237438

Figure 33

.543070. refitting 3. Moisten the gasket (2) with a thin layer of oil and place it in its seat.

Note Do not damage the new sealing ring while tightening.

4.

5.

Manually tighten the oil filter (1) on the mount (3) until fit up against the gasket (2).

Using specific tool, further tighten the oil filter (1) to a torque of: Tightening torque Oil filter (1 fitting) (1)

6.

60 ±5 N⋅m

Operate the engine for a few minutes and then recheck the level using the dipstick. Top up if necessary to compensate for the oil used for filling the filtering cartridge.

.543110. Heat exchanger removal-refitting

Tightening torques Blower turbo oil return pipe screws ( 2 screws M8x1.25x25)

20 ±2 N⋅m

Turbocharger oil delivery pipe screws ( 1 nut M18x1.5x)

50 ±5 N⋅m

Oil dipstick (1) nut M18x1.5

30 ±3 N⋅m 1.

2.

(1) screw M12x1.75x25

74 ±8 N⋅m

Heat exchanger (16 screws M8x1.25x50)

1.

Step 1

11.5 ±3.5 N⋅m

2.

Step 2

24.5 ±2.5 N⋅m

Heat exchanger and oil filter mount (15 M8x1.25x35 screws)

– P2D32C015E0116

(2) screws M8x1.25x55

25 ±2 N⋅m

Oil filler pipes

26 ±4 N⋅m

19

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 20

Removal - refitting of main components Heat exchanger removal-refitting

Main activity .543110. removal 1. Position a suitable container to collect the oil.

2. Unscrew the screws (2) securing the lubricant oil return pipe (3) from the lower part of the turbocharger (1) and recover the relative gasket.

Threaded parts Blower turbo oil return pipe screws ( 2 screws M8x1.25x25) (2)

3.

Unscrew the fitting of the lubricant oil return pipe (4) from the turbocharger and from the crankcase and remove the pipe.

Threaded parts Turbocharger oil delivery pipe screws ( 1 nut M18x1.5x) (4)

4.

237416

Figure 34

237476

Figure 35

237445

Figure 36

Unscrew the nut (2) and remove the dipstick together with the guide (1).

Threaded parts Oil dipstick (1) nut M18x1.5 (2)

5.

Unscrew the fastening screws (3, 5) and remove the oil filler pipe (4) together with the fastening bracket.

Threaded parts Oil filler pipes (3, 5)

6.

1.

(2) screws M8x1.25x55

2.

(1) screw M12x1.75x25

Unscrew the screws (3) and remove the heat exchanger (2) and the relative elements from the designated seat on the crankcase (4) .

Threaded parts Heat exchanger (16 screws M8x1.25x50) (3)

1.

Step 1

2.

Step 2

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Heat exchanger removal-refitting

.543110. refitting 7. Fit the heat exchanger (2), a new gasket and the relative elements to the crankcase (4).

8. Fasten the screws (3) and tighten them to the specified torque.

Tightening torque Heat exchanger and oil filter mount (15 M8x1.25x35 screws) (3)

9.

26 ±4 N⋅m

237445

Figure 37

237476

Figure 38

237416

Figure 39

Position the filler pipe (4), complete with the fastening bracket and tighten the fastening screws (3, 5) to the specified torque.

Tightening torque Oil filler pipes (3, 5)

1.

(2) screws M8x1.25x55

2.

(1) screw M12x1.75x25

25 ±2 N⋅m 74 ±8 N⋅m

10. Position the oil dipstick together with the guide (1) and tighten the fastening nut (2) to the specified torque.

Tightening torque Oil dipstick (1) nut M18x1.5 (2)

30 ±3 N⋅m

11. Fit the lubricant oil drain pipe(3), positioning the relative gasket and tighten the screws (2) on the turbocharger.

Tightening torque Blower turbo oil return pipe screws ( 2 screws M8x1.25x25) (2)

20 ±2 N⋅m

12. Tighten the fitting of the lubricant oil return pipe (4) to the turbocharger and crankcase.

Tightening torque Blower turbo oil return pipe screws ( 2 screws M8x1.25x25) (2)

– P2D32C015E0116

20 ±2 N⋅m

21

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 22

Removal - refitting of main components Starter motor removal-refitting

.760810. Starter motor removal-refitting

Tightening torques Starter motor

(3 nuts M10x1.5)

44 ±4 N⋅m

Main activity .760810. removal 1. Make sure that the starter motor(3) is suitably supported.

2. Unscrew the fastening nuts (4) and remove the electric starter motor (3) from the flywheel housing(2).

Threaded parts Starter motor (4)

(3 nuts M10x1.5)

237464

Figure 40

237464

Figure 41

.760810. refitting 3. Tighten the nuts (4) and secure the starter motor (3) to the flywheel housing (2).

4. Tighten the fastening nut (4) to a torque of: Tightening torque Starter motor (4)

(3 nuts M10x1.5) 44 ±4 N⋅m

.542020. Removal - refitting of the fuel pipes

Tightening torques Fuel pipe from the electronic control unit to the mechanical pump (1 fitting M16x1.5x34)

47.5 ±2.5 N⋅m

Fuel return pipe from pump to tank (1 fitting M14x1.5x30)

47.5 ±2.5 N⋅m

Fuel delivery pipe from the mechanical pump to the filter (2 fittings M14x1.5)

47.5 ±2.5 N⋅m

Fuel pipe from the filter to the high pressure pump (1 fitting M16x1.5)

47.5 ±2.5 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal - refitting of the fuel pipes

Pipe delivering fuel from the pump to the rail (2 M14x1.5 unions)

35 ±2 N⋅m

Preparatory operation ▶ Remove the engine cable. ( ➠ Page 9) Main activity .542020. removal 1.

Disconnect the low pressure fuel pipe (2) from the electronic control unit to the mechanical pump from the relative fitting.

Threaded parts Fuel pipe from the electronic control unit to the mechanical pump (1 fitting M16x1.5x34) (2)

2.

Disconnect the low pressure fuel return pipe (3) from the high pressure pump (1) to the tank.

Threaded parts Fuel return pipe from pump to tank (1 fitting M14x1.5x30) (3)

3.

237448

Figure 42

237449

Figure 43

237450

Figure 44

Unscrew the delivery pipe (2) fitting (4) from the mechanical pump to the fuel filter.

Threaded parts Fuel delivery pipe from the mechanical pump to the filter (2 fittings M14x1.5) (4)

4.

Unscrew the pipe (1) fitting (3) from the fuel filter to the high pressure pump.

Threaded parts Fuel pipe from the filter to the high pressure pump (1 fitting M16x1.5) (3)

5.

Unscrew the fittings (2, 5) of the high pressure fuel pipe (1) from the pump to the common rail and then, after having removed the screws (4) from the brackets (3) remove the pipe.

Threaded parts Pipe delivering fuel from the pump to the rail (2 M14x1.5 unions) (2, 5)

– P2D32C015E0116

23

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 24

Removal - refitting of main components Removal - refitting of the fuel pipes

.542020. refitting 6. Screw in the fittings (2, 5) of the high pressure fuel pipe (1) from the pump to the common rail, then screw in the screws (4) to the brackets (3) .

Tightening torque Pipe delivering fuel from the pump to the rail (2 M14x1.5 unions) (2, 5)

7.

35 ±2 N⋅m

237450

Figure 45

237449

Figure 46

237448

Figure 47

Screw in the delivery pipe (2) fitting (4) from the mechanical pump to the fuel filter.

Tightening torque Fuel delivery pipe from the mechanical pump to the filter (2 fittings M14x1.5) (4)

8.

47.5 ±2.5 N⋅m

Screw in the pipe (1) fitting (3) from the fuel filter to the high pressure pump.

Tightening torque Fuel pipe from the filter to the high pressure pump (1 fitting M16x1.5) (3)

9.

47.5 ±2.5 N⋅m

Connect the low pressure fuel pipe (2) from the electronic control unit to the mechanical pump using the relative fitting.

Tightening torque Fuel pipe from the electronic control unit to the mechanical pump (1 fitting M16x1.5x34) (2)

10.

47.5 ±2.5 N⋅m

Connect the low pressure fuel return pipe (1) from the high pressure pump (3) to the tank using the relative fitting.

Tightening torque Fuel return pipe from pump to tank (1 fitting M14x1.5x30) (1)

47.5 ±2.5 N⋅m

Subsequent operation ▶ Refit the engine cable. ( ➠ Page 10)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal - refitting of the high pressure pump

.771010. Removal - refitting of the high pressure pump

Tightening torques High pressure fuel pump (5 screws M8x1.25x25)

19 ±3 N⋅m

Preparatory operation 1. Removing the fuel filter support. ( ➠ Page 12) 2. Remove the fuel pipes. ( ➠ Page 23) Main activity .771010. removal 1. Make sure that the high pressure fuel pump (1) is suitably supported.

2. Unscrew the fastening screws (2) and remove the high pressure pump (1), complete with the gear (4) and gasket from the designated seat on the gear case.

Threaded parts High pressure fuel pump (5 screws M8x1.25x25) (2)

237433

Figure 48

237433

Figure 49

.771010. refitting 3. Use a new gasket and fit the high pressure pump (1), complete with gear (4) into the designated seat on the gear case (3) .

4. Tighten the fastening screws (2) to a torque of: Tightening torque High pressure fuel pump (5 screws M8x1.25x25) (2)

19 ±3 N⋅m

Subsequent operation 1. Refit the fuel pipes. ( ➠ Page 24) 2. Refitting the fuel filter support. ( ➠ Page 13)

– P2D32C015E0116

25

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 26

Removal - refitting of main components Removal - Refitting of air compressor seat cover

.790518. Removal - Refitting of air compressor seat cover

Tightening torques Air compressor seat cover (3 screws M12x1.75x25)

74 ±4 N⋅m

Main activity .790518. removal 1. Unscrew the screws (2) and remove the cover (1) from the power take-off seat (3).

Threaded parts Air compressor seat cover (3 screws M12x1.75x25) (2)

237436

Figure 50

237436

Figure 51

.790518. refitting 2. Rest the cover (1) on the power take-off seat (3) and tighten the screws (2) to the specified torque: Tightening torque Air compressor seat cover (3 screws M12x1.75x25) (2)

74 ±4 N⋅m

.540430. Oil sump removal-refitting

Tightening torques Engine oil sump (26 M10x1.5x45 screws)

41.5 ±3.5 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Oil sump removal-refitting

Main activity .540430. removal 1. Position an appropriate container for the oil collection under the sump in line with the drain plug (2).

Note It is recommended to drain the engine oil when hot.

2.

3.

To aid the flow of the oil, unscrew the oil filler cap on the tappet cover and remove the oil dipstick .

Unscrew the drain plug (2) and let the oil in the sump drain out completely.

237437

4.

Figure 52

Unscrew the screws (3) and remove the oil sump (4) together with the spacer (1) and the gasket (5).

.540430. refitting 5. Position the gasket (5) on the oil sump (4).

Note If not faulty the gasket can be reused.

6.

7.

8.

Fit the oil sump (4) in position on the crankcase .

Position the spacer (1) before inserting the oil sump fastening screws.

Tighten the fastening screws (3) to the prescribed torque.

Tightening torque Engine oil sump (26 M10x1.5x45 screws)

9.

41.5 ±3.5 N⋅m

237437

Figure 53

218524

Figure 54

Diagram of the tightening sequence for oil sump fastening screws.

– P2D32C015E0116

27

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 28

Removal - refitting of main components Tappet cover removal-refitting

Caution! ▶ ▶ ▶

Only use recommended oils or oils with the properties required for proper engine operation.

If topping up, do not mix oils with different properties.

Failure to observe these standards will invalidate the service warranties.

10. Using a new gasket, tighten the drain plug (2) to the specified torque and then fill it with clean oil.

11. Check the oil level with the dipstick : the level must be close to the MAX notch on the dipstick itself. Otherwise top-up the necessary quantity through the filler plug .

.540630. Tappet cover removal-refitting

Tightening torques Tappet cover (20 screws M6x1x50)

8.5 ±1.5 N⋅m

Preparatory operation ▶ Remove the engine cable. ( ➠ Page 9) Main activity .540630. removal 1. Unscrew the fastening screws (2, 4) and remove the tappet cover (3) from the cylinder head.

Threaded parts Tappet cover (20 screws M6x1x50) (2, 4)

237457

Figure 55

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal - refitting of the rocker arm unit

.540630. refitting 2. Install a new gasket in the tappet cover .

3. Install the tappet cover (3) on the cylinder head and tighten the screws (2, 4) to a torque of: Tightening torque Tappet cover (20 screws M6x1x50) (2, 4)

4.

8.5 ±1.5 N⋅m

237457

Figure 56

218020

Figure 57

Tightening sequence diagram for tappet cover fixing screws.

Subsequent operation ▶ Refit the engine cable. ( ➠ Page 10)

.541230. Removal - refitting of the rocker arm unit

Work material Tool for rocker arm shaft assembly and fitting

99360558

Tightening torques Rocker arm shaft (7 M12x1.75 screws)

Preparatory operation 1. Remove the engine cable. ( ➠ Page 9) 2. Remove the tappet cover. ( ➠ Page 28)

– P2D32C015E0116

104.5 ±10.5 N⋅m

29

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 30

Removal - refitting of main components Removal - refitting of the rocker arm unit

Main activity .541230. removal 1. Remove the screws (1) from the rocker arm assembly (2).

Threaded parts Rocker arm shaft (7 M12x1.75 screws) (1)

2.

237455

Figure 58

237456

Figure 59

237456

Figure 60

Grip the rocker arm assembly (2) with the specific tool (1), remove the control jumpers from the valves and then remove the rocker arm assembly from the cylinder head.

Tool / Material

Product Code

Tool for rocker arm shaft assembly and fitting

99360558

.541230. refitting 3. Position the rocker arm assembly (2) on the cylinder head with the help of the specific tool (1).

4.

Tool / Material

Product Code

Tool for rocker arm shaft assembly and fitting

99360558

Position the control bridges on valves with marks facing the exhaust manifold.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Common rail removal-refitting

5.

Tighten the screws(1) securing the rocker arm assembly (2) to the cylinder head (3) to a torque of: Tightening torque Rocker arm shaft (7 M12x1.75 screws) (1)

104.5 ±10.5 N⋅m

237455

Subsequent operation 1. Refit the tappet cover. ( ➠ Page 29) 2. Refit the engine cable. ( ➠ Page 10)

.774510. Common rail removal-refitting

Tightening torques Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel delivery pipe (1 fitting M18x1.5)

40 ±2 N⋅m

Fuel return pipe (1 fitting M14x1.5)

35 ±2 N⋅m

High pressure pipe (1 fitting M18x1.5)

40 ±2 N⋅m

High pressure pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Common Rail (3 M8x1.25x45 screws)

23 ±2 N⋅m

Preparatory operation ▶ Remove the rocker assembly. ( ➠ Page 30)

– P2D32C015E0116

Figure 61

31

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 32

Removal - refitting of main components Common rail removal-refitting

Main activity .774510. removal 1. Position a suitable container to collect the fuel.

2. Unscrew the fittings and disconnect the fuel return pipes (3) between the common rail and the cylinder head.

Threaded parts Fuel return pipe (1 fitting M16x1.5) Fuel return pipe (1 fitting M16x1.5)

3.

Unscrew the fittings (4) and disconnect the fuel delivery pipe from the high pressure pump to the common rail and remove the bracket.

Threaded parts Fuel delivery pipe (1 fitting M18x1.5) Fuel return pipe (1 fitting M14x1.5)

4.

237454

Figure 62

237461

Figure 63

Unscrew the couplings (1) and disconnect the high pressure fuel delivery pipes from the common rail (2) to the electroinjectors.

Threaded parts High pressure pipe (1 fitting M18x1.5) (4) High pressure pipe (1 fitting M14x1.5) (8)

5.

Unscrew the screws (4) and remove the common rail (1) from the spacers (2) on the cylinder head (3) .

Threaded parts Common Rail (3 M8x1.25x45 screws) (4)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal - refitting of the electro-injectors

.774510. refitting 6. Position the common rail (1) on the spacers (2) , located on the cylinder head (3) and tighten the screws (4) to a torque of: Tightening torque Common Rail (3 M8x1.25x45 screws) (4)

7.

23 ±2 N⋅m

237461

Figure 64

237454

Figure 65

Connect the fuel delivery pipes to the electro-injectors and to the common rail (2) using the fittings (1) and tighten to a torque of: Tightening torque

8.

High pressure pipe (1 fitting M18x1.5)

40 ±2 N⋅m

High pressure pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Connect the fuel return pipe between the common rail and the cylinder head, tighten the respective fittings (3) to a torque of: Tightening torque

9.

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Connect the fuel delivery pipe to the common rail (2) tightening the respective fittings (4) to a torque of: Tightening torque Fuel return pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Fuel delivery pipe (1 fitting M18x1.5)

40 ±2 N⋅m

Subsequent operation ▶ Refit the rocker arm unit. ( ➠ Page 30)

.775010. Removal - refitting of the electro-injectors

Work material Extraction tool for injectors

99342157

Tightening torques Electro-injector brackets (6 screws M10x1.5x40)

– P2D32C015E0116

41 ±2 N⋅m

33

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 34

Removal - refitting of main components Removal - refitting of the electro-injectors

Preparatory operation ▶ Remove the common rail. ( ➠ Page 32) Main activity .775010. removal 1. Remove the screws (1) and remove the brackets (4) securing the electro-injectors (2) to the cylinder head (3).

Threaded parts Electro-injector brackets (6 screws M10x1.5x40)

2.

237458

Figure 66

237459

Figure 67

237460

Figure 68

Using the specific tool (1) extract the electro-injectors (2) from the cylinder head .

Tool / Material

Product Code

Extraction tool for injectors

99342157

Note Recover the relative washer

.775010. refitting 3. Fit the electro-injectors (1) with the relative washer (2) into the seats on the cylinder head (3).

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Cylinder head removal-refitting

4.

Position the brackets (4) securing the electro-injectors (2) on the cylinder head (3) and tighten the screws to a torque of: Tightening torque Electro-injector brackets (6 screws M10x1.5x40) (1)

41 ±2 N⋅m

237458

Subsequent operation ▶ Refit the common rail. ( ➠ Page 33)

.540610. Cylinder head removal-refitting

Work material Arm for engine removal and refitting

99360585

Pair of gauges for angular tightening with 1/2" and 3/4" square heads

99395216

Torque wrench Tightening torques Cylinder head fixing screws (26 M16x2)

Preparatory operation 1. Remove the fuel pipes. ( ➠ Page 23) 2. Remove the electro-injectors. ( ➠ Page 34) 3. Remove the intake manifold. ( ➠ Page 18) 4. Remove the exhaust manifold. ( ➠ Page 16)

– P2D32C015E0116

1.

Step 1

50 N⋅m

2.

Step 2

100 ±5 N⋅m

3.

Step 3

90°

4.

Step 4

75°

Figure 69

35

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 36

Removal - refitting of main components Cylinder head removal-refitting

Main activity .540610. removal 1. Remove the cylinder head (1) fastening screws (2).

Threaded parts Cylinder head fixing screws (26 M16x2) (2)

2.

1.

Step 1

2.

Step 2

3.

Step 3

4.

Step 4

Hook the lifting eyelets (3) with metal cables or by means of the specific tool and use the lifting device to detach the cylinder head (1) from the crankcase .

Tool / Material

Product Code

Arm for engine removal and refitting

99360585

237462

Figure 70

237463

Figure 71

237462

Figure 72

.540610. refitting 3. After correctly positioning the cylinder head gasket (3) on the crankcase (4) hook the lifting eyelets (1) using metal ropes or by means of the specific tool (2) and use the lifting device to place the cylinder head (5) on the crankcase (4).

Tool / Material

Product Code

Arm for engine removal and refitting

99360585

Note If the valves were removed from the cylinder head, refit them before installing the cylinder head on the crankcase.

4.

After fitting the cylinder head (1), screw in the fixing screws (2) and tighten them in three stages, following the order and methods shown in the following figure.

Tool / Material

Product Code

Pair of gauges for angular tightening with 1/2" and 3/4" square heads

99395216

Note The screws (2) must be lubricated prior to the assembly of the cylinder head (1).

Note Use specific tool for angle tightening.

Note Before each assembly operation, check that the thread on the holes and the screws shows no sign of wear or dirt.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Removal - refitting of the damper flywheel

5.

Diagram of the tightening sequence for the cylinder head fixing screws: Tightening torque Cylinder head fixing screws (26 M16x2) (2)

1.

Step 1

2.

Step 2

3.

Step 3

50 N⋅m 100 ±5 N⋅m 90° 4.

Step 4 75°

Tool / Material Torque wrench

198348

Subsequent operation 1. Refit the exhaust manifold. ( ➠ Page 17) 2. Refit the intake manifold. ( ➠ Page 18) 3. Refit the electro-injectors. ( ➠ Page 34) 4. Refit the fuel pipes. ( ➠ Page 24)

.540860. Removal - refitting of the damper flywheel

Tightening torques 115 ±5 N⋅m

Damper flywheel (6 screws M12x1.75x30) Crankshaft pulley (6 screws M14x2x60)

Preparatory operation ▶ Remove the ancillary belt. ( ➠ Page 5)

– P2D32C015E0116

1.

Step 1 - Tightening with torque wrench to torque

70 N⋅m

2.

Step 2 - Angle tightening

50°

Figure 73

37

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 38

Removal - refitting of main components Change blow-by filter

Main activity .540860. removal 1. Remove the screws (4) and remove the damper flywheel (1) from the auxiliary device idler pulley (2).

Threaded parts Damper flywheel (6 screws M12x1.75x30) (4)

2.

Remove the screws (3) and remove the auxiliary device idler pulley (2) from the crankshaft.

Threaded parts Crankshaft pulley (6 screws M14x2x60) (3)

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

237422

Figure 74

237422

Figure 75

.540860. refitting 3. Fit the auxiliary device idler pulley (2)on the crankshaft and tighten the screws (3) to the specified torque.

Tightening torque Crankshaft pulley (6 screws M14x2x60) (3)

1.

Step 1 - Tightening with torque wrench to torque 70 N⋅m

2.

Step 2 - Angle tightening 50°

4.

Fit the damper flywheel (1) on the auxiliary device idler pulley (2) and tighten the screws (4) to the specified torque.

Tightening torque Damper flywheel (6 screws M12x1.75x30) (4)

115 ±5 N⋅m

Subsequent operation ▶ Refit the ancillary belt. ( ➠ Page 5)

.540480. Change blow-by filter

Tightening torques Gear cover (6 screws M8x1.25)

23 ±2 N⋅m

Blow-by filter (3 screws M6x1x16)

9 ±1 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine Removal - refitting of main components Change blow-by filter

Main activity .540480. removal 1. Unscrew the screws (3) and remove the gear case cover (4).

Threaded parts Gear cover (6 screws M8x1.25) (3)

2.

Unscrew the screws (1) and remove the blow-by filter (2).

Threaded parts Blow-by filter (3 screws M6x1x16) (1)

237426

Figure 76

237426

Figure 77

.540480. refitting 3. Fit the blow-by filter (2) and tighten the screws (1) to a torque of: Tightening torque Blow-by filter (3 screws M6x1x16) (1)

4.

9 ±1 N⋅m

Fit the gear case cover (4) and tighten the fastening screws (3) to a torque of: Tightening torque Gear cover (6 screws M8x1.25) (3)

– P2D32C015E0116

23 ±2 N⋅m

39

CURSOR 9 Tigercat Tier II R96 ‒ Removal-refitting of the main engine 40

Removal - refitting of main components

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul Contents

Contents General mechanical overhaul . . . . . . . . . . . . . . . . .

– P2D32C015E0116

3

1

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 2

Contents

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul Contents

Contents ENGINE DISASSEMBLING

. . . . . . . . . . . . . . . . . .

5

CYLINDER UNIT REPAIR OPERATIONS . . . . . . . .

24

OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

CYLINDER HEAD OVERHAUL . . . . . . . . . . . . . .

55

COMPLETE TIMING SYSTEM OVERHAUL . . . . . . .

57

ENGINE ASSEMBLY

63

– P2D32C015E0116

. . . . . . . . . . . . . . . . . . . . .

3

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 4

General mechanical overhaul

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE DISASSEMBLING

General mechanical overhaul .540110. ENGINE DISASSEMBLING

Work material Rotary telescopic stand(range 2000 daN, torque 375 daNm)

99322230

Extraction tool for crankshaft front ring seal

99340051

Extraction tool for crankshaft rear gasket

99340054

Extraction tool for injectors

99342157

Crankshaft lifting tool

99360500

Tool for rocker arm shaft assembly and fitting

99360558

Tool for engine T.D.C. positioning

99360612

Brackets for fastening engine to 99322230 rotary stand

99361042

Tightening torques Oil filter Ufi Filter

60 ±5 N⋅m

Oil filter mount (4 M8x1.25 screws)

20 ±2 N⋅m

Blower turbo collar (1 screw M6x1x50)

9 ±1 N⋅m

Blower turbo oil return pipe screws ( 2 screws M8x1.25x25)

20 ±2 N⋅m

Turbocharger on exhaust manifold (4 nuts M10x1.5)

1.

Step 1

35 ±5 N⋅m

2.

Step 2

46 ±2 N⋅m 30 ±3 N⋅m

Oil dipstick (1) nut M18x1.5 1.

(2) screws M8x1.25x55

25 ±2 N⋅m

2.

(1) screw M12x1.75x25

74 ±8 N⋅m

Heat exchanger (16 screws M8x1.25x50)

1.

Step 1

11.5 ±3.5 N⋅m

2.

Step 2

24.5 ±2.5 N⋅m

Exhaust manifold (24 screws M10x1.5x38)

1.

Step 1

30 ±5 N⋅m

2.

Step 2

60 ±5 N⋅m

Oil filler pipes

Starter motor

(3 nuts M10x1.5)

44 ±4 N⋅m

Air compressor seat cover (3 screws M12x1.75x25)

74 ±4 N⋅m

Fuel pipes (2 fittings M16x1.5)

40 ±5 N⋅m

Fuel temperature sensor (1 fitting M12x1.5)

30 ±2 N⋅m

Fuel filter clogged sensor (1 fitting M14x1.5)

30 ±2 N⋅m

Fuel filter mount (4 M8x1.25x60 screws)

24.5 ±2.5 N⋅m 19 ±3 N⋅m

High pressure fuel pump (5 screws M8x1.25x25) Air pressure and temperature sensor

(1 M6x1x18 screw)

5 ±0.5 N⋅m

Intake manifold

1.

(2 M10x1.5x110 screw)

50 ±5 N⋅m

2.

(2 M10x1.5x100 screw)

50 ±5 N⋅m

3.

(2 M10x1.5x150 screw)

50 ±5 N⋅m

Fitting (1 M16x1.5)

30 ±5 N⋅m

Control unit with crankcase (3 screws M8x1.25)

19 ±3 N⋅m

Thermostat cover (5 screws M8x1.25x70)

25 ±2 N⋅m

Water pump (4 screws M8x1.25x25)

24.5 ±2.5 N⋅m

– P2D32C015E0116

5

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 6

General mechanical overhaul ENGINE DISASSEMBLING

Oil vapour breather (3 bolts M6x1)

9 ±1 N⋅m

Water return pipe (2) screws M8x1.25x50

24 ±4 N⋅m

Damper flywheel (6 screws M12x1.75x30)

115 ±5 N⋅m

Crankshaft pulley (6 screws M14x2x60)

1.

Step 1 - Tightening with torque wrench to torque

70 N⋅m

2.

Step 2 - Angle tightening

50°

Front cover (9 screws M8x1.25x45)

19 ±3 N⋅m

Gear cover (6 screws M8x1.25)

23 ±2 N⋅m

Blow-by filter (3 screws M6x1x16)

9 ±1 N⋅m 23 ±2 N⋅m

Phonic wheel ( 3 screws M8x1.25) Engine flywheel (3 screws M10x1.5x45)

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

Engine flywheel (8 screws M18x1.5x72)

Flywheel housing

1.

Step 1 - Tightening with torque wrench to torque

30 ±1.5 N⋅m

2.

Step 2 - Angle tightening

90°

1.

Step 1 - Tightening with torque wrench to torque

120 ±6 N⋅m

2.

Step 2 - Angle tightening

90°

1.

(1 M10x1.5x110 screw)

41.5 ±3.5 N⋅m

2.

(3 screws M10x1.5x35)

41.5 ±3.5 N⋅m

3.

(1 M12X1.75X120 screw)

63 ±7 N⋅m

4.

(1 M10x1.5x180 screw)

41.5 ±3.5 N⋅m

5.

(7 screws M12x1.75x80)

63 ±7 N⋅m

6.

(2 screws M12x1.75x190)

63 ±7 N⋅m

1.

Torque tightening

30 ±3 N⋅m

2.

Angle tightening

90°

24.5 ±2.5 N⋅m

Oil pump (4 M8x1.25 screws) Idler gear (3) bolts M12x1.75x90

45° 20 ±2 N⋅m

Thrust plate (6 screws M8x1.25) Idle gear (3 screws M12x1.75)

25 ±2.5 N⋅m

Connecting rod (1 screw M8x1.25x16)

0+0 +0 N⋅m

Head cover (20 screws M6x1x50)

8.5 ±1.5 N⋅m

Rocker arm shaft (7 M12x1.75 screws)

104.5 ±10.5 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel delivery pipe (1 fitting M18x1.5)

40 ±2 N⋅m

Fuel return pipe (1 fitting M14x1.5)

35 ±2 N⋅m

High pressure pipe (1 fitting M18x1.5)

40 ±2 N⋅m

High pressure pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Common Rail (3 M8x1.25x45 screws)

23 ±2 N⋅m

Electro-injector brackets (6 screws M10x1.5x40)

41 ±2 N⋅m

Engine oil sump (26 M10x1.5x45 screws)

41.5 ±3.5 N⋅m

Oil sprayers for piston cooling (6 nuts M12x1.5)

50 ±5 N⋅m

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

7

ENGINE DISASSEMBLING

main activity 1. Before mounting the engine on the specified rotating stand, remove the following parts that may interfere with mounting the dedicated brackets.

2.

Tool / Material

Product Code

Rotary telescopic stand(range 2000 daN, torque 375 daNm)

99322230

Brackets for fastening engine to 99322230 rotary stand

99361042

Disconnect the electrical components and remove the engine cable.

Note Before disconnecting the electrical components, mark them with the engine cable.

.769140. Engine cable removal 3. Disconnect the engine cable connector (1) from the control unit (2).

4. Disconnect the engine cable (3) from all the sensors fitted on the engine.

237480

Figure 1

237438

Figure 2

.543070. Oil filter removal 5.

Remove the oil filter (1) from the oil filter support (3) and remove the relative gasket (2) .

Threaded parts Oil filter Ufi Filter (1)

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 8

General mechanical overhaul ENGINE DISASSEMBLING

6.

Unscrew the screws (2) and remove the oil filter support (3) from the crankcase (1).

Threaded parts Oil filter mount (4 M8x1.25 screws) (2)

237444

Figure 3

237417

Figure 4

237416

Figure 5

.542410. Turbocharger removal 7. Loosen the fastening collar (2) using the designated screw (3), remove the intake delivery pipe (1) from the turbocharger.

Threaded parts Blower turbo collar (1 screw M6x1x50) (3)

8.

Undo the screws (2) and remove the turbocharger lubrication return pipe (3) from the turbocharger (1).

Threaded parts Blower turbo oil return pipe screws ( 2 screws M8x1.25x25) (2)

9.

Remove the turbocharger lubrication delivery pipe(4) unscrewing the special coupling from the turbocharger (1).

Threaded parts Blower turbo oil return pipe screws ( 2 screws M8x1.25x25) (4)

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE DISASSEMBLING

10. Unscrew the nuts (1) and the relative studs(2), remove the turbocharger (4) with the relative gasket (3) from the exhaust manifold .

Threaded parts Turbocharger on exhaust manifold (4 nuts M10x1.5) (1)

1.

Step 1

2.

Step 2

237419

Figure 6

237476

Figure 7

237445

Figure 8

.543110. Heat exchanger removal 11. Unscrew the nut (2) and remove the dipstick together with the guide (1).

Threaded parts Oil dipstick (1) nut M18x1.5 (2)

12. Unscrew the fastening screws (3, 5) and remove the oil filler pipe (4).

Threaded parts Oil filler pipes (3, 5)

1.

(2) screws M8x1.25x55

2.

(1) screw M12x1.75x25

13. Position a suitable container to collect any engine oil which may leak out.

14. Unscrew the screws (3) and remove the heat exchanger (2) and the relative elements from the designated seat on the crankcase (4) .

Threaded parts Heat exchanger (16 screws M8x1.25x50) (3)

– P2D32C015E0116

1.

Step 1

2.

Step 2

9

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 10

General mechanical overhaul ENGINE DISASSEMBLING

.540720. Exhaust manifold removal 15. Unscrew the screws (2), remove the gaskets (1)and remove the exhaust manifold(3) from the cylinder head (4).

Threaded parts Exhaust manifold (24 screws M10x1.5x38) (2)

1.

Step 1

2.

Step 2

237466

Figure 9

237464

Figure 10

237436

Figure 11

.760810. Starter motor disassembly 16. Unscrew the nuts (4) and remove the starter motor (3) from the seat on the crankcase (2) .

Threaded parts Starter motor (4)

(3 nuts M10x1.5)

17. Remove the studs (1) from the seat on the crankcase(2).

.790518. Air compressor cover removal 18. Unscrew the screws (2) and remove the cover (1) from the power take-off seat (3).

Threaded parts Air compressor seat cover (3 screws M12x1.75x25) (2)

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE DISASSEMBLING

.542010. Fuel filter removal 19. Position a container to collect the diesel below the filter mount (3).

20. Use a suitable tool to unscrew and remove the fuel filter (4) and the relative gasket from the support (3).

21. Unscrew the fittings (5, 6) of the delivery pipes to the fuel filter and the delivery pipe to the high pressure pump from the filter support (3) and the pump and remove the pipes.

Threaded parts Fuel pipes (2 fittings M16x1.5) (5, 6)

22. Unscrew the temperature sensor (2)from the fuel filter support.

Threaded parts Fuel temperature sensor (1 fitting M12x1.5)

237446

Figure 12

237447

Figure 13

237433

Figure 14

23. Unscrew the filter clogged sensor (1) from the fuel filter support.

Threaded parts Fuel filter clogged sensor (1 fitting M14x1.5)

.542014. Removal of the fuel filter mount 24. Unscrew the fastening screws (2) and remove the fuel filter support (3) (1)from the engine crankcase.

Threaded parts Fuel filter mount (4 M8x1.25x60 screws) (2)

.771010. High-pressure pump removal 25. Remove the high pressure pump (1) together with the relative gear (4) from the seat (3), unscrewing the fastening nuts(2).

Threaded parts High pressure fuel pump (5 screws M8x1.25x25) (2)

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11

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 12

General mechanical overhaul ENGINE DISASSEMBLING

.540710. Intake manifold removal 26. Remove the collar (4) and remove the air inlet pipe (1) from the inlet manifold (5).

27. Unscrew the screw (6) and remove the air pressure and temperature sensor (3).

Threaded parts Air pressure and temperature sensor (6)

(1 M6x1x18 screw)

28. Unscrew the screws (2) and remove the intake manifold (5).

Threaded parts Intake manifold (2)

1.

(2 M10x1.5x110 screw)

2.

(2 M10x1.5x100 screw)

3.

(2 M10x1.5x150 screw)

237425

Figure 15

237451

Figure 16

29. Remove the starter device. .766161. EDC control unit disassembling 30. Act on the fitting (4) and disconnect the low pressure fuel pipe which connects the engine management control unit (1) to the mechanical pump.

Threaded parts Fitting (1 M16x1.5) (4)

31. Unscrew the fastening screws (2) and remove the engine management control unit (1) together with the heat exchanger from the engine crankcase (3).

Threaded parts Control unit with crankcase (3 screws M8x1.25) (2)

32. Act on the fitting and disconnect the pipe which connects the tank to the control unit (1).

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE DISASSEMBLING

.540110. Fixing engine on rotating stand

218038

Figure 17

33. Place the engine on the specific rotating stand after having fastened the dedicated brackets.

Tool / Material

Product Code

Rotary telescopic stand(range 2000 daN, torque 375 daNm)

99322230

Brackets for fastening engine to 99322230 rotary stand

99361042

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13

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 14

General mechanical overhaul ENGINE DISASSEMBLING

.543270. Removal of the thermostat assembly and removal of the thermostat 34. Remove the temperature sensor (3).

35. Unscrew the fastening screws (5) and remove the thermostat cover (1).

Threaded parts Thermostat cover (5 screws M8x1.25x70) (5)

36. Take off the gasket (2).

237440

Figure 18

237441

Figure 19

37. Remove the thermostat (1) from the seat on the cylinder head (2) .

.543411. Removal of the water pump / alternator drive belt (the following figure is provided for demonstration purposes only) Caution!

Spring belt Precaution during disassembly ▶

The flexible belt must be replaced with a new one every time it is removed from the vehicle.

38. Using an appropriate tool (4), act on the automatic belt tensioner (5) and remove the belt from the water pump control (1), crankshaft pulley (3) and guide pulleys (2).

218010

Figure 20

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE DISASSEMBLING

.543210. Water pump removal 39. Unscrew the screws (2) and remove the water pump (3) from the crankcase (1).

Threaded parts Water pump (4 screws M8x1.25x25) (2)

237442

Figure 21

237439

Figure 22

237421

Figure 23

.543417. Automatic belt tensioner removal 40. Unscrew the screw (4) and remove the automatic belt tensioner (3) from the alternator support.

41. Unscrew the screw (2) and remove the guide pulley (1) from the crankcase.

.540452. Blow-by case removal 42. Unscrew the fastening screws (2) and remove the blow-by vent (1) from the cylinder head.

Threaded parts Oil vapour breather (3 bolts M6x1) (2)

43. Unscrew the screws (3) and remove the water inlet pipe (4) from the crankcase.

Threaded parts Water return pipe (2) screws M8x1.25x50 (3)

– P2D32C015E0116

15

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 16

General mechanical overhaul ENGINE DISASSEMBLING

.540821. Crankshaft drive pulley removal 44. Unscrew the screws (4)and disconnect the damper flywheel (3) from the crankshaft drive pulley (1).

Threaded parts Damper flywheel (6 screws M12x1.75x30) (4)

45. Unscrew the screws (2) and remove the crankshaft drive pulley (1) from the crankshaft .

Threaded parts Crankshaft pulley (6 screws M14x2x60) (2)

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

237422

Figure 24

.540440. Crankshaft front cover removal 46. Apply the specified extractor (2).

Tool / Material

Product Code

Extraction tool for crankshaft front ring seal

99340051

47. Take off the gasket (1).

114551

Figure 25

48. Unscrew the screws (3) and remove the front cover (2) from the crankcase (1).

Threaded parts Front cover (9 screws M8x1.25x45) (3)

237432

Figure 26

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE DISASSEMBLING

.540486. Blow-by filter removal 49. Unscrew the screws (3) and remove the cover (4).

Threaded parts Gear cover (6 screws M8x1.25) (3)

50. Unscrew the screws (1) and remove the blow-by centrifugal filter (2).

Threaded parts Blow-by filter (3 screws M6x1x16) (1)

237426

Figure 27

237427

Figure 28

237429

Figure 29

.540850. Engine flywheel removal 51. Remove the phonic wheel revolution sensor(2) unscrewing the special screw (1).

52. Remove the phonic wheel (5) unscrewing the corresponding screws .

Threaded parts Phonic wheel ( 3 screws M8x1.25)

53. Remove the timing gear (4) unscrewing the corresponding screws (3).

Threaded parts Engine flywheel (3 screws M10x1.5x45) (3)

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

54. Unscrew the screws (1) and remove the thrust plate (2).

Threaded parts Thrust plate (6 screws M8x1.25) (1)

55. Unscrew the screws (3) and remove the idle gear (4).

Threaded parts Idle gear (3 screws M12x1.75) (3)

– P2D32C015E0116

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

17

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 18

General mechanical overhaul ENGINE DISASSEMBLING

56. Remove the flywheel increase revolution sensor(1) unscrewing the special screw .

57. Block rotation of the engine flywheel (2) using the specific tool, unscrew the retaining screws (3) and remove the engine flywheel.

Threaded parts Engine flywheel (8 screws M18x1.5x72) (3)

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612 237428

Figure 30

237430

Figure 31

237478

Figure 32

.540463. Flywheel case removal 58. Unscrew the screws (2) and remove the flywheel case (1).

Threaded parts Flywheel housing (2)

1.

(1 M10x1.5x110 screw)

2.

(3 screws M10x1.5x35)

3.

(1 M12X1.75X120 screw)

4.

(1 M10x1.5x180 screw)

5.

(7 screws M12x1.75x80)

6.

(2 screws M12x1.75x190)

Tool / Material

Product Code

Extraction tool for crankshaft rear gasket

99340054

.543010. Disassembling the oil pump 59. Remove the screws (4), slide off the cover (5) and disassemble the double gear (3) from the seat (8).

60. Unscrew the screws (6) and remove the oil pump (7).

Threaded parts Oil pump (4 M8x1.25 screws) (6)

61. Unscrew the fastening screws (4 ) and remove the cover (5 ).

Threaded parts Idler gear (3) bolts M12x1.75x90 (4 )

1.

Torque tightening

2.

Angle tightening

62. Remove the double gear (3) from the shaft (8).

63. Unscrew the retaining screw (2) and remove the articulated rod (1).

Threaded parts Connecting rod (1 screw M8x1.25x16) (2)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE DISASSEMBLING

.540640. Removal of head cover 64. Unscrew the screws (1) and remove the head cover (2) from the cylinder head(3).

Threaded parts Head cover (20 screws M6x1x50) (1)

237457

Figure 33

237455

Figure 34

237456

Figure 35

.541230. Rocker arm shaft removal 65. Unscrew and remove the screws (1) from the rocker arm assembly (2).

Threaded parts Rocker arm shaft (7 M12x1.75 screws) (1)

66. Grip the rocker arm assembly (2) with the specific tool (1), remove the control jumpers from the valves and then remove the rocker arm assembly from the cylinder head.

Tool / Material

Product Code

Tool for rocker arm shaft assembly and fitting

99360558

– P2D32C015E0116

19

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 20

General mechanical overhaul ENGINE DISASSEMBLING

.774510. Rail removal 67. Unscrew the fittings and disconnect the fuel return pipes (3) between the common rail and the cylinder head.

Threaded parts Fuel return pipe (1 fitting M16x1.5) Fuel return pipe (1 fitting M16x1.5)

68. Unscrew the fittings (4) and disconnect the fuel delivery pipe from the high pressure pump to the common rail and remove the bracket.

Threaded parts Fuel delivery pipe (1 fitting M18x1.5) Fuel return pipe (1 fitting M14x1.5)

69. Unscrew the couplings (1) and disconnect the high pressure fuel delivery pipes from the common rail (2) to the electroinjectors.

237454

Figure 36

237461

Figure 37

237458

Figure 38

Threaded parts High pressure pipe (1 fitting M18x1.5) High pressure pipe (1 fitting M14x1.5)

70. Unscrew the screws (4) and remove the common rail (1) from the spacers (2) on the cylinder head (3).

Threaded parts Common Rail (3 M8x1.25x45 screws) (4)

.775010. Removal of electronic injectors 71. Remove the screws (1) and disconnect the brackets (4) securing the electro-injectors (2).

Threaded parts Electro-injector brackets (6 screws M10x1.5x40)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

21

ENGINE DISASSEMBLING

72. Using the specific tool (1) extract the electro-injectors (2) from the cylinder head .

Tool / Material

Product Code

Extraction tool for injectors

99342157

237459

Figure 39

.541210. Removal of camshaft and cylinder head

45266

Figure 40

73. Extract the camshaft .

74. Using a suitable lifting device, lift the cylinder head (1) and remove the sealing gasket (2) from the crankcase.

Note If removing with the engine mounted on the vehicle, after having removed all timing side components, proceed as follows: - unscrew the screws securing the cylinder head - slide the head some centimetres forward to allow the "nose" of the camshaft axle to exit the housing on the gear case; By means of wire ropes, lift the cylinder head and remove the seal gasket - extract the camshaft from the head

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 22

General mechanical overhaul ENGINE DISASSEMBLING

.540430. Oil sump removal 75. Position an appropriate container for the oil collection under the sump in line with the drain plug (2).

76. Unscrew the plug (2).

77. Unscrew the screws (3) and remove the engine oil sump (4) together with the spacer (1) and the sealing gasket (5).

Threaded parts Engine oil sump (26 M10x1.5x45 screws) (3)

237437

Figure 41

.543060. Suction strainer removal 78. Slacken the screws (1) and remove the suction strainer (2).

125709

Figure 42

.540416. Lower crankcase removal 79. Unscrew the fastening screws and remove the lower crankcase using an appropriate lifting device.

Note Note down the assembly position of the top and bottom main half-bearings since, if reusing them, they will need to be fitted in the position found upon removal.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

23

ENGINE DISASSEMBLING

.540810. Crankshaft removal 80. Using the specified tool (1), remove the crankshaft (2).

Tool / Material

Product Code

Crankshaft lifting tool

99360500

114034

Figure 43

.540816. Main bearings removal 81. Disassemble main half-bearings (1).

47571

Figure 44

.540414. Oil sprayer removal 82. Unscrew the screws and remove the oil sprayers (2).

Threaded parts Oil sprayers for piston cooling (6 nuts M12x1.5)

83. Remove the cylinder sleeves as described in the related paragraph.

Note once the engine disassembly is complete, clean accurately the removed parts and check their integrity.

The following pages give instructions for checks and main measurements to do as to determine whether the parts can be reused.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

24

CYLINDER UNIT REPAIR OPERATIONS

.5406.

CYLINDER UNIT REPAIR OPERATIONS

Work material Cylinder liner protrusion gauge (to be used with 99370415-99395603 and special plates)

99360334

Tool for cylinder liner fastening

99360703

Tool to extract cylinder liners (use with special rings)

99360706

Ring (115 mm) (to be used with 99360706)

99360724

Dial gauge base to adjust lay shaft bearings (use with 99395603)

99370415

Dial gauge (0-5 mm)

99395603

Micrometer Tightening torques Protrusion checking tool screw

170 N⋅m

Technical data Cylinder liner protrusion compared to the cylinder head supporting surface

0.035 mm to0.065 mm

Main activity .540410. Crankcase checks 1. In order to check the inner diameter of cylinder liners and identify the degree of ovalisation, taper and wear, use gauge (2) fitted with a centesimal dial gauge (1), previously reset on the 117 mm ring gauge (3).

Note If the 117 mm ring gauge is not available, use a micrometer.

34994

Figure 45

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

25

CYLINDER UNIT REPAIR OPERATIONS

2.

Measurements should be carried out for every single cylinder liner at three different heights and on two (A-B) perpendicular plane levels as illustrated in Figure.

60596

1 1st measurement 2 2nd measurement 3.

Figure 46 3 3rd measurement

When wear is over 0.150 mm or maximum ovalisation is 0.100 mm compared to values A and B in the following tables and shown in the figure, replace the cylinder barrel since it is not possible to grind, lap or dress it.

Note Cylinder liners are equipped with spare parts belonging to selection class «A».

201440

A Selection class B Selection class

– P2D32C015E0116

Figure 47 X Selection class marking area

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 26

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

4.

The illustrated diagram refers to the outer diameters of cylinder liners (C) and (D) and the inner diameters of their seats (A) and (B).

5.

Cylinder liners can be removed and fitted several times into different housings, if needed.

114037

A Inner diameter of cylinder liner seat B Inner diameter of cylinder liner seat

193967

6.

Figure 48 C Outer diameter of cylinder liner D Outer diameter of cylinder liner

Figure 49

Letters A and B identify the selection class of the cylinder liners based on their use.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

7.

the figure shows the selection class marking area (Detail "X").

114040

Figure 50

.540420. Cylinder liners Removal 8. Position the specified parts (2) and the plate (4), as shown in the figure, checking that the specified plate (4) rests on the cylinder liner correctly.

9.

Tool / Material

Product Code

Tool to extract cylinder liners (use with special rings)

99360706

Ring (115 mm) (to be used with 99360706)

99360724

Fasten the screw nut (1) and take off the cylinder liner (3) from the crankcase.

47577

– P2D32C015E0116

Figure 51

27

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 28

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

.540420. Cylinder liner refitting and protrusion check 10. Always replace water sealing rings (3, 4, 5).

11. Install the adjustment ring (1) on the cylinder liner (2); lubricate the lower part of the liner and install it in the cylinder unit using the proper tool.

Note the adjustment ring (1) is equipped with a spare part having the following thickness: 0.08 mm - 0.10 mm 0.12 mm - 0.14 mm.

16798

Figure 52

12. Check cylinder liner protrusion using the specific tool (2) and tightening the screw (1) to the following torque.

Tightening torque Protrusion checking tool screw

170 N⋅m

Tool / Material

Product Code

Cylinder liner protrusion gauge (to be used with 9937041599395603 and special plates)

99360334

77812

Figure 53

13. Using the dial gauge provided with dial gauge stand (3), measure the cylinder liner protrusion compared to the cylinder head supporting surface, which must be the value indicated in the figure. Otherwise, replace the adjusting ring (1), supplied as spare part in different thicknesses.

Technical data Cylinder liner protrusion compared to the cylinder head supporting surface

0.035 mm to0.065 mm

Tool / Material

Product Code

Dial gauge (0-5 mm)

99395603

Dial gauge base to adjust lay shaft bearings (use with 99395603)

99370415

114041

Figure 54

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

14. On completing assembly, lock the cylinder liners (1) on the crankcase (2) with the specified stud bolts (3).

Tool / Material

Product Code

Tool for cylinder liner fastening

99360703

35012

Figure 55

.540810. Crankshaft measurements

181652

Figure 56

15. Check the condition of the crankshaft main journals; there must no be signs of scoring, ovalisation or excessive wear.

Note

The values shown refer to pin regular diameter.

– P2D32C015E0116

29

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 30

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

.540812. Measuring crankpins 16. Before grinding the pins, using a micrometer (1), measure the shaft pins (2) and decide, on the basis of the undersizing of the half-bearings, the final diameter to which the pins are to be ground.

Tool / Material Micrometer

Note It is advisable to enter readings in a table.

47536

Figure 57

17. During the grinding operation, pay attention to the values of the crankpins shown in Y. Note

The values shown refer to pin regular diameter.

Note All journals and crankpins must also be ground to the same undersizing class, in order to avoid any alteration to shaft balance.

114044

Figure 58

Y Crankpin fillet detail

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

36061

Figure 59

18. Write down the measurements of the main journals and crankpins of the crankshaft in the table. .540816. PRELIMINARY MEASUREMENT OF THE MAIN AND BIG-END BEARINGS 19. The following operations must be carried out for each main journal and crankpin.

20. MAIN JOURNALS. ◁ Determine the class of diameter of the seat in the casing. ◁ Determine the class of diameter of the main journal. ◁ Select the class of the semi bushings to be fit.

21. CRANKPINS. ◁ Determine the class of diameter of the connecting rod seat. ◁ Determine the class of diameter of the crankpin. ◁ Select the class of the semi bushings to be fit.

22. DEFINITION OF THE CLASS OF DIAMETER OF THE SEAT OF THE BEARINGS ON THE CRANKCASE. ◁ There is a set of seven numbers ( A) on the rear of the crankcase. ◁ The value of each number may be 1, 2 or 3 according to the nominal diameter class of each seat. ◁ The main bearing caps (B) are marked by a series of progressive numbers to locate them on the casing.

– P2D32C015E0116

31

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 32

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

2

1

B

1

2

3

3

4

4

5

6

5

7

6

7

A

210298

Figure 60

23. To identify the diameter class of the seats for the main half-bearings, look at the main bearing caps in the position shown in the figure.

CLASS

RATED DIAMETER OF MAIN BEARINGS mm.

1

99.000 - 99.009

2

99.010 - 99.019

3

99.020 - 99.030

.540810. Definition of the class of diameter of the seats for the half-bearings on the crankshaft 24. Main journals and crankpins are classified by the class of diameter.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

210301

Figure 61

25. There are three sets of numbers in the position shown in the figure.

26. The set of seven digits refers to the crankpins and is preceded by a single digit. ◁ The first digit indicates the tolerance class of the pin (1 = STD, 2= -0,127, 3 = -0,254, 4= - 0,508) mm. ◁ The remaining six digits, taken individually, supply the class of diameter for each of the crankpins 27. The set of eight digits refers to the main journals and is preceded by a single digit. ◁ The first digit indicates the tolerance class of the pin (1 = STD, 2= -0,127, 3 = -0,254, 4= - 0,508) mm. ◁ The remaining seven digits, taken individually, supply the class of diameter for each of the main journals 28. The set of five digits refers to the part-number of the crankshaft.

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33

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 34

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

.540816. Definition of the diameter class of the main journals (nominal diameter)

299594

Figure 62

29. Before selecting the main bearings, identify the diameter class of each main journal.

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35

CYLINDER UNIT REPAIR OPERATIONS

210315

Figure 63

30. In order to identify the diameter class of the main journals, identify the three sets of figures marked on the front of the crankshaft.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 36

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

.540831. Definition of the diameter class of the crankpins (nominal diameter)

299595

Figure 64

31. The diameter class of each connecting rod bearing must be selected before identifying the diameter of each crankpin.

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37

CYLINDER UNIT REPAIR OPERATIONS

210316

Figure 65

32. In order to identify the diameter class of the crankpins, identify the three sets of figures marked on the front of the crankshaft. .540816. Selecting the main half-bearings (nominal diameter pins) 33. After reading off the main data, for each main journal, on the crankcase and crankshaft, choose the type of half-bearings to use according to the following table.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 38

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

Main half-bearing selection (nominal diameter pins)

STD mm.

1 99.000 99.010

2 99.010 99.020

3 99.020 99.030

1 92.270 92.979

green

green

yellow*

green

yellow*

yellow*

2 92.980 92.989

red

green

green

green

green

yellow*

red

red

green

red

green

green

CLASS mm.

3 92.990 93.000

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

.540831. Selecting the big end half-bearings (pins with nominal diameter)

201455

Figure 66

34. There are three markings on the body of the connecting rod in the position shown in the view "A": 35. Letter that indicates the weight class: Gram [g] A (yellow)

3308 - 3338

B (green)

3339 - 3368

C (blue)

3369 - 3398

36. The number that identifies the degree of diameter.

Millimetre [mm] 1

85.987 - 85.996

2

85.997 - 86.005

3

86.006 - 86.013

3 ) Progressive number for identifying connecting rod.

37. Identify the most suitable half-bearings for each of the shaft pins (the half-bearings, if necessary, can have different classes from one journal to another).

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39

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 40

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

201455

Figure 66

Big end half-bearing thickness STD

+0.127

+0.254

+0.508

Red

1.994 - 2.002

–

–

–

Red/Black

–

2.057 - 2.065

–

–

Green

2.002 - 2.010

–

–

–

Green/Black

–

2.065 - 2.073

–

–

Yellow*

2.010 - 2.018

–

–

–

Yellow/Black*

–

2.073 - 2.081

–

–

Note Depending on the thickness, the half-bearings are selected in classes of tolerance marked by a coloured sign (red/black - green/black - yellow/black).

The tables give the specifications of the big end bearings available as spare parts in the standard sizes (STD) and in the permissible oversizes (+0.127, +0.254, +0.508). .540831. Main half-bearings selection (nominal diameter pins) 38. Determine the type of connecting rod half-bearing to fit on each pin by following the indications in the table.

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41

CYLINDER UNIT REPAIR OPERATIONS

Main half-bearings selection (nominal diameter pins)

STD

1 85.987 85.996

2 85.997 86.005

3 86.006 86.013

1 81.915 81.925

Green

Green

Yellow*

Green

Yellow*

Yellow*

2 81.925 81.935

Red

Green

Green

Green

Green

Yellow*

Red

Red

Green

Red

Green

Green

CLASS Millimetre [mm]

3 81.935 81.945

39. * not supplied as a spare part. .540831. Connecting rod half-bearings selection (rectified crankpins) Conditions ● Reground crankpins ▶

Make sure that the new diameter of the pins are as indicated in the table and identify the corresponding half-bearings.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 42

General mechanical overhaul CYLINDER UNIT REPAIR OPERATIONS

Selecting the connecting rod half-bearings (-0.127)

Millimetre [mm] - 0.127

CLASS Millimetre [mm]

1 81.789 81.799

2 81.799 81.809

3 81.809 81.819

1 85.987 85.996

2 85.997 86.005

3 86.006 86.013

Green/Black

Green/Black

Yellow/Black*

Green/Black

Yellow/Black*

Yellow/Black*

Red/Black

Green/Black

Green/Black

Green/Black

Green/Black

Yellow/Black*

Red/Black

Red/Black

Green/Black

Red/Black

Green/Black

Green/Black

1 85.987 85.996

2 85.997 86.005

3 86.006 86.013

red

green

green

red

green

green

red

red

green

red

red

green

Selecting the big end half-bearings (-0.254)

Millimetre [mm] -0.254

CLASS Millimetre [mm]

1 81.661 81.670

2 81.671 81.681

Selecting the big end half-bearings (-0.508) ( ➠ Page 43)

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

43

OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

Note If using big end bearings having different thicknesses, always fit the thickest bearing at the small end of the connecting rod.

Selecting the big end half-bearings (-0.508)

Millimetre [mm] 0.508

CLASS Millimetre [mm]

1 85.987 85.996

2 85.997 86.005

3 86.006 86.013

red

green

green

red

green

green

red

red

green

red

red

green

1 81.407 81.416

2 81.417 81.427

.5408.

OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

Work material Pliers for removing/refitting piston rings (105 -160 mm)

99360184

Clamp for fitting piston into cylinder liner (60 - 125 mm)

99360605

Pair of gauges for angular tightening with 1/2" and 3/4" square heads

99395216

Feeler gauge Micrometer Tightening torques Screws fixing connecting rod cap

50 N⋅m

Technical data Angle tightening rod caps fixing screws

90°

Offset between piston rings in assembly phase

120°

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 44

General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

main activity

47580

1 2 3 4 5 1.

Connecting rod body Half-bearings Connecting rod cap Cap retaining screws Circlip

6 7 8 9 10

Figure 67

Slotted oil scraper ring with spiral spring Claw seal ring Trapezoidal seal ring Piston pin Piston

Make sure the pistons do not show any sign of seizing, scoring, cracking or excessive wear; otherwise, replace as necessary.

.540842. Piston rings removal 2. Remove the piston rings from the piston (2) using the specific set of pliers (1).

Tool / Material

Product Code

Pliers for removing/refitting piston rings (105 -160 mm)

99360184

Note Pistons are equipped with three circlips: a sealing ring, with trapezoidal section; a sealing ring with chamfer cut; the third oil scraper.

Pistons are grouped into classes A and B for diameter.

126311

Figure 68

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

.540840. Piston removal 3. Remove the retaining piston rings (2) using round tipped pliers (1).

126312

4.

Figure 69

Remove the piston pin (1).

Note If removal is difficult use the appropriate drift.

49026

Figure 70

.540840. Piston measurement 5. Pin diameter (1) measuring with a micrometer (2).

Tool / Material Micrometer

32618

– P2D32C015E0116

Figure 71

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 46

General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

6.

7.

Conditions for correct pin-piston coupling.

Lubricate the pin (1) and the relevant housing on the piston hubs with engine oil; Pin must be inserted in the piston with a light finger pressure and it should not come out by gravity.

49026

181653

X 8.

0.6 ± 0.15 mm

*

Figure 72

Figure 73

The distance is measured at the Ø of 130 mm

Main data on piston, circlip and pin.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

.540842. Measuring seal rings 9. Check the thickness of the piston ring (2) using a micrometer (1).

Tool / Material Micrometer

16552A

Figure 74

16552B

Figure 75

10. Check the clearance between the sealing rings (2) and the related housings on the piston (1) using a feeler gauge (3).

Tool / Material Feeler gauge

11. The sealing ring (2) of the 1st seat is trapezoidal. Clearance " X" between the sealing ring and its seat is measured by placing the piston (1) with its ring in the cylinder liner (3), so that the sealing ring comes half way out of the cylinder liner.

3513

– P2D32C015E0116

Figure 76

47

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 48

General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

12. Using a feeler gauge (2), check the end gap of the sealing rings (1) entered in the cylinder liner (3).

Tool / Material Feeler gauge

13. If the distance between ends is lower or higher than the value required, replace split rings.

36134

Figure 77

.540830. Connecting rod checks Note Each connecting rod may only be mounted with its cap. If the cap is mounted backwards, the connecting rod must be discarded.

A missing area of less then 5 mm is allowed on the outer fracture line.

No cracks are allowed in the threaded area.

All the measurements indicated in the figure must be checked when the bushing is finished and assembled.

Caution!

Connecting rods weight class warning during assembly ▶

When installing connecting rods, make sure they all belong to the same weight class.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

49

OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

52.015-52.030 23.6±0.2

( 56.8)

Ø52.015 - 52.030

10.5

R3

.5 ±0 8.5

40°

22

5 R 1.0 0.95

2x45°

Ø

5 0.

.5 ±0 75

.1 +0 0

70

± 47

0 .4 0

43

.1 +0 0

±0 .5 51

.3 12

(86±0.013)

207± 0.025

R45

8 .0

43.83 43.83 ±0 .5 51

8 .0

62.1

209171

Figure 78

14. The connecting rod/cap is "torn"; before assembly, check that the connecting rod is not ruined.

Note The bushing corresponding to the connecting rod small end is worked together with the connecting rod and therefore if worn, the complete connecting rod needs to be replaced.

Note As a spare part, only the degree B connecting rod is supplied and can replace degree A and C.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 50

General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

187914

1

2 3

4

Figure 79

Coloured mark to identify weight CLASS A (Yellow) = 3,331 g - 3,361 g CLASS B (Green) = 3,362 g - 3,391 g CLASS C (Blue) = 3,392 g - 3,421 g Positioning socket visible from the front end of the engine Coloured mark to identify diameter class Yellow = 85.987 - 85.996 mm Green = 85.997 - 86.005 mm Blue = 86.006 - 86.013 mm Progressive number for identifying connecting rod

15. Perform the following checks of alignment, torsion and bend.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

.540830. Checking axes alignment 16. Check the parallelism of the connecting rod axis (1) using a suitable device (5) proceed as follows.

17. Fit the connecting rod (1) on the spindle of the tool (5) and lock it with the screw (4).

18. Set the spindle on the (3) on the prisms «V» resting the connecting rod (1) on the stop bar (2).

61696

Figure 80

.540830. Torsion check 19. Check the bend of the connecting rod (5) by comparing two points (A) and (B) of the pin (3) on the horizontal plane of the connecting rod axis.

20. Position the mount (1) of the dial gauge (2) so that this preloads by approx. 0.5 mm on the pin (3) at point A and set the dial gauge to zero (2). Shift the spindle (4) with the connecting rod (5) and compare any deviation on the opposite side B of the pin (3): the difference between A and B must not exceed 0.08 mm.

61694

– P2D32C015E0116

Figure 81

51

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 52

General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

.540830. Bending check 21. Check the bend of the connecting rod (5) by comparing two points C and D of the pin (3) on the vertical plane of the connecting rod axis. Position the vertical support (1) of the dial gauge (2) so that this rests on the pin (3) at point C. 22. Swing the connecting rod to and fro, establishing the highest position of the pin and reset the dial gauge (2) in this condition.

23. Move spindle (4) with connecting rod (5) and repeat the highest point check on opposite side D of pin (3).

24. The difference between points C and D must not exceed 0.08 mm.

Figure 82

61695

.540842. Fitting piston rings 25. Use the specified calliper (3) to fit the piston rings (1) on the piston (2).

Tool / Material

Product Code

Pliers for removing/refitting piston rings (105 -160 mm)

99360184

26. The rings shall be fitted with the marking «TOP» (4) facing upwards and their openings shall be displaced with each other: Technical data Offset between piston rings in assembly phase

120°

126313

Figure 83

115885

Figure 84

.540840. Assembling connecting rod - piston assemblies in the cylinder liners 27. Mount the half-bearings (1), chosen as described in the relative section (operation 540831) on both the connecting rod and the cap.

Note The pistons are supplied as spare parts in class A and can also be fitted in class B cylinder liners.

Caution!

Connecting rod caps Assembly precautions ▶

If the cap (1) is mounted backwards, the connecting rod must be discarded.

28. Using the band, install the connecting rod-piston assemblies (2), in the cylinder linings.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

Tool / Material

Product Code

Clamp for fitting piston into cylinder liner (60 - 125 mm)

99360605

29. Check the gap between the openings of the piston rings.

Technical data Offset between piston rings in assembly phase

120°

30. Verify that all pistons belong to the same class, A or B. 31. Verify that the ideogram stamped on the piston crown faces the engine flywheel; or the recess in the piston skirt matches the position of oil nozzles.

47593

61831

Figure 86

32. Connecting rod-piston assembly (1).

33. Marking area on the piston crown of ideogram specifying the assembly position and the selection class(2).

– P2D32C015E0116

Figure 85

53

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 54

General mechanical overhaul OVERHAULING THE CONNECTING ROD-PISTON ASSEMBLY

61831

Figure 86

34. Area of connecting rod punch marking(3). .540831. Checking assembly clearance of crankpins Caution!

Retaining screws Minimum thread diameter ▶

After the installation check the thread diameter of the screws (2). This must not be lower than 11.4 mm, otherwise replace the screw; lubricate the crankpins and connecting rod bearings.

35. Carry out the following operations to measure the clearance.

36. Connect the connecting rods to the relative crankpins, place a length of calibrated wire on the latter.

37. Connect the connecting rods to the relative crankpins.

38. Mount the connecting rod caps (1) together with half-bearings.

39. Tighten the connecting rod caps fixing screws (2) to the prescribed torque.

Tightening torque Screws fixing connecting rod cap

50 N⋅m

40. Using the specific tool (3), further tighten the screws with a specific angle.

Technical data Angle tightening rod caps fixing screws

90°

115886

Figure 87

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

55

CYLINDER HEAD OVERHAUL

Tool / Material

Product Code

Pair of gauges for angular tightening with 1/2" and 3/4" square heads

99395216

41. Remove the caps and check the clearance by comparing the width of the calibrated wire with the scale calibration on the envelope containing the wire.

.540610. CYLINDER HEAD OVERHAUL

Consumables LOCTITE 270 Work material Tool to remove and refit engine valves (to be used with special plates)

99360259

Tool to take down and fit back engine valves

99360264

Adjuster for gasket assembly on valve guide

99360329

Feeler gauge Line

main activity 1. Before removing cylinder head, check hydraulic tightness using specific tool; in case of leaks not caused by cup plugs or threaded plugs, replace cylinder head.

Tool / Material LOCTITE 270

Note In case of plugs removal/replacement, when assembling apply sealant Loctite 270 on the plugs. .540662. Valve removal Note Before removing cylinder head valves, number them in view of their remounting in the same position should they not have to be overhauled or replaced.

Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 56

General mechanical overhaul CYLINDER HEAD OVERHAUL

2.

Fit the specific tool (2) and fix it with the bracket (4); screw the lever (1) until you can disassemble the cotters (3); take out the tool (2) and extract the upper plate (5), spring (6) and bottom plate (7).

Tool / Material

Product Code

Tool to take down and fit back engine valves

99360264

Note Repeat this operation for all the valves.

3.

Turn the cylinder head upside down and remove the valves (8).

47583

Figure 88

36159

Figure 89

.540610. Checking the planarity of the head on the cylinder block 4. Check the supporting surface (1) of the head on the cylinder block with a rule (2) and a feeler gauge (3).

Tool / Material Line Feeler gauge

5.

If deformations exist, surface the head using proper surface grinder; the maximum amount of material to be removed is 0.2 mm.

Note After levelling, make sure that valve sinking and injector protrusion are as described in the relative paragraph.

.540662. Valve assembly 6. Lubricate the valve stem and insert the valves in the respective valve guides; fit the lower plates (1).

Note If the valves have not been overhauled or replaced, reassemble them according to the number sequence adopted during disassembly.

Intake valves are different form exhaust valves in that they have a notch placed at valve head centre.

193982

Figure 90

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul COMPLETE TIMING SYSTEM OVERHAUL

.540668. Mounting the oil seal ring 7. Using the specific keying device, fit the oil seal ring (2) on the valve guides (3) and then assemble the valves as follows.

8.

9.

Tool / Material

Product Code

Adjuster for gasket assembly on valve guide

99360329

155958

Figure 91

86290

Figure 92

Fit springs (6), upper plate (5).

Fit the specific tool (2) and fix it with the bracket (4); screw the lever (1) until you can assemble the cotters (3); remove the tool (2).

Tool / Material

Product Code

Tool to take down and fit back engine valves

99360264

Tool to remove and refit engine valves (to be used with special plates)

99360259

.5412.

COMPLETE TIMING SYSTEM OVERHAUL

Work material Drift to take down and fit back camshaft bushes

– P2D32C015E0116

99360487

57

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 58

General mechanical overhaul COMPLETE TIMING SYSTEM OVERHAUL

main activity .541211. Checking camshaft, cam lift and journals alignment

47506

1.

Place the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) using a dial gauge (2). The values are shown in the "Specifications and data" table.

47507

2.

Figure 93

Figure 94

Still with the camshaft (4) set on the tailstocks (1), check the alignment of the journals (3) with the dial gauge (2); it must not exceed 0.030 mm. To check the assembly clearance, measure the inside diameter of the bushings and the diameter of the journals of the camshaft.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

59

COMPLETE TIMING SYSTEM OVERHAUL

1

47505

3.

4.

In order to check the installation clearance, measure the bushing inner diameter and the camshaft pin (1) diameter; the real clearance is obtained by their difference.

If you find any clearances over 0.150 mm, replace the bushings and, if necessary, the camshaft as well.

228845

5.

Figure 95

Figure 96

The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth; whereas, if they show any signs of seizing or scoring, you should replace the shaft and the relevant bushings.

Tolerance characteristics TOLERANCES

CHARACTERISTIC SUBJECT OF TOLERANCE

ORIENTATION

Perpendicularity

POSITION

Concentricity or coaxiality

OSCILLATION

Circular oscillation

– P2D32C015E0116

GRAPHIC SYMBOL

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 60

General mechanical overhaul COMPLETE TIMING SYSTEM OVERHAUL

228845

Figure 96

Class of importance product characteristics CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS

GRAPHIC SYMBOL

CRITICAL IMPORTANT SECONDARY

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

61

COMPLETE TIMING SYSTEM OVERHAUL

.541213. Camshaft bushes check

114214

* 6.

7.

8.

Figure 97

Bushing inside diameter after driving in Verify that the surface of the bushings shows no sign of seizing or scoring; replace them if they do.

Measure the bushes inner diameters with a bore meter and replace them, if the value measured exceeds the tolerance value.

To remove and refit the bushes, use the proper drift.

Tool / Material

Product Code

Drift to take down and fit back camshaft bushes

99360487

.541233. Rocker shaft check Note The camshaft cams directly control the 12 rocker arms for the valves. The intake valve control rocker arms are keyed on the rocker shaft, while the exhaust valve control rocker arms are keyed on rocker arms shaft with positioning in between the levers with engine brake control eccentric pin. Rockers slide directly on the cam profiles via rollers. The other end acts on a bar supported by the stem of the two valves. A pad is placed between the rocker adjusting screw and the bar. Two lubrication holes are obtained inside the rockers.

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CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 62

General mechanical overhaul COMPLETE TIMING SYSTEM OVERHAUL

126315

9.

Figure 98

Rocker arm shaft has to be detached completely to reach all parts beneath.

114217

Figure 99

10. Check whether the shaft surface shows any trace of scoring or seizure. If so, replace it. .541231. Exhaust valve rocker arm check

181656

Figure 100

11. The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

.541231. Intake valve rocker arms check

181675

Figure 101

12. The bush surfaces must not show any trace of scoring of excessive wear; otherwise, replace bushes or the whole rocker.

.540110. ENGINE ASSEMBLY

Consumables LOCTITE 5970 Work material Rotary telescopic stand(range 2000 daN, torque 375 daNm)

99322230

Key to fit crankshaft rear gasket

99346260

Key to fit crankshaft front gasket

99346265

Tool for rotating the flywheel

99360341

Tool for retaining the flywheel

99360351

Crankshaft lifting tool

99360500

Tool for rocker arm shaft assembly and fitting

99360558

Tool for engine T.D.C. positioning

99360612

Tool for timing of phonic wheel on timing gear

99360613

Brackets for fastening engine to 99322230 rotary stand

99361042

Tool for rotating the flywheel

99368502

Tool to check timing (use with 99395606)

99370400

Pair of gauges for angular tightening with 1/2" and 3/4" square heads

99395216

Gauge for defining the distance between the centres of camshaft and timing gear

99395222

Gauge for camshaft timing

99395223

Gauge to determine centre distance between camshaft and high pressure pump

99395230

Dial gauge (0-5 mm)

99395603

Torque wrench

– P2D32C015E0116

63

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 64

General mechanical overhaul ENGINE ASSEMBLY

Socket threaded wrench Hoist Tightening torques Main bearing caps fastening screws (14 M16x2x168 bolts)

1.

Tightening: Phase 1

140 N⋅m

2.

Tighten screws to angle: Phase 2

60°

3.

Tighten screws to angle: Phase 3

60°

Stiffening plate screws ( 12 M10x1.5 )

49.5 ±2.5 N⋅m

Oil pump (4 M8x1.25 screws)

24.5 ±2.5 N⋅m

Connecting rod (1 screw M8x1.25x16)

0+0 +0 N⋅m

Idler gear (3) bolts M12x1.75x90 Flywheel housing

30 ±3 N⋅m

1.

Torque tightening

2.

Angle tightening

90°

1.

(1 M10x1.5x110 screw)

41.5 ±3.5 N⋅m

2.

(3 screws M10x1.5x35)

41.5 ±3.5 N⋅m

3.

(1 M12X1.75X120 screw)

63 ±7 N⋅m

4.

(1 M10x1.5x180 screw)

41.5 ±3.5 N⋅m

5.

(7 screws M12x1.75x80)

63 ±7 N⋅m

6.

(2 screws M12x1.75x190)

63 ±7 N⋅m

Engine flywheel fastening screws (8M18x1.5x72)

Pre-tightening

120 ±6 N⋅m

Engine flywheel fastening screws (8M18x1.5x72)

Angle tightening

90 ±4.5°

Cylinder head fixing screws (26 M16x2)

1.

Step 1

50 N⋅m

2.

Step 2

100 ±5 N⋅m

1.

Step 3

90°

2.

Step 4

75°

Cylinder head angle closing (26 M16x2).

Electro-injector brackets (6 screws M10x1.5x40)

41 ±2 N⋅m

Common Rail (3 M8x1.25x45 screws)

23 ±2 N⋅m

High pressure pipe (1 fitting M18x1.5)

40 ±2 N⋅m

High pressure pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Fuel delivery pipe (1 fitting M18x1.5)

40 ±2 N⋅m

Thrust plate (6 screws M8x1.25)

20 ±2 N⋅m

Idle gear (3 screws M12x1.75)

1.

Step 1 - Tightening with torque wrench to torque

30 ±1.5 N⋅m

2.

Step 2 - Angle tightening

90° 19 ±3 N⋅m

High pressure fuel pump (5 screws M8x1.25x25) Engine flywheel (3 screws M10x1.5x45)

1.

Step 1 - Tightening with torque wrench to torque

25 ±2.5 N⋅m

2.

Step 2 - Angle tightening

45°

Rocker arm shaft (7 M12x1.75 screws)

104.5 ±10.5 N⋅m

Phonic wheel ( 3 screws M8x1.25)

23 ±2 N⋅m

Camshaft gear fixing screws

1.

Pre-tightening

25 N⋅m

2.

Angle tightening

45°

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

Tappet cover (20 screws M6x1x50)

8.5 ±1.5 N⋅m

Blow-by filter (3 screws M6x1x16)

9 ±1 N⋅m

Gear cover (6 screws M8x1.25)

23 ±2 N⋅m

Engine oil sump (26 M10x1.5x45 screws)

41.5 ±3.5 N⋅m

Front cover (9 screws M8x1.25x45)

19 ±3 N⋅m

Crankshaft pulley (6 screws M14x2x60)

1.

Step 1 - Tightening with torque wrench to torque

70 N⋅m

2.

Step 2 - Angle tightening

50°

Damper flywheel (6 screws M12x1.75x30)

115 ±5 N⋅m

Oil vapour breather (3 bolts M6x1)

9 ±1 N⋅m

Water pump (4 screws M8x1.25x25)

25 ±2 N⋅m

Thermostat cover (5 screws M8x1.25x70)

25 ±2 N⋅m

Control unit with crankcase (3 screws M8x1.25)

19 ±3 N⋅m

Fitting (1 M16x1.5)

30 ±5 N⋅m

Intake manifold

Air pressure and temperature sensor

1.

(2 M10x1.5x110 screw)

50 ±5 N⋅m

2.

(2 M10x1.5x100 screw)

50 ±5 N⋅m

3.

(2 M10x1.5x150 screw)

50 ±5 N⋅m

(1 M6x1x18 screw)

5 ±0.5 N⋅m

Fuel filter mount (4 M8x1.25x60 screws)

24.5 ±2.5 N⋅m

Fuel temperature sensor (1 fitting M12x1.5)

30 ±2 N⋅m

Fuel filter clogged sensor (1 fitting M14x1.5)

30 ±2 N⋅m

Fuel pipes (2 fittings M16x1.5)

40 ±5 N⋅m

Fuel filter (1 fitting)

30 ±5 N⋅m 74 ±4 N⋅m

Air compressor seat cover (3 screws M12x1.75x25) Starter motor

(3 nuts M10x1.5)

44 ±4 N⋅m

Exhaust manifold (24 screws M10x1.5x38)

1.

Step I

30 ±5 N⋅m

2.

Step II

Oil filler pipes

1.

(2) screws M8x1.25x55

25 ±2 N⋅m

2.

(1) screw M12x1.75x25

74 ±8 N⋅m 30 ±3 N⋅m

Oil dipstick (1) nut M18x1.5 Turbocharger on exhaust manifold (4 nuts M10x1.5)

60 ±5 N⋅m 26 ±4 N⋅m

Heat exchanger and oil filter mount (15 M8x1.25x35 screws)

1.

Step 1

2.

Step 2

35 ±5 N⋅m 46 ±2 N⋅m

Blower turbo oil return pipe screws ( 2 screws M8x1.25x25)

20 ±2 N⋅m

Lubricant oil delivery pipe to turbocharger (2 fittings M14x1.5)

35 ±5 N⋅m

Blower turbo collar (1 screw M6x1x50)

9 ±1 N⋅m

Oil filter mount (4 M8x1.25 screws)

20 ±2 N⋅m

Oil filter Ufi Filter

60 ±5 N⋅m

Technical data Pin angle of reference

– P2D32C015E0116

135°

65

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 66

General mechanical overhaul ENGINE ASSEMBLY

main activity .540810. Crankshaft assembly 1. Mount the oil nozzles (2), making the grub screw match the hole (3) on the crankcase.

2. Install the half-bearings (1) and thrust half rings on the main bearings as shown in the figure.

114049

3.

Figure 102

Using the specific hoist and hook (1) assemble the crankshaft (2).

Tool / Material

Product Code

Hoist Crankshaft lifting tool

99360500

114034

4.

Figure 103

Install the half-bearings (1) on the main bearing caps (2).

114050

Figure 104

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

5.

6.

Position the main bearing caps (4).

Tighten the screws (3) using a torque wrench.

Tightening torque Main bearing caps fastening screws (14 M16x2x168 bolts) (3)

1.

Tightening: Phase 1 140 N⋅m

2.

Tighten screws to angle: Phase 2 60°

3.

Tighten screws to angle: Phase 3 60°

7.

8.

Assemble the stiffening plate (2).

Tighten the screws (1) using a torque wrench.

Tightening torque 49.5 ±2.5 N⋅m

Stiffening plate screws ( 12 M10x1.5 ) (1)

114615

Figure 105

Tool / Material Torque wrench

.543010. Installing the oil pump 9. Position the oil pump (7) and tighten the fastening screws (6) to a torque of: Threaded parts Oil pump (4 M8x1.25 screws) (6)

10. Position the connecting rod (1) and tighten the fastening screw (2) to a torque of: Threaded parts Connecting rod (1 screw M8x1.25x16) (2)

11. Position the double gear (3) in the seat (8), position the cover (5) and tighten the fastening screws (4) to the specified torque.

Threaded parts Idler gear (3) bolts M12x1.75x90 (4 )

1.

Torque tightening

2.

Angle tightening

237478

Figure 106

.540463. Fitting flywheel box 12. Clean the surfaces to be coupled to remove dirt and oil residues. Apply the specific silicon on the gear case (1) as indicated in the figure, in order to form seam (2) with a diameter of a few mm.

Tool / Material LOCTITE 5970

Note Application must be uniform (no lumps), without any air bubbles, thin areas or gaps. Any flaws must be corrected in as short a time as possible.

Fit the flywheel housing within 10' after sealant application.

218028

– P2D32C015E0116

Figure 107

67

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 68

General mechanical overhaul ENGINE ASSEMBLY

13. Use two suitable lifting hooks to lift and fit the flywheel casing to the crankcase using a hoist.

218028

Figure 107

14. Use a torque wrench to tighten the screws (1, 2, 3, 4, 6, 7) to the correct torque.

Tightening torque Flywheel housing (1, 2, 3, 4, 6, 7)

1.

(1 M10x1.5x110 screw) 41.5 ±3.5 N⋅m

2.

(3 screws M10x1.5x35) 41.5 ±3.5 N⋅m

3.

(1 M12X1.75X120 screw) 63 ±7 N⋅m

4.

(1 M10x1.5x180 screw) 41.5 ±3.5 N⋅m

5.

(7 screws M12x1.75x80) 63 ±7 N⋅m

6.

(2 screws M12x1.75x190) 63 ±7 N⋅m

Tool / Material Torque wrench 218507

Figure 108

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

15. The tightening sequence of the flywheel housing fastening screws is shown in the figure.

218029

Figure 109

45258

Figure 110

.540850. Engine flywheel assembly 16. Fit precisely the gasket (1), fit the specific keying device (2), drive in the gasket by screwing the nut (3).

Tool / Material

Product Code

Key to fit crankshaft rear gasket

99346260

Note If the teeth of the ring gear mounted on the engine flywheel used for starting the engine are very damaged, replace the ring gear. It must be fitted after heating the ring gear to a temperature of ~200 °C. Note The crankshaft has a centring pin that has to couple with the relevant seat on the engine flywheel.

17. Position the flywheel (1) on the crankshaft, lubricate the thread of the screws (2) with engine oil and screw them down.

– P2D32C015E0116

69

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 70

General mechanical overhaul ENGINE ASSEMBLY

18. Block the engine flywheel rotation using a suitable tool (3).

Tool / Material

Product Code

Tool for retaining the flywheel

99360351

19. Tighten the screws (2) in two steps.

20. Pre-tighten with a torque wrench (4) to the required torque.

Tightening torque Engine flywheel fastening screws (8M18x1.5x72) (2)

Pre-tightening 120 ±6 N⋅m

Tool / Material Torque wrench 49037

Figure 111

49036

Figure 112

21. Angle tighten to the specified value with the specific tool (1).

Tightening torque Engine flywheel fastening screws (8M18x1.5x72) (2)

Angle tightening 90 ±4.5°

Tool / Material

Product Code

Pair of gauges for angular tightening with 1/2" and 3/4" square heads

99395216

.540610. Cylinder head assembly 22. Check that the pistons (1 - 6) are exactly at the T.D.C. 23. Put the gasket (2) on the crankcase.

24. Use a suitable lifting hook to lift and fit the cylinder head on the crankcase.

Note If the valves have been removed from the head, refit them before refitting the head on the crankcase.

45266

Figure 113

Caution!

Cylinder head fixing screws Precaution during disassembly ▶

The removed screws must not be reused, but replaced with new screws.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

25. Mount the cylinder head (1) following the diagram in the figure.

Note In case the engine is mounted on the vehicle, insert the camshaft in the seat on the head before proceeding with its refitting 26. The fastening screws must be lubricated with MOLYKOTE before fitting onto the cylinder head.

Note The screws which have been removed, must not be reused. Only use new screws.

198348

Figure 114

45267

Figure 115

45268

Figure 116

27. Pre-tightening with the torque wrench (1): Tightening torque Cylinder head fixing screws (26 M16x2)

1.

Step 1 50 N⋅m

2.

Step 2 100 ±5 N⋅m

Tool / Material Torque wrench

28. Tighten at angle with specific tool (1).

Tightening torque Cylinder head angle closing (26 M16x2).

1.

Step 3 90°

2.

Step 4 75°

Tool / Material

Product Code

Pair of gauges for angular tightening with 1/2" and 3/4" square heads

99395216

– P2D32C015E0116

71

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 72

General mechanical overhaul ENGINE ASSEMBLY

.775010. assembling electro-injectors 29. Fit the electro-injectors (1) with the relative washer (2) into the seats on the cylinder head (3).

237460

Figure 117

237458

Figure 118

237461

Figure 119

30. Position the brackets (4) securing the electro-injectors (2) on the cylinder head (3) and tighten the screws (1) to a torque of: Tightening torque Electro-injector brackets (6 screws M10x1.5x40) (1)

41 ±2 N⋅m

.774510. Rail installation 31. Position the common rail (1) on the spacers (2) , located on the cylinder head (3) and tighten the screws (4) to a torque of: Tightening torque Common Rail (3 M8x1.25x45 screws) (4)

23 ±2 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

32. Connect the fuel delivery pipes to the electro-injectors and to the common rail (2) using the fittings (1) and tighten to a torque of: Tightening torque High pressure pipe (1 fitting M18x1.5) (1)

40 ±2 N⋅m

High pressure pipe (1 fitting M14x1.5) (1)

35 ±2 N⋅m

33. Connect the fuel return pipe between the common rail and the cylinder head, tighten the respective fittings (3) to a torque of: Tightening torque Fuel return pipe (1 fitting M16x1.5) (3)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5) (3)

35 ±2 N⋅m

237454

Figure 120

34. Connect the fuel delivery pipe to the common rail (2) tightening the respective fittings (4) to a torque of: Tightening torque Fuel return pipe (1 fitting M14x1.5) (4)

35 ±2 N⋅m

Fuel delivery pipe (1 fitting M18x1.5) (4)

40 ±2 N⋅m

.541210. Fitting camshaft 35. Position the crankshaft with the pistons (1 - 6) and at the top dead centre (T.D.C.).

36. This situation occurs when: 37. The hole with one reference mark (5) of the engine flywheel (4) can be seen through the inspection window.

38. The specific tool (1), through the seat (2) of the engine speed sensor, enters the hole (3) in the flywheel (4).

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

39. If this condition does not occur, turn the engine flywheel (4) appropriately.

40. Remove the specific tool (1).

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612 229574

– P2D32C015E0116

Figure 121

73

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 74

General mechanical overhaul ENGINE ASSEMBLY

41. Fit the camshaft (3), positioning it with the reference marks (→) as shown in the figure.

42. Clean the surface of the plate (1) to be coupled to remove impurities and oil residue.

43. Apply the prescribed silicone (6) on the gear housing (1) as shown in the figure.

Tool / Material LOCTITE 5970

44. The diameter of the bead of sealant should be approximately that shown in the table.

Note Take care NOT to put the sealant in the inner groove (5).

45. The sealant seam must be uniform (no lumps), without any air bubbles, thin areas or gaps. Any flaws must be corrected in as short a time as possible.

46. Within 10 minutes of applying sealant, fit the plate (1) with the gasket (2) and tighten the screws (4) to the specified torque.

149967

Figure 122

Tightening torque Thrust plate (6 screws M8x1.25) (4)

20 ±2 N⋅m

47. Use the specified gauge (1)to check and adjust the position of the link rod (3) for the idle gear; tighten the screw (2) to the specified torque.

Tool / Material

Product Code

Gauge for defining the distance between the centres of camshaft and timing gear

99395222

114269

Figure 123

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

48. Refit the idler gear (4) and tighten screws (3) to the specified torque using a suitable socket threaded wrench.

Tightening torque Idle gear (3 screws M12x1.75) (2)

1.

Step 1 - Tightening with torque wrench to torque 30 ±1.5 N⋅m

2.

Step 2 - Angle tightening 90°

Tool / Material Socket threaded wrench

Note Replace the idle gear bushing (1) when wear is detected. After driving the bushing, grind to bring it to 58.010 ± 0.10 mm.

237429

Figure 124

.771010. High pressure pump assembly 49. Clean the coupling surfaces to remove impurities and residual oil. Apply the prescribed silicone to the high pressure pump flange (1) as shown in the figure. The diameter of the sealant bead must be about 1.5 mm.

Tool / Material LOCTITE 5970

Note Fit the flange within 10 minutes after sealant application.

114263

– P2D32C015E0116

Figure 125

75

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 76

General mechanical overhaul ENGINE ASSEMBLY

50. Apply the gauge (1) to the flywheel housing (4) and check the centre line between the camshaft and the high pressure fuel pump.

Tool / Material

Product Code

Gauge to determine centre distance between camshaft and high pressure pump

99395230

51. Fit the coupling flange (2) on the tool (1) and tighten the fastening screws (3) to the specified torque using an Allen wrench.

52. Remove the tool (1) from the flywheel housing (4).

227374

Figure 126

237433

Figure 127

237435

Figure 128

53. Use a new gasket and fit the high pressure pump (1), complete with gear (4) into the designated flange on the gear case (3).

54. Tighten the fastening screws (2) to a torque of: Tightening torque High pressure fuel pump (5 screws M8x1.25x25) (2)

19 ±3 N⋅m

55. Connect the low pressure pipe (3) to the high pressure pump (5) and tighten the fastening screw of the clamp (4).

56. Connect the delivery pipes (6) and (7) to the high pressure pump (5) and to the fuel filter support (2) .

57. Connect the delivery pipe to the rail (1) to the high pressure pump (5).

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

77

ENGINE ASSEMBLY

.541210. Camshaft timing with tool 99395223 58. Turn the crankshaft with a tool so that the opening marked by two reference points (5) is visible through the lower inspection window of the flywheel casing.

Tool / Material

Product Code

Tool for rotating the flywheel

99360341

59. In this condition, insert the tool (1) through the seat (2) for the engine speed sensor in the opening (3) in the engine flywheel (4).

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

60. Rotate the crankshaft so the hole identified with two marks (5) is visible from the inspection window below the flywheel cover case.

61. In this condition, insert the tool (1), through the seat (2) of the engine speed sensor, enters the hole (3) in the flywheel (4).

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

229574

Figure 129

62. Apply the tool on the front of the camshaft (1).

Tool / Material

Product Code

Gauge for camshaft timing

99395223

116052

– P2D32C015E0116

Figure 130

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 78

General mechanical overhaul ENGINE ASSEMBLY

63. Turn the tool (1) so as to insert the pin (3) in the hole on the head. Fix the tool (1) using two screws (12) M8x1,25.

Tool / Material

Product Code

Gauge for camshaft timing

99395223

116053

Figure 131

64. Mount the camshaft control gear (1) so that it coincides with the fixing holes on the shaft, using the slots (2) on the control gear.

65. Place the gear (1) paying attention to place the spokes (4) as in the figure. This operation is necessary to correctly fit the phonic wheel that has only one assembly position regarding the gear.

66. Tighten the fastening screws (3).

Tightening torque Engine flywheel (3 screws M10x1.5x45) (3)

1.

Step 1 - Tightening with torque wrench to torque 25 ±2.5 N⋅m

2.

Step 2 - Angle tightening 45° 117691

Figure 132

Note Before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed 67. Position the rocker arm assembly (2) on the cylinder head with the help of the specific tool (1).

Tool / Material

Product Code

Tool for rocker arm shaft assembly and fitting

99360558

68. Position the control bridges on valves with marks facing the exhaust manifold.

237456

Figure 133

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

69. Tighten the screws(1) securing the rocker arm shaft (2) to the cylinder head (3) to a torque of: Tightening torque Rocker arm shaft (7 M12x1.75 screws) (1)

104.5 ±10.5 N⋅m

237455

Figure 134

.541215. Phonic wheel timing 70. Fit the phonic wheel (6) so that the tooth marked with an arrow (↑) corresponds to the seat of the sensor (2).

71. To check for correct positioning, insert the tool (1) in the timing sensor seat (2).

Tool / Material

Product Code

Tool for timing of phonic wheel on timing gear

99360613

72. Then tighten the screws (3).

Tightening torque Phonic wheel ( 3 screws M8x1.25) (3)

23 ±2 N⋅m

145834

73. Remove the tools .

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

Tool for timing of phonic wheel on timing gear

99360613

– P2D32C015E0116

Figure 135

79

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 80

General mechanical overhaul ENGINE ASSEMBLY

.541210. Camshaft timing without tool 99395223 74. Turn the crankshaft with a tool so that the opening marked by two reference points is visible through the lower inspection window of the flywheel casing.

Tool / Material

Product Code

Tool for rotating the flywheel

99360341

Note The arrow shows the direction of rotation of the engine when running.

Using the above-mentioned tool, turn the engine flywheel (1) in the direction of rotation of the engine so as to take the piston of cylinder no.1 to 54° before T.D.C. in the phase of compression (cylinder 6 in discharge phase).

This condition is verified when the hole with two notches (5) on the engine flywheel (1) is visible through the small inspection window (2).

149974

Figure 136

75. The exact position of the piston no. 1 at T.D.C., is obtained, under the previously described conditions, when the specific tool (1) is inserted through the engine revolution sensor seat (2) into the hole (3) located on the engine flywheel (4).

76. If this condition does not occur, turn and adjust the engine flywheel (4) appropriately.

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

229575

Figure 137

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

299593

Figure 138

77. Turn the camshaft so that an angle of α is formed on the rear side of the shaft: Technical data Pin angle of reference

135°

78. Mount the camshaft control gear (1) so that it coincides with the fixing holes on the shaft, using the slots (2) on the control gear.

79. Tighten the bolts (3).

Tightening torque Engine flywheel (3 screws M10x1.5x45) (3)

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

25 ±2.5 N⋅m 45°

117691

– P2D32C015E0116

Figure 139

81

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 82

General mechanical overhaul ENGINE ASSEMBLY

80. Position the rocker arm assembly (2) on the cylinder head with the help of the specific tool (1).

Tool / Material

Product Code

Tool for rocker arm shaft assembly and fitting

99360558

81. Position the control bridges on valves with marks facing the exhaust manifold.

237456

Figure 140

82. Remove the tool .

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

83. Turn crankshaft so as to check the following conditions: 84. the hole with two notches (5) is visible through the small inspection window.

85. The tool (1) enters the hole (3) in the engine flywheel (4) through the seat ( 2) of the engine speed sensor.

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

Note To recover play, turn the crankshaft clockwise until you pass the hole with two notches and then rotate in the opposite direction to reach the above conditions.

149970

Figure 141

86. Place the magnetic dial gauge (1) with the (flat bed) dipstick placed on the roller (2) of the rocker arm which controls the exhaust valve of cylinder no. 3 and preload it by 6­7 mm.

Tool / Material

Product Code

Tool to check timing (use with 99395606)

99370400

Dial gauge (0-5 mm)

99395603

185253

Figure 142

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

83

ENGINE ASSEMBLY

177714

Figure 143

87. To reset the dial gauge to zero, proceed as follows.

Caution!

Dial gauge pointer Pointer correct positioning ▶

Position the flat based dial gauge rod (see detailed part) so that its axis passes through the centre of the roller on which it is resting.

Caution!

Tolerances measure Checking and overhauling values ▶ ▶

During the CHECK phase, not during the engine overhaul phase, the allowed tolerance of the measurement is between -0.05 - +0.12 mm.

During OVERHAUL, the allowed tolerance is ± 0.05 mm.

88. Rotate the crankshaft with the specified tool in the other direction as for the operating direction until the hand of the dial gauge reaches the minimum value (maximum lift of the cam) beyond which it can no longer descend. Reset dial gauge.Rotate the flywheel anti-clockwise until the dial gauge reads the value of the cam lift of the camshaft.

Tool / Material

Product Code

Tool for rotating the flywheel

99368502

Note The measurement must be taken holding the rocker roller in contact with the profile of the exhaust cam of the camshaft.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 84

General mechanical overhaul ENGINE ASSEMBLY

237484

α Y

Camshaft rotation angle Cam lift based on the rotation angle of the camshaft

D

Figure 144 Cam lift in correspondence of 54° before the top dead centre, 1st cylinder end of compression

89. Reset the dial gauge to zero with reference to the following warnings.

Note The dial gauge is to be zeroed with the rocker arm roller in contact with the base radius of the cam profile.

90. The camshaft is in process if the values of cam lift show the following conditions: 91. the hole with two notches (5) is visible through the small inspection window.

92. The tool (1) enters the hole (3) in the engine flywheel (4) through the seat (2) of the engine speed sensor.

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

Note To recover play, turn the crankshaft clockwise until you pass the hole with two notches and then rotate in the opposite direction to reach the above conditions.

149970

Figure 145

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

93. If the conditions shown in the previous points are not obtained, proceed as follows: 94. Turn the engine flywheel until the dial gauge indicates the required cam lift.

95. Loosen the screws (2) that fasten the gear (1) to the camshaft and use the slots on the gear (1).

96. Act on the flywheel to obtain the conditions in the previous points and while keeping the cam lift value unchanged.

97. Lock the screws (2) and repeat timing check as described above.

98. Tighten the screws (2) to the specified torque.

Tightening torque Camshaft gear fixing screws (2) Lubrication Engine oil

1.

Pre-tightening

114281

25 N⋅m 2.

Figure 146

Angle tightening 45°

Note While performing this operation recover the clearance between the camshaft gears.

99. When adjustment via the slots is not sufficient for recovering the offset, proceed as follows: 100. Lock the screws (2) and turn the engine flywheel a 1/2 turn in the opposite direction of the operating direction.

101. Turn the engine flywheel in the engine operating direction until the dial gauge indicates the required camshaft lift value.

102. Remove the screws (2) and remove the gear (1) from the camshaft.

103. Turn the flywheel (4) again until the following conditions occur: Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

◁ ◁

the hole with two notches (5) is visible through the small inspection window. the specific tool (1), through the seat (2) of the engine speed sensor, enters the hole (3) in the flywheel (4).

229574

– P2D32C015E0116

Figure 147

85

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 86

General mechanical overhaul ENGINE ASSEMBLY

104. Mount the gear (1) with the 4 slots centred with the fixing holes of the camshaft. Lock the relevant screws (2) to the required torque.

Tightening torque Camshaft gear fixing screws (2) Lubrication Engine oil

1.

Pre-tightening 25 N⋅m

2.

Angle tightening 45°

105. Recover the clearance between the timing system gears by turning the flywheel in the opposite direction of the engine rotation direction and subsequently turning it in the engine rotation direction until the dial gauge shows the specific value.

Check the previously described conditions.

114281

Figure 148

.541215. Phonic wheel timing 106. Turn the crankshaft bringing the piston of cylinder no. 1 in compression to the Top dead centre. Turn the flywheel in the opposite direction to the normal rotation direction by about 1/4 turn.

107. Turn the flywheel again according to normal direction of rotation until the hole marked with the double notch (2) can be seen through the inspection hole (3) under the flywheel housing.

108. Install the tool (1) in the flywheel sensor seat (6).

Tool / Material

Product Code

Tool for engine T.D.C. positioning

99360612

109. Fit the phonic wheel (4) so that the tooth marked with an arrow (↑) corresponds to the seat of the sensor (6).

110. Insert the tool, via the seat of the timing sensor (2), onto the tooth obtained on the phonic wheel.

Tool / Material

Product Code

Tool for timing of phonic wheel on timing gear

99360613

111. Should tool fitting be difficult, loosen the screws (5) and direct the phonic wheel (4) properly to position the tool on the tooth.

112. Then tighten the screws (5).

Tightening torque Phonic wheel ( 3 screws M8x1.25) (5)

23 ±2 N⋅m

114284

Figure 149

113. Remove the specific tools.

Tool / Material

Product Code

Gauge for camshaft timing

99395223

Tool for engine T.D.C. positioning

99360612

Tool for timing of phonic wheel on timing gear

99360613

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

.540630. Installation of head cover 114. Fit a new gasket on the head cover.

115. Fit the head cover (3) on the cylinder head and tighten the screws (2, 4) to a torque of: Tightening torque Tappet cover (20 screws M6x1x50) (2, 4)

8.5 ±1.5 N⋅m

237457

Figure 150

218020

Figure 151

237426

Figure 152

116. Tightening sequence diagram for tappet cover fixing screws.

.540486. Blow-by filter fitting 117. Fit the blow-by centrifugal filter (2) and tighten the fastening screws (1) to a torque of: Threaded parts Blow-by filter (3 screws M6x1x16) (1)

118. Fit the gear cover (4) and tighten the fastening screws (3) to a torque of: Threaded parts Gear cover (6 screws M8x1.25) (3)

– P2D32C015E0116

87

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 88

General mechanical overhaul ENGINE ASSEMBLY

.543060. Suction strainer installation 119. Fit the suction strainer (2), tightening the screws (1) on the crankcase to the specified torque.

125709

Figure 153

.540430. Oil sump assembly 120. Position the gasket (5) on the oil sump (4).

Note If not faulty the gasket can be reused.

121. Fit the oil sump (4) in position on the crankcase .

122. Position the spacer (1) before inserting the oil sump fastening screws (3).

123. Tighten the fastening screws (3) to the prescribed torque.

Tightening torque Engine oil sump (26 M10x1.5x45 screws) (3)

41.5 ±3.5 N⋅m

237437

Figure 154

218524

Figure 155

124. Diagram of the tightening sequence for oil sump fastening screws.

Caution! ▶ ▶ ▶

Only use recommended oils or oils with the properties required for proper engine operation.

If topping up, do not mix oils with different properties.

Failure to observe these standards will invalidate the service warranties.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul

89

ENGINE ASSEMBLY

125. Using a new gasket, tighten the drain plug (2) to the specified torque and then fill it with clean oil.

126. Check the oil level with the dipstick : the level must be close to the MAX notch on the dipstick itself. Otherwise top-up the necessary quantity through the filler plug . .540440. Crankshaft front cover assembly 127. Clean the surfaces of the parts to be connected, removing any impurities and oil residue. Apply silicone LOCTITE 5970 to the cover as indicated in the figure.

Note Fit the front cover within 10 minutes of applying the sealant.

128. Fit the front cover (2) onto the crankcase (1) and tighten the fastening screws (3) to a torque of: Tightening torque Front cover (9 screws M8x1.25x45) (3)

19 ±3 N⋅m

237432

Figure 156

129. Key on the sealing gasket (1) using the designated tool (2), and drive in the sealing gasket (3) by screwing the nut (1) .

Tool / Material

Product Code

Key to fit crankshaft front gasket

99346265

114258

– P2D32C015E0116

Figure 157

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 90

General mechanical overhaul ENGINE ASSEMBLY

.540821. Fitting the drive pulley on the crankshaft 130. Place the drive pulley (1) on the crankshaft and tighten the screws (2) to a torque of: Tightening torque Crankshaft pulley (6 screws M14x2x60) (2)

1.

Step 1 - Tightening with torque wrench to torque 70 N⋅m

2.

Step 2 - Angle tightening 50°

131. Fit the damper flywheel (3) on the drive pulley (1) and tighten the fastening screws (4) to a torque of: Tightening torque Damper flywheel (6 screws M12x1.75x30) (4)

115 ±5 N⋅m

237422

Figure 158

237421

Figure 159

237439

Figure 160

.540452. Blow-by case fitting 132. Position the water inlet pipe (4) on the crankcase and tighten the fastening screws (3) to the specified torque.

133. Position the blow-by vent (1) on the cylinder head and tighten the fastening screws (2) to a torque of: Threaded parts Oil vapour breather (3 bolts M6x1) (2)

.543417. Automatic belt tensioner assembly 134. Fit the idler guide pulley (1) and tighten the fastening screw (2) to the specified torque.

135. Fit the automatic belt tensioner (3) and tighten the fastening screw (4) to the specified torque.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

.543210. Water pump assembly 136. Apply a new sealing ring to the water pump .

137. Position the water pump in its seat (3), tighten the fastening screws (2) to a torque of: Threaded parts Water pump (4 screws M8x1.25x25) (2)

237442

Figure 161

.543411. Fitting the water pump / alternator drive belt (the following figure is provided for demonstration purposes only) Caution!

Spring belt Precaution during disassembly ▶

The flexible belt must be replaced with a new one every time it is removed from the vehicle.

138. Place the water pump drive belt, crankshaft alternator.Using an appropriate tool (4), act on the automatic belt tensioner (5) and tension the belt.

218010

– P2D32C015E0116

Figure 162

91

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 92

General mechanical overhaul ENGINE ASSEMBLY

.543251. Fitting the water inlet pipe and thermostat assembly 139. Fit the thermostat (1) on the seat on the cylinder head (2) .

237441

Figure 163

237440

Figure 164

140. Fit a new gasket (2).

141. Fit the thermostat cover (1) and tighten the fastening screws (5) to a torque of: Threaded parts Thermostat cover (5 screws M8x1.25x70) (5)

142. Fit the temperature sensor (3).

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

.540110. Removing the engine from the stand

218038

Figure 165

143. Remove engine from rotary stand and take off brackets securing the engine.

Tool / Material

Product Code

Rotary telescopic stand(range 2000 daN, torque 375 daNm)

99322230

Brackets for fastening engine to 99322230 rotary stand

99361042

– P2D32C015E0116

93

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 94

General mechanical overhaul ENGINE ASSEMBLY

.766161. EDC control unit installation 144. Fit the engine management control unit (1) together with the heat exchanger, on the crankcase (3) and tighten the fastening screws (2) to a torque of: Tightening torque 19 ±3 N⋅m

Control unit with crankcase (3 screws M8x1.25) (2)

145. Act on the fitting (4) and connect the low pressure fuel pipe which connects the engine management control unit (1) to the mechanical pump.

Tightening torque 30 ±5 N⋅m

Fitting (1 M16x1.5) (4)

146. Act on the fitting and connect the low pressure fuel pipe which connects the tank to the engine management control unit (1).

237451

Figure 166

237425

Figure 167

237447

Figure 168

.540710. intake manifold assembly 147. Fit the starter device.

148. Position the intake manifold (5) and tighten the fastening screws (2) to a torque of: Threaded parts Intake manifold (2)

1.

(2 M10x1.5x110 screw)

2.

(2 M10x1.5x100 screw)

3.

(2 M10x1.5x150 screw)

149. Fit the air pressure and temperature sensor (3) in place, then tighten the fastening screw (6) to a torque of: Threaded parts Air pressure and temperature sensor (6)

(1 M6x1x18 screw)

150. Position the air inlet pipe (1) and secure it to the intake manifold with the collar (4) tightening the relative fastening screw to the specified torque. .542014. assembly of the fuel filter mount 151. Fit the fuel filter support (3) on the crankcase (1) and tighten the fastening screws (2) to a torque of: Tightening torque Fuel filter mount (4 M8x1.25x60 screws) (2)

24.5 ±2.5 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

152. Screw the temperature sensor to the fuel filter support (2).

Tightening torque Fuel temperature sensor (1 fitting M12x1.5) (2)

30 ±2 N⋅m

153. Screw the pressure sensor to the fuel filter support (1).

Tightening torque Fuel filter clogged sensor (1 fitting M14x1.5) (1)

30 ±2 N⋅m

154. Screw the fittings (5, 6) of the delivery pipes to the fuel filter and the delivery pipe to the high pressure pump onto the filter support (3).

Tightening torque Fuel pipes (2 fittings M16x1.5) (5, 6)

237446

Figure 169

237446

Figure 170

237436

Figure 171

40 ±5 N⋅m

.542010. Fuel filter assembly 155. Moisten the gasket of the fuel filter with a thin layer of oil.

156. Manually tighten the fuel filter (4) on the mount (3) until it fits up against the gasket .

157. Using a suitable tool, tighten the fuel filter (4) further to a torque of: Tightening torque Fuel filter (1 fitting) (4)

30 ±5 N⋅m

.790510. Fitting the air compressor cover 158. Rest the cover (1) on the power take-off seat (3) and tighten the screws (2) to a torque of: Tightening torque Air compressor seat cover (3 screws M12x1.75x25) (2)

– P2D32C015E0116

74 ±4 N⋅m

95

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 96

General mechanical overhaul ENGINE ASSEMBLY

.760810. Starter motor assembly 159. Fit the starter motor in the designated seat on the flywheel housing.

160. Tighten the nuts (4) and secure the starter motor (3) to the flywheel housing (2).

161. Tighten the fastening nut (4) to a torque of: Tightening torque Starter motor (4)

(3 nuts M10x1.5) 44 ±4 N⋅m

237464

Figure 172

237466

Figure 173

.540720. Exhaust manifold assembly 162. Position the exhaust manifold on the cylinder head .

163. Fit the exhaust manifold (3) in position with the new gaskets (1) on the cylinder head (4) and tighten the fastening screws (2) to a torque of: Tightening torque Exhaust manifold (24 screws M10x1.5x38) (2)

1.

Step I 30 ±5 N⋅m

2.

Step II 60 ±5 N⋅m

Note Always replace the gaskets with new spare parts. Check the thread of the fastening screws: it must not show signs of wear or deposits of dirt.

171168

Figure 174

164. Diagram of tightening sequence for exhaust manifold fastening screws.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

.543110. Heat exchanger assembly 165. Fit the heat exchanger (2), together with a new gasket and the relative elements to the crankcase (4).

166. Fit the fastening screws (3) and tighten them to a torque of: Tightening torque Heat exchanger and oil filter mount (15 M8x1.25x35 screws) (3)

26 ±4 N⋅m

237445

Figure 175

237476

Figure 176

237419

Figure 177

167. Position the oil filler pipe (4) and tighten the relative fastening screws (3, 5) to the specified torque.

Tightening torque Oil filler pipes (3, 5)

1.

(2) screws M8x1.25x55

2.

(1) screw M12x1.75x25

25 ±2 N⋅m 74 ±8 N⋅m

168. Position the oil dipstick together with the guide (1) and tighten the fastening nut (2) to the specified torque.

Tightening torque 30 ±3 N⋅m

Oil dipstick (1) nut M18x1.5 (2)

.542410. Turbocharger assembly 169. If removed, screw the studs (2) onto the exhaust manifold and turbocharger and tighten them to the specified torque.

170. Fit the turbocharger (4) with relative gasket (3) on the exhaust manifold and tighten the nuts (1) to the prescribed torque.

Tightening torque Turbocharger on exhaust manifold (4 nuts M10x1.5) (1)

1.

Step 1 35 ±5 N⋅m

2.

Step 2 46 ±2 N⋅m

– P2D32C015E0116

97

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 98

General mechanical overhaul ENGINE ASSEMBLY

171. Fit the lubricant oil drain pipe (3), complete with the new gasket and tighten the screws (2) on the turbocharger and tighten the fitting on the engine crankcase.

Tightening torque Blower turbo oil return pipe screws ( 2 screws M8x1.25x25) (2)

20 ±2 N⋅m

172. Fit the lubricant oil delivery pipe and tighten the fitting (4) to a torque of: Tightening torque Lubricant oil delivery pipe to turbocharger (2 fittings M14x1.5) (4)

35 ±5 N⋅m

237416

Figure 178

237417

Figure 179

237444

Figure 180

173. Fit the pipe (1) on the turbocharger and tighten the screw (3) of the clip (2) to a torque of: Tightening torque Blower turbo collar (1 screw M6x1x50) (3)

9 ±1 N⋅m

.543070. Oil filter assembly 174. Fit the oil filter support (3) and tighten the screws (2) securing to the crankcase (1) to a torque of: Tightening torque Oil filter mount (4 M8x1.25 screws) (2)

20 ±2 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul General mechanical overhaul ENGINE ASSEMBLY

175. Fit a new gasket (2) onto the oil filter (1).

176. Fit the oil filter (1) on the mount (3) and tighten it using the specific tool to a torque of: Tightening torque Oil filter Ufi Filter (1)

60 ±5 N⋅m

237438

Figure 181

237480

Figure 182

.769140. fitting the engine cable 177. Connect the engine cable connector (1) to the control unit connector (2).

178. Connect the engine cable (3) to all the sensors fitted on the engine.

– P2D32C015E0116

99

CURSOR 9 Tigercat Tier II R96 ‒ General mechanical overhaul 100

General mechanical overhaul

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications Contents

Contents Technical specifications . . . . . . . . . . . . . . . . . . . . .

– P2D32C015E0116

3

1

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications 2

Contents

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications Technical specifications Contents

Contents DATA - INSTALLATION CLEARANCES

. . . . . . . . .

5

Data - installation clearances . . . . . . . . . . . . . . .

5

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . .

Tightening torques

– P2D32C015E0116

. . . . . . . . . . . . . . . . . . . .

10 10

3

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications 4

Technical specifications

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications Technical specifications DATA - INSTALLATION CLEARANCES

Technical specifications DATA - INSTALLATION CLEARANCES Data - installation clearances type

F2CFA613T*E026

CYLINDER ASSEMBLY AND CRANK GEARS

mm

Cylinder liner housing: upper

130.500 ÷ 130.525

lower

129.510 - 129.535

upper

130.461 - 130.486

lower

129.475 - 129.500

Ø1

Cylinder liners - outer diameter: Ø2 Length

L

226.15

Cylinder liners - crankcase seat:

Outer diameter

upper

0.014 - 0.064

lower

0.010 - 0.060

Ø2

–

A*

117.000 - 117.012

B*

117.010 - 117.022

X

0.035 – 0.065

Cylinder liners - inner diameter Ø3

Protrusion (with 6,000 Kg load) Pistons:

Federal Mogul

Mahle

measuring point

X

15

18

outer diameter Ø 1

A●

116.894 - 116.906

116.871 ÷ 116.883

outer diameter Ø 1

B●●

116.904 - 116.916

116.881 ÷ 116.893

pin housing

Ø2

52.016 - 52.022

52.010 ÷ 52.018

● Class A pistons supplied as spare parts ●● Class B pistons fitted in production only and not supplied as spare parts

Piston protrusion

X

Piston - cylinder liners

– P2D32C015E0116

0.094 - 0.118

Federal Mogul

Mahle

A*

0.094 - 0.118

0.117 - 0.141

B*

0.094 - 0.118

0.117 - 0.141

Piston diameter

Ø1

–

Piston pin

Ø3

51.994 - 52.000

5

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications 6

Technical specifications DATA - INSTALLATION CLEARANCES

type

F2CFA613T*E026 Federal Mogul

Mahle

0.016 - 0.028

0.010 – 0.024

Federal Mogul

Mahle

X1*

2.582 - 2.716

2.585 - 2.615

X2

2.550 - 2.570

2.550 - 2.570

X3

4.020 - 4.040

4.020 - 4.040

Piston pin - pin seat *Indicates the selection class

Piston ring slots

Piston rings:

Federal Mogul

Mahle

trapezoidal seal

S1*

2.429 - 2.473

−

bevelled

S2

2.470 - 2.500

−

oilscraper

S3

3.970 –3.990

−

Federal Mogul

Mahle

1

0.109 - 0.287

−

2

0.050 - 0.100

−

3

0.030 - 0.070

0.050 - 0.100

* measured on Φ of 113 mm

Piston rings - slots

–

Piston rings Piston ring end gap in cylinder liners

Federal Mogul

Mahle

X1

0.30 - 0.40

−

X2

0.60 - 0.75

−

X3

0.35 - 0.65

−

Connecting rod small end bush seat

Ø1

55.69 - 55.71

Connecting rod bearing seat

Ø2

85.987 - 86.013

1

85.987 - 85.996

2

85.996 - 86.005

3

86.005 - 86.013

Ø selection classes

Bushing diameter at connecting rod small end:

internal

Ø3

Bush at connecting rod small end - housing

52.015 - 52.030

0.015 – 0.036 0.127* – 0.254 – 0.508

Connecting rod half-bearings Connecting rod weight A

3308 ÷ 3338 g

B

3339 ÷ 3368 g

C

3369 ÷ 3398 g

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications Technical specifications DATA - INSTALLATION CLEARANCES

type

F2CFA613T*E026

Measuring point

X

Main journals

Ø1

=

- rated

92.970 ÷ 93.000

- class 1

92.970 ÷ 92.980

- class 2

92.980 ÷ 92.990

- class 3

92.990 ÷ 93.000

Ø2 - rated

81.915 ÷ 81.945

- class 1

81.915 - 81.924

- class 2

81.925 - 81.934

- class 3

81.935 - 81.945

Main half-bearings

S1

Red colour

2.968 - 2.978

Green colour

2.978 - 2.988

Yellow colour

2.988 - 2.998

Connecting rod half-bearings

S2

Red colour

1.994 - 2.002

Green colour

2.002 - 2.010

Yellow colour

2.010 - 2.018

Main bearings - rated

99.000 - 99.030

- class 1

99.000 - 99.009

- class 2

99.010 - 99.019

- class 3

99.020 - 99.030

Half-bearings - main journals

0.044 - 0.084

Half-bearings - crankpins

0.035 - 0.079

Main half-bearings

0.127* – 0.254 – 0.508

Connecting rod half-bearings

0.127* – 0.254 – 0.508

* Factory-assembled only, not provided as spare part Thrust main journal 1–2–3–4–5–6 7

Thrust main bearings

– P2D32C015E0116

X1

X2

39.900 - 40.100 39.960 – 40.040

32.94 – 32.99

7

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications 8

Technical specifications DATA - INSTALLATION CLEARANCES

type

F2CFA613T*E026

Thrust half rings

X3

Crankshaft thrust

3.38 – 3.43

0.11 - 0.34

Alignment

1-2

–

Centring

1-2

0.04

Taper

1-2

0.01

CYLINDER HEAD - TIMING SYSTEM

Valve guide housing on cylinder head

Ø1

12.980 - 12.997

Inner diameter

Ø2

7.100 - 7.300

Outer diameter

Ø3

13.012 – 13.025

Valve guides

Valve guide outer diameter - housing on the head Valve guide oversizing

0.015 – 0.045 0.2 - 0.4

Valves: Ø4 α Ø4 α

7.970 – 7.985 60° 30' ± 0° 7' 30'' 7.970 – 7.985 60° 30' ± 0° 7' 30''

Valve stem and related guide 0.038 – 0.068 0.038 – 0.068 Housing on head for valve seat: Ø1

41.985 - 42.020

Ø1

40.985 - 41.020

Valve housing outer diameter - valve housing inclination on cylinder head: Ø2 α

42.060 - 42.075 60° - 30'

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications Technical specifications DATA - INSTALLATION CLEARANCES

type

F2CFA613T*E026

Ø2

Recessing

41.060 - 41.075

α

60° ± 30'

X

0.5 – 0.8

X

1.65- 1.95

Between valve seat and cylinder head

0.040 - 0.090

Valve spring Valve spring height:

H

BAUMANN

MUBEA

71.34

70.77

Under a load of: 460 ± 22 N 460 ± 22 N

H1 BAUMANN H1 MUBEA

51

731.4 ± 42 N 740 ± 33 N

H2 BAUMANN H2 MUBEA

39

Injector protrusion

X

1.53

Camshaft bush housing fitted in the cylinder head: I -> 7

Ø

69.00 - 69.03

Ø

64.924 - 64.940

Ø

69.090 - 69.130

Ø

65.080 - 65.116

Camshaft journals:

I -> 7 Camshaft bushing outer diameter:

Bushing inner diameter:

Bushings and seats in cylinder head

0.060 - 0.130

Bushings and supporting pins

0.140 - 0.192

Useful cam height: 7.404 8.211 Rocker-arm shaft Ø1

– P2D32C015E0116

31.964 - 31.980

9

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications 10

Technical specifications TIGHTENING TORQUES

type

F2CFA613T*E026

Rocker arm shaft bush seat 32.025 - 32.041 35.000 - 35.016 Rocker arm bush outer diameter: 35.07 ÷ 35.110 35.07 ÷ 35.110 Rocker arm bush inner diameter: 32.025 ÷ 35.041 32.025 ÷ 35.041 Bushes and housings: 0.054 - 0.110 0.054 - 0.110 Rocker arms and shaft 0.045 - 0.077 0.045 - 0.077

TIGHTENING TORQUES 540110

Tightening torques

Torques Tightening torque 50 ±5 N⋅m

Oil sprayers for piston cooling (6 nuts M12x1.5) Main bearing caps fastening screws (14 M16x2x168 bolts)

1.

Tightening: Phase 1 140 N⋅m

2.

Tighten screws to angle: Phase 2

3.

Tighten screws to angle: Phase 3

60° 60° Turbocharger oil delivery pipe screws ( 1 nut M18x1.5x)

50 ±5 N⋅m

Stiffening plate screws ( 12 M10x1.5 )

49.5 ±2.5 N⋅m

Engine oil sump (26 M10x1.5x45 screws)

41.5 ±3.5 N⋅m

Front cover (9 screws M8x1.25x45)

19 ±3 N⋅m

Gear cover (6 screws M8x1.25)

23 ±2 N⋅m

Blow-by filter (3 screws M6x1x16)

9 ±1 N⋅m

Oil vapour breather (3 bolts M6x1)

9 ±1 N⋅m

Cylinder head fixing screws (26 M16x2)

1.

Step 1

2.

Step 2

50 N⋅m 100 ±5 N⋅m 3.

Step 3

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications Technical specifications TIGHTENING TORQUES

Tightening torque Cylinder head fixing screws (26 M16x2)

3.

90°

4.

Step 4 75°

Tappet cover (20 screws M6x1x50)

8.5 ±1.5 N⋅m

Common Rail (3 M8x1.25x45 screws)

23 ±2 N⋅m

High pressure pipe (1 fitting M18x1.5)

40 ±2 N⋅m

High pressure pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M16x1.5)

35 ±2 N⋅m

Fuel return pipe (1 fitting M14x1.5)

35 ±2 N⋅m

Fuel delivery pipe (1 fitting M18x1.5)

40 ±2 N⋅m

Electro-injector brackets (6 screws M10x1.5x40)

41 ±2 N⋅m

Phonic wheel ( 3 screws M8x1.25)

23 ±2 N⋅m

Gear cover (12 screws M8x1.25)

23 ±2 N⋅m 104.5 ±10.5 N⋅m

Rocker arm shaft (7 M12x1.75 screws) Engine flywheel (3 screws M10x1.5x45)

1.

Step 1 - Tightening with torque wrench to torque 25 ±2.5 N⋅m

2.

Step 2 - Angle tightening 45°

Pipe delivering fuel from the pump to the rail (2 M14x1.5 unions)

35 ±2 N⋅m

Fuel delivery pipe from the mechanical pump to the filter (2 fittings M14x1.5)

47.5 ±2.5 N⋅m

Fuel pipe from the filter to the high pressure pump (1 fitting M16x1.5)

47.5 ±2.5 N⋅m

Fuel filter (1 fitting)

30 ±5 N⋅m

Fuel pipe from the electronic control unit to the mechanical pump (1 fitting M16x1.5x34)

47.5 ±2.5 N⋅m

Fuel return pipe from pump to tank (1 fitting M14x1.5x30)

47.5 ±2.5 N⋅m

Fuel pipes (2 fittings M16x1.5)

40 ±5 N⋅m

Fuel temperature sensor (1 fitting M12x1.5)

30 ±2 N⋅m

Fuel filter clogged sensor (1 fitting M14x1.5)

30 ±2 N⋅m

Fuel filter mount (4 M8x1.25x60 screws)

24.5 ±2.5 N⋅m

Air compressor seat cover (3 screws M12x1.75x25)

74 ±4 N⋅m

Diesel return pipe fitting (1 M16x1.5)

30 ±5 N⋅m

Control unit with crankcase (3 screws M8x1.25)

19 ±3 N⋅m

Starter motor

(3 nuts M10x1.5) 44 ±4 N⋅m

High pressure fuel pump (5 screws M8x1.25x25)

19 ±3 N⋅m

Pipe delivering air from the turbocharger to the intercooler (1 M6x1x50 screw)

8 ±0.5 N⋅m

Lubricant oil delivery pipe to turbocharger (2 fittings M14x1.5)

35 ±5 N⋅m

Turbocharger on exhaust manifold (4 nuts M10x1.5)

1.

Step 1 35 ±5 N⋅m

2.

Step 2 46 ±2 N⋅m

– P2D32C015E0116

11

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications 12

Technical specifications TIGHTENING TORQUES

Tightening torque Turbocharger oil delivery pipe screws ( 1 nut M18x1.5x)

50 ±5 N⋅m

Blower turbo oil return pipe screws ( 2 screws M8x1.25x25)

20 ±2 N⋅m

Oil pump (4 M8x1.25 screws)

24.5 ±2.5 N⋅m

Oil filter Ufi Filter.

60 ±5 N⋅m

Oil filter housing screws (4 screws M8x1.25x160)

33.5 ±3.5 N⋅m

Heat exchanger (16 screws M8x1.25x50)

1.

Step 1 11.5 ±3.5 N⋅m

2.

Step 2 24.5 ±2.5 N⋅m

Oil dipstick (1) nut M18x1.5

30 ±3 N⋅m

Water pump (4 screws M8x1.25x25)

24.5 ±2.5 N⋅m

Water inlet pipe (2 screws M8)

0+0 +0 N⋅m

Thermostat cover (5 screws M8x1.25x70)

24 ±2.5 N⋅m

Air pressure and temperature sensor

(1 M6x1x18 screw) 5 ±0.5 N⋅m

Intake manifold

1.

(2 M10x1.5x110 screw) 50 ±5 N⋅m

2.

(2 M10x1.5x100 screw) 50 ±5 N⋅m

3.

(2 M10x1.5x150 screw)

1.

Step 1

2.

Step 2

50 ±5 N⋅m Exhaust manifold (24 screws M10x1.5x38)

30 ±5 N⋅m 60 ±5 N⋅m Connecting rod (1 screw M8x1.25x16) Crankshaft pulley (6 screws M14x2x60)

0+0 +0 N⋅m 1.

Step 1 - Tightening with torque wrench to torque 70 N⋅m

2.

Step 2 - Angle tightening 50° 115 ±5 N⋅m

Damper flywheel (6 screws M12x1.75x30) Flywheel housing

1.

(1 M10x1.5x110 screw) 41.5 ±3.5 N⋅m

2.

(3 screws M10x1.5x35)

3.

(1 M12X1.75X120 screw)

41.5 ±3.5 N⋅m 63 ±7 N⋅m 4.

(1 M10x1.5x180 screw) 41.5 ±3.5 N⋅m

5.

(7 screws M12x1.75x80)

6.

(2 screws M12x1.75x190)

63 ±7 N⋅m 63 ±7 N⋅m

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications Technical specifications TIGHTENING TORQUES

Tightening torque Engine flywheel fastening screws (8M18x1.5x72)

Pre-tightening 120 ±6 N⋅m

Engine flywheel fastening screws (8M18x1.5x72)

Angle tightening 90 ±4.5°

Idle gear (3 screws M12x1.75)

1.

Step 1 - Tightening with torque wrench to torque

2.

Step 2 - Angle tightening

30 ±1.5 N⋅m 90° Engine flywheel (3 screws M10x1.5x45)

1.

Step 1 - Tightening with torque wrench to torque 25 ±2.5 N⋅m

2.

Step 2 - Angle tightening 45°

Thrust plate (6 screws M8x1.25)

– P2D32C015E0116

20 ±2 N⋅m

13

CURSOR 9 Tigercat Tier II R96 ‒ Technical specifications 14

Technical specifications

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Equipment Contents

Contents TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– P2D32C015E0116

3

1

CURSOR 9 Tigercat Tier II R96 ‒ Equipment 2

Contents

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Equipment TOOLS Contents

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

– P2D32C015E0116

5

3

CURSOR 9 Tigercat Tier II R96 ‒ Equipment 4

TOOLS

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Equipment TOOLS

TOOLS

Rotary telescopic stand(range 2000 daN, torque 375 daNm) (99322230)

Extraction tool for injectors (99342157)

Key to fit crankshaft rear gasket (99346260)

Key to fit crankshaft front gasket (99346265)

– P2D32C015E0116

5

CURSOR 9 Tigercat Tier II R96 ‒ Equipment 6

TOOLS

Pliers for removing/refitting piston rings (105 -160 mm) (99360184)

Plate for take downfit engine valves (to be used with 99360257) (99360256)

Tool for engine valve removal and refitting (to be used with 99360256) (99360257)

Punch for valve guide removal (99360288)

Adjuster for gasket assembly on valve guide (99360292)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Equipment TOOLS

Tool for valve guide refitting(to be used with 99360288) (99360294)

Cylinder liner protrusion gauge (to be used with 99370415-99395603 and special plates) (99360334)

Cylinder liner compression cap (to be used with 99360334) (99360335)

Tool for rotating the flywheel (99360341)

Tool for retaining the flywheel (99360351)

– P2D32C015E0116

7

CURSOR 9 Tigercat Tier II R96 ‒ Equipment 8

TOOLS

Crankshaft lifting tool (99360500)

Drift to take down and fit back camshaft bushes (99360505)

Tool for rocker arm shaft assembly and fitting (99360558)

Arm for engine removal and refitting (99360585)

Clamp for fitting piston into cylinder liner (60 - 125 mm) (99360605)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Equipment TOOLS

Tool for engine T.D.C. positioning (99360612)

Tool for timing of phonic wheel on timing gear (99360613)

Tool for cylinder liner fastening (99360703)

Tool to extract cylinder liners (use with special rings) (99360706)

Ring (115 mm) (to be used with 99360706) (99360724)

– P2D32C015E0116

9

CURSOR 9 Tigercat Tier II R96 ‒ Equipment 10

TOOLS

Brackets for fastening engine to 99322230 rotary stand (99361046)

Manual pump for measuring pressure and vacuum (99367121)

Set of 8 ignition keys 14X18 (13-17-18-19-21-22-24-27-30mm) (99368542)

Tool to check timing (use with 99395606) (99370400)

Dial gauge base to adjust lay shaft bearings (use with 99395603) (99370415)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Equipment TOOLS

14X18 coupling torque wrench (20-120 Nm) (99389833)

Torque screwdriver (1-6 Nm) for adjusting the locking nut of the injector solenoid valve connectors (99389834)

Sleeker for valve guide (99390310)

Pair of gauges for angular tightening with 1/2" and 3/4" square heads (99395216)

– P2D32C015E0116

11

CURSOR 9 Tigercat Tier II R96 ‒ Equipment 12

TOOLS

Gauge for defining the distance between the centres of camshaft and timing gear (99395222)

Gauge for camshaft timing (99395223)

Gauge to determine centre distance between camshaft and high pressure pump (99395230)

Dial gauge (0-5 mm) (99395603)

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Equipment TOOLS

Dial gauge (0-30 mm) (99395606)

– P2D32C015E0116

13

CURSOR 9 Tigercat Tier II R96 ‒ Equipment 14

TOOLS

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Safety regulations Contents

Contents SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . .

– P2D32C015E0116

3

1

CURSOR 9 Tigercat Tier II R96 ‒ Safety regulations 2

Contents

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Safety regulations SAFETY REGULATIONS Contents

Contents Standard safety precautions . . . . . . . . . . . . . . . . . .

5

Accident prevention . . . . . . . . . . . . . . . . . . . . . . .

5

During maintenance . . . . . . . . . . . . . . . . . . . . . . .

5

Protection of the environment . . . . . . . . . . . . . . . .

6

– P2D32C015E0116

3

CURSOR 9 Tigercat Tier II R96 ‒ Safety regulations 4

SAFETY REGULATIONS

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Safety regulations SAFETY REGULATIONS

5

Standard safety precautions

SAFETY REGULATIONS Standard safety precautions We direct your attention on some precautions that must be necessarily followed in a regular work environment and, in case of non-compliance, any other precaution will not be sufficient to protect the safety of the staff in charge of maintenance. ● ● ● ● ● ● ●

Please obtain information and inform the staff on applicable laws on safety, making the informative material available for consultation.

Please keep the rooms as clean as possible and properly ventilated.

Equip the rooms with specific, well-visible first-aid boxes, always stocked up with suitable medical aids.

Be equipped with suitable fire extinguishing devices, properly signalled and never obstructed. Check their operation on a regular basis and train the staff on the intervention priorities and methods.

Arrange gathering points for the evacuation of the rooms, properly signalling the exit routes.

Absolutely prohibit smoking in the areas where the works subject to fire hazard are carried out.

Draw the attention on prohibitions and indications with suitable signs, which are immediately comprehensible always in case of emergency.

Accident prevention ● ● ● ● ● ● ● ● ● ● ● ●

Do not wear cloths with loose edges, rings and chains, while working near engines and moving organs.

Use protective gloves and glasses when: - filling up inhibitors or antifreeze; - replacing or filling up lubricant; - using air or liquids under pressure (permitted pressure ≤ 2 bar).

Wear a protective helmet if working in an area with suspended loads or overhead systems.

Always wear safety shoes and cloths fitted to the body, better if equipped with rubber bands at the edges.

Use protective creams for hands.

Change wet clothes as soon as possible.

In the presence of voltage higher than 48-60V, check the effectiveness of the ground electric connections. Make sure your hands and feet are dry and perform the work standing on insulating platforms. Do not proceed if not qualified!

Do not smoke or spark free flames near batteries and any combustible material.

Return oily rags or solvents to fire-proof containers.

Do not perform operations without the necessary instructions.

Do not use equipment to perform works other than those for which they have been designed, you may sustain accidents, even of serious type.

In case of checks or calibrations that require the engine to be on, make sure that the room is properly ventilated and use proper fans to remove exhaust gases: intoxication and death hazard.

During maintenance ● ● ● ● ● ● ● ● ● ●

Never open the filling cap of the cooling circuit when the engine is hot. The operating pressure will spill the high temperature liquid with serious risk of burns. Wait until the temperature drops below 50 °C. Never add coolant to an overheated engine and only use appropriate fluids.

Always operate with engine off: in case particular circumstances require maintenance with the engine on, consider all the risks involved in these operations.

Use adequate and safe containers for draining the engine fluids and exhaust oil.

Preserve the engine clean from oil, gas oil stains and/or chemical solvents.

The use of solvents or detergents during maintenance may develop toxic vapours. Always ventilate the work rooms. Use safety masks when required.

Do not leave cloths soaked with flammable substances near the engine.

When starting up the engine after a repair operation, foresee suitable measures to stop air suction in case of over-revving.

Do not use quick screwers.

Do not disconnect the batteries whilst the engine is running.

– P2D32C015E0116

CURSOR 9 Tigercat Tier II R96 ‒ Safety regulations 6

SAFETY REGULATIONS Protection of the environment

● ● ● ● ● ● ● ● ● ●

Before any interventions involving the electrical circuits, disconnect the batteries.

Disconnect the batteries from the on-board network while charging.

After each intervention, make sure the polarity of the battery's terminals is respected and the latter are well tightened and protected against accidental short circuits and oxidation phenomena.

Do not disconnect and connect the electric connections when power is on.

Before carrying out removal operations on pipes (pneumatic, hydraulic or fuel pipes), check the possible presence of fluid or air under pressure. Adopt the necessary precautions, exhausting the residual pressures or closing the shut-off valves. Always wear suitable masks or protective glasses. Failure to follow these rules may cause serious accidents and intoxication.

Avoid improper tightening operations or out of torque. The engine's components may be damaged also seriously, thus prejudicing their life cycle.

Avoid draughts from fuel tanks in copper alloy and/or pipes without filters.

Do not apply changes to the cabling, their length must not be modified.

Do not connect any utility to the engine's electric equipment, unless specifically approved.

Do not modify the fuel or hydraulic systems without authorization. Any unforeseen change will void the warranty and may prejudice the engine's duration and life cycle.

For engines equipped with electronic units: ● ● ● ●

Do not carry out any arch welding without previously removing the electronic units.

Remove the electronic control units in case of interventions in which the temperatures will exceed 80 °C. Do not paint the electronic components and connections.

Do not modify or alter the data contained in the engine management electronic control unit. Any manipulation or alteration of the electronic components will invalidate the service warranty of the engine and may also affect its operation and duration.

Protection of the environment ● ● ● ●

Allows prioritise protection of the environment implementing all necessary precautions to protect the safety and health of staff.

Make sure you and all staff are fully aware of current standards for the treatment and disposal of fluids and engine oils. Set up adequate signage and specific courses to ensure a full understanding of the rules and the basic prevention measures.

Collect used oil in suitable containers with water tight seals also providing storage in areas which are adequately marked,ventilated, away from sources of heat and present no fire hazard.

Handle batteries with care in well ventilated areas and in antacid containers. Beware of fumes coming from the batteries: they may pose a serious risk of poisoning and contamination of the environment.

– P2D32C015E0116