1

ON ROAD application

CURSOR 11 TDCV
F3GFE611A*C
F3GFE611B*C
F3GFE611D*C

CURSOR 13 TDCV
F3HFE611A*C
F3HFE611B*C

TRAINING MANUAL

Course Nr. FPT_M05E_412_EU6_C_TDC_N_EN_141203

December 2014 - 1st EDITION

2

WARNING

This publication is a didactic support only.

Due to the natural and continuous evolution of the product, certain subjects dealt with in
this publication could not be updated.

For repairs refer to the workshop manual.

FPT declines any liability for mistakes and omissions due to improper operations on the
engine.

DIDACTIC PUBLICATION NOT SUBJECT TO UPDATING

Publication edited by:

FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
3

CONTENTS:

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

4

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

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TECHNICAL CODE – Cursor 11

F3 G F E 6 1 1 A * C 001
First number shows the injection system
0 = Common rail 4 valves
The other numbers show engine configuration

Emissions level:
C = Euro 6

Performances:
A,B,C…= Engine power or torque level

Application:
1 = Use (Truck)

Engine main characteristics:

1 = Diesel turbocharged, direct injection, intercooled

No. of cylinders

Cyilinder configuration:
E = 4 stroke vertical with post-treatment

F = Tier 4/ Euro 6

G = Engine family evolution (also irrespective of the displacement)

F3 = Engine family indication

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TECHNICAL CODE – Cursor 13

F3 H F E 6 1 1 A * C 001
First number shows the injection system
0 = Common rail 4 valves
The other numbers show engine configuration

Emissions level:
C = Euro 6

Performances:
A,B,C…= Engine power or torque level

Application:
1 = Use (Truck)

Engine main characteristics:

1 = Diesel turbocharged, direct injection, intercooled

No. of cylinders

Cyilinder configuration:
E = 4 stroke vertical with post-treatment

F = Tier 4/ Euro 6

H = Engine family evolution (also irrespective of the displacement)

F3 = Engine family indication

7

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

8
WALK AROUND – Cursor 11

1. Lifting eyelet - 2. Intarder retarder cooling water delivery pipe- 3. Intarder retarder cooling water return pipe – 4.
Crankshaft speed sensor – 5. Flywheel cover casing - 6. Motorized throttle valve (Exhaust flap) - 7. Turbocharger – 8. Exhaust
manifold – 9. Oil filter - 10. Engine coolant inlet pipe to water pump – 11. Oil sump - 12. Crankshaft pulley with damper
pulley – 13. Idler pulley – 14. Fan control coupling - 15. Automatic belt tensioner – 16. Water pump – 16. Coolant
temperature sensor - 17. Thermostat assembly– 18. Compressor air delivery pipe – 19. Oil filler cap - 20. Blow-by pressure
sensor
9

1. Lifting eyelet - 2. Fuel filter – 3. Alternator – 4. Intake manifold – 5. Oil level control dipstick - 6. Temperature/air
pressure sensor – 7. EDC control unit – 8. High-pressure fuel pump - 9. Air compressor - 10. Starter motor - 11. Engine
flywheel – 12. Flywheel cover casing – 13. Crankshaft speed sensor – 14. Blow-by filter cover – 15. Timing cover – 16.
Compressor air intake pipe - 17. Turbocharger - 18. Head cover
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WALK AROUND – Cursor 13

1. Lifting eyelet - 2. Intarder retarder cooling water delivery pipe- 3. Intarder retarder cooling water return pipe –
4. Crankshaft speed sensor – 5. Flywheel cover casing - 6. Motorized throttle valve (Exhaust flap) - 7. Turbocharger –
8. Exhaust manifold – 9. Oil filter - 10. Engine coolant inlet pipe to water pump – 11. Oil sump - 12. Crankshaft pulley with
damper pulley – 13. Idler pulley – 14. Fan control coupling - 15. Automatic belt tensioner – 16. Water pump – 17. Thermostat
assembly – 18. Compressor air delivery pipe – 19. Head cover - 20. Oil filler cap
11

1. Lifting eyelet - 2. Fuel filter – 3. Alternator – 4. Intake manifold – 5. Oil level control dipstick - 6. Temperature/air
pressure sensor – 7. EDC control unit – 8. High-pressure fuel pump - 9. Air compressor - 10. Starter motor - 11. Engine
flywheel – 12. Flywheel cover casing – 13. Blow-by filter cover – 14. Crankshaft speed sensor – 15. Timing cover – 16.
Compressor air intake pipe - 17. Lifting eyelet - 18. Head cover – 19. Oil filler cap
12

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

13

CHARACTERISTIC CURVES – Cursor 11

Power Speed Torque Speed
Technical code Technical code
kW (hp) rpm Nm (kgm) rpm
F3GFE611A 353 (480) 1,900 F3GFE611A 2,250 (229) 1,000-1,500

Power

Torque
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Power Speed Torque Speed

Technical code Technical code
kW (hp) rpm Nm (kgm) rpm
F3GFE611B 338 (460) 1,900 F3GFE611B 2,150 (219) 1,000-1,500

Power

Torque
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Power Speed Torque Speed

Technical code Technical code
kW (hp) rpm Nm (kgm) rpm
F3GFE611D 309 (420) 1,900 F3GFE611D 1,900 (194) 900-1,550

Power

Torque
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CHARACTERISTIC CURVES – Cursor 13

Power Speed Torque Speed
Technical code Technical code
kW (hp) rpm Nm (kgm) rpm
F3HFE611A 412 (560) 1,900 F3HFE611A 2,500 (255) 1,000-1,550

Power

Torque
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Power Speed Torque Speed

Technical code Technical code
kW (hp) rpm Nm (kgm) rpm
F3HFE611B 368 (500) 1,900 F3HFE611B 2,300 (234) 900-1,550

Power

Torque
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Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

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GENERAL SPECIFICATIONS – Cursor 11

F3G
Type
F3GFE611D F3GFE611B F3GFE611A
Cycle Diesel 4-stroke
Air supply Turbocharged with aftercooler
Direct - High pressure pump supply
Injection
and common rail system

Number of cylinders 6, in line

Bore mm 128

Stroke mm 144

Total displacement cm3 11,120

Compression ratio 16,5 : 1
309 338 353
Maximum power kW
(420) (460) (480)
(hp) rpm
1,900
Maximum torque Nm 1,900 2,150 2,250
(kgm) (194) (219) (229)
rpm 900 - 1,500 1,000 - 1,500 1,000 - 1,500
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F3G
Type
F3GFE611D F3GFE611B F3GFE611A
Idle speed with no load
550 ± 50
rpm

Maximum engine idle speed

2,420 ± 50
rpm
TURBOCHARGING Turbocharged - with aftercooler
Turbocharger type: GT 4502 V EVGT
variable geometry with electronic control system
Forced by gear pump,
LUBRICATION
pressure relief valve, oil filter

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

- at idle speed bar 0.6
- at maximum speed bar 3.5
COOLING Liquid cooled
Coolant pump control Belt driven
Thermostat:
- start of opening ºC 84 ± 2
- max. opening ºC 94 ± 2
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F3G
Type
F3GFE611D F3GFE611B F3GFE611A
TIMING
start before T.D.C. A 17º
end after B.D.C. B 32º

start before B.D.C. D 50º

end after T.D.C. C 9º
Checking operation
0.4 ± 0.05
mm X


mm 0.6 ± 0.05
FUEL SYSTEM High pressure fuel feed system BOSCH EDC17
Type injection (common rail, high pressure pump, electro-injectors,
EDC17 engine control unit)
Pump Type CPN 5.2

Injector CRIN 3.3

Firing order 1–4–2–6–3–5

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F3G
Type
F3GFE611D F3GFE611B F3GFE611A

Injection pressure bar 2,200

REFILLING
Cooling circuit (1) L -
ACEA E9 / API CJ-4 Lubrication circuit (2)
SAE 10W-40 total capacity (4) L (Kg) 28.5-29 (25.7-26.1)
Periodic replacement:
ACEA E6 - Sump at min. level L (Kg) 18 (16.2)
SAE 5W-30 (3) - Sump at max. level L (Kg) 26 (23.4)

Fuel tank (5) L -

NOTE Data, features and performances are valid only if the setter fully complies with all the installation
prescriptions provided by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to torque, power and
rpm based on which the engine has been designed.
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GENERAL SPECIFICATIONS – Cursor 13

F3H
Type
F3HFE611B F3HFE611A
Cycle Diesel 4-stroke
Air supply Turbocharged with aftercooler
Direct - High pressure pump supply
Injection
and common rail system

Number of cylinders 6, in line

Bore mm 135

Stroke mm 150

Total displacement cm3 12,880

Compression ratio 16,5 : 1
368 412
Maximum power kW
(500) (560)
(hp) rpm
1,900
Maximum torque Nm 2,300 2,500
(kgm) (234) (255)
rpm 900 - 1,550 1,000 - 1,550
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F3H
Type
F3HFE611B F3HFE611A
Idle speed with no load
550 ± 50
rpm

Maximum engine idle speed

2,320 ± 50
rpm
TURBOCHARGING Turbocharged - with aftercooler
Turbocharger type: GT 4502 V EVGT
variable geometry with electronic control system
Forced by gear pump,
LUBRICATION
pressure relief valve, oil filter

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

- at idle speed bar 1.5
- at maximum speed bar 4.5-5
COOLING Liquid cooled
Coolant pump control Belt driven
Thermostat:
- start of opening ºC 84 ± 2
- max. opening ºC 94 ± 2
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F3H
Type
F3HFE611B F3HFE611A
TIMING
start before T.D.C. A 19º
end after B.D.C. B 31º

start before B.D.C. D 50º

end after T.D.C. C 9º
Checking operation
0.4 ± 0.05
mm X


mm 0.6 ± 0.05
FUEL SYSTEM High pressure fuel feed system BOSCH EDC17
Type injection (common rail, high pressure pump, electro-injectors,
EDC17 engine control unit)
Pump Type CPN 5.2

Injector CRIN 3.3

Firing order 1–4–2–6–3–5

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F3H
Type
F3HFE611B F3HFE611A

Injection pressure bar 2,000

REFILLING
Cooling circuit (1) L -
ACEA E9 / API CJ-4 Lubrication circuit (2)
SAE 10W-40 total capacity (4) L (Kg) 30.5-31 (27.5-27.9)
Periodic replacement:
ACEA E6 - Sump at min. level L (Kg) 20 (18)
SAE 5W-30 (3) - Sump at max. level L (Kg) 28 (25.2)

Fuel tank (5) L -

NOTE Data, features and performances are valid only if the setter fully complies with all the installation
prescriptions provided by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to torque, power and
rpm based on which the engine has been designed.
27

Technical code Crankcase

Cylinder liners
Walk around Crankshaft

Main and connecting rod half-bearings

Characteristic curves
Connecting rods

General specifications Pistons

Connecting rod – piston assembly

Main mechanical components Crankshaft seal rings

Cylinder head
CURSOR engine timing
Camshaft
Fuel supply system Valve stems, springs, oil seals, seats and guides

Engine flywheel
Lubrication circuit
Engine flywheel box / Gear case

Oil vapour recirculating system (Blow-by) Auxiliary components operation

28

MAIN MECHANICAL COMPONENTS

Crankcase

1. Lower crankcase – 2. Main bearing cap fastening screws – 3. Main bearing housings – 4. Fuel high pressure pump seat – 5.
Coolant/lubricant oil heat exchanger seat – 6. Main bearing cap – 7. Coolant pump seat – 8. Cylinder liners seats – 9. Crankcase
29

Cylinder liners

CYLINDER BLOCK ASSEMBLY WITH CHROME- A. Quick cooling for hotter areas –
PLATED CYLINDER LINERS B. Slow cooling for cooler areas
1. Crankcase seat – 2. Rubber ring seals – 3. Cylinder liner
30

Cylinder liners: replacing and checking protrusion

1. Screw – 2. Tool 99360706 – 3. Cylinder liner – 4. Plate 1. Screw – 2. Tool 99360334 – 3. Dial gauge 99395603 with
99360724 base 99370415
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Crankshaft

99.970
100.000

92.970
93.000
CRANKSHAFT MAIN JOURNALS AND CRANKPINS MEASURED VALUES
32

Crankshaft: installation

1. Main journals – 2. Crankpins– 3. Piston cooling oil nozzles – 4. Main bearing shells – 5. Front tang – 6. Main bearing shells –
7. Lower crankcase – 8. Timing control and oil pump drive gear (rear side) – 9. Main bearing shells with axial thrust washers
33

Main and connecting rod half-bearings

1. Pistons - 2. . Upper connecting rod half bearings – 3. Connecting rods – 4. Crankpins - 5. Lower main half bearings - 6. Upper
main half bearings – 7. Upper main half bearing with axial thrust washers – 8. Main journals – 9. Lower main half bearing
with axial thrust washers – 10. Lower connecting rod half bearings
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Defining the diameter class of the seats for half-bearings on the crankcase

Rated diameter of the

Class
main bearing
1 106.300 - 106.300
2 106.310 - 106.319
3 106.320 - 106.330
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Definition of the diameter class of the main journals and crankpins

(nominal diameter) - Cursor 11

Rated diameter of the

Class
crankpin
1 99.970 - 99.979
2 99.980 - 99.989
3 99.990 - 100.000

Rated diameter of the

Class
main journal
1 92.970 - 92.979
2 92.980 - 92.989
3 92.990 - 93.000
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Selection of main half-bearings (nominal diameter pins)

The table contains the characteristics of the

main bearings available as spare parts in
standard measurement (STD)
Thickness of the main bearing shells

STD + 0.127 + 0.254 + 0.508

Red 3.110 - 3.120 - - -

Red/Black - - - -
Green 3.121 - 3.130 - - -
Green/Black - - - -
Yellow* 3.131 - 3.140 - - -
Yellow/Black - - - -
* Cursor 11 only (Not supplied as a spare part )
37

Selection of main half-bearings (nominal diameter pins) – Cursor 11

STD CLASS 1 2 3

green green yellow

1
green yellow yellow

red green green

2
green green yellow

red red green

3
red green green
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Selection of main half-bearings (nominal diameter pins) – Cursor 13

STD CLASS 1 2 3

green green green

1
green green green

red green green

2
red green green

red red green

3
red red green
39

Selecting the diameter class of the connecting rod seats

(nominal diameter pins)

Connecting rod
Class
half-bearing housings
F3G F3H
1 98.000 - 98.010 100.000 - 100.010
2 98.011 - 98.020 100.011 - 100.020
3 98.021 - 98.030 100.021 - 100.030

Class Weight [g]

F3G F3H

A
5000 - 5033 5537 - 5570
Yellow
B
5034 - 5067 5571 - 5604
Green
1. Numbers identifying the cap-connecting rod coupling - 2. Engine type C
– 3. Connecting rod identification plate – 4. Number indicating the 5068 - 5100 5605 - 5637
Blue
selection of the diameter of the half-bearing housing (1, 2, 3) – 5. Date
of manufacture – 6. Letter indicating the weight class (A, B, C)
40

Selection of the connecting rod half-bearings – Cursor 11

The table contains the characteristics of the

main bearings available as spare parts in
standard measurement (STD)
Thickness of the connecting rod bearing shells

STD + 0.127 + 0.254 + 0.508

Red 2.465 - 2.475 - - -

Red/Black - - - -

Blue 2.475 - 2.485 - - -

Blue/Black - - - -

Yellow* 2.485 - 2.495 - - -

Yellow/Black - - - -
* Not supplied as a spare part
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Selection of the connecting rod half-bearings

(nominal diameter pins) – Cursor 11

STD CLASS 1 2 3

green green yellow

1
green yellow yellow

red green green

2
green green yellow

red red green

3
red green green
42

Selection of the connecting rod half-bearings – Cursor 13

The table contains the characteristics of the

main bearings available as spare parts in
standard measurement (STD)
Thickness of the connecting rod bearing shells

STD + 0.127 + 0.254 + 0.508

Red 1.960 – 1.970 - - -

Red/Black - - - -

Green 1.971 – 1.990 - - -

Green/Black - - - -
* Not supplied as a spare part
43

Selection of main half-bearings (nominal diameter pins) – Cursor 13

STD CLASS 1 2 3

green green green

1
green green green

red green green

2
red green green

red red green

3
red red green
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Connecting rods main data – Cursor 11

* Dimension to be obtained after driving the bushing

45

Connecting rods main data – Cursor 13

* Dimension to be obtained after driving the bushing

46

Pistons

Cursor 11

MAIN DATA OF PISTON, SNAP RINGS AND PIN

X = 0.6 ± 0.3
47

Cursor 13

MAIN DATA OF PISTON, SNAP RINGS AND PIN

X = 0.6 ± 0.3
48

Connecting rod – piston assembly

PISTON CONNECTING ROD ASSEMBLY 1. Piston pin – 2. Bush – 3. Stop ring – 4. Conrod body – 5. Conrod cap
1. Piston - rod assembly - 2. Marking area of ideogram – 6. Conrod cap fastening screws – 7. Conrod half-bearings – 8. Stop
on the piston crown ring – 9. Piston ring grooves – 10. Piston
49

Crankshaft seal rings

Front

Rear

A. Outside body to flywheel side or front cover side – B. Seal lip – C. Part keyed to the cover – D. Axial seal area
1. Rubber spacer – 2. Sleeve – 3. Spring – 4. Metal insert
50

Crankshaft seal rings: front and rear installation

1. Crankshaft front seal – 2. Tool 99346250 – 3. Nut 1. Crankshaft front seal – 2. Tool 99346260 – 3. Nut
51

Cylinder head
1
11
2

10 3

4
9
5

6
8

1. Common rail – 2. Electro-injectors – 3. Camshaft – 4. Lifting eyelets - 5. Valves – 6. Exhaust manifold – 7. Engine coolant outlet
(to radiator) with engine coolant temperature sensor – 8. Thermostat – 9. Intake manifold – 10. Grid heater – 11. Rocker arm shaft
52

Camshaft

82.950
82.968

CAMSHAFT PINS MEASURED VALUES

A. Intake valve control – S. Exhaust valve control
53

Camshaft: intake and exhaust valve control

1. Rocker arms – 2. Nuts adjusting screws – 3. Bridges – 4. A. Intake valves – S. Exhaust valves
Spring – 5. Valve stem – 6. Camshaft – 7. Rocker arm shaft
54

Valve stems and springs – Cursor 11

* Measurement obtained
after fitting the valve
guides

Lift [mm] Loaded spring [N]

H (free) 80 Unloaded
F3G H1 (valve shut) 62 P1 660  33
H2 (valve open) 48.8 P2 1.140  57

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE

SPRINGS INTAKE EXHAUST
VALVE VALVE
55

Valve stems and springs – Cursor 13

* Measurement obtained
after fitting the valve
guides

Lift [mm] Loaded spring [N]

H (free) 76 Unloaded
F3H H1 (valve shut) 59 P1 775  39
H2 (valve open) 46 P2 1.366  68

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE

SPRINGS INTAKE EXHAUST
VALVE VALVE
56

Valves oil seals

1. Intake valve – 2. Exhaust valve 1. Valve oil seals

A. Intake side – S. Exhaust side
57

Valve seats – Cursor 11

INTAKE VALVE SEAT SECTION EXHAUST VALVE SEAT SECTION

1. Intake valve seat 2. Exhaust valve seat
58

Valve seats – Cursor 13

INTAKE VALVE SEAT SECTION EXHAUST VALVE SEAT

SECTION
59

Valve guides

CURSOR 11 CURSOR 13

31 ±0.20
31 ±0.20
* Ø 9.015 ÷ 9.030 * Ø 10.015 ÷ 10.030

* Measurement obtained after fitting the valve guides

60

Engine flywheel

1. Toothed rim – 2. Dowel pin – 3. Engine flywheel

61

Engine flywheel: installation and timing notches

120° 120°
E

54°
A-B- D
E
C
30°
0°
A. Hole on flywheel with a notch corresponding to pistons 3-4 TDC – B. Hole on flywheel with a notch, corresponding to piston
1-6 TDC – C. Hole on flywheel with a notch corresponding to pistons 2-5 TDC – D. Hole on flywheel with 2 notches, position
corresponding to 54° before TDC - E. Hole on flywheel with 3 notches, position corresponding to 30° before TDC
62

Engine flywheel box / Gear case

1
8
2

3
7

1
5

1. Timing sensor seat – 2. Fuel high pressure pump gear seat – 2

3. Clearance adjusting rod – 4. Engine flywheel seat – 5.
Starter electric motor seat – 6. Inspection hole – 7. Crankshaft 1. LOCTITE 5970 – 2. Engine flywheel box
rpm sensor seat – 8. Camshaft gear seat
63

Auxiliary components operation

1. Water pump – 2. Electromagnetic coupling – 3. Crankshaft pulley with damper pulley –

4. Poly-V belt – 5. Automatic belt tensioner – 6. Alternator
64

Technical code

Walk around

Determination to the centre between camshaft and

Characteristic curves high pressure pump
Engine flywheel timing: hole with one reference mark
General specifications
Camshaft installation

Main mechanical components Assembling the timing control gears

Camshaft timing
CURSOR engine timing

Fuel supply system

Lubrication circuit

Oil vapour recirculating system (Blow-by)

65

CURSOR ENGINE TIMING

Determination to the centre between camshaft and high pressure pump

1. Tool 99395226 – 2. High pressure pump support flange

66

Engine flywheel timing: hole with one reference mark

1. Tool 99360612 (1) – 2. Seat of the engine speed sensor -3.

Hole drilled in the engine flywheel – 4. Engine flywheel – 5.
Hole with one reference mark
67

Camshaft installation

1. Rear plate – 2. Gasket – 3. Camshaft – 4. Screws – 5. Inner groove – 6. LOCTITE 5970 sealant
68

Assembling the timing control gears

1. Gauge 99395227 – 2. Fastening screw – 3. Link rod 1. Idle gear– 2. Fastening screws
69

1. Magnetic dial gauge – 2. Gear – 3. Screw – 4. Screw – 5. Idle gear – 6. Screw

70

Camshaft timing

1. Engine flywheel – 2. Inspection window -3. Rear casing – 1. Tool 99360612 (1) – 2. Seat of the engine speed sensor -3.
4. One notche – 5. Two notches – 6. Three notches – 7. Tool Hole drilled in the engine flywheel – 4. Engine flywheel
(99360321+99360325)
71

1. Dial gauge (99395606) – 2. Magnetic base support (99370400) – 3. Flat based rod (99370400) – 4. Rocker arm roller
72

Cam timing dial

5.76 ±0.05 mm
gauge value

1. Tool 99360612 (1) – 2. Seat of the engine speed sensor -3. Hole drilled in the engine flywheel – 4. Engine flywheel –
5. Hole with two notches
73

Cam timing dial

5.76 ±0.05 mm
gauge value

Tightening torque
Pre-tightening
Camshaft gear 60 Nm
fixing screw (2) Angle tightening
60°

1. Gear – 2. Screw
74

Tightening torque
Cam timing Pre-tightening
5.76 ±0.05
dial gauge 60 Nm
mm Camshaft gear
value
fixing screw (2) Angle tightening
60°

1. Tool 99360612 (1) – 2. Seat of the engine speed sensor -3. 1. 4 slots – 2. Gear
Hole drilled in the engine flywheel – 4. Engine flywheel
–
5. Hole with two notches
75

Technical code

Walk around Hydraulic system

Fuel system layout

Characteristic curves
MAIN FUEL SUPPLY SYSTEM COMPONENTS

General specifications High pressure pump

Common Rail
Main mechanical components Electro-injectors

Pressure limiter valve

CURSOR engine timing
Fuel filter
Fuel supply system

Lubrication circuit

Oil vapour recirculating system (Blow-by)

76

FUEL SUPPLY SYSTEM

Hydraulic system

A. Fuel supply system – B. Tank return circuit

1. Common rail – 2. Electro-injectors – 3. Fuel filter – 4. Engine control unit – 5. Fuel pre-filter - 6. Fuel pump
77

Fuel system layout

HYDRAULIC SYSTEM DIAGRAM

A. High pressure – B. Low pressure
1. High-pressure pump – 2. Fuel filter – 3. Tank – 4. Fuel pre-filter – 5. Engine control unit – 6. Electro-injectors –
7. Overpressure valve – 8. Rail pressure accumulator – 9. Pressure sensor
78

MAIN FUEL SUPPLY SYSTEM COMPONENTS

High pressure pump

1. Fuel delivery to rail– 2. Fuel supply from filter – 3. Fuel supply from tank – 4. Fuel delivery to filter –
5. Plug – 6. Fuel return to tank
79

High pressure pump – Technical data

Pump characteristics
Transmission ratio 1:1
Number of cam
2/3
plungers / lobes
Incoming fuel temperature - 40 ± 80°C (90° max
(gear pump) 100h)
Maximum 280 Nm
at maximum flow
Max torque
at nominal speed
Average 80 Nm
at maximum flow
Average power required 18 kW
Weight 15.3 kg
Maximum speed in
2625 rpm
overspeed (250 h)
Nominal speed 2100 rpm
Overspeed (1h) 3150 rpm
Maximum pressure at gear
1. Plungers (2x) – 2. CP5 gear plungers – 3. Flow regulator 13 bar abs
pump output
Maximum pressure at gear
0.35 ± 1 bar abs
pump intake
80

Common Rail

Rail characteristics
Nominal rail volume 28.6 cm³
Inner diameter 9 mm
Nominal pressure 2,200 bar
Operating temperature −40 a140 ℃

1. Pressure sensor – 2. Common Rail – 3. Pipes to electro-injectors – 4. Fuel return - 5. Overpressure valve (DBV4) –
6. Intake from the high-pressure fuel pump
81

Electro-injectors

1. Electric connection
2. Coil
3. High-pressure fuel inlet fitting
4. Injector closing force
5. Nozzle
6. Vaporiser nozzle
7. Fuel return hole
8. QA codes
9. Production code
82

Electro-injectors - Operation

1. Coil – 2. High-pressure fuel inlet fitting – 3. Filter – 4. Pressure rod - 5. Needle – 6. Nozzle – 7. Pressure chamber –
8. Fuel return – 9. Control volume – 10. Pilot valve shutter
83

Pressure limiter valve

1. Common Rail – 2. Fuel backflow to tank – 3. Pressure

limiter valve
Rail nominal pressure 2,200 bar
84

Fuel filter

Fuel filter characteristics

Max flow rate 750 l/h
Nominal pressure < 13 bar
Operating temperature -40°C/+120°C
Pressure drop
with new filter < 0.5 bar
Pressure drop with filter
> 2 bar
at end of life

1. Clogged filter sensor – 2. Fuel temperature sensor – 3. Fuel filter – 4. Drain valve – 5. Fitting for bleeding
6. Fuel inlet from mechanical pump – 7. Fuel outlet to high-pressure pump
85

Technical code

Walk around

Characteristic curves
LUBRICATION CIRCUIT
General specifications
Oil pump

Main mechanical components Overpressure valve

Oil pressure regulator valve

CURSOR engine timing Engine oil filter

Lubricant oil/coolant heat exchanger

Fuel supply system
Oil sump

Lubrication circuit

Oil vapour recirculating system (Blow-by)

86

LUBRICATION CIRCUIT

A. Engine brake solenoid valve detail

B. Oil to brake cylinders 1 - 2 - 3 - 4 – 5
C. To engine brake cylinder 6
D. Oil dropping
E. Oil under pressure
87

Oil pump

1. Oil pump – 2. Crankshaft helical gear

88

Overpressure valve

Overpressure valve

Initial opening pressure 10 ±1 bar

OVERPRESSURE VALVE SECTION OVERPRESSURE VALVE SPRING

89

Oil pressure regulator valve

OIL PRESSURE REGULATOR VALVE SECTION OIL PRESSURE REGULATOR VALVE SPRING
A. Start opening – B. Opening end
Technical data

Start of opening pressure 5bar

90

Engine oil filter

1. Filter support – 2. Cap O-ring – 3. Cartridge O-ring – 4. Cartdrige – 5. Filter body – 6. Drain plug
91

Oil filter: characteristics

Filtering efficiency β 12 µc > 200 (99.5%)

Maximum
13 bar
operating pressure
Operating
-30 °C ÷ +120 °C
temperature
By-pass valve
3.4 ± 0.3 bar
opening pressure

Tightening
Ref No. Description
torques
(4) 1 Closing cap 60 ± 5 Nm
(3) 1 Drain plug 65 ± 1.5 Nm

1. By-pass valve 3.4 bar - 2. Cartridge – 3. Drain plug – 4. Filter body

92

Lubricant oil/coolant heat exchanger

1. Gasket – 2. Fastening screws – 3. Lubricant oil heat exchanger – 4. Crankcase

93

Heat exchanger

Technical data
By-pass valve opening pressure 2.5 ±0.3 bar

1. By-pass valve– 2. Heat exchanger– 3. Oil filter support seat

94

Oil sump

Tightening
Ref No. Description
torques
(3) 16 M10x1.5x45 45 ± 4.5 Nm

1. Oil sump drain plug – 2. Oil sump – 3. Fastening screws – 4. Alluminium element – 5. Rubber gasket
95

Technical code OIL VAPOUR RECIRCULATING SYSTEM (BLOW-BY)

Blow-by filter
Walk around

Characteristic curves

General specifications

Main mechanical components

CURSOR engine timing

Fuel supply system

Lubrication circuit

Oil vapour recirculating system (Blow-by)

96

OIL VAPOUR RECIRCULATING SYSTEM (BLOW-BY)

A. Oil vapour flow - 1. Vapour breather valve – 2. Blow-by box – 3. Blow-by filter – 4. High pressure pump drive gear
97

Blow-by filter

1. Screws fastening timing cover – 2. Blow-by cover – 3. Screws fastening blow-by filter – 4. Blow-by filter
98

COOLING CIRCUIT Cooling circuit

Check fan electromagnetic coupling clutch wear
Intake and exhaust system
Water pump

Thermostat Exhaust gas after-treatment system

Electrical equipment

Scheduled Maintenance

Assembly clearance

Tightening torques / sequences

Tools
99

COOLING CIRCUIT

A. Water leaving the thermostat - B. Water circulating in the engine – C. Pump inlet water - 1. Cylinder head cooling channels – 2.
Heat exchanger lubricant oil/coolant - 3. Motorized throttle valve actuator water return/delivery pipes – 4. Engine coolant inlet
pipe (from radiator) – 5. Water pump – 6. Thermostat – 7. Engine coolant outlet pipe (to radiator) – 8. Air compressor
100

Check fan electromagnetic coupling clutch wear

Gap
X Max. 2.5 mm

1. Pulley - 2. Anchor assembly

101

Water pump

WATER PUMP SECTION

1. Fastening screws – 2. Water pump – 3. Sealing gasket

(→) Threaded holes
102

Thermostat

Water circulating
in the engine

Water leaving
the thermostat

1. Thermostat – 2. Sealing ring – 3. Fastening screws – The valve starts to open at: 84 °C ± 2 °C
4. Engine coolant outlet – 5. Gasket
Minimum stroke 9.5 mm to: 94 °C ± 2 °C
103

Cold operation with thermostat closed Hot operation with thermostat open

A. Water circulating in the engine and the Intarder – A. Water circulating in the engine and the intarder –
B. To water pump B. From radiator to water pump – C. To radiator
104

INTAKE AND EXHAUST SYSTEM Cooling circuit

EVGT turbocharger

Motorized throttle valve (Exhaust flap) Intake and exhaust system

Exhaust gas after-treatment system

Electrical equipment

Scheduled Maintenance

Assembly clearance

Tightening torques / sequences

Tools
105

INTAKE AND EXHAUST SYSTEM

B
exhaust gas
compressed air (cold)
compressed air (hot) D
filtered air
C
1. Exhaust manifold – 2. Motorized throttle valve (Exhaust flap) – 3. Turbocharger – 4. Intake manifold
A. Cooled compressed air (cold) engine intake from intercooler – B. Turbocharger exhaust gas outlet from motorized throttle valve
(Exhaust flap) – C. Turbocharger filtered air inlet from air filter – D. Turbocharger compressed air (hot) outlet
106

EVGT turbocharger

1. Exhaust manifold – 2. Motorized throttle valve (Exhaust flap) – 3. Turbocharger lubrication oil discharge pipe (to oil sump) –
4. EVGT actuator - 5. Turbocharger –- 6. Turbocharger lubrication oil delivery pipe (from heat exchanger) –
7. Turbocharger compressed air outlet pipe to intercooler
107

Motorized throttle valve (exhaust flap)

1. Power supply
2. Ground
3. “CAN LOW” Line
4. “CAN HIGH”
Line

1. Motorized throttle valve (exhaust flap) - 2. V-clamping A. Throttle valve (exhaust flap) - B. Coolant inlet/outlet
collar screw - 3. Turbocharger coupling - C. Electric actuator
108

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic diagram
Cooling circuit
DOC+SCR configuration

Cooling / heating ATS System Intake and exhaust system

MAIN COMPONENTS OF THE ATS SYSTEM

Catalyst
Exhaust gas after-treatment system

DeNOx 2.2 Supply Module (SM)

DeNOx 2.2 Supply Module (SM) – Electrical components
Electrical equipment
inside

DeNOx 2.2 Dosing Module (DM) Scheduled Maintenance

Engine coolant 3 way valve

SCRT system sensors

Assembly clearance

SCRT tightening torque sensors

Tightening torques / sequences
Humidity and temperature detecting sensor

Exhaust gas temperature sensor Tools

Nitrogen oxides detecting sensor
NH3 control unit and sensor

Particulate trap pressure sensor (Δp)

109

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic diagram
08
04 05 07
02 09
06
03

11 12

01 10

13
CAN

14
34
33
15
32

ECU
31
29 30

26
28
27

24 25 18
23
DOC
CUC
SCR

22 17
16
ECU
19
21
ECU
20 ECU
110

Cooling / heating ATS System

COOLING CONDITION

CONDITION OF SIMULTANEOUS
HEATING AND COOLING

2 3

5
Engine coolant
AdBlue (low pressure)
AdBlue (high pressure)

1. Dosing module – 2. Engine – 3. Engine

coolant 3 way valve – 4. AdBlue tank – 5.
Supply module
111

MAIN COMPONENTS OF THE ATS SYSTEM

Catalyst

1. Temperature sensors – 2. Differential pressure sensor pressure point fittings – 3. APU Exhaust – 4. SCR Catalytic converters –
5. Nox sensor – 6. NH3 Sensor – 7. AdBlue metering module – 8. DPF (Diesel Particulate Filter) catalytic converter – 9. Oxidizing
catalytic converter (DOC)
112

1. Oxidizing catalytic converter (DOC) – 2. DPF (Diesel Particulate Filter) catalytic converter– 3. SCR Catalytic converters
113

DeNOx 2.2 Supply Module (SM)

1
8 2

7 3

5
4
1. Fluid output pipe of pump module heating – 2. AdBlue return pipe to tank – 3. Delivery pipe to dosing module –
4. Main filter – 5. Electrical connector – 6. Pressure compensation membrane – 7. Fluid input pipe of pump module
heating – 8. Supply pipe from tank