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    106 views22 pages

    SM-751 - 67 To 88 PDF

    Uploaded by

    namduong368

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 22
    CLARK — Lubricate the fixing ring @2) using engine oil and place it onthe ol filter (3). = Manually stat he oil filter (3) on the beating union (1) until counter-boring, further screw up the ail filter @) by 34 um, Place a new fixing ring on the block housing (6). — Apply, (if aceded) new fixing ring onthe ol tempor- ture/pressure sensor (4) and assemble itt the beating (1) tightening the fixing serews tothe prescribed cou ple, NOTE In some applications, the bearing of the exchanger shall be assembled to a serew threaded union connected tothe filter om the ‘opposite side of the engine, throughout two pipelines (see picture 2). NOTE ‘The shape and the dimensions of the alterna- {or support vary according t0 the use of the ‘engine. Therefore the relevant pictures pro- vide a general guideline of the procedures that are to be carried out. However the pro- cedures deserted are applicable. ~ Assemble the alternator bearing (1) ensuring thatthe pins (3 and 4) are against the engine block, = Tighten the serews (2) and lock them to the pre- seribed coupe Group 00, Engine(D-IVECO) NOTE Before assembly, always check that the threads of the ports and of the serews have no evidence of tear and wear nor dirt. Connect te altemator (1) tthe support. Tighten the serew without locking it) “Place the gasket (1) over the block, ‘The choice of the gaskt's thickness shall be made in consideration ofthe eylinder progusion measured with respect ta the block's upper surface NOTE ‘Verity that the engine block stand is clean. Do not grease the gasket. It fs recommended to keep the gasket inside packaging. until assembly tothe cylinder head. Gasket assembly shall be made following the direction of wording printed on the gasket ‘Sw7st right Intended for CLARK dealers only ‘OO(DAVECOYS-24 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) itself so that this willbe readable as indicated MI2 180 nT No + 180 dog's the picture. 20 Carry out the assembly of the rocker ams after previ ‘os check of the componens. ~Place he head (3) over the bloc and insert serews (1) and @). NOTE If the valves have been removed from the head, itis necessary to assemble them before assembling the head itself on the engine block ROCKER ARM UNIT COMPONENTS: 1. Elastic ing - 2. Spacer- 3. Rocker ams- 4. Support Check the coupling surfaces of bearing and shat: no evi- dence of excessive wear shal be detected or damages Replace if necessary. eee Qo ~Lutviate cylinder bed bolts and instal hea. A a Bolts must be torqued using stitching pattern starting ‘with the centre bolts and moving out. Bolts to be B ‘orqud in stages all bots torqued to snug torque, then 90 degrees rotation forall bolts: Then a further 90 degrees for the M12 x 140 and M12 x 180, fee (ee MI2x 70 0 Nm +90 dee's MI2 140 vrs Nan + 180 dog's fees ‘SHAFT AND ROCKER ARM BASIC DATA a Intended for CLARK dealers only (00(0-1VECO}3-25 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) 1 unscrewed, check adjustment quota Tighten the serew-threaded nut (1) o the 4 04 0.6 Nm couple. ROCKER ARM ADJUSTMENT SCREW Before executing assembly, check the Rocker Arm driv= ing rods: these shall not be deformed; the spherical ends in contact with the Rocker Armadjustment screw and with the tappet(arows) shall not present evidence of seizure ‘orwearin case of detection proceed replacing them. ‘Tho rods driving the intake and exhaust valves are ideni- cal and therfore interchangeable, loser the tappet driving rods and the Rocker Arm unit. ‘Before using the Fixing serews again,measre them ‘wice as indicated inthe pieture, checking D1 and D2 diameters ifD1 -D2 < 0,1 mm the serew can be used again; ifD1 -D2 > 0,1 mm the serew must be replaced; pa ba a © d-— D Tighten the screws (2) to the prescribed couple and assemble water temperate sensor (1), [Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Conect slack is “suction valves 0.25 40.05 mam exhaust valves 0.50 40.08 mm. NOTE In order carry out a quicker adjustment of the working lack between roeker arms and valves, proceed. as following: Rotate. the engine drive shaft, balance the valves of cy: Inder 1 and adjust the valves identified by star symbol, as indicated in the following table: ylinder wo 2 [2 | 3 [4 NOTE Rotate the engine drive shaft, balance the valves of cylinder 4 and adjast the valves ‘Sw7st she Intended for CLARK dealers only ‘OO(DAVECOYS-26 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) Identiti by star symbol, as indicated in the following table: Qylinder Wo] [2 [3 [@ “Assemble injectors after having replaced the sealing gasket (1). > NOTE During assembly of injectors, injector sphere is corectly positioned on the head housing. a oo: Assemble exhaust manifold (1) providing new gaskets ©) not matching your model. Anyhow, described procedure i apy a Hor i 5 a Assemble eylinder covers (2) with the respective eas- ets: Fit the seal nods and tight the serews fixing them to the prescribed couple NOTE Always replace the gaskets using new ones. s ‘Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation, Assemble thermostat unit (2) ineluding thermostat (5) and gasket (4). Sw75i she Intended for CLARK dealers only ‘OO(DIVECO}S-27 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) Tighten the serews tothe prescribed couple For applications with traditional bet stretcher NOTE In order to comect the POLY-V belt eany out the ‘The serews (1) have been have been utilised ‘operations described on page & vice versa tofix the bracket (3). NOTE Disassemble the bracket and reassemble i eee eee cae For belt stretching turn the alternator as Cnsaeae Indicated in the figure, tighten serew (1) and noe the bolt that fixes the alternator to the sup- port. NOTE ‘the old belt sto be reassembled examine it carefully in order to see if there may be inel- sons or evident sign of yielding. Assemble the pulley fan bering tightening the serews to the prescribed couple f ~ Assemble the alterator tensioning bracket “Mount pulley (3) and secure it to support through \ screws (2). Assemble the transmission pulley (1). For applications with automatic belt tensioner ‘Assemble belt Po-V (4) oa the pulley (5) of the engine shal, onthe jockey pulley (2), onthe water pump (6) and fn the alternator (3), tighten (syn. tension) the belt by means ofthe automatic belt tensioner ae Intended for CLARK dealers only OO(DAVECOYS-28 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) Mount Poly-V belt (4) on pulley (7), engine shaft pul- ley (5), guide pulleys (6), water pump 3) and altema tor (2); stretch the belt by operating on automatic belt tensioner (2). Also assemble the brackets (1) fixing the fuel pipe lines to the injectors: use the same screws (2) fixing the manifold plate as shown inthe pictur “Apply on the surface joining the suction manifold plate (1) asuicent coat of Loctite 5999 and provide. xing the serews tothe presribed couple IF the pipe (6) of the scion manifold plate (1) as bboen removed, reassemble it after having fit a new gasket). Tighten the serews (7 othe prescribed coupe NOTE For the versions provided with heater, also assemble components (3) and (4). Assemble priming pump (1) providing new gasket and tighten the srews (2) 10 the presribed eouple Also assemble feed pump (see specie procedure) and the power take-off undemeath, NOTE Pump mounting requires specific procedure contained inthis section. Sw75i right Intended for CLARK dealers only ‘O0(DAVECO}3-29 ‘Do not sel or dstibute Group 00, Engine(D-IVECO) 1. Roar bracket fing sccow (on suction coletor plate) 2. Fuel recovery pipeline o pump 3. Rotary feed pump ‘4 Connection nut to pumping elements 5. Injectar 6. Bracke hing screw to jection pump side 7. Font brackel xing screw (on suction collector plat) Assemble the pipes (1) and (2) proving fuel feed and recovery between pump and injectors; ‘Serew up the locking nuts and tighten the screws fix- ing the fuel recovery manifold; fix the pipes to the injectors throughout the brackets previously assem- the LDA pipeline (1) tothe engine head and to the feed pump. ~ Assemble the fuel fer bearing (4) t the bracket fixed tothe engine head. Connect the fel pipelines (2 and 3) respectively from priming pump to filter bearing an rom this ast, one to fed pump. — Using 99360076 equipment assemble ful filter (1). ‘Sw7st right Intended for CLARK dealers only ‘OO(DAVECO}S-30 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) NOTE ‘The filter shall be priory filled with fuel to facilitate feed system bleed operations. NOTE ‘To connect fuel pipelines (2 and 3, Figure 96) {in low pressure from the relating connection ‘unions iis necessary to pres the locking fas- tener (1) as showa in picture B. After having connected the pipeline, reset the fastener (1) into block position as shown in ure A. Wie [ GE =Ohia! For urbocompressed versions proceed assembling the turbocharger: — Hold the turbocharger and place it on the exhaust ‘manifold ater having interposed the gasket —- Serew up the fing nuts ofthe turbocharger to the exhaust manifold tightening them to the prescribed couple, — Tighten the lubrication pipe fixing ring. Operate in the same way on the other end ofthe pipe. Connect it to the upper part ofthe heat exchanger. ‘To complet engine assembly it is necessary to remove it fiom the turing stand Using rocker arm 99360595 hold the engine and loosen the screws fixing the brackets to the turing stand 99322208, Disassemble the brackets fom the engine after hav ing property putt on wooden bearing. Completion of the engine (On the right hand side: reassemble the pipes (1) from the union (2) 40 the lubrication oil filter (placed on the opposite sid): tighten the pipe rings (1) and conneet them to the NOTE ‘In some cases, the oll fer (3) 6 directly placed om the heat exchanger: in this case it shall he assembled using too! 99360076. Sw75i she Intended for CLARK dealers only 0(D-VECO}3-31 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) For turbocompressed versions (On the left hand side: Reassemble the lubrication oil exhaust pipeline (1) Assemble ol fier (1) together with bracket (fr the fiom the turbocharger: from underneath the turbo- versions with engine ol fier not directly assembled charger tighten the two serews (2) tighten the screw to the exchanger: tighten the screws 3) assembling (@) fixing the pipetinew the Block thoughout the the bracket (4) including fier bearing (3). ing collar (4 to the Bock; finally tighten the union (5) Using tool 99360076 screw up oil iter, to the Block, Assemble oil level rod togetherwith ide pipe (2) Fill CE up engine ol Insall the engine on the machine (for installation =< ‘operations please apply to specific issue. —Reassemble the state properly hold the starter (1) and tighten the fing crews tothe prescribed couple. ae Intended for CLARK dealers only OO(DAVECOYS-32 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) Rotary feed pump disassembly and assembly Ti following procedure analyses this second hypothesis 7 since it is the more complex. procedure NOTE "This procedure preseribes th = The fuel pipelines (from pumping ele- ‘ments to Injectors, bleeding recovery pipes from injectors to pump, LDA pipe- line and feed provided by priming pump) shall ll be disassembled. Electrical connection to feed pump shall be disconnected. ~ Accelerator eabl shal be disconnected. Engine versions wit tot (99360330) ‘ Disassemble the starter fromthe ywhel box and use root ad 99360330 2) 1 rotate the flywheel Find the top dead centre with the toot (99398097) - False injector Remove the rocker covers ofthe Luceylinder; remove the ‘scinjector and place the tool (1) tose the Ist cylinder top dead centre position (end-of-compression phase). Pre oad the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the Comparator and then checking thatthe intake and exhaust valves ar both closed. ‘Once PMS has been obtained, lock the My wheel by means of tol 99360339 Figure 104), Engine versions with tol (99360339) Disassemble the starter from the flywheel box (1) and use ‘99360339 (2) to rotate the flywheel Incase feed pump replacement is necessary, this shall be supplied pre-set aleady as spare par (On the other hand, in cas the pump shall be disassembled snd reassembled later on without being repaired wil be necessary to pre-set it while itis sil assembled 10 the engine and disasemble i only afterwards, Unscrew the side stew that locks the pump shat pat= tilly (1) and remove spacer (2). This must be kept on a Intended for CLARK dealers only 00(D-VECOYS-83 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) 4 side (we recommend to fix it on the pump with a wie ora clip), Tighten the lateral serew (1) blocking rotation of the ump sh. 9 From timing side, remove the cover (2) loosening the sorews (1) inorder to have access to the union fixing ‘nut G) tothe pump driving gear. Loosen the fixing nut (3) and remove the relating washer a ph ,-@ ~Prom the pump sie, loosen the fixing nuts (1) without removing them in order to enable moving the pump ‘backward using 99340035 extractor, Assemble the 99340035 extractor throughout the two threaded ports (4, Figure 107) and withdraw the gear fiom the pump shat Property hol! the feed pump and loosen completely the fixing nuts, Withdraw the pump from the studs, together with the ssket ‘When the supply pump i 1 be assembled on the engine the PAMLS. conditions at compression end stage eylinder No. | must be cared! ot NOTE Hold the pump driving gear to avoid inter- ference or crawling during timing gear rota- tion “Assemble the pump pre-set in its housing on the engine ting the shat into the gear port (not provided with wreneh) Tighten the fixing nuts (1) looking the pump flange in the slot centre NOTE ‘The gasket removed during pump disassem- biy shall not be utilised again. Always use original spare parts. ‘Sw7st she Intended for CLARK dealers only O/DAVECOYS-34 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) ~On th timing side, throughout the specially appointed por, fi the washer and serew up the fixing mt (3) to ‘he pump shaft. Lock the nut othe 90.98 Ne couple. and insert spacer (2). Tighten screw (I)so tat it locks spacer (2) inthis way the supply pur shaft will be bl orotate Feely. Assemble the cover (2, Figure 110) including gasket fad tighten the screws (1, Figure 110). Disassemble the flywheel rotationlocking toot ‘99360339 of 99360330; arrange the starting motor in Connect all pipeines (from pumping elements to injectors, bleeding recovery pipes from injectors t0 pump, LDA pipeline and feed provided by priming With the injection pump inserted in relating seat and securing screws loosened, mount comparator 99395613 (2) and 99395100 gauge tool (1), preloading the rod by 2.5 mm, Rotate the engine drive shaft to shift fom the cond tion ofthe frst eylinder to TDC end of compression phase. Reset the dial gauges and rotate the engine tive shaft condition of the Ist cylinder to TDC in phase of compression (ste Figure 105). From this position on the comparator applied on the [pump it must be posible to read the value listed onthe ‘pumping clement pre-lif table. Section 4 Rotate the pump in anti-clockwise direction if the stroke is shorter or in lockwise direction if he stoke is longer, until obtaining the stoke prescribed. Checking these conltions, lock the pump by tighten ing the relevant nist the prescribed! pir EEE co-neren) mm, * = oy em Connect electrical comections to clectr-magnets on the hydraulic head and on KSB. NOTE In case pump removal has been carried out while the engine was assembled, connect acceleration cable, [Ignition pump control and timing Sw751 Intended for CLARK dealers only 0(D-VECO}3-35 ‘Do not sel or dstibute CLARK Group 00, Engine(D-IVECO) Feed system bleed procedure ‘Version with A type fue iter In case any operation has been exccuted on the compo- nents ofthe feed circuit, itis necessary to execute bled- ing of air within the system. Loosen the bleedar vent seew (3) on the fuel fer (1) and keep working oa the bled lever of the priming pump @), Continue executing this operation until when fuel

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