Claas Renault Ares 546 556 566 616 626 636 696 Tractor Workshop Service Repair Manual

SUPPLY INJECTION S 5312 ARES 546 (Engine DPS 4045 TRT 53) S 5322 ARES 556 (Engine DPS 4045 TRT 54) S 5332 ARES 566 (Engine DPS 4045 TRT 55) S 8212 ARES 616 (Engine DPS 6068 TRT 50) S 8222 ARES 626 (Engine DPS 6068 TRT 53) S 8232 ARES 636 (Engine DPS 6068 TRT 54) S 8242 ARES 696 (Engine DPS 6068 TRT 55)

Issue 01

01 - 2004

Ref: 60 05 029 693

60 05 029 693 - 10.2003 - EN

CONTENTS

IDENTIFICATION IDENTIFICATION OF THE INJECTION PUMPS ................................................................................. A1.2

SPECIFICATIONS MAIN SPECIFICATIONS ................................................................................................................... A1.4 4-CYLINDER ENGINES ............................................................................................................... A1.4 6-CYLINDER ENGINES ............................................................................................................... A1.5

TIGHTENING TORQUES TIGHTENING TORQUES ................................................................................................................... A1.8

OPERATING PRINCIPLES SUPPLY ......................................................................................................................................... A1.10 PRIMARY FILTER ........................................................................................................................... A1.11 FUEL FILTER .................................................................................................................................. A1.11 INJECTION PUMP .......................................................................................................................... A1.12 INJECTORS .................................................................................................................................... A1.13

CHECKS - ADJUSTMENTS ENGINE SPEED ............................................................................................................................. A1.16 CHECKING THE MAXIMUM NO LOAD SPEED .............................................................................. A1.16 CHECKING AND ADJUSTING THE TICK-OVER ............................................................................. A1.16 STATIC ADJUSTMENT OF THE INJECTION PUMP ......................................................................... A1.17 DYNAMIC ADJUSTMENT OF THE INJECTION PUMP .................................................................... A1.17 INJECTOR ADJUSTMENT ............................................................................................................... A1.21 CRACKING PRESSURE ADJUSTMENT ......................................................................................... A1.21 NEEDLE STROKE ADJUSTMENT .................................................................................................. A1.22 SHUT-OFF SOLENOID VALVE FUNCTIONAL CHECK.................................................................... A1.23 COLD-START SWITCH FUNCTIONAL CHECK ................................................................................ A1.23 SUPPLY PRESSURE CHECK ........................................................................................................ A1.24

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CONTENTS (CONT’D)

REMOVAL / INSTALLATION FUEL FILTER REPLACEMENT ....................................................................................................... A1.26 INJECTION SYSTEM BLEEDING .................................................................................................... A1.26 INJECTION PUMP REMOVAL ........................................................................................................ A1.27 INJECTION PUMP INSTALLATION .................................................................................................. A1.28 INJECTOR REMOVAL ..................................................................................................................... A1.29 INJECTOR SEAT CLEANING (IF NECESSARY) ............................................................................. A1.29 INJECTOR INSTALLATION .............................................................................................................. A1.29 CARRYING OVER OF THE ADJUSTMENT MARK ONTO THE FRONT PLATE ............................... A1.30

CONTROL ADJUSTMENTS ADJUSTMENT OF THE ACCELERATOR CABLE............................................................................ A1.32

DIAGNOSTIC SHEETS “ENGINE START FAILURE” SHEET ................................................................................................ A1.34 “IRREGULAR ENGINE RUNNING” SHEET ...................................................................................... A1.35 “GREY OR BLACK SMOKE EMISSION” SHEET ............................................................................ A1.36 “WHITE SMOKE EMISSION” SHEET ............................................................................................. A1.37 “CHECKING THE FUEL SUPPLY SYSTEM” SHEET ...................................................................... A1.38

TOOLS INJECTIONS TOOLS ....................................................................................................................... A1.40

60 05 029 693 - 10.2003 - EN

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IDENTIFICATION

332 693 - 06.2002 - EN- EN 60MR 05 029 - 10.2003

A1.1

Identification Injection pumps identification TRACTOR Type

ARES 546 5312

ARES 556 5322

ARES 566 5332

ARES 616 8212

ARES626 8222

ARES 636 8232

ARES 696 8242

ENGINE

4045 TRT 53 4045 TRT 54 4045 TRT 55 6068 DRT 50 6068 TRT 53 6068 TRT 54 6068 TRT 55

INJECTION PUMP

STANADYNE

MODEL

D B4

TYPE

D B 4429 5742

D B 4429 5741

D B 4429 5732

D B 4629 5733

D B 4629 5708

D B 4629 5744

D B 4629 5729

STANADYNE injection pump Manufacturer’s plate (Fig. 3) (A) Date of manufacture code: K1

The alpha-numeric code is as follows: Letter (month) Number (year) A = January 1 = 2001 B = February 2 = 2002 C = March 3 = 2003 D = April 4 = 2004 E = May 5 = 2005 F = June 6 = 2006 G = July 7 = 2007 H = August 8 = 2008 J = September 9 = 2009 K = October L = November M = December (B) Type code: DB4 6 29 5729 DB4 = pump series D, rotor B, 4 plungers 6 = number of cylinders 29 = abbreviation for plungers diameter : 29 = 0.29" i.e. 7.37 mm 5729 = specification number (C) Nominal engine speed (D) Serial number (E) Engine manufacturer’s reference: DPSG → RE 506250

Fig. 1 A1-001

4-cylinder pump

Fig. 2

Fig. 3 A1-001a

A1.2

A1-002

06.2002 - EN - EN 60MR 05 332 029 -693 - 10.2003

6-cylinder pump

SPECIFICATIONS

06.2002 - EN - EN 60MR 05 332 029 -693 - 10.2003

A1.3

Specifications Main specifications 4-cylinder engines Tractor type

ARES 546

ARES 556

ARES 566

Engine

4045 TRT 53

4045 TRT 54

4045 TRT 55

Supply pump

Electric at continuous flow

Fuel flow measured at the filter inlet (motor stopped)

1.5 l/h

Fuel pressure at the filter inlet (nominal no load)

0.35 bar

Fuel pressure at the filter outlet (nominal no load)

0.3 bar

Injection pump

STANADYNE

Model Type

D B4 DB4429-5742

DB4429-5741

Number of piston plungers Dynamic setting angle at nominal speed under full load Injection sequencer

4 5°

6° 1-3-4-2

Tick-over speed (rev/min)

850 ± 25

Maximum no load speed (rev/min)

2390 ± 15

Nominal speed( rev/min)

2200

Injector

STANADYNE

Model

Pencil 9.5 mm

Reference

29729 RE 44508

Injector setting pressure (bar) New injector cracking pressure

250 255 to 260 bar

Minimum acceptable cracking pressure on a worn injector

235 bar

Maximum difference in cracking pressure between cylinders

7 bar

A1.4

DB4429-5732

332 -693 06.2002 - EN - EN 60MR 05 029 - 10.2003

5.5°

Specifications 6-cylinder engines

Tractor type

ARES 616

ARES 626

ARES 636

ARES 696

Engine

6068 DRT 50

6068 TRT 53

6068 TRT 54

6068 TRT 55

Supply pump

Electric at continuous flow

Fuel flow measured at the filter inlet (motor stopped)

1.5 l/h

Fuel pressure at the filter inlet (nominal no load)

0.25 bar

Fuel pressure at the filter outlet (nominal no load)

0.18 bar

Injection pump

STANADYNE

Model Type

D B4 DB4629-5733

DB4629-5708

Number of piston plungers Dynamic setting angle at nominal speed under full load

DB4629-5744

DB4629-5729

7°

6.5°

4

8,5°

7°

Injection sequencer

1-5-3-6-2-4

Tick-over speed (rev/min)

850 ± 25

Maximum no load speed (rev/min)

2390 ± 15

Nominal speed (rev/min)

2200

Injector

STANADYNE

Model

Pencil 9.5 mm

Reference

32261 RE 57469

29729 RE 44508

220

250

238 to 244 bar

255 to 260 bar

Minimum acceptable cracking pressure on a worn injector

198 bar

235 bar

Maximum difference in cracking pressure between cylinders

7 bar

7 bar

Injector setting pressure (bar) New injector cracking pressure

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A1.5

Specifications Personal notes:

A1.6

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TIGHTENING TORQUES

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A1.7

Tightening torques

A1-003

A1.8

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OPERATING PRINCIPLES

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A1.9

Operating principles Supply 4 or 6-cylinder system

6

7

4

M

5 +

-

3

1 -Supply valve 2 -Primary filter 3 -Supply pump 4 -Fuel filter 5 -Injection pump 6 -Injectors 7 -Fuel tank Supply pump Supply system (supply pump pressure) Injection pump pressure system Return system

A1-005

A1.10

332 693 - 06.2002 - FR- EN 60MR 05 029 - 10.2003

2

1

Operating principles Primary filter Filters : 149 microns

A1-006

Fuel filter 1 - Fuel outlet 2 - Fuel inlet 3 - Drain screw 4 - Filter

A1-007

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Fig. 3

A1.11

Operating principles Injection pump Injection pump STANADYNE (DB4)

A1-008

Description 1 - Drive shaft 2 - Distributor rotor 3 - Transfer pump vanes 4 - Pistons (4) 5 - Internal cam ring 6 - Hydraulic head 7 - Transfer pump pressure regulator 8 - Balance-weight cage 9 - Automatic advance 10 - Housing 11 - Regulator valve 12 - Recirculation valve 13 - Electric shut-offf device solenoid

A1.12

332 693 - 06.2002 - FR- EN 60MR 05 029 - 10.2003

Operating principles Injectors

A1-010

Description 1 - Injector nozzle 2 - Carbon deposit arrestor seal 3 - Needle 4 - Injector body 5 - Seal 6 - Injection pipe coupling 7 - Needle guide 8 - Union nut 9 - Spring retainer 10 - Adjustable spring

11 - Spacer 12 - Stroke adjustment screw 13 - Locknut 14 - T-union 15 - Locknut 16 - Pressure adjustment screw 17 - Nut 18 - Seal 19 - Clamp 20 - Olive 21 - Filter basket 22 - Injection pipe

332693 - 06.2002 - EN- EN 60 MR 05 029 - 10.2003

A1.13

Operating principles Personal notes :

A1.14

332 693 - 06.2002 - FR- EN 60MR 05 029 - 10.2003

CHECKS - ADJUSTMENTS

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A1.15

Checks - Adjustments Engine speed Checking the maximum no load speed Note: Before performing the maximum no load test, ensure that the accelerator lever contacts the stop (1). If not, adjust the cable (Refer to adjustment of controls in this chapter).

- Start the engine.

- Engage the 540 or 1,000 rpm power take-off (depending on the tractor type).

- Leave the engine running until it reaches its normal operating temperature.

- Check the rotational speed of the power take-off shaft using a tachometer.

- Adjust the stop screw (1) in order to achieve a rotational speed at the power take-off in accordance with the values specified in the table in the INJECTION SHEETS at the beginning of this chapter.

- Re-lock the stop screw.

Fig. 1 A1-011

IMPORTANT : If the screw locking seal is broken, it must be resealed immediately after adjustment.

Checking and adjusting the tick-over Note : Before checking the tick-over setting, ensure that the lever contacts the stop (2) (Refer to adjustment of controls in this chapter).

- Start the engine.

- Engage the 540 or 1,000 rpm power take-off (depending on the tractor type).

- Leave the engine running until it reaches its normal operating temperature.

- Position the accelerator lever in contact with the tickover stop.

- Check the rotational speed of the power take-off shaft using a tachometer.

- Adjust the stop screw (2) in order to achieve a rotational speed at the power take-off in accordance with the values specified in the table in the INJECTION SHEETS at the beginning of this chapter.

A1.16

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Checks - Adjustments Static adjustment of the injection pump It is MANDATORY to ensure that markings (A) on the front plate and (B) on the injection pump attachment flange are present before removing the pump from the engine.

If the setting mark (A) is missing from the front plate, scribe it as accurately as possible opposite mark (B).

- Static adjustment consists in accurately aligning mark (B) on the pump flange, with mark (A) on the front plate.

- Torque tighten the three nuts securing the pump to the front plate to 2,7 daN.m.

Fig. 2 A1-013

Dynamic adjustment of the injection pump The TIME-TRAC kit (1) electronically checks the start of injection in relation to the top dead centre (TDC) of the piston, enabling accurate adjustment of the injection pump to achieve optimum power whilst keeping exhaust gas emissions to a minimum.

The dynamic adjustment check is performed using 2 probes: - one probe is located on No. 1 injection pipe, to indicate the start of injection for the cylinder concerned, - the second probe is located on the engine flywheel casing and accurately transmits the piston top dead centre position (TDC).

These 2 probes are connected to a test set: the combined signals from these probes provide an instantaneous and accurate display of the DYNAMIC ENGINE ADJUSTMENT.

Fig. 3 A1-015

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A1.17

Checks - Adjustments Installation of the TIME-TRAC kit IMPORTANT :The probe which senses the start of injection should be installed on the injection pipe adjacent to the injector. If access to injection pipe No. 1 is difficult, the probe may be mounted on injection pipe No. 4 (4-cylinder engines) or No. 6 (6-cylinder engines).

Two types of probe may be used on the engine in order to detect the start of injection: • a 6-mm dia. clip-on probe (A), • an in-line probe (B).

1 -To install the clip-on probe (A), strip all the paint from the injection pipe at the position where the probe is to be fitted.

2 - Mount the probe (A) on the pipe (C)after cleaning it and stripping all the paint off.

3 - Tighten the probe and check it firmly grips the injection pipe (C).

4 - For engines where the in-line probe (B) is installed between the injector and the injection pipe, mount the stirrup (D).

5 - Install the harness (E) : - connect pin (F) to the probes (A) or (B) employed, - connect the spring clip (G) to ground, - connect plug (H) on harness (E) to the test set in the socket marked SR. 6 - Insert adjustment pin No. 5500 into the hole (J) in the engine flywheel casing to ensure the engine IS NOT stopped in the TDC position. If such were the case, the probe (K) could enter the adjustment hole on the engine flywheel and would then be damaged when the engine starts.

7 - Install the probe guide (M) in the engine flywheel casing (J) tapping it lightly in order to lock it in position.

8 - Insert probe (K) into the guide until it contacts the engine flywheel. Using a dial gauge, draw back probe (K) by 0.64 mm relative to the engine flywheel.

9 - Connect plug (N) for probe (K) to the socket on the test-set marked MP.

Fig. 4 A1-017

Fig. 5 A1-018

Fig. 6 A1-019

Fig. 7 A1-020

A1.18

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Checks - Adjustments Checking the injection pump dynamic adjustment 1 - Engine STOPPED. Press the "ON/CLEAR" push-button.

The display should indicate: "R = 0".

2Press the "MAG PROBE" (magnetic probe).

The display should indicate: "Trig level" (trigger level) 30 %.

Fig. 8 3 - Change this to 70 % and press "ENTER".

The display should indicate: "Offset": 20.0°.

A1-021

4 - Change the offset to 0° and press "ENTER".

The display should indicate: "Calibrate" ?

5 - Start the engine and press "ENTER".

6 - Run the engine at 1,300 rpm. Press "ENTER".

The display should indicate: "Calilbrating" followed by engine speed (rpm) and adjustment.

Note: If the display indicates «NO PROBE», this means that the probe mounted on the engine flywheel casing is not properly installed (the mounting distance is greater than 0.64 mm) or that some debris is lodged behind the engine flywheel.

Check that the mounting distance is correct or clean behind the engine flywheel. Insert a soft wooden peg into the engine adjustment pin hole whilst the engine is ticking over.

Fig. 9 A1-022

7 - Allow the engine to reach its normal operating temperature.

Fig. 10 A1-023

Fig. 11 A1-024

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A1.19

Checks - Adjustments 8 - Run the engine at full throttle then gradually apply a load until it reaches nominal speed.

Read the dynamic adjustment value and compare this with the value provided in the specifications at the beginning of this chapter.

Note: a negative value indicates that the signal from the clip-on probe is poor. Check the probe and the pipes are clean and that the installation is correct.

9 - Record the engine speed (rpm) and the adjustment angle.

IMPORTANT :stop the engine before attempting to set the adjustment. There is a risk of the injection pump seizing if the setting is performed whilst the engine is running.

Fig. 12 A1-025

10 - Stop the engine.

If the dynamic adjustment is retarded by more than 8 degrees in relation to the adjustment marks applied at the manufacturer’s, prior to delivery, on the pump flange and on the front plate, this may indicate that the advance on the pump is not functioning correctly. Check the following points: - replace the fuel filter, - check the pressure between the supply pump and the injection pump, - if none of the above checks provides conclusive results, remove the pump and have it repaired in an approved diesel engine repair workshop.

Setting the dynamic adjustment of the rotary injection pump (Fig. 13) 1 - Loosen the nuts (1) on the injection pump attachment flange and set the pump adjustment.

To advance the pump adjustment, turn it clockwise (2) as viewed from the rear (engine flywheel end).

To retard the adjustment, turn it anti-clockwise (3).

A 1.524 mm displacement of the injection pump flange is equivalent to 2 degrees of engine adjustment.

2 - Torque tighten the pump attachment collar-nuts to 2,7 daN.m. Start the engine and check again the dynamic adjustment of the injection pump. Set the adjustment as required.

3 - After completing all the final settings and achieving satisfactory engine performance, grind away the original adjustment mark and scribe a new mark (B) on the pump flange, in line with mark (A) on the front plate.

Fig. 13 A1-026

Fig. 14 A1-027

A1.20

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Checks - Adjustments Injector adjustment Preliminary operations 1 - Clamp the injector in a vice and loosen locknut (A).

2 - Then back off the needle rise adjustment screw (B) by 3 turns.

3 - Finally loosen locknut (C).

4 - Connect the injector to the calibration unit, inclining it at about 30° from the vertical. Check the sealing at all the connections.

5 - Close the valve on pressure gauge No. 8168 and quickly pump several strokes in order to bleed the injector, and for the needle to position itself.

WARNING : the injector nozzle must never be pointing towards the person performing the adjustment. The jet escaping from a port can pierce clothing and skin, and cause serious infections. It is recommended to contain the jet within a transparent container.

Fig. 15 A1-028

Cracking pressure adjustment Note : it is recommended to aim for the maximum rather than the minimum value. Repeat the adjustment in order to obtain a reliable result.

Open the valve on the calibration unit and, whilst operating the pump, tighten or loosen the opening pressure adjustment screw (D) until the correct pressure is achieved (refer to ‘Specifications’).

To increase the pressure, tighten the screw. Close the valve and quickly operate the pump several times to open and close the injector needle. Open the valve and check the cracking pressure; correct it if necessary.

Torque tighten locknut (C) to 1 daN.m.

A1-029

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Fig. 16

A1.21

Checks - Adjustments Needle stroke adjustment Carefully turn the stroke adjustment screw (B) inside the pressure adjustment screw (D) until screw (B) contacts the needle (E). Check as follows: - Increase the pressure beyond cracking pressure, a few drops of fuel may bleed, but this flow must remain limited.

- Unscrew (B) by 3/4 turn to achieve a correct stroke of the needle.

- Torque-tighten locknut (A) to 0.5 daN.m, whilst firmly holding the screw.

- Perform another accurate cracking pressure adjustment.

Note : If after cleaning and servicing operations, the characteristic hissing noise is not heard, it is possible that the injector parts are incorrectly aligned. In such case, tighten and loosen the pressure adjustment screw (D) several times and again adjust the needle stroke, as described above.

Disconnect the injector from the calibration unit and fit the protection cap.

A1-030

Fig. 17

A1.22

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Checks - Adjustments Shut-off solenoid valve functional check 1 - Disconnect the lead from the solenoid valve (A).

2 - Remove the valve, checking whether the plunger spool jams in the bore.

3 - Use an ohmmeter to measure the coil resistance.

It should be 4 â„Ś.

4 - Use a 12-volt supply to check the plunger spool retracts correctly.

Connect the positive lead to the socket terminal and the negative lead to the solenoid valve body.

From the relaxed position, the plunger spool should retract inside the solenoid valve body when the voltage is applied.

If the resistance is not to specification, and/or if the plunger spool does not retract, replace the solenoid valve.

5 - Re-install the solenoid valve and torque tighten to between 1.5 and 2 daN.m.

Fig. 18 A1-037

Cold-start switch functional check 1 - Disconnect the injection pump harness from the cold-start switch socket (B).

2 - Remove the cold-start switch (C) from the thermostat/water manifold unit.

3 - Immerse the switch in water at 60 °C for a few minutes.

4 - Check that the switch contact is open.

5 - Replace it if defective.

6 - Install the switch in the thermostat/water manifold unit and tighten to the specified torque.

Tightening torque: 5 daN.m.

7 - Connect the injection pump harness to the coldstart switch socket.

8 -Check the continuity and the resistance of the solenoid (D) : R = 23 â„Ś.

Fig. 19 A1-047

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A1.23

Checks - Adjustments Supply pressure check 1. Use the tool (1) réf. 60 05 005 521 as shown in Fig. 20.

2. Start the engine. Check the pressure of the supply pump according to the «specifications» provided at the beginning of this chapter.

3. If the pressure is too low, disconnect the fuel pipe at the filter inlet and direct it into a graduated container. The flow must be 1,5 l/m, engine stopped.

Fig. 20 A1-046

Fig. 25

A1.24

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REMOVAL / INSTALLATION

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A1.25

Removal/installation Fuel filter replacement To replace the fuel filter: 1 - Loosen retaining ring (A) and remove the filter body (B).

2 - Recover the retaining ring and the settling bowl (C) and install them on the new filter.

3 - Install the new filter, taking care to align the markings on the filter with the slots in the filter head unit base.

4 - Tighten the retaining ring (A) until it locks.

5 - Bleed the fuel filter.

Note: Correct positioning of the retaining ring is achieved when a relaxation is felt during tightening.

Injection system bleeding

Fig. 1 A1-032

1st case After replacing the fuel filter 1 - Loosen the bleed screw (D) located on the filter head.

2 - Switch on the ignition in order to completely bleed the air.

3 - Tighten the bleed screw (D). The engine should start.

2nd case After running the system completely dry 1 - Perform operations from 1 to 3 described under the 1st case.

2 - Loosen pipe (F) in order to completely bleed the air. Tighten pipe (F).

3 - Whilst turning the engine using the starter motor, loosen the couplings (H) until the fuel escaping from the coupling is free of air bubbles. Tighten the coupling whilst still turning the engine.

4 - Repeat the procedure for the other injectors until the engine starts.

Fig. 2 A1-033

Fig. 3 A1-035

A1.26

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Removal/installation Injection pump removal It is MANDATORY to ensure that markings (A) on the front plate and (B) on the injection pump attachment flange are present before removing the pump from the engine. If required, scribe them (Fig. 4).

IMPORTANT: Never use steam or cold water to clean a hot or operating injection pump.

1 - Disconnect the electrical cables and the accelerator cable.

2 - Disconnect the fuel return pipe (A).

3 - Disconnect the fuel supply pipe (B).

4 - Disconnect the injection pipes (C).

Fig. 4 A1-027

IMPORTANT: Take care not to turn the injection pump couplings when loosening the injection pipes, as this may cause internal damage to the pump.

5 - Blank off all the couplings (pump and pipes); do not use fraying materials.

6 - Remove the plug from the distributor housing.

7 - Using the engine flywheel turning tool No. 60 05 005 501, position the engine flywheel and lock it with adjustment pin No.60 05 005 500.

8 - Remove the nut and washer securing the injection pump drive pinion to the pump shaft.

9 - Mount special tool No. 60 05 005 514 (1) (Fig. 6) on the pinion.

10 -Remove the three nuts (D) securing the pump to the engine front plate.

11 -Turn the screw on the tool clockwise until the pump shaft lifts off the tapered seat for the drive pinion.

12 -Disengage the pump from the three studs by pulling it backwards.

Fig. 5 A1-036

Fig. 6

Note: Take care not to lose the half-moon key for the pump shaft when removing the injection pump.

A1-038

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A1.27

Removal/installation Injection pump installation 1 - Fit a new seal on the front face of the injection pump attachment flange.

2 - Slide the injection pump onto the mounting studs, whilst at the same time inserting the pump shaft into the drive pinion.

3 - Hand-tighten the nuts (D).

4 - After firmly engaging the drive pinion against the tapered part of the shaft, fit the washer and nut (E).

5 - Torque-tighten the nut (E) (Fig. 8) to 20 daN.m.

6 - Remove the setting pin.

7 - Align adjustment mark (B) with the mark (A) on the front plate (Fig. 9).

8 - Torque-tighten the nuts (D) to 2.7 daN.m.

9 - Tighten the injection pipes (C), then the return (A) and supply (B) pipes (Fig. 7).

10 -Connect up the various electric cables which were disconnected prior to removal of the pump.

11 -Connect the accelerator cable to the pump.

12 -Bleed the air from the fuel system.

Fig. 7 A1-036

Fig. 8 A1-039

Fig. 9 A1-027

A1.28

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Removal/installation Injector removal 1 - Loosen nuts (B) to disconect the leak off pipes (A) and the T-fittings.

2 - Disconnect the injectors from the injection pipes (D).

3 - Remove screw (C).

4 - Extract the injectors from the cylinder head using extractor tool No.60 05 005 514 (1).

IMPORTANT: Do not use a screwdriver or similar tool, as this could cause irreparable damage to the injectors.

Fig. 10 A1-040

Fig. 11 A1-041

Injector seating cleaning (if required) Remove the carbon deposit in the injector housings using tool No. 60 05 005 519 (2).

IMPORTANT: Always turn the tool clockwise, even when removing it, in order to prevent from blunting it.

Fig. 12 A1-042

Injector installation IMPORTANT: The lower carbon deposit arrestor seal (D) must be replaced every time an injector is removed.

Slide the top seal (E) onto the injector body. Position installation tool No. 60 05 005 513 (3) on the injector nozzle and slide the new seal (D) onto the injector body until it seats properly in the groove.

Fig. 13 A1-043

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A1.29

Removal/installation Carrying over of the adjustment mark onto the front plate Note: Front plates provided as spare parts are supplied unmarked.

In order to carry over the front plate marking from the original plate to the spare plate, make up a template from aluminium sheet as shown below (Fig. 15).

- Mount the template on the original front plate using three screws (Part No. 60 012 874) and carry over the mark from the original front plate (A) onto the template (B) with a pencil.

- Then mount the template on the replacement front plate and carry over the template mark onto the new plate (C) using a scriber.

Fig. 14 A1-044

Template for the front plate marking

A1-045

A1.30

Fig. 15

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CONTROL ADJUSTMENTS

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A1.31

Control adjustments Accelerator control adjustment The cable length should be adjusted in the following cases: - after replacing the cable, - after adjusting the tick-over and maximum no-load speed, - after removing the injection pump.

1 - Attach the control cable to the injection pump accelerator lever (1).

2 - Connect the control cable to the accelerator pedal (2).

3 - In the cab, check the hand control lever (3) is on the minimum position (A).

4 - Adjust the hand control cable in order to achieve the dimension 265 mm.

5 - Adjust the foot control cable in order to achieve the dimension 61 mm.

6 - Correct adjustment should enable the engine throttle control lever (5) to return to the mechanical stop (1) when the lever or pedal are on the minimum position, and allow extension of the accelerator control spring on the pump when the hand lever or pedal are on the maximum position.

Fig. 1 A1-046

Check that the pedal stroke is completely covered by the hand control stroke.

Position A: tick-over speed.

Position B: maximum speed.

Markings 4: cable adjustments.

B

A

2

Bare floor

265 mm

3

61 mm

Floor mat

4

5

1 4

4

A1-048

A1.32

60 05 029 693 - 10.2003 - EN

Fig. 2

DIAGNOSTIC SHEETS

60 05 029 693 - 10.2003 - EN

A1.33

Diagnostic sheets Note: before any diagnosis is made, check that the fuel is in sufficient quantity and quality.

"Cold engine start failure" sheet

A1-050

A1.34

60 05 029 693 - 10.2003 - EN

Diagnostic sheets "Irregular engine running" sheet

A1-051

60 05 029 693 - 10.2003 - EN

A1.35

Diagnostic sheets "Grey or black smoke emission" sheet

A1-052

A1.36

60 05 029 693 - 10.2003 - EN

Diagnostic sheets "White smoke emission" SHEET

A1-053

60 05 029 693 - 10.2003 - EN

A1.37

Diagnostic sheets "Checking the fuel supply system" sheet

A1-054

A1.38

60 05 029 693 - 10.2003 - EN

TOOLS

06.2002 - EN - EN 60MR 05 332 029 -693 - 10.2003

A1.39

Injection tools

60 05 005 500

5500

- Adjustment pin

60 05 005 513

- Fuel pipe (calibrating pump)

A1.40

5503

- Pencil injector extractor

5513

- Installation tool of injection seal

60 05 005 515

60 05 005 503

60 05 005 514

5514

- Injection pump extractor

5515

60 05 005 519

- Bore cleaning tool "pencil injectors"

06.2002 - EN - EN 60MR 05 332 029 -693 - 10.2003

5519

Injection tools

60 05 005 521

5521

- Pressure control kit - fuel supply system - supercharging system (pressure gauge from 0 to 2000 mbars) 60 05 005 530

60 05 005 528

5528

- Flywheel turning tool

5530

Time Trac kit spare parts: - 1 test set (60 05 005 564), - 1 magnetic probe TDC (60 05 005 562), - 1 injector in-line probe (60 05 005 561),

- Time Trac Kit Dynamic adjustment check 77 01 388 168

8168

- Injector calibrating pump

332 693 - 06.2002 - EN- EN 60 MR 05 029 - 10.2003

A1.41

Injection tools Personal notes:

A1.42

06.2002 - EN - FR 60MR 05 332 029 -693 - 10.2003

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