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10
C87 ENT M65.10
C87 ENT M62.11
C87 ENT M65.11
TECHNICAL AND
REPAIR MANUAL
MAY 2012 EDITION
C87 ENT M62.10 / C87 ENT M65.10
1.2 MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
FOREWORD
In particular
- Use of unsuitable fuels and oils may compromise the
engine's regular operation, reducing its performance,
reliability and working life.
- Exclusive use of FPT Original Parts is a necessary
condition to maintain the engine in its original integrity.
- Any tampering, modifications, or use of non-original
parts may jeopardize the safety of service personnel and
boat users.
To obtain spare parts, you must indicate:
- Commercial code, serial number and the indications
shown on the engine tag;
- The number of the spare part. This can be found in the
spare part catalog.
The information provided below refers to engine
characteristics current at the date of publication.
FPT reserves the right to make modifications at any time and
without advance notice, to meet technical or commercial
requirements or to comply with local legal and regulatory
requirements.
SECTION CONTENTS
Section Page
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . 43
3. ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . 51
4. DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 71
5. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 87
6. SERVICING OPERATIONS
ON INSTALLED ENGINE . . . . . . . . . . . . . . . 93
7. TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8. OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . 119
SECTION 1
Overview
Page
VIEWS OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 7
IDENTIFICATION DATA . . . . . . . . . . . . . . . . . . . . 13
COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . . . . 14
Turbocompressor . . . . . . . . . . . . . . . . . . . . . . . 17
SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Page Page
Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . . 36
Camshaft sensor . . . . . . . . . . . . . . . . . . . . . . . . 37
SYSTEM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . 39
Run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Pre-injection . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Idling adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Fuel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.7
C87 ENT M62.11 / C87 ENT M65.11
.
VIEWS OF ENGINE
M62.10 / M65.10 Engines
Figure 1
174584
Figure 2
177445
Figure 3
174585
FRONT VIEW
Figure 4
174582
REAR VIEW
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.9
C87 ENT M62.11 / C87 ENT M65.11
Figure 5
174581
TOP VIEW
C87 ENT M62.10 / C87 ENT M65.10
1.10 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 6
174584
Figure 7
174583
Figure 8
174585
FRONT VIEW
Figure 9
174582
REAR VIEW
C87 ENT M62.10 / C87 ENT M65.10
1.12 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 10
174581
TOP VIEW
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.13
C87 ENT M62.11 / C87 ENT M65.11
IDENTIFICATION DATA
Figure 11
174575
1. Trade name/version - 2. Homologation - 3. Production serial number- 4. Maximum rated power - 5. Family of engines -
6. Trade name - 7. Design number- 8. Programming code - 9. Year of production - 10. Homologation number.
Figure 12
143677
The engine identification data are stenciled on a tag positioned over the engine coolant tank
C87 ENT M62.10 / C87 ENT M65.10
1.14 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
COMMERCIAL CODE
The purpose of the commercial code is to make it easier to understand the characteristics of the product, categorizing the engines
according to their family, origins and intended application. The commercial code, therefore, cannot be used for technical purposes
and to identify the engine's components, this is the purpose of the ENGINE S/N.
C 87 E N T M 62 . 1 0
65 1
VERSION
VERSION:
TURBOCOMPRESSOR:
1 = COOLED
2 = NOT COOLED
APPLICATION: M = MARINE
The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize
its application and power output level. It is stamped on the side of the crank-case.
F 2 C H 0 6 8 6 A * A 0 0 1
VARIANTS TO
BASIC ENGINE
POWER RANGE
NO. OF CYLINDERS
ENGINE
DESIGN ITERATION
143694
Figure 14 Figure 16
134384
Turbocompressor
Figure 15
143670
143697
Figure 18
143671
Figure 19
174577
1. Sea water outlet to overboard discharge - 2. Sea water inlet from after cooler - 3. Coolant inlet from thermostatic valve -
4. Coolant outlet to pump.
C87 ENT M62.10 / C87 ENT M65.10
1.20 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 20
05_066_C
1. Bypass flow to engine - 2. Outflow from engine - 3. Outflow from exhaust manifold - 4. Inflow to exhaust manifold -
5. Flow to sea water heat exchanger - 6. Temperature sensor.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.21
C87 ENT M62.11 / C87 ENT M65.11
143698
Sea water
C87 ENT M62.10 / C87 ENT M65.10
1.22 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
174578
Sea water
Description and operation The configuration of the discharge lines depends on the
Sea water, drawn from under the keel and necessarily filtered, choice of a dry chimney exhaust, or a mixed one. The
is drawn by the pump and sent to the supercharger air heat outlet pipe will carry the water directly to the overboard
exchanger and from there to the water/water heat discharge or, if the water/exhaust gas mixer solution is
exchanger of the closed cooling loop; only after this will it adopted, a conduit will connect the outlet of the last heat
flow through the heat exchanger for the gearbox oil, if one exchanger with the mixer inflow junction pipe.
is provided.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.23
C87 ENT M62.11 / C87 ENT M65.11
Figure 23
139550
Figure 24
Delivery oil
Description and operation The blow-by vapor condenser, provided with filter and safety
The gear pump, rotated by the gears at the rear of the valve, is located on the upper part of the timing mechanism
flywheel sends the lubricating oil directly to the heat lid. The vapors, after returning to the liquid state, will flow
exchanger which, incorporated in the block and lapped by from the vapor condensor into the sump. The engine is
the coolant, reduces temperature to maintain optimal provided with the pre-lubrication system on request. This can
lubricating capability. inject enough oil into the engine's ducts to guarantee a totally
The thermostatic valve that regulates oil flow is located at the safe start.
inlet of the heat exchanger, opening the bypass pipe if The operation of the electrical pre-lubrication pump (on
temperature falls below calibration temperature. request), is automatically controlled by the ECU electronic
From the output of the heat exchanger, the oil is sent to the unit.
filter assembly and from this back to the engine block to This system, with the aid of the flow-switching solenoid valve,
lubricate all anti-friction elements. also permits the oil sump to be emptied and filled.
Detailed descriptions of this operation are provided in
Section 3.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.25
C87 ENT M62.11 / C87 ENT M65.11
Figure 25
SUPPLY
The Common Rail supply system is equipped with a special pump that maintains fuel at constant high pressure regardless
from phase and cylinder under injection and accumulated in an common duct shared by all electric injectors.
Therefore, fuel at injection pressure, calculated by ECU, is always available at electric injection inlet.
When the solenoid valve of an injector is energized by ECU, in related cylinder the injection of fuel taken directly from the
rail takes place.
Figure 26
149570
High pressure
Low pressure
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.27
C87 ENT M62.11 / C87 ENT M65.11
High pressure
Low pressure
127140
1. High-pressure pump - 2. Fuel filter - 3.Tank - 4. Fuel pre-filter - 5.ECU - 6. Electric injectors - 7.Common Rail -
8. Pressure sensor
ATTENTION
After high-pressure pipeline installation, during the following 20 hours of work, frequently check engine oil level.
( IT MUST NOT INCREASE ).
C87 ENT M62.10 / C87 ENT M65.10
1.28 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Pump assembly
Figure 28
1. Connector fuel outlet to rail - 2. High pressure pump - 3. Pressure control solenoid - 4. Fuel inlet connector from filter -
5. Fuel outlet connector to recirculation manifold - 6. Fuel inlet from tank - 7. Fuel outlet connector from low pressure
pump to filter - 8. Low pressure pump.
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
The gear wheel pump is assembled on the rear part of the It is set into rotation by the high pressure pump shaft. Under
high pressure pump. It transfers the fuel from the tank to the normal operation conditions, the fuel flow inside the
high pressure pump. mechanical pump is illustrated in Figure 29.
Figure 30
A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve.
In the case of overpressure at the outlet, Figure 30, the recir (2), recirculating the fuel in excess inside the pump and
culation valve comes into action. keeping a pressure rating equal to that of the setting of the
The existing pressure, overcoming the spring valve elastic valve.
strength (1), connects the outlet with the inlet through a duct
C87 ENT M62.10 / C87 ENT M65.10
1.30 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 31
A. Fuel inlet from tank - B. Fuel oulet to filter - 1. Recirculation valve - 2. By-pass valve.
Figure 32 Figure 33
High pressure pump During the induction stroke, the pumping, driven by the cam
located on the pump shaft, is fed through the pumping feeding
Figure 34 duct. The amount of fuel to send to the pumping is set by the
D-D section pressure control solenoid according to the PWM control
received by the electronic Central Unit. During the
compression stage of the pumping, the fuel reaches such a
pressure to open the delivery valve to common rail and
supply it through the outlet.
Figure 36
C-C section
Figure 35
B-B section
1, 3, 6. Pumping feed ducts - 2. Pump lubrication ducts -
4. Pumping feed main duct - 5. Pressure control solenoid -
7. Control exhaust duct - 8. Low pressure limiter valve -
9. Fuel feed duct from filter - 10. Fuel outlet.
In the section of Figure 36 the low pressure fuel paths inside
the pump are represented. The pumping feed main duct (4),
pumping feed ducts (1, 3, 6), ducts used for pump lubrication
(2), the pressure control valve (5), the low pressure limiter
valve (8) and the fuel exhaust (10), are outlined. The pump
shaft is lubricated by the fuel through the delivery and
backflow (2) ducts. The control valve enables to define the
fuel amount by which feeding pumpings; the excess fuel
backflow through duct (9).
The lower pressure limiter valve in addition to operate as
manifold of the high pressure pump fuel drainage, also keeps
pressure constant at the regulator inlet.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.33
C87 ENT M62.11 / C87 ENT M65.11
Figure 37
A-A section
in the rail.
The thereby-generated pressure makes the exhaust valve 1. Rail - 2. Fuel return - 3.Pipelines to injectors - 4. Fuel
open and the compressed fuel reaches the high-pressure supply to high pressure pump - 5. Pressure sensor -
circuit. 6. Overpressure valve
The pumping element compresses the fuel till the top dead The rail volume is of reduced sizes to allow a quick
center (delivery stroke) is reached. Afterwards, the pressure pressurisation at startup, at idle and in case of high flow-rates.
decreases till the exhaust valve is closed. It anyway has enough volume as to minimise use of plenum
The pumping element piston goes back towards the bottom chambers caused by injectors openings and closings and by
dead center and the remaining fuel is decompressed. the high-pressure pump operation. This function is further
enabled by a calibrated hole being set downstream of the
When the pumping element chamber pressure becomes less high-pressure pump.
than the supply pressure, the intake valve is again opened and
the cycle is repeated. A fuel pressure sensor (5) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a
The delivery valves must always be free in their movements, feed-back information, depending on which the rail pressure
free from impurities and oxidation. value is checked and, if necessary, corrected.
The rail delivery pressure is modulated by the electronic
control unit, through the pressure regulator solenoid valve.
The pump is lubricated and cooled by the fuel. Electroinjector
The radialjet pump disconnection reconnection time on
the engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting. Figure 39
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
114255
Figure 40 Figure 41
08_053_C
08_024_C
Figure 42 Figure 43
Figure 44 Figure 45
Fuel temperature sensor It provides the primary indication for the reckoning of the fuel
amount to be injected.
Figure 46 It is operated by the linkage of the controls on bridge or
assisted, produces in output a potentiometric variation of the
voltage which supplies it, in relation to the position where the
throttle lever is set.
A simultaneous safety indication is provided by the internal
switch to confirm the acceleration position: minimum - out
of minimum.
Such an indication in addition to the self-adative strategies of
the potentiometric signal, is used in the case of anomalies to
manage limp-home strategies, that enables to get back to
harbour notwithstanding the potentiometer being faulty.
Figure 47 114620
Ref Description
1 Earth
2 Pressure
3 Power supply
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERVIEW 1.39
C87 ENT M62.11 / C87 ENT M65.11
Cut off
It consists of non injecting fuel during the engine deceleration
phase. The function is operating until the idle speed is
reached below which it would be impossible to restore
engine thermic operation.
Derating
It can be considered as a recovery programme. It does not
produce a storage of an anomaly record. It is caused by the
recognition of fuel high temperature, coolant, or comburent
air. Derating consists of reducing the torque delivered by the
engine to preserve it from operation inefficiency. It takes
place when overcoming preset thresholds, in a way
proportional and gradual to the amount of the overcoming
of parameter; it does not entail fault signalling on the
instrument panel.
Recovery
It is a special way of control and management characterised
by the adoption of a number of strategies which enable the
system to operate even in the case selfdiagnosis has
recognized the presence of anomalies. In the majority of
cases seafaring can be continued regularly or with reduced
performance.
Adopting a recovery strategy entails the storing of an
anomaly code and the corresponding limitation of the
maximum power rating delivered by the engine.
The power rating limitation due to recovery strategy is active
up to the stopping of the engine even if the anomaly detected
is not there anymore. The blink code light on the instrument
and control panel will turn on only for the most serious
events.
After run
The stage following after every engine stop. It is characterised
by the delay in deenergizing the main supply solenoid
contained inside the ECU EDC. During this phase the central
unit is still powered for some seconds, during which the data
that have characterised the optimized management of the
engine up to that moment, are transferred from the main
volatile memory to the EEPROM non volatile memory; these
data will then be available for the next starting.
These data can be summarised into:
- Management modes (idle speed, torque delivery balance,
smoke limit...);
- Threshold setting min/max of signal recognition;
- Fault memory.
At every start up it is important to have available the data that
optimize the management and the engine behaviour in terms
of TORQUE AND POWER DELIVERY. It is therefore
mandatory to use engine stopping strategies (e.g. battery
disconnection) not different from those prescribed by the
manufacturer (key in OFF position) or which may prevent
the correct execution of the after run function.
C87 ENT M62.10 / C87 ENT M65.10
1.42 OVERVIEW MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 TECHNICAL DATA 2.43
C87 ENT M62.11 / C87 ENT M65.11
SECTION 2
Technical data
Page
SPECIFICATIONS C87 ENT M62.10 / M62.11 . . . . 47
Injection system
Type HPCR
System Bosch EDC7 UC31
Maximum injection pressure bar 1600
Cooling
Closed coolant loop with 50% mixture of water/Paraflu 11 or
sea water heat exchanger equiv. Compliant with SAE J 1034
specification
Total coolant quantity liters 38
Engine-only capacity liters 16
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm (Freshwater) l/h 22440
Temperature regulation with thermostatic valve
Initial opening C 68 78
Sea water line forced circulation
Sea water pump centrifugal self-priming
Max. pump capacity (Sea water) l/h 20000
Electrical system
Nominal voltage Vcc 24
Self-regulated alternator:
Voltage Vcc 28
Maximum current intensity A 90
Electrical starter motor:
Nominal voltage V 24
Absorbed electrical power W 4500
Recommended batteries capacity Ah 120
Current discharge at - 18 C (SAE J 537) A 900
C87 ENT M62.10 / C87 ENT M65.10
2.46 TECHNICAL DATA MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Weights
Without liquids and without gearbox kg 940
Dimensions
Figure 1
143679
Sizes in mm
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 TECHNICAL DATA 2.47
C87 ENT M62.11 / C87 ENT M65.11
ATTENTION
Low temperature diesel
EN 590 specifications distinguish different classes of diesel fuel, identifying the characteristics of those best suited to low
temperatures. It is entirely up to the Oil companies to comply with these regulations, which foresee that fuels suited to the
climactic and geographic conditions of the various Countries be distributed.
C87 ENT M62.10 / C87 ENT M65.10
2.48 TECHNICAL DATA MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
ATTENTION
Low temperature diesel
EN 590 specifications distinguish different classes of diesel fuel, identifying the characteristics of those best suited to low
temperatures. It is entirely up to the Oil companies to comply with these regulations, which foresee that fuels suited to the
climactic and geographic conditions of the various Countries be distributed.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 TECHNICAL DATA 2.49
C87 ENT M62.11 / C87 ENT M65.11
Injection system
Type HPCR
System Bosch EDC7 UC31
Maximum injection pressure bar 1600
Cooling
Closed coolant loop with 50% mixture of water/Paraflu 11 or
sea water heat exchanger equiv. Compliant with SAE J 1034
specification
Total coolant quantity liters 38
Engine-only capacity liters 16
Expansion tank standard
Forced circulation centrifugal pump
Flow rate at maximum rpm l/h 42300
Temperature regulation Initial opening with thermostatic valve
C 68 78
Sea water line forced circulation
Sea water pump centrifugal self-priming
Max. pump capacity l/h -
Electrical system
Weights
Without liquids and without gearbox kg 970
Dimensions
Figure 1
143679
Sizes in mm
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ELECTRICAL EQUIPMENT 3.51
C87 ENT M62.11 / C87 ENT M65.11
SECTION 3
Electrical equipment
Page
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . 53
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 61
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Mitsubishi 90A . . . . . . . . . . . . . . . . . . . . . . . . . 62
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Nippondenso model . . . . . . . . . . . . . . . . . . . 63
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
EQUIPOTENTIAL CONNECTIONS TO
ENGINE GROUND . . . . . . . . . . . . . . . . . . . . . 68
ELECTRICAL EQUIPMENT
Figure 1
10_032_C
1. Eelectronic Unit - 2. Mm Connector - 3. Wiring harness to be manufactured by the yard - 4.M Sensor for the presence of
water in the fuel - 5. Sedimenting pre-filter - 6. Power line for electric starter motor and alternator - 7. Relay box -
8. JECCM and JECCF connectors - 9. Analog to digital converter module -10. JG connector - 11. JSV connector - 12. JQA
connector set for connection to the main analog instrument panel - 13. Connector JE - 14. Connector JH - 15. Connector
JQ - 16. Connector J3 - 17. Connector J4 - 18. Connector - 19. Connector J2. - 20. Extension cables available in 3,5,7,10
and15
The electrical equipment of the engine comprises a series of Together with the coupling of all the wiring connectors it is
components provided separately from the engine to enable necessary to carry out the connection wiring (3) for the
an easy and diversified installation, according to the Yard's water in fuel sensor (4), the power network and the
design choices. The need to make accessible, at sea or connection of the accumulator with the engine wiring, in
underway, the controls to the electrical components and to order to complete the installation In order to activate the
the connector for diagnostics contained in the relay box may function which stops the engine in case of excitation, it is
be met through different installation arrangements. necessary to connect the JECCM and JECCF connectors with
each other.
C87 ENT M62.10 / C87 ENT M65.10
3.54 ELECTRICAL EQUIPMENT MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Engine cable
Figure 2
143680
10_034_C
EDCA. EDC connector A - C. Camshaft sensor - B. Crankshaft sensor - VS. Oil pressure/temperature sensor -
HP. Combustion air pressure/temperature sensor - ZH. Fuel high-pressure pump sensor - A. Fuel temperature sensor -
F. Coolant temperature sensor - PR. Rail pressure sensor - 1. Electroinjector - EDCA1. EDC connector A1
3.56
Figure 4
Wiring layout engine
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
ELECTRICAL EQUIPMENT
A. Fuel temperatu
1. Connector JB - 2. Oil filter clogging (U) - 3. Connector CAN BUS electronic handwheels (JD)- 4. Connector for RINA (JR) - 5. Water in fuel prefilter sensor
(M) - 6. Low coolant level sensor (J) - 7. Electrical oil pump (PO) - 8. Electrical valve oil charge/discharge (EC) - 9. Overspeed pick-up (BA) - 10. Exhaust gas
temperature sensor for gauge (O,O1) - 11. Accelerator potentiometer position sensor (PA) - 12. EDC connector B (EDC B) - 13. GN. Neutral gear sensor -
14. Connector for inverter (JINV) - 15. Oil pressure temperature sensor gear (VI) - 16. Oil temperature sensor gear box (SI) - 17. Clogging fuel filter sensor (Z)
- 18. Air filter clogging (K) - 19. Air filter clogging (K1) - 20. Blow by clogging sensor (X) - 21. Starter motor (MM) - 22. Grid heater relay (GH) -
23. Electrical valve by-pass (GX) - 24. Alternator (GG) - 25. Alternator B+ (B+).
143681
MAY 2012
MAY 2012
Figure 5
Wiring layout engine
ELECTRICAL EQUIPMENT
JB. Connector JB - JINV Connector for inverter - JD Connector CAN BUS electronic handwheels - JR. Connector for RINA -
K1 Air filter clogging - K. Air filter clogging - Z. Clogging fuel filter sensor - U. Oil filter clogging - O1. Exhaust gas temperature sensor for gauge -
O. Exhaust gas temperature sensor for gauge - X. Blow by clogging sensor - SI. Oil temperature sensor gear box - VI. Oil pressure temperature sensor gear -
J. Low coolant level sensor - M. Water in fuel prefilter sensor - GG. Alternator - B+. Alternator B+ - EDC B. EDC connector B - PA. Accelerator
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
potentiometer position sensor - GN Neutral gear sensor (in installation with no sensor, do not remove the cap of the GND connector to avoid compromising
start engine function) - GH. Grid heater relay - GX. Electrical valve by-pass - BA. Overspeed pick-up - MM. Starter motor - PO. Electrical oil pump -
EC. Electrical valve oil charge/discharge
3.57
10_035_C
C87 ENT M62.10 / C87 ENT M65.10
3.58 ELECTRICAL EQUIPMENT MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
177444
1. Air filter - 2. Common rail high pressure injection pump - 3. Air/sea-water heat exchanger - 4. Air pressure/temperature
sensor - 5. Chimney exhaust gas (pot.) - 6. Engine coolant-sea water heat exchanger - 7. Oilfilter - 8. Coolant temperature
sensor - 9. Thermostatic valve - 10. Alternator - 11. Inverter oil heat exchanger - 12. Electrical starter motor - 13. Sea water
pump - 14. Fuel Filter.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ELECTRICAL EQUIPMENT 3.59
C87 ENT M62.11 / C87 ENT M65.11
Figure 7
174587
1. Air filter - 2. Common rail high pressure injection pump - 3. Air/sea-water heat exchanger - 4. Air pressure/temperature
sensor - 5. Chimney exhaust gas (pot.) - 6. Engine coolant-sea water heat exchanger - 7. Oil filter clogging - 8. Coolant
temperature sensor - 9. Thermostatic valve - 10. Alternator - 11. Inverter oil heat exchanger - 12. Electrical starter motor -
13. Sea water pump - 14. Fuel Filter.
C87 ENT M62.10 / C87 ENT M65.10
3.60 ELECTRICAL EQUIPMENT MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 8
10_030_C
1. Connector JB - 2. Coolant expansion tank - 3. Coolant refill cap - 4. Coolant low level sensor - 5. Lifting U-bolt - 7. Oil
refill cap - 8. Clogged fuel filter sensor - 9. Clogged air filter sensor - 10. Cooled turbo-charger - 11. Exhaust gas and sea
water discharge - 12. Camshaft sensor - 13. Accelerator potentiometer position sensor - 14. Oil dipstick - 15. Cooled
exhaust manifold - 16. Oil sump emptying pump.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ELECTRICAL EQUIPMENT 3.61
C87 ENT M62.11 / C87 ENT M65.11
ELECTRICAL SYSTEM
Figure 9
09_061_N
ATTENTION
If magneto-thermal protecting breakers are inserted, they
must not be used to stop the engine and in any case they
must be activated only a few seconds after shut-down.
C87 ENT M62.10 / C87 ENT M65.10
3.62 ELECTRICAL EQUIPMENT MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
ALTERNATOR
Figure 10
05_093_C
81797
Alternator speed (rpm x 1000)
Specification
CHARACTERISTIC CURVES
Figure 12
Engine
electrical
ground
connection
point
Nippondenso model
Specification Figure 13
CHARACTERISTIC CURVES
Condition (20 C) Voltage (V) Current (A) Speed (rpm) Torque (Nm)
No load 23 120 3800 -
Load 16 690 900 49
Stall 6 1260 0 73.5
C87 ENT M62.10 / C87 ENT M65.10
3.64 ELECTRICAL EQUIPMENT MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 15
08_024_C
Pin Function
1 Injector cylinder 5
2 Injector cylinder 6
3 Injector cylinder 4
4 Injector cylinder 1
5 Injector cylinder 3
6 Injector cylinder 2
7 -
8 -
9 Pressure regulator
10 Pressure regulator
11 Injector cylinder 2
12 Injector cylinder 3
13 Injector cylinder 1
14 Injector cylinder 4
15 Injector cylinder 6
16 Injector cylinder 5
C87 ENT M62.10 / C87 ENT M65.10
3.66 ELECTRICAL EQUIPMENT MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 18
147000
1, 2, 3, 4. Copper braids
ATTENTION
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean
and not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ELECTRICAL EQUIPMENT 3.69
C87 ENT M62.11 / C87 ENT M65.11
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean and
not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
Figure 19
174588
1, 2, 3, 4. Copper braids
ATTENTION
To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean
and not oxidized. Thoroughly inspect and remove any impurities before each reinstallation procedure.
C87 ENT M62.10 / C87 ENT M65.10
3.70 ELECTRICAL EQUIPMENT MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 DIAGNOSTICS 4.71
C87 ENT M62.11 / C87 ENT M65.11
SECTION 4
Diagnostics
Page
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PT - BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FOREWORD
A successful troubleshooting is carried out with the Every time there is a breakdown claim and this breakdown
competence acquired by years of experience and attending is actually detected, it is necessary to proceed inquiring the
training courses. electronic unit in one of the ways indicated and then
proceed with the diagnostic research making trials and tests
When the user complains for bad efficiency or working
in order to have a picture of the working conditions and
anomaly, his indications must be kept into proper
identify the root causes of the anomaly.
consideration using them to acquire any useful information
to focus the intervention. In case the electronic device is not providing any indication,
it will be necessary to proceed relying on the experience,
Using FPT processing instruments, it is also possible to
adopting traditional diagnosis procedures.
establish a bi-directional connection with the central unit, by
which not only to decoding the failure codes but also input
an enquiry relying on memory files, in order to achieve any
further necessary information to identify the origin of the ATTENTION
anomaly.
Any kind of operation on the electronic center unit must
be executed by qualified personnel, duly authorized by FPT.
Any unauthorized tamper will involve decay of after-sales
service in warranty.
C87 ENT M62.10 / C87 ENT M65.10
4.74 DIAGNOSTICS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
PT - BOX
PT - BOX is a test tool to be connected to a Personal Computer.
Figure 1
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator -
5. Serial port indicator - 6. Error indicator - 7. CAN line indicator -
8. Line K indicator for automatic management
NO Engine does not start Batteries - Low charge - Recharge (disconnecting system
- Faulty terminal connections wiring)
- Clean, check, tighten terminals or
replace them
NO Engine does not start Electrical starter motor - Malfunction - Check
- Faulty terminal connections - Clean, check, tighten terminals
NO Engine does not start Relay to control power - Malfunction - Check supply wiring
supply to terminal 50 of - Check main relay, replace
the electric starter motor
(contained in the relay
box)
DIAGNOSTICS
NO Engine does not start Fuel feed pump - Priming incorrect (air leaking inside) - Check seal on intake branch
- Check pressure
NO Engine does not start Fuel circuit - Incorrect filling (air in fuel circuit) - Check seal
- Bleed circuit
NO Engine does not start Fuel filter and pre-filter - Filter and pre-filter clogged - Check reservoir
- Replace
NO Engine does not start Electrical grid heater (if - Malfunction - Check supply and earth connection
4.75
4.76
GUIDE TO SYMPTOM DIAGNOSIS
NO Engine overheats Coolant level - Below MIN level - Check for leaks
- Top up correct level
NO Engine overheats Coolant pump drive belt - Loose tension - Check tension
- Wear - Replace
- Verify liquid spillage on the belt
NO Engine overheats Coolant pump - Malfunction - Check belt tension
- Replace
NO Engine overheats Thermostatic valve - Locked, closed or only partially open - Check coolant liquid
- Replace
NO Engine overheats Coolant-sea water heat - Clogged - Clean or replace
DIAGNOSTICS
exchanger
NO Engine overheats Air filter - Clogged - Check filter clogged indicator
- Replace filter
NO Engine overheats Cylinder head gasket - Compression leaking from cylinder head gasket - Check water circuit pressure
- Replace head gasket
MAY 2012
MAY 2012
GUIDE TO SYMPTOM DIAGNOSIS
DIAGNOSTICS
NO Poor performance Turbocompressor - Blades inefficient - Check parts and lubrication circuit
- Bearings inefficient - Replace
NO Poor performance Control cams - Wear - Check, replace
- Incorrect timing - Check, restore
NO Poor performance Valves - Excessive or no clearance - Check, restore correct clearance
NO Poor performance Intake air pressure sensor - Output signal too low (below to the pressure - Using a multimeter on the component,
value) check the output voltage and refer to a
manometer
4.77
4.78
GUIDE TO SYMPTOM DIAGNOSIS
NO The engine emits greywhite Water in cylinders - Leakages from cylinder gasket - Check level and pressurization of water
smoke - Leakages from injector sleeves circuit
- Water in intake system - Check fuel tank, clean as required
- Water in fuel - Check water in fuel sensor
The engine emits blue Oil in cylinders - Excessive oil consumption - Check lubrication oil consumption
smoke - Oil leaking in turbocompressor - Overhaul
- Oil leaking from valve guides
NO Engine stops Fuel reservoir - Fuel reservoir empty - Refill and bleed fuel circuit
DIAGNOSTICS
NO Engine stops Net filter - Filter clogged - Clean, replace
Prefilter
Fuel filter
NO Engine stops Fuel circuit - See item Poor performance - See item Poor performance
MAY 2012
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 DIAGNOSTICS 4.79
C87 ENT M62.11 / C87 ENT M65.11
Legend:
MAX = 3 Electronic control unit has read value OVER range
MIN = 4 Electronic control unit has read value UNDER range
SIG = 2 Electronic control unit has read a FAILURE of signal
NPL = 12 Electronic control unit has read of UNPLAUSIBILITY of signal
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
Vehicle 1 (Sensors/Plausibility checks)
111 x x x x Fault path 1 for vehicle Speed sensing
211 x x x x Fault path 2 for vehicle Speed sensing(CAN)
311 x x x Fault path 3 for veh. Speed (max.pulse width)
112 x Accelerator Pedal 1
212 x x x Accelerator Pedal 2
113 x Accelerator Pedal and brake not plausible
114 x x x Multiple State Switch
116 x x Main clutch signal
117 x x Brake signal
118 x Engine brake preselection switch status
119 x No terminal 15 signals detected
11A x Terminal 50 always pressed
11B x High resolution wheel speed CAN message
21B x Vehicle dynamics control unit CAN message
11C x Water in fuel
21D x x x x Catalyst ageing limit exceeded
31D x x x x DCU state monitoring
11E x NH3Slip
21E x x x x Catalyst efficiency lower than first Nox prediction threshold level
31E x x x x Catalyst efficiency lower than first Nox prediction threshold level
41E x x x x Catalyst presence monitoring
11F x x x x Plausibility check of catalyst system
21F x x x x Boost pressure actuator current monitoring
31F x x x x Too high efficiency of catalyst system
Vehicle 2 (Lamps/relays/actuators)
121 x x x x Adjustable speed limit lamp
122 x x x x Power stage fault status for MIL
123 x x x x Power stage for system lamp
124 x x x x Cold start lamp
224 x x x x Coolant temperature lamp
Main relay defect (for High press pump P340/for engine brake
125 x x
decompr.valve P342)
C87 ENT M62.10 / C87 ENT M65.10
4.80 DIAGNOSTICS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
225 x Interrupted afterrun
126 x x Battery voltage fault
127 x x Eng.brake decompr.valve
128 x Main relay SCBatt (Lambda H./Grid H./Batt.switch)
228 x Main relay SCGND (Lambda H./Grid H./Batt.switch)
129 x x Main relay 3 (A/C compr./fuel filter heater)
12A x x Main relay 4 (Exhaust valve eng.brake flap)
22A x x x x Particulate filter lamp
12B x x x Power stage air heater 1 actuator
12C x x x Power stage air heater 2 actuator
12D x x Air heater test switch on (voltage<low thresh.)
22D x x Air heater test switch off (voltage>high thresh.)
12E x Grid heater always switched on
12F x x Air condition power stage CAN message
Engine 1 (Temperature and Pressure Sensors)
131 x x x x Coolant temperature sensor
132 x Coolant temperature sensor dynamic test
232 x Coolant temperature sensor absolute test
332 x x Engine temperature check
133 x x x Boost Temp. Signal
134 x x x x Boost pressure sensor
135 x x Fuel Temp. Signal
136 x x Rail pressure sensor CP3
236 x x x Rail pressure sensor offset monitoring
137 x x x Rail pressure relief valve
138 x x x x Oil Pressure Sensor
238 x Oil Pressure too low
338 x x x x Oil Pressure sensor lamp
13A x x x x Oil Temp. Sensor
23A x Oil Temperature above normal
13C x x x Atmospheric Temperature Sensor (Humidtiy?)
13D x x x Fuel pressure sensor
23D x x Fuel pressure sensor dynamic plausibility test
Engine 2 (Speed sensing/actuators)
141 x x Crankshaft sensor failure
142 x Running with camshaft sensor only
143 x x Camshaft sensor failure
144 x x Offset between camshaft and cranksh.
145 x x x x Power stage Fan actuator
146 x x Power stage Fan 2 actuator
147 x x Fan speed sensor signal
148 x x x x Air condition power stage
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 DIAGNOSTICS 4.81
C87 ENT M62.11 / C87 ENT M65.11
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
149 x x x x Fuel filter heating output
14A x Engine Compartment Start Button is stuck
24A x Engine Compartment Stop Button is stuck
14D x Engine overspeed protection
14E x x x x TurboCompound monitoring
Fuel metering CR Systems
151 x Rail pressure max.positive deviation exceeded
251 x Rail pressure positive deviation 2nd part
152 x Rail pr.max.pos.deviation exceeded conc.set flow of fuel
Maximum negative rail pressure deviation with metering unit on
153 x
lower limit is exceeded
154 x Minimum rail pressure exceeded
155 x Maximum rail pressure exceeded
156 x Rail pressure drop rate is higher than expected
157 x Setpoint of metering unit in overrun mode not plausible
Setpoint of fuel volume flow through metering unit is lower than
158 x
calculated limit
159 x x Metering unit PWM-powerstage
259 x Short circuit to battery of metering unit output
359 x Short circuit to ground of metering unit output
15A x x Metering unit AD-Channel
15B x High pressure test(deactivates rail pr.Monitor.)
15F x First collection fault path for potentially long term fault path
25F x Second collection fault path for potentially long term fault path
35F x Third collection fault path for potentially long term fault path
45F x Forth collection fault path for potentially long term fault path
55F x Fifth collection fault path for potentially long term fault path
Injectors 1
161 x x x x Cylinder1 - Short circuit Low/High
162 x x x x Cylinder2 - Short circuit Low/High
163 x x x x Cylinder3 - Short circuit Low/High
164 x x x x Cylinder4 - Short circuit Low/High
165 x x x x Cylinder5 - Short circuit Low/High
166 x x x x Cylinder6 - Short circuit Low/High
167 x x x x Cylinder1 - Open load
168 x x x x Cylinder2 - Open load
169 x x x x Cylinder3 - Open load
16A x x x x Cylinder4 - Open load
16B x x x x Cylinder5 - Open load
C87 ENT M62.10 / C87 ENT M65.10
4.82 DIAGNOSTICS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
16C x x x x Cylinder6 - Open load
16D x Fault path to disable rail monitor. while compr.test active
16E x x x x The minimum number of injections was not reached --> stop the engine
16F x x x x Additive valve actuator
Injectors 2
171 x x x x Bank 1 specific errors - Short circuit / not classifyable
172 x x x x Bank 1 specific warnings - Open load
173 x x x x Bank 2 specific errors - Short circuit / not classifyable
174 x x x x Bank 2 specific warnings - Open load
175 x Misfire Cylinder 1
275 x x leakage or misfiring in cylinder 1
176 x Misfire Cylinder 2
276 x x leakage or misfiring in cylinder 2
177 x Misfire Cylinder 3
277 x x leakage or misfiring in cylinder 3
178 x Misfire Cylinder 4
278 x x leakage or misfiring in cylinder 4
179 x Misfire Cylinder 5
279 x x leakage or misfiring in cylinder 5
17A x Misfire Cylinder 6
27A x x leakage or misfiring in cylinder 6
17B x Misfire in multiple cylinders
17C x x x x Chip-specific errors-->stop engine
27C x x x x Chip-specific errors-->stop engine
17D x Common fault in combustion monitoring
17E x x x x Fault path of injection limitation
Air inlet system / EGR
181 x x Induction exhaust differential pressure
184 x Messages SRA2EDC
187 x AirCtl permanent positive governor deviaton
287 x AirCtl permanent positive governor deviaton
188 x AirCtl permanent negative governor deviaton
288 x AirCtl permanent negative governor deviaton
189 x Short circuit to Batt. for EGR power stage
289 x Short circuit to ground for EGR power stage
389 x x No load/excessive temp. for EGR power stage
18A x x x Power stage for EGR Bypass valve actuator
28A x x x Intercooler Bypass Valve Powerstage
18B x SC to BATT for throttle valve actuator powerst.
28B x SC to GND for throttle valve actuator powerst.
38B x x No load and excess temp. for TVA powerst.
18F x x x x Monitoring of Lambdasensor 1 Heater powerstage
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 DIAGNOSTICS 4.83
C87 ENT M62.11 / C87 ENT M65.11
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
Boost system and turbine speed
790 x Monitoring of the controller
191 x x x Boost pressure actuator current AD-channel
192 x Short circuit to Battery for BPA powerstage
292 x Short circuit to Ground for BPA powerstage
392 x x No load/excessive temp.for BPA power stage
193 x x x x Turbine speed
293 x x x x Actual turbo speed evaluation for interface
194 x Multi signal defects in EPCtl
195 x x x P2 pressure errors in EPCtl
196 x P3 pressure errors in EPCtl
197 x x x Turbine speed errors in EPCtl
198 x Multi signal defects in PCR
199 x x x P2 pressure errors in PCR
19A x x Turbine speed errors in PCR
19B x High turbine speed and high air pressure
19C x x P3 pressure errors in PCR
19D x Indicates torque limitation due to performance limiter
29D x Torque limitation due to NTC
39D x Performance limit active due to either stage
49D x Indicates torque limitation due to particulate filter
59D x Indicates torque limitation due to SCR
19E x Indicates torque limitation due to smoke limitation
29E x Indicates torque limitation due to turbo compound
39E x Indicates torque limitation due to turbo charger protection
49E x Indicates the torque limitation due to engine protection
59E x Indicates torque limitation due to noise control
69E x Indicates torque limitation due to Fuel quantity Limitation
19F x Multi signal defects in EGSys_NOxEstIv
Exhaust system (Aftertreatment)
1A1 x x x Lambda linear signal of Nox Sensor
2A1 x x x Lambda binary signal of Nox Sensor
1A2 x x x x Nox signal of Nox Sensor
2A2 x x x x NOx Sensor drift test
3A2 x x x x Nox Sensor plausibility test
1A3 x x x Heater of Nox Sensor
1A4 x Message Nox Sensor timeout
1A5 x Message DM1DCU timeout
1A6 x Message SCR1 timeout
2A6 x Message SCR2 timeout
1A7 x x x x Urea level error path
2A7 x SCR2 message: low urea level
C87 ENT M62.10 / C87 ENT M65.10
4.84 DIAGNOSTICS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
3A7 x Not plausible CAN value of urea sensing
4A7 x Timeout for urea sensor
1A8 Error / Protection request on urea valve via SCR1
1AA x Not plausible CAN value of urea status
2AA x x x x Urea conductivity error path
3AA x x x x Urea concentration error path
1AB x x Exhaust gas temperature sensor before turbine
2AB x Exhaust Gas Pipe pressure sensor
1AC x x x x Heater used in EGR Mass Flow rate
2AC x CAN message EngGsFlowRt
1AD x x x x Recirculated Engine Exhaust Gas Temp. sensor
1AE x x Air humidity sensor
1AF x DM1DCU SPN1 message
2AF x DM1DCU SPN2 message
3AF x DM1DCU SPN3 message
4AF x DM1DCU SPN4 message
5AF x DM1DCU SPN5 message
Interfaces 1 (CAN-Bus)
1B1 x Busoff in CAN A
1B2 x Busoff in CAN B
1B3 x Busoff in CAN C
1B4 x Timeout for BC2EDC1
2B4 x Timeout for BC2EDC2
1B5 x Timeout for VM2EDC
1B6 x Timeout of CAN message WSI
1B7 x Timeout in CAN send messages
1B8 x Physical unplausibility of TSC-demand
1B9 x MIL visualization for BC2EDC1
1BA x Message Dashboard Display timeout
1BB x Message ERC1DR timeout
1BC x Message RxAMCONlv timeout
1BD x Timeout error of RxCCVS message
1BE x Physical plausibility DCS
1BF x CAN message RxEngTemp2
Interfaces 2 (CAN messages timeout)
1C1 x Timeout of CAN message EBC1
1C2 x Timeout of CAN message ETC1
1C3 x Timeout of CAN message TCO1
2C2 x Timeout of CAN message ETC2
1C4 x Timeout of CAN message TSC1-AE active
2C4 x Timeout of CAN message TSC1-AR active
3C4 x Timeout of CAN message TSC1-AE passive
4C4 x Timeout of CAN message TSC1-AR passive
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 DIAGNOSTICS 4.85
C87 ENT M62.11 / C87 ENT M65.11
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
1C5 x Timeout of CAN message TSC1-DE active
2C5 x Timeout of CAN message TSC1-DR active
3C5 x Timeout of CAN message TSC1-DE passive
4C5 x Timeout of CAN message TSC1-DR passive
1C6 x Timeout of CAN message TSC1-PE active
2C6 x Timeout of CAN message TSC1-PE passive
1C7 x Timeout of CAN message TSC1-TE active
2C7 x Timeout of CAN message TSC1-TR active
3C7 x Timeout of CAN message TSC1-TE passive
4C7 x Timeout of CAN message TSC1-TR passive
1C8 x Timeout of CAN message TSC1-VE active
2C8 x Timeout of CAN message TSC1-VR active
3C8 x Timeout of CAN message TSC1-VE passive
4C8 x Timeout of CAN message TSC1-VR passive
1C9 x Timeout of CAN message TF
2C9 x Timeout for message TimeDate
3C9 x Timeout for message HRVD (high resol.vehicle distance)
ECU 1 (internal checks)
1D1 x Communication error of CJ940
1D2 x x x Error state of EEPROM
1D3 x Recovery which is locked
2D3 x Recovery which is suppressed
2D4 x Recovery which is visible
1D4 x Communic.supervision Watchdog/Contr.-Flag
1D5 x x x Redundant shutoff paths during initial.
1D6 x Deviation between TPU and system time
1D7 x x Dataset variant coding
1D8 x Supervision of SPI-handler Flag
1D9 x x x x Error status ADC monitoring
Fault FMTC_trq2qBas_MAP containes non strictly monotonous q
1DA x
curves
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)
Short circuit to Batt or Ground, no load, excess.temp. for high side
1E1 x x
power stage
Short circuit to Batt or Ground, no load, excess.temp. for low side
2E1 x x x
power stage
1E2 x Error state of Immobilizer (no fuel release)
1E3 x Energising time exceeds limit of overrun monitor.
1E4 x Plausibility error in engine speed check
1E5 x x 12V sensor supply voltage
1E6 x x Sensor supply voltage 1
1E7 x x Sensor supply voltage 2
1E8 x x Sensor supply voltage 3
C87 ENT M62.10 / C87 ENT M65.10
4.86 DIAGNOSTICS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
DMx DMx
SPN FMI
Failure description
HEX MAX MIN SIG NPL
values =3 =4 =2 = 12
1E9 x Supply voltage CJ940 upper limit
1EA x Supply voltage CJ940 lower limit
1EB x x x Atmospheric Pressure Sensor
1EC x Runuptest is set to disable misfire detection during runup test
1ED x Fault path for Runup test
1EF x Mass of soot in oil beyond prescribed limit
Particulate trap
7F0 x Too long time spent in transition mode RgnNrm
1F1 x x Part.filter differential pressure sensor
1F2 x x Flow resistance monitoring
2F2 x Part.filter differential press.sensor not plaus.
1F3 x x x Differential pressure signal
2F3 x Dynamics of differential press.signal not plaus.
3F3 x Hose line defect so signal not plausible
4F3 x Pressure sensor blocked so signal not plaus.
1F4 x Pressure sensor frozen so signal not plausible
1F5 x Differential pressure above limit
1F6 x x Exhaust gas temp.sensor bef. oxidation catalyst
2F6 x Monitor.temp. upstream of Oxid.Catalyst
Temp.difference upstream from Oxidation catalyst of bank1 and 2
3F6 x
exceeded threshold
4F6 x Monitor.temperature upstream of Turbo charger
1F7 x x Part.filter pre temperature sensor
2F7 x Monitor.temp. upstream of Particul.filtre
Temp.difference upstream from Particulate filtre of bank1 and 2
3F7 x
exceeded threshold
1F8 x x x First exhaust gas temperature monitoring
2F8 x General temperature not plausible
3F8 x x x Second exhaust gas temperature monitoring
1F9 x Too high regeneration demand
1FA x Number of locked regenerations
2FA x Permanent regeneration
3FA x Regeneration demand number 2
4FA x Regeneration demand number 3
1FB x Error path of oxidation catalyst not present
1FC x Defect ratio between threshold limits
1FD x x Temperature of Outer control loop
2FD x x Temperature of Inner control loop
1FE x Mass of fuel in oil beyond warning limit
1FF x Mass of fuel in oil beyond action limit
2FF x Error check of critical time for oil dilution
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 MAINTENANCE 5.87
C87 ENT M62.11 / C87 ENT M65.11
SECTION 5
Maintenance
Page
PERIODICITY OF CHECKS AND MAINTENANCE
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 89
Execution of the operations indicated below requires competence and compliance with the safety regulations enforced in
various Countries.
Checks can be performed by the user of the vessel and/or by workshop personnel.
Periodic maintenance operations must be performed by qualified personnel and require the use of tools, work instruments,
and suitable protection means.
Extraordinary maintenance operations must be performed by FPT authorized workshop personnel with adequate training and
sufficient technical information.
Checks Periodicity
Check engine lubricating oil level Daily
Check engine coolant level Daily
Check oil level in the gearbox Daily
Inspect exhaust duct(s) Daily
Drain water from fuel pre-filter(s) (1) 150 hours
Check battery terminal tightening and cleanliness Half-yearly
Check electrolyte level in batteries (1) Half-yearly
Check condition of oil vapor filter with clogging indicator (with the engine 300 hours
running)
147001
C87 ENT M62.10 / C87 ENT M65.10
5.92 MAINTENANCE MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
SERVICING OPERATIONS C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ON INSTALLED ENGINE C87 ENT M62.11 / C87 ENT M65.11
6.93
SECTION 6
Servicing operations on installed engine
Page
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
REPLACING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
C87 ENT M62.10 / C87 ENT M65.10 SERVICING OPERATIONS
6.94 C87 ENT M62.11 / C87 ENT M65.11 ON INSTALLED ENGINE MAY 2012
SERVICING OPERATIONS C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ON INSTALLED ENGINE C87 ENT M62.11 / C87 ENT M65.11
6.95
FOREWORD
The successful outcome of repair work is assured by the To proceed with the overhaul of the engine or its parts, you
operator's experience and ability and by compliance with the must disconnect the electrical connections of the injection
following instructions. system's components and of the sensors providing
indications on the control panel.
Before performing work involving components of the
injection system, take note of the content of the ECU fault To proceed as indicated, we provide below the procedure
memory with the appropriate FPT diagnosis equipment, to avoid the risk that the ECU of the injection system may
writing the results down or printing them. detect and store errors or system faults.
- Replacement of the ECU EDC 7 must be authorized by - Set the key switch to the STOP position;
FPT after specific agreements with the Technical
- Wait 10 sec. and disconnect the battery terminals;
Assistance Service;
- Disconnect the connections according to the
- The electro-injectors cannot be overhauled; their
prescriptions set out in Section 3;
replacement must be authorized by FPT with the specific
agreement of the Technical Assistance Service; for - Remove, if necessary, the entire wiring harness from the
disassembly, follow the indications provided in the retaining bracket;
specific paragraph of this Section;
- Remove, if necessary, the complete electronic unit after
- Keep parts and components clean, making sure that disconnecting the multipolar connectors.
during handling and assembly (starting with the simple
replacement of filter and pre-filter) no sludge or foreign
matter is allowed to enter the lines, with particular
attention to the fuel supply line in the segment
downstream of the filter;
- Maintain the proper polarization of all electrical
connections;
- Tighten the threaded connections to the prescribed
torque;
- Ensure that the flywheel and camshaft sensors are
positioned so they abut, ensuring they are as close to
perpendicular as possible with the bearing surface.
ATTENTION
- Do not disconnect electrical connections without
removing power from the circuits first;
- Do not proceed with operating simulations with
unsuitable tools and instruments;
- Do not force measuring probes or mechanical tools
into the electrical connections;
- Do not proceed with arc welding without first
disconnecting electronic system units.
SERVICING OPERATIONS C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ON INSTALLED ENGINE C87 ENT M62.11 / C87 ENT M65.11
6.97
REPLACING BELT
Figure 1 Figure 3
114024
Figure 4
- With the tool (1) loosen the tensioning device acting in
the direction indicated by the arrow. Extract the auxiliary
organ drive belt (2), insert the new belt verifying that it
is correctly set onto the pulleys. Release the tensioning
device. The automatic tensioning device requires no
further adjustment.
Removal
Figure 2 114025
Figure 5
174574
147002
Figure 7
114287
Figure 11
147005
Figure 10
- Place under the cock a container to collect the exhaust
oil.
- Remove filters.
- Accurately clean surfaces.
- Moist seals of the new filters with some oil.
- Manaully tighten until contact is made, then tighten
again for 3/4 of turn.
- Dispose drained liquids observing current regulations in
force.
147006
Figure 12
147007
ATTENTION
Proceed with utmost care, considering the fluid high
temperature and the presence of moving parts. Always wear
suitable personal protection equipped.
ATTENTION
Do not exclude both filters at the same time to avoid any
damage.
SERVICING OPERATIONS C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ON INSTALLED ENGINE C87 ENT M62.11 / C87 ENT M65.11
6.101
MARINISATION OVERHAUL
Removal
Figure 13 Figure 16
143684 143687
Remove the oil filter mount (1) and the oil dipstick (2). Remove the air filter (4), the turbocharger (1), the pipe (2)
and the fuel pipes (3).
Figure 14
Figure 17
143685 143688
Remove the engine mountings (1), the oil drain pump (2) and Disconnect the exhaust stub pipe (1), the fuel filter (2) and
the sea water exhaust pipe (3). the intake duct (3).
Figure 15 Figure 18
143686
143689
Remove the electronic control unit (1), the stack exhaust (2)
(if present) and the combusted gas/sea water exhaust (3). Disconnect the oil inlet pipe from the inverter (1) and the oil
outlet pipe to the inverter (2).
C87 ENT M62.10 / C87 ENT M65.10 SERVICING OPERATIONS
6.102 C87 ENT M62.11 / C87 ENT M65.11 ON INSTALLED ENGINE MAY 2012
Figure 19 Figure 21 ()
1436922
Figure 22 (*)
Remove the sea water pump (1) and the inverter oil heat
exchanger (2)
177456
143691
143693
Disconnect the coolant temperature sensor (2), the
thermostat (1) and the coolant inlet pipe to the engine water Remove the combusted gas/sea water cooled exhaust
pump (3). manifold (1).
SERVICING OPERATIONS C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ON INSTALLED ENGINE C87 ENT M62.11 / C87 ENT M65.11
6.103
Figure 24
143699
1.Body - 2. Tube bundle - 3. Sealing rings - 4. Zinc sacrificial anode - 5. Tube bundle fixing screw -
6. Cover - 7. Spacer.
In order to guarantee a perfect operation of the heat - Reassemble screws (5) in order to suitably secure the
exchanger, regularly clean the tube bundle. If the surfaces of tube bundle and relevant plugs;
the heat exchanger come into contact with salted water,
- Check the zinc anode corrosion level (4); replace the
they may be subjected to biological fouling and to
anode if corrosion exceeds 50% of the volume.
hydrocarbon deposits which may be present in harbors'
waters; surfaces coming into contact with combusting air are
subject to oil deposits resulting from the fumes exhausted at
the base and sucked downstream of the air filter.
- Remove tube bundle fixing plugs and screws (5);
- Remove the tube bundle (2) from the exchanger body
and immerse it for a few minutes in a solution prepared
with water and a degreasing scale-remover detergent,
observing the detergent manufacturer's directions for
use. The cleansing solution should not damage copper,
brass, aluminum and tin;
- Complete tube cleaning by rinsing thoroughly with fresh
water, until detergent residuals are entirely removed;
- Reassemble the tube bundle (2) by correctly positioning
spacers (7), sealing rings (3) and covers (6);
C87 ENT M62.10 / C87 ENT M65.10 SERVICING OPERATIONS
6.104 C87 ENT M62.11 / C87 ENT M65.11 ON INSTALLED ENGINE MAY 2012
143770
Figure 26
177443
1. Tube bundle - 2. Body - 3. Sealing rings - 4. Cover - 5. Tube bundle fixing screw - 6. Spacer - 7. Zinc sacrificial anode
SERVICING OPERATIONS C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ON INSTALLED ENGINE C87 ENT M62.11 / C87 ENT M65.11
6.105
In order to guarantee a perfect operation of the heat exchanger, regularly clean the tube bundle. If the surfaces of the heat
exchanger come into contact with salted water, they may be subjected to biological fouling and to hydrocarbon deposits which
may be present in harbors' waters.
- Remove the tube bundle (1) from the exchanger body and immerse it for a few minutes in a solution prepared with water
and a degreasing scale-remover detergent, observing the detergent manufacturer's directions for use. The cleansing solution
should not damage copper, brass, aluminum and tin;
- Complete tube cleaning by rinsing thoroughly with fresh water, until detergent residuals are entirely removed;
- Reassemble the tube bundle (1) by correctly positioning spacer (6), sealing rings (3) and covers (4);
- Check the zinc anode corrosion level (7); replace the anode if corrosion exceeds 50% of the volume.
C87 ENT M62.10 / C87 ENT M65.10 SERVICING OPERATIONS
6.106 C87 ENT M62.11 / C87 ENT M65.11 ON INSTALLED ENGINE MAY 2012
Fitting
Figure 27 Figure 30
143693 143691
Fit the combusted gas/sea water cooled exhaust manifold (1). Reattach the coolant inlet pipe to the engine water pump (3),
the thermostatic valve (1) and the coolant sensor (2).
Figure 28 ()
Figure 31
143691
143690
() M62.10 / M65.10 ENGINES
Fit the inverter oil heat exchanger (2) and the sea water
Figure 29 (*) pump (1).
Figure 32
177456
Fit the air/water exchanger (1) and the water/water heat Connect the inverter oil inlet (1) and outlet (2) pipes.
exchanger (2).
SERVICING OPERATIONS C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 ON INSTALLED ENGINE C87 ENT M62.11 / C87 ENT M65.11
6.107
Figure 33 Figure 36
143688
Fit the exhaust stub pipe (1), the fuel filter (2) and the intake
duct (3). 143685
Fit the engine oil drain pump (2), the sea water exhaust pipe
Figure 34 (3) and the engine oil mounts (1).
143687
Connect the pipe (2), the turbocharger (1), the air filter (4) Figure 37
and reattach the fuel pipes (3).
Figure 35
143684
143686
Fit the oil filter mount (1) and the oil dipstick (2).
Fit the combusted gas/sea water exhaust (3), the stack
exhaust (2) (if present) and the electronic control unit (1).
C87 ENT M62.10 / C87 ENT M65.10 SERVICING OPERATIONS
6.108 C87 ENT M62.11 / C87 ENT M65.11 ON INSTALLED ENGINE MAY 2012
Handling
The engine must be handled by experienced personnel, using
the prescribed tool or a rocker arm that keeps the lifting lines
parallel and with adequate equipment in terms of capacity
and size.
The two eyebolts (provided exclusively for lifting the engine)
must always be used simultaneously.
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 TOOLS 7.109
C87 ENT M62.11 / C87 ENT M65.11
SECTION 7
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
C87 ENT M62.10 / C87 ENT M65.10
7.110 TOOLS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 TOOLS 7.111
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
Tool No. Description
PT - Box
99327281
TOOLS
TOOLS
Tool No. Description
TOOLS
Tool No. Description
99360603 Band for piston insertion into the cylinder (90 - 175 mm)
TOOLS
99360706 Tool to extract cylinder liners (to be used with specific rings)
Tool to take down-fit engine valves (to be used with special plates)
99368542
C87 ENT M62.10 / C87 ENT M65.10
7.116 TOOLS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
TOOLS
99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
Measuring pair for angular tightening with 1/2 and 3/4 square
99395216 couplings
TOOLS
SECTION 8
Overhaul
Page
Graph and symbols . . . . . . . . . . . . . . . . . . . . . . 123
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
C87 ENT M62.10 / C87 ENT M65.10
8.120 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Page Page
Measuring main journals and crank pins . . . . . . 148 Checking protrusion of injectors . . . . . . . . . . . . 169
Checking main journal installation clearance . . . 156 Twin idler gear . . . . . . . . . . . . . . . . . . . . . . . . . 170
PISTON CONNECTING ROD ASSEMBLY . . . . . . 158 Checking cam lift and pin alignment . . . . . . . . . 171
Removing deposits and checking the valves . . . 166 Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . . 176
REPLACING INJECTOR HOLDER CASES . . . . . . . 167 COMPONENTS OF THE COOLING SYSTEM . . . 178
Page
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Interference
Strained assembly
Thickness
Clearance
Intake
Exhaust
Operation
Compression ratio
Preload
Oversized
Higher than ...
Maximum, peak
Undersized
Less than ...
Minimum
Selection
Classes
Oversizing
C87 ENT M62.10 / C87 ENT M65.10
8.124 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
GENERAL CHARACTERISTICS
mm
Injection Direct
N. of cylinders 6 in line
Diameter mm 117
Stroke mm 135
Compression ratio 16 : 1
A
Valve timing
X mm 0.4 0.05
X
mm 0.6 0.05
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERHAUL 8.125
C87 ENT M62.11 / C87 ENT M65.11
Cylinder liners:
outer diameter:
L upper 130.461 to 130.486
2
lower 129.475 to 129.500
2 length L 226.15
Outside diameter 2 -
Cylinder sleeve
3 inside diameter 3A* 117.000 to 117.012
Pistons:
measuring dimension X 15
outside diameter 1 A* 116.894 to 116.906
1 external diameter 1 B** 116.904 to 116.916
pin bore 2 52.010 to 52.016
X
* Class A pistons supplied as
spares.
2
** Class B pistons are fitted in
production only and are not
supplied as spares.
Piston - cylinder sleeve A* 0.094 to 0.118
* Available dia. class B* 0.094 to 0.118
Piston diameter 1 -
X
Pistons protrusion X 0.873 to 1.117
X1 X1 3.120 to 3.140
X2 Piston ring grooves X2 2.550 to 2.570
X3 4.020 to 4.040
X3
Piston rings:
S1 trapezoidal seal S1 3.000
S2 lune seal S2 2.470 to 2.500
S3 milled scraper ring with slits
and internal spring S3 3.970 to 3.990
1 -
Piston rings - grooves 2 0.050 to 0.100
3 0.030 to 0.070
Piston rings -
mm
Main journals 1 Rated value 92.970 to 93.000
1 92.970 to 92.980
Selection class 2 92.980 to 92.990
3 92.990 to 93.000
Crankpins 2 Rated value 81.915 to 81.945
1 2 1 81.915 to 81.925
Selection class 2 81.925 to 81.935
3 81.935 to 81.945
Main bearing shells S1
Red 2.968 to 2.978
S1 S 2 Green 2.978 to 2.988
Yellow* 2.988 to 2.998
Big end bearing shells S2
Red 1.994 to 2.002
Green 2.002 to 2.010
Yellow* 2.010 to 2.018
* Fitted in production only
and not supplied as spares
Main bearing housings 3 Rated value 99.000 to 99.030
3 1 99.000 to 99.009
Selection class 2 99.010 to 99.019
3 99.020 to 99.030
Bearing shells - main journals 0.050 to 0.090
Bearing shells - big ends 0.0540 to 0.080
Main bearing shells 0.127 - 2.254 - 0.508
Big end bearing shells 0.127 - 2.254 - 0.508
Main journal,
thrust bearing X1 39.96 to 40.04
X1
X3
Thrust washer halves X3 3.38 to 3.43
2 8.023 to 8.038
Valve guide
3 13.012 to 13.025
3
4 Valves:
4 7.970 to 7.985
60 30' 7' 30
4 7.970 to 7.985
45 to 45 15'
1 41.985 to 42.020
1 40.985 to 41.020
1
Outside diameter of valve seat;
angle of valve seat in cylinder
head:
2 42,060 to 42,075
60 - 30
2 41.060 41.075
45 - 30'
X 0.5 to 0.8
Recessing
X of valve X 1.6 to 1.9
Camshaft bushing
outer diameter 69.090 to 69.130
Camshaft bushing
inner diameter 65.080 to 65.116
Cam lif
H 7.4034
8.2108
1
Rocker shaft 1 31.964 to 31.980
C87 ENT M62.10 / C87 ENT M65.10
8.130 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
32.025 to 32.041
0.045 to 0.077
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERHAUL 8.131
C87 ENT M62.11 / C87 ENT M65.11
TIGHTENING TORQUES
PART TORQUE
Nm kgm
Pipe union for piston cooling nozzle M12X1.5 50 5 3.5 0.2
Heat exchanger retaining screws 63 7 6.3 0.7
Plug 125 15 12.5 1.5
Spacer and oil sump fastening screws
M10 41.5 3.5 4.1 0.3
Gearcase fastening screws to cylinder block:
M10x1.25 41.5 3.5 4.1 0.3
M12x1.75 63 7 6.3 0.7
M8x1.25 23.5 1.5 2.3 1.5
Cylinder head fastening screw
First stage pre-tightening 50 5
Second stage pre-tightening 100 10
Third stage angle closing 90
Fourth stage angle closing 75
Rocker arm shaft fastening screw 104.5 10.5 10.4 1
Locknut for rocker arm adjusting screw 39 5 3.9 5
Electroinjector retaining bracket screws
M10 41 3 4.1 0.3
Shoulder plate fastening screws to head 23.5 3.5 2.3 0.3
Engine support bracket fastening screws to cylinder head 74 8 7.4 0.8
Gear fastening screws to camshaft M10x1,5x45
First stage pre-tightening 25 2.5
Second stage pre-tightening 45
Phonic wheel fastening screws to distribution gear 8.5 1.5 0.8 0.1
Exhaust pipe fastening screws
pre-tightening 32.5 7.5 3.2 0.7
tightening 47.5 2.5 4.7 0.2
Connecting rod cap fastening screws:
First stage pre-tightening 50 5
Second stage pre-tightening 90
Engine flywheel fastening screws M18x1.5x72
First stage pre-tightening 120 12
Second stage pre-tightening 90
Flywheel pulley fastening screws to crankshaft
First stage pre-tightening 70 7
Second stage pre-tightening 50
Main journal retaining screws
First stage pre-tightening 140 14
Second stage pre-tightening 60
Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly
C87 ENT M62.10 / C87 ENT M65.10
8.132 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
PART TORQUE
Nm kgm
Damper flywheel fastening screws 115 15 11.5 1.5
Idler gear pin fastening screws M12x1,75x90
First stage pre-tightening 30 3
Second stage angle closing 90
Idle gear link rod fastening screw 24.5 2.5 2.4 0.2
Oil pump fastening screw 24.5 2.5 2.4 0.2
Oil pump suction rose fastening screw 24.5 2.5 2.4 0.2
Front cover fastening screw to cylinder block 19 3 1.9 0.3
Control unit fastening screw to cylinder block 19 3 1.9 0.3
Fuel filter support fastening screw to cylinder head M10x1,25x60 37 3 3.7 0.3
Screw securing the engine support to the wheelcase
First stage pre-tightening 100 10
Second stage angle closing 60
Turbo-compressor fastening screws and nuts
pre-tightening 32.5 7.5 3.2 0.7
tightening 46 2 4.6 0.2
Water pump fastening screw to cylinder block 24.5 2.5 2.4 0.2
Pulley fastening screw to hub 55 5 5.5 0.5
Rocker arm cover fastening screws 8.5 1.5 0.8 0.1
Thermostat box fastening screws to cylinder head 24.5 2.5 2.4 0.2
Automatic tightener fastening screws to cylinder block 45 5 4.5 0.5
Fixed tightener fastening screws to cylinder block 105 5 10.5 0.5
Fan support fastening screws to cylinder block 24.5 2.5 2.4 0.2
Starter fastening screws 44 4 4 0.4
Air heater on cylinder head 30 3 5 0.5
Hydraulic power steering pump gear fastening nut 105 5 10.5 0.5
Air conditioner compressor fastening screw to support 24.5 2.5 2.4 2.5
Alternator support superior fastening screw 71.5 4.5 7.1 0.4
Alternator bracket fastening screw to cylinder block 24.5 2.5 2.4 0.2
Water pipe unions 35 3.5
Water temperature sensor 32.5 2.5 3.2 0.2
Lubricate with oil MOLYKOTE before assembly
Lubricate with graphitized oil before assembly
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERHAUL 8.133
C87 ENT M62.11 / C87 ENT M65.11
PART TORQUE
Nm kgm
Flywheel rev sensor fastening screw 84 0,8 0.2
Camshaft rev sensor fastening screw 84 0.8 0.4
P.D.E. solenoid connector fastening screw 1.62 0.3 0.1 0.3
Overboost pressure sensor fastening screw 82 0.8 0.2
Absolute pressure sensor fastening screw 22.5 2.5 2.2 0.2
P.W.M. control valve fastening screw/nut 82 0.8 0.2
Fuel/coolant temperature sensor 35 3.5
Coolant temperature indicator 23.5 2.5 2.3 0.2
Filter clogging sensor 10 1
Oil temperature switch 25 1 2.5 0.1
Oil pressure sensor 25 1 2.5 0.1
Electric wire fastening screw 82 0.8 0.2
Gear fastening screws to camshaft M14x50
First stage pre-tightening 40
Second stage pre-tightening 30
Gear fastening screws to camshaft M14x50
First stage pre-tightening 60
Second stage pre-tightening 45
Heater fastening screw 24.5 2.5 2.5 0.2
Gear fastening screws to camshaft
First stage pre-tightening 25
Second stage pre-tightening 9 1
Gear fastening screws to camshaft
First stage pre-tightening 25
Second stage pre-tightening 15 1
Alternator positive retaining nut M8x1.25 12.5 2.5 1.3 0.3
Starter terminal nut 30 M10x1.5 21 3.4 2.1 0.3
Starter terminal nut 50 M5x0.8 3.6 1 0.4 0.1
C87 ENT M62.10 / C87 ENT M65.10
8.134 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
First phase:
FRONT SIDE preliminary
tightening of
inner screws
(140 Nm)
80858
Second phase:
angle tightening
FRONT SIDE of inner screws
60
80858
Third phase:
FRONT SIDE angle tightening
of inner screws
60
80858
Fourth phase:
preliminary
tightening
FRONT SIDE of outer screws
(25 Nm)
80857
Fifth phase:
angle tightening
FRONT SIDE of outer screws
90
80859
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 OVERHAUL 8.135
C87 ENT M62.11 / C87 ENT M65.11
174573
Sequence
- First phase preliminary tightening 50 Nm Sequence as shown in figure;
- Second phase preliminary tightening 100 Nm Sequence as shown in figure;
- Third phase angle locking 90 Sequence as shown in figure;
- Fourth phase angle locking 75 Sequence as shown in figure.
Figure 3
80861
Sequence
- First phase tighten the screws 1-2-3 until they bear down on the rocker arm shaft;
- Second phase preliminary tightening 40 Nm Sequence as shown in figure;
- Third phase angle locking 60 Sequence as shown in figure.
C87 ENT M62.10 / C87 ENT M65.10
8.136 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
80862
Sequence
- First phase preliminary tightening 40 Nm Sequence as shown in figure;
- Second phase preliminary tightening 55 Nm Sequence as shown in figure.
Figure 5 Figure 6
Figure 7
147009
Sequence
- First phase preliminary tightening 15 Nm Sequence as shown in figure;
- Second phase preliminary tightening 22 Nm Sequence as shown in figure.
147010
174576
ATTENTION Figure 11
The operations described below refer to engines not
equipped with marinisation components.
143672
Remove the adapter for the oil filter (1) and the heat
exchanger (2).
Figure 10
Figure 12
174574
05_070_C
Figure 13 Figure 15
177449 114018
Apply extractor 99340051 (2) and remove seal (1). Unscrew the screws (1) and remove the cover (2). Remove
the centrifugal filter (3) below.
Unlock screws and remove front cover (3).
Figure 14 Figure 16
114015 114019
Remove screws (1) and blow-by box (2). Use specific spanner to unlock screws (2) and remove gear
(3) complete with tune wheel.
Unlock nut (4) and remove control gear (5) of high pressure
pump.
Remove rpm sensor (1).
ATTENTION
In case removal of gear (5) is difficult, release high pressure
pump screws with light beater strokes on control shaft and
remove gear (5).
C87 ENT M62.10 / C87 ENT M65.10
8.140 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 17 Figure 19
114009
Figure 20
Figure 18
114020 45257
Figure 21 Figure 23
114022
114023
Figure 22 Figure 25
114024
Figure 26 Figure 28
114025
45266
Figure 29
Figure 27
117690
Figure 30 Figure 32
114615
115881
ATTENTION
Rotate the block (1) to the vertical position. Note down the assembly position of the top and bottom
main bearing shells since, if reusing them, they will need to
be fitted in the position found upon removal.
Figure 33
177454
Figure 34
47571
115882 Remove the main bearing shells (1), unscrew the screws and
take out the oil nozzles (2).
Untighten screws (2) fixing the connecting rod cap (3) and Remove the cylinder liners as described under the relevant
remove it. Remove the connecting rod-piston (1) assembly subheading on page 134.
from the upper side.
Repeat these operations for the other pistons.
ATTENTION
ATTENTION After disassembling the engine, thoroughly clean
Keep the big end bearing shells in their respective housings disassembled parts and check their integrity.
and/or note down their assembly position since, if reusing Instructions for main checks and measures are given in the
them, they will need to be fitted in the position found upon following pages, in order to determine whether the parts can
removal. be re-used.
C87 ENT M62.10 / C87 ENT M65.10
8.144 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
Figure 35 (Demonstration)
225036
34994
A = Selection class 117 117.012 mm
B = Selection class 117.010 117.022 mm
Internal diameter of the cylinder liners is checked for X = Selection class marking area
ovalization, taper and wear, using a bore dial (1) centesimal
gauge 99395687 (2) previously reset to ring gauge (3), In case of maximum wear >0.150 mm or maximum
diameter 117 mm. ovalization >0.100 mm compared to the values indicated in
the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
ATTENTION
If dia.117 mm ring gage is not available, use a micrometer. ATTENTION
Cylinder liners are equipped with spare parts with A
selection class.
Figure 36 Figure 38
114035 114037
CYLINDER LINERS
Figure 39
114038
114039
77812
47577
With dial gauge 99395603 (5) placed on base 99370415 (6).
Place details 99360706 (1 and 2) and plate 99360724 (4) as Measure the cylinder barrel protrusion compared to the
shown in the figure, by making sure that the plate (4) is cylinder head supporting plane, it must be 0,035 to 0,065 mm
properly placed on the cylinder liners. (Figure 44); otherwise replace the adjusting ring (1,
Figure 42) fitted with spare parts having different thickness.
Tighten the screw nut (1) and remove the cylinder liner (3)
from the block.
Figure 44
Figure 42
114041
CYLINDER LINER PROTRUSION
Figure 45 (Demonstration)
16798
ATTENTION
The adjustment ring (1) is supplied as spare parts in the
following thicknesses: 0.08 mm - 0.10 mm - 0.12 mm. 35012
CRANKSHAFT
Figure 46
177453
MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.
Figure 47 Figure 48
114043 114044
Figure 49
47536
MEASURING CRANK PINS
During grinding, pay attention to journal and crank pins values
specified in figures 68 and 69.
47535
ATTENTION ATTENTION
It is advisable to enter the values found in a table (Figure 51). All journals and crank pins must also be ground to the same
undersizing class, in order to avoid any alteration to shaft
balance.
Figure 51
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
Min.
MAX.
Min.
MAX.
PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure 52 at top).
- The first set of digits (four) is the coupling number of the crankcase with its base.
- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure 52 at bottom).
- Each of these digits may be 1, 2 or 3.
Figure 52
99.000 to 89.009
99.010 to 99.019
99.020 to 99.030
114046
C87 ENT M62.10 / C87 ENT M65.10
8.150 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary,
can have different classes from one journal to another).
Depending on the thickness, the bearing shells are selected The following tables give the specifications of the main and
in classes of tolerance marked by a coloured sign big end bearing shells available as spares in the standard sizes
(red-green red/black green/black). (STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
Figure 53
STD +0.127
STD +0.127
DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 54 at top):
- The first number, of five digits, is the part number of the shaft.
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins
they refer to (Figure 54 at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the
status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the
main journals they refer to (Figure 54 at bottom).
Figure 54
CRANKPIN
CLASS
NOMINAL DIAMETER
81.915 to 81.925
81.925 to 81.935
81.935 to 81.945
177451
After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in
compliance with the following table:
Figure 55
STD.
114048
1 2 3
1
green yellow yellow
2
green green yellow
3
red green green
177450
C87 ENT M62.10 / C87 ENT M65.10
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C87 ENT M62.11 / C87 ENT M65.11
Figure 56
red/black =
mm 3.031 to 3.041
green/black =
mm 3.041 to 3.051
-0.127
green/black =
mm 3.0513 to 3.061
1 2 3
92.843 green/black green/black yellow/black
1
92.853 green/black yellow/black yellow/black
ATTENTION
The identification colours of the marks are given in the table
on page 31.
47557
Figure 58
STD.
1 2 3
Class yellow blue
green
2
green green yellow
3
red green green
C87 ENT M62.10 / C87 ENT M65.10
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C87 ENT M62.11 / C87 ENT M65.11
Figure 59
red/black =
mm 2.057 to 2.065
green/black =
mm 2.065 to 2.073 -0.127
green/black =
mm 2.073 to 2.081
1 2 3
81.789 green/black green/black yellow/black
1
81.799 green/black yellow/black yellow/black
Figure 60
177454
Using the hoist and hook 99360500 (1) mount the driving
shaft (2).
115883
ATTENTION
Before fitting the gear, spread Loctite type 603 on
approx. 5 mm wide band on crankshaft, at 30 mm from
contact surface.
After fitting the gear (1) on the crankshaft (2), heat it for
~15 minutes in an oven at temperature not higher than
180C.
Let them cool down after the installation.
If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.
Figure 61 Figure 63
114049 114050
Fit the oil jets (2) aligning the dowel with the opening (3) in Place bearing halves (1) on main journals (2).
the crankcase.
Check the installation clearance between the main journals
Position the half-bearings (1) and the thrust washers on the and the relative bearings as follows.
main journal supports as illustrated in Figure 46.
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Figure 64 Figure 65
114051 114615
Fit sized wire sections (2) on crankshaft (3) parallel to - Position the main journal caps (4) and fit the
longitudinal axis. strengthening plate (2) following the procedure
described:
Install main journals (1).
- Tighten the inner bolts and then the outer bolts by hand
starting from main journal 7 and continuing until main
journal 1.
- Tightening the bolts using torque wrench always starting
from main journal 7 and continuing until main journal
1:
1st stage: 140 Nm
2nd stage 60+60
Figure 66
47588
81041
Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Removal
Figure 69
Figure 68
126311 126312
Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin split rings (2) using the round tipped
(1). pliers (1).
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C87 ENT M62.11 / C87 ENT M65.11
Figure 70 Figure 71
49025 32618
Remove the piston pin (1). Measuring the gudgeon pin diameter (1) with a micrometer
(2).
If removal is difficult use the appropriate beater.
Figure 72
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.
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C87 ENT M62.11 / C87 ENT M65.11
Figure 73
177448
Piston rings
Figure 74
3513
Check the thickness of the piston ring (2) using a micrometer Figure 77
(1).
Figure 75
36134
Check the opening between the ends of the sealing rings (1),
using a thickness gauge (2), entered in the cylinder barrel (3).
16552
If the distance between ends is lower or higher than the value
Check the clearance between the sealing rings (2) and the required, replace split rings.
relative piston housings (1) using a thikness gauge (3).
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CONNECTING ROD
ATTENTION
When fitting the connecting rods, check that all of them are of same weight class and from the same supplier. The connecting
rod/cap is of torn type; before assembly verify that the connecting rod is not damaged. Each connecting rod can assembled
with the relative cap only. If the cap is assembled on the reverse side, the connecting rod must be rejected.
Figure 78
177447
1 Between the connecting rod bush and the connecting rod profile there must be a distance > 0.4 mm.
2 On the external breaking line, gap area allowed must be < 5 mm2.
3 No cracks are allowed in the threaded area.
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C87 ENT M62.11 / C87 ENT M65.11
Figure 79
115884
1. Coloured mark for identifying weight - 2. Coloured mark for identifying diameter grade - 3. Positioning stud visible from
the front of the engine - 4. Progressive number for identifying connecting rod
WEIGHT DIAMETER
85.987-85.996 Yellow
GRADE A
3331 g - 3361 g 85.997-86.005 Green
Yellow
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE B
3362 g - 3391 g 85.997-86.005 Green
Green
86.006-86.013 Blue
85.987-85.996 Yellow
GRADE C
3392 g - 3421 g 85.997-86.005 Green
Blue
86.006-86.013 Blue
C87 ENT M62.10 / C87 ENT M65.10
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C87 ENT M62.11 / C87 ENT M65.11
49029
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
117694 The rings need to be mounted with the word TOP (4)
facing upwards. Direct the ring openings so they are
staggered 120 apart.
ATTENTION
With the aid of the clamp 99360605 (1, Figure 82), fit the
connecting rod - piston assembly (2) in the cylinder liners,
according to the diagram of Figure 83, checking that:
- The openings of the piston rings are staggered 120
apart.
- The pistons are all of the same class, A or B.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil nozzles.
60616
Figure 83
60615
CYLINDER HEAD
Checking assembly clearance of big end pins Before taking down the cylinder head, check the seal using
To check the clearance proceed as follows: the appropriate tool; in case of leakage replace the cylinder
head.
- Connect the connecting rods to the relative main
journals, place a length of calibrated wire on the latter; Valve removal
Figure 85
Figure 84
81061
Install and fix tool 99360264 (2) with bracket (4); tighten by
81060 lever (1) until cotters are removed (3); remove the tool (2)
and the upper plate (3), the spring (6) and the lower plate (7).
- Install the connecting rod caps (1) with half-bearings; Repeat the operation on all the valves. Turn the cylinder head
tighten the connecting rod cap fixing screws (2) to upside down and remove the valves (8).
50 Nm (5 Kgm) torque. By tool 99395216 (3), tighten
the screws further at 90 angle;
- Remove the caps and check the clearance by comparing Checking the planarity of the head on the
the width of the calibrated wire with the scale calibration cylinder block
on the envelope containing the wire.
Figure 86
81062
ATTENTION
After leveling, make sure that valve sinking and injector
protrusion are as described in the relative paragraph.
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C87 ENT M62.11 / C87 ENT M65.11
VALVE Figure 88
Removing deposits and checking the valves
Figure 87
92841
VALVE GUIDES
Figure 89
47509
81067
Figure 91 Mounting
Figure 93
81068 8107
- Fasten extractor 99342149 (2) to case (2), by tightening - Lubricate sealing rings (3) and fit them to the case (4);
the nut (1), and pull out the case from cylinder head. fix tool 99365054 (2) to the cylinder head by means of
bracket A, install the new case, tighten the screw (1),
upsetting the case lower part.
Figure 92
Figure 94
81069
81071
- Adjust the casing hole (3) with borer 99394043 (1) and
guide bushing 99394045 (2).
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Figure 95 Figure 97
115891 114056
- Through miller 99394044 (1) and bushing 99394045 (2), INSTALLATION DIAGRAM FOR
ream the injector seat in the case (3), check the injector INJECTOR CASE
protrusion from the cylinder head plane which must be
1.2 to 1.5 mm.
Figure 96
47585
Using dial gauge (1), check the protrusion of the injector (2)
which must be 1.2 to 1.5 mm.
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C87 ENT M62.11 / C87 ENT M65.11
114210 114211
Figure 101
Intermediate gear pin
Figure 99
114212
ATTENTION
Bushing fitting in gears (2, Figures 78-79) must be performed
in arrow direction, placing them as shown in figures.
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Figure 102
81088
Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2); values are shown in table on
page 111.
Figure 103
81075
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not
exceed 0.030 mm.
If misalignment exceeds this value, replace the shaft.
Figure 104
81076
In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.If clearance exceeds 0.150 mm, replace bushes and, if necessary, the camshaft.
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CAMSHAFT
Figure 105
114213
114214
The bush surfaces must not show any sign of seizing or Measure the bush inner diameters with a baremeter and
scoring; if they do replace them. replace them, if the value measured exceeds the tolerance
value. To take down and fit back the bushes, use the proper
tool 99360505.
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Use beater 99360505 to change bushings Fitting the valves and oil seal ring
Removal
Figure 109
Figure 107
114280
VALVE SPRINGS
87051
Fitting
Lubricate the valve stem and insert the valves in the
For fitting, reverse operations performed for removal, with
respective valve guides; fit the lower caps (1). Use tool
care to make lube hole (1), drilled on bushing, coincide with
99360294 to fit the oil seal (2) on the valve guides (3) of the
corresponding hole in housing.
exhaust valves; then, to fit the valves, proceed as follows.
ATTENTION
Figure 108 Should valves not have been overhauled or replaced,
remount them according to numbering performed on
dismounting.
Intake valves are different form exhaust valves in that they
have a notch placed at valve head centre.
Figure 110
177446
86290
ROCKER SHAFT
Figure 111
114216
The camshaft eccentric elements control the 12 valve rocker arms directly. Valve control rocker arms are fitted directly on rocker
arm shaft. Rocker arms slide directly on cam profiles by rollers. The other end operates on a crosspiece laid directly on the two
valve rods. A pad is placed between rocker arm adjustment screw and crosspiece. Two lube ducts are machined inside rocker
a rms. Rocker arms shaft runs through the cylinder head; it must be removed to reach all units below.
Shaft
Figure 112
114217
114219
114218
Figure 115
1 6N
324 9N
43.65
33.5
22.95
22.95
117716
114245
MAIN DATA TO CHECK THE OVERPRESSURE
The oil pump (1) cannot be overhauled. On finding any VALVE SPRING
damage, replace the oil pump assembly.
See under the relevant heading for replacing the gear (2) of
the crankshaft.
Figure 116
112327
Figure 118
143676
73545
Figure 120
168 9
308 15
63
51
36.4
73542 88819
The oil pressure control valve is located on the left-hand side MAIN DATA TO CHECK THE OIL PRESSURE
of the crankcase. CONTROL VALVE SPRING
Start of opening pressure 5 bars.
Heat exchanger
Figure 122
143675
Figure 123
81101
05_148_C 05_149_C
1. By-pass flow to the engine - 2. Flow from the engine - 3. Flow from the exhaust manifold -
4. Flow to the exhaust manifold - 5. Flow to the sea water heat exchanger.
C87 ENT M62.10 / C87 ENT M65.10
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C87 ENT M62.11 / C87 ENT M65.11
Figure 126
174580 42566
ATTENTION
Removed screws must not be used again. Employ new
screws only.
Figure 127
Figure 129
174579
174573
45267
Figure 131
45268
Figure 133
114260
1. Install rail on cylinder head and lock retaining screws by TYPE DESCRIPTION LOCK TORQUE
hand. A M18 x 1.5 40 2 Nm
2. Install injectors in correct position and lock to required B M14 x 1.5 35 2 Nm
torque. C M16 x 1.5 40 2 Nm
ATTENTION
Check that the injectors (2) are equidistant from the springs
(1). Distance X which separates them should always be the ATTENTION
same.
After fitting the high-pressure pipelines, during the following
20 hours of work, frequently check engine oil level (IT MUST
3. Install pipes on rail and lock fittings by hand. NOT INCREASE).
4. Lock rail to cylinder head retaining screws at required
torque.
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114261
ATTENTION
Figure 135 Install gear casing within 10 min. from sealant application.
Figure 137
114264
Figure 138
45258
114272
Secure seal (1), install special tool 99346260 (2), lock nut (3)
Install high-pressure pump (1) on flange (2). to secure seal.
ATTENTION ATTENTION
If toothing on engine flywheel for engine start-up is very Crankshaft has a reference pin that must match with related
damaged, change crown wheel. housing on engine flywheel.
Refit crown wheel after heating up at approx. 200C.
Figure 140
114265
145832
49036
Camshaft installation
Figure 143
114267
Figure 147
114269
115064
Rotate the crankshaft with the tool 99360341 (3, Figure 154)
so that the opening marked with two references (5) is visible
from the lower inspection window in the flywheel cover
casing.
Figure 146 In this condition, insert the tool 99360612 (1) via the housing
(2) for the engine rpm sensor in the opening (3) in the engine
flywheel (4).
Figure 148
114270
Refit relay gear (2) and lock screws (1) using six-splined
spanner at required torque.
116052
ATTENTION
The relay gear (2) bushing can be replaced when worn out.
After securing bushing, grind it to reach dia. 58.010 0.10
mm.
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116055
Rotate the tool (1) 99395223 in order to insert the pin (3) ATTENTION
in the opening (2, Figure 148) in the head. Fasten the tool
(1) 99395223 using two M8x1.25 bolts (2). Before refitting rocker arm shaft assembly, check that all
adjustment screws have been fully unlocked.
Figure 150
Figure 152
114025
117691
Apply tool 99360558 (1) to rocker arm shaft (2) and install
Fit the camshaft drive gear (1) so that the fastening openings shaft on cylinder head.
in the shaft are aligned with the slots (2) in the drive gear. Lock retaining screws at required torque.
Position the gear (1) taking care to position the spokes (4)
as illustrated. This operation is necessary in order to be able
to fit the flywheel correctly which can only be fitted in one
position in relation to the gear.
Tighten the fixing bolts (3).
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Figure 154
145834
Fit the high pressure pump gear (5) tightening the nut (4) to
torque.
Use the flat washer (PN 17095914) in conjunction with the
nut (4) replacing the one supplied with the Bosch CP3 pump.
Fit the flywheel (6) so that the toothe marked with the arrow
() is in line with the sensor housing (2).
To check that the position is correct, insert tool (1)
99360613 in the timing sensor (2) housing.
Proceed with tightening the bolts (3). 114279
Remove the tools 99395223, 99360612 and 99360613. Secure special tool 99360341 (3) to gear casing.
ATTENTION
The arrow indicated engine rotation direction. Use tool
above to rotate engine flywheel (1) in engine rotation
direction to bring cylinder 1 piston approx. to TDC in blast
phase. This condition is reached when hole with notch (4),
following hole with two notches (5) drilled on engine
flywheel (1), is visible through manhole (2).
Figure 155
71774
114276
ATTENTION
Before refitting rocker arm shaft assembly, check that all
adjustment screws have been fully unlocked.
115063
Figure 159
Rotate the camshaft so that the openings at the rear of the
engine are arranged in the configuration illustrated in the
diagram.
Figure 157
114025
Apply tool 99360558 (1) to rocker arm shaft (2) and install
shaft on cylinder head.
Lock retaining screws at required torque.
Remove tool 99360612 (1, Figure 148).
Figure 160
117691
ATTENTION
Position the gear (1) taking care to position the spokes (4)
as illustrated.
This operation is necessary in order to be able to fit the
flywheel correctly which can only be fitted in one position 117693
in relation to the gear. Clean the surface of the parts to be joined removing
impurities and oil residuals. Apply silicon LOCTITE 275 (1)
on the front cover (2) as shown in the picture. The diameter
Lock retaining screws (3). of the sealing string must be 1.5 0.5/0.2 mm.
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115064
106535
114281
Position the dial gauge with a magnetic base (1) with the
(flat-based) rod positioned on the roller (2) for the rocker In case conditions shown in Figure 162 and shown at paras
arms which controls the exhaust valve for cylinder no. 3 and 1 and 2 are not found, operate as follows:
apply a pre-loading of 6 mm.
1) release screws (2) securing gear (1) of camshaft to as to
ATTENTION make control gear and camshaft independent;
During the measurement the rod for the dial gauge should 2) conveniently operate on engine flywheel so as to obtain
always be perpendicular to the engine axis and NOT to the conditions indicated at paras 1 and 2, Figure 163,
surface of the head. considering that cam lift value must remain unchanged;
Using tool 99360341 (3, Figure 154), rotate crankshaft 3) lock screws (2) and repeat control as already described;
clockwise till dial gage arrow reaches minimum value (max 4) lock screws (2) at required torque.
cam lift), after which it no longer varies.
Zero set dial gage.
Rotate engine flywheel anticlockwise till dial gage reads
camshaft cam lift value = 4.70 0.05 mm.
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114275
ATTENTION
Pipes previously removed ca no longer be refit.
Change them.
Install fuel supply pipeline (1) from high pressure pump to rail.
Lock nuts at 35 Nm torque.
ATTENTION
After high-pressure pipe installation, during the following
20 hours of work, frequently check engine oil level.
( IT MUST NOT INCREASE ).
114284
Figure 167
Install gear (7) of high pressure pump and lock nut (8) at
required torque.
ATTENTION
When refitting, use the flat washer (PN 17095914) in
conjunction with the nut (4) replacing the one supplied with
BOSCH pump CP3.
Fit the flywheel (4) so that the tooth marked with the arrow
() is in line with the sensor housing (6). 114285
Rotate crankshaft and bring cylinder n.1 piston to Install centrifugal filter (1) on tune wheel and lock screws (2)
compression phase at TDC: Rotate flywheel opposite to at required torque.
regular rotation direction by 1/4 of rev.
Rotate flywheel again in regular rotation direction till hole Figure 168
identified by double notch (2) shows through inspection hole
under flywheel cover box.
Insert tool 99360612 (1) in flywheel sensor housing (3).
Insert tool 99360613 through phase sensor housing (6) on
tooth machined on tune wheel.
In case tool (6) is difficult to insert, unlock screws (5) and
orient tune wheel (4) to properly match the tooth.
Lock screws (5).
114286
Figure 169
114287 114288
Install blow-by body (1) with related seal and lock screws (2)
Adjustment of clearance between rocker arms and at required torque.
intake/exhaust valve control crosspieces must be performed
with utmost care. Bring to blast phase cylinder to be adjusted; Install cover (3) and lock screws (4) at required torque.
the valves of this cylinder are closed while the symmetric
cylinder valves are balanced. Symmetric cylinders are 1-6; 2-5
and 3-4.
In order to perform these operations correctly, refer to Figure 171
procedure and table below.
- Use a polygonal spanner to release lock nut (1) of rocker
arm adjustment screw (2).
- Insert filler gage (3) having same value of operating
clearance shown in Characteristic and data tables.
- Use special spanner to lock/unlock adjustment screw.
- Check that filler gage (3) slides with a low friction.
- Lock nut (1) retaining the adjustment screw.
174574
Install cylinder head cover (1) and lock screws (2) at required
115880 torque following order shown in Figure 174 diagram.
17 14 13 1 4 5 8
18 9
19 10
20 11
16 15 12 2 3 6 7
Figure 175
117695
Rotate the engine. Before assembling the suction rose, it is necessary to seal the contact area (1) between basement, flywheel
casing and front cover with LOCTITE, following the herein instructions. Clean the surfaces of the parts to be joined removing
impurities and oil residuals. Apply silicon LOCTITE 275 (1) as shown in the picture. The diameter of the sealing string must be
1.5 0.5/0.2 mm.
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114031b
ATTENTION
Automatic tensioners do not require further adjustments
after the installation.
143674
Fit the oil sump (2), tightening the screws (1) to the
prescribed torque.
Figure 178
143672
Fit the oil filter adapter (1) and the heat exchanger (2).
C87 ENT M62.10 / C87 ENT M65.10
8.194 OVERHAUL MAY 2012
C87 ENT M62.11 / C87 ENT M65.11
C87 ENT M62.10 / C87 ENT M65.10
MAY 2012 SAFETY REGULATIONS 9.195
C87 ENT M62.11 / C87 ENT M65.11
SECTION 9
Safety regulations
Page
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . 197
SAFETY REGULATIONS
Standard safety regulations - Put rags smeared with oil, diesel fuel, or solvents in
Pay particular attention to some precautions that must be fireproof containers;
followed by all means in any working place and whose - Do not carry out any intervention you have not been
non-observance will make any other measures useless or not given all necessary instructions for;
sufficient to ensure safety to the personnel in charge of
maintenance. - Do not use any tool or equipment for any operation
different from the ones they have been designed and
- Be informed and also inform personnel of the laws in provided for. Serious injury may occur;
force regulating safety, by making informative
documentation available for consultation; - In case of test or calibration operations requiring the
engine to be in operation, ensure that the area is
- Keep working areas as clean as possible, and ensure sufficiently ventilated or use specific aspirators to
adequate ventilation; eliminate exhaust gas. Danger: poisoning and death.
- Ensure that working areas are provided with emergency
kits. These must be clearly visible and always fitted with During maintenance
adequate sanitary equipment; - Never open the filler cap of the cooling circuit when the
engine is hot. Operating pressure would provoke hot
- Provide for adequate fire extinguishing means, properly liquid to pour out with serious danger and risk of scalding.
indicated and always easy to reach. Their efficiency must Wait until the temperature decreases below 50 C;
be checked on a regular basis and the personnel must be
trained on intervention methods and priorities; - Never top up an overheated engine with cooler and use
only appropriate liquids;
- Provide specific exit points to evacuate the areas in case
of emergency, giving adequate indications of emergency - Always operate with the engine turned off: in case
escape paths; particular circumstances require maintenance
intervention on the running engine, be aware of all risks
- Smoking in working areas subject to fire danger must be involved in such operation;
strictly prohibited;
- Be equipped with adequate and safe containers for
- Provide warnings by means of adequate boards signaling draining engine liquids and exhaust oil;
danger, prohibitions, and indications to ensure easy
understanding of the instructions even in case of - Keep the engine clean from oil, diesel fuel, and/or
emergency. chemical solvents stains;
- The use of solvents or detergents during maintenance
Accident prevention may generate toxic vapors. Always keep working areas
- When working close to engines and equipment in ventilated. Whenever necessary wear a safety mask;
motion, do not wear unsuitable clothes, with loose ends,
nor jewels such as rings and chains; - Do not leave rags impregnated with flammable
substances close to the engine;
- Wear safety gloves and goggles when performing the
following operations: - Upon engine start after maintenance, undertake proper
preventive action to stop air suction in case of
- Filling inhibitors or antifreeze; overspeed;
- Topping or replacing lubrication oil; - Do not use fast screwdriver tools;
- Using compressed air or liquids under pressure - Never disconnect batteries when the engine is running;
(pressure allowed: 2 bar).
- Disconnect batteries before any intervention on the
- Wear a safety helmet when working close to hanging electrical system
loads or equipment operating at head height level;
- Disconnect batteries from the system to charge them
- Always wear safety shoes and clothes that adhere to the with the battery charger;
body, better if provided with elastics at the ends;
- After every intervention, verify that the battery clips`
- Use protection cream for your hands; polarity is correct and that the clips are tight and safe
- Change wet clothes as soon as possible; from accidental short circuit and oxidation;
- In presence of current tension exceeding 48-60 V verify - Do not disconnect or connect electrical connections
the efficiency of earth and mass electrical connections. while the power is connected.
Ensure that hands and feet are dry and carry out working
operations using isolating foot-boards. Do not carry out
working operations you are not trained for;
- Do not smoke nor have exposed flames close to
batteries and flammable material;
C87 ENT M62.10 / C87 ENT M65.10
9.198 SAFETY REGULATIONS MAY 2012
C87 ENT M62.11 / C87 ENT M65.11