Table of Contents

XTX Series Tractors

Service/Diagnostic Manual SM 8-15002

1 GENERAL
Safety Rules, General Information and Torque Specifications ............................1001 SM

2 ENGINE
NOTE: For Service and Overhaul procedures refer to your Engine Service Manual. SM
Error Codes: Tier 2 Tier 3
3 FUEL
NOTE: For Service and Overhaul procedures refer to your Engine Service Manual.

4 ELECTRICAL
Electrical Troubleshooting and Schematics.........................................................4001 SM
Instrument Cluster Programming.........................................................................4002 SM
Battery Servicing and Testing..............................................................................4004 SM

5 STEERING
Steering Column and Steering Hand Pump Removal .........................................5001 SM
Rexroth Steering Hand Pump..............................................................................5002 SM

6 TRANSMISSION
Transmission How it Works .......................................................................................6
Guidelines for Separating the Speed and Range Transmissions .......................6003 SM
8 Speed Powershift Transmission Servicing .......................................................6006 SM
Range Transmission Servicing ...........................................................................6007 SM
Differential and Differential Lock Servicing .........................................................6012 SM
MFD Clutch Servicing .........................................................................................6017 SM
Rear Axle Removal .............................................................................................6018 SM
PTO Servicing - shiftable/reversible ....................................................................6019 SM
MFD Front Axle (20.29 Rigid Axle) .....................................................................6021 SM
MFD Front Axle (20.43 Rigid Axle) ................................................................. 6021-A SM
MFD Front Axle (20.29 Suspended Axle) ...........................................................6022 SM
MFD Front Axle (20.43 Suspended Axle) ....................................................... 6022-A SM

7 BRAKES
Brakes How it Works................................................................................................. 7
Service Brakes ................................................................................................... 7002 SM

8 HYDRAULICS
Hydraulics How it Works ........................................................................................... 8
Hydraulic Troubleshooting and Schematic ......................................................... 8001 SM
Charge/Lubrication Pump ................................................................................... 8003 SM
Remote Valves........................................................................................... ......... 8008 SM

9 CHASSIS
Pedal, Lever and Switch Adjustments ................................................................ 9001 SM
10CONTROLLER SYSTEMS
Electrical Controllers How it Works......................................................................... 10
Auxiliary/Remote Valve Controller - Error Codes,
Troubleshooting and Schematics ................................................................. 10001 SM
Hitch/PTO Controller - Error Codes,
Troubleshooting and Schematics ................................................................. 10002 SM
Independent Front Suspension Axle Controller - Calibration,
Error Codes, Troubleshooting and Schematics............................................. 10003 SM
Transmission and Cab Controller - Calibration, Error Codes,
Troubleshooting and Schematics ................................................................. 10006 SM
Instrument Cluster Controller - Error Codes,
Troubleshooting and Schematics ................................................................. 10009 SM
Controller Reprogramming
(Using The McCormick Diagnostic Centre) .................................................. 10010 SM
Cab Suspension Controller - Calibration, Error Codes,
Troubleshooting and Schematics ................................................................. 10011 SM
Automatic Temperature Control - Error Codes,
Troubleshooting and Schematics ................................................................. 10012 SM

NOTE: Information contained in this manual may cover features that are not available in all markets
worldwide.

NOTE: References throughout this manual may be made to sections currently not available. These
Sections will be made available at a later date.
 1001
Section
1001

SAFETY, GENERAL INFORMATION

AND STANDARD TORQUE SPECIFICATIONS

© 2001 McCormick Tractors International Limited.

SM 8-10080 March 2001
 2 SECTION 1001

TABLE OF CONTENTS

SAFETY ................................................................................................................................................................... 3

GENERAL INFORMATION
Cleaning ............................................................................................................................................................... 5
Inspection ............................................................................................................................................................. 5
Bearings ............................................................................................................................................................... 5
Needle Bearings .................................................................................................................................................. 5
Gears ................................................................................................................................................................... 5
Oil Seals, O-Rings And Gaskets .......................................................................................................................... 5
Shafts ................................................................................................................................................................... 5
Service Parts ........................................................................................................................................................ 5
Lubrication ........................................................................................................................................................... 5

STANDARD TORQUE DATA FOR NUTS AND BOLTS

Chart 1 (Plain Nuts/Bolts) .................................................................................................................................... 6
Chart 2 (Phosphate Coated Nuts/Bolts) ............................................................................................................... 6
Chart 3 (Zinc or Cadmium Plated Nuts/Bolts) ...................................................................................................... 7

SM 8-10080 Issued 03-2001

 SECTION 1001 3

SAFETY

This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY

IS INVOLVED. The message that follows the symbol contains
! important information about safety. Carefully read the message.
Make sure you fully understand the causes of possible injury or
death.

To prevent injury always follow the Warning,

Caution and Danger notes in this section and
throughout the manual.
Put a warning tag as shown below on the key for the
key switch when carrying out servicing or repairs to
the tractor. Warning tags (publication number 2-1000)
are available from your McCormick dealer.
REASON/RAISON
WARNING: Before starting engine, study
Operator’s Manual safety messages.
Read all safety signs on machine. Clear
the area of other persons. Learn and
practice safe use of controls before
operating.
! It is your responsibility to understand and
follow manufacturers instructions on
machine operation, service, and to

observe pertinent laws and regulations.

!
VERNUNFT/RAZON

Operator’s and Service Manuals may be

obtained from you McCormick dealer.

DO NOT OPERATE WARNING: If you wear clothing that is too

NE PAS UTILISER loose or do not use the correct safety
NICHT BETREIBEN equipment for your job, you can be
NO UTILIZAR
injured. Always wear clothing that will not
! catch on objects. Extra safety equipment
that can be required includes hard hat,
safety shoes, ear protection, eye or face
protection, heavy gloves and reflector
clothing.
2-1000

WARNING: When working in the area of

WARNING: Read the operators manual to the fan belt with the engine running, avoid
! familiarize yourself with the correct ! loose clothing if possible, and use
control functions. extreme caution.

WARNING: Operate the machine and WARNING: When doing checks and tests
equipment controls from the seat on the equipment hydraulics, follow the
! position only. Any other method could ! procedures as they are written. DO NOT
result in serious injury. change the procedure.

WARNING: This is one a man machine, no WARNING: When putting the hydraulic
! riders allowed . cylinders on this machine through the
! necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.

WARNING: Use insulated gloves or

! mittens when working with hot parts.

SM 8-10080 Issued 03-2001

 4 SECTION 1001
CAUTION: Lower all attachments to the
ground or use stands to safely support
! the attachments before you do any
maintenance or service.
CAUTION: Pin sized and smaller streams
of hydraulic oil under pressure can
penetrate the skin and result in serious
infection. If hydraulic oil under pressure
does penetrate the skin, seek medical
treatment immediately. Maintain all hoses
! and tubes in good condition. Make sure
all connections are tight. Make a
replacement of any tube or hose that is
damaged or thought to be damaged. DO
NOT use your hand to check for leaks,
use a piece of cardboard or wood.
CAUTION: When removing hardened pins
such as a pivot pin, or a hardened shaft,
use a soft head (brass or bronze) hammer
! or use a driver made from brass or bronze
and a steel head hammer.
CAUTION: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
! grinder, wear eye protection that
completely encloses the eyes (approved
goggles or other approved eye
protectors).
CAUTION: Use suitable floor (service)
jacks or chain hoist to raise wheels or
! tracks off the floor. Always block machine
in place with suitable safety stands.
SM 8-10080
CAUTION: When servicing or repairing
the machine. Keep the shop floor and
operator’s compartment and steps free of
! oil, water, grease, tools, etc. Use oil
absorbing material and or shop cloths as
required. Use safe practices at all times.
CAUTION: Some components of this
machine are very heavy. Use suitable
! lifting equipment or additional help as
instructed in this Service Manual.
DANGER: Engine exhaust fumes can
cause death. If it is necessary to start the
engine in a closed place, remove the
! exhaust fumes from the area with an
exhaust pipe extension. Open the doors
and get outside air into the area.
DANGER: When the battery electrolyte is
frozen, the battery can explode if (1), you
try to charge the battery, or (2), you try to
jump start and run the engine. To prevent
! that battery electrolyte from freezing, try
to keep the battery at full charge. If you do
not follow these instructions, you or
others in the area can be injured.
DANGER: Batteries contain acid and
explosive gas. Explosions can result from
sparks, flames or wrong cable
connections. To connect the jumper
! cables correctly to the battery of this
machine see the Operator’s Manual.
Failure to follow these instructions can
cause serious injury or death.
Issued 03-2001
 SECTION 1001
GENERAL INFORMATION
Cleaning
Clean all metal parts except bearings, in mineral
spirits or by steam cleaning. Do not use caustic
soda for steam cleaning. After cleaning dry and put
oil on all parts. Clean oil passages with compressed
air. Clean bearings in kerosene, dry the bearings
completely and put oil on the bearings.
Inspection
Check all parts when the parts are disassembled.
Replace all parts that have wear or damage. Small
scoring or grooves can be removed with a hone or
crocus cloth. Complete visual inspection for
indications of wear, pitting and the replacement of
parts necessary will prevent early failures.
Bearings
Check bearings for easy action. If bearings have a
loose fit or rough action replace the bearing. Wash
bearings with a good solvent or kerosene and
permit to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR.
Needle Bearings
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position
put petroleum jelly on the inside and outside
diameter of the bearings.
SM 8-10080
5
Gears
Check all gears for wear and damage. Replace
gears that have wear or damage.
Oil Seals, O-Rings And Gaskets
Always install new oil seals, o-rings and gaskets.
Put petroleum jelly on seals and o-rings.
Shafts
Check all shafts that have wear or damage. Check
the bearing and oil seal surfaces of the shafts for
damage.
Service Parts
Always install genuine McCormick service parts,
when ordering refer to the Parts Catalog for the
correct part number of the genuine McCormick
replacement items. Failures due to the use of other
than genuine McCormick replacement parts are not
covered by warranty.
Lubrication
Only use the oils and lubricants specified in the
Operators or Service Manual. Failures due to the
use of non specified oils and lubricants are not
covered by warranty.
Issued 03-2001
 6 SECTION 1001

STANDARD TORQUE DATA FOR NUTS AND BOLTS

NOTE: A “click type” torque wrench is recommended for the bolt torques listed below.

Chart 1 (Plain Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SIZE MIN MAX MIN MAX
(mm) lb ft Nm lb ft Nm lb ft Nm lb ft Nm
M4 3.0 4.0 3.4 4.5 4.3 5.8 4.8 6.5
M5 4.8 6.5 5.5 7.5 7.0 9.5 7.8 10.5
M6 8.2 11.0 9.2 12.5 11.8 16.0 13.3 18.0
M8 20.0 27.0 22.5 31.0 28.7 39.0 32.3 44.0
M10 40.0 54.0 45.0 61.0 56.0 77.0 64.0 87.0
M12 69.0 94.0 78.0 106.0 100.0 134.0 110.0 151.0
M14 110.0 150.0 125.0 170.0 160.0 215.0 180.0 240.0
M16 175.0 235.0 190.0 260.0 245.0 335.0 275.0 375.0
M20 345.0 470.0 390.0 530.0 480.0 650.0 540.0 730.0
M22 475.0 640.0 530.0 720.0 655.0 890.0 735.0 1000.0
M24 600.0 810.0 675.0 915.0 830.0 1125.0 930.0 1265.0
M30 1190.0 1615.0 1340.0 1815.0 1645.0 2235.0 1855.0 2515.0
M36 2080.0 2825.0 2340.0 3175.0 2875.0 3900.0 3235.0 4390.0

Chart 2 (Phosphate Coated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SIZE MIN MAX MIN MAX
(mm) lb ft Nm lb ft Nm lb ft Nm lb ft Nm
M4 2.3 3.0 2.6 3.4 3.2 4.4 3.6 4.9
M5 3.6 4.9 4.1 5.6 5.2 7.1 5.9 8.0
M6 6.2 8.3 6.9 9.4 8.9 12.0 10.0 13.5
M8 15.0 20.3 16.9 23.3 21.5 29.2 24.2 32.8
M10 30.0 41.0 34.0 46.0 42.0 58.0 48.0 65.0
M12 52.0 71.0 59.0 80.0 75.0 101.0 83.0 113.0
M14 83.0 113.0 94.0 126.0 120.0 161.0 135.0 180.0
M16 131.0 176.0 143.0 195.0 185.0 251.0 205.0 280.0
M20 259.0 353.0 293.0 400.0 360.0 490.0 405.0 550.0
M22 355.0 480.0 400.0 540.0 490.0 665.0 550.0 750.0
M24 450.0 608.0 506.0 686.0 625.0 845.0 700.0 950.0
M30 893.0 1211.0 1005.0 1361.0 1235.0 1675.0 1390.0 1885.0
M36 1560.0 2119.0 1755.0 2381.0 2156.0 2925.0 2425.0 3295.0

SM 8-10080 Issued 03-2001

 SECTION 1001 7

Chart 3 (Zinc or Cadmium Plated Nuts/Bolts)

BOLT TYPE 8.8 TYPE 10.9

SIZE MIN MAX MIN MAX
(mm) lb ft Nm lb ft Nm lb ft Nm lb ft Nm
M4 2.6 3.5 2.9 3.9 3.7 5.0 4.1 5.6
M5 4.1 5.6 4.6 6.3 5.9 8.0 6.6 9.0
M6 7.0 9.5 7.8 10.6 10.0 13.6 11.3 15.3
M8 17.0 23.1 19.1 25.9 24.4 33.1 27.4 37.2
M10 34.0 46.0 38.3 52.0 48.0 65.0 54.0 74.0
M12 59.0 80.0 66.0 90.0 85.0 114.0 94.0 128.0
M14 94.0 128.0 106.0 145.0 136.0 183.0 153.0 205.0
M16 149.0 200.0 161.0 220.0 208.0 285.0 235.0 320.0
M20 293.0 400.0 330.0 450.0 408.0 555.0 460.0 620.0
M22 400.0 545.0 450.0 615.0 555.0 755.0 625.0 850.0
M24 510.0 690.0 575.0 780.0 705.0 955.0 790.0 1075.0
M30 1010.0 1375.0 1140.0 1545.0 1400.0 1900.0 1580.0 2140.0
M36 1770.0 2400.0 1990.0 2700.0 2445.0 3315.0 2750.0 3730.0

SM 8-10080 Issued 03-2001

Service Manual
Electronic Common Rail
6 Cylinder (Tier 2) Engines

© 2003 McCormick Tractors International Limited.

SM 8-12900 November 2003

i
This publication provides the features, data and correct
method of repair operations that can be performed on every
single component of the engine.
Following the instructions given and using the special tools will
ensure correct repairing, within the scheduled times, while
also protecting operators against possible accidents.
Before starting any repair work, make sure that all
accident-prevention equipment is close at hand and in
efficient conditions.
Therefore, check and wear the items specified by the rules of
safety: goggles, helmet, gloves, shoes.
Before use, check all the working, hoisting and handling
equipment.

The possibility exists that the information given in this manual

may not be up to date as a result of modifications adopted by
the Manufacturer at any time for reasons of a technical or
commercial nature or to adjust to the laws in force in the
different Countries.
The reproduction, even only in part, of the text and
illustrations is forbidden.
ED. NOVEMBER 2003 1

CONTENT OF SECTIONS

General information 1

Fuel 2

Duty - Industrial applications 3

Common Rail Engines

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four sepa-
rate parts:
1.. Mechanical part,
1 related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2.. Electrical part, concerning wiring harness, electrical
2
and electronic equipment with different characteristics
based on the relating specific duty.
3.. Maintenance planning and specific overhaul.
3
4.. Troubleshooting part dedicated to the operators who, being
4
entitled to provide technical assistance, shall have simple and
direct instructions to identify the cause of the major inconve-
niences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
The appendix reports general safety prescriptions to be follo-
wed by all operators whether being in-charge of installation or
maintenance, in order to avoid serious injury.
22 ED.
2003
NOVEMBER 2003
NEF ENGINES
 ED. NOVEMBER 2003 3

SPECIAL REMARKS
Where possible, the same sequence of procedures has been followed for easy reference.
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.

Example
‡1 Ø 1 = housing for connecting rod small end bush
Tighten to torque
Tighten to torque + angular value
§
‡ 2 Ø 2 = housing for connecting rod bearings
4 ED. NOVEMBER 2003

Graph and symbols

Removal Intake
Disconnection
Refitting Exhaust
Connection
Removal Operation
Disassembly
Fitting in place Compression ratio
Assembly ¸

Tighten to torque Tolerance

Weight difference

Tighten to torque + angle value Rolling torque

§

Press or caulk Replacement

Original spare parts

Regulation Rotation
Adjustment

Warning Angle
! Note Angular value
Visual inspection Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check

Equipment Temperature

Surface for machining Pressure

Machine finish bar

Interference Oversized
Strained assembly Higher than}.
Maximum, peak
Thickness Undersized
Clearance Less than}.
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Sealant Temperature < 0 qC
Adhesive Cold
Winter
Temperature > 0 qC
Air bleeding Hot
Summer
ED. NOVEMBER 2003 SECTION 1 - GENERAL SPECIFICATIONS 1

SECTION 1

General Specifications

Page

ENGINE ID. CODE 3

LUBRICATING CIRCUIT, 4 AND 6 CYLINDERS 5
OIL VAPOUR RECIRCULATING SYSTEM 7
COOLING CIRCUIT SYSTEM, 4 AND 6 CYLINDERS 8
AIR INDUCTION BOOST DIAGRAM 12
2 SECTION 1 - GENERAL SPECIFICATIONS ED. NOVEMBER 2003
 ED. NOVEMBER 2003 SECTION 1 - GENERAL SPECIFICATIONS 3

ENGINE IDENTIFICATION CODE

F 4 A E 0 6 8 4 F * D +

Exhaust emiss. level

Homologation power

Duty No.

Injection

Cylinder No.

Engine cycle — cylinder position

Engine

Type of Engine Block 0 = 4-stroke,

vertical
A =Not struct.
Engine series B = Not struct
C =Struct 4 = 4 cylind.
6 = 6 cylind.

8 = DI. TCA
0 = Different between the 5 = Genset
following applications 6 = Marine
1 = Truck 7 = Industrial
2 = Bus and fork lift truck
3 = Rail rood 8 = Cars and
4 = M.T. vehicles similar
and tractors 9 = Army

X Y Y Y Y Y Y Y Y Y

X = 1 Common Rail 4 valve Model No. within D.B.

4 SECTION 1 - GENERAL SPECIFICATIONS ED. NOVEMBER 2003

SPECIFIC ENGINE CODE

Y XX Y Y Y . Y XX . XX

Engineering code

Exhaust emiss. level

C = Euro3.
E = E (NRMM)
Power: U = EPA USA
A = Not superch. G = Gas
S = Supercharging M = Marine
T = Supercharging
with aftercooler

Engine block:
Feed system: N = Not struct.
M = Mechanical S = Struct.
E = Electronic

Total displacement or n.
of cylinders

Engine series:
N = Engine

EXAMPLES:
N40ENT.C
N = Engine
40 = 4 liters
E = Electronic
N = Type of Engine block
T = Supercharger with aftercooler
C = Euro3
 ED. NOVEMBER 2003 SECTION 1 - GENERAL SPECIFICATIONS 5

LUBRICATION (4 CYLINDERS)

Lubrication by forced circulation is achieved through oil rotary
expansion pump (1), placed in the front part of the basement,
driven by the straight-tooth gear splined to the shaft’s bar hold.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Lubrication involves the heat exchanger as well, the turbo-
blower and the eventual compressor for any eventual com-
pressed air system. All these components may often vary ac-
cording to the specific duty and will therefore be examined in
the specific section.

Figure 1

Oil recover from the

turbo-blower

To the exchan-
ger and to the
turbo-blower

Routing of oil under pressure

Routing of oil return by gravity to sump
Introduction of oil

LUBRICATION SYSTEM LAYOUT

6 SECTION 1 - GENERAL SPECIFICATIONS ED. NOVEMBER 2003

LUBRICATION (6 CYLINDERS)
Even for the 6 cylinders version lubrication is obtained by
forced circulation and achieved through an oil rotary expan-
sion pump similar to the 4 cylinders’ one.
Also in this case, the components such as the oil exchanger,
the turbo-blower and the eventual compressor are specifically
studied and made out to suit the equipment or the duty for
which the engine has been developed.

Figure 2

Oil recover from the

turbo-blower

To the exchan-
ger and to the
turbo-blower

Routing of oil under pressure

Routing of oil return by gravity to sump
Introduction of oil

LUBRICATION SYSTEM LAYOUT

 ED. NOVEMBER 2003 SECTION 1 - GENERAL SPECIFICATIONS 7

OIL VAPOUR RECYCLING

Figure 3

70484

Oil condensate
Oil vapours

1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine

The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).
8 SECTION 1 - GENERAL SPECIFICATIONS ED. NOVEMBER 2003

COOLING SYSTEM (4 CYLINDERS)

The engine cooling system, closed circuit forced circulation

type, generally incorporates the following components:
- Expansion tank; placement, shape and dimensions are
subject to change according to the engine’s equipment.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
- Viscous pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as
well will be specifically equipped based on the engine’s
development.
- Heat exchanger to cool the lubrication oil: even this
component is part of the engine’s specific equipment.
- Centrifugal water pump, placed in the front part of the
engine block.
- Thermostat regulating the circulation of the cooling
liquid.
- The circuit may eventually be extended to the
compressor, if this is included in the equipment.
 ED. NOVEMBER 2003 SECTION 1 - GENERAL SPECIFICATIONS 9

Figure 4

EXPANSION TANK

EXPANSION TANK

HEATER
(Optional)

RADIATOR

RADIATOR

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

COOLING SYSTEM LAYOUT 74194
10 SECTION 1 - GENERAL SPECIFICATIONS ED. NOVEMBER 2003

COOLING SYSTEM (6 CYLINDERS)

The engine cooling system, closed circuit forced circulation
type, is of a similar design as the 4 cylinders engine.
It incorporates necessary components such as the radiator,
the heat exchanger, the expansion tank and some ancillary
components such as the heater or the compressor for the
compressed air.
Such components always vary according to the engine’s
equipment and duty.
 ED. NOVEMBER 2003 SECTION 1 - GENERAL SPECIFICATIONS 11

Figure 5

EXPANSION TANK

EXPANSION TANK
HEATER
(Optional)

RADIATOR

RADIATOR

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

COOLING SYSTEM LAYOUT

12 SECTION 1 - GENERAL SPECIFICATIONS ED. NOVEMBER 2003

AIR INDUCTION - BOOST DIAGRAM

Figure 6

4 Cylinders version

AIR FILTRE TURBOCHARGER

EXHAUST

RADIATOR

6 Cylinders version

AIR FILTRE TURBOCHARGER

EXHAUST

RADIATOR

74195

Description
The turbocharger is composed by the following main parts:
one turbine, one transforming valve to regulate the boost
feeding pressure , one main body and one compressor.
During engine working process, the exhaust emissions flow
through the body of the turbine, causing the turbine disk
wheel’s rotation.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates,
compressing the drawn air through the air filter.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
The turbocharger is equipped with a transforming valve to
regulate the pressure , that is located on the exhaust
collector before the turbine and connected by piping to the
induction collector.
It’s funchon is to restrict the exhaust of the emissions ,
releasing part of them directly to the exhaust tube when the
boost feeding pressure, over the compressor, reaches the
prescribed bar value.
The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
ED. NOVEMBER 2003 SECTION 2 - FUEL 1

SECTION 2

Fuel

Page

COMMON RAIL 3
WORKING PROCESS 5
FUEL SYSTEM LAYAUT 6
MECHANICAL FUEL PUMP 8
CP3 HIGH PRESSURE PUMP 9
RAIL (PRESSURE ACCUMULATOR) 13
BOOST GAUGE VALVE 14
FLOW LIMITERS 15
ELECTRO-INJECTOR 16
PRESSURE LIMITER FOR FUEL RETURN 17
2 SECTION 2 - FUEL ED. NOVEMBER 2003
 ED. NOVEMBER 2003 SECTION 2 - FUEL 3

COMMON RAIL
General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1450 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.

System description
Electric system

Figure 1

1 6

3
9

10
5
11
74168

1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engine’s cooling liquid - 3. Fuel pressure sensor
cable - 4. Sensor of engine’s oil temperature and pressure - 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature
and air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor - 10. Pressure gauge cable -
11. EDC 7 gearbox.

Through the sensors, present on the engine, the ECU con-
trols the engine operation.
Air pressure/temperature sensor
It is a component integrating a temperature sensor and a
pressure sensor.
Fitted on the intake manifold, it measures the max. inlet air
capacity to calculate precisely the fuel quantity to inject at
every cycle.
The outlet voltage is proportional to the pressure or tem-
perature obtained by the sensor.
Engine oil temperature and pressure sensor
Same as air pressure/temperature sensor, it is fitted on the
engine oil filter, in a horizontal position.
It measures engine oil temperature and pressure.
4 SECTION 2 - FUEL ED. NOVEMBER 2003
Fuel pressure sensor
Assembled on a rail end, it measures the fuel pressure in the
rail in order to determine the injection pressure.
The injection pressure value is used to control the pressure
and to determine the electric injection control length.
Fuel temperature sensor
It is a sensor that is equal to the previous one.
It measures fuel temperature to provide the control unit with
an index of the diesel fuel thermal state.
Coolant temperature sensor
It is a variable-resistance sensor suitable to measure the
coolant temperature to provide the control unit with an
index of the engine thermal state.
Output shaft sensor
It is an inductive sensor placed on the front engine part.
Signals generated through the magnetic flow that is closed on
the phonic wheel, change their frequencies depending on
output shaft rotation speed.
Timing sensor
It is an inductive sensor placed on the engine rear left part.
It generates signals obtained from magnetic flow lines that are
closed through holes obtained on the keyed gear on the
camshaft. The signal generated by this sensor is used by the
ECU as injection phase signal.
Though being equal to the flywheel sensor, it is NOT
interchangeable since it has a different outside shape.
System functionality
Self-diagnosis
The ECU self-diagnostic system checks signals coming from
sensors by comparing them with threshold data.
Code recognition
The EDC7 control unit communicates with the Immobilizer
control unit (if fitted) to obtain the startup consent.
Engine pre-heating resistance check
The pre-post heating is activated when even only one of the
water, air or fuel temperature sensors signals a temperature
that is less than 5 qC.
Phase recognition
By means of signals coming from camshaft sensor and
flywheel sensor, the cylinder on which fuel must be injected
is recognised upon startup.
Injection control
The control unit, depending on information coming from
sensors, controls the pressure regulator, and changes
pre-injection and main injection modes.
Closed-loop control for injection pressure
Depending on engine load, measured by processing signals
coming from various sensors, the control unit controls the
regulator in order to always have the optimum pressure.
Pilot and main injection spark advance control
The control unit, depending on signals coming from various
sensors, computes the optimum injection point according to
an internal mapping.
Idle speed control
The control unit processes signals coming from various
sensors and adjusts the amount of injected fuel.
It controls the pressure regulator and changes the injection
time of injectors.
Within certain thresholds, it also takes into account the
battery voltage.
Maximum speed limiting
At 2700 rpm, the controlunit limits fuel flow-rate by reducing
the injectors opening time.
Over 3000 rpm it deactivates the injectors.
Cut Off
Fuel cut off upon release is controlled by the control unit
performing the following logics:
- it cuts off injectors supply;
- it re-activates the injectors shortly before idle speed is
reached;
- it controls fuel pressure regulator.
Smoke control upon acceleration
With strong load requests, the control unit, depending on
signals received by air inlet meter and engine speed sensor,
controls the pressure regulator and changes the injectors
actuation time, in order to avoid exhaust smoke.
Fuel temperature control
When the fuel temperature exceeds 75 qC (measured by the
sensor placed on fuel filter) the control unit intervenes by
reducing injection pressure.
If the temperature exceeds 90 qC, the power is reduced to
60%.
AC compressor engagement control
(if fitted)
The control unit is able to drive engagement and
disengagement of the electromagnetic compressor clutch
depending on coolant temperature.
If the coolant temperature reaches about 105 qC, it
disengages the clutch.
After Run
The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the
following startup.
 ED. NOVEMBER 2003 SECTION 2 - FUEL 5

WORKING PROCESS
Figure 2

High Pressure
Low Pressure

70492

1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on
chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
6 SECTION 2 - FUEL ED. NOVEMBER 2003

FUEL SYSTEM LAYOUT

This fuel system is a Common Rail injection with CP3 high
pressure pump and this layout is for 4 cylinder version.
(The 6 cylinder version is similar design as the 4 cylinder en-
gine).
The pressure regulator, placed upstream of the high-pressure
pump, adjusts the fuel flow that is necessary on the low-pres-
sure system. Afterwards, the high-pressure pump takes care
of supplying the rail properly. This arrangement, by pressuris-
ing the necessary fuel only, improves the energetic efficiency
and limits fuel heating in the system.
Function of the pressure relief valve (2), assembled on the
high-pressure pump, is keeping the pressure, at the pressure
regulator inlet, constant at 5 bars, independently from the
efficiency of the fuel filter and of the system set upstream.
The pressure relief valve (2) intervention brings about a fuel
flow increase in the high-pressure pump cooling circuit,
through inlet and drain piping (16) from piping (8).
The pressure relief valve housed on the cylinder head, as-
sembled on injector return (3), limits the fuel return flow
from injectors at a pressure of 1.3 to 2 bars.
Two by-pass valves are placed in parallel with the mechanical
supply pump.
The by-pass valve (18) allows fuel to flow from mechanical
pump outlet to its inlet, when the fuel filter inlet pressure ex-
ceeds the allowed threshold value.
The by-pass valve (17) allows filling the supply system
through the manual priming pump (10).

1. High-pressure pump. — 2. Pressure relief valve on high-pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel return
from injectors, 1.3 to 2 bars. — 4. Rail overpressure valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. — 8. Return piping.
— 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. —
12. Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High-pressure pump cooling piping.
— 17. By-pass valve. — 18. By-pass valve.
 ED. NOVEMBER 2003 SECTION2 - FUEL 7

Figure 3
8 SECTION 2 - FUEL ED. NOVEMBER 2003

Jettison condition
MECHANICAL FEEDING PUMP
Gear pump, placed on rear part of the high pressure pump, Figure 6

whose function is to feed the high pressure pump. It is driven

by the high pressure pump’s shaft.
Ordinary working condition

Figure 4

72594

72592
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter,
I - 2 By-pass valves in close position.
The dump by-pass valve (2) is activated in case, when the
engine is off, it is necessary to fill the feeding system through
the priming pump. In this condition the by pass valve (I) keeps
closed while the dump by-pass valve (2) opens up due to the
pressure effect on the entry unit so the fuel flows to the
exhaust unit B.

Overpressure condition in Exhaust unit

Figure 5 The mechanical feeding pump cannot be replaced

!
separately, therefore it must not be disassembled
from the high pressure pump.

72593

The by-pass valve (I) is activated in case of overpressure on B

Exhaust unit. The actual pressure, overcoming the resistance
of the valve’s spring (I), connects the exhaust with the entry
through the gallery (2).
 ED. NOVEMBER 2003 SECTION2 - FUEL 9

CP3 HIGH PRESSURE PUMP

Pump provided with 3 radial pumping elements driven by the
timing system gear, no need of timing. The mechanical feeding
pump driven by the high pressure pump’s shaft is assembled
to the rear side of the high pressure pump.

The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither
! the fixing screws must be tampered.The only operation allowed is the replacement of the driving gear.

Figure 7

72595

1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear - 5. Connector to
fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry flowing from engine
control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter - 9. Mechanical feeding
pump.
10 SECTION 2 - FUEL ED. NOVEMBER 2003

High pressure pump-inside structure

Figure 8

Sec. B-B

Sec. C-C

70498

1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.

Every pumping unit is composed of:

- a piston (5) actuated by a three-lobe element (2) floating - cap intake valve (3);
on the pump shaft (6). The element (2), being floating on - ball delivery valve (4).
a misaligned part of the shaft (6), when the shaft rotates,
does not rotate therewith but is only translated in a
circular movement along a wider radius, with the
resulting alternate actuation of the three pumping
elements;
 ED. NOVEMBER 2003 SECTION 2 - FUEL 11

Working principle
Figure 9

Sec. B - B

Sec. D - D 72597

1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. —
7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.

The pumping element (3) is orientated towards the pump’s During compression phase of the pumping element, the fuel
camshaft (4). During the intake phase, the pumping element achieves the level of pressure determining the opening of the
is fed through the feeding line (5). The quantity of fuel to flow by-pass valve to common rail (2), feeding it through the
to the pumping element is determined by the pressure exhaust unit (I).
regulating gauge (7). The pressure regulating gauge,
according to the PWM command received by the engine
control module, stops the fuel flow to the pumping element.
12 SECTION 2 - FUEL ED. NOVEMBER 2003

Figure 10 Figure 11

72601
72598

Sec. C - C Sec. A - A

1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. 1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel
— 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — exhaust flowing from pump with connector to high
7. Low-pressure fuel inlet. — 8. Pumping elements supplying pressure pipe for common rail.
fuel ducts.

Picture 10 shows the fuel runs at low pressure inside the Picture 11 shows the fuel flow under high pressure running
pump; the following elements are clearly visible: the main through the exhaust galleries of the pumping elements.
feeding line to the pumping elements (4); the feeding lines to
the pumping elements (1-3-6), the duct lines run for the
pump lubrication (2), the pressure gauge (5), the flow limiting
valve to 5 bar (8) and the fuel exhaust flue (7).
The pump shaft is lubricated by the fuel through the feeding
and recovery lines.
The pressure gauge (5) determines the quantity of fuel to
feed the pumping elements: the fuel in excess flows through
the exhaust gallery (9).
The limiting valve to 5 bar, in addition to recovering fuel
exhaust as a collector has also function to keep the pressure
constant to 5 bar limit at gauge entry.
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