1

ON ROAD application

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

CURSOR 13 TDCV
F3HFE611A*C
F3HFE611B*C

TRAINING MANUAL

Course Nr. FPT_M05E_412_EU6_C_TDC_N_EN_141203

December 2014 - 1st EDITION

2

WARNING

This publication is a didactic support only.

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

For repairs refer to the workshop manual.

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

DIDACTIC PUBLICATION NOT SUBJECT TO UPDATING

Publication edited by:

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

CONTENTS:

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

4

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

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TECHNICAL CODE – Cursor 11

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

Emissions level:
C = Euro 6

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

Application:
1 = Use (Truck)

 
Engine main characteristics:
1 = Diesel turbocharged, direct injection, intercooled

No. of cylinders

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

F = Tier 4/ Euro 6
 
 
G = Engine family evolution (also irrespective of the displacement)

F3 = Engine family indication

6

TECHNICAL CODE – Cursor 13

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

Emissions level:
C = Euro 6

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

Application:
1 = Use (Truck)

 
Engine main characteristics:
1 = Diesel turbocharged, direct injection, intercooled

No. of cylinders

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

F = Tier 4/ Euro 6
 
 
H = Engine family evolution (also irrespective of the displacement)

F3 = Engine family indication

7

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

8
WALK AROUND – Cursor 11

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

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

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

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

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

13

CHARACTERISTIC CURVES – Cursor 11

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

Power

Torque
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Power Speed Torque Speed

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

Power

Torque
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Power Speed Torque Speed

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

Power

Torque
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CHARACTERISTIC CURVES – Cursor 13

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

Power

Torque
17

Power Speed Torque Speed

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

Power

Torque
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Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

19

GENERAL SPECIFICATIONS – Cursor 11

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

Number of cylinders 6, in line

Bore mm 128

Stroke mm 144

Total displacement cm3 11,120

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

Maximum engine idle speed

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

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

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

start before B.D.C. D 50º

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

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

Injector CRIN 3.3

Firing order 1–4–2–6–3–5

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F3G
Type
F3GFE611D F3GFE611B F3GFE611A

Injection pressure bar 2,200

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

Fuel tank (5) L -

NOTE Data, features and performances are valid only if the setter fully complies with all the installation
prescriptions provided by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to torque, power and
rpm based on which the engine has been designed.
23

GENERAL SPECIFICATIONS – Cursor 13

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

Number of cylinders 6, in line

Bore mm 135

Stroke mm 150

Total displacement cm3 12,880

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

Maximum engine idle speed

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

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

- at idle speed bar 1.5
- at maximum speed bar 4.5-5
COOLING Liquid cooled
Coolant pump control Belt driven
Thermostat:
- start of opening ºC 84 ± 2
- max. opening ºC 94 ± 2
25

F3H
Type
F3HFE611B F3HFE611A
TIMING
start before T.D.C. A 19º
end after B.D.C. B 31º

start before B.D.C. D 50º

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

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

Injector CRIN 3.3

Firing order 1–4–2–6–3–5

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F3H
Type
F3HFE611B F3HFE611A

Injection pressure bar 2,000

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

Fuel tank (5) L -

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

Technical code Crankcase

Cylinder liners
Walk around Crankshaft

Main and connecting rod half-bearings

Characteristic curves
Connecting rods

General specifications Pistons

Connecting rod – piston assembly

Main mechanical components Crankshaft seal rings

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

Engine flywheel
Lubrication circuit
Engine flywheel box / Gear case

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

28

MAIN MECHANICAL COMPONENTS

Crankcase

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

Cylinder liners

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

Cylinder liners: replacing and checking protrusion

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

99.970
100.000

92.970
93.000
CRANKSHAFT MAIN JOURNALS AND CRANKPINS MEASURED VALUES
32

Crankshaft: installation

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

Main and connecting rod half-bearings

1. Pistons - 2. . Upper connecting rod half bearings – 3. Connecting rods – 4. Crankpins - 5. Lower main half bearings - 6. Upper
main half bearings – 7. Upper main half bearing with axial thrust washers – 8. Main journals – 9. Lower main half bearing
with axial thrust washers – 10. Lower connecting rod half bearings
34

Defining the diameter class of the seats for half-bearings on the crankcase

Rated diameter of the

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

(nominal diameter) - Cursor 11

Rated diameter of the

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

Rated diameter of the

Class
main journal
1 92.970 - 92.979
2 92.980 - 92.989
3 92.990 - 93.000
36

Selection of main half-bearings (nominal diameter pins)

The table contains the characteristics of the

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

STD + 0.127 + 0.254 + 0.508

Red 3.110 - 3.120 - - -

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

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

STD CLASS 1 2 3

green green yellow

1
green yellow yellow

red green green

2
green green yellow

red red green

3
red green green
38

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

STD CLASS 1 2 3

green green green

1
green green green

red green green

2
red green green

red red green

3
red red green
39

Selecting the diameter class of the connecting rod seats

(nominal diameter pins)

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

Class Weight [g]

F3G F3H

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

Selection of the connecting rod half-bearings – Cursor 11

The table contains the characteristics of the

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

STD + 0.127 + 0.254 + 0.508

Red 2.465 - 2.475 - - -

Red/Black - - - -

Blue 2.475 - 2.485 - - -

Blue/Black - - - -

Yellow* 2.485 - 2.495 - - -

Yellow/Black - - - -
* Not supplied as a spare part
41

Selection of the connecting rod half-bearings

(nominal diameter pins) – Cursor 11

STD CLASS 1 2 3

green green yellow

1
green yellow yellow

red green green

2
green green yellow

red red green

3
red green green
42

Selection of the connecting rod half-bearings – Cursor 13

The table contains the characteristics of the

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

STD + 0.127 + 0.254 + 0.508

Red 1.960 – 1.970 - - -

Red/Black - - - -

Green 1.971 – 1.990 - - -

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

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

STD CLASS 1 2 3

green green green

1
green green green

red green green

2
red green green

red red green

3
red red green
44

Connecting rods main data – Cursor 11

* Dimension to be obtained after driving the bushing

45

Connecting rods main data – Cursor 13

* Dimension to be obtained after driving the bushing

46

Pistons

Cursor 11

MAIN DATA OF PISTON, SNAP RINGS AND PIN

X = 0.6 ± 0.3
47

Cursor 13

MAIN DATA OF PISTON, SNAP RINGS AND PIN

X = 0.6 ± 0.3
48

Connecting rod – piston assembly

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

Crankshaft seal rings

Front

Rear

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

Crankshaft seal rings: front and rear installation

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

Cylinder head
1
11
2

10 3

4
9
5

6
8

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

Camshaft

82.950
82.968

CAMSHAFT PINS MEASURED VALUES

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

Camshaft: intake and exhaust valve control

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

Valve stems and springs – Cursor 11

* Measurement obtained
after fitting the valve
guides

  Lift [mm] Loaded spring [N]

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

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE

SPRINGS INTAKE EXHAUST
VALVE VALVE
55

Valve stems and springs – Cursor 13

* Measurement obtained
after fitting the valve
guides

  Lift [mm] Loaded spring [N]

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

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE

SPRINGS INTAKE EXHAUST
VALVE VALVE
56

Valves oil seals

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

A. Intake side – S. Exhaust side
57

Valve seats – Cursor 11

INTAKE VALVE SEAT SECTION EXHAUST VALVE SEAT SECTION

1. Intake valve seat 2. Exhaust valve seat
58

Valve seats – Cursor 13

INTAKE VALVE SEAT SECTION EXHAUST VALVE SEAT

SECTION
59

Valve guides

CURSOR 11 CURSOR 13

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

* Measurement obtained after fitting the valve guides

60

Engine flywheel

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

61

Engine flywheel: installation and timing notches

120° 120°
E

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

Engine flywheel box / Gear case

1
8
2

3
7

1
5

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

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

Auxiliary components operation

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

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

Technical code

Walk around

Determination to the centre between camshaft and

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

Main mechanical components Assembling the timing control gears

Camshaft timing
CURSOR engine timing

Fuel supply system

Lubrication circuit

Oil vapour recirculating system (Blow-by)

65

CURSOR ENGINE TIMING

Determination to the centre between camshaft and high pressure pump

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

66

Engine flywheel timing: hole with one reference mark

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

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

Camshaft installation

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

Assembling the timing control gears

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

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

70

Camshaft timing

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

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

Cam timing dial

5.76 ±0.05 mm
gauge value

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

Cam timing dial

5.76 ±0.05 mm
gauge value

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

1. Gear – 2. Screw
74

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

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

Technical code

Walk around Hydraulic system

Fuel system layout

Characteristic curves
MAIN FUEL SUPPLY SYSTEM COMPONENTS

General specifications High pressure pump

Common Rail
Main mechanical components Electro-injectors

Pressure limiter valve

CURSOR engine timing
Fuel filter
Fuel supply system

Lubrication circuit

Oil vapour recirculating system (Blow-by)

76

FUEL SUPPLY SYSTEM

Hydraulic system

A. Fuel supply system – B. Tank return circuit

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

Fuel system layout

HYDRAULIC SYSTEM DIAGRAM

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

MAIN FUEL SUPPLY SYSTEM COMPONENTS

High pressure pump

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

High pressure pump – Technical data

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

Common Rail

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

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

Electro-injectors

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

Electro-injectors - Operation

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

Pressure limiter valve

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

limiter valve
Rail nominal pressure 2,200 bar
84

Fuel filter

Fuel filter characteristics

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

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

Technical code

Walk around

Characteristic curves
LUBRICATION CIRCUIT
General specifications
Oil pump

Main mechanical components Overpressure valve

Oil pressure regulator valve

CURSOR engine timing Engine oil filter

Lubricant oil/coolant heat exchanger

Fuel supply system
Oil sump

Lubrication circuit

Oil vapour recirculating system (Blow-by)

86

LUBRICATION CIRCUIT

A. Engine brake solenoid valve detail

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

Oil pump

1. Oil pump – 2. Crankshaft helical gear

88

Overpressure valve

Overpressure valve

Initial opening pressure 10 ±1 bar

OVERPRESSURE VALVE SECTION OVERPRESSURE VALVE SPRING

89

Oil pressure regulator valve

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

Start of opening pressure 5bar

90

Engine oil filter

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

Oil filter: characteristics

Filtering efficiency β 12 µc > 200 (99.5%)

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

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

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

92

Lubricant oil/coolant heat exchanger

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

93

Heat exchanger

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

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

94

Oil sump

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

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

Technical code OIL VAPOUR RECIRCULATING SYSTEM (BLOW-BY)

Blow-by filter
Walk around

Characteristic curves

General specifications

Main mechanical components

CURSOR engine timing

Fuel supply system

Lubrication circuit

Oil vapour recirculating system (Blow-by)

96

OIL VAPOUR RECIRCULATING SYSTEM (BLOW-BY)

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

Blow-by filter

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

COOLING CIRCUIT Cooling circuit

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

Thermostat Exhaust gas after-treatment system

Electrical equipment

Scheduled Maintenance

Assembly clearance

Tightening torques / sequences

Tools
99

COOLING CIRCUIT

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

Check fan electromagnetic coupling clutch wear

Gap
X Max. 2.5 mm

1. Pulley - 2. Anchor assembly

101

Water pump

WATER PUMP SECTION

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

(→) Threaded holes
102

Thermostat

Water circulating
in the engine

Water leaving
the thermostat

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

Cold operation with thermostat closed Hot operation with thermostat open

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

INTAKE AND EXHAUST SYSTEM Cooling circuit

EVGT turbocharger

Motorized throttle valve (Exhaust flap) Intake and exhaust system

Exhaust gas after-treatment system

Electrical equipment

Scheduled Maintenance

Assembly clearance

Tightening torques / sequences

Tools
105

INTAKE AND EXHAUST SYSTEM

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

EVGT turbocharger

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

Motorized throttle valve (exhaust flap)

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

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

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic diagram
Cooling circuit
DOC+SCR configuration

Cooling / heating ATS System Intake and exhaust system

MAIN COMPONENTS OF THE ATS SYSTEM

Catalyst
Exhaust gas after-treatment system

DeNOx 2.2 Supply Module (SM)

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

DeNOx 2.2 Dosing Module (DM) Scheduled Maintenance

Engine coolant 3 way valve

SCRT system sensors

Assembly clearance

SCRT tightening torque sensors

Tightening torques / sequences
Humidity and temperature detecting sensor

Exhaust gas temperature sensor Tools

Nitrogen oxides detecting sensor
NH3 control unit and sensor

Particulate trap pressure sensor (Δp)

109

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic diagram
08
04 05 07
02 09
06
03

11 12

01 10

13
CAN

14
34
33
15
32

ECU
31
29 30

26
28
27

24 25 18
23
DOC
CUC
SCR

22 17
16
ECU
19
21
ECU
20 ECU
110

Cooling / heating ATS System

COOLING CONDITION

CONDITION OF SIMULTANEOUS
HEATING AND COOLING

2 3

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

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

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

MAIN COMPONENTS OF THE ATS SYSTEM

Catalyst

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

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

DeNOx 2.2 Supply Module (SM)

1
8 2

7 3

5
4
1. Fluid output pipe of pump module heating – 2. AdBlue return pipe to tank – 3. Delivery pipe to dosing module –
4. Main filter – 5. Electrical connector – 6. Pressure compensation membrane – 7. Fluid input pipe of pump module
heating – 8. Supply pipe from tank
114

DeNOx 2.2 Supply Module (SM) – Electrical components inside

Diaphragm pump characteristics

Power draw 400 ±200 mA
The values are to be intended in case of 28.5 V
battery and AdBlue pressure equal to 900kPa.

Pressure sensor characteristics

Power supply 5 ±0.25 V
With AdBlue pressure at 900 Kpa, supply the sensor
with 5 V at 18 ÷ 28°C, The value measured must be
equal to 3.357 V with a tolerance of ± 0.05V

Reverse valve characteristics

Coil resistance 21.10 ±3 Ω
The value is correct for temperatures between
18÷28°C

1. Reverse valve – 2. Pressure sensor – 3. Temperature sensor – 4. Electrical connector – 5. Diaphragm pump
115

DeNOx 2.2 Dosing Module (DM)

1. Electrical connector – 2. AdBlue inlet – 3. Coolant engine inlet/outlet

116

Engine coolant 3 way valve

3 1

1. Engine coolant pipe – 2. Dosing module coolant pipe – 3. AdBlue tank heating fluid pipe –
4. Electrical connector
117

SCRT system sensors

1. Differential pressure sensor – 2. Sensor detecting incoming nitrogen oxide (NOx) – 3. Catalytic converter intake exhaust gas
temperature sensor - 4. Exhaust gas temperature sensor for gas coming out of the particulate filter and upstream
of the SCR catalytic converter – 5. Exhaust gas temperature sensor downstream of the catalytic converter – 6. NH3 Sensor – 7.
Sensor detecting outgoing nitrogen oxide (NOx) from the catalytic converter – 8. Metering module
118

SCRT tightening torque sensors

Tightening torques
6 ± 0.9
1 Differential pressure sensor fixing screws
Nm
Sensor detecting incoming nitrogen oxide
2 52 ± 8 Nm
(NOx) to the catalytic converter
Sensor detecting incoming nitrogen 45 ± 4.5
3
oxide (NOx) to the catalytic converter Nm
Exhaust gas temperature sensor for gas
45 ± 4.5
4 coming out of the particulate filter and
Nm
upstream of the SCR catalytic converter
Exhaust gas temperature sensor 45 ± 4.5
5
downstream of the catalytic converter Nm
50 ± 10
6 NH3 Sensor
Nm
Sensor detecting outgoing nitrogen oxide
7 52 ± 8 Nm
(NOx) from the catalytic converter

8 Metering module fixing screws 8 ± 2 Nm

11.5 ± 1.5
9 NH3 control unit fixing screws
Nm
119

Humidity and temperature detecting sensor

WIRING DIAGRAM
1. Power supply – 2. Moisture percentage indicator –
3. Ground connection – 4. Temperature –
A. Sample frequency generator – B. Base oscillator –
Connector C. NTC temperature sensor – D. Amplifier low pass filter
CHARACTERISTICS OF HUMIDITY SENSOR VALUE
Voltage supply 5.00 ± 0.25 VDC
Current consumption 10 mA
Humidity operating range 0% RH ÷ 100% RH
Output impedance 70 Ω
Isolation resistance 1 MΩ @ 500 V

CHARACTERISTICS OF TEMPERATURE SENSOR VALUE

Temperature operating range –40 to 125 °C
Resistance at 25 °C NTC 2.186 kΩ ± 1%
Max power at 25 °C 100 mW
120

Exhaust gas temperature sensor

WIRING DIAGRAM
1. Supply voltage – 2. Variable output voltage –
3. Connector – 4. Grey signal cable – 5.White grounding
cable – 6. Sensor

CHARACTERISTICS OF EXHAUST GAS TEMPERATURE SENSOR VALUE

Power supply 5.00 V ± 0.1%
Output voltage @ Temperature –40 to 1000 °C 0.727 to 2.297 V
Pull up resistance 1000 Ω ± 0.1%
Lead resistance 1Ω
121

Nitrogen oxides detecting sensor

1. Positive – 2. Mass – 3. CAN L

line – 4. CAN H line – 5. Spare

CHARACTERISTICS OF NOx SENSOR VALUE

Ambient temperature electronics: – 40 to +105 °C
(+105 to +115 °C allowed for up to 10 min)
Wire temperature: 230 °C allowed for up to 100 h
122

NH3 control unit and sensor

Connector

A. Vehicle connector – B. Sensor connector

CHARACTERISTICS OF NH3 SENSOR VALUE

Normal operating voltage 10 to 32 V
Average current 1.2 A
Max current 4.0 A
Temperature / humidity rating –40 to 105 °C
123

Particulate trap pressure sensor (Δp)

Sensor pin-out Vo characteristic in function of Δp

1. Supply voltage (5V) – 2. Ground – 3. Output Vo. Outlet voltage – Δp. Difference between the outlet
voltage signal (Vo) and inlet voltage in the CRT
124

ELECTRICAL EQUIPMENT

EDC17CV41 electronic control unit

Cooling circuit
Engine cable

Electro-injector (CRIN3) Intake and exhaust system

Timing segment speed sensor (camshaft)

Flywheel increment speed sensor (crankshaft) Exhaust gas after-treatment system

Boost pressure and air temperature sensor
Electrical equipment
Engine oil pressure and temperature sensor

Rail pressure sensor (RDS4.4) Scheduled Maintenance

Coolant temperature sensor

Fuel temperature sensor Assembly clearance

Fuel filter clogging (pressure drop) sensor
Tightening torques / sequences
Crankcase pressure sensor

Fuel high pressure pump metering unit Tools

EVGT actuator

Motorized throttle valve actuator (Exhaust flap)

125

Cooling circuit

Intake and exhaust system

Pre-heating resistance (Grid-heater)
ALTERNATOR Exhaust gas after-treatment system
STARTER MOTOR
Electrical equipment

Scheduled Maintenance

Assembly clearance

Tightening torques / sequences

Tools
126

ELECTRICAL EQUIPMENT – CURSOR 11

9 1 2
8 3

7 4
5
6

1. Pressure sensor on crankcase – 2. Pressure regulator solenoid valve – 3. Timing segment speed sensor
(camshaft) - 4. Electronic injection solenoid valve – 5. Exhaust brake control solenoid valve –
6. Pressure adjustment sensor – 7. Connector ST-E – 8. Fuel filter clogging (pressure drop) sensor –
9. Fuel temperature sensor
127

2
7

6 3

1. Electromechanical actuator for engine brake on exhaust – 2. Trannsmitter for engine oil pressure gauge –
3. Engine rpm sensor – 4. Electromechanical actuator for VGT – 5. Turbocharger speed sensor –
6. Transmitter for engine oil temperature signalling thermometer – 7. Coolant temperature sensor (EDC)
128

1
2

5 3

1. Turbo blower air pressure and temperature sensor for EDC – 2. Alternator - 3. Engine control unit –
4. Starter motor - 5. Contactor for thermostarter activation consent
129

ELECTRICAL EQUIPMENT – CURSOR 13

9 1 2
8 3

7 4
5
6

1. Pressure sensor on crankcase – 2. Pressure regulator solenoid valve – 3. Timing segment speed sensor
(camshaft) - 4. Electronic injection solenoid valve – 5. Exhaust brake control solenoid valve –
6. Pressure adjustment sensor – 7. Connector ST-E – 8. Fuel filter clogging (pressure drop) sensor –
9. Fuel temperature sensor
130

2
7

6 3

1. Electromechanical actuator for engine brake on exhaust – 2. Trannsmitter for engine oil pressure gauge –
3. Engine rpm sensor – 4. Electromechanical actuator for VGT – 5. Turbocharger speed sensor –
6. Transmitter for engine oil temperature signalling thermometer – 7. Coolant temperature sensor (EDC)
131

5 3

1. Turbo blower air pressure and temperature sensor for EDC – 2. Alternator - 3. Engine control unit –
4. Starter motor - 5. Contactor for thermostarter activation consent
132

MAIN ELECTRICAL EQUIPMENT COMPONENTS

EDC17CV41 electronic control unit

1. Vehicle side connector – 2. Engine side connector

133

Vehicle side connector “1” (1/01 – 1/24)

Pin Description cable code
1 Positive +30 7151
2 Spare –
3 Earth 0000
4 Spare –
5 Earth 0000
6 Spare –
7 Urea pressure signal 6550
8 Signal of urea tank temperature 6542
9 Catalytic converter outlet temperature signal 6541
10 Ground for catalytic converter upstream and downstream 0540
temperature
11 Signal from the engine compartment stop switch 0151
12 Spare –
13 Water in fuel filter signal 5530
14 Spare –
15 R.H. fuel supply air signal 5173
16 Temperature upstream of the catalytic converter sensor positive 6449
17 Spare –
18 Spare –
19 Spare –
20 To pin 86 of contactor for terminal 15 8775
21 Spare –
22 Spare –
23 Metering module solenoid valve with SCR supply Red
24 Spare –
134

Vehicle side connector “1” (1/25 – 1/48)

Pin Description cable code
25 Positive +30 7151
26 Positive +30 7151
27 Positive for engine fan solenoid valve 7545
Free (FEP) −
28 Earth 0000
29 Spare –
30 Spare –
31 Urea level in the tank signal 6543
32 Intake catalytic converter temperature signal 6544
33 Spare –
34 Engine rpm signal for body builder connectors 5587
35 Spare –
36 Spare –
37 Spare –
38 Signal from the engine compartment start switch 8892
39 Ground for urea tank level and temperature sensor 0543
40 Combustion air temperature signal 5174
41 Spare –
42 Spare –
43 Ground for combustion air humidity and temperature sensor / 0173
ΔP
44 "EDC" system fault warning light 5535
Free (FEP) −
45 To pin 85 of contactor for terminal 15 0775
46 ECB can network WS/BI
47 ECB can network GN/VE
48 Spare –
135

Vehicle side connector “1” (1/49 – 1/68)

Pin Description cable code
49 Positive +30 7151
50 Positive for engine water flow solenoid valve for urea tank 7542
heater (78267) / urea to tank return valve [85140] / urea
module electro pump
51 Spare –
52 Earth 0152
53 Spare –
54 Spare –
55 ΔP signal 5284
56 Spare –
57 Spare –
58 Spare –
59 Spare –
60 Spare –
61 Spare –
62 Engine fan solenoid valve negative signal 0986
Free (FEP) −
63 Spare –
64 Spare –
Signal for engine fan rpm sensor (FEP) 9744
65 Spare –
Ground for engine fan rpm sensor (FEP) 0744
66 Spare –
67 Spare –
Power supply for engine fan rpm sensor (FEP) 7744
68 Urea pressure sensor positive 7537
136

Vehicle side connector “1” (1/69 – 1/90)

Pin Description cable code
69 User positive under key (+15) 8150
70 Engine ECU diagnostic line pin 7 ODB connector 2298
71 Spare –
72 Ground for engine water circulation solenoid valve control for 9542
urea tank heating (78267)
73 Positive +30 7151
74 Control signal for thermostarter activation consent contactor 7545
75 Earth 0000
76 Spare –
77 Spare –
78 Spare –
79 Spare –
80 Spare –
81 Spare –
82 Spare –
83 Contactor for thermostarter activation consent ground 0094
84 Ground for urea module electropump control 9549
85 Urea to tank return valve (85140) 0539
86 Spare –
87 Negative control signal for engine fan engagement consent 0014
(Baruffaldi)
Negative signal for engine fan engagement control (FEP) 0745
88 Spare –
89 Ground for urea module electropump 0549
90 Power supply for combustion air humidity and temperature 8173
sensor / ΔP
137

Vehicle side connector “1” (1/91 – 1/96)

Pin Description cable code

91 Spare –
92 Spare –
93 Spare –
94 Spare –
95 Spare –
138

Engine side connector “2” (2/01 – 2/24)

Pin Description cable code
1 Cylinder electro-injectors 4 –
2 Cylinder electro-injectors 6 –
3 Cylinder electro-injectors 5 –
4 Spare –
5 Spare –
6 Ground for oil pressure/temperature sensor –
7 Power supply for turbocharger air pressure and temperature sensor for –
EDC.
8 Spare –
9 Spare –
10 Spare –
11 Diesel (RPS) pin 3 pressure signal –
12 Diesel temperature sensor –
13 Oil temperature signal –
14 Spare –
15 Spare –
16 Spare –
17 CAN-H line (ECB2) White
18 CAN-L line (ECB2) Green
19 Spare –
20 Spare –
21 Spare –
22 Spare –
23 Spare –
24 Spare –
139

Engine side connector “2” (2/25 – 2/48)

Pin Description cable code
25 Electro-injector cylinder 4 –
26 Electro-injector cylinder 6 –
27 Electro-injector cylinder 5 –
28 Spare –
29 Spare –
30 Spare –
31 Power supply for oil pressure/temperature sensor –
32 Crankcase pressure sensor power supply –
33 Spare –
34 Spare –
35 Oil pressure signal –
36 Diesel (RPS) pin 2 pressure sensor ground –
37 Turbocharger air temperature sensor for EDC. –
38 Spare –
39 Engine coolant temperature sensor –
40 Spare –
41 Spare –
42 Crankcase pressure sensor ground –
43 Spare –
44 Spare –
45 Spare –
46 Spare –
47 Spare –
48 Spare –
140

Engine side connector “2” (2/49 – 2/68)

Pin Description cable code

49 Electro-injector cylinder 1 –
50 Electro-injector cylinder 2 –
51 Electro-injector cylinder 3 –
52 Spare –
53 Spare –
54 Spare –
55 Spare –
56 Spare –
57 Spare –
58 Fuel metering valve to 78013 pin 1 –
59 Engine coolant and fuel temperature sensor ground –
60 Diesel (RPS) pin 1 pressure sensor power supply –
61 Crankcase pressure sensor signal –
62 Spare –
63 Spare –
64 Spare –
65 Camshaft Engine rpm sensor pin 1 –
66 Camshaft Engine rpm sensor pin 2 –
67 Engine speed sensor pin 2 –
68 Engine speed sensor pin 1 –
141

Engine side connector “2” (2/69 – 2/90)

Pin Description cable code

69 Timing system and engine speed sensor braid –
70 Engine brake solenoid valve pin 1 –
71 Spare –
72 Spare –
73 Electro-injector cylinder 1 –
74 Electro-injector cylinder 2 –
75 Electro-injector cylinder 3 –
76 Spare –
77 Spare –
78 Spare –
79 Spare –
80 Spare –
81 Spare –
82 Spare –
83 Fuel metering valve to 78013 pin 2 –
84 Spare –
85 Spare –
86 EDC turbocharger air pressure sensor –
87 Spare –
88 Spare –
89 Spare –
90 Ground for turbocharger air pressure and temperature sensor for EDC. –
142

Engine side connector “2” (2/91 – 2/96)

Pin Description cable code

91 Spare –
92 Spare –
93 Turbocharger speed sensor –
94 Turbocharger speed sensor –
95 Engine brake solenoid valve pin 2 –
96 Spare –
143

Engine cable – CURSOR 11 / 13

2 3 4 5 6 7 8

1. Electronic injection solenoid valve N.6 – 2. . Exhaust brake control solenoid valve –
3. Electronic injection solenoid valve N.5 – 4. Electronic injection solenoid valve N.4 –
5. Electronic injection solenoid valve N.3 – 6. Electronic injection solenoid valve N.2 –
7. Pressure adjustment sensor - 8. Electronic injection solenoid valve N.1 – 9. Connector ST-E
144

Engine cable CURSOR 11

1 2
3 4
5

18 17

12
16
13
6
14 11
10
9
15
8 7
1. Fuel temperature sensor – 2. Fuel filter clogging (pressure drop) sensor – 3. Coolant temperature sensor (EDC) –
4. Connector ST-E – 5. Electromagnetic coupling – 6. Turbocharger speed sensor – 7. Not used – 8. Timing segment
speed sensor (camshaft) – 9. Pressure regulator solenoid valve – 10. Electromechanical actuator for VGT – 11. Contactor
for thermostarter activation consent – 12. Engine control unit – 13. Connection to frame wiring – 14. Turbo blower air
pressure and temperature sensor for EDC – 15. Engine rpm sensor – 16. Trannsmitter for engine oil temperature /
pressure gauge – 17. Pressure sensor on crankcase – 18. Electromechanical actuator for engine brake on exhaust
145

Engine cable CURSOR 13 2

1
18
3
17 4

16 5
8 7
15

14 11
10 9 6
12

13
Connector ST-E – 2. Coolant temperature sensor (EDC) – 3. Electromagnetic coupling – 4. Not used – 5. Turbocharger speed
sensor – 6. Electromechanical actuator for VGT – 7. Fuel temperature sensor – 8. Fuel filter clogging (pressure drop) sensor
– 9. Engine control unit – 10. Contactor for thermostarter activation consent – 11. Turbo blower air pressure and temperature
sensor for EDC – 12. Pressure regulator solenoid valve – 13. Timing segment speed sensor (camshaft) –
14. Connection to frame wiring – 15. Engine rpm sensor – 16. Pressure sensor on crankcase – 17. Trannsmitter for engine oil
temperature / pressure gauge – 18. Electromechanical actuator for engine brake on exhaust
146

Topographical wiring diagram - Engine side

20 1
2
19 2
4
5
18
17
16
15
14 6
13

7
9
12 10 8
11
1. Engine control unit – 2. Fuel temperature sensor – 3. Coolant temperature sensor (EDC) – 4. Trannsmitter for engine oil
temperature / pressure gauge – 5. Turbo blower air pressure and temperature sensor for EDC – 6. Turbocharger speed sensor –
7. Electromechanical actuator for engine brake on exhaust – 8. Electromechanical actuator for VGT – 9. Electromagnetic coupling –
10. Fuel filter clogging (pressure drop) sensor – 11. Not used – 12. Connection to frame wiring – 13. Pressure sensor on crankcase –
14. Timing segment speed sensor (camshaft) – 15. Engine rpm sensor – 16. Pressure regulator solenoid valve – 17. Pressure
adjustment sensor – 18. Exhaust brake control solenoid valve – 19. Electronic injection solenoid valve – 20. Connector ST-E
147

Electro-injector (CRIN3)

2
6

5 3

1. Coils for connection to engine cable – 2. High pressure 1. Low pressure fuel return from injector – 2. High pressure
fuel inlet – 3. Gasket – 4. Injector – 5. Cylinder head fuel inlet
anchorage bracket – 6. Fastening screw
148

INJECTOR SECTION
1. Coil – 2. High-pressure fuel inlet fitting – 3. Filter – 4. Pressure rod – 5. Needle – 6. Nozzle –
1. 7. Pressure chamber – 8. Control volume – 9. Pilot valve shutter – 10. Fuel return
149

Electro-injector wiring connectors

Injector Injector
Description ECU pin
No. PIN
1 Injector 1 “high”, Bank 1, Cylinder 1 2/49
1
2 Injector 1 “low”, Bank 1, Cylinder 1 2/73
1 Injector 2 “high”, Bank 1, Cylinder 2 2/50
2
2 Injector 2 “low”, Bank 1, Cylinder 2 2/74
1 Injector 3 “high”, Bank 1, Cylinder 3 2/51
3
2 Injector 3 “low”, Bank 1, Cylinder 3 2/75
1 Injector 1 “high”, Bank 2, Cylinder 4 2/25
4
2 Injector 1 “low”, Bank 2, Cylinder 4 2/01
1 Injector 3 “high”, Bank 2, Cylinder 5 2/27
5
2 Injector 3 “low”, Bank 2, Cylinder 5 2/03
1 Injector 2 “high”, Bank 2, Cylinder 6 2/26
6
2 Injector 2 “low”, Bank 2, Cylinder 6 2/02
150

Timing segment speed sensor (camshaft)

Cursor 11

Cursor 13

Connector

PIN Description ECU Pin Cable colour

1 Ground (-) 2/67 N
2 Signal (+) 2/68 B

WIRING DIAGRAM
151

Flywheel increment speed sensor (crankshaft)

Cursor 11

Cursor 13

Connector

PIN Description ECU Pin Cable colour

1 Ground (-) 2/65 N
2 Signal (+) 2/66 B

WIRING DIAGRAM
152

Boost pressure and air temperature sensor

3 2
4 1 Cursor 11

Cursor 13

Connector
PIN Description ECU Pin Cable colour
1 Ground 2/90 G
2 NTC signal (temperature) 2/37 R
3 Power supply (+5V) 2/07 V
4 Signal (pressure) 2/86 Z
WIRING DIAGRAM
153

Engine oil pressure and temperature sensor

3 2
Cursor 11
4 1

Cursor 13

Connector

PIN Description ECU Pin Cable colour

1 Ground 2/06 G
2 NTC signal (temperature) 2/13 V
3 Power supply (+5V) 2/31 R
4 Signal (pressure) 2/35 Z WIRING DIAGRAM
154

Rail pressure sensor (RDS4.4)

Cursor 11

Cursor 13

Connector

PIN Description ECU Pin Cable colour

1 Ground (-) 2/60 N
2 Signal (Output) 2/36 S
3 Power supply (+) 2/11 G WIRING DIAGRAM
155

Coolant temperature sensor

Cursor 11

Cursor 13

Connector

PIN Description ECU Pin Cable colour

1 NTC signal (temperature) 2/39 H
2 Common ground 2/59 L WIRING DIAGRAM
156

Fuel temperature sensor

Cursor 11

Cursor 13

Connector

PIN Description ECU Pin Cable colour

1 NTC signal (temperature) 2/12 H
2 Common ground 2/59 L WIRING DIAGRAM
157

Fuel filter clogging (pressure drop) sensor

Cursor 11

Cursor 13

1 2

Connector

P
PIN Description ECU Pin Cable colour
1 Ground - H
2 Signal (Output) - Z WIRING DIAGRAM
158

Crankcase pressure sensor

Cursor 11

Cursor 13

1 2 3

Connector

PIN Description ECU Pin Cable colour

1 Supply 2/32 L
2 Ground 2/42 Z
3 Signal 2/61 G WIRING DIAGRAM
159

Fuel high pressure pump metering unit

Cursor 11

Cursor 13

1. Fuel metering valve

PIN Description ECU Pin Cable colour

1 Supply 2/58 S
2 Signal 2/83 V
160

EVGT actuator

1. EVGT actuator

Cable
PIN Description ECU pin
colour
1 Power supply +30 2/17 8940
2 Ground 2/18 0000
3 CAN – L line - V
4 CAN – H line - B
161

Turbine speed sensor (if present)

Cable
PIN Description ECU pin
colour
1 Turbine rpm signal 93 G
2 Ground 94 L
3 Free -
162

Motorized throttle valve actuator (Exhaust flap)

Cursor 11

Cursor 13

Connector
PIN Description ECU Pin Cable colour
1 - - L
2 - - R
3 Ground 2/18 C
4 Power supply 2/17 G
163

Pre-heating resistance (Grid-heater)

Cursor 11

A B

Cursor 13

A B
Grid-heater performances
Rated voltage: D.C. 24V
Steady current: 120A ÷ 150A @ 24V
Pick-up current: 160A ÷ 290A @ 24V
A. - B. Connection terminals Insulation resistance: >1 MΩ @ 500 V D.C.
164

ALTERNATOR
Alternator “MITSUBISHI” 28 V – 120 A alternator self-refictyng alternator with built-in voltage regulator

Cursor 11

Cursor 13

Technical view
165

Prospective view with matching electrical connections

Alternator current delivery curve

Technical data
Rated voltage: 28.3 ± 0.5 V (20 °C)
Nominal power: 120 A
Operating speed 5,000 rpm
Belt tension 730 N Wiring diagram
Weight: 7 Kg. L. No battery charging signal – B+. Battery power
B-. Ground – R. Voltage regulator – IG. Alternator
activation – S. Battery voltage sensor
166

STARTER MOTOR
Starter motor “NIPPODENSO” 24 V – 5.5KW

Cable
Conn. Description
colour
Cursor 11 Positive +30 for starter motor power supply from
+30 7777
battery positive terminal (via the T.G.C.)
+30 Positive +30 to the alternator 7777
Positive +30 to contactor for engine preheat
+30 7777
activation consent
+50 Positive +50 from key switch 8888

Cursor 13
167

Technical data 5.5 Kw version

Rated voltage: 24 V
Nominal power: 5.5 kW
Coupling system Positive approach control
Adjusted time 30 s
Clockwise seen from pinion
Direction of rotation
end
Max. operating voltage 16 V
Weight 10.5 kg
Tightening torque for terminal
17.6 ÷ 24.5 Nm (M10x1.5)
+30
Tightening torque for terminal
2.6 ÷ 4.6 Nm (M5x0.8)
+50

Specific power 5.5 Kw version

Load Test conditions
No load 23 V 120 A (3,100 rpm) MAX
Load 16 V (49 Nm) 690 A (900 rpm) MAX
Stall 6V 1260 A (73.5 Nm) MAX
168

SCHEDULED MAINTENANCE Cooling circuit

Change engine lubricant oil

Change engine oil filter

Intake and exhaust system
Change fuel filter
Exhaust gas after-treatment system
Check the conditions of the auxiliary members' drive belt

Check fan electromagnetic coupling clutch wear Electrical equipment

Change blow-by filter

Change auxiliary members' drive belt Scheduled Maintenance

Adjustment of valve/rocker arm clearance
Assembly clearance
Change Automatic belt tensioner
SCHEDULED MAINTENANCE FOR ATS SYSTEM Tightening torques / sequences

Tools
169

SCHEDULED MAINTENANCE
1) Not supplied by FPT.
Standard services Frequency 2) If ACEA E9 lubricant is used, the
Every 150,000 km or 3,000 engine oil and filter must be changed
Change engine lubricant oil (2)(3)(4)(5) hours and every 300,000 km or every 80,000 km.
6,000 hours
3) In case of very low annual mileage
Every 150,000 km or 3,000 of less than 100,000 km/year
Change engine oil filter (2)(3) hours and every 300,000 km or (municipal use, concrete mixers, etc.),
6,000 hours
the engine oil and filters must be
Every 150,000 km or 3,000 changed every 12 months.
Change fuel filter hours and every 300,000 km or
4) It is strictly prohibited to top up the
6,000 hours
engine oil with lubricants other than
Every 150,000 km or 3,000 those already present in the sump.
Fuel pre-filter cartridge replacement (1) hours and every 300,000 km or
Lubricant 10W40 can only be used
6,000 hours
when a complete engine oil change is
Check the conditions of the auxiliary members' Every 150,000 km or 3,000
being carried out.
drive belt hours and every 300,000 km or
5) URANIA FE LS. FPT recommends
6,000 hours
the use of these types of oil in order to
Every 150,000 km or 3,000
obtain advantages in terms of "fuel
Check fan electromagnetic coupling clutch wear hours and every 300,000 km or
economy". FPT supplies the new
6,000 hours
assembly already with these types of
Every 150,000 km or 3,000
lubricants, which are also suitable for
Change blow-by filter hours and every 300,000 km or
6,000 hours
cold climates, with minimum
temperatures of -30ºC). The lubricant
Continue change intervals, stated in this folder
are relative to these types of oil.
170

Standard services Frequency 1) Not supplied by FPT.

2) This is required every two
Every 300,000 km or 6,000
Change auxiliary members‘ drive belt
hours
miscellaneous drive belt replacements

Extra planes services Frequency

Valve clearance check and adjustment First intervention at
150,000 km or 3,000 hours
Thereafter, every
300,000 km or 6,000 hours
Change automatic belt tensioner (2) Every 600,000 km or 12,000
hours

Time operations Frequency

Air system drying replacement (1) Every year
Engine coolant density check Every year before winter
Change engine coolant Every two years
171

Change engine lubricant oil – Cursor 11

1. Dipstick - 2. Drain plug – 3. Oil filling cap

172

Change engine lubricant oil – Cursor 13

1. Dipstick - 2. Drain plug – 3. Oil filling cap

173

Change engine oil filter

Tightening torques

Engine oil filter (5) 60 ± 5 Nm

Drain plug (6) 6.5 ± 1.5 Nm

1. Filter support – 2. Sealing gasket – 3. Cartridge O-ring – 4. Drainage plug – 5. Closing cap – 6. Cartridge
174

Change fuel filter

1. Vent plug – 2. Fuel filter support – 3. Fuel filter element – 4. Drain screw
175

Check the conditions of the auxiliary members' drive belt

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

4. Poly-V belt – 5. Automatic belt tensioner - 6. Alternator
176

Check fan electromagnetic coupling clutch wear

Gap
X Max. 2.5 mm

1. Pulley - 2. Anchor assembly

177

Change blow-by filter Tightening torque

Blow-by filter fixing 1. Pre-tightening
screws (2) Tightening sequence: 1 -2 -3
5 Nm
2. Tightening
Tightening sequence: 4 -5 -6
15 Nm
Screws (4) 7 ±1 Nm

1. Blow-by filter – 2. Screws fastening blow-by filter – 3. Blow-by filter cover – 4. Screws fastening blow-by filter cover
178

Change auxiliary members‘ drive belt

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

4. Poly-V belt – 5. Automatic belt tensioner - 6. Alternator
179

Adjustment of valve/rocker arm clearance

FIRING ORDER: 1 – 4 – 2 – 6 – 3 – 5

Start-up Balancing Adjusting

and clockwise valves of valve clearance of
rotation cylinder No. cylinder No.
Cyl. 1 – 6 at TDC 6 1
+120° 3 4
+120° 5 2
+120° 1 6
+120° 4 3
+120° 2 5

Tightening
Ref No. Description
torques
(-) 12 M10x1.25 39 ± 5 Nm

1. Polygonal wrench – 2. Rocker arm adjusting screw

3. Feeler gauge
180

Change automatic belt tensioner

Tightening torques
Screw fixing the
50 ± 5 Nm
automatic belt tensioner

1. Automatic belt tensioner - 2. Retaining screw – 3. Poly-V belt

181

SCHEDULED MAINTENANCE FOR ATS SYSTEM

Component Frequency 1) Frequencies valid for vehicles
No regular service planned destined for heavy duty mission
Tank pre-filter (200 µm) (cleaning, if required) (urban utility applications)
Cleaning every 160000 km or
Supply module pre-filter (100 µm) 3200 hours or 2 years 2) Frequency valid for vehicles
destined for short medium range
No regular service planned transport (regional or interregional)
Supply module inlet-filter (100 µm) (replacement, if required)

Change every 300000 km 3) Frequency valid for vehicles

Supply module main filter
destined for long range transport
No regular service planned (national or interregional, mainly
Supply module backflow-filter (100 µm) (replacement, if required) motorway)
No regular service planned
Dosing valve filter (36 µm)

Change every 240000 Km, 4

DPF (Diesel Particulate Filter) catalytic converter years or 3200 hours

300000 km or 800 hours or

AdBlue system check-up by diagnostic tool 1 year (1)
60000 Km (2), 80000 Km (3)
Only if damaged
Replace catalytic converter
182

FILTER LOCATION

1. Dosing module filter - 2. Dosing module - 3 AdBlue return filter from supply module to tank -
4. Supply module pre-filter - 5. Tank pre-filter - 6. AdBlue tank - 7. AdBlue inlet filter to supply module - 8. Supply module -
9. Supply module filter
183

Supply module main filter

1. Cover - 2. Element 1. Cover - 2. Element – 3. Tool

184

Tightening torques

AdBlue filter plug 20 ± 5 Nm

1. Element – 2. Filter
185

Replacing the DPF (Diesel Particulate Filter) catalytic converter

Removing

1. Screw 1. Screw – 2. Cover

186

1. Screw – 2. Collar – 3. Screw 1. Collar – 2. Screw

187

1. DPF catalytic converter 1. Pressure ring

188

Refitting

1. Collar – 2. DPF catalytic converter 1. Pressure ring

189

1. DPF catalytic converter – 2. Collar 1. DPF catalytic converter – 2. Collar

190

Tightening torques

Pre-tightening
1. Sequence: 1-2
DPF catalytic converter
8 Nm
fastening collar – Screw (1)
and (2) Tightening
2. Sequence: 1-2
12 ±1 Nm

Tightening torques

Pre-tightening
1. Sequence: 3-4
25 Nm
DPF catalytic converter clamp Pre-tightening
fastening collar - Screw (3) 2. Sequence: 3-4
and (4)
35 Nm
Tightening
3. Sequence: 3-4
1-2. Screw of the DPF catalytic converter fastening collar –
3-4. Screw of the DPF catalytic converter clamp fastening collar 42.5 ±2.5 Nm
– 5. Collar
191

Tightening torques Tightening torques

Cover fixing screws on the silencer 10.3 ±0.8 Nm Cover fixing screws on the silencer 10.3 ±0.8 Nm

1. Screw – 2. Cover 1. Screw

192

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance data

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

193

CLEARANCE DATA

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Upper cylinder liner housing Ø 1 -

Lower cylinder liner housing Ø 1 -

Upper cylinder liners outer Ø 2 143.961 - 143.986 153.461 - 153.486

Lower cylinder liners outer Ø 2 141.890 - 141.915 151.890 - 151.915

Lenght (L) 243.16 252.2

Upper cylinder liners – crankcase seat -

Lower cylinder liners – crankcase seat -
Cylinder liner – inner diameter Ø 3 128.00 – 128.02 135.000 - 135.020

Protrusion (with 8.000 kg load) 0.045 – 0.075

194

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Size X 23 50

Outside diameter Ø1 127.937 – 127.963 134.903 - 134.933

Pin housing Ø2 50.070 – 50.080 59.063 - 59.093

Piston protrusion -

Piston – cylinder liners - 0.067 - 0.117

Piston pin - Ø3 57.994 – 58.000

195

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Piston pin – pin seat 0.070 – 0.086 0.063 - 0.099

X1 2.460 (*) 2.480 - 2.510

Split ring slots
X2 2.580 – 2.600 2.580 - 2.610
*Measured on Ø123 mm
X3 4.030 - 4.050 4.050 - 4.080
Piston rings
*Measured at 2.5 mm from S1 2.296 – 2.340 (*) 2.296 – 2.340 (**)
Ø at the outside S2 2.470 - 2.500 2.470 - 2.500
**Measured at 2 mm from S3 3.970 ÷3.990 3.970 ÷3.990
Ø at the outside
1 0.120 – 0.164 0.140 - 0.214
Piston rings - slots 2 0.080 – 0.130 0.065 - 0.140
3 0.040 - 0.080 0.060 - 0.110
X1* 0.30 ÷0.40 0.35 - 0.45
Piston rings end gap in cylinder liners X2 0.65 – 0.80 0.65 – 0.80
X3 0.40 – 0.75 0.40 – 0.75
196

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Connecting rod small end bush seat Ø1 62.000 – 62.030 63.000 - 63.030

Connecting rod bearing seat Ø2 - 100.000 - 100.030

1 98.000 – 98.010 100.000 - 100.010

Ø Selection classes 2 98.011 – 98.020 100.011 - 100.020
3 98.021 – 98.030 100.021 - 100.030
external Ø4 52.015 ÷ 52.030 63.120 - 63.160

internal Ø3 - 59.060 - 59.076

Bushing diameter at Connecting rod half-bearings (S) thickness

connecting rod small end
Red 2.465 – 2.475 1.960 – 1.970
Green 2.476 – 2.485 1.971 - 1.980
Yellow* 2.486 – 2.495 1.981 - 1.990

* Fitted in production only and not supplied as spares.

197

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Bush at connecting rod small end - housing 0.330 – 0.976 0.090 - 0.160

Piston pin - bushing 0.060 – 0.082 0.060 – 0.082

Connecting rod half bearing 0.127; 0.254; 0.508

A 5000 - 5033 g 5537- 5570 g

Connecting rod weight B 5034 - 5067 g 5571 - 5604 g
C 5068 - 5100 g 5605- 5637 g
Measuring point X -
Maximum error in pararrelism of
- -
connecting rod axes
198

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Main journals Ø1
Nominal value 99.970 – 100.000
Class 1 99.970 – 99.979
Class 2 99.980 – 99.989
Class 3 99.990 – 100.000
Crankpins Ø2
Nominal value 92.970 – 93.000 95.970 - 96.000
Class 1 92.970 - 92.979 95.970 - 95.979
Class 2 92.980 - 92.989 95.980 – 95.989
Class 3 92.990 ÷ 93.000 95.990 – 96.000
Main half bearings S1
Red 3.110 – 3.120
Green 3.121 – 3.130
Yellow (not provided as spare part) 3.131 – 3.140
199

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Connecting rod-half bearings S2
Red 2.465 – 2.475 1.960 – 1.970
Green 2.476 – 2.485 1.971 - 1.980
Yellow (not provided as spare part) 2.486 – 2.495 1.981 - 1.990
Main bearings Ø3
Nominal value 106.300 – 106.330
Class 1 106.300 – 106.309
Class 2 106.310 – 106.319
Class 3 106.320 – 106.330
Half bearings – main journals 0.020 – 0.140 0.060 - 0.108
Half bearings – crankpins 0.010 – 0.130 0.060 - 0.100
Main half bearings -
Connecting rod half bearings -
200

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Thrust main journals X1 45.95 – 46.00 47.95 - 48.00

Thrust main bearings X2 38.94 – 38.99 40.94 - 40.99

Half thrust washers (thickness) X3 3.38 – 3.43

Crankshaft thrust 0.015 – 0.215 0.10 - 0.30

Alignement 1-2 0.025 -

Centering 1-2 0.040 -

201

Type F3GFE611 F3HFE611

CYLINDER HEAD TIMING SYSTEM mm mm

Valve guide housing on cylinder

Ø1 12.980 ÷ 12.997 15.980 - 15.997
head

Ø2 9.015 – 9.030 10.015 - 10.030

Valve guides

Ø3 15.012 – 15.025 16.012 - 16.025

Valve guides and seats on the head 0.015 – 0.045

Valve guides oversizing 0.2 ÷ 0.4 -

202

Type F3GFE611 F3HFE611

CYLINDER HEAD TIMING SYSTEM mm mm

Valves:
8.960 – 8.975 9.960 - 9.975
Ø4 60° 30’ ± 0° 7’ 30’’ 60° 30’ ± 0° 7’ 30’’
α
8.960 – 8.975 9.960 - 9.975
Ø4 60° 30’ ± 0° 7’ 30’’ 60° 30’ ± 0° 7’ 30’’
α

Valve stem and guide

0.040 – 0.070

0.040 – 0.070

Housing on head for valve seat:

Ø1 44.185 – 44.220 49.185 - 49.220

Ø1 42.985 – 43.020 46.985 - 47.020

203

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Valve seat outside diameter;
valve seat angle on cylinder
head:
Ø2 44.260 – 44.275 49.260 - 49.275
α 60° ± 30’ 60° ± 30’

Ø2 43.060 – 43.075 47.060 - 47.075

α 60° ± 30’ 60° ± 30’
Recessing

X
0.59 – 0.91 0.54- 0.86
X
1.79 – 2.11 1.65- 1.95

Between valve seat and cylinder head 0.040 ÷ 0.090

204

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Valve spring height: 80 (free H) 76

Under a load equal to: 62 59
660 ± 33 N H1 48.8 46
1140 ± 57 N H2

Camshaft bush housing fitted

in the cylinder head 1→7 Ø 88.020 – 88.050 88.000- 88.030

Camshaft bush housing fitted

82.950 – 82.968
in the cylinder head 1→7 Ø
205

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm mm

Camshaft bushing outer diameter Ø 88.153 – 88.183

Camshaft bushing inner diameter Ø 83.018 – 83.085

Bushing and seats in cylinder head 0.103 – 0.163 0.123 - 0.183

Bushing and supporting pins 0.050 – 0.135

9.30 9.231
Useful
Cam height
9.458 9.5607
206

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

Rocker arm shaft Ø1 41.984 – 42.000

42.045 – 42.061
Rocker arm internal diameter
59.000 – 59.019

-
Rocker arm bush outer diameter
59.070 – 59.110

-
Rocker arm bush inner diameter
56.045 – 56.064
207

Type F3GFE611 F3HFE611

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

-
Bushes and
housings
0.051 – 0.110

0.045 - 0.077
Rocker arm
and shaft
-

Engine brake control lever

Rocker arm
Bush inner Eccentric pin outer diameter Ø1 42.025 – 42.041
diameter
Rocker shaft seat Ø2 55.981 – 56.000
Rocker arm and lever 0.045 – 0.083
Rocker shaft and lever 0.025 – 0.057
208

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

209

TIGHTENING TORQUES / SEQUENCES

TORQUE
PART °
Nm kgm
Screws fixing the crankcase to the lower crankcase
First step: pre-tightening 120 12
Second step: 60°
Inner screws Angle tightening M18x2
Third step: Angle 60°
tightening
Fourth step: pre-tightening 30 3
Outer screws M12x1.75
Fifth step: Angle tightening 60°
Outer screws Tightening M10x1.5 44 ± 4 4.4 ± 0.4
Union for piston cooling nozzle 50 ± 5 5 ± 0.5
Screws securing heat exchanger to pre-tightening 11.5 ± 3.5 1.15 ± 0.35
M8x1.25
crankcase ★ tightening 24.5 ± 2.5 2.4 ± 0.25
Screws fixing elements inside the heat exchanger M8x1.25 20 ± 2 2 ± 0.2
Screws fixing suction strainer to bedplate 24.5 ± 2.5 2.4 ± 0.25
First step 45 ± 4.5 4.5 ± 0.45
Screws securing spacer and oil sump ★ M10x1.5
Second step 45 ± 4.5 4.5 ± 0.45
Oil sump drain plug 95 ± 10 9.5 ± 1
Oil level dipstick retainer 50 ± 5 5 ± 0.5
Screws securing flywheel case to crankcase ★ M12x1.75 63 ± 7 6.3 ± 0.7
Screws securing flywheel case to head ★ M10x1.5 50 ± 5 5 ± 0.5
Screws securing inspection cover on flywheel case 20 ± 2 2 ± 0.2
Screws fixing the control unit mount to the lower crankcase M8x1.25 19 ± 3 1.9 ± 3
* Lubricate with engine oil before assembly
** Lubricate with graphitised oil before assembly
★ See tightening sequence
210

TORQUE
PART °
Nm kgm
Screws fixing the control unit to the mount M6x1 8.5 ± 1.5 0.9 ± 0.1
Fuel coupling on control unit mount 50 ± 5 5 ± 0.5
First step: pre-tightening 60 6
Second step: pre-tightening 120 12
Cylinder head fixing screws (*) Third step: Angle tightening 120°
Fourth step: Angle 60°
tightening
First step: pre-tightening 25 2.5

Screws securing rocker arm shaft ★ Second step: pre-tightening M16x1.5 60 6

Third step: pretightening +
80 60°
angle tightening
Screws fastening oil pressure regulating valve 23.5 ±2.5 2.3 ± 0.2
M6x1 8.5 ± 1.5 0.8 ± 0.1
Rocker arm cover fastening screws
M8x1.25 35 ± 3 3.5 ± 0.3
Lock nut for rocker arm adjustment screw M10x1.25 39 ± 5 3.9 ± 0.5
Screws for injector mounting brackets M8x1.25 35 ± 2 3.5 ± 0.2
Screws securing camshaft shoulder plate First step 20 ± 2 2 ± 0.2
M8x1.25
★ Second step 20 ± 2 2 ± 0.2
Screws securing bracket on cylinder head to lift engine M12x1.75 100 ± 10 10 ± 1
First step: pre-tightening 60 6
Camshaft gear fastening screws (*) Second step: Angle M14x2 60°
tightening
211

TORQUE
PART °
Nm kgm
Screw fixing pulser ring to timing gear M8x1.25 24.5 ± 2.5 2.5 ± 0.2
First step: pre-tightening 70 7
Screws fastening connecting rod cap Second step: Angle M14x2 60°
tightening
First step: pre-tightening 120 12
Screws fixing engine flywheel (*) Second step: Angle M18x1.5 90 °
tightening
First step: pre-tightening 70 7
Screws fixing damper flywheel (*) Second step: Angle M14x2 50 °
tightening
First step: pre-tightening 70 7
Screws fixing the drive pulley (*) Second step: Angle M14x2 60°
tightening
First step: pre-tightening 30 3
Intermediate gear pin mount screw (*) Second step: Angle M12x1.75 90 °
tightening
Screw fixing link rod for idle gear M8x1.25 24.5 ± 2.5 2.4 ± 0.2
Screws fixing the oil pump M8x1.25 24.5 ± 2.5 2.4 ± 0.2
Screw fixing crankshaft gasket front cover M8x1.25 24.5 ± 2.5 2.4 ± 0.2
Diesel filter breather 18 ± 2 (1.8 ± 0.2)
Screw fastening fuel filter support M8x1.25 24.5 ± 2.5 2.4 ± 0.2
Fuel filter cap 32.5 ± 2.5 3.2 ± 0.2
212

TORQUE
PART
Nm ° kgm
Fuel filter drain 1.5 ± 0.5 0.2 ± 0.1
Screw fastening oil filter support M8x1.25 24.5 ± 2.5 2.5 ± 0.2
Oil filter cap 60 ± 5 6 ± 0,5
Oil filter drain plug 6.5 ± 1.5 0.7 ± 0.1
Turbocharger fixing nuts M12x1.75 75 7.5
Electrical actuator to turbocharger retainer nut 31.8 ± 1.75 3.2 ± 0.2
Screws fastening actuator bracket mount to turbocharger 23 ± 1.4 2.3 ± 0.1
Screws fastening oil return pipe to turbocharger M8x1 24.5 ± 2.5 2.4 ± 0.2
Screws fastening the oil delivery pipe to turbocharger M8x1 24.5 ± 2.5 2.4 ± 0.2
Collar fixing the air inlet pipe to the turbocharger 8.5 ±1.5 0.9 ± 0.2
Screw fixing the pipe from the intercooler to the mount M8x1.25 34.5 ± 3.5 3.5 ± 0.4
Thermostat assembly fastening screws M8x1.25 30 ± 3 3 ± 0.3
Screws securing water pump M8x1.25 24.5 ± 2.5 2.45 ± 0.25
Screws fixing water inlet pipe to crankcase M8x1.25 34.5 ± 3.5 3.4 ± 0.3
Screws securing water outlet pipe from head 30 ± 3 3 ± 0.3
Screws fastening fan to electromagnetic coupling M8x1.25 34.5 ± 3.5 3.4 ± 0.4
Screws fixing the electromagnetic coupling to the crankcase M12x1.75 100 ± 5 10 ±0.5
Screw fixing the automatic belt tensioner M10x1.5 50 ± 5 5 ± 0.5
Screws securing steady tensioner M12x1.75 105 ± 5 10.5 ± 0.5
Starter motor fastening screws M12x1.75 74 ± 8 7.4 ± 0.8
Screws fastening the air heater and intake manifold to the cylinder head M10x1.5 50 ± 5 5 ± 0.5
Screws fixing the intake manifold to the support bracket M8x1.25 34.5 ± 3.5 3.5 ± 0.3
213

TORQUE
PART
Nm ° kgm
Connection on the preheating device 16 ± 1 1.6 ± 0.1
Air compressor fixing screws (**) M12x1.75 74 ± 8 7.4 ± 0.8
M12x1.5 32.5 ± 2.5 3.2 ± 0.2
Screws fastening the HP pump to the support plate M10x1.5 45 ± 5 4.5 ± 0.5
M8x1.25 30 ± 5 3 ± 0.5
Screws fastening the HP pump support flange to the timing system 24.5 ± 2.5 2.4 ± 0.2
M8x1.25
casing
Nut for fastening high pressure pump gear M24x1.5 250 ± 15 25 ± 1.5
Screws fastening the HP pump to the support flange M10x1.5 37.5 ± 2.5 3.8 ± 0.3
Screws fixing the fuel fillers to the head M8x1.25 50 ± 2.5 5 ± 0.3
TI supplier 42 ± 2.5 4.2 ± 0.2
High pressure fuel pipe fitting (rail, head and injectors) CHESINI 60 ± 2.5 6 ± 0.2
supplier
Screws fixing the high pressure fuel pipe mount M8x1.25 24.5 ± 2.5 2.5 ± 0.3
M18 couplings for high pressure fuel pipes 50 ± 5 5 ± 0.5
Couplings fixing the LP fuel pipe to the HP pump M18x1.5 50 ± 5 5 ± 0.5
screws marked with M6x1 10 ± 1 1 ± 0.1
Screws securing Blow-by to timing case
numbers
★
screws marked with letters M6x1 7±1 0.7 ± 0.1
Coupling fixing the fuel return pipe to the rail M14x1.5 50 5
Rail safety valve M20x1.5 110 ± 5 11 ± 0,5
Screws/nuts fixing the rail to the head M8x1.25 23.5 ±2.5 2.4 ± 0.3
214

TORQUE
PART
Nm ° kgm
Blow-by filter fixing screws M6x1 7±1 0.7 ± 0.1
Screws fastening alternator support M8x1.25 44 ± 4 4.4 ± 0.4
Screws fastening alternator support M8x1.25 24.5 ± 2.5 2.45 ± 0.25
M10x1.5 44 ± 4 4.4 ± 0.4
Alternator fixing screws
M8x1.25 24.5 ± 2.5 2.45 ± 0.25
Securing rail pressure sensor M18x1.5 70 ± 5 7 ± 0.5
23.5 ± 2.5
(M8 x 1.25 -
L=25)
Flywheel rev sensor support fastening 2.3 ± 0.2
breakage
(M8 x 1.25 -
L=18)
Oil level sensor retainer 25 ± 5 2.5 ± 0.3
Oil temperature / pressure sensor retainer 8.5 ± 1.5 0.9 ± 0.2
Water temperature sensor retainer 25 ± 5 2.5 ± 0.3
Air temperature transmitter fastener 8.5 ± 1.5 0.9 ± 0.2
Phonic wheel position sensor retainer 8.5 ± 1.5 0.9 ± 0.2
Pressure sensor retainer on the rocker cover 27.25 ± 2.75 2.7 ± 0.28
Exhaust brake solenoid valve fastener M24x1.5 32 ± 3 3.2 ± 0.3
Nuts for injector electrical connection 1.5 ± 0.25 0.15
Head wiring connector fixing screw 8±2 0.8 ± 0.2
215

Lower crankcase

First step
Second step
Third step

Fourth step

Fift step
216

Tappet cover
Rocker arm shaft

Engine flywheel
Cylinder head
217

Exhaust manifold Control unit

Flywheel housing
Oil sump
218

Intake manifold Blow-by cover

Phonic wheel
219

Heat exchanger
Thrust plate

Thermostat

Alternator
220

Technical code Cooling circuit

Walk around Intake and exhaust system

Characteristic curves Exhaust gas after-treatment system

General specifications Electrical equipment

Main mechanical components Scheduled Maintenance

CURSOR engine timing Assembly clearance

Fuel supply system Tightening torques / sequences

Lubrication circuit Tools

Oil vapour recirculating system (Blow-by)

221

TOOL NO. DESCRIPTION

Telescopic revolving stand (bearing

99322230
capacity 2000 daN, torque 375 daNm)

99342157 Tool to extract injectors

Crankshaft front seal installer

99346250

99346260 Crankshaft rear seal installer

Socket wrench for idle gear support

99350072
fastening screws
222

TOOL NO. DESCRIPTION

Piston ring removal and refitting pliers

99360184
(105 - 160 mm)

99360259 Tool to remove and refit engine valves (to

be used with special plates)

Tool for engine valves removal and

99360262
refitting (use with 99360259)

99360295 Tool for valve guide refitting (use with

99360481)

99360321
Tool for rotating the flywheel
223

TOOL NO. DESCRIPTION

99360325 Spacer (to be used with 99360321)

Adjuster for gasket assembly on valve

99360328
guide

Cylinder liner protrusion gauge (to be used

99360334 with 99370415-99395603 and special
plates)

Cylinder liner compression cap (to be used

99360342
with 99360334)

99360351 Tool for retaining the flywheel

224

TOOL NO. DESCRIPTION

99360481 Punch for valve guide removal

Drift to take down and fit back camshaft

99360499
bushes

99360500 Crankshaft lifting tool

Bracket for removing and refitting engine

99360551
flywheel

99360553 Tool for rocker arm shaft assembly and

fitting
225

TOOL NO. DESCRIPTION

99360585 Arm for engine removal and refitting

99360612 Tool for engine T.D.C. positioning

Tool for timing of phonic wheel on timing

99360613
gear

99360703 Tool for cylinder liner fastening

Tool to extract cylinder liners (use with

99360706
special rings)
226

TOOL NO. DESCRIPTION

99360726 Ring (125 mm) (to be used with 99360706)

Brackets for fastening engine to 99322230

99361046
rotary stand

Tool for removing the high pressure pump

99366198
gear

Set of 8 ignition keys 14X18 (13-17-18-

99368542
19-21-22-24-27-30 mm)

99370400 Tool to check timing (use with 99395606)

227

TOOL NO. DESCRIPTION

Dial gauge base to adjust lay shaft bearings

99370415
(use with 99395603)

Torque wrench (20-120 Nm) with 1/2"

99389813
square head

Torque wrench (60-320 Nm) with 1/2"

99389817
square head

Torque wrench (10-60 Nm) with 3/8"

99389831
square head

14X18 coupling torque wrench (20-120

99389833
Nm)
228

TOOL NO. DESCRIPTION

Torque screwdriver (1-6 Nm) for adjusting

99389834 the locking nut of the injector solenoid
valve connectors

99390311 Sleeker for valve guide

Tap screw (M17x2) to regrind the threaded

99390426 holes for the cylinder head/crankcase and
crankcase/lower crankcase bolts

Set of gauges for angle tightening with

99395216
square connection - 1/2" and 3/4"

Gauge to determine centre distance

99395226
between camshaft and high pressure pump
229

TOOL NO. DESCRIPTION

Gauge for defining the distance between

99395227
the centres of camshaft and timing gear

99395603 Dial gauge (0-5mm)

99395606 Dial gauge (0-30 mm)

Centring ring of crankshaft front gasket

99396035
cover