Contents

Introduction

General information

• Scope and scope of the publication
• Terms and definitions
• Purpose and features of a complete set of power units
• Powertrain specifications

Engine design and operation

• Cylinder block
• Cylinder head
• Crankshaft
• Flywheel
• Connecting rod
• Crankshaft bearing shells
• Cylinder liner
• Piston
• Piston rings
• Piston pin
• Packing options liner - piston - piston rings
• Gas distribution mechanism
• Camshaft
• Pushers
• Pusher axles
• Push rods
• Valve rocker arms
• Inlet and outlet valves
• Lubrication system
• Power system
• Fuel pump drive
• High pressure fuel pump
• Design and operation of the high pressure fuel pump
• Speed ??controller
• Basic adjustments provided by the regulator design
• Damper clutch
• Fuel priming pump
• Injectors
• Injectors models 267-02 and 204-50.01
• Injector model 51-01
• Coarse fuel filter
• Fine fuel filter
• Fuel lines
• Aspiration
• Model 122 turbocharger device
• Cooling system
• Water pump
• Fan drive
• Design and operation of the fan friction drive
• Electromagnetic switch
• Liquid-oil heat exchanger
• Electrical equipment
• Generators
• Generator model 1322.3771
• Generator model 1702.3771
• Generator model 6582.3701-03
• Generator model 5702.3701-30
• Starters
• Starter 25.3708-21
• Starter AZF 4581
• Electric torch device
• Tightening torques for main screw connections

Maintenance of engines

Complete engine disassembly procedure

Parsing nodes

• Disassembly of the CPG
• Crankshaft disassembly
• Disassembly of the water pump
• Disassembly of the oil pump
• Fan drive disassembly
• Disassembly of the injection pump drive
• Dismantling the fine fuel filter
• Oil filter disassembly
• Disassembly of the centrifugal oil filter
• LMC disassembly

Assembly of units and assemblies

• Subassembly of the centrifugal oil filter
• Oil filter subassembly
• Subassembly of the fine fuel filter
• Injection pump drive subassembly
• Fan drive subassembly
• Sub-assembly of the oil pump
• Subassembly of the water pump
• Crankshaft subassembly
• ShPG subassembly
• Camshaft subassembly
• Cylinder head subassembly
• Water pump tensioner subassembly

Engine subassembly

• Cylinder block subassembly
• Installing the injection pump drive
• Installing pushers
• Installing oil piston cooling nozzles
• Installing the camshaft (7511.1006010)
• Installing the upper crankshaft main bearing shells
• Pressing in the pins of the crankshaft thrust half rings
• Installing the lower crankshaft main bearing shells
• Installing the crankshaft
• Installing cylinder liners.
• Installing ShPG in cylinder liners
• Installing cylinder heads
• Installing the timing gear cover
• Assembling the cover of the upper block with a fine fuel filter
• Installing the flywheel housing
• Installing the flywheel
• Installing the front support bracket and centrifugal oil cleaner
• Installation of pipes and manifolds
• Assembling the oil pump with pipes
• Installing the oil sump

Final engine assembly

• Installing the tensioner and water pump belt
• Assembling the injection pump with low pressure pipes and installing it on the engine
• Fastening the low pressure pipes to the filter, the plunger pair return pipes and the oil return pipes to the injection pump
• Installing injectors on the engine
• Installation of high pressure pipes and connecting pipe
• Installing the inlet pipe
• Installation of rocker arms of MGR valves
• Installing the oil filter
• Installing the fan drive
• Installing an electric torch device
• Bypass pipe installation
• Installing the branch pipe-bracket on the flywheel housing platform
• Assembling the turbocharger with oil drain pipe
• Installing the turbocharger
• Installation of the connecting pipe
• Installing the cylinder head covers
• Installing the engine on a stand
• Installing the starter and water channel plugs
• Installing an oil-liquid heat exchanger
• Installing the generator
• Installing the union in the cylinder block
• Installing the air inlet tube
• Installing the oil supply pipe to the turbocharger
• Setting the fuel injection advance angle

Technical requirements for fault detection of parts and assembly units

• General technical requirements for engine disassembly
• General technical requirements for fault detection and repair
• Special requirements for components (fault detection cards)
• Group 1001
• Engine mount
• Group 1002
• Cylinder block
• Cylinder liner
• Top block cover
• Distribution gear cover
• Flywheel housing
• Oil deflectors
• Stub
• Group 1003
• Cylinder head
• Nozzle glass
• Cylinder head cover
• Eye plate
• Group 1004
• Piston
• Piston pin
• Connecting rod
• Connecting rod bolts
• Group 1005
• Crankshaft
• Front counterweight
• Crankshaft gear
• Crankshaft pulley
• Hub
• Hub bolt
• Flywheel
• Thrust bearing half ring
• Group 1006
• Camshaft
• Camshaft gear
• Thrust flange
• Group 1007
• Inlet and outlet valves
• Valve springs
• Poppet, poppet bushing and valve spring washer
• Rocker arm axis
• Rocker arm with sleeve
• Rocker arm adjusting screw
• Push rod
• Pusher
• Pusher axle bushings
• Pusher axles
• Group 1008
• Exhaust manifold
• Bracket spigot
• Group 1009
• Oil sump
• Group 1011
• Oil pump housing
• Oil pump cover
• Driven oil feed gear
• Driving oil feed gear
• Reducing valve
• Differential valve
• Intermediate gear for oil pump drive
• Idler axis
• Flange of the thrust shaft of the idler gear
• Driven pump drive gear
• Oil pump intake cup
• Oil intake mesh
• Suction pipe
• Piston cooling pipes
• Piston cooling nozzle
• Group 1012
• Oil filter housing
• Group 1013
• Oil-liquid heat exchanger housing
• Heat transfer element
• Front heat exchanger cover
• Rear heat exchanger cover
• Group 1028
• Centrifugal oil cleaner housing
• The axis of the centrifugal oil cleaner
• Rotor housing with bushings
• Rotor cover
• Centrifugal oil cleaner hood
• Group 1029
• Driven gear
• The axis of the driven gear with bearing and collar assembly
• Leading half-coupling
• Group 1104
• High pressure pipes
• Group 1115
• Intake manifold
• Intake manifold connecting pipe
• Group 1306
• Tee with connecting pipes
• Bypass pipe
• Group 1307
• Water pump roller
• Water pump drive pulley
• Group 1308
• Fan impeller

Specifications for assembly and testing of engine components and assemblies

• General technical requirements for assembly
• Technical requirements for assembly and testing of units and assemblies
• Oil pump, det. 7511.1011014-01
• Oil filter, det. 238B-1012010-B
• Centrifugal oil cleaner, det. 238-1028010
• Coarse fuel filter, det. 840.1105010
• Fine fuel filter, det. 236-1117010-A4
• Turbocharger, det. 122.1118010
• Installing a damper and a pulley on the engine, 7511.1005050
• Installing a pulley on the engine, 7601.1005050
• Installing the injection pump drive, 7511.1029002-01
• General requirements for running-in, adjustment and acceptance tests of engines
• General requirements
• Preparing the engine for start
• Engine start and operation
• Engine adjustment
• Engine bulkhead
• Acceptance tests
• Engine break-in modes