CURSOR Series Marine application C87 ENT M38.10 C87 ENT M62.10
C87 ENT M62.10 TECHNICAL AND REPAIR MANUAL OCTOBER 2010 EDITION
OCTOBER 2010 C87 ENT M62.10 1.3 SECTION CONTENTS Section 1. OVERVIEW... 5 2. TECHNICAL DATA... 35 3. ELECTRICAL EQUIPMENT... 43 4. DIAGNOSTICS... 61 5. MAINTENANCE... 77 6. SERVICING OPERATIONS ON INSTALLED ENGINE... 83 7. TOOLS... 99 8. OVERHAUL... 109 9. SAFETY REGULATIONS... 183
OCTOBER 2010 OVERVIEW C87 ENT M62.10 1.5 SECTION 1 OVERVIEW IDENTIFICATION DATA... 7 COMMERCIAL CODE... 8 PRODUCT MODEL NUMBER... 9 COMBUSTION AIR INTAKE AND EXHAUST SYSTEM... 10 Comburent air filter... 11 Turbocompressor... 11 Air/sea-water heat exchanger... 11 COOLING FRESH WATER CLOSED LOOP 12 Tube bundle water/water heat exchanger... 13 Bypass junction for thermostatic valve... 13 SEAWATER OPEN COOLING LOOP... 14 Sea water pump... 15 ENGINE OIL - LUBRICATION LOOP... 16 Oil fume recycle (Blow-by)... 17 SUPPLY... 18 FUEL SUPPLY DIAGRAM... 19 Pump assembly... 20 Low pressure feed pump... 21 Pressure control solenoid valve... 23 Low pressure limiter valve... 23 High pressure pump... 24 Operation... 26 RAIL (PRESSURE ACCUMULATOR)... 26 Electroinjector... 26
1.6 C87 ENT M38.10 C87 ENT M62.10 OVERVIEW OCTOBER 2010 EDC 7 Electronic Central Unit... 27 Air pressure/temperature sensor... 27 Atmospheric pressure sensor... 27 Oil pressure/temperature sensor... 28 Crankshaft sensor... 28 Camshaft sensor... 29 Coolant temperature sensor... 29 Fuel temperature sensor... 30 Throttle lever position... 30 Fuel pressure sensor on rail... 30 SYSTEM FUNCTIONS... 31 Run up... 31 Starting... 31 Metering and fuel injection... 31 Injection advance management... 31 Pre-injection... 32 Injection pressure modulation... 32 Idling adjusting... 32 Self-diagnosis... 32 EDC indicator light... 32 Fuel heating... 32 Linearization of the acceleration gradient... 32 Balance of the cylinder torque delivery... 32 Rotation speed control... 32 Top speed limitation... 32 Cut off... 33 Derating... 33 Recovery... 33 After run... 33
OCTOBER 2010 OVERVIEW C87 ENT M62.10 1.7 IDENTIFICATION DATA Figure 1 1. Trade name/version - 2. Homologation - 3. Production serial number- 4. Maximum rated power - 5. Family of engines - 6. Trade name - 7. Design number- 8. Programming code - 9. Year of production - 10. Homologation number. 04_002_N Figure 2 The engine identification data are stenciled on a tag positioned over the engine coolant tank 143677
1.8 C87 ENT M38.10 C87 ENT M62.10 OVERVIEW OCTOBER 2010 COMMERCIAL CODE The purpose of the commercial code is to make it easier to understand the characteristics of the product,categorizing the engines according to their family, origins and intended application. The commercial code, therefore, cannot be used for technical purposes and to identify the engine's components, this is the purpose of the ENGINE S/N. C 87 E N T M 38. 1 0 62 VERSION VERSION: TURBOCOMPRESSOR: 1 = COOLED 2 = NOT COOLED MAXIMUM PERFORMANCE LEVEL ACHIEVABLE 38 = 380 CV 62 = 620 CV APPLICATION: M = MARINE AIR INTAKE: T = INTERCOOLED SUPERCHARGED BLOCK: N = NON STRUCTURAL FUEL SUPPLY: E = ELECTRONIC INJECTION DISPLACEMENT: 8.710 c.c. ENGINE FAMILY IDENTIFIER: C = CURSOR
OCTOBER 2010 OVERVIEW C87 ENT M62.10 1.9 PRODUCT MODEL NUMBER The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize its application and power output level. It is stamped on the side of the crank-case. F 2 C E 0 6 8 6 A * A 0 0 1 VARIANTS TO BASIC ENGINE ACTUAL POWER OUTPUT POWER RANGE INTENDED USE (6 = MARINE) FUEL + INJECTION (8 = DIESEL, TCA, DIRECT INJECTION) NO. OF CYLINDERS NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL) ENGINE DESIGN ITERATION ENGINE FAMILY IDENTIFIER
OCTOBER 2010 TECHNICAL DATA C87 ENT M62.10 2.35 SECTION 2 TECHNICAL DATA SPECIFICATIONS C87 ENT M38.10... 37 SPECIFICATIONS C87 ENT M62.10... 40
OCTOBER 2010 ELECTRICAL EQUIPMENT C87 ENT M62.10 3.43 SECTION 3 ELECTRICAL EQUIPMENT ELECTRICAL EQUIPMENT... 45 PARTS AND COMPONENTS ENGINE... 50 ELECTRICAL SYSTEM... 52 ALTERNATOR... 53 Mitsubishi 90A... 53 Specification... 53 ELECTRICAL STARTER ENGINE... 54 Nippondenso model... 54 Specification... 54 CONNECTIONS OF THE CENTRAL ELECTRONIC UNITCONVERTER MODULE... 55 Identification of terminal function... 55 Identification of terminal function... 56 Identification of terminal function... 57 EQUIPOTENTIAL CONNECTIONS TO ENGINE GROUND... 59
OCTOBER 2010 DIAGNOSTICS C87 ENT M62.10 4.61 SECTION 4 DIAGNOSTICS FOREWORD... 63 PT - BOX... 64 GUIDE TO SYMPTOM DIAGNOSIS... 65 FAULTS CODE - EDC 7 UC31... 69
OCTOBER 2010 MAINTENANCE C87 ENT M62.10 5.77 SECTION 5 MAINTENANCE PERIODICITY OF CHECKS AND MAINTENANCE OPERATIONS... 79 PREPARING THE ENGINE FOR LONG IDLE PERIODS... 81 ENGINE'S FIRST START/RESTORING NORMAL OPERATING CONDITIONS... 81
OCTOBER 2010 SERVICING OPERATIONS ON INSTALLED ENGINE C87 ENT M62.10 6.83 SECTION 6 SERVICING OPERATIONS ON INSTALLED ENGINE FOREWORD... 85 PRESCRIPTIONS FOR WORK ON THE INJECTION SYSTEM AND ITS COMPONENTS 86 REPLACING BELT... 87 REPLACING THE ELECTRO-INJECTORS... 87 Removal... 87 Intake and exhaust rocker arm clearance adjustment... 88 Engine lubricant replacement... 88 Air filter/s replacement... 89 Fuel filter/s replacement... 89 Oil filter replacement... 89 Filter support with exclusion levers... 90 MARINISATION OVERHAUL... 91 Removal... 91 CLEANING THE AIR/SEA WATER HEAT EXCHANGER... 93 CLEANING THE ENGINE COOLANT/SEA WATERHEATEXCHANGER... 94 Fitting... 95 INSTRUCTIONS FOR DISEMBARKING THE ENGINE... 97 Handling... 97
OCTOBER 2010 TOOLS C87 ENT M62.10 7.99 SECTION 7 TOOLS TOOLS... 101
OCTOBER 2010 OVERHAUL C87 ENT M62.10 8.109 SECTION 8 OVERHAUL Graph and symbols... 111 GENERAL CHARACTERISTICS... 112 ASSEMBLY CLEARANCE DATA... 113 TIGHTENING TORQUES... 119 CYLINDER BLOCK... 132 Checks and measurements... 132 CYLINDER LINERS... 133 Replacing cylinder liners... 134 Removal... 134 Fitting and checking protrusion... 134 CRANKSHAFT... 135 Measuring main journals and crank pins... 136 PRELIMINARYMEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA.. 137 Selecting the main and big end bearing shells. 138 Replacing the timing control gear and the oil pump... 144 (cont)
8.110 C87 ENT M38.10 C87 ENT M62.10 OVERHAUL OCTOBER 2010 PISTON CONNECTING ROD ASSEMBLY.. 146 Removal... 146 CONNECTING ROD... 149 Version C87 ENT M38.10... 150 Version C87 ENT M62.10... 151 Mounting the connecting rod - piston assembly... 152 Mounting the piston rings... 152 Fitting connecting rod - piston assemblies in the cylinder liners... 153 Checking piston protrusion... 153 Checking assembly clearance of big end pins. 154 CYLINDER HEAD... 154 Valve removal... 154 Checking the planarity of the head on the cylinder block... 154 VALVE... 155 Removing deposits and checking the valves.. 155 VALVE GUIDES... 155 Replacing of valve guides... 156 REPLACINGINJECTORHOLDERCASES.. 156 Removal... 156 Mounting... 157 Checking protrusion of injectors... 158 TIMING GEAR... 159 Camshaft drive... 159 Intermediate gear pin... 159 Idler gear... 159 Twin idler gear... 159 Replacing the bushings... 159 Checking cam lift and pin alignment... 160 CAMSHAFT... 161 BUSHES... 161 Use beater 99360505 to change bushings... 162 VALVE SPRINGS... 162 Fitting the valves and oil seal ring... 162 ROCKER SHAFT... 163 Shaft... 163 Rockers... 163 LUBRICATION CIRCUIT COMPONENTS.. 164 Oil pump... 164 Overpressure valve... 164 Engine oil filter adapter... 165 Filter by-pass valve... 165 Oil pressure control valve... 166 Heat exchanger... 166 COMPONENTS OF THE COOLING SYSTEM 167 Water pump... 167 Thermostatic valve... 167 ASSEMBLY... 168 High pressure pump installation... 172 ENGINE FLYWHEEL... 172 Engine flywheel installation... 172 Camshaft installation... 173 TIMING CAMSHAFT AND FLYWHEEL USING TOOL 99395223... 174 Timing camshaft... 174 Timing flywheel... 176 TIMING CAMSHAFT AND FLYWHEEL WITHOUT TOOL 99395223... 176 Timing camshaft... 176 Timing flywheel... 179 Intake and exhaust rocker arm clearance adjustment... 180
OCTOBER 2010 SAFETY REGULATIONS C87 ENT M62.10 9.183 SECTION 9 SAFETY REGULATIONS SAFETY REGULATIONS... 185 Standard safety regulations... 185 Accident prevention... 185 During maintenance... 185 Respecting the Environment... 186