Manitou ENGINE V2607-CR-E4B REPAIR MANUAL – PDF DOWNLOAD
FILE DETAILS:
Manitou ENGINE V2607-CR-E4B REPAIR MANUAL – PDF DOWNLOAD
Language : English
Pages :576
Downloadable : Yes
File Type : PDF
ENGINE
V2607-CR-E4B,
V2607-CR-TE4B,
V2607-CR-TIE4B (DOC ONLY),
V3307-CR-TE4B,
V3307-CR-TIE4B (DOC ONLY)
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Manitou ENGINE V2607-CR-E4B REPAIR MANUAL – PDF DOWNLOAD
Page de garde / Front page 1
WORKSHOP MANUAL 3
V2607-CR-E4B,V2607-CR-TE4B,V2607-CR-TIE4B (DOC only),V3307-CR-TE4B,V3307-CR-TIE4B (DOC only) 0
TO THE READER 4
I INFORMATION 6
INFORMATION 7
1 SAFETY FIRST 8
2 SPECIFICATIONS 12
3 PERFORMANCE CURVES 14
4 DIMENSIONS 19
5 WIRING DIAGRAM 24
[1] ENGINE INTERMEDIATE HARNESS (ENGINE SIDE HARNESS) 24
[2] INJECTOR INTERMEDIATE HARNESS (ENGINE SIDE HARNESS) 26
[3] ECU INTERMEDIATE HARNESS (OEM SIDE HARNESS) 27
[4] SYSTEM WIRING DIAGRAM 32
G GENERAL 34
GENERAL 35
1 ENGINE IDENTIFICATION 36
[1] MODEL NAME AND ENGINE SERIAL NUMBER 36
[2] E4B ENGINE 38
[3] CYLINDER NUMBER 38
2 MUFFLER FULL ASSEMBLY IDENTIFICATION 39
[1] PART NUMBER AND SERIAL NUMBER 39
3 GENERAL PRECAUTIONS 40
4 MAINTENANCE CHECK LIST 41
5 CHECK AND MAINTENANCE 45
[1] DAILY CHECK POINTS 45
[2] INITIAL 50 HOURS 48
[3] EVERY 50 HOURS 49
[4] EVERY 250 HOURS 49
[5] EVERY 500 HOURS 51
[6] EVERY 1000 HOURS 55
[7] EVERY 1500 HOURS 56
[8] EVERY 3000 HOURS 58
[9] EVERY 1 YEAR 66
[10] EVERY 2 YEARS 68
6 SPECIAL TOOLS 72
1 ENGINE 90
MECHANISM 91
1 ENGINE BODY 92
[1] CYLINDER BLOCK 92
[2] COOLING JACKET 92
[3] HALF-FLOATING HEAD COVER 93
[4] CYLINDER HEAD 94
[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE 95
[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) 96
[7] GEAR TRAIN CONFIGURATION 96
[8] PISTON 97
2 LUBRICATING SYSTEM 98
[1] OIL COOLER 98
3 COOLING SYSTEM 99
[1] THERMOSTAT 99
[2] BOTTOM BYPASS SYSTEM100
4 FUEL SYSTEM101
[1] OVERVIEW101
[2] SUPPLY PUMP102
[3] RAIL105
[4] INJECTOR106
[5] ENGINE CONTROL SYSTEM109
(1) Engine ECU110
(2) Sensor110
5 EGR SYSTEM112
[1] EGR VALVE112
[2] REED VALVE112
[3] EGR COOLER113
6 AFTER TREATMENT SYSTEM114
[1] AFTER TREATMENT DEVICES [V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B]114
[2] AFTER TREATMENT DEVICES [V2607-CR-TIE4B / V3307-CR-TIE4B]120
SERVICING121
1 TROUBLESHOOTING122
2 SERVICING SPECIFICATIONS126
3 TIGHTENING TORQUES135
[1] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR GENERAL USE135
[2] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR SPECIAL USE136
4 CHECKING, DISASSEMBLING AND SERVICING139
[1] CHECKING AND ADJUSTING139
(1) Engine Body139
(2) Lubricating System141
(3) Cooling System141
(4) Electrical System143
(5) Turbocharger147
[2] DISASSEMBLING AND ASSEMBLING148
(1) Draining Engine Oil and Coolant148
(2) External Components149
(3) Turbocharger and EGR162
(4) Common Rail163
(5) Cylinder Head and Valves165
(6) Thermostat172
(7) SCV173
(8) Fuel Temperature Sensor175
(9) Supply Pump176
(10) Water Pump and Oil Cooler179
(11) Front Cover180
(12) Flywheel and Timing Gears181
(13) Piston and Connecting Rod188
(14) Crankshaft and Crankcase192
(15) Starter194
(16) Alternator195
[3] SERVICING197
(1) Cylinder Head and Valves197
(2) Timing Gears206
(3) Piston and Connecting Rod211
(4) Crankshaft215
(5) Cylinder221
(6) Oil Pump222
(7) Relief Valve223
(8) Starter223
(9) Alternator225
DIAGNOSIS MANUAL227
Diag 9Y110-01992 ENpdf 0
V2607-CR-E4B,V2607-CR-TE4B,V2607-CR-TIE4B (DOC only),V3307-CR-TE4B,V3307-CR-TIE4B (DOC only)227
I INFORMATION229
INFORMATION230
1 SAFETY FIRST231
1 COMMON RAIL SYSTEM234
MECHANISM235
1 BASIC SYSTEM INFORMATION236
[1] SYSTEM CONFIGURATION236
[2] FUEL SYSTEM237
[3] INTAKE AND EXHAUST SYSTEM238
[4] WIRING DIAGRAM239
(1) Engine Intermediate Harness (Engine Side Harness)239
(2) Injector Intermediate Harness (Engine Side Harness)241
(3) ECU Intermediate Harness (OEM Side Harness)242
(4) System Wiring Diagram247
[5] AVAILABLE DATA MONITOR SIGNALS (LEVEL 1)249
(1) Monitor Items249
(2) Normal Value252
[6] ECU TERMINAL LAYOUT255
(1) ECU Terminal Layout 1 (Engine Side)255
(2) ECU Terminal Layout 2 (Machine Side)258
SERVICING261
1 GENERAL264
[1] OVERALL DIAGNOSTIC PROCEDURE264
[2] QUESTIONING265
[3] LIST OF MALFUNCTION SYMPTOM268
[4] ACTIONS FOR NON-REOCCURRING MALFUNCTIONS269
2 DIAGNOSTIC TOOL CONNECTION PROCEDURE271
[1] DIAGNOSTIC CONNECTOR POSITIONS271
[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE271
[3] CHECKING THE COMMUNICATION OPERATION OF THE INTERFACE (DST-i)272
[4] CHECKING THE OPERATION OF THE ECU273
(1) Starting Diagmaster273
(2) DST-i Communication Settings275
3 ACTIVE TEST AND SUPPLY PUMP DIFFERENCE LEARNING279
4 DIAGNOSIS BY MALFUNCTION SYMPTOM281
[1] LIST OF MALFUNCTION CAUSES BY SYMPTOM281
[2] DIAGNOSIS BY MALFUNCTION SYMPTOM285
(1) Engine Warning Light Comes On285
(2) Engine Does Not Start285
(3) Takes A Long Time Before Engine Starts289
(4) Idle Failure293
(5) Engine Noise296
(6) High fuel consumption298
(7) Poor Acceleration (Insufficient Output)303
(8) Abnormal Black Smoke Emitted308
(9) Abnormal White Smoke Emitted312
(10) Engine Stalls On Deceleration317
5 DIAGNOSTIC PROCEDURE BY DTC321
[1] DTC LIST321
[2] DIAGNOSTIC PROCEDURE BY DTC384
(1) NE – G Phase Shift (DTC P0016 / 636-7)387
(2) Intake Air Temperature Built-in MAF Sensor: Abnormality (DTC P0072 / 171-4, DTC P0073 / 171-3)388
(3) Pressure Limiter Emergency Open (DTC P0087 / 633-7)391
(4) High Rail Pressure (DTC P0088 / 157-0)396
(5) SCV Stuck (DTC P0089 / 1347-7)401
(6) Fuel Leak (in High Pressured Fuel System) (DTC P0093 / 1239-1)406
(7) Intake Air Volume: Low (DTC P0101 / 132-1)411
(8) MAF Sensor Abnormality (DTC P0102 / 132-4, P0103 / 132-3)412
(9) Intake Air Temperature: High (Inter Cooler Model Only) (DTC P0111 / 172-0)414
(10) Intake Air Temperature Error (DTC P0112 / 172-4, P0113 / 172-3)415
(11) Coolant Temperature Sensor Abnormality (DTC P0117 / 110-4, P0118 / 110-3)418
(12) Fuel High Temperature (DTC P0181 / 174-0)421
(13) Fuel Temperature Sensor Abnormality (DTC P0182 / 174-4, P0183 / 174-3)422
(14) Rail Pressure Sensor Abnormality (DTC P0192 / 157-4, P0193 / 157-3)425
(15) Injector Charge Voltage: High (DTC P0200 / 523535-0)429
(16) Open Circuit of Harness/Coil (DTC P0201 / 651-3, P0202 / 653-3, P0203 / 654-3, P0204 / 652-3)431
(17) Engine Overheat (DTC P0217 / 110-0)434
(18) Engine Overrun (DTC P0219 / 190-0)436
(19) Boost Pressure Sensor Abnormality (DTC P0237 / 102-4, P0238 / 102-3)437
(20) Crankshaft Position Sensor (NE Sensor) Abnormality (DTC P0335 / 636-8, P0336 / 636-2)441
(21) Camshaft Position Sensor (G Sensor) Abnormality (DTC P0340 / 723-8, P0341 / 723-2)446
(22) Air Heater Relay Driving Circuit Abnormality (DTC P0380 / 523544-3 / 523544-4)450
(23) EGR Actuator Abnormality (DTC P0403 / 523574-3, DTC P0404 / 523574-4, P0409 / 523572-4)454
(24) Oil Pressure Error (P0524 / 100-1)457
(25) Exhaust Gas Temperature Sensor 1 (T1) Abnormality (DTC P0543 / 3242-4, P0544 / 3242-3)459
(26) Exhaust Gas Temperature Sensor 0 (T0) Abnormality (DTC P0546 / 4765-4, P0547 / 4765-3)462
(27) Battery Voltage Abnormality (DTC P0562 / 168-4, P0563 / 168-3)465
(28) QR Data Abnormality (DTC P0602/523538-2, P0602/523538-7)468
(29) ECU Flash-ROM and CPU Abnormality (DTC P0605 / 628-2, P0606 / 1077-2, P0606/ 523527-2)469
(30) Injector Charge Voltage Abnormality (DTC P0611 / 523525-1)471
(31) SCV Drive System Abnormality (DTC P0628 / 1347-4, P0629 / 1347-3)473
(32) Sensor Supply Voltage 1 Abnormality (DTC P0642 / 3509-4, P0643 / 3509-3)477
(33) Sensor Supply Voltage 2 Abnormality (DTC P0652 / 3510-4, P0653 / 3510-3)479
(34) Main Relay is Locked in Closed Position (DTC P0687 / 1485-2)481
(35) Pump Seizing (DTC P1274 / 523539-2, P1275 / 523540-2)484
(36) EEPROM Check Sum Error (DTC P1990 / 523700-13, P1991 / 523701-13, P1992 / 523702-13)489
(37) Intake Throttle Feedback Error (DTC P2108 / 523580-2)491
(38) Accelerator Position Sensor 1 Abnormality (DTC P2122 / 91-4, P2123 / 91-3)493
(39) Accelerator Position Sensor 2 Abnormality (DTC P2127 / 29-4, P2128 / 29-3)497
(40) Accelerator Position Sensor Error (CAN) (DTC P2131 / 523543-2)501
(41) Accelerator Position Sensor Correlation Error (DTC P2135 / 91-2)503
(42) Common 1 System Injector Drive Circuit Open (DTC P2146 / 523523-2)504
(43) Common 1 TWV Actuation System Short (DTC P2147 / 523523-4, P2148 / 523523-3)507
(44) Common 2 System Injector Drive Circuit Open (DTC P2149 / 523524-2)511
(45) Common 2 TWV Actuation System Short (DTC P2150 / 523524-4, P2151 / 523524-3)514
(46) Barometric Pressure Sensor Error (DTC P2228 / 108-4, P2229 / 108-3)518
(47) EGR (DC Motor) Abnormality (DTC P2413 / 523575-7, P2414 / 523576-2, P2415 / 523577-2)520
(48) Exhaust Gas Temperature Sensor 2 (T2) Abnormality (DTC P242C / 3246-4, P242D / 3246-3)523
(49) Differential Pressure Sensor 1 Abnormality (DTC P2454 / 3251-4, P2455 / 3251-3)526
(50) Intake Throttle Lift Sensor Abnormality (DTC P2621 / 523583-4, P2622 / 523582-3)530
(51) Emission Deterioration (DTC P3001 / 3252-0)532
(52) Exhaust Gas Temperature Sensor 0: Emergency High (DTC P3002 / 4765-0)534
(53) Exhaust Gas Temperature Sensor 1: Emergency High (DTC P3003 / 3242-0)536
(54) Exhaust Gas Temperature Sensor 2: Emergency High (DTC P3004 / 3246-0)538
(55) Excessive PM3 (DTC P3006 / 3701-15)540
(56) Excessive PM4 (DTC P3007 / 3701-16)541
(57) Excessive PM5 (DTC P3008 / 3701-0)542
(58) Boost Pressure Low (DTC P3011 / 132-15)543
(59) Low Coolant Temperature in Parked Regeneration (DTC P3012 / 523589-17)545
(60) Parked Regeneration Time Out (DTC P3013 / 523590-16)546
(61) All Exhaust Gas Temperature Sensor Failure (DTC P3018 / 523599-0)548
(62) Initial Pump-calibration Incomplete (DTC P3019 / 523600-0)549
(63) High Exhaust Gas Temperature After Emergency High Temperature DTC (DTC P3023 / 523601-0)550
(64) High Frequency of Regeneration (DTC P3024 / 523602-0)551
(65) Over Heat Pre-caution (DTC P3025 / 523603-15)552
(66) CAN2 Bus Off (DTC U0075 / 523547-2)553
(67) No Communication with EGR (DTC U0076 / 523578-2)555
(68) CAN1 Bus Off (DTC U0077 / 523604-2)557
(69) CAN2 Frame Error (DTC U0081 / 523548-2, U0082 / 523591-2, U0083 / 523592-2, U0084 / 523593-2, U0085 / 523594-2, U0086 / 523595-2, U0087 / 523596-2, U0089 / 523598-2)558
6 INSPECTION PROCEDURE FOR EACH SYSTEM562
[1] AIR INTAKE SYSTEM INSPECTION PROCEDURE562
[2] FUEL SYSTEM INSPECTION PROCEDURE563
[3] ELECTRIC SYSTEM INSPECTION PROCEDURE568
(1) Basics Of Checking Electrical / Electronic Circuit Systems568
(2) Connector Connection Fault Verification Method571
(3) Checking The Power And Ground System (Main Relay, ECU Circuit)572
S.M 11/24
