Test compression pressure

AR01.00-B-1200TCA

Test compression pressure

12.02.16



Remove

Danger!

Risk of accident through uncontrolled movement while the engine is working. Risk of crush and burn injury by contact when the engine starts or is working

Make sure that the vehicle is protected against uncontrolled movement. Wear protective clothing closed and properly fastened. Do not touch heated or moving pieces.

AS00.00-B-0005-01A

1

Start the engine, let it heat up to operating temperature, and then turn it off

 Coolant temperature approximately 70 to 95 °C.

2

Switch off ignition

Danger!

Risk of crush injury and obstruction while tilting the cab

During back and forth cab tilting, stay away from tilting area and take preventive measures to avoid non-authorized people from entering tilting area. Always tilt the cab to its final position and secure it with the safety device.

AS60.80-B-0001-01A

3

Tilt the cab



Indications on cab tilting

AH60.80-B-0003-01A

4

Remove and tie button Start / Stop Engine (S10.1) in the collector of supercharging air

 Do not separate the button Start / Stop Engine (S10.1) from the electric harness of the engine.

5

Remove the collector of supercharging air

AR09.41-B-8681TD

6

Remove the head lids

AR01.20-B-5014TC

7

Remove the injecting pipes

AR07.15-B-9235TC

8

Remove injector holder sets

AR07.03-B-6831TD

Danger!

Risk of explosion through ignition, poisoning by inhalation and ingestion of fuel, and injury by contact of the eyes and skin with fuel

No firing, sparking, burning or smoking. Fuel must be stored only in suitable containers and properly labeled. Wear suitable protective clothing and equipment when handling with fuel.

AS47.00-B-0001-01A

9

Install fuel return pipe (2) in the injecting units

AR07.15-B-2000-06TC



*BA07.15-B-1004-01B



*000589680300



*000589403700



Fuel return pipe (2) from the injecting units to the compression rate test

WF58.50-B-0700-02A

10

Connect Star Diagnosis and turn off the command of the injecting units

 Only when not all cylinders are tested.

By turning off the command of the injecting units through Star Diagnosis, the engine will not start.

11

Turn ignition on

 When not all cylinders are tested, by turning the ignition off or temporarily disconnecting Star Diagnosis, the command of the injecting units becomes active once again and the engine is capable of starting.

12

Press the button Start / Stop Engine (S10.1) and rotate the engine several times with the starter



Inspect

13

Install the connection (3) with the seal stopper in the heat protective stopper and fasten it with the fixing frame (4)

 To fasten, screw the fixing frame (4) with a suitable screw (5).



*BA07.15-B-1003-01B



*904589012100

14

Install the compression-indicating manometer (1) and the angular connection (6) in the connecting piece (3) and put or position the diagram sheet (7)



*001589782100

15

Press the button Start / Stop Engine (S10.1) and run the engine for at least 8 rotations with the starter

 The measured values are recorded in the diagram sheet (7).

16

Remove the fixing frame (4) and separate the connection (3) from the heat protective gloves

 Extract the seal stopper of the heat protective stopper with an extraction tool.



*906589026300

17

Check the other cylinders likewise

18

Compare data from the diagram sheet (7) with allowed values

 In case of variation of the allowed values, determine the cause and correct the failures.

*BE01.00-B-1001-01C

*BE01.00-B-1002-01C



Install

 Danger!

Risk of explosion through ignition, poisoning by inhalation and ingestion of fuel, and injury by contact of the eyes and skin with fuel

No firing, sparking, burning or smoking. Fuel must be stored only in suitable containers and properly labeled. Wear suitable protective clothing and equipment when handling with fuel.

AS47.00-B-0001-01A

19

Remove fuel return pipe (2) from the injecting units

AR07.15-B-2000-06TC



*000589680300

20

Install injector holder sets

AR07.03-B-6831TD

21

Install injecting pipe

AR07.15-B-9235TC

22

Install head lids

AR01.20-B-5014TC

23

Install the collector of supercharging air

AR09.41-B-8681TD

24

Install button Start / Stop Engine (S10.1) in the collector of supercharging air



*BA15.00-B-1001-01A

Danger!

Risk of crush injury and obstruction while tilting the cab

During back and forth cab tilting, stay away from tilting area and take preventive measures to avoid non-authorized people from entering tilting area. Always tilt the cab to its final position and secure it with the safety device.

AS60.80-B-0001-01A

25

Return the cab to its original position



Indications on cab tilting

AH60.80-B-0003-01A

26

Delete the failure records with Star Diagnosis

Número

Denominação

Engine 457.9,

BE01.00-B-1001-01C

Minimum allowed compression pressure (at sea level)

bar

28

BE01.00-B-1002-01C

Maximum variation between cylinders of an engine.

bar

4

Número

Denominação

Engine 457.9; 460.9

BA07.15-B-1003-01B

Attachment support of the cylinder head injector

Nm

50

BA07.15-B-1004-01B

Injection pipe, from the injection unit to the injector pressure pipe

1st stage

Nm

15

2nd stage

angular

90°

Número

Denominação

Engine 457.9; 460.984

BA15.00-B-1001-01A

Engine start and stop button on the intake air manifold

Nm

25