Celtis Engine PDF

DPS ENGINE
Technical support Chapter A
Celtis 00 11 354 320 – Edition 09.2007

Celtis – 09.2007 – GB
A – DPS ENGINE
Celtis – 09.2007 – GB
CONTENTS
ENGINE
INLET AND EXHAUST .......................................................................................................................................3
COOLING ..........................................................................................................................................................21
LUBRICATION ..................................................................................................................................................30
MECHANICAL INJECTION ..............................................................................................................................42
ELECTRONIC INJECTION ...............................................................................................................................55

HYDRAULIC PART ............................................................................................................................................................ 66
ELECTRONIC COMPONENTS.......................................................................................................................................... 76
MOVING ASSEMBLY .......................................................................................................................................98
ACCESSORY GEAR TRAIN...........................................................................................................................108
VISCOUS FAN COUPLING ............................................................................................................................113
Celtis – 09.2007 – GB
ENGINE
Description
101msm00
The "manufacturer's" plate (A), located on the rear right hand side of the block, enables the engine
to be identified:
Celtis – 09.2007 – GB A.1

First line (1): Serial number (13 characters)
Tractor prior to May 2005 Tractor after May 2005

CD Engine built at the Saran factory CD Engine built at the Saran factory
4 4 cylinders 4 4 cylinders
O45 4,5 litres capacity O45 4,5 litres capacity
D Normally aspirated engine B Uncertified engine
T Turbo-charged engine C Tier 1 engine (will be followed by
the letter E then F when the
counter reaches 999999)
H Turbo-charged engine with G Tier 2 engine (will be followed by
intercooler the letter J then K when the
counter reaches 999999)
5 Tier 1 engine 123456 Number within the series
7 Tier 2 engine
12345 Number within the series
Second line (2): Engine type
4 See above
045
T
RT RENAULT Agriculture application
52 Application issue
A.2 Celtis – 09.2007 – GB

Inlet and exhaust
Technical description
Cylinder head
131msm00
This can be identified by: The cross-flow design.

Inlet ducts have been redesigned to increase turbulence in the cylinders SWIRL, and hence
improve air/fuel mixing.
A cast letter (H) in the inlet port identifies the model of cylinder head.
The cylinder head now incorporates a housing for the direct mounting of the thermostat.
The cylinder head gasket is specific.
It has a compressed graphite film on both surfaces.
Celtis – 09.2007 – GB A.3

Valves
A – Collets.
B – Valve rotator.
C – Spring.
D – Umbrella seal.
D
C
B
A
131hsm10
The valve guides are machined directly in the cylinder head. A helicoidal open groove improves
lubrication between the guide and valve. An "umbrella" type seal (D) allows the passage of a
controlled quantity of oil to provide lubrication for the valve stem.
Each valve is fitted with a rotator (B) ensuring a rotation of 2° each time the valve operates. The
contact surface between the valve head and the seat insert is thus always clean.
A.4 Celtis – 09.2007 – GB

Schematic diagram
Air circulation
I J
t°
K
t°
F
E
M
C
141msm00
Celtis – 09.2007 – GB A.5

A – Filter. H – Pre-heat flange.
B – Filter blockage thermal switch. I – Pre-heat relay.
C – Pneumatic compressor. J – Instrument panel.
D – Turbocharger. K – Intake/exhaust.
E – Intercooler. L – Particulate rebreathing.
F – Turbocharger pressure sensor (according M – Check valve.
to model).
G – Air temperature thermistance.
A.6 Celtis – 09.2007 – GB

Technical specifications
Pre-heating
– Mechanical injection:
Pre-heating is activated by holding the key at position III on the master switch. The pre-heat
warning light illuminates.
Maximum pre-heat duration is 20 seconds (Instrument panel time delay).
A 1 200 W heater is fitted between the manifold and the intake pipe.
– Electronic injection:
Both the pre-heating and the illumination of the instrument panel warning light are controlled by
the engine ECU.
Particulate rebreathing
Particulate rebreathing is achieved by a duct subject to a venturi effect between the exhaust pipe
and the air filter.
DIMENSIONS
Cylinder head
A
130hsm00
A.
Minimum acceptable cylinder head thickness 104,87 mm
Maximum acceptable cylinder head thickness 105,13 mm
Maximum acceptable cylinder head rework 0,73 mm
Minimum cylinder head thickness after rework 104,11 mm
B.
Cylinder head flatness over entire length 0,08 mm
Celtis – 09.2007 – GB A.7

Valves
C G
D H
F J
E I
131hsm00
INTAKE EXHAUST
C. G.
Minimum diameter of valve stem 7,864 mm Minimum diameter of valve stem 7,848 mm
Maximum diameter of valve stem 7,884 mm Maximum diameter of valve stem 7,874 mm
D. H.
Minimum clearance between stem 0,05 mm Minimum clearance between 0,05 mm
and guide stem and guide
Maximum clearance between stem 0,10 mm Maximum clearance between 0,10 mm
and guide stem and guide
Wear limit 0,15 mm Wear limit 0,15 mm
E. I.
Minimum valve withdrawal 0,61 mm Minimum valve withdrawal 1,22 mm
Maximum valve withdrawal 1,11 mm Maximum valve withdrawal 1,72 mm
Wear limit 1,63 mm Wear limit 2,26 mm
F. J.
Minimum diameter of valve head 46,47 mm Minimum diameter of valve head 42,37 mm
Minimum diameter of valve head 46,73 mm Minimum diameter of valve head 42,63 mm
A.8 Celtis – 09.2007 – GB

Rocker shaft
313hsm01
Adm. – Intake
Ech. – Exhaust
LU. – Wear limit
Celtis – 09.2007 – GB A.9

A.
Uncompressed length 54 mm
Length compressed to 24 daN 46 mm
Length compressed to 68 daN 34,5 mm
A.10 Celtis – 09.2007 – GB

Turbocharger
Type of turbocharger CZ
Normal turbocharger pressure at full load 0,83 bar
nominal speed
165hsm00
Celtis – 09.2007 – GB A.11

Check of valve lift
Note: Measuring valve lift enables any wear in the cam to
be detected.
– Fit the flywheel rotating tool 60 05 005 501

in (A).
– Using tool No. 60 05 005 501 turn the
flywheel in its normal direction (clockwise
when viewed from the water pump) until piston A
No. (1) (at the front) is at top dead centre B
(TDC) of its compression stroke.
– Fit the lock pin n° 60 05 005 576 in (B).
– Eliminate the clearance between the rocker
arm and the valve stems on exhaust valves
n° 1 - 3 and inlet valves n° 1 - 2.
– Place a dial gauge on the valve spring cup or 131msm13
on the valve cap and then set to 0.

– Remove the lock pin, turn the engine, and
observe the dial gauge up to the point of
maximum valve opening.
– Measure valve lift and compare it with the
values mentioned in "Dimensional
specifications".
– Turn the engine by a full revolution 360°. Lock
the engine at TDC on the compression stroke
for piston (4).
– Eliminate the clearance between the rocker
arm and the valve stems on exhaust valves
n° 2 - 4 and inlet valves n° 3 - 4.
– If the specifications are not followed, remove
and check the camshaft condition.
– Place a dial gauge on the valve spring cup or
on the valve cap and then set to 0.
131msm02
– Measure valve lift and compare it with the
values mentioned in "Dimensional
specifications"..
– If the lift of one or several valves is not within
specifications, remove and inspect the entire
valve set and camshaft.
A.12 Celtis – 09.2007 – GB

Head gasket failure - investigation procedure
Preliminary checks
Three types of seal failures can occur:
– Combustion gas faulty sealing.
– Cooling system faulty sealing.
– Lubrication system faulty sealing.
A – Combustion gas sealing surface
B – Oil sealing surfaces
C – Coolant sealing surfaces
A B C
135msm03
Celtis – 09.2007 – GB A.13

Visual inspection to be carried out before intervention on the cylinder head gasket:
– Presence of oil or coolant on the seal face or
adjacent surfaces.
– Seal displaced in respect of its normal
position.
– Discoloration or presence of soot caused by a
combustion gas leak
– Leak on the radiators (oil and water), the
tank, overflow, or pipe hoses.
– Coolant leaking at the water pump bleed
hole.
– Presence of coolant on the cylinder head
gasket. A
– Presence of coolant in the crankcase. 131hsm16
– Insufficient coolant level.

– High oil level.
– Presence of cooling liquid in the engine
breather (A).
Pressurized test of the cooling system:
Before the test, warm the engine.
Let the engine cool down, and remove the

radiator cap cautiously. 0,7 bar
If no leak is visible, but if pressure drops, there

may be an internal coolant leak or an internal
leak in the seal between the block and the
cylinder head.
131hsm15
A.14 Celtis – 09.2007 – GB

Combustion gas sealing
Symptoms:
– Loss of power.
– Irregular engine running.
– White smoke at the exhaust pipe.
– Air bubbles in the water radiator or the overflow tank.
– Cooling fluid leak from overflow pipe.
– Engine overheating.
– Loss of heating in driver's cab.
– Coolant in a cylinder.
– Coolant in the crankcase oil.
– Insufficient coolant level.
Possible causes:
– Cracks, folds in the seal surfaces.
– Damages, punctures in the elastomer ribs.
– Cracks, folds in the seal surfaces. O-ring damaged or missing at the push rod oil orifice.
– Excessive liner protrusion.
– Excessive difference in liner protrusion between the cylinders.
– Insufficient tightening torque.
– Distorted, damaged, or irregular engine block surface.
– Distorted, damaged, or irregular cylinder head surface.
– Oil or fluid overheating.
IMPORTANT: Oil cooling failures can cause the presence of oil in the cooling fluid.
Celtis – 09.2007 – GB A.15

Coolant sealing
Symptoms:
– Coolant leaking through the cylinder head gasket.
– Coolant in the oil pan.
– Insufficient level in the tank.
– High oil level.
– Coolant leaking through the crankcase breather.
Possible causes:
– Deformed, damaged, or irregular engine block surface.
– Deformed, damaged or irregular cylinder head surface.
– Oil or coolant temperature too high.
– Cylinder head gasket surface deformed or cracked.
– Elastomer parts of cylinder head gasket damaged or cracked.
Lubrication system sealing

Symptoms:
– Oil leaking through the cylinder head gasket.
– Oil in the coolant.
– Insufficient oil level in the crankcase.
– Insufficient rocker lubrication (abnormal noises).
Possible causes:
– Deformed, damaged, or irregular engine block surface.
– Deformed, damaged or irregular cylinder head surface.
– Oil or coolant temperature too high.
– Cylinder head gasket surface deformed or cracked.
– Elastomer parts of cylinder head gasket damaged or cracked.
– O-rings damaged in the oil passages to the rockers.
IMPORTANT: Oil cooling failures can cause the presence of oil in the cooling fluid.
A.16 Celtis – 09.2007 – GB

Checking the turbocharger pressure
– Remove the plug (1) or (2).
– Install the pressure gauge n° 60 05 005 521
– Before checking, run the engine. 1
101msm50
– Observe the pressure gauge.

The lift pressure should be, when the engine is running at full load and reaches nominal speed:
4045 TRT 77 engine 0,52 bar

If the pressure is too low, check the following points:
– Air filter clogging.
– Leak at the intake circuit, between the turbocharger and cylinder head.
– Faulty turbocharger.
Celtis – 09.2007 – GB A.17

Turbo checks
Radial shaft play

– Fit on the turbocharger a comparator fitted
onto a support with a graduated extension,
and fit the graduated extension on the shaft of
the compressor, by passing it through the
lubrication orifice.
– Push and pull alternately the compressor
shaft.
– With equal pressure applied to both ends of
the shaft, the clearance should not exceed the
values indicated in the chapter "Dimensional
specifications".
251msm27
Axial shaft play

– Using a comparator contacting the shaft,
measure axial clearance.
– Move the shaft axially by hand in both
directions and compare the value read with
the values specified in the chapter
"Dimensional specifications".
251msm18
A.18 Celtis – 09.2007 – GB

Reconditioning the turbocharger
IMPORTANT: It is difficult to recondition a turbocharger without the tools and training required: do not totally
disassemble a turbocharger. If a turbo is found to be faulty when checked, replace it.
Note: When refitting, use the recommended torque settings.
IMPORTANT: When refitting, oil the turbo bearings to ensure lubrication on engine start-up.
167msm00
Celtis – 09.2007 – GB A.19

Cooling
Cooling system
251msm00
A.20 Celtis – 09.2007 – GB

A – Water pump. N – Drain plug.
B – Coolant passage adaptor. O – Water pump suction side.
C – Oil cooler drain plug. P – High temperature cooling fluid.
D – Oil cooler plates. Q – Low temperature cooling fluid.
E – Cooling fluid passage. R – Cabin heater valve.
F – Cooling fluid envelope. S – Cabin heater radiator.
G – Passages in the upper part of the block. T – Engine management thermistance.
H – Passages. U – Instrument panel thermistance (depending
I – Thermostat. on the model).
J – Water manifold/thermostat housing. V – Heat exchanger.
L – Bypass circuit. W – Expansion bottle.
M – Towards the radiator upper tank.
Celtis – 09.2007 – GB A.21

Schematic diagram
Cooling system
A D
J
t˚ G
F
L
t˚
R
T
I
t˚
W V
221msm05
x – Depending on installation.
A.22 Celtis – 09.2007 – GB

Thermostat
The thermostat sits within the cylinder head under the water housing. Part of the coolant flow is
diverted to the water pump via a steel tube. The temperature is regulated between 82 and 95°C.
A – Coolant temperature probe
251msm01
During filling, bleed the system by loosening the

temperature probe or the plug (depending on
installation) at position (A).
251msm02
Celtis – 09.2007 – GB A.23

Water pump
The water pump is fitted under the accessory

gear train cover and uses the cavity in the cover
as the pump body.
251msm03
Degraded modes
Coolant temperature too high

First check coolant quality and level. Check for leaks from external engine system components.
1. FAULTY
Go to 2.
GOOD
Go to 4.
2. CHECK FOR THE PRESENCE OF OIL YES
IN THE COOLANT HEADER TANK. Check the cylinder head and the cylinder head
gasket.
See: Head gasket failure - investigation
procedure.
NO
Go to 3.
3. DRAIN THE COOLANT. YES
– Refill to the correct level. Go to 4.
Does the problem remain ? NO
Problem solved.
4. CHECK THE RADIATOR: YES
– Dirt ; Go to 5.
– Leaks ; NO
Problem solved.
– Blockage.
Repair or replace the defective components.
Does the problem remain ?
A.24 Celtis – 09.2007 – GB

5. CHECK THE FAN, MOTOR, BELT YES
AND TENSIONER. Go to 6.
– Repair or replace the defective NO
components. Problem solved.
6. CHECK CONDITION AND YES
OPERATION OF THERMOSTAT. Go to 7.
7. CHECK CONDITION AND Repair or replace the defective components.
OPERATION OF WATER PUMP.
DIMENSIONAL CHARACTERISTICS (in mm)
Thermostat
Thermostat opening temperature 82°C (80-84°C)

Temperature for full opening of the thermostat 94°C
Cooling system pressure 0,7 bar
Celtis – 09.2007 – GB A.25

Water pump and fan drive support
250hsm00
A.26 Celtis – 09.2007 – GB

Checking the thermostat
– Heat water in a container, and check the
thermostat triggering temperatures.
– Stir while water is heating.
IMPORTANT: Caution when heating the water, keep the
thermostat or thermometer away from the edge or bottom
of the container. This could result in overheating and
breaking.
– Take the thermostat out of the water and

check that it closes as it cools down.
Note: At room temperature, the thermostat must close
completely and slowly (when its temperature reaches
80°C).
– If not, change it.

251hsm24
Reminder of the triggering values:

– Nominal opening value 82°C.
– Initial opening 80-84°C.
– Full opening (nominal) 94°C.
Check of the belt and the tensioner spring
Check of the belt condition

– Refer to the user manual, chapter L.
Celtis – 09.2007 – GB A.27

Check of the tensioner spring force
Note: A belt tension gauge does not provide accurate
measurement of belt tension when a spring-operating
automatic tensioner is used. Measure the tensioner spring
force with a torque wrench as follows:
– Loosen the tension on the belt using a nut

spinner and a socket on the tension arm.
Remove the belt from the pulleys. A
– Release the tension exerted on the tension B
arm and remove the nut spinner.
– Scribe a mark (A) on the tensioner swivel arm
as shown in the figure.
– Measure 21 mm from (A) and scribe a mark
(B) on the tensioner mounting base.
101msm30
– Swivel the arm using a torque wrench to align

the markings (A), (B) and (C).
– Note the measure on the torque wrench and
compare it to the specification below:
– The value should be between 0,8 and
2,2 daN.m.
– Change the tensioner if required.
101msm31
A.28 Celtis – 09.2007 – GB

Lubrication
Lubrication system
H
G
221msm01
A – Oil pump. O – Connecting rod bearings.

B – Oil suction pipe. Q – Camshaft bushes.
C – Oil outlet tube. R – Gudgeon pin and bush.
D – Oil cooling casing. S – Rocker shaft.
E – Coolant passage adaptor. T – Turbocharger oil supply duct.
F – Oil filter. V – Rockers.
G – Oil filter manifold/adaptor. X – Oil feed.
H – Oil filler tube. Y – Oil pressure regulator.
I – Oil cooler. Z – Oil bypass valve.
K – Crankshaft oil galleries. AA – Pressurized oil.
N – Main lubrication duct. AB – Non pressurized oil.
Celtis – 09.2007 – GB A.29

Schematic diagram
Lubrication system
V S
F
L
Z
A
Y
221msm00
A.30 Celtis – 09.2007 – GB

Oil system components
221msm02
1 – Seal
The oil cooler, with 7 plates, is a heat exchanger installed between the oil pump and filter.
It speeds up oil warm-up on engine start thanks to the flow of water from the cylinder head pumped
by the water pump.
It then regulates and evens out the temperature. It is fitted in a cavity of the cylinder block
221msm03
Celtis – 09.2007 – GB A.31

Under very cold conditions, the bypass valve's role is to divert some of the oil directly to the main
gallery by short-circuiting for a short time the filter and the cooler. This valve requires no
adjustment or maintenance.
221msm04
The oil spray nozzles screwed to the galleries provide lubrication to the liners and gudgeon pins
as well as cooling for the piston skirts, with a flow of around 1,3 l/m.
A.32 Celtis – 09.2007 – GB

Degraded modes
Sheet n° 1 "Excessive oil consumption"

First check for leaks from the external pipes and the cap/plug seals.
1. PRESENCE OF OIL IN THE COOLING YES

SYSTEM. Go to 2.
NO
Go to 4.
2. CHECK OIL COOLER. FAULTY
GOOD
Go to 3.
3. DOES THE PROBLEM REMAIN ? YES
.:
– Cylinder head gasket ;
– Cylinder head ;
– Cylinder liner gaskets ;
– Engine block.
NO
Problem solved.
4. CHECK FOR EXCESSIVE YES
PRESSURE IN CRANKCASE (CRANK See: Sheet n° 2 "Engine oil pressure too high".
CASE GAS). NO
Go to 5.
5. CHECK SEAL IN TURBO. FAULTY
See: Checking the turbocharger oil sealing.
GOOD
Problem with pistons, rings, liners or valve
guides.
Celtis – 09.2007 – GB A.33

Sheet n° 2 "Engine oil pressure too high"
First check oil level and quality and the oil filter.
1. CHECK OIL LEVEL AND QUALITY. FAULTY

Go to 2.
GOOD
Go to 3.
2. DRAIN THE OIL. YES
– Fill with oil and check the level. Go to 3.
– Replace the filter. NO
Problem solved.
3. CHECK OPERATION OF PRESSURE YES
REGULATOR. Go to 4.
– Replace defective parts if necessary. NO
Does the problem remain ? Problem solved.
4. CHECK OPERATION OF BY-PASS YES

VALVE. Go to 5.
– Replace defective parts if necessary. NO
5. SOURCE OF THE PROBLEM: Repair or replace the defective components.

– Piston cooling holes are blocked.
Or
– Piston lubrication is faulty or deficient.
A.34 Celtis – 09.2007 – GB

Leaflet n° 3 Engine oil pressure too low
First check oil level and quality, the oil filter, and operation of the oil pressure switch.
1. CHECK OIL LEVEL AND QUALITY. FAULTY

Go to 2.
GOOD
Go to 3.
2. DRAIN THE OIL. YES
– Fill with oil and check the level. Go to 3.
– Replace the filter. NO
Problem solved.
3. CHECK THE BY-PASS VALVE IN THE YES
OIL FILTER HOUSING. Go to 4.
4. CHECK OIL COOLER. YES
– Repair or replace the defective Go to 5.
components. NO
5. CHECK OPERATION OF PRESSURE YES

REGULATOR. Go to 6.
6. CHECK OPERATION AND YES
CONDITION OF THE OIL PUMP AND Go to 7.
OIL PIPES. NO
– Repair or replace the defective Problem solved.
components.
7. SOURCE OF THE PROBLEM: Repair or replace the defective components.
– Excessive wear in crankshaft bearings or
connecting rod bearing shells.
Or
– Piston lubrication is faulty or deficient.
DIMENSIONS
Celtis – 09.2007 – GB A.35

Oil pump
Oil pump delivery at maximum speed, at 3 bar 70 l/min

pressure.
Minimum oil pressure at tick-over, with the oil at 1 bar minimum
90°C.
Minimum oil pressure at maximum idle speed, oil at 90 °C:
All engine types 3 bar minimum
Bypass valve spring:
Spring length (off-load) 51 mm
Spring force at a length of 29 mm 8,7 daN.m
B = Ø 16,05 → 16,10
A = Ø 16,02 → 16,03
35,97 → 36,05
D = 0,04 → 0,165
C = Ø 12,35 → 12,36
A = Ø 12,31 → 12,33
D = 0,04 → 0,165
0,131 → 0,211
1
0,21
1→
0,13
220hsm00
A.36 Celtis – 09.2007 – GB

A – Shaft C – Bore
B – Bush D – Axial clearance
Celtis – 09.2007 – GB A.37

Check of engine oil pressure
– Remove the oil pressure probe and install
pressure gauge No. (A) on the block.
– Before checking the pressure, warm up the
engine.
At idle speed and with a temperature of 93°C,
the pressure gauge should indicate a minimum
pressure of 1 bar.
At full load nominal speed and with a service
temperature of 105°C, the pressure gauge
should indicate a pressure between 2,6 and 3,3
bar.
A
101msm32
Checking procedure of the high oil pressure in the crankcase
Excessive gas pressure inside the breather pipe

can be caused by a sealing defect on the
turbocharger or the piston rings.
– Remove the turbo oil return pipe (A) and
direct it too a container.
– Start the engine, at maximum no-load speed.
– Check that supercharging pressure expels oil
into the drain pipe.
If yes, there is a problem with the turbo seals.
If no, gas pressure is present at the breather
pipe; check seal between piston ring and
A
cylinder liner.
251hsm23
A.38 Celtis – 09.2007 – GB

Checking the turbocharger oil sealing
– Check that the oil return pipe (A) is neither
twisted nor cracked. Replace if necessary.
– Check there is no obstruction in the air filter,
hoses, and connecting tube.
– Check there is no obstruction in the exhaust
A
system, also check the proper position of the
exhaust orifice.
101hsm09
Celtis – 09.2007 – GB A.39

Mechanical injection
Description
STANADYNE DB2 injector pump DB4
164msm12
CELTIS 426 CELTIS 436 CELTIS 446

Engine type 4045DRT76 4045TRT77 4045TRT78
Pump DB2 435-5930 DB4 429-5929 DB4 429-5928
Bore x stroke 106,5 x 127 106,5 x 127 106,5 x 127
Air supply Normally aspirated Turbocharged Turbocharged
DPS injection pump RE524031 RE524032 RE524033

Fuel filter 5 µm 5 µm 5 µm
Injector calibration pressure 241 ± 5 bar 245 ± 5 bar 245 ± 5 bar
Fluid capacities 11 L 11 L 11 L
Oil change interval 500 h 500 h 500 h
Oil filter 30 µm 30 µm 30 µm
Number of heat exchanger plates 5 7 7
Thermostat setting 82 - 94 ºC 82 - 94 ºC 82 - 94 ºC
A.40 Celtis – 09.2007 – GB

Coolant 11,3 L 11,3 L 11,3 L
Rated speed (rpm) 2300 0/+ 50 2300 0/+ 50 2300 0/+ 50

Rpm for max. torque 1600 1500 1500
Max. no load rpm 2490 ± 50 2490 ± 50 2490 ± 50
Idle rpm 850 ± 50 850 ± 50 850 ± 50
Dynamic advance at nominal full 2,5° – 0,3° 0,5°

power rpm
Celtis – 09.2007 – GB A.41

Injector pump
164msm00
1 – Drive shaft 8 – Flyweight cage

2 – Distributor rotor 9 – Automatic advance
3 – Transfer pump vanes 10 – Casing
4 – Pistons 11 – Regulator valve
5 – Internal cam ring 12 – Recirculation valve
6 – Hydraulic head 13 – Electric shut-offf device solenoid
7 – Transfer pressure regulator
A.42 Celtis – 09.2007 – GB

Fuel system
x4
B
5µ 190 µ
160msm01
Celtis – 09.2007 – GB A.43

The Stanadyne pencil injectors are of the
conventional type. They are fitted with a red seal.
165msm04
A.44 Celtis – 09.2007 – GB

Engine electrical system
J35
307 043
1 2 K K 28
308 042
2 1 T T 32
J66 P02 J02
345 045
3 2 L L 15
P02 J02
319 046
4 M M 36
P02 J02
065
5 33
60
316 082
6 V V 19
P02 J02
345 105
7 W W 15
P02 J02
°C P0 1 2
160msm02
Celtis – 09.2007 – GB A.45

1 – Engine temperature. 6 – Pre-heat relay.
2 – Engine temperature warning. 7 – Electric pump shutdown.
3 – Engine oil pressure. 8 – Coolant temperature switch.
4 – Air filter blocked. 9 – Cold advance electric valve.
5 – Preheat indicator.
A.46 Celtis – 09.2007 – GB

Degraded modes
Leaflet n° 1 "Engine fails to start"

The engine does not start or won't go.
1. SHUT-OFF SOLENOID VALVE FAULTY

FUNCTIONAL CHECK. Go to 2.
GOOD
Go to 3.
2. CHECK COIL RESISTANCE AT THE FAULTY
SOLENOID VALVE TERMINALS. Replace solenoid valve.
GOOD
Check electrical circuit.
3. CHECK FOR FUEL AT INJECTORS. FAULTY
Sheet n° 5 "Check the fuel feed circuit".
GOOD
Go to 4.
4. CHECK FOR OBSTRUCTION IN AIR FAULTY
INTAKE. Repair or replace the component.
GOOD
Go to 5.
5. CHECK PUMP SETTING. FAULTY
Adjust or replace the injector pump.
GOOD
Go to 6.
6. CHECK COMPRESSION. FAULTY
guides.
GOOD
Go to 7.
7. CHECK INJECTORS. FAULTY
Replace the injectors.
GOOD
Have the pump repaired.
Celtis – 09.2007 – GB A.47

Leaflet n° 2 "Erratic engine operation"
The engine misfires and/or fails to operate smoothly.
1. YES
– Wrap a cloth around the injector connector Sheet n° 5 "Check the fuel feed circuit".
– Slowly loosen and note any change in rpm. NO
Go to 2.
– Repeat the operation for the other cylinders.
Do the misfires occur with each cylinder?
2. CHECK THE CYLINDER HEAD FAULTY
GASKET. Replace the cylinder head gasket.
GOOD
Go to 3.
3. CHECK THE FUEL FEED PIPE. FAULTY
Repair or replace the pipe(s).
GOOD
Go to 4.
Go to 6.
GOOD
Go to 5.
GOOD
6. FAULTY
– Apply a small amount of oil to the piston ring Go to 7.
area through the injector hole. GOOD
– Check compression. Problem with pistons, rings, liners or valve
guides.
7. CHECK VALVE CLEARANCES. FAULTY
Adjust the clearances and repeat the test.
GOOD
Go to 8.
8. CHECK VALVE LIFT. FAULTY
Wear on camshaft, cam followers or rocker
arm shaft.
GOOD
guides.
A.48 Celtis – 09.2007 – GB

Leaflet n° 3 "Emission of grey or black smoke"
The engine emits excessive grey or black smoke from the exhaust.
1. CHECK FOR POSSIBLE BLOCKAGE YES

IN THE INTAKE OR EXHAUST OR AN Repair or replace the defective components.
AIR LEAK. NO
Go to 2.
2. CHECK PUMP STATIC AND FAULTY
DYNAMIC ADJUSTMENT. Make all the adjustments necessary to ensure
a correct shim.
GOOD
Go to 3.
3. CHECK THE TURBO: FAULTY
– Inlet and outlet of the compressor ; Repair or replace the defective components.
– Inlet and outlet of the turbine: GOOD
Go to 4.
– Centre body ;
– Axial clearance ;
– Turbocharger pressure.
GOOD
Go to 5.
5. CHECK FUEL RETURN LINE. FAULTY
GOOD
Go to 6.
GOOD
Celtis – 09.2007 – GB A.49

Leaflet n° 4 "Emission of white smoke"
The engine emits excessive white smoke from the exhaust.
1. CHECK FOR POSSIBLE HEAD YES

GASKET FAILURE. Repair or replace the defective components.
See Inspection procedure of the cylinder head NO
gasket Go to 2.
2. CHECK PUMP DYNAMIC FAULTY
ADJUSTMENT. Make all the adjustments necessary to ensure
a correct shim.
GOOD
Go to 3.
guides.
GOOD
Go to 4.
GOOD
A.50 Celtis – 09.2007 – GB

Leaflet n° 5 "Check of fuel supply system"
Irregular engine running.
1. CHECK FOR POSSIBLE PRESENCE YES

OF AIR IN THE FUEL SUPPLY SYSTEM. Purging the circuit.
NO
Go to 2.
2. CHECK FUEL SUPPLY PRESSURE FAULTY
AND FLOW. Repair or replace the defective components.
GOOD
Go to 3.
3. CHECK FUEL RETURN SYSTEM: FLOW OF FUEL FROM THE VALVE
– Disconnect the fuel line from the injector BUT THE ENGINE DOES NOT START
pump overflow valve ; Go to 4.
– Slacken the valve ; NO FLOW OR INADEQUATE FLOW
Go to 5.
– Select "start" using the ignition/starter
switch ;
– Operate the hand primer located on the fuel
filter.
If fuel does not flow, retighten all connectors.
4. CHECK FUEL LINES: FAULTY
– Between the injector and the injector pump. Repair or replace the pipe(s).
GOOD
– Between the filter and the injector pump. Repair or replace the pipe(s).
GOOD
Celtis – 09.2007 – GB A.51

Supply pressure check
– Fit the tool (1) n° 60 05 005 521.
– Start the engine. The fuel pump should
maintain the minimum pressure shown in the A B
injector cards chapter A. If the pressure is low,
change the filters and start the check again.
A B
D
161msm07
A.52 Celtis – 09.2007 – GB

Electronic injection
Description
Changes to standards
The increasingly demanding requirements relating to exhaust emissions (Tier 2 standards) require
greater control over a range of parameters (accurate fuel quantity dosage and injection timing);
this is partly facilitated by the electronic governor systems that are replacing their mechanical
equivalents.
Thanks to the increasingly widespread use of electronics, the "engine management" system will
be able to dialogue with other functions within the tractor (transmission function, etc.).
1 – Supply
3 – Return to reservoir
1
3
164msm11
Celtis – 09.2007 – GB A.53

DE 10 injection pump
This includes two systems:
– A low pressure system, including a vane-type transfer pump that supplies diesel fuel to the
high pressure system. Excess fuel emerges from the pump via a relief valve.
– A high pressure system, including a pump with radial pistons. The amount of fuel vented is
controlled by a high pressure solenoid valve. The distributor shaft that rotates in the hydraulic
head feeds the outputs to the cylinders in sequence.
11 10
9
1
8
2
3 4 5 6
161msm00
1 – Fuel inlet 7 – High pressure valve

2 – Drive shaft 8 – Distributor rotor
3 – Transfer pump 9 – Fuel temperature sensor
4 – Cam ring 10 – Pressure regulator
5 – Pipe coupling for injector 11 – Fuel return
6 – Fuel control solenoid
A.54 Celtis – 09.2007 – GB

Injector
1 – Injector nozzle
2 – Carbon deposit arrestor seal
3 – Needle 11 20
4 – Injector body 14
15
5 – Seal 12
6 – Injection pipe coupling 13
7 – Needle guide 10
8 – Union nut
16 18 19
9 – Spring retainer
9
10 – Adjustable spring
11 – Stroke adjustment screw
12 – Locknut 7
13 – Union 4 5 6 17
8
14 – Locknut
15 – Pressure adjustment screw 3
16 – Clamp
2
17 – Olive
18 – Filter basket
1
19 – Injection pipe
161msm03
20 – Hub cap
Celtis – 09.2007 – GB A.55

Degraded modes
Leaflet n° 1 "Engine fails to start"

The engine does not start or won't go.
1. CONNECT METADIAG© AND ACTIVE ANOMALY CODES

SWITCH ON. If the codes contain "SPN637", diagnose them
in advance.
Repair based on the code (see chapter ).
NO ACTIVE ANOMALY CODE
Go to 2.
2. CHECK FOR FUEL AT INJECTORS. FAULTY
Sheet n° 5 "Check the fuel feed circuit".
GOOD
Go to 3.
3. CHECK FOR OBSTRUCTION IN AIR FAULTY
INTAKE. Repair or replace the component.
GOOD
Go to 4.
guides.
GOOD
Go to 5.
GOOD
A.56 Celtis – 09.2007 – GB

Leaflet n° 2 "Erratic engine operation"
The engine misfires and/or fails to operate smoothly.
Beforehand, check for:
– Air leak on the intake manifold ;
– Mechanical problems ;
– Transmission problems ;
– Problems in the engine accessories ;
– Electromagnetic disturbance.

in advance.
Go to 2.
2. YES
– Wrap a cloth around the injector connector Sheet n° 5 "Check the fuel feed circuit".
– Slowly loosen and note any change in rpm. NO
Go to 3.
– Repeat the operation for the other cylinders.
Do the misfires occur with each cylinder?
3. CHECK THE CYLINDER HEAD FAULTY
GASKET. Replace the cylinder head gasket.
GOOD
Go to 4.
4. CHECK THE FUEL FEED PIPE. FAULTY
Repair or replace the pipe(s).
GOOD
Go to 5.
Go to 7.
GOOD
Go to 6.
GOOD
7. FAULTY
– Apply a small amount of oil to the piston ring Go to 8.
area through the injector hole. GOOD
– Check compression. Problem with pistons, rings, liners or valve
guides.
Celtis – 09.2007 – GB A.57

GOOD
Go to 9.
9. CHECK VALVE LIFT. FAULTY
Wear on camshaft, cam followers or rocker
arm shaft.
GOOD
guides.
A.58 Celtis – 09.2007 – GB

Leaflet n° 3 "Emission of grey or black smoke"
The engine emits excessive grey or black smoke from the exhaust.

in advance.
Go to 2.
2. CHECK FOR POSSIBLE BLOCKAGE YES
IN THE INTAKE OR EXHAUST OR AN Repair or replace the defective components.
AIR LEAK. NO
Go to 3.
3. CHECK THE TURBO: FAULTY
– Inlet and outlet of the compressor ; Repair or replace the defective components.
– Inlet and outlet of the turbine: GOOD
Go to 4.
– Centre body ;
– Axial clearance ;
– Turbocharger pressure.
GOOD
Go to 5.
5. CHECK FUEL RETURN LINE. FAULTY
GOOD
Go to 6.
GOOD
Celtis – 09.2007 – GB A.59

Leaflet n° 4 "Emission of white smoke"
The engine emits excessive white smoke from the exhaust.

in advance.
Go to 2.
2. CHECK FOR POSSIBLE HEAD YES
GASKET FAILURE. Repair or replace the defective components.
See Inspection procedure of the cylinder head NO
gasket Go to 3.
guides.
GOOD
Go to 4.
GOOD
A.60 Celtis – 09.2007 – GB

Leaflet n° 5 Fault in fuel supply system
Irregular engine running.

in advance.
Go to 2.
2. CHECK FOR POSSIBLE PRESENCE YES
OF AIR IN THE FUEL SUPPLY SYSTEM. Purging the circuit.
NO
Go to 3.
3. CHECK FUEL SUPPLY PRESSURE FAULTY
AND FLOW. Repair or replace the defective components.
GOOD
Go to 4.
– Between the injector and the injector pump ; Repair or replace the pipe(s).
– Between the filter and the injector pump. GOOD
Celtis – 09.2007 – GB A.61

Leaflet n° 6 "Lack of power"
The engine does not reach its full power.
Note: Before starting this diagnosis procedure:
– Check for the absence of problems at the transmission level ;

– Check for the absence of mechanical problems at the engine level ;
– Check for the absence of excessive load at the engine level ;
– Check that the air and fuel filters are not obstructed ;
– Check that the fuel quality is the appropriate one.

in advance.
Go to 2.
2. ENGINE SPEED AT FULL LOAD THE ENGINE EMITS EXCESSIVE GREY
(NOMINAL SPEED). OR BLACK SMOKE FROM THE
EXHAUST
Sheet n° 3 "Grey or black smoke emission".
THE ENGINE EMITS EXCESSIVE
WHITE SMOKE FROM THE EXHAUST
Sheet n° 4 "White smoke emission".
A.62 Celtis – 09.2007 – GB

Supply pressure check
– Fit the tool (1) n° 60 05 005 521.
– Start the engine. The fuel pump should
maintain the minimum pressure shown in the A B
injector cards chapter A. If the pressure is low,
change the filters and start the check again.
A B
D
161msm07
Celtis – 09.2007 – GB A.63

Hydraulic part
Schematic diagram
Complete system
3 2
4
7
5 6 1
13
12
15 11
161msm16
1 – Fuel pump. 8 – Internal pressure regulator.

2 – Filter. 9 – Discharge accumulator.
3 – Transfer pump. 10 – Plunger pistons.
4 – Booster ring. 11 – High pressure output.
5 – Charge accumulator. 12 – Solenoid valve.
6 – Degassing wire. 13 – Injector.
7 – Transfer pressure regulator.
A.64 Celtis – 09.2007 – GB

Transfer pump
The role of the low pressure system is to supply an adequate fuel flow to the high pressure system.
1 2 3
161msm36
The vane-type transfer pump is attached to the drive shaft. The fuel arrives via an inlet port and
exits via a delivery port.
1 – Cylinder
2 – Vane 1 3
3 – Spring
4 – Rotor
5 – Inlet port
6 – Delivey port
6
2 4
161msm37
Celtis – 09.2007 – GB A.65

Transfer pressure regulator
The pressure regulator ensures that transfer pressure does not become excessive at high speed.
When the pressure exceeds the spring setting, the piston uncovers a port and the fuel returns to
the inlet side of the vane pump. When the temperature rises, leaks around piston (1) increase. The
pressure in the spring chamber (2) rises to assist the spring. Thus the vent port reduces in size.
This device enables a transfer pressure to be achieved that is relatively unaffected by changes in
temperature.
1 – Piston
2 – Spring
3 – Transfer pressure 4
4 – Supply pressure
161msm38
A.66 Celtis – 09.2007 – GB

Transfer pressure
The viscosity compensation valve enables a constant pressure to be achieved despite changes in
temperature.
4,1
3,5
2,8
1,4
3
5
0,7
400 800 1 200 1 600 2 000 2 400

2
161msm39
1 – Pressure 3 – Hot diesel fuel with temperature

2 – Engine speed compensation
4 – Cold diesel fuel
5 – Hot diesel fuel without temperature
compensation
Celtis – 09.2007 – GB A.67

Internal pressure regulator
The fuel that circulates within the pump ensures that it is both cooled and purged.
The purge flow rate is controlled by a spring-loaded valve. The flow of fuel that returns to the tank
is thus controlled by this valve.
1 – O-ring.
2 – Spring.
3 – Internal pressure.
4 – Return pressure.
161msm40
A.68 Celtis – 09.2007 – GB

Fuel booster system
161msm40
1 – Fuel supply.
2 – Transfer pressure regulator.
3 – Charge accumulator.
Celtis – 09.2007 – GB A.69

Discharge and charge accumulator
The discharge and charge accumulators provide compensation for the changes in fuel flow
resulting from large variations in transfer pressure during the injection cycle.
161msm42
High-pressure lines
Rotor, plunger pistons and HP valve unit:
161msm43
A.70 Celtis – 09.2007 – GB

Cam, drive shaft, pads and rollers:
161msm44
Solenoid, hydraulic head and rotor:
161msm45
Celtis – 09.2007 – GB A.71

Functional logic
Injection cycle
– Solenoid valve not powered.
– Distribution ports aligned.
– The rollers climb up the slope of the cam.
– Valve open. The volume pumped is not
compressed.
161msm17
– Solenoid valve powered.

– Valve closed. The pressure increases and the
volume is fed to the injector.
161msm18
– Solenoid valve not powered.

– Valve open. The pressure is discharged, and
injection is complete.
161msm17
A.72 Celtis – 09.2007 – GB

2
1 3
161msm19
1 – Retraction gradient. 5 – Core displacement.

2 – Refilling range. 6 – Closure time.
3 – Pumping gradient. 7 – Pumping (injection).
4 – Injection order.
Celtis – 09.2007 – GB A.73

Electronic components
Sensors
Accelerator pedal sensor

– Hall effect sensor, operated by the hand or
foot pedal accelerator.
– Elobau effect sensor; this records power
supply, signal and connectivity characteristics.
This sensor requires adjustment.
161msm61
Crankshaft position sensor
This is an inductive sensor located on the

crankshaft nose (left-hand side).
161msm26
A.74 Celtis – 09.2007 – GB

Coolant temperature sensor
This is an NTC temperature sensor (negative

temperature coefficient: resistance reduces as
temperature rises).
The sensor is located on the thermostat housing.
161msm27
Manifold air temperature sensor

temperature rises).
The sensor is located in the air intake collector,
just before the pre-heater element.
161msm28
Fuel temperature sensor

temperature rises).
The sensor is located on the injector pump.
161msm29
Celtis – 09.2007 – GB A.75

Component layout
582msm30
1 – Manifold air temperature sensor 4 – Crankshaft position sensor

2 – Coolant temperature sensor 5 – Pump control solenoid
3 – Fuel temperature sensor 6 – Calculator
A.76 Celtis – 09.2007 – GB

7 – Accelerator pedal potentiometer
582msm24
Operating summary
161msm21
The target wheel is keyed to the crankshaft nose.
Celtis – 09.2007 – GB A.77

2 3
4
5
161msm22
1 – Sensor signal. 6 – Advance angle.

2 – TDC for cylinder N°(1). 7 – Angle between the marked tooth and TDC
3 – TDC for cylinder N°(3). for cylinder n° (1) (factory setting).
4 – Start of injection to cylinder N°(3).
5 – Number of pulses between two TDC points.
A.78 Celtis – 09.2007 – GB

Measurement and check points
Accelerator detector
– Hall effect detector.
– Output voltage measurement: Master switch on.
– Using the wiring n° 60 05 005 577 measure the voltage of the "cursor".
2
0,5 V < U < 0,9 V 0,85 V
V
3,1 V < U < 4,5 V 3,47 V
+ APC
60 05 005 577
2
B B B B
3
C C C C
1 A A
A A
1
D3 B3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
582msm28
1 – Accelerator detector
2 – Values measured on a tractor
3 – Computer connector
Celtis – 09.2007 – GB A.79

Refer to manual Metadiag 2007.
– Inductive sensor.
– Informs the calculator of the engine speed.
– Tightening torque: 14 N.m
B B
A A
B2 D2
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
582msm06
B2 – Crankshaft position input 1 – ECU

D2 – Sensor return 2 – Crankshaft position sensor
Checking the voltage with a multimeter:
Remove the engine control unit connector then measure the resistance between points B2 and D2
using multimeter n° .
Resistance: 3 ± 0,3 kohms.
The shim wheel is composed of 46 teeth uniformly spaced and of 2 missing teeth which determine
the high neutral position.
A.80 Celtis – 09.2007 – GB

Coolant temperature sensor
– CTN type sensor.
– Informs the calculator of the amount of fuel to supply for starting up.
– Determines the idling speed.
– Engine protection.
– Tightening torque: 15 N.m.
˚t B B
A A
B1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
582msm04
B1 – Temperature input 1 – ECU

D3 – Sensor earth 2 – Coolant temperature sensor
Remove the engine control unit connector then measure the resistance between points B1 and D3
using multimeter n° 60 05 005 744.
Temperature Measurement of sensor Tolerance

resistance XX (t°)
16°C 4,2 kohm ±_10 %
60°C 134 ohm ±_10 %
90°C 51,2 ohm ±_10 %
100°C 38,5 ohm ±_10 %
Celtis – 09.2007 – GB A.81

Manifold air temperature sensor
– Informs the air temperature calculator so as to have the correct quantity of fuel in normal mode
and at the end of cold starting up.
– Tightening torque: 10 N.m.
˚t B B
A A
D1 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
582msm03
D1 – Temperature input 1 – ECU

D3 – Sensor earth 2 – Manifold air temperature sensor
A.82 Celtis – 09.2007 – GB

Temperature (°C) V ± 0,4 %

-20 4,914
-10 4,850
0 4,748
10 4,595
20 4,378
30 4,089
40 3,730
50 3,313
60 2,867
70 2,422 161msm47
80 2,004
90 1,632
100 1,315
110 1,053
120 0,841
Use multimeter N° 60 05 006 744.
Celtis – 09.2007 – GB A.83

Fuel temperature sensor
– Informs the calculator of the correct quantity of fuel to supply.
– Tightening torque: 13 to 18 N.m.
˚t B B
A A
C3 D3
A3 B3 C3 D3 E3 F3 G3 H3 J3 K3
A2 B2 C2 D2 E2 F2 G2 H2 J2 K2 1
A1 B1 C1 D1 E1 F1 G1 H1 J1 K1
582msm05
C3 – Temperature input 1 – ECU

D3 – Sensor earth 2 – Fuel temperature sensor
A.84 Celtis – 09.2007 – GB

Temperature (°C) V ± 0,4 %

-20 4,914
-10 4,850
0 4,748
10 4,595
20 4,378
30 4,089
40 3,730
50 3,313
60 2,867
70 2,422 161msm56
80 2,004
90 1,632
100 1,315
110 1,053
120 0,841
Use multimeter N° 60 05 006 744.
Celtis – 09.2007 – GB A.85

Pump control solenoid
– Depending on whether the calculator controls authorise or not the fuel to reach the injection
pressure.
A1 A2 A3
B1 B2 B3
2
C1 C2 C3
D1 D2 D3
A3 E1 E2 E3
B B
1
A A K2
F1 F2 F3
G1 G2 G3
H1 H2 H3
J1 J2 J3
K1 K2 K3
582msm07
A3 – Solenoid valve return 1 – ECU

K2 – Solenoid valve feed 2 – Pump control solenoid
Remove the engine control unit connector then measure the resistance between points A3 and K2
using multimeter n° 60 05 005 744.
Resistance: 0,3 to 0,4 ohms at 18 °C.
A.86 Celtis – 09.2007 – GB

Management
Description
Injection order
161msm20
1 – Electrical supply. 3 – Moving core.

2 – Coil. 4 – High pressure valve.
The injection pump does not have its own computer. It is controlled directly by the engine
computer.
The computer controls directly the high pressure valve to determine the point at which injection
starts and the duration of the injection.
Celtis – 09.2007 – GB A.87

Only one computer is required to manage the injection system. This computer combines the roles
of engine and pump computer.
The computer monitors all engine operation via a range of sensors (measuring rotational speeds,
temperatures, etc.).
Stored mapping enables the amount to be injected and the advance point to be determined as a
function of the various parameters measured.
It controls the solenoid valve (high pressure) so that the desired parameters are achieved.
161msm23
The engine computer is located close to the injection pump.
A.88 Celtis – 09.2007 – GB

Engine computer inputs and outputs
K1 K3
A2 J1
J2 K2
C1 A3
C3 G3 + 12 V
D1 G2 + 12 V
B1 E3
NC
D3 A1
NC
B3 C2
NC
E1
E2
NC
F2
NC
F3 H1
NC
B2 H2
NC
D2 H3
NC
G1 J3
F1
161msm63
K1 – + AVC (30). B2 D2 – Crankshaft sensor.

A2 – + APC (15). G1 – CAN H.
J2 – (31) earth. F1 – CAN L.
C1 – Curves (only on Celtis). K3 – Preheating relay control.
C3 – Fuel T°. J1 – Coolant temperature gauge T° (Only on
D1 – Air T°. Celtis and Ergos).
B1 – water. K2 A3 – Pump solenoid control.
D3 – Sensor returns;. G3 – Preheating indicator (+diagnostic on
B3 – Accelerator pedal (Only on Celtis and Celtis and Ergos).
Ergos). G2 – Coolant temperature warning light (Only
E2 – + 5 V sensor power supply (only on Celtis on Celtis and Ergos).
and Ergos).
Celtis – 09.2007 – GB A.89

Pin Type Allocation
A1 NC
A2 Supply Supply + APC (15)
A3 Output Pump solenoid valve (return)
B1 Analog input Coolant temperature.
B2 Input Crankshaft position
B3 Analog input Accelerator position (A) (on Celtis and Ergos)
C1 Analog input Selection of torque curve (B) (only on Celtis)
C2 NC
C3 Analog input Fuel temperature
D1 Analog input Intake air temperature
D2 Input Crankshaft position (return)
D3 Input Air, water and fuel sensors return
E1 NC
E2 Supply output Supply output + 5 V (on Celtis and Ergos)
E3 Frequency output Unused
F1 CAN L CAN L
F2 NC
F3 Analog input Unused
G1 CAN H CAN H
G2 Output Engine temperature warning light (on Celtis and
Ergos)
G3 Output Pre-heater and engine defect warning light (on
Celtis and Ergos)
H1 NC
H2 NC
H3 NC
J1 Coolant temperature gauge (on Celtis and Ergos)
J2 Supply ECU earth
J3 NC
K1 Supply Supply + AVC (30)
K2 Output Pump solenoid valve (power supply)
K3 Output Preheating relay control
A.90 Celtis – 09.2007 – GB

Functional logic
Pre-heating automation
1. – If the oil temperature is lower than -15°C, go

Master switch on: to 2.
– If the oil temperature is between -15
and -5°C, go to 3.
– If the oil temperature is higher than -5°C, go
to 4
2. – Go to 4.
Preheating time: 20 seconds
3. – Go to 4.
Preheating time: 15 seconds
4.
Starter activated.
Pre-heating:
If the engine is started before completion of pre-heating, the latter is terminated to limit electrical
power drain.
Celtis – 09.2007 – GB A.91

Idle automation
1. – If the oil temperature is lower than 0°C, go

When the tractor is started: to 2.
– If the oil temperature is between 0
and 20°C, go to 3.
– If the oil temperature is higher than 20°C, go
to 4
2. – Wait 3 min.
Idle speed is locked at a speed of 1050 rpm. – Go to 4.
3. – Wait 3 min.
Idle speed is locked at a speed between 850 – Go to 4.
and 1050°C.
4.
Idle speed is locked at a speed of 850 rpm.
Idle:
Idle automation reduces:
– Pollution when cold.
– Engine warm-up time.
A.92 Celtis – 09.2007 – GB

Degraded modes
Coolant temperature
1. – If the coolant temperature is lower

Engine running. than 108°C, go to 5.
– If the coolant temperature is between 108
and 113°C, go to 2.
– If the coolant temperature is between 113
and 118°C, go to 3
– If the coolant temperature is higher
than 118°C, go to 4.
2. Go to 1.
The engine power goes down to 95%.
3. Go to 1.
4. Go to 1.
5. Go to 1.
Full power is available.
Engine protection:
Available power is electronically limited to protect the engine if coolant temperature rises
excessively.
Celtis – 09.2007 – GB A.93

Fuel temperature
1. – If the oil temperature is lower than 120°C,

Engine running. go to 3.
– If the oil temperature is higher than 120°C,
go to 2
2. Go to 1.
3. Go to 1.
Engine protection:
Available power is electronically limited to protect the engine if fuel temperature rises excessively.
Air temperature
1. – If the air temperature is lower than 100°C,

Engine running. go to 3.
– If the air temperature is higher than 100°C,
go to 2
2. Go to 1.
3. Go to 1.
Engine protection:
This protection is only used on tractors fitted with an intercooler.
Available power is electronically limited to protect the engine if the intercooler becomes blocked.
A.94 Celtis – 09.2007 – GB

Transmission of error codes
Error codes are generated by the computer on the ADC ("CAN") bus. These faults are coded in
accordance with standard SAE J1939.
The code consists of three parts:
– SPN Suspect Parameter Number (2 or 4 digits).
– FMI Fault Mode Indicator (2 digits).
– OC (OCcurrence) Number of times the error occurs.
Thus the SPN indicates the defective component and the FMI indicates the value of the failure (too
high, too low, etc).
Error codes can be read using the Métadiag Engine application.
If the error is present, it will be found under the heading: Active errors.
If the error is no longer present, it will be found under the heading: passive errors.
Each error code is associated with a page in the repair manual; this contains a definition of the
error code and a suggested diagnostic method.
1 CAN
161msm35
1 – Engine defect
Celtis – 09.2007 – GB A.95

Moving assembly
Thrust bearings
121msm00
The thrust bearings ore monobloc; one is plain and the other has a groove for lubrication. Several
sizes are available for the adjustment of crankshaft end float.
A.96 Celtis – 09.2007 – GB

Crankshaft
121msm01
Celtis – 09.2007 – GB A.97

Pistons
1 1
121msm03
1 – Sharp-edged. 3 – Re-entrant bowl (chamber-in-piston).

2 – "Snake head" conrod.
Both the pistons and the connecting rods are specific to this type of engine. The combustion
chamber, centered in the piston crown, is of the "re-entrant" type. The latter forms a sharp edge
with the piston crown and these features give improved combustion. The marking "front" has to be
fitted facing the front of the engine. A special conically shaped tool must be used to check the
piston ring grooves; a set of shims cannot be used.
Connecting rods
The "snake head" shaped small ends improve bearing seating.
Metric threads are used for the conrod bolts.
A.98 Celtis – 09.2007 – GB

Rings
1 1
3
A
B
3
121msm04
The top compression ring is as close as possible to the top of the piston to reduce waste space.
This has necessitated the use of an insert that has better temperature resistance.
An accumulation groove between the top compression ring and the compression ring gives the
gases a greater expansion volume. The top compression ring thus remains in contact with its
bearing surface, reducing the passage of gas to the lower part of the engine.
1- The top compression ring is trapezoid shaped with a contact face of the barrel type.
2- The compression ring has a trapezoid cross-section, with a skewed contact face. It is marked
with a dot (A).
3- The oil control ring has a classical shape. It is marked with 2 points (B).
Punch marks ("TOP" or "T") on the compression and sealing rings show the side to be fitted
uppermost.
Celtis – 09.2007 – GB A.99

DIMENSIONS
Liners and pistons
Ø 126,33 → 126,35
6,022 → 6,058 Ø 106,48 → 106,52 0,03 → 0,1*
Ø 120,61 → 120,69
Ø 5,952 → 5,988
Ø 120,70 → 120,75
0,1 → 0,14
10
Ø 115,724 → 115,748
E
Ø 71,64 → 71,70
Ø 115,75 → 115,80
A C
Ø 106,38 → 106,40
19
4045 DRT 76 = Ø 34,935 → 34,945

4045 TRT 77 = Ø 34,935 → 34,945 B D
4045 TRT 78 = Ø 34,935 → 34,945
4045 TRT 72 = Ø 41,285 → 41,295
0,08 → 0,30
0,09 → 0,14
121msm21
E – Clearance:
– First assembly clearance between 0,025
and 0,075 mm.
– Second assembly clearance between 0
and 0,075 mm.
A.100 Celtis – 09.2007 – GB

Compare A, B, C and D to determine whether the liner is conical or oval.
Maximum ovalization 0,05 mm

Maximum taper 0,05 mm
Wear limit 0,1 mm
Celtis – 09.2007 – GB A.101

Connecting rods
4045 DRT 76 = ø 34,950 – LU = 35,026

4045 DRT 76 = ø 34,92 → 34,93 – LU = 34,907 4045 TRT 77 = ø 34,950 – LU = 35,026
4045 TRT 77 = ø 34,92 → 34,93 – LU = 34,907 4045 TRT 78 = ø 34,950 – LU = 35,026
4045 TRT 78 = ø 34,92 → 34,93 – LU = 34,907 4045 TRT 72 = ø 41,300 – LU = 41,376
4045 TRT 72 = ø 41,27 → 41,28 – LU = 41,257
4045 DRT 76 = ø 38,087 → 78,113

4045 TRT 77 = ø 38,087 → 78,113
4045 TRT 78 = ø 38,087 → 78,113
4045 TRT 72 = ø 46,025 → 46,051
LU = 0,10
121msm22
LU. – Wear limit

After measuring A, B and C (bearing bush removed), the maximum difference must be 0,038 mm.
A.102 Celtis – 09.2007 – GB

Crankshaft, bearings, and flywheel
0,050 → 0,127
0,05 → 0,25
101msm46
Ø – Diameter O – Out-of-round wear

C – Taper LU. – Wear limit
Celtis – 09.2007 – GB A.103

Checking compression
Note: before starting the test, make sure that the battery is fully charged and that the injector area is perfectly clean.
– Start the engine, and run it at nominal speed to heat it.
Warning: Burning risk during operations on

the engine.
– Disconnect the power connector from the
injection pump.
– Remove the exhaust silencer (A). 1
– Remove the heat shield (B). 2
– Remove the injectors:

– Refer to the work card in chapter A:
Reconditioning of injectors.
101msm51
– Mount tool No. 60 05 005 516 with the seal

1
(1) on compression tester No 60 05 721 169. 3
– Put the gas knob in the "STOP" position
– Turn the engine using the starter motor during
a few seconds.
The compression value should be 24 bar
minimum. It must be measured on each cylinder. 131hsm14
The difference between the min. and the max.

value should be inferior to 3,5 bar. 2 1
131hsm02
A.104 Celtis – 09.2007 – GB

– Refit in the reverse order to that used for dismantling.
– Bleed the air from the fuel circuit.
– For electronic injection engines:
– Refer to the error codes of Metadiag 2007® engine application. Refer to manual Metadiag
2007®.
– Check that the errors are no longer active.
– Reset passive errors.
Celtis – 09.2007 – GB A.105

Accessory gear train
121msm05
Fuel distribution is powered by a helical toothed gear train. Depending on the model, an additional
pinion driven by the camshaft pinion is used to drive the hydraulic pumps (for this purpose, a bush
will be found in the camshaft bore).
Marks engraved on the pinions indicate meshing positions to obtain fuel distribution settings.
A.106 Celtis – 09.2007 – GB

Balance shaft
121msm06
A – Counterweights
B – Counter boring
C – Cotter
The 4 cylinder engine is equipped with with two balance shafts with detachable
counterweights (A) to counter vibrations from the rotating components (bushes are also mounted
in the bores).
"Damper"
On a 4 cylinder engine, vibration resulting from the crankshaft's torsional response are absorbed
by an elastomeric-hubbed pulley (the crankshaft "Damper").
1 – Pulley
2 – "Damper"
3 – Screw
4 – Washer
1
2 4
101msm23
Celtis – 09.2007 – GB A.107

DIMENSIONS
Camshaft
Adm : 6,93 → 7,42 – LU = 6,68

Ech : 6,76 → 7,26 – LU = 6,50
3,935 → 3,985 – LU = 3,83
Ø 55,872 → 55,898 – LU = 55,85
A = 0,08 → 0,23 – LU = 0,38
B = 0,08 → 0,14 C = 0,06 → 0,11
111hsm09
Adm. – Intake A – Axial clearance

Ech. – Exhaust B – Bearing clearance
LU. – Wear limit C – Clearance of bearing n° 1 with bush
A.108 Celtis – 09.2007 – GB

A = 0,095 → 0,145
Ø 69,802 → 69,832
Ø 69,757 → 69,777
0,08 → 0,75
0,08 → 0,75
B = 0,075 → 0,125
0,005 → 0,68
A = 0,095 → 0,145
0,07 → 0,6 0,06 → 0,58

Ø 44,437 → 44,463
Ø 44,489 → 44,539
0,06 → 0,65
0,007 → 0,65
0,08 → 0,6
B = 0,026 → 0,102
132hsm00
Celtis – 09.2007 – GB A.109

Balance shaft
Balance shaft belt
Maximum Maximum
Internal diameter 40,177 mm 40,237 mm
Balance shaft journal
Maximum Maximum
External diameter 40,135 mm 40,161 mm
Lubrication play - Between balance shaft journal and belt
Maximum Maximum
Lubrication play 0,016 mm 0,102 mm
Cylinder block probe for balance shaft belt
Maximum Maximum
Internal diameter 43,262 mm 43,288 mm
A.110 Celtis – 09.2007 – GB

Viscous fan coupling
Viscous fan coupling

The viscous clutch has 3 main parts:
– Drive part: Rotor (1) + Plate (2) fitted with annular grooves.
– Driven part Hub (1) for the fan + Body (7) fitted with annular grooves.
– Regulator part: Thermostatic spring (3) + Valve (4) that controls the flow of coupling fluid.
This silicon-based viscous fluid is stored in tank (5).
When the temperature of the air flowing through the radiator reaches a predetermined level the
thermostatic spring operates the valve which opens the orifice. By centrifugal force, the liquid
travels towards the annular grooves in the hub and the body. The torque is transmitted by the
internal friction of the highly viscous liquid and its adhesion to the walls. The fan is thus powered
and the cooling is improved.
1 – Shaft.
2 – Plate. 6
2
3 – Thermostatic spring.
1
4 – Valve.
5 – Reservoir.
7
6 – Hub.
5
7 – Body.
4
253msm00
Note: Warning for the storage of Visco.
Celtis – 09.2007 – GB A.111

Procedure for checking the viscous fan coupling
Preliminary checks
– Coolant level in the chamber and cleanliness of all the radiators (water, oil and air).
– Belt status.
– Operation of the thermostat(s).
– Operation of the temperature probe.
Note: The rotation speed of the pulley (A) is given as an indication for when a check is carried out.
Note: When the engine is cold, slippage on the viscous fan coupling is approximately 7%. Allow the engine to warm
up properly before measuring.
Optional Without air-conditioning With air-conditioning with

with or without or without pneumatic
pneumatic braking braking
Ambient temperature in °C 25 25
Engine speed at full load 2200 2200
Engine speed / viscous fan coupling ratio 1,12 1,34
Speed of the pulley driving the viscous 2464 2948
fan coupling in rpm (A)
Minimum fan speed in rpm (B) 1602 1916
Maximum slip tolerated in % 35 35
A.112 Celtis – 09.2007 – GB

Checking the viscous fan coupling
– Place the tractor on the power bench at 2200 rpm at full load for 30 minutes minimum.
– Check with an electronic rev counter th speed of the fan (B) and compare it with the values in
the table above.
– The measured slip must correspond to (or can be slightly different from) the values described
above. In all cases, if the slip rate exceeds 35 %, consider replacing the viscous fan coupling.
IMPORTANT: The fan speeds indicated in the above table were measured at an ambient temperature of 25 °C. During
the inspection, if the temperature is lower than 25 °C (for example 20 °C), reduce "reasonably" the speeds of fan (B)
and vis-versa if the ambient temperature is higher than 25 °C.
Celtis – 09.2007 – GB A.113

Notes
A.114 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.115
A.116 Celtis – 09.2007 – GB

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DPS ENGINE

Technical support Chapter A

Celtis 00 11 354 320 – Edition 09.2007

INLET AND EXHAUST .......................................................................................................................................3

MECHANICAL INJECTION ..............................................................................................................................42

ELECTRONIC INJECTION ...............................................................................................................................55

MOVING ASSEMBLY .......................................................................................................................................98

ACCESSORY GEAR TRAIN...........................................................................................................................108

VISCOUS FAN COUPLING ............................................................................................................................113

Celtis – 09.2007 – GB A.1

Tractor prior to May 2005 Tractor after May 2005

Second line (2): Engine type

A.2 Celtis – 09.2007 – GB

This can be identified by: The cross-flow design.

Celtis – 09.2007 – GB A.3

A.4 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.5

A.6 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.7

A.8 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.9

A.10 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.11

– Fit the flywheel rotating tool 60 05 005 501

on the valve cap and then set to 0.

A.12 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.13

– Presence of coolant in the crankcase. 131hsm16

– Insufficient coolant level.

Let the engine cool down, and remove the

If no leak is visible, but if pressure drops, there

A.14 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.15

Lubrication system sealing

A.16 Celtis – 09.2007 – GB

– Observe the pressure gauge.

4045 TRT 77 engine 0,52 bar

Celtis – 09.2007 – GB A.17

Radial shaft play

Axial shaft play

A.18 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.19

A.20 Celtis – 09.2007 – GB

Celtis – 09.2007 – GB A.21

A.22 Celtis – 09.2007 – GB

During filling, bleed the system by loosening the

Celtis – 09.2007 – GB A.23

The water pump is fitted under the accessory

Coolant temperature too high

A.24 Celtis – 09.2007 – GB

DIMENSIONAL CHARACTERISTICS (in mm)

Thermostat opening temperature 82°C (80-84°C)

Celtis – 09.2007 – GB A.25

A.26 Celtis – 09.2007 – GB

– Take the thermostat out of the water and

– If not, change it.

Reminder of the triggering values:

Check of the belt and the tensioner spring

Check of the belt condition

Celtis – 09.2007 – GB A.27

– Loosen the tension on the belt using a nut

– Swivel the arm using a torque wrench to align

A.28 Celtis – 09.2007 – GB