Repair manual

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CURSOR TIER 3

SERIES

Industrial application

C13 TURBOCOMPOUND

Technical and Repair manual

Summary of content (166 pages)

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CURSOR TIER 3 SERIES Industrial application C13 TURBOCOMPOUND Technical and Repair manual
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This publication contains data, features, instructions and methods for performing repair interventions on the assembly and its components. This publication is addressed to qualified, specialised personnel. Check that you have the publication related to the assembly on which you are about to work available before you start. Make sure that you have all the necessary safety apparatuses, such as, for example, protective eyewear, helmet, gloves, footwear, etc.
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1 F3C CURSOR ENGINES 13 CURSOR ENGINES TURBOCOMPOUND (F3C) Section Introduction General specifications 1 Fuel 2 Industrial application 3 Overhaul and technical specifications 4 Tools 5 Safety prescriptions Print P2D32C005 E Appendix Base - May 2007
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2 Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES 1 INTRODUCTION Introduction Page Print P2D32C005 E PREFACE TO USER’S GUIDELINE MANUAL . . 3 SYMBOLS 5 ............................. - Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - Service operations . . . . . . . . . . . . . . . . . . . . . . 3 GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5 GENERAL WARNINGS ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . 7 - Bonding and screening . . . . . . . . . . . . . . . . . . .
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2 INTRODUCTION Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES INTRODUCTION 3 PREFACE TO USER’S GUIDELINE MANUAL Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
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4 INTRODUCTION Removal Disconnection Intake Refitting Connection Exhaust Removal Disassembly Operation Fitting in place Assembly α ! F3C CURSOR ENGINES ρ Compression ratio Tighten to torque Tolerance Weight difference Tighten to torque + angle value Rolling torque Press or caulk Rotation Regulation Adjustment Angle Angular value Warning Note Preload Visual inspection Fitting position check Number of revolutions Measurement Value to find Check Temperature Equipment bar Pressure
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F3C CURSOR ENGINES INTRODUCTION 5 GENERAL WARNINGS ! Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
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6 INTRODUCTION F3C CURSOR ENGINES Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
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F3C CURSOR ENGINES INTRODUCTION 7 GENERAL WARNINGS ON THE ELECTRIC SYSTEM ! If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated.
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8 INTRODUCTION F3C CURSOR ENGINES Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: - Electronic central units must be connected to system bonding when they are provided with a metallic shell.
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F3C CURSOR ENGINES INTRODUCTION 9 OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling directives issued. It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel.
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10 INTRODUCTION F3C CURSOR ENGINES KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of vehicle Printout number Base - May 2007 Section title Language Publication Basic edition referred to month - year editorial phase closing Page number When month - year update is present (revi) to the basic edition Print P2D32C005 E
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F3C CURSOR ENGINES INTRODUCTION 11 UPDATING Section Print P2D32C005 E Description Page Date of revision Base - May 2007
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12 INTRODUCTION Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES 1 SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General specifications Page Print P2D32C005 E CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE . . . . . . . . . . . . . 3 VIEWS OF ENGINE F3CE0684A*E001 . . . . . . . 5 VIEWS OF ENGINE F3CE0684B*E003 . . . . . . . . 8 LUBRICATION DIAGRAM . . . . . . . . . . . . . . . . . 11 - Engine F3CE0684A*E001 . . . . . . . . . . . . . . . . 11 - Engine F3CE0684B*E003 . . . . . . . . . . . . . . . . 12 - Oil pump . . . . . . . .
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2 SECTION 1 - GENERAL SPECIFICATIONS Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 3 CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE Print P2D32C005 E Technical Code Commercial Code F3CE0684A*E001 F3CE0684B*E003 - Base - May 2007
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4 SECTION 1 - GENERAL SPECIFICATIONS Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 5 VIEWS OF ENGINE F3CE0684A*E001 Figure 1 110587 LEFT-HAND SIDE VIEW Figure 2 110588 RIGHT-HAND SIDE VIEW Print P2D32C005 E Base - May 2007
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6 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES Figure 3 110589 FRONT VIEW Figure 4 110590 REAR VIEW Base - May 2007 Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 7 Figure 5 110591 TOP VIEW Print P2D32C005 E Base - May 2007
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8 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES VIEWS OF ENGINE F3CE0684B*E003 Figure 6 110594 LEFT-HAND SIDE VIEW Figure 7 110595 RIGHT-HAND SIDE VIEW Base - May 2007 Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 9 Figure 8 110596 FRONT VIEW Figure 9 110598 REAR VIEW Print P2D32C005 E Base - May 2007
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10 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES Figure 10 110597 TOP VIEW Base - May 2007 Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 11 LUBRICATION DIAGRAM F3CE0684A*E001 Engine Figure 11 Dropping oil Pressure oil 110604 Print P2D32C005 E Base - May 2007
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12 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES F3CE0684B*E003 Engine Figure 12 Dropping oil Pressure oil 110599 Base - May 2007 Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 13 Overpressure valve Oil pump Figure 13 Figure 15 60560 73540 The oil pump (1) cannot be overhauled. On finding any damage, replace the oil pump assembly. MAIN DATA TO CHECK THE OVERPRESSURE VALVE SPRING See under the relevant heading for replacing the gear (2) of the crankshaft. Figure 14 1 73541 OIL PUMP CROSS-SECTION 1. Overpressure valve — Start of opening pressure 10 ± 1 bars.
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14 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES Oil pressure control valve Figure 17 Figure 16 73542 The oil pressure control valve is located on the left-hand side of the crankcase. Start of opening pressure 5 bars. 73543 MAIN DATA TO CHECK THE OIL PRESSURE CONTROL VALVE SPRING Heat exchanger Figure 18 104236 HEAT EXCHANGER The heat exchanger is fitted with: 1. Oil pressure/temperature sensor - 2. By-pass valve - 3. Heat valve.
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 15 This is a new generation of filters that permit much more thorough filtration as they are able to holder back a greater amount of particles of smaller dimensions than those held back by conventional filters with a paper filtering element.
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16 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES COOLING Figure 22 Water flowing out of the thermostat Water circulating in the engine Water flowing into the pump 104278 ILLUSTRATIVE DIAGRAM Base - May 2007 Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS Water pump 17 Figure 25 Figure 23 TO THE RADIATOR TO THE EXPANSION TUB FROM THE ENGINE TO THE BY PASS 60748 104239 Water leaving the thermostat Check the thermostat works properly; replace it if in doubt. CROSS-SECTION OF THE WATER PUMP The water pump comprises: rotor, shaft with bearing. T-gasket and drive pulley. Temperature of start of travel 84°C ±2°C. Minimum travel 15 mm at 94°C ±2°C.
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18 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES TURBOCHARGER The turbocharger increases the air flow rate during the suction stroke of the combustion cycle. The contribution of extra air improves combustion and increases engine efficiency. The exhaust gases are conveyed towards the turbocharger turbine where they give part of their energy and turn the turbine itself. During this step, the exhaust gas temperature drops to approximately 600˚C.
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F3C CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 19 TURBOCOMPOUND SYSTEM In a turbocompound system, a second ”power” turbine is mounted in series to the normal engine turbocharger and coupled to a Voith hydraulic coupling. The ”power” turbine, via a gear set, transmits energy to the crankshaft obtaining a power increase of approximately 8% without increasing fuel consumption.
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20 SECTION 1 - GENERAL SPECIFICATIONS F3C CURSOR ENGINES Figure 28 TCD turbocharger rate (krpm) TCD turbocharger power (kW) Engine rate (rpm) 110602 The graph shows the power curve pattern and ”power” turbine rate according to engine rpm.
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F3C CURSOR ENGINES SECTION 2 - FUEL 1 SECTION 2 Fuel Page Print P2D32C005 E FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 FUEL SUPPLY DIAGRAM . . . . . . . . . . . . . . . . . . 4 - Injector-pump . . . . . . . . . . . . . . . . . . . . . . . . . 5 - Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 SECTION 2 - FUEL Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 2 - FUEL 3 FEEDING Fuel is supplied via a fuel pump, filter and pre-filter, 6 pump-injectors governed by the camshaft via rocker arms and by the electronic control unit. Figure 1 Return circuit Supply circuit 104280 1. Valve for return circuit, starts opening at 3.5 bars - 2. Valve for return circuit, starts opening at 0.2 bars.
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4 SECTION 2 - FUEL F3C CURSOR ENGINES FUEL SUPPLY DIAGRAM Figure 2 104242 1. Temperature sensor - 2. Bleed valve - 3. Secondary fuel filter - 4. By-pass valve (0.3 ÷ 0.4 bar) - 5. Fuel supply pump 6. Integrated valve (3.5 bar) - 7. Pressure relief valve (5 bar) - 8. Fuel tank - 9. Priming pump - 10. Primary fuel filter 11. Check valve (opening 0.1 bar) - 12. Heater - 13. Electronic control unit - 14. Fuel return union with valve built in (0.2 bar) - 15. Pump-injectors.
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F3C CURSOR ENGINES SECTION 2 - FUEL 5 Pumping element The pumping element is operated by a rocker arm governed directly by the cam of the camshaft. The pumping element is able to ensure a high delivery pressure. The return stroke is made by means of a return spring. Fuel pump Figure 3 73547 A. Fuel inlet — B. Fuel delivery — C. By-pass nut — D. Fuel return from the pump-injectors — E. Pressure relief valve — Opening pressure: 5 - 5.8 bars. Figure 4 73548 CROSS-SECTION OF THE FUEL PUMP 1.
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6 SECTION 2 - FUEL F3C CURSOR ENGINES Figure 6 104245 For each injector replaced, hook up to the diagnostic station and, when asked by the program, enter the code punched on the injector (→) to reprogram the control unit.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 1 SECTION 3 Industrial application Page Print P2D32C005 E CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . 3 PART ONE MECHANICAL COMPONENTS . . . . . . . . . 5 ENGINE OVERHAUL PROCEDURE . . . . . . . . 7 - Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 7 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . .
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2 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Page INJECTOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . 44 - Engine coolant temperature sensor . . . . . . . . . 45 - Fuel temperature sensor . . . . . . . . . . . . . . . . . 46 - Flywheel pulse transmitter . . . . . . . . . . . . . . . . 47 - Distribution pulse transmitter . . . . . . . . . . . . . 48 - Alternator (For F3CE0684B*E003) . . . . . . . . . 49 - Alternator (For F3CE0684A*E001) . . . . . . . . .
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 3 CLEARANCE DATA Type ρ F3CE0684A*E001 16.5 ± 0.8 Compression ratio Max. output Max.
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4 SECTION 3 - INDUSTRIAL APPLICATION Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 5 PART ONE MECHANICAL COMPONENTS Print P2D32C005 E Base - May 2007
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6 SECTION 3 - INDUSTRIAL APPLICATION Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES 7 SECTION 3 - INDUSTRIAL APPLICATION ENGINE OVERHAUL PROCEDURE Disassembling Figure 9 Handle all parts with great care. Never put your hands or fingers between one part and another. Wear suitable personal protective equipment such as a visor, gloves and safety shoes. Cover all electrical components before washing with high-pressure water jets. Figure 7 104781 Loosen the locking screws and remove the compressor (1) complete with its support (2) from the engine.
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8 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Only for F3CE0684A*E001 engine Figure 13 Figure 11 104251 104249 Using a suitable tool (3), work in the direction of the arrow on the tightener (2) and remove the belt (1).
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 15 9 Figure 17 119480 104247 Remove: - the starter motor (1); - the control unit (2) and its support; - the oil dipstick (3) from the crankcase. Remove the engine supports; Remove the drive (1). Figure 18 Figure 16 99361 With the extractor 99340053 (2) applied as shown in the figure, extract the seal (4). Undo the screws (3) and take off the cover (1). 104248 Secure the engine to the rotary stand with the brackets (1).
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10 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Figure 19 Figure 21 119481 On exhaust side of the engine: - loosen the clamps (1 and 2); - remove the connection manifold turbocharger and power turbine.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 23 11 Figure 25 119489 Loosen and remove the screws (1) fastening the oil return pipe (2) to the hydraulic coupling. 119486 Loosen and remove the screws (1) fastening the power turbine (2) to the hydraulic coupling. Figure 26 Detach the power turbine (2) from the hydraulic coupling. Figure 24 119490 Loosen and remove the screws (1) fastening the hydraulic coupling (2) to the flywheel casing.
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12 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Figure 27 Figure 29 104783 Loosen the screws (1) and remove the intake manifold (2) from the engine. 119491 Remove the plate (1) and remove traces of sealant from the part in contact with the flywheel casing. NOTE The air intake joint (3) may have different positions depending on the type of engine. Figure 30 Figure 28 60496 - Unscrew the screws (2) and remove the gear (1) fitted with phonic wheel.
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F3C CURSOR ENGINES 13 SECTION 3 - INDUSTRIAL APPLICATION Figure 32 Figure 35 60498 60501 Unscrew the screws (2) and remove the transmission gear (1). Unscrew the screws (1) and take down the gearbox (2). Figure 36 Figure 33 119492 In sequence, take out the: 60499 Stop the engine flywheel (3) rotation by means of tool 99360351 (1), unscrew the fixing screws (2) and remove the engine flywheel (3). - idle gear (1); - oil pump gear (2) - transmission gear (3);.
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14 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Figure 38 Figure 41 60514 104257 - Disconnect the electrical connections from the pump injectors. - Unscrew the screws (1) fixing the rocker arm shaft. - Fit the plugs 99360180 (1) instead of injectors. - Remove the camshaft (2). - Unscrew the fixing screws on the cylinder head (3). Figure 39 Figure 42 116814 Apply tool 99360553 (1) to the rocker holder shaft (5) and remove the shaft (5) from the cylinder head.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Only for F3BC0684A*E001 engine Figure 44 15 Engine assembly Figure 46 60563 104784 Using the centring ring 99396035 (2), check the exact position of the cover (1). If it is wrong, proceed accordingly and lock the screws (3). Figure 47 Loosen screws (3), then remove sump (1) complete with spacer (2) and seal gasket (4). Figure 45 60564 Key on the gasket (1), mount the key 99346250 (2) and, screwing down the nut (3), drive in the gasket (1).
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16 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Figure 49 Figure 52 α 61270 Diagram of the tightening sequence of the screws fixing the cylinder head. 60567 Mount the oil pump (4), the intermediate gears (2) together with the link rod (1) and lock the screws (3) in two phases: - pre-tightening 30 Nm. - closing to angle 90°. Figure 50 Figure 53 60565 - Pre-tightening with the torque wrench (1): 1st phase: 60 Nm (6 kgm). 2nd phase: 120 Nm (12 kgm).
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 55 17 Figure 57 119496 Fit the intermediate gear (1) on the support shaft. Fasten the fastening screws (2) and tighten at a torque of 115 Nm. Only for F3BC0684B*E003 engine Figure 56 119497 Using a torque wrench, tighten the highlighted screws with the following sequence and tightening torques: 104311 : 8 screws M12 x 1.75 x 100 63 Nm 2 screws M12 x 1.75 x 160 63 Nm 6 screws M12 x 1.75 x 35 63 Nm 2 screws M12 x 1.
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18 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Only for F3BC0684A*E001 engine Figure 59 Figure 60 104785 Apply LOCTITE 5970 IVECO n˚ 2992644 silicone on the gear housing, using appropriate tools (1), as shown in the figure. The sealer string (1) diameter is to be 1,5 ± 0.5 0.2 NOTE Mount the gear housing within 10 min. of applying the sealant.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 19 ENGINE FLYWHEEL Fitting engine flywheel (For F3CE0684B*E003 engines) Figure 62 b d a c 104283 A B VIEW OF HOLES: VIEW OF A—B—C HOLE: D DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS = Hole on flywheel with one reference mark, C = Hole on flywheel with one reference mark, corresponding to the TDC of pistons 3-4. corresponding to the TDC of pistons 2-5.
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20 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Fitting camshaft Figure 64 Figure 66 104286 60570 Position the crankshaft with the pistons 1 and 6 at the top dead centre (T.D.C.). This situation occurs when: 1. The hole with reference mark (5) of the engine flywheel (4) can be seen through the inspection window. 2. The tool 99360612 (1), through the seat (2) of the engine speed sensor, enters the hole (3) in the engine flywheel (4).
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 68 21 Figure 70 5 60572 Position the gear (2) on the camshaft so that the 4 slots are centred with the holes for fixing the camshaft, without fully locking the screws (5). Using the dial gauge with a magnetic base (1), check that the clearance between the gears (2 and 3) is 0.073 — 0.
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22 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Camshaft timing Figure 72 (For F3CE0684B*E003) Figure 74 70567A SCHEME OF SCREW TIGHTENING SEQUENCE SECURING ROCKER ARMS 104316 Screw screws (1 - 2 - 3) until rocker arms are brought to contact relating seats on cylinder head, tighten the screws according to sequence indicated in figure operating in two steps as indicated in successive figure.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 23 Figure 78 Figure 76 104286 104288 The exact position of piston no.1 at the T.D.C. is obtained when in the above-described conditions the tool 99360612 (1) goes through the seat (2) of the engine speed sensor into the hole (3) in the engine flywheel (4). If this is not the case, turn and adjust the engine flywheel (4) appropriately. Remove the tool 99360612 (1). Figure 77 The camshaft is in step if at the cam lift values of 5.31 ±0.
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24 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Mount the gear (2) Figure 80 with the 4 slots (1) centred with the fixing holes of the camshaft, locking the relevant screws to the required tightening torque. Check the timing of the shaft by first turning the flywheel clockwise to discharge the cylinder completely and then turn the flywheel anticlockwise until the dial gauge gives a reading of 5.31 ± 0.05. Check the timing conditions described in Figure 78.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 25 Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors Figure 83 119499 ADJUSTING INTAKE/EXHAUST ROCKERS AND INJECTION Adjustment of clearances between rockers and valve studs and preloading of pump injector rockers should be carried out with extreme care.
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26 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Figure 84 Figure 85 85480 Fit the timing cover (1). 85481 Apply LOCTITE 5970 on the breather body (1) forming a bead (2) as shown in figure ∅ 1,5 + 0,5 0,2 Tighten the fastening screws on the rocker arm cover (1) in the order shown in figure 79. ! Fit the blow-by casing (7) with corresponding seal and tighten the screws (8) at the specified torque. Fit the filter (5) with the corresponding seals (4 and 6).
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F3C CURSOR ENGINES 27 SECTION 3 - INDUSTRIAL APPLICATION ENGINE COMPLETION Figure 90 Figure 87 101607 Fit the suction rose (1) and tighten the fastening screws at the specified torque. 119500 DIAGRAM OF ENGINE OIL SUMP FIXING SCREWS TIGHTENING SEQUENCE Only for engine F3CE0684A*E001 Figure 88 101606 Figure 91 Arrange the seal (4) on the oil sump (1), arrange the shim (2), fit the sump on the crankcase and tighten the screws (3) at the specified torque.
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28 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Figure 92 Figure 94 101605 104254 Fit heat exchanger (2) with its respective gasket, then tighten fastening screws (1) to the torque specified and according to the sequence indicated in Figure 92. Fit the oil filters (1) on the relevant supports as follows: - oil the seals; screw the filters down for the seals to make contact with the supporting bases; tighten the filters to a torque of 35 to 40 Nm. Fit, with the respective gaskets.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 96 29 Figure 98 119489 Fit the oil return pipe (1). 119486 Fasten the screws (2) fastening the pipe (1) to the crankcase. Tighten the screws (2) at a torque of 23 Nm. Fit the power turbine (2) onto the hydraulic coupling. NOTE Lubricate the accommodation seat on the hydraulic coupling with Loctite AS600 before fitting the power turbine.
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30 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Figure 100 Figure 102 119481 Position the clamps (1) and (2) respectively on the turbocharger and on the power turbine. 119484 Fit the turbocharger (2) on the exhaust manifold making sure that the seal (4) is positioned between the two parts. Fit the connection manifold (3) between turbocharger and power turbine. Fasten the manifold to the two turbines by means of the clamps (1) and (2).
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Only for engine: F3CE0684A*E001 Figure 104 Figure 106 104249 104251 Fit, with the following parts: - 31 Using a suitable tool (3), work in the direction of the arrow on the tightener (2) and mount the belt (1). automatic tightener support (1); automatic tightener (2); damper flywheel (3) and pulley beneath; fixed tightener (5); water pump (7); the pulley (4); pipe comprehensive of coolant (6); thermostat assembly (8).
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32 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES For all types Figure 108 Only for F3CE0684B*E003 Figure 110 104247 Fit the arm 99360585 onto the engine lifting hooks and hook the arm onto the hoist. Take out the screws fixing the brackets 99361036 to the rotary stand. Lift the engine and remove the above-mentioned brackets from it.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 33 Figure 112 Figure 111 104780 104781 Assemble the belt on the pulleys and tightening rollers, making sure that it is correctly inserted in its seats. Assemble the alternator support (3) on the engine and tighten the locking screws to the specified torque. Assemble the alternator (4) and tighten the locking screws to the specified torque value.
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34 SECTION 3 - INDUSTRIAL APPLICATION Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 35 PART TWO ELECTRICAL EQUIPMENT Print P2D32C005 E Base - May 2007
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36 SECTION 3 - INDUSTRIAL APPLICATION Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 37 Components on the engine F3CE0684A*E001 Figure 1 ENGINE RIGHT-HAND SIDE VIEW 110586 Figure 2 110585 ENGINE LEFT-HAND SIDE VIEW A. Resistance for engine warming - B. Fuel filter clogged signalling switch - C. Fuel temperature sensor - D. Engine rpm sensor on camshaft - E. Starter motor - G. Alternator - H. Temperature/air pressure sensor - I. Conditioner compressor L. EDC 7 control unit - M.
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38 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Components on the engine F3CE0684B*E003 Figure 3 ENGINE RIGHT-HAND SIDE VIEW 110593 Figure 4 ENGINE LEFT-HAND SIDE VIEW 110592 A. Resistance for engine warming - B. Fuel filter clogged signalling switch - C. Fuel temperature sensor - D. Engine rpm sensor on camshaft - E. Starter motor - G. Alternator - H. Temperature/air pressure sensor - I. Conditioner compressor L. EDC 7 control unit - M.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 39 BLOCK DIAGRAM Figure 5 116816 KEYS 1. Engine coolant temperature sensor — 2. Oversupply air temperature sensor — 3. Fuel temperature sensor — 4. Oversupply air pressure sensor — 5. Engine oil pressure and temperature sensor - 6. CAL L-H line — 7. Pump-injectors — 8. Remote control switch for pre/post-heating activation — 9. Pre/post-heating resistance — 10. Main remote control switch — 11. Flywheel sensor — 12. Distribution sensor — 13.
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40 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES EDC 7 UC31 electronic control unit Figure 6 C A B 102373 A. Electro-injector connector - B. Chassis connector - C. Sensor connector.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 41 EDC control unit PIN-OUT Electric injector connector ”A” Figure 7 12 16 11 6 Colour legend B black R red U blue W white P purple G green N brown Y yellow O orange E grey K pink ECU Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Print P2D32C005 E 102374 1 Colour legend Black Black Black White Green Red Yellow Red Red Bleu Green Purple 5 Function Solenoid valve for electronic cylinder 5 injection Solenoid valve for electronic cylinder 6 injec
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42 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES EDC control unit PIN-OUT Sensor connector ”C” Figure 8 Base - May 2007 8 16 9 15 22 1 3 23 30 36 29 4 5 Colour legend B black R red U blue W white P purple G green N brown Y yellow O orange E grey K pink ECU Pin 1÷8 9 10 11÷14 15 16 ÷17 18 19 20÷22 23 24 25 26 27 28 29÷31 32 33 34 35 36 6 102375 Cable colour W R K O/B B W N W Y O/B U O R G W/R O Function Free Valve gear camshaft sensor Valve gear camshaft sensor Free Coolant tempe
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 43 EDC control unit PIN-OUT Chassis connector ”B” Figure 9 71 89 72 54 6 11 1 7 12 53 ECU Pin 1 2 3 4 5 6 7 8 9 10 11 12 13÷25 26 27 28 29 30 31 32 33 34 35 36÷39 40 41 42 43÷55 56 57 58÷67 68 69÷74 75 76÷88 89 Print P2D32C005 E Cable 7151 7153 0151 0151 7151 7151 0151 0151 0094 5163 Green White 9164 2298 35 18 36 17 102376 Function Free +30 positive +30 positive Free Ground Ground Free +30 positive +30 positive Ground Ground Preheating
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44 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES INJECTOR PUMP Figure 10 102405 INJECTOR SECTION The new pump injectors are capable, thanks to the higher injection pressure, of atomizing the fuel in the combustion chamber to a greater extent, thus improving combustion and therefore reducing the polluting exhaust emissions.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 45 Engine coolant temperature sensor This N.T.C. type sensor located on the water outlet sump on the engine head left measures coolant temperature for the various operating logics with a hot or cold engine and identifies injection enrichment requirements for a cold engine or fuel reduction requirements for a hot engine. It is connected to electronic center pins 15/26. Sensor behavior as a function of temperature: - 10 °C 8.10 ÷ 10.77 kOhm + 20 °C 2.
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46 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Fuel temperature sensor Specifications Supplier Max.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 47 . Flywheel pulse transmitter Specifications Supplier Max.
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48 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Distribution pulse transmitter Features Vendor Torque Resistance BOSCH 8 ± 2 Nm 880 ÷ 920 Ω This induction type sensor located on the camshaft generates signals obtained from the magnetic flow lines that close through the 6 plus 1 phase teeth of a sound wheel mounted on the shaft. The electronic center uses the signal generated by this sensor as an injection step signal.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 49 Air pressure/temperature sensor (85156). This component incorporates a temperature sensor and a pressure sensor. Figure 16 IIt replaces the temperature sensors (85155) and pressure sensors (85154) available in the preceding systems. It is fitted onto the intake manifold and measures the maximum supplied air flow rate used to accurately calculate the amount of fuel to be injected at every cycle. The sensor is powered with 5 V.
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50 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Alternator for F3CE0684B*E003 Supplier Technical features ISKRA 14V - 175A Figure 19 104313 Base - May 2007 Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 51 Alternator for F3CE0684A*E001 Supplier Technical features LEECE NEVILLE 12V - 185A Figure 20 104314 Pin Description R AC Connector L Driver warning light connector B- Negative B+ Positive Print P2D32C005 E Base - May 2007
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52 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES Starting motor Figure 21 104315 F3CE0684A*E001 Supplier Type DENSO 428000 - 4250 Voltage Nominal output Base - May 2007 F3CE0684B*E003 228000 - 7550 24 V 5.5 kW 7.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 53 PRE/POST-HEATING RESISTANCE The resistance is ~ 0,7 Ohm. Such resistance is placed between the cylinder head and the suction manifold. It is used to heat up air during pre/post-heating operations.
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54 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES EDC SYSTEM FUNCTIONS The EDC 7 UC31 electronic center manages the following main functions: Fuel injection Accessory functions such as cruise control, speed limiter, PTO and the like Self-diagnosis Recovery It also enables: Interfacing with other electronic systems (if any) available on the vehicle Diagnosis Fuel dosing Fuel dosing is calculated based on: - accelerator pedal position - engine rpm - quantity of air admitted.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 55 Injection lead electronic control Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted.
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56 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before 10 seconds at least after engine cutout. In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown memory and the engine operates at lower performance at next start while the EDC warning light stays on.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 57 PART THREE - TROUBLESHOOTING Print P2D32C005 E Base - May 2007
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58 SECTION 3 - INDUSTRIAL APPLICATION Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES PREFACE A successful troubleshooting is carried out with the competence acquired by years of experience and attending training courses. When the user complains for bad efficiency or working anomaly, his indications must be kept into proper consideration using them to acquire any useful information to focus the intervention.
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60 SECTION 3 - INDUSTRIAL APPLICATION F3C CURSOR ENGINES FAULT CODE DTC Faulty component Vehicle 1 (Sensors/Plausibility checks) 1.1.9 PLAUSIBILITY +15 1.1.A PLAUSIBILITY +50 Vehicle 2 (Warning lights/Relays/Actuators) 1.2.5 MAIN RELAY 1.2.6 BATTERY VOLTAGE 1.2.8 MAIN RELAY - SHORT CIRCUIT TO BATTERY 1.2.9 CONDITIONER COMPRESSOR RELAY 1.2.B THERMO STARTER RELAY 1 (HEATER) 1.2.E PRE/POST-HEATER CONTROL SYSTEM (ACTIVE) 2.2.5 INTERRUPTED AFTER-RUN 2.2.
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F3C CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION DTC 61 Faulty component Injectors 1 1.6.1 INJECTOR CYLINDER 1 / SHORT CIRCUIT 1.6.2 INJECTOR CYLINDER 2 / SHORT CIRCUIT 1.6.3 INJECTOR CYLINDER 3 / SHORT CIRCUIT 1.6.4 INJECTOR CYLINDER 4 / SHORT CIRCUIT 1.6.5 INJECTOR CYLINDER 5 / SHORT CIRCUIT 1.6.6 INJECTOR CYLINDER 6 / SHORT CIRCUIT 1.6.7 INJECTOR CYLINDER 1 / SHORT CIRCUIT 1.6.8 INJECTOR CYLINDER 2 / SHORT CIRCUIT 1.6.9 INJECTOR CYLINDER 3 / SHORT CIRCUIT 1.6.
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62 SECTION 3 - INDUSTRIAL APPLICATION DTC F3C CURSOR ENGINES Faulty component ECU 2 (power unit/Immobilizer/overspeed/sensor power) 1.E.3 MONITORING ERROR IN ECU 1.E.4 MONITORING ERROR IN ECU 1.E.5 SENSOR POWER ERROR (12V) 1.E.6 POWER SUPPLY SENSORS 1 1.E.7 POWER SUPPLY SENSORS 2 1.E.8 POWER SUPPLY SENSORS 3 1.E.9 ERROR IN ECU 1.E.A ERROR IN ECU 1.E.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1 SECTION 4 Overhaul and technical specifications Page Print P2D32C005 E GENERAL CHARACTERISTICS . . . . . . . . . . . . . 3 ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . 5 ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 11 ENGINE REMOVAL AT THE BENCH . . . . . . . . 11 REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 12 CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . .
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2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES Page Page - Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - Checking injector protrusion . . . . . . . . . . . . . . 38 - Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . 31 - Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - Checking connecting rod alignment . . . . . . . . . 32 - Checking cam lift and pin alignment . . . . . . . . .
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 3 GENERAL CHARACTERISTICS Type F3C Cycle 4-stroke Diesel engine Fuel feed Turbocharged Injection Direct No. of cylinders 6 in line ∅ + Print P2D32C005 E + Bore mm 135 Stroke mm 150 cm3 12880 +..
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4 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES F3C Type A VALVE TIMING opens before T.D.C. A closes after B.D.C. B 17° B 30° C opens before B.D.C. D closes after T.D.C. C 50° 9° D For timing check mm 0.4 mm 0.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 5 ASSEMBLY CLEARANCE DATA F3C Type CYLINDER BLOCK AND CRANKMECHANISM COMPONENTS ∅1 Bores for cylinder liners: mm upper 153.500 to 153.525 lower 152.000 to 152.025 upper 153.461 to 153.486 lower L 151.890 to 151.915 - upper lower 0.014 to 0.039 0.085 to 0.135 ∅1 Cylinder liners: external diameter: L ∅2 ∅2 length Cylinder liners crankcase bores External diameter ∅2 - Cylinder sleeve ∅3 X inside diameter ∅3A* 135.
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6 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES F3C Type mm X1 X2 X3 Piston rings: trapezoidal seal p S1 S2 S3 X1 X2 X3 3.100 to 3.120 1.550 to 1.570 5.020 to 5.040 S1* Piston ring grooves lune seal S2 3.000 1.470 to 1.500 milled ill d scraper ring i with slits and internal spring S3 4.970 to 4.990 1 2 3 0.100 to 0.120 0.050 to 0.100 0.030 to 0.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 7 F3C Type mm X Measuring dimension X Max. connecting rod axis misalignment tolerance ∅1 ∅2 S1 S 2 ∅3 125 0.
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8 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES F3C Type CYLINDER HEAD - VALVE TRAIN ∅ 1 mm Valve guide housings in cylinder head ∅1 15.980 to 15.997 ∅2 ∅3 10.015 to 10.030 16.012 to 16.025 ∅ 2 Valve guide ∅ 3 Valve guides - housings in the cylinder heads 0.015 to 0.045 Valve guide ∅ 4 - Valves: ∅4 α ∅4 α α Valve stem and its guide 9.960 to 9.975 60° 30′ ± 7′ 30″ 9.960 to 9.975 45° 30’ ± 7′ 30″ 0.040 to 0.070 Valve seat in head ∅ 1 ∅1 49.185 to 49.220 ∅1 46.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 9 Table 1 F3C Type mm Valve spring height: H free height under a load of: H 2 575 ± 28 N 1095 ± 54 N H1 H H1 H2 73.40 59 45 Injector protrusion X 0.53 to 1.34 Camshaft bushing housing in the cylinder head: 1⇒7 Ø 88.000 to 88.030 Camshaft bearing journals: 1⇒7 Ø 82.950 to 82.968 ∅ Outer diameter of camshaft bushings: ∅ 88.153 to 88.183 ∅ Inner diameter of camshaft bushings: ∅ 83.018 to 83.
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10 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES F3C Type mm Bushing housing in rocker arms 45.000 to 45.016 59.000 to 59.019 ∅ 46.000 to 46.016 Bushing outer diameter for rocker arms 45.090 to 45.130 59.100 to 59.140 ∅ 46.066 to 46.091 Bushing inner diameter for rocker arms 42.025 to 42.041 56.030 to 56.049 ∅ 42.015 to 42.071 Between bushings and housings 0.074 to 0.130 0.081 to 0.140 0.050 to 0.091 Between bushings of rocker arms and shaft 0.025 to 0.057 0.025 to 0.057 0.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH 11 Figure 3 The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well. (See Section 3 of the manual herein). The section illustrates therefore all the most important engine overhaul procedures.
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12 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES REPAIR OPERATIONS CYLINDER BLOCK Checks and measurements Figure 6 Figure 8 x (Demonstration) 60595 34994 Internal diameter of the cylinder liners is checked for ovalization, taper and wear, using a bore dial (1) centesimal gauge (2) previously reset to ring gauge (3), diameter 135 mm. NOTE If a 135 mm ring gauge is not available use a micrometer caliper. A = Selection class Ø 135.000 to 135.012 mm B = Selection class Ø 135.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 13 Cylinder liners Figure 10 60598 CRANKCASE ASSEMBLY WITH CYLINDER LINERS Figure 11 Selection class A 135.000 to 135.013 mm B 135.011 to 135.
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14 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Replacing cylinder liners Removal F3C CURSOR ENGINES Figure 15 Figure 13 60520 47577 Position the parts 99360706 (2) and the plate 99360728 (4) as shown in the figure, checking that the plate (4) rests on the cylinder liner correctly. Screw down the nut of screw (1) and extract the cylinder liner (3) from the crankcase.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 15 Crankshaft Figure 18 Top main bearing shells Bottom main bearing shells 101504 MAIN DATA OF CRANKSHAFT AND MAIN BEARING SHELLS Check the state of the main journals and crankpins of the crankshaft. They must not be scored or be too ovalized or worn. The data given refer to the normal diameter of the journals. Figure 19 Figure 20 POLISHED BUFF GROUND GROUND GROUND 101505 X.
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16 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Measuring the main journals and crankpins F3C CURSOR ENGINES Figure 22 Before grinding the journals, use a micrometric gauge (1) to measure the journals of the shaft (2) and establish, on the basis of the undersizing of the spare bearing shells, to what diameter it is necessary to reduce the journals. Figure 21 47536 MEASURING CRANKPINS 47535 MEASURING THE MAIN JOURNALS NOTE It is advisable to note the measurements in a table (Figure 22).
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 17 Preliminary measurement of main and big end bearing shell selection data For each of the journals of the crankshaft, it is necessary to carry out the following operations: MAIN JOURNALS: CRANKPINS: - Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the crankcase. connecting rod. - Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
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18 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES Selecting the main bearing and big end bearing shells To obtain the required assembly clearances, the main bearing and big end bearing shells have to be selected as described hereunder. This operation makes it possible to identify the most suited bearing shells for each of the journals of the shaft (the bearing shells may even have different classes for different pins).
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 19 DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter) Main journals and crankpins: determining the class of diameter of the journals. Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 26 at top): - The first number, of five digits, is the part number of the shaft.
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20 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES Selecting the main bearing shells (Journals with nominal diameter) After reading off the data, for each of the main journals, on the crankcase and crankshaft, you choose the type of bearing shells to use according to the following table: Figure 27 STD.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 21 SELECTING THE MAIN BEARING SHELLS (GROUND JOURNALS) If the journals have been ground, the procedure described so far cannot be applied. In this case, it is necessary to check that the new diameter of the journals is as shown in the table and to mount the only type of bearing shell envisaged for the relevant undersizing. Figure 28 red/black = 3.173 to 3183 mm -0.127 green/black = 3.184 to 3.193 mm 1 2 3 99.843 1 99.
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22 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES SELECTING THE BIG END BEARING SHELLS (JOURNALS WITH NOMINAL DIAMETER) There are three markings on the body of the connecting rod in the position indicated as ”A”: 1 Letter indicating the class of weight: A B C 2 = = = VIEW FROM “A” 4756 to 4795 g. 4796 to 4835 g. 4830 to 4875 g. Number indicating the selection of the diameter of the big end bearing seat: 1 2 3 3 Figure 29 = = = 94.000 to 94.010 mm 94.011 to 94.020 mm 94.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 23 Selecting big end bearing shells (ground journals) If the journals have been ground, the procedure described so far cannot be applied. In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of the crankpins and to mount the bearing shells identified with the relevant table. Figure 31 red/black = 2.028 to 2.038 mm -0.127 green/black = 2.039 to 2.048 mm 1 2 3 89.
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24 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Replacing the timing gear and oil pump F3C CURSOR ENGINES Figure 34 Check that the teeth of the gears are not damaged or worn, otherwise remove them using the appropriate extractor. Figure 32 1 2 47578 Using the hoist and hook 99360500 (1) mount the driving shaft (2). Figure 35 49020 When fitting gear (1) onto drive shaft (2), the gear must be heated for 2 hours max. in a furnace, at a temperature not higher than 180˚C.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 36 25 Figure 37 α 60559 47578 Set two journals of the crankshaft (2) parallel to the longitudinal axis, a section of calibrated wire. Using appropriate hooks and tackle, mount the crankcase base (1). - Lubricate the internal screws (1) with UTDM oil and tighten them with a torque wrench (3) to a torque of 120 Nm, using tool 99395216 (4), to an angle of 60°, following the diagram below.
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26 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ASSEMBLING BENCH THE ENGINE ON THE F3C CURSOR ENGINES Figure 44 Figure 41 49022 Fit the underblock by means of a suitable hoist and hooks (1). 49021 Place the half-bearings (1) on the main bearings in the underblock (2). Figure 45 Figure 42 α 47581 47595 By means of suitable equipment (1) apply silicone LOCTITE 5970 IVECO No. 2992644 to the block, as shown in the figure.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 27 DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER Figure 47 stage 1: pretightening outer screws FRONT SIDE (30 Nm) 60592 stage 2: pretightenig inner screws FRONT SIDE (120 Nm) 60593 stage 3: angle inner screws FRONT SIDE (60º) 60593 stage 4: angle inner screws FRONT SIDE (55º) 60593 stage 5: angle outer screws FRONT SIDE (60º) 60594 Print P2D32C005 E Base - May 2007
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28 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES PISTON CONNECTING ROD ASSEMBLY Figure 48 60607 PISTON CONNECTING ROD ASSEMBLY 1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring 6. Scraper ring with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston. Make sure the piston does show any trace of seizing, scoring, cracking; replace as necessary.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 51 29 Figure 53 1 2 49025 Remove the piston pin (1). If removal is difficult use the appropriate beater. 32618 Measuring the gudgeon pin diameter (1) with a micrometer (2).
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30 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES Figure 55 104292 MAIN DATA OF THE PISTON, PISTON RINGS AND PIN Figure 58 Piston rings Figure 56 3513 16552 Check the thickness of the piston ring (2) with a micrometer (1). The seal (2) of the 1st slot has a V shape. The clearance ”X” between the seal and its seat is measured by setting the piston (1) with the ring in the cylinder liner (3) so that the seal comes half out of the cylinder liner.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 31 Connecting rod Figure 60 Punched on the big end of the connecting rod are the data relating to the section in classes relating to the connecting rod seats and the weights. VIEW FROM “A” NOTE On assembling the connecting rods, check they are all of the same class of weight. Connecting rod punch markings 1 Letter indicating the class of weight: A B C = = = 4661 to 4694 g. 4695 to 4728 g. 4729 to 4762 g.
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32 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Checking connecting rod alignment Figure 62 F3C CURSOR ENGINES Checking bending (Demonstration) Figure 64 (Demonstration) 61695 61696 Checking axis alignment Check the parallelism of the rod axes (1) by using a suitable device (5) and operating as follows: - Fit the connecting rod (1) on the spindle of the tool (5) and lock it with the screw (4). - Set the spindle (3) on the V-prisms, resting the connecting rod (1) on the stop bar (2).
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Fitting the connecting rod-piston assembly into the piston liners 33 Figure 68 Figure 66 49030 47593 Fit the half-bearings (1), selected as described on pages 22 to 23, both on the connecting rod and on the stand. NOTE As spares, class A pistons are provided and can be fitted also to cylinder barrels belonging to class B. Fit the connecting rod-piston assemblies (1) into the piston liners (2) using band 99360605 (1, Figure 68).
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34 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES Checking assembly clearance of big end pins CYLINDER HEAD To check the clearance proceed as follows: Before taking down the cylinder head, check the seal using the appropriate tool; in case of leakage replace the cylinder head. Connect the connecting rods to the relative main journals, place a length of calibrated wire on the latter.
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F3C CURSOR ENGINES 35 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Removing deposits and checking the valves Figure 72 Valves Figure 73 INTAKE EXHAUST 71718 48625 MAIN DATA - VALVES AND VALVE GUIDES Remove carbon deposits using the metal brush supplied. Check that the valves show no signs of seizure or cracking. Check the diameter of the valve stem using a micrometer (see Figure 73) and replace if necessary.
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36 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Replacing of valve guides Remove valve guides by means of tool 99360143. Install by means of tool 99360143 equipped with part 99360296, which determines the exact installation position of valve guides into the cylinder heads; if they are not available, install the valve guides in the cylinder head so that they project out by mm 30.8 to 31.2 (Figure 74). After installing the valve guides, smooth their holes with sleeker 99390330.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 37 Assembly Figure 77 Figure 79 60622 60620 - Screw the extractor 99342149 (2) into the case (3). Screw down the nut (1) and take the case out of the cylinder head. - Lubricate the seals (3) and fit them on the case (4). Using tool 99365056 (2) secured to the cylinder head with bracket A, drive in the new case, screwing down the screw (1) upsetting the bottom portion of the case.
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38 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 81 F3C CURSOR ENGINES Figure 83 71720 INJECTOR CASE ASSEMBLY DIAGRAM 60624 - Using the milling cutter 99394043 (1-2), regrind the injector seat in the case (3). Checking injector protrusion Figure 82 47585 Check injector protrusion (2) with the dial gauge (1). The protrusion must be 0.52 - 1.34 mm.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 39 Camshaft Checking cam lift and pin alignment Figure 84 47506 Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2). Figure 85 47507 When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not exceed 0.030 mm. If misalignment exceeds this value, replace the shaft.
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40 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES Figure 87 60626 MAIN DATA OF THE CAMSHAFT AND TOLERANCES The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth. Whereas, if they show any signs of seizing or scoring, you should replace the shaft and the relevant bushings.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 41 Replacing camshaft bushes using beater 99360499 Figure 89 107217 A. Drift with seat for bushings to insert/extract. - B. Grub screw for positioning bushings. - C. Reference mark to insert seventh bushing correctly. - D. Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (red marks). - E. Guide bushing. F. Guide line. - G. Guide bushing to secure to the seventh bushing mount. - H.
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42 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3C CURSOR ENGINES Fitting the valves and oil seal ring Figure 93 Figure 96 Rear 71724 To insert bushing (7), proceed as follows: - Unscrew the grip (I) and the extension (N). - Refit the guide (G) from the inside as shown in the figure. - Position the bushing on the drift (A) and bring it close up to the seat, making the bushing hole match the lubrication hole in the head. Drive it home.
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 43 The camshaft cams directly control rockers: 6 for injectors and 12 for valves. Rockers slide directly on the cam profiles via rollers. The other end acts on a bar directly supported by the two valves stems. A pad is placed between the rocker adjusting screw and the bar. Two lubrication holes are obtained inside the rockers. The rocker shaft practically covers the whole cylinder head; remove it to have access to all the underlying components.
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44 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TIMING GEAR Camshaft drive F3C CURSOR ENGINES Twin intermediate gear pin Twin idler gear Figure 106 Figure 104 86925 TIMING CONTROL COMPONENT PARTS 1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod 5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear - 8. Drive shaft driving gear. 101601 * This measurement is obtained after assembling.
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 45 TIGHTENING TORQUE PART Capscrews, undercrankcase to crankcase ♦ M12x1.75 outer screws Stage 1: pretightening M 17x2 inner screws Stage 2: pretightening Inner screws Stage 3: angle Inner screws Stage 4: angle Outer screws Stage 5: angle Piston cooling nozzle union ♦ Capscrews, heat exchanger to crankcase ♦ pretightening tightening Piston cooling nozzle union ♦ Spacer and oil sump capscrews ♦ pretightening tightening M 12x1.
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46 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TORQUE PART Screw fastening the engine supporting bracket to the flywheel case Stage 1: pretightening Stage 2: angle Camshaft gear capscrews ♦ Stage 1: pretightening Stage 2: angle Screw fixing phonic wheel to timing system gear ♦ Exhaust manifold capscrews • pretightening tightening Capscrews, connecting rod caps ♦ Stage 1: Stage 2: Engine flywheel capscrews ♦ Stage 1: Stage 2: Screws fixing damper flywheel: ♦ First phase Second phase F3C CURSOR ENGI
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F3C CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 47 TORQUE PART Nm kgm 30 ± 3 44 ± 4 (3 ± 0.3) (4.4 ± 0.4) Screws fixing air-conditioner compressor to mount 24.5 ± 2.5 (2.5 ± 0.25) Screws fixing guard 24.5 ± 25 (2.5 ± 0.25) 55 ± 5 (5.5 ± 0.5) Water/fuel temperature sensor fastener 35 (3.5) Thermometric switch/transmitter fastener 25 (2.5) Air temperature transmitter fastener 35 (3.5) 8±2 (0.8 ± 0.2) 1.36 ± 1.92 (0.13 ± 0.
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48 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 5 - TOOLS 1 SECTION 5 Tools Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 SECTION 5 - TOOLS Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES SECTION 5 - TOOLS 3 TOOLS TOOL NO.
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4 SECTION 5 - TOOLS F3C CURSOR ENGINES TOOLS TOOL NO.
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F3C CURSOR ENGINES SECTION 5 - TOOLS 5 TOOLS TOOL NO.
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6 SECTION 5 - TOOLS F3C CURSOR ENGINES TOOLS TOOL NO.
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F3C CURSOR ENGINES SECTION 5 - TOOLS 7 TOOLS TOOL NO. DESCRIPTION 99360500 Tool to lift crankshaft 99360553 Tool for assembling and installing rocker arm shaft 99360585 Swing hoist for engine disassembly assembly 99360605 Belt to insert piston in cylinder liner (60 - 125 mm) 99360612 Tool for positioning engine P.M.S.
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8 SECTION 5 - TOOLS F3C CURSOR ENGINES TOOLS TOOL NO.
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F3C CURSOR ENGINES SECTION 5 - TOOLS 9 TOOLS TOOL NO.
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10 SECTION 5 - TOOLS F3C CURSOR ENGINES TOOLS TOOL NO.
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F3C CURSOR ENGINES APPENDIX 1 Appendix Page SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . .
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2 APPENDIX Base - May 2007 F3C CURSOR ENGINES Print P2D32C005 E
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F3C CURSOR ENGINES APPENDIX 3 SAFETY PRESCRIPTIONS Standard safety prescriptions - Do not execute any intervention if not provided with necessary instructions. Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.
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4 APPENDIX - Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved by Iveco.