Iveco Cursor10 Cursor13 Repair Manual Iveco Cursor10 Cursor13 Repair Manual

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CURSOR TIER 3

SERIES

Industrial application

C10

C10 ENT X

C13

C13 ENT X

CURSOR G-DRIVE

CURSOR 10 TE X CURSOR 13 TE X

Technical and Repair manual

This publication provides unit and relevant component repair data, specifications, instructions and methodologies.

This publication has been drawn up for qualified and specialised personnel.

Before performing any operation check that the part relevant to the unit on which you must work is available along with all safety devices for accident-prevention, such as, goggles, helmet, gloves, shoes, etc. and hoisting and transporting equipment.

Operations are to be performed by following the indications included here, using the special equipment indicated and assuring proper repair, compliance with schedule and operator’s safety requirements.

Each repair must aim to restore operating efficiency and safety in compliance with the FPT provisions.

FPT cannot be held liable for modifications, alterations or other interventions non authorised by FPT on the vehicle and if the unit is warranted the above mentionedinterventions will cause its expiration.

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the interventions and all the instructions that are not included on this publication.

Data included in this publication may not be up-to-date therefore subject to Manufacturer’s modifications that can be added at any time for technical or commercial purposes and also to meet new law regulations in other Countries.

If issues on this publication differ from what is actually noticed on the unit, please get in touch with the FPT network before starting any intervention”.

It is forbidden to copy this text or any of its parts and all illustrations included.

Publication edited by FIAT Powerrtrain Technologies Mkt. Advertising & Promotion Viale dell’Industria, 15/17 20010 Pregnana Milanese Milano (Italy) Print P2D32C003 E -2

Ed. 05.2007

Produced by:

B.U. TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio, 15/19 10156 Turin - Italy

CURSOR ENGINES TIER 3

CURSOR ENGINES

Cursor F3A Part 1

Cursor F3B Part 2

Cursor engines application G-Drive Part 3

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CURSOR ENGINES TIER 3

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RYR

CURSOR ENGINES TIER 3

PRELIMINA

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. The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the control units peculiar to the electric system. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.

EMARKS

SYMBOLS - WARNINGS

Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

Danger of serious damage for the assembly

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may sometimes cause the warranty to become null and void.

NOTE

General danger

It includes the dangers of above described signals.

Environment protection

Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect the environment as much as possible.

It indicates an additional explanation for a piece of information.

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GENERAL WARNINGS

Warnings shown cannot be representativeof 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.

The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path.

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.

In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position.

Keep personnel not authorised to operations clear of working area.

You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly follow all the safety indications found on the assembly.

CURSOR ENGINES TIER 3

Do not leave the running assembly unattended when making repairs.

When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist.

When you h ave to operate on assemblies powered by natural gas, follow the instructions contained in the document, as well as all the specific safety standards provided for.

Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out.

Inflammable fuel and all inflammable fluidsand liquids must be handled with care, according to what contained on harmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers.

Worn out, damaged or consumable parts must be replaced by original spares.

During workshopactivity, always keep the work place clean; timely clear or clean floors from accidentalliquid or oil spots. Electric sockets and electric equipment necessary to perform r epair interventions must meet safety rules.

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CURSOR ENGINES TIER 3

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.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking nuts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document.

Before welding:

- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)

and detach connectors.

- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Await about 15 minutes before welding.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials

flow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central units.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

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GENERALWARNINGS O N 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.

Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals.

Do not cause sparks to be generated in checking if the circuit is energised.

Do not use a test lamp in c hecking circuit continuity, but only use proper control apparatuses.

Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with system and are carefully recovered after repair or maintenance interventions.

Measurements in drive electronic central units, plugged connections and electric connections to components can only be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers, clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which would later cause contact problems.

CURSOR ENGINES TIER 3

To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special truck.

A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries) can cause them to be destroyed.

Disconnect the batteries from the system during their recharging with an external apparatus.

On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque.

Before disconnecting the junction connector from an electronic central unit, isolate the system.

Do not directly supply electronic central units servo components at nominal vehicle voltage.

Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according to original arrangement.

NOTE

Connectors presentmust be seen from cable side. Connectors views contained in the manual arerepresentative of cable side.

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CURSOR ENGINES TIER 3

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.

- Electronic central units negative c ables must be connected both to a system bonding point such as the dashboard opening bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.

- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation. Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

Figure 1

1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE ! 0

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CURSOR ENGINES TIER 3

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 by FPT. 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.

It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular, the data interconnection line between central units (CAN line) is to be considered inviolable.

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power

1 kW = 1.36 metric HP 1 kW = 1.34 HP 1 metric HP = 0.736 kW 1 metric HP = 0.986 HP 1 HP = 0.746 kW 1 HP = 1.014 metric HP

Torque

1 Nm = 0.1019 kgm 1 kgm = 9.81 Nm

Revolutions per time unit

1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602

Pressure

1 bar = 1.02 kg/cm 1 kg/cm 1bar = 10

= 0.981 bar

Where accuracy is not particularly needed:

- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1

1 kgm = 10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm

1 kg/cm

=1bar.

according to ratio 1:1

Temperature

0° C=32° F 1° C = (1 x 1.8 + 32) ° F

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CURSOR ENGINES F3A

Part 1 CURSOR ENGINES F3A

Section

General specifications

Fuel 2

Duty - Industrial application 3

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the F3A engine illustrating its features and working in general.

Section 2 describes the type of fuel feed.

Section 3 relatesto the specific dutyand is dividedin four separate parts:

1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating specific duty.

2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating specific duty.

3. Maintenance planning and specific overhaul.

4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct instructions to identify the causeof the major inconveniences.

Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on standand the necessary equipment to execute such operations. The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order to prevent serious accidents taking place.

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CURSOR ENGINES F3A

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CURSOR ENGINES F3A

SPECIAL REMARKS

Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures.

Example

∅

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

∅

Tighten to torque Tighten to torque + angular value

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SYMBOLS - ASSISTANCE OPERATIONS

CURSOR ENGINES F3A

Removal Disconnection

Refitting Connection

Removal Disassembly

Fitting in place Assembly

Tighten to torque

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Regulation Adjustment

Visual inspection Fitting position check

Intake

Exhaust

Operation

Compression ratio

Tolerance Weight difference

Angle Angular value

Preload

Measurement Value to find

Number of revolutions

Check

Equipment Temperature

Surface for machining Machine finish

Interference Strained assembly

Thickness Clearance

Lubrication Damp Grease

Sealant Adhesive

bar

Pressure

Oversized Higher than…. Maximum, peak

Undersized Less than…. Minimum

Selection Classes Oversizing

Temperature < 0 °C Cold Winter

Temperature > 0 °C

Air bleeding

Hot Summer

Replacement Original spare parts

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CURSOR ENGINES F3A

UPDATING

Section Description Page Date of revision

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CURSOR ENGINES F3A

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CURSOR ENGINES F3A

SECTION 1 - GENERAL SPECIFICATIONS

SECTION 1

General Specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL

AND COMMERCIAL CODES 3............

VIEWS OF THE ENGINE

(ONLY FOR TYPE F3AE0684P*E904) 5......

VIEWS OF THE ENGINE (FOR TYPES: F3AE0684P*E906 -

F3AE0684L*E906 - F3AE0684P*E905) 8.....

VIEWS OF THE ENGINE

(ONLY FOR TYPE: F3AE0684N*E907) 11.....

VIEWS OF THE ENGINE

(ONLY FOR TYPE: F3AE0684N*E907) 14.....

LUBRICATION DIAGRAM

(ONLY FOR TYPE: F3AE0684P*E904 ) 16.....

LUBRICATION DIAGRAM

(FOR TYPES: F3AE0684P*E906 - F3AE0684L*E906 -

F3AE0684P*E905) 17.....................

LUBRICATION DIAGRAM

(ENGINES F3AE0684N*E907) 18............

- Oil pump 19.............................

- Overpressure valve 19.....................

- Oil pressure control valve 20................

- Heat exchanger (for type: F3AE0684P*E906 -

F3AE0684L*E906 - F3AE0684P*E905 -

F3AE0684N*E907) 20.....................

- Heat exchanger

(only for type: F3AE0684P*E904) 21..........

- By-pass valve 22..........................

- Thermostatic valve 22......................

- Engine oil filters 22........................

COOLING 23.............................

- Description 23...........................

- Operation 23............................

- Water pump 25..........................

- Thermostat 25...........................

TURBOCHARGING 26......................

EGR EXHAUST GAS

RECIRCULATION SYSTEM 27.............

INTERNAL EGR ACTING ON

THEINTAKEVALVES 27..................

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SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

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CURSOR ENGINES F3A

SECTION 1 - GENERAL SPECIFICATIONS

CORRESPONDENCE BETWEEN TECHNICAL AND COMMERCIAL CODES

Technical Code Commerciale Code

F3AE0684P*E904

F3AE0684P*E906

F3AE0684L*E906

F3AE0684P*E905 C10 ENT X

F3AE0684N*E907

F3AE9687A*E001

F3AE9687B*E001

F3AE9687C*E001

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SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

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CURSOR ENGINES F3A

VIEWS OF THE ENGINE (ONLY FOR TYPE F3AE0684P*E904)

Figure 1

SECTION 1 - GENERAL SPECIFICATIONS

Figure 2

104224

LEFT-HAND SIDE VIEW

RIGHT-HAND SIDE VIEW

104225

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SECTION 1 - GENERAL SPECIFICATIONS

Figure 3

CURSOR ENGINES F3A

Figure 4

104226

FRONT VIEW

104227

REAR VIE W

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CURSOR ENGINES F3A

Figure 5

SECTION 1 - GENERAL SPECIFICATIONS

TOP VIEW

104228

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SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

VIEWS OF THE ENGINE (FOR TYPES: F3AE0684PE906 - F3AE0684LE906 - F3AE0684P*E905)

Figure 6

Figure 7

104229

LEFT-HAND SIDE VIEW

104230

RIGHT SIDE VIEW

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CURSOR ENGINES F3A

Figure 8

SECTION 1 - GENERAL SPECIFICATIONS

Figure 9

104231

FRONT SIDE VIEW

REAR SIDE VIEW

104232

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SECTION 1 - GENERAL SPECIFICATIONS

Figure 10

CURSOR ENGINES F3A

TOP SIDE VIEW

104233

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CURSOR ENGINES F3A

VIEWS OF THE ENGINE (ONLY FOR TYPE: F3AE0684N*E907)

Figure 11

SECTION 1 - GENERAL SPECIFICATIONS

Figure 12

104755

LEFT-HAND SIDE VIEW

RIGHT SIDE VIEW

104756

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SECTION 1 - GENERAL SPECIFICATIONS

Figure 13

CURSOR ENGINES F3A

Figure 14

104757

FRONT SIDE VIEW

104758

REAR SIDE VIEW

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CURSOR ENGINES F3A

Figure 15

SECTION 1 - GENERAL SPECIFICATIONS

TOP SIDE VIEW

104759

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SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

VIEWS OF THE ENGINE (FOR TYPES: F3AE9687AE001 - F3AE9687BE001 - F3AE9687C*E001)

Figure 16

Figure 17

116763

LEFT-HAND SIDE VIEW

116764

RIGHT SIDE VIEW

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CURSOR ENGINES F3A

Figure 18

SECTION 1 - GENERAL SPECIFICATIONS

Figure 19

116761

FRONT SIDE VIEW

TOP SIDE VIEW

116762

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SECTION 1 - GENERAL SPECIFICATIONS

LUBRICATION DIAGRAM (ONLY FOR TYPE: F3AE0684P*E904)

Figure 20

CURSOR ENGINES F3A

Dropping oil

Pressure oil

104234

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CURSOR ENGINES F3A

SECTION 1 - GENERAL SPECIFICATIONS

LUBRICATION DIAGRAM (FOR TYPES: F3AE0684PE906 - F3AE0684LE906 - F3AE0684P*E905)

Figure 21

Dropping oil Pressure oil

104235

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SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

LUBRICATION DIAGRAM (ENGINES F3AE0684N*E907 - F3AE9687A*E001 - F3AE9687B*E001

- F3AE9687C*E001)

Figure 22

Dropping oil

Pressure oil

104760

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CURSOR ENGINES F3A

SECTION 1 - GENERAL SPECIFICATIONS

Oil pump

Figure 23

60560

The oil pump (1) cannot be overhauled. On finding any damage, replace the oil pump assembly.

See under the relevant heading for replacing the gear (2) of the crankshaft.

Overpressure valve

Figure 25

73540

MAIN DATA TO CHECK THE OVERPRESSURE

VALVE SPRING

Figure 24

OIL PUMP CROSS-SECTION

1. Overpressure valve — Start of opening pressure 10.1 ±0.7 bars.

73541

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SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

Oil pressure control valve

Figure 27

Figure 26

73542

The oil pressure co ntrol valve is located on the left-hand side of the c rankcase.

MAIN DATA TO CHECK THE OIL PRESSURE

CONTROL VALVE SPRING

73543

Start of opening pressure 5 bars.

Heat exchanger (for type: F3AE0684P*E906 - F3AE0684L*E906 - F3AE0684P*E905 - F3AE0684N*E907 F3AE9687A*E001 - F3AE9687B*E001 - F3AE9687C*E001)

Figure 28

104236

HEAT EXCHANGER

The heat exchan ger is fitted with: 1. Oil pressure/temperature sensor - 2. By-pass valve - 3. Heat valve.

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CURSOR ENGINES F3A

Heat exchanger (only for type: F3AE0684P*E904)

Figure 29

SECTION 1 - GENERAL SPECIFICATIONS

104237

HEAT EXCHANGER

The following elements are fitted on the intercooler: 1. By-pass valve - 2. Oil pressure/temperature sensor - 3. Heat valve.

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SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

By-pass valve

Figure 30

The valve quickly o pens at a pressure of: 3 bars.

Thermostatic valve

Figure 31

73545

This is a new generation of filters that permit much more thorough filtration as they are able to holder back a great er amount of particles of smaller dimensions than those held back by conventional filters with a paper filtering element.

These high-filtration devices, to date used only in industrial processes, make it possible to:

- reduce the wear of engine components over time;

- maintain the performance/specifications of the oil and

thereby lengthen the time intervals between changes.

External spiral winding

The filtering elements are closely wound by a spiral so that each fold is firmly anchored to the spiral with respect to the others. This produces a uniform use of the element even in the worst conditions such as cold starting with fluids with a high viscosity and peaks of flow. In addition, it ensures uniform distribution of the flow over the entire length of the filtering element, with consequent optimization of the loss of load and of its working life.

Mount upstream

To optimize flow distribution and the rigidity of the filtering element, this has an exclusive mount composed of a strong mesh made of nylon and an extremely strong synthetic material.

Start of opening:

- travel 0.1 mm at a temperature of 82 ±2°C End of opening:

- travel 8 mm at a temperature of 97°C

Engine oil filters

Figure 32

Filtering element

73546

Composed of inert inorganic fibres bound with an exclusive resin to a structure with graded holes, the element is manu-

factured exclusively to precise procedures and strict quality control.

Mount downstream

A mount for the filtering element and a strong nylon mesh make it even stronger, which is especially helpful during cold starts and long periods of use. The performance of the filter remains constant and reliable throughout its working life and from one element to another, irrespective of the changes in working conditions.

Structural parts

The o-rings equipping the filtering element ensure a perfect seal between it and the container, eliminating by-pass risks and keeping filter performance constant. Strong corrosionproof bottoms and a sturdy internal metal core complete the structure of the filtering element.

When mounting the filters, keep to the following rules:

- Oil and fit new seals.

- Screw down the filters to bring the seals into contact

with the supporting bases.

- Tighten the filter to a torque of 35-40 Nm.

47447

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CURSOR ENGINES F3A

SECTION 1 - GENERAL SPECIFICATIONS

COOLING

Description

The engine cooling system is of the closed-circuit, forced circulation type. It consists mainly of the following components:

- expansion tank, not supplied;

- a heat exchanger to cool down lubrication oil;

- a water pump with centrifugal system incorporated in the cylinder block;

- fan, not supplied;

- a 2-way thermostat controlling t h e coolant circulation.

Operation

The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to t he cylinder block, especially to the cylinder head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the thermostat is opened and from here the coolant flows into the radiator and is cooled down by the fan. The pressure inside the system, due to temperature change, is adequately controlled t hrough t he expansion vessel.

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SECTION 1 - GENERAL SPECIFICATIONS

Figure 33

CURSOR ENGINES F3A

Water flowing out of the thermostat

Water circulating in the engine

Water flowing into the pump

104238

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CURSOR ENGINES F3A

SECTION 1 - GENERAL SPECIFICATIONS

Water pump

Figure 34

104239

CROSS-SECTION OF THE WATER PUMP

The water pump consists of: rotor, shaft with bearing, T-gasket and drive pulley with dust sh ield.

Figure 36

TO THE

RADIATOR

TO THE

EXPANSION

TUB

TO THE

FROM

THE ENGINE

BY PASS

60748

Water leaving the thermostat

Check the t hermostat works properly; replace it if in doubt.

Temperature of start of travel 84°C ±2°C. Minimumtravel15mmat94°C ±2°C.

Check that the pump body has no cracks or water leakage; if it does, replace the entire water pump.

Thermostat

View of thermostat operation

Figure 35

TO THE

RADIATOR

TO THE

EXPANSION

TUB

FROM

THE ENGINE

Water circulating in the engine

TO THE BY PASS

60747

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SECTION 1 - GENERAL SPECIFICATIONS

TURBOCHARGING

The turbocharging system consists of:

- air filter;

- Wastegate turbocharger.

Figure 37

CURSOR ENGINES F3A

1. TURBOCHARGER HX55

Exhaust gas

Inlet air

Compressed air (hot )

Intake compressed air

104240

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CURSOR ENGINES F3A

SECTION 1 - GENERAL SPECIFICATIONS

EGR EXHAUST GAS RECIRCULATION SYSTEM

The exhaust gases may be partially conveyed back into the cylinders to reduce the maximum combustion temperature responsible for producing nitrogen oxides (NOx). The exhaust gas recirculation (EGR) system, by reducing the combustion temperature, thus represents an effective NOx emission controlling system.

INTERNAL EGR ACTING ON THE INTAKE VALVES

Through a modification to the design of the intake cams, the internal EGR system enables part of the exhaust gas to be conveyed back into the engine’s cylinders. This type of EGR, called internal EGR, has n o electronically controlled elements, the system is always active. Its configuration requires no additional elements such as control valves, pipes or heat exchangers, so the profile of the engine remains unchanged. In addition to the main lobe, the intake cam presents an additional lobe (3) with respect to the configuration without EGR. During the exhaust stroke of the cylinder concerned, this lobe opens the intake valve slightly earlier (*). In this way, part of the exhaust gas is trapped in the intake pipe and then, during the int ake stroke of the cylinder, is returned to the load of the cy linder forthepowerstroke.

Figure 38

Y: Lift of valves in mm.

Y: Regulation of engine

shaft in degrees

1. Exhaust cams - 2. Intake cams - 3. EGR lobe - S. Exhaust pipes - A. Intake pipes.

104761

Base - May 2007Print P2D32C003 E

SECTION 1 - GENERAL SPECIFICATIONS

CURSOR ENGINES F3A

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 2- FUEL

SECTION 2

Fuel

FEEDING 3...............................

FUEL SUPPLY DIAGRAM (ALL TYPES) 4.......

- Fuel pump 5............................

- Injector-pump 5.........................

Page

Base - May 2007Print P2D32C003 E

SECTION 2 - FUEL

CURSOR ENGINES F3A

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

FEEDING

Fuel is supplied via a fuel pump, filter and pre-filter, 6 pump-injectors govern ed by the camshaft via rocker arms and by the electronic control unit.

Figure 1

SECTION 2- FUEL

1. Fuel pressure damper - 2. Valve for return circuit, starts opening at 3.5 bars -

3. Valve for return circuit, starts opening at 0.2 bars.

Return circuit

Supply circuit

104241

Base - May 2007Print P2D32C003 E

SECTION 2 - FUEL

FUEL SUPPLY DIAGRAM (ALL TYPES)

Figure 2

CURSOR ENGINES F3A

104242

1. Temperature sensor - 2. Bleed valve - 3. Secondary fuel filter - 4. By-pass valve (0.3 ÷ 0.4 bar) - 5. Fuel su pply pump -

6. Integrated valve (3.5 bar) - 7. Pressure relief valve (5 bar) - 8. Fuel tan k - 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-inject ors.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 2- FUEL

Fuel pump

Figure 3

A. Fuel inlet — B. Fuel delivery — C. By-pass nut —

D. Fuel return from the pump-injectors —

E. Pressure relief valve — Opening pressure: 5-8 bars.

Figure 4

CROSS-SECTION OF THE FUEL PUMP

1. Oil and fuel leakage indicator.

Injector-pump

73547

73548

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.

Nozzle

Garages are authorized to perform fault diagnosis solely on the entire injection system and may not work inside the injector-pump, which must only be replaced. A specific fault-diagnosis program, included in the control unit, is able to check the operation of each injector (it deactivates one at a time and checks the delivery of the other five). Fault diagnosis makes it possible to distinguish errors of an electrical origin from ones of a mechanical/hydraulic origin. It indicates broken pump-injectors. It is therefore n ecessary to interpret all the control unit error messages correctly. Any defects in the injectors are to be resolved by replacing them.

Solenoid valve

The solenoid, which is energized at each active phase of the cycle, via a signal from the control unit, controls a slide valve that shuts off the pumping element delivery pipe. When the solenoid is not energized, the valve is open, the fuel is pumped but it flows back into th e return pipe with the normal transfer pressure of approximately 5 bars. When the solenoid is energized, the valve shuts and the fuel, not being able to flow back into the return pipe, is pumped into the nozzle at high pressure, causing the needle to lift. The amount of fuel injected depends on the length of time the slide valve is closed and therefore on the time for which the solenoid is energized. The solenoid valve is joined to the injector body and cannot be removed. On the top there are two screws securing the electrical wiring from the c ontrol unit. To ensure signal transmission, tighten the screws with a torque wrenchtoatorqueof1.36—1.92Nm(0.136—0.192kgm).

Figure 5

104243

1. Fuel/oil seal — 2. Fuel/diesel seal — 3. Fuel/exhaust gas seal.

The injector-pump is composed of: pumping element, nozzle, solenoid valve.

Base - May 2007Print P2D32C003 E

Figure 6

SECTION 2 - FUEL

CURSOR ENGINES F3A

104245

Foreachinjectorreplaced,hook up to the diagnostic station and, when asked by the program, enter the code punchedon the injector (→) to reprogram the control unit.

NOTE

When checking the clearance of the rocker arms, it is important to check the injector-pump pre-load.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION

SECTION 3

Industrial application

CLEARANCE DATA 3.....................

PART ONE -

MECHANICAL COMPONENTS 5.........

ENGINE DISASSEMBLY ASSEMBLY 7.........

ENGINE ASSEMBLY 14......................

ENGINE FLYWHEEL 16.....................

- Fitting engine flywheel 16...................

- Fitting camshaft 17........................

- Fitting pump-injectors 18...................

- Fitting rocker-arm shaft assembly 18..........

Page

- Camshaft timing 19.......................

- Phonic wheel timing 21....................

- Intake and exhaust rocker play adjustment and

pre-loading of rockers controlling pump injectors 22

ENGINE COMPLETION 23..................

PART TWO -

ELECTRICAL EQUIPMENT 29.............

- Components on the engine F3A

(For all types except F3AE0684P*E904) 31.....

- Components on the engine F3A

(only for type F3AE0684P*E904) 32..........

- Components on the engine F3A

(only for type F3AE0684N*E907) 33.........

- Components on the engine F3A

(only for type F3AE9687A*E001) 34..........

BLOCK DIAGRAM 35.......................

- EDC 7 UC31 electronic control unit 36.......

- EDC control unit PIN-OUT 37..............

- Pump injector 40.........................

- Engine coolant temperature sensor 41........

- Fuel temperature sensor 42.................

- Flywheel pulse transmitter 43................

- Distribution pulse transmitter 44.............

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

-Sensor de temperatura/presión del aire 45.....

-Sensor de presión/temperatura de aceite 45....

-Alt ernator 46............................

-Starting motor 47.........................

-Pre/post-heating resistance 48...............

EDC SYSTEM FUNCTIONS 49................

PART THREE - TROUBLESHOOTING 53......

PREFACE 55...............................

METHODS OF DIAGNOSIS 56...............

-PT-01 56...............................

PT-01 PORTABLE TESTER 57.................

CURSOR ENGINES F3A

Page

-Main functions 57.........................

-Test parameters 57.......................

FAILURE CODES 58........................

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

Typ

CLEARANCE DATA

SECTION 3 - INDUSTRIAL APPLICATION 3

F3AE0684

P*E904 P*E906 L*E906 P*E905 N*E907

bar

Compression ratio 16.5:1

Max. output kW

(HP) rpm

Max. torque Nm

(kgm) rpm

Loadless engine idling rpm

Loadless engine peak rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type

LUBRICATION

Oil pressure (warm engine)

317

(430)

2100

1900

(190)

1500

1000 1000 1000 1000 600

2110 2110 2110 2110 2110

317

(430)

2100

1900

(190)

1500

Forced by gear pump, relief valve single action

335

(455)

2100

1900

(190)

1500

125 x 140

10300

Intercooler

Direct injection

HOLSET HX55

oil filter

317

(430)

2100

1900

(190)

1500

291

(395)

2100

1820

(182)

1500

NOTE

- idling bar

- peak rpm bar

COOLING

Water pump control

Thermostat

- start of opening ºC

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT.

Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

By means of belt

Liquid

Base - May 2007Print P2D32C003 E

Typ

SECTION 3 - INDUSTRIAL APPLICATION

CLEARANCE DATA

CURSOR ENGINES F3A

F3AE9687

A*E001 B*E001 C*E001

bar

Compression ratio 16.5:1

Max. output kW

(HP) rpm

Max. torque Nm

(kgm) rpm

Loadless engine idling rpm

Loadless engine peak rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type

LUBRICATION

Oil pressure (warm engine)

315

(428)

2100

1900 (190) 1500

800 800 800

2300 2300 2300

DIRECT INJECTION INTERCOOLER

Forced by gear pump, relief valve single action

290

(394)

2100

1800

(180)

1500

125 x 140

10300

HOLSET HX55

oil filter

265

(360)

2100

1700

(170)

1500

NOTE

- idling bar

- peak rpm bar

COOLING

Water pump control

Thermostat

- start of opening ºC

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT.

Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

By means of belt

Liquid

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 5

PART ONE -

MECHANICAL COMPONENTS

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 7

ENGINE DISASSEMBLY ASSEMBLY

Handle all parts extremely carefully. Never get your hands or fingers between pieces. Wear the required safety clothing such as goggles, gloves and safety shoes.

Protect the electric parts before doing any washing with high-pressure jets.

Figure 1

Figure 3

104247

- Remove the engine supports;

- removethedrive(1).

99357

Before securing the engine on the rotary stand, remove:

- the engine electric cable, disconnecting it from the control unit and from all the sensors/transmitters connected to it;

For all types except F3AE0684P*E904 and F3AE0684N*E907.

- using a suitable tool (3), work in the direction of the arrow on the tightener and remove the compressor drive belt (1);

- remove the compressor (2) together with the engine support.

Figure 2

Figure 4

- Remove the oil pressure adjuster valve (1).

104246

104248

- Secure the engine to the rotary stand with the brackets

993601036.

- Drain the lubricating oil from the sump.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 5

104249

For all types excluding F3AE0684P*E904

- Using a suitabletool (3), work in the direction of the arrow on the tightener (2) and remove the belt (1).

Figure 6

Figure 8

104251

Remove:

- thermostat assembly (8);

- pipes complete with coolant (6);

- pulley (4);

- water pump (7);

- automatic tightener support (1);

- fixed tightener ( 5);

- damper flywheel (3) and pulley beneath;

- automatic tightener (2);

104250

Only for type F3AE0684P*E904

- Using a suitable tool, operate on the belt take-up units (1) and (3) in order to remove the belts (2) and (4).

- Remove the compressor (5) and the fan hub (6) with related supports.

Figure 7

104249/A

Remove:

-alternator(2).

- supports (1 and 3).

Figure 9

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). Disconnect all the electrical connections and sensors.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 9

Figure 10

On the engine exhaust side, remove the following parts:

- oil delivery pipe (1);

- oil return pipe (4);

- turbocharger (3);

- exhaust manifold (2).

104252

Figure 12

101960

- using tool 99360314 unscrew the oil filters (1).

Figure 11

99258

Only for type F3AE0684P*E904

- disconnect the oil pipes (3) and (4) and disengage them

from the clamps (←);

- take out the fixing screws (1) and remove the cooler (2);

Figure 13

99362

- Disconnect the pipes (2) from the support (1) disengaging them from the clamps and remove them.

- Take out the screws (3) and remove the supports (1).

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 14

104306

For all types excluding F3AE0684P*E904 only, using tool 99360314 (2), unscrew the oil filters (1).

Figure 16

104253

For all types except F3AE0684N*E907.

Take out the screws (2) and remove the intake manifold (1).

Figure 17

Figure 15

Disconnect the fuel pipes (1) from the fuel pump (2).

Remove:

- the fuel pump (2);

- the fuel filter unit (3) and pipes (1).

104254

Only for type F3AE0684N*E907

104763

Loosen the screws (1) and remove the intake manifold (2).

Figure 18

Remove:

104255

- the starter motor (1);

- the control unit (2) and its support;

- the oil dipstick (3) from the crankcase.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 11

Figure 19

104256

- Unscrew the screws (1) and remove the heat exchanger (4);

- unscrew the screws (2) and remove the water line (3).

Figure 21

60496

- Unscrew the screws (2) and remove the gear (1) fitted with phonic wheel.

Figure 20

85480

Remove the rocker arm cover (1), take off the screws (2) and remove: the cover (3), the filter (5) and the gaskets (4 and 6). Take off the screws (8) and remove the blow-by case (7).

Figure 22

60497

- Unscrew the screws (1); tighten one screw in a reaction hole and remove the shoulder plate (2), remove the sheet gasket.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 23

60498

Unscrew the screws (2) and remove the transmission gear (1).

Figure 24

Figure 26

60501

Unscrew the screws (1) and take down the gearbox (2).

Figure 27

60499

Stop the engine flywheel (3) rotation by means of tool 99360351 (1), unscrew the fixing screws (2) and remove the engine flywheel.

Figure 25

60500

Apply the extractor 99340054 (2) and pull out the seal gasket (1).

99364

In sequence, take out the:

- idle gear (1);

- oil pump gear (2).

Figure 28

104257

- Disconnect the electrical connections from the pump

injectors from the pump injector solenoid valves.

- Unscrew the screws (1) fixing the rocker arm shaft.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 13

Figure 29

116814

Apply tool 99360553 (1) to the rocker holder shaft (2) and remove the shaft (2) from the cylinder head.

Figure 30

Figure 32

60515

- By means of metal ropes, lift the cylinder head (1).

- Remove the seal (2).

Figure 33

102935

To extract pump injector from cylinder head, use the tool operating as follows:

- hook tool 99342149 part (3) to pump injector (4);

- mount part (2) on part (3) resting part (2) on cylinder

head;

- screw nut (1) and extract pump injector (4) from cylinder

head.

Figure 31

60514

- Fit the plugs 99360180 (1) instead of injectors.

- Remove the camshaft (2).

- Unscrew the fixing screws on the cylinder head (3).

99268

For all types except F3AE0684P*E904 and F3AE0684N*E907

Undo the screws (2) and remove the engine oil sump (1) together with the spacer ( 3) and the seal (4).

Figure 34

81871

Only valid for types F3AE0684P*E904 - F3AE0684N*E907 F3AE9687A*E001 - F3AE9687B*E001 - F3AE9687C*E001.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 35

Undo the screws and remove the suction strainer (1).

A. F3AE0684P*E904 - F3AE0684N*E907 -

F3AE9687A*E001 - F3AE9687B*E001 F3AE9687C*E001

B. F3AE0684P*E906 - F3AE0684L*E906

F3AE0684P*E905 - F3AE0684N*E907.

99367

Figure 38

60515

Check that the pistons 1-6 are exactly at the T.D.C. Put the gasket (2) on the crankcase. Mount the cylinder head (1) and tighten the screws as shown in Figs. 38 - 39 - 40.

NOTE

Lubricate the thread of the screws with engine oil before assembly. Use new screws every time for head assembly.

ENGINE ASSEMBLY

Figure 36

60563

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 37

Figure 39

61270

Diagram of the tightening sequence of the screws fixing the cylinder head.

Figure 40

60564

Key on the gasket (1), mount the key 99346250 (2) and, screwing down the nut (3), drive in the gasket (1).

Base - May 2007 Print P2D32C003 E

- Pre-tightening with the torque wrench (1):

phase: 60 Nm (6 kgm).

phase: 120 Nm (12 kgm).

60565

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 15

Figure 41

- Closing to angle with tool 99395216 (1):

phase: angle of 120°.

phase: angle of 60°.

Figure 42

60566

NOTE

Figure 44

Mount the gear housing within 10 min. of applying the sealant.

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 43

60633

Using a torque wrench, tighten the highlighted screws with the following sequence and tightening torques:

10 screws M12 x 1.75 x 100 63 Nm

2 screws M12 x 1.75 x 70 63 Nm

4 screws M12 x 1.75 x 35 63 Nm

1 screw M12 x 1.75 x 120 63 Nm

2 screws M12 x 1.75 x 193 63 Nm

Figure 45

47592

Apply LOCTITE5970 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

60568

Key on the gasket (1), mount the keying device 99346251 (2) and, screwing down the nut (3), drive i n the gasket.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

ENGINE FLYWHEEL Fitting engine flywheel (For types: F3AE0684P*E904 - F 3AE0684P*E906 - F 3AE0684L*E906)

Figure 46

VIEW OF HOLES:

A—B—C

VIEW OF HOLE:

60668

DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS

A = Hole on flywheel with one reference mark,

corresponding to the TDC of pistons 3-4.

B = Hole on flywheel with one reference mark,

corresponding to the TDC of pistons 1-6.

C = Hole on flywheel with one reference mark,

corresponding to the TDC of pistons 2-5.

D = Hole on flywheel with two reference marks, position

corresponding to 54°.

Fitting engines flywheel (Only for type: F3AE0684N*E907 - F3AE9687A*E001 - F3AE9687B*E001 F3AE9687C*E001)

Figure 47

104764

DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS

A = Hole on flywheel with one reference mark,

corresponding to the TDC of pistons 3-4.

B = Hole on flywheel with one reference mark,

corresponding to the TDC of pistons 1-6.

Base - May 2007 Print P2D32C003 E

C = Hole on flywheel with one reference mark,

corresponding to the TDC of pistons 2-5.

D = Hole on flywheel with two reference marks, position

corresponding to 54°.

CURSOR ENGINES F3A

If the teeth of the ring gear mounted on the engine flywheel, for starting the engine, are very damaged, replace the ring gear. It must be fitted after heatingthe ring gear to a temperature of approx. 200°C.

Figure 48

SECTION 3 - INDUSTRIAL APPLICATION 17

Fitting camshaft

Figure 50

49037

NOTE

The crankshaft has a locating peg that has to couple with the relevant seat on the engine flywheel.

Position the flywheel (1) on the crankshaft, lubricate the thread of the screws (2) with engine oil and screw them down. Lock rotation with tool 99360351 (3). Lock the screws (2) in three phases. First phase: pre-tightening with torque wrench (4) to a torque of 120 Nm (12 kgm).

Figure 49

Position the crankshaft with the pistons 1 and 6 at the top dead

72436

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).

If this condition does not occur, turn the engine flywheel (4) appropriately. Remove the tool 99360612 (1).

Figure 51

73843

Fit the camshaft (4), positioning it observing the reference marks (→) as shown in the figure.

Lubricate the seal (3) and fit it on the shoulder plate (2).

Mount the shoulder plate (2) with the sheet metal gasket (1) and tighten the screws (5) to the required torque.

49036

Second and third phase: closing to angle of 60° +30° with tool 99395216 (1).

Figure 52

60570

- Apply the gauge 99395218 (1). Check and adjust the position of the link rod (3) for the idle gear. Lock the screw (2) to the required torque.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 53

60571

- Fit the idle gear (1) back on and lock the screws (2) to the

required torque.

Fitting pump-injectors

Figure 55

104243

Fit the seals (1) (2) (3) on the injectors.

Figure 56

Figure 54

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 — 0.195 mm; if this is not so, adjust the clearance as follows:

- Loosen the screws (4) fixing the idle gear (3).

- Loosen the screw (2, Figure 52) fixing the link rod. Shift

the link rod (3, Figure 52) to obtain the required clearance.

- Lock the screw (2, Figure 52) fixing the link rod and

screws (2, Figure 53) fixing the idle gear to the required torque.

Mount:

104260

- The injectors (1) and, using a torque wrench, lock the

bracket fixing screws to a torque of 26 Nm.

- The crosspieces (2) on the valve stem, all with the largest

holeonthesameside.

Fitting rocker-arm shaft assembly

Figure 57

NOTE

Apply the tool 99360553 (1) to the rocker arm shaft (2) and mount the shaft on the cylinder head.

Before refitting the rocker-arm shaft assembly, make sure that all the adjustment screws have been fully unscrewed.

116814

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 19

Figure 58

70567A

SCHEME OF SCREW TIGHTENING SEQUENCE

SECURING ROCKER ARMS

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.

Camshaft timing

Figure 60

71776

Figure 59

104261

Apply the tool 99360321 (7) and the spacer 99360325 (6) to the gearbox (3).

NOTE

The arrow shows the direction of rotation of the engine when running. Using the above-mentioned tool, turn the engine flywheel (1) in the direction of rotation of the engine so as to take the piston of cylinder no.1 to approximately the T.D.C. in the phase of combustion. This condition occurs when the hole with one reference mark (4), after the hole with two reference marks (5) on the engine flywheel (1), can be seen through the inspection window (2).

Lock the screws (2) fixing the rocker-arm shaft as follows:

- 1

- 2

phase: tightening to a torque of 80 Nm (8 kgm) with

thetorquewrench(1);

phase: closing with an angle of 60° using the tool

99395216 (3).

Fit and connect the wiring to the injectors.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 61

71774

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 thehole(3)intheengineflywheel(4). If this is not the case, turn and adjust the engine flywheel (4) appropriately. Remove the tool 99360612 (1).

Figure 63

77259

The camshaft is in step if at the cam lift values of 4.44 ±0.05 mm there are the following conditions:

1) theholemarkedwithanotch(5)canbeseenthroughthe inspection window;

2) the tool 99360612 (1) through the seat (2) of the engine speed sensor goes into the hole (3) in the engine flywheel (4).

Figure 62

60573

Set the dial gauge with the magnetic base (1) with the rod on the roller (2) of the rocker arm that governs the injector of cylinder no.1 and pre-load it by 6 mm.

With tool 99360321 (7) Figure 60, turn the crankshaft clockwise until the pointer of the dial gauge reaches the minimum value beyond which it can no longer fall.

Reset the dial gauge.

Turn the engine flywheel anticlockwise until the dial gauge gives a reading for the lift of the cam of the camshaft of 4.44 ±0.05 mm.

Figure 64

60575

If you do not obtain the conditions illustrated in Figure 63 and described in points 1 and 2, proceed as follows:

1) loosen the screws (2) securing the gear (1) to the camshaft

and utilize the slots (see Figure 65) on the gear (1);

2) turn the engine flywheel appropriately so as to bring about

the conditions described in points 1 and 2 Figure 63, it being understood that the cam lift must not change at all;

3) lock the screws (2) and repeat the check as described

above.

Tighten the screws (2) to the required torque.

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CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 21

Figure 65

71778

When the adjustment with the slots (1) is not enough to make up the phase difference and the camshaft turns because it becomes integral with the gear (2); as a result, the reference value of the cam lift varies, in this situation it is necessary to proceed as follows:

1) lock the screws (2, Figure 64) and turn the engine flywheel clockwise by approx. 1/2 turn;

2) turn the engine flywheel anticlockwise until the dial gauge gives a reading of the lift of the cam of the camshaft of 4.44 ±0.05 mm;

3) take out the screws (2, Figure 64) and remove the gear (1) from the camshaft.

Mount the gear (2) Figure 65 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 4.44 ±0.05. Check the timing conditions described in Figure 63.

Phonic wheel timing

Figure 67

Figure 66

72436

Turn the flywheel (4) again to bring about the following conditions:

- a notch (5) can be seen through the inspection window;

- the tool 99360612 (1) inserted to the bottom of the seat

of the engine speed sensor (2) and (3).

77260

Turn the crankshaft by taking the piston of cylinder no. 1 into the compression phase at T .D.C.; turn the fly wheel in the opposite direction to the normal direction of rotation by approximately 1/4 of a turn.

Again turn the flywheel in its normal direction of rotation until you see the hole marked with the double notch (4) through the inspection hole under the flywheel housing. Insert tool 99360612 (5) into the seat of the flywheel sensor (6).

Insert the tool 99360613 (2), via the seat of the phase sensor, onto the tooth obtained on the phonic wheel.

Should inserting the tool (2) prove difficult, loosen the screws (3) and adjust the phonic wheel (1) appropriately so that the tool (2) gets positioned on the tooth c orrectly. Go ahead and tighten the screws (3).

Base - May 2007Print P2D32C003 E

pumpinj

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Intake and exhaust rockerplay adjustment andpre-loadingofrockers controllin

Figure 68

ectors

ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS

The adjustment of clearance between the rockers and rods controlling the intake and exhaust valves, as well as the adjustment of pre-loading of the rockers controlling pump injectors, must be carried out carefully.

Take the cylinder where clearance must be adjusted to the bursting phase; its valves are closed while balancing the symmetric cylinder valves. Symmetric cylinders are 1-6, 2-5 and 3-4.

In order to properly operate, follow these instructions and data specified on the table.

Adjustment of clearance between the rockers and controlling intake and exhaust

valves:

rods

- use a polygonal wrench to slacken the locking nut (1) of

the rocker arm adjusting screw (2).

- insert the thickness gauge blade (3);

- tighten or untighten the adjustment screw with the

appropriate wrench;

- make sure that the gauge blade (3) can slide with a slight

friction;

- lock the nut (1), by blocking the adjustment screw.

Pre-loading of rockers controlling pump

injectors:

- using a polygonal wrench, l oosen the nut locking the

rocker adjustment screw (5) controlling the pump injector (6);

104262

- using an appropriate wrench(4), loosenthe adjustment

screw until the pumping element is at the end-of-stroke;

- tighten the adjustment screw, with a dynamometric

wrench, to 5 Nm tightening torque (0.5 kgm);

- untighten the adjustment screw by 1/2 to 3/4 rotation;

- tighten the locking nut.

FIRING ORDER

Clockwise

start-up

and rotation

1and6atTDC 6 1 5

Adjusting

cylinder

valve no.

1-4-2-6-3-5

Adjusting clearance

of cylinder

valve no.

Adjusting

pre-loading

of cylinder

injector no.

120º 3 4 1 120º 5 2 4 120º 1 6 2 120º 4 3 6 120º 2 5 3

NOTE

In order to properly carry out the above-mentioned adjustments, follow the sequence specified in the table, checking the exact position in each rotation phase by means of pin 99360612, to be inserted in

the 11

hole in each of the three sectors with 18

holes each.

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CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 23

Figure 69

85480

Fit the distribution cover (1).

NOTE

The valve rocker arm cover fastening screws (1) shall be tightened according to the sequence shown in Figure 70.

Fit the blow-by case (7) and its gasket and then tighten the screws (8) to the prescribed torque. Install the filter (5) and the gaskets (4 and 6).

ENGINE COMPLETION

Figure 71

99367

Fit the suction strainer (1) and tighten the fixing screws to the prescribed torque.

A. F3AE0684P*E904 - F3AE0684N*E907 -

F3AE9687A*E001 - F3AE9687B*E001 F3AE9687C*E001

B. F3AE0684P*E906 - F3AE0684L*E906

F3AE0684P*E905.

NOTE

The filter (5) operation is unidirectional, therefore it must be assembled with the two sight supports as illustrated in the figure.

Fit the cover (3) and tighten the fastening screws (2) to the prescribed torque.

NOTE

Apply silicone LOCTITE 5970 IVECO n˚ 2992644 on the blow-by case (7) surface of engines f itted with P.T.O. according to the procedure described in the following figure.

Figure 70

17 14 13 1 4 5 8

18 19

16 15 12 2 3 6 7

45363

DIAGRAM OF ROCKER ARM CAP FIXING SCREWS

TIGHTENING SEQUENCE

Figure 72

9 10

99268

For all types except F3AE0684P*E904 and F3AE0684N*E907

Place gasket (4) on oil sump (1), position spacer (3) and fit the sumpontheenginebasebytighteningscrews(2)tothe specified torque, by complying with the tightening sequence showninFigure74.

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SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 73

81871

Only for types F3AE0684P*E904 and F3AE0684N*E907 F3AE9687A*E001 - F3AE9687B*E001 - F3AE9687C*E001

Figure 74

12 11 10 3

913

Check the state of the flexible elements of the control unit support and change them if they have deteriorated.

Figure 76

104763

Only for type F3AE0684N*E907 - F3AE9687A*E001 F3AE9687B*E001 - F3AE9687C*E001 Assemble the intake manifold (2), insert the locking screws (1) and tighten to the specified torque.

45672

DIAGRAM OF ENGINE OIL SUMP FIXING SCREWS

TIGHTENING SEQUENCE

Figure 75

45362

Figure 77

104255

Tightening the fixing screws to the prescribed torque, mount:

- the starter motor (1);

- the control unit (2) and its support;

- the oil dipstick (3) in the crankcase.

For all types except.

Fit the intake manifold (1) and tighten the fixing screws (2) to the

104253

prescribed torque.

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CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 25

Figure 78

99362

Only for type F3AE0684P*E904

Mount the support (1) and tighten the fixing screws (3). Connect the oil pipes (2) to the support (1) tightening the fittings to the prescribed torque.

Figure 80

99363

For all types excluding F3AE0684P*E904

Mount the oil filters (1) on the support as follows:

- oil the seal;

- screw the filters down for the seals to make contact with the supporting bases;

- tighten the fil ters to a torque of 35 to 40 Nm.

Figure 79

101960

Fittheoilfilters(1)ontherelevantsupportsasfollows:

- oil the seals;

- screw the filters down for the seals to make contact with the supporting bases;

- tighten the fil ters to a torque of 35 to 40 Nm.

Figure 81

104254

Fit, with the respective gaskets.

- the fuel pump (2);

- fuel filter unit (3) and pipes (1);

- connect the pipes (1) to the fuel pump (2).

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SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 82

99258

Only for type F3AE0684P*E904

Mount the cooler (2) with the relevant seal and tighten the fixing screws (1) to the prescribed torque.

Tighten the screws (←) fixing the clamps retaining the pipes (3 and 4) to the spacer.

Figure 83

Figure 85

54852854 11

63 27 63 47 63 27

45359

DIAGRAM OF EXHAUST MANIFOLD FIXING SCREWS

TIGHTENING SEQUENCE

Figure 86

DIAGRAM OF HEAT EXCHANGER FIXING SCREWS

TIGHTENING SEQUENCE

Figure 84

Mount the following with new seals:

- exhaust manifold (2);

- turbocharger (3);

- oil pipe (1 and 4);

455361

45360

DIAGRAM OF TURBOCHARGER FIXING SCREWS AND

NUTS TIGHTENING SEQUENCE

SEQUENCE: Preliminary tightening 4 - 3 - 1 - 2

Tightening 1-4-2-3

104252

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CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 27

Figure 87

Fit, with the following parts:

- 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).

104251

Figure 89

104249

For all types excluding F3AE0684P*E904

Using a suitable tool (3), work in the direction of the arrow on the tightener (2) and mount the belt (1).

NOTE

The take-up units are of the automatic type; therefore no further adjustments are required after assembly.

Figure 88

99360

Mount the following, tightening the screws to the prescribed torque:

- the supports (1 and 3);

-alternator(2).

Figure 90

101701

DIAGRAM FOR FITTING BELT DRIVING FAN - WATER

PUMP - ALTERNATOR

1. Alternator - 2. Water pump - 3. Crankshaft -

4. Compressor.

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SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Figure 91

104250

Only for type F3AE0684P*E904

Fit the fan hub (6) and the compressor (5) with related supports.

Using a suitable tool, operate on the belt take-up units (1) and (3) and fit the belts (2) and (4).

Figure 93

104246

- mount the oil pressure adjuster valve (1).

NOTE

The take-up units are of the automatic type; therefore no further adjustments are required after assembly.

Figure 92

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. Complete engine assembly with the following parts, tightening the fixing screws or nuts to the prescribed torque:

- mount the drive (1);

- mount the engine supports;

Figure 94

99357

For all types except F3AE0684P*E904 and F3AE0684N*E907

Fit the engine support together with the air-conditioner compressor (2). Using a suitable tool (3), work in the direction of the arrow and mount the belt (1).

Connect the engine electric cable to the sensors and control unit. Refill the engine with lubricating oil of the prescribed gradeand quantity.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 29

PART TWO -

ELECTRICAL EQUIPMENT

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 31

Components on the engine F3A (For all types except F3AE0684P*E904)

Figure 1

ENGINE RIGHT-HAND SIDE VIEW

Figure 2

104263

104264

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. Air temperature/pressure sensor - I. Conditioner compressor - L. EDC 7

control unit - M. Connector on engine block for connection with electro-injectors - N. Water temperature for EDC 7 -

O. Water temperature sensor - P. Oil pressure/temperature transmitter - Q. Engine speed on flywheel sensor - R. Low oil

pressure transmitter.

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SECTION 3 - INDUSTRIAL APPLICATION

Components on the engine F3A (only for type F3AE0684P*E904)

Figure 3

CURSOR ENGINES F3A

ENGINE RIGHT-HAND SIDE VIEW

Figure 4

104307

ENGINE LEFT-HAND SIDE VIEW

104308

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. Air temperature/pressure sensor - I. Conditioner compressor - L. EDC 7

control unit - M. Connector on engine block for connection with electro-injectors - N. Water temperature for EDC 7 -

O. Water temperature sensor - P. Oil pressure/temperature transmitter - Q. Engi ne speed on flywheel sensor -

R. Low oil pressure transmitter.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

Components on the engine F3A (only for type F3AE0684N*E907)

Figure 5

SECTION 3 - INDUSTRIAL APPLICATION 33

ENGINE RIGHT-HAND SIDE VIEW

Figure 6

104765

104766

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. Air temperature/pressure sensor - I. Conditioner compressor - L. EDC 7

control unit - M. Connector on engine block for connection with electro-injectors - N. Water temperature for EDC 7 -

O. Water temperature sensor - P. Oil pressure/temperature transmitter - Q. Engi ne speed on flywheel sensor -

R. Low oil pressure transmitter.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

Components on the engine F3A (only for type F3AE9687A*E001)

Figure 7

CURSOR ENGINES F3A

ENGINE RIGHT-HAND SIDE VIEW

Figure 8

116711

116712

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. Air temperature/pressure sensor - I. Conditioner compressor - L. EDC 7

control unit - M. Connector on engine block for connection with electro-injectors - N. Water temperature for EDC 7 -

O. Water temperature sensor - P. Oil pressure/temperature transmitter - Q. Engi ne speed on flywheel sensor -

R. Low oil pressure transmitter.

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

BLOCK DIAGRAM

Figure 9

SECTION 3 - INDUSTRIAL APPLICATION 35

116816

KEYS

1. Engine coolant temperature sensor - 2. Boost air pressure temperature sensor - 3. Fuel temperature sensor - 4. Boost air

pressure sensor - 5. Engine oil temperature and pressure sensor - 6. CAN H/L line - 7. Injectors - pump - 8. Pre-heating and

heating contactor - 9. Oil electric heater - 10. Main remote-control switch - 11. Flywheel sensor - 12. Distribution sensor -

13. Primary/secondary brake switch.

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

EDC 7 UC31 electronic control unit

Figure 10

CURSOR ENGINES F3A

102373

A. Electro-injector connector - B. Chassis connector - C. Sensor connector

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

EDC control unit PIN-OUT

Electric injector connector ”A”

Figure 11

SECTION 3 - INDUSTRIAL APPLICATION 37

Colour legend B black

R red U blue W white P purple G green N brown Y yellow O orange e E grey K pink

102374

ECU

Colour legend Function

1 Black Solenoid valve for electronic cylinder 5 injection 2 Black Solenoid valve for electronic cylinder 6 injection 3 Bleu Solenoid valve for electronic cylinder 4 injection 4 White Solenoid valve for electronic cylinder 1 injection 5 Green Solenoid valve for electronic cylinder 3 injection 6 Red Solenoid valve for electronic cylinder 2 injection 7 - Free 8 - Free

9 - Free 10 - Free 11 Yellow Solenoid valve for electronic cylinder 2 injection 12 Red Solenoid valve for electronic cylinder 3 injection 13 Red Solenoid valve for electronic cylinder 1 injection 14 Bleu Solenoid valve for electronic cylinder 4 injection 15 Green Solenoid valve for electronic cylinder 6 injection 16 Brown Solenoid valve for electronic cylinder 5 injection

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

EDC control unit PIN-OUT

Sensor connector ”C”

CURSOR ENGINES F3A

Figure 12

6 8 16 9 15 22

Colour legend B black

R red U blue W white P purple G green N brown Y yellow O orange e E grey K pink

ECU

Cable colour Function

1 - Free 2 - Free 3 - Free

4÷8 - Free

9 W Valve gear camshaft sensor

10 R Valve gear camshaft sensor

11÷14 - Free

15 K Coolant temperature sensor

16 ÷17 - Free

Free

18 O/B Fuel temperature sensor 19 B Flywheel sensor 20 - Free

21÷22 - Free

23 W Flywheel sensor 24 N Engine oil temperature/pressure sensor ground 25 W Air temperature/pressure sensor power supply 26 Y Coolant temperature sensor 27 O/B Oil temperature signal from the engine oil temperature/pressure sensor 28 U Oil pressure signal from the engine oil temperature/pressure sensor 29 - Free 30 - Free 31 - Free 32 O Engine oil temperature/pressure sensor power supply 33 R Air temperature/pressure sensor power supply 34 G Air pressure signal from the air temperature/ pressure sensor 35 W/R Fuel temperature sensor 36 O Air temperature signal from the air temperature / pressure sensor

36 29302331

102375

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

EDC control unit PIN-OUT

Chassis connector ”B”

SECTION 3 - INDUSTRIAL APPLICATION 39

Figure 13

ECU

Cable Function

1 - Free 2 7151 +30 positive 3 7153 +30 positive 4 - Free 5 0151 Ground 6 0151 Ground 7 - Free 8 7151 +30 positive

9 7151 +30 positive 10 0151 Ground 11 0151 Ground 12 0094 Preheating actuation enable relay ground

13÷25 - Free

26 - Free 27 - Free 28 - Free 29 5163 EDC system diagnosis inducing switch power supply (presetting) 30 - Free 31 - Free 32 - Free 33 - Free 34 Green CAN - L line (ECB) 35 White CAN - H line (ECB)

36÷39 - -

40 - +15 positive 41 - Free 42 - H2O present in fuel oil sensor signal

43÷55 - Free

56 - Free 57 - Free

58÷67 - Free

68 - Free

69÷74 - -

75 9164 Preheating actuation enable relay positive

76÷88 - Free

89 2298 EDC control unit diagnosis K line

102376

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

Pump injector

Figure 14

CURSOR ENGINES F3A

102405

N3.1 INJECTOR SECTION

The new N 3.I 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.

Figure 15

The function of the fuel pressure damper located on the delivery pipe between the fuel filter and the cylinder head is to attenuate the supply r eturn back pressure due to the increase of the injection pressure.

102606

FUEL PRESSURE DAMPER

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CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 41

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°C8,10÷ 10,77 kOhm

+20°C2,28÷ 2,72 kOhm +80°C0,29÷ 0,364 kOhm

At 60 to 90 _C, voltage at A5 and A22 ranges from 0.6 to 2.4V.

Figure 16

Description

Cable colour

To EDC center pin 15 (Sensor connector ”C”) K

To EDC center pin 26 (Sensor connector ”C”) Y

Base - May 2007Print P2D32C003 E

104266

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Fuel temperature sensor

Specifications

Supplier BOSCH Max. tightening torque 35 Nm

Figure 17

104267

Description Cable colour

To pin 18 of EDC control unit (Sensor connector ”C”) O/B

To pin 35 of EDC control unit (Sensor connector ”C”) W/R

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CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 43

Flywheel pulse transmitter

Specifications

Supplier BOSCH Max. tightening torque 8 ± 2Nm

Figure 18

Description Cable colour

To pin 19 of EDC control unit (Sensor connector ”C”) B

To pin 23 of EDC control unit (Sensor connector ”C”) W

Base - May 2007Print P2D32C003 E

104269

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Distribution pulse transmitter

Features

Vendor BOSCH Torque 8 ± 2Nm Resistance 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.

Though electrically identical to engine rpm sensor mounted in the camshaft in is NOT interchangeable with it as it cable is shorter and it features a larger diameter.

This sensor’s air gap is NOT ADJUSTABLE.

Figure 19

104269

Description

Cable colour

To EDC center pin 9 (Sensor connector ”C”) W

To EDC center pin 10 (Sensor connector ”C”) R

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

Ref.D

ipt

SECTION 3 - INDUSTRIAL APPLICATION 45

Figure 20

Figure 21

Air pressure/temperature sensor (85156).

This component incorporates a temperature sensor and a pressure sensor.

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.

The output voltage is proportional to the pressure or temperature measured by the sensor.

Pin (EDC) 25/C - 33/C Power supply Pin (EDC) 36/C Temperature Pin (EDC) 34/C Pressure

50324

Sensor external view

Oil temperature/pressure sensor (42030 / 47032)

This component is identical to the air pressure/temperature sensor and replaced single sensors 47032 / 42030.

It is fitted onto the engine oil filter, in a horizontal position.

It measures the engine oil temperature and pressure.

The measured signal is sent to the EDC control unit which controls, in turn, the indicator instrument on the dashboard (low pressure warning lights / gauge).

Pin (EDC) 24/C - 32/C Power supply Pin (EDC) 27/C Temperature Pin (EDC) 28/C Pressure

The engine oil temperature is used only by the EDC control unit.

50323

Linking connector

Figure 22

Control unit pin

escr

Oil Air

1 Ground 24C 25C

2 Temp. Sign. 27C 36C

3 +5 32C 33C

4 Press. Sign. 28C 34C

50344

Wiring diagram

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Alternator

Supplier MITSUBISHI Technical features 24V - 90A

Figure 23

Figure 24

116714

Figure 25

116715

Figure 26

116713 116716

Pin Description

S +30

L Battery recharge light

B- Negative

B+ Positive

IG +15

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

SECTION 3 - INDUSTRIAL APPLICATION 47

Starting motor

Specifications

Supplier DENSO Type 2280007550 Electrical system 24 Volt Nominal output 5.5 Kw

Figure 27

104315

Base - May 2007Print P2D32C003 E

SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

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.

When the ignition key is inserted, should any one of the temperature sensors — water, air, gas oil — detect a value below 10°C, the electronic control unit will activate pre/post-heating and turn on the relevant dashboard warning light for a variable time depending on the temperature.

After that time, the warning light starts blinking thus informing the driver that the engine can be started.

When the engine is running the warning light goes off, while the resistance is being fed for a certain time as a result of post-heating.

If the engine is not started, with the warning light flashing, in 20 / 25 seconds, the operation is cancelled to prevent draining the battery.

On the contrary, if reference temperatures are over 10°C, when the ignition key is inserted the warning light comes on for about 2 seconds and carries out the test and then goes out to signal that the engine can be started.

Figure 28

104270

Base - May 2007 Print P2D32C003 E

CURSOR ENGINES F3A

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 position

-enginerpm

- quantity of air admitted.

The result can be corrected based on:

- water temperature

or to prevent:

-noise

-fumes

-overloads

-overheating

SECTION 3 - INDUSTRIAL APPLICATION 49

Pressure can be adjusted in case of:

- engine brake actuation

- external device actuation (e.g. speed reducer, cruise control)

- serious defects involving load reduction or engine stop. After determining the mass of air introduced by measuring its volume and temperature, the center calculates the corresponding mass of fuel to be injected into the cylinder involved, with account also taken of gas oil temperature.

Delivery correction based on water temperature

When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating plays are not optimized yet. Fuel injected also tends to condense on c old metal surfaces. Fuel dosing with a cold engine is therefore greater than when hot.

Delivery correction t o prevent noise, fumes or overloads

Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center to prevent them.

De-rating

In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.

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SECTION 3 - INDUSTRIAL APPLICATION

CURSOR ENGINES F3A

Injection lead electronic control

Injection l ead, 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 accordingto engine load, namely, accelerator position, engine rpm and air admitted. Lead is corrected as required:

- during acceleration

- according to water temperature and to obtain:

- reduced emissions, noise abatement and no overload

- better vehicle acceleration High injection lead is set at start, based on water temperature. Delivery start feedback is given by injection electro valve impedance variation.

Engine start

Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn by the starter motor.

Cold start

Pre-post reheating is activated when even only one of the three water, air or gas oil temperature sensors records a temperature of below 10 _C. The pre-heat warning light goes on when the ignition key is inserted and stays on for a variable period of time according to temperature, while the intake duct input resistor heats the air, then starts blinking, at which point the engine can be started. The warning light switches off with the engine revving, while the resistor continues being fed for a variable period of time to complete post-heating. The operation is cancelled to avoid uselessly discharging the batteries if the engine is not started within 20 ÷ 25 seconds with the warning light blinking. The pre-heat curve is also variable based on battery voltage.

Hot start

On inserting the ignition key the warning light goes on for some 2 seconds for a short test and then switches off when all reference temperatures are above 10 _C. The engine can be started at this point.

Run Up

When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run), and diagnoses the system.

After Run

At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the microprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom) memory to make tem available for the next start (Cf. Run Up). These data essentially consists of:

- miscellaneous settings, such as engine idling and the like

- settings of some components

- breakdown memory The process lasts for some seconds, typically from 2 to 7 according to the amount of data to be stored, after which the ECU sends a command to the main relay and makes it disconnect from the battery.

Base - May 2007 Print P2D32C003 E

Iveco Cursor10 Cursor13 Repair Manual Iveco Cursor10 Cursor13 Repair Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CURSOR ENGINES

SYMBOLS - WARNINGS

GENERAL WARNINGS

GENERALWARNINGS O N THE ELECTRIC SYSTEM

Bonding and screening

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

SPECIAL REMARKS

SYMBOLS - ASSISTANCE OPERATIONS

UPDATING

SECTION 1 - GENERAL SPECIFICATIONS

General Specifications

CORRESPONDENCE BETWEEN TECHNICAL AND COMMERCIAL CODES

VIEWS OF THE ENGINE (ONLY FOR TYPE F3AE0684P*E904)

VIEWS OF THE ENGINE (FOR TYPES: F3AE0684P*E906 - F3AE0684L*E906 - F3AE0684P*E905)

VIEWS OF THE ENGINE (ONLY FOR TYPE: F3AE0684N*E907)

VIEWS OF THE ENGINE (FOR TYPES: F3AE9687A*E001 - F3AE9687B*E001 - F3AE9687C*E001)

LUBRICATION DIAGRAM (ONLY FOR TYPE: F3AE0684P*E904)

LUBRICATION DIAGRAM (FOR TYPES: F3AE0684P*E906 - F3AE0684L*E906 - F3AE0684P*E905)

Oil pump

Overpressure valve

Oil pressure control valve

Heat exchanger (only for type: F3AE0684P*E904)

By-pass valve

Thermostatic valve

Engine oil filters

COOLING

Description

Operation

Water pump

Thermostat

TURBOCHARGING

EGR EXHAUST GAS RECIRCULATION SYSTEM

INTERNAL EGR ACTING ON THE INTAKE VALVES

SECTION 2- FUEL

Fuel

FEEDING

FUEL SUPPLY DIAGRAM (ALL TYPES)

Fuel pump

Injector-pump

SECTION 3 - INDUSTRIAL APPLICATION

Industrial application

CLEARANCE DATA

ENGINE DISASSEMBLY ASSEMBLY

ENGINE ASSEMBLY

Fitting camshaft

Fitting pump-injectors

Fitting rocker-arm shaft assembly

Camshaft timing

Phonic wheel timing

ENGINE COMPLETION

Components on the engine F3A (For all types except F3AE0684P*E904)

Components on the engine F3A (only for type F3AE0684P*E904)

Components on the engine F3A (only for type F3AE0684N*E907)

Components on the engine F3A (only for type F3AE9687A*E001)

BLOCK DIAGRAM

EDC 7 UC31 electronic control unit

EDC control unit PIN-OUT

Pump injector

Engine coolant temperature sensor

Fuel temperature sensor

Flywheel pulse transmitter

Distribution pulse transmitter

Alternator

Starting motor

Pre/post-heating resistance

EDC SYSTEM FUNCTIONS

VIEWS OF THE ENGINE (FOR TYPES: F3AE0684PE906 - F3AE0684LE906 - F3AE0684P*E905)

VIEWS OF THE ENGINE (FOR TYPES: F3AE9687AE001 - F3AE9687BE001 - F3AE9687C*E001)

LUBRICATION DIAGRAM (FOR TYPES: F3AE0684PE906 - F3AE0684LE906 - F3AE0684P*E905)