Iveco Cursor 10, Cursor 13 Repair Manual
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
nd
Ed. 05.2007
Produced by:
B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15/19
10156 Turin - Italy
CURSOR ENGINES TIER 3
1
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
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.
5
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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6
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.
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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.
7
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
2
= 0.981 bar
5
2
Pa
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;
2
- bar unit is for the sake of simplicity converted into kg/cm
2
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
1
Part 1
CURSOR ENGINES F3A
Section
General specifications
Fuel 2
Duty - Industrial application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
1
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
3
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
1
Ø 2 = housing for connecting rod bearings
∅
2
Tighten to torque
Tighten to torque + angular value
α
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4
SYMBOLS - ASSISTANCE OPERATIONS
CURSOR ENGINES F3A
Removal
Disconnection
Refitting
Connection
Removal
Disassembly
Fitting in place
Assembly
ρ
Tighten to torque
Tighten to torque + angle value Rolling torque
α
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
5
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6
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.....................
1
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
3
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
5
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
7
TOP VIEW
104228
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8
SECTION 1 - GENERAL SPECIFICATIONS
CURSOR ENGINES F3A
VIEWS OF THE ENGINE (FOR TYPES: F3AE0684P*E906 - F3AE0684L*E906 - 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
9
Figure 9
104231
FRONT SIDE VIEW
REAR SIDE VIEW
104232
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10
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
11
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
13
TOP SIDE VIEW
104759
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14
SECTION 1 - GENERAL SPECIFICATIONS
CURSOR ENGINES F3A
VIEWS OF THE ENGINE (FOR TYPES: F3AE9687A*E001 - F3AE9687B*E001 - F3AE9687C*E001)
Figure 16
Figure 17
116763
LEFT-HAND SIDE VIEW
116764
RIGHT SIDE VIEW
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