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Cursor C9
Repair Manual
162 pgs18.03 Mb36

Iveco Cursor C9 Repair Manual

CURSOR SERIES
C9
Technical and Repair manual
This publication describes the characteristics, data and correct methods for repair operations on each component of the ve­hicle.
If the instructions provided are followed and the specified equipment is used, correct repair operations in the pro­grammed time will be ensured, safeguarding against possible accidents.
Before starting to perform whatever type of repair, ensurethat all accident prevention equipment i s available and efficient.
All protections specified by safety regulations, i.e.: goggles, helmet, gloves, boot, etc. must be checked and worn.
All machining, lifting and conveying equipment should be in­spected before use.
The data contained in this publication was correct at the time of going to press but due to possible modifications made by the Manufacturer for reasons of a technical or commercial na­ture or for adaptation to the legal requirements of the differ­ent countries, some changes may have occurred.
No part of this publication, including the pictures, may be re­produced in any form or by any means.
st
Ed. 2006
Produced by:
B.U. TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio, 15 10156 Torino (TO) - Italy
RYR
F2C CURSOR ENGINES
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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4
GENERAL WARNINGS
Warnings shown cannot berepresentative of all danger situations possiblyoccurring. 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.
Do not leave the running assembly unattended when making repairs.
F2C CURSOR ENGINES
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 have 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 allinflammable fluids and liquids must be handledwith care, according to whatcontained onharmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparksin 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 IVECO Motors original spares.
During workshop activity,always keepthe work placeclean; timely clearor clean floors from accidental liquidor oil spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
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F2C CURSOR ENGINES
GENERALWARNINGS
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.
5
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO Motors 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 80qC (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 ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
!
Before connecting the batteries to the system, make sure that the system is well isolated.
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 checking 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 IVECO Motors 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.
F2C CURSOR ENGINES
NOTE
To start up the engine, donot use fast chargers. Start up must only be performed with either separate batteriesor 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 com ponents 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.
Connectors present mustbe seen from cable side.Connectors views contained in the manual are representative of cable side.
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F2C CURSOR ENGINES
Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables 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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F2C CURSOR ENGINES
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 IVECO Motors. 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
1 kg/cm
2
=1bar.
according to ratio 1:1
Temperature
0q C=32q F 1q C = (1 x 1.8 + 32) q F
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F2C CURSOR ENGINES
1
F2C CURSOR ENGINES
Section
General specifications
Fuel 2
Industrial application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
1
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the F2C engine illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to thespecific duty and is divided in 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 directinstructions to identify the causeof the major incon­veniences.
Sections 4 and 5 illustrate the overhaul operationsof the engi­ne overhaul on stand andthe necessary equipmentto 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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F2C CURSOR ENGINES
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F2C CURSOR ENGINES
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 = h ousing for connecting rod small end bush
1
Tighten to torque Tighten to torque + angular value
§
Ø 2 = h ousing for connecting rod bearings
2
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Graph and symbols
F2C CURSOR ENGINES
Removal Disconnection
Refitting Connection
Removal Disassembly
Fitting in place Assembly
Tighten to torque
Tighten to torque + angle value Rolling torque
§
Press or caulk
Regulation Adjustment
!
Warning Note
¸
Intake
Exhaust
Operation
Compression ratio
Tolerance Weight difference
Replacement Original spare parts
Rotation
Angle Angular value
Visual inspection Fitting position check
Measurement Value to find Check
Equipment Temperature
Surface for machining Machine finish
Interference Strained assembly
Thickness Clearance
Lubrication Damp Grease
Sealant Adhesive
Air bleeding
bar
Preload
Number of revolutions
Pressure
Oversized Higher than}. Maximum, peak
Undersized Less than}. Minimum
Selection Classes Oversizing
Temperature < 0 qC Cold Winter
Temperature > 0 qC Hot Summer
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F2C CURSOR ENGINES
UPDATING
Section Description Page Date of revision
5
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F2C CURSOR ENGINES
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F2C CURSOR ENGINES
SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General Specifications
Page
TECHNICAL CODE 3......................
VIEWS OF THE ENGINE (for types: F2CE9684A*E004 -
F2CE9684B*E001 - F2CE9684C*E001 ­F2CE9684D*E001 - F2CE9684C*E002 -
F2CE9684E*E002) 5.....................
VIEWS OF THE ENGINE
(for types: F2CE9684L*E005) 8.............
LUBRICATION DIAGRAM 11.................
- Oil pump 12.............................
- Overpressure valve 12.....................
- Oil pressure control valve 13................
- Heat exchanger 13........................
ENGINE OIL FILTER 14......................
- Characteristics 14.........................
- Lock torques 14..........................
- Installation rule 14.........................
- Filter by-pass valve 14......................
- Oil fume recycle (Blow-by) 15...............
COOLING 16.............................
- Description 16...........................
- Operation 16............................
- Water pump 18..........................
- Thermostat 18...........................
TURBOCHARGING 19......................
EGR EXHAUST GAS RECYCLE SYSTEM 20......
INTERNAL EGR OPERATING ON
SUCTION VALVES 20.....................
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SECTION 1 - GENERAL SPECIFICATIONS
F2C CURSOR ENGINES
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F2C CURSOR ENGINES
TECHNICAL CODE
SECTION 1 - GENERAL SPECIFICATIONS 3
Technical Code
F2CE9684A*E004 F2CE9684B*E001 F2CE9684C*E001 F2CE9684D*E001 F2CE9684C*E002
F2CE9684E*E002
F2CE9684H*E003
F2CE9684L*E005
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SECTION 1 - GENERAL SPECIFICATIONS
F2C CURSOR ENGINES
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F2C CURSOR ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
VIEWS OF THE ENGINE (for types: F2CE9684A*E004 - F2CE9684B*E001 - F2CE9684C*E001 ­F2CE9684D*E001 - F2CE9684C*E002 - F2CE9684E*E002)
Figure 1
5
Figure 2
113047
LEFT-HAND SIDE VIEW
113048
RIGHT-HAND SIDE VIEW
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SECTION 1 - GENERAL SPECIFICATIONS
Figure 3
F2C CURSOR ENGINES
Figure 4
113049
FRONT HAND SIDE VIEW
113050
REAR HAND SIDE VIEW
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F2C CURSOR ENGINES
Figure 5
SECTION 1 - GENERAL SPECIFICATIONS
7
TOP VIEW
113051
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SECTION 1 - GENERAL SPECIFICATIONS
VIEWS OF THE ENGINE (for types: F2CE9684L*E005)
Figure 6
F2C CURSOR ENGINES
Figure 7
114203
RIGHT-HAND SIDE VIEW
114204
LEFT-HAND SIDE VIEW
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F2C CURSOR ENGINES
Figure 8
SECTION 1 - GENERAL SPECIFICATIONS
9
Figure 9
114205
FRONT-HAND SIDE VIEW
104206
REAR-HAND SIDE VIEW
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SECTION 1 - GENERAL SPECIFICATIONS
Figure 10
F2C CURSOR ENGINES
TOP SIDE VIEW
114207
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F2C CURSOR ENGINES
LUBRICATION DIAGRAM
Figure 11
SECTION 1 - GENERAL SPECIFICATIONS
11
Dropping oil
Pressure oil
114244
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SECTION 1 - GENERAL SPECIFICATIONS
F2C CURSOR ENGINES
Oil pump
Figure 12
114245 77820
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 14
190 r 6N
324 r 9N
43.65
33.5
22.95
MAIN DATA TO CHECK THE OVERPRESSURE
VALVE SPRING
Figure 13
112327
OIL PUMP CROSS-SECTION
1. Overpressure valve — Start of opening pressure 10.1 r0.7 bars.
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F2C CURSOR ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
13
Oil pressure control valve
Figure 15
73542
The oil pressure control valve is located on the left-hand side of the crankcase. Start of opening pressure 5 bars.
Heat exchanger
Figure 17
Figure 16
168 r 9
308 r 15
63
51
36.4
88819
MAIN DATA TO CHECK THE OIL PRESSURE
CONTROL VALVE SPRING
114246
1. Exchanger seal - 2. Internal heat exchanger element - 3. Cover - 4.Oil filter - 5. Oil filter seal
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SECTION 1 - GENERAL SPECIFICATIONS
ENGINE OIL FILTER
Figure 18
F2C CURSOR ENGINES
1. Closure cap - 2. Cartridge - 3. Spring - 4. Support O-ring - 5. Tank O-ring - 6. Washer - 7. Washer - 8. Support -
9. Plug M14x1.5 - 10. Plug M38x1.5 - 11. By-pass valve 3.4 bars.
Characteristics
1. Max working pressure: 13 bars
Filter by-pass valve
Figure 19
2. Working temperature: - 30q C y + 120q C
3. By-pass valve opening value: 3,4 r 0,3 bar
Lock torques
Cap (part 1): 60 r 5Nm
Plug (part 9): 30 r 5Nm
Plug (part 10): 90 r 5Nm
Installation rule
Use threadlock for plug (part 10).
Valve opens quickly at 3,4 r 0,3 bar pressure.
114247
73545
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F2C CURSOR ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
Oil fume recycle (Blow-by)
Part of gas produced by combustion during engine operation leaks through piston elastic ring openings into sump, mixing with oil fumes in sump.
This mixture, conveyed upward, is partially separated from oil by a device located in timing cover upper part an d introduced in air intake circuit.
The device mainly consists of a rotary filter secured on propeller shaft and by a front cover h ousing n ormally closed valves controlling mixture flow.
Figure 20
15
Gas with oil contents greater than 10 g/h
Gas with oil contents approx. 0,2 g/h
Condensed oil returning to oil sump
114248
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SECTION 1 - GENERAL SPECIFICATIONS
F2C CURSOR ENGINES
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 (by IVECO);
- a heat exchanger to c ool down lubrication oil;
- a water pump with centrifu gal system incorporated in the cylinder block;
- fan, not supplied;
- a 2-way th ermostat c ontrolling the coolant circulation.
Operation
The water pump is actuated by the crankshaft throu gh a poli-V belt and sends coolant to the 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 through the expansion vessel.
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