Iveco CURSOR EURO 4 Repair Manual

CURSOR EURO 4 ENGINES

Vehicle application

C78

C78 ENT C

C10

C10 ENT C

C13

C13 ENT C

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, ensure that all accident prevention equipment is 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.

Publication edited by Iveco Motors

Iveco SpA

PowerTrain

Mkt. Advertising & Promotion Viale dell’Industria, 15/17 20010 Pregnana Milanese Milano (Italy)

Print P1D32C002 E - 1st Ed. 09.2006

Produced by:

B.U. TECHNICAL PUBLISHING

Iveco Technical Publications

Lungo Stura Lazio, 15/19

10156 Turin - Italy

CURSOR EURO 4 ENGINES			1
		CURSOR EURO 4 ENGINES	Part 1
		F2B Cursor engines
		F3A Cursor engines	Part 2
		F3B Cursor engines	Part 3

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2	CURSOR EURO 4 ENGINES

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CURSOR EURO 4 ENGINES	3

SPECIAL REMARKS

The subjects usually dealt with in each section are:

Technical data table, Driving torques, Equipment, Diagnostic, Removal and Fitting in place, Repair operations. Where possible, the same sequence of procedures has been followed for easy reference.

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

1	Ø 1	= housing for connecting rod small end bush	Tighten to torque
		α	Tighten to torque + angular value
2	Ø 2	= housing for connecting rod bearings

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4	CURSOR EURO 4 ENGINES

Graph and symbols

Removal

Disconnection

Refitting

Connection

Removal

Disassembly

Fitting in place

Assembly

Tighten to torque

Tighten to torque + angle value

α

Press or caulk

Regulation

Adjustment

Warning

!Note

Visual inspection Fitting position check

Measurement

Value to find

Check

Equipment

Surface for machining

Machine finish

Interference

Strained assembly

Thickness

Clearance

Lubrication

Damp

Grease

Sealant

Adhesive

Air bleeding

Intake

Exhaust

Operation

ρCompression ratio

Tolerance

Weight difference

Rolling torque

Replacement

Original spare parts

Rotation

Angle

Angular value

Preload

Number of revolutions

Temperature

Pressure

bar

Oversized

Higher than….

Maximum, peak

Undersized

Less than….

Minimum

Selection

Classes

Oversizing

Temperature < 0 °C

Cold

Winter

Temperature > 0 °C

Hot

Summer

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F2B CURSOR EURO 4 ENGINES	1

Part 1

F2B CURSOR EURO 4 ENGINES

	Section
General specifications	1
Fuel	2
Vehicle application	3
General overhaul	4
Tools	5
Safety prescriptions	Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the F2B engine illustrating its features and working in general.

Section 2 describes the type of fuel feed.

Section 3 relates to the specific 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 direct instructions to identify the cause of the major inconveniences.

Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such operations.

The appendix reports general safety prescriptions to be followed by all operators whether being in-charge of installation or maintenance, in order to avoid serious injury.

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F2B CURSOR EURO 4 ENGINES	3

UPDATING

Section	Description	Page	Date of revision

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS	1
	SECTION 1
	General specifications
		Page
	CORRESPONDENCE BETWEEN TECHNICAL CODE
	AND COMMERCIAL CODE . . . . . . . . . . . . .	3
	ENGINE SECTIONS . . . . . . . . . . . . . . . . . . . . . .	5
	LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .	7
	- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	8
	- Overpressure valve . . . . . . . . . . . . . . . . . . . . .	8
	- Oil pressure control valve . . . . . . . . . . . . . . . .	9
	- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .	9
	- By-pass valve inside the filter support/heat
	exchanger assembly . . . . . . . . . . . . . . . . . . . . .	10
	- Thermostatic valve . . . . . . . . . . . . . . . . . . . . . .	10
	- Engine oil filters . . . . . . . . . . . . . . . . . . . . . . . .	10
	- Valve integrated in piston cooling nozzle . . . . .	11
	COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12
	- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .	13
	TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . .	14
	VGT TURBOCHARGER . . . . . . . . . . . . . . . . . . .	14
	- Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	15
	- Solenoid valve for VGT control . . . . . . . . . . . .	15
	DENOX SYSTEM 2 . . . . . . . . . . . . . . . . . . . . . . .	16
	- General remarks . . . . . . . . . . . . . . . . . . . . . . . .	16
	- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	- AdBlue fluid level gauge control . . . . . . . . . . . .	18

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2	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 ENGINES
		Page
- By-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . .		18
- Pump module . . . . . . . . . . . . . . . . . . . . . . . . .		19
- Dosing module . . . . . . . . . . . . . . . . . . . . . . . .		19
- Catalyst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		19
- Exhaust gas temperature sensor . . . . . . . . . . .		20
- Humidity detecting sensor . . . . . . . . . . . . . . . .		21

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		F2B CURSOR EURO 4 ENGINES		SECTION 1 - GENERAL SPECIFICATIONS 3
		CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
			Technical Code	Commercial Code
			F2BE3681C	C78 ENT C
			F2BE3681B	C78 ENT C
			F2BE3681A	C78 ENT C

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS	5

ENGINE SECTIONS

Figure 1

78841

ENGINE - CROSS SECTION

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6	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 ENGINES

Figure 2

78839

ENGINE - LONGITUDINAL SECTION

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS	7

LUBRICATION

Engine lubrication is obtained with a gear pump driven by the crankshaft via gears.

A heat exchanger governs the temperature of the lubricating oil.

The oil filter, signalling sensors and safety valves are installed in the intercooler.

Figure 3

Dropping oil

Pressure oil

B.Engine oil sump (auxiliary oil pump version)

C.Auxiliary oil pump

86930

LUBRICATION CIRCUIT

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8	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 ENGINES

Oil pump

Figure 4

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.

Figure 5

Overpressure valve

Figure 6

190 ± 6N

324 ± 9N

43,65

33,5

22,95

77820

MAIN DATA TO CHECK THE OVERPRESSURE

VALVE SPRING

112327

OIL PUMP CROSS-SECTION

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

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS	9

Oil pressure control valve

Figure 7

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 9

Figure 8

168 ± 9

308 ± 15

63

51

36,4

88819

MAIN DATA TO CHECK THE OIL PRESSURE

CONTROL VALVE SPRING

77818

HEAT EXCHANGER

The following elements are fitted on the intercooler: 1. Transmitter for low pressure warning lamp - 2. By-pass valve - 3. Oil temperature sensor - 4. Oil pressure sensor for single gauge - 5. Heat valve. Number of intercooler elements: 7

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10	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 ENGINES

By-pass valve inside the filter support/heat exchanger assembly

Figure 10

73545

The valve quickly opens at a pressure of: 3 bars.

Thermostatic valve

Figure 11

73546

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 12

47447

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

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.

Filtering element

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

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS 11

Valve integrated in piston cooling nozzle

Figure 13

109080

The valve allows oil to enter only above the threshold pressure of 1.7 ± 0.2 bar. This permits filling the circuit and therefore lubricating the most stressed parts even when working at lower pressures.

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12	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 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 cool down lubrication oil;

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

-fan, not supplied;

-a 2-way thermostat controlling the coolant circulation.

Operation

The water pump is actuated by the crankshaft through 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.

Figure 14

Water leaving the thermostat

Water circulating in the engine

Water entering the pump

92824

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS 13

Water pump

Figure 15

44915

WATER PUMP SECTION

The water pump consists of: rotor, seal bearing and control pulley.

Make sure that the pump casing has no cracking or

!water leakage; otherwise, replace the entire pump.

Thermostat

THERMOSTAT OPERATION VIEW

Figure 16

TO THE HEATER

TO BY-PASS

FROM THE HEAD

45357

Water circulating in the engine

Figure 17

TO THE HEATER

TO RADIATOR

TO EXPANSION TANK

FROM THE HEAD

45358

Water issuing from thermostat

Check thermostat operation, in case of doubts, replace it.

Start of stroke temperature	84 _C ± 2 _C
Minimum stroke 15 mm at	94 _C ± 2 _C

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14	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 ENGINES

TURBOCHARGING

The turbocharging system consists of:

-air filter;

-a variable geometry or a fixed geometry turbocharger;

-“intercooler” radiator.

Figure 18

Engine exhaust gas

Intake air

Compressed air (hot)

Compressed air (cooled)

44916

DIAGRAM OF SUPERCHARGING WITH THE VGT TURBOCHARGER

VGT TURBOCHARGER

Operating principle

The variable geometry turbocharger (VGT) consists of a centrifugal compressor and a turbine, equipped with a mobile device which adjusts the speed by changing the area of the passing section of exhaust gases to the turbine.

Thanks to this solution, gas velocity and turbine speed can be high even when the engine is idling.

If the gas is made to go through a narrow passage, in fact, it flows faster, so that the turbine rotates more quickly.

The movement of the device, choking the exhaust gas flowing section, is carried out by a mechanism, activated by a pneumatic actuator.

This actuator is directly controlled by the electronic control unit by a proportional solenoid valve.

The device is in maximum closing condition at idle speed.

At high engine operating speed, the electronic control system is activated and increases the passing section, in order to allow the in-coming gases to flow without increasing their speed.

A toroidal chamber is obtained during the casting process in the central body for the passage of the coolant.

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS 15

Actuator

Figure 19

71834

1.Air inlet - 2. Gasket - 3. Piston - 4. External spring -

5.Internal spring control disc - 6. Internal spring -

7.O-ring - 8. Spring holder - 9. Limit stop - 10. Dust seal -

11.Control rod.

Figure 20

[bar]

Stroke [mm]

72421

aGradient characterized by the effect of the external spring (4, Figure 19).

bGradient characterized by the effect of the external (4, Figure 19) and internal (6) springs.

Working principle (See Figure 19)

The actuator piston, connected to the drive rod, is controlled with the compressed air introduced through the air inlet (1) on the top of the actuator.

Modulating the air pressure varies the movement of the piston and turbine control rod. As the piston moves, it progressively compresses the external spring (4) until the base of the piston reaches the disc (5) controlling the internal spring (6).

On further increasing the pressure, the piston, via the disc (5), interferes with the bottom limit stop (10).

Using two springs makes it possible to vary the ratio between the piston stroke and the pressure. Approximately 85% of the stroke of the rod is opposed by the external spring and 15% by the internal one.

Solenoid valve for VGT control

This N.C. proportional solenoid valve is located on the left-hand side of the crankcase under the turbine.

The electronic control unit, via a PWM signal, controls the solenoid valve, governing the supply pressure of the turbine actuator, which, on changing its position, modifies the cross-section of the flow of exhaust gases onto the blades of the impeller and therefore its speed.

The resistance of the coil is approx. 20-30 Ohms.

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16	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 ENGINES

DeNOx SYSTEM 2 General remarks

In order to keep the exhaust emission values of nitric oxides (NOx) within the limits prescribed by the Euro 4 standard, with low fuel consumption, a system for post-processing of the above substances found in exhaust gas has been fitted to the vehicles. This system essentially consists of an electronic-control oxidizing catalyst.

The system converts, through the SCR (Selective Catalytic Reduction) process, nitric oxides (NOx) into inert compounds: free nitrogen (N2) and water vapour (H2O).

The SCR process is based on a series of chemical reactions, which leads, due to ammonia reacting with exhaust gas oxygen, to a reduction of nitric oxides (NOx) found in exhaust gas.

Figure 21

115785

SCR SYSTEM DIAGRAM

A.PUMP MODULE - B. MEASURING OUT MODULE

1.Supply module - 2. MV4 - 3. Pre-filters - 4. Tank vent - 5. AdBlue tank with gridle - 6. Dosing module - 7. MV2 - 8. Mixer -

9.- 10. Temperature sensors - 11. Nox sensor (*) - 12. Membrane pump - 13. MV1 - 14. MV3 - 15. Main filter.

*Future application

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F2B CURSOR EURO 4 ENGINES	SECTION 1 - GENERAL SPECIFICATIONS 17

The system is essentially made up of:

-a tank (9) for reagent solution (water - urea: AdBlue), equipped with level gauge (8);

-an H2O diverter valve (1);

-pump module (10);

-a mixing and injection module (2);

-catalyst (4);

-two exhaust gas temperature sensors (5, 6) on catalyst output (4);

-a moisture detection sensor (7) fitted on the engine air intake pipe downstream from the air cleaner.

SCR system is electronically managed by DCU (Dosing Control Unit) incorporated into pump module (10); depending on engine rpm, supplied torque, exhaust gas temperature, quantity of nitrogen oxides and humidity of air sucked in, the control unit regulates the flow rate of AdBlue solution to be let into the system.

Figure 22

Pump module (10) takes reagent solution out of tank (9), then sends it under pressure into measuring out module (2); finally, the reagent solution is injected into the exhaust pipe upstream of catalyst (4).

Here, the first phase of the process is realized: the reagent solution will vaporize immediately, due to the exhaust gas temperature, and will be converted into ammonia (2NH3) and carbon dioxide (CO2), owing to hydrolysis. At the same time, vaporization of the solution will cause a decrease in the exhaust gas temperature: the latter will get near the optimum temperature required for the process.

Exhaust gas added with ammonia - and at the reaction temperature - will flow into catalyst where the second phase of the process will be realized: ammonia will, by reacting with the exhaust gas oxygen, convert into free nitrogen (N) and water vapour (H2O).

108125

POSITION OF SCR SYSTEM COMPONENTS ON THE VEHICLE

1.H2O valve - 2. Dosing module - 3. Nitric oxide detecting sensor (*) - 4. Catalyst -

5.Outlet temperature sensor - 6. Inflow exhaust gas temperature sensor - 7. Sucked air humidity and temperature sensor - 8. Level gauge - 9. Water-urea solution (AdBlue) tank - 10. Pump module.

*Future application

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18 SECTION 1 - GENERAL SPECIFICATIONS

Tank

Figure 23

102295

The tank equipped with level gauge control (1) contains the reducing substance required for the SCR process, which consists of a 35%-urea and water solution called AdBlue.

AdBlue fluid level gauge control

Figure 24

116181

1.AdBlue fluid suction pipe - 2. AdBlue fluid return pipe - 3. Engine cooling hot fluid inlet pipe -

4.AdBlue (NTC) temperature sensor -

5.Engine cooling hot fluid outlet pipe - 6. Float -

7.AdBlue fluid heating coil - 8. AdBlue air vent.

F2B CURSOR EURO 4 ENGINES

Figure 25

102308

FUNCTIONAL WIRING DIAGRAM

The AdBlue fluid level gauge control consists of a device made up of a set of resistors, a float, a NTC temperature sensor, and a coil used to heat the fluid under low temperature conditions.

It informs the control unit of any current change due to the resistor determined by the float position with respect to the AdBlue fluid level.

By-pass valve

Figure 26

108127

FUNCTIONAL WIRING DIAGRAM

1.Coolant inlet - 2. Coolant outlet -

6.Electrical connection.

The valve, which is a Normally Closed type valve, allows AdBlue tank to be heated by engine coolant.

The NTC temperature sensor controls the by-pass valve which closes or opens (depending on temperature) the passage of the engine cooling hot fluid into the heating coil.

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F2B CURSOR EURO 4 ENGINES SECTION 1 - GENERAL SPECIFICATIONS 19

Pump module		Dosing module
Figure 27		Figure 28

108129

1. AdBlue infeed - 2. Electrical connection -

3. AdBlue outlet.

108128

The function of this module is to dose the AdBlue solution to 1. AdBlue return pipe to the tank - 2. AdBlue return pipe be conveyed to the injector.

from dosing module - 3. AdBlue solution outlet - 4. AdBlue solution infeed - 5. Electrical connection - 6. DCU control unit connector - 7. Filter - 8. Prefilter.

Catalyst

Figure 29

102301

Catalyst (1), equipped with sound-proofing material, replaces the exhaust silencer.

Inside the catalyst, the exhaust gas nitric oxides are, by reacting with ammonia, converted into free nitrogen and water vapour.

Temperature sensors (2 & 3) and nitric oxide detecting sensor

(4) are fitted onto catalyst (1).

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20	SECTION 1 - GENERAL SPECIFICATIONS	F2B CURSOR EURO 4 ENGINES

Exhaust gas temperature sensor

Figure 30

102303

Figure 31

102304

FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Earth cable (white) - 6. Sensor.

The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to calculate the amount of urea to be injected into the system.

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