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Fiat Cursor Tier 3 Series Technical And Repair Manual

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CURSOR TIER 3

Technical and Repair manual

Industrial application

CURSOR G-DRIVE

CURSOR 10 TE X

CURSOR 13 TE X

SERIES

C10 ENT X

C13 ENT X

C10

C13

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Summary of Contents for Fiat Cursor Tier 3 Series

Page 1 CURSOR TIER 3 SERIES Industrial application C10 ENT X C13 ENT X CURSOR G-DRIVE CURSOR 10 TE X CURSOR 13 TE X Technical and Repair manual...
Page 2 It is forbidden to copy this text or any of its parts and all illustrations included. Produced by: Publication edited by FIAT Powerrtrain Technologies Mkt. Advertising & Promotion B.U. TECHNICAL PUBLISHING Viale dell’Industria, 15/17 Iveco Technical Publications...
Page 3 CURSOR ENGINES TIER 3 CURSOR ENGINES Part 1 Cursor F3A Part 2 Cursor F3B Part 3 Cursor engines application G-Drive Print P2D32C003 E Base - May 2007...
Page 4 CURSOR ENGINES TIER 3 Base - May 2007 Print P2D32C003 E...
Page 5: Preliminary Remarks
CURSOR ENGINES TIER 3 PRELIMINARY REMARKS 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.
Page 6: General Warnings
CURSOR ENGINES TIER 3 GENERAL WARNINGS Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks.
Page 7 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;...
Page 8: General Warnings On The Electric System
CURSOR ENGINES TIER 3 GENERAL WARNINGS ON THE ELECTRIC SYSTEM If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated.
Page 9: Bonding And Screening
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.
Page 10: Conversions Between The Main Units Of Measurement Of The International System And Most Used Derived Quantities
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.
Page 11: Preface To User's Guideline Manual
CURSOR ENGINES F3A Part 1 CURSOR ENGINES F3A Section General specifications Fuel Duty - Industrial application Overhaul and technical specifications Tools Appendix Safety prescriptions 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.
Page 12 CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 13: Special Remarks
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...
Page 14 CURSOR ENGINES F3A SYMBOLS - ASSISTANCE OPERATIONS Removal Intake Disconnection Refitting Exhaust Connection Removal Operation Disassembly Fitting in place ρ Compression ratio Assembly Tolerance Tighten to torque Weight difference Tighten to torque + angle value Rolling torque α Press or caulk Rotation Regulation Angle...
Page 15 CURSOR ENGINES F3A UPDATING Section Description Page Date of revision Print P2D32C003 E Base - May 2007...
Page 16 CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 17: Table Of Contents
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General Specifications Page 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) .
Page 18: Section 1 - General Specifications
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 19 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 Print P2D32C003 E Base - May 2007...
Page 20 SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 21: Right-Hand Side View
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS VIEWS OF THE ENGINE (ONLY FOR TYPE F3AE0684P*E904) Figure 1 104224 LEFT-HAND SIDE VIEW Figure 2 104225 RIGHT-HAND SIDE VIEW Print P2D32C003 E Base - May 2007...
Page 22: Front View
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Figure 3 104226 FRONT VIEW Figure 4 104227 REAR VIEW Base - May 2007 Print P2D32C003 E...
Page 23: Top View
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS Figure 5 104228 TOP VIEW Print P2D32C003 E Base - May 2007...
Page 24: Right Side View
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A VIEWS OF THE ENGINE (FOR TYPES: F3AE0684P*E906 - F3AE0684L*E906 - F3AE0684P*E905) Figure 6 104229 LEFT-HAND SIDE VIEW Figure 7 104230 RIGHT SIDE VIEW Base - May 2007 Print P2D32C003 E...
Page 25: Front Side View
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS Figure 8 104231 FRONT SIDE VIEW Figure 9 104232 REAR SIDE VIEW Print P2D32C003 E Base - May 2007...
Page 26: Top Side View
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Figure 10 104233 TOP SIDE VIEW Base - May 2007 Print P2D32C003 E...
Page 27: Views Of The Engine (Only For Type: F3Ae0684N*E907)
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS VIEWS OF THE ENGINE (ONLY FOR TYPE: F3AE0684N*E907) Figure 11 104755 LEFT-HAND SIDE VIEW Figure 12 104756 RIGHT SIDE VIEW Print P2D32C003 E Base - May 2007...
Page 28 SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Figure 13 104757 FRONT SIDE VIEW Figure 14 104758 REAR SIDE VIEW Base - May 2007 Print P2D32C003 E...
Page 29 CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS Figure 15 104759 TOP SIDE VIEW Print P2D32C003 E Base - May 2007...
Page 30: Views Of The Engine
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A VIEWS OF THE ENGINE (FOR TYPES: F3AE9687A*E001 - F3AE9687B*E001 - F3AE9687C*E001) Figure 16 116763 LEFT-HAND SIDE VIEW Figure 17 116764 RIGHT SIDE VIEW Base - May 2007 Print P2D32C003 E...
Page 31 CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS Figure 18 116761 FRONT SIDE VIEW Figure 19 116762 TOP SIDE VIEW Print P2D32C003 E Base - May 2007...
Page 32: Lubrication Diagram (Only For Type: F3Ae0684P*E904)
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A LUBRICATION DIAGRAM (ONLY FOR TYPE: F3AE0684P*E904) Figure 20 Dropping oil Pressure oil 104234 Base - May 2007 Print P2D32C003 E...
Page 33: Lubrication Diagram (For Types: F3Ae0684P*E906 - F3Ae0684L*E906 - F3Ae0684P*E905)
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS LUBRICATION DIAGRAM (FOR TYPES: F3AE0684P*E906 - F3AE0684L*E906 - F3AE0684P*E905) Figure 21 Dropping oil Pressure oil 104235 Print P2D32C003 E Base - May 2007...
Page 34: Lubrication Diagram (Engines F3Ae0684N*E907)
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 Base - May 2007 Print P2D32C003 E...
Page 35: Oil Pump
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS Overpressure valve Oil pump Figure 25 Figure 23 73540 60560 The oil pump (1) cannot be overhauled. On finding any MAIN DATA TO CHECK THE OVERPRESSURE damage, replace the oil pump assembly. VALVE SPRING See under the relevant heading for replacing the gear (2) of the crankshaft.
Page 36: Oil Pressure Control Valve
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Oil pressure control valve Figure 27 Figure 26 73543 73542 MAIN DATA TO CHECK THE OIL PRESSURE The oil pressure control valve is located on the left-hand side CONTROL VALVE SPRING of the crankcase. Start of opening pressure 5 bars.
Page 37: Heat Exchanger (Only For Type: F3Ae0684P*E904)
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS Heat exchanger (only for type: F3AE0684P*E904) Figure 29 104237 HEAT EXCHANGER The following elements are fitted on the intercooler: 1. By-pass valve - 2. Oil pressure/temperature sensor - 3. Heat valve. Print P2D32C003 E Base - May 2007...
Page 38: By-Pass Valve
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A By-pass valve This is a new generation of filters that permit much more thorough filtration as they are able to holder back a greater Figure 30 amount of particles of smaller dimensions than those held back by conventional filters with a paper filtering element.
Page 39: Cooling
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;...
Page 40 SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Figure 33 Water flowing out of the thermostat Water circulating in the engine Water flowing into the pump 104238 Base - May 2007 Print P2D32C003 E...
Page 41: Water Pump
CURSOR ENGINES F3A SECTION 1 - GENERAL SPECIFICATIONS Water pump Figure 36 Figure 34 TO THE RADIATOR TO THE EXPANSION TO THE BY PASS FROM THE ENGINE 60748 Water leaving the thermostat 104239 Check the thermostat works properly; replace it if in doubt. Temperature of start of travel 84°C ±2°C.
Page 42: Turbocharging
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A TURBOCHARGING The turbocharging system consists of: - air filter; - Wastegate turbocharger. Figure 37 Exhaust gas Inlet air Compressed air (hot) Intake compressed air 104240 1. TURBOCHARGER HX55 Base - May 2007 Print P2D32C003 E...
Page 43: Egr Exhaust Gas Recirculation System
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 responsi- ble for producing nitrogen oxides (NOx). The exhaust gas recirculation (EGR) system, by reducing the combustion temperature, thus represents an effective NOx emis- sion controlling system.
Page 44 SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 45 CURSOR ENGINES F3A SECTION 2- FUEL SECTION 2 Fuel Page FEEDING ....... FUEL SUPPLY DIAGRAM (ALL TYPES) .
Page 46: Section 2 - Fuel
SECTION 2 - FUEL CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 47 CURSOR ENGINES F3A SECTION 2- FUEL FEEDING Fuel is supplied via a fuel pump, filter and pre-filter, 6 pump-injectors governed by the camshaft via rocker arms and by the electronic control unit. Figure 1 Return circuit Supply circuit 104241 1. Fuel pressure damper - 2. Valve for return circuit, starts opening at 3.5 bars - 3.
Page 48 SECTION 2 - FUEL CURSOR ENGINES F3A FUEL SUPPLY DIAGRAM (ALL TYPES) Figure 2 104242 1. Temperature sensor - 2. Bleed valve - 3. Secondary fuel filter - 4. By-pass valve (0.3 ÷ 0.4 bar) - 5. Fuel supply pump - 6.
Page 49: Fuel Pump
CURSOR ENGINES F3A SECTION 2- FUEL Pumping element Fuel pump The pumping element is operated by a rocker arm governed Figure 3 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.
Page 50 SECTION 2 - FUEL CURSOR ENGINES F3A Figure 6 104245 For each injector replaced, hook up to the diagnostic station and, when asked by the program, enter the code punched on the injector (→) to reprogram the control unit. NOTE When checking the clearance of the rocker arms, it is important to check the injector-pump pre-load.
Page 51 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION SECTION 3 Industrial application Page CLEARANCE DATA ..... PART ONE - MECHANICAL COMPONENTS .
Page 52 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Page -Sensor de temperatura/presión del aire ..-Sensor de presión/temperatura de aceite ..-Alternator ......-Starting motor .
Page 53: Clearance Data
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION CLEARANCE DATA F3AE0684 Type Type P*E904 P*E906 L*E906 P*E905 N*E907 ρ Compression ratio 16.5:1 Max. output (430) (430) (455) (430) (395) (HP) 2100 2100 2100 2100 2100 Max. torque 1900 1900 1900 1900 1820 (kgm)
Page 54 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A CLEARANCE DATA F3AE9687 Type Type A*E001 B*E001 C*E001 ρ Compression ratio 16.5:1 Max. output (428) (394) (360) (HP) 2100 2100 2100 Max. torque 1900 1800 1700 (kgm) (190) (180) (170) 1500 1500 1500 Loadless engine idling...
Page 55: Mechanical Components
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION PART ONE - MECHANICAL COMPONENTS Print P2D32C003 E Base - May 2007...
Page 56 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 57: Engine Disassembly Assembly
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION ENGINE DISASSEMBLY ASSEMBLY Figure 3 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.
Page 58 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 5 Figure 8 104249 For all types excluding F3AE0684P*E904 Using a suitable tool (3), work in the direction of the arrow on the tightener (2) and remove the belt (1). Figure 6 104251 Remove: thermostat assembly (8);...
Page 59 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Figure 10 Figure 12 104252 101960 On the engine exhaust side, remove the following parts: using tool 99360314 unscrew the oil filters (1). oil delivery pipe (1); oil return pipe (4); turbocharger (3); exhaust manifold (2).
Page 60 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 14 Figure 16 104253 For all types except F3AE0684N*E907. Take out the screws (2) and remove the intake manifold (1). 104306 Figure 17 For all types excluding F3AE0684P*E904 only, using tool 99360314 (2), unscrew the oil filters (1).
Page 61 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Figure 19 Figure 21 104256 60496 Unscrew the screws (1) and remove the heat exchanger (4); Unscrew the screws (2) and remove the gear (1) fitted with phonic wheel. unscrew the screws (2) and remove the water line (3). Figure 20 Figure 22 85480...
Page 62 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 23 Figure 26 60498 60501 Unscrew the screws (2) and remove the transmission gear (1). Unscrew the screws (1) and take down the gearbox (2). Figure 27 Figure 24 99364 60499 In sequence, take out the: Stop the engine flywheel (3) rotation by means of tool - idle gear (1);...
Page 63 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Figure 29 Figure 32 116814 60515 Apply tool 99360553 (1) to the rocker holder shaft (2) and - By means of metal ropes, lift the cylinder head (1). remove the shaft (2) from the cylinder head. - Remove the seal (2).
Page 64: Engine Disassembly Assembly
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 35 Figure 38 60515 Check that the pistons 1-6 are exactly at the T.D.C. Put the gasket (2) on the crankcase. 99367 Mount the cylinder head (1) and tighten the screws as shown Undo the screws and remove the suction strainer (1).
Page 65 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Figure 41 NOTE Mount the gear housing within 10 min. of applying the sealant. Figure 44 α 60566 - Closing to angle with tool 99395216 (1): phase: angle of 120°. phase: angle of 60°. Figure 42 α...
Page 66: Engine Flywheel
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: VIEW OF HOLE: 60668 A — B — C DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS A = Hole on flywheel with one reference mark, C = Hole on flywheel with one reference mark, corresponding to the TDC of pistons 3-4.
Page 67: Fitting Camshaft
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Fitting camshaft If the teeth of the ring gear mounted on the engine Figure 50 flywheel, for starting the engine, are very damaged, replace the ring gear. It must be fitted after heating the ring gear to a temperature of approx.
Page 68: Fitting Pump-Injectors
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Fitting pump-injectors Figure 53 Figure 55 104243 Fit the seals (1) (2) (3) on the injectors. 60571 - Fit the idle gear (1) back on and lock the screws (2) to the Figure 56 required torque.
Page 69: Camshaft Timing
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Camshaft timing Figure 58 Figure 60 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.
Page 70 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 61 Figure 63 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 the hole (3) in the engine flywheel (4).
Page 71: Phonic Wheel Timing
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Mount the gear (2) Figure 65 with the 4 slots (1) centred with Figure 65 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.
Page 72: Intake And Exhaust Rocker Play Adjustment And Pre-Loading Of Rockers Controlling Pump Injectors
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors Figure 68 104262 ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS - using an appropriate wrench (4), loosen the adjustment The adjustment of clearance between the rockers and rods screw until the pumping element is at the controlling the intake and exhaust valves, as well as the...
Page 73: Engine Completion
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Figure 69 ENGINE COMPLETION Figure 71 99367 85480 Fit the suction strainer (1) and tighten the fixing screws to the Fit the distribution cover (1). prescribed torque. NOTE The valve rocker arm cover fastening screws (1) shall F3AE0684P*E904 - F3AE0684N*E907 - be tightened according to the sequence shown in F3AE9687A*E001 - F3AE9687B*E001 -...
Page 74 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 73 Check the state of the flexible elements of the control unit support and change them if they have deteriorated. Figure 76 81871 Only for types F3AE0684P*E904 and F3AE0684N*E907 - F3AE9687A*E001 - F3AE9687B*E001 - F3AE9687C*E001 Figure 74 104763 Only for type F3AE0684N*E907 - F3AE9687A*E001 -...
Page 75 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Figure 78 Figure 80 99362 Only for type F3AE0684P*E904 99363 Mount the support (1) and tighten the fixing screws (3). For all types excluding F3AE0684P*E904 Connect the oil pipes (2) to the support (1) tightening the fittings to the prescribed torque.
Page 76 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 82 Figure 85 45359 99258 DIAGRAM OF EXHAUST MANIFOLD FIXING SCREWS TIGHTENING SEQUENCE 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.
Page 77 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Figure 87 Figure 89 104249 104251 For all types excluding F3AE0684P*E904 Fit, with the following parts: Using a suitable tool (3), work in the direction of the arrow on automatic tightener support (1); the tightener (2) and mount the belt (1).
Page 78 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Figure 91 Figure 93 104250 104246 Only for type F3AE0684P*E904 mount the oil pressure adjuster valve (1). 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).
Page 79: Part Two
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION PART TWO - ELECTRICAL EQUIPMENT Print P2D32C003 E Base - May 2007...
Page 80 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 81: Components On The Engine F3A (For All Types Except F3Ae0684P*E904)
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Components on the engine F3A (For all types except F3AE0684P*E904) Figure 1 104263 ENGINE RIGHT-HAND SIDE VIEW Figure 2 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.
Page 82: Components On The Engine F3A (Only For Type F3Ae0684P*E904)
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Components on the engine F3A (only for type F3AE0684P*E904) Figure 3 104307 ENGINE RIGHT-HAND SIDE VIEW Figure 4 104308 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.
Page 83: Components On The Engine F3A (Only For Type F3Ae0684N*E907)
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Components on the engine F3A (only for type F3AE0684N*E907) Figure 5 104765 ENGINE RIGHT-HAND SIDE VIEW Figure 6 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.
Page 84: Components On The Engine F3A (Only For Type F3Ae9687A*E001)
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Components on the engine F3A (only for type F3AE9687A*E001) Figure 7 116711 ENGINE RIGHT-HAND SIDE VIEW Figure 8 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.
Page 85: Block Diagram
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION BLOCK DIAGRAM Figure 9 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.
Page 86: Edc 7 Uc31 Electronic Control Unit
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A EDC 7 UC31 electronic control unit Figure 10 102373 A. Electro-injector connector - B. Chassis connector - C. Sensor connector Base - May 2007 Print P2D32C003 E...
Page 87: Edc Control Unit Pin-Out
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION EDC control unit PIN-OUT Electric injector connector ”A” Figure 11 Colour legend black blue white 102374 purple green brown yellow orange e grey pink Colour legend Function Black Solenoid valve for electronic cylinder 5 injection Black Solenoid valve for electronic cylinder 6 injection Bleu...
Page 88 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A EDC control unit PIN-OUT Sensor connector ”C” Figure 12 Colour legend black blue white purple green brown yellow orange e grey pink 102375 Cable colour Function Free Free Free 4÷8 Free Valve gear camshaft sensor Valve gear camshaft sensor 11÷14 Free...
Page 89 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION EDC control unit PIN-OUT Chassis connector ”B” Figure 13 102376 Cable Function Free 7151 +30 positive 7153 +30 positive Free 0151 Ground 0151 Ground Free 7151 +30 positive 7151 +30 positive 0151 Ground 0151 Ground...
Page 90: Pump Injector
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Pump injector Figure 14 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...
Page 91: Engine Coolant Temperature Sensor
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION 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.
Page 92: Fuel Temperature Sensor
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”) To pin 35 of EDC control unit (Sensor connector ”C”) Base - May 2007 Print P2D32C003 E...
Page 93: Flywheel Pulse Transmitter
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Flywheel pulse transmitter Specifications Supplier BOSCH 8 ± 2 Nm Max. tightening torque Figure 18 104269 Description Cable colour To pin 19 of EDC control unit (Sensor connector ”C”) To pin 23 of EDC control unit (Sensor connector ”C”) Print P2D32C003 E Base - May 2007...
Page 94 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Distribution pulse transmitter Features Vendor BOSCH 8 ± 2 Nm Torque 880 ÷ 920 Ω Resistance 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.
Page 95 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Air pressure/temperature sensor (85156). Figure 20 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.
Page 96: Alternator
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Alternator Supplier MITSUBISHI Technical features 24V - 90A Figure 23 Figure 25 116714 116715 Figure 24 Figure 26 116713 116716 Description + 30 Battery recharge light Negative Positive + 15 Base - May 2007 Print P2D32C003 E...
Page 97: Starting Motor
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Starting motor Specifications Supplier DENSO Type 2280007550 Electrical system 24 Volt Nominal output 5.5 Kw Figure 27 104315 Print P2D32C003 E Base - May 2007...
Page 98: Pre/Post-Heating Resistance
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.
Page 99: Edc System Functions
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION 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...
Page 100 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Injection lead electronic control Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted. Lead is corrected as required: during acceleration according to water temperature...
Page 101 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before 10 seconds at least after engine cutout. In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown memory and the engine operates at lower performance at next start while the EDC warning light stays on.
Page 102 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 103: Part Three - Troubleshooting
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION PART THREE - TROUBLESHOOTING Print P2D32C003 E Base - May 2007...
Page 104 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 105: Preface
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Every time there is a breakdown claim and this breakdown is PREFACE actually detected, it is necessary to proceed inquiring the A successful troubleshooting is carried out with the electronic unit in one of the ways indicated and then proceed with the diagnostic research making trials and tests in order to competence acquired by years of experience and attending training courses.
Page 106: Methods Of Diagnosis
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A METHODS OF DIAGNOSIS The available diagnosis systems are currently: - BLINK CODE - PT-01 - SYMPTOMS PT-01 Figure 1 117696 1. Connector with diagnosis outlet - 2. LED signalling communication between the instrument - control unit and correct power supply - 3.
Page 107: Pt-01 Portable Tester
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Test parameters PT-01 PORTABLE TESTER Engine revolutions; Spark advance; Using PT-01 with portable tester it is possibile to execute troubleshooting and test the EDC7 electronic module of NEF Battery voltage; engines. Accelerator foot pedal position; PT-01 has been designed and developed to ensure stoutness Over voltage pressure;...
Page 108: Failure Codes
SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A FAILURE CODES Component failure Vehicle 1 (Sensors/ Plausibility checks) 1.1.9 PLAUSIBILITY +15 1.1.A PLAUSIBILITY +50 Vehicle 2 (Warning signals / Relays / Actuators) 1.2.5 MAIN RELAY 1.2.6 BATTERY VOLTAGE 1.2.8 MAIN RELAY - BATTERY SHORTED 1.2.9 AIR CONDITIONER COMPRESSOR RELAY 1.2.B...
Page 109 CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Component failure Injectors 1 1.6.1 CYLINDER INJECTOR 1 / SHORT CIRCUIT 1.6.2 CYLINDER INJECTOR 2 / SHORT CIRCUIT 1.6.3 CYLINDER INJECTOR 3 / SHORT CIRCUIT 1.6.4 CYLINDER INJECTOR 4 / SHORT CIRCUIT 1.6.5 CYLINDER INJECTOR 5 / SHORT CIRCUIT 1.6.6...
Page 110 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Component failure ECU 2 (Supplier/ Immobilizer /Runaway speed / Sensor supply) 1.E.3 CONTROL UNIT INTERNAL MONITORING ERROR 1.E.4 CONTROL UNIT INTERNAL MONITORING ERROR 1.E.5 ERRORE SENSOR SUPPLY (12V) 1.E.6 SENSOR SUPPLY 1 1.E.7 SENSOR SUPPLY 2 1.E.8...
Page 111: Section 3 - Industrial Application
CURSOR ENGINES F3A SECTION 3 - INDUSTRIAL APPLICATION Print P2D32C003 E Base - May 2007...
Page 112 SECTION 3 - INDUSTRIAL APPLICATION CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 113 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS SECTION 4 Overhaul and technical specifications Page GENERAL CHARACTERISTICS ... . . ASSEMBLY CLEARANCE DATA ... . ENGINE OVERHAUL .
Page 114 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Page - Fitting connecting rod - piston assemblies in the cylinder liners ....- Checking piston protrusion .
Page 115: General Characteristics
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS GENERAL CHARACTERISTICS Type Cycle 4-stroke Diesel engine Turbocharged Fuel feed Injection Direct No. of cylinders 6 in line ∅ Bore Stroke +.. = Total displacement 10300 Print P2D32C003 E Base - May 2007...
Page 116: Valve Timing
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Type VALVE TIMING opens before T.D.C. 17° closes after B.D.C. 4° opens before B.D.C. 56° closes after T.D.C. 9° For timing check Running 0.35 to 0.45 0.45 to 0.55 Through fuel pump - filters FEED Injection With electronically regulated injectors VIN 3.1...
Page 117: Assembly Clearance Data
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ASSEMBLY CLEARANCE DATA Type CYLINDER BLOCK AND CRANKMECHANISM COMPONENTS ∅ 1 Bores for cylinder liners: 142.000 to 142.025 upper ∅1 140.000 to 140.025 lower Cylinder liners: external diameter: 141.961 to 141.986 upper ∅2 139.890 to 139.915...
Page 118 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Type Type 1.947 * Piston ring grooves 1.550 to 1.570 4.020 to 4.040 Piston rings: trapezoidal seal 1.973 to 1.929 1.973 to 1.929 1.470 to 1.500 lune seal milled scraper ring ill d with slits and internal 3.970 to 3.990...
Page 119 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Type Type Measuring dimension Max. connecting rod axis misalignment 0.08 tolerance ∅1 Main journals - nominal 92.970 to 93.000 - class 92.970 to 92.979 - class 92.980 to 92.989 - class 92.990 to 93.000 ∅...
Page 120: Cylinder Head - Valve Train
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Type CYLINDER HEAD - VALVE TRAIN ∅ 1 Valve guide housings in cylinder head ∅1 14.980 to 14.997 ∅ 9.015 to 9.030 ∅2 ∅2 Valve guide Valve guide ∅3 15.012 to 15.025 ∅...
Page 121 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Table 1 Type Type Valve spring height: free height under a load of: H 2 N 500 ±25 N 972 ±48 48.8 Injector protrusion 1.14 to 1.4 Camshaft bushing housing in the cylinder head: 1 ⇒...
Page 122 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Type Type Bushing housing in rocker arms 45.000 to 45.016 59.000 to 59.019 ∅ 46.000 to 46.016 Bushing outer diameter for rocker arms 45.090 to 45.130 59.100 to 59.140 ∅ 46.066 to 46.091 Bushing inner diameter for rocker arms...
Page 123: Engine Overhaul
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ENGINE OVERHAUL Figure 3 ENGINE REMOVAL AT THE BENCH The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well.
Page 124: Repair Operations
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A REPAIR OPERATIONS Figure 8 CYLINDER BLOCK Checks and measurements (Demonstration) Figure 6 60595 A = Selection class ∅ 125 — 125.013 mm 34994 B = Selection class ∅ 125.011 — 125.024 mm Internal diameter of the cylinder liners is checked for X = Selection class marking area ovalization, taper and wear, using a bore dial (1) centesimal...
Page 125: Cylinder Liners
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Cylinder liners Figure 10 60598 BLOCK WITH CYLINDER LINERS Figure 11 116810 A 125.000 to 125.013 mm Selection class B 125.011 to 125.024 mm CYLINDER LINERS MAIN DATA Figure 12 60601 DETAIL “X”...
Page 126: Replacing Cylinder Liners
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Replacing cylinder liners Figure 15 Refitting Figure 13 60520 47577 Check the protrusion of the cylinder liners, using tool Place details 99360706 (2) and plate 99360726 (4) as shown 99360334 (2) and tightening screw (1) to 225 Nm torque. in the figure, by making sure that the plate (4) is properly Using a dial gauge (3), measure the cylinder liner protrusion, placed on the cylinder liners.
Page 127: Crankshaft
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CRANKSHAFT Figure 18 Upper main journal half bearings Lower main journal half bearings 99369 MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
Page 128: Measuring The Main Journals And Crankpins
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Measuring the main journals and crankpins Figure 23 Before grinding the crank pins using a micrometer (1), measure the main journals and the crank pins (2) and decide, on the basis of the undersizing of the bearings, the final diameter to which the pins are to be ground.
Page 129: Preliminary Measurement Of Main And Big End Bearing Shell Selection Data
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Preliminary measurement of main and big end bearing shell selection data For each of the journals of the crankshaft, it is necessary to carry out the following operations: MAIN JOURNALS: CRANKPINS: - Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the...
Page 130: Selecting The Main And Big End Bearing Shells
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Selecting the main and big end bearing shells NOTE To obtain the required assembly clearances, the main and big end bearing shells need to be selected as described hereunder. This operation makes it possible to identify the most suitable bearing shells for each of the journals (the bearing shells, if necessary, can have different classes from one journal to another).
Page 131 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter) Main journals and crankpins: determining the class of diameter of the journals. Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 26 at top): - The first number, of five digits, is the part number of the shaft.
Page 132 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A SELECTING THE MAIN BEARING SHELLS (Journals with nominal diameter) After reading off the data, for each of the main journals, on the crankcase and crankshaft, you choose the type of bearing shells to use according to the following table: Figure 27 STD.
Page 133 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS SELECTING THE MAIN BEARING SHELLS (GROUND JOURNALS) If the journals have been ground, the procedure described so far cannot be applied. In this case, it is necessary to check that the new diameter of the journals is as shown in the table and to mount the only type of bearing shell envisaged for the relevant undersizing.
Page 134 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A SELECTING THE BIG END BEARING SHELLS Figure 29 (JOURNALS WITH NOMINAL DIAMETER) There are three markings on the body of the connecting rod in the position shown in the view from ”A”: Letter indicating the class of weight: VIEW FROM “A”...
Page 135 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS SELECTING BIG END BEARING SHELLS (GROUND JOURNALS) If the journals have been ground, the procedure described so far cannot be applied. In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of the crankpins and to mount the bearing shells identified with the relevant table.
Page 136: Replacing The Timing Gear And Oil Pump
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Replacing the timing gear Figure 34 and oil pump Check that the toothing of the gear is neither damaged nor worn; if it is, take it out with an appropriate extractor and replace it.
Page 137: Front Side
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 36 Figure 37 α 60559 Set two journals of the crankshaft (2) parallel to the 47578 longitudinal axis, a section of calibrated wire. Using - Lubricate the internal screws (1) with UTDM oil and appropriate hooks and tackle, mount the crankcase base (1).
Page 138: Assembling The Engine On The Bench
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A ASSEMBLING ENGINE Figure 44 BENCH Figure 41 49022 Fit the underblock by means of a suitable hoist and hooks (1). Figure 45 49021 Place the half-bearings (1) on the main bearings in the underblock (2).
Page 139 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 47 stage 1: FRONT SIDE pretightening outer screws (30 Nm) 60592 stage 2: FRONT SIDE pretightenig inner screws (120 Nm) 60593 stage 3: FRONT SIDE angle inner screws (90º) 60593 stage 4: FRONT SIDE...
Page 140: Piston Connecting Rod Assembly
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Piston connecting rod assembly Figure 48 60607 PISTON CONNECTING ROD ASSEMBLY 1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6.
Page 141 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 51 Figure 53 49025 32618 Remove the piston pin (1). Measuring the gudgeon pin diameter (1) with a micrometer (2). If removal is difficult use the appropriate beater. Measuring the diameter of the pistons Figure 52 Conditions for correct gudgeon pin-piston coupling 47584...
Page 142: Piston Rings
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Figure 55 116811 MAIN DATA OF THE PISTON, PISTON RINGS AND PIN Piston rings Figure 58 Figure 56 3513 The sealing ring (2) of the 1st cavity is trapezoidal. Clearance “X”...
Page 143: Connecting Rods
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Connecting rods Figure 60 Data concerning the class section of connecting rod housing and weight are stamped on the big end. VIEW FROM “A” NOTE When installing connecting rods, make sure they all belong to the same weight class.
Page 144: Bushings
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Bushings Figure 64 Figure 62 73535 74052 Check the bushing in the small end has not come loose and shows no sign of scoring or seizure; replace it if it does. Fit the pin (2) and fasten it on the piston (1) with the split rings The bushing (2) is removed and fitted with a suitable drift (1).
Page 145: Fitting The Big End Bearing Shells
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Fitting the big end bearing shells Figure 66 49030 Fit the bearing shells (1), selected as described under the heading ”Selecting the main and big end bearing shells”, on both the connecting rod and the cap. If reusing bearing shells that have been removed, fit them back into their respective seats in the positions marked during removal.
Page 146: Checking Piston Protrusion
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Checking piston protrusion On completing assembly, check the protrusion of the pistons from the cylinder liners; it must be 0.23 — 0.53 mm. Figure 68 60615 ASSEMBLY DIAGRAM OF CONNECTING ROD — PISTON ASSEMBLY IN CYLINDER LINER 1.
Page 147: Checking The Planarity Of The Head On The Cylinder Block
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Checking the planarity of the head on the Checking crankpin assembly clearance cylinder block To check the clearance proceed as follows. Connect the connecting rods to the relative main journals, Figure 71 (Demonstration) place a length of calibrated wire on the latter.
Page 148: Valves
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Valves Figure 74 Figure 73 41032 Check the valve seats (2). If you find any slight scoring or 60617 burns, regrind the surfaces (1) according to the angles shown in Figure 73 and Figure 75. If it is necessary to replace them, MAIN DATA OF VALVES AND VALVE GUIDES and taking care not to affect the cylinder head, remove as * Measurement to be made after driving in the valve guides...
Page 149: Checking Clearance Between Valve-Stem And Associated Valve Guide
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Checking clearance between valve-stem and Replacing injector cases associated valve guide Removal Using a dial gauge with a magnetic base, check the clearance between the valve stem and the associated guide. If the clearance is too great, change the valve and, if necessary, the Figure 77 valve guide.
Page 150 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Assembly Figure 78 Figure 80 60622 - Lubricate the seals (3) and fit them on the case (4). Using tool 99365056 (2) secured to the cylinder head with bracket A, drive in the new case, screwing down the screw (1) upsetting the bottom portion of the case.
Page 151: Checking Injector Protrusion
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 82 Figure 84 116812 INJECTOR CASE ASSEMBLY DIAGRAM 60624 - Using grinder 99394041 (1-2), ream the injector seat in the case (3), check the injector protrusion from the cylinder head plane which must be 1.14 to 1.4 mm. Checking injector protrusion Figure 83 47585...
Page 152: Timing Gear
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A TIMING GEAR Twin intermediate gear pin Camshaft drive Twin idler gear Figure 85 Figure 87 86925 TIMING CONTROL COMPONENT PARTS 86934 1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod - 5.
Page 153: Camshaft
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Camshaft Checking cam lift and pin alignment Figure 88 47506 Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2). Figure 89 47507 When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2);...
Page 154: Camshaft
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A ‘ Camshaft Figure 91 60626 MAIN DATA - CAMSHAFT AND TOLERANCES The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring, replace the shaft and the relative bushes.
Page 155 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Replacing camshaft bushings with drift 99360499 Figure 93 107217 A = Drift with seat for bushings to insert/extract. = Grub screw for positioning bushings. C = Reference mark to insert seventh bushing correctly. D = Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (red marks).
Page 156: Valve Springs
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Valve springs Figure 96 Front Figure 98 Rear 70000 71723 Indicative figure. Before assembly, check the efficiency of the spring. To insert the bushing (6), proceed as follows: Compare the load and elastic deformation data with those of the new springs given in the following figure.
Page 157: Fitting Valves And Oil Seal
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Fitting valves and oil seal Figure 101 Figure 100 86290 - Mount the springs (6) and the top plate (5). - Fit the tool 99360262 (2) and secure it with the bracket (4).
Page 158: Shaft
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Shaft Figure 103 73539 MAIN DATA OF THE ROCKER ARM SHAFT Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it. Rocker arms Figure 104 SECTION A-A...
Page 159: Tightening Torque
CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TIGHTENING TORQUE TORQUE PART PART Capscrews, undercrankcase to crankcase ♦ M12x1.75 outer screws Stage 1: pretightening M 17x2 inner screws Stage 2: pretightening Inner screws Stage 3: angle 90° Inner screws Stage 4: angle 45°...
Page 160 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A TORQUE PART PART Screws fixing damper flywheel: ♦ First phase pre-tightening Second phase closing to angle 50° Screws fixing intermediate gear pins: ♦ First phase pre-tightening Second phase closing to angle 90°...
Page 161 CURSOR ENGINES F3A SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TORQUE PART PART 8 ± 2 0.8 ± 0.2 Pressure transmitter fastener 32.5 ± 2.5 3.2 ± 0.2 Water/fuel temperature sensor fastener 23 ± 2.5 2.5 ± 0.2 Thermometric switch/transmitter fastener 32.5 ±...
Page 162 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 163 CURSOR ENGINES F3A SECTION 5 - TOOLS SECTION 5 Tools Page TOOLS ....... . Print P2D32C003 E Base - May 2007...
Page 164 SECTION 5 - TOOLS CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 165 CURSOR ENGINES F3A SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 8093731 Tester PT01 Rotary telescopic stand (range 2000 daN, torque 375 daNm) 99322230 99340053 Extractor for crankshaft front gasket 99340054 Extractor for crankshaft rear gasket 99340205 Percussion extractor 99342149 Extractor for injector-holder Print P2D32C003 E Base - May 2007...
Page 166 SECTION 5 - TOOLS CURSOR ENGINES F3A TOOLS TOOL NO. DESCRIPTION 99346250 Tool to install the crankshaft front gasket 99346251 Tool to install the crankshaft rear gasket 99348004 Universal extractor for 5 to 70 mm internal components 99350072 Box wrench for block junction bolts to the underblock 99360180 Injector housing protecting plugs (6) Pliers for assembling and disassembling piston split rings...
Page 167 CURSOR ENGINES F3A SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION Tool to take down-fit engine valves 99360261 (to be used with special plates) Plate for take down-fit engine valves 99360262 (to be used with 99360261) 99360295 Tool to fit back valve guide (to be used with 99360481) 99360314 Tool to remove oil filter (engine) 99360321...
Page 168 SECTION 5 - TOOLS CURSOR ENGINES F3A TOOLS TOOL NO. DESCRIPTION 99360328 Tool to install gasket on valve guide Compression tool for checking the protrusion of cylinder liners 99360334 (to be used with 99370415-99395603 and special plates) 99360336 Spacer (to be used with 99360334) Cylinder liner compression plate 99360337 (to be used with 99360334-99360336)
Page 169 CURSOR ENGINES F3A SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION Tool to take down and fit back camshaft bushes 99360499 99360500 Tool to lift crankshaft 99360553 Tool for assembling and installing rocker arm shaft 99360585 Swing hoist for engine disassembly assembly Belt to insert piston in cylinder liner (60 - 125 mm) 99360605 99360612...
Page 170 SECTION 5 - TOOLS CURSOR ENGINES F3A TOOLS TOOL NO. DESCRIPTION 99360613 Tool for timing of phonic wheel on timing gear 99360703 Tool to stop cylinder liners 99360706 Tool to extract cylinder liners (to be used with specific rings) 99360726 Ring (125 mm) (to be used with 99360706) 99361036 Brackets fixing the engine to rotary stand 99322230...
Page 171 CURSOR ENGINES F3A SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99370415 Base supporting the dial gauge for checking cylinder liner protrusion (to be used with 99395603) Torque screwdriver for calibrating the injector solenoid 99389834 valve connector check nut 99390311 Valve guide sleeker 99390426 Male (M 17 x 2) - for a revision of threaded holes screw joint of...
Page 172 SECTION 5 - TOOLS CURSOR ENGINES F3A TOOLS TOOL NO. DESCRIPTION 99390805 Guide bush (to be used with 99390804) 99394015 Guide bush (to be used with 99394041 or 99394043) Cutter to rectify injector holder housing 99394041 (to be used with 99394015) Reamer to rectify injector holder lower side 99394043 (to be used with 99394015)
Page 173 CURSOR ENGINES F3A SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99395603 Dial gauge (0 - 5 mm) Centering ring of crankshaft front gasket cap 99396035 Print P2D32C003 E Base - May 2007...
Page 174 SECTION 5 - TOOLS CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 175 CURSOR ENGINES F3A APPENDIX Appendix Page SAFETY PRESCRIPTIONS ....- Standard safety prescription ....- Prevention of injury .
Page 176 APPENDIX CURSOR ENGINES F3A Base - May 2007 Print P2D32C003 E...
Page 177: Safety Prescriptions
CURSOR ENGINES F3A APPENDIX - Do not execute any intervention if not provided with SAFETY PRESCRIPTIONS necessary instructions. Standard safety prescriptions Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different must be followed absolutely in a standard working area and operation from the ones they’ve been designed and whose non fulfillment will make any other measure useless...
Page 178 APPENDIX CURSOR ENGINES F3A - Avoid incorrect tightening or out of couple. Danger: Respect of the Environment incorrect tightening may seriously damage engine’s - Respect of the Environment shall be of primary components, affecting engine’s duration. importance: all necessary precautions to ensure - Avoid priming from fuel tanks made out of copper alloys personnel’s safety and health shall be adopted.
Page 179: Preface To User's Guideline Manual
F3B CURSOR ENGINES Part 2 F3B CURSOR ENGINES Section General specifications Fuel Industrial application Overhaul and technical specifications Tools Appendix Safety prescriptions PREFACE TO USER’S GUIDELINE MANUAL Section 1 describes the F3B engine illustrating its features and working in general. Section 2 describes the type of fuel feed.
Page 180 F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 181: Special Remarks
F3B CURSOR ENGINES 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...
Page 182 F3B CURSOR ENGINES SYMBOLS - ASSISTANCE OPERATIONS Removal Intake Disconnection Refitting Exhaust Connection Removal Operation Disassembly Fitting in place ρ Compression ratio Assembly Tolerance Tighten to torque Weight difference Tighten to torque + angle value Rolling torque α Press or caulk Rotation Regulation Angle...
Page 183 F3B CURSOR ENGINES UPDATING Section Description Page Date of revision Print P2D32C003 E Base - May 2007...
Page 184 F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 185: General Specifications
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General specifications Page CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE ... . . VIEWS OF ENGINE (FOR TYPES: F3BE0684H*E901 - F3BE0684G*E901) .
Page 186 SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 187: Commercial Code
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE Technical Code Commercial Code F3BE0684H*E901 F3BE0684G*E901 F3BE0684J*E902 C13 ENT X C13 ENT X F3BE9687A*E001 F3BE9687B*E001 F3BE9687C*E001 Print P2D32C003 E Base - May 2007...
Page 188 SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 189: Views Of Engine (For Types: F3Be0684H*E901 - F3Be0684G*E901)
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS VIEWS OF ENGINE (FOR TYPES: F3BE0684H*E901 - F3BE0684G*E901) Figure 1 104768 LEFT-HAND SIDE VIEW Figure 2 104769 RIGHT-HAND SIDE VIEW Print P2D32C003 E Base - May 2007...
Page 190: Front View
SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES Figure 3 104770 FRONT VIEW Figure 4 104275 REAR VIEW Base - May 2007 Print P2D32C003 E...
Page 191: Top View
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS Figure 5 104771 TOP VIEW Print P2D32C003 E Base - May 2007...
Page 192: Views Of Engine (Only For Type F3Be0684J*E902)
SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES VIEWS OF ENGINE (ONLY FOR TYPE F3BE0684J*E902) Figure 6 104772 LEFT-HAND SIDE VIEW Figure 7 104773 RIGHT-HAND SIDE VIEW Base - May 2007 Print P2D32C003 E...
Page 193 F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS Figure 8 104774 FRONT VIEW Figure 9 104775 REAR VIEW Print P2D32C003 E Base - May 2007...
Page 194 SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES Figure 10 104776 TOP VIEW Base - May 2007 Print P2D32C003 E...
Page 195: Views Of Engine
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS VIEWS ENGINE (ONLY TYPES: F3BE9687A*E001 F3BE9687B*E001 F3BE9687C*E001) Figure 11 116765 LEFT-HAND SIDE VIEW Figure 12 116766 RIGHT-HAND SIDE VIEW Print P2D32C003 E Base - May 2007...
Page 196 SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES Figure 13 116767 FRONT VIEW Figure 14 116768 TOP VIEW Base - May 2007 Print P2D32C003 E...
Page 197: Lubrication Diagram
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS LUBRICATION DIAGRAM (ONLY FOR TYPES F3BE0684J*E902 - F3BE9687A*E001 - F3BE9687B*E001 - F3BE9687C*E001) Figure 15 Dropping oil Pressure oil 104778 Print P2D32C003 E Base - May 2007...
Page 198: For Types: (F3Be0684G*E901 - F3Be0684H*E901)
SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES For types: (F3BE0684G*E901 - F3BE0684H*E901) Figure 16 Dropping oil Pressure oil 106770 Base - May 2007 Print P2D32C003 E...
Page 199 F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS Overpressure valve Oil pump Figure 17 Figure 19 60560 73540 The oil pump (1) cannot be overhauled. On finding any MAIN DATA TO CHECK THE OVERPRESSURE damage, replace the oil pump assembly. VALVE SPRING See under the relevant heading for replacing the gear (2) of the crankshaft.
Page 200: Oil Pressure Control Valve
SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES Oil pressure control valve Figure 21 Figure 20 73542 73543 The oil pressure control valve is located on the left-hand side MAIN DATA TO CHECK THE OIL PRESSURE of the crankcase. CONTROL VALVE SPRING Start of opening pressure 5 bars.
Page 201: By-Pass Valve
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS By-pass valve This is a new generation of filters that permit much more thorough filtration as they are able to holder back a greater Figure 23 amount of particles of smaller dimensions than those held back by conventional filters with a paper filtering element.
Page 202: Cooling
SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES COOLING Figure 26 Water flowing out of the thermostat Water circulating in the engine Water flowing into the pump 104278 ILLUSTRATIVE DIAGRAM Base - May 2007 Print P2D32C003 E...
Page 203: Water Pump
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS Water pump Figure 29 Figure 27 TO THE RADIATOR TO THE EXPANSION TO THE BY PASS FROM THE ENGINE 60748 Water leaving the thermostat 104239 Check the thermostat works properly; replace it if in doubt. Temperature of start of travel 84°C ±2°C.
Page 204: Turbocharging
SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES TURBOCHARGING The turbocharging system consists of: - air filter; - turbocharger. ILLUSTRATIVE DIAGRAM Figure 30 Exhaust gas Inlet air Compressed air (hot) Intake compressed air 116769 TURBOCHARGER HX55 Base - May 2007 Print P2D32C003 E...
Page 205: Egr Exhaust Gas Recirculation System
F3B CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS EGR EXHAUST GAS RECIRCULATION SYSTEM (ONLY FOR F3BE0684J*E902) The exhaust gases may be partially conveyed back into the cylinders to reduce the maximum combustion temperature responsi- ble for producing nitrogen oxides (NOx). The exhaust gas recirculation (EGR) system, by reducing the combustion temperature, thus represents an effective NOx emis- sion controlling system.
Page 206: Early Closing System For The Intake Valves
SECTION 1 - GENERAL SPECIFICATIONS F3B CURSOR ENGINES EARLY CLOSING SYSTEM FOR THE INTAKE VALVES (”MILLER” CYCLE) - (FOR TYPES F3BE0684H*E901 - F3BE9687A*E001 - F3BE9687B*E001 - F3BE9687C*E001) The ”Miller” system is used to reduce the maximum combustion temperature in the cylinder, which is responsible for producing nitrogen oxides (NOx).
Page 207 F3B CURSOR ENGINES SECTION 2 - FUEL SECTION 2 Fuel Page FEEDING ....... FUEL SUPPLY DIAGRAM .
Page 208 SECTION 2 - FUEL F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 209 F3B CURSOR ENGINES SECTION 2 - FUEL FEEDING Fuel is supplied via a fuel pump, filter and pre-filter, 6 pump-injectors governed by the camshaft via rocker arms and by the electronic control unit. Figure 1 Return circuit Supply circuit 104280 1.
Page 210 SECTION 2 - FUEL F3B CURSOR ENGINES FUEL SUPPLY DIAGRAM Figure 2 104242 1. Temperature sensor - 2. Bleed valve - 3. Secondary fuel filter - 4. By-pass valve (0.3 ÷ 0.4 bar) - 5. Fuel supply pump - 6. Integrated valve (3.5 bar) - 7. Pressure relief valve (5 bar) - 8. Fuel tank - 9. Priming pump - 10. Primary fuel filter - 11.
Page 211 F3B CURSOR ENGINES SECTION 2 - FUEL Pumping element Fuel pump The pumping element is operated by a rocker arm governed Figure 3 directly by the cam of the camshaft. The pumping element is able to ensure a high delivery pressure.
Page 212 SECTION 2 - FUEL F3B CURSOR ENGINES Figure 6 104245 For each injector replaced, hook up to the diagnostic station and, when asked by the program, enter the code punched on the injector (→) to reprogram the control unit. NOTE When checking the clearance of the rocker arms, it is important to check the injector-pump pre-load.
Page 213: Industrial Application
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION SECTION 3 Industrial application Page CLEARANCE DATA ..... PART ONE - MECHANICAL COMPONENTS .
Page 214 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Page INJECTOR PUMP ......- Engine coolant temperature sensor .
Page 215: Clearance Data
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION CLEARANCE DATA Type F3BE0684H*E901 F3BE0684G*E901 F3BE0684J*E902 ρ 16.5 ± 0.8 Compression ratio Max. output (441) (389) (467) (HP) 2000 2000 2100 Max. torque 2164 1914 2144 (kgm) (216) (191) (214) 1400 1400 1500 Loadless engine...
Page 216 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES CLEARANCE DATA F3BE9687 Type Type A*E001 B*E001 C*E001 ρ 16.5 ± 0.8 Compression ratio Max. output (442) (476) (510) (HP) 2100 2100 2100 Max. torque 2140 2140 2140 (kgm) (218) (218) (218) 1400 1400 1400...
Page 217: Part One
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION PART ONE - MECHANICAL COMPONENTS Print P2D32C003 E Base - May 2007...
Page 218 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 219: Assembling And Disassembling The Engine
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION ASSEMBLING AND DISASSEMBLING THE Figure 3 ENGINE Handle all parts with great care. Never put your hands or fingers between one part and another. Wear suitable personal protective equipment such as a visor, gloves and safety shoes. Cover all electrical components before washing with high-pressure water jets.
Page 220 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Only for types: F3BE0684J*E902 - F3BE9687A*E001 - Figure 5 F3BE9687B*E001 - F3BE9687C*E001 Figure 7 104247 Remove the engine supports; 104249 remove the drive (1). Using a suitable tool (3), work in the direction of the arrow on the tightener (2) and remove the belt (1).
Page 221 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 9 Figure 11 104252 On the engine exhaust side, remove the following parts: oil delivery pipe (1); oil return pipe (4); turbocharger (3); 104251 exhaust manifold (2). Remove: thermostat assembly (8); Figure 12 pipes complete with coolant (6);...
Page 222 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Figure 14 Figure 16 85480 Remove the rocker arm cover (1), take off the screws (2) and 104783 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). Loosen the screws (1) and remove the intake manifold (2) from the engine.
Page 223 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 19 Figure 22 60498 60501 Unscrew the screws (2) and remove the transmission gear (1). Unscrew the screws (1) and take down the gearbox (2). Figure 20 Figure 23 99364 60499 Stop the engine flywheel (3) rotation by means of tool In sequence, take out the: 99360351 (1), unscrew the fixing screws (2) and remove the...
Page 224 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Figure 25 Figure 28 60515 116814 - By means of metal ropes, lift the cylinder head (1). Apply tool 99360553 (1) to the rocker holder shaft (5) and - Remove the seal (2) remove the shaft (5) from the cylinder head.
Page 225 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 31 Figure 34 60515 Check that the pistons 1-6 are exactly at the T.D.C. 101607 Put the gasket (2) on the crankcase. Mount the cylinder head (1) and tighten the screws as shown Loosen the screws, then remove suction strainer (1).
Page 226 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Figure 37 NOTE Mount the gear housing within 10 min. of applying the sealant. Figure 40 α 60566 - Closing to angle with tool 99395216 (1): phase: angle of 120°. phase: angle of 60°. Figure 38 α...
Page 227 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Only for types: F3BE0684J*E902 - F3BE9687A*E001 - Mount the gear housing within 10 min. of applying NOTE F3BE9687B*E001 - F3BE9687C*E001 the sealant. Figure 42 Figure 43 104785 Apply LOCTITE 5970 IVECO n˚ 2992644 silicone on the gear housing, using appropriate tools (1), as shown in the figure.
Page 228: Engine Flywheel
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES ENGINE FLYWHEEL Fitting engine flywheel (For types: F3BE0684H*E901 - F3BE0684G*E901) Figure 45 104283 VIEW OF HOLES: VIEW OF A — B — C HOLE: D DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS A = Hole on flywheel with one reference mark, C = Hole on flywheel with one reference mark, corresponding to the TDC of pistons 3-4.
Page 229 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Fitting camshaft For all types Figure 49 Figure 47 104286 60570 - Apply the gauge 99395219 (1). Check and adjust the Position the crankshaft with the pistons 1 and 6 at the top dead centre (T.D.C.).
Page 230: Fitting Pump-Injectors
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Figure 51 Figure 53 60572 104260 Position the gear (2) on the camshaft so that the 4 slots are Mount: centred with the holes for fixing the camshaft, without fully - The injectors (1) and, using a torque wrench, lock the locking the screws (5).
Page 231 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Camshaft timing Figure 55 (For types: F3BE0684N*E901 - F3BE0684G*E901) Figure 57 70567A SCHEME OF SCREW TIGHTENING SEQUENCE 104316 SECURING ROCKER ARMS Using the tool, turn the engine flywheel (1) in the direction of Screw screws (1 - 2 - 3) until rocker arms are brought to rotation of the engine so as to take the piston of cylinder no.1 contact relating seats on cylinder head, tighten the screws...
Page 232 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES For all types Figure 61 Figure 59 104286 The camshaft is in step if at the cam lift values of 5.45 ±0.05 mm 104288 there are the following conditions: The exact position of piston no.1 at the T.D.C. is obtained 1) the hole marked with a notch (5) can be seen through the when in the above-described conditions the tool 99360612 inspection window;...
Page 233: Phonic Wheel Timing
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Mount the gear (2) Figure 63 with the 4 slots (1) centred with Figure 63 the fixing holes of the camshaft, locking the relevant screws to the required tightening torque. Check the timing of the shaft by first turning the flywheel clockwise to discharge the cylinder completely and then turn the flywheel anticlockwise until the dial gauge gives a reading of 5.45 ±0.05.
Page 234: Intake And Exhaust Rocker Play Adjustment And Pre-Loading Of Rockers Controlling Pump Injectors
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors Figure 66 116815 ADJUSTING INTAKE/EXHAUST ROCKERS AND INJECTION - Lock the adjusting screw to a torque of 5 Nm (0.5 kgm) Adjustment of clearances between rockers and valve studs and preloading of pump injector rockers should be carried out by means of a torque wrench.
Page 235 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 67 Figure 68 45363 DIAGRAM OF ROCKER ARM CAP FIXING SCREWS TIGHTENING SEQUENCE 85480 Fit the distribution cover (1). The rocker arm cover lock screws (1) must be NOTE tightened in the order indicated in NO TAG. Fit the blow-by case (7) and its gasket and then tighten the screws (8) to the prescribed torque.
Page 236: Engine Completion
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES ENGINE COMPLETION For all types except: F3BE0684J*E902 - F3BE9687A*E001 - F3BE9687B*E001 - F3BE9687C*E001 Figure 69 Figure 71 101607 Fit the strainer (1) and tighten the lock screw to the torque 104784 prescribed. Place gasket (4) on oil sump (1), position spacer (2) and fit the sump onto the engine base by tightening screws (3) to the specified torque, by complying with the tightening sequence...
Page 237 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 73 Figure 75 104310 Tightening the fixing screws to the prescribed torque, mount: the starter motor (1); 101605 the control unit (2) and its support; Fit heat exchanger (2) with its respective gasket, then tighten the oil dipstick (3) in the crankcase.
Page 238 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Figure 77 Figure 79 45360 104254 Fit, with the respective gaskets. DIAGRAM OF TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING SEQUENCE the fuel pump (2); fuel filter unit (3) with its respective pipes (1); SEQUENCE: Preliminary tightening 4 - 3 - 1 - 2 Tightening...
Page 239 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Only for type: F3BE0684J*E902 Figure 83 Figure 81 104249 104251 Fit, with the following parts: Using a suitable tool (3), work in the direction of the arrow on the tightener (2) and mount the belt (1). automatic tightener support (1);...
Page 240 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Figure 87 Only for types: F3BE9687A*E001 - F3BE9687B*E001 - F3B9687C*E001 Figure 86 106223 - driving belt. To mount belt (1), belt tensioner (2) has to be operated by proper tooling (3) according to the direction indicated by the 108845 arrow in Figure.
Page 241 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION For all types Only for types: F3BE0684H*E901 and F3BE0684G*E901 Figure 88 Figure 90 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.
Page 242 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Assemble the alternator support (3) on the engine and tighten the locking screws to the specified torque. Assemble the alternator (4) and tighten the locking screws to the specified torque value. Assemble the compressor (1) complete with its support (2) on the engine and tighten the locking screws to the specified torque.
Page 243: Part Two
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION PART TWO - ELECTRICAL EQUIPMENT Print P2D32C003 E Base - May 2007...
Page 244 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 245 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Components on the engine F3B (For types: F3BE0684H*E901 - F3BE0684G*E901) Figure 1 104790 ENGINE RIGHT-HAND SIDE VIEW Figure 2 104791 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.
Page 246: F3Be0684J*E902)
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Components on the engine F3B (Only for type: F3BE0684J*E902) Figure 3 104792 ENGINE RIGHT-HAND SIDE VIEW Figure 4 104793 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.
Page 247 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Components on the engine F3B (F3BE9687A*E001 - F3BE9687B*E001 - F3BE9687C*E001) Figure 5 ENGINE RIGHT-HAND SIDE VIEW 116818 Figure 6 116819 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.
Page 248: Block Diagram
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES BLOCK DIAGRAM Figure 7 116816 KEYS 1. Engine coolant temperature sensor — 2. Oversupply air pressure temperature sensor — 3. Fuel temperature sensor — 4. Oversupply air pressure sensor — 5. Engine oil pressure and temperature sensor - 6. CAL L-H line — 7. Pump-injectors — 8.
Page 249: Edc 7 Uc31 Electronic Control Unit
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION EDC 7 UC31 electronic control unit Figure 8 102373 A. Electro-injector connector - B. Chassis connector - C. Sensor connector. Print P2D32C003 E Base - May 2007...
Page 250: Edc Control Unit Pin-Out
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES EDC control unit PIN-OUT Electric injector connector ”A” Figure 9 Colour legend black blue 102374 white purple green brown yellow orange grey pink Colour legend Function Black Solenoid valve for electronic cylinder 5 injection Black Solenoid valve for electronic cylinder 6 injection Black...
Page 251 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION EDC control unit PIN-OUT Sensor connector ”C” Figure 10 Colour legend black blue white purple green brown yellow orange grey pink 102375 Cable colour Function 1÷8 Free Valve gear camshaft sensor Valve gear camshaft sensor 11÷14 Free Coolant temperature sensor...
Page 252 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES EDC control unit PIN-OUT Chassis connector ”B” Figure 11 102376 Cable Function Free 7151 +30 positive 7153 +30 positive Free 0151 Ground 0151 Ground Free 7151 +30 positive 7151 +30 positive 0151 Ground 0151 Ground...
Page 253: Injector Pump
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION INJECTOR PUMP Figure 12 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. The fuel pressure damper situated on the discharge line Figure 13 between the fuel filter and the cylinder head, has the function...
Page 254: Engine Coolant Temperature Sensor
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES 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.
Page 255: Fuel Temperature Sensor
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Fuel temperature sensor Specifications Supplier BOSCH Max. tightening torque 35 Nm Figure 15 104267 Description Cable colour To pin 18 of EDC control unit (Sensor connector ”C”) To pin 35 of EDC control unit (Sensor connector ”C”) Print P2D32C003 E Base - May 2007...
Page 256: Flywheel Pulse Transmitter
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Flywheel pulse transmitter Specifications Supplier BOSCH 8 ± 2 Nm Max. tightening torque Figure 16 104269 Description Cable colour To pin 19 of EDC control unit (Sensor connector ”C”) To pin 23 of EDC control unit (Sensor connector ”C”) Base - May 2007 Print P2D32C003 E...
Page 257: Distribution Pulse Transmitter
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Distribution pulse transmitter Features Vendor BOSCH 8 ± 2 Nm Torque 880 ÷ 920 Ω Resistance 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.
Page 258 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Air pressure/temperature sensor (85156). Figure 18 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.
Page 259: F3Be0684G*E901)
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Alternator (For types: F3BE0684H*E901 - F3BE0684G*E901) Supplier ISKRA Technical features 14V - 175A Figure 21 104313 Print P2D32C003 E Base - May 2007...
Page 260: Alternator (For Type: F3Be0684J*E902)
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Alternator (For type: F3BE0684J*E902) Supplier LEECE NEVILLE Technical features 12V - 185A Figure 22 104314 Description AC Connector Driver warning light connector Negative Positive Base - May 2007 Print P2D32C003 E...
Page 261: Alternator (For Types: F3Be9687A*E001 - F3Be9687B*E001 - F3Be9687C*E001)
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Alternator (For types: F3BE9687A*E001 - F3BE9687B*E001 - F3BE9687C*E001) Supplier MITSUBISHI Technical features 24V - 90A Figure 23 Figure 25 116714 116715 Figure 24 Figure 26 116713 116716 Description + 30 Battery recharge light Negative Positive + 15...
Page 262: Starting Motor
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Starting motor Specifications Supplier DENSO Type 2280007550 Electrical system 24 Volt Nominal output 5.5 Kw Figure 27 104315 Base - May 2007 Print P2D32C003 E...
Page 263: Pre/Post-Heating Resistance
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 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.
Page 264: Edc System Functions
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES EDC SYSTEM FUNCTIONS The EDC 7 UC31 electronic center manages the following main functions: Fuel injection Accessory functions such as cruise control, speed limiter, PTO and the like Self-diagnosis Recovery It also enables: Interfacing with other electronic systems (if any) available on the vehicle Diagnosis Fuel dosing...
Page 265 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Injection lead electronic control Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder to another and is calculated similarly to delivery according to engine load, namely, accelerator position, engine rpm and air admitted. Lead is corrected as required: during acceleration according to water temperature...
Page 266 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES This procedure must never be interrupted, by cutting the engine off from the battery cutout or disconnecting the latter before 10 seconds at least after engine cutout. In this case, system operation is guaranteed until the fifth improper engine cutout, after which an error is stored in the breakdown memory and the engine operates at lower performance at next start while the EDC warning light stays on.
Page 267: Part Three - Troubleshooting
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION PART THREE - TROUBLESHOOTING Print P2D32C003 E Base - May 2007...
Page 268 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 269: Methods Of Diagnosis
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION METHODS OF DIAGNOSIS The available diagnosis systems are currently: - BLINK CODE - PT-01 - SYMPTOMS PT-01 Figure 1 117696 1. Connector with diagnosis outlet - 2. LED signalling communication between the instrument - control unit and correct power supply - 3.
Page 270: Preface
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Every time there is a breakdown claim and this breakdown is PREFACE actually detected, it is necessary to proceed inquiring the A successful troubleshooting is carried out with the electronic unit in one of the ways indicated and then proceed with the diagnostic research making trials and tests in order to competence acquired by years of experience and attending training courses.
Page 271: Pt-01 Portable Tester
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Test parameters PT-01 PORTABLE TESTER Engine revolutions; Spark advance; Using PT-01 with portable tester it is possibile to execute troubleshooting and test the EDC7 electronic module of NEF Battery voltage; engines. Accelerator foot pedal position; PT-01 has been designed and developed to ensure stoutness Over voltage pressure;...
Page 272: Failure Codes
SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES FAILURE CODES Component failure Vehicle 1 (Sensors/ Plausibility checks) 1.1.9 PLAUSIBILITY +15 1.1.A PLAUSIBILITY +50 Vehicle 2 (Warning signals / Relays / Actuators) 1.2.5 MAIN RELAY 1.2.6 BATTERY VOLTAGE 1.2.8 MAIN RELAY - BATTERY SHORTED 1.2.9 AIR CONDITIONER COMPRESSOR RELAY 1.2.B...
Page 273 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Component failure Injectors 1 1.6.1 CYLINDER INJECTOR 1 / SHORT CIRCUIT 1.6.2 CYLINDER INJECTOR 2 / SHORT CIRCUIT 1.6.3 CYLINDER INJECTOR 3 / SHORT CIRCUIT 1.6.4 CYLINDER INJECTOR 4 / SHORT CIRCUIT 1.6.5 CYLINDER INJECTOR 5 / SHORT CIRCUIT 1.6.6...
Page 274 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Component failure ECU 2 (Supplier/ Immobilizer /Runaway speed / Sensor supply) 1.E.3 CONTROL UNIT INTERNAL MONITORING ERROR 1.E.4 CONTROL UNIT INTERNAL MONITORING ERROR 1.E.5 ERRORE SENSOR SUPPLY (12V) 1.E.6 SENSOR SUPPLY 1 1.E.7 SENSOR SUPPLY 2 1.E.8...
Page 275: Section 3 - Industrial Application
F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION Print P2D32C003 E Base - May 2007...
Page 276 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 277 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS SECTION 4 Overhaul and technical specifications Page GENERAL CHARACTERISTICS ... . . ASSEMBLY CLEARANCE DATA ... . ENGINE OVERHAUL .
Page 278 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Page Page - Piston rings ......- Checking injector protrusion .
Page 279: General Characteristics
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS GENERAL CHARACTERISTICS Type Cycle 4-stroke Diesel engine Turbocharged Fuel feed Injection Direct No. of cylinders 6 in line ∅ Bore Stroke +.. = Total displacement 12880 Print P2D32C003 E Base - May 2007...
Page 280: Valve Timing
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Type VALVE TIMING opens before T.D.C. 17° closes after B.D.C. 30° opens before B.D.C. 50° closes after T.D.C. 9° For timing check Running 0.35 to 0.45 0.45 to 0.55 Through fuel pump - filters FEED Injection With electronically regulated injectors UIN3...
Page 281 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ASSEMBLY CLEARANCE DATA Type CYLINDER BLOCK AND CRANKMECHANISM COMPONENTS ∅ 1 Bores for cylinder liners: upper 153.500 to 153.525 ∅1 lower 152.000 to 152.025 Cylinder liners: external diameter: 153.461 to 153.486 upper ∅2 151.890 to 151.915...
Page 282 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Type Type 3.100 to 3.120 Piston ring grooves 1.550 to 1.570 5.020 to 5.040 Piston rings: trapezoidal seal 3.000 3.000 1.470 to 1.500 lune seal milled scraper ring ill d with slits and internal 4.970 to 4.990 4.970 to 4.990...
Page 283 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Type Type Measuring dimension Max. connecting rod axis misalignment 0.08 tolerance ∅1 Main journals - rated value 99.970 to 100.000 - class 99.970 to 99.979 - class 99.980 to 99.989 - class 99.990 to 100.000 ∅...
Page 284: Cylinder Head - Valve Train
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Type CYLINDER HEAD - VALVE TRAIN ∅ 1 Valve guide housings in cylinder head ∅1 15.980 to 15.997 ∅ 10.015 to 10.030 ∅2 ∅2 Valve guide Valve guide ∅3 16.012 to 16.025 ∅...
Page 285 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Table 2 Type Type Valve spring height: free height 73.40 under a load of: H 2 575 ± 28 N 1095 ± 54 N Injector protrusion 0.53 to 1.34 Camshaft bushing housing in the cylinder head: 1 ⇒...
Page 286 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Type Type Bushing housing in rocker arms 45.000 to 45.016 59.000 to 59.019 ∅ 46.000 to 46.016 Bushing outer diameter for rocker arms 45.090 to 45.130 59.100 to 59.140 ∅ 46.066 to 46.091 Bushing inner diameter for rocker arms...
Page 287: Engine Overhaul
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ENGINE OVERHAUL Figure 3 ENGINE REMOVAL AT THE BENCH The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well.
Page 288: Repair Operations
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES REPAIR OPERATIONS Figure 8 CYLINDER BLOCK Checks and measurements (Demonstration) Figure 6 60595 A = Selection class Ø 135.000 to 135.012 mm B = Selection class Ø 135.011 to 135.023 mm 34994 X = Selection class marking area Internal diameter of the cylinder liners is checked for...
Page 289: Cylinder Liners
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Cylinder liners Figure 10 60598 CRANKCASE ASSEMBLY WITH CYLINDER LINERS Figure 11 101503 A 135.000 to 135.013 mm Selection class B 135.011 to 135.024 mm MAIN CYLINDER LINER DATA Figure 12 101502 DETAIL “X”...
Page 290: Replacing Cylinder Liners
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Replacing cylinder liners Figure 15 Removal Figure 13 60520 47577 Check the protrusion of the cylinder liners with tool 99360334 Position the parts 99360706 (2) and the plate 99360728 (4) (2) and tightening the screw (1) to a torque of 225 Nm.
Page 291: Crankshaft
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Crankshaft Figure 18 Top main bearing shells Bottom main bearing shells 101504 MAIN DATA OF CRANKSHAFT AND MAIN BEARING SHELLS Check the state of the main journals and crankpins of the crankshaft. They must not be scored or be too ovalized or worn. The data given refer to the normal diameter of the journals.
Page 292: Measuring The Main Journals And Crankpins
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Measuring the main journals and crankpins Figure 22 Before grinding the journals, use a micrometric gauge (1) to measure the journals of the shaft (2) and establish, on the basis of the undersizing of the spare bearing shells, to what diameter it is necessary to reduce the journals.
Page 293: Preliminary Measurement Of Main And Big End Bearing Shell Selection Data
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Preliminary measurement of main and big end bearing shell selection data For each of the journals of the crankshaft, it is necessary to carry out the following operations: MAIN JOURNALS: CRANKPINS: - Determine the class of diameter of the seat in the - Determine the class of diameter of the seat in the...
Page 294: Selecting The Main Bearing And Big End Bearing Shells
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Selecting the main bearing and big end bearing shells NOTE To obtain the required assembly clearances, the main bearing and big end bearing shells have to be selected as described hereunder. This operation makes it possible to identify the most suited bearing shells for each of the journals of the shaft (the bearing shells may even have different classes for different pins).
Page 295 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS DEFINING THE CLASS OF DIAMETER OF THE MAIN JOURNALS AND CRANKPINS (Journals with nominal diameter) Main journals and crankpins: determining the class of diameter of the journals. Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 26 at top): - The first number, of five digits, is the part number of the shaft.
Page 296 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Selecting the main bearing shells (Journals with nominal diameter) After reading off the data, for each of the main journals, on the crankcase and crankshaft, you choose the type of bearing shells to use according to the following table: Figure 27 STD.
Page 297 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS SELECTING THE MAIN BEARING SHELLS (GROUND JOURNALS) If the journals have been ground, the procedure described so far cannot be applied. In this case, it is necessary to check that the new diameter of the journals is as shown in the table and to mount the only type of bearing shell envisaged for the relevant undersizing.
Page 298 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES SELECTING THE BIG END BEARING SHELLS Figure 29 (JOURNALS WITH NOMINAL DIAMETER) There are three markings on the body of the connecting rod in the position indicated as ”A”: Letter indicating the class of weight: VIEW FROM “A”...
Page 299 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Selecting big end bearing shells (ground journals) If the journals have been ground, the procedure described so far cannot be applied. In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of the crankpins and to mount the bearing shells identified with the relevant table.
Page 300: Checking Main Journal Installation Clearance
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Replacing the timing gear and oil pump Figure 34 Check that the teeth of the gears are not damaged or worn, otherwise remove them using the appropriate extractor. Figure 32 47578 Using the hoist and hook 99360500 (1) mount the driving shaft (2).
Page 301: Checking Crankshaft End Float
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 36 Figure 37 α 60559 Set two journals of the crankshaft (2) parallel to the longitudinal axis, a section of calibrated wire. Using 47578 appropriate hooks and tackle, mount the crankcase base (1). - Lubricate the internal screws (1) with UTDM oil and tighten them with a torque wrench (3) to a torque of NOTE...
Page 302: Assembling The Engine On The Bench
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES ASSEMBLING ENGINE Figure 44 BENCH Figure 41 49022 Fit the underblock by means of a suitable hoist and hooks (1). Figure 45 49021 Place the half-bearings (1) on the main bearings in the underblock (2).
Page 303: Diagram Showing The Underblock Fixing Screws Tightening Order
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER Figure 47 stage 1: FRONT SIDE pretightening outer screws (30 Nm) 60592 stage 2: FRONT SIDE pretightenig inner screws (120 Nm) 60593 stage 3: FRONT SIDE angle...
Page 304: Piston Connecting Rod Assembly
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES PISTON CONNECTING ROD ASSEMBLY Figure 48 60607 PISTON CONNECTING ROD ASSEMBLY 1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6.
Page 305 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 51 Figure 53 49025 32618 Remove the piston pin (1). Measuring the gudgeon pin diameter (1) with a micrometer (2). If removal is difficult use the appropriate beater. Measuring the diameter of the pistons Figure 52 Conditions for correct gudgeon pin-piston coupling...
Page 306: Piston Rings
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Figure 55 104292 MAIN DATA OF THE PISTON, PISTON RINGS AND PIN Piston rings Figure 58 Figure 56 3513 The seal (2) of the 1st slot has a V shape. The clearance ”X” between the seal and its seat is measured by setting the piston (1) with the ring in the cylinder liner (3) so that the seal comes half out of the cylinder liner.
Page 307: Connecting Rod
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Connecting rod Figure 60 Punched on the big end of the connecting rod are the data relating to the section in classes relating to the connecting rod seats and the weights. VIEW FROM “A”...
Page 308: Checking Connecting Rod Alignment
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Checking connecting rod alignment Checking bending Figure 62 (Demonstration) Figure 64 (Demonstration) 61695 Check the bending of the connecting rod (5) by comparing two points C and D of the pin (3) on the vertical plane of the axis of the connecting rod.
Page 309: Fitting The Connecting Rod-Piston Assembly Into The Piston Liners
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Fitting the connecting rod-piston assembly Figure 68 into the piston liners Figure 66 49030 47593 Fit the half-bearings (1), selected as described on pages 22 to - all pistons belong to the same class, A or B; 23, both on the connecting rod and on the stand.
Page 310: Checking Assembly Clearance Of Big End Pins
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Checking assembly clearance of big end pins Checking the planarity of the head on the To check the clearance proceed as follows: cylinder block Connect the connecting rods to the relative main journals, place a length of calibrated wire on the latter.
Page 311: Valve
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Valves Check, by means of a micrometer, that valve stem diameters Figure 73 are as specified; if necessary, grind the valves seat with a grinder, removing the minimum quantity of material. INTAKE EXHAUST 71718...
Page 312: Replacing Of Valve Guides
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Replacing of valve guides Replacing injector cases Removal Remove valve guides by means of tool 99360143. Install by means of tool 99360143 equipped with part 99360296, which determines the exact installation position of valve guides into the cylinder heads;...
Page 313: Assembly
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Assembly Figure 77 Figure 79 60622 - Lubricate the seals (3) and fit them on the case (4). Using tool 99365056 (2) secured to the cylinder head with bracket A, drive in the new case, screwing down the screw (1) upsetting the bottom portion of the case.
Page 314: Checking Injector Protrusion
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Figure 81 Figure 83 71720 INJECTOR CASE ASSEMBLY DIAGRAM 60624 - Using the milling cutter 99394043 (1-2), regrind the injector seat in the case (3). Checking injector protrusion Figure 82 47585 Check injector protrusion (2) with the dial gauge (1).
Page 315: Camshaft
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Camshaft Checking cam lift and pin alignment Figure 84 47506 Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2). Figure 85 47507 When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2);...
Page 316: Bushings
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Figure 87 60626 MAIN DATA OF THE CAMSHAFT AND TOLERANCES The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth. Whereas, if they show any signs of seizing or scoring, you should replace the shaft and the relevant bushings. TOLERANCES FEATURE SUBJECT OF TOLERANCE SYMBOL...
Page 317: Replacing Camshaft Bushes Using Beater 99360499
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Replacing camshaft bushes using beater 99360499 Figure 89 107217 A. Drift with seat for bushings to insert/extract. - B. Grub screw for positioning bushings. - C. Reference mark to insert seventh bushing correctly.
Page 318: Valve Springs
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Fitting the valves and oil seal ring Figure 93 Figure 96 Rear 71724 To insert bushing (7), proceed as follows: - Unscrew the grip (I) and the extension (N). - Refit the guide (G) from the inside as shown in the figure. - Position the bushing on the drift (A) and bring it close up to the seat, making the bushing hole match the lubrication hole in the head.
Page 319: Rocker Shaft
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ROCKER SHAFT Figure 98 44925 The camshaft cams directly control rockers: 6 for injectors and 12 for valves. Rockers slide directly on the cam profiles via rollers. The other end acts on a bar directly supported by the two valves stems. A pad is placed between the rocker adjusting screw and the bar.
Page 320: Timing Gear
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES TIMING GEAR Twin intermediate gear pin Camshaft drive Twin idler gear Figure 106 Figure 104 86925 101601 TIMING CONTROL COMPONENT PARTS 1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod - This measurement is obtained after assembling.
Page 321: Tightening Torque
F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TIGHTENING TORQUE TORQUE PART PART Capscrews, undercrankcase to crankcase ♦ M12x1.75 outer screws Stage 1: pretightening M 17x2 inner screws Stage 2: pretightening (12) Inner screws Stage 3: angle 60° Inner screws Stage 4: angle 55°...
Page 322 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES TORQUE PART PART Screw fastening the engine supporting bracket to the flywheel case Stage 1: pretightening (10) Stage 2: angle 60° Camshaft gear capscrews ♦ Stage 1: pretightening Stage 2: angle 60°...
Page 323 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TORQUE PART PART 30 ± 3 (3 ± 0.3) Screw fixing alternator M 10x1,5 I = 35 mm 44 ± 4 (4.4 ± 0.4) M 10x1,5 I = 60 mm 24.5 ±...
Page 324 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 325 F3B CURSOR ENGINES SECTION 5 - TOOLS SECTION 5 Tools Page TOOLS ....... . Print P2D32C003 E Base - May 2007...
Page 326 SECTION 5 - TOOLS F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 327 F3B CURSOR ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION Rotary telescopic stand (range 2000 daN, torque 375 daNm) 99322230 99340053 Extractor for crankshaft front gasket 99340054 Extractor for crankshaft rear gasket 99340205 Percussion extractor 99342149 Extractor for injector-holder 99346250 Tool to install the crankshaft front gasket Print P2D32C003 E...
Page 328 SECTION 5 - TOOLS F3B CURSOR ENGINES TOOLS TOOL NO. DESCRIPTION 99346251 Tool to install the crankshaft rear gasket 99348004 Universal extractor for 5 to 70 mm internal components 99350072 Box wrench for block junction bolts to the underblock 99360143 Box wrench for block junction bolts to the underblock 99360180 Injector housing protecting plugs (6)
Page 329 F3B CURSOR ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION Tool to take down-fit engine valves 99360261 (to be used with special plates) Plate for take down-fit engine valves 99360263 (to be used with 99360261) 99360296 Tool to fit back valve guide (to be used with 99360481) 99360314 Tool to remove oil filter (engine) 99360321...
Page 330 SECTION 5 - TOOLS F3B CURSOR ENGINES TOOLS TOOL NO. DESCRIPTION 99360329 Tool to install gasket on valve guide Compression tool for checking the protrusion of cylinder liners 99360334 (to be used with 99370415-99395603 and special plates) 99360336 Spacer (to be used with 99360334) Cylinder liner compression plate 99360338 (to be used with 99360334-99360336)
Page 331 F3B CURSOR ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99360500 Tool to lift crankshaft 99360553 Tool for assembling and installing rocker arm shaft 99360585 Swing hoist for engine disassembly assembly Belt to insert piston in cylinder liner (60 - 125 mm) 99360605 99360612 Tool for positioning engine P.M.S.
Page 332 SECTION 5 - TOOLS F3B CURSOR ENGINES TOOLS TOOL NO. DESCRIPTION 99360703 Tool to stop cylinder liners 99360706 Tool to extract cylinder liners (to be used with specific rings) 99360728 Ring (135 mm) (to be used with 99360706) 99361036 Brackets fixing the engine to rotary stand 99322230 99365056 Tool for injector holder heading 99370415...
Page 333 F3B CURSOR ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION Torque screwdriver (1-6 Nm) for calibrating the injector solenoid 99389834 valve connector check nut 99390330 Valve guide sleeker 99390772 Tool for removing injector holding case deposits Tool for threading injector holding cases to be extracted 99390804 (to be used with 99390805) 99390805...
Page 334 SECTION 5 - TOOLS F3B CURSOR ENGINES TOOLS TOOL NO. DESCRIPTION Cutter to rectify injector holder housing 99394041 (to be used with 99394015) Reamer to rectify injector holder lower side 99394043 (to be used with 99394015) Measuring pair for angular tightening with 1/2” 99395216 and 3/4”...
Page 335 F3B CURSOR ENGINES APPENDIX Appendix Page SAFETY PRESCRIPTIONS ....Print P2D32C003 E Base - May 2007...
Page 336 APPENDIX F3B CURSOR ENGINES Base - May 2007 Print P2D32C003 E...
Page 337 F3B CURSOR ENGINES APPENDIX - Do not execute any intervention if not provided with SAFETY PRESCRIPTIONS necessary instructions. Standard safety prescriptions Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different must be followed absolutely in a standard working area and operation from the ones they’ve been designed and whose non fulfillment will make any other measure useless...
Page 338 APPENDIX F3B CURSOR ENGINES - Avoid incorrect tightening or out of couple. Danger: Respect of the Environment incorrect tightening may seriously damage engine’s - Respect of the Environment shall be of primary components, affecting engine’s duration. importance: all necessary precautions to ensure - Avoid priming from fuel tanks made out of copper alloys personnel’s safety and health shall be adopted.
Page 339 CURSOR ENGINES G-DRIVE Part 3 G-DRIVE CURSOR ENGINES Section General specifications G-Drive Application PREFACE TO USER’S GUIDELINE MANUAL Section 1 describes engines F3A and F3B in their characteri- stics and general operation. Section 2 is specific of use. Print P2D32C003 E Base - May 2007...
Page 340 CURSOR ENGINES G-DRIVE NOTE Part no. 4 is characterized by describing a particular industrial/agricultural application: G-Drive motors. These engines are marketed as an assembly that is also equipped with the air/coolant and possibly air/air (intercooler) cooling device. The description of this application gives the differences with the industrial application (given in the preceding Parts) and reference must be made to it for all repair and maintenance work.
Page 341 CURSOR ENGINES G-DRIVE 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...
Page 342 CURSOR ENGINES G-DRIVE Graph and symbols Removal Intake Disconnection Refitting Exhaust Connection Removal Operation Disassembly Fitting in place ρ Compression ratio Assembly Tolerance Tighten to torque Weight difference Tighten to torque + angle value Rolling torque α Press or caulk Rotation Regulation Angle...
Page 343 CURSOR ENGINES G-DRIVE UPDATING Section Description Page Date of revision Print P2D32C003 E Base - May 2007...
Page 344 CURSOR ENGINES G-DRIVE Base - May 2007 Print P2D32C003 E...
Page 345: General Specifications
CURSOR ENGINES G-DRIVE SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General specifications Page CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE ..VIEWS OF ENGINES ..... LUBRICATION .
Page 346 SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES G-DRIVE Base - May 2007 Print P2D32C003 E...
Page 347 CURSOR ENGINES G-DRIVE SECTION 1 - GENERAL SPECIFICATIONS CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE F3A engine Technical Code Commercial Code F3AE9685A*E001 CURSOR 10TE X CURSOR 10TE X F3AE9685B*E002 F3B engine Technical Code Commercial Code F3BE9685A*E001 CURSOR 13TE X Print P2D32C003 E Base - May 2007...
Page 348: Views Of Engines
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES G-DRIVE VIEWS OF ENGINES (DEMONSTRATION) Figure 1 LEFT-HAND SIDE VIEW 107891 Figure 2 RIGHT-HAND SIDE VIEW 107892 Base - May 2007 Print P2D32C003 E...
Page 349 CURSOR ENGINES G-DRIVE SECTION 1 - GENERAL SPECIFICATIONS Figure 3 FRONT VIEW 107893 Figure 4 REAR VIEW 107894 Print P2D32C003 E Base - May 2007...
Page 350 SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES G-DRIVE Figure 5 TOP VIEW 107895 Base - May 2007 Print P2D32C003 E...
Page 351: Lubrication
CURSOR ENGINES G-DRIVE SECTION 1 - GENERAL SPECIFICATIONS 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 6 (Demonstration) Dropping oil...
Page 352: Cooling
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES G-DRIVE COOLING Description The engine cooling system is of the closed-circuit, forced circulation type. It consists mainly of the following components: - expansion tank, - a heat exchanger to cool down lubrication oil; - a water pump with centrifugal system incorporated in the cylinder block;...
Page 353: Fuel Feed
CURSOR ENGINES G-DRIVE SECTION 1 - GENERAL SPECIFICATIONS FUEL FEED Fuel feed is obtained by means of a pump, fuel filter and pre-filter, 6 pump-injectors controlled by the camshaft by means of rockers and by the electronic control unit. Figure 8 (Demonstration) Return circuit Delivery circuit...
Page 354: F2B Engine Fuel Supply Pump
SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES G-DRIVE F3A engine fuel supply pump Pumping element The pumping element is operated by a rocker arm governed Figure 9 directly by the cam of the camshaft. The pumping element is able to ensure a high delivery pressure.
Page 355: Turbocharging
CURSOR ENGINES G-DRIVE SECTION 1 - GENERAL SPECIFICATIONS TURBOCHARGING The turbocharging system consists of: - air filter; - Turbocharger. Figure 12 (Demonstration) Engine exhaust gas Intake air A = Inlet S = Exhaust 107897 SUPERCHARGING SYSTEM DIAGRAM Print P2D32C003 E Base - May 2007...
Page 356 SECTION 1 - GENERAL SPECIFICATIONS CURSOR ENGINES G-DRIVE Base - May 2007 Print P2D32C003 E...
Page 357 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION SECTION 2 G-Drive application Page F3A ENGINE CLEARANCE DATA ..F3B ENGINE CLEARANCE DATA ..F3A GENERAL CHARACTERISTICS .
Page 358 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Base - May 2007 Print P2D32C003 E...
Page 359 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION F3A ENGINE CLEARANCE DATA F3AE9685 Type A*E001 B*E002 ρ Compression ratio 16.5 to 1 Europe market Max. output (HP) (407.8) 1500/50 Hz Max. torque (kgm) USA market Max. output (455.4) (HP) 1800/60 Hz Max.
Page 360 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE F3B ENGINE CLEARANCE DATA Type F3BE9685A*E001 ρ Compression ratio 16.5 to 1 Europe market Max. output (HP) Max. torque (kgm) USA market Max. output (537) (HP) 1800/60 Hz Max. torque (kgm) Bore x stroke 135 x 150 Displacement 12880...
Page 361: F3A General Characteristics
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION F3A GENERAL CHARACTERISTICS Type Cycle Diesel 4 strokes Turbocharged Feeding Injection Direct N. of cylinders 6 on-line ∅ Diameter Stroke +.. = Total displacement 10300 Europe market Max. output (HP) (407.8) 1500/50 Hz Max.
Page 362: Valve Timing
SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type VALVE TIMING opens before T.D.C. 17° closes after B.D.C. 4° opens before B.D.C. 56° closes after T.D.C. 9° For timing check Running 0.35 to 0.45 0.45 to 0.55 Through fuel pump - filters FEED Injection With electronically regulated injectors PDE/N3...
Page 363 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION F3A ASSEMBLY CLEARANCE DATA Type CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS ∅ Cylinder sleeve bore 142.000 to 142.025 upper ∅ 1 lower 140.000 to 140.025 Cylinder liners: outer diameter: upper 141.961 to 141.986 ∅...
Page 364 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type Type 3.620 to 2.640 Piston ring grooves 1.550 to 1.570 4.020 to 4.040 Piston rings: trapezoidal seal 2.500 2.500 1.470 to 1.500 lune seal milled scraper ring ill d with slits and internal 3.970 to 3.990 3.970 to 3.990 spring...
Page 365 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Type Type Measuring dimension Max. connecting rod axis misalignment 0.08 tolerance ∅1 Main journals - nominal 92.970 to 93.000 - class 92.970 to 92.979 - class 92.980 to 92.989 - class 92.990 to 93.000 ∅...
Page 366: Cylinder Head - Valve Train
SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type CYLINDER HEAD - VALVE TRAIN ∅ 1 Valve guide housings in cylinder head ∅1 14.980 to 14.997 ∅ 9.015 to 9.030 ∅2 ∅2 Valve guide Valve guide ∅3 15.012 to 15.025 ∅...
Page 367 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Table 3 Type Type Valve spring height: free height under a load of: H 2 N 500 ±25 N 972 ±48 47.8 Injector protrusion 0.14 to 1.4 Camshaft bushing housing in the cylinder head: 1 ⇒...
Page 368 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type Type Bushing housing in rocker arms 45.000 to 45.016 59.000 to 59.019 ∅ 46.000 to 46.016 Bushing outer diameter for rocker arms 45.090 to 45.130 59.100 to 59.140 ∅ 46.066 to 46.091 Bushing inner diameter for rocker arms 42.025 to 42.041...
Page 369: F3B General Characteristics
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION F3B GENERAL CHARACTERISTICS Type *E001 F3BE9685A Cycle 4-stroke Diesel engine Fuel feed Turbocharged Injection Direct No. of cylinders 6 in line ∅ Bore Stroke +.. = Total displacement 12880 ρ 16.5 ± 1 Compression ratio Europe market Max.
Page 370 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type VALVE TIMING opens before T.D.C. 17° closes after B.D.C. 30° opens before B.D.C. 50° closes after T.D.C. 9° For timing check Running 0.35 to 0.45 0.55 to 0.65 Through fuel pump - filters FEED Injection With electronically regulated injectors PDE N3...
Page 371: F3B Assembly Clearance Data
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION F3B ASSEMBLY CLEARANCE DATA Type CYLINDER BLOCK AND CRANKMECHANISM COMPONENTS ∅ 1 Bores for cylinder liners: 153.500 to 153.525 upper ∅1 lower 152.000 to 152.025 Cylinder liners: external diameter: 153.461 to 153.486 upper ∅2 lower...
Page 372 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type Type 3.100 to 3.120 Piston ring grooves 1.550 to 1.570 5.020 to 5.040 Piston rings: trapezoidal seal 3.000 3.000 1.470 to 1.500 lune seal milled scraper ring ill d with slits and internal 4.970 to 4.990 4.970 to 4.990 spring...
Page 373 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Type Type Measuring dimension Max. connecting rod axis misalignment 0.08 tolerance ∅1 Main journals - rated value 99.970 to 100.000 - class 99.970 to 99.979 - class 99.980 to 99.989 - class 99.990 to 100.000 ∅...
Page 374 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type CYLINDER HEAD - VALVE TRAIN ∅ 1 Valve guide housings in cylinder head ∅1 15.980 to 15.997 ∅ 10.015 to 10.030 ∅2 ∅2 Valve guide Valve guide ∅3 16.012 to 16.025 ∅...
Page 375 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Table 4 Type Type Valve spring height: free height 72,40 under a load of: H 2 575 ± 28 N 1095 ± 54 N Injector protrusion 0.53 to 1.34 Camshaft bushing housing in the cylinder head: 1 ⇒...
Page 376 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Type Type Bushing housing in rocker arms 45.000 to 45.016 59.000 to 59.019 ∅ 46.000 to 46.016 Bushing outer diameter for rocker arms 45.090 to 45.130 59.100 to 59.140 ∅ 46.066 to 46.091 Bushing inner diameter for rocker arms 42.025 to 42.041...
Page 377: Engine Connection And Disconnection From The Radiator
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION ENGINE CONNECTION AND DISCONNECTION FROM THE RADIATOR Figure 1 (Demonstration) 112827 Refitting Removal For the connection operation repeat the described operations for the disconnection on the contrary To prearrange a suited container near the sleeve (6) to and apply the following instructions: recover the cooling liquid.
Page 378: Engine Assembly/Disassembly
SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE ENGINE ASSEMBLY/DISASSEMBLY Figure 2 F3A engine disassembly 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.
Page 379 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Figure 4 Figure 7 99361 104249 Apply the extractor 99340053 (2) as is illustrated in the figure Use specific tool (3) to operate on belt tensioner (2) in and take off the sealing ring (4). Undo the screws (3) and take direction of arrow, remove water pump alternator and off the lid (1).
Page 380 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Figure 9 Figure 12 104253 101960 Take out the screws (2) and remove the intake manifold (1). Unscrew the oil filters (1) by tool 99360314. Figure 13 Figure 10 99258 104255 - disconnect the oil piping (3) and (4) and take off the clips Disassemble: (←);...
Page 381: F2B Engine Assembly
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION F3A engine assembly Figure 15 To assembly again the engine inverting the described operations for the disassembly. F3B engine disassembly 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.
Page 382 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Figure 17 Figure 20 87204 107903 Use specific tool (3) to operate on belt tensioner (2) in Block the flywheel rotation with tool 99360351. direction of arrow, remove water pump alternator and Remove screws (4), then disassemble damper flywheel (3).
Page 383 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Figure 23 Figure 26 107972 107975 Remove retaining screws and support (1) of fuel filter. Remove screws (2) and remove intake manifold (3). Unscrew the oil filter (1) by tool 99360314. Figure 27 Figure 24 107973 107976...
Page 384: F3B Engine Assembly
SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Figure 29 107972 Remove screws (1) and remove power takeoff (2). Remove screws and remove starter motor (3). Therefore, continue with the disassembly of the engine as described for engines used for industrial applications. F3B engine assembly To assembly again the engine inverting the described operations for the disassembly.
Page 385: Maintenance Planning
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION MAINTENANCE PLANNING Print P2D32C003 E Base - May 2007...
Page 386 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Base - May 2007 Print P2D32C003 E...
Page 387: Maintenance Planning
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION MAINTENANCE PLANNING Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks.
Page 388: Checks Not Included In Maintenance Planning-Daily Checks
SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers. - Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
Page 389 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Replace fuel sedimentation tank prefilter Check Blow-by filter conditions by means of a clogging indicator Figure 30 Figure 32 108395 Disconnect electric connector. Unlock prefilter (1) and change it. Before refitting a new cartridge, wet seal with fuel oil or engine oil.
Page 390 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Check for any water in the fuel filter Lock plus (3) under oil sump at predefined tightening torque. Pour oil in prescribed quantity and quality in engine through The components of the system can be damaged filler (2) of tappet cover.
Page 391 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Valve lash check a adjustment For correct operation, follow instructions contained in related chapter in section 3 — Industrial Application. Change dry air filter and clean its container Refit container cover, remove cartridge from air filter. Carefully clean container inside, insert new cartridge and refit cover.
Page 392: Principle Electrical Diagram
SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE PRINCIPLE ELECTRICAL DIAGRAM Figure 36 119624 Base - May 2007 Print P2D32C003 E...
Page 393: Key To Components
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Key to components Starter battery 12V Starter motor Battery charger alternator Fuel filter heating resistor TRFC Fuel filter heating thermostat TPAC Water in the fuel filter transmitter TBLA Low engine water level transmitter Engine oil pressure switch TBPO Low engine oil level pressure switch...
Page 394: Engine Interface Box
SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE ENGINE INTERFACE BOX Description Figure 37 107437 LIST OF COMPONENTS K1. Power relay with key inserted (+15) - K2. Starting phase signal relay - K3. Starting relay - K4. Relay for pre-heating resistance enabling - JP1.
Page 395: Connectors
CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION Connectors Figure 38 107439 107438 107437 CONNECTOR J1 on engine — control panel interface box for power supply (GECURSOR300E/350E/400E) To terminal 50 of starter motor Supply from F3 for fuel filter heating resistance Battery negative Direct positive to battery Spare...
Page 396 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE CONNECTOR J2 on engine — control panel interface box for EDC ECU connections Key- on positive (+15) for EDC ECU supply Connection with J2 pin 12 Signal from engine oil low pressure switch for visual indication on panel (to connector J3 pin 3) Signal from engine water temp.
Page 397 CURSOR ENGINES G-DRIVE SECTION 2 - G-DRIVE APPLICATION CONNECTOR J3 inside the engine interface box for signals to control panel Free From the engine water temperature transmitter for signal to thermometer on control panel From the low engine oil pressure switch for visual warning on control panel From engine oil pressure switch for signal to pressure gauge on control panel Free To the key switch (+50) on control panel...
Page 398 SECTION 2 - G-DRIVE APPLICATION CURSOR ENGINES G-DRIVE Base - May 2007 Print P2D32C003 E...

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