F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 27

Figure 83 Figure 85

99357
99254

Fit the arm 99360585 onto the engine lifting hooks and hook Fit the engine support together with the air-conditioner
the arm onto the hoist. compressor (2).
Take out the screws fixing the brackets 99361036 to the Using a suitable tool (3), work in the direction of the arrow and
rotary stand. Lift the engine and remove the above-mentioned mount the belt (1).
brackets from it. Connect the engine electric cable to the sensors and control
Complete engine assembly with the following parts, tightening unit.
the fixing screws or nuts to the prescribed torque: Refill the engine with lubricating oil of the prescribed grade and
quantity.
- mount the drive (1);
- mount the engine supports;

Figure 84

99253

- mount the oil pressure adjuster valve (1).

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 28 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 29

PART TWO -
ELECTRICAL EQUIPMENT

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 30 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 31

Components on the engine F3B

Figure 86

ENGINE RIGHT-HAND SIDE VIEW 99370

Figure 87

99371
ENGINE LEFT-HAND SIDE VIEW
A. Resistance for engine warming - B. Fuel filter clogged signalling switch - C. Fuel temperature sensor - D. Engine rpm sensor
on camshaft - E. Starter motor - F. Engine intake air temperature sensor - G. Alternator - H. Boosting pressure sensor -
I. Conditioner compressor - L. EDC (MS6.2) control unit - M. Connector on engine head for connection with injector solenoid
valves - N. Water temperature for EDC (MS6.2) - O. Water temperature sensor - P. Oil pressure transmitter -
Q. Engine speed on flywheel sensor - R. Low oil pressure transmitter.

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 32 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

BLOCK DIAGRAM
Figure 88

101609

KEYS
1. Accelerator pedal position sensor / switch accelerator depressed è2. Engine coolant temperature sensor è3. Oversupply
air temperature sensor è4. Fuel temperature sensor è5. Oversupply air pressure sensor è6. Input for electronic tachograph
(if available) è7. Output for electronic revs counter (if available) è8. E.D.C. system failure warning light è9. Blinkècode button
(if available) è10. Diagnosis connector è11. CAL LèH line è12. Pumpèinjectors è13. Warning light for pre/postèheating
activated è14. Remote control switch for pre/postèheating activation è15. Pre/postèheating resistance è16. Main remote
control switch è17. Flywheel sensor è18. Distribution sensor è19. Cruise Control buttons (if available) è20. Clutch switch è
21. Primary / secondary brake switch.

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 33

EDC MS 6.2 electronic control unit

Figure 89

Connector âAâengine

Connector âBâchassis/cabin

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 34 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

EDC control unit PIN-OUT

Connector âAâ(Engine)
Pin Function
1- Engine rev sensor
2- Distribution rev sensor
3- ---
4- Air temperature sensor mass
5- Engine coolant temperature sensor mass
6- Engine oil temperature and fuel temperature sensor ground
7- ---
8- ---
9- ---
10 - Engine oil temperature sensor signal
11 - Fuel temperature sensor signal
12 - Oversupply pressure sensor signal
13 - Engine rev sensor
14 - Distribution rev sensor
15 - ---
16 - ---
17 - Boosting pressure sensor ground
18 - ---
19 - ---
20 - ---
21 - Air temperature sensor signal
22 - Engine coolant temperature sensor signal
23 - Oversupply pressure sensor power supply
24 - Injector power supply for cylinders 1 / 2 / 3
25 - Injector power supply for cylinders 4 / 5 / 6
26 - Cylinder 4 injector control
27 - Cylinder 6 injector control
28 - Cylinder 5 injector control
29 - ---
30 - ---
31 - ---
32 - ---
33 - Cylinder 3 injector control
34 - Cylinder 2 injector control
35 - Cylinder 1 injector control

Figure 90

Colour code
1 12
B White
BG Beige
C Orange
G Yellow
23
H Grey
13
L Blue
M Brown
N Black
R Red
24 35 000576t S Pink
V Green
EDC CONTROL UNIT DIAGRAM WITH ELECTRICAL CONNECTIONS TO CONNECTOR èAè Z Purple

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 35

EDC control unit PIN-OUT

Connector âBâ(Frame area)

Pin Functions
1- Negative direct from battery / blink button ècode
2- Negative direct from battery / blink button ècode
3- Positive from main remote switch
4- Positive from main remote switch
5- Signal for electronic rev. counter (if available)
6- Negative for EDC / blink button ècode warning light (if available)
7- CAN line for Multiplex electric system architecture
8- ---
9- Engine phase signal for diagnosis connector
10 - Negative for pre-post heating remote switch engagement
11 - CAN - L line for interconnection of the CAN line with control units (if any) available with the application
12 - CAN - H line for interconnection of the CAN line with control units (if any) available with the application
13 - K line for diagnosis connector
14 - ---
15 - Key controlled supply positive
16 - Accelerator pedal position sensor supply
17 - Negative from idler switch
18 - Negative for warning light pre èpost heating
19 - ---
20 - Positive from N.C. clutch switch (if available)
21 - Function èRESUMEèCruise Control (if available)
22 - Positive from speed reducer switch (if available)
23 - Accelerator pedal position signal sensor
24 - L line for diagnosis connector
25 - Negative for accelerator pedal, multiple-state switch for torque reducer and negative for engine speed and vehicle
speed sensors
26 - Positive from primary N.C. brake switch
27 - Negative for main remote switch
28 - Signal from the multiple-state switch for the torque reducer (if available)
29 - Vehicle speed (D3 tachograph) signal (if available)
30 - PWM line
31 - Positive from N.C. redundant brake switch
32 - Function èSET èèCruise Control (if available)
33 - Function èOFF +èCruise Control (if available)
34 - Function èSET +èCruise Control (if available)
35 - Negative for accelerator pedal position sensor

Figure 91

1 12

23
13

24 35 000576t

WIRING DIAGRAM OF EDC CONTROL UNIT WITH CONNECTIONS TO CONNECTOR èBè

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 36 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

PUMP INJECTOR
It consists mainly of:
A) Solenoid valve
B) Pumping element
C) Nozzle
These three parts CANNOT be replaced individually and CANNOT be overhauled.
The pumping element, mechanically actuated at every rocker arm cycle, compresses the fuel container in the delivery chamber.
The nozzle, whose composition and operation are similar to those of traditional injectors, is opened by the fuel under pressure
and sprays it into the combustion chamber.
A solenoid valve, directly controlled by the electronic control unit, determines delivery according to the control signal.
A casing houses the lower part of the pump injector in the cylinder head.

Figure 92

000578t

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 37

Pump-injector replacement

If the operation is carried out when the engine is on the vehicle, before removing the pump-injectors drain the fuel in
the cylinder head pipes by releasing the delivery and return pipe unions on the cylinder head.

Connect to the diagnosis instrument for each replaced injector and, when required by the programme, enter the control unit
re-programming code stamped on the injector.

In an emergency, when the Modus is not available, it is possible to replace 1 injector without the control unit recognition.

Figure 93

0 4 11 7 0 0 0 0 2
XXXXXX XXXX X
868 U S A /

61487

When inspecting the rocker arm clearance, check also the pump-injector preload.

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 38 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.
It is connected to electronic center pins A5/A22.
Sensor behavior as a function of temperature:
- 10 C 8,10 10,77 kOhm
+ 20 C 2,28 2,72 kOhm
+ 80 C 0,29 0,364 kOhm
At 60 to 90 _C, voltage at A5 and A22 ranges from 0.6 to 2.4V.
Figure 94

000602t
8527

TECHNICAL VIEW WIRING DIAGRAM

000693t

PERSPECTIVE VIEW

Connector Function Cable colour

2 To EDC center pin A 5 â
3 To EDC center pin A 22 â

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 39

Fuel temperature sensor

Specifications
Supplier BOSCH
Max. tightening torque 35 Nm

Figure 95

8528
8527

TECNICAL VIEW WIRING DIAGRAM

8530
8529

PERSPECTIVE VIEW RESISTANCE TREND

Pin Function Cable colour

2 To pin 6 of EDC control unit â
3 To pin 11 of EDC control unit â

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 40 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

Flywheel pulse transmitter

Specifications
Supplier BOSCH
Max. tightening torque 8 2 Nm

Figure 96

8518 8519

TECNICAL VIEW WIRING DIAGRAM

Figure 97

8520

Pin Function Cable colour

1 To pin 1 of EDC control unit â
2 To pin 13 of EDC control unit â
3 Screens â

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 41

Distribution pulse transmitter

Features
Vendor BOSCH
Torque 8 2 Nm
Resistance 880 920
This induction type sensor located on the camshaft generates signals obtained from the magnetic flow lines that close through the
6 plus 1 phase teeth of a sound wheel mounted on the shaft.
The electronic center uses the signal generated by this sensor as an injection step signal.
Though electrically identical to engine rpm sensor mounted in the camshaft in is NOT interchangeable with it as it cable is shorter
and it features a larger diameter.
This sensorè
s air gap is NOT ADJUSTABLE.

TECHNICAL VIEW WIRING DIAGRAM

PERSPECTIVE VIEW 000606t REFERENCE ON SOUND WHEEL 8520

Connector Function Cable colour

1 To EDC center pin A 2 â
2 To EDC center pin A 14 â
3 Shields â

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 42 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

Boosting pressure transmitter

Specifications
Supplier BOSCH
Code B 281022 018
Operating pressure field 50 400 kPa
Max. tightening torque 10 Nm
Figure 98

UA
[V]
5

30 100 200 300 400 P

8521 [kPa]
8522

TECNICAL VIEW MAX ABSOLUTE PRESSURE SPECIFICATIONS 600 KPA

Figure 99

8523
PERSPECTIVE VIEW

Pin Function Cable colour

1 To pin 12 of EDC control unit â
2 To pin 23 of EDC control unit â
3 To pin 17 of EDC control unit â

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 43

Air temperature transmitter on manifold

Specifications
Supplier BOSCH
Max. tightening torque 35 Nm
The device should be marked with the supplierè
s identification, catalogue number and date of manufacture.

Figure 100

8531 8532

TECHNICAL VIEW WIRING DIAGRAM

8533 8530

PERSPECTIVE VIEW RESISTANCE TREND

Pin Function Cable colour

1 To pin 21 of EDC control unit â
2 To pin 4 of EDC control unit â

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 44 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

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 èwater, air, gas oil èdetect a value below 10 C,
the electronic control unit will activate pre/post-heating and turn on the relevant dashboard warning light for a variable time
depending on the temperature.
After that time, the warning light starts blinking thus informing the driver that the engine can be started.
When the engine is running the warning light goes off, while the resistance is being fed for a certain time as a result of post-heating.
If the engine is not started, with the warning light flashing, in 20 / 25 seconds, the operation is cancelled to prevent draining the
battery.
On the contrary, if reference temperatures are over 10 C, when the ignition key is inserted the warning light comes on for about
2 seconds and carries out the test and then goes out to signal that the engine can be started.

Figure 101

001256t

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 45

EDC SYSTEM FUNCTIONS

The MS6.2 electronic center manages the following main functions:

Fuel injection
Accessory functions
Self-diagnosis
Recovery

It also enables:

Interfacing with other electronic systems (if any) available on the vehicle
Diagnosis
Fuel dosing
Fuel dosing is calculated based on:
- accelerator pedal position
- engine rpm
- quantity of air admitted.
The result can be corrected based on:
- water temperature
or to prevent:
- noise
- fumes
- overloads
- overheating

Pressure can be adjusted in case of:

- engine brake actuation
- external device actuation
- serious defects involving load reduction or engine stop.
After determining the mass of air introduced by measuring its volume and temperature, the center calculates the corresponding
mass of fuel to be injected into the cylinder involved, with account also taken of gas oil temperature.
Delivery correction based on water temperature
When cold, the engine encounters greater operating resistance, mechanical friction is high, oil is till very viscous and operating plays
are not optimized yet.
Fuel injected also tends to condense on cold metal surfaces.
Fuel dosing with a cold engine is therefore greater than when hot.
Delivery correction to prevent noise, fumes or overloads
Behaviors that could lead to the defects under review are well known, so the designer has added specific instructions to the center
to prevent them.
De-rating
In the event of engine overheating, decreasing delivery proportionally to the temperature reached by the coolant changes injection.

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 46 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

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.
Lead is corrected as required:
- during acceleration
- according to water temperature
and to obtain:
- reduced emissions, noise abatement and no overload
- better vehicle acceleration
High injection lead is set at start, based on water temperature.
Delivery start feedback is given by injection electro valve impedance variation.
Engine start
Cylinder 1 step and recognition signal synchronization (flywheel and drive shaft sensors) takes place at first engine turns. Accelerator
pedal signal is ignored at start. Star delivery is set exclusively based on water temperature, via a specific map. The center enables
the accelerator pedal, when it detects flywheel acceleration and rpm such as to consider the engine as started and no longer drawn
by the starter motor.
Cold start
Pre-post reheating is activated when even only one of the three water, air or gas oil temperature sensors records a temperature
of below 10 _C. The pre-heat warning light goes on when the ignition key is inserted and stays on for a variable period of time
according to temperature, while the intake duct input resistor heats the air, then starts blinking, at which point the engine can be
started.
The warning light switches off with the engine revving, while the resistor continues being fed for a variable period of time to
complete post-heating. The operation is cancelled to avoid uselessly discharging the batteries if the engine is not started within 20
25 seconds with the warning light blinking. The pre-heat curve is also variable based on battery voltage.
Hot start
On inserting the ignition key the warning light goes on for some 2 seconds for a short test and then switches off when all reference
temperatures are above 10 _C. The engine can be started at this point.
Run Up
When the ignition key is inserted, the center transfers data stored at previous engine stop to the main memory (Cf. After run),
and diagnoses the system.
After Run
At each engine stop with the ignition key, the center still remains fed by the main relay for a few seconds, to enable the
microprocessor to transfer some data from the main volatile memory to an non-volatile, cancelable and rewritable (Eeprom)
memory to make tem available for the next start (Cf. Run Up).
These data essentially consists of:
- miscellaneous settings, such as engine idling and the like
- settings of some components
- breakdown memory
The process lasts for some seconds, typically from 2 to 7 according to the amount of data to be stored, after which the ECU sends
a command to the main relay and makes it disconnect from the battery.

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 47

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.
Repeated procedure interruptions could in fact lead to center damage.

Cut-off
It refers to the supply cut-off function during deceleration.
Cylinder Balancing
Individual cylinder balancing contributes to increasing comfort and operability.
This function enables individual personalized fuel delivery control and delivery start for each cylinder, even differently between each
cylinder, to compensate for injector hydraulic tolerances.
The flow (rating feature) differences between the various injectors cannot be evaluated directly by the control unit. This information
is provided by the entry of the codes for every single injector, by means of the diagnosis instrument.
Synchronization search
The center can anyhow recognize the cylinder to inject fuel into even in the absence of a signal from the camshaft sensor.
If this occurs when the engine is already started, combustion sequence is already acquired, so the center continues with the
sequence it is already synchronized on; if it occurs with the engine stopped, the center only actuates one electro valve. Injection
occurs onside that cylinder within 2 shaft revs at the utmost so the center is only required to synchronize on the firing sequence
and start the engine.

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 49

PART THREE - TROUBLESHOOTING

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 51

PREFACE Every time there is a breakdown claim and this breakdown is

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
competence acquired by years of experience and attending with the diagnostic research making trials and tests in order to
training courses. have a picture of the working conditions and identify the root
causes of the anomaly.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper In case the electronic device is not providing any indication, it
consideration using them to acquire any useful information to will be necessary to proceed relying on the experience,
focus the intervention. adopting traditional diagnosis procedures.
After the detection of the existing anomaly, it is In order to compensate the operatorsèlack of experience in
recommended to proceed with the operations of this new system, we are hereby providing the USERè s
troubleshooting by decoding the auto-troubleshooting data GUIDELINE FOR TROUBLESHOOTING in the following
provided by the EDC system electronic central unit. pages.
The continuous efficiency tests of the components connected The GUIDELINE is composed of three different parts:
to, and the check of working conditions of the entire system
- Part 1: Blink Code, relating to the anomalies identified by
carried out during working, can offer an important diagnosis
the gearbox, mainly of electric and electrical nature;
indication, available through the decoding of the
èfailure/anomalyècodes issued by blinking of the failure led: - Part 2: Troubleshooting guide using PT-01 portable
the èblinkècodeè(whether programmed). tester.
Tool identified as IVECO p/n 8093731.
Please consider that the interpretation of the indications
provided by the blink-code is not sufficient to guarantee the - Part 3: Guideline for troubleshooting without blink code,
solution to the existing anomalies. divided per symptoms, describing all possible anomalies
not detected by the electronic gearbox, often of
Using Iveco Motors processing instruments, it is also possible
mechanical and hydraulic nature.
to establish a bi-directional connection with the central unit,
by which not only to decoding the failure codes but also input
an enquiry relying on memory files, in order to achieve any
further necessary information to identify the origin of the
anomaly. NOTE Any kind of operation on the electronic center unit
must be executed by qualified personnel, duly
authorized by Iveco Motors.

Any unauthorized tamper will involve decay of

after-sales service in warranty.

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 52 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

PART 1
EDC MS6.2 SW control unit Blink Table
Blink code EDC warning lamp * Fault
VEHICLE AREA
1.1 GLOWING STEADILY Vehicle speed signal
1.2 GLOWING STEADILY Torque selector (if available)
1.3 OFF Cruise Control
1.4 GLOWING STEADILY Accelerator pedal
1.5 OFF Clutch pressure switch
1.6 GLOWING STEADILY Plausibility of brake pedal signal switches
1.7 OFF Plausibility between accelerator / brake pedal
ENGINE AREA
2.1 OFF Water temperature sensor
2.2 OFF Air temperature sensor
2.3 OFF Fuel temperature sensor
2.4 GLOWING STEADILY Supercharging pressure sensor
2.5 OFF Ambient pressure sensor (inside control unit)
3.5 OFF Battery voltage
INJECTORS
5.1 GLOWING STEADILY Fault on injector cylinder 1
5.2 GLOWING STEADILY Fault on injector cylinder 2
5.3 GLOWING STEADILY Fault on injector cylinder 3
5.4 GLOWING STEADILY Fault on injector cylinder 4
5.5 GLOWING STEADILY Fault on injector cylinder 5
5.6 GLOWING STEADILY Fault on injector cylinder 6
ENGINE RPM SENSORS
6.1 GLOWING STEADILY Flywheel sensor
6.2 GLOWING STEADILY Timing gear sensor
6.4 FLASHING Engine over revving
INTERFACES WITH OTHER CONTROL UNITS
7.2 OFF CAN line
7.6 OFF CAN line (ASR control)
7.7 OFF CAN line (gearbox data control)
CONTROL UNIT
9.1 FLASHING Faulty control unit
9.2 GLOWING STEADILY Incorrect data in EPROM
9.4 GLOWING STEADILY Main relay
9.5 GLOWING STEADILY Incorrect engine stopping procedure
9.6 GLOWING STEADILY Incorrect data recording in control unit
* Blink code warning lamp off = slight error
Blink code warning lamp glowing steadily = significant error
Blink code warning lamp flashing = serious error

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 53

PART 2

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 55

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 57

PART 3

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 59

PART FOUR - MAINTENANCE PLANNING

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 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 61

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.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.

Inspection and/or maintenance interventions

Intervention type Frequency (hours)

Engine
Engine visual inspection Daily
Check presence of water in fuel prefilter Daily
Engine oil change -
Engine oil filter change -
Fuel prefilter change (when it is required by the application) -
Fuel filter change -
Check Blow-by filter condition by clogging indicator -
Check condition of water pump/alternator control belt -
Check-up of EDC system by diagnostics tool -
Check valve lash and adjust, if required -
Dry air filter change and container cleaning -

NOTE The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.

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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 vehicleè
s drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Checking the coolant level.

MAINTENANCE PROCEDURES Cooling system check

Checks and controls The check must be executed both when the engine
disconnected and when it is running.
Engine oil level check. Check the pipes from the engine to the radiator and vice versa;
note any seepage and the state of the pipes especially near the
The check must be executed when the engine is disconnected coupling clamps.
and possibly cool. Verify that the radiator is clean, the correct working of the fan
The check can be made using the specially provided flexible flywheels, the presence of any leakage from the connectors,
rod (1). from the manifold and from the radiating unit.
Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level. Due to the high temperatures achieved by the
Whether it should be difficult to make the evaluation, proceed system, do not operate immediately after the engineè
s
cleaning the rod using a clean cloth with no rag grinding and disconnection, but wait for the time deemed
put it back in its slot. Draw it off again and check the level. necessary for the cooling.
Protect the eyes and the skin from any eventual high
In case the level results being close to the tag showing pressure jet of cooling liquid.
minimum level, provide filling lubrication of the engineè
s
components.
The density of the cooling liquid must be checked any how
To provide filling, operate through the upper top (1) or every year before winter season and be replaced in any case
through the lateral top (2). During filling operation, the tops every two year.
must be removed as well as the rod in order to make the oil
flow easierè. NOTE In case of new filling, proceed bleeding system,
Refill through upper tappet cover plug. During refill, remove through the bleeds on the engine.
dipstick for easier oil drain.
If bleeding of the system is not carried out, serious
inconvenience might be caused to the engine due
to the presence of air pockets in the engineè s head.
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Lubricating system check
Adequately protect the skin and the eyes, operate The check must be executed both when the engine
in full compliance with safety regulations. disconnected and when it is running.
Verify the presence of any oil leakage or blow-by from the
Disposal must be carried out properly, and in full head, from the engine pan of from the heat exchanger.
compliance with the law and regulations in force.
The engine oil is highly polluting and harmful.
Check of fuel system In case of contact with the skin, rinse well with water
The check must be executed both when the engine and detergent.
disconnected and when it is running. Adequately protect the skin and the eyes, operate in
The check is made by observing the fuel pipes from the tank full compliance with safety regulations.
to the fuel pump and to the injectors. Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 63

Replace fuel sedimentation tank prefilter (when it is Check Blow-by filter conditions by means of a clogging
required by the application) indicator
Figure 102 Figure 104

108395

Disconnect electric connector. Unlock prefilter (1) and

change it. Before refitting a new cartridge, wet seal with fuel
oil or engine oil. Lock cartridge by hand till in contact with
support, then lock it by º of a rev. at predefined tightening
torque.
72563

- Check filter (3) conditions by means of a clogging

NOTE At change, filter cartridge must not be prefilled to indicator (1). In case the red area appears, change it.
prevent circulating dirt that could damage - For screw (2) change, remove carter, pull out filter (3) and
injector/pump system components. Bleed air from replace it with a new one. Filter has a one-way operation,
fuel filter as described in previous pages. therefore it must be installed with the two reinforcement
bars visible, as shown in the picture.

Check of water pump/alternator control belt condition

Fuel filter change Figure 105

Figure 103

107903
112859
Visually check that belt (1) is not worn out or broken; change
Use tool 99360314 to remove fuel filter (1). it as described below, if required.
Before fitting the new cartridge, wet seal with fuel oil or engine
oil. Lock the new one by hand and carefully check that rubber Water pump/alternator control belt change
seal and contact surface are clean and in perfect conditions. In order to remove and refit belt (1), operate using a specific
Lock cartridge by hand till contact with support and then lock tool (3) on belt tensioner (2) in direction shown by arrow.
it for ºof a rev. at prescribed tightening torque. Bleed air from
supply system as described in paragraph below:

NOTE Belt tensioner is automatic and requires no

adjustment.

Print P2D32C001 E Base - April 2006

 64 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

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
NOTE The components of the system can be damaged filler (2) of tappet cover.
very quickly in presence of water or impurity within
- After the complete drainage, screw the plug and carry out
the fuel.
the clean oil filling.
Take prompt action on the filter to drain off the
water in the fuel circuit.
NOTE Use only the recommended oil or oil having the re-
Fuel filter is equipped with pump screw-valve to drain the quested features for the corrrect motor function-
water eventually mixed with fuel. ing.
In case of topping up, donè
t mix oils having different
Place a container underneath the filter and slightly loosen the features.
screw. Drain the water eventually contained in the filterè s If you donè t comply with theses rules, the service
bottom. warranty is no more valid.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.
- Check the level through the dipsick until when the filling
Engine oil change is next to the maximum level notch indicated on the dip-
sick.
Figure 106
Engine oil filter change
Figure 107

85493

We recommend to carry out the oil drainage when the motor

is hot.
Warning: We recommend to wear proper protec-
tions because of high motor service temperature. 99363

The motor oil reaches very high temperature: you Drain oil as described in èEngine oil changeèchapter. Use tool
must always wear protection gloves. 99360314 (2) to remove the oil filters (1).

- Place a proper container for the oil collecting under the

pan connected with the drain plug (3). NOTE Warning: the oil filter contains inside a quantity of
oil of about 1 kg.
- Unscrew the plug (3) and then take out the control dip-
sick (1) and the inserting plug (2) to ease the downflow Place properly a container for the liquid.
of the lubrication oil. Warning: avoid the contact of skin with the motor
oil: in case of contact wash the skin with running
water.
The motor oil is very pollutant: it must be disposed
The oil motor is very pollutant and harmful. of according to the rules.
In case of contact with the skin, wash with much water
and detergent.
NOTE Before refitting the new cartridge, wet seal using
Protect properly skin and eyes: operate according to engine oil.
safety rules.
Dispose of the residual properly following the rules. Lock oil filter (1) by hand till contact to support and then lock
by º of a rev. at prescribed tightening torque; pour oil in
engine ad described in èEngine oil changeèchapter.

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 3 - INDUSTRIAL APPLICATION 65

Valve lash check a adjustment

For correct operation, follow instructions contained in related
chapter in section 3 èIndustrial Applications.
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.

Print P2D32C001 E Base - April 2006

 66 SECTION 3 - INDUSTRIAL APPLICATION F3B CURSOR ENGINES

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1

SECTION 4
Overhaul and technical specifications

Page

GENERAL CHARACTERISTICS . . . . . . . . . . . . . 3

ASSEMBLY CLEARANCE DATA . . . . . . . . . . . . 5

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . 13

ENGINE REMOVAL AT THE BENCH . . . . . . . . 13

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . 14

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 14

- Checks and measurements . . . . . . . . . . . . . . . 14

- Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . 15

- Replacing cylinder liners . . . . . . . . . . . . . . . . . 16

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

- Assembly and checking protrusion . . . . . . . . . 16

- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- Measuring the main journals and crankpins . . . 18

- Preliminary measurement of main and big end

bearing shell selection data . . . . . . . . . . . . . . . 19

- Selecting the main bearing and big end

bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . 20

- Replacing the timing control gear and the oil pump 26

- Checking main journal installation clearance . . 26

- Checking crankshaft end float . . . . . . . . . . . . . 27

ASSEMBLING THE ENGINE ON THE BENCH . 28

DIAGRAM SHOWING THE UNDERBLOCK FIXING

SCREWS TIGHTENING ORDER . . . . . . . . . 29

PISTON CONNECTING ROD ASSEMBLY . . . . 30

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

- Measuring the diameter of the pistons . . . . . . 31

- Conditions for correct gudgeon pin-piston

coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Print P2D32C001 E Base - April 2006

 2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Page Page

- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 - Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

- Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . 33 - Checking cam lift and pin alignment . . . . . . . . . 42

- Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Replacing camshaft bushes using beater 99360499 44
- Checking connecting rods . . . . . . . . . . . . . . . . 34
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Mounting the connecting rod èpiston assembly 35
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Mounting the piston rings . . . . . . . . . . . . . . . . 35
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Fitting the big end bearing shells . . . . . . . . . . . 35
- Fitting the valves and oil seal ring . . . . . . . . . . . 45
- Fitting connecting rod - piston assemblies in
the cylinder liners . . . . . . . . . . . . . . . . . . . . . . . 36 ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 46
- Checking piston protrusion . . . . . . . . . . . . . . . 36 - Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
- Checking head bearing surface on cylinder - Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Checking crankpin assembly clearance . . . . . . . 37
- Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . 47
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . 37
- Idler gear pin . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Dismounting the valves . . . . . . . . . . . . . . . . . . 37
- Idler gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Twin intermediate gear pin . . . . . . . . . . . . . . . 47
- Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Twin idler gear . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Checking clearance between valve-stem and
associated valve guide . . . . . . . . . . . . . . . . . . . 39 - Replacing the bushings . . . . . . . . . . . . . . . . . . . 47

- Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 REAR POWER TAKEOFF . . . . . . . . . . . . . . . . . . 48

- Replacing injector cases . . . . . . . . . . . . . . . . . . 39 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

- Checking injector protrusion . . . . . . . . . . . . . . 41 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . 49

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 3

GENERAL CHARACTERISTICS

Type F3B

Cycle 4-stroke Diesel engine

Fuel feed Turbocharged
Injection Direct

No. of cylinders 6 in line

Bore mm 135

Stroke mm 150

+ + +.. = Total displacement cm3 12880

Print P2D32C001 E Base - April 2006

 4 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Type F3B

A
VALVE TIMING

opens before T.D.C. A

19
closes after B.D.C. B
B 36
C

opens before B.D.C. D

50
closes after T.D.C. C
9
D

For timing check

mm
X -
X mm
-
Running

mm 0.35 to 0.45
X
mm 0.45 to 0.55

FEED Through fuel pump - filters

Injection With electronically regulated injectors PDE 31
type: Bosch pump injectors controlled by overhead camshaft

Nozzle type _

Injection order 1-4-2-6-3-5

bar 1500
Injection pressure bar

Injector calibration bar 290 12

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 5

ASSEMBLY CLEARANCE DATA

Type F3B

CYLINDER BLOCK AND

mm
CRANKMECHANISM COMPONENTS
1
Bores for cylinder liners:
upper 153.500 to 153.525
1
lower 152.000 to 152.025

Cylinder liners:
external diameter:
L upper 153.461 to 153.486
2
lower 151.890 to 151.915
2 length L -
Cylinder liners -
crankcase bores
upper 0.014 to 0.039
lower 0.085 to 0.135

External diameter 2 -

Cylinder sleeve
3
inside diameter 3A* 135.000 to 135.013
X
inside diameter 3B* 135.011 to 135.024

Protrusion X 0.045 to 0.075

* Selection class
* Under a load of 800 N
Pistons: FEDERAL MOGUL MAHLE MONDIAL
1 measuring dimension X 20 20
X external diameter 1AF 134.884 to 134.996 134.881 to 134.893
external diameter 1BFF 134.895 to 134.907 134.892 to 134.894
2 pin bore 2 54.010 to 54.018
Piston - cylinder sleeve
A* 0.104 to 0.129 0.107 to 0.132
B* 0.104 to 0.129 0.107 to 0.132
* Selection class

Piston diameter 1 -

X
Pistons protrusion X 0.12 to 0.42

3 Gudgeon pin 3 53.994 to 54.000

Gudgeon pin - pin housing 0.010 to 0.024

F Class A pistons supplied as spares.
FF Class B pistons are fitted in production only and are not supplied as spares.

Print P2D32C001 E Base - April 2006

 6 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

F3B
Type
mm
FEDERAL MOGUL MAHLE MONDIAL
X1 X1* 3.433 3.445 to 3.475
X2 Piston ring grooves X2 3.060 to 3.080 3.050 to 3.070
X3 X3 5.020 to 5.040 5.020 to 5.040
* measured on of 130 mm
Piston rings:
trapezoidal
p seal S1* 3.296 to 3.364
S1 lune seal S2 2.970 to 2.990
S2
S3 milled
ill d scraper ring
i
with slits and internal
spring S3 4.970 to 4.990
* measured on of 130 mm
1 0.069 to 0.137 0.81 to 0.179
Piston rings - grooves 2 0.070 to 0.110 0.060 to 0.100
3 0.030 to 0.070 0.030 to 0.070

Piston rings -

X1 Piston ring end gap

in cylinder liners
X2
X1 0.40 to 0.55
X3
X2 0.65 to 0.80
X3 0.40 to 0.75

Small end bush housing

1 nominal 1 59.000 to 59.030

Big end bearing housing

nominal 2 94.000 to 94.030
2
- Class 1 94.000 to 94.010
- Class
- Class
{ 2
3
94.011 to 94.020
94.021 to 94.030
4 Small end bush diameter
outside 4 59.085 to 59.110
3
inside 3 54.019 to 54.035
Big end bearing shell S
S Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow 1.986 to 1.995
Small end bush - housing 0.055 to 0.110
Piston pin - bush 0.019 to 0.041

Big end bearing 0.127 - 0.254 - 0.508

Connecting rod weight g.

A 4741 to 4780
Class B 4781 to 4820
C 4821 to 4860

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 7

F3B
Type
mm
X
Measuring dimension X 125

Max. connecting rod

axis misalignment
tolerance 0.08

Main journals 1
- rated value 99.970 to 100.000
- class 1 99.970 to 99.979
- class 2 99.980 to 99.989
- class 3 99.990 to 100.000
1 2
Crankpins 2
- rated value 89.970 to 90.000
- class 1 89.970 to 89.979
- class 2 89.980 to 89.989
- class 3 89.990 to 90.000
S1 S 2 Main bearing shells S1
Red 3.110 to 3.120
Green 3.121 to 3.130
Yellow* 3.131 to 3.140
Big end bearing shells S2
Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow* 1.986 to 1.995
Main bearing housings 3
- rated value 106.300 to 106.330
3 - class 1 106.300 to 106.309
- class 2 106.310 to 106.319
- class 3 106.320 to 106.330
Bearing shells -
0.060 to 0.108 * - 0.061 to 0.119 ** - 0.060 to 0.130 ***
main journals f
Bearing shells -
0.050 to 0.108 * - 0.051 to 0.109 ** - 0.050 to 0.098 ***
big ends f
Main bearing shells 0.127 - 2.254 - 0.508
Big end bearing shells 0.127 - 2.254 - 0.508

Main journal,
thrust bearing X1 47.95 to 48.00
X1

Main bearing housing,

thrust bearing X2 40.94 to 40.99
X2
X3 Thrust washer
halves X3 3.38 to 3.43

Crankshaft end float 0.10 to 0.30

1 2 Alignment 1-2 0.025

Ovalization 1-2 0.010

0.010
Taper 1-2
* Fitted in production only and not supplied as spares
f Spares provided: : * = standard spares - 0.127; ** = 0.254 - 0.508

Print P2D32C001 E Base - April 2006

 8 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Type F3B

CYLINDER HEAD - VALVE TRAIN mm

1

Valve guide housings

in cylinder head
1 15.980 to 15.997

Valve guide 2 10.015 to 10.030

3 16.012 to 16.025
3

Valve guides - housings

0.015 to 0.045
in the cylinder heads

Valve guide -

4 Valves:

4
9.960 to 9.975
60 30 7 30
4 9.960 to 9.975
45 30è 7 30
Valve stem and its guide 0.040 to 0.070
Valve seat in
head

1 49.185 to 49.220

1 1 46.985 to 47.020
Outside diameter of valve
2 seat; angle of valve seat
in cylinder head:
49.260 to 49.275
2
60 è30è
47.060 to 47.075
2
45 - 30
X 0.45 to 0.75
Recessing of valve
X X 1.65 to 1.95

Between valve
seat and head 0.040 to 0.090

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 9
Table 2

F3B
Type
mm
Valve spring height:

free height H 73.40

H H1 under a load of:
H 2 575 28 N H1 59
1095 54 N H2 45

Injector protrusion X 0.53 to 1.34

X

Camshaft bushing housing

in the cylinder head:
1 7 88.000 to 88.030

Camshaft bearing
journals:
1 7 82.950 to 82.968
1 3

Outer diameter of
camshaft bushings:
88.153 to 88.183

Inner diameter of
camshaft bushings: 83.018 to 83.085

Bushings and housings

0.123 to 0.183
in the cylinder head
Bushings and bearing
journals 0.050 to 0.135
Cam lift:
9.231

H 9.5607

11.216

1
Rocker shaft 1 41.984 to 42.000

Print P2D32C001 E Base - April 2006

 10 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

F3B
Type
mm
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

56.030 to 56.049

42.015 to 42.071

Between bushings and

housings
0.074 to 0.130

0.081 to 0.140

0.050 to 0.091

Between bushings of
rocker arms and shaft
0.025 to 0.057

0.025 to 0.057

0.015 to 0.087

O1
Engine brake control lever
Eccentric pin outer
diameter 1 55.981 56.000
O2 Rocker arms shaft seat 2 42.025 42.041

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 11

Type F3B

mm
Rocker arms and engine
brake control lever pin

0.025 to 0.057

Rocker arm shaft and seat

on engine brake control
lever

0.025 to 0.057

TURBOCHARGER
Type HOLSET HX 60W
End float 0.025 to 0.127
Radial play 0.406 to 0.584

Print P2D32C001 E Base - April 2006

 12 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 13

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. (See Section 3 of the manual herein).
The section illustrates therefore all the most important
engine overhaul procedures.

Figure 1

47576
By means of proper and splined wrenches, untighten the
screws (1) and (2) and remove the under-block (3).

Figure 4

47574

Rotate the block (1) to the vertical position.

47570

Remove the crankshaft (2) with tool 99360500 (1).

Figure 5

Figure 2

47571

Remove the crankshaft half-bearings (1), untighten the

screws and remove oil spray nozzles (2).
Take down cylinder liners as specified in the relative
paragraph on page 16.

NOTE After disassembling the engine, thoroughly clean

disassembled parts and check their integrity.
47575 Instructions for main checks and measures are
given in the following pages, in order to determine
Untighten screws (2) fixing the connecting rod cap (3) and whether the parts can be re-used.
remove it. Remove the connecting rod-piston assembly from
the upper side. Repeat these operations for the other pistons.

Print P2D32C001 E Base - April 2006

 14 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

REPAIR OPERATIONS Figure 8

CYLINDER BLOCK x
Checks and measurements
Figure 6 (Demonstration)

60595
A = Selection class 135.000 to 135.013 mm
34994 B = Selection class 135.011 to 135.024 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 On finding maximum wear greater than 0.150 mm or
gauge 99395687 (2) previously reset to ring gauge (3), maximum ovalization of 0.100 mm compared to the values
diameter 135 mm. shown in the figure, you need to replace the cylinder liner as
no grinding, facing or reconditioning is permitted.

NOTE If a 135 mm ring gauge is not available use a NOTE

micrometer caliper. The cylinder liners are supplied as spare parts with
selection class èAè.

Figure 7

Figure 9

60596

60597
A = 153.500 to 153.525 mm
1 = 1st measurement B = 152.000 to 152.025 mm
2 = 2nd measurement C = 153.461 to 153.486 mm
3 = 3rd measurement D = 151.890 to 151.915 mm
The diagram shown in the figure gives the outside diameter
The measurements have to be made on each single cylinder of the cylinder liner and inside diameter of its seat.
liner at three different heights and on two levels (A-B) at right
angles to each other as shown in Figure 7. The cylinder liners can, if necessary, be extracted and fitted
several times in different seats.

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 15

Cylinder liners
Figure 10

60598

CRANKCASE ASSEMBLY WITH CYLINDER LINERS

Figure 11

101503
Selection class A 125.000 to 125.013 mm
B 125.011 to 125.024 mm
MAIN CYLINDER LINER DATA

Figure 12

101502
DETAIL èXè
èYèèSelection class marking area
Print P2D32C001 E Base - April 2006
 16 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.
as shown in the figure, checking that the plate (4) rests on the Using the dial gauge 99395603 supplied as standard with the
cylinder liner correctly. dial gauge base 99370415 (3), check that the protrusion of
Screw down the nut of screw (1) and extract the cylinder the cylinder liner over the supporting face of the cylinder
liner (3) from the crankcase. head is 0.045 - 0.075 mm (Figure 16); if this is not so, replace
the adjustment ring (1) (Figure 14), supplied as a spare part
Assembly and checking protrusion with several thicknesses.
Figure 14
Figure 16 0.045 to 0.075

49017
CYLINDER LINER PROTRUSION
Figure 17
16798

Always replace the water seals (3, 4 and 5).

Fit the adjustment ring (1) on the cylinder liner (2). Lubricate
the bottom of it and mount it in the cylinder assembly using
the appropriate tool.

NOTE
The adjustment ring (1) is supplied as a spare part
with the following thicknesses: 0.08 mm - 0.10 mm
- 0.12 mm - 0.14 mm.
60521

On completing assembly, lock the cylinder liners (1) to the

crankcase (2) with the pins 99360703 (3).

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 17

Crankshaft
Figure 18

Top main bearing shells

101504
Bottom main bearing shells
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.
Figure 19 Figure 20

POLISHED
BUFF

GROUND
GROUND

GROUND
101505 101506

X. Detail of the main journal unions Y. Detail of the crankpin unions

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 18 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.

Figure 21

47536

MEASURING CRANKPINS
When grinding, pay the utmost attention to the values of the
47535
unions of the main journals and of the crankpins given in
Figure 19 and Figure 20.
MEASURING THE MAIN JOURNALS

NOTE It is advisable to note the measurements in a table NOTE All the main journals and crankpins should always
(Figure 22). be ground to the same undersizing class so as not
to alter the balance of the shaft.

Figure 23
Table for noting down the measurements of the main journals and crankpins of the crankshaft.

MAIN JOURNALS

MIN.
MAX.

MIN.
MAX.

CRANKPINS 36061

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 19

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
crankcase. connecting rod.
- Determine the class of diameter of the main journal. - Determine the class of diameter of the crankpin.
- Select the class of the bearing shells to mount. - Select the class of the bearing shells to mount.
DEFINING THE CLASS OF DIAMETER OF THE SEATS FOR BEARING SHELLS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure 24 at top).
- The first set of digits (four) is the coupling number of the crankcase with its base.
- The following seven digits, taken singly, are the class of diameter of each of the seats referred to (Figure 24 at bottom).
- Each of these digits may be 1, 2 or 3.

CLASS MAIN BEARING HOUSING

Figure 24 NOMINAL DIAMETER

106.300 to 106.309

106.310 to 106.319

106.320 to 106.330

47535

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 20 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).
Depending on the thickness, the bearing shells are selected Figure 25 gives the specifications of the main bearing and big
in classes of tolerance marked by a colour (red-green - end bearing shells available as spare parts in the standard sizes
red/black - green/black). (STD) and in the permissible oversizes (+0.127, +0.254,
+0.508).
Figure 25

Big end bearing shells STD +0.127 +0.254 +0.508

red 1.965 to 1.975 2.092 to 2.102 2.219 to 2.229

red/black 2.028 to 2.038

green 1.976 to 1.985 2.103 to 2.112 2.230 to 2.239

green/black 2.039 to 2.048

Main bearing shells STD +0.127 +0.254 +0.508

red 3.110 to 3.120 3.237 to 3.247 3.364 to 3.374

red/black 3.173 to 3.183

green 3.121 to 3.130

green/black 3.184 to 3.193

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 21

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.
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken singly, give the class of diameter of each of the crankpins
they refer to (Figure 26 at top).
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the
status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the class of diameter of each of the
main journals they refer to (Figure 26 at bottom).

Figure 26

CRANKPIN
CLASS
NOMINAL DIAMETER

89.970 to 89.979

89.980 to 89.989

89.990 to 90.000

CLASS MAIN JOURNALS

NOMINAL DIAMETER

99.970 to 99.979
99.980 to 99.989
99.990 to 100.000

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 22 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.

1 2 3

green green green

1
green green green

red green green

2
red green green

red red green

3
red red green

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 23

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.
Figure 28

red/black = -0.127
3.173 to 3183 mm

green/black =
3.184 to 3.193 mm
1 2 3
99.843 green/black green/black green/black
1
99.852 green/black green/black green/black

99.853 red/black green/black green/black

2
99.862 red/black green/black green/black

99.863 red/black red/black green/black

3
99.873 red/black red/black green/black

-0.254

red =
3.237 to 3.247 mm
1 2 3

red red red

99.726
99.746 red red red

-0.508

red =
3.364 to 3.374 mm
1 2 3

red red red

99.468
99.508 red red red

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 24 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 èAè:

1 Letter indicating the class of weight:

VIEW FROM âAâ
A = 4741 to 4780 g.
B = 4781 to 4820 g.
C = 4821 to 4860 g.
2 Number indicating the selection of the diameter of the
big end bearing seat:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3 Numbers identifying the cap-connecting rod coupling.

The number, indicating the class of diameter of the bearing

shell seat may be 1, 2 o 3.
Determine the type of big end bearing to fit on each journal
by following the indications in the table (Figure 30). 47557

Figure 30

STD.

CLASS 1 2 3

green green green

1
green green green

red green green

2
red green green

red red green

3
red red green

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 25

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.
Figure 31
red/black =
2.028 to 2.038 mm -0.127
green/black =
2.039 to 2.048 mm
1 2 3
89.843 green/black green/black green/black
1
89.852 green/black green/black green/black

89.853 red/black green/black green/black

2
89.862 red/black green/black green/black

89.863 red/black red/black green/black

3
89.873 red/black red/black green/black

-0.254
red =
2.092 to 2.102 mm
green =
1 2 3
2.103 to 2.112 mm

89.726 red green green

89.735 red green green

89.736 red red green

89.746 red red green

-0.508
red =
2.219 to 2.229 mm
green =
1 2 3
2.230 to 2.239 mm

red green green

89.472
89.481 red green green

89.482 red red green

89.492 red red green

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 26 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Replacing the timing control gear and the oil Figure 34

pump
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).
Figure 35

49020

When fitting gear (1) onto drive shaft (2), the gear must be
heated for 2 hours max. in a furnace, at a temperature not
higher than 180 C.
Let them cool down after the installation.
If changing the pin (3), after fitting it on, check it protrudes
from the crankshaft as shown in the figure.

49021
Install the half-bearings (1) on the main bearings in the
underblock (2).
Check the installation clearance between the main journals
and the relative bearings as follows:
Checking main journal installation clearance
Figure 36

Figure 33

101507

By means of suitable equipment (1) apply silicone LOCTITE

5970 to the block, as shown in the figure.
47579 Frame shows the application scheme for the LOCTITE 5970
sealant.
Install the oil spray nozzles (2) and have the dowel coincide NOTE Fit the underblock within 10èof the application of
with the block hole (3). the sealant.
Install the half-bearings (1) on the main bearings.

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 27

Figure 37 Figure 38

60559 47578

Set two journals of the crankshaft (2) parallel to the - Lubricate the internal screws (1) with UTDM oil and
longitudinal axis, a section of calibrated wire. Using tighten them with a torque wrench (3) to a torque of
appropriate hooks and tackle, mount the crankcase base (1). 120 Nm, using tool 99395216 (4), to an angle of 60 ,
following the diagram below.
Figure 39

FRONT SIDE

60593

DIAGRAM OF SEQUENCE FOR TIGHTENING THE SCREWS FIXING

THE BOTTOM CRANKCASE BASE TO THE CRANKCASE
Figure 40 Checking crankshaft end float

Figure 41

- Remove the crankcase base. 47579

The clearance between the main bearings and their journals

is measured by comparing the width taken on by the
calibrated wire (2) at the point of greatest crushing with the 47588
graduated scale on the case (1) containing the calibrated
wire. The end float is checked by setting a dial gauge (1) 99395603
The numbers on the scale give the clearance of the coupling with a magnetic base on the crankshaft (2) as shown in the
in millimetres. If you find the clearance is not as required, figure. If you find the clearance to be greater than as required,
replace the bearing shells and repeat the check. replace the rear main bearing shells carrying the thrust
bearings and repeat the clearance check.

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 28 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

ASSEMBLING THE ENGINE ON THE Figure 45

BENCH
Figure 42

49022

Fit the underblock by means of a suitable hoist and hooks (1).

49021

Place the half-bearings (1) on the main bearings in the Figure 46

underblock (2).

Figure 43

47581

Fit the sub-engine block and use a dynamometric wrench (2)

to tighten the outer hexagonal-grooved screws (1) to 30 Nm
47595
according to the diagrams on the following page.
By means of suitable equipment (1) apply silicone LOCTITE
5970 IVECO No. 2992644 to the block, as shown in the
figure. Figure 47

Figure 44

47596

Sealant application diagram 47579

Close the inner screws (1) to 120 Nm torque by means of

NOTE Fit the underblock within 10èof the application of a dynamometric wrench (3), then with two further angular
the sealant. phases 60 + 55 , using tool 99395216 (4). Tighten again the
outer screws (1, Figure 46) with 60 angular closing, using
tool 99395216 (3, Figure 46).
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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 29

DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER

Figure 48

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
(60Ø)

60593

stage 4:
FRONT SIDE
angle
inner
screws
(55Ø)

60593

stage 5:
FRONT SIDE angle
outer
screws
(60Ø)
60594

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 30 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

PISTON CONNECTING ROD ASSEMBLY

Figure 49

60607

PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring -
6. Scraper ring with spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston.

Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.

Removal
Figure 50 Figure 51

60608 49024

Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin split rings (2) using the round tipped
(1). pliers (1).
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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 31

Figure 52 Figure 54

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 53

Conditions for correct gudgeon pin-piston

coupling
71714

Using a micrometer (2), measure the diameter of the piston

(1) to determine the assembly clearance; the diameter has to Figure 55
be measured at the value X shown:

49026

Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.

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 32 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Figure 56

106242

MAIN DATA OF THE PISTON, PISTON RINGS AND PIN

* MAHLE MONDIAL piston - ** FEDERAL MOGUL piston
F Dimension detected on 130 mm . - J measured at 2.5 mm from outer - X = 0,8 0,1
Piston rings Figure 59
Figure 57

3513

The seal (2) of the 1st slot has a V shape. The clearance èXè
between the seal and its seat is measured by setting the
piston (1) with the ring in the cylinder liner (3) so that the
16552
seal comes half out of the cylinder liner.
Check the thickness of the piston ring (2) with a micrometer
(1).
Figure 60
Figure 58

36134

Using a feeler gauge (2), check the opening between the ends
of the seals (1) inserted in the cylinder liner (3).
60610
If you find the distance between the ends is less than or
Check the clearance between the seals (2) and their seats on greater than as required, replace the piston rings.
the piston (1) with a feeler gauge (3).

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 33

Connecting rod
Figure 61

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.

NOTE On assembling the connecting rods, check VIEW FROM âAâ

they are all of the same class of weight.

Connecting rod punch markings

1 Letter indicating the class of weight:

A = 4741 to 4780 g.
B = 4781 to 4820 g.
C = 4821 to 4860 g.
2 Number indicating the selection of the diameter
of the big end bearing seat:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3 Number indicating the selection of diameter
for the big end bearing housing:

47957

Figure 62

54.000
54.030

54.085 50.019* 49.994

54.110 50.035* 50.000

1.970
2.000

87.000
87.030

71716

MAIN DATA OF THE BUSHING, CONNECTING ROD, PIN AND BEARING SHELLS
* Measurement to be made after driving in the bushing.

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 34 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Bushings Checking torsion

Figure 63 Figure 65

73535

Check the bushing in the small end has not come loose and 61694
shows no sign of scoring or seizure; replace it if it does.
The bushing (2) is removed and fitted with a suitable drift (1). Check the torsion of the connecting rod (5) by comparing
When driving it in, make absolutely sure that the holes for the two points (A and B) of the pin (3) on the horizontal plane
oil to pass through in the bushing and small end coincide. of the axis of the connecting rod.
Using a boring machine, rebore the bushing so as to obtain Position the mount (1) of the dial gauge (2) so that this
a diameter of 54.019 è54.035. pre-loads by approx. 0.5 mm on the pin (3) at point A and
zero the dial gauge (2). Shift the spindle (4) with the
connecting rod (5) and compare any deviation on the
opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.
Checking connecting rods
Figure 64 Checking bending
Figure 66

61696 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
Checking axis alignment axis of the connecting rod.
Check the alignment of the axes of the connecting rods (1) Position the vertical mount (1) of the dial gauge (2) so that this
with device 99395363 (5), proceeding as follows: rests on the pin (3) at point C.
Fit the connecting rod (1) on the spindle of the tool Swing the connecting rod backwards and forwards seeking the
99395363 (5) and lock it with the screw (4). highest position of the pin and in this condition zero the dial
gauge (2). Shift the spindle (4) with the connecting rod (5) and
Set the spindle (3) on the V-prisms, resting the connecting repeat the check on the highest point on the opposite side D
rod (1) on the stop bar (2). of the pin (3). The difference between point C and point D
must be no greater than 0.08 mm.
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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 35

Mounting the connecting rod âpiston assembly Mounting the piston rings

Figure 67 Figure 69

60614

To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
73536
The rings need to be mounted with the word èTOPè(4)
facing upwards. Direct the ring openings so they are
The piston (1) has to be fitted on the connecting rod (2) so staggered 120 apart.
that the graphic symbol (4), showing the assembly position
in the cylinder liner, and the punch marks (3) on the
connecting rod are observed as shown in the figure.
Fitting the big end bearing shells
Figure 70
Figure 68

1
2

49030
74052
Fit the bearing shells (1), selected as described under the
Fit the pin (2) and fasten it on the piston (1) with the split rings heading èSelecting the main and big end bearing shellsè, on
(3). 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.

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 36 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Fitting connecting rod - piston assemblies in Figure 71

the cylinder liners
With the aid of the clamp 99360605 (1, Figure 71), fit the
connecting rod èpiston assembly (2) in the cylinder liners,
according to the diagram of Figure 72, checking that:
- The openings of the piston rings are staggered 120
apart.
- The pistons are all of the same class, A or B.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil nozzles.

60616

Checking piston protrusion

NOTE The pistons are supplied as spares in class A and can On completing assembly, check the protrusion of the pistons
be fitted in class B cylinder liners. from the cylinder liners it must be 0.12 è0.42 mm.

Figure 72

60615

ASSEMBLY DIAGRAM OF CONNECTING ROD èPISTON ASSEMBLY IN CYLINDER LINER

1. Connecting rod èpiston assembly è2. Area of punch marking on the top of the piston,
symbol showing assembly position and selection class è3. Connecting rod punch mark area

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 37

Checking crankpin assembly Figure 74

clearance
To measure the clearance, carry out the following
operations.
Connect the connecting rods to the relevant journals of the
crankshaft, placing a length of calibrated wire on the journals.
Figure 73

47583

Mount and secure the tool 99360263 (2) with the bracket
(4). Screw down with the device 99360261 (1) to be able to
remove the cotters (3). Take out the tool (2) and extract the
top plate (5), spring (6) and bottom plate (7).
Repeat this process on all the valves.
47594 Turn over the cylinder head and take out the valves (8).
Mount the connecting rod caps (1) together with the bearing
shells. Tighten the screws (2) fixing the connecting rod caps
to a torque of 60 Nm (6 kgm). Using tool 99395216 (3),
further tighten the screws with an angle of 60 .
NOTE The thread of the screws (2), before assembly, has
to be lubricated with engine oil.

Remove the caps and determine the clearance by comparing

the width of the calibrated wire with the graduated scale on Checking head bearing surface on cylinder
the case containing the calibrated wire. block
Upon final assembly: check the diameter of the thread of the
screws (2), it must be no less than 13.4 mm; if it is, change the Figure 75 (Demonstration)
screw. Lubricate the crankpins and connecting rod bearings.
Tighten the screws (2) as described above.

CYLINDER HEAD
Before dismounting cylinder head, check cylinder head for
hydraulic seal by proper tooling; in case of leaks not caused
by cup plugs or threaded plugs, replace cylinder head.

NOTE In case of plugs dismounting/replacement, on

mounting, apply sealant Loctite 270 on plugs.
36159

Check the supporting surface (1) of the head on the cylinder

Dismounting the valves block with a rule (2) and a feeler gauge (3). If you find any
deformation, level the head on a surface grinder; maximum
amount of material that can be removed 0.2 mm.
NOTE Before dismounting cylinder head valves, number
them in view of their remounting in the position
observed on dismounting should they not have to
be overhauled or replaced.
NOTE After this process, you need to check the valve
recessing and injector protrusion.

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 38 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Valves Figure 77
Decarbonizing and checking valves

Figure 76

71718

48625 MAIN DATA OF VALVES AND VALVE GUIDES

Remove the carbon deposits on the valves with a wire brush. * Measurement to be made after driving in the valve guides
Check that the valves show no signs of seizure or cracking
and check with a micrometer that the valve stem diameter
comes within the required values (see Figure 77); replace the Check with a micrometer that the diameter of the valve
valves if it does not. stems is as indicated. If necessary, grind the valve seats with
a grinding machine, removing as little material as possible.

Valve seats
Regrinding âreplacing valve seats

NOTE The valve seats are reground whenever the valves

or valve guides are ground and replaced.

Figure 78

1 2

73555

MAIN DATA OF VALVE SEATS

1. Intake valve seat è2. Exhaust valve seat

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 39

Figure 79 Part 99360296 determines the exact position of assembly of

the valve guides in the cylinder head. If they are not available,
you need to drive the valve guides into the cylinder head so
they protrude by 30.8 31.2 mm.
After driving in the valve guides, rebore their holes with the
smoother 99390330.

Replacing injector cases

Removal

Figure 81

41032

Check the valve seats (2). If you find any slight scoring or
burns, regrind them with tool 99305019 (1) according to the
angles shown in Figure 78. If it is necessary to replace them,
using the same tool and taking care not to affect the cylinder
head, remove as much material as possible from the valve
seats so that, with a punch, it is possible to extract them from
the cylinder head.
Heat the cylinder head to 80 100 C and, using a drift, fit
in the new valve seats (2), chilled beforehand in liquid
nitrogen. Using tool 99305019 (1), regrind the valve seats
according to the angles shown in Figure 78.
After regrinding the valve seats, using tool 99370415 and dial
gauge 99395603, check that the position of the valves in
relation to the plane of the cylinder head is:
- -0.45 -0.75 mm (recessing) intake valves
- -1.65 -1.95 mm (recessing) exhaust valves.
Checking clearance between valve-stem and
associated valve guide
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
valve guide.
Valve guides
Replacing valve guides
Figure 80

60619

To replace the injector case (2), proceed as follows:

- Thread the case (2) with tool 99390804 (1).
The steps described in Figs. 81 - 84 - 85 - 86 need to be
carried out by fixing the tools, with the bracket A, to the
cylinder head.

71719

The valve guides are removed with the drift 99360143.

They are fitted with the drift 99360143 equipped with part
99360296.

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 40 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Figure 82 Assembly
Figure 84

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
60620
screw (1) upsetting the bottom portion of the case.
- Screw the extractor 99342149 (2) into the case (3).
Screw down the nut (1) and take the case out of the Figure 85
cylinder head.
Figure 83

60621

- Using the tool 99390772 (2) remove any residues (1) left
60623
in the groove of the cylinder head.
- Using the reamer 99394041 (1-2), rebore the hole in the
case (3).
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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 41

Figure 86 Figure 88

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 87

47585

Check injector protrusion (2) with the dial gauge (1).

The protrusion must be 0.52 - 1.34 mm.

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 42 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Camshaft
Checking cam lift and pin alignment
Figure 89

47506

Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2); values are shown in table on page
9.

Figure 90

47507

When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not
exceed 0.030 mm. If misalignment exceeds this value, replace the shaft.

Figure 91
1

47505

In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.
If clearance exceeds 0.135 mm, replace bushes and, if necessary, the camshaft.

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 43

Figure 92

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

DIRECTION Perpendicularity
POSITION Concentricity or coaxiality
SWING Circular oscillation
CLASS OF IMPORTANT ASCRIBED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL
IMPORTANT
SECONDARY

Bushings
Figure 93

60627

MAIN DATA OF THE BUSHINGS FOR THE CAMSHAFT AND SEATS ON THE CYLINDER HEAD
* Bushing inside diameter after driving in
The surface of the bushings must show no sign of seizing or If you find a higher value than the tolerance, replace them.
scoring; replace them if they do. To remove and fit the bushings, use the appropriate drift
Measure the inside diameter of the bushings with a bore 99360499.
gauge.
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 44 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

Replacing camshaft bushes using beater 99360499

Figure 94

A B C D E F D L G H D I 71721

A. Drift with seat for bushings to insert/extract. - B. 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). - E. Guide bushing. -
F. Guide line. - G. Guide bushing to secure to the seventh bushing mount. - H. Plate fixing yellow bushing to cylinder head.
- I. Grip. - L. Extension coupling.
Removal
Figure 95 1 Position the bushing to insert on the drift (A) making the
grub screw on it coincide with the seat (B) (Figure 94) on
the bushing.
2 Position the guide bushing (E) and secure the guide
bushing (G) (Figure 94) on the seat of the 7 th bushing
with the plate (H).
3 While driving in the bushing, make the reference mark (F)
match the mark (M). In this way, when it is driven home,
the lubrication hole on the bushing will coincide with the
oil pipe in its seat.
The bushing is driven home when the 1st red reference
mark (D) is flush with the guide bushing (G).

Rear 71725

The sequence for removing the bushings is 7, 6, 5, 4, 3, 2, 1.

The bushings are extracted from the front of the single seats. Figure 97
Removal does not require the drift extension for bushings 5,
6 and 7 and it is not necessary to use the guide bushing.
For bushings 1, 2, 3 and 4 it is necessary to use the extension
and the guide bushings.
Position the drift accurately during the phase of removal.

Assembly
Figure 96

Rear

71723

To insert the bushing (6), proceed as follows:

- Unscrew the grip (I) and the extension (N).
- Position the extension (N) and the guide bushing (E) as
shown in the figure.
77795 - Repeat steps 1, 2, 3.
Assemble the drift together with the extension.
To insert bushings 1, 2, 3, 4 and 5, proceed as follows:

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 45

Figure 98 Fitting the valves and oil seal ring

Figure 101

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. Drive it home.
The 7th bushing is driven in when the reference mark (C)
is flush with the bushing seat.

VALVE SPRINGS
87051
Figure 99

NOTE Should valves not have been overhauled or

replaced, remount them according to numbering
performed on dismounting.

Lubricate the valve stem and insert the valves in the

respective valve guides; fit the lower caps (1). Use tool
99360329 to fit the oil seal (2) on the valve guides (3) of the
exhaust valves; then, to fit the valves, proceed as follows.

70000

Before assembly, the flexibility of the valve springs has to be Figure 102
checked with the tool 99305047.
Compare the load and elastic deformation data with those
of the new springs given in the following figure.
Figure 100

Free spring height

Valve closed

Valve open
86290

- fit springs (6) and the upper plate (5);

99375
- apply tool 99360263 (2) and block it with bracket (4);
tighten the lever (1) until cotters are installed (3),
MAIN DATA TO CONTROL EXHAUST AND remove tool (2).
DISCHARGE VALVE SPRING

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 46 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

ROCKER SHAFT
Figure 103

99281
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.
Two lubrication holes are obtained inside the rockers.
The rocker shaft practically covers the whole cylinder head; remove it to have access to all the underlying components.
Shaft
Figure 104

73557

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
Figure 105 Figure 107

SECTION A-A

SECTION B-B

99376

71728 The bush surfaces must not show any trace of scoring of
PUMP INJECTOR ROCKER excessive wear; otherwise, replace bushes or the whole
rocker.
Figure 106 Figure 108

SECTION A-A
SECTION A-A SECTION
B-B
SECTION B-B

71729 71730

EXHAUST VALVES ROCKER DISCHARGE VALVE ROCKER

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 47

TIMING GEAR Twin intermediate gear pin

Camshaft drive Twin idler gear
Figure 109 Figure 111

86925
101601

TIMING CONTROL COMPONENT PARTS

1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod - * This measurement is obtained after assembling.
5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear
- 8. Drive shaft driving gear.

Idler gear pin

Idler gear
Replacing the bushings
Figure 110
Bushings (2) can be replaced when they are worn. Put up the
bushing, then bore it to obtain the diameter shown on
Figure 110 or Figure 111.

NOTE The bushing must be driven into the gear by

following the direction of the arrow and setting the
latter to the dimension shown on Figure 110 or
Figure 111.

Rated assembling play between gear bushings and pins:

Figure 110 è0.045 0.075 mm
Figure 111 è0.045 0.085 mm.

101602

* This measurement is obtained after assembling.

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 48 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

REAR POWER TAKEOFF

Figure 112

107991

1. Gear - 2. Nut - 3. Shaft - 4. Washer - 5. Spacer - 6. Support - 7. Cover - 8. Screw - 9. Seal.

Figure 113
Removal

Remove retaining screws (8) and disconnect cover (7) with

seal (9) from support (6).
Lock shaft (3) rotation and remove nut (2) .
Remove from shaft (3): washer (4), gear (1) and spacer (5).
Remove shaft (3) from support (6).

107992
Refitting
For refitting, reverse operations described for
Shaft
removal according to instructions below:
- install a new seal (9); Figure 114

- lubricare shaft shank (3) with engine oil;

- lock screws and nut at prescribed torque.

107993

Rated shaft/rear power takeoff supporting bushing backlash

: 0,05 0,10 mm.

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 49

TIGHTENING TORQUE
TORQUE
PART
Nm kgm
Capscrews, undercrankcase to crankcase
M12x1.75 outer screws Stage 1: pretightening 30 (3)
M 17x2 inner screws Stage 2: pretightening 120 (12)
Inner screws Stage 3: angle 60
Inner screws Stage 4: angle 55
Outer screws Stage 5: angle 60
Piston cooling nozzle union 35 2 (3.5 0.2)
Capscrews, heat exchanger to crankcase
pretightening 11.5 3.5 (1.15 0.35)
tightening 19 (1.9 0.3)
Piston cooling nozzle union 24,5 2,5 (2.4 0.25)
Spacer and oil sump capscrews
pretightening 38 (3.8)
tightening 45 (4.5)
M 12x1.75 screws, gear case to crankcase 63 7 (6.3 0.7)
M 12x1.75 screws, gear case to crankcase 24 2,5 (2.4 0.25)
Cylinder head capscrews
Stage 1: pretightening 60 (6)
Stage 2 pretightening 120 (12)
Stage 3: angle 90
Stage 4: angle 65
Rocker shaft capscrew
Stage 1: pretightening 80 (8)
Stage 2: angle 60
Locknut, rocker adjusting screw 39 5 (3.9 0.5)
Capscrews, injector securing brackets 26 (2.6)
Capscrews, injector securing brackets 8,5 1,5 (0.8 0.15)
Capscrews, thrust plates to head 19 3 (1.9 0.3)
Screw fastening the engine supporting bracket to the cylinder head
Stage 1: pretightening 120 (12)
Stage 2: angle 45
Before assembly, lubricate with UTDM oil
Before assembly, lubricate with graphitized oil

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 50 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

TORQUE
PART
Nm kgm
Screw fastening the engine supporting bracket to the flywheel case
Stage 1: pretightening 100 (10)
Stage 2: angle 60
Camshaft gear capscrews
Stage 1: pretightening 60 (6)
Stage 2: angle 60
Screw fixing phonic wheel to timing system gear 8.5 1.5 (0.85 0.15)
Exhaust manifold capscrews
pretightening 40 5 (4 0.5)
tightening 70 5 (7 0.5)
Capscrews, connecting rod caps
Stage 1: pretightening 60 (6)
Stage 2: angle 60
Engine flywheel capscrews
Stage 1: pretightening 120 (12)
Stage 2: angle 90
Screws fixing damper flywheel:
First phase pre-tightening 70 (7)
Second phase closing to angle 50
Screws fixing intermediate gear pins:
First phase pre-tightening 30 (3)
Second phase closing to angle 90
Screw fixing connecting rod for idle gear 24.5 2.5 (2.45 0.25)
Screws fixing oil pump 24.5 2.5 (2.45 0.25)
Screws fixing crankshaft gasket cover 24.5 2.5 (2.45 0.25)
Screws fixing fuel pump/filter 19 (1.9)
Screw fixing control unit mount to crankcase 19 3 (1.9 0.3)
Screws and nuts fixing turbocharger
pre-tightening 35 (3.5
tightening 46 (4.6)
Screws fixing water pump to crankcase 22 2 (2.2 0.2)
Screws fixing water pump to crankcase 25 (2.5)
Screw fixing automatic tensioner to crankcase 26 3 (2.6 0.3)
Screw fixing fixed tensioner to crankcase 50 5 (5 0.5)
Screws fixing fan mount to crankcase 105 5 (10.5 0.5)
Screws fixing starter motor 74 4 (7.4 0.4)
Screws fixing air heater to cylinder head 30 3 (3 0.3)

Before assembly, lubricate with UTDM oil

Before assembly, lubricate with graphitized oil

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 F3B CURSOR ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 51

TORQUE
PART
Nm kgm
Screw fixing alternator M 10x1,5 I = 35 mm 30 3 (3 0.3)
M 10x1,5 I = 60 mm 44 4 (4.4 0.4)
Screws fixing air-conditioner compressor to mount 24.5 2.5 (2.5 0.25)
Screws fixing guard 24.5 25 (2.5 0.25)
Filter clogging sensor fastening 55 5 (5.5 0.5)
Water/fuel temperature sensor fastener 35 (3.5)
Thermometric switch/transmitter fastener 25 (2.5)
Air temperature transmitter fastener 35 (3.5)
Pulse transmitter fastener 8 2 (0.8 0.2)
Injector-pump connections fastener 1.36 1.92 (0.13 0.19)
Before assembly, lubricate with UTDM oil
Before assembly, lubricate with graphitized oil

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 52 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F3B CURSOR ENGINES

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 F3B CURSOR ENGINES SECTION 5 - TOOLS 1

SECTION 5
Tools

Page

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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 2 SECTION 5 - TOOLS F3B CURSOR ENGINES

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 F3B CURSOR ENGINES SECTION 5 - TOOLS 3

TOOLS
TOOL NO. DESCRIPTION

Full-optional tool-kit to rectify valve seat

99305019

99305047 Spring load tester

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

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 4 SECTION 5 - TOOLS F3B CURSOR ENGINES

TOOLS
TOOL NO. DESCRIPTION

99342149 Extractor for injector-holder

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

99360143 Box wrench for block junction bolts to the underblock

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 F3B CURSOR ENGINES SECTION 5 - TOOLS 5

TOOLS
TOOL NO. DESCRIPTION

99360144 Tools (12 + 6) holding rocker adjustment screw blocks when

removing/refitting the rocker shaft

99360180 Injector housing protecting plugs (6)

Pliers for assembling and disassembling piston split rings

99360184 (105-106 mm)

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)

99360296 Tool to fit back valve guide (to be used with 99360481)

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 6 SECTION 5 - TOOLS F3B CURSOR ENGINES

TOOLS
TOOL NO. DESCRIPTION

99360314 Tool to remove oil filter (engine)

99360321 Tool to rotate engine flywheel (to be used with 99360325)

99360325 Spacer (to be used with 99360321)

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)

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 F3B CURSOR ENGINES SECTION 5 - TOOLS 7

TOOLS
TOOL NO. DESCRIPTION

Cylinder liner compression plate

99360337 (to be used with 99360334-99360336)

99360351 Tool to stop engine flywheel

Tool to take down and fit back camshaft bushes

99360499

99360500 Tool to lift crankshaft

99360551 Bracket to take down and fit engine flywheel

99360553 Tool for assembling and installing rocker arm shaft

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 8 SECTION 5 - TOOLS F3B CURSOR ENGINES

TOOLS
TOOL NO. DESCRIPTION

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.

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)

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 F3B CURSOR ENGINES SECTION 5 - TOOLS 9

TOOLS
TOOL NO. DESCRIPTION

99360726 Ring (125 mm) (to be used with 99360706)

99361036 Brackets fixing the engine to rotary stand 99322230

99365056 Tool for injector holder heading

99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)

99378100 Tool for printing engine identification plates

(to be used with special punches)

Punches (B) for printing engine identification plates

99378101* (to be used with 99378100)
99378103
99378105H

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 10 SECTION 5 - TOOLS F3B CURSOR ENGINES

TOOLS
TOOL NO. DESCRIPTION

Torque screwdriver for calibrating the injector solenoid

99389834 valve connector check nut

99390311 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 Guide bush (to be used with 99390804)

99394015 Guide bush (to be used with 99394041 or 99394043)

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 F3B CURSOR ENGINES SECTION 5 - TOOLS 11

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 1/2è

99395216 and 3/4èsquare couplings

Gauge for defining the distance between the centres

99395218 of camshaft and transmission gear

99395363 Complete square to check connecting rod squaring

99395603 Dial gauge (0 - 5 mm)

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 12 SECTION 5 - TOOLS F3B CURSOR ENGINES

TOOLS
TOOL NO. DESCRIPTION

99395687 Reaming gauge (50 - 178 mm)

Centering ring of crankshaft front gasket cap

99396035

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 F3B CURSOR ENGINES APPENDIX 1

Appendix

Page

SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3

Print P2D32C001 E Base - April 2006

 2 APPENDIX F3B CURSOR ENGINES

Base - April 2006 Print P2D32C001 E

 F3B CURSOR ENGINES APPENDIX 3

SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
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 theyè ve been designed and
whose non fulfillment will make any other measure useless provided for: serious injury may occur.
or not sufficient to ensure safety to the personnel in-charge
of maintenance. - In case of test or calibration operations requiring engine
Be informed and inform personnel as well of the laws in force running, ensure that the area is sufficiently aerated or
regulating safety, providing information documentation utilize specific vacuum equipment to eliminate exhaust
available for consultation. gas. Danger: poisoning and death.
- Keep working areas as clean as possible, ensuring
adequate aeration. During maintenance
- Ensure that working areas are provided with emergency
boxes, that must be clearly visible and always provided - Never open filler cap of cooling circuit when the engine
with adequate sanitary equipment. is hot. Operating pressure would provoke high
temperature with serious danger and risk of burn. Wait
- Provide for adequate fire extinguishing means, properly unit the temperature decreases under 50ØC.
indicated and always having free access. Their efficiency
must be checked on regular basis and the personnel - Never top up an overheated engine with cooler and
must be trained on intervention methods and priorities. utilize only appropriate liquids.
- Organize and displace specific exit points to evacuate - Always operate when the engine is turned off: whether
the areas in case of emergency, providing for adequate particular circumstances require maintenance
indications of the emergency exit lines. intervention on running engine, be aware of all risks
- Smoking in working areas subject to fire danger must be involved with such operation.
strictly prohibited. - Be equipped with adequate and safe containers for
- Provide Warnings throughout adequate boards signaling drainage operation of engine liquids and exhaust oil.
danger, prohibitions and indications to ensure easy
comprehension of the instructions even in case of - Keep the engine clean from oil tangles, diesel fuel and or
emergency. chemical solvents.
- Use of solvents or detergents during maintenance may
Prevention of injury originate toxic vapors. Always keep working areas
aerated. Whenever necessary wear safety mask.
- Do not wear unsuitable cloths for work, with fluttering
ends, nor jewels such as rings and chains when working - Do not leave rags impregnated with flammable
close to engines and equipment in motion. substances close to the engine.

- Wear safety gloves and goggles when performing the - Upon engine start after maintenance, undertake proper
following operations: preventing actions to stop air suction in case of runaway
- filling inhibitors or anti-frost speed rate.
- lubrication oil topping or replacement - Do not utilize fast screw-tightening tools.
- utilization of compressed air or liquids under pressure
(pressure allowed: 2 bar) - Never disconnect batteries when the engine is running.

- Wear safety helmet when working close to hanging - Disconnect batteries before any intervention on the
loads or equipment working at head height level. electrical system.

- Always wear safety shoes when and cloths adhering to - Disconnect batteries from system aboard to load them
the body, better if provided with elastics at the ends. with the battery loader.

- Use protection cream for hands. - After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
- Change wet cloths as soon as possible from accidental short circuit and oxidation.
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections
efficiency of earth and mass electrical connections. in presence of electrical feed.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry - Before proceeding with pipelines disassembly
out working operations if not trained for. (pneumatic, hydraulic, fuel pipes) verify presence of liquid
or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
- Put the dirty rags with oil, diesel fuel or solvents in Non fulfillment of these prescriptions may cause serious
anti-fire specially provided containers. injury and poisoning.

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 4 APPENDIX F3B CURSOR ENGINES

- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engineè s
components, affecting engineè
s duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys personnelè
s safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine
changed. exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that
equipment unless specifically approved by Iveco. personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
Iveco specific approval has been released. Any - Collect exhaust oils in adequate specially provided
unauthorized modification will compromise warranty containers with hermetic sealing ensuring that storage is
assistance and furthermore may affect engine correct made in specific, properly identified areas that shall be
working and duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having environment and within anti-acid containers. Warning:
priory removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80ØC temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.

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 G-DRIVE CURSOR ENGINES 1

Part 4
G--DRIVE CURSOR ENGINES
Section

General specifications 1

G-Drive Application 2

PREFACE TO USER'
S GUIDELINE MANUAL

Section 1 describes engines F2B and F3B in their characteristics

and general operation.

Section 2 is specific of use.

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 2 G-DRIVE CURSOR ENGINES

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.

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 G-DRIVE CURSOR ENGINES 3

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

Example

1 1 = housing for connecting rod small end bush

Tighten to torque
Tighten to torque + angular value

2 2 = housing for connecting rod bearings

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 4 G-DRIVE CURSOR ENGINES

Graph and symbols

Removal
Intake
Disconnection

Refitting
Exhaust
Connection

Removal
Operation
Disassembly

Fitting in place
Compression ratio
Assembly

Tolerance
Tighten to torque
Weight difference

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Regulation Angle
Adjustment Angular value

Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check

Equipment Temperature

Surface for machining

Pressure
Machine finish bar

Oversized
Interference
Higher than .
Strained assembly
Maximum, peak
Undersized
Thickness
Less than .
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 C
Sealant
Cold
Adhesive
Winter
Temperature > 0 C
Air bleeding Hot
Summer
Replacement
Original spare parts

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 G-DRIVE CURSOR ENGINES 5

UPDATING

Section Description Page Date of revision

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 6 G-DRIVE CURSOR ENGINES

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 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 1

SECTION 1
General specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL

CODE AND COMMERCIAL CODE . . . . . . . 3

VIEWS OF F2B ENGINE . . . . . . . . . . . . . . . . . . . 5

VIEWS OF F3B ENGINE . . . . . . . . . . . . . . . . . . . 8

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 11

COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

FUEL FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

- F2B engine fuel supply pump . . . . . . . . . . . . . . 17

- Heated sedimentation tank prefilter . . . . . . . . . 17

TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . 18

- HX 40W turbocompressor . . . . . . . . . . . . . . . 18

- HX 60W turbocompressor . . . . . . . . . . . . . . . 19

Print P2D32C001 E Base - April 2006

 2 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 3

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

F2B engine

Technical Code Commercial Code

F2BE0685A*B301 CURSOR 78 TE2

F3B engine

Technical Code Commercial Code

F3BE0685C*B001 CURSOR 13 TE1
F3BE0685B*B001 CURSOR 13 TE2
F3BE0685A*B001 CURSOR 13 TE3

Print P2D32C001 E Base - April 2006

 4 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 5

VIEWS OF F2B ENGINE

Figure 1
LEFT-HAND SIDE VIEW

107875

Figure 2

RIGHT-HAND SIDE VIEW

107876

Print P2D32C001 E Base - April 2006

 6 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Figure 3
FRONT VIEW

107877

Figure 4
REAR VIEW

107878

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 7

Figure 5

TOP VIEW

107879

Print P2D32C001 E Base - April 2006

 8 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

VIEWS OF F3B ENGINE

Figure 6
LEFT-HAND SIDE VIEW

107891

Figure 7
RIGHT-HAND SIDE VIEW

107892

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 9

Figure 8
FRONT VIEW

107893

Figure 9
REAR VIEW

107894

Print P2D32C001 E Base - April 2006

 10 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Figure 10

TOP VIEW

107895

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 11

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 11

Dropping oil
Pressure oil
DETAIL A 107880

ENGINE F2B LUBRICATION DIAGRAM

Print P2D32C001 E Base - April 2006

 12 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Figure 12

Dropping oil
DETAIL A Pressure oil 107896

ENGINE F3B LUBRICATION DIAGRAM

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 13

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;
- fan;
- a 2-way thermostat controlling the coolant circulation.

Operation
The water pump is actuated by the crankshaft through a poli-V belt and sends coolant to the cylinder block, especially to the cylinder
head (bigger quantity). When the coolant temperature reaches and overcomes the operating temperature, the thermostat is
opened and from here the coolant flows into the radiator and is cooled down by the fan.

Figure 13

Water flowing out of the thermostat

Water circulating in the engine

Water flowing into the pump

107882

F2B ENGINE COOLING SYSTEM DIAGRAM

Print P2D32C001 E Base - April 2006

 14 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Figure 14

Water flowing out of the thermostat

Water circulating in the engine

Water flowing into the pump

107899

F3B ENGINE COOLING SYSTEM DIAGRAM

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 15

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 15

Delivery circuit

Return circuit

112860

F2B ENGINE FEED SCHEME

1. Pump injectors - 2. Pressure control valve (start of opening at 5 bar) - 3. Feed pump - 4. Fuel pre-filter with
priming pump - 4. Valve, to recirculate fuel from injectors, integrated in feed pump (start of opening at 3.5 bar) -
5. Overpressure valve to return fuel to tank (start of opening at 0.2 bar) - 6. Fitting - 7. Central unit - 8. Heat exchanger -
9. Fuel filter - 10. Fuel sedimentation pre-filter with priming pump.
A. Fuel arriving at injectors - B. Fuel returning to tank - C. Fuel entering from injectors into feed pump

Print P2D32C001 E Base - April 2006

 16 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Figure 16

Return circuit

Delivery circuit 112861

F3B ENGINE FEED SCHEME

1. Fuel filter - 2. Valve, to recirculate fuel from injectors, integrated in feed pump (start of opening at 3.5 bar) - 3. Feed pump
- 4. Overpressure valve to return fuel to tank (start of opening at 0.2 bar) - 5. Pressure control valve (start of opening at 5
bar) - 6. Fuel pre-filter with priming pump - 7. Fitting - 8. Central unit - 9. Heat exchanger- 10. Pump injectors
A. Fuel arriving at injectors - B. Fuel returning to tank - C. Fuel entering from injectors into feed pump

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 17

F2B engine fuel supply pump Heated sedimentation tank prefilter

Figure 17 Figure 18

92830

Engine feed pump

1. Overpressure valve - 2. Pressure control valve -
3. Sucking in fuel - 4. Delivering fuel to injectors.

Pump performances
Pump rotation speed (rpm) 2600 600 170 100 107885

Minimum flow rate (l/h) 310 45 12

Negative pressure
on aspiration (bar) 0.5 0.3 0.3 0.3 1. Thermostat - 2. Support - 3. Air bleed screw -
4. Heater - 5. Heater connector - 6. Water separation
Pressure on delivery cartridge - 7. Water present indication sensor -
Test (bar) 5 3 0,3 0.3 8. Connector - 9. Priming pump -
conditions A. Water accumulation capacity- E. Fuel entry -
Test liquid
temperature (§C) 30 30 30 30 U. Fuel exit .
Test liquid ISO 4113 Characteristics
Water accumulation capacity 270 ml
Field of use
Thermostat:
Pump rotation speed (rpm) 2600 - opening temperature +5 3 C
Overrunning rotation speed (max 5 min) 4100 max - closing temperature -3 3 C
(rpm) -25/+80
Diesel oil temperature (§C) Tightening torque
Filtering rate on aspiration 30
(micron) 0.5 max
Bleed screw locking (3) 7 1 Nm
Negative pressure on aspiration (bar)
Cartridge locking (6) 18 2 Nm
Locking water present indicator sensor 0.8 0.1 Nm
Pressure control valve
Valve calibration 5 5.8

Injectors return valve

Valve calibration 3.2 3.8

Print P2D32C001 E Base - April 2006

 18 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

TURBOCHARGING
The turbocharging system consists of:
- air filter;
- Wastegate turbocharger.

F2B engine
Figure 19

Intake air

Compressed air (hot)

Compressed air (cooled)

Exhaust 107901

F2B ENGINE SUPERCHARGING SYSTEM DIAGRAM

HX 40W turbocompressor The turbocompressor is a turbocompressor with a return

valve.
Figure 20 It is mainly composed by:
- a central unit where a shaft is positioned supported by
bushings, a turbine rotor and a compressor rotor are
mounted on each end;
- a turbine unit and a compressor unit mounted at the end
of the central unit;
- return valve applied on the turbine unit. It divides burnt
gases outlet, sending one part directly to the outlet tube
when the boost of the compressor reaches the setting
value.

71766

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 1 - GENERAL SPECIFICATIONS 19

F3B engine
Figure 21

Engine exhaust gas

Intake air

A = Inlet

S = Exhaust 107897

F3B ENGINE SUPERCHARGING SYSTEM DIAGRAM

HX 60W turbocompressor The turbocompressor is a turbocompressor with a return

valve.
Figure 22 It is mainly composed by:
- a central unit where a shaft is positioned supported by
bushings, a turbine rotor and a compressor rotor are
mounted on each end;
- a turbine unit and a compressor unit mounted at the end
of the central unit;
- return valve applied on the turbine unit. It divides burnt
gases outlet, sending one part directly to the outlet tube
when the boost of the compressor reaches the setting
value.

71766

Print P2D32C001 E Base - April 2006

 20 SECTION 1 - GENERAL SPECIFICATIONS G-DRIVE CURSOR ENGINES

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 1

SECTION 2
G-Drive application

Page

F2B ENGINE CLEARANCE DATA . . . . . . . . . . 3

F3B ENGINE CLEARANCE DATA . . . . . . . . . . 4

F2B GENERAL CHARACTERISTICS . . . . . . . . . 5

F2B ASSEMBLY CLEARANCE DATA . . . . . . . . 7

F3B GENERAL CHARACTERISTICS . . . . . . . . . 13

F3B ASSEMBLY CLEARANCE DATA . . . . . . . . 15

ENGINE CONNECTION AND DISCONNECTION

FROM THE RADIATOR . . . . . . . . . . . . . . . . 22

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ENGINE ASSEMBLY/DISASSEMBLY . . . . . . . . . 23

- F2B engine disassembly . . . . . . . . . . . . . . . . . . 23

- F2B engine assembly . . . . . . . . . . . . . . . . . . . . 26

- F3B engine disassembly . . . . . . . . . . . . . . . . . . 26

- F3B engine assembly . . . . . . . . . . . . . . . . . . . . 29

PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

MAINTENANCE PLANNING . . . . . . . . . . . . . . 31

- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

- Inspection and/or maintenance interventions . 33

- Checks not included in maintenance

planning-daily checks . . . . . . . . . . . . . . . . . . . . 34

MAINTENANCE PROCEDURES . . . . . . . . . . . . 34

- Checks and controls . . . . . . . . . . . . . . . . . . . . 34

Print P2D32C001 E Base - April 2006

 2 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 3

F2B ENGINE CLEARANCE DATA

F2BE0685
Type
A*B301
Compression ratio 16 0.8

Europe market
Max. output kW 234.8
(HP) (319.2)
rpm 1500/50 Hz

Max. torque Nm 1494.5

(kgm) (152.28)
rpm 1500

USA market
Max. output kW 257.3
(HP) (249.9)
rpm 1800/60 Hz

Max. torque Nm 1365.2

(kgm) (139.1)
rpm 1500

Bore x stroke mm 115 x 125

Displacement cm3 7790
SUPERCHARGING

Turbocharger type HX40W

LUBRICATION
Forced by gear pump, relief valve single action
oil filter
bar Oil pressure
(warm engine)

- idling bar
4
- peak rpm bar
5

NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

Print P2D32C001 E Base - April 2006

 4 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

F3B ENGINE CLEARANCE DATA

Type F3BE0685C*B001 F3BE0685B*B001 F3BE0685A*B001

Compression ratio 16.5 0.8

Europe market 295 345 400
Max. output kW (420) (469) (544)
(HP)
rpm 1500/50Hz 1500/50Hz 1500/50Hz

Max. torque Nm 1879 2198 2548

(kgm) (1914) (223.9) (259.6)
rpm 1500 1500 1500

USA market - - 420

Max. output kW (5712)
(HP)
rpm - - 1800/60Hz

Max. torque Nm - - 2229.5

(kgm) (227.18)
rpm 1500 1500 1500

Bore x stroke mm 135 x 150

Displacement cm3 12880

SUPERCHARGING
Direct injection

HOLSET HX60W
Turbocharger type

LUBRICATION Forced by gear pump, relief valve single action

oil filter
bar Oil pressure
(warm engine)

- idling bar 4
- peak rpm bar 5

COOLING Liquid
Water pump control Through belt
Thermostat
­start of opening ØC 80

NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by Iveco Motors.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 5

F2B GENERAL CHARACTERISTICS

Type F2B

Cycle Diesel 4 strokes

Feeding Turbocharged

Injection Direct

N. of cylinders 6 on-line

Diameter mm 115

Stroke mm 125

+ + +.. = Total displacement cm3 7790

Europe market
Max. output kW 234.8
(HP) (319.2)
rpm 1500/50 Hz

Max. torque Nm 1494.5

(kgm) (152.28)
rpm 1500

USA market
Max. output kW 257.3
(HP) (249.9)
rpm 1800/60 Hz

Max. torque Nm 1365.2

(kgm) (139.1)
rpm 1500

Print P2D32C001 E Base - April 2006

 6 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Type F2B

A
VALVE TIMING

opens before T.D.C. A 17

closes after B.D.C. B 31

B

opens before B.D.C. D

48
closes after T.D.C. C 9
D

For timing check

mm _
X
X mm _

Running

mm 0.40 to 0.50
X
mm 0.40 to 0.50

FEED Through fuel pump - filters

With electronically regulated injectors PDE 30
Injection
pump injectors controlled by overhead camshaft
type: Bosch
MS6.2 ECU

Nozzle type DLLA 143P894

Injection order 1-4-2-6-3-5

bar
Injection pressure bar 1500

Injector calibration bar -

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 7

F2B ASSEMBLY CLEARANCE DATA

Type F2B

CYLINDER BLOCK AND CRANK

mm
MECHANISM COMPONENTS
1
Cylinder sleeve bore
upper 130.200 to 130.225
1
lower 128.510 to 128.535

Cylinder liners:
outer diameter:
L upper 130.161 to 130.186
2
lower 128.475 to 128.500
2 length L
Cylinder sleeve -
crankcase bore
upper 0.014 to 0.064
lower 0.010 to 0.060

Outside diameter 2

Cylinder sleeve
3 inside diameter 3 A* 115.000 to 115.012

X
inside diameter 3 B* 115.010 to 115.022
Protrusion X 0.035 to 0.065
* Available dia. class
Pistons:
1
measuring dimension X 18
X
outside diameter 1A 114.888 to 114.900
2 outside diameter 1B 114.898 to 114.910
outside diameter 2 46.010 to 46.016
Class A pistons supplied as spares.
Class B pistons are fitted in production only and
are not supplied as spares.
Piston - cylinder sleeve 0.100 to 0.124

Piston diameter 1 _

X
Pistons protrusion X -

3 Gudgeon pin 3 45.994 to 46.000

Gudgeon pin - pin housing 0.010 to 0.022

Print P2D32C001 E Base - April 2006

 8 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

F2B
Type
mm
X1* 2.71 to 2.74
X1
Piston ring grooves X2 2.56 to 2.58
X2
X3 4.02 to 4.04
X3
*measured on of 112 mm
Piston rings: AE GOETZE DANA
S 1 trapezoidal seal S1* 2.429 to 2.463 2.565 to 2.599
S 2 2.470 to2.490 2.470 to2.490
lune seal S2
S 3
milled
ill d scraper ring
i
with slits and internal
spring S3 3.975 to 3.990 3.975 to 3.990
D From the outer diameter measured at mm 2 1.5
AE GOETZE DANA
1 0.247 to 0.311 0.111 to 0.175
Piston rings - 2 0.070 to 0.110
3 0.030 to 0.065

Piston rings _

Piston ring end gap in

X1 AE GOETZE DANA
cylinder liners:
X2 X1 0.35 to 0.50 0.30 to 0.45
X3 X2 0.70 to 0.95 0.60 to 0.80
X3 0.30 to 0.60 0.30 to 0.60
Small end bush housing
1 1 49.975 to 50.000
Big end bearing
housing 2 77.000 to 77.030

2 1 77.000 to 77.010
Selection classes 2 2 77.011 to 77.020
3 77.021 to 77.030
4 Small end bush diameter
outside 4 50.055 to 50.080
3
inside 3 46.015 to 46.030
Big end bearing shell S
S Red 2.000 to 2.010
Green 2.011 to 2.020
YellowD 2.021 to 2.030
Small end bush - housing 0.055 to 0.105
Piston pin - bush 0.015 to 0.036

Big end bearing shells 0.127 - 0.254 - 0.508

Connecting rod weight g.

A 2865 to 2895
Class B 2896 to 2925
C 2926 to 2955

D Fitted in production only and not supplied as spares

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 9

F2B
Type
mm
X
Measuring dimension X 125

Max. connecting rod

axis misalignment
0.08
tolerance
Main journals 1
- nominal 82.910 to 82.940
- class 1 82.910 to 82.919
- class 2 82.920 to 82.929
- class 3 82.930 to 82.940
1 2
Crankpins 2
- nominal 72.915 to 72.945
- class 1 72.915 to 72.924
- class 2 72.925 to 72.934
- class 3 72.935 to 72.945
S1 S 2 Main bearing shells S1
Red 3.000 to 3.010
Green 3.011 to 3.020
YellowD 3.021 to 3.030
Big end bearing shells S2
Red 2.000 to 2.010
Green 2.011 to 2.020
YellowD 2.021 to 2.030
Main bearing housings 3
- nominal 89.000 to 89.030
3 - class 1 89.000 to 89.009
- class 2 89.010 to 89.019
- class 3 89.020 to 89.030
Bearing shells -
0.040 to 0.098 * - 0.040 to 0.0110 **
main journals
Bearing shells -
0.035 to 0.093 * - 0.035 to 0.083 **
big ends
Main bearing shells 0.127 - 0.254 - 0.508
Big end bearing shells 0.127 - 0.254 - 0.508

Main journal,
thrust bearing X1 39.96 to 40.04
X1

Main bearing housing,

thrust bearing X2 32.94 to 32.99
X2
X3 Thrust washer
halves X3 3.38 to 3.43

Driving shaft shoulder 0.11 to 0.34

1 2 Alignment 1-2 0.05

Ovality 1-2 _0.010
Taper 1-2 0.010
D Fitted in production only and not supplied as spares
f Spares provided: : * = standard spares - 0.127; ** = 0.254 - 0.508

Print P2D32C001 E Base - April 2006

 10 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Type F2B

CYLINDER HEADS - VALVE TRAIN mm

1

Valve guide housings

in cylinder head
1 12.980 to 12.997

2 8.023 to 8.038
Valve guide
3 13.012 to 13.025
3

Valve guides - housings

0.015 to 0.045
in the cylinder heads

Valve guide 0.2 to 0.4

4 Valves:
7.970 to 7.985
4
60 30 7 30

4 7.970 to 7.985
45 + 15
Valve stem and its guide 0.038 to 0.068
Housing in head for valve
seat

1 41.985 to 42.020

1 1 40.985 to 41.020
Outside diameter of valve
seat; angle of valve seat in
2 cylinder head:

2 42.060 to 42.075
60 ­30­
2 41.060 to 41.075
45 - 30
Recessing of 0.5 to 0.8
valve
X X 1.6 to 1.9

Between valve
seat and head 0.040 to 0.090

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 11

Type F2B

mm
Valve outside spring
height:
free height H 63.6
H H1 under a load of:
H 2 N 454 22 H1 49.5
N 840 42 H2 37.5

Injector protrusion X 0.7

X

Camshaft bush housing

fitted in the cylinder head:
1 7 80.000 to 80.030

Camshaft journal diameter:

1 7 75.924 to 75.940

1 3

Camshaft bushing outer

diameter: 80.090 to 80.115

Camshaft bushing
inner diameter: 6 75.990 to 76.045
7 76.008 to 76.063
Bushings and housings in
0.060 to 0.115
engine block
Bushings and
journals 1 6 0.050 to 0.121
7 0.068 to 0.139
Cam lift:
8.07

H 7.33

8.820

1
Rocker shaft 1
37.984 to 38.000

Print P2D32C001 E Base - April 2006

 12 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Type F2B

mm
Bushing housing in rocker
arms
41.000 to 41.016

41.000 to 41.016

42.000 to 42.016

Bushing outer diameter

for rocker arms:
41.097 to 41.135

41.097 to 41.135

42.066 to 42.091

Bushing inner diameter

for rocker arms:
38.025 to 38.041

38.025 to 38.041

38.015 to 38.071

Between bushings and

housings
0.081 to 0.135

0.081 to 0.135

0.050 to 0.091

Between rocker arms and

shaft
0.025 to 0.057

0.225 to 0.057

0.015 to 0.087

TURBOCHARGER
Type HOLSET HX40W
End float 0.025 to 0.127
Radial play 0.254 to 0.356
Wastegate opening stroke at
1.8 0.01 bar pressure:
- control 0.33 to 1.27
- adjustment 0.5 to 1.04

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 13

F3B GENERAL CHARACTERISTICS

Type F3BE0685C F3BE0685B F3BE0685A

Cycle 4-stroke Diesel engine

Fuel feed Turbocharged
Injection Direct

No. of cylinders 6 in line

Bore mm 135

Stroke mm 150

+ + +.. = Total displacement cm3 12880

Compression ratio 16.5 0.8

Europe market 295 345 400
Max. output kW (420) (469) (544)
(HP)
rpm 1500/50Hz 1500/50Hz 1500/50Hz

Max. torque Nm 1879 2198 2548

(kgm) (191.4) (223.9) (259.6)
rpm 1500 1500 1500
USA market - - 420
Max. output kW (571.2)
(HP)
rpm - - 1800/60Hz

Max. torque Nm - - 2229.5

(kgm) (227.18)
rpm - - 1500

Print P2D32C001 E Base - April 2006

 14 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Type F3B

A
VALVE TIMING

opens before T.D.C. A

19
closes after B.D.C. B
B 36
C

opens before B.D.C. D

50
closes after T.D.C. C
9
D

For timing check

mm
X -
X mm
-
Running

mm 0.35 to 0.45
X
mm 0.45 to 0.55

FEED Through fuel pump - filters

Injection With electronically regulated injectors PDE 31
type: Bosch pump injectors controlled by overhead camshaft

Nozzle type _

Injection order 1-4-2-6-3-5

bar Injection pressure bar 1500

Injector calibration bar 290 12

Base - April 2006 Print P2D32C001 E

 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 15

F3B ASSEMBLY CLEARANCE DATA

Type F3B

CYLINDER BLOCK AND

mm
CRANKMECHANISM COMPONENTS
1
Bores for cylinder liners:
upper 153.500 to 153.525
1
lower 152.000 to 152.025

Cylinder liners:
external diameter:
L upper 153.461 to 153.486
2
lower 151.890 to 151.915
2 length L -
Cylinder liners -
crankcase bores
upper 0.014 to 0.039
lower 0.085 to 0.135

External diameter 2 -

Cylinder sleeve
3
inside diameter 3A* 135.000 to 135.013
X
inside diameter 3B* 135.011 to 135.024

Protrusion X 0.045 to 0.075

* Selection class
* Under a load of 800 N
Pistons: FEDERAL MOGUL MAHLE MONDIAL
1 measuring dimension X 20 20
X external diameter 1AF 134.884 to 134.996 134.881 to 134.893
external diameter 1BFF 134.895 to 134.907 134.892 to 134.904
2 pin bore 2 54.010 to 54.018
Piston - cylinder sleeve
A* 0.107 to 0.132
B* 0.096 to 0.132
* Selection class

Piston diameter 1 -

X
Pistons protrusion X 0.12 to 0.42

3 Gudgeon pin 3 53.994 to 54.000

Gudgeon pin - pin housing 0.010 to 0.024

F Class A pistons supplied as spares.

FF Class B pistons are fitted in production only and are not supplied as spares.
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 16 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

F3B
Type
mm
FEDERAL MOGUL MAHLE MONDIAL
X1 X1* 3.433 3.445 to 3.475
X2 Piston ring grooves X2 3.060 to 3.080 3.050 to 3.070
X3 X3 5.020 to 5.040 5.020 to 5.040
* measured on of 130 mm
Piston rings:
trapezoidal
p seal S1* 3.296 to 2.364
S 1 lune seal S2 2.970 to 2.990
S 2
S 3 milled
ill d scraper ring
i
with slits and internal
spring S3 4.970 to 4.990
* measured on of 130 mm
1 0.069 to 0.137 0.081 to 0.179
Piston rings - grooves 2 0.070 to 0.110 0.060 to 0.100
3 0.030 to 0.070 0.030 to 0.070

Piston rings -

X1 Piston ring end gap

in cylinder liners
X2
X1 0.40 to 0.55
X3
X2 0.65 to 0.80
X3 0.40 to 0.75

Small end bush housing

1 nominal 1 59.000 to 59.030

Big end bearing housing

nominal 2 94.000 to 94.030
2
- Class 1 94.000 to 94.010
- Class
- Class
{ 2
3
94.011 to 94.020
94.021 to 94.030
4 Small end bush diameter
outside 4 59.085 to 59.110
3
inside 3 54.019 to 54.035
Big end bearing shell S
S Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow 1.986 to 1.995
Small end bush - housing 0.055 to 0.110
Piston pin - bush 0.019 to 0.041

Big end bearing 0.127 - 0.254 - 0.508

Connecting rod weight g.

Ag 4741 to 4780
Class Bg 4781 to 4820
Cg 4821 to 4860

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 17

F3B
Type
mm
X
Measuring dimension X 125

Max. connecting rod

axis misalignment
0.08
tolerance
Main journals 1
- rated value 99.970 to 100.000
- class 1 99.970 to 99.979
- class 2 99.980 to 99.989
- class 3 99.990 to 100.000
1 2
Crankpins 2
- rated value 89.970 to 90.000
- class 1 89.970 to 89.979
- class 2 89.980 to 89.989
- class 3 89.990 to 90.000
S1 S 2 Main bearing shells S1
Red 3.110 to 3.120
Green 3.121 to 3.130
Yellow* 3.131 to 3.140
Big end bearing shells S2
Red 1.965 to 1.975
Green 1.976 to 1.985
Yellow* 1.986 to 1.995
Main bearing housings 3
- rated value 106.300 to 106.330
3 - class 1 106.300 to 106.309
- class 2 106.310 to 106.319
- class 3 106.320 to 106.330
Bearing shells - main journals f 0.060 0.108 * - 0.061 0.119 ** - 0.060 0.130 ***
Bearing shells - big ends f 0.050 0.108 * - 0.051 0.109 ** - 0.050 0.098 ***
Main bearing shells 0.127 - 2.254 - 0.508
Big end bearing shells 0.127 - 2.254 - 0.508

Main journal,
thrust bearing X1 47.95 to 48.00
X1

Main bearing housing,

thrust bearing X2 40.94 to 40.99
X2
X3 Thrust washer
halves X3 3.38 to 3.43

Crankshaft end float 0.10 to 0.30

1 2 Alignment 1-2 0.025

Ovalization 1-2 0.010

0.010
Taper 1-2
* Fitted in production only and not supplied as spares
f Spares provided: : * = standard spares - 0.127; ** = 0.254 - 0.508

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 18 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Type F3B

CYLINDER HEAD - VALVE TRAIN mm

1

Valve guide housings

in cylinder head
1 15.980 to 15.997

Valve guide 2 10.015 to 10.030

3 16.012 to 16.025
3

Valve guides - housings

0.015 to 0.045
in the cylinder heads

Valve guide 0.2 - 0.4

4 Valves:

4
9.960 to 9.975
60 30 7 30
4 9.960 to 9.975
45 30­ 7 30
Valve stem and its guide 0.040 to 0.070
Valve seat in
head

1 49.185 to 49.220

1 1 46.985 to 47.020

Outside diameter of valve

2 seat; angle of valve seat
in cylinder head:
49.260 to 49.275
2
60 ­30­
47.060 to 47.075
2
45 - 30
X 0.45 to 0.75
Recessing of valve
X X 1.65 to 1.95

Between valve
seat and head 0.040 to 0.090

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 19
Table 3

F3B
Type
mm
Valve spring height:

free height H 73.40

H H1 under a load of:
H 2 575 28 N H1 59
1095 54 N H2 45

Injector protrusion X 0.53 to 1.34

X

Camshaft bushing housing

in the cylinder head:
1 7 88.000 to 88.030

Camshaft bearing
journals:
1 7 82.950 to 82.968
1 3

Outer diameter of
camshaft bushings:
88.153 to 88.183

Inner diameter of
camshaft bushings: 83.018 to 83.085

Bushings and housings

0.123 to 0.183
in the cylinder head
Bushings and bearing
journals 0.050 to 0.135
Cam lift:
9.560

H 9.231

11.216

1
Rocker shaft 1 41.984 to 42.000

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 20 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

F3B
Type
mm
Seats for bushings in
rocker arms:
45.000 to 45.016

59.000 to 59.019

46.000 to 46.016

Outside diameter of
bushings for rocker arms:
45.090 to 45.130

59.100 to 59.140

46.066 to 46.091

Inside diameter of bushings

for rocker arms:
42.025 to 42.041

56.030 to 56.049

42.015 to 42.071

Bushings and seats:

0.074 to 0.130

0.081 to 0.140

0.050 to 0.091

Rocker arm bushings and shaft:

0.025 to 0.057

0.025 to 0.057

0.015 to 0.087

O1
Engine brake control lever
Eccentric pin outer
diameter 1 55.981 to 56.000
O2 Rocker arms shaft seat 2 42.025 to 42.041

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 21

Type F3B

mm

Rocker arms and engine

0.030 to 0.058
brake control lever pin

Rocker arm shaft and seat

on engine brake control 0.025 to 0.057
lever
TURBOCHARGER
Type 380 CV Engine HOLSET HX 60
End play 0.025 0.127
Radial play 0.406 0.580

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 22 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

ENGINE CONNECTION AND DISCONNECTION FROM THE RADIATOR

Figure 1

112827

Refitting
NOTE Here are described the F2B engines control and/or
For the connection operation repeat the described
maintenance operations which are similar to the
operations for the disconnection on the contrary
operations for F3B engines. For this reason they are
and apply the following instructions:
valid for F3B engines as well.
- to control the engine elastic supports and to
replace them in case of deterioration ;
- to control that the exhaust pipes are not
Removal
deteriorated or are going to deteriorate; in this
case you shall replace them;
To prearrange a suited container near the sleeve (6) to - to clamp the screws and/or nuts to the
recover the cooling liquid. Disconnect and remove the sleeve described couple;
(6) and (8) by means of suited hose clamps.
To disconnect and to remove pipes (7) and (11) from engine - to fill the cooling system with cooling liquid;
and radiator by means of the suited collars hanger. (12). - to carry out bleeding operation from the fuel
To remove the protection grids (10) and the ventilator guard supply system as described in the suited
(9) by means of clamps. paragraph.
To block the radiator unit (13) and to release it form the
mounting by means of the clamps operating by both sides. - to control engine oil level;
Detach the air filter (3) form the engine complete with - to carry out the tests and controls as described
support (4) by means of clamps(5) after disconnecting the oil in the suited chapter.
vapour pipes (2) and the sleeve (1) from the
turbocompressor.
To remove the engine fixing screws from the mounting and
to disconnect the engine.

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 23

ENGINE ASSEMBLY/DISASSEMBLY Figure 2

F2B engine disassembly

NOTE 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.
Here are described and illustrated the engine disassembly
operation which are different form the operations for the
industrial or agricultural applications engines.
Before securing the engine on the rotary stand, remove:
- the electric engine cable (1) by disconnecting it from the
107887
control unit and all the sensors/transmitters to which it is
connected;
- the starting motor; - Remove the engine supports.
- air compressor (if available). - Remove screws (1) and remove oil pressure adjustment
valve (2).

Figure 3

112643

Fix the engine to the rotary stand 99322230, by means of brackets 99361035 (1).
Disconnect line to manual pump (2) from oil sump and drain engine oil.
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 24 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Figure 4 Figure 7

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).
ventilator control belt (1). Remove screws and disconnect
electromagnetic ventilator coupling (4). Remove the screws (2) and the pulley (1).

Figure 5 Figure 8

45254
107904
Remove guard (3). Install extractor 99340051 (2) and remove the seal gaskets
Remove retaining screws and remove alternator (2) from (1). Unscrew the screws and remove the cover.
bracket (1) and from support (4), then remove the latter from Disconnect all electric connections and sensors.
block.
Figure 6 Figure 9

1
2

3
4
107889
107890
Remove thermostat (1), ventilator support (2), automatic belt
tensioner (3), fixed belt tensioner (4), pipeline (5), guard (6), Disconnect oil pipes (1 and 4) of turbo compressor (2).
water pump (7). Disconnect turbo compressor (2) from exhaust manifold (3).

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 25

Figure 10 Figure 13

107943
107940

Unscrew the oil filter (1) by tool 99360314 (2). Take out the screws (2) and remove the intake manifold (1).

Figure 14

Figure 11

107944

107941
Disconnect fuel line (1) from central unit (3).
Remove screws (2) and disconnect central unit (3).
Unscrew the screws (1) and remove the entire heat
exchanger (2).
Figure 15
Figure 12

107945
107942

Disconnect fuel lines (1) from cylinder head; (2) and supply Remove screws (2) and disconnect power takeoff (1)
pump. complete with supply pump (3).
Remove screws (5) and support (6) complete with fuel filter To go on with the engine disassembly as described for the
(3) and sedimentation filter (4). industrial/agricultural applications engines.

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 26 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

F2B engine assembly Figure 16

To assembly again the engine inverting the described
operations for the disassembly.

F3B engine disassembly

NOTE 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.
Here are described and illustrated the engine disassembly
operations which are different from the operations for the
industrial application engines.
Before securing the engine on the rotary stand, remove:
- the electric engine cable (1) by disconnecting it from the
control unit and all the sensors/transmitters to which it is
107970
connected.
- Remove the engine supports. Remove screws (1) and remove oil pressure adjustment valve
(2).

Figure 17

107971

Secure the engine to the rotary stand with the brackets 99361036 (1).
To release the lubrication oil from the pan.
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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 27

Figure 18 Figure 21

107903 87204

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
ventilator control belt (1). Remove screws and disconnect Remove screws (4), then disassemble damper flywheel (3).
electromagnetic ventilator coupling (4). Remove the screws (2) and the pulley (1).

Figure 19
Figure 22

107904
45254
Remove guard (3). Install extractor 99340051 (2) and remove the seal gaskets
Remove retaining screws and remove alternator (2) from (1). Unscrew the screws and remove the cover.
bracket (1) and from support (4), then remove the latter from Disconnect all electric connections and sensors.
block.
Figure 20
Figure 23

1
2

3
4
107890
107889

Remove thermostat (1), ventilator support (2), automatic belt

tensioner (3), fixed belt tensioner (4), pipeline (5),guard (6), Disconnect oil pipes (1 and 4) of turbo compressor (2).
water pump (7). Disconnect turbo compressor (2) from exhaust manifold (3).

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 28 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Figure 24 Figure 27

107972 107975

Remove retaining screws and support (1) of fuel filter.

Unscrew the oil filter (1) by tool 99360314. Remove screws (2) and remove intake manifold (3).

Figure 25 Figure 28

107973 107976

Unscrew the screws (1) and remove the heat exchanger (2). Remove screws (1) and bracket (3) supporting sedimentation
tank prefilter (2).

Figure 26 Figure 29

107977
107974

Remove screws (1) and disconnect ECU (2).

Disconnect the fuel pipes (1 and 4) from the fuel pump (2).
Remove supply pump (3) and fuel filter (5).

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 29

Figure 30

107972

Remove screws (1) and remove power takeoff (2).

Remove screws and remove starter motor (3).

F3B engine assembly

To assembly again the engine inverting the described
operations for the disassembly.

PISTONS

Figure 31

108389

MAIN DATA ON PISTONS, PISTONS RINGSAND PIN

* Dimension detected on 112 mm . - Y measured from outer at : A (AEGOETZE) = 2 mm - B (DANA) = 1.5 mm
: X = 0.7 0.1

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 30 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 31

MAINTENANCE PLANNING

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 32 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 33

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.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.

NOTE Here are described the F2B engines control and/or maintenance operations which are similar to the operations for F3B
engines. For this reason they are valid for F3B engines as well.

Inspection and/or maintenance interventions

Intervention type Frequency (hours)

Engine
Engine visual inspection Daily
Check presence of water in fuel prefilter Daily
Engine oil change -
Engine oil filter change -
Fuel prefilter change -
Fuel filter change -
Check Blow-by filter condition by clogging indicator -
Check condition of water pump/alternator control belt -
Check-up of EDC system by diagnostics tool -
Check valve lash and adjust, if required -
Dry air filter change and container cleaning -

NOTE The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.

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 34 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

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.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Checking the coolant level.

MAINTENANCE PROCEDURES Cooling system check

Checks and controls The check must be executed both when the engine
disconnected and when it is running.
Engine oil level check. Check the pipes from the engine to the radiator and vice versa;
note any seepage and the state of the pipes especially near the
The check must be executed when the engine is disconnected coupling clamps.
and possibly cool. Verify that the radiator is clean, the correct working of the fan
The check can be made using the specially provided flexible flywheels, the presence of any leakage from the connectors,
rod (1). from the manifold and from the radiating unit.
Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level. Due to the high temperatures achieved by the
Whether it should be difficult to make the evaluation, proceed system, do not operate immediately after the engine­
s
cleaning the rod using a clean cloth with no rag grinding and disconnection, but wait for the time deemed
put it back in its slot. Draw it off again and check the level. necessary for the cooling.
Protect the eyes and the skin from any eventual high
In case the level results being close to the tag showing pressure jet of cooling liquid.
minimum level, provide filling lubrication of the engine­
s
components.
The density of the cooling liquid must be checked any how
To provide filling, operate through the upper top (1) or every year before winter season and be replaced in any case
through the lateral top (2). During filling operation, the tops every two year.
must be removed as well as the rod in order to make the oil
flow easier­. NOTE In case of new filling, proceed bleeding system,
Refill through upper tappet cover plug. During refill, remove through the bleeds on the engine.
dipstick for easier oil drain.
If bleeding of the system is not carried out, serious
inconvenience might be caused to the engine due
to the presence of air pockets in the engine­ s head.
The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Lubricating system check
Adequately protect the skin and the eyes, operate The check must be executed both when the engine
in full compliance with safety regulations. disconnected and when it is running.
Verify the presence of any oil leakage or blow-by from the
Disposal must be carried out properly, and in full head, from the engine pan of from the heat exchanger.
compliance with the law and regulations in force.
The engine oil is highly polluting and harmful.
Check of fuel system In case of contact with the skin, rinse well with water
The check must be executed both when the engine and detergent.
disconnected and when it is running. Adequately protect the skin and the eyes, operate in
The check is made by observing the fuel pipes from the tank full compliance with safety regulations.
to the fuel pump and to the injectors. Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 35

Replace fuel sedimentation tank prefilter Check Blow-by filter conditions by means of a clogging
indicator
Figure 32 Figure 34

108395

Disconnect electric connector. Unlock prefilter (1) and

change it. Before refitting a new cartridge, wet seal with fuel
oil or engine oil. Lock cartridge by hand till in contact with
support, then lock it by º of a rev. at predefined tightening
torque.
72563

- Check filter (3) conditions by means of a clogging

NOTE At change, filter cartridge must not be prefilled to indicator (1). In case the red area appears, change it.
prevent circulating dirt that could damage - For screw (2) change, remove carter, pull out filter (3) and
injector/pump system components. Bleed air from replace it with a new one. Filter has a one-way operation,
fuel filter as described in previous pages. therefore it must be installed with the two reinforcement
bars visible, as shown in the picture.

Check of water pump/alternator control belt condition

Fuel filter change Figure 35

Figure 33

107903
108396
Visually check that belt (1) is not worn out or broken; change
Use tool 99360314 to remove fuel filter (1). it as described below, if required.
Before fitting the new cartridge, wet seal with fuel oil or engine
oil. Lock the new one by hand and carefully check that rubber Water pump/alternator control belt change
seal and contact surface are clean and in perfect conditions. In order to remove and refit belt (1), operate using a specific
Lock cartridge by hand till contact with support and then lock tool (3) on belt tensioner (2) in direction shown by arrow.
it for ºof a rev. at prescribed tightening torque. Bleed air from
supply system as described in paragraph below:

NOTE Belt tensioner is automatic and requires no

adjustment.

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 36 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

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
NOTE The components of the system can be damaged filler (2) of tappet cover.
very quickly in presence of water or impurity within
- After the complete drainage, screw the plug and carry out
the fuel.
the clean oil filling.
Take prompt action on the filter to drain off the
water in the fuel circuit.
NOTE Use only the recommended oil or oil having the re-
Fuel filter is equipped with pump screw-valve to drain the quested features for the corrrect motor function-
water eventually mixed with fuel. ing.
In case of topping up, don­
t mix oils having different
Place a container underneath the filter and slightly loosen the features.
screw. Drain the water eventually contained in the filter­ s If you don­ t comply with theses rules, the service
bottom. warranty is no more valid.
Lock the screw (max 0.5 Nm locking couple) as soon as fuel
starts bleeding.
- Check the level through the dipsick until when the filling
Engine oil change is next to the maximum level notch indicated on the dip-
sick.
Figure 36
Engine oil filter change
Figure 37

85493

We recommend to carry out the oil drainage when the motor

is hot.
Warning: We recommend to wear proper protec- 107940
tions because of high motor service temperature.
Drain oil as described in ­Engine oil change­chapter.
The motor oil reaches very high temperature: you By means of 99360314 tool (2) to disassemble oil filter (1) or
must always wear protection gloves. filters for F3B engine .

- Place a proper container for the oil collecting under the

pan connected with the drain plug (3). Warning: the oil filter contains inside a quantity of
NOTE oil of about 1 kg.
- Unscrew the plug (3) and then take out the control dip-
sick (1) and the inserting plug (2) to ease the downflow Place properly a container for the liquid.
of the lubrication oil. Warning: avoid the contact of skin with the motor
oil: in case of contact wash the skin with running
water.
The motor oil is very pollutant: it must be disposed
The oil motor is very pollutant and harmful. of according to the rules.
In case of contact with the skin, wash with much water
and detergent.
NOTE Before refitting the new cartridge, wet seal using
Protect properly skin and eyes: operate according to engine oil.
safety rules.
Dispose of the residual properly following the rules. Lock oil filter (1) by hand till contact to support and then lock
by º of a rev. at prescribed tightening torque; pour oil in
engine ad described in ­Engine oil change­chapter.

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 G-DRIVE CURSOR ENGINES SECTION 2 - APPLICATION G-DRIVE 37

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.

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 38 SECTION 2 - APPLICATION G-DRIVE G-DRIVE CURSOR ENGINES

Base - April 2006 Print P2D32C001 E