F2CE9684
F3AE9684
ENGINES CNH CURSOR
Tier3
F2CE9684 - F3AE9684
ENGINES CNH CURSOR
Tier3
Repair Manual Print No. 87476950A English Repair Manual
Alltheinformation,illustrationsanddataprovidedbythismanualarebaseduponthemostrecentinformationavailable atthetimeofitspublication.
CNHITALIAS.p.A.reservestherighttoimplementmodifications,atanytime,withoutcommunications.
REPAIRINSTRUCTIONMANUAL CNHENGINES
ENGINESFAMILY: F2CE9684--F3AE9684
CNHITALIAS.p.A. STAMPATON.87476950A Edizione--February2008
TOTHEREADER
- ThisManualiswrittenforanexperttechnicianto providethetechnicalinformationrequiredtoperformrepairoperationsonthismachine.
- Pleasereadcarefullythismanualforthecorrect informationregardingtherepairprocedures.
- Foranyquestionorcomment,orincaseany errorregardingthecontentofthismanualis found,youareaskedtopleasecontact: CNHITALIAS.p.A. StradaSettimo,323 SanMauroTorinese(TO) 10099ITALIA PARTS&SERVICE Fax++390110077357
SYMBOLS
Thismanualincludessafetywarningsymbolsandindicationstorecalltheattentiononpossiblepersonal injuriesordamagestothemachine.
Thissymbolrecallstheattentiontopointsrelativetosafety. Whenyouseethissymbol,itisnecessarytoproceedwithattentionsincethereisthepossibilityof personalinjuries.
Complyscrupulouslywiththeprecautionsidentifiedbythissymbol. Thesafetywarningsymbolisalsousedtoattractattentiontotheweightofacomponentorapart. Topreventpersonalinjuriesordamages,makesurethattheappropriateliftingequipmentand techniquesareimplementedwhenhandlingheavyloads.
! IN--1 FOREWORD
FOREWORD
UNITSOFMEASURE
Inthismanual,theunitsofmeasureoftheIS(InternationalSystem)areused. Theunitsofmeasureofthe MKSAsystemarelistedinparenthesisaftertheunits oftheInternationalsystem. Example:24.5Mpa(250kgf/cm2).
Herebelow,aconversiontableoftheunitsoftheISandsomeunitsofmeasureofothersystemsislisted.as areference.
IN--2
Quantity Toconvert from (SI) into (Others) Multiply by Quantity Toconvert from (SI) into (Others) Multiply by Length mm in 0.03937 Pressure MPa kgf/cm2 10.197 eng mm ft 0.003281 ressure MPa psi 145.0 L USgal 0.2642 Power kW PS 1.360 Volume L USqt 1.057 ower kW HP 1.341 m3 yd3 1.308 Temperature °C °F °Cx1.8+32 Mass kg lb 2.205 Velocity km/h mph 0.6214 Force N kgf 0.10197 oc min --1 rpm 1.0 orce N lbf 0.2248 Flow L/min USgpm 0.2642 Torque N.m kgf.m 0.10197 ow mL/rev cc/rev 1.0 orque N.m lbf.ft 0.7375
CURSORENGINES
CursorF2CEngines
CursorF3AEngines
Part1
Part2
1 CURSORENGINES
2 CURSORENGINES
Introduction
INTRODUCTION3
SYMBOLS3 - Warnings3 - Serviceoperations3
GENERALWARNINGS5
GENERALWARNINGS ONTHEELECTRICSYSTEM7 - Bondingandscreening8
OPTIONALELECTRICALANDMECHANICAL PARTSINSTALLATIONS9
CONVERSIONSBETWEENTHEMAINUNITS OFMEASUREMENTOFTHEINTERNATIONAL SYSTEMANDMOSTUSEDDERIVED QUANTITIES9
INTRODUCTION 3 CURSORENGINES
Page
4 INTRODUCTION CURSORENGINES
INTRODUCTION
ManualsforrepairsaresplitintoPartsandSections,eachoneof whichismarkedbyanumeral;thecontentsofthesesectionsare indicatedinthegeneraltableofcontents.
Thesectionsdealingwiththingsmechanicintroducethespecifications,tighteningtorquevalues,toollists,assembly detaching/reattachingoperations,benchoverhaulingoperations,diagnosisproceduresandmaintenanceschedules.
Thesections(orparts)oftheelectric/electronicsystemincludethedescriptionsoftheelectricnetworkandtheassembly’s electronicsystems,wiringdiagrams,electricfeaturesofcomponents,componentcodingandthediagnosisproceduresforthe controlunitspeculiartotheelectricsystem.
Section1describestheenginesillustratingitsfeaturesandworkingingeneral.
Section2describesthetypeoffuelfeed.
Section3relatestothespecificdutyandisdividedinfourseparateparts:
1.Mechanicalpart,relatedtotheengineoverhaul,limitedtothosecomponentswithdifferentcharacteristicsbasedontherelating specificduty.
2.Electricalpart,concerningwiringharness,electricalandelectronicequipmentwithdifferentcharacteristicsbasedontherelating specificduty.
3.Maintenanceplanningandspecificoverhaul.
4.Troubleshootingpartdedicatedtotheoperatorswho,beingentitledtoprovidetechnicalassistance,shallhavesimpleanddirect instructionstoidentifythecauseofthemajorinconveniences.
Sections4and5illustratetheoverhauloperationsoftheengineoverhaulonstandandthenecessaryequipmenttoexecutesuch operations.
Theappendixcontainsalistofthegeneralsafetyregulationstoberespectedbyallinstallationandmaintenanceengineersinorder topreventseriousaccidentstakingplace.
Themanualusespropersymbolsinitsdescriptions;thepurposeofthesesymbolsistoclassifycontainedinformation.Inparticular, therehavebeendefinedasetofsymbolstoclassifywarningsandasetforassistanceoperations.
SYMBOLS-Warnings
Dangerforpersons
Missingorincompleteobservanceoftheseprescriptionscancauseseriousdangerforpersons’safety.
Dangerofseriousdamagefortheassembly
Failuretocomply,bothfullyorinpart,withsuchprescriptionswillinvolveseriousdamagetotheassemblyandmay sometimescausethewarrantytobecomenullandvoid.
Generaldanger
Itincludesthedangersofabovedescribedsignals.
Environmentprotection
Moreover,itdescribesthecorrectactionstobetakentoensurethattheassemblyisusedinsuchawaysoastoprotect theenvironmentasmuchaspossible.
Itindicatesanadditionalexplanationforapieceofinformation.
!
NOTE
Serviceoperations Example Ø1=housingforconnectingrodsmallendbush Ø2=housingforconnectingrodbearings α Tightentotorque Tightentotorque+angularvalue 1 ∅ ∅ 2 INTRODUCTION 5 CURSORENGINES
α
Removal
Disconnection
Refitting Connection
Removal
Disassembly
Fittinginplace Assembly
Tightentotorque
Tightentotorque+anglevalue
Pressorcaulk
Regulation Adjustment
Visualinspection Fittingpositioncheck
Measurement
Valuetofind Check
Equipment
Surfaceformachining Machinefinish bar
Interference
Strainedassembly
Thickness Clearance
Lubrication Damp Grease
Sealant Adhesive
Airbleeding
CNH PARTS Replacement Originalspareparts
Intake
Exhaust
Operation
Compressionratio
Tolerance Weightdifference
Rollingtorque
Rotation
Angle Angularvalue
Preload
Numberofrevolutions
Temperature
Pressure
Oversized Higherthan…. Maximum,peak
Undersized Lessthan Minimum
Selection Classes
Oversizing
Temperature<0 °C Cold Winter
Temperature>0 °C Hot Summer
6 INTRODUCTION CURSORENGINES
ρ
GENERALWARNINGS
Warningsshowncannotberepresentativeofalldangersituationspossiblyoccurring.Therefore,itissuggestedtocontact immediatesuperiorswhereadangersituationoccurswhichisnotdescribed.
Usebothspecificandgeneral-purposetoolingsaccordingtotheprescriptionscontainedinrespectiveuseand maintenancehandbooks.Checkusestateandsuitabilityoftoolsnotsubjectedtoregularcheck.
Themanualhandlingofloadsmustbeassessedinadvancebecauseitalsodepends,besidesweight,onitssizeandon thepath.
Handlingbymechanicalmeansmustbewithhoistersproperasforweightaswellasforshapeandvolume.Hoisters, ropesandhooksusedmustcontainclearindicationsonmaximumcarryingcapacityacceptable.Theuseofsaidmeans iscompulsorilypermittedtoauthorisedpersonnelonly. Staydulyclearoftheload,and,anyhow,neverunderit.
Indisassemblingoperations,alwaysobserveprovidedprescriptions;preventmechanicalpartsbeingtakenoutfrom accidentallystrikingworkshoppersonnel.
Workshopjobsperformedinpairsmustalwaysbeperformedinmaximumsafety;avoidoperationswhichcouldbe dangerousfortheco-operatorbecauseoflackofvisibilityorofhis/hernotcorrectposition.
Keeppersonnelnotauthorisedtooperationsclearofworkingarea.
Youshallgetfamiliarwiththeoperatingandsafetyinstructionsfortheassemblypriortooperatingonthelatter.Strictly followallthesafetyindicationsfoundontheassembly.
Donotleavetherunningassemblyunattendedwhenmakingrepairs.
Whencarryingoutworkontheassemblyliftedofftheground,verifythattheassemblyisfirmlyplacedonitssupporting stands,andthatthemanual/automaticsafetydeviceshavebeenactuatedintheeventthattheassemblyistobelifted bymeansofahoist.
Whenyouhavetooperateonassembliespoweredbynaturalgas,followtheinstructionscontainedinthedocument, aswellasallthespecificsafetystandardsprovidedfor.
Onlyremoveradiatorcapwhentheengineiscoldbycautiouslyunscrewingitinordertoletsystemresidualpressure out.
Inflammablefuelandallinflammablefluidsandliquidsmustbehandledwithcare,accordingtowhatcontainedonharmful materials12-pointcards.Refuellingmustbeperformedoutdoorswiththeengineoff,avoidinglitcigarettes,freeflames orsparksinordertopreventsuddenfires/bursts.Adequatelystoreinflammable,corrosiveandpollutingfluidsandliquids accordingtowhatprovidedbyregulationsinforce.Compulsorilyavoidtousefoodcontainerstostoreharmfulliquids. Avoidtodrillorborepressurisedcontainers,andthrowclothsimpregnatedwithinflammablesubstancesintosuitable containers.
Wornout,damagedorconsumablepartsmustbereplacedbyoriginalspares.
Duringworkshopactivity,alwayskeeptheworkplaceclean;timelyclearorcleanfloorsfromaccidentalliquidoroilspots. Electricsocketsandelectricequipmentnecessarytoperformrepairinterventionsmustmeetsafetyrules.
! INTRODUCTION 7 CURSORENGINES
Puton,whererequiredbytheintervention,garmentsandprotectionsprovidedinaccidentpreventionrules;contact withmovingpartscancauseseriousinjuries.Usesuitable,preferablytight-fittedgarments,andavoidtousejewels, scarves,etc.
Donotleavetheengineinmotionatworkshoplocationsnotprovidedwithapipetoscavengeexhaustgasoutside.
Avoidtobreathefumescomingfromheatingorfrompaintweldingbecausetheycancausedamagestohealth;operate outdoorsorinsuitablyventilatedareas.Puton properinspiratorifpaintpowderispresent.
Avoidcontactwithhotwaterorsteamcomingfromtheengine,radiatorandpipingsbecausetheycouldcauseserious burns.Avoiddirectcontactwithliquidsandfluidspresentinvehiclesystems;whereanaccidentalcontacthasoccurred, referto12-pointcardsforprovisionstomake.
Cleantheassembliesandcarefullyverifythattheyareintactpriortooverhauling.Tidyupdetachedordisassembled partswiththeirsecuringelements(screws,nuts,etc.)intospecialcontainers.
Checkfortheintegrityofthepartswhichpreventscrewsfrombeingunscrewed:brokenwashers,dowels,clips,etc. Self-lockingnutswithaninsertmadeofnylonmustalwaysbereplaced.
Avoidcontactofrubberpartswithdieseloil, petrolorothernotcompatiblesubstances.
Beforewashingunderpressuremechanicalparts,protectelectricconnectors,andcentralunits,ifpresent.
Tighteningscrewsandnutsmustalwaysbeaccordingtoprescriptions;CNHcommercialandassistancenetworkis availabletogiveallclarificationsnecessarytoperformrepairinterventionsnotprovidedinthisdocument.
Beforewelding:
- Disconnectallelectroniccentralunits,takepowercableoffbatterypositiveterminal(connectittochassisbonding) anddetachconnectors.
- Removepaintbyusingpropersolventsorpaintremoversandcleanrelevantsurficeswithsoapandwater.
- Awaitabout15minutesbeforewelding.
- Equipwithsuitablefireresistantprotectionstoprotect hosesorothercomponentswherefluidsorothermaterials flowwhichmaycatchfireeasilyonwelding.
Shouldthevehiclebesubjectedtotemperaturesexceeding80°C(dryerovens),disassembledriveelectroniccentral units.
Thedisposalofallliquidsandfluidsmustbeperformedwithfullobservanceofspecificrulesinforce.
8 INTRODUCTION CURSORENGINES
NOTE
Ifaninterventionhastobemadeontheelectric/electronicsystem,disconnectbatteriesfromthesystem;inthiscase, alwaysdisconnect,asafirstone,thechassisbondingcablefrombatteriesnegativeterminal.
Beforeconnectingthebatteriestothesystem, makesurethatthesystemiswellisolated.
Disconnecttheexternalrechargingapparatusfromthepublicutilitynetworkbeforetakingapparatuspinsoffbattery terminals.
Donotcausesparkstobegeneratedincheckingifthecircuitisenergised.
Donotuseatestlampincheckingcircuitcontinuity,butonlyusepropercontrolapparatuses.
Makesurethattheelectronicdeviceswiringharnesses(length,leadtype,location,strapping,connectiontoscreening braiding,bonding,etc.)complywithCNHsystemandarecarefullyrecoveredafterrepairormaintenanceinterventions.
Measurementsindriveelectroniccentralunits,pluggedconnectionsandelectricconnectionstocomponentscanonly bemadeonpropertestinglineswithspecialplugsandplugbushes.Neveruseimpropermeanslikewires,screwdrivers, clipsandthelikeinordertoavoidthedangerofcausingashortcircuit,aswellasofdamagingpluggedconnections,which wouldlatercausecontactproblems.
Tostartuptheengine,donotusefastchargers.Startupmustonlybeperformedwitheitherseparatebatteriesorspecial truck.
Awrongpolarisationofsupplyvoltageindriveelectroniccentralunits(forinstance,awrongpolarisationofbatteries) cancausethemtobedestroyed.
Disconnectthebatteriesfromthesystemduringtheirrechargingwithanexternalapparatus.
Onconnecting,onlyscrewupconnector(temperaturesensors,pressuresensorsetc.)nutsatprescribedtightening torque.
Beforedisconnectingthejunctionconnectorfrom anelectroniccentralunit,isolatethesystem.
Donotdirectlysupplyelectroniccentralunits servocomponentsatnominalvehiclevoltage.
Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/body structure.
Oncetheinterventionontheelectricsystemhasbeencompleted,recoverconnectorsandwiringharnessesaccording tooriginalarrangement.
Connectorspresentmustbeseenfromcableside.Connectorsviewscontainedinthemanualarerepresentativeofcable side.
GENERAL WARNINGSONTHEELECTRICSYSTEM
!
INTRODUCTION 9 CURSORENGINES
Bondingandscreening
Negativeleadsconnectedtoasystembondedpointmustbebothasshortandpossibleand“star“-connectedtoeachother,trying thentohavetheircenteringtidilyandproperlymade(Figure1,re.M).
Further,followingwarningsaretobecompulsorilyobservedforelectroniccomponents:
-Electroniccentralunitsmustbeconnectedtosystembondingwhentheyareprovidedwithametallicshell.
-Electroniccentralunitsnegativecablesmustbeconnectedbothtoasystembondingpointsuchasthedashboardopening bonding(avoiding“serial“or“chain“connections),andtobatterynegativeterminal.
-Analogbonding(sensors),althoughnotconnectedtobatterynegativesystem/terminalbonding,musthaveoptimalisolation. Consequently,particularlyconsideredmustbeparasiticresistancesinlugs:oxidising,clinchingdefects,etc.
-Screenedcircuitsbraidingmustonlyelectricallycontactthe endtowardsthecentralunitenteredbythesignal(Figure2).
-Ifjunctionconnectorsarepresent,unscreenedsection d,nearthem,mustbeasshortaspossible(Figure2).
-Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/bodystructure.
10 INTRODUCTION CURSORENGINES
1. NEGATIVECABLES “STAR“ CONNECTIONTOSYSTEMBONDING M
d.
88039
2. SCREENINGTHROUGHMETALLICBRAIDINGOFACABLETOANELECTRONICCOMPONENT—
C.
CONNECTOR
DISTANCE ! 0
Figure1
Figure2
OPTIONALELECTRICALANDMECHANICALPARTSINSTALLATIONS
Assembliesshallbemodifiedandequippedwithadditions-andtheiraccessoriesshallbefitted-inaccordancewiththeassembling directivesissued.
Itisremindedthat,especiallyabouttheelectricsystem,severalelectricsocketsareprovidedforasseries(oroptional)socketsin ordertosimplifyandnormalisetheelectricalinterventionthatiscareofpreparationpersonnel.
Itisabsolutelyforbiddentomakemodificationsorconnections toelectriccentralunitswiringharnesses;inparticular, thedatainterconnectionlinebetweencentralunits(CANline)istobeconsideredinviolable.
CONVERSIONSBETWEENTHEMAINUNITSOFMEASUREMENTOFTHE INTERNATIONALSYSTEMANDMOSTUSEDDERIVEDQUANTITIES
Power
1kW=1.36metricHP
1kW=1.34HP
1metricHP=0.736kW
1metricHP=0.986HP
1HP=0.746kW
1HP=1.014metricHP
Torque
1Nm=0.1019kgm
1kgm=9.81Nm
Revolutionspertimeunit
1rad/s=1rpmx0.1046
1rpm=1rad/sx9.5602
Pressure
1bar=1.02kg/cm2
1kg/cm2 =0.981bar
1bar=105 Pa
Whereaccuracyisnotparticularlyneeded:
- Nmunitisforthesakeofsimplicityconvertedintokgmaccordingtoratio10:1 1kgm=10Nm;
- barunitisforthesakeofsimplicityconvertedintokg/cm2 accordingtoratio1:1 1kg/cm2 =1bar.
Temperature
0° C=32° F
1° C=(1x1.8+32) ° F
INTRODUCTION 11 CURSORENGINES
12 INTRODUCTION CURSORENGINES
Section Generalspecifications 1 Fuel 2 Industrialapplication 3 Overhaulandtechnicalspecifications 4 Tools 5 Safetyprescriptions Appendix Part1 F2CCURSORENGINES 1 F2CCURSORENGINES
2 F2CCURSORENGINES
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