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Engine Iveco C10/C13/C78/Cursor 13/Cursor 78. Manual - part 19

PA
RT

IO
N
3

STRIAL

APPL

ATIO

F2
B

SO
R

rin

2D
32C001

ril

2006

SIGNALLED

ANOMALY

BLINK

CODE

EDC

WAR-

NING

LIGHT

POSSIBLE

CAUSE

POSSIBLE

RELATED

ANOMALIES

RECOMMENDED

TESTS OR

MEASURES

REMARKS

The battery goes flat
quickly.

Pre-heating

resistor

powered continuously.

Local overheating.

The engine will stop or
won’t start.

Fuel pre-filter clogged.

Difficult start when the
engine is either hot or
cold.

The 3.5 bar valve on fuel
return is stuck open.

Slight overheating.

Either 0.3 bar tank return
valve

return

piping

clogged.

After the new vehicle
has been delivered, the
engine will stop after a
short

operation

time.The tank holds a
lot of fuel; all the rest is
O.K.

Reversed tank suction /
return pipes.

The engine is fed by the
return pipe, the suction
of which in the tank is
lower. When the pipe
sucks no more, the
engine will stop.

Reduced

power

difficult

engine

maneuverability.

Injection

system

the

engine operates with one
cylinder failing:
- injector plunger seizure;
- valve rocker arm seizure.

Overheating

Engine test: cylinder efficiency test.
If the trouble is not related to
electric components (Blink code
5.x), the rocker arm holder shaft
needs be disassembled. Check the
rocker arm roller and bushing as
well as the respective cam.

Fuel

consumption

increase.

Air filter clogging with no
signal from the warning
light on the instrument
board.

Smoke.

Check the cabling, connections and
component.

IO
N
3

STRIAL

APPL

ATIO

F2
B

SO
R

ril

2006

rin

2D
32C001

SIGNALLED

ANOMALY

BLINK

CODE

EDC

WAR-

NING

LIGHT

POSSIBLE

CAUSE

POSSIBLE

RELATED

ANOMALIES

RECOMMENDED

TESTS OR

MEASURES

REMARKS

The engine does not
reach the other speeds
under load conditions.

The

boosting

pressure

sensor provides too high
values, which, in any case,
fall within the range.

Smoke.

The driver feels that the
engine is not working
correctly like it did
before.

Impaired

hydraulic

performance of an injector.

Engine test: check-up

Replace the injector of
the cylinder in which
Modus detects lower
performance

levels

(compared

with

the

others) only after verify-
ing that the control
rocker arm adjustment is
correct.

The driver feels that the
engine is not working
correctly like it did
before.

Wrong adjustment of an
injector control rocker arm.

Engine test: check up.

Perform correct adjust-
ment, then repeat the
engine test.

The engine operates
with

five

cylinders;

noise (knock).

Plunger seizure.

Possible overheating.

Engine test: cylinder efficiency.

Replace the injector of
the cylinder in which the
diagnosis instrument de-
tects lower performance
levels (compared with
the others).

Wrong adjustment of the
injector control rocker arm
(excessive

travel)

with

impact on the plunger on
the nozzle.

Possible mechanic damage to
the areas surrounding the
injector.

Engine test: cylinder efficiency.

Replace the injector of
the cylinder in which the
diagnosis instrument de-
tects lower performance
levels (compared with
the others).

The engine will stop or
won’t start again.

Presence of air in the fuel
supply circuit.

It might even not switch off; it
might

have

operation

oscillations, or start, yet with
difficulty and after making
many attempts.

Bleed air.

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

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

NOTE

SECTION 3 - INDUSTRIAL APPLICATION

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

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.

Checks not included in maintenance planning-daily checks

MAINTENANCE PROCEDURES
Checks and controls

Engine oil level check.

The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided flexible
rod (1).

Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level.

Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.

In case the level results being close to the tag showing
minimum level, provide filling lubrication of the engine’s
components.

To provide filling, operate through the upper top (1) or
through the lateral top (2). During filling operation, the tops
must be removed as well as the rod in order to make the oil
flow easier”.

Refill through upper tappet cover plug. During refill, remove
dipstick for easier oil drain.

The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.

Adequately protect the skin and the eyes, operate
in full compliance with safety regulations.

Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

Check of fuel system
The check must be executed both when the engine
disconnected and when it is running.
The check is made by observing the fuel pipes from the tank
to the fuel pump and to the injectors.

Cooling system check
The check must be executed both when the engine
disconnected and when it is running.
Check the pipes from the engine to the radiator and vice versa;
note any seepage and the state of the pipes especially near the
coupling clamps.
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.

Due to the high temperatures achieved by the
system, do not operate immediately after the engine’s
disconnection, but wait for the time deemed
necessary for the cooling.
Protect the eyes and the skin from any eventual high
pressure jet of cooling liquid.

The density of the cooling liquid must be checked any how
every year before winter season and be replaced in any case
every two year.

In case of new filling, proceed bleeding system,
through the bleeds on the engine.

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.

NOTE

Lubricating system check
The check must be executed both when the engine
disconnected and when it is running.
Verify the presence of any oil leakage or blow-by from the
head, from the engine pan of from the heat exchanger.

The engine oil is highly polluting and harmful.
In case of contact with the skin, rinse well with water
and detergent.
Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

SECTION 3 - INDUSTRIAL APPLICATION

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