john s.c. thorpe - iveco engine training aid manual

IVECO ENGINE

TRAINING AID BUILD

The purpose of this project was to finishing building a working

engine training aid for the diesel lab and have ability to control the

engine with a ComAp© controller through the Can-Bus.

John S.C. Thorpe

©2015

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http://www.pittstate.edu/department/auto/about-the-department/index.dot

Iveco Engine Training Aid Build ©2015

John S.C. Thorpe FOR EDUCATIONAL PURPOSES ONLY 1 | P a g e

IVECO ENGINE TRAINING

AID BUILD

By: John S.C. Thorpe

FOR EDUCATIONAL

PURPOSES ONLY




Table of Contents

Legal Notice, Disclaimer, Terms of Usage:.................................................................................... 4

Use of Material in the Iveco Engine Training Aid Build Document:.......................................... 4

Sites Linked From the Iveco Engine Training Aid Build Document: .......................................... 5

Disclaimer of Warranty: ............................................................................................................. 5

Limitation of Liability: ................................................................................................................ 6

Copyright and Trademark Notices: ............................................................................................ 6

Special Thanks: ............................................................................................................................... 7

Project Description: ........................................................................................................................ 8

Questions & Concerns: ................................................................................................................... 8

Procedures: ...................................................................................................................................... 9

Intake System: ............................................................................................................................. 9

Cooling System:......................................................................................................................... 11

Fuel System: .............................................................................................................................. 12

Electrical System: ...................................................................................................................... 15

Recommended Tools: ............................................................................................................ 15

Harness Set Up For Engine and ComAp Controller: ............................................................ 15

Starting System Set Up: ......................................................................................................... 17

Schematics: ................................................................................................................................... 19

ComAp Schematic: .................................................................................................................... 19

Engine Harness Schematic: ...................................................................................................... 19

InteliDrive Nano ComAp Programing: ......................................................................................... 20

Updating Firmware: ................................................................................................................. 20

Programing Outputs: ................................................................................................................ 21

Parts List: ...................................................................................................................................... 23

Fuel Parts:................................................................................................................................. 23

Engine Side: ........................................................................................................................... 23

Tank Side: .............................................................................................................................. 24

Electrical Parts: ........................................................................................................................ 25

Controller, Adapter Panel Mount Cable & On/Off Switch: .................................................. 25




Relays & Solenoid: ................................................................................................................ 25

Connectors: ............................................................................................................................ 25

Pins, Sockets, & Crimping Tool: ........................................................................................... 26

Terminal Tools: ..................................................................................................................... 26

Terminals: .............................................................................................................................. 26

Wire: ...................................................................................................................................... 27

Bosch Terminals and ECU Connector: ................................................................................. 27

Project Summary:.......................................................................................................................... 28

Resource Websites: ....................................................................................................................... 29

Appendix: ...................................................................................................................................... 31

Activity Log: .............................................................................................................................. 31




Legal Notice, Disclaimer, Terms of Usage:

Access to and use of the Iveco Engine Training Aid Build Document (By the Author John S.C.

Thorpe) is provided subject to these terms and conditions. PLEASE READ THESE TERMS

CAREFULLY AS USE OF THIS DOCUMENT CONSTITUTES ACCEPTANCE OF THESE

TERMS AND CONDITIONS.

Use of Material in the Iveco Engine Training Aid Build Document:

The information, artwork, text, video, audio, or pictures (collectively, "Materials") contained in

the Iveco Engine Training Aid Build Document are protected by copyright laws. You may only

access and use the Materials for personal or educational purposes only and not for production.

You may not modify or use the Materials for any other purpose without Author’s. ("John S.C.

Thorpe") express written consent. Except as provided below, you may not reproduce, republish,

post, transmit or distribute any Materials in the Iveco Engine Training Aid Build Document.

You may print the Iveco Engine Training Aid Build Document for personal or educational

purposes only, and you must include any copyright notice originally included with the Materials

in all copies.

The Materials included in the Iveco Engine Training Aid Build Document have been compiled

by John S.C. Thorpe from a variety of sources, and are subject to change without notice.

All electronic files of the Iveco Engine Training Aid Build Document are protected by copyright

laws. You may not, under any circumstances, reproduce, record, publish, publicly exhibit, or

distribute any electronic files made available for use without John S.C. Thorpe's express written

consent. You may not attempt to "pass-off" any of John S.C. Thorpe's content as your own work.




Sites Linked From the Iveco Engine Training Aid Build Document:

The sites linked from the Iveco Engine Training Aid Build Document are not under John S.C.

Thorpe's control, and Thorpe does not assume any responsibility or liability for any

communications or materials available at such linked sites. Thorpe does not intend links in the

Iveco Engine Training Aid Build Document to be referrals or endorsements of the linked entities,

and are provided for convenience only.

Disclaimer of Warranty:

The services, information, software or data (collectively, "Information") made available the

Iveco Engine Training Aid Build Document are provided "AS IS", without warranties of any

kind. Thorpe expressly disclaims any representations and warranties, including without

limitation, the implied warranties of merchantability and fitness for a particular purpose. Thorpe

shall have absolutely no liability in connection with the services including without limitation,

any liability for damage to your computer hardware, data, information, Materials and business

resulting from the Information or the lack of information available in the Iveco Engine Training

Aid Build Document.

Thorpe shall have no liability for:

Any loss, personal injury, death or damages caused, in whole or in part, by its actions, omissions,

or negligence, or for contingencies beyond its control, in procuring, compiling, or delivering the

Information; Any errors, omissions, or inaccuracies in the Information regardless of how caused,

or delays or interruptions in delivery of the Information; or Any decision made or action taken or

not taken in reliance upon the Information furnished hereunder. Thorpe makes no warranty,

representation or guaranty as to the content, sequence, accuracy, timeliness or completeness of

the Information or that the Information may be relied upon for any reason. Thorpe makes no

warranty, representation or guaranty that the Information will be uninterrupted or error free or

that any defects can be corrected. For purposes of this section, John S.C. Thorpe and any third-

party providers or sources of information or data.




Limitation of Liability:

Under no circumstances shall John S.C. Thorpe be liable for any losses, personal injury, death or

damages whatsoever, from the use of, or reliance on, the Information, or from the use of the

Iveco Engine Training Aid Build Document.

For purposes of this section, John S.C. Thorpe and any third-party providers or sources of

information or data.

Copyright and Trademark Notices:

Copyright and Trademark Notices Copyright (c) John S.C. Thorpe©2015 all rights reserved.

Before using any information in the Iveco Engine Training Aid Build Document for any other

purpose without Author’s. ("John S.C. Thorpe") express written consent.

All other trademarks and Logos are the property of their respective owners.




Special Thanks:

Special thanks to the following people and companies who helped in the completion of this

project:

Case IH by FPT – Iveco 10.3L Cursor Engine Donation & Engine Harness

Mr. Kelly Burgess – New Product Quality – Case New Holland Industrial

Mr. Bob Schroer –Associate Professor/Diesel Coordinator - Automotive Technology

Department– Pittsburg State University – Project Advisor

Mr. Bruce Rhodes – KTC Research Technologist – Pittsburg State University

SRC Power Systems INC. – InteliDrive Nano ComAp Donation

Mr. Bob Jones – R&D Electronics Supervisor – SRC Power Systems Inc.




Project Description:

The purpose of this project was to finish building a working engine training aid for the diesel lab

by finishing the intake system, cooling system, fuel system, and the electrical system. Also, the

project provides the ability to control the engine with a ComAp controller through the Can-Bus.

All the following steps will only apply to the Iveco 10.3L Cursor Diesel Engine.

Questions & Concerns:

If there are any questions or concerns please do not hesitate to contact the author at the following

email address:

[email protected]


mailto:[email protected]



Procedures:

The following steps are broken down into four groups: the Intake, Coolant, Fuel, and Electrical

System.

The first step in this project was to talk to Mr. Schroer on what needed to be done on the engine,

and to be ran successfully. The next thing was to make a to-do list. The list consisted of what

things needed to be done to the intake system, the coolant system, fuel system, and the electrical

system. The final thing to be done was to evaluate the parts needed to complete this project, by

creating a parts list. (Please see parts list section of this document.)

Intake System:

To complete the intake system, determine what is needed to be done. Order two (2) 3/8in pipe

plugs for the turbo intake adapter from the local auto parts store. Plug both sides of the turbo

intake adapter shown in figures 1 & 2.

Fabricate an intake tube from the aftercooler to the intake manifold, in order to finish the intake

system. (This intake tube was fabricated for this configuration by taking existing steel tubing

supplied by the diesel lab and connecting it to the after cooler.) Clock the tubing and mark the

tubing on the engine. Please refer figures 3-5 on the following page.

3/8in

Pipe

Plug

Fig. 1 Fig. 2

2015©John S.C. Thorpe




John S.C. Thorpe FOR EDUCATIONAL PURPOSES ONLY 10 |

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Once the one section of the intake tubing clocked, the tubing should be tack welded together so

while when welding the tubing it does not move from its clocked position. Weld first section of

tubing then grind welds down as in figures 4 & 5 if this is your preference. Repeat this step until

desired tube configuration is completed. Install intake tubing configuration onto the intake

system of the engine. Clamp intake system steel tubes and rubber hoses together that hold the

steel tubing in place as in figures 6-8 below.

When completed, paint the intake tube if desired as seen in figure 9 below.

Fig. 3 Fig. 4 Fig. 5

Fig. 6 Fig. 7 Fig. 8

Fig.9










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Cooling System:

Install hoses on the cooling system. There is a total of 3 hoses (2) 3/8in I.D. and (1) 1 1/2in I.D.

Connect the (2) 3/8in I.D. hose to the coolant reservoir tank in figure 10 & 12 from port-1 and

port-2. Take the other end of each hose and connect them as shown in figures 11 & 13.

Attach (1) 1 1/2in I.D. hose to the bottom of the tank reservoir shown in figure 12 and the other

end of the hose to the coolant tube that goes to the engine water pump. Now both coolant tubes

are going from the radiator to the engine block. Paint if desired as show in figure 14.

Fig.10 Fig.11

Fig.12 Fig.13

Port-1 Port-2

From

Port-2

From

Port-1

Coolant

tube

Fig.14

Bottom

of

reservoir

tank









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Fuel System:

When fabricating the fuel tank, a 5 Gallon Air Tank is used from local auto parts store. Remove

the air hose fitting from the tank as shown in figure 15. Remove the handle and feet from the

tank.

Take a Hole-Saw to cut a 1 1/2in hole at the center of tank in line with the hole that you have just

removed the air fitting from, as shown in figure 15. Drill a 18/25 hole but first drill a pilot hole

this will make it easier to drill the main hole size. Install the tank breather fill cap.

Install and weld adapter fitting into the tank as shown in figure 16. You will also weld a piece of

1 1/2in pipe and weld it to the tank as shown in figure 16.

Weld

fitting to

this spot

on tank

Weld

pipe here

on tank

Breather

Cap

Remove

Fig.16

Fig.15

Use Hole-Saw here

Drill hole here





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Fabricate the mounting by cutting two (2) pieces of angle iron about 4in H x 3in W x 13 3/4in L.

Notch out the angle iron so that tank sets on the two (2) pieces of angle iron. Proceed to weld the

tank first onto the angle iron then weld the assembly to the engine stand that has been built for

this engine shown in figure 17.

To fabricate the hard and soft fuel lines, refer to parts section for this part of the build. Take the

hard line tubing cut to length and bend to desired length and configuration. Take a Male JIC 37o

to 60o metric tube seat adapters shown in figures 18 & 19 and machine out the center adapter to

the diameter of both hard line tubing. Install these adapters to the hard lines. Install the hard lines

to the engine itself as shown in figures 18 & 19.

Fig.17

Fuel line to

engine

Weld tank to

angle iron here

Weld assembly

to frame here

Fig.18 Fig.19

Male JIC

37o to 60o

metric tube

seat

adapters 2015©John S.C. Thorpe






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Use the left over 12mm tubing and 1/2 pipe to 3/4 JIC 37 fitting. Machine out the center of the

fitting to the O.D. of the tubing so that tubing inserts into the fitting. Weld or braze the tubing to

the fitting, cut the tubing to a desired length so that this becomes a pick up tube for the fuel tank

and set about 1/4in from the bottom of the fuel tank as shown in figure 20.

Cut the following fuel line hoses, one (1) of each size a 5/16in I.D. and a 1/2in I.D. to desired

length. Install the fuel line hose fittings to each end of the hose. Install hoses to the hard lines and

tank as shown in figure 21. These fittings and hose parts can be found in the parts list section of

this document.

5/16in I.D.

hose and

fittings

1/2in I.D.

hose and

fittings

Fig. 21

Fig. 20

Tube

welded to

the fuel

fitting to

make a

pick up line

for fuel






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Electrical System:

Recommended Tools:

In this section the electrical system will be worked on.

Digital Multimeter, T-pin, and gator clips.

Deutsch connector kit this is for pins and receptacles.

Heat Shrink and Heat Gun.

Use 10 and 16 gauge wire. Colors used are Black, Red, Green, Yellow, and Orange. These parts

can be found in the parts list section of this document.

Harness Set Up For Engine and ComAp Controller:

NOTE: Order all the electrical parts in the parts list section of this document.

WARNING: THIS IS A 12/24 VOLT SYSTEM.

Check continuity of all wires for the electrical harness coming out of the Engine ECU using the

provided schematic for the engine harness in this document. Once the connections have been

checked for continuity label each wire connection as shown in figure 22. (Make your own

harness if you wish.)

Fig. 22





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Once this has been done, heat shrink the ends of the extra wires so the Engine ECU does not

short out. Save these other wires for later, to add anything to the device being used control the

engine. Such as the InteliDrive Nano ComAp Controller as shown in figure 23.

Wire the ComAp controller. To do this, follow the electrical diagram section to wire the

InteliDrive Nano ComAp Controller as shown in figure 24. An on/off switch is wired into this

controller to cut the power off from the Controller and Engine ECU. To prevent battery drain and

eliminates the need to put in a battery disconnect switch into the electrical system. For the wiring

of the controller you will need to use a Duetsch 8 Pin bridged connector refer to parts list section.

Fabricate wire splitters as shown in figure 25 for the relay and the on/off switch. Make a positive

version of this wire shown in figure 25. If desired to make this ComAp controller in a full

housing a panel mounted communications connector is needed, which can be found in the parts

list of this document. This is also the same for the cannon plugs.

Fig. 23 Fig. 24

Fig. 25 Fig. 26

Cannon

Connector 2015©John S.C. Thorpe







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Starting System Set Up:

WARNING: THIS IS A 12/24 VOLT SYSTEM.

Since this is a 12/24 volt system, pay close attention the wiring schematic for the engine harness.

The engine ECU and Alternator are a 12 volt system and the Starter is a 24 volt system. The

solution to this problem is a 12/24 volt solenoid relay shown in figure 27. Mount to desired

location.

Remove the relay, as shown in figure 28, from next to the Engine ECU and mount it near the

12/24 volt solenoid relay show in figure 29.This requires two relays and refer to parts list section

of this document.

Fig. 28 Fig. 29

Fig. 27







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Due to the complexity of the wiring of this system, have a set of dedicated batteries to this

engine. Such as the batteries shown in figure 30.

Note: Fabricate a cage for these batteries and mount the cage to the frame of the engine

stand.

Now it is time to wire everything together. If the provided wiring schematics are followed

correctly, there should not be a problem with starting this engine.

This is how the wiring should look for this solenoid relay and relays being wired together in

figures 31& 32. Cover the wires and do not leave them exposed. Use wire loom to cover.

NOTE: The harness contains 2 connectors that will fit the Tyco relays. Use both ends

witch, have a common blue wire and different yellow wires, this common blue wire will be

wired to pin B on the cannon plug on the harness side.

Fig. 31 Fig. 32



Fig. 30





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Schematics:

NOTE: Click on schematics to download larger versions.

ComAp Schematic:

Engine Harness Schematic:


https://drive.google.com/file/d/0B9qprpYn0eonSElJUUY3UVpyYmM/view?usp=sharing

https://drive.google.com/file/d/0B9qprpYn0eonOVdFbktpWGxBcDQ/view?usp=sharing



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InteliDrive Nano ComAp Programing:

Updating Firmware:

Sign up on the ComAp website to download ID-Nano 1.6 Installation Suite program to

configure the software in the InteliDrive Nano. Download the following document InteliDrive

Nano 1.6 Reference Guide for any questions one may have about the controller and provides

more in depth knowledge of the use of the controller. The following is just a quick start guide to

get the engine running.

Once installed, connect the software to the controller through USB cable that can be found at

your local electronics store or in the parts section of this document.

Open up the DriveEdit Program by double clicking on the icon on the desktop of the computer.

Click on Firmware update shown in figure 33. This will allow an update the firmware or check if

the firmware has been updated from factory. If it has not, then the next step will guide one

through this.

Update the firmware and write it to the controller by simply clicking on to the InteliDrive Nano

name of the firmware. Click on the write firmware to controller icon to update the controller as

in figure 34.

Fig. 33 Modified Screen Shot Using ComAp Program

Click here

and will go to

the next

screen.



http://www.comap.cz/products/detail/intelidrive-nano/



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Programing Outputs:

Once firmware update is completed to the controller, click on download from the controller

button as shown in figure 34. It will then show the next screen which is shown in figure 35.

Click on outputs shown in figure 35, it will then go to the next screen show in figure 36. Click on

the following section show in figure 36, it will then go to the next screen shown in figure 37.



Click here

first

Click here

next

Click here

last



Click here

next




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Click on numbers 04 & 05 then select Starter, it will be normally opened as shown in figure 37.

Do the same for 06 & 07 of this block. Select Fuel Solenoid on the Output function selection.

Click on the upload to controller button in figure 37. It will notify that it has been successfully

uploaded to device, click ok and ready to use. Refer to the InteliDrive Nano Manual to control

engine RPM.



Click on

this section



Click to

finish

Click this section, then

select Fuel Solenoid

Click on this section,

then select Starter




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Parts List:

NOTE: Each Part is hyperlinked to the picture. Click on the pictures and it will go directly

to the part’s website. All parts are marked with the name, size, and quantity.

Fuel Parts:

Engine Side:

(10mm to JIC 37 Qty. 1) (12mm to JIC 37 Qty. 1)

(12mm Sleeve Qty. 2) (10mm Nut Qty. 2) (12mm Nut Qty. 2)

(10mm Sleeve Qty. 2) (12mm O.D. Steel Tube Pipe Qty. 1) (10mm O.D. Steel Tube Pipe Qty. 1)


http://www.mcmaster.com/#50295k272/=uyyrvi

http://www.mcmaster.com/#50295k292/=uyyrw4

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Adapter-Fitting/_/R-WH_7165X10MM_0084728845

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Adapter-Fitting/_/R-WH_7165X12MM_0084728845

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Adapter-Fitting/_/R-WH_MH7105X10_0084728845

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Adapter-Fitting/_/R-WH_MH7105X12_0084728845

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Adapter-Fitting/_/R-WH_MC5207X6X10_0084728845

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Adapter-Fitting/_/R-WH_MC5207X8X12_0084728845



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Tank Side:

(1/4in Pipe Fitting Qty. 1) (1/2in I.D. Hose Sold By FT)

(1 1/2in Breather Qty. 1) (5 gallon Tank Qty. 1) (1/2in Hose Fitting Qty. 2) (5/16in Hose Fitting Qty. 2)

(5/16in I.D. Hose Sold By FT)

(1/4 pipe to 9/16 JIC 37Qty. 1) (1/2 pipe to 3/4 JIC 37 Qty. 1)


http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Crankcase-Breather-Cap/_/R-BK_7031707_0439964264

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Air-Tank-Portable-5-gal/_/R-BK_8211350_0006381729

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hose-End-1-2-Hose-ID/_/R-WH_24710N608_0075090767

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hose-End-5-16-Hose-ID/_/R-WH_24706N606_0071310977

http://www.mcmaster.com/#46685k262/=uyyr0m

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Hoses-Bulk-General-Purpose-Truck-Hose-Medium-Pressure-Medium-Pressure-Truck-Hydraulics-Systems-Air-Brake-Fuel-Oil-Grease-Lines-Eaton-Weatherhead-SAE-100R5-J1402-Type-II/_/R-WH_H06910_0006422661

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Hydraulic-Hoses-Bulk-General-Purpose-Truck-Hose-Medium-Pressure-Medium-Pressure-Truck-Hydraulics-Systems-Air-Brake-Fuel-Oil-Grease-Lines-Eaton-Weatherhead-SAE-100R5-J1402-Type-II/_/R-WH_H06906_0006422661

http://www.mcmaster.com/#50695k166/=uyywml

http://www.mcmaster.com/#50695k163/=uyyw7k



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Electrical Parts:

Controller, Adapter Panel Mount Cable & On/Off Switch:

Relays & Solenoid:

Connectors:

(DT04-08P Qty. 1) (DT06-08S Qty. 1) (HD36-18-14SN-HD30 Qty. 1)

(Lock Washer Qty. 1) (Panel Nut Qty. 1)

(LED Switch Qty. 1) (Panel Mount USB Qty. 1)

(Tyco High Current Relay Qty. 1) (12V-4 Pin Relay Qty. 1) (12/24V Relay Solenoid Qty. 1)

(USB 2.0 A/B Cable Qty. 1)

(HD34-18-14PE-HD30 Qty. 1)


http://www.oreillyauto.com/site/c/detail/CTI0/84897.oap?ck=Search_84897_-1_138&keyword=84897

http://www.cablestogo.com/product/28070

http://www.cablestogo.com/product/28102

http://www.newark.com/te-connectivity/v23132a2001b200/relay-high-current-130a-12v-spst/dp/78T5582?CMP=AFC-OP

http://www.autozone.com/electrical/relay-and-resistors/novita-4-pin-40-amps-12-volts-accessory-relay/203873/?_requestid=161411

http://www.texasindustrialelectric.com/relays_1119844.asp

http://www.nexelec.com/product-p/deut-dt0408p.htm

http://www.nexelec.com/ProductDetails.asp?ProductCode=DT0608S_n44

http://www.wirecare.com/product.asp?pn=WC03520718&gclid=Cj0KEQiA5K-kBRDZ9r71gOvlxOMBEiQAwkK52NuWQSkoAAe7RXMthy6mYVbuD8xw1hen8iV4aUgcTaMaAlYK8P8HAQ

http://www.wirecare.com/product.asp?pn=WC03493621





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Pins, Sockets, & Crimping Tool:

Terminal Tools:

Terminals:

(Size 16 Pins Qty. 25)

(Terminal Tool Kit Qty. 1)

(1/2in to 12G Qty. Box)

(Size 16 Sockets Qty. 25) (Crimp Tool Qty. 1)

(3/8in to 12G Qty. Box) (#10 to 12G Qty. Box) (Slide to 16G Qty. Box)

(2/0 to 3/8 Qty. Box) (2/0 to 1/2 Qty. Box)





http://www.amazon.com/Lisle-57750-Wire-Terminal-Tool/dp/B007WQQHA2/ref=pd_sim_sbs_auto_3?ie=UTF8&refRID=022GVDG0RXPMR3QA7ZT3

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Primary-Wire-Heat-Shrink-Terminal-Solder-Seal-Ring-Terminal/_/R-NW_784415_0063685229



http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Primary-Wire-Heat-Shrink-Terminal-Crimp-Solder-Slide-Terminal/_/R-NW_785927_0063685229

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Battery-Starter-Cable-Lug-2-0-GROTE/_/R-GRO849435_0459879947

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Battery-Starter-Cable-Lug-2-0-GROTE/_/R-GRO849436_0459879948



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Wire:

Bosch Terminals and ECU Connector:

NOTE: Only Buy If Plan To Make Own Harness

(Yellow 16G Qty. Roll) (Green 16G Qty. Roll) (Orange 16G Qty. Roll) (Black 16G Qty. Roll)

(Red 16G Qty. Roll) (Red 10G Qty. Roll) (Black 10G Qty. Roll)

(Terminal, BMK 0.6 Qty. Any) (Terminal, BDK 2.8 Qty. Any) (Seal, BDK, White Qty. Any)

(Connector, 89-Way Qty. 1) (Cover, 89-Way Qty. 1)


http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Wire-Primary-Yellow/_/R-BEL785404_0452807332

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Wire-Primary-Green/_/R-BEL785405_0452808488

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Wire-Primary-Orange/_/R-BEL785403_0452798775

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Wire-Primary-Black/_/R-BEL785400_0452796935

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Wire-Primary-Red/_/R-BEL785402_0452795862

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Wire-Primary-Black/_/R-BEL785700_0452798756

http://www.napaonline.com/Catalog/CatalogItemDetail.aspx/Wire-Primary-Red/_/R-BEL785702_0452798755

http://store.chiefenterprises.com/s.nl/it.A/id.184/.f

http://store.chiefenterprises.com/Products/Bosch-Damping-Terminals-BDK/1928498055-BDK-Terminal-Gold-14-16-AWG

http://store.chiefenterprises.com/Products/Wire-Seals-Plugs/1928300600-Seal

http://store.chiefenterprises.com/Products/High-Pole-8-Poles/1928404195-Bosch-89-Way-Connector

http://store.chiefenterprises.com/Products/Connector-Accessories/1928404196-Bosch-Connector-Cover



P a g e

Project Summary:

This project has been a great learning experience for me. Went through the intake system, the

cooling system, the fuel system of the engine, and the electrical side of the engine to be a part of

this guide. This has be a successful project in first getting the engine to run, the second success

was when the InteliDrive Nano was successfully connected and had the ability to start, stop, and

change RPM. The next stage is for anyone who works on this engine next and wants to start

putting bugs into this and make it a great training aid. I would like to thank those again who have

help me successfully finish this project.




P a g e

Resource Websites:

Amazon. (2014, December 15). Retrieved from Amazon: http://www.amazon.com

Auto Zone. (2014, December 15). Retrieved from Auto Zone: http://www.autozone.com

Cables To Go. (2014, December 15). Retrieved from Cables To Go: http://www.cablestogo.com

Case IH. (2014, December 15). Retrieved from Case IH: http://beready.caseih.com/equipment-

technology/case-ih-and-fiat-powertrain-technologies-working-together-to-bring-you-the-

best-high-horsepower-engines/

Chief Enterprises. (2014, December 15). Retrieved from Chief Enterprises:

http://store.chiefenterprises.com/

ComAp InteliDrive Nano Downloads. (2014, December 15). Retrieved from ComAp InteliDrive

Nano Downloads: http://www.comap.cz/products/detail/intelidrive-nano/downloads

McMaster-Carr. (2014, December 15). Retrieved from McMaster-Carr:

http://www.mcmaster.com/

NAPA. (2014, December 15). Retrieved from http://www.napaonline.com

Newark. (2014, December 15). Retrieved from Newark: http://www.newark.com

Nexus Electronics. (2014, December 15). Retrieved from Nexus Electronics:

http://www.nexelec.com

O'reilly Auto. (2014, December 15). Retrieved from O'reilly Auto: http://www.oreillyauto.com

Pittsburg State University - Automotive Technology. (2014, December 15). Retrieved from

Pittsburg State University - Automotive Technology:


Server Parts Warehouse. (2014, December 15). Retrieved from Server Parts Warehouse:

http://www.serverpartswarehouse.com

Smart Draw Communicate Visually. (2014, December 15). Retrieved from Smart Draw

Communicate Visually: http://www.smartdraw.com/

SRC Power Systems Inc. (2014, December 15). Retrieved from SRC Power Systems Inc.:

http://srcpowersystems.com

Texas Industrial Electric. (2014, December 15). Retrieved from Texas Industrial Electric:

http://www.texasindustrialelectric.com




P a g e

Wire Care Cable Management Superstore. (2014, December 15). Retrieved from Wire Care

Cable Management Superstore: http://www.wirecare.com




P a g e

Appendix:

Activity Log:

TE 807 Problem Solving & Creative Thinking

Department of Technology and Workforce Learning

Pittsburg State University

DATE: Description of Activities: HOURS:

8/21/2014 Installed radiator hose from reservoir to engine.

Then checked and tighten radiator hose clamps.

Then started to mock up intake tube from after

cooler to engine intake. Made a parts list of parts

needed then sent parts list to Bob Schroer through

an email.

3

8/25/2014 Worked on engine fabricating intake tube from

after cooler to intake. Not fully done yet. Installed

some remaining hose clamps that needed to be put

on engine and then started to route coolant lines

from reservoir to bleed valves on top of engine

block of engine and to radiator top tube.

4

8/25/2014 Did some research on parts that are needed for

engine and also did some tool research to order

steel line tube benders. Went to NAPA to pick up

some fittings and ordered another intake boost

hose. Came back to lab and installed fittings into

engine for coolant lines then finished installing

coolant lines. Then plugged 2 ports on the turbo

outlet hose adapter.

4




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8/26/2014 Picked up the intake boost hose then took to shop

and did some research on the engine to see what

else we need to get this engine up and running

looked for some electrical information on the

engine ECM.

1

8/29/2014 Finished welding intake tube together and installed

fuel line on one of the fuel line ports by custom

bending and cut to length. Removed accessory

drive belt and belt tensioner. Torqued flywheel

bolts to initial torque and then give a 60* torque

turn.

4

8/29/2014 Started to go through schematics to map out

electrical system to see what wires we need to

connect to an InteliDrive Nano engine controller.

4

9/5/2014 Met with Bob Schroer to discuss what actions

needed to be taken next and what parts and tools

needed to be ordered. Bob Schroer also gave me

engine schematic files for the engine I am working

on. Took electrical harness and InteliDrive Nano

controller to my apartment.

4

9/15/2014 I further worked on gathering information on the

Controller by downloading information directly

from the manufactures website. Downloaded

programing Program and schematics for

InteliDrive Nano Controller. Started to go through

harness of controller to see what pins went where.

4




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9/24/214 Emailed Bob Jones of SRC POWER SYSTEMS

after speaking with him at the company day event

for about an hour who has experience with the

Nano controller. He sent me some stuff to guide me

on this build then I started to go through and read

what he gave me.

2

9/30/2014 Started to read more on InteliDrive Nano

Controller to better understand. What I need to do

to get this engine connected to this controller. I

went through the guide and updated the controller

software.

2

10/3/2014 Finished fabricating last fuel line and install on to

engine. Fitting had not crushed right and had to

take to machinist to get machined so that the fuel

line would go into fitting and crush sleeve would

crush around fuel line and seal to fitting. Sat down

with Mr. Schroer to go through wiring diagrams

and to better to understand the engine control

module. Found out that the engine harness does not

match the engine. We also looked at how to connect

the engine control harness to the control module.

6.5

10/7/2014 Painted all coolant lines and intake tubes.

Reinstalled all lines and intake tube. Installed

Coolant and engine oil into engine with proper

level. Found a leak in the coolant system and had to

drain coolant and fix where the leak was and fill

cooling system back up.

6




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10/28/2014 Started to work on fuel tank for fuel went and

picked up parts from the local napa dealer and

then started to drive holes out for a pipe fitting on

the tank welded fitting on for fuel return.

3

10/30/2014 Cut a hole out of the top of the tank then cut a piece

of round pipe then welded the round pipe to the

tank. Then had machinist machine out suction side

fitting to make fuel line tube fit it the fitting. Then I

welded this tube onto the fitting and pressure tested

the fittings weld to see if any air bubbles would

come out once I had water on the fitting.

6

10/31/2014 Cut some angle iron to mount the tank to. Then I

notched out the angle iron so the round part of the

tank could fit on the angle iron.

4

11/4/2014 Welded the tank to the angle iron to the fuel tank.

Got with Bob Schroer to order electrical

connectors. Also ordered fuel line hose.

4




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11/7/2014 Welded the tank on to the engine frame and then

painted the tank. Then cute the lengths for each

side of the fuel system of the fuel line hose and

installed fittings on to the hoses. Then cleaned the

hoses out with brake clean and shop air. Then

installed them on to the engine and tank. Then

filled tank with fuel.

4

11/11/201 Started to go through schematics to map out

electrical system to see what wires we need to

connect to an InteliDrive Nano engine controller.

Also researched and ordered pins and connectors.

4

11/25/2014 Started to finish mapping out and testing

continuity for each wire that is needed coming from

the engine harness from the ECU to the ComAp

controller. Labeled each wire to the correct

function of the wire. Ran into a problem found out

that the engine ECU and Alternator are both 12

volt system but the starter itself was 24 volts.

Worked with Mr. Schroer to fix this problem we

started to research for engine starters relay that

can switch between 12 and 24 volt system. Once we

found this item we had one ordered.

6

12/2/2014 Installed the 12/24 volt solenoid onto the engine

frame then removed the large relay that was

supplied with the engine then removed a second

one from another engine of the same. Installed both

onto the engine controller support. Once this was

done I mapped out both relays and 12/24 volt

solenoid wire connections. Then ordered black and

red 10 gauge wire from napa along with 3/8in to 10

gauge ring terminals, #10 to 10 gauge terminals,

and 2-0 to 3/8in battery cable terminals.

4




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12/3/2014 Started to wire the engine relays and 12/24 volt

solenoid cutting the wires to desired length. Then I

moved to work on the battery cables to desired

length and routed them. Crimped terminals to each

battery cable and relay solenoid wires. Placed heat

shrink on each wire and battery cables to prevent

any exposed wires to come in contact. Wired up the

alternator to the batteries.

6

12/4/2014 Rechecked all my wires. Then tested the main

control relays and 12/24 volt solenoid starter relay.

All worked then connect the starter up the 12/24

volt solenoid starter relay. Went and got Mr.

Schroer had cameras read and got ready to start

the engine. Started the engine after checking all the

engine fluid and filled the fuel tank with diesel.

Started the engine started out at low engine idle

then ramped up to 1500 RPM automatically.

4

12/8/2014 Connect engine controller to engine harness and

then started to zip-tie and wrap all the wires and

routed to look neat. Once everything was done we

were able to start the engine and control the engine

RPM with the ComAp Engine Controller.

6

Total

Hours

95.5


john s.c. thorpe - iveco engine training aid manual

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