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
FOREDUCATIONAL
PURPOSESONLY

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:
j.s.c.thorpe@gmail.com

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 2015©John S.C. Thorpe

John S.C. Thorpe FOR EDUCATIONAL PURPOSES ONLY 10 |
P a g e
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
2015©John S.C. Thorpe
2015©John S.C. Thorpe 2015©John S.C. Thorpe 2015©John S.C. Thorpe

P a g e
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

P a g e
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

P a g e
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
adapters2015©John S.C. Thorpe 2015©John S.C. Thorpe

P a g e
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

P a g e
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

P a g e
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. Thorpe2015©John S.C. Thorpe

P a g e
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
2015©John S.C. Thorpe2015©John S.C. Thorpe

P a g e
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

P a g e
Schematics:
NOTE: Click on schematics to download larger versions.
ComAp Schematic:
Engine Harness Schematic:

P a g e
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.

P a g e
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

P a g e
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

P a g e
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)

P a g e
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)

P a g e
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)

P a g e
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)

P a g e
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)

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

P a g e
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

P a g e
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

P a g e
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

P a g e
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

P a g e
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

Recommended

Recommended

More Related Content

Viewers also liked

Viewers also liked (12)

Similar to John S.C. Thorpe - Iveco Engine Training Aid Manual

Similar to John S.C. Thorpe - Iveco Engine Training Aid Manual (20)

John S.C. Thorpe - Iveco Engine Training Aid Manual