6 - Nef Engine Tier 3

LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine

Chapter 3 NEF ENGINE TIER 3

Monthyon, november 2007

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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine 9 1 – Engine controller; 2 – Crankshaft sensor; 5

3 – High pressure pump 7

;4 – Fuel filter; 5 – Injection pressure sensor; 6 – PTO; 7 – Preheating grid; 8 – Water pump; 6

9 – Turbocharged;

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LOADER-BACKHOE CASE “580-590-695 SR2 Series”

3.1. Identification plate TIER 3 NEF Engine

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1: Engine code F4 = Engine familiy (NEF) H = Non structural engine block - 4 valves on each cylinder E = Engine 0 = Engine configuration (4 strokes, vertical) 4 = Number of cylinders 8 = Injection and intake (Turbocharged, Diesel, ID, Intercooler) 4 = Application (Tractors and construction machinery) E = Homologation power J = Emission level (Tier 3) 2: Date of manufacturing (month - year) 3: Gross power given in in Hp 4: Displacement given in cubic inches: 272 cu. in. = 4490 cc. 5: Max fuel quantity delivered by each pump piston in one cycle, given in mg/stroke 6: Engine minimum idle speed 7: Injection advanced mode data (not used) 8: Intake valve backlash (inches) 9: Exhaust valve backlash (inches)


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Engine

Maker - Model …………………………………………..

NEF - FHHE9484 C J 101 XXXX (Tier 3)

Bore x stroke ……………………………………………... 104mm x 132mm Displacemen…………………………………………………4.5 Litres Rated speed ………………………………………………. 2200 rpm Gross power per SAE J1995 @ 2000 RPM …… 82 Kw @ 2000 rpm Firing order ………………………………………………...1 – 3 – 4 – 2 Intake ………………………………………………….…….Turbo aftercooler Maximum operating slope)……………………..……..35%


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Nomenclature of engine - Turbo side 5 4 COMPONENTS 1. High pressure pump; 6

2. Fuel filter; 3. Engine controller; 4. Common Rail with high pressure relief valve 5. Intake air (from aftercooler) 6. Engine oil filling

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7. Low pressure pump 1 2

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Nomenclature of engine - Turbo side 3

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COMPONENTS 1. Turbocharged with wastegate 2. Engine oil filter

4 CONNECTIONS 3. To muffler 4. Air intake to aftercooler 5. Air intake (from filter) 2


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Nomenclature of engine - Front COMPONENTS

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1. Engine controller 2. Common rail

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3. Turbocharged 4. Water pump

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Nomenclature of engine - Actuators and sensors

COMPONENTS

1. Common rail relief valve 2. Engine air pressure-temperature

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combined sensor ( turbocharging)

3. Fuel discharge from electric-

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injector

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3 4. Fuel discharge from common rail

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1 – Common Rail; 2 – Injection pressure sensor; Monthyon, november 2007

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E.G.R. – Exaust Gas Recirculation In general on tier 3 engines has been developped a new system called E.G.R in order to reduce the pollution. EGR stand for Exaust Gas Recirculation. Practically part of exhaust gas is introduced in the cylinders in order to reduce the combustion temperature. In fact, the exhaust gas doesn’t contain oxygen, practically are neutral and are as obstacle to heat propagation. Since the production of oxide of nitrogen (pollution) is directly proportional to combustion temperature, it means that if we reduce the combustion temperature, we reduce pollution. IVECO NEF got the EGR just mdifying the cams shaft. So when the gas is going outside of cylinder, part re-enter in the same cylinders. Note: in the picture there is a solution adopted by isuzu.


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E.G.R. – Exaust Gas Recirculation

On NEF engines an extra lobe on the cam shaft let to get the exhaust gas recirculation during the intake cycle by keeping the exhaust valve open for a short time.

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E.G.R. – Exaust Gas Recirculation


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COMPONENTS 3

1. Proportional valve 2. Low pressure pump 3 - High pressure pump 4. Fuel filter; 5. Fuel temperature sensor;

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Nomenclature of engine - Actuators and sensors 2 COMPONENTS 1. Engine oil filter;

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2. Engine oil pressure temperature sensore; 3. Coolant temperature sensor; 3


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Nomenclature of engine - Actuators and sensors 1 COMPONENTS 1. Timing gear sensor (camshaft); 2. Cranshaft sensor;

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COMPONENTS

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1 – Fuel pre-filter; 2

2 – Breather screw; 3 – Fuel lifting pump; 4 – Water in fuel sensor;

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4


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1. Fuel filter 2. To high pressure pump To fuel tank Monthyon, november 2007

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Injection pump

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1 – From engine controller 2 – To fuel filter 3 – From fuel filter to high pressure pump 4 – Return fuel to filter 5 – To Common Rail


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“Common rail” injection system

High pressure pump

Fuel filter Fuel prefilter Fuel radiator

Low pressure pump


Fuel tank

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3.7. “Common Rail” injection system

A. Fuel return port - B. Fuel inlet port from EDC heat exchanger - C. Fuel inlet port from fuel filter - D. Fuel outlet port from low pressure pump to fuel filter - E. Fuel outlet port from high pressure pump to the rail. 1. High pressure pump - 2. Fuel supply pump -3. Fuel pressure regulator (N.O. proportional solenoid valve controlled by PWM signal from EDC7 electronic control unit).


High pressure pump

1. Cylinder - 2. Three lobes cam - 3. Suction valve - 4. Delivery valve - 5. Piston - 6. Pump shaft - 7. Low pressure fuel inlet - 8. Piston fuel supply channels.

Pump with three radial piston driven by the timing gear. No timing adjustment is required. With fuel supply gear pump installed on the back of the high pressure pump. 20


3.7. “Common Rail” injection system

Electric injector - rest condition


1.

Pressure rod

2.

Needle

3.

Nozzle

4.

Coil

5.

Pilot valve

6.

Ball shutter

7.

Control area

8.

Pressure chamber

9.

Control volume

10.

Supply-contro line

11.

Control fuel outlet

12.

Electrical connector

13.

Spring.

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3.7. “Common Rail” injection system Injection starting When the coil (4) is energized, the ball shutter (6)is moved upward. The fuel in the control chamber (9) flows out through the return line (11) causing a pressure drop in the control chamber (9). From Rail

At the same time, the fuel pressure in the pressure chamber (8) pushes the needle (2)upward, allowing the fuel spraying into the cylinder combustion chamber. To reservoir

Injection end When the coil (4) is de-energized, the ball shutter (6) takes back its closed position, in order to restore a force balance suitable to keep closed the injector needle (2) and shut off the fuel injection.


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“Common Rail” injection system Engine controller input /output signals Coolant temperature sensor

Intake manifold combined pressure/temp. sensor

Engine oil combined pressure/temp sensor

Timing gear sensor

Fuel temperature sensor

Crankshaft speed sensor

Ambient pressure sensor

Throttle potentiommeter signal

Common rail fuel pressure sensor

Proportional solenoid valve installed on high pressure pump

Diagnostic connector

Injector solenoids


Preheating grid relay

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TECHNICAL TECHNICALDATAS DATAS STALLS STALLS


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In case of Cluster replacement


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View information or download


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After cluster replacement is necessary to enter in this screen and set properly the following parameters : Air conditioning; Preheating grid; Pilot control, than send the values to the controler

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Select Language


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INJECTORS CUT OFF


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LOADER-BACKHOE CASE “580-590-695 SR2 Series” PRESENTATION


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Programming

This ECU software download procedure is required if any one of the following conditions exist: • Blank ECU from Service Parts - Programming an engine controller from

service parts that has no software pre-loaded (normal service part). • Black ECU from an interrupted Download - Programming an engine controller that has lost its information due to an interrupted download process for a normal update. •Wrong ECU - Programming an engine controller from service parts or from a different machine that is loaded with inappropriate software for the selected machine. Monthyon, november 2007

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Blank Controller Download Downloading to a blank controller requires a two part download process: • One process to initialize the controller. • A second process to download the software file to the ECU. The progress bar will be displayed two times. The time required for this type of download will be about 60% longer than for the Normal Machine Update download.


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Chose here the right program

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** ********** *** *


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FAULT CODE LIST


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How to record engine parameter with the E.S.T


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6 - Nef Engine Tier 3

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