Case New Holland Kobelco Iveco Komatsu F4CE F4DE F4GE F4HE Service Repair Manual For Engine Overhaul ( Mechanical Injection and Electronic Common Rail ).pdf

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ENGINES CNH NEF

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Repair Manual

4 Cylinders, Mechanical and Electronic Drive Common Rail

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Tier III

F4CE - F4DE - F4GE - F4HE

Print No. 87659057A English

ENGINES CNH NEF F4CE - F4DE - F4GE - F4HE 4 Cylinders, Mechanical and Electronic Drive Common Rail

Repair Manual Tier III

REPAIR INSTRUCTION MANUAL CNH ENGINES

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ENGINES FAMILY: F4CE9484 -- F4DE9484 -- F4GE9484 -- F4HE9484

All the information, illustrations and data provided by this manual are based upon the most recent information available at the time of its publication. CNH ITALIA S.p.A. reserves the right to implement modifications, at any time, without communications.

CNH ITALIA S.p.A. STAMPATO N. 87659057A Edizione -- May 2007

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ENGINE

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TROUBLESHOOTING

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IN--1

FOREWORD

TO THE READER - For any question or comment, or in case any error regarding the content of this manual is found, you are asked to please contact:

- This Manual is written for an expert technician to provide the technical information required to perform repair operations on this machine. - Please read carefully this manual for the correct information regarding the repair procedures.

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CNH ITALIA S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PARTS & SERVICE Fax ++39 011 0077357

SYMBOLS This manual includes safety warning symbols and indications to recall the attention on possible personal injuries or damages to the machine.

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This symbol recalls the attention to points relative to safety. When you see this symbol, it is necessary to proceed with attention since there is the possibility of personal injuries. Comply scrupulously with the precautions identified by this symbol. The safety warning symbol is also used to attract attention to the weight of a component or a part. To prevent personal injuries or damages, make sure that the appropriate lifting equipment and techniques are implemented when handling heavy loads.

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FOREWORD

UNITS OF MEASURE In this manual, the units of measure of the IS (International System) are used. The units of measure of the MKSA system are listed in parenthesis after the units of the International system. Example: 24.5 Mpa (250 kgf/cm2). Here below, a conversion table of the units of the IS and some units of measure of other systems is listed. as a reference.

Torque

Pressure Power Temperature Velocity Flow

into (Others)

Multiply by

kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

10.197 145.0 1.360

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0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 0.10197 0.7375

To convert from (SI) MPa MPa kW kW °C km/h min --1 L/min mL/rev

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Force

in ft US gal US qt yd3 lb kgf lbf kgf.m lbf.ft

Quantity

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Mass

Multiply by

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Volume

into (Others)

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Length

To convert from (SI) mm mm L L m3 kg N N N.m N.m

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Quantity

°C x 1.8 + 32 0.6214 1.0 0.2642 1.0

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NEF ENGINES Section Introduction

1

Fuel

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Duty - Industrial application

3

Overhaul and technical specifications

4

Tools

5

Engine technical cards

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General specifications

Safety prescriptions

Appendix

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SPECIAL REMARKS Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures.

Example ∅1

Ø 1 = housing for connecting rod small end bush α

Tighten to torque Tighten to torque + angular value

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∅ 2 Ø 2 = housing for connecting rod bearings

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SYMBOLS - ASSISTANCE OPERATIONS Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly Tighten to torque

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Angle Angular value

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Regulation Adjustment Visual inspection Fitting position check

Preload

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Interference Strained assembly

Lubrication Damp Grease Sealant Adhesive Air bleeding CNH

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Surface for machining Machine finish

Replacement Original spare parts

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Equipment

Thickness Clearance

Number of revolutions

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Measurement Value to find Check

PARTS

Compression ratio

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α

ρ

Temperature

bar

Pressure Oversized Higher than…. Maximum, peak Undersized Less than…. Minimum Selection Classes Oversizing Temperature < 0 °C Cold Winter Temperature > 0 °C Hot Summer

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UPDATING Page

Date of revision

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Description

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Section

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INTRODUCTION

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Introduction Page 3

SYMBOLS

...............................

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- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

- Service operations . . . . . . . . . . . . . . . . . . . . . .

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GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . .

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GENERAL WARNINGS ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . . .

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- Bonding and screening . . . . . . . . . . . . . . . . . . .

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OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS . . . . . . . . . . . . . . . . . .

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CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PREFACE TO USER’S GUIDELINE MANUAL . . . .

INTRODUCTION

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INTRODUCTION

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PREFACE TO USER’S GUIDELINE MANUAL

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Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules. The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the control units peculiar to the electric system. Section 1 describes the engines illustrating its features and working in general. Section 2 describes the type of fuel feed. Section 3 relates to the specific duty and is divided in four separate parts: 1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating specific duty. 2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating specific duty. 3. Maintenance planning and specific overhaul. 4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct instructions to identify the cause of the major inconveniences. Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such operations. The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order to prevent serious accidents taking place. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.

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SYMBOLS - Warnings

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Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

General danger It includes the dangers of above described signals.

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Danger of serious damage for the assembly Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may sometimes cause the warranty to become null and void.

Environment protection Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect the environment as much as possible. NOTE

It indicates an additional explanation for a piece of information.

Service operations Example ∅1

Ø 1 = housing for connecting rod small end bush α

∅ 2 Ø 2 = housing for connecting rod bearings

Tighten to torque Tighten to torque + angular value

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INTRODUCTION

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Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly Tighten to torque

Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation Angle Angular value

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Regulation Adjustment Warning Note

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Measurement Value to find Check

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Equipment Surface for machining Machine finish

Preload

Number of revolutions

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Visual inspection Fitting position check

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Compression ratio

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α

ρ

Temperature

bar

Pressure Oversized Higher than…. Maximum, peak

Interference Strained assembly

Undersized Less than…. Minimum

Thickness Clearance

Selection Classes Oversizing

Lubrication Damp Grease

Temperature < 0 °C Cold Winter

Sealant Adhesive

Temperature > 0 °C Hot Summer

Air bleeding

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INTRODUCTION

5

GENERAL WARNINGS Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check. The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path. Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it. In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel. Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position. Keep personnel not authorised to operations clear of working area.

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You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly follow all the safety indications found on the assembly. Do not leave the running assembly unattended when making repairs.

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When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist.

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When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document, as well as all the specific safety standards provided for.

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Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out.

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Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers. Worn out, damaged or consumable parts must be replaced by original spares.

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During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

INTRODUCTION

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Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside. Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present. Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers. Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking nuts with an insert made of nylon must always be replaced.

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Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances. Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

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Tightening screws and nuts must always be according to prescriptions; CNH commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document. Before welding:

- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding) and detach connectors.

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- Await about 15 minutes before welding.

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- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.

- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding.

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Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central units.

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The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

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INTRODUCTION

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GENERAL WARNINGS ON THE ELECTRIC SYSTEM

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If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated. Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals. Do not cause sparks to be generated in checking if the circuit is energised. Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses. Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with CNH system and are carefully recovered after repair or maintenance interventions.

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Measurements in drive electronic central units, plugged connections and electric connections to components can only be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers, clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which would later cause contact problems.

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To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special truck.

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A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries) can cause them to be destroyed.

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Disconnect the batteries from the system during their recharging with an external apparatus. On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque. Before disconnecting the junction connector from an electronic central unit, isolate the system.

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Do not directly supply electronic central units servo components at nominal vehicle voltage.

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Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure. Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according to original arrangement.

NOTE

Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable side.

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INTRODUCTION

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Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: Electronic central units must be connected to system bonding when they are provided with a metallic shell.

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Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.

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Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation. Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

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Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).

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If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).

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Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.

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Figure 1

NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

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SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE ! 0

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INTRODUCTION

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OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling directives issued. It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel.

It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular, the data interconnection line between central units (CAN line) is to be considered inviolable.

Torque 1 Nm 1 kgm

= =

0.1019 kgm 9.81 Nm

= = =

1.02 kg/cm2 0.981 bar 105 Pa

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Pressure 1 bar 1 kg/cm2 1 bar

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Revolutions per time unit 1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602

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1.36 metric HP 1.34 HP 0.736 kW 0.986 HP 0.746 kW 1.014 metric HP

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= = = = = =

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Power 1 kW 1 kW 1 metric HP 1 metric HP 1 HP 1 HP

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CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Where accuracy is not particularly needed: - Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1 1 kgm

=

10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1 1 kg/cm2

=

1 bar.

Temperature 0° C = 32° F 1° C = (1 x 1.8 + 32) ° F

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SECTION 1 - GENERAL SPECIFICATIONS

1

SECTION 1 General Specifications

Page 3

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

OIL VAPOUR RECIRCULATING SYSTEM . . . . . . .

7

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

7

AIR INDUCTION BOOST DIAGRAM . . . . . . . . . .

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- Boosting version engines . . . . . . . . . . . . . . . . .

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- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

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- Inter-cooled engine version . . . . . . . . . . . . . . .

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NOMENCLATURE (Coding of the engines of origin)

- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .

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EXHAUST GAS RE-CIRCULATION SYSTEM (EGR)

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NOMENCLATURE (Coding of the engines of origin)

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4

B

E

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4

8

4

E

*

J

+

Emission level Power homologated Use Inlet / injection J = TIER 3

Configuration of cylinders

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Engines family

4 = 4- cylinders

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Type of cylinder block: C = structural 2-valves D = structural 4-valves G = non structural 2-valves H = non structural 4-valves

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Engine

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No. of cylinders

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8 = Diesel turbocharged Direct Injection with Intercooler 5 = Diesel turbocharged Direct Injection

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4 = Earth Moving Machines and Tractors

X

Y

Y

X = 6 Rotary injection pump 2-valves 1 Common rail 4-valves 2 Common rail 2-valves 5 Rotary injection pump 4-valves Y = Engine variant

Y

Y

Y

Y

Production progressive number

Y

Y

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LUBRICATION Lubrication by forced circulation is achieved through oil rotary expansion pump, placed in the front part of the basement, driven by the straight-tooth gear splined to the shaft’s bar hold. From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.

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All these components may often vary according to the specific duty.

NOTE

Lubrication involves the heat exchanger (2,3), the turboblower for turbocompressed versions, and for any compressed air system.

Some groups can be located on the engine in different positions due to requirements dictated by the application, and have variable shapes and dimensions depending upon the use and the versions of the engine itself.

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Figure 3

Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil

116396

LUBRICATION SYSTEM LAYOUT 1. Heat exchanger body - 2. Lubrication oil pipe to supercharger - 3. Oil filter - 4. Heat exchanger 5. Oil rotary expansion pump.


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Lines of oil under pressure Return lines of oil by gravity Oil filler

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Figure 4

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112885

LUBRICATION DIAGARAM (Other application)

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OIL VAPOUR RECIRCULATING SYSTEM Figure 5

1

2

3240t

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1. Valve - 2. Breather pipe - 3. Tappet Cap

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On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity, to the Tappet cap underneath. The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example (connection towards these vapours shall be designed by the Engineer).

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COOLING SYSTEM The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment. - Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.

- Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment. - Centrifugal water pump, placed in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.

- Visc pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development. Figure 6

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TO RADIATOR

FROM RADIATOR

Water coming out from thermostat Water recirculating in engine Water coming into pump

COOLING SYSTEM LAYOUT

03241t

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AIR INDUCTION BOOST DIAGRAM Boosting version engines Figure 7

TURBOCHARGER

AIR FILTER

88208

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EXHAUST

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4 cylinders version

Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation. The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter. The air coming out of the compressor is sent via the intake manifold directly to the pistons.

The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s duty is to choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

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Inter-cooled engine version Figure 8

AIR FILTER

TURBOCHARGER

74195

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RADIATOR

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EXHAUST

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4 cylinders version

Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation. The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter. The above mentioned air is then cooled by the radiator and flown through the piston induction collector.

The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s duty is to choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

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EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) In the TIER 3 version, the profile of the exhaust cam has been modified in order to allow the partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders. The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitric acid (NOx). The exhaust gas re-circulation system (EGR), reducing the combustion temperature by means of the diminishing of the concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission of NOx .

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The internal EGR system is not equipped with any electronically controlled elements: the system is always active. Its configuration does not need additional elements i.e.checking valves, piping or heat exchangers. The exhaust cam (B) has another lobe apart from the major lobe (see Section. A-A fig.) with respects to the configuration without EGR. The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the aspiration phase inside the cylinder.

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Figure 9

NOTE

For the dimension of the camshaft, please refer to Section 6 ”General Mechanical Overhaul” A. Aspiration valve control - B. Exhaust valve control.

114789


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SECTION 2 - FUEL

1

SECTION 2 Fuel Page

3

- General information . . . . . . . . . . . . . . . . . . . . .

3

- Description of working principles . . . . . . . . . . .

4

FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

- Example of identification . . . . . . . . . . . . . . . . .

5

CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . .

6

- High pressure pump-inside structure . . . . . . . .

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4-CYLINDER ENGINES WITH BOSCH ROTARY MECHANICAL PUMP . . . . . . . . . . . . . . . . . .

8

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . .

11

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

HIGH PRESSURE ELECTRONIC INJECTION SYSTEM (COMMON RAIL) . . . . . . . . . . . . . . . . . . . . .

14

EDC 7 OPERATION . . . . . . . . . . . . . . . . . . . . . .

15

WORKING PROCESS . . . . . . . . . . . . . . . . . . . .

16

FUEL SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . .

17

N

O T

FO

R

PR

- Working principle . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 - FUEL

O T

FO

R

PR

IN T

NEF ENGINES

N

2

NEF ENGINES

3

SECTION 2 - FUEL

4-CYLINDER ENGINES WITH BOSCH ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) - Priming pump, assembled to the engine and driven by the camshaft - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed rotary pump - Injector feed pipeline (from fuel feed pump to injectors) - Injectors

IN T

Figure 1

2 4

N

7

O T

FO

R

PR

1

5 3 6

74168

1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.

4

SECTION 2 - FUEL

NEF ENGINES

116385

R

PR

IN T

Figure 2

O T

Description of working principles

FO

1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.

N

Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft. Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For applications to be equipped in cold climate areas, the fuel filter is provided with heater). Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.

The fuel arrives therefore to the valve gauging the pressure inside feed pump. The distribution plunger further increases this pressure and delivers fuel throughout the delivery pipe fitting to the injectors. The fuel drawing from the injectors is recovered and delivered to the tank again.

NOTE

Some groups can be located on the engine in different positions due to requirements dictated by the application, and have variable shapes and dimensions depending upon the use and the versions of the engine itself.

NEF ENGINES

5

SECTION 2 - FUEL

FEED PUMP The rotary type pump is driven by a gear mating the camshaft’s one.

Example of identification V

=

Distribution rotary plunger

E

=

Pump dimensions

4

=

4 cylinders engine

12 =

Distribution plunger in mm.

1150

=

LV =

Left direction of rotation

N°. of pump revolutions per minute

IN T

Figure 3

1

PR

2

FO

4

12

N

6

13

O T

5

14

R

3

15

7 8

9 11 10 30454

Injection pump longitudinal section 1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk 9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate 14. Gauge pin - 15. Counteracting spring.

6

SECTION 2 - FUEL

NEF ENGINES

CP3 HIGH PRESSURE PUMP Pump provided with 3 radial pumping elements driven by the timing system gear, no need of timing. The mechanical feeding pump driven by the high pressure pump’s shaft is assembled to the rear side of the high pressure pump.

NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither the fixing screws must be tampered. The only allowed interventions concern control gear and pressure regulator replacement.

N

O T

FO

R

PR

IN T

Figure 4

72595

1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear 5. Connector to fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry flowing from engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter 9. Mechanical feeding pump.

NEF ENGINES

SECTION 2 - FUEL

7

High pressure pump-inside structure Figure 5

IN T

Sec. B-B

N

O T

FO

R

PR

Sec. C-C

70498

1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — 7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.

Every pumping unit is composed of: - a piston (5) actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), being floating on a misaligned part of the shaft (6), when the shaft rotates, does not rotate therewith but is only translated in a circular movement along a wider radius, with the resulting alternate actuation of the three pumping elements;

- cap intake valve (3); - ball delivery valve (4).

8

SECTION 2 - FUEL

NEF ENGINES

Working principle

IN T

Figure 6

N

O T

FO

R

PR

Sec. B-B

Sec. D-D

72597

1. Fuel outlet joint to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element inlet duct - 6. Pressure regulator inlet duct - 7. Pressure regulator.

The pumping element (3) is orientated towards the pump’s camshaft (4). During the intake phase, the pumping element is fed through the feeding line (5). The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge (7). The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element.

During compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to common rail (2), feeding it through the exhaust unit (I).

NEF ENGINES

9

SECTION 2 - FUEL

Figure 8

1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel exhaust flowing from pump with connector to high pressure pipe for common rail.

FO

R

1. Inlet to pumping element - 2. Pump lubrication ducts 3. Inlet to pumping element - 4. Pumping element feeding main duct - 5. Pressure regulator - 6. Pumping element inlet - 7. Regulator discharge duct - 8. Pressure relief valve 5 bar - 9. Fuel discharge from regulator inlet.

72601

Sec. A - A

PR

72598

Sec. C - C

IN T

Figure 7

O T

Figure 7 shows the fuel runs at low pressure inside the pump; the following elements are clearly visible: the main feeding line to the pumping elements (4); the feeding lines to the pumping elements (1-3-6), the duct lines run for the pump lubrication (2), the pressure gauge (5), the flow limiting valve to 5 bar (8) and the fuel exhaust flue (7).

N

The pump shaft is lubricated by the fuel through the feeding and recovery lines. The pressure gauge (5) determines the quantity of fuel to feed the pumping elements: the fuel in excess flows through the exhaust gallery (9). The limiting valve to 5 bar, in addition to recovering fuel exhaust as a collector has also function to keep the pressure constant to 5 bar limit at gauge entry.

Figure 8 shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.

10

SECTION 2 - FUEL

NEF ENGINES

Operation

RAIL

The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements (about 2 bars).

Figure 9

The amount of fuel supplying the high-pressure pump is metered by the pressure regulator, placed on the low-pressure system; the pressure regulator is controlled by the EDC7 control unit through a PWM signal. When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, not being able to come out, is compressed above the supply pressure value existing in the rail.

The pumping element piston goes back towards the bottom dead center and the remaining fuel is decompressed. When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated. The delivery valves must always be free in their movements, free from impurities and oxidation.

O T

The radialjet pump disconnection — reconnection time on the engine is highly reduced in comparison with traditional injection pumps, because it does not require setting.

If the pipe between fuel filter and high-pressure pump is to be removed-refitted, be sure that hands and components are absolutely clean.

N

A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.

FO

The pump is lubricated and cooled by the fuel.

It anyway has enough volume as to minimise system spikes and the use of plenum chambers caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.

R

The rail delivery pressure is modulated between 250 and 1600 bars by the electronic control unit, through the pressure regulator solenoid valve.

The rail volume is comparatively small to allow a quick pressurisation at startup, at idle and in case of high flow-rates.

IN T

The pumping element compresses the fuel till the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed.

1. Rail — 2. Fuel inlet from high-pressure pump — 3. Overpressure valve - 4. Pressure sensor.

PR

The thereby-generated pressure makes the exhaust valve open and the compressed fuel reaches the high-pressure circuit.

108609

RELIEF VALVE Mounted on the end of the rail, it has the function of protecting the system’s components in case the failure of the rail pressure sensor or the pressure regulator of pump CP3 causes an excessive pressure increase in the high-pressure plant. When the rail pressure reaches 1800 bars, the valve initially intervenes in order to allow the fuel to flow and subsequently to reduce the pressure within safety limits and then it mechanically regulates the rail pressure to approx. 800 bars. This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of the fuel preserving the return pipes to the tank.

NEF ENGINES

SECTION 2 - FUEL

11

PRIMING PUMP This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to the engine basement and driven by the camshaft.

FO

R

PR

IN T

Figure 10

N

O T

1. Priming pump - 2. Drive lever - 3. Camshaft.

88209

12

SECTION 2 - FUEL

NEF ENGINES

FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperature sensor. On some versions, a water presence sensor is present at filtering cartridge base.

O T

FO

R

PR

IN T

Figure 11

N

1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.

88210

NEF ENGINES

SECTION 2 - FUEL

13

Figure 12

1 5 1

2

4

FO

R

3

PR

IN T

4

3243t

N

O T

1. Fuel filter bearing- 2. Heater - 3. Water dump screw- 4. Filter cartridge 5. Temperature sensor.

3

3244t

14

SECTION 2 - FUEL

NEF ENGINES

HIGH PRESSURE ELECTRONIC INJECTION SYSTEM (COMMON RAIL) Introduction Extremely high injection pressures are necessary in order to reduce PARTICULATE emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar, while the injection precision obtained by electronic control of the system serves to optimise operation of the engine while limiting emissions and fuel consumption.

For engines more powerful than 152 kW, the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar, whilst for engines less powerful than 152 kW, DSLA nozzles are fitted which work a pressures up to 1450 bar. Description of system The injection system is composed of an electrical part and a hydraulic part. Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.

N

O T

FO

R

PR

IN T

Figure 1

107851

1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engine’s cooling liquid - 3. Fuel pressure sensor cable - 4. Sensor of engine’s oil temperature and pressure 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and air pressure sensor 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor 10. Pressure gauge cabling - 11. EDC 7 gearbox.

NEF ENGINES

SECTION 2 - FUEL

Engine preheating element control Pre-post heating is activated when even just one of the water, air or fuel temperature sensors detects a temperature ≤ 5 °C. Phase recognition By means of signals transmitted by the camshaft and crankshaft sensors, the cylinder into which fuel must be injected is determined at the time of starting. Injection control On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds. Injection pressure closed loop control On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control unit administrates the regulator to maintain injection pressure at constantly optimal values. Pilot and main injection advance control On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on the basis of internal mapping.

After Run After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, including the faults log so that they will be available the next time the engine is started. Control of working speed in normal operating conditions Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions. If the load causes a reduction in power, the control unit increases torque i.e. it increases the amount of fuel injected in order to restore the engine to maximum power. Recovery strategies Recovery strategies are characterized by certain differences as application varies, i.e. - Control of fuel leaks In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained with a low number of revs and high torque values in order to inject the maximum quantity of fuel.

FO

R

PR

Idle speed control The control unit processes signals transmitted by the various sensors and adjusts the quantity of fuel injected. It also controls the pressure regulator and modulates injection duration of the electro-injectors. Within specific limits, the control unit also monitors battery voltage.

Smoke control under acceleration With intense load demands, in accordance with signals received from the air inlet meter and the engine speed sensor, the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent the emission of smoke from the exhaust.

IN T

EDC 7 OPERATION

15

O T

Overheating protection If the water temperature reaches 110 °C, the control unit reduces engine performance. When the temperature returns below 100 °C, the engine resumes normal operation, (in some applications, the over boosting temperature is the reference temperature).

N

Maximum engine speed limiting Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine speed surpasses these limits the control unit activates power reduction strategies by controlling energization time of the electro-injectors. In some applications the maximum limiting response consists in stopping the engine. Cut Off Fuel cut-off in release phases is managed by the control unit with the following logical interventions: - disactivation of the electro-injectors; - reactivation of electro-injectors immediately prior to arrival at idle speed; - control of fuel pressure regulator.

- Control of pressure in the rail When the pressure in the rail exceeds safety values, the engine reduces power. - Synchronism problems In the case of synchronism problems, faulty rev sensors, the system controls the engine by increasing the number of revs in order to improve interpretation of the signals. - Power restrictions as operating temperature increases When the temperature of the supercharging air rises above 88 °C, power reduction is started; when a temperature of 120 °C is reached, performance is further reduced and is comparable to that of the same engine if it were aspirated. - Reduction of power as reference temperature varies In normal operating conditions, the system knows the supercharging air, oil and water temperatures. If the temperature of the engine water is not available, the system takes the temperature of the oil as reference and when this reaches the threshold of 103 °C, it starts to reduce the power available. On reaching 113 °C, power is reduced to 50%.

16

SECTION 2 - FUEL

NEF ENGINES

WORKING PROCESS

PR

IN T

Figure 2

R

High Pressure

FO

Low Pressure Fuel outlet

108607

O T

1. Electro-injector - 2. Common Rail - 3. Pressure limiting device for fuel return 4. Common rail pressure relief valve - 5. Pre-filter mounted on the frame - 6. High-pressure pump 7. Mechanical vane pump - 8. Fuel filter.

N

The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors. Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet. When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place in the related cylinder. The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit. The high-pressure circuit is composed of the following pipings: - piping connecting high-pressure pump outlet to rail; - pipings supplying injectors from rail. The low-pressure circuit is composed of the following pipings: - fuel suction piping from tank to prefilter; - pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter; - pipings supplying the high-pressure pump through the fuel filter. The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

NEF ENGINES

SECTION 2 - FUEL

FUEL SYSTEM LAYOUT This fuel system is a Common Rail injection with CP3 high pressure pump and this layout is for 4 cylinder version. (The 6 cylinder version is similar design as the 4 cylinder engine). The pressure regulator, placed upstream of the high-pressure pump, adjusts the fuel flow that is necessary on the low-pressure system. Afterwards, the high-pressure pump takes care of supplying the rail properly. This arrangement, by pressurising the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system. Function of the pressure relief valve (2), assembled on the high-pressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream.

17

The pressure relief valve (2) intervention brings about a fuel flow increase in the high-pressure pump cooling circuit, through inlet and drain piping (16) from piping (8). The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 to 2 bars. Two by-pass valves are placed in parallel with the mechanical supply pump. The by-pass valve (18) allows fuel to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value. The by-pass valve (17) allows filling the supply system through the manual priming pump (10).

IN T

Figure 3

EXHAUST

HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE) HIGH PRESSURE

N

O T

FO

R

PR

INTAKE (LOW PRESSURE)

108608

1. High-pressure pump. — 2. Pressure relief valve on high-pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars. — 4. Rail overpressure valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. — 8. Return piping. — 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. — 12. Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High-pressure pump cooling piping. — 17. By-pass valve. — 18. By-pass valve.

SECTION 2 - FUEL

O T

FO

R

PR

IN T

NEF ENGINES

N

18

NEF ENGINES

SECTION 3 - INDUSTRIAL APPLICATION

1

SECTION 3 Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

3

PART ONE - MECHANICAL COMPONENTS . .

5

OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 9

- Installation of rear components . . . . . . . . . . . .

18

- Installation of rear components with reduced distribution . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

- Flywheel installation . . . . . . . . . . . . . . . . . . . . .

23

- Installation of front components . . . . . . . . . . .

23

N

O T

FO

R

PR

IN T

- Disassembly of application components . . . . .

- Assembly of additional masses . . . . . . . . . . . .

25

- Timing of additional masses . . . . . . . . . . . . . . .

23

- Completion of engine re-assembly . . . . . . . . .

35

- Rotary feed pump disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

- Feed system bleed procedure . . . . . . . . . . . . .

39

- Power take-off disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

- Checks and controls . . . . . . . . . . . . . . . . . . . .

40

PART ONE - MECHANIC OVERHAUL OF ENGINES WITH ELECTRONIC CONTROL (COMMON RAIL) . . . . . . . . . . . . . . . . . . . . . . 41 RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . . . .

43

PRESSURE LIMITER FOR FUEL RETURN . . . . . . .

44

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . .

45

- Section pictures of complete engine - common rail version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2


NEF ENGINES

Page

Page - Fuel pressure sensor . . . . . . . . . . . . . . . . . . . .

81

46

- Fuel temperature sensor . . . . . . . . . . . . . . . . .

81

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . .

46

- Resistor pre-post heating . . . . . . . . . . . . . . . . .

81

- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

- Cooling liquid temperature sensor . . . . . . . . . .

81

- Disassembly of application components . . . . .

48

- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

- Assembly of application components . . . . . . .

55

- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . .

82

- Completion of the engine . . . . . . . . . . . . . . . .

65

PART THREE - TROUBLESHOOTING (MECHANICALS ENGINES) . . . . . . . . . . . . . . .

83

PART THREE - TROUBLESHOOTING (ELECTRONICS ENGINES) . . . . . . . . . . . . . . .

91

- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . . . . .

PART TWO ELECTRICAL EQUIPMENT - MECHANICALS ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67

93

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . .

94

- Cooling liquid temperature sensor . . . . . . . . . .

70

PART FOUR - MAINTENANCE PLANNING . . .

99

- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

MAINTENANCE PLANNING . . . . . . . . . . . . . . . .

101

- KSB Water temperature sensor . . . . . . . . . . . .

70

- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101

- Electromagnets assembled to feed pump . . . .

71

- Planning of controls and periodical intervention

101

- Oil pressure switch . . . . . . . . . . . . . . . . . . . . .

71

- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71

- Pre-post heating resistor . . . . . . . . . . . . . . . . .

71

73

LOCATION OF MAIN ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . .

75

- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .

76

- Connector to injectors (A) . . . . . . . . . . . . . . .

77

N

PR

R

FO

O T

PART TWO ELECTRICAL EQUIPMENT - ELECTRONICS ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IN T

METHODS OF DIAGNOSIS . . . . . . . . . . . . . . . . . ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES WITH ROTARY PUMP) . . . . . . . . . . . . . . . . . . . 69

- Feed connector (B) to components and to functions of the specific equipment . . . . . . . . . . . . . . . . . 78 - Connector to sensors (C) . . . . . . . . . . . . . . . .

79

- Temperature and air-pressure sensor . . . . . . .

80

- Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 MAINTENANCE PROCEDURES . . . . . . . . . . . . . .

102

- Checks and controls . . . . . . . . . . . . . . . . . . . .

102

- Engine oil level check. . . . . . . . . . . . . . . .

102

- Check of fuel system . . . . . . . . . . . . . . . .

102

- Cooling system check . . . . . . . . . . . . . . .

103

- Lubricating system check . . . . . . . . . . . . .

103

- Check of water presence within fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 103 - Check of drive belt tensioning . . . . . . . . .

104

- Check of belt’s tear and wear status . . . .

104

- Check and setting of tappet clearance . . .

104

- Sensor of engine’s oil temperature and pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80

- Oil motor and filter replacement . . . . . . .

104

- Driving shaft sensor . . . . . . . . . . . . . . . . . . . . .

80

- Fuel filter replacement . . . . . . . . . . . . . . .

105

- Timing system sensor . . . . . . . . . . . . . . . . . . . .

80

- Alternator belt replacement . . . . . . . . . . .

106

x

NEF ENGINES


3

GENERAL INFORMATION

FO

R

PR

IN T

Figure 1

O T

NEF engines have been designed and developed by Iveco Motors specifically for transportation by land and farming equipment in general.

N

They are characteristed by diesel cycle 4 stroke atmospheric or supercharged 4 and 6 cylinders each with 2 valves. Feed is provided by rotary mechanical pump or on line according to the equipment application. It differs from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine.

NOTE The picture shows application designed for 4 cylinders version, 2 valves per cylinder, having fuel feed mechanical pump

03220t

NOTE Data, technical specifications and performances granted shall be valid only if the Setter will follow and comply with all installation prescriptions provided by Iveco Motors. Furthermore, the expanders assembled by the Setter must always comply with couple, power and number of revolutions based on which the engine has been designed. The section herein described is composed or four directories: - directory of mechanical overhaul prescribed in accordance to the engine’s specific duty, illustrating all necessary operations to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover; - electrical directory, describing the connections of the different components, of the pre-post heating gearbox (only for some versions) and of the sensors assembled to the engine; - troubleshooting directory; - directory of preventive and regular maintenance operations, providing instructions for the execution of the main operations.


NEF ENGINES

N

O T

FO

R

PR

IN T

4

x

NEF ENGINES

PR

IN T


N

O T

FO

R

PART ONE - MECHANICAL COMPONENTS

5


NEF ENGINES

N

O T

FO

R

PR

IN T

6

x

NEF ENGINES

7


OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface

Figure 3

Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well.

2

NOTE With regard to the engine disassembly operations, please apply for information consulting the specific manual. All operations of engine disassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. 3

The following information relate to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties.

4

NOTE For specific application exigencies, some units can be assembled to the engine in different positions.

Within ”General overhaul” section, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.

Figure 2

N

3

O T

FO

R

2

PR

Engine setting operations for the assembly on turning stand

IN T

1 5

75671

- disassemble lubrication oil exhaust pipe from the turbo-blower: Underneath the turbo-blower loosen the two screws (2), loosen the screw (3) fixing the pipe throughout the stop collar (4) fixing the block; finally loosen and remove the union (5) from the block; plug the pipe ends and the exhaust of the turbo-blower.

Figure 4 1

3

75670

In order to apply the brackets 380000661 to the engine block to fix it on to the stand 380000301 for the overhaul, it is necessary to perform the following operations: On the right hand side: - disassemble pipes (1) from the union (2) fitting the lubrication oil filter (assembled on the opposite side): unlock the nuts fixing the pipes (1) and remove them from the union (2); drain the oil eventually still inside the pipes and plug them properly in order to avoid impurity inlet.

2

1 NOTE

For some versions, the oil filter (3) is directly assembled on to the heat exchanger:in such case it shall be disassembled using tool 380000670. Warning: the oil filter contains inside aprx. 1 kg. of engine oil. Provide for oil recovery and disposal in compliance with the law and regulations in force.

75672

- Disassemble the starter; Properly hold the starter (1) and loosen the fixing screws (2); - assemble the bracket bearing 99361037 using the four screw threaded ports (3).

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Figure 5

Figure 6 1 3 4 5 1

2 75673 75674

On the left hand side:

From the left-hand side:

- Disassemble oil filter (1) and bracket as well (for versions with engine oil filter not directly assembled on to the exchanger); Using tool 380000670 operate on oil filter; Loosen the screws (3) removing the bracket together with the filter bearing (4 and 5).

- Assemble the second bracket 380000661 throughout the screw-threaded ports (1).

IN T

PR

- Drain the oil through the cap underneath the plug.

R

Warning: the oil filter contains inside aprx. 1 kg. of engine oil. Provide tank with sufficient capacity to contain the liquid.

- Lift the engine using the rocker arm 380000216 and put it on the turning stand 380000301.

FO

Warning: avoid contact of engine oil with the skin: in case of skin contamination rinse in running water.

O T

Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.

N

- Remove the oil level rod together with guide pipe (2); (loosen the guide pipe disassembling from the block); properly pipe the screw-threaded port to avoid inlet of foreign matters.

x

Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.

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Disassembly of application components

9

Figure 9

Figure 7 1

70126

75675

Proceed disassembling the supercharger:

- Loosen the screw nuts fixing the supercharger on the exhaust manifold.

R

PR

- Hold up the supercharger and after lifting it remove the gasket.

NOTE To disconnect fuel pipelines (2 and 3, Figure 8), in low pressure from the relating pipe fittings, it is Necessary to press the locking fastener (1) as shown in picture B.

IN T

- loosen the fixing nut (1) and remove the lubrication pipe from the supercharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger.

BOSCH VE 4/12 F Pump Figure 10

N

O T

FO

Figure 8

After having disconnected the pipeline, reset the locking fastener (1) in lock position as shown in. picture A, to avoid any possible deformation of the fastener itself.

1

90502

- Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. Carry out complete drainage of the fuel contained therein. - Screw out completely the faucet and, using equipment 380000670 disassemble oil filter (1). - Disconnect fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump. - Remove the fuel filter bearing (4) from the bracket fixed to the engine head.

75677

- Disconnect the LDA pipe (1) from the head and from the feed pump. Pipe the ends of the pipelines as well as the feed pump and the engine head.

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Figure 11

1

2 3 7

4 6

IN T

5

75680

PR

1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump 4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing screw (on suction collector plate).

Figure 13

FO

R

Figure 12 1

2

N

O T

1

75679 88102

- Disconnect the pipelines (1) and (2) that provide feed and fuel recovery between pump and injectors; screw out the nuts fixing the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery pipeline; loosen the screws holding the fixing brackets of such pipelines (1,6, and 7, SENZA CODICE); pipe the pipeline ends. - Disassemble the injectors and remove them from their slot: remove the gaskets.

x

- Loosen the two fixing screws (2) and disassemble priming pump (1).

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Figure 14

11

Figure 16 2

1 87406

75683

- Disassemble rocker arm bearings; loosen the two fixing screws (2) and remove the complete rocker arm bearing; withdraw tappet rods. Repeat the operation for all the remaining rocker arm bearings.

- Remove tappet caps: Loosen the four fixing screws (1) and lift the caps (2); remove the gaskets.

PR

NOTE On the central cap there is a blow-by valve for the lubrication oil vapours. All the gaskets shall always be replaced during assembly.

IN T

- Disassemble water temperature transmitter (1).

Figure 17

FO

R

For applications with automatic belt stretcher

N

O T

Figure 15

86571

87409

- Disassemble suction and exhaust manifolds: loosen the 8 screws (1) fixing the suction manifold plate to the cylinder head (two of them have already been screwed-out since fixing the pipe brackets to the injectors); from the exhaust manifold side; loosen the (2) fixing screws; remove the gaskets.

- Remove the belt tightener (2). - Remove the belt (4) of the ancillary members by acting on the alternator fixing bracket (1). - Remove the alternator (3), the water pump (6), the fan pulley (5) and the jockey pulley (7). - Remove the pulley support (8). - Remove the engine block cooling system connector (3).

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For applications with traditional belt stretcher

Figure 20

Figure 18 1 4

2

5

3 75685

- Loosen screw (1) and relevant nut on belt stretcher bracket (3). - Loosen screw (2, Figure 19) in order to slide out POLY-V belt (2).

- Disassemble thermostat unit; loosen the three fixing screws (1) and disassemble the thermostat unit (2) together with the bracket (3); remove the gasket (4) and the thermostat (5). - Assemble the bracket in the original position fixing it with the screws of the thermostat unit.

IN T

88089

- Remove the belt stretcher bracket (3).

R

PR

- Disassemble the driven pulleys and the guide rollers.

FO

Figure 19

Figure 21

2

N

O T

1

75686 88091

- Properly hold the alternator (1) separating it from its bearing by loosening the screw (2); remove screw nut and washer.

- Loosen the screws (1) and withdraw the alternator bearing (2).

NOTE The shape and the dimensions of the support of the alternator vary according to the use of the engine. The relevant pictures provide a general trace of the intervention that is to be carried out. The procedures described are always applicable.

x

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Figure 22

13

Figure 24 2

1

3 4

75692

75810

- Loosen the screws (1) and disassemble the oil filter/heat exchanger bearing (2), interlayer plate (6) and relating gaskets. - Disassemble oil level sensor (5) (whether provided).

- Loosen the flywheel fixing screws (4) to engine drive shaft.

NOTE In some versions there is provided 380000144 tool checking the flywheel.

PR

- Disassemble injection pump (see specific procedure) and the power take-off underneath.

- Use the tool 380000988 (2) to operate on the flywheel cover box (1) in order to block flywheel rotation (3). (Utilise starter holding down studs and fixing screw nuts).

IN T

- Loosen the screws (4) and disassemble the oil pressure/temperature sensor (3) (if fitted).

N

Figure 23

O T

FO

R

NOTE The shape and the dimensions of the support of the alternator vary according to the use of the engine. The relevant pictures provide a general trace of the intervention that is to be carried out. The procedures described are always applicable.

Figure 25

1 2

3

4 75688 90504

- Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.

- Loosen the screws (1) and disassemble the pulley (2).

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Figure 28

Figure 26

116242

- Loosen the screws (1 and 3) and remove the front cover (2).

IN T

Figure 29

75811

- Loosen the screws (1) and remove oil pump (2). Figure 30

N

Figure 27

O T

FO

R

- Remove the engine drive shaft fixing ring from the front cover. Use the tool 380000665 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3).

NOTE Take note of the screw (1 and 3) assembly position, since the screws have different length.

PR

78256

1

2

4 3 75691

00904t

- Using the specially provided tie rod (3) for the tool 380000669 and the lever (4), withdraw the external holding ring (2) from the front cover (1). x

- Screw out the opposite screws (1) from the ports where the withdrawal pins shall be introduced (see picture following). - Loosen remaining flywheel fixing screws (3) to the engine drive shaft (4). - Remove the flywheel block tool (2).

NEF ENGINES


Figure 31

15

Figure 33

1

4

2

3 70153

75690

- Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.

- Loosen the screws (2) and remove the flywheel cover box (1). NOTE Take note of the screw (1) assembly position, since the screws have different length.

PR

IN T

Figure 34

N

O T

FO

R

Figure 32

00903t

- Remove the flywheel cover box fixing ring using the tool 380000663 (3) to operate on the back tang (5) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring using Ø 3,5 mm drill for a 5mm depth. - Fix the tool 380000663 (3) to the ring (1) tightening the 6 screws specially provided (4). - Proceed with drawing the ring (1) tightening the screw (2). - Using the specially provided tie rod (3) for the tool 380000669 and the lever (4), withdraw the external holding ring of the flywheel cover box.

88046

- Turn the engine upside-down. - Loosen the screws (2), disassemble the plate (3) and remove the oil pan (1). NOTE The shape and dimensions of the pan and of the rose pipe may vary according to the engine application. The relating illustrations provide general guidelines of the operation to be performed. The procedures described are applicable anyway.

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Version with suction rose type A

Figure 38

Figure 35

99222

- Loosen the screws (1) and disassemble the oil suction rose pipe (3). - Loosen the screws (2) and remove the stiffening plate (4).

O T

FO

R

PR

IN T

Version with suction rose type B Figure 36

86601

- Loosen the screws (1) and disassemble the gear from the camshaft (2).

Figure 39

N

- Remove the screws (1) and (4) and disassembled the suction rose (5). - Remove the screws (2) and disassemble the stiffening plate (3) Version with additional masses Figure 37

90505

70157

- Loosen the screws (2) and disassemble the timing gearbox (1). 86578

By means of pin (1) lock the additional masses (2) in the P.M.S. Loosen the fixing screws (3) and remove the additional masses (2). x

NOTE Take note of the screw (2) assembly position, since the screws have different length.

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Version with reduced distribution

17

Figure 42

Figure 40

87424

87422

N

Figure 41

O T

FO

R

NOTE Take note of the screw (2) assembly position, since the screws have different length.

IN T

PR

- Loosen the screws (2) and remove the flywheel cover box (1).

- Remove the screws (1) and disassemble the gears (3) and (4) from the camshaft (2).

87655

- Remove the gear (1) transmitting motion to the ignition pump and the relevant support.

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Installation of rear components

Figure 44 1

Figure 43

9

10

6 4

8

3

2

1 7

5

1

75711

!

It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal.

- Tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below, following the order as shown in the picture. Screws M12 Screws M8 Screws M10

65 ÷ 89 Nm 20 ÷ 28 Nm 42 ÷ 52 Nm

R

Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter.

DIAGRAM SHOWING SCREW TIGHTENING FIXthe REAR GEARBOX - Reassemble to box TO (1) to engine block.

IN T

DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION WITHIN GEARBOX AREAS - Accurately clean the timing gearbox (1) and the engine block.

PR

75712

FO

It must be uniform (no crumbs), with no air blisters, thinner or irregular zones.

NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

Any eventual imperfection shall be correct as soon as possible.

Figure 45

O T

Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages.

N

Couplings must be assembled within 10 minutes after completing the sealing operation.

70211

- With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the upright surface on which a groove has been created for the ignition timing. NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.

x

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Figure 48

R

PR

IN T

Figure 46

19

90508

FO

90506

- Tighten the screws (1) fixing the gear to the camshaft (3) and lock them to the prescribed couple.

Figure 49

N

Figure 47

O T

- Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).

90507

1 75708

- Position comparator (1) on timing system gear (2) and check that the clearance between gears (2) and (3) is within 0.076 ÷ 0.280 mm range.

DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION.

20


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Figure 51

NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. Couplings must be assembled within 10 minutes after completing the sealing operation.

0901t

IN T

- Apply to engine drive shaft rear tang (6), the detail (5) of the tool 380000666, fix it tightening the screws (4) and key the new holding ring on it (3).

PR

- Place detail (1) on detail (5), tighten the screw nut (2) until complete assembly of the fixing ring (3) into the flywheel cover box (7). Figure 50 1

Figure 52

14

8

17

7

6 18

13 5

20

2

N

4

12

9

10

3 75709

DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX. - Reassemble the box (1) to the engine block, tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below, following the order as shown in the picture.

x

2

11 1

21

Screws M12

75 ÷ 95 Nm

Screws M10

44 ÷ 53 Nm

!

1

O T

19

R

15

FO

16

Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

75696

- Check the contact surface (1) of the clutch plate and if it is scratched, proceed with turning. - Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.

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Installation of rear components with reduced distribution

21

Figure 55

Figure 53

87653

- Place the dial gauge (1) on the timing gear (2) and check that the slack between the gears (2) and (3) is included in the range between 0,076 ÷ 0,280 mm.

R

NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.

Figure 56

PR

- With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the upright surface on which a groove (3) has been created for the ignition timing.

IN T

70211

O T

FO

Figure 54

87654

N

- Fit the screws (1) fastening the gears (2) to the camshaft (3) and tighten them to the prescribed pair. Figure 57

114791

- Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).

87655

- Spline the gear (1) transferring motion to the ignition pump.

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Figure 58

Figure 60

87656

- Re-assemble the box (1) to the engine basement. - Tighten the fastening screws (2) to the same position detected before disassembly.

IN T

- Fit the power take-off gear (2) (if available) into the specially provided housing and fasten the screws (1),

87658

Figure 59

Figure 61

FO

R

PR


O T

87657

N

DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. Couplings must be assembled within 10 minutes after completing the sealing operation.

x

87659

- Apply to the rear tongs hold (3) of the engine drive shaft the part (6) of the tool 380000664, fix it with the screws (1) and spline the new tight ring to it (2). - Place the part (5) on the part (6), tighten the nut (4) until tight ring assembly (2) into the flywheel box is completed.

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Flywheel installation

23

Installation of front components

Figure 62

Figure 65

1

4

2

3 75690

70220

- Assemble oil pump (1). - Tighten fixing screws (2) and lock them to the prescribed couple.

IN T

- Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling . - Using a hoist, handle the flywheel to place it in its housing inside the flywheel cover box. - Screw up to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine flywheel (1) properly placing it inside the flywheel cover box. Figure 63

Figure 66

1

PR

2

CNH

R

PARTS

FO

3

75692

N

1 α

O T

4 - Tighten the screws (4) fixing the engine flywheel (3) to the engine shaft. Use tool 380000988 (2) to operate on the flywheel cover box (1) to block engine flywheel rotation. Figure 64

70221

- Apply to the water pump (1) a new fixing ring (2).

Figure 67

2

75695

Tighten the engine flywheel (1) fixing screws (2) in two phases: - 1st phase; tightening by means of dynamometric wrench to couple 30 ± 4 Nm; - 2nd phase, 60º ± 5º angle dwell with tool 380000304. 76112


- Assemble the water pump (1). - Tighten the screws (2) and lock them to the prescribed couple.

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Figure 68

Figure 71

CNH PARTS

106549

- Remove the fixing ring (2) from the front cover (1), accurately clean the plug surface. Figure 69

00902t

- Apply on engine drive shaft front tang (6) the detail (4) of the tool 380000666, fix it with the screws (5) and key the new holding ring on it (7).

IN T

- Place the detail (2) on the detail (4), screw-up the threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover.

O T

FO

R

PR

Figure 72

75710

Figure 70

- Assemble the plate (1), the rose pipe (2), tighten the fixing screws (3) and fix them to the prescribed couple. Figure 73

N

- Accurately clean the contact surface of engine block and apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs.

87260

86601 106550

- Assemble the front cover (2) to the block and tighten the screws (1) fixing them to the prescribed couple. x

- Assemble the plate (3), the suction rose (5) and tighten the fixing screws (1, 2 and 4) to the prescribed torque.

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25

Fit the additional masses (2) and tighten the screws (3) on the engine block.

Assembly of additional masses Figure 74

Remove the lock pin (1) of the additional masses.

86578

Timing of additional masses

IN T

Version with reduced distribution Match the signs (A) engraved on the gears for timing, insert the pin in the hole (B) on the balancing mass.

N

O T

FO

R

PR

Figure 75

86614

1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) 4. Additional masses.

26


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Figure 76

Figure 78

- Provide for new gasket replacement (1) of the oil pan (2). 3

IN T

NOTE The pictures illustrating the pan and of the rose pipe may not correspond to the ones of your model. However the procedures described are applicable anyway.

1

75697

PR

Figure 77

2

- Assemble the pulley (1) to the engine drive shaft , and the distance ring (3).

O T

FO

R

- Tighten the fixing screws (2) and lock them to the 68 ± 7 Nm couple.

Figure 79 CNH

N

PARTS

75814

- Assemble oil pan (1), apply the plate over it (2). Tighten the screws (2) and lock them to the prescribed couple.

- Assemble the following elements to the block: new gasket (1), heat exchanger (2), new gasket (3), oil filter bearing (4). Tighten the screws (5) and lock them to the prescribed couple.



88046

x

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Figure 80

27

Figure 82 1

2

CNH PARTS

75686

76113

- Manually start the oil filter (3) on the bearing union (1) until counter-boring, further screw up the oil filter (3) by 3/4 turn. - Place a new fixing ring on the block housing (6).

- Tighten the screw without locking it (2).

Figure 83

PR

- Apply, (if needed) new fixing ring on the oil temperature/pressure sensor (4) and assemble it to the bearing (1) tightening the fixing screws to the prescribed couple.

- Connect the alternator (1) to the support.

IN T

- Lubricate the fixing ring (2) using engine oil and place it on the oil filter (3).

N

O T

FO

R

Figure 81

76114

- Assemble the alternator bearing (1) ensuring that the pins (3 and 4) are against the engine block. - Tighten the screws (2) and lock them to the prescribed couple. NOTE The shape and the dimensions of the alternator support vary according to the use of the engine. Therefore the relevant pictures provide a general guideline of the intervention that is to be carried out. However the procedures described are applicable.

87759

- Place the gasket (1) over the block. The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface.

NOTE Verify that the engine block stand is clean. Do not grease the gasket. It is recommended to keep the gasket inside packaging until assembly to the cylinder head.


Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture.

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Figure 84

Figure 86 1

4

2 1 3 3 2 2 3

1 4

75705 75688

NOTE If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.

- Carry out the assembly of the rocker arms after previous check of the components. ROCKER ARM UNIT COMPONENTS: 1. Elastic ring - 2. Spacer- 3. Rocker arms4. Support.

IN T

- Place the head (3) over the block and insert screws (1) and (2).

Figure 87

PR

18.975 18.963

Figure 85

4

1

5

13

7

2

8

11

3

6

14

N

- Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. Then a further 90 degrees for the M12 x 140 and M12 x 180. 50 Nm + 90 deg’s 40 Nm + 180 deg’s 70 Nm + 180 deg’s

19.000 19.026 75704

76115

- Lubricate cylinder head bolts and install to head.

M12 x 70 M12 x 140 M12 x 180

19.000 19.026

12

O T

9

FO

10 α

R

CNH PARTS

SHAFT AND ROCKER ARM BASIC DATA Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary. Figure 88 1

19.00 16.00 75702

ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the i 0.4 - 0.6 Nm couple.

x

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Figure 89

29

Figure 91 2

CNH PARTS

1 75683

32655

Figure 90

FO

75703

O T

Figure 92

IN T

2

1 3

D1

R

D2

- Insert the tappet driving rods and the Rocker Arm unit. Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced;

N

- Tighten the screws (2) to the prescribed couple and assemble water temperature sensor (1).

PR

Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable.

75806

Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Correct slack is: - suction valves 0.25  0.05 mm - exhaust valves 0.50  0.05 mm.

NOTE On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.

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Figure 93

Figure 95

CNH PARTS

1

CNH PARTS

1 2

75707

- Assemble injectors after having replaced the sealing gasket (1). NOTE During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing.

75808

- Assemble exhaust manifold (1) providing new gaskets (2).

IN T

NOTE The illustration of exhaust manifold may be not matching your model. Anyhow, described procedure is applicable.

R

PR

Figure 94

FO

CNH

O T

PARTS

Figure 96 1 4

N

CNH PARTS

2 87406

3

- Assemble cylinder covers (2) with the respective gaskets; - Fit the seal nods and tighten the screws fixing them to the prescribed couple.

5

75685

- Assemble thermostat unit (2) including thermostat (5) and gasket (4). - Tighten the screws to the prescribed couple.

NOTE Always replace the gaskets using new ones. Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit.

NOTE The screws (1) have been have been utilised to fix the bracket (3).

Seal nods shall have no visible deformation. In such case provide for replacement with new nods.

Disassemble the bracket and reassemble components from 1 to 5 as shown in the picture. The gasket must be new.

x

NEF ENGINES


31


Figure 97

Figure 98 2

CNH PARTS

3

1

88090

- Tighten the control belt turning the alternator as illustrated.

PR

IN T

- Tighten the screws (1) and the alternator fixing bolt to the support.

For applications with automatic belt tensioner Figure 99

R

75687

FO

- Assemble the pulley fan bearing tightening the screws to the prescribed couple. - Assemble the alternator tensioning bracket.

O T

- Mount pulley (3) and secure it to support through screws (2). - Assemble the transmission pulley (1).

N

- Fit the new belt onto the pulleys and guide rollers.

NOTE If the old belt is to be reassembled examine it carefully in order to see if there may be incisions or evident signs of yielding.

86571

Assemble belt Poli-V (4) on the pulley (5) of the engine shaft, on the jockey pulley (2), on the water pump (6) and on the alternator (3), tighten (syn.: tension) the belt by means of the automatic belt tensioner.

32


NEF ENGINES

Figure 100

Figure 101

1

7

2 6 CNH

CNH

5

PARTS

PARTS

4

2

3 1 75701

- Apply on the surface joining the suction manifold plate (1) a sufficient coat of Loctite 5999 and provide. fixing the screws to the prescribed couple.

IN T

- If the pipe (6) of the suction manifold plate (1) has been removed, reassemble it after having fit a new gasket (5).

75700

- Assemble the brackets (1) fixing the fuel pipelines to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture. Figure 102

N

O T

FO

R

NOTE For the versions provided with heater, also assemble components (3) and (4).

PR

- Tighten the screws (7) to the prescribed couple.

88102 88102

- Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple. - Also assemble feed pump (see specific procedure) and the power take-off underneath.

NOTE Pump mounting requires specific procedure contained in this section.

x

NEF ENGINES

33


BOSCH VE 4/12 F pump Figure 103

1

2 3

IN T

7

5

6

4 75680

R

PR

1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump 4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing screw (on suction collector plate).

FO

Figure 104

N

O T

1

Figure 105

1

2

75679

- Assemble the pipes (1) and (2) providing fuel feed and recovery between pump and injectors; Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold; fix the pipes to the injectors throughout the brackets previously assembled.

1

75677

- Fix the LDA pipeline (1) to the engine head and to the feed pump.

34


NEF ENGINES

Figure 106

Figure 108 1

75675 90502

- Using 99360076 equipment assemble fuel filter (1).

NOTE The filter shall be priory filled with fuel to facilitate feed system bleed operations.

- Hold the turbocharger and place it on the exhaust manifold after having interposed the gasket. - Screw up the fixing nuts of the turbocharger to the exhaust manifold tightening them to the prescribed couple.

IN T

- Connect the fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to feed pump.

Proceed assembling the turbocharger:

- Tighten the lubrication pipe fixing ring. Operate in the same way on the other end of the pipe. Connect it to the upper part of the heat exchanger.

PR

- Assemble the fuel filter bearing (4) to the bracket fixed to the engine head.

To complete engine assembly it is necessary to remove it from the turning stand.

FO

R

- Using rocker arm 380000301 hold the engine and loosen the screws fixing the brackets to the turning stand 380000301.

N

O T

Figure 107

70126

NOTE To connect fuel pipelines (3 and 4, Figure 108) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B. After having connected the pipeline, reset the fastener (1) into block position as shown in picture A.

x

- Disassemble the brackets 380000661 from the engine after having properly put it on a wooden bearing.

NEF ENGINES

35


Completion of the engine

Figure 111

Figure 109 2

1

3

1 75717

75670

On the right hand side: - re-assemble the starting engine (1); opportunely support the starting engine (1) and tighten the two fastening screws to the prescribed torque.

IN T

- reassemble the pipes (1) from the union (2) to the lubrication oil filter (placed on the opposite side): tighten the pipe rings (1) and connect them to the union

PR

NOTE In some cases, the oil filter (3) is directly placed on the heat exchanger: in this case it shall be assembled using tool 99360076.

Figure 112

R

Figure 110

3

FO

4

N

O T

2

5 1

3

2 75673

4 On the left hand side: 1 5

- Assemble oil filter (1) together with bracket (for the versions with engine oil filter not directly assembled to the exchanger); tighten the screws (3) assembling the bracket (4) including filter bearing (5). Using tool 99360076 screw up oil filter; - Assemble oil level rod together with guide pipe (2).Fill up engine oil.

75671

- Reassemble the lubrication oil exhaust pipeline (1) from the turbocharger: from underneath the turbocharger tighten the two screws (2); tighten the screw (3) fixing the pipeline to the block throughout the fixing collar (4) to the block; finally tighten the union (5) to the block.

- Install the engine on the machine (for installation operations please apply to specific issue).

36


NEF ENGINES

Rotary feed pump disassembly and assembly procedure

In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part.

NOTE This procedure prescribes that:

On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine and disassemble it only afterwards.

- the fuel pipes (from the pumping elements to the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed; - the electrical disconnected.

connections

have

been

- Accelerator cable shall be disconnected.

The following procedure analyses this second hypothesis since it is the more complex. Find the top dead centre with the tool (380000977) - False injector Figure 115

Engine versions with tool (380002385)

PR

IN T

Figure 113

88140

O T

Disassemble the starter from the flywheel box and use tool 380002385 to rotate the flywheel. Engine versions with tool (380000988)

Searching for the top dead centre with timing gear blocking pin Figure 116

N

Figure 114

88141

Remove the rocker covers of the 1st cylinder; remove the 1st injector and place the tool (1) to set the 1st cylinder top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed. Once PMS has been obtained, lock the flywheel by means of tool 380000988 (Figure 114).

R

FO

1

1

2

1

75714 84071

Disassemble the starter from the flywheel box (1) and use tool 380000988 (2) to rotate the flywheel. x

Turn the flywheel until, when pushing the pin 380002729 (1), it blocks the gear (2) obtaining the TDC of the 1° cylinder.

NEF ENGINES


BOSCH VE 4/12 F Pump

37

Figure 119

Figure 117

1

2

1

75694 75721

- Tighten the lateral screw (1) blocking rotation of the pump shaft.

- Assemble the 380000322 extractor throughout the two threaded ports (4, Figure 118) and withdraw the gear from the pump shaft.

IN T

- Unscrew the side screw that locks the pump shaft partially (1) and remove spacer (2). This must be kept on a side (we recommend to fix it on the pump with a wire or a clip).

- From the pump side, loosen the fixing nuts (1) without removing them in order to enable moving the pump backwards using 380000322 extractor.

- Properly hold the feed pump and loosen completely the fixing nuts.

PR

- Withdraw the pump from the studs, together with the gasket. When the supply pump is to be assembled on the engine the P.M.S. conditions at compression end stage cylinder No. 1 must be carried out.

R

Figure 118

4

N

O T

FO

1

2

3 75693

- From timing side, remove the cover (2) loosening the screws (1) in order to have access to the union fixing nut (3) to the pump driving gear. - Loosen the fixing nut (3) and remove the relating washer.

NOTE Hold the pump driving gear to avoid interference or crawling during timing gear rotation.

38


NEF ENGINES

Figure 120

Figure 122 1

CNH PARTS

1

2

75721

- Assemble the pump pre-set in its housing on the engine, fitting the shaft into the gear port (not provided with wrench). - Tighten the fixing nuts (1) locking the pump flange in the slot centre.

PR

NOTE The gasket removed during pump disassembly shall not be utilised again. Always use original spare parts.

IN T

75694

- Loosen screw (1) that prevents pump shaft rotation and insert spacer (2). Tighten screw (1)so that it locks spacer (2): in this way the supply pump shaft will be able to rotate freely. - Assemble the cover (2, Figure 121) including gasket and tighten the screws (1, Figure 121). - Disassemble the flywheel rotation/locking tool 380000388 or 380002385; arrange the starting motor in its seat. - Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump). - Connect electrical connections to electro-magnets on the hydraulic head and on KSB.

Figure 121

1

Ignition pump control and timing Figure 123 (Demonstration)

N

O T

FO

4

R

NOTE If the pump has been removed with the engine mounted, connect the accelerator cable, if present in the application.

2

3 75693

- On the timing side, throughout the specially appointed port, fit the washer and screw up the fixing nut (3) to the pump shaft. Lock the nut to the 90-95 Nm couple.

x

87720

- With the injection pump inserted in relating seat and securing screws loosened, mount comparator 380000228 (2) and 380000229 gauge tool (1), preloading the rod by 2.5 mm. - Rotate the engine derive shaft to shift from the condition of the first cylinder to TDC end of compression phase. Reset the dial gauges and rotate the engine drive shaft into the opposite direction until recovering the condition of the 1st cylinder to TDC in phase of compression (see Figure 116). From this position on the comparator applied on the pump it must be possible to read the value listed on the pumping element pre-lift table. Section 4. - Rotate the pump in anti-clockwise direction if the stroke is shorter or in clockwise direction if the stroke is longer, until obtaining the stroke prescribed. - Checking these conditions, lock the pump by tightening the relevant nuts to the prescribed pair.

NEF ENGINES


Feed system bleed procedure

39

Power take-off disassembly and assembly procedure Figure 126

Version with A type fuel filter Figure 124

1

2

4

3

75720

Where designed, there is a power take-off able to transmit motion to different auxiliary parts.

- Disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the priming pump.

Disassembly of such mechanism shall be executed as following:

- Continue the operation until when fuel outflows.

- Loosen the two screws (3) and after having removed the cover (1) with a specially provided extractor, withdraw the power take-off (2).

PR

- Connect the (1) to the filter.

IN T

87751

R

- The two gaskets (4) shall be replaced in phase of reassemble.

FO

Version with B type fuel filter

N

O T

Figure 125

76211

In case any operation has been executed on the components of the feed circuit, it is necessary to execute bleeding of air within the system. - Loosen the bleeder vent screw (3) on the fuel filter (1) and keep working on the bleed lever of the priming pump (2). - Continue executing this operation until when fuel drains from the bleeder vent screw. - Tighten the bleeder vent screw (3).

- Vary out the assembly fitting the power take-off in its housing, providing new gasket and checking the sprocket gear meshing. - Assemble cover and gasket and tighten the screws to the prescribed couple.

40


NEF ENGINES

Checks and inspections NOTE The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.

Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:

- There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings.

- There is no fuel leakage from fuel pipelines. - There is no blow-by from pneumatic pipes (if provided).

FO

R

- Verify correct working of the lighting leds of the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection.

PR

- There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings.

IN T

- Carefully check the fuel connection pipes to the respective unions.

N

O T

- Check and blow by with care the engine cooling system, carrying out frequent drainage.

x

NEF ENGINES

PR

IN T


PART ONE -

N

O T

FO

R

MECHANIC OVERHAUL OF ENGINES WITH ELECTRONIC CONTROL (COMMON RAIL)

41


NEF ENGINES

N

O T

FO

R

PR

IN T

42

x

NEF ENGINES


RAIL

43

ELECTRO-INJECTOR As for NEF TIER 3 engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power developed by the engine.

108609

1. Rail — 2. Fuel inlet from high-pressure pump — 3. Overpressure valve - 4. Pressure sensor. The rail volume is comparatively small to allow a quick pressurisation at startup, at idle and in case of high flow-rates. It anyway has enough volume as to minimise system spikes and the use of plenum chambers caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump.

Jet

Powers kW

Pressures bar

DLLA

Up to 152

250 ÷ 1600

DSLA

Lower to 152

250 ÷ 1400

The injector is similar as construction to the traditional ones, apart from the absence of plunger return springs. The injector can be deemed as composed of two parts: - actuator — spray nozzle composed of pressure rod (1), plunger (2) and nozzle (3); - control solenoid valve composed of coil (4) and pilot valve (5). The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

IN T

Figure 127

Figure 128

RELIEF VALVE

15

O T

FO

R

PR

A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.

N

Mounted on the end of the rail, it has the function of protecting the system’s components in case the failure of the rail pressure sensor or the pressure regulator of pump CP3 causes an excessive pressure increase in the high-pressure plant. When the rail pressure reaches 1800 bars, the valve initially intervenes in order to allow the fuel to flow and subsequently to reduce the pressure within safety limits and then it mechanically regulates the rail pressure to approx. 800 bars. This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of the fuel preserving the return pipes to the tank. 70505

1. Pressure rod — 2. Plunger — 3. Nozzle — 4. Coil — 5. Pilot valve — 6. Ball shutter — 7. Control area — 8. Pressure chamber — 9. Control volume — 10. Control duct — 11. Supply duct — 12. Control fuel outlet — 13. Electric connection — 14. Spring — 15. High-pressure fuel inlet.


NEF ENGINES

Injection start

PRESSURE LIMITER FOR FUEL RETURN It is housed on the rear cylinder head part, and adjusts the pressure of fuel returning from injectors at a pressure included between 1.3 and 2 bars. By guaranteeing this pressure to the return fuel, the fuel vapours formation inside injectors is avoided, optimising fuel spraying and combustion.

Figure 129

Figure 130

15

FO

R

When coil (4) is energised, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, with following fuel injection into the cylinder.

A

Injection end

N

O T

When coil (4) is de-energised, shutter (6) goes back to its closing position, in order to re-create such a force balance as to make plunger (2) go back to its closing position and end the injection.

NOTE The injector cannot be overhauled and therefore it must not be disassembled.

x

To tank — B From injectors

PR

70506

IN T

44

70507

NEF ENGINES


45

GENERAL SPECIFICATIONS Section pictures of complete engine - common rail version

FO

R

PR

IN T

Figure 1

O T

The and F4DE9684 engines are turbocharged a 4-stroke diesel engines with 6 cylinders, with 4 valves per cylinder.

N

They have high pressure injection fuelling (common rail) and are entirely electronically driven in order to optimise the working process in accordance to the operation, limiting as much as possible the pollution emissions and consumption.

116362

The section herein described is composed or four sections: - Section of mechanical overhaul prescribed in accordance to the engine’s specific duty, illustrating all necessary operation to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover; - Electrical section, describing the connections to the different components of the engine control module and of the sensors assembled to the engine; - Diagnosis section; - Section of preventive maintenance operations, providing instructions for the execution of the main operations.

NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by Iveco Motors. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

46


NEF ENGINES

ENGINE OVERHAUL Preface

Figure 3

Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well.

NOTE With regard to the engine disassembly operations from the machine, please apply for Information consulting the specific manual. All operations of Engine disassembly operations as well as overhaul operations must be executed by qualified technicians provided with the specific tooling and equipment required.

Engine setting operations for the assembly on turning stand

After disconnecting the pipe, reset the clamp (1) in locking position (Figure A) to prevent distortions.

Disconnect the high pressure fuel pipeline (7, Figure 4) from the rail diffuser and from the high pressure pump (8) and disassemble it from the engine block removing the fixing clamps.

FO

R

Figure 2

NOTE Press clamp (1), as shown in Figure B, to disconnect the low pressure fuel pipes (3 — 4 — 5, Figure 4) from the corresponding connections.

IN T

In section 4, ”General overhaul”, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.

70126

PR

The following information relates to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties.

Disconnect the pipeline (9) from the high pressure pump.

O T

NOTE Because of the high pressure in the pipelines running from the high pressure pump to the rail and from this last one to the electro-injectors, it is absolutely required NOT to:

N

- disconnect the pipelines when the engine is working; - re-use the disassembled pipelines. 116364

In order to apply the brackets 380000661 to the engine block to fix it on to the stand for the overhaul, it is necessary to perform the following operations on the left hand side of the engine: - Using the tool 380000670 disassembly the fuel filter (6) and remove it from the support (1); - Disconnect the electrical connection (2) from the support (1) and the heater’s one (placed on the filter support as well); - Disconnect the fuel low pressure pipelines (3-4-5) from the support (1); - Disconnect pipeline (9) from the support (1); - Remove the sustaining support bracket (1) from the block. x

NEF ENGINES


On the right side of the engine

47

Figure 5

Figure 4

IN T

116366

Disconnect the lubricating pipe (2) from the upper side of the heat exchanger on the turbo blower (1). Undo the fastening screws (4) and remove the support (3).

PR

Disassemble the thermostat body including the seal.

116365

FO

Disconnect the oil filling pipe (1).

R

Figure 6

N

O T

Unscrew the fixing screws and disconnect the starting motor (2) from its seat.

116367

Make holes (1) and (2) on both sides of the engine base, brackets 380000661 and then fix by means of the later, the engine to revolving stand 380000301. Empty the engine oil by removing the cap of the sump.

Collect and dispose of the engine oil according to enforced regulations.

48


NEF ENGINES

Disassembly of application components

N

O T

FO

R

PR

IN T

Figure 7

116360

1. Connections for Electro-injectors - 2. Engine cooling liquid temperature’s sensor - 2. Cable of the fuel pressure sensor 4. Sensor of engine’s oil temperature and pressure - 5. Driving shaft sensor 6. Electro-injector - 7. Temperature - air pressure sensor - 8. Timing system sensor - 9. Cable of fuel heater and fuel temperature’s sensor - 10. Cable of pressure regulating gauge - 11. EDC 7 electronic module.

Disconnect the engine’s cable from the connectors (1, SENZA CODICE) wiring harness to Electro-injectors (6); (7) air pressure/temperature sensor; (3) fuel pressure sensor; (11) engine control module; (10) high pressure pump sensor; (8) timing system sensor; (2) Thermostat sensor of engine cooling liquid’s temperature; (5) sensor of engine’s revolutions. x

Disassemble the engine from the engine block removing the fixing clamps.

NEF ENGINES


Figure 8

49

Figure 10

116370 116368

Now disassemble the supercharger:

IN T

Disconnect from the rail (2): the fuel pipe (7) according to procedures described in figure (24). Disconnect fuel pipes (5) from rail (2) and injector manifolds (6).

Unscrew fixing nuts (3) of the turbo-blower (4) on exhaust manifold (4). Hold up turbo-blower (4) and get the seal. Undo the fastening screws (1) and detach the exhaust manifold (2).

N

Figure 9

Figure 11

O T

FO

R

PR

Remove the screws (1) and disconnect the rail (2).

116371 116369

Disconnect the fuel return pressure limiter (1), the pipeline by acting on the connections as described on Figure 6. Remove the external vent pipe (2). Loosen the nuts (3) and disconnect the tappet cap (4).

On the opposite side, loosen the fixing screws (2) of the inlet manifold (1) and disassemble the joint to the air heater for the cold start. Remove the pressure-air temperature sensor from the induction manifold (1).

50


NEF ENGINES

Figure 12

Figure 14

116372

Remove nuts (3) and remove fuel manifolds (4).

NOTE Disassembled fuel manifolds (4) must not be used again, but however replaced with other new ones.

FO

R

Undo the fastening screws and remove the belt tightener (2). Undo the fastening screws and remove the drawback pulley (3 and 5). Undo the fastening screws and remove the belt tightener (7). Undo the fastening screws on the cylinder head and remove the support (6). Undo the fastening screws and remove the ventilator support (1).

Remove screws (1) and disconnect injector wiring support (2) including the gasket.

PR

116378

IN T

Remove nuts (6) and disconnect the electrical cables from injectors (5).

O T

Figure 13

N

Figure 15

70132

70133

Remove injector fastening screws. Use tool 380001099 (1) to remove injectors (2) from the cylinder head.

x

Loosen tappet adjustment fastening nuts (1) and unscrew the adjusters. Remove the screws (2), remove the rocker assembly (3), consisting of: bracket (6), rockers (4), shafts (5) and remove jumpers (7) from valves. Remove rods (8).

NEF ENGINES


Figure 16

51

Figure 18

IN T

116377

Use tool 380000670 to remove the oil filter (1).

PR

116373

Remove the fastening screws (1) from the cylinder head (2). NOTE The highlighted screws are shorter.

FO

R

Figure 19

N

O T

Figure 17

88555

Unscrew the fixing screws (1) and disassemble the pipeline union (2).

116374

Fix suitable clips (1) to the cylinder head (2). By means of opportune metal cables and a hoist, detach the cylinder head (2) from the engine crankcase.

52


NEF ENGINES

Figure 20

Figure 22

88558

Unscrew screws (2) and disconnect oil temperature pressure sensor (3). Unscrew screws(4) and disconnect oil filter support (5) from the base, and remove the relevant seals.

Loosen the engine shaft flywheel fixing screws.

N

Figure 21

Figure 23

O T

FO

R

Remove the heat exchanger from its seat.

IN T

Disconnect connector (1) from the oil temperature pressure sensor.

Apply the tool (1) to stop flywheel rotation (2) through the hole (3) made on the base. Tool (1) positioned in hole (3) is to be inserted in the groove made on the flywheel blocking its rotation.

PR

88556

116376

Undo the screws (1), disassemble the silencer (2) and the pulley (3).

88557

Remove nuts (1) and disconnect high pressure pump (2) along with the fuel pump (3). x

The blocking tool of the engine flywheel can facilitate disassembly of dampening flywheel (2) assembled on pulley (3).

NEF ENGINES

53


Figure 24

Figure 26

1

2

88560

00900t

Remove the screws (1) and take out the front cover (2).

IN T

NOTE Take note of screw (1) assembling positions since they have different lengths.

N

Figure 25

Figure 27

O T

FO

R

PR

Remove the ring sealing the engine’s driving shaft from the front cover. Use the tool 380000665 (4) to operate on the front bar hold of the driving shaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool to the ring tightening the 6 screws provided with the equipment. Then proceed removing the ring (2) by tightening the screw (3).

88561 00904t

Using the specific tie rod (3) of the tool 380000669 and the ancillary lever (4), remove the external holding ring (2) from the front cover (1).

Remove two opposite screws (1) from the area where the withdrawal pins will be introduced (2, Figure 28). Loosen the remaining flywheel fixing screws (3) from the driving shaft (2). Remove the flywheel locking tool (4).

54


NEF ENGINES

Figure 28

Figure 30

88307

Turn the engine upside down. Remove screws (2) and disconnect oil sump (1). Disconnect the high pressure pump stroke sensor. Unscrew the screws(3) and remove timing gear distribution box (4) from the base.

PR

Tighten two screws of medium length into the holes (4) to sling the flywheel with the hoist. Throughout the two guide pins (2) previously screw into the driving shaft holes (3) withdraw the engine flywheel (1) after slinging it with the hoist.

IN T

88562

Figure 31

N

O T

FO

R

Figure 29

00903t

Remove the holding ring of the flywheel cover box using the tool 380000663 (3) to operate on the driving shaft’s back bar hold (5). Through the steering holes of the tool, perforate the inside holding ring with a straight way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool 380000663 (3) to the ring (1) tightening the 6 screws provided with the equipment (4). Then proceed removing the ring (1) by tightening the screw (2). Using a specific tie rod of the tool 99363204 and an ancillary lever, remove the external holding ring (2) from the front cover. x

88564

Undo the screws (1) and remove the bevel gear (3) from the distribution shaft (2).

NEF ENGINES


Assembly of application components

55

Figure 34

Figure 32

88567

Tighten the screws (1) fastening gear (2) to camshaft (3) to the specified torque (36 Nm ± 4 Nm). 70211

FO

IN T

R

NOTE Fasten screwing of the two pins to facilitate the operation of engine driving shaft rotation.

Figure 35

PR

With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) on the upright surface where a groove has been created for the ignition timing.

70214

LOCTITE 5205 SEALANT APPLICATION AREAS Clean accurately the timing gear case and the engine block.

N

O T

Figure 33

116375

Turn the engine shaft and the distribution shaft so that, by mounting the bevel gear on the latter, the tooth with the gear groove of the engine shaft coincides between the two marks created on the bevel gear (1).

NOTE Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5205 to obtain a bead (1) of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).

56


NEF ENGINES

Figure 36

Figure 38

88569 88571

GEARCASE FIXING SCREW TIGHTENING DIAGRAM

Put a new seal ring on the water pump.

Reassemble box (1) on the engine.

Assemble water pump (1); tighten the screws (2) up to the prescribed torque. Figure 39

IN T

Tighten fixing screws (2) on the same position from where they had been removed up to the tightening torque indicated below. Screws M8 20 ÷ 28 Nm Screws M10 42 ÷ 52 Nm

FO

R

NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

PR

Reconnect stroke sensor (3) of the high pressure pump.

Figure 37

O T

88572

N

Disassemble seal ring (2) from the front cap (1), clean the coupling surface accurately.

Figure 40

88570

Apply tool 380000664 part (6) to the rear output shaft tang (5), secure it by screws (4) and fit the new sealing ring (3). Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into housing.

88573

Accurately clean the contact surface on the engine block and position seal (1) on the base. x

NEF ENGINES


Figure 41

57

Figure 44

88574

Assemble oil pump (1) on the block and tighten the screws up to the prescribed torque. Figure 42

88307

Fit the new sheath on the basement. Assemble the oil pan (1). Fit the screws (2) and tighten them to the prescribed pair. Tighten the exhaust caps to the prescribed pair.

IN T

NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. CNH

R

PR

PARTS

FO

88575

N

Figure 43

Figure 45

O T

Apply tool 380000666 part (4) to the front output shaft tang (6), secure it by screws (5) and fit the new sealing ring (7). Position part (2) on part (4), screw nut (3) until completing sealing ring (7) fitting into front cover (1).

88581

116376

Adjust the pulley (3), and the silencer (1) on the engine shaft. Tighten screws (1) up to torque 68 ± 7 Nm. Assemble a new seal ring on the revolution sensor. Assemble the revolution sensor in the front cap and tighten the fixing screws up to the prescribed torque.

Check the contact surface (1) of the clutch plate and if it is scratched, proceed with turning. Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.

58


NEF ENGINES

Figure 46

Figure 49 CNH PARTS

88582

Screw two manoeuvring hooks or lunettes on flywheel (1) using holes (4). With the help of a hoist bring the flywheel closer to its seat inside the flywheel housing box. Screw two pins (2) with proper length for shaft holes (3) and use them as guides, assemble engine flywheel (1) by arranging it properly in the flywheel housing box.

80359

Fit on the engine block: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter support (4). Tighten the screws (5) to the specified torque.


PR

IN T

Figure 47

FO

R

Figure 50

88583

α

CNH PARTS

N

Figure 48

O T

Screw engine flywheel (3) fixing screws (4) on the engine shaft. Put the tool in the proper hole (2) in order to block engine flywheel rotation.

88586

Lubricate the sealing ring (2) with engine oil and set it on the oil filter (3).

88584

x

Screw manually to seat the oil filter (3) on the support connection (1) and then screw again the oil filter (3) by ¾ turn.

Tighten engine flywheel (1) fastening screws (2).

Apply a new sealing ring on the oil temperature/pressure sensor (4) and fit it on the support (1).

NOTE Tightening to angle is performed using tool 380000304. Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

Tighten the screws (5) to the specified torque. Fit a new sealing ring (6) in the engine block seat.

NEF ENGINES


Figure 51

59

Figure 53

88590 88587

Assemble pipeline union (1) and tighten screws (2) up to the prescribed torque.

PR

IN T


Refit the high pressure pump (2) including the feed pump (3) and tighten the nuts (1) to the specified torque.

N

Figure 52

O T

FO

R

Figure 54

CNH PARTS

116378

116374

Apply a new gasket to the engine block and then place the cylinder head (2) slung by the hanger brackets (1).

Re-attach the ventilator support (1) fastening the screws to the prescribed torque. Re-attach the support (6) tightening the fastening screws to the cylinder head. Re-attach the belt tightener (7) and the drawback pulleys (3 and 5). Re-assemble the belt tightener (2).

60


NEF ENGINES

Figure 57

Figure 55

CNH PARTS

α 70338

70336

Fit a new sealing ring (2) lubricated with petroleum jelly and a new sealing washer (3) on injector (1).

Assemble cylinder head (1), tighten the screws (2) in three following steps, following order and mode shown in the figure below.

Figure 58

PR

D1

R

D2

IN T

NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.

FO

75703

70339

Fit injectors (1) on the cylinder head seats, directed so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side.

Figure 59

N

Figure 56

O T

NOTE The angle tightening is carried out through tool 380000304 (3).

α

A 6-cylinder engine 70476

Tightening order layout for cylinder head fastening screws: - 1st step pre-tightening with dynamometric wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm A • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm - 2nd step tightening with a 90° ± 5° angle

x

70133

- 3rd step tightening with a 90° ± 5° angle

Use tool 380001099 (1) to fit the injector (2) into its seat.

A = Front side

Screw injector fastening screws without tightening them.

NEF ENGINES


Figure 60

61

Figure 62

CNH PARTS

70343

ROCKER ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.

70341

PR

NOTE Disassembled fuel manifolds (2) must not be used again, but however replaced with other new ones.

Figure 63

IN T

Fit a new sealing ring (3) lubricated with vaseline on the fuel manifold (2) and fit it into the cylinder head seat so that the positioning ball (5) is coinciding with the relevant housing (4).

Screw the fastening nuts (2, Figure 61) without locking them.

SHAFT-ROCKER MAIN DATA Check that shaft/rocker coupling surfaces are not showing excessive wear or damages. Figure 64

N

Figure 61

O T

FO

R

NOTE During this operation, the injector (1) shall be moved so that the manifold (2, Figure 58) is properly inserted into the fuel inlet hole (2, Figure 60).

CNH PARTS

70342

Use the torque wrench to tighten gradually and alternately the injector fastening screws (1) to 8.5 ± 0.8 Nm torque. Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm torque. Carry out the assembly of the equalisers’ unit , after previous check of the components.

32655

Rocker control rods shall not be distorted; the ball seats in touch with the rocker adjusting screw and with tappets (arrows) shall not show seizing or wear; otherwise replace them. Intake and exhaust valve control rods are identical and are therefore interchangeable.

62


NEF ENGINES

Figure 65

Figure 67

70520 70345

Fit the rods (2). Position jumpers (1) on valves with marks (→) facing the exhaust manifold.

Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.

IN T

Figure 66

O T

FO

R

PR


70346

N

Check that tappet adjusters (1) are loose to prevent their balking on the rods (2, Figure 65) when refitting the rocker assembly. Then refit the rocker assembly consisting of: bracket (5), rockers (3), shafts (4) and secure them to the cylinder head by tightening the fastening screws (2) to 36 Nm torque.

x

NEF ENGINES


Figure 68

63

Figure 70

116371

116379

IN T

Fit the wiring support (2) and tighten the screws (1) to the specified torque. NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.

PR

Apply to the coupling surface of the intake manifold (1) equipped with heater a sufficient coat of LOCTITE 5999 and provide tightening the screws (2) to the prescribed matching couple. Fit temperature and air pressure sensor.

FO

R

Connect the electric cables to the electro-injectors (3) and with dynamometric wrench 380000158, fasten fixing nuts to the prescribed (4) torque.

CNH PARTS

O T

Figure 71 CNH PARTS

N

Figure 69

70352 70355

Check electrical cable (5) conditions, replace if damaged by cutting the support (2) clamps and removing the screws (5) that secure it to connections (3). Fit a new gasket (1) on the support (2).

Fit a new gasket (2) on the tappet cover (1). Place the tappet cover on, install the bolts in the correct position and tighten.

64


NEF ENGINES

Figure 72

Figure 74

CNH PARTS

CNH PARTS

116370 116380

Sling the turbocharger (4) and place it over the manifold after having first inserted a new gasket, tighten the fastening screws (3) to the specified torque.

IN T

Assemble the rail (2) and fasten the fixing screws (1) to the prescribed torque. Connect new fuel pipes (6) to the rail (2) and to the manifold for electro-injectors (5).

Reconnect the exhaust manifold (2) with new gaskets. Tighten the fastening screws (1) to the specified torque.

FO

R

Connect the fuel pipe (4) to the rail based on the procedure described in the following illustration.

PR

NOTE The pipe joints (3) must be fastened to the 20 Nm torque.

Figure 75

N

O T

Figure 73

70126

Press the clamp (1) in arrow direction (Figure B) and connect the pipe to the rail, reset the clamp to the initial locking position “A”. 116366

NOTE Check proper fuel pipe connection.

x

Connect the oil discharge pipe (2) to the turbo-compressor junction (1) and to the support of the oil filter heat exchanger. Assemble the support (3) and fasten with the screws (4).

NEF ENGINES


Figure 76

65

Figure 78

116381

Completion of the engine

Assemble the bracket and the support (1) of the fuel filter (6). Proceed connecting in sequence the pipelines (9,3,4 and 5) of the support (1) to the high pressure pump (8). Connect the pipeline (7) from the high pressure pump to the rail diffuser.

PR

Properly handle the engine holding it by a lifter, remove it from the rotating shaft, remove the brackets 380000661 and place it on proper suitable support to carry out the completion.

116364

IN T

Connect the piping (2) to the fuel return pressure limiting device (1). Connect the external vent pipe (3) to the head cover and to the crankcase.

Figure 77

N

O T

FO

R

Figure 79

70126

All the fuel pipelines are fixed using the clamps shown in the picture. For the connection of the pipes, press the clamp (I) following the arrow’s direction (Figure B) and connect the pipe to the clamp on the high pressure pump or on the support of the fuel filter. Reset the clamp in the initial locking ”A” position.

116365

Assemble oil filling pipe (1). Screw fixing screws and assemble starting motor (2) in place.

NOTE In case the pipes are re-employed, they must keep the sealing tops at the edges. Make sure that the fuel pipeline is correctly connected. Reconnect the engine harness to all the sensors, the engine control module and the rail diffuser.


NEF ENGINES

N

O T

FO

R

PR

IN T

66

x

NEF ENGINES

PR

IN T


PART TWO -

N

O T

FO

R

ELECTRICAL EQUIPMENT - MECHANICALS ENGINES

67


NEF ENGINES

N

O T

FO

R

PR

IN T

68

x

NEF ENGINES

69


ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES WITH ROTARY PUMP) Figure 80

A

N

O T

FO

R

PR

IN T

B

Below there are listed the electric components which are present on F4GE94--- engines. 1.

Cooling liquid temperature sensor;

2.

Starter;

3.

KSB Water temperature sensor;

4.

Electromagnets assembled to feed pump: (A) on hydraulic head unit (B) on KSB;

5.

Oil pressure sensor;

6.

Resistance for cold start up (where provided for);

7.

Alternator;

116392

70


NEF ENGINES

Cooling liquid temperature sensor

Starter

Figure 81

Figure 82

1 75717

Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch assembled to the starter itself.

A

B

Specifications:

B

BOSCH 3 kW - 12V

C

PR

A

IN T

C

KSB Water temperature sensor 75718

It is a component integrating a temperature sensor.

R

Figure 83

FO

It is assembled to the engine head close to the thermostat unit and its duty is to detect engine cooling liquid temperature. Specifications: Range of working temperatures:

-40 ÷ +150 ºC for < 10 min.

Bulb side on engine:

-40 ÷ +140 ºC

Working tensions:

6 ÷ 28 V

N

Settings:

O T

Connection side

80 ºC

0.304 ÷ 0.342 kΩ

20 ºC

2.262 ÷ 2.760 kΩ

-10 ºC

8.244 ÷ 10.661 kΩ

75719

It is assembled to the cylinder head on the engine left hand side. Specifications: Working tensions:12 ÷ 24 V

x

Electrical Power load:

2.5 A (induction) 5.0 A (resistance)

Setting:

63±3 ºC Contact opening upon increasing temperature 53±3 ºC Contact closure upon decreasing temperature

NEF ENGINES


Electromagnets assembled to feed pump

71

Alternator

Figure 84

Figure 86

1 75725

It is place front view on the right hand side of the engine, and is driven by tooth belt.

2

Specifications:

75724a

12 V

Current delivered:

90A (at 6000 rpm)

IN T

1 - Hydraulic head Electro-magnet; 2 - KSB Electro-magnet

Working tension:

≤ 1mA

Sense of rotation:

clockwices

PR

Oil pressure switch

Absorption in stand-by:

Pre-post heating resistor

Figure 85

N

O T

FO

R

Figure 87

75723 75722

It is assembled to the block on the engine’s left hand side.

It is a resistor assembled to the suction collector and is utilised to heat the air during pre-post heating operations.

Specifications:

It is fed by a tele-switch usually placed very close to the engine. 12 ÷ 24 V

Specifications:

Contact closure upon lower pressure:

0.2 bar

Contact opening upon higher pressure:

Working tension: Maximum possible air flow:

0.9 bar

Working tensions:

12 V 2 cc / min (pressure 138 kPa)


NEF ENGINES

N

O T

FO

R

PR

IN T

72

x

NEF ENGINES

PR

IN T


PART TWO -

N

O T

FO

R

ELECTRICAL EQUIPMENT - ELECTRONICS ENGINES

73


NEF ENGINES

N

O T

FO

R

PR

IN T

74

x

NEF ENGINES

75


LOCATION OF MAIN ELECTRICAL COMPONENTS

N

O T

FO

R

PR

IN T

Figure 88

116382

The and F4DE9684 engines are fully driven by the electronic engine control module.

The electrical and electronic components of the engine are listed here following:

Through the engine control module it is possible to verify the correct working of the engine. (See part three of the hereby user’s guide specifically dedicated to diagnostic).

1.

Temperature sensor of cooling liquid;

2.

Electro-injector;

3.

Starter;

4.

Pressure sensor assembled to rail diffuser;

5.

Temperature and air pressure sensor;

6.

Timing system sensor;

7.

Fuel temperature sensor;

8.

EDC7 electronic module (not positioned on engine);

9.

Driving shaft sensor;

10. Sensor of engine’s oil temperature and pressure; 11. Pre-post heating resistor.

76


NEF ENGINES

EDC7 ECU

N

O T

FO

R

PR

IN T

Figure 89

01525t

A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled); C - Connector to sensors.

x

NEF ENGINES


Connector to injectors (A) Figure 90 16

12

6

11

5

1

Colour legend C A B L G H M N W S R V Z

CN

ORANGE SKY BLUE WHITE BLUE YELLOW GREY BROWN BLACK LIGHT BROWN PINK RED GREEN PURPLE

CB CL

IN T

FUNCTION

PR

Injector cylinder 2 (**) Injector cylinder 3 (**) / Injector cylinder 4 (*) Injector cylinder 4 (**) Injector cylinder 2 (**) Earth Injector cylinder Injector cylinder 1 (*) / (**) Injector cylinder 6 (**) / Injector cylinder 2 (*) Injector cylinder 5 (**) / Injector cylinder 3 (*) Injector cylinder 3 (**) / Injector cylinder 4 (*) Injector cylinder 1 (*) / (**) Injector cylinder 4 (**) Injector cylinder 6 (**) / Injector cylinder 2 (*) Injector cylinder 5 (**) / Injector cylinder 3 (*)

R

O T

MN MV VB HR MB VN VG HN HG

N

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

CABLE COLOUR

FO

PIN ECU

50350

(*) Only for 4 cyl. versions (**) Only for 6 cyl. versions

77

78


NEF ENGINES

Feed connector (B) to components and to functions of the specific equipment Figure 91

72 54 6

89

71

11

53

7 35

x

18

36

CABLE COLOUR

IN T

0000 8150 0000 0094 0150 8153 0156 5535 2298 8837 8888 8051 9905 9906 5553 5584 0158 6109 6108 5158 0160 5503 0535 0159 0159 8162 0157 5157 -

PR

9 12/13 14/15 16 19 20 27 28 31 32 36 37 39 44 45 46 49 50 52 53 55 62 63 64 72 73 78 81 83 87

Negative for switch of fuel filter heater/starter Earth Positive for pre-post heating resistor Positive driven by battery Positive for blink-code button/ oil low pressure led/ pre-heating led/ Air conditioner switch (if available) / EDC Earth Positive driven by battery Earth Negative for post-heating resistor Negative start-stop push buttons from eng./accelerator pressed Positive from change over switch to key in starting phase (+50) Positive from blink-code button Positive for EDC diagnostic led K Line for diagnosis connector, 30 poles (2 pin) Negative for multi-switch couple-limiter Positive for fuel filter heating switch Positive for starter Positive from key switch/ L line for diagnosis connector 30 poles (pin 11) Negative from starter push button from engine Negative from engine stop push button from engine Negative for pre-heating led in on position Diagnosis connector (pin 28) Negative from accelerator push button pressed CAN Line (whether equipped), diagnosis connector (pin 22) CAN Line (whether equipped), diagnosis connector (pin 22) Positive for sensor of foot accelerator pedal pos. / Earth multi-switch Negative for clutch sensor Negative for engine oil low pressure led Negative for EDC diagnosis led Positive from pressed accelerator push button / multi-switch signal Positive redundant from pressed accelerator push button Positive air conditioner device (whether equipped) Negative sensor of foot accelerator pedal pos. / Earth multi-switch Signal from sensor of foot accelerator pedal pos. / Signal multi-switch

R

8150 0087 0000 8885/0159 8150 7777

N

03210t

FUNCTION

O T

1 2 3 4 7 8

12

17

FO

PIN ECU

1

Positive for couple multi-switch limiter

NEF ENGINES


Connector to sensors (C) Figure 92

Colour legend 6

8

16

9

15

5

22

4

29

1

CABLE COLOUR

5 7 9 10 12 17 18 19 20 21 23 24 25 27 28 29 30 33 34 35 36

C V MN CR HN BL CV GV BZ GN R B R RV LN BH B GR CN NS BG

03211t

FUNCTION

Earth for pressure regulator Pressure regulating drive Feed for engine oil temperature/pressure sensor Feed for air pressure and temperature sensor Feed for rail pressure sensor Earth for fuel temperature sensor Earth for cooling liquid temperature sensor Earth for engine oil temperature pressure Feed for rail pressure sensor Feed for air pressure - temperature sensor Timing system sensor Driving shaft sensor Driving shaft sensor Signal from rail pressure sensor Signal from air pressure sensor Signal from air temperature sensor Earth for timing system sensor Signal from engine oil temperature sensor Signal from fuel temperature sensor Signal from engine oil pressure Signal from cooling oil temperature

R

FO

O T N

36

30

PR

PIN ECU

23

IN T

3

C A B L G H M N W S R V Z

ORANGE SKY BLUE WHITE BLUE YELLOW GREY BROWN BLACK LIGHT BROWN PINK RED GREEN PURPLE

79

80


NEF ENGINES

Temperature and air-pressure sensor

Driving shaft sensor

Figure 93

Figure 94

50319

3 2 1

50342

It is an inductive type sensor and it is placed on the front part of the engine.

It is assembled to the suction inlet manifold and measures the maximum capacity of air introduced, in order to provide to the engine control module the necessary data to calculate the quantity of fuel to be injected per each cycle.

It is connected to the engine control module by pin 25C (signal) and 24C (signal). The third pin is for screening. The resistance value of the sensor is of about 900 Ω.

R

It is connected to the engine control module by 21C and 29C pin (temperature), 10C and 28C (pressure) and has a 5 volt feeding.

IN T

It is a component integrating one temperature sensor and a pressure one.

PR

88438

It generates some signals originated by the magnetic flow lines that close up through the openings of a phonic wheel splined to the driving shaft. The same signal is utilised to control the eventual electronic engine speed indicator placed on the vehicle instrument board.

FO

21C Earth 29C NTC signal (temperature) 10C +5V feed

Figure 95

50320

3 2 1

N

O T

28C Signal (pressure)

Timing system sensor

Sensor of engine’s oil temperature and pressure It is a component integrating one temperature sensor and a pressure one. It is assembled on the engine oil filter support. It measures the temperature and the pressure of the engine’s oil. It is connected to the engine control module by 19C and 33C, 9C and 35C. 19C Earth 33C NTC signal (temperature) 9C

+5V feed

35C Signal (pressure)

50342

It is an inductive type sensor and it is placed on the back left part of the engine. It generates some signals originated by the magnetic flow lines that close up through the ports drilled on the gear splined to the camshaft. The signal generated by this sensor is utilised by the electronic engine control module as signal of injection phase. Even being equal to the flywheel sensor it is not interchangeable since the external shape is different. It is connected to the engine control module by pin 23C (signal) and 30C (signal). The third pin is for screening. The resistance value of the sensor is of about 900 Ω.

x

NEF ENGINES


Fuel pressure sensor

81

Resistor pre-post heating

Figure 96

Figure 98

116384 116383

It is a resistor placed on the suction inlet manifold and is utilised to heat the air during the heating pre-post operations.

1 - Earth; 2- Signal; 3- Feed.

PR

The value of the injection pressure is utilised to control the pressure itself and to determine the duration of the electronic injection device.

IN T

It is fed by a tele-switch usually placed very close to the engine. It is a sensor assembled to one end of the rail and measures the pressure of the fuel available in order to determine the injection pressure.

R

It is connected to the engine control module by pin 20C (Earth), 27C (signal) and 12C (feed).

Usually, the same signal is driven by the engine control module to the temperature device placed within the vehicle’s dashboard. It is connected to the engine control module by pin 18C (Earth) and 36C (temperature signal).

N

Figure 97

The resistor to 20 ºC = 2,5 kΩ.

88440

1 - Fuel temperature sensor It is a sensor with variable resistor, able to detect the fuel temperature to provide to the engine control module an index of the fuel thermal status. It is connected to the engine control module by pin 17C (Earth) and 34C (temperature signal). The resistor to 20 ºC = 2,5 kΩ.

Cooling liquid temperature sensor It is a sensor with variable resistor, able to detect the cooling liquid temperature to provide to the engine control module an index of the engine thermal status.

O T

Fuel temperature sensor

FO

It has 5 volt feeding.

82


NEF ENGINES

Starter

Figure 99

The starter is usually driven by the starting block assembled to the vehicle’s dashboard and provides positive voltage to pin B20 of the EDC.

Electro-injectors This is a N.A. type solenoid valves They are individually connected to the EDC gearcase on connector A. The resistance of each injector coil is 0.56 ÷ 0.57 Ω.

88314

1. Feeding relay of the starter

6 cylinder engines REFERENCE

CONNECTOR 2

1 2 3 4

Injector cylinder 4 Injector cylinder 4 Injector cylinder 3 Injector cylinder 3

1 2 3 4


FO

3A 6A 13 A 9A 5A 14 A 12 A 4A 10 A 15 A 16 A 11 A

N

Figure 100

O T

CONNECTOR 3

IN T


R

CONNECTOR 1

1 2 3 4

PIN EDC

PR

REFERENCE

50343

50349

x

NEF ENGINES

PR

IN T


PART THREE - TROUBLESHOOTING

N

O T

FO

R

(MECHANICALS ENGINES)

83


NEF ENGINES

N

O T

FO

R

PR

IN T

84

x

The engine does not start

ANOMALY Check and recharge battery. Replace battery if necessary.

RECOMMENDED TESTS OR INTERVENTION

Refuel.

Overhaul or replace the fuel or transfer pump.

Drain feed system.

No power supply.

Faulty starter motor.

IN T

Repair or replace the starter motor.

PR

Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in pump. fact present and also check the fuel pump. Eliminate the air from the injection pump by unscrewing the cap and working the fuel pump by hand.

R

FO

Disconnect the hoses and clean them Drain feed system. using a jet of compressed air. Dismantle and clean the injection pump. Remove water from tank and refuel.

Deposits or water in the fuel tank.

O T Check and correctly time the injection See your CNH dealer. pump.

NOTE

Incorrect timing of injection pump.

N

Connections to battery terminals cor- Clean, examine and tighten the nuts on roded or loose. the battery terminals. Replace the cable terminals and the nuts if excessively corroded.

Battery flat or faulty.

POSSIBLE CAUSE (*) = if available in the equipment

NEF ENGINES SECTION 3 - INDUSTRIAL APPLICATION

85

x



The engine cuts out.

N

O T

FO

Dismantle and replace if necessary.

PR

Replace the faulty parts.

R

Burnt, corroded or chalky valves.

Replace the valves, rectify or replace the cylinder head seatings.

IN T

Abnormal clearance between camshaft Adjust clearance by replacing shims. cams and tappets.

Broken injection pump controls.

See your CNH dealer.


NOTE

Disconnect the hoses and clean them Drain feed system. using a jet of compressed air. Dismantle and clean the injection pump. Remove water from fuel tank and refuel.

Adjust flow.

Adjust with adjustment screw.

Presence of air in the fuel and injection Check that the hoses are not cracked or system. the unions loose. Replace worn parts, remove the air from the hoses and deaerate the injection pump and fuel filter by unscrewing the caps and working the primer pump by hand.

Clogged fuel filter.

Impurities or water in the fuel lines.

Irregular flow of injection pump.

Idle rpm too low.

K.S.B. device for cold spark advance con- Check or replace the injection pump. trol operating incorrectly.

The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use peratures forming due to the use of unsuitable fuel. at low temperatures. Replace the fuel filters.

ANOMALY

86 SECTION 3 - INDUSTRIAL APPLICATION NEF ENGINES

Engine operation is irregular and lacks power

The engine overheats

ANOMALY

Replace the thermostat.

Malfunctioning thermostat.

Check or replace injection pump.

Check and correctly calibrate the regula- See your CNH dealer. tor.

Excessive piston wear.

Incorrect calibration of speed regulator.

K.S.B. automatic cold advance device mal- Check or replace injection pump. functioning.

IN T

PR

Check the performance on an injection See your CNH dealer. pump test bench. In case the values measured do not correspond to the prescribed ones, replace the changer spring.

Faulty automatic advance changer.

R

Check timing and correctly set pump.

Clean the air filter or replace if necessary.

Dry air cleaner blocked.

Incorrect timing of injection pump.

Correct the delivery rate of the pump on See your CNH dealer. a bench so that the injection is at the specified rate.

FO

Check timing and tune correctly.

Top-up radiator with coolant.

Check and adjust the tightness of the belt. On applications provided with automatic tensioner, check corret worching of such device.

NOTE

Incorrect calibration of injection pump.

Incorrect engine timing.

Coolant level too low.

O T

Water pump drive belt slack.

N

Fouling in coolant openings in the cylinder Wash following the standards specified head and cylinder groups. for the type of descaling product used.

Check the unit and replace if necessary. Replace the gasket.


Faulty water pump.



87

x

Engine running with abnormal knocking

Engine operation is irregular and lacks power

ANOMALY


O T R

FO

If necessary drain feed system.

NOTE

Check that the diaphragm is not perfor- See your CNH dealer. ated, that the counter spring is suitable and that it has the correct loading (check on test bench). Check that there is adequate air pressure inside the intake manifold in relation to the engine rpm under full-load conditions.

Clean or replace air cleaner.

Replace complete unit.

Dismantle the hoses, clean them and replace those that are seriously dented. Correct the set-up of the pump so that in- See your CNH dealer. jection occurs at the specified angle.

Fuel lines blocked.

Incorrect set-up of injection pump.

IN T

Replace all injectors.

Faulty operation of injectors.

PR

Tie rods between accelerator pedal and Adjust the tie-rods so that the command regulation lever incorrectly adjusted. lever can be moved to the full delivery position.

Faulty operation of L.D.A. device

Air cleaner blocked.

Faulty turbocharger.

N

Incorrect play between camshaft cams Check and correct play and tappets.

Impurities or water in the fuel and injec- Carefully clean the system and refuel. tion system.

Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using ation of injectors. the appropriate tools and completely overhaul the injectors.




Replace the rods.

Misalignment of rods.

Noisy timing.

PR

NOTE

There is an excessive delay on the injec- Correct the set-up. tion pump.

K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust tioning. correctly as described in the manual.

IN T

Disconnect the pump and adjust delivery See your CNH dealer. in accordance with the data given in the calibration table.

R

Adjust the play between camshaft cams and tappets and check that there are no broken springs, that there is no excessive play between the valve stems and the valve guides, tappets and seatings.

FO

Noise from piston journals due to excess- Replace the piston journal and/or the pisive play of piston hubs and in the rod ton and rod bushing. bushing. Loose bushings in the rod seatings. Replace with new bushings.

O T

Replace the loosened screws and tighten all the screws to the specified torque.

Loosening of screws securing flywheel.

N

Check alignment of crankshaft.

Crankshaft unbalanced.

Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and inplay on one or more main or rod bearings stall smaller bearings. Replace the thrust or excessive play on shoulders. half-rings.


The engine smokes abnormally. Black or Excessive maximum pump output. dark grey smoke.

Engine running with abnormal knocking

ANOMALY


89

x



O T

Clean or replace the filter element.

Engine too cold (thermostat blocked or Replace the thermostat. inefficient).

Engine oil passing through the intake Recondition the cylinder head. guides-valves following wearing of guides or valve stems.

IN T

PR

Replace the injector.

Leaking of oil from the piston rings caused Overhaul the engine. by glued or worn rings or wearing of cylinder liner walls.

Faulty injector.


K.S.B. automatic cold advance device mal- Check or replace injection pump. functioning.

R


NOTE

Correct the set-up of the pump.

Blue, grey-blue, grey smoke tending to Excessive delay in injection pump. white.

Injection hoses with an unsuitable internal Check conditions of the end or unions diameter, end of hoses pinched due to re- and where necessary replace the hoses. peated blocking.

FO

Unsuitable injectors, different types of in- Replace or calibrate the injectors. jectors or incorrectly calibrated.

Loss of compression in the engine due to: Overhaul the engine or limit the intervenstuck or worn flexible rings; tions to the relative parts. worn cylinder liners; valves deteriorated or badly adjusted.

N

Air cleaner blocked or deteriorated.

The holes in the atomisers (or some of Replace the injectors with a series of new them) are partially or entirely blocked. injectors or clean and rectify the original ones using suitable equipment.

The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up. dark grey smoke. vance.

ANOMALY


NEF ENGINES

PR

IN T


PART THREE - TROUBLESHOOTING

N

O T

FO

R

(ELECTRONICS ENGINES)

91


NEF ENGINES

N

O T

FO

R

PR

IN T

92

x

NEF ENGINES


93

CNH -- EST DIAGNOSTIC TOOL

FO

R

PR

IN T

Figure 1

88201

O T

The EST system allows carrying out diagnoses onmainmachine assemblies by detecting the operating parameters of electronic control components (control units, sensors etc.) and the check of flow--rates, pressures and temperatures; it is further arranged for searching inconveniences and detect data for electronically--controlled CNH engines.

N

Code

Description

Language

380060157

Italian

380060158

French

380060159

English

380060160 380060161

CE EST diagnostic kit

German Spanish

380060162

Holland

380060163

Danish

380060164

Portuguese

94


NEF ENGINES

FAULT CODES Failure code

Failure description Vehicle 1 ((Sensors / Consistency tests)

1.1.2

ACCELERATOR PEDAL

1.1.9

PLAUSIBILITY +15

1.1.A

PLAUSIBILITY +50 Vehicle 2 (Indicator lamps / Relais / Actuators) EDC LAMP

1.2.5

MAIN RELAY DEFECT

1.2.6

BATTERY VOLTAGE

1.2.8

MAIN RELAY - SHORT CIRCUIT TO BATTERY

1.2.9

AIR-CONDITIONER COMPRESSOR RELAY

1.2.B

THERMOSTARTER RELAY 1 (HEATER)

1.2.E

MANAGEMENT SYSTEM PRE/POST-HEATING (ACTIVE)

2.2.5

INTERRUPTED AFTER-RUN

2.2.8

MAIN RELAY - SHORT CIRCUIT TO GROUND

IN T

1.2.3

Engine 1 (Temperature and pressure sensors) COOLANT TEMPERATURE SENSOR

1.3.2

COOLANT TEMPERATURE SENSOR (TEST)

1.3.3

AIR TEMPERATURE SENSOR BOOST AIR

1.3.4

BOOST PRESSURE SENSOR

1.3.5

FUEL TEMPERATURE SENSOR

1.3.6

RAIL PRESSURE SENSOR OR SIGNAL ERROR

1.3.7

DBV VALVE MANAGEMENT (BOOST PRESSURE)

1.3.8

OIL PRESSURE SENSOR

1.3.A

OIL TEMPERATURE SENSOR

2.3.2

COOLANT TEMPERATURE SENSOR ABSOLUTE TEST

2.3.6

RAIL PRESSURE SENSOR OFFSET

2.3.8

OIL LOW PRESSURE

2.3.A

OIL TEMPERATURE ABOVE NORMAL

N

O T

FO

R

PR

1.3.1

Engine 2 (Speed sensors/actuators)

1.4.1

CRANKSHAFT SPEED

1.4.2

ENGINE WORKING ONLY WITH CAMSHAFT SENSOR

1.4.3

CAMSHAFT SENSOR

1.4.4

FAULT BETWEEN FLYWHEEL SENSOR AND CAMSHAFT Damage information

x

1.4.D

ENGINE OVERSPEED

1.5.B

HIGH PRESSURE TEST (DEACTIVATES RAIL PRESS.MONITORING)

1.9.D

INDICATES TORQUE LIMITATION DUE TO PERFORMANCE LIMITER

4.9.E

INDICATES THE TORQUE LIMITATION DUE TO ENGINE PROTECTION

6.9.E

INDICATES TORQUE LIMITATION DUE TO FUEL QUANTITY LIMITATION

NEF ENGINES


Failure code

Failure description Fuel metering

1.5.1

HIGH PRESSURE SYSTEM

1.5.2

FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (POSITIVE DEVIATION)

1.5.3

FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (NEGATIVE DEVIATION)

1.5.4

RAIL PRESSURE ERROR: TOO LOW

1.5.5

RAIL PRESSURE ERROR: TOO HIGH

1.5.6


1.5.7

ERROR ON THE RAIL PRESSURE (EXCESSIVE DUTY CYCLE)

1.5.8


1.5.9

PRESSURE MPROP REGULATOR ERROR

2.5.9

PRESSURE MPROP REGULATOR ERROR (SHORT CIRCUIT TO POSITIVE)

3.5.9

SHORT CIRCUIT TO GROUND OF METERING UNIT OUTPUT Injectors 1 INJECTOR CYLINDER 1 / SHORT CIRCUIT

1.6.2

INJECTOR CYLINDER 2 / SHORT CIRCUIT

1.6.3


1.6.4


1.6.5


1.6.6


1.6.7

INJECTOR CYLINDER 1 / OPEN CIRCUIT

1.6.8


1.6.9


1.6.A


1.6.B


1.6.C


1.6.E

THE MINIMUM NUMBER OF INJECTIONS WAS NOT REACHED: STOP THE ENGINE

O T

FO

R

PR

IN T

1.6.1

Injectors 2

BENCH 1 CC

1.7.3

BENCH 2 CC

1.7.C

BENCH 1 INJECTORS CHECK (INTERNAL ECU)

2.7.C

BENCH 2 INJECTORS CHECK (INTERNAL ECU)

N

1.7.1

Boosting system and turbine speed 1.9.E

TORQUE REDUCTION DUE TO SMOKE LIMITATION Interfaces 1 (CAN-Bus)

1.B.1

ERROR ON CAN CONTROLLER A

1.B.3

ERROR ON CAN CONTROLLER C

1.B.4

TIMEOUT CAN MESSAGE BC2EDC1

1.B.5

TIMEOUT CAN MESSAGE VM2EDC

1.B.D

TIMEOUT CAN MESSAGE CCVS

2.B.4

TIMEOUT CAN MESSAGE BC2EDC2 Interfaces 2 (CAN line timeout messages)

1.C.6

ERROR MESSAGE CAN TSC1-PE

95

96


NEF ENGINES

Failure code

Failure description

1.C.8

ERROR MESSAGE CAN TSC1-VE

1.C.9

ERROR MESSAGE CAN TF

2.C.6

TIMEOUT OF CAN MESSAGE TSC1-PE PASSIVE

3.C.8

TIMEOUT OF CAN MESSAGE TSC1-VE PASSIVE

1.D.1

ECU OVERRUN MONITORING ERROR

1.D.2


1.D.3


1.D.4


1.D.5


1.D.6

ECU INTERNAL ERROR (TPU)

1.D.7

INTERNAL ECU ERROR (VARIANT AREA)

1.D.8


1.D.9


2.D.3


3.D.3

ERRORE INTERNO CENTRALINA

IN T

ECU 1 (internal checks)

ECU 2 (Power supply / Immobilizer / Runaway / Sensor power supply) ECU: SHORT CIRCUIT OR OPEN CIRCUIT

1.E.3

ERROR FOR ECU INTERNAL MONITORING

1.E.4

ERROR FOR ECU INTERNAL MONITORING

1.E.5

SENSORS POWER SUPPLY FAULT (12V)

1.E.6

SENSOR POWER SUPPLY 1

1.E.7


1.E.8


1.E.9


1.E.A


1.E.B

ATMOSPHERIC PRESSURE SENSOR

2.E.1

SHORT CIRCUIT TO BATT OR GROUND, NO LOAD, EXCESS.TEMP. FOR LOW SIDE POWER STAGE

R FO

O T

N x

PR

1.E.1

O T

Replace the air filter.

FO

PR

Replace the fuel filter.

IN T

Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if valve. there are any significant blow-by from the boost gauge valve; in such case replace the valve.

R

Excessive fuel blow-by from rail boost Check the O Rings and the correct convalve. nection of the pipe fittings under the feeding pump (the lockers must stay outside and the fittings must be well locked). Visually check the low pressure pipeline integrity.

Obstructed air filter.

N

Check fuel level.


Fuel tank device partially obstructed by Check if the priming pump of the pre-filter impurities or deformed because of over- is working correctly. heating. If the pump plunger is permanently depressed disassemble and check the tank pick.-up tube. If this is in order, replace the pre-filter.

Insufficient fuel level in the tank.


The engine suddenly stops (with no previ- Obstructed fuel filter. ous problems) and does not start again.

Possible blink-code 8.1

Possible exessive smoke.

Low performance at load request.

ANOMALY

Solve the cause of the filter’s obstruction (empty and clean the tank and the part of the circuit over the filter, refill with clean fuel).

Unless the leakage is significant, no performance failures will be detected. To verify O-rings integrity, extract from the tank the fuel recycling pipeline, seal the end and activate the priming pump driving the low pressure circuit.

Solve the cause of the filter’s obstruction.

The excessive smoke is due to the fact that, in case of insufficient fuel feeding, the engine control module tries to compensate prolonging the injectors working time.

REMARKS


TROUBLESHOOTING 97

x

POSSIBLE CAUSE (*) = if available in the equipment REMARKS

IN T

PR

The engine works with one cylinder less, Injector blocked in closed position. without memorising failure blink codes in the engine control module.

Identify the injector that is not working The non-working injector is easily recogany more and the relating high pressure nisable detecting by feeling the absence of filler. pulsing within the relevant high pressure pipe.

Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the origscrews. inal position.

R

FO

Usually, whether such symptoms appear, it is instinctive to give up engine start. However, by insisting, it is possible to start the engine. As a matter of facts, by insisting, if within the rail the pressure makes the flow limiter close up, the engine starts with one cylinder less and gradually the grade of fumes reduces and disappears.

O T

Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recogfollowed by huge white exhaust fumes, no return). nisable detecting by feeling the absence of and a fuel smell. pulsing within the relevant high pressure pipe.

N

In case of low entity blow-by, inficiating the mechanical working of the injector but not involving flow limiter activation, there is no error memorisation in the engine control module. If the flow limiter is activated. Check error code memory.

After having excluded any other possible cause, replace the high pressure pump.

Eliminate the short circuit and replace the Verify that the wire line, close to the EDC. pedal, is not exposed to.


Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recoggine running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of pulsing within the relevant high pressure pipe.

Difficult start and low performance in all Inefficient high pressure pump. conditions.

EDC ”burned” by short circuit on the wiring harness of the friction clutch.

The engine disconnects or does not start. (*)

ANOMALY


NEF ENGINES

PR

IN T


N

O T

FO

R

PART FOUR - MAINTENANCE PLANNING

99


NEF ENGINES

N

O T

FO

R

PR

IN T

100

x

NEF ENGINES


101

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.

Planning of controls and periodical intervention

Frequency (hours)

IN T

Controls and periodical intervention

Daily

Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily -

Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4000 500

Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000 500

Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1500

N

O T

FO

R

PR

Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

102


NEF ENGINES

Checks not included in maintenance planning-daily checks 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) - Visual check of cooling liquid level, in the expansion tank.

R

The check can be made using the specially provided flexible rod (1).

1

PR

Engine oil level check The check must be executed when the engine is disconnected and possibly cool.

IN T

Figure 3

MAINTENANCE PROCEDURES Checks and controls

FO

Figure 2

N

O T

MAX

1

MIN

75749

75748

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. In order to guarantee a perfect performance, the following pages contain the checks, surveys and adjustments which need to be made on all the various vehicle elements according to scheduled deadlines. x

2

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”. Some applications are equipped with a level transmitter alerting dashboard instruments in case of insufficient lubrication oil within the pan. 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.

NEF ENGINES


Check of fuel system The check must be executed both when the engine disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the injection pump and to the injectors.

103

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.

Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips. 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.

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.

IN T

Cooling system check The check must be executed both when the engine disconnected and when it is running.

Check of water presence within fuel filter or pre-filter

NOTE The components of the system can be damaged very quickly in presence of water or impurity within the fuel.

R

PR

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.

FO

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.

O T

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

N

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.

Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.

Fuel filter is equipped with pump screw-valve to drain the water eventually mixed with fuel (some applications of 6 cylinders engines will be equipped with two fuel filters, both provided with drainage. Place a container underneath the filter and slightly loosen the screw. Drain the water eventually contained in the filter’s bottom. Lock the screw (max 0.5 Nm locking couple) as soon as fuel starts bleeding.

104


NEF ENGINES

Oil motor and filter replacement

Check of drive belt tensioning Some applications are equipped with an automatic tensioner that provides correcting belt tensioning.

Warning: We recommend to wear proper protections because of high motor service temperature.

Check of belt’s tear and wear status

The motor oil reaches very high temperature: you must always wear protection gloves.

Carefully verify the belt’s surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing; check end and surface grinding. Danger: if the engine is switched off but is still hot, unexpected motion of the belt may occur. Wait for engine temperature cooling as a precaution in order to avoid serious danger injury.

Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications. We recommend to carry out the oil drainage when the motor is hot. - Place a proper container for the oil collecting under the pan connected with the drain plug. - Unscrew the plug and then take out the control dipsick and the inserting plug to ease the downflow of the lubrication oil.

IN T

Check and setting of tappet clearance Figure 4

1

The oil motor is very pollutant and harmful.

3

In case of contact with the skin, wash with much water and detergent.

PR

2

Protect properly skin and eyes: operate according to safety rules.

FO

R

Dispose of the residual properly following the rules.

O T

75806

N

Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Working clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.51 ± 0.05 mm.


x

- After the complete drainage, screw the plug and carry out the clean oil filling.

!

Use only the recommended oil or oil having the requested features for the corrrect motor functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with theses rules, the service warranty is no more valid.

- Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dipsick.

NEF ENGINES


Whereas you replace the lubrication oil, it is necessary to replace the filter.

Fuel filter replacement

According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.

During this operation don’t smoke and don’t use free flames. Avoid to breathe the vapors coming from filter.

- The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the 380000670-tool.

Warning: the oil filter contains inside a quantity of oil of about 1 kg.

105

!

After filters replacement the supply equipment deaeration must be carried out.

Place properly a container for the liquid. Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water. The motor oil is very pollutant: it must be disposed of according to the rules.

According to the applications the filters position and the quantity can change. However the following operations are valid for all applications.

- Unscrew the cartridge by using the 380000670-tool. - Collect the eventual fuel inside the filtering cartridge.

PR

- Replace the filtering cartidge with a new one and screw manually until when the gasket is in contact with the support.

IN T

- Drain the fuel inside the filter by operating the water release screw. Collect the fuel in a container without impurities.

- Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.

- Operate the motor for some minutes and check the level through the dipsick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

- Screw manually the new filtering cartdrige until when the gasket is completely on its seat.

N

O T

FO

R

- Tigthen by means of the 380000670-tool of three fourth turn.

- Tigthen through the 380000670-tool at 10-5 Nm torque.

106


NEF ENGINES

Alternator belt replacement Due to several applications the belt run can change very much. We describe the replacement of a belt mounted on a 4-cylinders motor with traditional belt tension.

Warning: with switched off motor (but still hot) the belt can operate without advance notice. Wait for the motor temperature lowering to avoid very serious accidents.


IN T

Figure 5

CNH

R

PR

PARTS

FO

88089

- Loosen screw (1) and the relevant nut on belt stretching bracket (3).

O T

- Loosen the bolt that fixes the alternator to the support. - Fit the new belt on the pulleys and guide rollers. - Stretch POLY-V belt (2).

N

- Lock screw (1) and the bolt that fixes the alternator to the support - Run the engine for a few hours and check proper belt stretching.

x

NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

1

SECTION 4 Overhaul and technical specifications Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

5

CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .

6 12

MECHANICALS ENGINES OVERHAUL . . . . . .

13

ENGINE REMOVAL AT THE BENCH . . . . . . . .

13

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .

14

CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . .

14

IN T

TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS . . . . . . . . . . . . . . . . . . . .

- Checks and measurements . . . . . . . . . . . . . . .

14

N

O T

FO

R

PR

- Checking head supporting surface on cylinder unit 15 TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

16

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

- Checking cam lift and pin alignment . . . . . . . .

171

BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

- Bush replacement . . . . . . . . . . . . . . . . . . . . . .

18

- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

- Fitting tappets — camshaft . . . . . . . . . . . . . . . .

18

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .

19

- Measuring journals and crankpins (4 cylinders)

19

- Replacing oil pump control gear . . . . . . . . . . .

21

- Fitting main bearings . . . . . . . . . . . . . . . . . . . .

21

- Finding journal clearance . . . . . . . . . . . . . . . . .

21

- Checking output shaft shoulder clearance . . .

22

CONNECTING ROD — PISTON ASSEMBLY . .

22

2


NEF ENGINES

Page

Page

23

- Measuring piston diameter . . . . . . . . . . . . . . . .

23

- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

- Conditions for proper pin-piston coupling . . . .

24

FITTING CYLINDER HEAD . . . . . . . . . . . . . . . .

33

- Refitting the cylinder head . . . . . . . . . . . . . . . .

34

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .

35

ELECTRONICS ENGINES OVERHAUL . . . . . . .

37

ENGINE REMOVAL AT THE BENCH . . . . . . . .

37

REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .

38

CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . .

38

- Checks and measurements . . . . . . . . . . . . . . .

38

24

- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .

25

- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Fitting connecting rod-piston assembly . . . . . .

26

- Checking head supporting surface on cylinder unit 39

- Connecting rod-piston coupling . . . . . . . . . . . .

26

TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .

26

- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

- Checking cam lift and pin alignment . . . . . . . . .

41

BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

- Bush replacement . . . . . . . . . . . . . . . . . . . . . .

42

- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

- Fitting tappets — camshaft . . . . . . . . . . . . . . . .

43

OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .

44

- Measuring journals and crankpins (4 cylinders)

46

- Replacing oil pump control gear . . . . . . . . . . .

48

- Fitting main bearings . . . . . . . . . . . . . . . . . . . .

48

- Finding journal clearance . . . . . . . . . . . . . . . . .

48

27

- Checking piston protrusion . . . . . . . . . . . . . . .

28

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .

29 29

- Checking cylinder head wet seal . . . . . . . . . . .

30

- Checking cylinder head supporting surface . . .

30

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

N

- Removing the valves . . . . . . . . . . . . . . . . . . . .

O T

FO

R

- Finding crankpin clearance . . . . . . . . . . . . . . . .

- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IN T

- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PR

- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

40

- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . . . . . . . 31

- Checking output shaft shoulder clearance . . . .

49

CONNECTING ROD — PISTON ASSEMBLY . .

49

VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .

32

- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

- Measuring piston diameter . . . . . . . . . . . . . . . .

50

- Regrinding — replacing the valve seats . . . . . . .

32

- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .

33

- Conditions for proper pin-piston coupling . . . .

51

NEF ENGINES


3 Page

Page - Connecting rods . . . . . . . . . . . . . . . . . . . . . . .

52

- Checking cylinder head supporting surface . . .

58

- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

- Fitting connecting rod-piston assembly . . . . . .

53

- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

- Connecting rod-piston coupling . . . . . . . . . . . .

53

- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .

54

- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . . . . . . . 59 VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .

60

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

55

- Regrinding — replacing the valve seats . . . . . . .

60

- Checking piston protrusion . . . . . . . . . . . . . . .

56

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .

62

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .

57

FITTING CYLINDER HEAD . . . . . . . . . . . . . . . .

62

- Removing the valves . . . . . . . . . . . . . . . . . . . .

57

- Refitting the cylinder head . . . . . . . . . . . . . . . .

63

- Checking cylinder head wet seal . . . . . . . . . . .

58

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .

64

N

O T

FO

R

PR

IN T

- Finding crankpin clearance . . . . . . . . . . . . . . . .


PR

IN T

NEF ENGINES

R FO O T N

4

NEF ENGINES


GENERAL SPECIFICATIONS Type

4 CYLINDERS

Cycle

Four-stroke diesel engine

Power

See properties described in Section 3

Injection

Direct

Number of cylinders

4 in-line

∅

+

+

Bore

mm

104

Stroke

mm

132

cm3

4485

+.. = Total displacement

start before B.D.C. end after T.D.C.

D C

FO

Checking timing

PR

A B

-

-

R

start before T.D.C. end after B.D.C.

IN T

TIMING

mm

-

mm

-

mm

0.25 to 0.05

mm

0.50 to 0.05

Bosch

VE 4/12 F

Checking operation X

N

X

O T

X

FUEL FEED Injection Type: Nozzle type

Injection sequence

-

1-3-4-2

5

6


NEF ENGINES

CLEARANCE DATA

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1

mm 104.000 to 104.024

∅1

Cylinder barrels X

0.4

∅1 X ∅2

Spare pistons type: Size Outside diameter Pin housing

X ∅1 ∅2

55.9 103.714 to 103.732 38.010 to 38.016

CNH PARTS

0.268 to 0.310

Piston diameter

∅1

Piston protrusion

X

IN T

Piston — cylinder barrels

0.4

O T

FO

Piston pin — pin housing

R

∅3

Piston pin

N

∅ 3

PR

X

0.28 to 0.52

37.994 to 38.000 0.010 to 0.022

NEF ENGINES


Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1* X1 Split ring slots X2 X3 X2 X3 * measured on a ∅ of 99.00 mm S 1 S 2 S 3

CNH

Split rings

S 1* S2 S3

Split rings - slots

1 2 3

0.100 to 0.175 0.060 to 0.110 0.040 to 0.080

X1 X2 X3

X3

∅ 3

∅1

∅2

Small end bush diameter Outside ∅4 Inside ∅3 Spare big end half bearings S

40.987 to 41.013 72.987 to 73.013

38.019 to 38.033 1.955 to 1.968

Piston pin — bush

0.019 to 0.039

Big end half bearings

0.250 to 0.500

N

S

0.30 to 0.40 0.60 to 0.80 0.30 to 0.55

FO

∅ 2

Small end bush housing Big end bearing housing

O T

∅1

IN T

Split ring end opening in cylinder barrel:

PR

X 2

0.4

R

X1

CNH

2.560 to 2.605 2.350 to 2.380 3.970 to 3.990

Split rings

PARTS

PARTS

mm 2.705 to 2.735 2.440 to 2.460 4.030 to 4.050

7

8


NEF ENGINES

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS

mm

X Size

-

X

Max. tolerance on connecting rod axis alignment

Journals Crankpins

∅1 ∅2

82.99 to 83.01 68.987 to 69.013

Main half bearings Big end half bearings

S1 S2

2.456 to 2.464 1.955 to 1.968

Main bearings No. 1 — 5 No. 2 — 3 — 4

∅3 ∅3

S 2

∅ 3

Half bearings — Journals No. 1 — 5 No. 2 — 3 — 4

FO

Half bearings - Crankpins CNH


O T

PARTS

87.982 to 88.008 87.977 to 88.013 0.022 to 0..053 0.019 to 0.055 0.019 to 0.058 0.250 to 0.500

X1

37.475 to 37.550

Shoulder main bearing

X2

32.180 to 32.280

Shoulder half-rings

X3

37.28 to 37.38

N

Shoulder journal

PR

S 1

IN T

∅2

R

∅1

-

X 1

X 2 X 3

Output shaft shoulder

0.095 to 0.270

NEF ENGINES


Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM ∅ 1

mm

Valve guide seats on cylinder head

∅ 4

∅1

8.019 to 8.039

∅4 α

7.960 to 7.980 60º

∅4 α

7.960 to 7.980 45º

Valves:

α Valve stem and guide

0.059 to 0.086

IN T

Housing on head for valve seat:

46.987 to 47.013

∅1

∅ 1

PR

∅1

Valve seat outside diameter; valve seat angle on cylinder head: ∅2 α

FO

R

∅ 2

∅2 α

O T

α

Sinking

N

X

Between valve seat and head

CNH PARTS

Valve seats

43.637 to 43.663

47.063 to 47.089 60º 43.713 to 43.739 45º

X

1 to 1.52

X

1 to 1.52 0.050 to 0.102 0.050 to 0.102 -

9

10


NEF ENGINES

Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

mm

Valve spring height: free spring H

H1

H 2 under a load equal to: 339.8 ± 9 N 741 ± 39 N Injector protrusion

H

63.50

H1 H2

49.02 38.20

X

-

X 59.222 to 59.248

Camshaft housings No. 2-3-4

54.089 to 54.139

IN T

∅ ∅ ∅ 1 23 4 5

Camshaft bush housings No. 1-5

∅

Bush inside diameter

∅

FO

∅

Bushes and journals

H

O T

Cam lift:

R

∅ 3

N

∅ 1

Camshaft journals: 1⇒5

PR

∅ 2

53.995 to 54.045

54.083 to 54.147 0.038 to 0.162

H

-

H

-

NEF ENGINES


Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

mm

∅1 Tappet cap housing on block ∅2 ∅ 3

Tappet cap outside diameter:

∅2

CNH PARTS

∅1

16,000 ÷ 16,030

∅2 ∅3

15.924 to 15.954 15.965 to 15.980

Between tappets and housings

-

Tappets

-

∅ 1

Rockers

∅2

∅ 2

N

O T

FO

R

Between rockers and shaft

18.963 to 18.975

IN T

∅1

PR

Rocker shaft

19.000 to 19.026

0.025 to 0.063

11

12


NEF ENGINES

TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS

Pre-lift (mm)

F4GE9454C*J602

0.7

F4GE9484A*J601

0.65

F4GE9484A*J602

0.65

F4GE9484D*J600

0.65

F4GE9484D*J603

0.65

F4GE9484E*J600

0.75

F4GE9484F*J600

0.8

F4GE9484H*J600

0.65

F4GE9484J*J600

0.8

F4GE9484K*J601

-

N

O T

FO

R

PR

IN T

4-CYLINDER ENGINES

Technical Code

NOTE

INJECTION PUMP CALIBRATION Overhaul and calibration interventions are up to BOSCH assistance network. The contract technical specification containing the data to calibrate the pump at the bench is identified by the code shown on injection pump body and is available at BOSCH technical assistance network. Otherwise, refer to CNH Technical Assistance Service.

NEF ENGINES


MECHANICALS ENGINES OVERHAUL ENGINE REMOVAL AT THE BENCH

13

Figure 3

The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well. (See Section 3 of the manual herein). The section illustrates therefore all the most important engine overhaul procedures. The following operations are relating to the 4 cylinders engine but are analogously applicable for the 6 cylinders.

Figure 1

70160

The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).

IN T

NOTE Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.

PR

Figure 4

70158

FO

R

Remove the screws (1) fastening the connecting rod caps (2) and remove them. Withdraw the pistons including the connecting rods from the top of the engine block.

O T

NOTE Keep the half-bearings into their housings since in case of use they shall be fitted in the same position found at removal. Use tool 380000362 (1) and hoist to remove the output shaft (2) from the block.

N

Figure 2

70161

Figure 5

70159

Remove the screws (1) and the main bearing caps (2).

Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3).

70162

14


NEF ENGINES

zs

REPAIR OPERATIONS CYLINDER UNIT Checks and measurements

Figure 6

Figure 9

s

70163

Remove the screws (1) and disconnect camshaft (3) retaining plate (2). 70166

NOTE Take note of plate (2) assembling position.

Once engine is disassembled, clean accurately the cylinder-block assembly. Use the proper rings to handle the cylinder unit.

IN T

The engine block shall not show cracks.

Figure 7

Check operating plug conditions and replace them in case of uncertain seal or if rusted.

PR

Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear.

FO

R

Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter.

NOTE Should the ring gauge be not available, use a micrometer for zero-setting.

70164

Figure 10

N

Figure 8

O T

Withdraw carefully the camshaft (1) from the engine block.

70167

Measurements shall be performed on each cylinder, at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement. 70165

Withdraw the tappets (1) from the engine block.

Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.5 mm and to the specified assembling clearance.

NEF ENGINES


15

Check main bearing housings as follows:

Figure 11

- fit the main bearings caps on the supports without bearings; - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value.

α

Replace if higher value is found.

Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit.

R

PR

IN T

Planarity error shall not exceed 0.075 mm. Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.

FO

107804

N

O T

NOTE In case of regrinding, all barrels shall have the same oversize (0.5 mm).

16


NEF ENGINES

TIMING SYSTEM Camshaft

IN T

Figure 12

70169

PR

CAMSHAFT MAIN DATA (4 CYL.) Specified data refer to pin standard diameter

N

O T

FO

R

Figure 13

70512

MAIN DATA ABOUT CAMSHAFT PINS (6 CYL.)

Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the

camshaft and the bushes.

NEF ENGINES


Checking cam lift and pin alignment

17

BUSHES

Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft.

Figure 15

Figure 14

70172

IN T

Camshaft bush (2) shall be pressed into its housing. Internal surface must not show seizing or wear. Use bore dial gauge (3) to measure camshaft bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.

PR

70171

R

Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.

FO

Figure 16

N

O T

Sec. A-A

107399

MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (4-cylinder engines) * Value to be obtained after driving the bushes.

18


Bush replacement

NEF ENGINES

Fitting tappets — camshaft Figure 19

Figure 17

CNH PARTS 70176 70174

IN T

Figure 20

Figure 18

70164

Lubricate the camshaft support bearing and install the camshaft (1) being careful to ensure that the bearing or the shaft support seats are not damaged during the operation. Figure 21

N

Tappets

O T

FO

R

NOTE When installing the bearing (1) it must be oriented so that the lubrication holes are aligned with those on the seats of the crankcase

Lubricate the tappets (1) and fit them into the relevant housings on the engine block.

PR

To replace the bearing (1) use tool 380000667 (2) and handle 380000668 (3) to remove and install it.

70238 84053

MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK

Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque.

NEF ENGINES


19

OUTPUT SHAFT Measuring journals and crankpins

Figure 22

Figure 24

70179

Check camshaft end float (1). It shall be 0.23 ± 0.13 mm.

70182

Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.

IN T

Figure 23

PR

NOTE It is recommended to insert the found values in the proper table. See Figure 25.

R

Undersize classes are:

FO

70180

N

Figure 25

O T

Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.

NOTE Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB

108487

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value

20


NEF ENGINES

Figure 26

measured on > 45.5 mm radius between adjacent journals

IN T

70183

OUTPUT SHAFT MAIN TOLERANCES

TOLERANCE CHARACTERISTIC Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation

PR

TOLERANCES SHAPE

FO

R

DIRECTION POSITION OSCILLATION

O T

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS CRITICAL

MAIN BEARING ON TIMING SYSTEM CONTROL SIDE

GRAPHIC SYMBOL © ⊕ ⊝

N

IMPORTANT SECONDARY

GRAPHIC SYMBOL ○ /○/ //

INTERMEDIATE MAIN BEARINGS

FIRST MAIN BEARING ON FRONT SIDE

70237

NEF ENGINES


21

Finding journal clearance

Replacing oil pump control gear

Figure 29

Figure 27

CNH PARTS 70161

Refit the output shaft (2). Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3). When fitting the new gear, heat it to 180°C for 10 minutes in an oven and then key it to the output shaft.

Figure 30

PR

Fitting main bearings

Check the backlash between output shaft main journals and the relevant bearings as follows:

IN T

70184

R

Figure 28

FO

CNH

70186

- clean accurately the parts and remove any trace of oil; - position a piece of calibrated wire (3) on the output shaft pins (4) so that it is parallel to the longitudinal axis; 70185

N

O T

PARTS

- fit caps (1), including the half bearings (2) on the relevant supports.

NOTE Refit the main bearings that have not been replaced, in the same position found at removal.

Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter. NOTE Do not try to adapt the bearings.

Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings. The second last main half bearing (1) is fitted with shoulder half rings.


D2

D1

75703

22


NEF ENGINES

Checking output shaft shoulder clearance

Figure 31

Figure 34

70187

Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, with dynamometric wrench to 50 ± 6 Nm. - 2nd stage, with dynamometric wrench to 80 ± 6 Nm.

70190

This check is performed by setting a magnetic-base dial gauge (2) on the output shaft (3) as shown in the figure, standard value is 0.068 to 0.41.

Figure 32 α

R

PR

IN T

If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between output shaft pins and main half bearings.

70188

FO

- 3rd stage, with tool 380000304 (1) set as shown in the figure, tighten the screws (2) with 90° ± 5° angle.

Figure 35

N

O T

Figure 33

CONNECTING ROD — PISTON ASSEMBLY

70189

70191

- Remove caps from supports. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire.

CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.

The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described.

NOTE Pistons are supplied spare with 0.4 mm oversize.

NEF ENGINES


23

Pistons Measuring piston diameter

Figure 36

Figure 39

32613

Remove split rings (1) from piston (2) using pliers 380000221 (3).

32615

Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance. NOTE The diameter shall be measured at 12 mm from the piston skirt.

IN T

Figure 37

FO

R

PR

Figure 40

32614

70192

The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.

N

Figure 38

O T

Piston pin (1) split rings (2) are removed using a scriber (3).

87760

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

24


NEF ENGINES

Piston pins

Figure 44

Figure 41

18857

32620

To measure the piston pin (1) diameter use the micrometer (2).

Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1).

Conditions for proper pin-piston coupling

Figure 45

FO

R

PR

IN T

Figure 42

32619

O T

Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.

Figure 43

Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).

N

Split rings

41104

DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING

In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.

16552

Use a micrometer (1) to check split ring (2) thickness.

NEF ENGINES


Figure 46

25

Figure 48

70194

Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).

IN T

Connecting rods

PR

Figure 47

80339

FO

R

NOTE Every connecting rod is marked as follows: - On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.

N

O T

- On body with a letter showing the weight of the connecting rod assembled at production:

S

V, 1820 to 1860 (yellow marking);

S

W, 1861 to 1900 (green marking);

S

X, 1901 to 1940 (blue marking);

Spare connecting rods are of the W class with green marking *. Material removal is not allowed. 88607

NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls.

26


NEF ENGINES

Bushes

Figure 51

Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.

Fitting connecting rod-piston assembly Connecting rod-piston coupling 72705

Figure 49

IN T

Position the piston (1) on the connecting rod according to the diagram shown in the figure, fit the pin (3) and stop it by the split rings (2).

Fitting split rings

R

70198

PR

Figure 52

O T

FO

The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block; 3. Marking showing 1st slot insert testing; 4. Manufacturing date.

N

Figure 50

32613

Use pliers 380000221 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°.

NOTE Split rings are supplied spare with the following sizes:

70199

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure.

-

standard;

-

0.4 mm oversize.

NEF ENGINES


Figure 53

27

Figure 55

70202

DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL 70200

- Split ring openings shall be displaced with each other by 120°; - connecting rod-piston assemblies shall have the same weight;

Fit half bearings (1) on connecting rod and cap.

IN T

- the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.

NOTE Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings.

PR

Finding crankpin clearance

FO

R

Figure 56

N

Figure 54

O T

Fitting connecting rod-piston assembly into cylinder barrels

70203

To measure the clearance proceed as follows: - clean the parts accurately and remove any trace of oil; - set a piece of calibrated wire (2) on the output shaft pins (1); - fit the connecting rod caps (3) with the relevant half bearings (4).

70201

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 380000220 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number.


D2

D1 75703

28


NEF ENGINES

Figure 57

Figure 60

α

70204

- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometric wrench (2).

70207

If a different clearance value is found, replace the half bearings and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.

IN T

Figure 58 α

FO

R

PR

Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.250 to 0.275 mm.

70205

Checking piston protrusion Figure 61

N

Figure 59

O T

- Apply tool 380000304 (1) to the socket wrench and tighten screws (2) of 60°.

70208

70206

- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).

Once connecting rod-piston assemblies refitting is over, use dial gauge 39395603 (1) fitted with base 380000364 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm.

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29


CYLINDER HEAD Removing the valves

Figure 63

1

2 3

Figure 62

4

1 2

6

5 A

75751

Intake (1) and exhaust (2) valves have heads with the same diameter. The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.

Repeat this operation for all the valves.

IN T

75750

Valve removal shall be performed using tool 380000302 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Overturn the cylinder head and withdraw the valves (5). Figure 64

PR

Should cylinder head valves be not replaced, number them before removing in order to refit them in the same position.

2

O T

FO

R

A = intake side — S = exhaust side

1

N

NOTE

75752

NOTE Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.

30


NEF ENGINES

Checking cylinder head wet seal

Figure 66

Figure 65

D 0,4 C 0,025 / ¯ 25,4

1

A

B

0,4 TOTAL 0,01 / ¯ 50

C

75756 75753

This check shall be performed using the proper tools.

The rated thickness A for the cylinder head is 95 ± 0.25 mm, max. metal removal shall not exceed thickness B by 0.13 mm.

Use a pump to fill with water heated to approx. 90°C and 2 to 3 bar pressure.

FO

Replace the cylinder head if leaks are found.

O T

Checking cylinder head supporting surface

Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure.

N

IN T

R

NOTE Before refitting, smear the plug surfaces with water-repellent sealant.

NOTE After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

PR

Replace the cup plugs (1) if leaks are found, use the proper beater for their removal/refitting.

NEF ENGINES


VALVES

31

Figure 69

Figure 67 EXHAUST VALVE

INTAKE VALVE

18882

Check the valve stem (1) using a micrometer (2), it shall be 7.960 ± 7.980.

IN T

116395

FO

R

PR

INTAKE AND EXHAUST VALVE MAIN DATA

CNH

Checking clearance between valve stem and valve guide and valve centering Figure 70

N

Figure 68

O T

Removing carbon deposits, checking and grinding valves

1

PARTS

2

18625

Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Regrind the valve seats, if required, using tool 99305018 and removing as less material as possible.

75757

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.056 ± 0.096 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm.

32


VALVE GUIDE

NEF ENGINES

VALVE SEATS Regrinding — replacing the valve seats

Figure 71

Figure 72

1 2

75754

70328

Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.

Check the valve seats (2). If slight scoring or burnout is found, regrind seats using tool 99305018 (1) according to the angle values shown in Figure 73.

IN T

EXHAUST

INTAKE

PR

Figure 73

CNH

N

O T

FO

R

PARTS

116356

INTAKE

EXHAUST

VALVE SEAT MAIN DATA Should valve seats be not reset just by regrinding, replace them with the spare ones. Use adequate tool to remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

Heat the cylinder head to 80° - 100°C and using the proper beater, fit the new valve seats, previously cooled, into the cylinder head. Use adequate tool to regrind the valve seats according to the values shown in figure.

NEF ENGINES

33


FITTING CYLINDER HEAD

Figure 74

Figure 76

1

3

1

2 3

CNH

1

PARTS

2

75758

75759

Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal.

IN T

After regrinding, check that valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial gauge 380000228 (1).

Fit the sealing rings (2 and 3) on the valve guide.

PR

NOTE Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green.

VALVE SPRINGS

O T

FO

R

Figure 75

Figure 77

N

50676

1

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before refitting use adequate tool to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table.

2 3 4

6

Height

Under a load of

mm

N

H (free)

63.50

0

H1

49.02

329

H2

38.20

641

5 75751

Position on the cylinder head: the spring (4), the upper cap (3); use tool 380000302 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2).

34


Refitting the cylinder head

NEF ENGINES


Figure 78

CNH PARTS

D2

D1

75703

87759

IN T

Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “TOP” (1) facing the head. The arrow shows the point where the gasket thickness is given.

PR

Figure 79

CNH

O T

FO

R

PARTS

88775

N

There are two types of head seals, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on figure , at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average: S cil1 = S1 + S2 2 For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value. S=

S cil1 + S cil2 + S cil3 + S cil4 4

NEF ENGINES


TIGHTENING TORQUE TORQUE

COMPONENT 1st stage 2nd stage 3rd stage

1st stage 2nd stage 3rd stage

FO

O T

N

24 ± 4 24 ± 4 49 ± 5 8±1

2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5 0.8 ± 0.1

24 ± 4 24 ± 4 30 ± 3 60 ± 5

2.4 ± 0.4 2.4 ± 0.4 3.0 ± 0.3 6.0 ± 0.5 60º ± 5º

R

Ladder frame assembly (M10x1.25x25) Oil rifle plugs (M10x1) (M14x1.5) Assemble oil suction tube (M8x1.25x20) Oil pan assembly (M8x1.25x25) (M18x1.50) Set timing pin Fuel pump assembly M8 screw M6 screw M6 nut M10x1.5 flange head nuts pre-torque Final torque Fuel pump gear (drive gear nut) Snug torque Final torque Timing pin cap of fuel pump Rocker assys (M8) Cylinder head bolts (M12x70) (M12x140) (M12x180) Assy rocker covers (M8x1.25x25) Intake manifold (M8x1.25) Assy air intake connection (M8x1.25) Oil bypass valve into lube filter head (M22x1.5x10) Plug (M12x1.5x12) Exhaust manifold (M10x1.5x65) Water pump (M8x1.25x25) Water outlet connection (M8x1.25x35) (M8x1.25x70) Fan support (M10x1.5x20) Fan pulley (M6) (M10)

kgm 1.5 ± 0.3 5.0 ± 0.6 8.0 ± 0.6 90º ± 5º

IN T

Rear gear housing assembly (M8x1.25x40) (M8x1.25x25) (M10x1.5) Oil pump (M8x1.25x30) Front cover assembly (M8x1.25x45) (M8x1.25x30) Connecting rod bolts (M11x1.25)

Nm 15 ± 3 50 ± 6 80 ± 6

PR

Cooling Nozzles (M8x1.25x10) Main bearing cap

43 ± 5

4.3 ± 0.5

6±1 11 ± 2 24 ± 4

0.6 ± 0.1 1.1 ± 0.2 2.4 ± 0.4

24 ± 4 60 ± 9 5±1

2.4 ± 0.4 6.0 ± 0.9 0.5 ± 0.1

24 ± 4 10 ± 1 10 ± 1 10 - 15 50 - 55 15 - 20 85 - 90 30 - 35 24 ± 4

2.4 ± 0.4 1.0 ± 0.1 1.0 ± 0.1 1.0 - 1.5 5.0 - 5.5 1.5 - 2.0 8.5 - 9.0 3.0 - 3.5 2.4 ± 0.4

50 + 90º 40 + 180º 70 + 180º 24 ± 4 24 ± 4 24 ± 4 80 ± 8 10 ± 1 43 ± 6 24 ± 4

5.0 + 90º 4.0 + 180º 7.0 + 180º 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 8.0 ± 0.8 1.0 ± 0.1 4.3 ± 0.6 2.4 ± 0.4

24 ± 4 24 ± 4 33 ± 5

2.4 ± 0.4 2.4 ± 0.4 3.3 ± 0.5

10 ± 2 43 ± 6

1.0 ± 0.2 4.3 ± 0.6

35

36


NEF ENGINES

TORQUE

COMPONENT Rear lifting bracket (M12x1.75x30) Crankshaft pulley (M12x1.75x10.9) Flywheel housing (M12x120) (M12x80) (M10x80) (M10x40) Flywheel housing (M12x1.25)

8.5 ± 1.0 8.5 ± 1.0 4.9 ± 0.5 4.9 ± 0.5 3.0 ± 0.4

24 ± 4 60 ± 5 24 ± 4 43 ± 6 24 ± 4 35 ± 5 24 ± 4 24 ± 4 24 ± 4 24 ± 4 49 ± 5 43 ± 6 10 ± 2 49 ± 5 15 ± 3 50 ± 6 80 ± 6

2.4 ± 0.4 6.0 ± 0.5 2.4 ± 0.4 4.3 ± 0.6 2.4 ± 0.4 3.5 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5 4.3 ± 0.6 1.0 ± 0.2 4.9 ± 0.5 1.5 ± 0.3 5 ± 0.6 8 ± 0.6

IN T PR R

1st stage 2nd stage 3rdd stage

FO

O T

85 ± 10 85 ± 10 49 ± 5 49 ± 5 60º ± 5º

Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M11 for fastening connecting rod caps 1st stage 2ndd stage

N

kgm 7.7 ± 1.2 11.0 ± 0.5

30 ± 4

1st stage 2nd stage Assy rear cover plate to flywheel housing (M8x1.25x16) Fuel injectors Fuel lift pump Turbocharger to exhaust manifold (M10) Oil feed to oil filter head Oil feed to turbocharger (M12x1.5) Oil drain (M8x1.25x16) Alternator to alternator support (M8x1.25x30) Alternator to water inlet conn. assy (M8x1.25x30) Lower alternator mounting (M10x1.25x25) Alternator upper pivot to support (M10) Alternator mounting hardware (M12x1.75x120) Alternator wiring (M6x1.0 nut) Starter motor to gear case (M10) Screw M8 for fastening cylinder barrel lubricating nozzles Screw M12 for fastening output shaft caps

Nm 77 ± 12 110 ± 5

90º ± 5º 24 ± 4 36 ± 4 60 ± 5

2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60º ± 5º

NEF ENGINES


ELECTRONICS ENGINES OVERHAUL ENGINE REMOVAL AT THE BENCH

37

Figure 3

The following instructions assume that the engine has previously been placed on the rotating bench and that removal of all specific components of the Iveco Motors equipment have been already removed as well. (See Section 3 of the manual herein). The section illustrates therefore all the most important engine overhaul procedures. The following operations are relating to the 4 cylinder engine but are similar and applicable for the 6 cylinder. Figure 1 70160

The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).

PR

70158

IN T

NOTE Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.

Figure 4

R

Loosen the fixing screws (1) and remove the rod caps (2). Withdraw the pistons including the connecting rods from the top of the engine block.

O T

FO

NOTE Keep the half-bearings into their housings since in case of use they shall be fitted in the same position found at removal.

N

Figure 2

70161

Use tool 380000362 (1) and hoist to remove the crankshaft (2) from the block. Figure 5

70159

Remove the screws (1) and the main bearing caps (2).

Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3).

70162

38


NEF ENGINES

zs

REPAIR OPERATIONS CYLINDER UNIT Checks and measurements

Figure 6

Figure 9

s

70163

Remove the screws (1) and disconnect camshaft (3) retaining plate (2). 70166

Once engine is disassembled, clean accurately the cylinder-block assembly. Use the proper rings to handle the cylinder unit. The engine block shall not show cracks. Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear. Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter.

IN T

NOTE Take note of plate (2) assembling position.

FO

R

PR

Figure 7

NOTE Should the ring gauge be not available, use a micrometer for zero-setting.

70164

Figure 10

N

Figure 8

O T

Withdraw carefully the camshaft (1) from the engine block.

70167

Measurements shall be performed on each cylinder, at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement.

70165

Withdraw the tappets (1) from the engine block.

Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.4 mm and to the specified assembling clearance.

NEF ENGINES


39

Check main bearing housings as follows:

Figure 11

- fit the main bearings caps on the supports without bearings; - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value.

α

Replace if higher value is found.

Checking head supporting surface on cylinder unit

FO

R

PR

IN T

When finding the distortion areas, replace the cylinder unit. Planarity error shall not exceed 0.075 mm. Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.

O T

107804

N

NOTE In case of regrinding, all barrels shall have the same oversize (0.4 mm).

40


NEF ENGINES

TIMING SYSTEM Camshaft Figure 12

70169

R

PR

IN T

CAMSHAFT MAIN DATA (4 cyl.) Specified data refer to pin standard diameter

N

O T

FO

Figure 13

84089

MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders) Specified data refer to pin standard diameter

Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the

camshaft and the bush.

NEF ENGINES


Checking cam lift and pin alignment

41

BUSHES

Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft. Check cam lift; found values shall be: 6.045 mm for exhaust cams and 7.582 mm for intake cams, in case of different values replace the camshaft.

Figure 15

Figure 14

70172

PR

Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.

IN T

70171

Camshaft bush (2) shall be pressed into its housing. Internal surface must not show seizing or wear. Use bore dial gauge (3) to measure camshaft bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.

FO

N

O T

Sec. A-A

R

Figure 16

107399

CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.) * Value to be obtained after driving the bush.

42


NEF ENGINES

Figure 17 sec. A-A

IN T

107268

MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS

PR

*Height to be obtained after driving the bush.

Tappets

R

Bush replacement

Figure 19

N

O T

FO

Figure 18

CNH PARTS

70174 112890

To replace bush (1), remove and refit them using the beater 380000367 (2) and the handgrip 380000368 (3). MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK NOTE When refitting the bush (1), direct them to make the lubricating holes (2) coincide with the holes on the block housing.

NEF ENGINES


Fitting tappets — camshaft

43

Figure 22

Figure 20

70238

Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque. 70176

IN T

Lubricate the tappets (1) and fit them into the relevant housings on the engine block.

70179

Check camshaft end float (1). It shall be 0.23 ± 0.13 mm.

N

Figure 21

O T

FO

R

PR

Figure 23

Figure 24

70164 70180

Lubricate the camshaft bush and fit the camshaft (1) taking care not to damage the bush or the housings. Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.

44


OUTPUT SHAFT Measuring journals and crankpins

NEF ENGINES

NOTE It is recommended to insert the found values in the proper table. See Figure 26.

Figure 25

Undersize classes are:

NOTE Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB. 70182

IN T

Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.

N

O T

FO

R

PR

Figure 26

108487

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.) *Rated value

NEF ENGINES

45


Figure 27

measured on > 45.5 mm radius between adjacent journals

IN T

70183

OUTPUT SHAFT MAIN TOLERANCES


PR

TOLERANCES SHAPE

FO

R

DIRECTION POSITION OSCILLATION

SECONDARY



N

IMPORTANT

O T





70237

46


NEF ENGINES

Measuring journals and crankpins (6 cyl.)

IN T

Figure 28

107269

PR

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value

N

O T

FO

R

Figure 29

* Measured on a radius greater than 45.5 mm ** ↗ 0.500 between adjacent main journals MAIN OUTPUT SHAFT TOLERANCES

70577

NEF ENGINES

47


Figure 30




70237

TOLERANCES


IN T

SHAPE DIRECTION

PR

POSITION OSCILLATION

R


FO

IMPORTANT

N

O T

SECONDARY



48


Replacing oil pump control gear

NEF ENGINES

Finding journal clearance Figure 33

Figure 31

CNH PARTS

70161

Refit the crankshaft (2). Check the backlash between crankshaf main journals and the relevant bearings as follows: 70184

Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3).

Figure 34

PR

Fitting main bearings

IN T

When fitting the new gear, heat it to 180°C for 10 minutes in an oven and then key it to the crankshaft.

R

Figure 32

FO

CNH

70186

- clean accurately the parts and remove any trace of oil; - position a piece of calibrated wire (3) on the crankshaft pins (4) so that it is parallel to the longitudinal axis; - fit caps (1), including the half bearings (2) on the relevant supports.

70185

N

O T

PARTS

NOTE Refit the main bearings that have not been replaced, in the same position found at removal.

Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter.


D2

D1

NOTE Do not try to adapt the bearings. 75703

Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings. The second last main half bearing (1) is fitted with shoulder half rings. Revi - February 2007

NEF ENGINES


49

Checking crankshaft shoulder clearance

Figure 35

Figure 38

70187

Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, with torque wrench to 50 ± 6 Nm. - 2nd stage, with torque wrench to 80 ± 6 Nm.

70190

This check is performed by setting a magnetic-base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 to 0.41.

Figure 36 α

R

PR

IN T

If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft pins and main half bearings.

70188

FO

- 3rd stage, with tool 380000304 (1) set as shown in the figure, tighten the screws (2) with 90 ± 5° angle.

Figure 39

N

O T

Figure 37

CONNECTING ROD — PISTON ASSEMBLY

70189

- Remove caps from supports. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire.

70191

CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.

The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described.

NOTE The pistons are supplied spare with the following sizes: - standard; - 0.4 mm oversize.

Revi - February 2007

50


NEF ENGINES

Pistons Measuring piston diameter

Figure 40

Figure 43

32613

Remove split rings (1) from piston (2) using pliers 380000221 (3).

32615

Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.

IN T

Figure 41

FO

R

PR

Figure 44

32614

N

Figure 42

O T

Piston pin (1) split rings (2) are removed using a scriber (3).

1.5

*

2.560 2.605

2.350 2.380

3.970 3.990

70192

The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.

2.705 2.735

2.420 2.440

2˚±20’

38.010 38.016

37.994 38.000 114797

MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS * Value measured on 101 mm diameter

NEF ENGINES


51

Figure 45

114798

MAIN DATA OF THE PISTON WITHOUT PIN TUNNEL AND PLASTIC RINGS

IN T

* Value measured on 101 mm diameter

Piston pins Figure 46

FO

R

PR

Figure 48

18857

O T

To measure the piston pin (1) diameter use the micrometer (2).

16552


Figure 47

N

Conditions for proper pin-piston coupling Figure 49

32619

Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.

32620

Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1).

52


NEF ENGINES

Connecting rods

Figure 50

Figure 52

41104

DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING

88607

MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS

PR

In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.

IN T

Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).

R

* Value for inside diameter to be obtained after driving in connecting rod small end and grinding.

N

O T

FO

Figure 51

70194

Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).


NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls.

NEF ENGINES


53

Bushes

Figure 53

Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.

CONNECTING ROD BODY CONNECT- CONNECTING ROD ING ROD BODY BODY

*

Fitting connecting rod-piston assembly Connecting rod-piston coupling Figure 54

CONNECTING ROD BODY CONNECTING ROD BODY

CONNECTING ROD BODY

IN T

CONNECTING ROD BODY

NOTE Every connecting rod is marked as follows:

FO

R

- On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.

PR

70196

O T

- On body with a letter showing the weight of the connecting rod assembled at production: V, 1820 to 1860 (yellow marking);

S

W, 1861 to 1900 (green marking);

S

X, 1901 to 1940 (blue marking);

The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block; 3. Manufacturing date. 4. Marking showing 1st slot insert testing;

Figure 55

N

S

70198

Spare connecting rods are of the W class with green marking *. Material removal is not allowed.

108597

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure.

54


NEF ENGINES

Figure 56

Figure 58

72705 70200

Position the piston (1) on the connecting rod according to the diagram shown in the figure, fit the pin (3) and stop it by the split rings (2).

Fit half bearings (1) on connecting rod and cap.

Fitting split rings NOTE Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings.

FO

R

PR

IN T

Figure 57

32613

Figure 59

N

O T

Use pliers 380000221 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°.

Fitting connecting rod-piston assembly into cylinder barrels

NOTE Split rings are supplied spare with the following sizes: -

standard, yellow marking;

-

0.4 mm oversize, yellow/green marking;

70201

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 380000220 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number.

NEF ENGINES


Figure 60

55

Figure 62

α

108596

DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL

70204

- connecting rod-piston assemblies shall have the same weight;

Figure 63 α

PR

- the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.

IN T

- Split ring openings shall be displaced with each other by 120°;

- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench (2).

FO

70205

- Apply tool 380000304 (1) to the socket wrench and tighten screws (2) of 60°.

O T

Finding crankpin clearance

R

Figure 61

N

Figure 64

70203

To measure the clearance proceed as follows: - clean the parts accurately and remove any trace of oil; - set a piece of calibrated wire (2) on the output shaft pins (1); - fit the connecting rod caps (3) with the relevant half bearings (4). NOTE Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the centre of the thread length is not < 0.1 mm than the diameter measured at approx. 10 mm from screw end.

70206

- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).


56


NEF ENGINES

Checking piston protrusion

Figure 65

Figure 66

70207

If a different clearance value is found, replace the half bearings and repeat the check.

Once connecting rod-piston assemblies refitting is over, use dial gauge 380000228 (1) fitted with base 380000364 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block.

IN T

Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.

70208

N

O T

FO

R

PR

Protrusion shall be 0.28 to 0.52 mm.


NEF ENGINES

57


CYLINDER HEAD Removing the valves

Figure 68

Figure 67

70321

Intake (1) and exhaust (2) valves have heads with the same diameter. The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.

Repeat this operation for all the valves.

IN T

70319

Valve removal shall be performed using tool 380000302 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Overturn the cylinder head and withdraw the valves (5).

N

O T

FO

A = intake side — S = exhaust side

R

NOTE Should cylinder head valves be not replaced, number them before removing in order to refit them in the same position.

PR

Figure 69

70322

Remove sealing rings (1 and 2) from the valve guide.

NOTE Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.

58


NEF ENGINES

Checking cylinder head wet seal

Figure 71

Figure 70

70323

70325

This check shall be performed using the proper tools. Use a pump to fill with water heated to approx. 90°C and 2 to 3 bar pressure.

The rated thickness A for the cylinder head is 105 ± 0.25 mm, max. metal removal shall not exceed thickness B by 1 mm.

NOTE After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.

PR

NOTE Before refitting, smear the plug surfaces with water-repellent sealant.

IN T

Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting.

FO

R

Replace the cylinder head if leaks are found.

Checking cylinder head supporting surface

O T

Distortion found along the whole cylinder head shall not exceed 0.20 mm.

N

If higher values are found grind the cylinder head according to values and indications shown in the following figure.

NEF ENGINES


VALVES

59

Figure 74

Figure 72 INTAKE VALVE

EXHAUST VALVE

18882

Check the valve stem (1) using a micrometer (2), it shall be 6.970 ÷ 6.990.

IN T

107280

FO

R

PR

INTAKE AND EXHAUST VALVE MAIN DATA

CNH

Checking clearance between valve stem and valve guide and valve centering Figure 75

N

Figure 73

O T

Removing carbon deposits, checking and grinding valves

PARTS

18625

Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. If necessary, rectify the valve seats, taking away the least amount of material possible.

70327

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 ÷ 0.092 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm.

60


VALVE GUIDE

NEF ENGINES

VALVE SEATS Regrinding — replacing the valve seats

Figure 76 Figure 77

70330

EXHAUST

79457

PR

Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.

Should slight scratches or burns be found, go over with the adequate tool (1) according to the inclination values indicated in the Figure 78.

IN T

INTAKE

N

O T

FO

R

Figure 78

INTAKE

EXHAUST

70331

VALVE SEAT MAIN DATA (4 CYL.)

NEF ENGINES


Should valve seats be not reset just by regrinding, replace them with the spare ones. Using a suitable tool, remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.

61

Heat the cylinder head to 80° - 100°C and using the proper punch, fit the new valve seats, previously cooled, into the cylinder head. Therefore, with an adequate tool, go over the valve seats according to the values stated in the Figure 78.

Figure 79

INTAKE

PR

IN T

EXHAUST

70332

After regrinding, check that valve (3) sinking value is the specified one by using the base 380000364 (2) and the dial gauge 380000228 (1).

N

Figure 80

O T

FO

R

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD

70333

62


VALVE SPRINGS

NEF ENGINES

FITTING CYLINDER HEAD

Figure 81

Figure 82

CNH PARTS

50676

MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS

70334

Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal.

IN T

Before refitting use tool to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table.

Fit the sealing rings (2 and 3) on the valve guide.

Under a load of

mm

N 47.75

Free

H1

35.33

P

339.8 ± 19 N

H2

25.2

P1

741 ± 39 N

Figure 83

N

O T

FO

H

R

Height

PR

NOTE Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green.

770321

Position on the cylinder head: the spring (4), the upper cap (3); use tool 380000302 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2).

NEF ENGINES


63

There are two types of head seals, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on Figure 85, at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average:

Refitting the cylinder head Figure 84

CNH PARTS

S cil1 = S1 + S2 2 For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value.

S=

70335

For 6 cylinder versions: Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

IN T

Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “TOP” (1) facing the head. The arrow shows the point where the gasket thickness is given.

S cil1 + S cil2 + S cil3 + S cil4 4

S=

S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6 6

PR

If S is > 0,40 mm use seal type A. If S is < 0,40 mm use seal type B.

R

Figure 85

FO

CNH

O T

PARTS


N

D2

D1

75703 88775


64


NEF ENGINES

TIGHTENING TORQUE TORQUE

COMPONENT

Nm 8±2 12 ± 2 77 ± 12 47 ± 5 24 ± 4 10 ± 2 8±1 24 ± 4 24 ± 4 24 ± 4 36 ± 4 43 ± 5 105 ± 5 24 ± 4 24 ± 4 36 ± 5 12 ± 2 8.5 ± 0.35

Studs M6 for camshaft sensors Studs M8 for feed pump Screw M12 for fastening rear gear case Screw M10 for fastening rear gear case Screw M8 for fastening rear gear case Nut M6 for fastening camshaft sensor 1st stage 2nd stage

Screw M8 for fastening oil pump

IN T

Screw M8 for fastening front cover Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M10 for fastening crankcase plate Nut M18 for fastening high pressure pump gear Nuts M8 for fastening fuel pump ½ inch plug on cylinder head ¼ inch plug on cylinder head ¾ inch plug on cylinder head

R

FO

Nut fastening for injector feed connector Nut M6 for flame start grille on intake manifold Screw M8 for fastening intake manifold Screw M12 for fastening rear brackets for engine lifting Screws M8 for fastening Common Rail Connectors M14 for high pressure fuel pipes Screw M12 (12 x 1.75 x 130) for fastening cylinder head

PR

1st stage 2ndd stage

Screw M6 for fastening injectors

Screw M12 (12 x 1.75 x 150) for fastening cylinder head

}1

st

stage

2nd stage 3rd stage

N

O T

Screw for fastening rocker bracket Valve clearance adjusting nuts Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail Screw M8 for fastening high pressure pipe connector Screw M6 for fastening wiring bulkhead Screw M8 for fastening electric wiring support for injector feed Nuts for fastening wiring on each injector Screw M12 for fastening fuel filter bracket Screw M8 for fastening fuel filter holder Fuel filter Screw M22 for fastening oil pressure relief valve on oil filter support Screw M8 for radiator seal and oil filter support Oil filter 11/8 inch connection on filter support for turbine lubrication Nut M12 for fastening turbine lubrication pipe Screw M10 for fastening engine coolant inlet connection 90° elbow fastening (if required) to engine coolant inlet connection Pipe on cylinder head for compressor cooling

kgm 0.8 ± 0.2 1.2 ± 0.2 7.7 ± 1.2 4.7 ± 0.5 2.4 ± 0.4 1 ± 0.2 0.8 ± 0.1 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 3.6 ± 0.4 4.3 ± 0.4 10.5 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 3.6 ± 0.5 1.2 ± 0.2 0.85 ± 0.035 75º ± 5º

50 ± 5 8±2 24 ± 4 77 ± 12 24 ± 4 20 ± 2 35 ± 5 55 ± 5

5 ± 0.5 0.8 ± 0.2 2.4 ± 0.4 7.7 ± 1.2 2.4 ± 0.4 2 ± 0.2 3.5 ± 0.5 5.5 ± 0.5 90º ± 5º 90º ± 5º

36 ± 5 3.6 ± 0.5 24 ± 4 2.4 ± 0.4 20 ± 2 2 ± 0.2 24 ± 4 2.4 ± 0.4 10 ± 2 1 ± 0.2 24 ± 4 2.4 ± 0.4 1.5 ± 0.25 0.15 ± 0.025 77 ± 8 7.7 ± 0.8 24 ± 4 2.4 ± 0.4 contact + ¾ turn 80 ± 8 8 ± 0.8 24 ± 4 2.4 ± 0.4 contact + ¾ turn 24 ± 4 2.4 ± 0.4 10 ± 2 1 ± 0.2 43 ± 6 4.3 ± 0.6 24 ± 4 2.4 ± 0.4 22 ± 2 2.2 ± 0.2

NEF ENGINES


TORQUE

COMPONENT Screw M6 for fastening engine coolant drain connector Pin fastening on engine block for exhaust manifold Screw M10 for fastening exhaust manifold on cylinder head

Turbine u b e fixingg to eexhaust aust manifold a od

FO

4-cyl.

{ pins nuts t pins { nuts

M8 M8 M8 M8

R

6-cyl.

PR

IN T

Screw M12 for fastening damper adapter 1st stage and damper on output shaft 2nd stage Screw M10 for fastening pulley on output shaft Screw M8 for fastening water pump Screw M10 for fastening auxiliary component control belt tensioners Screw M10 for fastening fixed pulleys for auxiliary component control belt Screw M10 for fastening flywheel housing Screw M12 for fastening flywheel housing Screw M6 for fastening heat exchanger for control unit Screw M8 for fastening heat exchanger for control unit Connection M12 for fuel inlet-outlet on heat exchanger Nut M8 for fastening valve cover Screw M6 for fastening camshaft sensor Screw M6 for fastening output shaft sensor Screw M14 for fastening coolant temperature sensor Screw M5 for fastening oil pressure/temperature sensor Screw for fastening fuel pressure sensor Screw M14 for fastening fuel temperature sensor Screw for fastening air temperature/pressure sensor on intake manifold Screw M12 for fastening engine oil level sensor

N

O T

Adapter M12 on turbine for lubricant oil pipes (inlet) Pipe fixing on adapter M10 for turbine lubrication Oil pipe fixing on adapter M10 for turbine lubrication to block Oil drain pipe fixing M8 on turbine Connector fixing M6 for oil return from cylinder head to flywheel housing Screw M12 for fastening engine flywheel 1st stage 2ndd stage Screw M8 for fastening front bracket for engine lifting Screw for fastening engine oil sump Screw M8 for fastening cylinder barrel lubricating nozzles Screw M12 for fastening output shaft caps

1st stage 2nd stage 3rdd stage

Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M11 for fastening connecting rod caps 1st stage 2ndd stage Alternator M10 Screw, Bracket fixing on water feed pipefitting M10 Screw, alternator locking Starter Starter fixing screw

Nm 10 ± 2 10 ± 2 53 ± 5 50 ± 5

kgm 1 ± 0.2 1 ± 0.2 5.3 ± 0.5 5 ± 0.5 90º

68 ± 7 24 ± 4 43 ± 6 43 ± 6 85 ± 10 49 ± 5 10 ± 2 24 ± 4 12 ± 2 24 ± 4 8±2 8±2 20 ± 3 6±1 35 ± 5 20 ± 3 6±1 12 ± 2 7±1 43 ± 6 7±1 24 ± 4 35 ± 5 35 ± 5 43 ± 6 24 ± 4 10 ± 2 30 ± 4

6.8 ± 0.7 2.4 ± 0.4 4.3 ± 0.6 4.3 ± 0.6 8.5 ± 1 4.9 ± 0.5 1 ± 0.2 2.4 ± 0.4 1.2 ± 0.2 2.4 ± 0.4 0.8 ± 0.2 0.8 ± 0.2 2 ± 0.3 0.6 ± 0.1 3.5 ± 0.5 2 ± 0.3 0.6 ± 0.1 1.2 ± 0.2 0.7 ± 0.1 4 3 ± 0.6 4.3 06 00.77 ± 0.1 01 2.4 ± 0.4 3.5 ± 0.5 3.5 ± 0.5 4.3 ± 0.6 2.4 ± 0.4 1 ± 0.2 3 ± 0.4 60º ± 5º

24 ± 4 24 ± 4 15 ± 3 50 ± 6 80 ± 6

2.4 ± 0.4 2.4 ± 0.4 1.5 ± 0.3 5 ± 0.6 8 ± 0.6 90º ± 5º

24 ± 4 36 ± 4 60 ± 5

2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60º ± 5º

43 ± 6 43 ± 6

4.3 ± 0.6 4.3 ± 0.6

43 ± 6

4.3 ± 0.6

65


PR

IN T

NEF ENGINES

R FO O T N

66

NEF ENGINES

SECTION 5 - TOOLS

1

SECTION 5 Tools Page

N

O T

FO

R

PR

IN T

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

SECTION 5 - TOOLS

O T

FO

R

PR

IN T

NEF ENGINES

N

2

NEF ENGINES

SECTION 5 - TOOLS

TOOLS DESCRIPTION

380000144

Tool for flywheel holding

380000216

Lifting rig for engine removal/refitting

380000220

Band for fitting piston into cylinder barrel (60 — 125 mm)

FO

R

PR

IN T

TOOL NO.

Pliers for removing/refitting piston rings (65 — 110 mm)

N

O T

380000221

380000228

Dial gauge (0 — 5 mm)

380000229

Dial gauge holder for rotary injection pump timing (use with 380000228)

3

4

SECTION 5 - TOOLS

NEF ENGINES

DESCRIPTION

380000301

Revolving stand for overhauling units (1000 daN/m capacity, 120 daN/m torque)

380000302

Tool for removing/refitting engine valves

380000304

Pair of gauges with ½” and ¾” square head for angle tightening

FO

R

PR

IN T

TOOL NO.

380000322

N

O T

Injection pump gear extractor.

380000362

Tool for lifting the output shaft

380000364

Gauge base for different measurements (to be used with 380000228)

NEF ENGINES

SECTION 5 - TOOLS

DESCRIPTION

380000661

Brackets for fastening engine to revolving stand 99322205

380000663

Tool to remove output shaft rear gasket

380000664

Tool for fitting output shaft rear gasket

FO

R

PR

IN T

TOOL NO.

Tool to remove output shaft front gasket

380000666

380000667

N

O T

380000665

Tool for fitting output shaft rear gasket

Beater for removing/refitting camshaft bushes (to be used with 380000668)

5

6

SECTION 5 - TOOLS

NEF ENGINES

v

DESCRIPTION

380000668

Interchangeable willow handgrip

380000669

Tool to remove gaskets

380000670

Tool to remove oil filter (engine)

FO

R

PR

IN T

TOOL NO.

380000671

380000988

380000989

N

O T

Tool to remove injectors

Tool for stopping the engine flywheel

Adapter, cylinder compression test (use with 380001006)

NEF ENGINES

SECTION 5 - TOOLS

DESCRIPTION

380000997

Gauge base for different measurements (to be used with 380001005)

380001005

Dial gauge (0 — 10 mm)

380001006

Diesel fuel engine cylinder compression control device

FO

R

PR

IN T

TOOL NO.

Flywheel crank handle

N

O T

380002385

3800002729

Band for fitting piston into cylinder barrel (60 — 125 mm)

7

SECTION 5 - TOOLS

O T

FO

R

PR

IN T

NEF ENGINES

N

8

NEF ENGINES

SECTION 6 - ENGINES FEATURES F4CE - F4DE - F4GE - F4HE

1

SECTION 6 Engines features F4CE - F4DE - F4GE - F4HE Page 3

- General characteristics . . . . . . . . . . . . . . . . . .

3

- Clearance data . . . . . . . . . . . . . . . . . . . . . . . .

9

ENGINES F4DE . . . . . . . . . . . . . . . . . . . . . . . . . . .

15


15

- Clearance data . . . . . . . . . . . . . . . . . . . . . . . .

19

ENGINES F4GE . . . . . . . . . . . . . . . . . . . . . . . . . . .

25


25

- Clearance data . . . . . . . . . . . . . . . . . . . . . . . .

27

ENGINES F4HE . . . . . . . . . . . . . . . . . . . . . . . . . . .

35


35

- Clearance data . . . . . . . . . . . . . . . . . . . . . . . .

37

N

O T

FO

R

PR

IN T

ENGINES F4CE . . . . . . . . . . . . . . . . . . . . . . . . . . . .


R

PR

IN T

NEF ENGINES

FO O T N

2

NEF ENGINES


F4CE ENGINES General characteristics Type

F4CE9484

Cycle


Power

Supercharged with intercooler

Injection

Direct

Number of cylinders

4 in-line

∅

+

mm

104

Stroke

mm

132

cm3

4485


IN T

+

Bore

A B


D C

-

-

FO

R


PR

TIMING

Checking timing

mm

-

mm

-

mm

0.25 to 0.05

mm

0.50 to 0.05

Bosch

VE 4/12 F

X

O T

X

Checking operation

N

X

FUEL FEED Injection Type: Nozzle type

-

Injection sequence

1-3-4-2

bar

Injection pressure

bar

-

3

4


NEF ENGINES

F4CE9484A*J600

Type Compression ratio Max. output

16.5:1 56 (76)

kW (HP) rpm

Max. torque

2300 340 (34.7)

Nm (kgm) rpm

Loadless engine idling

rpm

Loadless engine peak rpm

rpm

Bore x stroke Displacement

mm cm3

1300

-

104 x 132 4485 with intercooler

IN T

ρ

SUPERCHARGING Turbocharger type

PR

-

LUBRICATION

- idling - peak rpm COOLING

bar bar

R

Oil pressure (warm engine)

FO

bar

Forced by gear pump, relief valve single action oil filter

Water pump control Thermostat - start of opening ºC

Liquid

O T

Through belt

N

81 ± 2

FILLING

15W40 ACEA E3

- engine sump* liters

-

liters

-

engine sump + filter

NOTE

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

NEF ENGINES


F4CE9484D*J600

Type

ρ

5

Compression ratio Max. output

16.5:1 kW (HP)

82 (111)

rpm Nm (kgm)

2200 455 (46.4)

rpm

14000

rpm

-

Max. torque

Loadless engine idling Loadless engine peak rpm rpm Bore x stroke mm Displacement cm3 SUPERCHARGING

LUBRICATION

IN T

bar bar

FO

- idling - peak rpm

COOLING

O T N

Through belt 81 ± 2

FILLING - engine sump* liters engine sump + filter liters

NOTE

Liquid


15W40 ACEA E3

HOLSET HX25


R


bar

PR

Turbocharger type


-


6


NEF ENGINES

F4CE9484L*J600

Type

ρ


16.5:1 kW (HP)

78 (106)

rpm Nm (kgm)

2300 448 (45.7)

rpm

1300

rpm

-

rpm mm cm3

104 x 132 4485

Max. torque



IN T

Loadless engine peak

SUPERCHARGING

with intercooler

PR

Turbocharger type


LUBRICATION

- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

-


Liquid Through belt

N

81 ± 2

FILLING

15W40 ACEA E3

- engine sump* liters engine sump + filter

-

liters

NOTE


NEF ENGINES


F4CE9484M*J601

Type

ρ

7


16.5:1 kW (HP)

71 (97)

rpm Nm (kgm)

2300 418 (42,6)

rpm

1300

rpm

-

rpm mm cm3

104 x 132 4485

Max. torque



IN T


SUPERCHARGING

FO

R

Oil pressure (warm engine) - idling - peak rpm

-

bar bar

COOLING

O T

Liquid

N


15W40 ACEA E3

-


LUBRICATION bar

PR

Turbocharger type

with intercooler


FILLING - engine sump* liters engine sump + filter

-

liters

NOTE


8


NEF ENGINES

F4CE9484N*J601

Type

ρ


16.5:1 kW (HP)

63 (86)

rpm Nm (kgm)

2300 370 (37.7)

rpm

1300

rpm

-

rpm mm cm3

104 x 132 4485

Max. torque



IN T


SUPERCHARGING

with intercooler

PR

Turbocharger type


LUBRICATION

- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

-


Liquid Through belt

N

81 ± 2

FILLING

15W40 ACEA E3

- engine sump* liters engine sump + filter

-

liters

NOTE


NEF ENGINES


Clearance data

F4CE9484

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1

mm 104.000 to 104.024

∅1

Cylinder barrels X

0.4

∅1 X

Pistons Size Outside diameter Pin housing

∅2

X ∅1 ∅2

55.9 103.714 to 103.732 38.010 to 38.016

CNH PARTS

0.252 to 0.294

Piston diameter

∅1

Piston protrusion

X

IN T


∅3

Piston pin

R

∅ 3

PR

X

N

O T

FO


0.4

-

37.994 to 38.000 0.010 to 0.022

9

10


NEF ENGINES

F4CE9484

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S 2 S 3

CNH

X1* X2 X3

Split ring slots

* measured on 101 mm ∅ Split rings

S 1* S2 S3

2.560 to 2.605 2.350 to 2.380 3.970 to 3.990

Split rings - slots

1 2 3

0.100 to 0.175 0.060 to 0.110 0.040 to 0.080

Split ring end opening in cylinder barrel: X1 X2 X3

X3

∅ 3

∅2


O T

S

∅1

Piston pin — bush

N

0.30 to 0.40 0.60 to 0.80 0.30 to 0.55

R

∅ 2


FO

∅1

IN T

X 2

0.4

PR

X1

CNH

2.705 to 2.735* 2.440 to 2.460 4.030 to 4.050

Split rings

PARTS

PARTS

mm


40.987 to 41.013 72.987 to 73.013

38.019 to 38.033 1.955 to 1.968 0.019 to 0.039 0.250 to 0.500

NEF ENGINES


F4CE9484

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS

mm

X Size

-

X

Max. tolerance on connecting rod axis alignment

Journals Crankpins

∅1 ∅2

82.990 to 83.010 68.987 to 69.013


S1 S2

2.456 to 2.464 1.955 to 1.968


∅3 ∅3

S 1

IN T

∅2

S 2

∅ 3

R


PR

∅1

-

0.064 to 0.095 0.059 to 0.100

Half bearings - Crankpins

0.033 to 0.041


0.250 to 0.500

FO

CNH

O T

PARTS

87.982 to 88.008 87.977 to 88.013

X1

37.475 to 37.545


X2

32.180 to 32.280

Shoulder half-rings

X3

37.28 to 37.38

N

Shoulder journal

X 1

X 2 X 3


0.095 to 0.265

11

12


NEF ENGINES

F4CE9484

Type CYLINDER HEAD — TIMING SYSTEM ∅ 1

mm


∅ 4

∅1

8.019 to 8.039

∅4 α

7.960 to 7.980 60°

∅4 α

7.960 to 7.980 45°

Valves:


0.039 to 0.079

IN T


46.987 to 47.013

∅1

∅ 1


FO

R

∅ 2

PR

∅1

∅2 α

Sinking

N

X

O T

α


CNH PARTS

Valve seats

43.637 to 43.663

47.063 to 47.089 60o 43.713 to 43.739 45o

X

1 to 1.52

X

1.05 to 1.52 0.050 to 0.102 0.050 to 0.102 -

NEF ENGINES


F4CE9484

Type CYLINDER HEAD — TIMING SYSTEM

mm


H1


H

63.50

H1 H2

49.02 38.20

X

not adjustable

X

59.222 to 59.248


54.089 to 54.139

IN T

∅ ∅ ∅ 1 23 4 5




∅

FO

∅

R

∅ 3

54.083 to 54.147 0.038 to 0.162

Housings and journals Cam lift:

0.044 to 0.144

O T

H

53.995 to 54.045

Bushes and journals

N

∅ 1

∅

PR

∅ 2

H

11.02

H

10.74

13

14


NEF ENGINES

F4CE9484


mm



∅2

∅1

16,000 ÷ 16,030

∅2 ∅3

15.929 to 15.959 15.965 to 15.980

Between tappets and housings CNH

0.020 to 0.065

Tappets

PARTS

-

∅ 1

Rockers

∅2

18.963 to 18.975

IN T

∅1

19.000 to 19.026

PR

Rocker shaft

∅ 2

N

O T

FO

R


0.025 to 0.063

NEF ENGINES


F4DE ENGINES General characteristics Type

F4DE9484

Cycle


Power

Supercharged with intercooler

Injection

Direct

Number of cylinders

4 in-line

∅

+

+

Bore

mm

104

Stroke

mm

132

cm3

4485



D C

-

-

mm

-

mm

-

mm

0.20 to 0.30

mm

0.45 to 0.55

Bosch

high pressure common rail EDC7 ECU

FO

Checking timing

PR

A B

R


IN T

TIMING

X

X

X

N

O T

Checking operation

FUEL FEED Injection Type:

Injectors

CRIN 2

Nozzle type

DSLA and DLLA

Injection sequence

1-3-4-2

bar

Injection pressure

bar

0.250 - 1600

15

16


NEF ENGINES

F4DE9464B*J101

Type Compression ratio Max. output

Max. torque

16.5:1 kW (HP)

97 (132)

rpm

2200

Nm (kgm)

534 (54.4)

rpm

1400


rpm


rpm


mm cm3

-

2500 104 x 132 4485 with intercooler

IN T

ρ

PR

SUPERCHARGING Turbocharger type


bar bar

O T

- idling - peak rpm

FO

bar

R

LUBRICATION

COOLING

-


Liquid


N


FILLING 15W40 ACEA E3


-

liters

-


NOTE


NEF ENGINES


F4DE9484D*J101

Type

ρ

17


16.5:1 kW (HP)

89 (121)

rpm Nm (kgm)

2200 563 (57.4)

rpm

14000

rpm

-

rpm mm cm3


Max. torque



IN T


SUPERCHARGING

PR

Turbocharger type LUBRICATION


FO

R


bar

- idling - peak rpm

-

bar bar

COOLING

O T

Liquid

N


15W40 ACEA E3


FILLING - engine sump* liters

-

liters

-


NOTE

-


18


NEF ENGINES

F4DE9484E*J100

Type

ρ


16.5:1 82 (111)

kW (HP) rpm

Max. torque

2200 520 (53)

Nm (kgm) rpm

1400

Loadless engine idling rpm

-

mm cm3


IN T

Loadless engine peak rpm rpm Bore x stroke Displacement

SUPERCHARGING

PR

Turbocharger type LUBRICATION


- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

-


Liquid Through belt

N

81 ± 2

FILLING

15W40 ACEA E3


-

liters

-


NOTE


NEF ENGINES


Clearance data

F4DE9484


mm 104.000 to 104.024

∅1

Cylinder barrels X

0.4

∅1 X ∅2


X ∅1 ∅2

55.9 103.714 to 103.732 38.010 to 38.016

CNH PARTS

0.252 to 0.294

Piston diameter

∅1

Piston protrusion

X

IN T


∅3

Piston pin

R

∅ 3

PR

X

N

O T

FO


0.4

-

37.994 to 38.000 0.010 to 0.022

19

20


NEF ENGINES

F4DE9484


mm

Split ring slots

X1* X2 X3

2.705 to 2.735 2.440 to 2.460 4.030 to 4.050

Split rings

S 1* S2 S3

2.560 to 2.605 2.350 to 2.380 3.970 to 3.990

* measured on 98 mm ∅ 1 2 3

Split rings - slots CNH

Split rings

X 2

Split ring end opening in cylinder barrel: X1 X2 X3

X3

S

CNH

R

∅2

0.30 to 0.40 0.60 to 0.80 0.30 to 0.55

42.987 to 43.553 72.987 to 73.013

FO

∅ 3

∅1


O T

∅ 2


38.019 to 38.033 1.955 to 1.968

Piston pin — bush

0.019 to 0.039


0.250 to 0.500

N

∅1

IN T

X1

0.4

PR

PARTS

PARTS

0.100 to 0.175 0.060 to 0.110 0.040 to 0.080

NEF ENGINES


F4DE9484


∅2

S 1

mm

Journals Crankpins

∅1 ∅2

82.99 to 83.01 68.99 to 69.01


S1 S2

2.456 to 2.464 1.955 to 1.968

S 2 *provided as spare part

CNH


∅ 3 ∅3


0.041 to 0.119 0.041 to 0.103


0.033 to 0.041


0.250 to 0.500

PR

PARTS

X1

37.475 to 37.545

R

Shoulder journal

FO

X 1

Shoulder half-rings

N

X 2

O T


X 3

87.982 to 88.008 87.977 to 88.013

IN T

∅ 3


X2

25.98 to 26.48

X3

37.28 to 37.38 0.068 to 0.41

21

22


NEF ENGINES

F4DE9484


mm


∅1

7.042 to 7.062

∅2

-

∅3

-

∅ 2

Valve guides ∅ 3

CNH

-

IN T

Valve guides and seats on head Valve guides

PARTS

∅ 4

-

∅4 α ∅4 α

R

α

PR

Valves:

FO

Valve stem and guide

6.970 to 6.999 60o ± 0.25o 6.970 to 6.999 45o ± 0.25o 0.052 to 0.092

O T


∅ 1

∅1

34.837 to 34.863

N

∅2 α

α

X

Sinking Between valve seat and head

CNH

34.837 to 34.863


∅ 2

PARTS

∅1

Valve seats

34.917 to 34.931 60o 34.917 to 34.931 45o

X

0.59 to 1.11

X

0.96 to 1.48 0.054 to 0.094 0.054 to 0.094 -

NEF ENGINES


F4DE9484


mm


H1


H

47.75

H1 H2

35.33 25.2

X

-

X

59.222 to 59.248


54.089 to 54.139

IN T

∅ ∅ ∅ 1 23 4 5




∅

FO

∅

R

∅ 3

Bushes and journals

H

O T

Cam lift:

N

∅ 1

∅

PR

∅ 2

53.995 to 54.045

54.083 to 54.147 0.038 to 0.162

H

6.045

H

7.582

23

24


NEF ENGINES

F4DE9484


mm



∅2

∅1

16.000 to 16.030

∅2 ∅3

15.924 to 15.954 15.960 to 15.975


0.025 to 0.070

Tappets

PARTS

-

∅ 1

Rockers

∅2

21.965 to 21.977

IN T

∅1

22.001 to 22.027

PR

Rocker shaft

∅ 2

N

O T

FO

R


0.024 to 0.162

NEF ENGINES


25

F4GE ENGINE General characteristics

F4CE9454C*J602

Type

ρ


Max. torque


17.5:1 kW (HP)

67 (91)

rpm

2300

Nm (kgm)

372 (38)

rpm

1300

rpm

1150

Loadless engine peak rpm rpm mm cm3

2530 104 x 132 4485 with intercooler

IN T


Turbocharger type


FO

bar

R

LUBRICATION

PR

SUPERCHARGING

- idling - peak rpm

N

O T

Liquid



FILLING - engine sump liters

13

liters

14


NOTE


0.70 3.50

bar bar

COOLING

15W40 ACEA E3

HOLSET HX25

Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by CNH. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.

26


NEF ENGINES

F4GE9484D*J600

Type

ρ


Max. torque

17.5:1 kW (HP)

93 (126)

rpm

2200 510 (52)

Nm (kgm) rpm

1250


-

mm cm3

104 x 132 4485

IN T

Loadless engine peak rpm rpm Bore x stroke Displacement

SUPERCHARGING

with intercooler

PR

Turbocharger type


LUBRICATION

- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

HOLSET HX25


0.70 3.50 Liquid Through belt

N

81 ± 2

FILLING

15W40 ACEA E3

- engine sump liters

-

liters

-


NOTE


NEF ENGINES


27

Clearance data

F4GE9484E*J600

Type

ρ


Max. torque

17.5:1 kW (HP)

90 (122)

rpm

2000 525 (53.5)

Nm (kgm) rpm

1200


-

rpm Loadless engine peak rpm rpm mm cm3

IN T


SUPERCHARGING

LUBRICATION Oil pressure (warm engine)

PR

FO

bar

with intercooler

R

Turbocharger type

COOLING

N

HOLSET HX25


0.70 3.50

bar bar

O T

- idling - peak rpm

104 x 132 4485

Liquid



FILLING 15W40 ACEA E3


-

liters

-


NOTE


28


NEF ENGINES

F4GE9484F*J600

Type

ρ


Max. torque

17.5:1 kW (HP)

74 (101)

rpm Nm (kgm)

2200 (-)

rpm

-

rpm

-

rpm mm cm3

104 x 132 4485



IN T


SUPERCHARGING

with intercooler

PR

Turbocharger type


LUBRICATION

- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

HOLSET HX25

Liquid Through belt 81 ± 2

N


0.70 3.50

FILLING

15W40 ACEA E3


-

liters

-


NOTE


NEF ENGINES


F4GE9484H*J600

Type

ρ

29


17.5:1 kW (HP)

84 (114)

rpm Nm (kgm)

2000 495 (50.5)

rpm

1200

rpm

-

rpm mm cm3

104 x 132 4485

Max. torque



IN T


SUPERCHARGING

FO

R


0.70 3.50

bar bar

COOLING

O T

Liquid

N


15W40 ACEA E3

HOLSET HX25


LUBRICATION bar

PR

Turbocharger type

with intercooler



-

liters

-


NOTE


30


NEF ENGINES

F4GE9484J*J600

Type

ρ


Max. torque

17.5:1 kW (HP)

88 (120)

rpm

2200 515 (52.5)

Nm (kgm) rpm

1250


-

rpm mm cm3

104 x 132 4485


IN T


SUPERCHARGING

with intercooler

PR

Turbocharger type


LUBRICATION

- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

HOLSET HX25


N


0.70 3.50

FILLING

15W40 ACEA E3


-

liters

-


NOTE


NEF ENGINES


F4GE9484A*J601

Type

ρ

31


Max. torque

17.5:1 kW (HP)

94 (128)

rpm

2300

Nm (kgm) rpm

1300 515 (52.5)


-

rpm mm cm3

104 x 132 4485


IN T


SUPERCHARGING

FO

R


0.70 3.50

bar bar

COOLING

O T

Liquid

N


15W40 ACEA E3

HOLSET HX25


LUBRICATION bar

PR

Turbocharger type

with intercooler



-

liters

-


NOTE


32


NEF ENGINES

F4GE9484K*J601

Type

ρ

Compression ratio

17.5:1 74 (101)

Max. output

kW (HP) rpm

Max. torque

Nm (kgm)

2300 (-)

rpm

-

rpm

-

rpm mm cm3

104 x 132 4485



IN T


SUPERCHARGING

with intercooler

PR

Turbocharger type


LUBRICATION

- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

HOLSET HX25


0.70 3.50 Liquid Through belt

N

81 ± 2

FILLING

15W40 ACEA E3


-

liters

-


NOTE


NEF ENGINES


F4GE9484A*J602 F4GE06

Type Type

ρ

33


17.5:1 94 (128)

kW (HP) rpm

Max. torque

2300 515 (52.5)

Nm (kgm) rpm

1300


-

rpm mm cm3

104 x 132 4485


IN T


SUPERCHARGING

FO

R


0.70 3.50

bar bar

COOLING

O T

Liquid

N


15W40 ACEA E3

HOLSET HX25


LUBRICATION bar

PR

Turbocharger type

with intercooler



-

liters

-


NOTE


34


NEF ENGINES

F4GE9484D*J603

Type

ρ

Compression ratio

17.5:1 93 (126)

Max. output

kW (HP) rpm

Max. torque

Nm (kgm)

2200 510 (52)

rpm

1250


-

rpm Loadless engine peak rpm rpm mm cm3

104 x 132 4485

IN T


SUPERCHARGING

PR

with intercooler

Turbocharger type


FO

bar

R

LUBRICATION

bar bar

COOLING

HOLSET HX25


0.70 3.50

O T

Liquid

N



FILLING

15W40 ACEA E3


-

liters

-


NOTE


NEF ENGINES


F4HE ENGINES General characteristics Type

F4HE9484

Cycle


Power

Turbocharged with intercooler

Injection

Direct

Number of cylinders

4

∅

+

+

Bore

mm

104

Stroke

mm

132

cm3

4485



D C

18.5º 29.5º

67º 35º

mm

-

mm

-

mm

0.20 to 0.30

mm

0.45 to 0.55

Bosch

high pressure common rail EDC7 ECU

FO

Checking timing

PR

A B

R


IN T

TIMING

X

X

X

N

O T

Checking operation

FUEL FEED Injection Type:

Injector

CRIN 2

Nozzle type

DSLA and DLLA

Injection sequence

1-3-4-2

bar

Injection pressure

bar

250 - 1600

35

36


NEF ENGINES

F4HE9484C*J102

Type

ρ


Max. torque

17.5:1 kW (HP)

82 (111)

rpm Nm (kgm)

2200 1400

rpm

516 (52.6)

rpm

950

rpm mm cm3

2430 104 x 132 4485



IN T


SUPERCHARGING

with intercooler

PR

Turbocharger type


LUBRICATION

- idling - peak rpm

bar bar

O T

COOLING

R


FO

bar

-


N


-

FILLING

15W40 ACEA E3


-

liters

-


NOTE


NEF ENGINES


Clearance data

F4HE9484

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1 Cylinder barrels X X ∅2 CNH PARTS


∅1

104.000 to 104.024

∅1

0.4

X ∅1 ∅2

55.9 103.714 to 103.732 38.010 to 38.016

Piston diameter

∅1

Piston protrusion

X

0.4

IN T

∅1

mm

X

PR

∅ 3

0.28 to 0.52

∅3

Piston pin

N

O T

FO

R


37.994 to 38.000 0.01 to 0.022

37

38


NEF ENGINES

F4HE9484


CNH

X1* X2 X3

2.705 to 2.735 2.440 to 2.460 4.030 to 4.050

Split rings

S 1* S2 S3

2.560 to 2.605 2.350 to 2.380 3.970 to 3.990

Split rings - slots

1 2 3

0.100 to 0.175 0.060 to 0.110 0.040 to 0.080

Split ring slots * measured on 101 mm

Split rings

X 2

Split ring end opening

∅ 3

∅1

R

∅2

Inside Big end half bearings

N

Piston pin — bush

PARTS

40.987 to 41.013 72.987 to 73.013

Small end bush diameter

O T

S


FO

∅ 2

0.30 to 0.40 0.60 to 0.80 0.30 to 0.55

X1 X2 X3

X3

∅1

IN T

X1

0.4

PR

PARTS

CNH

mm


∅3

S

38.019 to 38.033 1.955 to 1.968 0.019 to 0.039 0.250 ; 0.500

NEF ENGINES


F4HE9484

Type CYLINDER UNIT AND CRANKSHAFT COMPONENTS

mm

X Size

-

X

Max. tolerance on connecting rod axis alignment ∅2

S 2

∅ 3

∅1 ∅2

82.99 to 83.01 68.987 to 69.013


S1 S2

2.456 to 2.464 1.955 to 1.968

Main bearings No. 1 — 5 / 1- 7 No. 2 — 3 — 4

∅ 3 ∅3

Half bearings — Journals No. 1—5 / 1-7 No. 2—3—4 / 2-3-4-5-6

CNH


FO

PARTS

R


87.982 to 88.008 87.977 to 88.013 0.041 to 0.119 0.041 to 0.103 0.033 to 0.041 0.250 to 0.500

X1

37.475 to 37.545


X2

32.180 to 32.280

Shoulder half-rings

X3

37.28 to 37.38

O T

Shoulder journal

IN T

S 1

Journals Crankpins

PR

∅1

-

N

X 1

X 2 X 3


0.095 to 0.265

39

40


NEF ENGINES

F4HE9484


mm


∅ 4

∅1

7.042 to 7.062

∅4 α

6.970 to 6.990 60o ± 0.25o

∅4 α

6.970 to 6.990 45o ± 0.25o

Valves:


0.052 to 0.092

IN T


34.837 to 34.863

∅1

∅ 1


FO

R

∅ 2

PR

∅1

∅2 α

Sinking

N

X

O T

α


CNH PARTS

Valve seats

34.837 to 34.863

34.917 to 34.931 60o 34.917 to 34.931 45o

X

0.59 to 1.11

X

0.96 to 1.48 0.054 to 0.094 0.054 to 0.094 -

NEF ENGINES


F4HE9484


mm


H1


H

47.75

H1 H2

35.33 25.2

X

-

X Camshaft bush housings No. 1 (flywheel side) Camshaft housings No. 2-3-4-5/2-3-4-5-6-7 ∅

∅ 2

∅


∅

FO

∅

R

∅ 3

Bushes and journals

H

O T

Cam lift:

N

∅ 1

PR


54.089 to 54.139

IN T

∅ ∅ ∅ 1 23 4 5

59.222 to 59.248

53.995 to 54.045

54.083 to 54.147 0.038 to 0.162

H

6.045

H

7.582

41

42


NEF ENGINES

F4HE9484


mm



∅2

∅1

16.000 to 16.030

∅2 ∅3

15.924 to 15.954 15.960 to 15.975


0.025 to 0.070

Tappets

PARTS

-

∅ 1

Rockers

∅2

∅ 2

N

O T

FO

R


21.965 to 21.977

IN T

∅1

PR

Rocker shaft

22.001 to 22.027

0.024 to 0.162

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APPENDIX

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Appendix Page

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SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . .

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APPENDIX

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APPENDIX

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SAFETY PRESCRIPTIONS Standard safety prescriptions

- Do not execute any intervention if not provided with necessary instructions.

Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance. Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation. - Keep working areas as clean as possible, ensuring adequate aeration. - Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. - Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities. - Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines. - Smoking in working areas subject to fire danger must be strictly prohibited.

- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur.

- Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.

- Keep the engine clean from oil tangles, diesel fuel and or chemical solvents.

- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.

During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids.

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- Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation.

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- Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.

Prevention of injury

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- Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion.

- Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas aerated. Whenever necessary wear safety mask. - Do not leave rags impregnated with flammable substances close to the engine. - Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate.

- Wear safety helmet when working close to hanging loads or equipment working at head height level.

- Disconnect batteries before any intervention on the electrical system.

- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.

- Disconnect batteries from system aboard to load them with the battery loader.

- Use protection cream for hands.

- After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.

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- Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed: ≤ 2 bar)

- Change wet cloths as soon as possible - In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections. Ensure that hands and feet are dry and execute working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material. - Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.

- Do not utilize fast screw-tightening tools. - Never disconnect batteries when the engine is running.

- Do not disconnect and connect electrical connections in presence of electrical feed. - Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning.

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- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved by Iveco. - Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80ºC temperature.

Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted. - Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger. - Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.

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- Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.

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- Do not paint the components and the electronic connections.

Case New Holland Kobelco Iveco Komatsu F4CE F4DE F4GE F4HE Service Repair Manual For Engine Overhaul ( Mechanical Injection and Electronic Common Rail ).pdf

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