sm_4 Cylinders F5_EN.pdf

ENGINES CNH F5C - F5A Structural and Non Structural Version

Manual

ENGINES CNH F5C - F5A

Tier III

Structural and Non Structural Version

Repair

4 Cylinders, Mechanical

Print No. 87736548A English

Repair Manual Tier III

Copyright ©

REPAIR INSTRUCTION MANUAL CNH ENGINES ENGINES FAMILY: F5AE9484 F5AE 9484 -- F5AE9454 F5AE 9454 -- F5CE948 F5CE9484 4 -- F5CE9454 F5CE 9454 -- F5CE545 F5CE5454 4

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. 87736548A Edizione -- October 2007

Copyright ©

Copyright © ININ -- 1

FOREWORD

TO THE READER - This Manual is written for for an expert technician to

- For any question or comment, or in case any

provid provide e the techni technical cal inform informati ation on requir required ed to perperform repair operations on this machine. - Please read carefully this manual for for the correct information regarding the repair procedures.

error error regard regarding ing the conten contentt of this this man manual ual is found,, you are asked to please found please contact: CNH ITALIA S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA 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.

!

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 attention to the weight of a component 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.

Copyright © ININ -- 2

FOREWORD

UNITS OF MEASURE In this manual, the units of measure measure of the IS (International (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, below, a conversion conversion table of the units of the IS and some units of measure measure of other systems is listed. as a reference.

Quantity eng

Volume Mass orce orque

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

into (Others)

Multiply by

in ft US gal US qt yd3

0. 0.03937 0.003281 0.2642 1.057 1.308

lb kgf lbf kgf.m lbf.ft

2.205 0.10197 0.2248 0.10197 0.7375

Quantity

ressure

ower Temperature e oc ty ow

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

into (Others)

Multiply by

kgf/cm2 psi PS HP °F

10.197 145.0 1.360 1.341 °C x 1.8 + 32

m ph rp m US US gpm cc/rev

0.6214 1.0 0. 0 .2642 1.0

Copyright © 3

F5 ENGINES

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 descriptions of some operations operations or procedures. procedures.

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

Copyright © 4

F5 ENGINES

UPDATING Section

Description

Page

Date of revision

Copyright © F5 ENGINES

INTRODUCTION

1

Introduction

Page PREFACE TO USER’S GUIDELINE MANUAL . . . .

3

SYMBOLS

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

3

-

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

-

Service operations . . . . . . . . . . . . . . . . . . . . . .

3

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

5

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

7

-

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

8

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

9

Copyright © 2

INTRODUCTION

F5 ENGINES


INTRODUCTION

3

PREFACE PREFACE TO USER’S USER’S GUIDELINE GUIDELINE MANUAL MANUAL 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 section sectionss dealing dealing with with things things mechan mechanic ic introdu introduce ce the specif specificat ications ions,, tighten tightening ing torque torque values, values, tool tool lists, lists, assemb assembly ly 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. Mechani Mechanical cal part, part, related related to the engine engine overhau overhaul,l, limited limited to those those compon component entss with with differe different nt charac characteri teristi stics cs based based on the relatin relatingg specific duty. 2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based based on the relating specific duty. 3. Maintenance Maintenance planning and specific overhaul. 4. Troubl Troublesh eshoot ooting ing part part dedica dedicated ted to the operat operators ors who, who, being being entitle entitled d to provid provide e technic technical al assist assistanc ance, e, shall shall have have simple simple and direct direct instructions instructions to identify identify the cause of the major inconveniences. 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 takin g 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.

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

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.

!

General danger It includes the dangers of above described signals.

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

It indicates an additional additional explanation explanation for a piece of information. 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

Copyright © 4

INTRODUCTION

F5 ENGINES

Removal Disconnection

Intake

Refitting Connection

Exhaust

Removal Disassembly

Operation

Fitting in place Assembly

ρ

Tighten Tighten to torque

Compression ratio Tolerance Weight difference

Tighten to torque + angle value

Rolling torque

Press or caulk

Rotation

Regulation Adjustment

Angle Angular value

α

!

Warning Note

Preload

Visual inspection Fitting position check

Number of revolutions

Measurement Value to find Check

Temperature

Equipment

bar

Pressure

Surface Surface for machining machining Machine finish

Oversized Higher than… than…. Maximum, peak

Interference Strained assembly

Undersized Less than… than…. Minimum

Thickness Clearance

Selection Classes Oversizing

Lubrication Damp Grease

Temperature < 0 ° 0 °C C Cold Winter

Sealant Adhesive

Temperature > 0 ° 0 °C C Hot Summer

Air bleeding


INTRODUCTION

5

GENERAL WARNINGS

!

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate immediate superiors where a danger situation situation occurs which is not described. described. Use both both specif specific ic and general general-p -purp urpose ose tooling toolingss accord according ing to the prescr prescript iptions ions contai contained ned in respec respective tive 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 because it also depends, 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. You shall get familiar with the operating and safety instructions for the assembly assembly prior to operating on the latter. Strictly Strictly follow all the safety indications found on the assembly. Do not leave the running assembly assembly unattended unattended when making repairs. repairs. When carrying out work on the assembly lifted off the ground, verif y that the assembly is firmly placed on its supporting stands, stands, and that the manual/autom manual/automatic atic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist. 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. Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Inflamm Inflammabl able e fuel fuel andall inflamm inflammabl able e fluidsand fluidsand liquid liquidss must must be handled handled with with care, care, accord according ing to what what contai contained ned on harmful harmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparksin sparksin order order to preven preventt sudden sudden fires/b fires/burs ursts. ts. Adequ Adequate ately ly store store inflamm inflammabl able, e, corros corrosive ive and pollut polluting ing fluids fluids and liquid liquidss 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. During During worksh workshop op activit activity, y, alwayskeep alwayskeep the work work place place clean; clean; timely timely clear clear or clean clean floors floors fromaccident fromaccidental al liquid liquid or oil spots. spots. Electric sockets sockets and electric equipment equipment necessary to perform repair interventions interventions must meet safety rules.

Copyright © 6

INTRODUCTION

F5 ENGINES

Put on, where required by the intervention, garments and protections protections provided in accident accident prevention rules; contact 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 Avoid to breathe breathe fumes coming coming from heating heating or from paint paint welding welding becaus because e they they can cause cause damage damagess to health; health; operat operate e 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 securing elements (screws, nuts, etc.) into special 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. Avoid contact contact of rubber parts with diesel oil, petrol or other not compatible compatible substances. substances. Before washing under pressure mechanical mechanical parts, parts, protect protect electric connectors, connectors, and central central units, if present. present. Tightening screws and nuts must always be according to prescriptions; CNH commercial and assistance network is available available to give all clarifications clarifications necessary necessary to perform repair interventions interventions not provided provided in this document. document. Before welding: - Discon Disconnec nectt all electr electroni onic c centra centrall units, units, take take power power cable cable off off bat batter tery y positi positive ve termin terminal al (connec (connectt it to chaschas-

sis bonding) and detach connectors. - Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and

water. - Await about 15 minutes minutes before welding. - Equ Equip ip with with suitab suitable le fire fire resist resistant ant protec protectio tions ns to protec protectt hoses hoses or oth other er compon component ents s where where fluids fluids or oth other er

materials flow which may catch fire easily on welding. Should the vehicle be subjected subjected to temperatures temperatures exceeding exceeding 80° 80°C (dryer ovens), disassemble drive electronic central units.

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


INTRODUCTION

7

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

!

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, disconnect, as a first one, the chassis bonding cable from batteries batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated. Disconnect Disconnect the external recharging recharging apparatus apparatus from the public utility network before taking apparatus 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 electronic devices wiring harnesses harnesses (length, lead type, location, location, strapping, strapping, connection connection to screening braidin braiding, g, bondin bonding, g, etc.) etc.) comply comply with with CNH system system and are careful carefully ly recove recovered red after after repair repair or mainte maintenanc nance e interve interventio ntions. ns. Measurements in drive electronic central units, plugged connections and electric connections to components can only be made on proper testing testing lines with special special plugs and plug bushes. bushes. Never use improper improper means like wires, screwdrivers, screwdrivers, clips clips and and the the like like in orde orderr to avoidthe avoidthe dang danger er of caus causin ingg a shortcirc shortcircuit uit,, as well well as of dama damagin gingg plugg plugged ed conn connec ectio tions ns,, whic which h would later cause contact problems.

To star startt up the the engin engine, e, donot use use fast fast char charge gers rs.. Star Startt up mustonly mustonly be perfo perform rmed ed with with either either sepa separat rate e batt batteri eries es or spec special ial truck. A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries) can cause them to be destroyed. Disconnect Disconnect the batteries batteries from the system during their recharging recharging with an external apparatus. apparatus. On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque. Before disconnecting disconnecting the junction junction connector connector from an electronic central unit, isolate isolate the system. Do not directly directly supply electronic central units servo components components at nominal nominal vehicle voltage. voltage. 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

Connect Connectorspresen orspresentt must must be seen seen fromcableside. Connect Connectorsviews orsviews contai contained ned in the manual manual are repres representa entativeof tiveof cable cable side.

Copyright © 8

INTRODUCTION

F5 ENGINES

Bonding and screening Negati Negative ve leads leads connec connected ted to a system system bonded bonded point point must must be both as short short and possi possible ble and “star““star“-con connec nected ted to each each other, other, trying trying then to have their centering tidily and properly made (Figure 1, re. M). Further, Further, following following warnings warnings are to be compulsorily compulsorily observed observed for electronic electronic components: components: -

Electronic Electronic central central units must be be connected connected to system system bonding bonding when they are provided provided with with a metallic metallic shell.

-

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

-

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

-

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

-

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

-

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

Figure 1

1.

NEGATIVE CABLES “ STAR “ CONNECTION TO SYSTEM BONDING M

Figure 2

88039

2.

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


INTRODUCTION

9

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Assem Assembli blies es shall shall be modifie modified d and equipp equipped ed with with additio additions ns - and their their access accessorie oriess shall shall be fitted fitted - in accord accordanc ance e with with the assemb assembling ling 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 simplify and normalise normalise the electrical electrical intervention that is care of preparation preparation personnel. 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.

Copyright © 10 INTRODUCTION

F5 ENGINES

Copyright © 1

F5 ENGINES

F5 ENGINES Section F5CE Engines

Part 1

F5AE Engines

Part 2

Copyright © 2

F5 ENGINES

Copyright © 1

F5CE ENGINES

PART 1 - F5CE ENGINES Section General information

1

Supply

2

Industrial appliance

3

Overhaul and specifications

4

Tools

5

Safety rules

Appendix

Copyright © 2

F5CE ENGINES

Copyright © F5CE ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

1

SECTION 1 General specifications Page TECHNICAL CODING . . . . . . . . . . . . . . . . . . . . .

3

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . .

7

-

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

-

Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . .

9

ENGINE OIL VAPOUR RECIRCULATION . . . . . .

10

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . .

11

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Working system . . . . . . . . . . . . . . . . . . . . . . .

12

HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . .

13

E.G.R. SYSTEM (EXHAUST GAS RECIRCULATION) . . . . . . . .

14

INTERNAL EGR . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

EXTERNAL EGR . . . . . . . . . . . . . . . . . . . . . . . . . .

15

BOOSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

-

Copyright © 2

SECTION 1 - GENERAL SPECIFICATIONS SPECIFICATIONS

F5CE ENGINES



TECHNICAL CODING

Technical Code F5CE5454B F5CE9484E F5CE9484C F5CE9454E F5CE9454C F5CE9454G TECHNICAL DESIGNATION

TYPE F

5

C

E

9

4

8

PART NUMBER 4

B * A

0

0

1

-

Progressive production number Variant number Level of Gas Emissions (Tier 3) Engine torque and power level Use (eg 4 = tractors) Air feed + injection (TCA, direct injection diesel engine) Number of cylinders 5 - External EGR 9 - Internal EGR Engine (invariable)

rpm B 61 kW / 2500 rpm 2300 rpm C 65 kW / 2300

Engine family evolution (also irrespective irrespective of the displaceme displacement) nt) Indicates the engine family

E 55 kW / 2500 rpm G 48 kW / 2300 rpm

3

Copyright © 4


F5CE ENGINES

ENGINE VIEWS Figure 1

118979

ENGINE FRONT VIEW Figure 2

118977

ENGINE RIGHT SIDE VIEW



5

Figure 3

118978

ENGINE LEFT SIDE VIEW Figure 4

118980

ENGINE REAR VIEW

Copyright © 6


F5CE ENGINES

Figure 5

118981

ENGINE TOP VIEW



LUBRICATION SYSTEM Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and driven by the toothed gear splined splined on the shank of the engine drive shaft. From From the the oil pan, pan, the the lubr lubrica icatio tion n oil oil is dist distrib ribut uted ed to the the engin engine e drive shaft, the camshaft and the valve control.

7

The lubric lubricatio ation n system system also also compri comprises ses the heat exchang exchanger, er, he centrifugal centrifugal blower blower for the versions versions with with turbosuperch turbosupercharger arger and eventually the compressor if the compressed air system is also fitted. All the above above mentio mentioned ned compon componentsvary entsvary depend depending ing on their their use and therefore will be illustrated in the specific section.

Figure 6

Pressurized oil Dropping oil

118982

LUBRICATION SYSTEM DIAGRAM 1. Turbosupercharger lubrication feed pipe - 2. Heat exchanging unit - 3. Heat exchanger - 4. Oil pump - 5. Oil filter

Copyright © 8


F5CE ENGINES

Oil pump Figure 7

119405

PUMP SPECIFICATIONS Rotating speed Feed pressure Rated flow Oil type Max. oil temperature

750 rpm - 4200 rpm 2 Bar - 4 Bar 12.2 l/min - 75.9 l/min SAE 20/30 80 °C ° C

1. Main gear - 2. Secondary gear - 3. Pump unit - 4. Drive shaft - 5. Secondary shaft 6. Cover - 7. Internal rotor - 8. External rotor - 9. Bush.



9

Engine oil filter Figure 8

119406

1. Protective cover - 2. Cartridge Booster pressure:

20 bar (ISO 4548/3)

Dynamic pres ressure: re:

0-1 0-15 bar (1H (1Hz) > 50,00 ,000 cycles (IS (ISO 4548/5)

Operating temperature:

-40 / + 140 C

Torque wrench setting:

18 ±2 Nm

Maximum flow:

50 l/min.

Load Load loss loss at the end of life cyc cycle: le:

2.5 bar

Accumulation:

> 15 gr with 2.5 bar load loss (ISO 16889)

˚

Copyright © 10


F5CE ENGINES

ENGINE OIL VAPOUR RECIRCULATION Figure 9

119407

1. Valve - 2. Breather - 3. Tappet cover On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop by gravity on the underlying tappet cover (3). The remaining non condensed vapours will be duly conveyed through the breather (2), for instance by suction (appropriate connection connection must be provided by the outfitter).



ENGINE COOLING SYSTEM The closed circuit forced circulation engine cooling system is composed of the following parts: - expansion tank: position, form and dimensions may vary depending on the engine fitting;

11

exchanger cooling cooling the lubricant lubricant oil. This component component - heat exchanger may vary depending on the specific engine fitting; - centrif centrifuga ugall water water pump pump positio positioned ned in the front front part part of of the engine basement; - thermostat controlling cooling liquid circulation.

- radiator radiator dissip dissipati ating ng the heat heat absorb absorbed ed by the engine engine cooling liquid. This component’s component’s position and dimensions may vary depending on the outfit; - fan fan incr increa easi sing ng the the radi radiat ator or’s ’s cool coolin ingg powe power. r. This This component may vary depending on the specific engine fitting;

Figure 10

Closed thermostat Open thermostat

Water in flow Engine cooling water Water ou tflow from thermostat

118983

ENGINE COOLING SYSTEM DIAGRAM

Copyright © 12


F5CE ENGINES

WATER PUMP Figure 11

120047

WATER PUMP SECTION 1. Hub - 2. Shaft with bearing - 3. Pump unit - 4. Sheath - 5. Impeller. The water pump is a centrifugal blade turbine type pump. The pump’s bearing (2) is connected to the impeller’s shaft as a whole. Water tight between the pump unit u nit (3) and the shaft (2) is ensured by the sheath (4).

THERMOSTAT Figure 12

119412

THERMOSTAT DIAGRAM

Working system When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermostat, which cuts cuts out water water circula circulatio tion n to the radiat radiator. or. Thi Thiss way, way, water water circulat circulation ion willonly be possib possible le in the pumppump-engi engine ne circuit circuit,, insofarallowi insofarallowing ng engine heat-up quickly. The thermostat valve starts opening at nearly 80 C, allowing water circulation into the radiator and also obstructing obstructing direct return towards the engine. Check the thermostat thermostat efficiency and replace it in case of doubtful doubtful functioning. 1. Stroke Stroke starts starts at 79 ± 2 C 2. 7 mm mm strok stroke e at at 94 ±2 C ˚

˚

˚

˚

˚



13

HEAT EXCHANGER EXCHANGER Figure 13

SECTION A-A

SECTION B-B

119408

The heat exchanger within the engine cooling system has the duty to control the engine oil temperature, reducing it by absorbing heat throughout the engine cooling liquid.

Copyright © 14


F5CE ENGINES

EGR EXHAUST GAS RECIRCULATION The exhaust exhaust gascan be partia partially lly recycle recycled d to cylind cylinders ers to reduce reduce maximu maximum m temper temperatu ature re values values of combus combustion tion that that produc produce e nitrogen nitrogen oxides (NOx). The exhaust exhaust gasrecycle gasrecycle system system (EGR) (EGR) reduce reducess combus combustio tion n temper temperatu ature re and therefor therefore e is an efficien efficientt NOx NOx emissi emission on contro controll system system..

INTERNAL EGR (F5CE9454 - F5CE9484 ENGINES) The specific design of suction cams of the internal EGR system allows part of exhaust gas to be recycled to engine cylinders. This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always active. Its configuration requires requires no additional additional parts such as control valves, pipelines pipelines or heat exchangers therefore engine profile remains unchanged. Besides main lobe, suction cam has an additional lobe as to configuration without EGR. During concerned cylinder exhaust phase, this lobe allows a shaft advanced opening of intake valve. In this way, part of the exhaust gas is trapped in the suction duct and later, during cylinder suction phase, this gas is recycled to cylinder inlet for combustion phase.

Aspiration cam profile Figure 14

X. Cam rotation angle - Y. Cam lift

114026



15

EXTERNAL E.G.R. (F5CE5454 ENGINES) Figure 15

119409

1. Valve unit - 2. Heat exchanger - 3. Water pipe - 4. Exhaust gas pipe - 5. Intake manifold 6. Exhaust manifold - 7. Engine head.

Working system The external EGR system is a device fitted between the exhaust manifold and the intake manifold. Allows partial exhaust gas recovery into the engine cylinders after having been cooled throughout a heat exchanger. This way the combustion temperature maximum values, responsible of the formation of Nitrogen oxides (NOx) can be reduced. Hence, reducing the aforesaid temperatures by decreasing the concentration of oxygen in the combustion chamber, the EGR system efficiently efficie ntly controls NOx emissions. The exhaust gases through the conduit (4) and only after receiving the consent by the electronic control unit EGR, cross cross the valve (1) (1) and and reac reach h the the heat heat exchan exchange gerr (2) wher where, e, than thanks ks to the the engine engine cool coolantrecy antrecycl cle, e, are cool cooled ed to be then then entere entered d into into the the aspi aspira ratio tion n manifold (5).

Copyright © 16


F5CE ENGINES

BOOSTING

The boosting system is composed composed of the following parts: - Air filter; - Turbosupercharger.

Figure 16

EGR closed valve EGR open valve

Sucked air Heated compressed air Engine exhaust gas Exhaust gas recirculation 119413


SECTION 2 - SUPPLY

1

SECTION 2 Supply Page SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

PIPE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

-

Working System Description . . . . . . . . . . . . .

5

SUPPLY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

-

Identification coding example . . . . . . . . . . . . .

6

WORKING SYSTEM DESCRIPTION . . . . . . . . . . .

7

-

Supply Phase . . . . . . . . . . . . . . . . . . . . . . . . . .

7

-

Delivery Phase . . . . . . . . . . . . . . . . . . . . . . . . .

7

-

End of Delivery Phase . . . . . . . . . . . . . . . . . . .

8

-

Engine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

-

L.D.A .D.A.. Load Deliv livery Adjustment ent device . . . . .

9

-

Working System . . . . . . . . . . . . . . . . . . . . . . .

9

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

10

FUEL FILTER

11

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

Copyright © 2

SECTION 2 - SUPPLY

F5CE ENGINES


SECTION 2 - SUPPLY

3

SUPPLY The engine supply supply system consists of the following following components: components: - Fuel tank tank (aboard (aboard the the vehicle) vehicle)

pipes - Fuel delivery and return pipes - Fuel pre-filter pre-filter (if fitted, it is placed nearby nearby the engine on the vehicle’s vehicle’s chassis)

Priming pump, fitted on the engine and driver by the engine camshaft - Priming - Fuel filter filter (its position position on the engine may vary depend depending ing on the outfit and use) - Supply rotary pump - Injector feed feed pipe (from the fuel supply pump to the fuel injectors) injectors) - Injectors

Figure 1

119420

SUPPLY SYSTEM DIAGRAM 1. Injectors - 2. Fuel filter - 3. Tank - 4. Supply rotary pump - 5. Ignition pump.

Copyright © 4

SECTION 2 - SUPPLY

F5CE ENGINES

PIPE LAYOUT

Figure 2

118976

1. Injector feed pipe - 2. Fuel exhaust pipe from injectors - 3. Supply rotary pump - 4. Union for pressure gauge pipe within LDA intake manifold - 5. KSB thermal bulb - 6. Solenoid valve - 7. Injector.


SECTION 2 - SUPPLY

5

Figure 3

119961

Working system description The fuel (5) is primed from the fuel tank from the priming pump (6). The latter is fitted on the engine basement and is driven by the engine camshaft. Throughout the filter (4), fuel is conveyed to the transfer pump, which is placed inside the supply rotary pump (2), which is a turbine blade pump type. The supply rotary pump duty is to increase the fuel pressure based on the increase of engine revolutions’ number.

Then, Then, the fuel fuel reaches reaches the valve valve control controlling ling fuel fuel pressur pressure e within within the supply pump. The distributor distributor piston further increases increases such pressure pressure and delivers the fuel to the injectors (1) throughout the delivery pipe fitting. The fuel leak (3) from the injectors is recovered and sent back to the fuel tank.

Copyright © 6

SECTION 2 - SUPPLY

F5CE ENGINES

SUPPLY PUMP The rotary type supply pump is driven by a gear which is coupled to the engine camshaft gear.

Identification coding example V

= rota rotary ry distr distrib ibuto utorr pist piston on pump pump

E

= pump ump dime imensio nsions ns

4

= four four cyli cylind nder er engi engine ness

12

= distr distrib ibuto utorr pisto piston n siz size e in mm

1150 = no. of pump pump rev./min. rev./min. RV

= right right directi direction on rotatio rotation n Figure 4

1 15 2 14 3 4

5 13 12 6

7 8

9 11 10 30454

Ignition pump longitudinal section 1. Membrane Membrane - 2. Setting ring - 3. Feeler pin - 4. Drive lever - 5. Speed regulator regulator - 6. Transfer Transfer pump - 7. Drive shaft 8. Cam disk - 9. Spark lead adjuster adjuster - 10. Distributor piston piston - 11. Feed pipe fitting - 12. Hydraulic Hydraulic head - 13. Control Control plate 14. Adjusting pin - 15. Counter spring.


7

SECTION 2 - SUPPLY

WORKING SYSTEM DESCRIPTION DESCRIPTION Supply phase Figure 5

119415

1. Fuel supply pipe - 2. Solenoid valve - 3. Axial groove - 4. Compression chamber - 5. Fuel delivery pipe from pump to injectors - 6. Distributor piston - 7. End of delivery port - 8. Cursor - 9. Injector. The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the compression chamber chamber (4) through through the feed pipe (1) which is kept open by the solenoid valve valve (2).

Delivery Delivery phase Figure 6

119416

1. Fuel feed pipe - 2. Compression Compression chamber - 3. Distributor Distributor piston inner pipe 4. Fuel delivery pipe from pump to injector - 5. Distributor piston - 6. Injector. The distrib distributorpiston utorpiston (5) driven driven by the cam disk, disk, goes goes up to the T.D.C T.D.C.. and simulta simultaneo neously usly rotate rotatess on its ownaxle. Thecombinati Thecombination on of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within the chamber (2). The distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to the injectors (6).

Copyright © 8

SECTION 2 - SUPPLY

F5CE ENGINES

End of delivery phase Figure 7

119417

1. Fuel feed pipe - 2. Compression chamber - 3. Fuel delivery pipe - 4. End of delivery pipe 5. Cursor - 6. Distributor Distributor piston. The distri distribut butor or piston piston (6) moving moving toward towardss the T.D.C T.D.C.. connects connects the high high pressur pressure e inner inner chambe chamberr to the pipe pipe (1), (1), thereb therebyy establi establishin shingg pressure balance between the distributor piston inner chamber, the injectors’ delivery pipe and the pump interior. Since such pressure is lower than the one required to start the injector, end of delivery will be determined.

Engine stop Figure 8

119418

1. Fuel feed pipe - 2. Mobile cap - 3. Spring - 4. Solenoid valve - 5. Compression chamber.

Engine stop is provoked cutting out the starter contact. The electric flux to the solenoid valve (4) is cut out. The solenoid valve, throughout its spring (3), drives the mobile cap to the end of stroke (2) and the mobile cap obstructs the fuel feed pipe (1).


SECTION 2 - SUPPLY

9

L.D.A. Load Delivery Delivery Adjustment Adjustment device Figure 9

119419

Working system The duty of the L.D.A. L.D.A. device is to adjust the fuel delivery delivery depending depending on the air pressure within within the intake manifold. manifold. Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there is a conical housing housing (5) in which the feeling feeling pin runs (6). The setting pin (4) axial motion motion drives the feeling pin (6) shift and the latter acts on the stop lever (7). The stop lever rotates rotates on its own axle (8) (8) and acts on on the control control plate in order order to adjust the fuel delivery delivery depending depending on the air quantity quantity within the the cylinders. cylinders.

Copyright © 10

SECTION 2 - SUPPLY

F5CE ENGINES

PRIMING PUMP The The prim primingpum ingpump p duty duty is to prim prime e the the fuel fuel from from the tank tank and and conve conveyy it to the fuel fuel supp supply ly pump pump.. It is fitte fitted d on the engin engine e base baseme ment nt and driven by the engine camshaft.

Figure 10

88209

1. Pump - 2. Control lever - 3. Camshaft.


SECTION 2 - SUPPLY

11

FUEL FILTER The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water from the fuel in which it is contained. At the bottom of the filtering cartridge there may be a water drainage device; depending on the appliance (use in cold climate conditions), the fuel filter support may be equipped with a heater and a temperature sensor. Some versions are also equipped with a water detecting sensor at the bottom of the cartridge filter. Figure 11

119411

1. Fuel filter support support - 2. Cartridge Cartridge filter- 3. Water drainage device (not available on all versions). versions).

Copyright © 12

SECTION 2 - SUPPLY

F5CE ENGINES


1

SECTION 3 - INDUSTRIAL APPLICATION

SECTION 3 Industrial application Page

MAIN SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .

3

PART ONE MECHANICAL COMPONENTS . . . . . . . . . . .

3

ENGINE DISASSEMBLY ON BENCH . . . . . . . . . .

3

- Cylinder 1 T.D.C. search . . . . . . . . . . . . . . . . .

8

- BOSCH VE 4/12F pump . . . . . . . . . . . . . . . . .

9

- Timing gearcase . . . . . . . . . . . . . . . . . . . . . . .

12

- Rear side component assembly . . . . . . . . . . .

14

- Flywheel assembly . . . . . . . . . . . . . . . . . . . . .

14

- Front side component assembly . . . . . . . . . . .

15

- Timing

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

16

- Piston projection measurement . . . . . . . . . . .

17

- Checks and inspection . . . . . . . . . . . . . . . . . .

22

PART TWO ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . .

23

CABLE FOR ENGINES WITH EXTERNAL EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

EGR (ELECTRONIC CONTROL UNIT) ELECTRICAL LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- EGR Electronic Control Unit . . . . . . . . . . . . . .

27

- Pin out EGR Electronic Control Unit . . . . . . .

28

Engin ine e cool coolin ingg liq liquid uid tem temperat eratur ure e sens senso or . . . . - Eng

29

- Oil pressure switch

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

30

- KSB coo cooling ing liqu iquid tem temperatur ture senso nsor . . . . . .

31

- Temperature and air pressure sensor

......

32

- Engine drive shaft sensor . . . . . . . . . . . . . . . .

32

- EGR solenoid valve . . . . . . . . . . . . . . . . . . . . .

32

- Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

- Starter

32

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

Copyright © 2

SECTION 3 - INDUSTRIAL INDUSTRIAL APPLICATION

F5CE ENGINES

Page PART THREE - DIAGNOSIS

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

32

DIAGNOSIS BY FAILURE . . . . . . . . . . . . . . . . . . .

32

PART FOUR SCHEDULED MAINTENANCE . . . . . . . . . . . .

45

SCHEDULED MAINTENANCE . . . . . . . . . . . . . . .

47

- Servicing plan . . . . . . . . . . . . . . . . . . . . . . . . .

47

- Basi Basicc chec checki king ng and and main mainte tena nanc nce e oper operat atio ions ns . .

47

Page



MAIN SPECIFICATIONS

F5CE9454C

Type

Cycle

F5CE9454G

F5CE9454E

Diesel 4 strokes

Feeding

Turbocharged with intercooler

Injection

Direct

N. of cylinders

4 on-line

∅

+

Diameter

mm

99

Stroke

mm

104

cm3

3202

+

otal displac laceme ement +.. = Tota

ρ

Compression ratio Max. power

Max. torque

17 ± 17 ± 0.5 : 1 KW (HP)

40 (54)

48 (65)

55 (75)

rpm

2300

2300

2500

Nm (kgm)

220 (22)

260 260 (26)

275 (28)

rpm

1400

1400

1400

Loadless engine idling

rpm

Loadless engine peak

rpm

1150 ± 1150 ± 50

2750 ± 2750 ± 50 50

3

Copyright © 4


F5CE ENGINES

F5CE9484E

Type

Cycle

F5CE5454B

F5CE9484C

Diesel 4 strokes

Feeding


Injection

Direct

N. of cylinders

4 on-line

∅

+

Diameter

mm

99

Stroke

mm

104

cm3

3202

+

ent +.. = Total displacement

ρ


Max. torque

17 ± 17 ± 0.5 : 1 KW (HP)

57 (77)

61 (83)

65 (88)

rpm

2300

2500

2300

Nm (kgm)

315 (32)

310 (31)

340 (34)

rpm

1400

1400

1400


rpm


rpm

1150 ± 1150 ± 50

2750 ± 2750 ± 50 50



DIAGNOSI

PART ONE - MECHANICAL COMPONENTS

5

Copyright © 6


F5CE ENGINES



7

zl

540110

NOTE

ENGINE BENCH

DISASSEMBLY

ON

- Remove Remove the water delivery delivery pipe (1) from the exchanger. exchanger. - Loose the clip and disconnect the pipe (2); remove remove oil delivery pipe connected to the turbocharger (3) and t the oil return pipe (4).

Engine Engine disasse disassemb mbly ly operatio operations ns to remove remove the engine engine from from the vehicle vehicle aredescribe aredescribed d in the specifi specificc section. Engine disassembly operations, as well as engine overhaul, overhaul, must be executed by qualified qualified enginee engineers rs only, only, duly duly provid provided ed with the specifi specificc tools required.

NOTE

Depending on the appliance, some units may have different different position on the engine.

NOTE

Here Here are the the F5CE5 5CE545 454 4 engin ngine e over overha haul ul opera operation tionss which, which, except except for the EGR extern external al assembly apply as well to the engines F5CE9484 and F5CE9454.

NOTE

Befo Before re fitti fitting ng the engin engine e on the rotar rotaryy stand stand 38000097 380000978, 8, disass disassemb emble le the parts parts which which may interfere with the bracket assembly. Depending on the appliance, it may be necessary to remove the starter and the oil filter.

Drain the engine oil from the oil pan collecting it in a suitable container. Warning! Avoid skin contact with the engine oil: in case of contact wash your skin with running water. The engine engine oil is highly highly polluti polluting:waste ng:waste dispos disposal al must must be execute executed d complyi complying ng with the laws laws andregulati andregulations ons in force.

- Remove the turbocharger turbocharger unit (5)

Figure 2

122434

- Using Using pince pincers rs,, remo remove ve the the clips clips (1) (1) and and the wate water r delivery pipe connected to the valve support and the exchanger (2). Loosen the clip (3) and detach the pipe (4), (4), from the EGR valve housing housing.. Unscre Unscrew w the EGR fastening screws on the front side (5), and those on the valve support side (6), then remove the EGR unit. - Duly hold the starter starter (7), unscrew the fastening screws screws and remove the starter.

Figure 3

- Remo Remove ve the wiri wiring ng harn harnes esss from from all comp compon onen ents ts indicated in part II, electrical equipment.

Figure 1

119105

- Remove the L.D.A. pipe. Remove the fast clutch fuel pipes from the priming pump (1) to the filter and from the filter to the ignition pump (2), then fit the specially provided caps to the pipes, the pumps and the filter. Unscrew the screws (3), fastening the fuel ignition pipes and remove them. 119904

Copyright © 8


F5CE ENGINES

Cylinder 1 T.D.C. search

Figure 4

Figure 5

119106

- Unscrew the pump fastening screws on the rear part of the gear cover. To disassemble the pump, fit tool to the pump wheel and fix it with the three screws (1). Using the specially specially provided provided wrench, slowly tighten the screw (2) holding the rear part of the pump removing the pump completely. c ompletely.

NOTE

Before pump disassembly, check whether a drive shaft locking system is is available for for that model. In such such case case,, using using the the spec specia ially lly prov provid ided ed tool tool (380000 (380000150) 150),, lock the engine engine into the positio position n corr corres espo pond ndin ingg to T.D. T.D.C. C. for for cyli cylind nder er 1 (as (as described in the procedure here following). Then, throughout the specific locking system available, lock the pump drive shaft. At this point, the pump should be in phase and therefore no timing will be reques requested ted in phase phase of reasse reassembl mblyy (unles (unlesss any maintenance operation is necessary).

112012

Position the engine drive shaft at T.D.C. T.D.C. of cylinder cylinder 1 rotating rotating the flywheel until achieving the following conditions: - the notch (2) is visible from the inspection inspection hole; - tool 380000150 (1) should should be fitted through the carter carter into the port on the flywheel.



9

BOSCH VE 4/12F Pump Figure 6

118976

1. Fuel delivery pipes - 2. Fuel recovery pipes - 3. Mechanical pump - 4. LDA - 5. Wax KSB - 6. Injectors.

Copyright © 10


F5CE ENGINES

Figure 7

Figure 9

5

2

1 6

4

3 119108 119107

- Place Place a contain container er under under the the diesel diesel fuel fuel filter filter and and unscre unscrew w the condense drainage faucet under said filter; completely completely drain the diesel fuel container therein. - Disassemble Disassemble the diesel fuel filter (1), the filter support support (2), the priming pump (3), the oil filter (4), the oil filter support (5), and the KSB water sensor (6).

Warning! The oil filter contains cont ains a certain quantity of engine oil. Collect the engine oil and dispose it complying with the applicable laws and regulations in force.

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

Loosen n the screw screw (2, Figure Figure 10) in order order to withdra withdraw w the - Loose belt (2). - Remove the belt tensioning bracket (3). - Disassemble the pulleys and the guide rollers. Figure 10

1

2

Figure 8

75686

Duly hold hold the altern alternat ator or (1) (1) and and detac detach h it from from its - Duly supp suppor ortt loos loosen ening ing the screw screw (2): (2): recov recover er nut nut and and washer. Figure 11

122435

Unscrew the injector support support fastening screws (1), disas- Unscrew semble the injector supports and remove the injectors (2). - Loosen the screws (3) and remove remove the tappet covers.

Remove the intake manifold (6). - Remove - Remo Remove ve the therm thermos ostat tat unit unit (4) (4) and and the exha exhaust ust manifold (5).

NOTE

On the the centr central al cove coverr there there is a lubri lubrica catio tion n oil vapour blow-by valve. All the gaskets must always be replaced replaced in phase of assembly.

119109

- Place Place a containe containerr under under the heat heat exchan exchanger(2) ger(2) to collect collect the cooling liquid contained therein. - Loos Loosen en the the screw screwss (1) (1) and and disa disasse ssemb mble le the heat heat exchanger unit (2).



Figure 12

11

Figure 14

119110

119112

- Remove Remove the electromagn electromagnetic etic joint support (1) and the water pump (2).

- Fit tool (1) 380002385 to the flywheel box and, and, using a wrench, wrench, lock the flywheel flywheel rotation. rotation.

remove the pulley pulley (3). - Loosen the screw (4) and remove

- Loosen the screws screws fastening fastening the flywheel to the engine drive shaft.

Figure 13 Figure 15

119113

- Screw two medium length screws in the ports (4), in order to secure the flywheel with a sling. - By mean meanss of two two guid guide e pins pins (2) (2) prev previou iouslyscre slyscrewe wed d in the engi engine ne driv drive e shaf shaftt port portss (3), (3), guid guide e the the flyw flywhe heel el withdrawal throughout a hoist. - Withdraw Withdraw the flywheel flywheel casing casing grommet. grommet.

Withdraw the grommet grommet of the timing timing gearcase. gearcase. - Withdraw

119111

- Loosen the fastening screws (1), remove remove the overhead overhead holding the whole rocker arm unit (2) and recover the two gaskets (3).

Copyright © 12


F5CE ENGINES

Timing gearcase Figure 16

119114

part (1), of the timing gearcase cover. - Remove the rear part

Figure 17

119115

rods (1). - Remove the tappet rods - Disassemble the cylinder head; head; loosen the cylinder head (3) fastening screws (2); hook the brackets with metal ropes and, throughout a hoister, detach the cylinder head with valves from the basement. - Remove the cylinder head gasket.



Figure 18

13

Figure 20

119130

- Turn the engine upside upside down.

Loosen the screws screws (2), disassem disassemble ble the plate plate (3) and - Loosen remove the oil pan (1).

119117

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

Figure 21 NOTE

The shape and dimensions of the oil pan and the suction rose may vary depending on the engine appliance. appliance. Hence, the figures figures provide provide a general general indicat indication ion of the opera operation tion to be execute executed. d. Yet, Yet, the herein description of the procedures is exhaustive and applicable.

Figure 19

119118

- Loosen the rocker arm fastening screw (1) from the disassembled rocker arm holding unit and then remove the rocker arm.

Figure 22 119116

- Loosen Loosen the suction rose support support fastening screws (1). - Loosen the suction rose (3) fastening screws (3) and then remove the suction rose.

119119

- Withdraw the rocker arm (1) from one side recovering the equalizers (2) from the other.

Copyright © 14


F5CE ENGINES

Rear side component assembly

Figure 24

Figure 23

122431

SCHEME SCHEME FOR THE APPLIANCE APPLIANCE OF LOCTITE 5699 SEALER ON THE TIMING GEARCASE - Accurat Accurately ely clean clean the timing timing gearca gearcase se and the engine engine basement.

!

It is absolutely necessary to clean the surface to be sealed in order to obtain perfect tightness. Apply Apply LOCTIT LOCTITE E 5699 5699 sealer sealer on the gearca gearcase se in orde orderr to form form a seali sealing ng bead bead of 1,5 1,5 —+0,0,52 mm. mm.

- Fit the specific specific tool 99346259 99346259 (5) (5) to the rear rear shank (6) (6) of the engine drive shaft, fix it with the screws (4) and spline the new grommet (3) thereon. - Position Position part (1) on part (5), tighten tighten the screw nut (2) until the grommet has been fitted (3) into the flywheel casing casing (7). (7).

Flywheel Flywheel assembly Figure 25

The sealing sealing bead bead must must be homoge homogeneo neous us (no lumps) lumps),, free of air bubbles, thinner areas and gaps. Any imperf imperfecti ection on must must be correc corrected ted as soon soon as possible. Avoid Avoid the excess excess of sealer sealer:: too much much sealin sealingg materi material al would leak and pour out on both sides of the joint parts and, and, as a consequence, consequence, obstruct obstruct the passage passage of the lubricant. After having applied the sealer, the parts must be joined within 10 minutes. 119113

- Screw Screw two hook hookss or eyebo eyebolts lts on the flywh flywhee eell (1) (1) through the ports (4).

By mean meanss of a hoist hoister er,, draw draw the the flywh flywhee eell up to its housi housing ng - By inside the casing. NOTE

The flywheel has a reference dowel that couples with the relevant seat on the box.

- Screw two pins (2) of appropriate length into the shaft’s ports (3) and, using them as a guide, duly fit the engine flywheel (1) into its casing. - Tighten Tighten the screws fastening the engine flywheel flywheel to the engine engine drive drive shaft. shaft. Fit the tool 3800023 380002385 85 to theflywheel theflywheel casing in order to lock the engine flywheel rotation.


15


Figure 28

Figure 26

α

119463

Tighten the engine flywheel (2) fastening screws (1) in two steps:

119127

SCHEME FOR THE APPLIANCE OF LOCTITE 5699 SEALER

- Step Step 1: 30 ± 30 ± 5 Nm torque setting ; - Step 2: 90º ± 5º angular angular fastening. fastening.

NOTE

NOTE Angular Angular fasteni fastening ng must must be execute executed d using using tool 380000304. Befo Before re asse assemb mbly, ly, alwa always ys check check that that the the port port threads and the s crews show no trace of wear and dirt.

It is absolutely necessary to clean the surface to be sealed sealed in order order to obtain perfect perfect tightness. tightness. Apply LOCTITE 5699 sealer on the gearcase in 0,5 orde orderr to form form a seal sealin ingg bead bead of 1,5 1,5 —+0,2 mm. mm. The The seal sealing ing bead bead must must be homo homoge gene neou ouss (no (no lumps), free of air bubbles, thinner areas and gaps. Any imperfection must be corrected as soon as possible. Avoi Avoid d the exces excesss of seal sealer er:: too much much seali sealing ng material would leak and pour out on both sides of the joint parts and, as a consequence, obstruct the passage passage of the lubricant.

Front side component installation Figure 27

After having applied the sealer, the parts must be joined within 10 minutes.

- Assemble the front case (1) and tighten the fastening screws to the prescribe prescribed d torque wrench.

119117

- Assemble Assemble the oil pump (2). (2). - Screw Screw the fastening fastening screws screws (1) withou withoutt fully fully locking locking them. - With magnetic base comparator, check the clearance among the engine shaft gear and the oil pump gear: it must be 0.068 ÷ 0.168 mm. - Fully tighten tighten the fastening screws (1). (1).

Copyright © 16


F5CE ENGINES

Timing

Figure Figure 30

Figure 29

119126

- Fit the ignition pump cogwheel cogwheel (1) into its housing. - Fit the pre-set ignition pump into its housing on the engine, inserting the shaft into the gear hole. - Tighten the three screw nuts on the rear part of the timing gearcase and the front cover fixing the shaft to the gear. - With magnetic base comparator, check the clearance among the engine shaft gear and the oil pump gear: it must be 0.068 ÷ 0.168 mm. - Fit the new gasket using the centring pins (2) on the casing for its correct positioning. - Fit the casing’ casing’ss cover cover using the centrin centringg pins pins (2) to correc correctly tly positio position n it and then then tighten tighten the fasteni fastening ng screws to the prescribed torque wrench. 119125

- Seize the 45 bevel tooth (1) of the engine drive shaft gear gear with with the the timing timing gear toot tooth h mark marked ed with with two two notches (2), as shown in the figure. ˚

Figure Figure 31

- Rotate the camshaft keeping the timing gear fix until the camshaft’s pin fits into the relevant housing within the timing gear. - Screw the screws of the transmission transmission gear without without fully tightening them. - With magnetic base comparator, check the clearance among the engine shaft gear and the cam shaft gear: it must be 0.068 ÷ 0.168 mm. - Screw the fastening screws (1) of the transmission gear. 119461

inner part part of tool to the front front shank of the engine - Fit the inner drive shaft. Make sure that the engine drive shaft pin is correctly fitted into the tool spline in order to avoid damaging it. Fix it with the screw (1) and spline the new grommet thereon. - Place the outer section of the tool on the previously fitted one, tighten the screw nut (2) until completely fitting the grommet (3) into the casing.



Figure 32

17

Figure 34

70221

119573

grommet (2) to the water pump pump (1). - Fit a new grommet - Assemble the water pump (1).

Tighten the fastening screws screws to the prescribed prescribed torque torque - Tighten wrench.

Piston projection measurement

- Fit the gasket gasket (1) on the basement basement centring it taking the pins (2) as a reference. The gasket’s thickness must be selected selected based on the piston projection projection in respect respect to the upper plan of the basement.

NOTE Check that the block’s laying plan is clean.

Figure 33

Do not grease the gasket. It is recommended to keep keep the gasket gasket inside inside its wrapp wrapping ing until until it has to be fitted. The fitting direction direction is univocal and defined defined by the centring centring pins on the basement, basement, which must match with the ports on the gasket.

Figure 35

119462

Piston projection from basement A (mm)

Engine gasket thickness B Thickness (mm)

From 0.07 to 0.07

0.80

From 0.08 to 0.22

0.70 119115

- Measure the piston projection and refer to the table above to select the appropriate thickness of the sheath.

NOTE

Always use new screws for assembly.

- Lubrica Lubricate te the head head fastenin fasteningg screws screws (2) and tighten tighten them to the prescribed torque wrench. - Place the head (3) on the block taking the centring centring pins as a reference.

Copyright © 18


F5CE ENGINES

Figure 36

Figure 38

122432

- Reassemble Reassemble the the electromagne electromagnetic tic joint support support (1). - Reassemble the pulley pulley (2).

- Fit the discha discharge rge manifo manifold ld (3) provid provided ed with new seal seal (2) and tighten tighten the nuts (1) with studs applying applying the required required torque..

Figure 39

- Reassemble Reassemble the pulley (3), tighten the fastening screw (4) to the prescribed torque setting. - Reasse Reassembl mble e the heat heat exchang exchanger er remind reminding ing to replacethe replacethe old gasket with a new one; tighten the fastening screws to the prescribed torque setting.

Figure 37

32655

Before reassembly, check that the rocker arm rods must not be deformed; there must be no trace of wear or seizure on the spherical housings of the rocker arm adjusting screws as well as on the tappets tappets (pointers) (pointers);; otherwise otherwise these parts parts must be repl replace aced. d. The The suctio suction n valv valve e rods rods are are iden identic tical al and and therefore interchangeable. control rods in their housing. housing. - Fit the control Figure 40 119108

- Put the alternator alternator back in place (1, Figure Figure 10).

without tightening (2). - Screw up without - Fit the drive belt on the pulley and the guide rollers. rollers.

Tension the drive belt rotating rotating the alternator alternator as shown - Tension in the figure. - Tighten Tighten the screw (1) and the screw nut (2, Figure 10) fastening the alternator to the support.

119119

- Fit the rocker arm positioning the equalizer couples: the suction equalizer equalizer first (short (short rod) and then the exhaust exhaust equalizer (long rod) (2). - Tighten Tighten the fastening screw (1). (1).



Figure 41

19

Figure 43

119128

- Make the holes (1) for fuel exhaust all face the same direction.

Figure 44

5

2

1 119111

Replace the gasket gasketss (3), (3), reasse reassemb mble le the rocker rocker arm - Replace holding case (2) and tighten the fastening fastening screws to the prescribed torque setting. - After having completed the assembly, check that the rocker arms are correctly positioned on the valves and the tappet control rods.

Figure 42

6

4

3 119107

- Reassemble the KSB water temperature temperature sensor (6), the oil oil filter filter supp suppor ortt (5), (5), the prim primin ingg pump pump (3), (3), the dies diesel el fuel fuel filter support (2), the fuel filter (1) and the oil filter (4).

Figure 45

119122

- Reassemble the injectors (2) replacing the grommets. Tighte Tighten n the fasteni fastening ng screws screws(1) (1) to the prescri prescribedtorqu bedtorque e setting.

119905

replacing the gaskets gaskets (2). - Fit the head covers (1) replacing

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F5CE ENGINES

Figure 46

Figure 48

119716

- Reassemble the fuel exhaust pipes (1). (1).

119105

- Reassemble the pipe from the pump to the injector and tighten the brackets’ fastening screws (3). - Reassemble the pipe from the pump to the fuel filter (2) and from the fuel filter to the priming pump (1).

Figure 47

- Reassemble the L.D.A. L.D.A. pipe

Figure 49

119116

- Reasse Reassembl mble e the suction suction rose rose tighten tightening ing the suppor supportt fasteni fastening ng screws screws (1) and the screw screw fixing fixing the suction suction rose rose (2) to the prescribed torque setting. 119124

Figure 50

- Reassemble the whole intake manifold (1) replacing the gasket (2) and (3).

119123

- Fit the new gasket gasket (1) to the oil pan (2).


21


Figure 51

Figure 53

119130

Assemble the oil pan (1) and fit the plate thereon thereon (3). - Assemble Tighten Tighten the fasten fastening ing screws screws (2) to the prescri prescribe bed d torque setting. NOTE

Before assembly, check that the port threads and the gaskets show no trace of wear or dirt.

119904

- Reassemble the turbocharger turbocharger (5) unit. - Reassemble Reassemble the pipe (2) and fit the clip in the correct housing. - Reassemble the oil delivery pipe (3) and the return pipe (4).

Figure 52

Figure 54

122434

E.G.R. on the intake manifold, manifold, tighten - Place the whole E.G.R. the front side (5) and valve support (6) fastening screws to the prescribed torque pair. - Connect the pipe (4) to the E.G.R. valve housing and then tighten the clip (3). - Reas Reasse semb mble le the the pipe pipe (2) (2) and, and, using using pince pincers rs,, fit the relevant relevant clip (1). - Fit Fit the the start starter er (7) (7) and and tighte tighten n the the faste fastenin ningg screw screwss to the prescribed torque setting.

119903

Disconnect the fuel filter filter pipe (1) and act act on the priming priming - Disconnect pump (2) drainage lever. - Continue drainage until fuel discharge discharge is completed.

Connect the pipe (1) to the filter. filter. - Connect

Copyright © 22


Checks and inspections

!

The following checks must be executed after the engine fitting on vehicle. vehicle.

F5CE ENGINES

Inje Injecti ction on pump pump stati static c adva advanc nce e cont contro roll on engine at cylinder 1 TDC (illustration Fig.)

Check that the liquid refuelling or top up has been provided to the correct levels prescribed.

Start the engine, keep it running at a number of rev./ rev./min min.. slightly slightly over over idling idling and wait wait until until the cooling cooling liquid temperature reaches the value prescribed for thermostat valve opening and then provide checking the following: check ther there e is no wate waterr leak leak from from the the mani manifo fold ldss - check connect connecting ing the engine engine cooling cooling circuit circuit pipes pipes and the cabin cabin interior heating pipes, eventually further tightening the O-rings. - Carefully Carefully check the fuel filter pipe fittings. fittings. - Check there is no oil leakage from cylinder head and cover, cover, oil pan and baseme basement, nt, heat heat exchan exchangeroil geroil filter filter and relevant relevant housings housings in between between the various various lubrication lubrication circuit pipes.

there is no fuel leakage leakage from the fuel pipes. - Check there - Check there there is no air leak from the pneumatic pneumatic pipes pipes (if fitted). - Check that the warning lights on the instrument panel panel and equipment disco iscon nnected ted upon engin ngine e disconnection efficiently work. - Check and carefully bleed the engine cooling system throughout reiterated drainage.

87720

With injection pump inserted in its housing and retaining screws released, fit dial gage 380000228 (2) and dial gage holder 380000225 (1), preloading rod by 2,5 mm. Rotate e crank cranksha shaft ft and and move move from from 1st cylind cylinder er at TDC TDC to - Rotat end of compression compression phase phase condition. condition. - Rese Resett dial dial gage and rota rotate te cranks cranksha haft ft in opposit opposite e dire directi ction on to retu return rn to 1st cylind cylinder er at TOD TOD duri during ng compre compressio ssion. n. In this position, position, the dial dial gage gage fitted fitted on pump must display values below: • 1 ± 0.05 mm (61 kW engines); • 0,88 ± 0.05 mm (55 kW engines); • 0,65 ± 0.05 mm (48 kW engines); • 0,76 ± 0.05 mm (57 kW - 65 kW engines). - Rotat Rotate e pump pump antic anticloc lockw kwise ise is strok stroke e is shor shorte terr or clockwi clockwise se if stroke stroke is longer longer till obtaini obtaining ng require required d stroke. stroke. - Lock pump when checking these conditions and lock related nuts at predefined torque.



PART TWO - ELECTRICAL EQUIPMENT

23

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F5CE ENGINES



25

CABLE FOR ENGINES WITH EXTERNAL EGR SYSTEM Figure 1

3 1 3 8 8

g n i n o i t c e S . 5 r o s n e s s n o i t u l o v e t f a h s e v i r d e n i g n E . 4 e v l a V R G E . 3 r o s n e s e r u s s e r p e r u t a r e p m e t r i A . 2 r o s n e s e r u t a r e p m e t r e t a W . 1

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F5CE ENGINES

EGR E.C.U. ELECTRICAL LAYOUT Figure 2

. 1 t 2 h 1 g 1 i 6 l g . - i n r t r n o r a s t a n s w e s h t i s e i s r w o u s t n a e g r c a i e v i p D r e m s . e r 4 8 t o 4 e f r r 8 5 u o t t s s a e t r h u i g p m l r g i m i A n o . c n 6 r 5 y a 1 e w 5 K e 8 . r 2 u 0 t . 5 a U r . 2 e C 5 p . - m E r e o t R s G r n E e e . t s . a 0 o w 2 0 n h . i g 6 v e h 8 r e e e n l v n i i g a g v n n E d E i - o . 5 5 n 0 3 e 1 l 0 8 o 8 s 4 5 - t R G h h c i g E t . i l 9 w g 2 s n 0 g i n 8 r n i a 7 t a w e ) R h - n G e o E r r p ( g o r i n f o a t r f l e s o o h r n t e e n r s o P e c . r u e 1 t t a o 0 r 1 e m 8 5 p e - m R . g t e 1 n i 0 r t e 2 a t 5 e a 2 h - w - e r e y r p i n e g t e n t i n a E g . b n r e 4 3 e r t 0 r o 7 a f t 4 r S . o t 0 s i 0 s 0 e 0 R 2 119452



27

EGR E.C.U. Figure 3

119453

Technical specifications. Manufacturer

Bitron

Rated Voltage

13.5 V

Actual Voltage

10 ÷ 16 V

Working temperature

-30 ÷ 100 C ˚

Maximum current input

<5 A

EGR valve control signal

PWM 140 ± 7 Hz

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F5CE ENGINES

Pin out EGR E.C.U. Ref.

Description

1

PWM output output signal for EGR solenoid solenoid valve

2

-

3

ECU Mass

4

Mass for pre-heating pre-heating (on) warning warning light

5

ECU supply supply (+ 15)

6

K line signal

7

Intake manifold temperature and pressure sensor supply

8

EGR solenoid valve feed (potentiometer)

9

K line mass

10

EGR solenoid valve mass (potentiometer)

11

Cooling liquid temperature sensor mass, on thermostat unit

12

Air pressure and temperature sensor mass

13

Engine revolutions redundancy signal

14

E.C.U. supply supply (+30)

15

Pre-heating remote control switch

16

Engine high temperature temperature warning light

17

Diagnosis warning light

18

Start

19

EGR solenoid valve position signal

20

Cooling liquid temperature temperature sensor, sensor, on thermostat thermostat unit

21

Air temperature sensor signal

22

Pressure Pressure sensor sensor signal, signal, on intake manifold manifold

23

Negative from engine drive shaft impulse transmitter

24

Engine drive shaft transmitter mass

25

Positive from engine drive shaft impulse transmitter



29

ELECTRIC CABLE TO CONNECT KSB WITH CERA Figure 1

5 3 0 0 2 1

P O T S . 4 r o s n e s r i A . 3 l a n g i s B S K . 2 e c a f r e t n I . 1

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F5CE ENGINES

Engine cooling liquid temperature sensor The sensor is fitted on the thermostat unit. It consists of two NTC thermistors with two reophores. Figure 2

Calibration 80 C [k]Ω [k]Ω



0.304 - 0.342

2.262 - 2.760

8.244 - 10.661

˚

˚

˚

119454

Characteristics Working temperature range -

Connector’s side

-40 C ÷ 130 130 C; 150 C for periods < 10 min.

-

Bulb’s side on engine

-40 C ÷ 140 C

Voltage

˚

˚

6 ÷ 28 V

˚

˚

˚



31

Oil pressure switch Figure 3

75722

Characteristics Voltage:

12 ÷ 24 V

Contact closure with decrea reasing ing pres ressure: re:

0.2 bar

Contact opening with incr ncreasing pres ressure: re:

0.9 bar

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F5CE ENGINES

Cooling liquid temperature sensor for KSB Figure 4

ELECTRICAL LAYOUT

119455

Characteristics. Contact closing temperature

65 ÷ 5 C

Maximum load on contacts

Max 15A

˚



33

Air pressure temperature sensor It consists of an NTC temperature sensor and a pressure sensor, both integrated in a single device. Figure 5

Mass NTC +5 V Output signal (pressure)

119455

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F5CE ENGINES

Engine drive shaft sensor It is an inductive type sensor placed on the front left side of the engine. It generates signals signals obtained by the magnetic flow lines closing up through the openings openings of a phonic wheel splined on the engine drive shaft. The same signal is used to pilot the electronic revolution counter eventually fitted on the vehicle instrument panel. It is connect connected ed to the Electro Electronic nic ControlUnit ControlUnit pins pins 25C (signal)and (signal)and 24C(signal). 24C(signal). The third third pin is for shield shielding. ing. The Sensor Sensor’s ’s resist resistanc ance e value is nearly 900 Ω 900 Ω.. Figure 6

Pin 25 E.C.U. Pin 23 E.C.U. Pin 24 E.C.U.

119457

Torque setting

10 ± 2 Nm



35

EGR Solenoid valve Figure 7

119458

A. Exhaust gas input - B. Exhaust gas output Figure 8

119459

Coil characteristic

Potentiometer characteristic

Resistance

8 ± 0.5 Ω

Total resistance

4 kΩ : ± 40%

Frequency

125 ± 25Hz

Maximum voltage

1 5V

Voltage

14±2V

Supply current

10 mA

Self inductance

82± 15mH

Circ ircuit uit configu iguration

Voltage divi ivider

Copyright © 36


Starter

F5CE ENGINES

Figure 9

Manufacturer

BOSCH

Electrical system

12 V

Rated output

3 kW

119464

Figure 10

119460



PART THREE - TROUBLESHOOTING

37

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F5CE ENGINES

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F5CE ENGINES


DIAGNOSIS BY FAILURE NOTE

In case of EGR system failure, its operation is disabled and the related EGR failure indicator lamp flashes (if applicable).

r s y e s S l y a c l p i p n u h s c S e e E T h T t H O d N e N e C l b o t s y . y . a l p e w m p c l e A i v A t - l s y d e n r m a r h n e n o e t a a t c i h e t y e l k m y t n r S b a t . e r n e a t e l T i n m . a t t t i v y a i e r S g e e l s l g s m e n b E i s e c r a i s l u h e a s a t E e T s f m c s h i Y c e h x i t . t d n i h e c t e D D e D r e c a p e n . a E E n t l t f n e i a m s t p e e i f h D u e j n M d n i e t s r l p i p c r g i E a r N y i R u a t . n n p d t y e s E R r e t o e d n t i e a t d a M R t e a t n i s h t a u w n w t e s p f n M O a b k e g r b i r e t m c c O w c p u o e r e h e e e s t h C h h m p e t e c c e . t n c . E s o n n , n h c k l R k c t l d o a n o e c c i e l a d e e s a t s c h e i p u n t n r e i n d e f i i h e l h o C D w i e g p r C R C m a r l d e e e u c f d n p o e a r E i m h r S l t u o p p n c U p y i n s A a r e n o e t i C e t t c o i i a h n t n T t b e c g i s e o d e O n e r t e n h p O e g t o l a R r f c b m l e o t E a a a a g d n c f L i n w i i l B I p o m m r i r S p d o t e a e S t e t s g c f t i r O y s e i s a r r o P = h o k r e o c t p l o ) i t r s e c * a a n D n ( D B o I t

E R U L I A F

t r a t s t o n s e o d e n i g n e e h T

f - r d o i n i o n r a . e m s e i p l t u p E n a m a . i c p c u p e m p d m h y r t u u d e l p p p e n i e i p r t h y n v a l t u t o o r s a p r t p i e i p e t s e u c n c h s s e y g t a l i a l e e a g h t p o h i t n e t h c i e r t t s d e a a c s e p n l m s r r p i p a e p o p e o m p e f r e o r c u h e r l i p h n t u y r a e o t s y g l r a l a e r k h e n i i f n e r u c r s a u v s a p e e p a f e o n a h i r t e n e r o m R R O t C a a l e h t n i r o s p m u p l e e v u r f e s e e h r r t e l t e r n p i a u f t s m s t e y u l l n e p b e p v i i p b t n c u i u c f o i s f b e t f i u r e s o i n n g I N A i D r o y l p p u s

39

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. e c m i v e r e t s y S s l a S y c l i E p n p T h c u s O e e N T h t H d N e e C l b o t s y y a l p w p l A A . i l f - s - l r . g e e e t e n i h e e t e d e c d c n h p e l i n n r t i . e u i a . t a a u a f l t g a h r i l e p i p n t l w i p f f s p s e t p p e l r t i u h e r m e j f e e m e d y S e m m p u s i r r u d u l l n e h u a t n o T h t R e a r d p h a f a d e o p E c h n . o o s S t e . u a l e y s o l e g g f s l e n t k e E h r i n e h t p b a u l n l p h t d r e i a t u e r t u o o T i n i p a m n d e h r i d Y w t c . g h a y i m p l a p u e t s p i t h n v a c s r s m l e k D e t D l r n r e a i s n o i p l c d e m c e c e h E E e e a a r t n t p r s E u u p h p h e u o h a v a r i . f a t l e l l D t p c o n M f m m i e v w p s p t D y e g t e , o l g n r d u E n N e e e s e t . n e r c l h e i r o h s p i a n i a s p t o E R i . f a e i t l e g n e i y p j l i t i n c t i t k l v i s w p l d e . r s n n M R i e c o c r r n a n e e e i x o . r e h e i s d w i r a a t p a i m i v u g l c o p v a d i M i O e l s e l e e s r a t n r n r l t l e p p f o e h r i e o e s e r e t e e h a a g e p O h c d t . e e i e c d o h o l b y h i l h t p r s t t f C f e h w t e t h s m f m r e u y e t g t e n e l t R h E v e a a . a e l e l n e l t g e i n . r s t u t a a o s c c y g s h k a R t l s s s s u o p p e s e c g n d i s e l n u l u r b a u a v n a u c m n c a s n e j n a e a i e i j u g i t p t f p c j s s v e e a i t o e a h d h d r l o e l e h e o n e C i t i C u s h t O A d a R D o c i t e D n f a b l m R A p R t l f s n d i e e n o n o o u i c i e f a t e t g i n a e s n n t a E i m u f h a g t i a S l r h h c n o e d i U p . s p f n h y r d t n r a a m y A a e e a e a t e . y k l v c C e b o l i d l t p o h n k w e e f r n k r T t i p o e d b a u e t c o o O s p u r s c d s a l e r t u a e l e o w c O e r c . d g r u h l t n s l t t R t s l e r g . o e n b b n e s o b i d c n t r E a o a i o k s e e r r r r r d c i c . L i k y g l e o o . l m r c d p g i e f p l p r a B a I p e c f o u w f l e o m m s w u o S p t r c c l o y l n l i u r o i e s S a s y r f t v t p c . o p i . e f c o n e e e e c s i s f a b s c O t t n a e t l i r d y n i t . r r l o r m f t , P = p a i . r t o o e r s e i i u e l n B t t s p e . t i i o o ) p p u r s e r e n p i e s c p c l n * u f n S . i u u y a m p g I n ( d I g I n S o u K I p F P s I t B m e t w o l t a t r E a s R t U t o L n I s A s p F e o o t d s e e n n i s i g r e g n n e u e t a e e r h e h T p T e c i v r e S l a c i n h c e T H N C o t y l p p A

F5CE ENGINES

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F5CE ENGINES

- e o h t t u t a a h h t i t e c w k i c v d r e . e h g e p S c n p i l i , k a S u e r c i E q c o i n e v w T h s e c e O d l y e c t N T n g c a i n r e i l H n r p o N o p i c a s C f n i o o t e s t e e y s i c i l c a t p v c a p e n m d I A . f - e i c d e i e i s f h h n s i t . r e t t c s i t i g e I . p c e u t o w p s e e t e h S c o e u h s l n j c t a d T l f i d n i o e b p a u o S e o t F t i e h t q . t t d b g . E i r h l y e n r T n t c a c n g r i Y d a a a o u l s n o d g d i e f s l D r D n p a y n r o i o e E E t h t . e s a c d r r e o c i o n e p v t c D e e s n b l i c i M n h d o l a n r a s e p E u t o i N s i r a v o n d c E R l e e t m u r g o e s r a c t p . e i t n r o l e m t M R h t e i a h y l d e i . m r l h e . s f a p p M O w e t s r e e i r d g u r a s n b e i v e i p b n e O e r r l e a i ; w h n e e e o h t y t e i i u C h m e t o h h i d t s r t q t t a t t t u d h E e a t p e a t s t c s k c r u r k R k u l s l s m e n a c e c c j u u u r a b . e e e p r c e p t n i c e y r s n c h h e e c n v h d l o e o c C n R A i i C T l C A i t s C r a g d p o e n n o i c m l t a ( u n o p d a o E i n c a S l r o e i p e t s h t U p a u a r A a o r e i b w . i r l d C e a a w n e h v i c l o T t h l y t t . c e . o p c O g e o n t t . h t h e f o i r o . O e m a t r t l t l u m r R n f i o n e s i e t t b p c ) l o o h v i E a r n f t o i e i s e n i l m c e L i w s n r i i t w l o r e e d g p l B p a e a i t I g n m u a t n d S p w h o e t q t u o s e i t . S a e o t s l n e i p t l t a f v v e c c e i i i a g i O t r p i t e n t u c b i n r r s c c o P = e o f l r t i d t . f e u e i t h b s o o i r u ) f v i u i e f e n c s c g o n * n r i q n d C I n I g h O ( D D I i l u I

E R U L I A F

p u s t a e h y l e v i s s e c x e e n i g n e e h T


e c i v r e S l a c i n h c e T H N C o t y l p p A e n - h e h o m t t . g o p n c e p c u t i a l o m g n u o n p n i i e p t t o r t c t , n e n s s f d o u e i e t d n i t e c o n . p e e g . i y t d c l m g t e e o e n c u i r b h p d i e r p r t r s r n e s c p s e d o u c n l o e e c a r a p i a t v p i c l i p g n e e e v n g h e r m i i d h u t t r m p e I i f h n g o t n h . i t i t t k h g u s o t c w n c i t e i s n y a j h d n e e l h g T C i b p c A g n i g n a h c . c i g t n a i m m o i t t t u c a e r r d a o e l c n k i a p r p m s u e p i . n v t e c i o e i c t f i e v n e g I D d r r a l a l u u g g e r e r r i r i d d n a n a r r e e w w o p o p e n e n i i g n g n e e g t n g t n n n i i e n i e n i c i c i o o i i f f t t f f c c u u s n s n u u n n I f I f

e c i v r e S l a c i n h c e T H N C o t y l p p A d n a t . l i u e a t h a r r e i b v . l a o t s c r a d e n p n i a g n r r n o e o a t w l f u h o g t t i e w n r e h e m t d e e c k e c a c l e o p h r r e C P

g n i g n a h c d a e l k r . a r a p s e w c i e t v a i . e s m r s e o u t l c i u a x a f e e . i c n o B . t v S s . e i K d P

. n o i t a r b i l a c r o t a l u g e r d e e p s t c e r r o c n I

41

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42


. e c i m v e r t s e y S s l a y l c i p n p h u c s e e T h t H d N e e C l b o t s y y l a p w l p A A - i s s n e e e r r a h h o k e l o g t t v a f t t r e s o n n e i e i t o t d w r t p u ( p s t e o n a n o s d a h t . n t i e h i o y g r t . d r t u n a i e t s e a i a n t o i l c e n o e s t r l h e s a l s t r u m h e i . n y u t . p t i l c j p e a o d t e w r c n i d a r c b r n a n o e e i s u q l e s d u r e e i m r t l o r l c h e u z n e r o s r . g u e f z d a l s e m t c e s r o r e n t o i t l k t d d t i o n i e a n r o a f h c h c v c n a w p a h a r d t t e l o j e l s e i a a s e e e i t t e r c . e e n h p h i t h e h d a h t y e t p i e n g h t l d s n t r t . e l h a t i a p ) l c o e k k k r a h t f n i o c c i i a n c l c d r n e e u a c l a e e n c u p n g u p e p e e f a e l c h l h h e a A r e C m n t p e C R C s h C C a a b e e e d v h n i t t a c n t e i f f a e r d e h s t r a m o w . a c f s n o m n o i . . e e t r t e e c e s e c c u y w g r . i n r v s r t t e e a s e e s n d t h b b c l e i o . r i f o t k o i p i A r . b c n e r a r l D a g . l i z u o s t d L z d e s n t o s . e t e e n . i v v c s c i i a e r t t t u i t l o r l y r c r c t a e f r p t i u e e c p s f t o p r e p b e e p c j a i m u n a n I P s I t D O D r a l u g e r r i d n a r e w o p e n i g n e g t n n i e n i c i o i f t f c u s n u n I f

F5CE ENGINES

e c i v r e S l a c i n h c e T H N C o t y l p p A d o i . n v e t n o l d r i a t p e d e e i l t n b e n m g a m h e i e t d t e u h a t t l b o y h m i s t o n g t a x u o i a n r o s d e i l e m r c r . g d r t , e n o o s i e s l c o r t . g t e e c s n e n p r i r i a e s a v t a o p s t e t u p d l a o d c e h a o l m l e j t u e r h o d t r n i t p e e e k . i i s e o e r r t n e l n h r a o b h h o e a i p c t t t t c h s i m t e s e e e t e c d t h c s o c t e b s p l e a a s l a r u b r a y i j e y p i s p r d k o e e c A a t r e R D r C m s - e n h t o c d s d n o a r . l g a e i n d t e i t t e p e h s t r f o t . c o a t s e t r e r . r n p o e s i e l r p c e . o m c l r n t t c e i s e c a u v u e p f j e j d n e l m i d a h s e t e u t ’ t r p v c g t c o i n t e u r r c t i a e n o l r i t s i t u f o c b g e c n e r e D O I n n g I

s e k o r t s e n i g n e s u o l a m o n A

Copyright ©

F5CE ENGINES

S E T O N

t t i s f u r d n t a h S s T e n h S i t p E t e T f Y a c a h D D s l E E e p e D v R M i r . E d s N E R e g . s n n i M g R i r n a g i M O n e r f O e b l a e e h C h z g E t i s n R d r i e r n i a r d n e G u b . f g k e o i c b c a n k r l s c a o E i l a r l s S p e s d g l U p e i n u v r o A a i s s a C e e e h s h c b e T t x t v o e f O a i s t s h e O e s s e k c l u n x R b a a e E a c r c s c r L i o l e B e s I p k r g o o n S p r S a t m i r s f a i O r e e o P = i b n ) g e d * n n n ( E o e

E R U L I A F

s e k o r t s e n i g n e s u o l a m o n A


e e c c i i v v r r e e S S l l a a c c i i n n h h c c e e T T H H N N C C o o t t y y l l p p p p A A - e s k n d n d v c a i a t . n e g e l h n . o l . t t a t k e a s t n e f l i s h s i e e i o n d t i g o r f p e d e i s l m t t t a b h c k e r t u e i n e a h t a l g b s g h s . t d o i t p p t t l a s n n a e t e e s m h l a a u u n . r h v a j r a e t s q . / t o e s d f c e a s r o r a r d v t a i o h d u a k t t o c n h o w n d n b a r d s e t e n a n r e p k e h a d e r g n v b e r a d a m c i c c e n e l v o e i i w s b l i , u p e r s a t h t r p e e t r m r m c p h i c e d e g r e n i b k o t e s s n c c n n e n u e o h , . c o p o g t a k i t s n l m s e t e n i c e r e t o r s e c h i i o g n c o e a t i e i p h n l c p t n t c v n v e t s h l g t e e e e n i e h t g . e a t p r v p c i s e e n e d s d e t h t u t h n t h t o c r e h a h h u F g a n r t t t t e t t n . o e e n e e e n c s i s n f t t t c c c k h e g e s e n l a o r s g a m l a l a t c l w r u u w c e p r n i e j e j p p p t d s a r e y r p i e h d d o e e e n e w D r c A C h C R h t R R a A a t p s b e s c . f d B c o n . e e . S o y f . k c a e c h K l s e . a e d l u y h d s d r s b t . e e y i t s e l n v d s i . e v o o l e i t w u i c t . i f e v j s r g e n a s v r d d s g n h e e s e c i a s s n c i s e m m x t u c d y e g u l n c g e x t o v n i g e h i n i e i c m r l r i n n e g a r d e i s n x o n i r s f a r i t e e o a s p o s n f m m n c h a h i t c m c i g n d p l d n i u p n i n o d p m e e s r a r e a g . n u e d h o n l e s h d g n o b p i t e o n s w i o i s e c e k u u r i t r y t m l v v n c i p h i b g t i . i n a t a f s e l g e e e c i n s y n y i p . n i a c s ) s s s s e e t o i i n o t f b e o c c v e r o e n o s o i o e x e h v o C o i U L N p L n N E D d T ( t k r a d r o k c a l B . s e m u f e n i g n e . s s u e o m l a f m u y o e n r A g

43

Copyright ©

44


e e c i c i v v r r e S e S l l a a S c i c i E n n T h c h c O e e N T T H H N N C C o t o t y y l l p p p p A A r e e e d w c o h h h n e e t t t a s n p d e s g r n e c n n S c n o a i i a e a l s e u l T s l e p e p e c S i e h . p e r t , i r s E r . d e e p r e t r a s i . T v e m t y o e e l Y t t n a i s o l h h i i a e a l f e D t D . h . l r p t n f u g i r r r i E E t r t . a i t i e a e o n n p t e n o n a d w . . i D t t M e n s v e s s e s n t g . e e i t s l n r i a i r n l E m r N o f e r o n h n y o e o t i i i t o s o n o n t g o i t t E R s t c t m g i t c c n i p n j c a e e e s u e n d e r M t e e R j e d c j e n g s e r j d m i h h m l n a a e a n n e t h t i n a M i t O a u i p o e i , p p p h s h c r n e e e e h e O h u e n t t g t . e o i r l h o h h h e q e i t l o t h n t t t i C t t i h h e n e u i u t e r s i t t a t t t i E r e e t a t a d c o h c e u d t i c c c c o f o k h . n R r f e s . t t n i n a r a a r a s c l l l r b B o c u c a i e e o r l e e e j . l p p n p p c e c p e v o p p d a S o e j l h i e e v e e . R e e i n r C R i s C O t R C p i p A C K O R R , g . . t s e e c e s d d n r i r e r o v n e p e e a n l i e c . t t i m n e s o a e y j p g a t k c e n e u n i v r t i w n c s a v a i e t d s i E i v r m b n e e e o c l i s k e l l a s S l a i . e t d a e s s ) e a r e v a t d d r c g r t l U p e h a e p e d a e l r t c t n n r t s f l i i m a v t a a a f i A i a x r b i f o y e e r n b e l l l n e e d i r C e t h r n o a h m i p r t . , c c e e h k t s r h s a i o o h t t ; r d e f e T t i t e r s e y a r n s s e p i o o t d h i g r g i d ( t p o d a y l O t e w i p n g n s c u o t t c t t e e e u ) l ; c u n r e . o a ’ O e l p i e g e d e i r n l r i m r s r n l r d o . . d e t i u l k r v h r p R p h s i r o r a o s o g t s i d t r a t r o b a o c s e c i s n r r n o k t c n d s l a r c E a p c e g o o e e r r b o c i s b t m c n i n o u t c s o n k i L i f w i o e c t t o r n t j e o y p k l r e ( l e f r s k B p p a a i e o o j c e d i n r d m u t a I n o d o i t s a p r l c n t m l d e g m e r o t t i s r S p u s e i e e o e n e n p r t s o o l o l g c r i i o S a p i s z e u u t l t e t a i o a f b p z n f v c l r . a t v u o d d f : o y g i k i n i r r O , a c t o e c a o e d t e s . e s e i n a o t o n n i o e s i c l s . m e P = i o n o g e r e w r t j n d e i n k u . r e i e g s t B y e r r r d f s s n . o l e ) i v t i s l e g g c S o o u o o t l e i y s n i c n o n i l * n h i f r . a e e x o n a u o g n ( n I T t C L d w w d v U o t I d E K n D O b i E g E w k r . a s d e r m o u f k y c e a r l g B . h s s E e i t i R m h U f u w L I e d n n A i a g F n y e e r s s g u e e o l u m l a u b f m , y e o e u n l A r g B

F5CE ENGINES



PART FOUR - MAINTENANCE PLANNING

45

Copyright © 46


F5CE ENGINES



47

SCHEDULED SCHEDULED MAINTENANCE Servicing Plan

!

Engine lubrication frequency has been calculated presuming the use of fuel with content of Sulphur < 0.5%. WARNING! In case of use of fuel containing a percentage of Sulphur e > 0.5 %, the engine oil replacement interval must be halved.

Use engine engine oil SAE 15W40 15W40 T2

Overhaul and/or basic maintenance Checks and regular servicing

Frequency Frequency (hours) (hours)

Engi Engine ne visu visual al insp inspec ecti tion on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Chec Checkk for for pres presenc ence e of wat water er in the the fuel fuel filt filter er or prepre-fil filte terr . . . . . . . . . . . . . . . . . .

Daily

Chec Checkk eng engin ine e oil oil leve levell

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

Daily

Chec Checkk air air filt filter er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Chec Checkk bat batttery ery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every six months

Chec Checkk coo cooliling ng liqu liquid id leve levell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Check the the wear conditions conditions of of the alternator’s alternator’s belt belt and of the the water pump pump . . . . .

300 (2)

Chec Checkk for for pres presenc ence e of wat water er in in the the pre-f pre-filt ilter er . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 (1)

Check for presence of water in the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every six months (1)

Chec Checkk the the comp compres resso sor’s r’s belt belt wea wearr cond condit itio ions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300

Igni Igniti tion on pump pump over overha haul ul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000

Check turbo-compressor and clean it if necessary . . . . . . . . . . . . . . . . . . . . . . . . .

1200

Tapp Tappet et chec checkk and and adju adjust stme ment nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000

Chan Change ge engi engine ne oil oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500

Repla eplace ce engi engine ne oil oil fil filte terr

500

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

Repl Replac ace e fue fuell pre pre-f -fililte terr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000

Repla eplace ce fuel fuel filt filter er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 (1) (3)

Repl Replac ace e the the alte alterna rnato tor’s r’s belt belt and and the the wat water er pum pump p .. .. .. .. .. .. .. .. .. .. .. ..

1200

Repla eplace ce air air fil filtter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1200 (2)

Repl Replac ace e the the com compr pres esso sor’ r’ss bel beltt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1500

Chan Change ge the the coo cooliling ng liqu liquid id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 2 years or 1200 hours

1) Using fuel complyi complying ng with with EN590 EN590 Standard Standard (2) Depending Depending on appliance appliance (3) Using filters with filtering filtering degree < 12 μ 12 μ and β and β > 200 μ 200 μ filtering efficiency

(1)

Copyright © 48


F5CE ENGINES


SECTION 4 - MECHANICAL OVERHAUL

1

SECTION 4 Mechanical overhaul Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . .

3

DATA - ASSEMBLY SLACK . . . . . . . . . . . . . . . . .

4

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

10

ENGINE DISASSEMBLY ON BENCH . . . . . . . . . .

10

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

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

11

- Checks and measurements

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

11

- Chec Checki king ng head head base base surf surfac ace e on cyli cylind nder er unit unit .

12

TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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

13

- Cam lift and pin alignment check . . . . . . . . . .

13

BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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

15

- Tappets

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

15

- Tappet - Camshaft assembly . . . . . . . . . . . . . .

15

ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . .

16

- Main journals journals and crankshaft crankshaft bearing bearing pin measurement . . . . . . . . . . . . . . . . . . . . . . . . .

16

- Crankshaft bearing assembly

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

18

- Mai Main n jour journa nall asse assemb mbly ly slac slackk measu easurreme ement . . .

18

- Che Check ckin ingg outp output ut shaf shaftt shou should lde er cle cleara arance nce . . .

19

CONNECTING ROD-PISTON UNIT

.........

19

- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

- Piston diameter measurement . . . . . . . . . . . .

20

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

21

- Cond Conditi ition onss for for the corre correct ct pinpin-pi pisto ston n coupl coupling ing

21

Copyright © 2

SECTION 4 - MECHANICAL MECHANICAL OVERHAUL

F5CE ENGINES

Page

Page

- Snap rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

- Valve disassembly . . . . . . . . . . . . . . . . . . . . . . .

26

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

22

- Cylinder head base surface check . . . . . . . . . .

27

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

23

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

- Connecting rod-piston unit assembly . . . . . . . .

23

- Valve scaling, checking and grinding . . . . . . . .

27

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

23

VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

- Snap ring assembly . . . . . . . . . . . . . . . . . . . . . .

23

- Valve guide replacement . . . . . . . . . . . . . . . . .

28

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

rod-piston unit fixing - Connecting rod-piston into cylinder barrel . . . . . . . . . . . . . . . . . . . . . .

24

- Crankshaft bearing bearing assembly assembly slack measurement . . . . . . . . . . . . . . . . . . . . . . . . . .

24

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . .

29

- Piston projection check

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

25

- Cylinder head reassembly . . . . . . . . . . . . . . . .

30

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .

26

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

31



GENERAL SPECIFICATIONS Type

4 CYLINDERS

Cycle

Diesel 4 strokes

Power

See the specifications reported in Section 3

Injection

Direct

Number of cylinders

4

∅

+

+

Bore

mm

99

Stroke

mm

104

cm3

3200

Totall disp displac lacem ement ent +.. = Tota TIMING start before T.D.C. end after B.D.C.

A B

19° 19° ± 30’ 37° 37° ± 30’

start before B.D.C .D.C.. end after T.D.C.

D C

61° 61° ± 30’ 21° 21° ± 30’

Checking timing mm

0.25 ± 0.05

mm

0.50 ± 0.05

mm

0.20 to 0.40

mm

0.45 to 0.65

Bosch

VE 4/12F

X X

Checking operation X

FUEL FEED Injection Type:

Nozzle type

Injection sequence

BOSCH DSLA138PV 33

1-3-4-2

3

Copyright © 4


F5CE ENGINES

DATA - ASSEMBLY SLACKS

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS

mm

∅1 Cylinder barrels X

∅1 X 2 ∅

Spare pistons type: Size Outside diameter Pin housing

∅1

99.000 to 99.020

∅1

0.4

X ∅ 1 ∅ 2

10 98.908 to 98.918 36.003 to 36.009

Piston — cylinder barrels

0.082 to 0.112

Piston diameter

∅1

Piston protrusion

X

Piston pin

∅3

0.4

X

∅ 3

Piston pin — pin housing

-0.22 ÷ +0.07

35.990 to 35.996 0.004 to 0.019



Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S 2 S 3

Split ring slots

X1* X1* X2 X3

* theoretical theoretical measurement on a Ø of 96-0.25 mm Split rings

S 1* S2 S3

*measured at 1.5 mm from external Ø Split rings - slots

1 2 3

Split rings X 1 X 2

2.21 2.05 to 2.070 2.540 to 2.560

2.068 to 2.097 1.970 to 1.990 2.470 to 2.490 0.06 to 0.100 0.05 to 0.09 0. 4

Split ring end opening in cylinder cylinder barrel:

X3

Crankshaft bearing bush seat

∅1

mm

X1 X2 X3

0.20 to 0.35 0.60 to 0.80 0.30 to 0.60

∅ 1

39.460 to 39.49

Big end bearing seat X 0

67.833 to 67.841 67.842 to 67.848

Crankshaft bearing bush diameter Internal ∅ 3 ∅ 4*

36.010 to 36.020 39.570 to 39.595

∅ 2

∅ 3 ∅4

S

Red Crankshaft half bearings Blue Green * dimens dimension ion not measur measurabl able e at free state

1.875 to 1.884 1.883 to 1.892 1.891 to 1.900

Piston pin — bush

0.011 to 0.024

Big end half bearings

0.254; 0.508

5

Copyright © 6


F5CE ENGINES

Type

4 CYLINDERS


mm

X Measurement quota

X

Maximum error on parallelism of connecting rod axles ∅1

125

0.09

∅2 Crankshaft bearing pins No. 1-2-3-4 ∅ 1 No. 5 ∅ 1 Big end bearing pins ∅ 2 Crankshaft Crankshaft half bearings bearings S 1 Big end half bearings S2 ∅ 3

Crankshaft supports No. 1-2-3-4 No. 5

∅3 ∅3

76.182 to 76.208 83.182 to 83.208 64.015 to 64.038 2.165 to 2.174 1.876 to 1.883 80.588 to 80.614 87.588 to 87.614

Half bearings — Journals Journals No. 1-2-3-4 No. 5

0.064 to 0.095 0.059 to 0.100

Half bearings - Crankpins

0.033 to 0.041

Main half bearings bearings Big end half bearings

Crankshaft pin for shoulder

0.127; 0.254; 0.508

X1

31.85 to 32.150

Crankshaft support for shoulder X2

32.50 to 32.55

X 1

X 2 X 3

Shoulder half-rings

X3

Engine drive shaft shoulder

2.51 to 2.56 0.095 to 0.270



Type

4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM

mm

∅ 1 Valve guide seats on cylinder cylinder head

∅1

12.960 to 12.995

∅ 2

0.023 to 8.038

∅ 3

12.950 to 12.985

∅ 4 α

7.985 to 8.000 60 30’ ± 0 10’

∅ 4 α

7.985 to 8.000 60 30’ ± 0 10’

∅ 2

Valve guides ∅ 3 ∅ 4

Valves:

α Valve stem and guide

˚

˚

˚

˚

0.040 to 0.053

Valve seat on cylinder head

∅ 1

∅1

39.987 to 40.013

∅1

43.787 to 43.813

Valve Valve seat seat outsid outside e diamet diameter; er; valv valve e seat seat angle angle on cylin cylinde der r head: ∅ 2 α

∅ 2

∅ 2 α

α

X

40.063 to 40.088 60 ± 1 ˚

˚

40.863 to 43.88 60 ± 1 ˚

˚

X

0.3 to 0.7

Recess Recessing ing of valve valve X

0.3 to 0.7

Between Between valve seat and head Valve seats

0.050 to 0.101 0.050 to 0.101 -

7

Copyright © 8


F5CE ENGINES

Type

4 CYLINDERS


mm

Valve spring height:

H

H1

H 2

free spring

H

44.6

under a load equal to: 270 ± 14 N 528 ± 28 N

H1 H2

34 23.8

Injector protrusion

X

1.7 to 2.35

X

∅ ∅ ∅ 1 23 4 5

Seat for camshaft no. 5 bushes (Timing System side)

59.222 to 59.248

Camshaft housings No. 2-3-4 No. 1

50.069 to 50.119 40.069 to 40.119

Camshaft supporting pins

53.995 to 54.045

∅ 2 1 2 ⇒ 4 ∅ 1

∅

Bush inside diameter

49.975 to 50.025 53.995 to 54.045

5

∅ 3 ∅

39.975 to 40.025

∅ 5

Bushes and journals

54.083 to 54.147 0.038 to 0.162

Cam lift: H

H

5.5105

H

6.213



Type

4 CYLINDERS


mm

∅1 Tappet cap housing on block ∅ 2 ∅ 3

Tappet cap outside diameter:

∅2

∅ 1

∅ 2 ∅ 3

Between ta tappets an and ho housings Tappets

15,000 ÷ 15,018

15.924 to 15.954 15.960 to 15.975 0.03 to 0.068 -

∅ 1 Rocker shaft

∅1

18.979 to 19.000

Rockers

∅2

19.020 to 19.033

∅ 2 Between rockers and shaft

0.020 to 0.054

9

Copyright © 10


F5CE ENGINES

ENGINE OVERHAUL OVERHAUL ENGINE DISASSEMBLY ON BENCH

Figure 3

To execute the operations described here following, it is necessary to fit the engine on the rotary stand after having removed all the appliance’s specific components (see Section 3 of the herein manual). This section illustrates all the more important procedures of engine bock overhaul. overhaul.

119546

Figure 1

The third third (centra (central) l) main main bearing bearing cap (1) and associat associated ed support have a bearing-half (2) equipped with thrust. NOTE

Note down the assembly position of the upper and lower half bearings since, in case of reuse after the overhaul, they will have to be reassembled in the same position.

Figure 4 70158

Loosen the screws(1) fastening the connecting rod caps (2) and remove the fastening the connecting rod caps. Withdraw the pistons with the connecting rods from the upper part of the crankcase. NOTE Keep the half bearings in their respective housings since, in case of reuse after the overhaul, they will have to be reassembled in the same position.

119547

Using tool 380000362 (1) and a hoister, remove the engine drive shaft (2) from the crankcase.

Figure 2

Figure 5

119545

Loosen the screws (1) and disassemb disassemble le the crankshaft crankshaft bearing bearing caps (2).

120173

Disassemble the crankshaft half bearings (1). Loosen Loosen the fasten fastening ing screws screws (2) and disassem disassemble ble the oil nozzles (3).



11

zs

REPAIRS CYLINDER UNIT Checks and measurements

Figure 6

Figure 9

s

119548

Loos Loosen en the faste fasteni ning ng screw screwss (1) and and disa disasse ssemb mble le the camshaft (3) holding plate (2). 70166

NOTE

Once completed the engine disassembly, carefully clean the cylinder-crankcase units. Use suitable eyebolts to handle the cylinder unit. Carefully check the crankcase has for cracks. Check Check the conditions conditions of the processing caps: replace them if oxidized or in case cas e their tight is doubtful. Check the surface of the cylinder barrels: there must be no trace of meshing, scratches, oval or conical shaping and excessive wear. Cylinder barrel inner diameter check to detect any oval or conical shaping or wear shall be executed throughout the bore meter (1) equipped with comparator, which must be previously be reset on the ring calliper (2) of the cylinder barrel diameter.

Note down the plate assembly assembly position position (2).

Figure 7

NOTE If the ring calliper is unavailable, use a micrometer for reset. reset. 119549

Figure 10 Carefully Carefully withdraw withdraw the camshaft (1) from the engine bock. bock.

Figure 8

70167

70165

Withdraw the tappets (1) from the engine bock.

The measurements must be made for each cylinder, at three different heights from the barrel and on two perpendicular planes planes:: one paralle parallell to the engine engine longitud longitudinal inal axle axle (A)and the other other perpen perpendicu dicular larly ly (B). (B). Genera Generally, lly, maximu maximum m wear wear is detected on the perpendicular plane (B) and with the first measurement. If oval oval or conical conical shapin shapingg or wear wear is detect detected, ed, proc proceed eed boring boring and grinding grinding the cylinder barrels. barrels. Cylinder barrel grinding must be executed based on the spare pistons’ diameter plus 0,4 mm of the rated value and at the prescribed assembly slack.

Copyright © 12


F5CE ENGINES

Check the crankshaft bearing seats proceeding as follows:

Figure 11

- fit the crankshaft bearing bearing caps on the supports supports without bearings; - tighten the fastening screws to the prescribed torque setting; α

- with a suitable suitable comparator, comparator, check that the inner barrel diameter corresponds to the prescribed value.

If the detected value is higher, replace the crankcase. Il terzo (quello centrale) cappello di banco (1) e il relativo supporto hanno il semicuscinetto (2) dotato di spallamento.

Checking head base surface on cylinder unit After having detected any deformed areas, grind the head base surface using a grinding machine. Planar Planarity ity error error must must not exceed exceed 0.075 mm. Check Check the conditions of the cylinder unit processing caps: replace them if oxidized or in case their tight is doubtful.

119550

NOTE In case case of of grinding, grinding, all the barrels barrels must result having the same oversize (0.4 mm).



13

TIMING SYSTEM Camshaft Figure 12

119551

MAIN DATA ABOUT CAMSHAFT PINS

The The surfa surface ce of the camsha camshaft ft pins pins and and of cams cams must must be extremely smooth. In case any trace of meshing or scratches are detected, replace the shaft and the relevant bushes.

BUSH Figure 14

Checking cam lift and pin alignment Plac Place e the cams camsha haft ft on foots footstoc tocks ks and, and, throu through ghou outt a centesimal comparator placed on the central support, check that the radial oscillation does not exceed 0.015 mm otherwise otherwise replace the shaft.

Figure 13

70172

The front camshaft bush (2) must be thrust in the respective seat. There must be no trace of meshing or wear in the inner surface. Using a bore meter (3) measure the front adiameter of the camshaft bush (2). Measurements must be made on two perpendicular axles.

70171

Using a micrometer (1), check the diameter of the camshaft (2) supporting pins on the two perpendicular axles.

Copyright © 14


F5CE ENGINES

Figure 15

119552

MAIN DATA OF THE CAMSHAFT CAMSHAFT BUSH AND RELEVANT RELEVANT SEAT * Quota to obtain after bush fixing.



Bush replacement

15

Tappet - camshaft assembly Figure 18

Figure 16

70176 70174

Use the beater 380000667 (2) and handgrip 380000999 (3) to disassemble and replace the bush (1).

NOTE

Lubricate the tappets (1) and fit them into the relevant seats on within the crankcase. crankcase. Figure 19

In phase phase of assemb assembly, ly, the bush bush (1) must must be orient oriented ed making making the lubric lubricatio ation n ports ports coincid coincide e with those those on the crankcase.

119549

Lubricate the camshaft supporting bush and assemble the camsha camshaft ft (1) paying paying attentio attention, n, during during the afores aforesaid aid operat operation, ion, not to damage the bush or the shaft’s seats

Tappets Figure 20

Figure 17

119554

119553

TAPPET AND RELEVANT SEAT ON CRANKCASE MAIN DATA

Position the camshaft (3) holding plate (1) with the slot towards the upper side of the crankcase and the marking towards the operator; tighten the fastening screws (2) to the prescribed torque setting.

Copyright © 16


F5CE ENGINES

ENGINE DRIVE SHAFT Measurement of main journals and crankshaft bearing pins

Figure 21

Figure 23

119555

Check the camshaft axial shaft (1). The prescribed value is 0.23 ± 0.1 3 mm.

119557

Figure 22

In case case meshin meshing, g, scratche scratchess or excess excessive ive oval shaping shaping is detected on the main journals and crankshaft bearing pins, it is necessary to grind the pins. Before proceeding with pin (2) grinding, measure the shaft pins by means of a micrometer (1) in order to establish to which diameter diameter the pins must be reduced. NOTE Itis Itis reco recomm mmen ende ded d to note note down down the valu values es detected in a prospect. See Figure 24. Undersize Undersize classes are: 0.254 - 0.508 mm. 70180

Fit the nozzle nozzless (2) and tighten tighten the fasten fastening ing screws screws (1) to the prescribed torque setting.

NOTE The main main journals journals and cranks crankshaf haftt bearin bearingg pins pins must must always be grinded to the same undersize classes in order not to alter the shaft’s balance.

Figure 24

119556

PROSPECT REPORTING MEASUREMENT VALUES OF THE ENGINE DRIVE SHAFT MAIN JOURNALS AND CRANKSHAFT BEARING PINS * Rated value


17


Figure 25

119558

ENGINE DRIVE SHAFT MAIN TOLERANCES TOLERANCES

DIRECTION POSIT SITION

TOLERANCE CHARACTERISTIC

Roundness Cilindricity Parallelism Verticality Straightness Concent centrricit city or coa coaxiality lity Circular oscillation Total oscillation oscillation

LEV LEVELS ELS OF IMP IMPORTA ORTAN NCE FOR PROD RODUCT CHARA HARAC CTERI TERIST STIC ICS S

GRAPHIC SYMBOL ○ /○/ //

GRAP GR APHI HIC C SYMB SYMBOL OL

CRITICAL

©

IMPORTANT

⊕

SECONDARY

⊝

TIMING SIDE BENCH

INTERMEDIATE BENCHES

FIRST BENCH ON FRONT SIDE

119574

Copyright © 18


F5CE ENGINES

Crankshaft bearing assembly

Measurement of main journal assembly slack

Figure 26

Figure 27

70185

NOTE

If it is not necessary necessary to replace replace the crankshaf crankshaftt bearings, these shall be reassembled in the same order and position they were before disassembly.

The spare crankshaft bearings (1) have undersize internal diameter diameter of 0.254 - 0.508 mm. NOTE

119547

Assemble the engine drive shaft (2). Check Check the slack slack betwe between en the the engine engine drive drive shaft shaft main main journa journals ls and the respec respective tive cranks crankshaf haftt beari bearings ngs proce proceedi eding ng as follow follows: s: Figure 28

Do not try to adapt the bearings.

Care Careful fully ly clean clean the crank cranksha shaft ft half half bear bearing ingss (1) (1) havi having ng lubrication port and fit them in their respective seats. The penultimate crankshaft half bearing (1) is provided with shoulder half rings. 119962

- carefully carefully clean the parts and eliminate eliminate any oil residuals; residuals; - place on the engine drive drive shaft pins (4) in parallel parallel with longitudinal axle, a piece of gauged wire (3); - ffit the caps (1) and the half bearings (2) on the relevant supports.

NOTE

Always use new screws in phase of assembly.



19

Checking output shaft shoulder clearance

Figure 29

Figure 32

70187

Tighten the pre-lubricated screws (1) and tighten them in three subsequent phases: - 1st phase with torque wrench setting at 50 ± 5 Nm. - 2nd with torque wrench setting at 80 ± 6 Nm. Figure 30

70190

The check of the shoulder clearance is performed with a magnetic based comparator (2) placed on the engine shaft (3) as indicated in the figure. If the clearance is above the one prescribed replace the semi-cr semi-crank anksha shaft ft bearin bearings gs of the thrust thrust hold hold rear rear suppor supportt next next to the last (1) and check again the clearance between the engine shaft pins and the semi-crankshaft bearings.

α

119559

-

3rd

phase using tool 380000304 (1) fitted as shown in the figure and further tighten the screws (2) by 90º ± 5º angle. Figure 31

CONNECTING ROD — PISTON ASSEMBLY Figure 33

119560

- Remove Remove the caps from their support. support. The slack between the crankshaft bearings and the relevant pins should be detected detected comparing the width measured by the gauge wire (2) in the point of maximum flattening with the scale graduation reported on the shield (1) of the gauge wire. The numbers reported on the scale indicate the coupling slack in millimetres. millimetres. If the slack slack detect detected ed differ differss from from the prescri prescribed bed value,repla value,replace ce the half bearings and repeat the measurement; once achiev achieving ing the slack slack prescr prescribe ibed, d, lubric lubricate ate the cranks crankshaf haftt bearings bearings and finally assemble the supports tightening the fastening screws as described previously.

70191

CONNECTING ROD-PISTON UNIT COMPONENTS 1. Grommets. - 2. Pin. - 3. Piston. - 4. Snap rings. - 5. Screws - 6. Half bearings. - 7. Connecting rod. - 8. Bush.

NOTE The The spar spare e pisto pistons ns are are suppl supplie ied d with with stand standar ard d dimensions or oversize by 0.4 mm.

Copyright © 20


F5CE ENGINES

Pistons Piston diameter measurement

Figure 34

Figure 37

32613

Using Using pincer pincerss 38000022 380000221 1 (3), (3), removethe removethe snap snap rings rings (1) from from the piston (2).

32615

Using the micrometer (2), measure the piston diameter (1) to determine the t he assembly slack. NOTE The diameter must be measured at 10 mm from the base of the piston shell.

Figure 35

Figure 38

32614

Remove the piston pin (1) grommet using the nail (3). 70192

Figure 36

The slack between piston and cylinder barrel can also be measu measured red by means means of callipe calliperr and gauge gauge (1), (1), as shown shown in the figure.

119561

MAIN DATA OF THE PISTON, PINS AND SNAP RINGS * Quota detected on Ø 96 mm.



Piston pins

21

Figure 42

Figure 39

18857

Measurement of the piston pin diameter (1) throughout a micrometer (2).

Conditio Conditions ns for the the correct correct couplin coupling g of pins and and pistons

32620

Check the slack between the grommets (3) of the 2nd and 3rd slots and relevant relevant housing on the the piston (2) (2) using calliper calliper and gauges (1). Figure 43

Figure 40

32619 41104

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.

SCHEME FOR THE MEASUREMENT OF SLACK BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL GROMMET SCHE SCHEME ME FOR THE MEAS MEASU UREMEN EMENT T OF SLAC SLACK K BETW ETWEEN EEN THE FIRST IRST PIST ISTON SLOT SLOT AND AND TH THE E TRAPEZOIDAL GROMMET Due Due to the part particu icula larr for for of the first first grom gromme met, t, havin havingg trapezoidal section, the slack between said grommet and the slot must be measured as follows: the piston (1) must be project projected ed from the crankca crankcase se so that that nearly nearly half of the gromm grommet et (2) in questio question n come comess out of the cylinde cylinderr barre barrell (3). (3).

Split rings Figure 41

In this position, using a gauge calliper, calliper, measure measure the slack (X) between grommet and slot: the slack must comply with the prescribed value.

16552

Check Check the thickness thickness of the gromm grommets ets (2) throug throughou houtt a micrometer (1).

Copyright © 22


F5CE ENGINES

Figure 44

Figure 46

70194

Measurement of slack between the snap ring ends (2) fitted into the cylinder barrel (3) throughout gauge calliper (1).

Connecting rods Figure 45

119563

A. Class of weight - B. Part number - C. Date of production production (DD/MM) - D. Date of production production (year) E. Marking for connecting connecting rod-cap rod-cap coupling.

NOTE

119562

NOTE The connecting rod-connecting rod cap surfaces are knurled to ensure better coupling. Therefore, it is recommended not to remove the knurling.

In phase phase of assemb assembly, ly, ensure ensure that all the connect connecting ing rods belong to the same manufacturer and class of weight.



Bushes

23

Figure 49

Check that the connecting rod shoe bush is not loose and that there is no trace of meshing or scratches otherwise replace it. Disass Disassemb embly ly and reasse reassembl mblyy must must be execute executed d using using a suitable beater. When fixing it, make sure that the ports for oil passage on the bush and on the connecting rod coincide. Throughout a bori boring ng machi machine ne,, bore bore the bush bush in orde orderr to obta obtain in the prescribed diameter.

Connecting rod-piston unit assembly Connecting rod-piston coupling

72705

Fit the pin (1) snap rings (2).

Figure 47

Snap ring assembly Figure 50

119564

The following references are marked on the piston crown: 1. Spare part number number and modification modification numbe number; r; 2. Indicative Indicative sign for piston piston assemb assembly ly in the cylinder barrel; barrel; it must be turned towards the flywheel; 3. Stamping Stamping proving proving 1st slot slot insert insert inspection; inspection; 4. Date Date of manufa manufactur cture e

32613

Use the pincers 380000221 (3) to fit the snap fasteners (1) to the piston (2). The snap rings must be fitted with ”TOP” marking upwards. Furthermore, ring opening must be misaligned by 120º.

Figure 48

NOTE The spare snap rings are available in the following sizes:

119565

Thro Throug ugho hout ut the the pin pin (3), (3), conne connect ct the the pisto piston n (2) (2) to the the connecting rod (4) following the indication of the reference arrow arrow (1) to correctly correctly fixing the piston (2) into the cylinder barrel barrel,, also also taking taking into conside considerat ration ion the numbe numbers rs (5) printe printed d on the connecting rod (4), as shown in the figure.

-

stan stand dard; ard;

-

over oversi size ze by 0.4 0.4 mm. mm.

Copyright © 24


F5CE ENGINES

Figure 51

Figure 53

119566 70200

Fit the half bearings (1) on the connecting rod and cap.

SCHEME FOR CORRECTLY FIXING THE CONNECTING ROD-PISTON UNIT INTO THE HOLLOW - The snap rings’ openings openings must be misaligned by 120º;

NOTE

if it is not necess necessary ary to replace replace the big end bearin bearings, gs, reasse reassembl mble e the existi existing ng ones ones in the same same order order and position they were before disassembly. Do not adapt the half bearings.

rod/piston units must have the same - all the connecting rod/piston weight; - the engine drive shaft sign (1) printed on the piston crown must be turned towards the flywheel while the notch on the piston shield must match the oil nozzles’ position.

Warning! The connecting rod must not collide with the cylinder wall.

Connecting rod assembly slack measurement Figure 54

Fitting Fitting connecting connecting rod-pisto rod-piston n assembly assembly into cylinder barrels Figure 52

70203

For slack measurement proceed as follows: - carefully carefully clean the parts eliminating eliminating any oil residuals; - place a piece piece of gauge gauge wire (2) on on the engine drive drive shaft pins (1); 70201

Lubricate the pistons, the snap pins and the cylinder barrel interior. Using the band 380000220 (2), fit the connecting connecting rod-piston rod-piston unit (1) into the cylinder barrel, checking that : - the number of each connecting rod corresponds corresponds to the coupling cap number.

- fit the connecting rod caps (3) and the relevant half bearings (4).

NOTE




Figure 55

25

In case the slack measured differs from the prescribed value, replace the half bearings and measure the slack again.

Piston projection check

α

NOTE

70204

- lubricate the fastening screws (1) with engine oil and tighten them to the prescribed torque setting (50 ± 5 Nm) using a torque wrench.

Figure 56

α

70205

- fit the tool 380000304 (1) to the socket wrench and then further tighten the screws (2) by 70º ± 5º.

Figure 57

70206

- remove the cap and measure the slack comparing the width measured by the gauge wire (1) with the scale graduation reported on the gauge wire shield (2).

See page 17 of Section 3.

Copyright © 26


F5CE ENGINES

CYLINDER HEAD Valve disassembly

Figure 59

Figure 58

1 2

119567

A

75750

The intake valves (1) and exhaust valves (2) have different head diameter.

Valve disassemb disassembly ly must be executed executed using tool 380000302 (1) to slightly press the plate (3) so that, compressing the spring (4), it is possible to remove the half cone (2). Then remove the plate (3) and the spring (4). Repeat the operation in correspondence of each valve. Turn Turn the cylinde cylinderr head head upside upside down down and withdra withdraw w the valves valves (5). Figure 60

NOTE Numberthe Numberthe valves valves befor before e removin removingg them them from from the cylinder head in order to be able to reassemble them in the same order in case replacement is not n ot necessary. A = intake side

119568

Remove the grommets (1 and 2) from their valve guides.



27

VALVES

Cylinder head base surface check

Figure 62 Any defor deformat mation ion detect detected ed on the whole length of the cylinder head must not exceed 0.20 mm. In case higher value is detected, grind the cylinder head in order order to obtain obtain the prescri prescribed bed value. value. Refer Refer to the main spec specifi ificat catio ions ns repo report rted ed here here follo followi wing ng and and follo follow w the instructions accompanying the figures below.

EXHAUST VALVE

INTAKE VALVE

Figure 61

119569

119591

INTAKE AND EXHAUST VALVE MAIN DATA

Valve scaling, checking and grinding A rated thickness of the cylinder head is 90 ± 0,1 mm.

Figure 63

18625

Eliminate carbon deposits from the valves using the specially provided metal brush. Check the valves valves for meshing, meshing, cracks or burns. burns. If necessary, necessary, grind the the valve seats seats removing removing as less material material as possible. Figure 64

18882

Using a micrometer (2) measure the valve stem (1): the prescribed value is 7,985 to 8,000 mm.

Copyright © 28


F5CE ENGINES

VALVE GUIDE

Valve guide replacement replacement

Figure 65

Valve guide assembly and disassembl disassemblyy is performed performed with beater 380000219. Insert the valve guide in the cylinder head so that they stick out from it for 8.1 ÷ 8.9 mm.

INTAKE

EXHAUST

119570

Using Using a bore bore meter, meter, measur measure e the valve valve guide guide inner inner diame diameter ters, s, which must correspond correspond to the values reported in the figure below.

VALVE SEATS Figure 66

122433

VALVE SEAT SPECIFICATIONS

If the valve seat are damaged replace them with the spare ones included in the supply. With the tools and being careful not to indent the cylinder heads, remove as much material as possible form the valve seats until removal from cylinder head is possible by means of a punch.

Heat cylinder head up to 80º ÷ 100ºC and with the beater assemble assemble the new valve seats previously previously cooled in them.



VALVE SPRINGS

29

CYLINDER HEAD ASSEMBLY

Figure 67

Figure 68

50676

MAIN SPECIFICATIONS FOR INTAKE AND EXHAUST VALVE SPRING TEST Before assembly, test the valve spring flexibility using specific tool. Compare the load and elastic strain test results with the technical specifications of the new springs, reported in the table below.

119572

Lubricate the valve stems (1) and fit them in the relevant valv valve e guid guides es in the the same same posi positi tion on they they were were befo before re disassembly. Fit the grommets (2 and 3) to the valve guide using tool 380000134.

Elastic strain

Under load of

mm

N

H (free)

44,.6

0

H1

34

270 ± 14

H2

23.8

528 ± 26

Figure 69

119567

Place the spring (4) and the upper plate (3) on the cylinder head head.. Using Using tool tool 38000 38000030 0302 2 (1), (1), compr compres esss the spri spring ng (4) (4) and and constr constrain ain the part partss to the valv valve e (5) (5) throu through ghou outt the half half cones cones (2).

Copyright © 30


F5CE ENGINES

Cylinder head reassembly Figure 70

119573

Chec Checkk that that the cylind cylinder er head head and and cran cranks ksha haft ft coupl couplin ingg surfaces are clean. Do not foul the cylinder head gasket. Fit the gasket (1) on the crankshaft in the correct centred position, taking the pins as reference (2).



TORQUE SETTING TORQUE

Threaded cap with O-ring n t a i P n l i U O Oil pan spacer fastening

k c o b e n i g n E

e s a c r a e g g n i m i T

Crankshaft caps pre pre-tigh -tighte teni ning ng tigh tighte teni ning ng angle tightening Piston cooling nozzle 3/8” conical threaded cap 1/8” conical threaded cap Water drainage cap Oil turbo delivery pipe fixing Conical threaded cap Gear cooling nozze Cover fastening Cover fastening Cover fastening Ignition pump screw stud Timing pin seat cap Gearcase fastening Gearcase fastening Gearcase fastening

Case fastening l e e e h a s Case fastening w y c l F Case fastening Cylinder head fastening First phase d Second phase a e T h hird phase r e Cylinder head fastening d n First phase i l y Second phase C Third phase Threaded cap fastening

(M8x1.25 6g x 35)

Nm

kgm

50 ± 5

5 ± 0.5

25 ± 5

2.5 ± 0.5

50 ± 50 ± 5 80 ± 80 ± 5

5 ± 0.5 8 ± 0.6 90 ± 5 ± 5 ˚

˚

(M8x1.25 6g x 25) (M8x1.25 6g x 35) (M8x1.25 6g x 50)

18 ± 2 40 ± 5 15 ± 5 25 ± 25 ± 5 40 ± 5 15 ± 5 15 ± 5 25 ± 5 25 ± 5 25 ± 5 4 ± 1 25 ± 5 25 ± 5 25 ± 5 25 ± 5

1,8 ± 0.2 ± 0.2 4 ± 0.5 1.5 ± 0.5 ± 0.5 2.5 ± 0.5 ± 0.5 4 ± 0.5 1.5 ± 0.5 1.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 4 ± 0.1 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5

(M8x1.25 6g x 25)

35 ± 5

3.5 ± 0.5

(M12x 1.75 6g x 60)

120 ± 5

12 ± 0.5

(M12x 1.75 6g x 40)

120 ± 5

12 ± 0.5

130 ± 10 ± 10

13 ± 13 ± 1 1

(M8x1.25 6g x 35) (M8x1.25 6g x 35) (M8x1.25 6g x 16.5)

(M15x 1.5 6g x 193) 90 ± 5 ± 5 90 ± 5 ± 5 ˚

˚

˚

˚

(M12x 1.5 6g x 165) 65 ± 5 ± 5

6 ± 0.5 90 ± 5 ± 5 60 ± 5 ± 5 ˚

˚

˚

˚

40 ± 5

4 ± 0.5

25 ± 5

2.5 ± 0.5

(M8x1.25 6g x 30)

25 ± 5

2.5 ± 0.5

(M8x1.25 6g x 50)

25 ± 5

2.5 ± 0.5

Valve adjusting nut

20 ± 5

2 ± 0.5

Inspection cover fastening

25 ± 5

2.5 ± 0.5

Rocker arm dowel

d a e Overhead fastening h r e Overhead fastening v O

31

Copyright © 32


F5CE ENGINES

TORQUE Intake manifold fastening

d e l o k f i a Intake manifold fastening t n n a I m Throw fastening to intake manifold t s l o Exhaust manifold fastening f u i a n h x a m Turbo-blower stud screw E Heat exchanger fastening to valve unit t Heat exchanger fastening to throw i n EGR fastening to intake manifold U R Valve fixing G E Manifold fastening nut screws Manifold fastening rings Engine drive shaft pulley fastening Connecting rod cap fastening fastening n n-Connecting n i p r e t i g h t e n i n g o C ce- angle tightening Phonic wheel fastening Flywheel fastening - pre-tightening - angle tightening

g Thrust block fastening n i m i T Gear fastening

Nm

kgm

(M8x1 .25 6g x 60)

25 ± 5

2.5 ± 0.5

(M8x1.25 6g x 55)

25 ± 5

2.5 ± 0.5

25 ± 5

2.5 ± 0.5

35 ± 5

3.5 ± 0.5

15 ± 5

1.5 ± 0.5

25 ± 25 ± 25 ± 10 ± 25 ± 10 ± 350 ±

5 5 5 5 5 5 15

2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 1 ± 0.5 2.5 ± 0.5 1 ± 0.5 35 ± 1.5

50 ± 5

5 ± 0.5 70 ± 5 ˚

˚

15 ± 3

1.5 ± 0.3

30 ± 5

3 ± 0.5 90 ± 5 ˚

˚

25 ± 5

2.5 ± 0.5

36 ± 5

3.6 ± 0.5

25 ± 4

2.5 ± 0.4

15 ± 5 30 ± 5

1.5 ± 0.5 3 ± 0.5

20 ± 5

2 ± 0.5

20 ± 5

2 ± 0.5

10 ± 5

1 ± 0.5

10 ± 5

1 ± 0.5

36 ± 36 ± 5

3.6 ± 0.5

Union fixing to support l r e e t u l i F f Fuel filter fastening

25 ± 5

2.5 ± 0.5

25 ± 5

2.5 ± 0.5

y p Supply pump fastening l p m Inlet p u u S p

25 ± 5

2.5 ± 0.5

25 ± 5

2.5 ± 0.5

Fast clutch

25 ± 5

2.5 ± 0.5

Injector fastening

10 ± 5

1 ± 0.5

Pump fastening

25 ± 5

2.5 ± 0.5

25 ± 25 ± 25 ± 25 ± 15 ±

2.5 2.5 2.5 2.5 1.5

s r o t c e j n I

Injector stud screw fastening Injector fastening nut - pre-tightening - tightening

A Pipe fixing on manifold side D L Pipe fixing on pump side r r Engine drive shaft speed sensor fixing o o t s Camshaft speed sensor fixing c n e j n s I Water temperature sensor fixing

r o r t c a c e s j n I

Collector fastening screw nuts o re Oil delivery inlet fixing b r w o Delivery pipe fastening screw nut u l T b Exhaust pipe fixing to heat exchanger Exhaust pipe fixing to turbo

5 5 5 5 5

± ± ± ± ±

0.5 0.5 0.5 0.5 0.5



TORQUE Nm 25 ± 5 25 ± 25 ± 5 40 ± 5

2.5 ± 0.5 2.5 ± 0.5 4 ± 0.5

45 ± 5

4.5 ± 0.5

25 ± 5

2.5 ± 0.5

15 ± 5

1.5 ± 0.5

10 ± 2

1 ± 0.2

35 ± 5

3.5 ± 0.5

45 ± 5

4.5 ± 0.5

25 ± 5

2.5 ± 0.5

Oil filter cartridge fastening

18 ± 2

1.8 ± 0.2

Oil pump fastening 1st step 2nd step

15 ± 15 ± 5 25 ± 25 ± 5

1.5 ± 1.5 ± 0.5 0.5 2.5 ± 0.5

45 ± 5

4.5 ± 0.5

25 ± 5

2.5 ± 0.5

25 ± 5

2.5 ± 0.5

g Water pipe fixing to the heat exchanger n i e l p Water pipe fixing to the support o i o pp C 3/8” conical threaded cap Oil pressure control valve fastening l e k v c Oil level dipstick fastening e e l l i hc O Oil inlet pipe fastening

e s Flange fastening to block o r n o i t c Stirrup fastening to block u S Cartridge union

r e y t l d Oil filter fastening i f o l i b O

Threaded caps r e g t n a a Exchanger unit fixing e h H c x e Heat exchanger fastening

t a t s Thermostat unit fixing o m r e h Bleed vent fixing T

25 ± 5

2.5 ± 0.5

40 ± 5

4 ± 0.5

Water pump fastening

t r Bearing fixing o n p p a p Fan support fixing F u s

25 ± 25 ± 5

2.5 ± 0.5

40 ± 5

4 ± 0.5

25 ± 5

2.5 ± 0.5

Pulley fixing

40 ± 5

4 ± 0.5

Support fastening to block

50 ± 5

5 ± 0.5

50 ± 5

5 ± 0.5

50 ± 5

5 ± 0.5

r o p Alternator fastening (screw + nut) t a u n o r e r g Push rod fixing t l A Alternator push rod fixing (screw + nut)

s r o s n e S

5 5 5 5 5 5 2 2

5 ± 0.5 5 ± 0.5 7 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 1 ± 0.2 1 ± 0.2

pre-tightening

18 ± 2

1.8 ± 0.2

tightening

90 ± 5

9 ± 0.5

25 ± 5

2.5 ± 0.5

Front hook fastening Rear hook fastening Water temperature sensor fixing Oil temperature sensor fixing Water temperature sensor fixing Impulse transmitter fixing Air pressure sensor fixing Pump gear fixing

n o p i t m c u e j p n I

50 ± 50 ± 70 ± 25 ± 25 ± 25 ± 25 ± 10 ± 10 ±

Fuel pump fixing (screw nuts)

33

Copyright © 34


F5CE ENGINES


SECTION 5 - TOOLS

1

SECTION 5 Tools Pagina TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Copyright © 2

SECTION 5 - TOOLS

F5CE ENGINES


SECTION 5 - TOOLS

TOOLS

TOOL No.

DEFINITION

380000134

Shrink fitter for valve guide gasket assembly assembly

380000150

Tool for engine P.M.S. positioning positioning

380000219

Beater for valve guide disassembly and reassembly

380000220

Ring for plunger introduction into the cylinder barrel (60 ÷ 125 mm)

380000221

Pliers for plunger plunger snap ring disassemb disassembly ly and reassembly reassembly (65 - 1 10 mm)

380000222

Sleeker for valve guide

3

Copyright © 4

SECTION 5 - TOOLS

F5CE ENGINES

TOOL No.

DEFINITION

380000228

Comparator Comparator (0 to 5 mm)

380000229

Comparator holding tool for rotatory injection pump phasing (use with 380000228)

380000302

Tool for engine valve disassembly and reassembly

380000304

Pair of measuring measuring devices devices for angular angular tightening tightening with 1/2“ and 3/4” square coupling

380000364

Compar Comparato atorr holdin holdingg base base for miscel miscellane laneous ous measur measures es (use (use with with 380000228)

380000667

Beater Beater for removi removing/ ng/refi refitti tting ng camsha camshaft ft bushes bushes (to be used used with with 380000999)


SECTION 5 - TOOLS

TOOL No.

DEFINITION

380000670

Tool for cartridge filter disassembly

380000978

Rotary stand for overhauling overhauling units (capacity (capacity 1000 daN, torque 120 daNm)

380000999

Handle for interchangeable beaters

380001006

Diesel engine cylinder compression control device

380002385

Tool for rotating rotating the engine flywheel flywheel

380100072

Puller for the gear coupling coupling the injection injection pump to the engine

5

Copyright © 6

SECTION 5 - TOOLS

F5CE ENGINES

TOOL No.

DEFINITION

380100073

Tool for drive shaft lifting

380100074

Adap Adapte terr for for count counterp erpres ressu sure re check checking ing in cylin cylinde ders rs (use (use with with 380001006)

380100075

Shrink fitter for the assembly assembly of the drive shaft front gasket gasket

380100076

Shrink fitter for the assembly assembly of the drive shaft rear gasket


APPENDIX

1

Appendix Page SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . .

3

Copyright © 2

APPENDIX

F5CE ENGINES


APPENDIX

3

SAFETY PRESCRIPTIONS Standard safety prescriptions

- Do not execute any intervention if not provided with necessary instructions.

Particular attention shall be drawn 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 sufficient to ensure ensure safety to the personnel personnel in-charge of maintenance.

- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided provided for: serious injury may occur.

Be infor informe med d and and infor inform m pers person onne nell as well well of the laws laws in forc force e regulat regulating ing safety, safety, provid providing ing informa information tion docume documenta ntation tion available for consultation.

- In case of test or calibration operations operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.

- Keep Keep work working ing area areass as clean clean as possi possibl ble, e, ensur ensuring ing adequate aeration.

During maintenance

- Ensure that working areas are provided with emergency boxes, boxes, that must be clearly visible and always provided provided with adequate sanitary equipment.

- Never open filler cap of cooling circuit when the engine is hot. hot. Oper Operat atin ingg pres pressu sure re woul would d prov provok oke e high high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC.

- Provide for adequate 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. - Provide Provide Warnings Warnings throughout throughout adequate adequate boards boards signaling signaling danger danger,, prohib prohibitio itions ns and indicat indications ions to ensure ensure easy easy compre comprehen hensio sion n of the instruc instruction tionss even even in case of emergency.

Prevention of injury - Do not wear unsuitable cloths for work, with fluttering fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion. - 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: ≤ allowed: ≤ 2 2 bar) - Wear Wear safety safety helmet helmet when working working close to hanging hanging loads or equipment working at head height level.

safety shoes when and cloths adhering adhering to - Always wear safety the body, better if provided with wit h elastics at the ends. - Use protection cream for hands. - Change Change wet cloths as soon as possible possible - In presence of current tension exceeding exceeding 48-60 V verify verify efficie efficiency ncy of earth earth and mass mass electri electrical cal connecti connections ons.. 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.

dirty rags rags with oil, diesel diesel fuel fuel or solvent solventss in - Put the dirty anti-fire specially provided containers.

- Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether whether part partic icul ular ar circ circum umst stan ance cess requ requir ire e main mainte tena nanc nce e intervention on running engine, be aware of all risks involved with such operation. - Be equip equipped ped with adequa adequate te and safe containe containers rs for drainage drainage operation operation of engine liquids and exhaust exhaust oil. - Keep the engine clean from oil tangles, diesel fuel and or chemical solvents. - Use of solvents or detergents detergents during maintenance may origin originate ate toxic toxic vapors vapors.. Always Always keep keep workin workingg areas areas aerated. Whenever necessary wear safety mask. - Do Do not not leav leave e rags rags impr impreg egna nate ted d with with flam flamma mabl ble e substances close to the engine.

proper - Upon engine start after maintenance, undertake proper preventing preventing actions to stop air suction in case of runaway runaway speed rate. - Do not utilize fast screw-tightenin screw-tighteningg tools. - Never disconnect batteries when the engine is running. - Disconnect batteries batteries before any intervention intervention on the electrical system. - Disconnect Disconnect batteries batteries from system aboard to load them with the battery loader. - After After every every interve interventio ntion, n, verify verify that that batter batteryy clamp clamp polarity polarity is correct correct and that the clamps are tight and safe from accidental accidental short circuit and oxidation. oxidation. - Do not disconnect and connect electrical connections connections in presence presence of electrical electrical feed.

Before re proc procee eedi ding ng with with pipe pipeliline ness disa disass ssem embl bly y - Befo (pneum (pneumati atic, c, hydrau hydraulic, lic, fuel fuel pipes)verifyprese pipes)verifypresence nce of liquid 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.

Copyright © 4

APPENDIX

- Avoid incorrect tightening or out of couple. Danger: incorr incorrect ect tighten tightening ing may seriou seriously sly damage damage engine engine’s ’s components, affecting engine’s duration. - Avoid priming priming from from fuel fuel tanks made out of copper copper alloys and/or and/or with ducts not being provided provided with filters. filters. - Do not modify cable wires: their length shall not be changed. - Do not not conne connect ct any any user user to the engi engine ne elec electr trica icall equipment unless specifically approved by CNH.

unless - Do not modify fuel systems or hydraulic system unless CNH CNH spec specif ific ic appr approv oval al has has been been rele releas ased ed.. Any Any unauthorized unauthorized modification modification will compromise compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: execute electric electric arc welding welding without without having having - Do not execute priory removed electronic gearbox. - Remove Remove electronic gearbox gearbox in case of any intervention intervention requiring heating over 80ºC temperature. - Do not not pain paintt the the compo compone nents nts and and the elec electro tronic nic connections. - Do not vary or alter any data filed in the electronic gear gearbo box x drivi driving ng the the engi engine ne.. Any mani manipu pula latio tion n or alter alterat ation ion of elec electr tron onic ic comp compon onen ents ts shall shall total totally ly com compromi romise se engi engine ne assi assist stan ance ce warr arranty anty and furthe furthermo rmore re may may affect affect engine engine correc correctt working working and duration.

F5CE ENGINES

Respect of the Environment - Res Respe pect ct of the the Envi Enviro ronm nmen entt shal shalll be of prim primar ary y impo import rtan ance ce:: all all nece necess ssar aryy prec precau autio tions ns to ensur ensure e personnel’s safety and health shall be adopted. - Be informed and 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 orga organi nize ze speci specific fic traini training ng cour course sess to ensur ensure e that that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect Collect exhaus exhaustt oils in adequa adequate te special specially ly provid provided ed 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 Handle the batteries with care, storing them in aerated aerated environment and within anti-acid containers. Warning: batt batter eryy exha exhala lati tion on repr repres esen entt seri seriou ouss dang danger er of intoxication and environment contamination.

Copyright © 1

F5AE ENGINES

PART 2 - F5AE ENGINES Section General information

1

Supply

2

Industrial appliance

3

Overhaul and specifications

4

Tools

5

Safety rules

Appendix

Copyright © 2

F5AE ENGINES

Copyright © F5AE ENGINES


1

SECTION 1 General Page TECHNICAL CODING . . . . . . . . . . . . . . . . . . . . .

3

ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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

7

-

Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

-

Counterotating mass balancing device . . . . . . .

9

-

Engine oil filter . . . . . . . . . . . . . . . . . . . . . . . .

10

ENGINE OIL VAPOUR RECIRCULATION . . . . . .

11

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

12

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

-

Working system . . . . . . . . . . . . . . . . . . . . . . .

13

HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . .

14

TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . . .

15

EGR EXHAUST GAS RECIRCULATION . . . . . . . .

16

Copyright © 2


F5AE ENGINES



TECHNICAL CODING

Technical Code F5AE9484A F5AE9484B F5AE9484G F5AE9454A F5AE9454G TECHNICAL DESIGNATION

TYPE F

5

A

E

9

4

8

PART NUMBER 4

A * A

0

0

1

-

Progressive production number Variant number Level of Gas Emissions (Tier 3) Engine torque and power level Use (eg 4 = tractors) Air feed + injection injection (TCA, (TCA, direct injection injection diesel engine) Number of cylinders 5 - External EGR 9 - Internal EGR Engine (invariable)

2300 rpm A 48 kW / 2300

B 57 kW / 2300 rpm Engine family evolution (also irrespective irrespective of the displacement) displacement) Indicates Indicates the engine family

2300 rpm G 65 kW / 2300

3

Copyright © 4


F5AE ENGINES

ENGINE VIEWS Figure 1

120013

FRONT VIEW OF ENGINE Figure 2

120014

LEFT SIDE VIEW OF ENGINE



5

Figure 3

120015

RIGHT SIDE VIEW OF ENGINE Figure 4

120016

REAR VIEW OF ENGINE

Copyright © 6


F5AE ENGINES

Figure 5

120017

TOP VIEW OF ENGINE



LUBRICATION Forced circulation lubrication is controlled by the rotor oil pump housed in the front part of the engine basement and driven by the toothed gear splined splined on the shank of the engine drive shaft. From From the the oil pan, pan, the the lubr lubrica icatio tion n oil oil is dist distrib ribut uted ed to the the engin engine e drive shaft, the camshaft and the valve control.

7

The lubric lubricatio ation n system system also also compri comprises ses the heat exchang exchanger, er, the centrifugal blower for the versions with turbosupercharger and eventually the compressor if the compressed air system is also fitted. All the above above mentio mentioned ned compon componentsvary entsvary depend depending ing on their their use and therefore will be illustrated in the specific section.

Figure 6

Pressurized oil

Dropping oil

120007

LUBRICATION SYSTEM LAYOUT

1. Turbosupercharg Turbosupercharger er lubrication lubrication feed pipe - 2. Heat exchanging exchanging unit - 3. Heat exchanger exchanger 4. Oil pump - 5. Oil filter

Copyright © 8


F5AE ENGINES

Oil pump Figure 7

119405

PUMP SPECIFICATIONS Rotating speed Feed pressure Rated flow Oil type Max oil temperature

750 rpm - 4200 rpm 2 Bar - 4 Bar 12.2 l/min - 75.9 l/min SAE 20/30 80 °C ° C

1. Main gear - 2. Secondary gear - 3. Pump unit - 4. Drive shaft - 5. Secondary shaft 6. Cover - 7. Internal rotor - 8. External rotor - 9. Bush



9

Counterotating mass balancing device Figure 8

119717

1. Reference notches notches for alignment and timing - 2. Balancing masses masses -3. Bushes - 4. Shouldering Shouldering fifth wheels - 5. Shaft - 6. Box.

Copyright © 10


F5AE ENGINES

Engine oil filter Figure 9

119406

1. Protective cover - 2. Cartridge Booster pressure

20 bar (ISO 4548/3)

Dynamic press essure:

0-1 0-15 bar (1Hz) > 50,000 000 cycles les (ISO 4548/5)

Operating temperature:

-40 / + 140 C

Torque wrench setting:

18 ±2Nm

Maximum flow:

50 l/min.

Load Load loss loss at the end of life life cyc cycle: le:

2.5 bar

Accumulation:

> 15 gr with 2.5 bar load loss (ISO 16889)

˚



11

ENGINE OIL VAPOUR RECIRCULATION Figure 10

119407

1. Valve - 2. Breather - 3. Tappet cover On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop by gravity on the underlying tappet cover (3). The remaini remaining ng non conden condensedvapou sedvapours rs willbe duly duly convey conveyed ed throug through h the breath breather er (2), (2), for instan instance ce by suction(appr suction(appropr opriat iate e connecconnec tion must be provided by the outfitter).

Copyright © 12


F5AE ENGINES

COOLING SYSTEM The closed circuit forced circulation circulation engine cooling system system is composed of the following parts: - expansion tank: position, form and dimensions may vary depending depending on the engine fitting. fitting.

heatexchanger coolingthe coolingthe lubrica lubricant nt oil. Thi Thiss compon component ent - heatexchanger may vary depending on the specific engine fitting. - centrifu centrifugal gal water water pump pump positi positioned oned in the front front part part of of the engine basement; - thermostat controlling cooling liquid circulation.

- radiat radiator or dissip dissipatin atingg the heat absorbed absorbed by the engine engine cooling liquid. This component’s component’s position and dimensions may vary depending on the outfit. - fan fan incr increa easi sing ng the the radi radiat ator or’s ’s cool coolin ingg powe power. r. This This component may vary depending on the specific engine fitting.

Figure 11

Closed thermostat Open thermostat

Water inflow Engine cooling water Water ou tflow from thermostat

120018

COOLING SYSTEM LAYOUT



13

WATER PUMP Figure 12

120047

WATER PUMP SECTION 1. Hub - 2. Shaft with bearing - 3. Pump unit - 4. Sheath - 5. Impeller. The water pump is a centrifugal blade turbine type pump. The pump’s bearing (2) is connected to the impeller’s shaft as a whole. Water tight between the pump unit un it (3) and the shaft (2) is ensured by the sheath (4).

THERMOSTAT Figure 13

119412

THERMOSTAT DIAGRAM

Working system When the engine is i s cool, water output from the front part of the cylinder head flows into an inlet containing containin g the thermostat, which cuts cuts out water water circula circulation tion to the radiat radiator. or. This way, way, water water circulat circulation ion will only be possib possible le in in the pumppump-engi engine ne circuit circuit,, insof insofar ar allowing allowing engine heat-up quickly. The thermostat valve starts opening at nearly 80 C, allowing water circulation into the radiator and also obstructing direct return towards the engine. Check the thermostat efficiency and replace it in case of doubtful functioning. 1. Stro Stroke ke start startss at at 79 79 ± 2 C 2. 7 mm mm stro stroke ke at 94 ±2 C ˚

˚

˚

˚

˚

Copyright © 14


F5AE ENGINES

HEAT EXCHANGER Figure 14

SECTION A-A

SECTION B-B

119408

The heat exchanger within the engine cooling system system has the duty to control the engine oil temperature, temperature, reducing it by absorbing heat throughout the engine cooling liquid.



15

TURBOCHARGING

The turbocharging turbocharging system system is composed of the following parts: parts: - air filter; - turbosupercharger.

Figure 15

Sucked air Heated compressed air Engine exhaust gas 120019

Copyright © 16


F5AE ENGINES

EGR EXHAUST GAS RECIRCULATION The exhaust exhaust gascan be partia partially lly recycle recycled d to cylind cylinders ers to reduce reduce maximu maximum m temper temperatu ature re values values of combus combustion tion that that produc produce e nitrogen nitrogen oxides (NOx). The exhaust exhaust gasrecycle gasrecycle system system (EGR) (EGR) reduce reducess combus combustio tion n temper temperatu ature re and therefor therefore e is an efficien efficientt NOx NOx emissi emission on contro controll system system..

INTERNAL EGR The specific design of suction cams of the internal EGR system allows part of exhaust gas to be recycled to engine cylinders. This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always active. Its configuration requires requires no additional additional parts such as control valves, pipelines pipelines or heat exchangers therefore engine profile remains unchanged. Besides main lobe, suction cam has an additional lobe as to configuration without EGR. During concerned cylinder exhaust phase, this lobe allows a shaft advanced opening of intake valve. In this way, part of the exhaust gas is trapped in the suction duct and later, during cylinder suction phase, this gas is recycled to cylinder inlet for combustion phase.

Aspiration cam profile Figure 16

X. Angolo rotazione camma - Y. Alzata camma

114026


SECTION 2 - SUPPLY

1

SECTION 2 Supply Page SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

PIPE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

-

Working System Description . . . . . . . . . . . . .

5

SUPPLY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Identification coding example . . . . . . . . . . . . .

6

WORKING SYSTEM DESCRIPTION . . . . . . . . . . .

7

-

Supply phase . . . . . . . . . . . . . . . . . . . . . . . . . .

7

-

Delivery phase . . . . . . . . . . . . . . . . . . . . . . . . .

7

-

End of delivery phase . . . . . . . . . . . . . . . . . . . .

8

-

Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

-

L.D.A .D.A.. Load Deliv livery Adjustment ent device . . . . .

9

-

Working system . . . . . . . . . . . . . . . . . . . . . . .

9

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

10

FUEL FILTER

11

-

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

Copyright © 2

SECTION 2 - SUPPLY

F5AE ENGINES


SECTION 2 - SUPPLY

3

SUPPLY The engine supply supply system consists of the following following components: components: - Fuel tank tank (aboard (aboard the the vehicle) vehicle)

pipes - Fuel delivery and return pipes - Fuel pre-filter pre-filter (if fitted, it is placed nearby nearby the engine on the vehicle’s vehicle’s chassis) Priming pump, fitted on the engine and driver by the engine camshaft - Fuel filter filter (its position position on the engine may vary depend depending ing on the outfit and use) - Supply rotary pump - Injector feed feed pipe (from the fuel supply pump to the fuel injectors) injectors) - Injectors

Figure 1

119420

SUPPLY SYSTEM DIAGRAM 1. Injectors - 2. Fuel filter - 3. Tank - 4. Supply rotary pump - 5. Ignition pump.

Copyright © 4

SECTION 2 - SUPPLY

F5AE ENGINES

PIPE LAYOUT

Figure 2

118976

1. Injector feed pipe - 2. Fuel exhaust pipe from injectors - 3. Supply rotary pump - 4. Union for pressure gauge pipe within LDA intake manifold manifold - 5. KSB thermal thermal bulb - 6. Solenoid valve valve - 7. Injector Injector


SECTION 2 - SUPPLY

5

Figure 3

119961

Working system description The fuel (5) is primed from the fuel tank from the priming pump (6). The latter is fitted on the engine basement and is driven by the engine camshaft. Throughout the filter (4), fuel is conveyed to the transfer pump, which is placed inside the supply rotary pump (2), which is a turbine blade pump type. The supply rotary pump duty is to increase the fuel pressure based on the increase of engine revolutions’ number.

Then, Then, the fuel fuel reaches reaches the valve valve control controlling ling fuel fuel pressur pressure e within within the supply pump. The distributor distributor piston further increases increases such pressure pressure and delivers the fuel to the injectors (1) throughout the delivery pipe fitting. The fuel leak (3) from the injectors is recovered and sent back to the fuel tank.

Copyright © 6

SECTION 2 - SUPPLY

F5AE ENGINES

SUPPLY PUMP The rotary type supply pump is driven by a gear which is coupled to the engine camshaft gear.

Identification coding example V

= rota rotary ry distr distrib ibuto utorr pisto piston n pump pump

E

= pump pump dime dimens nsio ions ns

4

= four four cyli cylind nder er engi engine ness

12

= distr distribu ibutor tor piston piston size in mm

1150 = no. of pump rev./min. rev./min. RV

= Counterclock Counterclockwise wise rotation rotation direction direction

Figure 4

1 15 2 14 3 4

5 13 12 6

7 8

9 11 10 30454

Ignition pump longitudinal section 1. Membrane Membrane - 2. Setting ring - 3. Feeler pin - 4. Drive lever - 5. Speed regulator regulator - 6. Transfer Transfer pump - 7. Drive shaft 8. Cam disk - 9. Spark lead adjuster adjuster - 10. Distributor piston piston - 11. Feed pipe fitting - 12. Hydraulic Hydraulic head - 13. Control Control plate 14. Adjusting pin - 15. Counter spring.


7

SECTION 2 - SUPPLY

WORKING SYSTEM DESCRIPTION DESCRIPTION Supply phase Figure 5

119415

1. Fuel supply pipe - 2. Solenoid valve - 3. Axial groove - 4. Compression chamber - 5. Fuel delivery pipe from pump to injectors injectors - 6. Distributo Distributorr piston piston - 7. End End of deliver deliveryy port - 8. Cursor Cursor - 9. Injector. Injector. The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the compression chamber chamber (4) through through the feed pipe (1) which is kept open by the solenoid valve valve (2).

Delivery Delivery phase Figure 6

119416

1. Fuel feed pipe - 2. Compression Compression chamber - 3. Distributor Distributor piston inner pipe 4. Fuel delivery pipe from pump to injector - 5. Distributor piston - 6. Injector. The distrib distributorpiston utorpiston (5) driven driven by the cam disk, disk, goes goes up to the T.D.C T.D.C.. and simulta simultaneo neously usly rotate rotatess on its ownaxle. Thecombinati Thecombination on of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within the chamber (2). The distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to the injectors (6).

Copyright © 8

SECTION 2 - SUPPLY

F5AE ENGINES

End of delivery phase Figure 7

119417

1. Fuel feed pipe - 2. Compression chamber - 3. Fuel delivery pipe - 4. End of delivery pipe 5. Cursor - 6. Distributor Distributor piston. The distri distribut butor or piston piston (6) moving moving toward towardss the T.D.C T.D.C.. connects connects the high high pressur pressure e inner inner chambe chamberr to the pipe pipe (1), (1), thereb therebyy establi establishin shingg pressure balance between the distributor piston inner chamber, the injectors’ delivery pipe and the pump interior. Since such pressure is lower than the one required to start the injector, end of delivery will be determined.

Engine stop Figure 8

119418

1. Fuel feed pipe - 2. Mobile cap - 3. Spring - 4. Solenoid valve - 5. Compression chamber.

Engine stop is provoked cutting out the starter contact. The electric flux to the solenoid valve (4) is cut out. The solenoid valve, throughout its spring (3), drives the mobile cap to the end of stroke (2) and the mobile cap obstructs the fuel feed pipe (1).


SECTION 2 - SUPPLY

9

L.D.A. Load Delivery Delivery Adjustment Adjustment device Figure 9

119419

Working system The duty of the L.D.A. L.D.A. device is to adjust the fuel delivery delivery depending depending on the air pressure within within the intake manifold. manifold. Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there is a conical housing housing (5) in which the feeling feeling pin runs (6). The setting pin (4) axial motion motion drives the feeling pin (6) shift and the latter acts on the stop lever (7). The stop lever rotates rotates on its own axle (8) (8) and acts on on the control control plate in order order to adjust the fuel delivery delivery depending depending on the air quantity quantity within the the cylinders. cylinders.

Copyright © 10

SECTION 2 - SUPPLY

F5AE ENGINES

PRIMING PUMP The The prim primingpum ingpump p duty duty is to prim prime e the the fuel fuel from from the tank tank and and conve conveyy it to the fuel fuel supp supply ly pump pump.. It is fitte fitted d on the engin engine e base baseme ment nt and driven by the engine camshaft.

Figure 10

88209

1. Pump - 2. Control lever - 3. Camshaft


SECTION 2 - SUPPLY

11

FUEL FILTER The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water from the fuel in which it is contained. At the bottom of the filtering cartridge there may be a water drainage device; depending on the appliance (use in cold climate conditions), the fuel filter support may be equipped with a heater and a temperature sensor. Some versions are also equipped with a water detecting sensor at the bottom of the cartridge filter.

Figure 11

119411

1. Fuel filter support support - 2. Cartridge Cartridge filter- 3. Water drainage device (not available on all versions). versions).

Copyright © 12

SECTION 2 - SUPPLY

F5AE ENGINES



1

SECTION 3 Industrial appliance Page MAIN SPECIFICATIONS . . . . . . . . . . . . . . . . . .

3

PART ONE MECHANICAL COMPONENTS . . . . . . . . .

5

ENGINE DISASSEMBLY ON BENCH . . . . . . . .

7

- BOSCH VE 4/12F pump . . . . . . . . . . . . . . . . .

8

- Timing gearcase . . . . . . . . . . . . . . . . . . . . . . .

11

- Rear side component assembly . . . . . . . . . . .

13

- Flywheel assembly . . . . . . . . . . . . . . . . . . . . .

13

- Front side component assembly . . . . . . . . . . .

14

- Timing

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

15

- Piston projection measurement . . . . . . . . . . .

16

- Inspection and checks

21

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

- Check of injection injection pump static static advance on engine engine at the TDC of cylinder 1 . . . . . . . . . . . . . . . . . 22

PART TWO - ELECTRICAL EQUIPMENT . . .

23

ELECTRIC CABLE TO CONNECT KSB WITH CERA . . . . . . . . . . . . . . . . . . . . . . . . .

25

- Eng Engin ine e cool coolin ingg liq liquid uid tem temperat eratur ure e sens senso or . . . .

26

- Oil pressure switch

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

27

- KSB coo cooling ing liqu iquid tem temperatur ture senso nsor . . . . . .

28

- Engine pulse transmitter . . . . . . . . . . . . . . . . .

29

PART THREE - DIAGNOSIS . . . . . . . . . . . . . .

31

DIAGNOSIS BY FAILURE . . . . . . . . . . . . . . . . .

33

PART ART FOUR FOUR - SCHE SCHEDU DULE LED D MAIN MAINTE TENA NANC NCE E

39

SCHEDULED MAINTENANCE . . . . . . . . . . . . .

41

- Servicing plan . . . . . . . . . . . . . . . . . . . . . . . . .

41

Basicc chec checki king ng and and main mainte tena nanc nce e oper operat atio ions ns . . - Basi

41

Copyright © 2


F5AE ENGINES



MAIN SPECIFICATIONS

F5AE9454 A

Type

Cycle

F5AE9484 A

F5AE9454 D

Diesel 4 strokes

Feeding


Injection

Direct

N. of cylinders

4 on-line

∅

+

Diameter

mm

99

Stroke

mm

104

cm3

3202

+

otal displac laceme ement +.. = Tota

ρ


Max. torque

17 ± 17 ± 0.5 : 1 KW (HP)

44 (60)

48 (65)

55 (75)

rpm

2500

2300

2300

Nm (kgm)

210 (21)

260 260 (26)

220 (22)

rpm

1400

1400

1400


rpm


rpm

1150 ± 1150 ± 50

2750 ± 2750 ± 50 50

3

Copyright © 4


F5AE ENGINES

F5AE9484 B

Type

Cycle

F5AE9484 G

Diesel 4 strokes

Feeding


Injection

Direct

N. of cylinders

4 on-line

∅

+

Diameter

mm

99

Stroke

mm

104

cm3

3202

+

ent +.. = Total displacement

ρ


Max. torque

17 ± 17 ± 0.5 : 1 KW (HP)

57 (77)

65 (88)

rpm

2300

2300

Nm (kgm)

315 (32)

340 (34)

rpm

1400

1400


rpm


rpm

1150 ± 1150 ± 50

2750 ± 2750 ± 50 50



DIAGNOSI

PART ONE - MECHANICAL COMPONENTS

5

Copyright © 6


F5AE ENGINES



7

zl

5401 540110 10

ENGINE ENGI NE DISA DISASS SSEM EMBL BLY Y ON BENCH

Figure 2

NOTE

Engine Engine disasse disassemb mbly ly operatio operations ns to remove remove the engine engine from from the vehicle vehicle aredescribe aredescribed d in the specifi specificc section. Engine disassembly operations, as well as engine overhaul, overhaul, must be executed by qualified qualified enginee engineers rs only, only, duly duly provid provided ed with the specifi specificc tools required.

NOTE

Depending on the appliance, some units may have different different position on the engine.

NOTE

Befo Before re fitti fitting ng the engin engine e on the rotar rotaryy stand stand 38000097 380000978, 8, disass disassemb emble le the parts parts which which may interfere with the bracket assembly. Depending on the appliance, it may be necessary to remove the starter and the oil filter.

- Drain the engine oil from the oil pan collecting it in a suitable container.

Warning! Avoid skin contact with the engine oil: in case of contact wash your skin with running water.

119720

- Remove the L.D.A. pipe. Remove the fast clutch fuel pipes from the priming pump to the filter (1) and from the filter to the ignition pump (2), then fit the specially provided caps to the pipes, the pumps and the filter. Unscrew the screws (3), fastening the fuel ignition pipes and remove them.

Figure 3

The engine engine oil is highly highly polluti polluting:waste ng:waste dispos disposal al must must be execute executed d complyi complying ng with the laws laws andregulati andregulations ons in force. - Remove Remove the electric wiring from the injection pump.

Figure 1

119106

- Unscrew the pump fastening screws on the rear part of the gear cover. To disassemble the pump, fit tool 99340025 to the pump wheel and fix it with the three screws (1). Using the specially specially provided provided wrench, slowly tighten the screw (2) holding the rear part of the pump removing the pump completely. NOTE

119718

- Remove Remove oil delive delivery ry pipe pipe connec connected ted to the turboch turbocharg arger er (3) and t the oil return pipe (1).

turbocharger unit (2). - Remove the turbocharger - Duly hold the starter starter (5), unscrew the fastening screws screws and remove the starter. - Remove Remove the water hose (4).

Before removing the pump verify if, for the model used, a shaft block system exists. In that case, block the engine by means of the specific tool in the corresponding position, to the TDC of cylinder 1, (at compression compression end, end, as shown in the procedur procedure e at page 19). Now block with the specific system the pump shaft; this way the pump should be timed, so that when refitting refit ting (if no maintenance intervention is required on it) no adjustment is necessary.

Copyright © 8


F5AE ENGINES

zl

BOSCH VE 4/12F Pump Figure 4

118976

1. Fuel delivery pipes - 2. Fuel recovery pipes - 3. Mechanical pump - 4. LDA - 5. Wax KSB - 6. Injectors.



Figure 5

9

Figure 7

120021 119721

- Place Place a contain container er under under the diesel diesel fuel fuel filter filter and and unscrew unscrew the condense drainage faucet under said filter; completely completely drain the diesel fuel container therein. - Disassemble the diesel fuel filter (1), the filter support (2), the priming pump (3), the oil filter (4), the oil filter support (5), and the KSB water sensor (6).

- Loosen the screw (1) and the relevant screw nut on the belt tensioning bracket (3). - Loosen the screw (2, Figure 8) in order to withdraw the belt (2). - Remove the belt tensioning bracket (3). - Disassemble Disassemble the pulleys and the guide rollers. rollers.

Figure 8 Warning! The oil filter contains c ontains a certain quantity of engine oil. Collect the engine oil and dispose it complying with the applicable laws and regulations in force.

Figure 6

119722

Duly hold hold the the alte altern rnato atorr (1) (1) and and deta detach ch it from from its - Duly suppo support rt loose loosenin ningg the screw screw (2): (2): recov recover er nut nut and and washer. Figure 9

120020

- Unscrew Unscrew the injector injector suppor supportt fasteni fastening ng screws screws (1), (1), disasse disassembl mble e the injector injector suppor supports ts and remove remove the injectors (2). - Loosen the screws (3) and remove remove the tappet covers. - Remove Remove the intake manifold (6). - Remo Remove ve the therm thermos ostat tat unit unit (4) (4) and and the exha exhaust ust manifold (5).

NOTE

On the centr central al cover cover ther there e is a lubri lubrica catio tion n oil oil vapour vapour blow-b blow-byy valve. valve. All the gaskets must always be replaced replaced in phase of assembly.

119109

- Place Place a containe containerr under under the heat heat exchan exchanger(2) ger(2) to collect collect the cooling liquid contained therein. - Loos Loosen en the screw screwss (1) (1) and and disa disass ssem embl ble e the heat heat exchanger unit (2).

Copyright © 10


F5AE ENGINES

Figure 10

Figure 12

119112

119723

- Remove Remove the electromagnetic electromagnetic joint support (1) and the water pump (2).

- Fit tool (1) 380000988 to the flywheel box and, and, using a wrench, wrench, lock the flywheel rotation. rotation. - Loosen the screws screws fastening fastening the flywheel to the engine drive shaft.

remove the pulley pulley (3). - Loosen the screw (4) and remove

Figure 11 Figure 13

119724

- Screw Screw two two aver averag age e leng length th screw screwss (2), (2), to sling sling the flywheel with a lifting device. - By mean meanss of two two guid guide e pins pins (4) (4) prev previo iousl uslyy screw screwed ed in the engine engine drive drive shaft shaft ports ports (3), (3), guide guide the flywhee flywheell (1) withdrawal withdrawal throughout a hoist. - Withdraw Withdraw the flywhee flywheell casing grommet. grommet.

Withdraw the grommet grommet of the timing timing gearcase. gearcase. - Withdraw

119111

- Unscrew Unscrew the fasteni fastening ng screws screws (1) and remove remove the camshaft holding overhead assembly (2), recovering the two seals (3).



11

Timing gearcase Figure 14

119725

Remove e the rear rear cove coverr (2) (2) from from the tran transm smiss issio ion n - Remov gearbox (1).

Figure 15

119115

Remove the tappet rods rods (1). - Remove - Disassemble the cylinder head; loosen the cylinder head (3) fastening screws (2); hook the brackets with metal ropes and, throughout a hoister, detach the cylinder head with valves from the basement.

head gasket. - Remove the cylinder head

Copyright © 12


F5AE ENGINES

Figure 16

Figure 18

119726

- Turn the engine upside upside down.

Remove the screws (2) and detach detach the oil sump (1). - Remove

119117

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

- Remove Remove the suction rose rose

Figure 19

Figure 17

1 119118

- Loosen the rocker arm fastening screw (1) from the disassembled rocker arm holding unit and then remove the rocker arm.

2 Figure 20

3

120148

- Remove Remove the seal (3). - Unscre Unscrew w the screws screws (1) which which fasten fasten the additio additional nal mass mass box (2) and remove it.

119119

- Withdraw the rocker arm (1) from from one side recovering the equalizers (2) from the other.



Rear side component assembly

13

Figure 22

Figure 21

119729

SCHEME FOR THE APPLIANCE OF LOCTITE 5699 SEALER ON THE TIMING GEARCASE - Accurat Accurately ely clean clean the timing timing gearca gearcase se and the engine engine basement.

!

It is absolutely necessary to clean the surface to be sealed in order to obtain obtain perfect perfect tightness. tightness. Apply Apply LOCTIT LOCTITE E 5699 sealer sealer on the gearcase gearcase in 0,5 orde orderr to form form a seal sealing ing bead bead of 1,5 1,5 —+0,2 mm. mm.

119730

specific tool 99346259 99346259 (5) to the rear rear shank (6) (6) - Fit the specific of the engine drive shaft, fix it with the screws (4) and spline the new grommet (3) thereon. - Position Position part (1) on part (5), tighten tighten the screw nut (2) until the grommet has been fitted (3) into the flywheel casing casing (7). (7).

Flywheel Flywheel assembly Figure 23

The sealing sealing bead bead must must be homoge homogeneo neous us (no lumps) lumps),, free of air bubbles, thinner areas and gaps. Any imperf imperfecti ection on must must be correc corrected ted as soon soon as possible. Avoid Avoid the excess excess of sealer sealer:: too much much sealin sealingg mater material ial would leak and pour out on both sides of the joint parts and, and, as a consequence, consequence, obstruct the passage passage of the lubricant. After having applied the sealer, the parts must be joined within 10 minutes.

119731

- Screw Screw two two hand handlin lingg hook hookss (2) (2) or eyeb eyebolt oltss on the the flywheel (4). - By By mean meanss of a hoist hoister er,, draw draw the the flywh flywhee eell up to itshousing itshousing inside the casing.

NOTE

The flywheel has a reference dowel that couples with the relevant seat on the box.

- Screw two pins (1) of appropriate length into the shaft’s ports (3) and, using them as a guide, duly fit the engine flywheel (4) into its casing.

screws fastening the engine flywheel flywheel to the - Tighten the screws engine engine drive shaft. shaft. Fit the tool tool (380000 (380000988 988)) to the flywhee flywheell casing casing in order order to lock the engine engine flywheel flywheel rotation.

Copyright © 14


F5AE ENGINES

Figure 26

Figure 24

α

119732

Tighten the engine flywheel (2) fastening screws (1) in two steps:

119733

SCHEME FOR THE APPLIANCE OF LOCTITE 5699 SEALER

- Step 1: 30 ± 5 Nm torque setting ;

fastening. - Step 2: 90º ± 5º angular fastening.

NOTE

NOTE Angula Angularr fasten fastening ing must must be execute executed d using using tool tool 380000304. Befo Before re asse assemb mbly, ly, alwa always ys check check that that the port port threads and the screws show no trace of wear and dirt.

BIt is absolutely necessary to clean the surface to be sealed in order order to obtain perfect perfect tightness. tightness. Apply LOCTITE 5699 sealer on the gearcase in orde orderr to form form a seal sealing ing bead bead of 1,5 1,5 —+0,0,52 mm. mm. The The seal sealing ing bead bead must must be homo homoge gene neou ouss (no (no lumps), free of air bubbles, thinner areas and gaps. Any imperfection must be corrected as soon as possible. Avoi Avoid d the exce excess ss of seal sealer er:: too much much seal sealing ing material would leak and pour out on both sides of the joint joi nt parts and, as a consequence, obstruct the passage of the lubricant.

Front side component installation

After having applied the sealer, the parts must be joined within 10 minutes.

Figure 25

- Assemble the front case (1) and tighten the fastening screws to the prescribed torque wrench.

119117

Assemble the oil pump (2). - Assemble - Screw Screw the fasteni fastening ng screws screws (1) without without fully fully locking locking them. - With magnetic base comparator, check the clearance among the engine shaft gear and the oil pump gear: it must be 0.068 ÷ 0.168 mm. - Fully tighten the fastening fastening screws (1).



Timing

15

Figure 28

Figure 27

119735

- Fit the ignition pump cogwheel cogwheel (1) into its housing. - Fit the pre-set ignition pump into its housing on the engine, inserting the shaft into the gear hole. - Tighten the three screw nuts on the rear part of the timing gearcase and the front cover fixing the shaft to the gear. - With magnetic base comparator, check the clearance among the engine shaft gear and the oil pump gear: it must be 0.068 ÷ 0.168 mm. - Fit the new gasket using the centring pins (2) on the casing for its correct positioning. casing’ss cover cover using the centrin centringg pins pins (2) to - Fit the casing’ correctl correctlyy positio position n it and then then tighten tighten the fasteni fastening ng screws to the prescribe prescribed d torque wrench. 119734

Figure 29 - Seize the 45 bevel tooth (1) of the engine drive shaft gear gear with with the timing timing gear toot tooth h mark marked ed with with two two notches (2), as shown in the figure. ˚

- Rotate the camshaft keeping the timing gear fix until the camshaft’s pin fits into the relevant housing within the timing gear.

transmission gear without without fully - Screw the screws of the transmission tightening them. - With magnetic base comparator, check the clearance among the engine shaft gear and the cam shaft gear: it must be 0.068 ÷ 0.168 mm. - Screw the fastening screws (1) of the transmission gear.

119736

part of tool 99346262 to the front shank of of - Fit the inner part the engine drive shaft. Make sure that the engine drive shaft pin is correctly fitted into the tool spline in order to avoid damaging it. Fix it with the screw (1) and spline the new grommet thereon. t hereon. - Place the outer section of the tool on the previously fitted one, tighten the screw nut (2) until completely fitting the grommet (3) into the casing.

Copyright © 16


F5AE ENGINES

Figure 30

Figure 32

70221

- Fit a new grommet grommet (2) to the water pump pump (1).

119573

- Assemble the water pump (1). (1). - Tighten the fastening screws to the prescribed torque wrench.

- Fit the gasket (1) on the basement basement centring it taking the pins (2) as a reference. The gasket’s thickness must be selected selected based on the piston projection projection in respect respect to the upper plan of the basement.

NOTE Check that the block’s laying plan is clean. Do not grease the gasket. It is recommended to keep keep the gasket gasket inside inside its wrappi wrapping ng until until it has to be fitted. The fitting direction direction is univocal and defined defined by the centring pins on the basement, which must match with the ports on the gasket.

Piston projection measurement Figure 31 Figure 33

119462 119115

Piston projection from basement B (mm)

Engine gasket thickness A Thickness (mm)

From 0.07 to -0.07

0.80

From -0.08 to -0.22

0.70

- Measure the piston projection and refer to the table above to select the appropriate thickness of the gasket.

NOTE

Always use new screws for assembly.

- Place the head (3) on the block taking the centring centring pins as a reference. - Lubrica Lubricate te the head head fasteni fastening ng screws screws (2)and tighten tighten them to the prescribed torque wrench.



Figure 34

17

Figure 36

122432 119723

- Reassemble Reassemble the electroma electromagnetic gnetic joint support support (1).

- Mount the discharge manifold (3) complete of new seal (2) and tighten the nuts (1) with the stud bolts applying applying the required torque.

- Reassemble the pulley pulley (2). - Reassemble the pulley (3), tighten the fastening screw (4) to the prescribed torque setting.

Figure 37

- Reasse Reassembl mble e the heat heat exchan exchangerremin gerremindin dingg to replacethe replacethe old gasket with a new one; tighten the fastening fastening screws to the prescribed torque setting.

Figure 35

32655

Before reassembly, check that the rocker arm rods must not be deformed; there must be no trace of wear or seizure on the spherical housings of the rocker arm adjusting screws as well as on the tappets tappets (pointers) (pointers);; otherwise otherwise these parts parts must be repl replace aced. d. The The suctio suction n valv valve e rods rods are are iden identic tical al and and therefore interchangeable. - Fit the control rods rods in their housing.

Figure 38 119108

- Put the alternator alternator back in place (1, Figure 8).

tightening (2). - Screw up without tightening - Fit the drive belt on the pulley and the guide rollers. rollers.

Tension the drive belt rotating rotating the alternator alternator as shown - Tension in the figure. - Tighten the screw (1) and the screw nut (2, Figure 8) fastening the alternator to the support.

119119

- Fit the rocker arm positioning the equalizer couples: the suction equalizer first (short rod) and then the exhaust equalizer (long rod) (2). - Screw the fastening fastening screws.

Copyright © 18


F5AE ENGINES

Figure 39

Figure 41

119128

- Make the holes (1) for fuel exhaust all face the same direction.

Figure 42

119111

- Replace Replace the seals seals (3), (3), refit refit the camsha camshaft ft holdin holdingg overhe overhead ad (2) and tighten the screws (1) applying the required torque. - After having completed the assembly, check that the rocker arms are correctly positioned on the valves and the tappet control rods.

119721

temperature sensor (6), the - Reassemble the KSB water temperature oil oil filte filterr suppo support rt (5), (5), the prim priming ing pump pump (3), (3), the dies diesel el fuel fuel filter support (2), the fuel filter (1) and the oil filter (4).

Figure 40

Figure 43

120020

- Reassemble the injectors (2) replacing the grommets. Tighte Tighten n the fasten fastening ing screws screws(1) (1) to the prescr prescribe ibed d torque torque setting. - Replace Replace the thermostat thermostat unit (4).

119905

- Fit the head covers (1) replacing replacing the gaskets gaskets (2).



Figure 44

19

Figure 46

119716

- Reassemble the fuel exhaust pipes (1).

Figure 45

112012

Position the engine shaft at the TDC of cylinder 1, rotating the flywheel until the following conditions are achieved: - the notch (2) can be seen from the inspection inspection window; window; - the tool 380000150 (1) is inserted through the guard in the hole located on the flywheel.

Figure 47

120034

- Reassemble the whole intake manifold (1) replacing the gasket (2).

119727

In the above conditions (correct engine timing), mount the box containing the additional masses (1) taking care that the reference notches (2) coincide as shown in figure. Position the new seal (3) on the engine block. Remove the tool 380000150 (1, Figure 46).

Copyright © 20


F5AE ENGINES

Figure 48

Figure 50

119105

- Reassemble the pipe from the pump pump to the injector and tighten the brackets’ fastening screws (3). - Reassemble the pipe from the pump to the fuel filter (2) and from the fuel filter to the priming pump (1).

112011

NOTE

Verify Verify that that the misali misalignm gnment ent betwe between en flywhee flywheell cover box (1) and oil sump (2) is within the range 0 ± 0.1 mm

L.D.A. pipe. - Reassemble the L.D.A. Figure 51 Figure 49

119726

- Fit the suction rose.

screws (2) and tighten - Mount the oil sump (1). Screw screws them applying the required torque. NOTE

Befor Before e mountin mounting, g, verify verify that the thread threadss of the holes and the screws are not worn or dirty.

119718

- Reassemble the turbocharger turbocharger (2) unit. - Reassemble Reassemble the pipe (4) and fit the clip in the correct housing. - Reassemble the oil delivery pipe (3) and the return pipe pipe (1). - Refit the starter starter (5).



21

Checks and inspections

Figure 52

!

The following checks must be executed after the engine fitting on vehicle. Check that the liquid refuelling or top up has been provided to the correct levels prescribed.

Start the engine, keep it running at a number of rev./m rev./min. in. slightly slightly over over idling idling and wait wait until until the cooling cooling liquid temperature reaches the value prescribed for thermostat valve opening and then provide checking the following:

- Disconnect Disconnect the fuel fuel filter filter pipe pipe (1) and act act on the priming priming pump (2) drainage lever.

check ther there e is no wate waterr leak leak from from the the mani manifo fold ldss - check connecti connecting ng the engine engine cooling cooling circuit circuit pipes pipes and the cabin cabin interior heating pipes, eventually further tightening the O-rings.

- Continue drainage until fuel discharge is completed.

- Carefully Carefully check the fuel filter pipe fittings. fittings.

- Connect Connect the pipe (1) to the filter.

- Check there is no oil leakage from cylinder head and cover, cover, oil pan and baseme basement, nt, heat heat exchan exchanger ger oil filter filter and relevant relevant housings housings in between between the various various lubrication lubrication circuit pipes. pipes.

119728

there is no fuel leakage leakage from the fuel pipes. - Check there - Check there there is no air leak from the pneumatic pneumatic pipes (if fitted). - Check that the warning lights on the instrument instrument panel and equip uipment disco iscon nnected ted upon engine ine disconnection efficiently work. - Check and carefully bleed the engine cooling system throughout reiterated drainage.

Copyright © 22


F5AE ENGINES

Check Check of injec injectio tion n pump pump static static advan advance ce on engine at the TDC of cylinder 1 (demonstrative figure)

87720

With the injection pump inserted in its seat and loosened fastening fastening screws, mount mount the comparator comparator 380000228 380000228 (2) and the comparator holder tool 380000229 (1), precharging the rod of 2.5 mm. - Rotate the engine engine shaft to move from the condition of 1st cylinder at the TDC compression phase end. - Rest the comparator comparator and rotate the engine shaft in the opposite direction until it returns to the condition of 1st cylind cylinder er at the TDC TDC in compr compres essio sion n phas phase. e. In this this position, on the comparator applied on the pump you should read the following following value: • 0,76 ± 0,05 mm (engines 48 kW; 57 kW; 65 kW); • 0,88 ± 0,5 mm (engines 55 kW).

!

The prelifting values shown are provisional provisional.. They may change.

- Rotate the pump anticlockwise if the run is lower, or clockwi clockwise se if the run is higher higher until until you reach reach the the requir required ed run. - Verifying these conditions, lock the pump tightening the nuts applying the required torque.



PART TWO ELECTRICAL ELECTRICAL EQUIPMENT EQUIPMENT

23

Copyright © 24


F5AE ENGINES



25

ELECTRIC CABLE TO CONNECT KSB WITH CERA Figure 1

5 3 0 0 2 1

P O T S . 4 r o s n e s r i A . 3 l a n g i s B S K . 2 e c a f r e t n I . 1

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F5AE ENGINES

Engine cooling liquid temperature sensor The sensor is fitted on the thermostat unit. It consists of two NTC thermistors with two reophores. Figure 2

Calibration 80 C [k Ω]



0.304 - 0.342

2.262 - 2.760

8.244 - 10.661

˚

˚

˚

119454

Characteristics Working temperature range - Connector’s side

-40 C ÷ 130 130 C; 150 C for periods < 10 min.

- Bulb’s side on engine

-40 C ÷ 140 C

Voltage Tightening torque

6 ÷ 28 V 20 ÷ 30 Nm

˚

˚

˚

˚

˚



27

Oil pressure switch Figure 3

120036

Characteristics Voltage Calibration Tightening torque

12 ÷ 24 V 0.6 ÷ 0.9 bar 35 Nm

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SECTION 3 - INDUSTRIAL APPLICATION APPLICATION

F5AE ENGINES

Cooling liquid temperature sensor for KSB Figure Figure 4

119455

Characteristics Operating tension Contact opening with raising temperature Contact closing with decreasing temperature Tightening torque

12 - 24 V 63 ± 3 C 53 ± 3 C 30 Nm MAX ˚

˚



29

Engine pulse transmitter It is an inductive type sensor placed on the front left side of the engine. It generates signals obtained by the magnetic flow lines closing up through the openings of a phonic wheel splined on the engine drive shaft. The same signal is used to pilot the electronic revolution revolution counter eventually eventually fitted on the vehicle instrument instrument panel. It is conne connect cted ed to the the Elect Electron ronic ic Cont Control rol Unit Unit pins pins 25C 25C (sig (signal nal)) and and 24C 24C (sig (signa nal). l). The The third third pin pin is for shiel shieldi ding ng.. The The Sens Sensor’ or’ss resis resista tanc nce e value is nearly 900 Ω 900 Ω..

Figure 5

119457

Torque setting

8 ± 2 ± 2 Nm

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F5AE ENGINES



PART THREE - DIAGNOSIS

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F5AE ENGINES

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F5AE ENGINES


DIAGNOSIS BY FAILURE

. . e c i m v t e r e s y S s l a S y c l i E p n p T h c u s O e e N T h t H d N e e C l b o t s y y a l p w p l A A . f - r d - l - s - l r s r s e s e i h r o i t e n i e u o n a i n l f e e o v u o r i s r t i g r f n c e i . w r s m s e a p n i p r e y s e l c t a u e m p r y c y S e é E m . r n l r a e e e s l m t . t t a x . i a c e h t n c p c u T i r a d t t p . h v l n p i e e S e y t e p a e g o e a m m d g r e s m t t b h n n l s E y h b a y r r a i r t u e l k l u . e e a s a n t e e p T d n p p p s m n c n m i R e r i Y h e h x i e i o l a p r p e v y t t c s m l . s n o u r t c c t e a u t l D D e c e e e o r s a s i p s s i r s p d a l i e n a l e r E E r n t l p f i e E i p e t e ’ e n i t s s u e m i i . f t p c u s a n t h f D e t s s M d h i u e h t t e n s g y s t D s i a l e t p e . n h g r a u E a y i e e a g h N e t e b t R t a c o h . u i p t y r n E R r o i t t n n n e h s e a c e i i e r j a l d t o l t t p l t n s d p e a e a a c t n u c i M R t i c p t r m i i e e é n t b a n w l e r e m r a . d s a n M h p a r O a e s i e p d e e s o p e x n g t r t i r p e d e k e t a a c w r f O b h c e o r s l é o c d e c s e , e e e r h e e l p i t y h e s r n C h t h r t w n s h u y r a e x e e c e . y r o t n e m f . a . t s y g l t e c o E s , n l s h r u a i c n l t d o b o e s t k o e h r k e R k n n p a p r o p u r c c c i a a d e t a c m n e u v s n e m e p a e l e i p p s s s n c f n s d t e i e e e h a e o h h r e l e e o u n n o o i t o o m R C R C m a r N d c m C D c i t e R O p C a a l l r e e e o h u c t f . d n p e e n i a E i d m h l r S p o t u r o . p i r U p y n o s r n a A c p e s o e i C e t t t c m i n h a n u n o T t b i e p g t i e s . l c o d O e e e t r e e v h u p n O e g r f t a n e l R f r s e o b m e . o t e c h r E a a r t l a g e d c l L i a t . n w e r l f i n p n i B i a u I p o r f t m s i m m . s S p d o t t r e y u l l e t S a g n e e t p s b p f v e p b n c i t i i i r O y . t e s c u u o a r i r c P = h f o r . e i s e f b e t c s t k p f o i u ) i t s r o o e n e c s n * a l n D a n N i ( o g D B I t I A i D

E R U L I A F

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. e c i v r e S l a c i n h c e T H N C o t y l p p A

. . e c i m v t e r e s y S s l a S y c l i E p n p T h c u s O e e N T h t H d N e e C l b o t s y y a l p w p l A A . i l f - s - l r . g e e e t e n i h e e t e d e c d c n h p e l i n n r t i . e u i a . t a a u a f l t g a h r i l e p i p n t l w i p f f s p s e t p p e l r t i u h e r m e j f e e m e d y S e m m p u s i r r u d u l l n e h u a t n o T h t R e a r d p h a f a d e o p E c h n . o o s S t e . u a l e y s o l e g g f s l e n t k e E h r i n e h t p b a u l n l p h t d r e i a t u e r t u o o T i n i p a m n d e h r i d Y w t c . g h a y i m p l a p u e t s p i t h n v a c s r s m l e k D e t D l r n r e a i s n o i p l c d e m c e c e h E E e e a a r t n t p r s E u u p h p h e u o h a v a r i . f a t l e l l D t p c o n M f m m i e v w p s p t D y e g t e , o l g n r d u E n N e e e s e t . n e r c l h e i r o h s p i a n i a s p t o E R i . f a e i t l e g n e i y p j l i t i n c t i t k l v i s w p l d e . r s n n M R i e c o c r r n a n e e e i x o . r e h e i s d w i r a a t p a i m i v u g l c o p v a d i M i O e l s e l e e s r a t n r n r l t l e p p f o e h r i e o e s e r e t e e h a a g e p O h c d t . e e i e c d o h o l b y h i l h t p r s t t f C f e h w t e t h s m f m r e u y e t g t e n e l t R h E v e a a . a e l e l n e l t g e i n . r s t u t a a o s c c y g s h k a R t l s s s s u o p p e s e c g n d i s e l n u l u r b a u a v n a u c m n c a s n e j n a e a i e i j u g i t p t f p c j s s v e e a i t o e a h d h d r l o e l e h e o n e C i t i C u s h t O A d a R D o c i t e D n f a b l m R A p R t l f s n d i e e n o n o o u i c i e f a t e t g i n a e s n n t a E i m u f h a g t i a S l r h h c n o e d . i U p . s p f n h y r d t n r a a m y A a e e a e a t e . y k l v c C e b o l i d l t p o h n k w e e f r n k r T t i p o e d b a u e t c o o O s p u r s c d s a l e r t u a e l e o w c O e r c . d g r u h l t n s l t t R t s l e r g . o e n b b n e s o b i d c n t r E a o a i o k s e e r r r r r d c i c . L i k y g l e o o . l m r c d p g i e f p l p r a B a I p e c f o u w f l e o m m s w u o S p t r c c l o y l n l i u r o i e s S a s y r f t v t p c . o p i . e f c o n e e e e c s i s f a b s c O t t n a e t l i r d y n i t . r r l o r m f t , P = p a i . r t o o e r s e i i u e l n B t t s p e . t i i o o ) p p u r s e r e n p i e s c p c l n * u f n S . i u u y a m p g I n ( d I g I n S o u K I p F P s I t B m e t w o l t a t r E a s R t U t o L n I . s s A e p F o o t d s e . e n n i s i g r e g n n e u e t a e e r h e h T p T

F5AE ENGINES

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F5AE ENGINES

- e o h t t u t a a h h . t i t e c w k i c v d r e . e e h g p S n p c i l i , k a S u e r c i E q c o i n e v w T h s e c e O d l y e c t N T n g c a i n r e i l H n r p o N o p i c a s C f n i o o t e s t e e y s i c i l c a t p v c a p e n m d I A . f - e i c d e i e i s f h h n s i t . r e t t c s i t i g e I . p c e u t o w p s e e t e h S c o e u h s l n j c t a d T l f i d n i o e b p a u o S e o t F t i e h t q . t t d b g . E i r h l y e n r T n t c a c n g r i Y d a a a o u l s n o d g d i e f s l D r D n p a y n r o i o e E E t h t . e s a c d r r e o c i o n e p v t c D e e s n b l i c i M n h d o l a n r a s e p E u t o i N s i r a v o n d c E R l e e t m u r g o e s r a c t p . e i t n r o l e m t M R h t e i a h y l d e i . m r l h e . s f a p p M O w e t s r e e i r d g u r a s n b e i v e i p b n e O e r r l e a i ; w h n e e e o h t y t e i i u C h m e t o h h i d t s r t q t t a t t t u d h E e a t p e a t s t c s k c r u r k R k u l s l s m e n a c e c c j u u u r a b . e e e p r c e p t n i c e y r s n c h h e e c n v h d l o e o c C n R A i i C T l C A i t s C r a g d p o e n n o i c m l t a ( u n o p d a o E i n c a S l r o e i p e t s h t U p a u a r A a o r e i b w . i r l d C e a a w n e h v i c l o T t h l y t t . c e . o p c O g e o n t t . h t h e f o i r o . O e m a t r t l t l u m r R n f i o n e s i e t t b p c ) . l o o h v i E a r n f t o i e i s e n i l m c e L i w s n r i i t w l o r e e d g p l B p a e a i t I g n m u a t n d S p w h o e t q t u o s e i t . S a e o t s l n e i p t l t a f v v e c c e i i i a g i O t r p i t e n t u c b i n r r s c c o P = e o f l r t i d t . f e u e i t h b s o o i r u ) f v i u i e f e n c s c g o n * n r i q n d C I n I g h O ( D D I i l u I

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. p u s t a e h y l e v i s s e c x e e n i g n e e h T


. e c i v r e S l a c i n h c e T H N C o t y l p p A e n - h e h o m t t . g o p n c e p c u t i a l o m g n u o n p n i i e p t t o r t c t , n e n s s f d o u e i e t d n i t e c o n . p e e g . i y t d c l m g t e e o e n c u i r b h p d i e r p r t r s r n e s c p s e d o u c n l o e e c a r a p i a t v p i c l i p g n e e e v n g h e r m i i d h u t t r m p e I i f h n g o t n h . i t i t t k h g u s o t c w n c i t e i s n y a j h d n e e l h g T C i b p c A g n i g n a h c . c i g t n a i m m o i t t t u c a e r r d a o e l c n k i a p r p m s u e p i . n v t e c i o e i c t f i e v n e g I D d r a l u g e r r i d n a r e w o p e n i g n e . g t n n i e n i c i o i f t f c u s n u n I f

e c i v r e S l a c i n h c e T H N C o t y l p p A d n a t . l i u e a t h a r r e i b v . l a o t s c r a d e n p n i a g n r r n o e o a t w l f u h o g t t i e w n r e h e m t d e e c k e c a c l e o p h r r e C P

g n i g n a h c d a e l k r . a r a p s e w c i e t v a i . e s m r s e o u t l c i u a x a f e e . i c n o B . t v S s . e i K d P

. n o i t a r b i l a c r o t a l u g e r d e e p s t c e r r o c n I

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. . . e e c c i i m v v e r r t s e e y S S s l l a a S y l c c i i E p n n p T h h u c c s O e e e N T T h t H H d N N e e C C l b o o t t s y y y l l a p p w l p p A A A - i s s n e e t e r d o i . n r v a e h h n o k o l e l d r o g t i t v t a f a t p e d e e i t r l t s i o e n n e i n e e o b n t S m w r g a t t p h e i u d ( m e t p s T t e d t e u o n h a n b a t o s d h t l a S h o y h t . n t i e i o m y g i r E t s t o . d r t n g u n e a i t a x t s t e u o i a i a r n l T a n c i o e s Y r o s d o h e t n i l e s a l e e l s m r t r u m D c e D h i . r . g n y d u t . p l c j p e a o r t d , e n E E t i o o t s e w e i r c n s i l d a r c c o t i o r . b r g t n a e e D n c e M s u q r s l e t l i n e n p r r i e r r s d u o e e e i m a e E l s a N a c u s v t h o p u n e o t . r t e t E R z e l u p g s l z d d a f s d a c r e m c e h m o a s r t o l o l e r n k h t o d M e R n e t d r i e o i r r h t u d l o j o e a i n f c a t n n c M h i t e w i p d i a O v c a t p e e h a r l k . t i e t s o e o e r e l s r t n n e l e a t t s e O e r j e e i r a e e o b h n c . e h h h a o a i i p c h t e t d a t C h t p p i t t h c e h g h t s i m d h s n t a r t i t t e s e e e t y e a . l E n k e l t k e c p ) d t h l h c c o e s k r o R a c h t f t e b s p l e n i o c c i i a n a a s l c l c d r n j e e u a r u a c l a b r a y i e e n e y p i c u p n g u p s e p e e f p r a e k l c h l h h d o e e e a A r e C m n t p c e C R C s h C C a a b e A a t r e R D r C m s - e e e d e i n h h n c v t t o t a c n c n t e d a s i E i f f d n a e S l r o a h p d e r s U p . l t g a a e m A a r i n d o t e i w . a t c C e t e f s p h n e h o T t i m s n o t r . . e e t f t r t o e o O e e e . c o a t t c c c s s e y w g r t r . i O e u n r e r v s r t t . r n e l s e p o a t e R e h s i e d s n b e l r b p c l e e i o . . c E a b o r m i f c l r n t t t k o c o c p i A L i e i r s e . c i a b l l c n u v e u e p B r a r f j D a g l I p z e j . u l o i d n e m s t d L i d S p z a s d h u e e ’ s t S a o s . e e e t t t t r p e n n r i . i f v v v c s c i c g t c a e o i i l O t n t t t e u u i t o y r r r r r c t e c c t i a e n l o P = i a e f l r p r i u e t c p s f s i t t t u f o o ) r p c e p b b g e e e p c c j n * a n e r e D O I m u n a n n g ( P i I s I t D O D I r a l u g e r r i d n a r E e R w o U p L I e A i n F g n e . g t n n i e n i c i o i f t f c u s n u n I f

F5AE ENGINES

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. . e e c c i i v v r r e e S S l l a a S c c i i E n n T h h c c O e e N T T H H N N C C o o t t y y l l p p p p A A t t - e s k i n d n d s f v c a i a t . n e g e l h n . o l . u t t a t k e a s t n r d e f l i s h s i e e o n h n d t i g o r t f i p e d a e i S s l m t t t a b h c k e r t u e i s e n e a T h t a l g b s g h s . n t d o i t p S i h p t t l a s t n n a e t e p e s m h l a a u E u n . r h v a j r a e t e f t s q . / t o e s d T f c e a s r o r Y a c a r d v t a i o h d u a k a h t t o c n l o w n D d D h n b a r d s s r e n a n r e p k e t g a d e h E E e p e r e v b e a d a m c i c c n e n e l v R o D v e i i w s b l i , M i u p e r s a t h t r r p e e t r m r m c p h . i E d s c N e d g r e e n i b k o t e n c c n E R e g . e s s n e n u o h , . s n c o p o g t a i k i t s n l m s e t e n n r n M g i R i c e r e t o r s e c h i i o g n c a o e g a t i i e i p h n l M c p t O n e r n t c v n v e t s h l g t e i e t g b e f n . e e a t e e p O l r v p c i s e e n e d s d a e h t h t u t h e e h n t h t o C h c r e h a h h u F g a n r t t z t t t n . E o t i e e e n e e e n g k c t c c h c s n s i s n f t t t e R d r g e s e n l a o r s g a m l a l a t c l w r e i r u u w c e n p r n i e j e j i p p p a t d s a r e y r p i r d e h d d o e h e e n e C R e w D r c A C h G n u b t R R a A a t p s b e s c . . f g k f d B c e o i o n . e c e c k b l . S o y a f . k c n c r s a e c h K l s e . a l o E i a a e d r l u y l h d s d s r S p e s d s b t . e e g y i l t s U p e i e l n v d n s i . e u v o o l v r o f e i t w u i c A a i t . i e v j s r g s e n a s v s a h r d d s C e e e g n h s e e s e c i a h c b s s n c i s e m e e T t x m x t u c d y t i g v u l f n c g e x e t o v o O n a i g s e h n i e i c m t e h s r i l r i n n e g a r O e s s e d e s n x o n i r s f c e t a i r i l u k e R o a n x s p o b a s n f m m n c h a e i a h t c E a c r m c i g n r d p l d n c s c i L i u p n i o n e o l e d p m . e s B r a e r e a s I p k r g g . n u e d h o n l e s h g n o b o o n d p S p r i t e o n s w i i o i s S a t e c e k u u r i m r n l t r y t m f v v f c i p h i i s r a b g t i O . i n a t a e s e e l g e e c i n s y n y i p P = i . n i a e n o b b c s ) s s s s e e t o i i n o t f e ) g e d n o o c c v e r o e s o i o e * n n n x e h v o C o i ( E o e U L N p L n N E D d T ( t k r a d r o k c a l B . . s s e E k e R o m U r u t f s L I e e n n A i i g F g n n e e . s s s u u e o o m l l a a f m m u y o o e n n r A A g

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38


. e . e c c i v i v r r e e S l S l a a S c i c i E n n T h c h c O e e N T T H H N N C C o t o t y y l l p p p p A A r e e e d w c o h h h n e e t t t a s n p d e s g r n e c n n S c n o a i i a e a l s e u l T s l e p e p e c S i e h . p e r t , i r s E r . d e e p r e t r a s i . T v e m t y o e e l Y t t n a i s o l h h i i a e a l f e D t D . . h . l r p t n s f u g i r r r i E E t r t . a i t i e a e r o n n p t e n o n a d u w . . i D t . t M e n s v e s s t s e e n t g . e e i t s l n r i a i r n l E m r N o f e r o n h n c y o e o t i i i t o s o n o n t g o i t t E R s t e c t m g i j t c c i i p n j c a e e e s u e n d n n e r M t e e R j e d c j e n g s e r j d m i h h m l n a a e a n n e s e t h t i n a M i t O a u i p o e i , p p l p h s h c r n e e e e h e O h u e n t t g r t . e o i r l h o h h h e q e i t l o t h n t t e t i C t t i h h e n e c u i u t e r s i t t a t t t i E r e e t a t a d a h c o h c e u l d t i c c c c o f o k . n R r f e s . t p t n i n a r a a r a s c l l l r b B o c u c a i e e o r l e e e j . l p p n p p m c e c p e v o p p d a S o e j l h i e e e v e e . R e e i n r C R i s C O t R C p i p A C K R O R R , g . . t s e e c e s d d n r i r e r o v n e p e e a n l i e c . t t i m n e s o a e y j p g a t k c e u n e n i v r t i w n c s a v a i e t d s i E i v r m b n e e e o c l i e s k l l a s S l a i . e t d a e s s ) e a r e v a t d d r c g r t l U p e h a e p e d a e l r t c t n n r t s f l i i m a v t a a a f i A i x a r b i f o y e e r n b e l l l n e e d i r C e t h r n o a h m i p r t . , c c e e h k t s r h s a i o o h t t ; r d e f e T t i t e r s e y a r n s s e p i o o t d h i g r g i d ( t p o d a y l O t e w i p n g n s c u o t t c t t e e e u ) l ; c u n r e . o a ’ O e l p i e g e d e i r n l r i m r s r n l r d o . . d e t i u l k r v h r p R p h s i r o r a o s o g t s i d t r a t r o b a k o c s e c i s n r r n o t c n d s l a r c E a p c e g o o e e r r b o c i s b t m c n i n o u t c s o n k i L i f w i o e c t t o r n t j e o y p k l r e ( l e r s k B p p a a i e o o j c e d i n r d m u f t a I n o d o i t s a p r l c n t m l d e g m e r o t t i s r S p u s e i e e e o n e n p r t s o o l o l g c r i i o S a p i s z e u u t l t e t a i o a f b p z n f v c l r . a t v u o d d f : o y g i k i n i r r O , a c t o e c a o e d t e s . e s e i n a o t o n n i o e s i c s . m e P = i o n o g e r e w r t j n d e i n k u . r l e i e g s t B y e r r r d f s s n . o l e ) i v t i s l e g g c S o o u o o t l i y s n i e c n o n i l * n h i f r . a e e x o n a u o g n ( n I T t C L d w w d v U o t I d E K n D O b i E g E w k r . a s d e r m o u f k y c e a r l g B . h s s E e i t i R m h U f u w L I e d n n A i a g F n y e e r . s s g u e e o l u m l a f b m u , y e o e u n l A r g B

F5AE ENGINES



PART FOUR SCHEDULED MAINTENANCE

39

Copyright © 40


F5AE ENGINES



41

SCHEDULED SCHEDULED MAINTENANCE Servicing Plan

!

Engine lubrication frequency has been calculated presuming the use of fuel with content of Sulphur < 0.5%. WARNING! In case of use of fuel containing a percentage of Sulphur e > 0.5 %, the engine oil replacement interval must be halved.

Use engine engine oil SAE 15W40 15W40 T2

Overhaul and/or basic maintenance Checks and regular servicing

Frequency Frequency (hours) (hours)

Engi Engine ne visu visual al insp inspec ecti tion on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Check for presence of water in the fuel filter or pre-filter . . . . . . . . . . . . . . . . . . .

Daily

Chec Checkk eng engin ine e oil oil leve levell

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

Daily

Chec Checkk air air filt filter er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Chec Checkk bat batttery ery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every six months

Chec Checkk coo cooliling ng liqu liquid id leve levell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily

Check the the wear conditions conditions of of the alternator’s alternator’s belt belt and of the the water pump pump . . . . .

300 (2)

Chec Checkk for for pres presenc ence e of wat water er in in the the pre-f pre-filt ilter er . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 (1)

Check for presence of water in the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every six months (1)

Chec Checkk the the comp compres resso sor’s r’s belt belt wea wearr cond condit itio ions ns . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300

Igni Igniti tion on pump pump over overha haul ul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3000

Check turbo-compressor and clean it if necessary . . . . . . . . . . . . . . . . . . . . . . . . .

1200

Tapp Tappet et chec checkk and and adju adjust stme ment nt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000

Chan Change ge engi engine ne oil oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500

Repla eplace ce engi engine ne oil oil fil filte terr

500

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

Repl Replac ace e fue fuell pre pre-f -fililte terr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000 (1)

Repla eplace ce fuel fuel filt filter er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 (1) (3)

Repl Replac ace e the the alte alterna rnato tor’s r’s belt belt and and the the wat water er pum pump p .. .. .. .. .. .. .. .. .. .. .. ..

1200

Repla eplace ce air air fil filtter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1200 (2)

Repl Replac ace e the the com compr pres esso sor’ r’ss bel beltt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1500

Chan Change ge the the coo cooliling ng liqu liquid id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Every 2 years or 1200 hours

(1) Using fuel complying complying with EN590 EN590 Standard Standard (2) Depending Depending on appliance appliance (3) Using filters with filtering filtering degree < 12 μ 12 μ and β and β > 200 μ 200 μ filtering efficiency

Copyright © 42


F5AE ENGINES



1

SECTION 4 Mechanical overhaul Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .

3

DATA - ASSEMBLY SLACK . . . . . . . . . . . . . . .

4

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

10

ENGINE DISASSEMBLY ON BENCH . . . . . . . .

10

REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

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

11

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

11

- Chec Checki king ng head head base base surf surfac ace e on cyli cylind nder er unit unit .

12

TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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

13

- Cam lift and pin alignment check . . . . . . . . . .

13

BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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

15

- Tappets

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

15

- Tappet - Camshaft assembly . . . . . . . . . . . . . .

15

ENGINE DRIVE SHAFT . . . . . . . . . . . . . . . . . . .

16

- Main journals journals and crankshaft crankshaft bearing bearing pin measurement . . . . . . . . . . . . . . . . . . . . . . . . .

16

- Crankshaft bearing assembly

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

18

Main n jour journa nall asse assemb mbly ly slac slackk measu easurreme ement . . . - Mai

18

- Engine drive ive shaft should ulder slac lack check heck . . . . . .

19

CONNECTING ROD-PISTON UNIT

19

.......

- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

- Piston diameter measurement . . . . . . . . . . . .

20

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

21

- Cond Conditi ition onss for for the corre correct ct pinpin-pi pisto ston n coupl coupling ing

21

Copyright © 2


F5AE ENGINES

Page

- Snap rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

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

22

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

23

- Connecting rod-piston unit assembly . . . . . . . .

23

- Snap ring assembly . . . . . . . . . . . . . . . . . . . . . .

23

- Snap ring fixing . . . . . . . . . . . . . . . . . . . . . . . . .

23

Page - Valve disassembly . . . . . . . . . . . . . . . . . . . . . . .

25

- Cylinder head base surface check . . . . . . . . . .

26

VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

- Valve scaling, checking and grinding . . . . . . . .

26

VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .

27

- Valve guide replacement . . . . . . . . . . . . . . . . .

27

VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

- Connecting Connecting rod-piston rod-piston unit fixing fixing into cylinder barrel . . . . . . . . . . . . . . . . . . . . . . . . .

24

VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .

28

- Conne Connecti cting ng rod rod asse assemb mbly ly slack slack meas measur urem emen entt

24

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . .

28

- Piston projection check

25

- Cylinder head assembly . . . . . . . . . . . . . . . . . .

28

25

TORQUE SETTING . . . . . . . . . . . . . . . . . . . . . .

29

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

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .



GENERAL SPECIFICATIONS Type

4 CYLINDERS

Cycle

Diesel 4 strokes

Power

See the specifications reported in Section 3

Injection

Direct

Number of cylinders

4

∅

+

+

Bore

mm

99

Stroke

mm

104

cm3

3200

Totall disp displac lacem ement ent +.. = Tota TIMING start before T.D.C. end after B.D.C.

A B

19° 19° ± 30’ 37° 37° ± 30’

start before B.D.C .D.C.. end after T.D.C.

D C

61° 61° ± 30’ 21° 21° ± 30’

Checking timing mm 0.20 to 0.30

X mm X

0.45 to 0.55 Checking operation mm 0.20 to 0.40

X mm

0.45 to 0.65 FUEL FEED Injection Type: Nozzle type

Injection sequence

Bosch

VE 4/12F BOSCH DSLA138PV 33

1-3-4-2

3

Copyright © 4


F5AE ENGINES

DATA - ASSEMBLY SLACKS

Type

4 CYLINDERS


mm

∅1 Cylinder barrels X

∅1 X 2 ∅

Spare pistons type: Size Outside diameter Pin housing

∅1

99.000 ÷ 99.020

∅1

0.4

X ∅ 1 ∅ 2

10 98.908 ÷ 98.918 36.003 ÷ 36.009

Piston — cylinder barrels

0.082 ÷ 0.112

Piston diameter

∅1

Piston protrusion

X

0.4

X

∅ 3

Piston pin Piston pin — pin housing

-0.22 ÷ +0.07

∅3

35.990 ÷ 35.996 0.004 ÷ 0.019



Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S 2 S 3

X1* X1* X2 X3

Split ring slots

mm 2.21 2.05 ÷ 2.070 2.540 ÷ 2.560

* theoretical theoretical measurement on a Ø of 96 -0.25 mm S 1* S2 S3

Split rings

2.068 ÷ 2.097 1.970 ÷ 1.990 2.470 ÷ 2.490

* measured at 1.5 mm from external Ø 1 2 3

Split rings - slots

0.06 ÷ 0.100 0.05 ÷ 0.09

Split rings X 1 X 2

0. 4

Split ring end opening in cylinder cylinder barrel: X1 X2 X3

X3

Crankshaft bearing bush seat ∅ 1

∅1

0.20 ÷ 0.35 0.60 ÷ 0.80 0.30 ÷ 0.60

42.987 to 43.553

Big end bearing seat X 0

67.833 ÷ 67.841 67.842 ÷ 67.848

Crankshaft bearing bush diameter Internal ∅ 3 ∅ 4*

36.010 ÷ 36.020 39.570 ÷ 39.595

∅ 2

∅ 2

∅ 3 ∅4

S

Red Crankshaft Crankshaft half bearings bearings Blue Green * dimension not measurable at free state

1.875 ÷ 1.884 1.883 ÷ 1.892 1.891 ÷ 1.900

Piston pin — bush

0.011 ÷ 0.024

Big end half bearings

0.254; 0.508

5

Copyright © 6


F5AE ENGINES

Type

4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS X

Measurement quota

X

mm 125

Maximum error on parallelism of connecting connecting rod axles Maximale Abweichung des Parallelismus der Pleuelachsen ∅1

0.09

∅2

∅ 3

Crankshaft bearing pins No. 1-2-3-4 ∅ 1 No. 5 ∅ 1 Big end bearing pins ∅ 2

76.182 ÷ 76.208 83.182 ÷ 83.208 64.015 ÷ 64.038

Crankshaft Crankshaft half bearings bearings S 1 Big end half bearings bearings S 2

2.165 ÷ 2.174 1.876 ÷ 1.883

Main bearings No. 1-2-3-4 No. 5

∅3 ∅3

80.588 ÷ 80.614 87.588 ÷ 87.614

Half bearings — Journals Journals No. 1-2-3-4 No. 5

0.064 ÷ 0.095 0.059 ÷ 0.100

Half bearings - Crankpins

0.033 to 0.041

Crankshaft half bearings Big end half bearings

Crankshaft pin for shoulder

0.127; 0.254; 0.508

X1

31.85 ÷ 32.150

Crankshaft support for shoulder X2

32.50 ÷ 32.55

X 1

X 2 X 3

Shoulder half-ringser

X3

Engine drive shaft shoulder

2.51 ÷ 2.56 0.095 ÷ 0.270



Type

4 CYLINDERS


mm

∅ 1 Valve guide seats on cylinder cylinder head

∅1

12.960 ÷ 12.995

∅ 2

8.023 ÷ 8.038

∅ 3

12.950 ÷ 12.985

∅ 4 α

7.985 ÷ 8.000 60 30’ ± 0 10’

∅ 4 α

7.985 ÷ 8.000 60 30’ ± 0 10’

∅ 2

Valve guides ∅ 3 ∅ 4

Valves:

α Valve stem and guide

˚

˚

˚

˚

0.040 ÷ 0.053

Housing on head for valve seat:

∅ 1

∅1

39.987 ÷ 40.013

∅1

43.787 ÷ 43.813

Valve Valve seat seat outsid outside e diamet diameter; er; valv valve e seat seat angle angle on cylin cylinde der r head: ∅ 2 α

∅ 2

∅ 2 α

α

X

Rece Recess ssing ing of valve valve Between Between valve seat and head Valve seats

40.063 ÷ 40.088 60 ± 1 ˚

˚

40.863 ÷ 43.88 60 ± 1 ˚

˚

X

0.3 ÷ 0.3 ÷ 0.7 0.7

X

0.3 ÷ 0.3 ÷ 0.7 0.7 0.050 ÷ 0.101 0.050 ÷ 0.101 -

7

Copyright © 8


F5AE ENGINES

Type

4 CYLINDERS


mm

Valve spring height:

H

H1

H 2

free spring

H

44.6

under a load equal to: 270 N 528 N

H1 H2

34 23.8

Injector protrusion

X

1.7 ÷ 2.35

X

∅ ∅ ∅ 1 23 4 5

Seat for camshaft no. 5 bush (Timing System side)

59.222 ÷ 59.248

Camshaft seats No. 2-3-4 No. 1

50.069 ÷ 50.119 40.069 ÷ 40.119

∅ 2 Camshaft supporting pins 1 2 ⇒ 4 ∅ 1

∅

Bush inside diameter

49.975 ÷ 50.025 53.995 ÷ 54.045

5

∅ 3 ∅ 5

39.975 ÷ 40.025

∅ 5

Bushes and journals

54.083 to 54.147 0.038 ÷ 0.162

Cam lift: H

H

5.5105

H

6.213



Type

4 CYLINDERS


mm

∅1 Tappet cap housing on block ∅ 2 ∅ 3

Tappet cap outside diameter:

∅2

∅1

15.000 ÷ 15.018

∅ 2 ∅ 3

14.776 ÷14.780 14.950 ÷ 14.970

Between tappets and housings

-

Tappets

-

∅ 1 Rocker shaft

∅1

18.979 ÷ 19.000

Rockers

∅2

19.020 ÷ 19.033

∅ 2 Between rockers and shaft

0.020 ÷ 0.054

9

Copyright © 10


F5AE ENGINES

ENGINE OVERHAUL OVERHAUL ENGINE DISASSEMBLY ON BENCH

Figure 3

To execute the operations described here following, it is necessary to fit the engine on the rotary stand after having removed all the appliance’s specific components (see Section 3 of the herein manual). This section illustrates all the more important procedures of engine bock overhaul. overhaul.

119546

Figure 1

The third third main main bearingcap bearingcap (1),the centra centrall one,and itssupport, itssupport, have the half bearing (2) provided with shoulder. NOTE

Note down the assembly position of the upper and lower half bearings since, in case of reuse after the overhaul, they will have to be reassembled in the same position.

Figure 4 70158

Loosen the screws(1) fastening the connecting rod caps (2) and remove the fastening the connecting rod caps. Withdraw the pistons with the connecting rods from the upper part of the crankcase. NOTE

Keep the half bearings in their respective housings since, in case of reuse after the overhaul, they will have to be reassembled in the same position.

120037

Using tool 380000362 (1) and a hoister, remove the engine drive shaft (2) from the crankcase. Figure 2

Figure 5

119545

Loosen the screws (1) and disassemb disassemble le the crankshaft crankshaft bearing bearing caps (2).

120173

Disassemble the crankshaft half bearings (1). Loosen Loosen the fasten fastening ing screws screws (2) and disassem disassemble ble the oil nozzles (3).



11

zs

REPAIRS CYLINDER UNIT Checks and measurements

Figure 6

Figure 9

s

119548

Loos Loosen en the faste fasteni ning ng screw screwss (1) and and disa disasse ssemb mble le the camshaft (3) holding plate (2). 70166

NOTE

Once completed the engine disassembly, carefully clean the cylinder-crankcase units. Use suitable eyebolts to handle the cylinder unit. Carefully check the crankcase has for cracks. Check Check the conditions conditions of the processing caps: replace them if oxidized or in case cas e their tight is doubtful. Check the surface of the cylinder barrels: there must be no trace of meshing, scratches, oval or conical shaping and excessive wear. Cylinder barrel inner diameter check to detect any oval or conical shaping or wear shall be executed throughout the bore meter (1) equipped with comparator, which must be previously be reset on the ring calliper (2) of the cylinder barrel diameter.

Note down the plate assembly assembly position position (2).

Figure 7

NOTE If the ring calliper is unavailable, use a micrometer for for rese reset. t. 119549

Figure 10 Carefully Carefully withdraw withdraw the camshaft (1) from the engine bock. bock.

Figure 8

70167

70165

Withdraw the tappets (1) from the engine bock.

The measurements must be made for each cylinder, at three different heights from the barrel and on two perpendicular planes planes:: one paralle parallell to the engine engine longitud longitudinal inal axle axle (A)and the other other perpen perpendicu dicular larly ly (B). (B). Genera Generally, lly, maximu maximum m wear wear is detected on the perpendicular plane (B) and with the first measurement. If oval oval or conical conical shapin shapingg or wear wear is detect detected, ed, proc proceed eed boring boring and grinding grinding the cylinder barrels. barrels. Cylinder barrel grinding must be executed based on the spare pistons’ diameter plus 0,4 mm of the rated value and at the prescribed assembly slack.

Copyright © 12


F5AE ENGINES

Check the crankshaft bearing seats proceeding as follows:

Figure 11

- fit the crankshaft bearing bearing caps on the supports supports without bearings; - tighten the fastening screws to the prescribed torque setting; α

- with a suitable suitable comparator, comparator, check that the inner barrel diameter corresponds to the prescribed value.

If the detected value is higher, replace the crankcase.

Checking head supporting surface on cylinder unit After having detected any deformed areas, grind the head base surface using a grinding machine. Planar Planarity ity error error must must not exceed exceed 0.075 mm. Check Check the conditions of the cylinder unit processing caps: replace them if oxidized or in case their tight is doubtful.

119550

NOTE In case case of of grinding, grinding, all the barrels barrels must result having the same oversize (0.4 mm).



13

TIMING SYSTEM Camshaft Figure 12

119551

MAIN DATA ABOUT CAMSHAFT PINS

The The surfa surface ce of the camsha camshaft ft pins pins and and of cams cams must must be extremely smooth. In case any trace of meshing or scratches are detected, replace the shaft and the relevant bushes.

BUSH Figure 14

Cam lift and pin alignment check Plac Place e the cams camsha haft ft on foots footstoc tocks ks and, and, throu through ghou outt a centesimal comparator placed on the central support, check that the radial oscillation does not exceed 0.015 mm otherwise otherwise replace the shaft.

Figure 13

70172

The bush (2) of the camshaft must be forced in its housing. The internal surfaces must have no trace of seizure or wear. Measur Measure e the diamet diameter er of the bush bush with with the bore bore control control tool (3). The The measur asure ement mentss must ust be carr carrie ied d out out on two two perpendicular axes.

70171

Using a micrometer (1), check the diameter of the camshaft (2) supporting pins on the two perpendicular axles.

Copyright © 14


F5AE ENGINES

Figure 15

119552

MAIN DATA OF THE CAMSHAFT CAMSHAFT BUSH AND RELEVANT RELEVANT SEAT * Quota to obtain after bush fixing.



Bush replacement

15

Tappet - camshaft assembly Figure 18

Figure 16

70176 70174

Use the beater 380000667 (2) and handgrip 380000999 (3) to disassemble and replace the bush (1).

NOTE

Lubricate the tappets (1) and fit them into the relevant seats on within the crankcase. crankcase. Figure 19

In phase phase of assemb assembly, ly, the bush bush (1) must must be orient oriented ed making making the lubric lubricatio ation n ports ports coincid coincide e with those those on the crankcase.

119549

Lubricate the camshaft supporting bush and assemble the camsha camshaft ft (1) paying paying attentio attention, n, during during the afores aforesaid aid operat operation, ion, not to damage the bush or the shaft’s seats.

Tappets Figure 20

Figure 17

119554

119553

TAPPET AND RELEVANT SEAT ON CRANKCASE MAIN DATA

Position the camshaft (3) holding plate (1) with the slot towards the upper side of the crankcase and the marking towards the operator; tighten the fastening screws (2) to the prescribed torque setting.

Copyright © 16


F5AE ENGINES

ENGINE DRIVE SHAFT Measurement of main journals and crankshaft bearing pins

Figure 21

Figure 23

119555

Check the camshaft axial shaft (1). The prescribed value is 0.23 ± 0.23 ± 0.13 0.13 mm.

119557

Figure 22

In case case meshin meshing, g, scratche scratchess or excess excessive ive oval shaping shaping is detected on the main journals and crankshaft bearing pins, it is necessary to grind the pins. Before proceeding with pin (2) grinding, measure the shaft pins by means of a micrometer (1) in order to establish to which diameter diameter the pins must be reduced. NOTE it is recom recomme mend nded ed to note note down down the values values detected in a prospect See Figure 24. Undersize Undersize classes are: 0.254 - 0.508 mm. 70180

Fit the nozzle nozzless (2) and tighten tighten the fasten fastening ing screws screws (1) to the prescribed torque setting.

NOTE The main main journals journals and cranks crankshaf haftt bearin bearingg pins pins must must always be grinded to the same undersize classes in order not to alter the shaft’s balance.

Figure 24

120038

PROSPECT REPORTING MEASUREMENT VALUES OF THE ENGINE DRIVE SHAFT MAIN JOURNALS AND CRANKSHAFT BEARING PINS * Rated value


17


Figure 25

120039

ENGINE DRIVE SHAFT MAIN TOLERANCES TOLERANCES

DIRECTION POSIT SITION

CHARACTERISTIC

GRAPHIC SYMBOL

Roundness

○

Cilindricity

/○/ //

Parallelism Verticality Straightness Concent centrricit city or coa coaxiality lity Circular oscillation Total oscillation oscillation

LEV LEVELS ELS OF IMP IMPORTA ORTAN NCE FOR PROD RODUCT CHARA HARAC CTERI TERIST STIC ICS S

GRAP GR APHI HIC C SYMB SYMBOL OL

CRITICAL

©

IMPORTANT

⊕

SECONDARY

⊝

TIMING SIDE BENCH

INTERMEDIATE BENCHES

FIRST BENCH ON FRONT SIDE

119574

Copyright © 18


F5AE ENGINES

Crankshaft bearing assembly

Measurement of main journal assembly slack

Figure 26

Figure 27

120037 120173

NOTE

If it is not necessary necessary to replace replace the crankshaf crankshaftt bearings, these shall be reassembled in the same order and position they were before disassembly.

Assemble the engine drive shaft (2). Check Check the slack slack betwe between en the the engine engine drive drive shaft shaft main main journa journals ls and the respec respective tive cranks crankshaf haftt beari bearings ngs proce proceedi eding ng as follow follows: s: Figure 28

The spare crankshaft bearings (1) have undersize internal diameter diameter of 0.254 - 0.508 mm. NOTE

Do not adapt on bearings.

Care Careful fully ly clean clean the crank cranksha shaft ft half half bear bearing ingss (1) (1) havi having ng lubrication port and fit them in their respective seats. The penultimate crankshaft half bearing (1) is provided with shoulder half rings.

119962

- clean accurately accurately the parts and remove remove any trace of oil;

drive shaft pins (4) in parallel parallel with - place on the engine drive longitudinal axle, a piece of gauged wire (3); - fit the caps (1) and the half bearings (2) on the relevant relevant supports.

NOTE




19

Engine drive shaft shoulder slack check

Figure 29

Figure 32

70187

Tighten the pre-lubricated screws (1) and tighten them in three subsequent phases: - 1st phase with torque wrench setting at 50 ± 5 Nm. - 2nd phase with torque wrench setting at 80 ± 6 Nm. Figure 30

70190

The check of the shoulder clearance is performed with a magnetic based comparator (2) placed on the engine shaft (3) as indicated in the figure. If the clearance is above the one prescribed replace the semi-cr semi-crank anksha shaft ft bearin bearings gs of the thrust thrust hold hold rear rear suppor supportt next next to the last (1) and check again the clearance between the engine shaft pins and the semi-crankshaft bearings.

α

119559

- 3rd phase using tool 380000304 (1) fitted as shown in the figure and further tighten the screws (2) by 90º ± 5º angle. Figure 31

CONNECTING ROD — PISTON ASSEMBLY Figure 33

119560

- Remove Remove the caps from their support. support. The slack between the crankshaft bearings and the relevant pins should be detected detected comparing the width measured by the gauge wire (2) in the point of maximum flattening with the scale graduation reported on the shield (1) of the gauge wire wire.. The The numbe numbers rs repo report rted ed on the the scale scale indi indicat cate e the coupling coupling slack in millimetres. millimetres. If the slack slack detect detected ed differ differss from from the prescri prescribed bed value,repla value,replace ce the half bearings and repeat the measurement; once achiev achieving ing the slack slack prescr prescribe ibed, d, lubric lubricate ate the cranks crankshaf haftt bearings bearings and finally assemble the supports tightening the fastening screws as described previously.

70191

CONNECTING ROD-PISTON UNIT COMPONENTS 1. Grommets. - 2. Pin. - 3. Piston. - 4. Snap rings. 5. Screws - 6. Half bearings. - 7. Connecting rod. - 8. Bush.

NOTE The The spar spare e pisto pistons ns are are suppl supplie ied d with with stand standar ard d dimensions or oversize by 0.4 mm.

Copyright © 20


F5AE ENGINES

Pistons Piston diameter measurement

Figure 34

Figure 37

32613

Using Using pincer pincerss 38000022 380000221 1 (3), (3), removethe removethe snap snap rings rings (1) from from the piston (2).

32615

Using the micrometer (2), measure the piston diameter (1) to determine the t he assembly slack. NOTE The diameter must be measured at 10 mm from the base of the piston shell.

Figure 35

Figure 38

32614

Remove the piston pin (1) grommet using the nail (3). 70192

Figure 36

The slack between piston and cylinder barrel can also be measu measured red by means means of callipe calliperr and gauge gauge (1), (1), as shown shown in the figure.

119561

MAIN DATA OF THE PISTON, PINS AND SNAP RINGS * Quota detected on Ø 96 mm.



Piston pins

21

Figure 42

Figure 39

18857

Measurement of the piston pin diameter (1) throughout a micrometer (2).

Conditio Conditions ns for the the correct correct couplin coupling g of pins and and pistons

32620

Check the slack between the grommets (3) of the 2nd and 3rd slots and relevant relevant housing on the the piston (2) (2) using calliper calliper and gauges (1). Figure 43

Figure 40

32619 41104

Lubricate the pin (1) with engine oil and the relevant seat on the piston hubs; the pin must fit into the piston applying a slight pressure pressure with fingers and must not slip out for gravity.

SCHEME FOR THE MEASUREMENT OF SLACK BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL GROMMET Due Due to the part particu icula larr for for of the first first grom gromme met, t, havin havingg trapezoidal section, the slack between said grommet and the slot must be measured as follows: the piston (1) must be project projected ed from the crankca crankcase se so that that nearly nearly half of the gromm grommet et (2) in questio question n come comess out of the cylinde cylinderr barre barrell (3). (3).

Snap rings Figure 41

In this position, using a gauge calliper, calliper, measure measure the slack (X) between grommet and slot: the slack must comply with the prescribed value.

16552

Check Check the thickness thickness of the gromm grommets ets (2) throug throughou houtt a micrometer (1).

Copyright © 22


F5AE ENGINES

Figure 44

Figure 46

70194

Measurement of slack between the snap ring ends (2) fitted into the cylinder barrel (3) throughout gauge calliper (1).

Connecting rods Figure 45

119563

A. Class of weight - B. Part number - C. Date of production production (DD/MM) - D. Date of production production (year) E. Marking for connecting connecting rod-cap rod-cap coupling.

NOTE

119562

NOTE The connecting rod-connecting rod cap surfaces are knurled to ensure better coupling. Therefore, it is recommended not to remove the knurling.

In phase phase of assemb assembly, ly, ensure ensure that all the connect connecting ing rods belong to the same manufacturer and class of weight.



Bushes

23

Figure 49

Check that the connecting rod shoe bush is not loose and that there is no trace of meshing or scratches otherwise replace it. Disass Disassemb embly ly and reasse reassembl mblyy must must be execute executed d using using a suitable beater. When fixing it, make sure that the ports for oil passage on the bush and on the connecting rod coincide. Throughout a bori boring ng machi machine ne,, bore bore the bush bush in orde orderr to obta obtain in the prescribed diameter.

Connecting rod-piston unit assembly Connecting rod-piston coupling

72705

Fit the pin (1) snap rings (2).

Figure 47

Snap ring fixing Figure 50

119564

The following references are marked on the piston crown: 1. Spare part number number and modification modification numbe number; r; 2. Indicative Indicative sign for piston piston assemb assembly ly in the cylinder barrel; barrel; it must be turned towards the flywheel; 3. Mark Mark statin statingg t the the 1st 1st slot slot inser insertt 4. Date Date of manufa manufactur cture. e.

32613

Use the pincers 380000221 (3) to fit the snap fasteners (1) to the piston (2). The snap rings must be fitted with ”TOP” marking upwards. Furthermore, ring opening must be misaligned by 120º.

Figure 48

NOTE The spare snap rings are available in the following sizes:

119565

Thro Throug ugho hout ut the the pin pin (3), (3), conne connect ct the the pisto piston n (2) (2) to the the connecting rod (4) following the indication of the reference arrow arrow (1) to correctly correctly fixing the piston (2) into the cylinder barrel barrel,, also also taking taking into conside considerat ration ion the numbe numbers rs (5) printe printed d on the connecting rod (4), as shown in the figure.

-

stan stand dard; ard;

-

over oversi size ze by 0.4 0.4 mm. mm.

Copyright © 24


F5AE ENGINES

Figure 51

Figure 53

119566 70200

Fit the half bearings (1) on the connecting rod and cap. NOTE

SCHEME FOR CORRECTLY FIXING THE CONNECTING ROD-PISTON UNIT INTO THE HOLLOW openings must be misaligned by 120º; - The snap rings’ openings

If it is not necess necessary ary to replace replace the big end beari bearings ngs,, reasse reassembl mble e the existi existing ng ones ones in the same same order order and position they were before disassembly. Do not adapt the half bearings.

- all the connecting rod/piston rod/piston units must have the same weight; - the engine drive shaft sign (1) printed on the piston crown must be turned towards the flywheel while the notch on the piston shield must match the oil nozzles’ position.

Warning! The connecting rod must not collide with the cylinder wall.

Connecting rod assembly slack measurement Figure 54

Fitting Fitting connecting connecting rod-pisto rod-piston n assembly assembly into cylinder barrels Figure 52

70203

For slack measurement proceed as follows: - carefully carefully clean the parts eliminating eliminating any oil residuals; - place a piece piece of gauge gauge wire (2) on on the engine drive drive shaft pins (1); 70201

Lubricate the pistons, the snap pins and the cylinder barrel interior. Using the band 380000210 (2), fit the connecting connecting rod-piston rod-piston unit (1) into the cylinder barrel, checking that : - the number of each connecting rod corresponds corresponds to the coupling cap number.

- fit the connecting rod caps (3) and the relevant half bearings (4).

NOTE



25


Figure 55

In case the slack measured differs from the prescribed value, replace the half bearings and measure the slack again.

Piston projection check

α

NOTE

See page 16 of Section 3.

70204

- Lubricate the fastening screws (1) with engine oil and tighten them to the prescribed torque setting (50 ± 5 Nm) using a torque wrench.

CYLINDER HEAD Valve disassembly Figure 58

Figure 56

1 α

2

A

75750 70205

- Fit the tool 380000304 (1) to the socket wrench and then further tighten the screws (2) by 70º ± 5º.

The intake valves (1) and exhaust valves (2) have different head diameter.

Figure 57 NOTE Numbe Numberr the valves valves before before removi removing ng them them from from the cylinder head in order to be able to reassemble them in the same order in case replacement is not necessary. A = intake side

70206

Remove the cap and measure measure the slack comparing comparing the - Remove width measured by the gauge wire (1) with the scale graduation reported on the gauge wire shield (2).

Copyright © 26


F5AE ENGINES

VALVES

Figure 59

Figure 62 EXHAUST VALVE

INTAKE VALVE

119567

Valve disassembl disassemblyy must be executed executed using tool 380000302 (1) to slightly press the plate (3) so that, compressing the spring (4), it is possible to remove the half cone (2). Then remove the plate (3) and the spring (4). Repeat the operation in correspondence of each valve. Turn Turn the cylinde cylinderr head head upside upside down down and withdr withdraw aw the valves valves (5). Figure 60

119569

INTAKE INTAKE AND EXHAUST EXHAUST VALVE VALVE MAIN SPECIFICATIONS

Valve scaling, checking and grinding Figure 63

18625 119568

Remove the grommets (1 and 2) from their valve guides.

Cylinder head base surface check Any defor deformat mation ion detect detected ed on the whole length of the cylinder head must not exceed 0.20 mm. In case higher value is detected, grind the cylinder head in order order to obtain obtain the prescri prescribed bed value. value. Refer Refer to the main spec specifi ificat catio ions ns repo report rted ed here here follo followi wing ng and and follo follow w the instructions accompanying the figures below.

Eliminate carbon deposits from the valves using the specially provided metal brush. Check the valves valves for meshing, meshing, cracks cracks or burns. If necessary, necessary, grind the the valve seats seats removing removing as less material material as possible. Figure 64

Figure 61

18882 119591

A rated thickness of the cylinder head is 90 ± 0,1 mm.

Using a micrometer (2) measure the valve stem (1): the prescribed value is 7,985 ÷ 8,000 mm.



VALVE GUIDE

27

Valve guide replacement replacement

Figure 65

Valve guide assembly and disassembly disassembly is performed performed with beater 380000219. Insert the valve guide in the cylinder head so that they stick out from it for 8.1 ÷ 8.9 mm.

INTAKE

EXHAUST

119570

Using Using a bore bore meter, meter, measur measure e the valve valve guide guide inner inner diame diameter ters, s, which must correspond correspond to the values reported in the figure below.

VALVE SEATS Figure 66

122433

VALVE SEAT SPECIFICATIONS A. Seat of the aspiration valve - B. Seat of the discharge valve. If the valve seat are damaged replace them with the spare ones included in the supply. With the tools and being careful not to indent the cylinder heads, remove as much material as possible form the valve seats until removal from cylinder head is possible by means of a punch.

Heat cylinder head up to 80º ÷ 100ºC and with the beater assemble assemble the new valve seats previously previously cooled in them.

Copyright © 28


F5AE ENGINES

VALVE SPRINGS

Figure 69

Figure 67

119567 50676

MAIN SPECIFICATIONS FOR INTAKE AND EXHAUST VALVE SPRING TEST

Place the spring (4) and the upper plate (3) on the cylinder head head.. Using Using tool tool 38000 3800003 0302 02 (1), (1), compr compres esss the spri spring ng (4) (4) and and constra constrain in the parts parts to the valve valve (5) throug throughout hout the half half cones cones (2).

Before assembly, test the valve spring flexibility using specific tool. Compare the load and elastic strain test results with the technical specifications of the new springs, reported in the table below.

Cylinder head reassembly Elastic strain

Under load of

mm

N

H (free)

44.6

H1

34

270 ± 14

H2

23.8

528 ± 26

Figure 70

0

CYLINDER HEAD ASSEMBLY Figure 68 119573

Chec Checkk that that the the cylind cylinder er head head and and cran cranks ksha haft ft coupl coupling ing surfaces are clean. Do not foul the cylinder head sheath. Fit the gasket (1) on the crankshaft in the correct centred position, taking the pins as reference (2).

119572

Lubricate the valve stems (1) and fit them in the relevant valv valve e guid guides es in the the same same posi positi tion on they they were were befo before re disassembly. Fit the grommets (2 and 3) to the valve guide using tool 380000134.



TORQUE SETTING TORQUE

t i n U n a P l i O

k c o l b e n i g n E

e s a c r a e g g n i m i T

d a e h e v O

kgm

Side cap

M6

40 ± 5

4 ± 0.5

Side caps

M22

50 ± 5

5 ± 0.5

Front cap

M35

40 ± 5

4 ± 0.5

70 ± 5

7 ± 0.5

50 ± 50 ± 5 80 ± 80 ± 6

5 ± 0.5 8 ± 0.6

Fixing of sump Crankshaft caps pre pre-tigh -tighte teni ning ng tigh tighte teni ning ng angle tightening Piston cooling nozzle 3/8” conical threaded cap 1/8” conical threaded cap Water drainage cap Oil turbo delivery pipe fixing Conical threaded cap Gear cooling nozze Cover fastening Cover fastening Cover fastening Ignition pump screw stud Timing pin seat cap Gearcase fastening Gearcase fastening Gearcase fastening

l Case fastening e e e h s a w y c l Case fastening F

d a e h r e d n i l y C

Nm

90 ± 5 ± 5 ˚

18 ± 2 40 ± 5 15 ± 5 25 ± 25 ± 5 40 ± 5 15 ± 5 15 ± 5 25 ± 5 25 ± 5 25 ± 5 4 ± 1 25 ± 5 25 ± 5 25 ± 5 25 ± 5

1,8 ± 0.2 ± 0.2 4 ± 0.5 1.5 ± 0.5 ± 0.5 2.5 ± 0.5 ± 0.5 4 ± 0.5 1.5 ± 0.5 ± 0.5 1.5 ± 0.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 4 ± 0.1 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5

M8

35 ± 5

3.5 ± 0.5

M12

120 ± 5

12 ± 0.5

130 ± 10 ± 10

13 ± 13 ± 1 1

(M8x1.25 6g x 35) (M8x1.25 6g x 35) (M8x1.25 6g x 16.5)

(M8x1.25 6g x 25) (M8x1.25 6g x 35) (M8x1.25 6g x 50)

Cylinder head fastening First phase Second phase Third phase Cylinder head fastening First phase Second phase Third phase Threaded cap fastening Rocker arm dowel

(M15x 1.5 6g x 193)

Overhead fastening Overhead fastening Valve adjusting nut Inspection cover fastening

˚

90 ± 5 ± 5 90 ± 5 ± 5 ˚

˚

˚

˚

(M12x 1.5 6g x 165) 65 ± 5 ± 5

6 ± 0.5 90 ± 5 ± 5 60 ± 5 ± 5 ˚

˚

˚

˚

40 ± 5 25 ± 5

4 ± 0.5 2.5 ± 0.5

(M8x1.25 6g x 30)

25 ± 5

2.5 ± 0.5

(M8x1.25 6g x 50)

25 ± 5

2.5 ± 0.5

20 ± 5 25 ± 5

2.5 ± 0.5 2.5 ± 0.5

29

Copyright © 30


F5AE ENGINES

TORQUE

d Intake manifold fastening e l o k f a i n n a I m Throw fastening to intake manifold t d Exhaust manifold fastening s l o u f i a n h x a Turbo-blower stud screw E m c d e o n n r g o i C n t

Engine drive shaft pulley fastening Connecting Connecting rod rod cap fastening fastening - pre-tightening - angle tightening Phonic wheel fastening Flywheel fastening - pre-tightening - angle tightening

g Thrust block fastening n i m i T Gear fastening

(M8x1 .25 6g x 60)

Nm

kgm

25 ± 5

2.5 ± 0.5

25 ± 5

5 ± 0.5

35 ± 5

3.5 ± 0.5

15 ± 5

1.5 ± 0.5

350 ± 15

35 ± 1.5

50 ± 5

5 ± 0.5 70 ± 5 ˚

˚

15 ± 3

1.5 ± 0.3

30 ± 5

3 ± 0.5 90 ± 5 ˚

˚

25 ± 5

2.5 ± 0.5

36 ± 5

3.6 ± 0.5

25 ± 5

2.5 ± 0.5

15 ± 5 30 ± 2 20 ± 5

1.5 ± 0.5 3 ± 0.5 2 ± 0.5

20 ± 5

2 ± 0.5

10 ± 5

1 ± 0.5

36 ± 36 ± 5

3.6 ± 0.5

Union fixing to support l r e e t u l i F f Fuel filter fastening

25 ± 5

2.5 ± 0.5

25 ± 5

2.5 ± 0.5

y p Supply pump fastening l p m Inlet p u u S p Fast clutch

25 ± 5

2.5 ± 0.5

25 ± 5

2.5 ± 0.5

25 ± 5

2.5 ± 0.5

Injector fastening

10 ± 5

1 ± 0.5

Pump fastening

25 ± 5

2.5 ± 0.5

Collector fastening screw nuts Oil delivery inlet fixing Delivery pipe fastening screw nut Exhaust pipe fixing to heat exchanger Exhaust pipe fixing to turbo

25 ± 25 ± 25 ± 25 ± 15 ±

2.5 2.5 2.5 2.5 1.5

Injector stud screw fastening Injector fastening nut - pre-tightening - tightening A Pipe fixing on manifold side D L Pipe fixing on pump side

s r o t c e j n I

o r o Engine drive shaft speed sensor fixing s c e n j n e s Water temperature sensor fixing I

r o r t c a c e s j n I

o re b r w u o T lb

5 5 5 5 5

± ± ± ± ±

0.5 0.5 0.5 0.5 0.5



TORQUE Nm

kgm

Water pipe fixing to the heat exchanger Water pipe fixing to the support 3/8” conical threaded cap

25 ± 5 25 ± 25 ± 5 40 ± 5

2.5 ± 0.5 2.5 ± 0.5 4 ± 0.5

Oil pressure control valve fastening

45 ± 5

4.5 ± 0.5

10 ± 2

1 ± 0.2

45 ± 5

4.5 ± 0.5

25 ± 5

2.5 ± 0.5

18 ± 2

1.8 ± 0.2

Oil pump fastening 1st step 2nd step

15 ± 15 ± 5 25 ± 25 ± 5

1.5 ± 1.5 ± 0.5 0.5 2.5 ± 2.5 ± 0.5 0.5

Threaded caps

45 ± 5

4.5 ± 0.5

Exchanger unit fixing

25 ± 5

2.5 ± 0.5

Heat exchanger fastening

25 ± 5

2.5 ± 0.5

Thermostat unit fixing

25 ± 5

2.5 ± 0.5

Bleed vent fixing

40 ± 5

4 ± 0.5

Water pump fastening

25 ± 25 ± 5

2.5 ± 0.5

t Bearing fixing r o Fan support fixing n a p p F u s Pulley fixing

40 ± 5

4 ± 0.5

25 ± 5

2.5 ± 0.5

40 ± 5

4 ± 0.5

r o p t a n u o r e g l A

Support fastening to block

50 ± 5

5 ± 0.5

Alternator fastening (screw + nut)

50 ± 5

5 ± 0.5

Push rod fixing

50 ± 5

5 ± 0.5

g n i e l p o i o pp C l e k v c e e l l h i c O

n o e i s Fixing of suction rose to the sump t c r u o S r e y Cartridge union t l i f d o Oil filter fastening l i b O Oil filter cartridge fastening

r e g t n a a e h c x e o t m a r t e h s T

Alternator push rod fixing (screw + nut) Front hook fastening Rear hook fastening Water temperature sensor fixing Oil temperature sensor fixing Water temperature sensor fixing Impulse transmitter fixing Air pressure sensor fixing Pump gear fixing n o p pre-tightening i t c u - tightening e j n pp Fuel pump fastening nuts I

s g e - i n l s s Masses box fastening a c a B n a m l t Fastening of support o e r t k n c o s o C Cover fastening

50 ± 50 ± 70 ± 25 ± 25 ± 25 ± 30 ± 30 ± 10 ± 10 ±

5 5 5 5 5 5 2 2

5 ± 0.5 5 ± 0.5 7 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5 1 ± 0.2 1 ± 0.2

18 ± 2 90 ± 5 25 ± 5

1.8 ± 0.2 9 ± 0.5 2.5 ± 0.5

70 ± 5

7 ± 0.5

40 ± 5

4 ± 0.5

25 ± 5

2.5 ± 0.5

31

Copyright © 32


F5AE ENGINES


SECTION 5 - TOOLS

1

SECTION 5 Tools Pagina TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Copyright © 2

SECTION 5 - TOOLS

F5AE ENGINES


SECTION 5 - TOOLS

TOOLS

TOOL No.

DEFINITION

-

Puller for the gear coupling coupling the injection injection pump to the engine

-

Shrink fitter for the assembly assembly of the drive shaft rear gasket

-

Shrink fitter for the assembly assembly of the drive shaft front gasket

-

Adap Adapte terr for for count counterp erpres ressu sure re chec checki king ng in cylin cylinde ders rs (use (use with with 380001006)

-

Brackets Brackets for fastening fastening the engine to the rotatory rotatory stand 99322205 99322205

-

Dynamometri Dynamometricc wrench (20 -120 Nm) with 1/2” square coupling coupling

3

Copyright © 4

SECTION 5 - TOOLS

TOOL No.

-

F5AE ENGINES

DEFINITION

Dynamometric Dynamometric wrench (60 -320 Nm) with 1/2” square coupling coupling

380000134

Shrink fitter for valve guide gasket gasket assembly assembly

380000150

Tool for engine P.M.S. positioning positioning

380000219

Beater for valve guide disassembly and reassembly

380000220

Ring for plunger introduction into the cylinder barrel (60 ÷ 125 mm)

380000221

Pliers Pliers for plunger plunger snap snap ring disass disassemb embly ly and reassem reassembly bly (65 - 110 mm) mm)


SECTION 5 - TOOLS

TOOL No.

DEFINITION

380000222

Sleeker for valve guide

380000228

Comparator Comparator (0 to 5 mm)

380000229

Comparator Comparator holding holding tool for rotatory rotatory injection injection pump phasing phasing (use with 380000228)

380000302

Tool for engine valve disassembly and reassembly

380000304

Pair of measuring measuring devices devices for angular angular tightening tightening with 1/2” and 3/4” square coupling

380000362

Tool for drive shaft lifting

5

Copyright © 6

SECTION 5 - TOOLS

F5AE ENGINES

TOOL No.

DEFINITION

380000364

Compar Comparato atorr holding holding base base for miscel miscellane laneous ous measur measures es (use (use with with 380000228)

380000667

Beater for distribution shaft bush disassembly and reassembly (use with 380000999) 380000999)

380000670

Tool for cartridge filter disassembly

380000978

Rotary Rotary stand for overhauling overhauling units (capacity (capacity 1000 daN, torque 120 daNm)

380000988

Tool for stopping stopping the engine flywheel flywheel

380000999

Handle for interchangeable beaters


SECTION 5 - TOOLS

TOOL No.

DEFINITION

380001006

Diesel engine cylinder compression control device

7

Copyright © 8

SECTION 5 - TOOLS

F5AE ENGINES


APPENDIX

1

Appendix Page SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . .

3

Copyright © 2

APPENDIX

F5AE ENGINES


APPENDIX

3

SAFETY PRESCRIPTIONS Standard safety prescriptions

- Do not execute any intervention if not provided with necessary instructions.

Particular attention shall be drawn 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 sufficient to ensure ensure safety to the personnel personnel in-charge of maintenance.

- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided provided for: serious injury may occur.

Be infor informe med d and and infor inform m pers person onne nell as well well of the laws laws in forc force e regulat regulating ing safety, safety, provid providing ing informa information tion docume documenta ntation tion available for consultation.

- In case of test or calibration operations operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.

- Keep Keep work working ing area areass as clean clean as possi possibl ble, e, ensur ensuring ing adequate aeration.

During maintenance

- Ensure that working areas are provided with emergency boxes, boxes, that must be clearly visible and always provided provided with adequate sanitary equipment.

- Never open filler cap of cooling circuit when the engine is hot. hot. Oper Operat atin ingg pres pressu sure re woul would d prov provok oke e high high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC.

- Provide for adequate 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. - Provide Provide Warnings Warnings throughout throughout adequate adequate boards boards signaling signaling danger danger,, prohib prohibitio itions ns and indicat indications ions to ensure ensure easy easy compre comprehen hensio sion n of the instruc instruction tionss even even in case of emergency.

Prevention of injury - Do not wear unsuitable cloths for work, with fluttering fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion. - 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: ≤ allowed: ≤ 2 2 bar) - Wear Wear safety safety helmet helmet when working working close to hanging hanging loads or equipment working at head height level.

safety shoes when and cloths adhering adhering to - Always wear safety the body, better if provided with wit h elastics at the ends. - Use protection cream for hands. - Change Change wet cloths as soon as possible possible - In presence of current tension exceeding exceeding 48-60 V verify verify efficie efficiency ncy of earth earth and mass mass electri electrical cal connecti connections ons.. 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.

dirty rags rags with oil, diesel diesel fuel fuel or solvent solventss in - Put the dirty anti-fire specially provided containers.

- Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether whether part partic icul ular ar circ circum umst stan ance cess requ requir ire e main mainte tena nanc nce e intervention on running engine, be aware of all risks involved with such operation. - Be equip equipped ped with adequa adequate te and safe containe containers rs for drainage drainage operation operation of engine liquids and exhaust exhaust oil. - Keep the engine clean from oil tangles, diesel fuel and or chemical solvents. - Use of solvents or detergents detergents during maintenance may origin originate ate toxic toxic vapors vapors.. Always Always keep keep workin workingg areas areas aerated. Whenever necessary wear safety mask. - Do Do not not leav leave e rags rags impr impreg egna nate ted d with with flam flamma mabl ble e substances close to the engine.

proper - Upon engine start after maintenance, undertake proper preventing preventing actions to stop air suction in case of runaway runaway speed rate. - Do not utilize fast screw-tightenin screw-tighteningg tools. - Never disconnect batteries when the engine is running. - Disconnect batteries batteries before any intervention intervention on the electrical system. - Disconnect Disconnect batteries batteries from system aboard to load them with the battery loader. - After After every every interve interventio ntion, n, verify verify that that batter batteryy clamp clamp polarity polarity is correct correct and that the clamps are tight and safe from accidental accidental short circuit and oxidation. oxidation. - Do not disconnect and connect electrical connections connections in presence presence of electrical electrical feed.

Before re proc procee eedi ding ng with with pipe pipeliline ness disa disass ssem embl bly y - Befo (pneum (pneumati atic, c, hydrau hydraulic, lic, fuel fuel pipes)verifyprese pipes)verifypresence nce of liquid 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.

Copyright © 4

APPENDIX

- Avoid incorrect tightening or out of couple. Danger: incorr incorrect ect tighten tightening ing may seriou seriously sly damage damage engine engine’s ’s components, affecting engine’s duration. - Avoid priming priming from from fuel fuel tanks made out of copper copper alloys and/or and/or with ducts not being provided provided with filters. filters. - Do not modify cable wires: their length shall not be changed. - Do not not conne connect ct any any user user to the engi engine ne elec electr trica icall equipment unless specifically approved by CNH.

unless - Do not modify fuel systems or hydraulic system unless CNH CNH spec specif ific ic appr approv oval al has has been been rele releas ased ed.. Any Any unauthorized unauthorized modification modification will compromise compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: execute electric electric arc welding welding without without having having - Do not execute priory removed electronic gearbox. - Remove Remove electronic gearbox gearbox in case of any intervention intervention requiring heating over 80ºC temperature. - Do not not pain paintt the the compo compone nents nts and and the elec electro tronic nic connections. - Do not vary or alter any data filed in the electronic gear gearbo box x drivi driving ng the the engi engine ne.. Any mani manipu pula latio tion n or alter alterat ation ion of elec electr tron onic ic comp compon onen ents ts shall shall total totally ly com compromi romise se engi engine ne assi assist stan ance ce warr arranty anty and furthe furthermo rmore re may may affect affect engine engine correc correctt working working and duration.

F5AE ENGINES

Respect of the Environment - Res Respe pect ct of the the Envi Enviro ronm nmen entt shal shalll be of prim primar ary y impo import rtan ance ce:: all all nece necess ssar aryy prec precau autio tions ns to ensur ensure e personnel’s safety and health shall be adopted. - Be informed and 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 orga organi nize ze speci specific fic traini training ng cour course sess to ensur ensure e that that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect Collect exhaus exhaustt oils in adequa adequate te special specially ly provid provided ed 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 Handle the batteries with care, storing them in aerated aerated environment and within anti-acid containers. Warning: batt batter eryy exha exhala lati tion on repr repres esen entt seri seriou ouss dang danger er of intoxication and environment contamination.

sm_4 Cylinders F5_EN.pdf

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