case new holland kobelco iveco komatsu f4ce f4de f4ge f4he service repair manual for engine overhaul...

8/10/2019 Case New Holland Kobelco Iveco Komatsu F4CE F4DE F4GE F4HE Service Repair Manual For Engine Overhaul ( M…

http://slidepdf.com/reader/full/case-new-holland-kobelco-iveco-komatsu-f4ce-f4de-f4ge-f4he-service-repair-manual 1/277

ENGINESCNHNEFF4CE - F4DE - F4GE - F4HE

4 Cylinders, Mechanical and

Electronic Drive Common Rail

ENGINESCNH NEF

F4CE - F4DE - F4GE - F4HE

4 Cylinders, Mechanicaland Electronic

Drive Common Rail

Repair

Manual

Tier III

Print No. 87659057AEnglish

Repair

Manual

Tier III



REPAIR INSTRUCTION MANUAL

CNH ENGINES

ENGINES FAMILY:

F4CE9484 -- F4DE9484 -- F4GE9484 -- F4HE9484

All the information, illustrations and data provided by this manual are based upon the most recent information available at the time of its publication.

CNH ITALIA S.p.A. reserves the right to implement modifications, at any time, without communications.

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



2 ENGINE

2

TROUBLESHOOTING



- This Manual is written for an expert technician toprovide the technical information required to per-form repair operations on this machine.

- Please read carefully this manual for the correctinformation regarding the repair procedures.

- For any question or comment, or in case anyerror regarding the content of this manual isfound, you are asked to please contact:

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

TO THE READER

SYMBOLS

This manual includes safety warning symbols and indications to recall the attention on possible personalinjuries 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 to the weight of a component or a part.

To prevent personal injuries or damages, make sure that the appropriate lifting equipment andtechniques are implemented when handling heavy loads.

!

IN--1

FOREWORD



UNITS OF MEASURE

In this manual, the units of measure of the IS (International System) are used.

The units of measure of the MKSA system are listed in parenthesis after the units of the International system.

Example: 24.5 Mpa (250 kgf/cm2).

Here below, a conversion table of the units of the IS and some units of measure of other systems is listed. asa reference.

IN--2

FOREWORD

QuantityTo convert

from(SI)

into(Others)

Multiplyby

QuantityTo convert

from(SI)

into(Others)

Multiplyby

mm in 0.03937 MPa kgf/cm2 10.197eng

mm ft 0.003281 ressure

MPa psi 145.0

L US gal 0.2642 kW PS 1.360

Volume L US qt 1.057 ower kW HP

m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32

Mass kg lb 2.205 km/h mph 0.6214

N kgf 0.10197 e oc ty

min--1 rpm 1.0orce

N lbf 0.2248 L/min US gpm 0.2642

N.m kgf.m 0.10197 ow

mL/rev cc/rev 1.0orque

N.m lbf.ft 0.7375



Section

Introduction

General specifications 1

Fuel 2

Duty - Industrial application 3

Overhaul and technical specifications 4

Tools 5

Engine technical cards 6

Safety prescriptions Appendix

NEF ENGINES

NEF ENGINES 1



2 NEF ENGINES



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

Example

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

α

Tighten to torqueTighten to torque + angular value

1∅

∅ 2

NEF ENGINES 3

SPECIAL REMARKS



4 NEF ENGINES

SYMBOLS - ASSISTANCE OPERATIONS

Removal

Disconnection Intake

Refitting

Connection Exhaust

Removal

Disassembly Operation

Fitting in place

Assembly ρ Compression ratio

Tighten to torque Tolerance

Weight difference

α

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Regulation

Adjustment

Angle

Angular value

Visual inspection

Fitting position check Preload

Measurement

Value to find

Check

Number of revolutions

Equipment Temperature

Surface for machining

Machine finish bar Pressure

Interference

Strained assembly

Oversized

Higher than….Maximum, peak

Thickness

Clearance

Undersized

Less than….Minimum

Lubrication

Damp

Grease

Selection

Classes

Oversizing

Sealant

Adhesive

Temperature < 0 °C

Cold

Winter

Air bleedingTemperature > 0 °C

HotSummer

CNH

PARTS

Replacement

Original spare parts



NEF ENGINES 5

UPDATING

Section Description Page Date of revision



6 NEF ENGINES



INTRODUCTION 1NEF ENGINES

Introduction

Page

PREFACE TO USER’S GUIDELINE MANUAL 3. . . .

SYMBOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Service operations 3. . . . . . . . . . . . . . . . . . . . . .

GENERAL WARNINGS 5. . . . . . . . . . . . . . . . . . . . .

GENERAL WARNINGSON THE ELECTRIC SYSTEM 7. . . . . . . . . . . . . . .

- Bonding and screening 8. . . . . . . . . . . . . . . . . . .

OPTIONAL ELECTRICAL AND MECHANICALPARTS INSTALLATIONS 9. . . . . . . . . . . . . . . . . .

CONVERSIONS BETWEEN THE MAIN UNITSOF MEASUREMENT OF THE INTERNATIONALSYSTEM AND MOST USED DERIVEDQUANTITIES 9. . . . . . . . . . . . . . . . . . . . . . . . . . .



2 INTRODUCTION NEF ENGINES



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

to prevent serious accidents taking place.The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,

there have been defined a set of symbols to classify warnings and a set for assistance operations.

General danger

It includes the dangers of above described signals.

Danger of serious damage for the assembly

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

Environment protection

Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect

the environment as much as possible.

Danger for persons

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

SYMBOLS - Warnings

It indicates an additional explanation for a piece of information.

!

NOTE

PREFACE TO USER’S GUIDELINE MANUAL

Service operations

Example

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

α

Tighten to torque

Tighten to torque + angular value

1∅

∅ 2





RemovalDisconnection

Intake

RefittingConnection

Exhaust

RemovalDisassembly

Operation

Fitting in placeAssembly ρ Compression ratio

Tighten to torque Tolerance

Weight difference

α

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

RegulationAdjustment

AngleAngular value

! WarningNote

Preload

Visual inspectionFitting position check

Number of revolutions

Measurement

Value to findCheck

Temperature

Equipmentbar

Pressure

Surface for machiningMachine finish

OversizedHigher than….Maximum, peak

InterferenceStrained assembly

UndersizedLess than….Minimum

ThicknessClearance

SelectionClassesOversizing

LubricationDampGrease

Temperature < 0 °CCold

Winter

SealantAdhesive

Temperature > 0 °CHotSummer

Air bleeding



GENERAL WARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contactimmediate superiors where a danger situation occurs which is not described.

Use both specific and general-purpose toolings according to the prescriptions contained in respective use andmaintenance handbooks. Check use state and suitability of tools not subjected to regular check.

The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path.

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said meansis 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 fromaccidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could bedangerous 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 prior to operating on the latter. Strictly follow all the safety indications found on the assembly.

Do not leave the running assembly unattended when making repairs.

When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supportingstands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be liftedby 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 pressureout.

Inflammable fuel andall inflammable fluidsand liquids must be handled with care, according to what contained on harmfulmaterials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flamesor sparksin order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquidsaccording 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 suitablecontainers.

Worn out, damaged or consumable parts must be replaced by original spares.

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

!




Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembledparts with their securing elements (screws, nuts, etc.) into special containers.

Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.Self-locking nuts with an insert made of nylon must always be replaced.

Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.

Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.

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

Before welding:

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

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

- Await about 15 minutes before welding.

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

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

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

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contactwith moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,scarves, etc.

Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operateoutdoors 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 seriousburns. 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.




GENERAL WARNINGS ON THE ELECTRIC SYSTEM

To start up the engine, donot use fast chargers. Start up mustonly be performed with either separate batteries or special 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 the batteries from the system during their recharging with an external apparatus.

On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque.

Before disconnecting the junction connector from an electronic central unit, isolate the system.

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

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.

Before connecting the batteries to the system, make sure that the system is well isolated.

Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery

terminals.

Do not cause sparks to be generated in checking if the circuit is energised.

Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.

Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screeningbraiding, bonding, etc.) comply with CNH system and are carefully recovered after repair or maintenance interventions.

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

Connectorspresent must be seen fromcableside. Connectorsviews contained in the manual are representativeof cableside.

!

NOTE





Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M).

Further, following warnings are to be compulsorily observed for electronic components:

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

- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening

bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.

- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.

Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.

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

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

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

1. NEGATIVE CABLES “STAR “ CONNECTION TO SYSTEM BONDING M

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

88039

Figure 1

Figure 2




OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

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

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

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power

1 kW = 1.36 metric HP1 kW = 1.34 HP1 metric HP = 0.736 kW1 metric HP = 0.986 HP1 HP = 0.746 kW1 HP = 1.014 metric HP

Torque

1 Nm = 0.1019 kgm

1 kgm = 9.81 Nm

Revolutions per time unit

1 rad/s = 1 rpm x 0.10461 rpm = 1 rad/s x 9.5602

Pressure

1 bar = 1.02 kg/cm2

1 kg/cm2 = 0.981 bar 1 bar = 105 Pa

Where accuracy is not particularly needed:

- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1

1 kgm = 10 Nm;- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1

1 kg/cm2 = 1 bar.

Temperature

0° C = 32° F1° C = (1 x 1.8 + 32) ° F



SECTION 1 - GENERAL SPECIFICATIONS 1NEF ENGINES

SECTION 1

General Specifications

Page

NOMENCLATURE (Coding of the engines of origin) 3

LUBRICATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL VAPOUR RECIRCULATING SYSTEM 7. . . . . . .

COOLING SYSTEM 7. . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION BOOST DIAGRAM 9. . . . . . . . . .

- Boosting version engines 9. . . . . . . . . . . . . . . . .

- Description 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Inter-cooled engine version 10. . . . . . . . . . . . . . .

- Description 10. . . . . . . . . . . . . . . . . . . . . . . . . . .

EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) 11



2 SECTION 1 - GENERAL SPECIFICATIONS NEF ENGINES



NOMENCLATURE (Coding of the engines of origin)

F 4 B E 9 4 8 4 E * J +

J = TIER 3

4 = 4- cylinders

Emission level

No. of cylinders

Power homologated

Use

Inlet / injection

Configuration of cylinders

Engine

Type of cylinder block:C = structural 2-valvesD = structural 4-valvesG = non structural 2-valvesH = non structural 4-valves

Enginesfamily

8 = Diesel turbochargedDirect Injection withIntercooler 5 = Diesel turbochargedDirect Injection

4 = Earth Moving Machines and Tractors

X = 6 Rotary injection pump 2-valves1 Common rail 4-valves2 Common rail 2-valves5 Rotary injection pump 4-valvesY = Engine variant

Production progressive number

X Y Y Y Y Y Y Y Y




Figure 3

LUBRICATION

Lubrication by forced circulation is achieved through oil rotary expansion pump, placed in the front part of the basement,driven by the straight-tooth gear splined to the shaft’s bar hold.

From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.

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

All these components may often vary according to the specificduty.

LUBRICATION SYSTEM LAYOUT

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

116396

Routing of oi l undepressure

Routing of oil returnby gravity to sump

Introduction of oil

Some groups can be located on the engine indifferent positions due to requirements dictated by

the application, and have variable shapes anddimensions depending upon the use and theversions of the engine itself.

NOTE




Figure 4

LUBRICATION DIAGARAM (Other application)

Lines of oil underpressure

Return lines of oil by gravity

Oil filler

112885




3240t

Figure 5

OIL VAPOUR RECIRCULATING SYSTEM

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

On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity, to the Tappet cap underneath.

The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example (con-nection towards these vapours shall be designed by the Engineer).

1

2

3




Figure 6

COOLING SYSTEM

The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:

- Expansion tank; placement, shape and dimensions aresubject to change according to the engine’s equipment.

- Radiator, which has the duty to dissipate the heatsubtracted to the engine by the cooling liquid. Also thiscomponent will have specific peculiarities based on theequipment developed, both for what concerns theplacement and the dimensions.

- Visc pusher fan, having the duty to increase the heatdissipating power of the radiator. This component as wellwill be specifically equipped based on the engine’sdevelopment.

- Heat exchanger to cool the lubrication oil: even thiscomponent is part of the engine’s specific equipment.

- Centrifugal water pump, placed in the front part of theengine block.

- Thermostat regulating the circulation of the coolingliquid.

- The circuit may eventually be extended to thecompressor, if this is included in the equipment.

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

COOLING SYSTEM LAYOUT

FROM RADIATOR

TO RADIATOR

03241t




Figure 7

AIR FILTER TURBOCHARGER

EXHAUST

4 cylinders version

88208

AIR INDUCTION BOOST DIAGRAMBoosting version engines

Description

The turbocharger is composed by the following main parts:one turbine, one transforming valve to regulate the boostfeeding pressure , one main body and one compressor.

During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates,compressing the sucked air through the air filter.

The air coming out of the compressor is sent via the intakemanifold directly to the pistons.

The turbocharger is equipped with a transforming valve toregulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the inductioncollector.

It’s dutyis tochoke the exhaust ofthe emissions, releasingpartof them directly to the exhaust tube when the boost feedingpressure, over the compressor, reaches the prescribed bar value.

The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.




74195

Figure 8

The turbocharger is composed by the following main parts:one turbine, one transforming valve to regulate the boostfeeding pressure , one main body and one compressor.

During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation.

The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates,compressing the sucked air through the air filter.

The above mentioned air is then cooled by the radiator and

flown through the piston induction collector.

The turbocharger is equipped with a transforming valve toregulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the inductioncollector.

It’s duty isto choke the exhaust of the emissions , releasing partof them directly to the exhaust tube when the boost feedingpressure, over the compressor, reaches the prescribed bar value.

The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.

Description

RADIATOR

AIR FILTER TURBOCHARGER

EXHAUST

4 cylinders version

Inter-cooled engine version




EXHAUST GAS RE-CIRCULATION SYSTEM(EGR)

In the TIER 3 version, the profile of the exhaust cam has beenmodified in order to allow the partial opening of the relativevalve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of

the exhaust gas into the engine cylinders.The exhaust gases can partially be re-directed into the

cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitricacid (NOx).The exhaust gas re-circulation system (EGR), reducing thecombustion temperature by means of the diminishing of theconcentration of oxygen in the combustion chamber,represents therefore an efficient control system of theemission of NOx .

Figure 9

A. Aspiration valve control - B. Exhaust valve control.

114789

The internal EGR system is not equipped with any electronically controlled elements: the system is always active.Its configuration does not need additional elementsi.e.checking valves, piping or heat exchangers.

The exhaust cam (B) has another lobe apart from the major lobe (see Section. A-A fig.) with respects to the configurationwithout EGR.The additional lobe, during the aspiration phase in the cylinder

in question, allows a brief opening of the exhaust valvegenerating re-circulation due to the intake of the exhaust gasescaused by depression which is created in the aspiration phaseinside the cylinder.

For the dimension of the camshaft, please refer to Section 6”General Mechanical Overhaul”

NOTE




2 SECTION 2 - FUEL NEF ENGINES



74168

1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure

gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.

4-CYLINDER ENGINES WITH BOSCH ROTARY MECHANICAL PUMP

General informationFuel feed system is composed by:

- Fuel tank (placed on the machine)

- Fuel delivery and back-flow to tank

- Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)

- Priming pump, assembled to the engine and driven by the camshaft

- Fuel filter (assembled to the engine in different positions according to equipment application and duty)

- Fuel feed rotary pump

- Injector feed pipeline (from fuel feed pump to injectors)

- Injectors

Figure 1

12

7

4

5

3

6

SECTION 2 - FUEL 3NEF ENGINES



Figure 4

72595

1. Fuel exhaust connector to rail - 2. High pressure pump - 3. Pressure regulating gauge - 4. Driving gear -5. Connector to fuel entry flowing from filter - 6. Connector to fuel exhaust to filter support - 7. Connector to fuel entry

flowing from engine control module heat exchanger - 8. Connector to fuel exhaust flowing from mechanic pump to filter -9. Mechanical feeding pump.

CP3 HIGH PRESSURE PUMPPump provided with 3 radial pumping elements driven by the timing system gear, no need of timing. The mechanicalfeeding pump driven by the high pressure pump’s shaft isassembled to the rear side of the high pressure pump.

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

NOTE




70498

Figure 5

Every pumping unit is composed of:

- a piston (5) actuated by a three-lobe element (2) floatingon the pump shaft (6). The element (2),being floating ona misaligned part of the shaft (6), when the shaft rotates,does not rotate therewith but is only translated in acircular movement along a wider radius, with theresulting alternate actuation of the three pumpingelements;

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

Sec. B-B

Sec. C-C

- cap intake valve (3);

- ball delivery valve (4).

High pressure pump-inside structure




Figure 6

Working principle

72597

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

Sec. D-D

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

During compression phase of the pumping element, the fuelachieves the level of pressure determining the opening of theby-pass valve to common rail (2), feeding it through theexhaust unit (I).

Sec. B-B




Figure 7

72601

1. Inlet to pumping element - 2. Pump lubrication ducts -3. Inlet to pumping element - 4. Pumping element feeding

main duct - 5. Pressure regulator - 6. Pumping elementinlet - 7. Regulator discharge duct - 8. Pressure relief valve

5 bar - 9. Fuel discharge from regulator inlet.

Sec. C - C 72598

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

The pump shaft is lubricated by the fuel through the feedingand recovery lines.

The pressure gauge (5) determines the quantity of fuel tofeed the pumping elements: the fuel in excess flows through the exhaust gallery (9).

The limiting valve to 5 bar, in addition to recovering fuel

exhaust as a collector has also function to keep the pressureconstant to 5 bar limit at gauge entry.

Figure 8

Sec. A - A

1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuelexhaust flowing from pump with connector to high

pressure pipe for common rail.

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




Figure 9

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

The amount of fuel supplying the high-pressure pump ismetered by the pressure regulator, placed on thelow-pressure system; the pressure regulator is controlled by the EDC7 control unit through a PWM signal.

When fuel is sent to a pumping element, the related pistonis moving downwards (suction stroke). When the pistonstroke is reversed, the intake valve closes and the remainingfuel in thepumping element chamber, not beingableto comeout, is compressed above the supply pressure value existingin the rail.

The thereby-generated pressure makes the exhaust valveopen and the compressed fuel reaches the high-pressurecircuit.

The pumping element compresses the fuel till the top deadcenter (delivery stroke) is reached. Afterwards, the pressuredecreases till the exhaust valve is closed.

The pumping element piston goes back towards the bottomdead center and the remaining fuel is decompressed.

When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated.

The delivery valves must always be free in their movements,free from impurities and oxidation.

The rail delivery pressure is modulated between 250 and1600 bars by the electronic control unit, through thepressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

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

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

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

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

It anyway has enough volume as to minimise system spikes

and the use of plenum chambers caused by injectorsopenings and closings and by the high-pressure pumpoperation. This function is further enabled by a calibratedhole being set downstream of the high-pressure pump.

A fuel pressure sensor (4) is screwed to the rail. The signalsent by this sensor to the electronic control unit is afeed-back information, depending on which the rail pressurevalue is checked and, if necessary, corrected.

RAIL

108609

RELIEF VALVEMounted on the end of the rail, it has the function of protecting the system’s components in case the failure of therail pressure sensor or the pressure regulator of pump CP3causes an excessive pressure increase in the high-pressureplant.

When the rail pressure reaches 1800 bars, the valve initially intervenes in order to allowthe fuel to flow and subsequently to reduce the pressure within safety limits and then it

mechanically regulates the rail pressure to approx. 800 bars.This valve allows the engine to work for long periods at alimited efficiency and avoids the excessive overheating of thefuel preserving the return pipes to the tank.




PRIMING PUMP

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

Figure 10

88209

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




Figure 11

FUEL FILTER

The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities andseparation of water from fuel.

On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on thebearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperaturesensor. On some versions, a water presence sensor is present at filtering cartridge base.

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

88210




Figure 12

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

3244t

1

2

5

4

3

3243t

1

3

4




Figure 1

1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engine’s cooling liquid - 3. Fuel pressure sensor cable - 4. Sensor of engine’s oil temperature and pressure -

5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and air pressure sensor -8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor -

10. Pressure gauge cabling - 11. EDC 7 gearbox.

HIGH PRESSURE ELECTRONIC INJECTIONSYSTEM (COMMON RAIL)IntroductionExtremely high injection pressures are necessary in order toreduce PARTICULATE emissions.The common rail system makes it possible to inject fuel atpressures of up to 1450 - 1600 bar, while the injection preci-sion obtained by electronic control of the system serves to

optimise operation of the engine while limiting emissions andfuel consumption.

For engines more powerful than 152 kW, the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600bar, whilst for engines less powerful than 152 kW, DSLAnozzles are fitted which work a pressures up to 1450 bar.

Description of system

The injection system is composed of an electrical part and ahydraulic part.

Electrical system

The electronic control unit monitors engine control para-meters by means of the various sensors on the engine.

107851




EDC 7 OPERATION

Engine preheating element control

Pre-post heating is activated when even just one of the water,air or fuel temperature sensors detects a temperature ≤ 5 °C.

Phase recognition

By means of signals transmitted by the camshaft and

crankshaft sensors, the cylinder into which fuel must beinjected is determined at the time of starting.

Injection control

On the basis of information transmitted by the sensors, thecontrol unit administrates the pressure regulator andmodifies the pre-injection and main injection mode.On F4 engines pre-injection is activated at all engine speeds.

Injection pressure closed loop control

On the basis of the engine load, as determined by processingof data transmitted by the various sensors, the control unitadministrates the regulator to maintain injection pressure atconstantly optimal values.

Pilot and main injection advance control

On the basis of signals transmitted by the various sensors, thecontrol unit determines the optimum injection point on thebasis of internal mapping.

Idle speed control

The control unit processes signals transmitted by the varioussensors and adjusts the quantity of fuel injected.It also controls the pressure regulator and modulatesinjection duration of the electro-injectors. Within specific limits, the control unit also monitors battery voltage.

Overheating protection

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

Maximum engine speed limiting

Depending on the application, the control unit memory cancontain appropriate engine speed limits. When the enginespeed surpasses these limits the control unit activates power reduction strategies by controlling energization time of theelectro-injectors. In some applications the maximum limiting

response consists in stopping the engine.

Cut Off

Fuel cut-off in release phases is managed by the control unitwith the following logical interventions:

- disactivation of the electro-injectors;

- reactivation of electro-injectors immediately prior toarrival at idle speed;

- control of fuel pressure regulator.

Smoke control under acceleration

With intense load demands, in accordance with signalsreceived from the air inlet meter and the engine speedsensor, the control unit manages the pressure regulator andmodulates the activation time of the electro-injectors toprevent the emission of smoke from the exhaust.

After Run

After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, including the faults log so that they will be available the next time theengine is started.

Control of working speed in normal operatingconditions

Each time work load varies, the control unit adjusts torqueso as to maintain the engine in maximum power conditions.If the load causes a reduction in power, the control unitincreases torque i.e. it increases the amount of fuel injectedin order to restore the engine to maximum power.

Recovery strategies

Recovery strategies are characterized by certain differencesas application varies, i.e.

- Control of fuel leaksIn the case of fuel supply problems, the system controls the engine with suitable constant power values obtainedwith a low number of revs and high torque values inorder to inject the maximum quantity of fuel.

- Control of pressure in the rail When the pressure in the rail exceeds safety values, theengine reduces power.

- Synchronism problemsIn the case of synchronism problems, faulty rev sensors, the system controls the engine by increasing the number of revs in order to improve interpretation of the signals.

- Power restrictions as operating temperature increases When the temperature of the supercharging air risesabove 88 °C, power reduction is started; when a temperature of 120 °C is reached, performance isfurther reduced and is comparable to that of the sameengine if it were aspirated.

- Reduction of power as reference temperature variesIn normal operating conditions, the system knows thesupercharging air, oil and water temperatures.If the temperature of the engine water is not available,

the system takes the temperature of the oil as referenceand when this reaches the threshold of 103 °C, it starts to reduce the power available. On reaching 113 °C,power is reduced to 50%.




Figure 2

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

7. Mechanical vane pump - 8. Fuel filter.

The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke andcylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.

Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.

When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takesplace in the related cylinder.

The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.

The high-pressure circuit is composed of the following pipings:

- piping connecting high-pressure pump outlet to rail;

- pipings supplying injectors from rail.

The low-pressure circuit is composed of the following pipings:

- fuel suction piping from tank to prefilter;

- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;

- pipings supplying the high-pressure pump through the fuel filter.

The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.

WORKING PROCESS

High Pressure

Low Pressure

Fuel outlet108607




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

piping. — 17. By-pass valve. — 18. By-pass valve.

FUEL SYSTEM LAYOUTThis fuel system is a Common Rail injection with CP3 highpressure pump and this layout is for 4 cylinder version.(The 6 cylinder version is similar design as the 4 cylinder en-gine).

The pressure regulator, placed upstream of the high-pressurepump, adjusts the fuel flow that is necessary on the low-pres-sure system. Afterwards, the high-pressure pump takes careof supplying the rail properly. This arrangement, by pressuris-ing the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system.

Function of the pressure relief valve (2), assembled on thehigh-pressure pump, is keeping the pressure, at the pressureregulator inlet, constant at 5 bars, independently from theefficiency of the fuel filter and of the system set upstream.

The pressure relief valve (2) intervention brings about a fuelflow increase in the high-pressure pump cooling circuit, through inlet and drain piping (16) from piping (8).

The pressure relief valve housed on the cylinder head, as-sembled on injector return (3), limits the fuel return flowfrom injectors at a pressure of 1.3 to 2 bars.

Two by-pass valves are placed in parallel with the mechanical

supply pump.The by-pass valve (18) allows fuel to flow from mechanicalpump outlet to its inlet, when the fuel filter inlet pressure ex-ceeds the allowed threshold value.

The by-pass valve (17) allows filling the supply system through the manual priming pump (10).

108608

Figure 3

INTAKE (LOW PRESSURE)

HIGH PRESSURE

HIGH-PRESSURE PUMP SUPPLY(LOW PRESSURE)

EXHAUST




SECTION 3 - INDUSTRIAL APPLICATION 1NEF ENGINES

SECTION 3

Engine

GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . .

PART ONE - MECHANICAL COMPONENTS 5. .

OVERHAUL OF THE 4 CYLINDER ENGINEPROVIDED WITH MECHANICAL ROTARYPUMP 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Preface 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Engine setting operations for the assembly on turningstand 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Disassembly of application components 9. . . . .

- Installation of rear components 18. . . . . . . . . . . .

- Installation of rear components with reduceddistribution 21. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Flywheel installation 23. . . . . . . . . . . . . . . . . . . . .

- Installation of front components 23. . . . . . . . . . .

- Assembly of additional masses 25. . . . . . . . . . . .

- Timing of additional masses 23. . . . . . . . . . . . . . .

- Completion of engine re-assembly 35. . . . . . . . .

- Rotary feed pump disassembly and assembly

procedure 36. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Feed system bleed procedure 39. . . . . . . . . . . . .

- Power take-off disassembly and assembly procedure 39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checks and controls 40. . . . . . . . . . . . . . . . . . . .

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

RAIL 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RELIEF VALVE 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRO-INJECTOR 43. . . . . . . . . . . . . . . . . . . . . . .

PRESSURE LIMITER FOR FUEL RETURN 44. . . . . . .

GENERAL SPECIFICATIONS 45. . . . . . . . . . . . . . . . .

- Section pictures of complete engine - common railversion 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 3 - INDUSTRIAL APPLICATION NEF ENGINES

x

Page

- Engine setting operations for the assembly on turning stand 46. . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OVERHAUL 46. . . . . . . . . . . . . . . . . . . . . . .

- Preface 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Disassembly of application components 48. . . . .

- Assembly of application components 55. . . . . . .

- Completion of the engine 65. . . . . . . . . . . . . . . .

PART TWO -ELECTRICAL EQUIPMENT - MECHANICALSENGINES 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

- Cooling liquid temperature sensor 70. . . . . . . . . .

- Starter 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- KSB Water temperature sensor 70. . . . . . . . . . . .

- Electromagnets assembled to feed pump 71. . . .

- Oil pressure switch 71. . . . . . . . . . . . . . . . . . . . .

- Alternator 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Pre-post heating resistor 71. . . . . . . . . . . . . . . . .

PART TWO -ELECTRICAL EQUIPMENT - ELECTRONICSENGINES 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION OF MAIN ELECTRICALCOMPONENTS 75. . . . . . . . . . . . . . . . . . . . . . . . .

- EDC7 ECU 76. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connector to injectors (A) 77. . . . . . . . . . . . . . .

- Feed connector (B) to components and to functionsof the specific equipment 78. . . . . . . . . . . . . . . . .

- Connector to sensors (C) 79. . . . . . . . . . . . . . . .

- Temperature and air-pressure sensor 80. . . . . . .

- Sensor of engine’s oil temperature andpressure 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Driving shaft sensor 80. . . . . . . . . . . . . . . . . . . . .

- Timing system sensor 80. . . . . . . . . . . . . . . . . . . .

Page

- Fuel pressure sensor 81. . . . . . . . . . . . . . . . . . . .

- Fuel temperature sensor 81. . . . . . . . . . . . . . . . .

- Resistor pre-post heating 81. . . . . . . . . . . . . . . . .

- Cooling liquid temperature sensor 81. . . . . . . . . .

- Starter 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Electro-injectors 82. . . . . . . . . . . . . . . . . . . . . . . .

PART THREE - TROUBLESHOOTING(MECHANICALS ENGINES) 83. . . . . . . . . . . . . . .

PART THREE - TROUBLESHOOTING(ELECTRONICS ENGINES) 91. . . . . . . . . . . . . . .

METHODS OF DIAGNOSIS 93. . . . . . . . . . . . . . . . .

FAULT CODES 94. . . . . . . . . . . . . . . . . . . . . . . . . . . .

PART FOUR - MAINTENANCE PLANNING 99. . .

MAINTENANCE PLANNING 101. . . . . . . . . . . . . . . .

- Recovery 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Planning of controls and periodical intervention 101

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

MAINTENANCE PROCEDURES 102. . . . . . . . . . . . . .

- Checks and controls 102. . . . . . . . . . . . . . . . . . . .

- Engine oil level check. 102. . . . . . . . . . . . . . .

- Check of fuel system 102. . . . . . . . . . . . . . . .

- Cooling system check 103. . . . . . . . . . . . . . .

- Lubricating system check 103. . . . . . . . . . . . .

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

- Check of drive belt tensioning 104. . . . . . . . .

- Check of belt’s tear and wear status 104. . . .

- Check and setting of tappet clearance 104. . .

- Oil motor and filter replacement 104. . . . . . .

- Fuel filter replacement 105. . . . . . . . . . . . . . .

- Alternator belt replacement 106. . . . . . . . . . .



Figure 1

GENERAL INFORMATION

NEF engines have been designed and developed by IvecoMotors specifically for transportation by land and farmingequipment in general.

They are characteristed by diesel cycle 4 stroke atmosphericor supercharged 4 and 6 cylinders each with 2 valves.

Feed is provided by rotary mechanical pump or on lineaccording to the equipment application.

It differs from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine. The section herein described is composed or four directories:

- directory of mechanical overhaul prescribed inaccordance to the engine’s specific duty, illustrating allnecessary operations to remove and assembly theexternal components of the engine, including cylinder heads, gearbox of the timing system and of the front partcover;

- electrical directory, describing the connections of thedifferent components, of the pre-post heating gearbox(only for some versions) and of the sensors assembled to

the engine;

- troubleshooting directory;

- directory of preventive and regular maintenance

operations, providing instructions for the execution of themain operations.

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

Data, technical specifications and performancesgranted shall be validonlyif the Setter will follow andcomply with all installation prescriptions providedby Iveco Motors.

Furthermore, the expanders assembled by theSetter must always comply with couple, power andnumber of revolutions based on which the enginehas been designed.

NOTE

NOTE

03220t





x



PART ONE - MECHANICAL COMPONENTS





x



The following information relate to the engine overhauloperations only for what concerns the different componentscustomising the engine, according to its specific duties.

With regard to the engine disassembly operations,please apply for information consulting the specificmanual. All operations of engine disassembly operations as well as overhaul operations must beexecuted by qualified engineers provided with thespecific tooling and equipment required.

Figure 2

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

Engine setting operations for the assembly onturning stand

For specific application exigencies, some units canbe assembled to the engine in different positions.

- disassemble lubrication oil exhaust pipe from the turbo-blower:Underneath the turbo-blower loosen the two screws(2), loosen the screw (3) fixing the pipe throughout thestop collar (4) fixing the block; finally loosen and remove

the union (5) from the block; plug the pipe ends and theexhaust of the turbo-blower.

Figure 3

75671

75672

- Disassemble the starter;Properly hold the starter (1) and loosen the fixing screws(2);

- assemble the bracket bearing 99361037 using the four screw threaded ports (3).

2

3

4

1

5

1

2

3

Figure 4

OVERHAUL OF THE 4 CYLINDER ENGINEPROVIDED WITH MECHANICAL ROTARYPUMPPreface

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

NOTE

NOTE

75670

In order to apply the brackets 380000661 to the engineblock to fix it on to the stand 380000301 for the overhaul,it is necessary to perform the following operations:

On the right hand side:

- disassemble pipes (1) from the union (2) fitting thelubrication oil filter (assembled on the opposite side):unlock the nuts fixing the pipes (1) and remove them from the union (2); drain the oil eventually still inside the pipesand plug them properly in order to avoid impurity inlet.

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

compliance with the law and regulations in force.

3

2

1

NOTE




Figure 5

From the left-hand side:

- Assemble the second bracket 380000661 throughout

the screw-threaded ports (1).- Lift the engine using the rocker arm 380000216 and put

it on the turning stand 380000301.

- Drain the oil through the cap underneath the plug.

Figure 6

On the left hand side:

- Disassemble oil filter (1) and bracket as well (for versions

with engine oil filter not directly assembled on to theexchanger);Using tool 380000670 operate on oil filter;Loosen the screws (3) removing the bracket together with the filter bearing (4 and 5).

75673

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

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

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

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

75674

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

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

2

1

3

4

5

1


x



Figure 7

Proceed disassembling the supercharger:

- loosen the fixing nut (1) and remove the lubrication pipefrom the supercharger. Analogously carry out the sameoperation on the other end of the pipe and remove itfrom the upper part of the heat exchanger.

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

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

75675

1

Disassembly of application components

70126

Figure 8

To disconnect fuel pipelines (2 and 3, Figure 8), in

low pressure from the relating pipe fittings, it isNecessary to press the locking fastener (1) asshown in picture B.

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

NOTE

Figure 9

- Place a container under the fuel filter and screw out thecondense drain faucet underneath said filter. Carry outcomplete drainage of the fuel contained therein.

- Screw out completely the faucet and, using equipment380000670 disassemble oil filter (1).

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

- Remove the fuel filter bearing (4) from the bracket fixed

to the engine head.

90502

Figure 10

75677

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

1

BOSCH VE 4/12 F Pump




7

6 5

1

2

3

4

Figure 11

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

screw (on suction collector plate).

75680

- Disconnect the pipelines (1) and (2) that provide feedand fuel recovery between pump and injectors; screwout the nuts fixing the pipes to the pumping elements;loosen the fuel recovery pipe collar on the injectionpump; operate on the nuts assembled to the injectorsand loosen the screws fixing the fuel recovery pipeline;loosen the screws holding the fixing brackets of suchpipelines (1,6, and 7, SENZA CODICE); pipe thepipeline ends.

- Disassemble the injectors and remove them from their slot: remove the gaskets.

Figure 12

75679

1 1

2

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

88102

Figure 13


x



1

2

Figure 14

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

87406

On the central cap there is a blow-by valve for thelubrication oil vapours.All the gaskets shall always be replaced duringassembly.

NOTE

Figure 15

- Disassemble suction and exhaust manifolds: loosen the8 screws (1) fixing the suction manifold plate to thecylinder head (two of them have already beenscrewed-out since fixing the pipe brackets to theinjectors); from the exhaust manifold side;loosen the (2) fixing screws; remove the gaskets.

87409

Figure 16

- Disassemble rocker arm bearings; loosen the two fixingscrews (2) and remove the complete rocker armbearing;withdraw tappet rods. Repeat the operation for all theremaining rocker arm bearings.

- Disassemble water temperature transmitter (1).

75683

Figure 17

- Remove the belt tightener (2).

- Remove the belt (4) of the ancillary members by actingon the alternator fixing bracket (1).

- Remove the alternator (3), the water pump (6), the fanpulley (5) and the jockey pulley (7).

- Remove the pulley support (8).

- Remove the engine block cooling system connector (3).

86571

For applications with automatic belt stretcher




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

- Loosen screw (2, Figure 19) in order to slide outPOLY-V belt (2).

- Remove the belt stretcher bracket (3).

- Disassemble the driven pulleys and the guide rollers.

88089

88091

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

75686

- Properly hold the alternator (1) separating it from itsbearing by loosening the screw (2); remove screw nutand washer.

1 2

Figure 18

Figure 19

Figure 20

The shape and the dimensions of the support of the alternator vary according to the use of theengine. The relevant pictures provide a general trace of the intervention that is to be carried out.

The procedures described are always applicable.

NOTE

1

2

4

5

3

Figure 21

75685

- Disassemble thermostat unit; loosen the three fixingscrews (1) and disassemble the thermostat unit (2) together with the bracket (3); remove the gasket (4) and the thermostat (5).

- Assemble the bracket in the original position fixing it with

the screws of the thermostat unit.

For applications with traditional belt stretcher


x



Figure 22

Figure 23

- Disassemble cylinder head;loosen thescrews (1) and (2) fixing thecylinder head (3);

hook the brackets with metal ropes and, throughout ahoist withdraw cylinder head from the block.

75688

3

4

1

2

3

4

1

2

75692

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

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

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

90504

In some versions there is provided 380000144 toolchecking the flywheel.

Figure 24

75810

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

- Loosen the screws (1) and disassemble the oil filter/heatexchanger bearing (2), interlayer plate (6) and relatinggaskets.

- Disassemble oil level sensor (5) (whether provided).

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

Figure 25

NOTE

The shape and thedimensions of thesupport ofthealternator vary according to the use of the engine.The relevant pictures provide a general trace of theintervention that is to be carried out.The procedures described are always applicable.

NOTE




Figure 31

75690

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

00903t

- Remove the flywheel cover box fixing ring using the tool 380000663 (3) to operate on the back tang (5) of the engine drive shaft. Throughout the tool guide ports,drill the internal holding ring using Ø 3,5 mm drill for a 5mm depth.

- Fix thetool 380000663 (3) to the ring (1) tighteningthe6 screws specially provided (4).

- Proceed with drawing the ring (1) tightening the screw(2).

- Using the specially provided tie rod (3) for the tool380000669 and the lever (4), withdraw the external

holding ring of the flywheel cover box.

Figure 32

70153

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

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

Figure 33

- Turn the engine upside-down.

- Loosen the screws (2), disassemble the plate (3) andremove the oil pan (1).

88046

The shape and dimensions of the pan and of therose pipe may vary according to the engineapplication. The relating illustrations providegeneral guidelines of the operation to be

performed. The procedures described areapplicable anyway.

1

2

3

4

Figure 34

NOTE

NOTE




- Loosen the screws (1) and disassemble the oil suctionrose pipe (3).

- Loosen the screws (2) and remove the stiffening plate(4).

90505

Figure 35

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

70157

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


Figure 36

Version with suction rose type B

Figure 37

Figure 38

- Remove the screws (1) and (4) and disassembled thesuction rose (5).

- Remove the screws (2) and disassemble the stiffeningplate (3)

Version with suction rose type A

99222

86601 Figure 39

86578

By means of pin (1) lock the additional masses (2) in the

P.M.S. Loosen the fixing screws (3) and remove the additionalmasses (2).

Version with additional masses

NOTE


x



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


87424

87422

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

87655

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

Version with reduced distribution

Figure 40

Figure 41

Figure 42

NOTE




- Reassemble to box (1) to the engine block.- Tighten the fixing screws in the same position as found

out during disassembly and fix the screws to the lockingcouples listed here below, following the order as shownin the picture.

Screws M12 65 ÷ 89 NmScrews M8 20 ÷ 28 NmScrews M10 42 ÷ 52 Nm

DIAGRAM SHOWING SCREWTIGHTENING TO FIX REAR GEARBOX

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

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

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

Any eventual imperfection shall be correct as soonas possible.

Avoid using material in excess to seal the joint. Toomuch sealing material would drop out on both sidesof the joint and obstruct lubricant passages.

Couplings must be assembled within 10 minutesafter completing the sealing operation.

Figure 43

Installation of rear components

DIAGRAM SHOWING SEALING LOCTITE 5205APPLICATION WITHIN GEARBOX AREAS

- Accurately clean the timing gearbox (1) and the engineblock.

75712

!

75711

Figure 44

Figure 45

70211

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

Screw up two pins to facilitate operation of enginedrive shaft rotation.

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

1

1

2

34

5

6

7

8

9 10

1

NOTE

NOTE


x



Figure 46

90506

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

Figure 47

90507

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

Figure 48

75708

DIAGRAM SHOWING SEALING LOCTITE 5205APPLICATION.

1

Figure 49

90508

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





Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It mustbe uniform(no crumbs), withno air blisters,thinner or irregular zones.


Avoid using material in excess to seal thejoint. Toomuch sealing material would drop out on bothsides of the joint and obstruct lubricant passages.


Figure 50

75709

DIAGRAM SHOWING SCREWTIGHTENING TO FIX FLYWHEEL COVER BOX.

- Reassemble the box (1) to the engine block, tighten thefixing screws in the same position as found out duringdisassembly and fix the screws to the locking coupleslisted here below, following the order as shown in thepicture.

Screws M12 75 ÷ 95 Nm

Screws M10 44 ÷ 53 Nm

!Before assembly, always check that the threads of the ports and of the screws have no evidence of tear

and wear nor dirt.

1

2

34

5

6

78

9 10

11

12

13

14

1516

17

18

19

20

21

1

Figure 51

Figure 52

- Apply to engine drive shaft rear tang (6), the detail (5)

of the tool 380000666, fix it tightening the screws (4)and key the new holding ring on it (3).

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

1 2

0901t

75696

NOTE

- Check the contact surface (1) of the clutch plate and if it is scratched, proceed with turning.

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


x



DIAGRAM SHOWING SEALING LOCTITE 5205APPLICATION

87656


Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It mustbe uniform (no crumbs), with no air blisters,thinner or irregular zones.


Avoid using material in excess to seal the joint. Toomuch sealing material would drop out on bothsides of the joint and obstruct lubricant passages.


- Re-assemble the box (1) to the engine basement.

- Tighten the fastening screws (2) to the same positiondetected before disassembly.

87659

- Apply to the rear tongs hold (3)of the engine drive shaft the part (6) of the tool 380000664, fix it with the screws(1) and spline the new tight ring to it (2).

- Place the part (5) on the part (6), tighten the nut (4)until tight ring assembly (2) into the flywheel box iscompleted.


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

87657

87658

Figure 58

Figure 59

Figure 60

Figure 61

NOTE

NOTE


x



Figure 62

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

- Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling .

- Usinga hoist, handle the flywheel to place it in its housinginside the flywheel cover box.

- Screw up to pins (2) having appropriate length, in theshaft ports (3) and using them as guide, assemble theengine flywheel (1) properly placing it inside the flywheel

cover box.

75690

Figure 63

75692

1

2

3

4

2

1

3

4

Figure 64

α

Tighten the engine flywheel (1) fixing screws (2) in twophases:- 1st phase; tightening by means of dynamometric wrench

to couple 30 ± 4 Nm;- 2nd phase, 60º± 5º angle dwell with tool 380000304.

Before assembly, always check that the threads of

the ports and of the screws have no evidence of tear and wear nor dirt.

1

2

75695

70220

- Assemble oil pump (1).

- Tighten fixing screws (2) and lock them to the prescribed

couple.

Figure 65

Figure 66

70221

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

CNH

PARTS

- Assemble the water pump (1).

- Tighten the screws (2) and lock them to the prescribedcouple.

Figure 67

76112

Flywheel installation Installation of front components

NOTE




Figure 68

- Assemble the plate (3), the suction rose (5) and tighten

the fixing screws (1, 2 and 4) to the prescribed torque.

Figure 69

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

- Place the detail (2) on the detail (4), screw-up the

threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover.

CNH

PARTS

00902t

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

Figure 70

Figure 71

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

86601

75710

Figure 72

87260

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

Figure 73

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

106549

106550


x



Figure 74

Figure 75

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

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

86578

Assembly of additional masses

Timing of additional massesVersion with reduced distribution

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

86614

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




Figure 76

75814

CNH

PARTS

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


75697

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

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

Figure 77

- Provide for new gasket replacement (1) of theoil pan(2).

The pictures illustrating the pan and of the rose

pipe may not correspond to the ones of your model. However the procedures described areapplicable anyway.

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

88046

Before assembly, always check that the threads of

the ports and of the screws have no evidence of tear and wear nor dirt.

Figure 78

Figure 79

1 2

3

NOTE

NOTE NOTE


x



Figure 80

Figure 81

76114

75686

- Connect the alternator (1) to the support.

- Tighten the screw without locking it (2).

Figure 82


Figure 83

- Place the gasket (1) over the block.

The choice of the gasket’s thickness shall be made inconsideration of the cylinder protrusion measured withrespect to the block’s upper surface.

Verify that the engine block stand is clean.

Do not grease the gasket. It is recommended tokeep the gasket inside packaging until assembly to the cylinder head.

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

76113

1 2

87759

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

- Manually start the oil filter (3) on the bearing union (1)until counter-boring, further screw up the oil filter (3) by 3/4 turn.

- Place a new fixing ring on the block housing (6).

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

CNH

PARTS

- Assemble the alternator bearing (1) ensuring that thepins (3 and 4) are against the engine block.

- Tighten the screws (2) and lock them to the prescribed

couple.

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

NOTE

NOTE

NOTE




Figure 84

Figure 85

75688

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

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

76115

Figure 86

- Carry out the assembly of the rocker arms after previouscheck of the components.

ROCKER ARM UNIT COMPONENTS:1. Elastic ring - 2. Spacer- 3. Rocker arms-

4. Support.

Figure 87

75702

SHAFT AND ROCKER ARM BASIC DATA

Check the couplingsurfaces of bearing and shaft: no evidenceof excessive wear shall be detected or damages.Replace if necessary.

CNH

PARTS

Figure 88

ROCKER ARM ADJUSTMENT SCREW

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

couple.

- Lubricate cylinder head bolts and install to head.

- Bolts must be torqued using stitching pattern startingwith the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then90 degrees rotation for all bolts. Then a further 90degrees for the M12 x 140 and M12 x 180.

M12 x 70 50 Nm + 90 deg’sM12 x 140 40 Nm + 180 deg’sM12 x 180 70 Nm + 180 deg’s

1

2

3

4 5

6

7 8

9

10 11

12

13 14

α

1

2

3

4 75705

1

2

3

4

1

2

3

75704

18.97518.963

19.00019.026

19.00019.026

1

19.0016.00

NOTE


x



Figure 89

Figure 90

32655

Before executing assembly, check the Rocker Arm drivingrods: these shall not be deformed; the spherical ends incontact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear:in case of detection proceed replacing them.

The rods driving the suction and exhaust valves are identicaland therefore interchangeable.

75703

- Insert the tappet driving rods and the Rocker Arm unit.Before using the fixing screws again, measure themtwiceas indicated in the picture, checking D1 and D2diameters:if D1 - D2 < 0,1 mm the screw can be utilised again;if D1 - D2 > 0,1 mm the screw must be replaced;

Figure 91

75683

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

Figure 92

75806

CNH

PARTS

Adjust the slack between rockerarms and valves using socketwrench (1), point wrench (3) and feeler gauge (2).

Correct slack is:- suction valves 0.25 0.05 mm- exhaust valves 0.50 0.05 mm.

1

2

D1D2

2 1

3

On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use thevalve clearance adjustment procedure thatrequires adjusting the clearance of all the valves by positioning the crankshaft 2 times only.Each cylinder must be checked by taking it to theT.D.C. (top dead centre) at the endof compression

and adjusting the clearance of both valves on thecylinder in question.

NOTE




75685

Figure 93

Figure 94

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

Figure 95

75808

- Assemble thermostat unit (2) including thermostat (5)and gasket (4).

- Tighten the screws to the prescribed couple.

Figure 96

- Assemble injectors after having replaced the sealinggasket (1).

75707

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

Disassemble the bracket and reassemblecomponents from 1 to 5 as shown in the picture.

The gasket must be new.

CNH

PARTS

CNH

PARTS

CNH

PARTS

1

- Assemble cylindercovers (2) with the respectivegaskets;

- Fit the seal nods and tighten the screws fixing them to the prescribed couple.

During assembly of injectors, verify that theinjector sphere is correctly positioned on the head housing.

Always replace the gaskets using new ones.

Check the threads of the fixing screws: there shallbe no evidence of wear or dirt deposit.

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

CNH

PARTS1

2

1

2

3

4

5

The illustration of exhaust manifold may be notmatching your model. Anyhow, describedprocedure is applicable.

NOTE

87406

NOTE

NOTE

NOTE


x



Figure 97

Figure 98

88090

If the old belt is to be reassembled examine itcarefully in order to see if there may be incisions or

evident signs of yielding.

75687

CNH

PARTS

1

3

2

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

- Assemble the alternator tensioning bracket.

- Mount pulley (3) and secure it to support throughscrews (2).

- Assemble the transmission pulley (1).

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

- Tighten the control belt turning the alternator asillustrated.

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

NOTE


For applications with automatic belt tensioner

Figure 99

86571

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




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

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

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

75701

3

4

5

6

71

2

Figure 100

For the versions provided with heater, alsoassemble components (3) and (4).

CNH

PARTS

NOTE - Assemble the brackets (1) fixing the fuel pipelines to the

injectors: use the same screws (2) fixing the manifoldplate as shown in the picture.

Figure 101

CNH

PARTS

75700

1

2

88102

- Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple.

- Also assemble feed pump (see specific procedure) and the power take-off underneath.

Pump mounting requires specific procedurecontained in this section.

Figure 102

NOTE

88102


x



Figure 103

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

screw (on suction collector plate).

75680

7

6 5

1

2

3

4

BOSCH VE 4/12 F pump

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

Figure 104

75679

1 1

2

Figure 105

75677

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

1




70126

Figure 106

To connect fuel pipelines (3 and 4, Figure 108) inlow pressure from the relating connection unionsit is necessary to press the locking fastener (1) asshown in picture B.

After having connected the pipeline, reset thefastener (1) into block position as shown in picture

A.

NOTE

Figure 107

Proceed assembling the turbocharger:

- Hold the turbocharger and place it on the exhaustmanifold after having interposed the gasket.

- Screw up the fixing nuts of the turbocharger to theexhaust manifold tightening them to the prescribedcouple.

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

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

- Using rocker arm 380000301 hold the engine andloosen the screws fixing the brackets to the turningstand380000301.

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

75675

1

Figure 108

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

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

feed pump.

- Using 99360076 equipment assemble fuel filter (1).

90502

The filter shall be priory filled with fuel to facilitatefeed system bleed operations.

NOTE


x



1

2

3

4

1

5

75670

Figure 109

On the right hand side:

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

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

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

to the block; finally tighten the union (5) to the block.

Figure 110

75671

Completion of the engine

3 1

2

Figure 111

75717

Figure 112

75673

On the left hand side:

- Assemble oil filter (1) together with bracket (for theversions with engine oil filter not directly assembled to the exchanger); tighten the screws (3) assembling thebracket (4) including filter bearing (5).Using tool 99360076 screw up oil filter;

- Assemble oil level rod together with guide pipe (2).Fill upengine oil.

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

2

1

5

4

3

NOTE

- re-assemble the starting engine (1); opportunely support the starting engine (1) and tighten the two fasteningscrews to the prescribed torque.




Figure 113

Rotary feed pump disassembly and assemblyprocedure

This procedure prescribes that:

- the fuel pipes (from the pumping elements to the injectors, recovering blow-by from theinjectors to the pump and the supply from thepriming pump) have all been removed;

- the electrical connections have beendisconnected.

- Accelerator cable shall be disconnected.

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

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

The following procedure analyses this second hypothesis

since it is the more complex.

Disassemble the starter from the flywheel box and use tool380002385 to rotate the flywheel.

75714

Figure 114

Engine versions with tool (380002385)

Engine versions with tool (380000988)

88140

1

1

2

Disassemble the starter from the flywheel box (1) and use

tool 380000988 (2) to rotate the flywheel.

Figure 115

88141

Find the top dead centre with the tool (380000977) - Falseinjector

1

Remove the rocker covers of the 1st cylinder; remove the 1st

injector and place the tool (1) to set the 1st cylinder top deadcentre position (end-of-compression phase). Pre-load the

gauge.The searched condition is obtained by rotating the engineshaft properly until you find the maximum value on thecomparator and then checking that the intake and exhaustvalves are both closed.Once PMS has been obtained, lock the flywheel by means of tool 380000988 (Figure 114).

Figure 116

84071

Searching for the top dead centre with timing gear blockingpin

Turn the flywheel until, when pushing the pin 380002729 (1),

it blocks the gear (2) obtaining the TDC of the 1 ° cylinder.

NOTE


x



Figure 117

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

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

- From timing side, remove the cover (2) loosening thescrews (1) in order to have access to the union fixingnut(3) to the pump driving gear.

- Loosen the fixing nut (3) and remove the relatingwasher.

Figure 118

Figure 119

75693

75694

- From the pump side, loosen the fixing nuts (1) withoutremoving them in order to enable moving the pumpbackwards using 380000322 extractor.

- Assemble the 380000322 extractor throughout the two

threaded ports (4, Figure 118) and withdraw the gear from the pump shaft.

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

- Withdraw the pump from the studs, together with thegasket.

When the supply pump is to be assembled on the engine theP.M.S. conditions at compression end stage cylinder No. 1must be carried out.

Hold the pump driving gear to avoid interferenceor crawling during timing gear rotation.

75721

2 1

1

1

2 3

4

BOSCH VE 4/12 F Pump

NOTE




75694

Figure 120

- Assemble the pump pre-set in its housing on the engine,fitting the shaft into the gear port (not provided withwrench).

- Tighten the fixing nuts (1) locking the pump flange in theslot centre.

- On the timing side, throughout the specially appointedport, fit the washerand screw up the fixing nut (3) to thepump shaft. Lock the nut to the 90-95 Nm couple.

Figure 121

Figure 122

75693

- Loosen screw (1) that prevents pump shaft rotation andinsert spacer (2). Tighten screw (1)so that it locks spacer (2): in this way the supply pump shaft will be able torotate freely.

- Assemble the cover (2, Figure 121) including gasket and tighten the screws (1, Figure 121).

- Disassemble the flywheel rotation/locking tool380000388 or 380002385; arrange the starting motor inits seat.

- Connect all pipelines (from pumping elements toinjectors, bleeding recovery pipes from injectors topump, LDA pipeline and feed provided by primingpump).

- Connect electrical connections to electro-magnets on the hydraulic head and on KSB.

The gasket removed during pump disassembly shallnot be utilised again.Always use original spare parts.

CNH

PARTS

If the pump has been removed with the enginemounted, connect the accelerator cable, if presentin the application.

1

1

2 3

4

1 2

75721

Figure 123

- With the injection pump inserted in relating seat andsecuring screws loosened, mount comparator 380000228 (2) and 380000229 gauge tool (1),preloading the rod by 2.5 mm.

- Rotate theenginederive shaft to shift from theconditionof the first cylinder to TDC end of compression phase.Reset the dial gauges and rotate the engine drive shaftinto the opposite direction until recovering thecondition of the 1st cylinder to TDC in phase of compression (see Figure 116).From this position on the comparator applied on thepump it must be possible to read the value listed on thepumping element pre-lift table. Section 4.

- Rotate the pump in anti-clockwise direction if the strokeis shorter or in clockwise direction if the stroke is longer,

until obtaining the stroke prescribed.- Checking these conditions, lock the pump by tightening the relevant nuts to the prescribed pair.

Ignition pump control and timing

87720

(Demonstration)

NOTE

NOTE


x



Power take-off disassembly and assemblyprocedure

75720

1

2

34

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

Disassembly of such mechanism shall be executed asfollowing:

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

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

- Vary out the assembly fitting the power take-off in itshousing, providing new gasket and checking the sprocketgear meshing.

- Assemble cover and gasket and tighten the screws to theprescribed couple.

Figure 124

Figure 125

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

- Continue the operation until when fuel outflows.

- Connect the (1) to the filter.

87751

Feed system bleed procedure

Version with A type fuel filter Figure 126

In case any operation has been executed on the componentsof the feed circuit, it is necessary to execute bleeding of air within the system.

- Loosen the bleeder vent screw (3) on the fuel filter (1)and keep working on the bleed lever of the primingpump (2).

- Continue executing this operation until when fuel drainsfrom the bleeder vent screw.

- Tighten the bleeder vent screw (3).

76211

Version with B type fuel filter




Checks and inspections

The following tests shall be made after engineassembly to the vehicle.Preventively check that the liquid levels have beencorrectly restored.

- There is no water bleeding from the manifoldsconnecting engine cooling circuit pipelines and cabininternal heating, eventually providing to further tighten the locking rings.

- Carefully check the fuel connection pipes to therespective unions.

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

- There is no fuel leakage from fuel pipelines.

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

- Verify correct working of the lighting leds of thedashboard containing the tools as well as of theequipment that was disconnected during engine

disconnection.- Check and blow by with care the engine cooling system,

carrying out frequent drainage.

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

NOTE


x



PART ONE -

MECHANIC OVERHAUL OF ENGINES WITH ELECTRONIC CONTROL(COMMON RAIL)





x



Figure 127

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

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

It anyway has enough volume as to minimise system spikes

and the use of plenum chambers caused by injectorsopenings and closings and by the high-pressure pumpoperation. This function is further enabled by a calibratedhole being set downstream of the high-pressure pump.

A fuel pressure sensor (4) is screwed to the rail. The signalsent by this sensor to the electronic control unit is afeed-back information, depending on which the rail pressurevalue is checked and, if necessary, corrected.

RAIL

108609

RELIEF VALVEMounted on the end of the rail, it has the function of protecting the system’s components in case the failure of therail pressure sensor or the pressure regulator of pump CP3causes an excessive pressure increase in the high-pressureplant.

When the rail pressure reaches 1800 bars, the valve initially intervenes in order to allow thefuel to flow and subsequently to reduce the pressure within safety limits and then it

mechanically regulates the rail pressure to approx. 800 bars.This valve allows the engine to work for long periods at alimited efficiency and avoids the excessive overheating of thefuel preserving the return pipes to the tank.

15

70505

Figure 128

The injector is similar as construction to the traditional ones,apart from the absence of plunger return springs.The injector can be deemed as composed of two parts:- actuator — spray nozzle composed of pressure rod (1),

plunger (2) and nozzle (3);- control solenoid valve composed of coil (4) and pilot

valve (5).The solenoid valve controls spray nozzle plunger lift.

Injector in rest position

1. Pressure rod — 2. Plunger — 3. Nozzle — 4. Coil — 5. Pilotvalve — 6. Ball shutter — 7. Control area — 8. Pressurechamber — 9. Control volume — 10. Control duct —

11. Supply duct — 12. Control fuel outlet — 13. Electricconnection — 14. Spring — 15. High-pressure fuel inlet.

ELECTRO-INJECTOR

As for NEF TIER 3 engines, BOSCH - CRIN2electro-injectors with different injection tubes are usedworking on power developed by the engine.


Jet Powers

kWPressures

bar

DLLA Up to 152 250 ÷

1600DSLA Lower to 152 250 ÷ 1400



70506

Figure 129

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

Injection end

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

Injection start

The injector cannot be overhauled and thereforeit must not be disassembled.

15

NOTE

PRESSURE LIMITER FOR FUEL RETURNIt is housed on the rear cylinder head part, and adjusts thepressure of fuel returning from injectors at a pressureincluded between 1.3 and 2 bars. By guaranteeing thispressure to the return fuel, the fuel vapours formation insideinjectors is avoided, optimising fuel spraying and combustion.

70507

Figure 130

A To tank — B From injectors


x



Figure 1

GENERAL SPECIFICATIONSSection pictures of complete engine - common railversion

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

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

The section herein described is composed or four sections:

- Section of mechanical overhaul prescribed inaccordance to the engine’s specific duty, illustrating allnecessary operation to remove and assembly theexternal components of the engine, including cylinder heads, gearbox of the timing system and of the front partcover;

- Electrical section, describing the connections to thedifferent components of the engine control module andof the sensors assembled to the engine;

- Diagnosis section;

- Section of preventive maintenance operations,providinginstructions for the execution of the main operations.

Data, features and performances are valid only if the setter fully complies with all the installationprescriptions provided by Iveco Motors.

Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on whichthe engine hasbeen designed.

116362

NOTE




The following information relates to the engine overhauloperations only for what concerns the different componentscustomising the engine, according to its specific duties.

In section 4, ”General overhaul”, all the operations of engineblock overhaul have been contemplated. Therefore theabove mentionedsection is to be consideredas following thepart hereby described.

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

In order to apply thebrackets380000661to theengineblock to fix it on to the stand for the overhaul, it is necessary toperform the following operations on the left hand side of theengine:

- Using the tool 380000670 disassembly the fuel filter (6)and remove it from the support (1);

- Disconnect the electrical connection (2) from thesupport (1) and the heater’s one (placed on the filter support as well);

- Disconnect the fuel low pressure pipelines (3-4-5) from the support (1);

- Disconnect pipeline (9) from the support (1);

- Remove the sustaining support bracket (1) from theblock.

Figure 2

70126

Figure 3

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

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

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

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

Because of the high pressure in the pipelinesrunningfromthe high pressure pumpto the rail andfrom this last one to the electro-injectors, it isabsolutely required NOT to:

- disconnect the pipelines when the engine isworking;

- re-use the disassembled pipelines.

Engine setting operations for the assembly onturning stand

ENGINE OVERHAUL

Preface

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

NOTE

NOTE

NOTE

116364


x



On the right side of the engine

Figure 4

Disconnect the oil filling pipe (1).

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

Figure 5

Disconnect the lubricating pipe (2) from the upper side of theheat exchanger on the turbo blower (1).

Undo the fastening screws (4) and remove the support (3).

Disassemble the thermostat body including the seal.

Figure 6

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

116365

116366

116367

Collect and dispose of the engine oil according toenforced regulations.




Figure 7

Disassembly of application components

1. Connections for Electro-injectors - 2. Engine cooling liquid temperature’s sensor - 2. Cable of the fuel pressure sensor -4. Sensor of engine’s oil temperature and pressure - 5. Driving shaft sensor -

6. Electro-injector - 7. Temperature - air pressure sensor - 8. Timing system sensor - 9. Cable of fuel heater and fuel temperature’s sensor - 10. Cable of pressure regulating gauge - 11. EDC 7 electronic module.

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

Disassemble the engine from the engine block removing thefixing clamps.

116360


x



Figure 8

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

Disconnect from the rail (2): the fuel pipe (7) according toprocedures describedin figure (24). Disconnect fuel pipes (5)from rail (2) and injector manifolds (6).

Figure 9

Figure 10

Disconnect the fuel return pressure limiter (1), the pipelineby acting on the connections as described on Figure 6.

Remove the external vent pipe (2).

Loosen the nuts (3) and disconnect the tappet cap (4).

Figure 11

116368

116369

Now disassemble the supercharger:

Unscrew fixing nuts (3) of the turbo-blower (4) on exhaustmanifold (4).

Hold up turbo-blower (4) and get the seal.

Undo the fastening screws (1) and detach the exhaust mani-fold (2).

On theopposite side, loosen the fixing screws (2) of the inletmanifold (1) and disassemble the joint to the air heater for the cold start.

Remove the pressure-air temperature sensor from theinduction manifold (1).

116370

116371




Figure 12

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

Figure 13

Figure 14

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

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

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

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

Figure 15

70132

Loosen tappet adjustment fastening nuts (1)and unscrew theadjusters.Remove the screws (2), remove the rocker assembly (3),consisting of: bracket (6), rockers (4), shafts (5) and remove

jumpers (7) from valves.Remove rods (8).

116378

70133

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

116372

NOTE


x



Figure 16

Figure 17

Figure 18

Figure 19

116373

116374

Remove the fastening screws (1) from the cylinder head (2).

The highlighted screws are shorter.NOTE

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

116377

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

Unscrew the fixing screws (1) and disassemble the pipelineunion (2).

88555




Figure 20

Figure 21

88557

88556

Disconnect connector (1) from the oil temperature pressuresensor.

Unscrew screws (2) and disconnect oil temperature pressuresensor (3).

Unscrew screws(4) and disconnect oil filter support (5) from the base, and remove the relevant seals.

Remove the heat exchanger from its seat.

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

Figure 22

Figure 23

88558

Apply the tool (1) to stop flywheel rotation (2) through the

hole (3) made on the base. Tool (1) positioned in hole (3)is to be inserted in the groove made on the flywheel blockingits rotation.

Loosen the engine shaft flywheel fixing screws.

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

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

116376


x



Figure 24

Figure 25

Remove the ring sealing the engine’s driving shaft from thefront cover. Use the tool 380000665 (4) to operate on the

front bar hold of the driving shaft. Through the steering holesof the tool, perforate the inside holding ring (1) with a straightway drill (diam. 3,5mm) for the depth of 5mm. Fix the tool to the ring tightening the 6 screws provided with theequipment. Then proceed removing the ring (2) by tightening the screw (3).

00900t

Figure 26

00904t

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

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

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

88560

1

2

NOTE

Figure 27

88561

Remove two opposite screws (1) from the area where thewithdrawal pins will be introduced (2, Figure 28).

Loosen the remaining flywheel fixing screws (3) from the

driving shaft (2).Remove the flywheel locking tool (4).




Figure 28

Figure 29

Tighten two screws of medium length into the holes (4) tosling the flywheel with the hoist.

Throughout the two guide pins (2) previously screw into thedriving shaft holes (3) withdraw the engine flywheel (1) after slinging it with the hoist.

00903t

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

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

cover.

88562

Figure 30

88307

Turn the engine upside down.

Remove screws (2) and disconnect oil sump (1).Disconnect the high pressure pump stroke sensor.

Unscrew the screws(3) and remove timing gear distributionbox (4) from the base.

Figure 31

88564


x



Figure 32

Assembly of application components

70211

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

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

Figure 33

NOTE

116375

Turn the engine shaft and the distribution shaft so that, by mounting thebevel gear on thelatter, thetooth with thegear groove of the engine shaft coincides between the two markscreated on the bevel gear (1).

Perfect seal is only obtained by cleaning accurately the surface to seal.

Smear the case with LOCTITE 5205 to obtain abead (1) of few mm diameter.

It shall be uniform (no clots), without air bubbles,

thin areas or discontinuities.

Any imperfection shall be corrected as soon aspossible.

Avoid to use excess material to seal the joint.

Excessive sealant could come out from joint sidesand cause lubricant passage clogging.

After applying the sealant, the joint shall beassembled immediately (10 — 20 minutes).

Figure 34

88567

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

Figure 35

70214

LOCTITE 5205 SEALANT APPLICATION AREAS

Clean accurately the timing gear case and the engine block.

NOTE




Figure 36

88569

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

GEARCASE FIXING SCREW TIGHTENING DIAGRAM

Reassemble box (1) on the engine.

Tighten fixing screws (2) on the same position from where

they had been removed up to the tightening torque indicatedbelow.Screws M8 20 ÷ 28 NmScrews M10 42 ÷ 52 Nm

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

Figure 37

88570

Apply tool 380000664 part (6) to the rear output shaft tang(5), secure it by screws (4) and fit the new sealing ring (3).

Position part (1) on part (5), screw nut (2) until completingsealing ring (3) fitting into housing.

NOTE

Figure 38

Figure 39

Figure 40

88571

Put a new seal ring on the water pump.

Assemble water pump (1); tighten the screws (2) up to theprescribed torque.

88572

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

88573

Accurately clean the contact surface on the engine block andposition seal (1) on the base.


x



Figure 41

Figure 42

88574

Assemble oil pump (1) on the block and tighten the screwsup to the prescribed torque.

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

CNH

PARTS

88575

Figure 43

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

116376

Figure 44

88307

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

Figure 45


Check the contact surface (1) of the clutch plate and if it isscratched, proceed with turning.

Check ring gear teeth (2), if breakage or excessive wear isfound remove the ring gear from the engine flywheel (1)using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ringgear inside diameter shall be facing the engine flywheel.

88581

NOTE




Figure 46

88582

Figure 47

Figure 48

Screw two manoeuvring hooks or lunettes on flywheel (1)using holes (4). With the help of a hoist bring the flywheel closer to its seatinside the flywheel housing box.Screw two pins (2) with proper length for shaft holes (3) anduse them as guides, assemble engine flywheel (1) by arrang-

ing it properly in the flywheel housing box.

88583

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

α

88584

Tightening to angle is performed using tool380000304. Before any assembly operation alwaysverify that the hole and screw threads have no

evidence of wear or dirt.

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

NOTE

Figure 49

Figure 50

88586

80359

CNH

PARTS

Fit on the engine block: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter support (4).

Tighten the screws (5) to the specified torque.


CNH

PARTS

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

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

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

Tighten the screws (5) to the specified torque.

Fit a new sealing ring (6) in the engine block seat.

NOTE


x



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

and 5).Re-assemble the belt tightener (2).

Figure 51

Figure 52

88587

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


NOTE

116378

CNH

PARTS

Apply a new gasket to the engine block and then place the

cylinder head (2) slung by the hanger brackets (1).

116374

Figure 53

88590

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

Figure 54




Figure 55

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

The angle tightening is carried out through tool380000304 (3).

α

70336

Tightening order layout for cylinder head fastening screws:

- 1st step pre-tightening with dynamometric wrench:• Screw 12x1.75x130 ( ) 35± 5 NmA • Screw 12x1.75 x 150 ( ) 55± 5 Nm

- 2nd step tightening with a 90° ± 5° angle

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

A = Front side

70476

α

Figure 56

A6-cylinder engine

NOTE

Figure 57

70338

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

CNH

PARTS

70339

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

Figure 58

70133

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

Screw injector fastening screws without tightening them.

Figure 59

75703

D1D2

NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 andD2 diameters:if D1- D2< 0,1 mmthescrewcanbe utilisedagain;if D1 - D2 > 0,1 mm the screw must be replaced.


x



Figure 65

Figure 66

Figure 67

70345

Fit the rods (2).

Position jumpers (1) on valves with marks (→) facing theexhaust manifold.

70346

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

70520

Adjust clearance between rockers and valves using setscrewwrench (1), box wrench (3) and feeler gauge (2).

Clearance shall be as follows:- intake valves 0.25 ± 0.05 mm- exhaust valves 0.50 ± 0.05 mm.

On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use thevalve clearance adjustment procedure thatrequires adjusting the clearance of all the valves by positioning the crankshaft 2 times only.Each cylinder must be checked by taking it to theT.D.C. (top dead centre) at the endof compressionand adjusting the clearance of both valves on thecylinder in question.

NOTE


x



Figure 68

Apply to the coupling surface of the intake manifold (1)equipped with heater a sufficient coat of LOCTITE 5999 andprovide tightening the screws (2) to the prescribed matching

couple.Fit temperature and air pressure sensor.

70352

Figure 69

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

CNH

PARTS

Figure 70

Fit the wiring support (2) and tighten the screws (1) to thespecified torque.


NOTE

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

Figure 71

Fit a new gasket (2) on the tappet cover (1).

Place the tappet cover on, install the bolts in the correctposition and tighten.

CNH

PARTS

70355

116371116379




Figure 72

Connect the oil discharge pipe (2) to the turbo-compressor junction (1) and to the support of the oil filter heat

exchanger.Assemble the support (3) and fasten with the screws (4).

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

Sling the turbocharger (4) and placeit over the manifold after

having first inserted a new gasket, tighten the fastening screws(3) to the specified torque.

CNH

PARTS

Assemble the rail (2) and fasten the fixing screws (1) to theprescribed torque.

Connect new fuel pipes (6) to the rail (2) and to themanifoldfor electro-injectors (5).

Figure 73

116380

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

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

NOTE

70126

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

Check proper fuel pipe connection.

Figure 74

NOTE

CNH

PARTS

116370

Figure 75

116366


x



Figure 76

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

Figure 77

Assemble thebracket and thesupport (1) of thefuel filter (6).

Proceed connecting in sequence the pipelines (9,3,4 and 5)of the support (1) to the high pressure pump (8).

Connect the pipeline (7) from the high pressure pump to therail diffuser.

Figure 78

70126

All the fuel pipelines are fixed using the clamps shown in thepicture.

For the connection of the pipes, press the clamp (I) following the arrow’s direction (Figure B) and connect the pipe to theclamp on the high pressure pump or on the support of thefuel filter.

Reset the clamp in the initial locking ”A” position.

In case the pipes are re-employed, they must keep the sealing tops at the edges.Make sure that the fuel pipeline is correctly connected.

Reconnect the engine harness to all the sensors, the engine

control module and the rail diffuser.

Figure 79

Assemble oil filling pipe (1).

Screw fixing screws and assemble starting motor (2) in place.

Completion of the engineProperly handle the engine holding it by a lifter, remove itfrom the rotating shaft, remove the brackets 380000661 andplace it on proper suitable support to carry out thecompletion.

116381

116365

116364

NOTE





x



PART TWO -

ELECTRICAL EQUIPMENT - MECHANICALS ENGINES





x



Figure 80

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

1. Cooling liquid temperature sensor;

2. Starter;

3. KSB Water temperature sensor;

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

5. Oil pressure sensor;

6. Resistance for cold start up (where provided for);

7. Alternator;

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

116392

A

B




Cooling liquid temperature sensor

It is a component integrating a temperature sensor.

It is assembledto the engine head close to the thermostat unitand its duty is to detect engine cooling liquid temperature.

Specifications:

Range of working temperatures:

Connection side -40 ÷ +150 ºC for < 10 min.

Bulb side on engine: -40 ÷ +140 ºC

Working tensions: 6 ÷ 28 V

Settings:

80 ºC 0.304 ÷ 0.342 k Ω

20 ºC 2.262 ÷ 2.760 k Ω

-10 ºC 8.244 ÷ 10.661 k Ω

Starter

Starter is usually driven by starting unit placed on the vehicledashboard and provides positive tension to the tele-switch as-

sembled to the starter itself.

Specifications:

BOSCH 3 kW - 12V

Figure 81 Figure 82

75717

KSB Water temperature sensor

It is assembled to the cylinder head on the engine left hand si-de.

Specifications:

Working tensions:12 ÷ 24 V

Electrical Power load: 2.5 A (induction)5.0 A (resistance)

Setting: 63±3 ºC Contact openingupon increasing temperature53±3 ºC Contact closureupon decreasing temperature

Figure 8375718

B

C

A

A B

C

1

75719


x



Figure 84

Oil pressure switch

Figure 85

Electromagnets assembled to feed pump

75724a

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

75722

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

Specifications:

Working tensions: 12 ÷ 24 V

Contact closureupon lower pressure: 0.2 bar

Contact openingupon higher pressure: 0.9 bar

2

1

Alternator

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

Specifications:

Working tension: 12 V

Current delivered: 90A (at 6000 rpm)

Absorption in stand-by: ≤ 1mA

Sense of rotation: clockwices

75725

Figure 86

Pre-post heating resistor

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

It is fedby a tele-switch usually placed very close to the engine.

Specifications:

Working tension: 12 VMaximum possibleair flow: 2 cc / min

(pressure 138 kPa)

Figure 87

75723





x



PART TWO -

ELECTRICAL EQUIPMENT - ELECTRONICS ENGINES





x



Figure 88

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

Through the engine control module it is possible to verify thecorrect working of the engine. (See part three of the hereby

user’s guide specifically dedicated to diagnostic).

The electrical and electronic components of the engine arelisted here following:

1. Temperature sensor of cooling liquid;

2. Electro-injector;

3. Starter;

4. Pressure sensor assembled to rail diffuser;

5. Temperature and air pressure sensor;

6. Timing system sensor;

7. Fuel temperature sensor;

8. EDC7 electronic module (not positioned on engine);

9. Driving shaft sensor;

10. Sensor of engine’s oil temperature and pressure;

11. Pre-post heating resistor.

LOCATION OF MAIN ELECTRICAL COMPONENTS

116382




Figure 89

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

01525t

EDC7 ECU


x



Connector to injectors (A)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

-

-

MN

MV

VB

HR

-

-

MB

VN

VG

HN

HG

CN

CB

CL

-

-

Injector cylinder 2 (**)

Injector cylinder 3 (**) / Injector cylinder 4 (*)



Earth

Injector cylinder

Injector cylinder 1 (*) / (**)




Injector cylinder 1 (*) / (**)




Figure 90

12 16

116

1 5 50350

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

C ORANGEA SKY BLUEB WHITEL BLUEG YELLOWH GREYM BROWNN BLACK

W LIGHT BROWNS PINK R REDV GREENZ PURPLE

PIN ECU CABLE COLOUR FUNCTION




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

PIN ECU CABLE COLOUR FUNCTION

1

2

3

4

78

9

12/13

14/15

16

19

20

27

28

31

32

36

37

39

44

45

46

49

50

52

53

55

62

63

64

72

73

78

81

83

87

8150

0087

0000

8885/0159

81507777

0000

8150

0000

0094

0150

8153

0156

5535

2298

-

8837

8888

8051

9905

9906

5553

5584

0158

6109

6108

5158

0160

5503

0535

0159

0159

8162

0157

5157

-

Figure 91

Negative for switch of fuel filter heater/starter

Earth

Positive for pre-post heating resistor

Positive driven by battery

Positive for blink-code button/ oil low pressure led/ pre-heating led/Air conditioner switch (if available) / EDC

Earth

Positive driven by battery

Earth

Negative for post-heating resistor

Negative start-stop push buttons from eng./accelerator pressed

Positive from change over switch to key in starting phase (+50)

Positive from blink-code button

Positive for EDC diagnostic led

K Line for diagnosis connector, 30 poles (2 pin)

Negative for multi-switch couple-limiter

Positive for fuel filter heating switch

Positive for starter

Positive from key switch/ L line for diagnosis connector 30 poles (pin 11)

Negative from starter push button from engine

Negative from engine stop push button from engine

Negative for pre-heating led in on position

Diagnosis connector (pin 28)

Negative from accelerator push button pressed

CAN Line (whether equipped), diagnosis connector (pin 22)

CAN Line (whether equipped), diagnosis connector (pin 22)

Positive for sensor of foot accelerator pedal pos. / Earth multi-switch

Negative for clutch sensor

Negative for engine oil low pressure led

Negative for EDC diagnosis led

Positive from pressed accelerator push button / multi-switch signal

Positive redundant from pressed accelerator push button

Positive air conditioner device (whether equipped)

Negative sensor of foot accelerator pedal pos. / Earth multi-switch

Signal from sensor of foot accelerator pedal pos. / Signal multi-switch

Positive for couple multi-switch limiter

6547289

71

53

35

1

11

7

12 03210t

18 36 17


x



Temperature and air-pressure sensor

Sensor of engine’s oil temperature andpressure

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

It is assembled on the engine oil filter support.

It measures the temperature and the pressure of the engine’soil.

It is connected to the engine control module by 19C and 33C,9C and 35C.

19C Earth

33C NTC signal (temperature)

9C +5V feed

35C Signal (pressure)

Driving shaft sensor

Timing system sensor

Figure 93 Figure 94

23 1

50342

50319

23 1

50342

50320

88438

Figure 95

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

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

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

21C Earth

29C NTC signal (temperature)

10C +5V feed

28C Signal (pressure)

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

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

It is connected to the engine control module by pin 25C(signal) and 24C (signal). The third pin is for screening.

The resistance value of the sensor is of about 900 Ω .

It is an inductive type sensor and it is placed on the back leftpart of the engine.

It generates some signals originated by the magnetic flow lines that close up through the ports drilled on the gear splined to the camshaft. The signal generated by this sensor is utilised by the electronic engine control module as signal of injectionphase.

Even being equal to the f lywheel sensor it is notinterchangeable since the external shape is different.

It is connected to the engine control module by pin 23C

(signal) and 30C (signal). The third pin is for screening.The resistance value of the sensor is of about 900 Ω .


x



Fuel pressure sensor

Figure 96

Resistor pre-post heating

Figure 97

Cooling liquid temperature sensor

It is a sensor with variable resistor, able to detect the coolingliquid temperature to provide to the engine control modulean index of the engine thermal status.

Usually, the same signal is driven by the engine controlmodule to the temperature device placed within the vehicle’sdashboard.

It is connected to the engine control module by pin 18C(Earth) and 36C (temperature signal).

The resistor to 20 ºC = 2,5 k Ω.

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

Fuel temperature sensor

1 - Fuel temperature sensor

Figure 98

88440

It is a sensor assembled to one end of the rail and measures the pressure of the fuel available in order to determine theinjection pressure.

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

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

It has 5 volt feeding.

It is a sensor with variable resistor, able to detect the fuel temperature to provide to the engine control module anindex of the fuel thermal status.

It is connected to the engine control module by pin 17C

(Earth) and 34C (temperature signal).The resistor to 20 ºC = 2,5 k Ω.

Itis a resistor placedon the suctioninlet manifold and isutilised

to heat the air during the heating pre-post operations.It is fedby a tele-switch usually placed very close to the engine.

116383

116384




Electro-injectorsThis is a N.A. type solenoid valvesThey are individually connected to the EDC gearcase on con-nector A.The resistance of each injector coil is 0.56 ÷ 0.57 Ω .

Starter

The starter is usually driven by the starting block assembled to the vehicle’s dashboard and provides positive voltage to pinB20 of the EDC.

Figure 99

1. Feeding relay of the starter

Figure 100

88314

PIN EDCREFERENCEREFERENCE

CONNECTOR 1

CONNECTOR 2

1

2

3

4

Injector cylinder 2

Injector cylinder 2

Injector cylinder 1

Injector cylinder 1

3 A

6 A

13 A

9 A

1

2

3

4

Injector cylinder 4

Injector cylinder 4

Injector cylinder 3

Injector cylinder 3

5 A

14 A

12 A

4 A

12

3

4

Injector cylinder 6

Injector cylinder 6

Injector cylinder 5

Injector cylinder 5

10 A

15 A

16 A

11 A

CONNECTOR 3

6 cylinder engines

50343

50349


x



PART THREE - TROUBLESHOOTING

(MECHANICALS ENGINES)





x




A N O M A L Y

P O S S I B L E C A U S E

( * ) = i f a v a i l a b l e i n t h e e q u i p m e n t

R E C O M M E N D E D

T E S T S O R

I N T E R V E N T I O N

N O T E

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

B a t t e r y

f l a t o r f a u l t y .

C h e c k a n d r e c h a r g e b a t t e r y . R e p l a c e b a t -

t e r y i f n e c e s s a r y .

C o n n e c t i o n s t o b a t t e r y t e r m i n a l s c o r -

r o d e d o

r l o o s e .

C l e a n , e x a m i n e a n d t i g h t e n t h e n u t s o n

t h e b a t t e r y t e r m i n a l s . R e p l a c e t h e c a b l e

t e r m i n a l s a n d t h e n u t s i f e x c e s s i v e l y c o r -

r o d e d .

I n c o r r e c t t i m i n g o f i n j e c t i o n p u m p .

C h e c k a n d c o r r e c t l y t i m e t h e i n j e c t i o n

p u

m p .

S e e y o u r C N H d e a l e r .

D e p o s i t s o r w a t e r i n t h e f u e l t a n k .

D i s c o n n e c t t h e h o s e s a n d c l e a n t h e m

u s i n g a j e t o f c o m p r e s s e d a i r .

D i s m a n t l e a n d c l e a n t h e i n j e c t i o n p u m p

.

R e

m o v e w a t e r f r o m t a n k a n d r e f u e l .

D r a i n f e e d s y s t e m .


R e

f u e l .

N o p o w

e r s u p p l y .

O v e r h a u l o r r e p l a c e t h e f u e l o r t r a n s f e r

p u

m p .

A i r b u b

b l e s i n t h e f u e l l i n e s o r i n j e c t i o n

p u m p .

C h e c k t h e h o s e s t o e n s u r e t h a t a i r i s i n

f a c t p r e s e n t a n d a l s o c h e c k t h e f u e l p u m p

.

E l i m i n a t e t h e a i r f r o m t h e i n j e c t i o n p u m p

b y

u n s c r e w i n g t h e c a p a n d w o r k i n g t h e

f u e l p u m p b y h a n d .

F a u l t y s t a r t e r m o t o r .

R e

p a i r o r r e p l a c e t h e s t a r t e r m o t o r .




x

A N O M A L Y




T E S T S O R


N O T E

T h e e n g i n e d o e s n o t s t a r t a t l o w t e m -

p e r a t u r e s

F u e l s y s

t e m c l o g g e d w i t h p a r a f f i n c r y s t a l s

f o r m i n g

d u e t o t h e u s e o f u n s u i t a b l e f u e l .

R e

p l a c e t h e f u e l w i t h f u e l s u i t a b l e f o r u s e

a t

l o w t e m p e r a t u r e s . R e p l a c e t h e f u e l f i l -

t e r s .

K . S . B . d e v i c e f o r c o l d s p a r k a d v a n c e c o n -

t r o l o p e r a t i n g i n c o r r e c t l y .

C h e c k o r r e p l a c e t h e i n j e c t i o n p u m p .


T h e e n g i n e c u t s o u t .

I d l e r p m

t o o l o w .

A d j u s t w i t h a d j u s t m e n t s c r e w .

I r r e g u l a r f l o w o f i n j e c t i o n p u m p .

A d j u s t f l o w .


I m p u r i t i e s o r w a t e r i n t h e f u e l l i n e s .

D i s c o n n e c t t h e h o s e s a n d c l e a n t h e m

u s i n g a j e t o f c o m p r e s s e d a i r . D i s m a n t l e

a n d c l e a n t h e i n j e c t i o n p u m p . R e m o v e

w a t e r f r o m f u e l t a n k a n d r e f u e l .


C l o g g e d f u e l f i l t e r .

D i s m a n t l e a n d r e p l a c e i f n e c e s s a r y .

P r e s e n c

e o f a i r i n t h e f u e l a n d i n j e c t i o n

s y s t e m .

C h e c k t h a t t h e h o s e s a r e n o t c r a c k e d o r

t h e u n i o n s l o o s e . R e p l a c e w o r n p a r t s , r e -

m o v e t h e a i r f r o m t h e h o s e s a n d d e a e r a t e

t h e i n j e c t i o n p u m p a n d f u e l f i l t e r b y u n -

s c r e w i n g t h e c a p s a n d w o r k i n g t h e p r i m e r

p u

m p b y h a n d .

B r o k e n

i n j e c t i o n p u m p c o n t r o l s .

R e

p l a c e t h e f a u l t y p a r t s .

A b n o r m

a l c l e a r a n c e b e t w e e n c a m s h a f t

c a m s a n d t a p p e t s .

A d j u s t c l e a r a n c e b y r e p l a c i n g s h i m s .

B u r n t , c

o r r o d e d o r c h a l k y v a l v e s .

R e

p l a c e t h e v a l v e s , r e c t i f y o r r e p l a c e t h e

c y l i n d e r h e a d s e a t i n g s .




A N O M A L Y




T E S T S O R


N O T E

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

F a u l t y w

a t e r p u m p .

C h e c k t h e u n i t a n d r e p l a c e i f n e c e s s a r y .

R e

p l a c e t h e g a s k e t .

M a l f u n c

t i o n i n g t h e r m o s t a t .

R e

p l a c e t h e t h e r m o s t a t .

F o u l i n g

i n c o o l a n t o p e n i n g s i n t h e c y l i n d e r

h e a d a n

d c y l i n d e r g r o u p s .

W

a s h f o l l o w i n g t h e s t a n d a r d s s p e c i f i e d

f o r t h e t y p e o f d e s c a l i n g p r o d u c t u s e d .

W a t e r p u m p d r i v e b e l t s l a c k .

C h e c k a n d a d j u s t t h e t i g h t n e s s o f t h e b e l t . O n a p p l i c a t i o n s p r o v i d e d w i t h a u t o

m a t i c

t e n s i o n e r , c h e c k c o r r e t w o r c h i n g o

f s u c h

d e v i c e .

C o o l a n t l e v e l t o o l o w .

T o

p - u p r a d i a t o r w i t h c o o l a n t .

I n c o r r e c t e n g i n e t i m i n g .

C h e c k t i m i n g a n d t u n e c o r r e c t l y .

I n c o r r e c t c a l i b r a t i o n o f i n j e c t i o n p u m p . C o r r e c t t h e d e l i v e r y r a t e o f t h e p u m p o n

a b e n c h s o t h a t t h e i n j e c t i o n i s a t t h e

s p e c i f i e d r a t e .


D r y a i r

c l e a n e r b l o c k e d .

C l e a n t h e a i r f i l t e r o r r e p l a c e i f n e c e s s a r y .

E n g i n e o p e r a t i o n i s i r r e g u l a r a n d l a c k s

p o w e r

I n c o r r e c t t i m i n g o f i n j e c t i o n p u m p .

C h e c k t i m i n g a n d c o r r e c t l y s e t p u m p .

F a u l t y a

u t o m a t i c a d v a n c e c h a n g e r .

C h e c k t h e p e r f o r m a n c e o n a n i n j e c t i o n

p u

m p t e s t b e n c h . I n c a s e t h e v a l u e s

m e a s u r e d d o n o t c o r r e s p o n d t o t h e p r e -

s c r i b e d o n e s , r e p l a c e t h e c h a n g e r s p r i n g

. S e e y o u r C N H d e a l e r .

K . S . B . a u t o m a t i c c o l d a d v a n c e d e v i c e m a l -

f u n c t i o n i n g .

C h e c k o r r e p l a c e i n j e c t i o n p u m p .

E x c e s s i v e p i s t o n w e a r .


I n c o r r e c t c a l i b r a t i o n o f s p e e d r e g u l a t o r . C h e c k a n d c o r r e c t l y c a l i b r a t e t h e r e g u l a -

t o r .





x

A N O M A L Y




T E S T S O R


N O T E

E n g i n e o p e r a t i o n i s i r r e g u l a r a n d l a c k s

p o w e r

P a r t i a l b

l o c k a g e o f n o z z l e s o r f a u l t y o p e r -

a t i o n o f i n j e c t o r s .

C l e a n t h e n o z z l e s o f t h e a t o m i s e r s u s i n g

t h e a p p r o p r i a t e t o o l s a n d c o m p l e t e l y

o v

e r h a u l t h e i n j e c t o r s .

I m p u r i t i e s o r w a t e r i n t h e f u e l a n d i n j e c -

t i o n s y s

t e m .

C a r e f u l l y c l e a n t h e s y s t e m a n d r e f u e l .

I f n e c e s s a r y d r a i n f e e d s y s t e m .

I n c o r r e c t p l a y b e t w e e n c a m s h a f t c a m s

a n d t a p

p e t s .

C h e c k a n d c o r r e c t p l a y

F a u l t y t u r b o c h a r g e r .

R e

p l a c e c o m p l e t e u n i t .

A i r c l e a

n e r b l o c k e d .

C l e a n o r r e p l a c e a i r c l e a n e r .

F a u l t y o

p e r a t i o n o f L . D . A . d e v i c e

C h e c k t h a t t h e d i a p h r a g m i s n o t p e r f o r -

a t e d , t h a t t h e c o u n t e r s p r i n g i s s u i t a b l e

a n d t h a t i t h a s t h e c o r r e c t l o a d i n g ( c h e c k

o n

t e s t b e n c h ) .

C h e c k t h a t t h e r e i s a d e q u a t e a i r p r e s s u r e

i n s i d e t h e i n t a k e m a n i f o l d i n r e l a t i o n t o

t h e e n g i n e r p m u n d e r f u l l - l o a d c o n d i t i o n s .


T i e r o d

s b e t w e e n a c c e l e r a t o r p e d a l a n d

r e g u l a t i o n l e v e r i n c o r r e c t l y a d j u s t e d .

A d j u s t t h e t i e - r o d s s o t h a t t h e c o m m a n d

l e v e r c a n b e m o v e d t o t h e f u l l d e l i v e r y

p o

s i t i o n .

E n g i n e r u n n i n g w i t h a b n o r m a l k n o c k i n g

F a u l t y o

p e r a t i o n o f i n j e c t o r s .

R e

p l a c e a l l i n j e c t o r s .

F u e l l i n e s b l o c k e d .

D i s m a n t l e t h e h o s e s , c l e a n t h e m a n d r e -

p l a c e t h o s e t h a t a r e s e r i o u s l y d e n t e d .

I n c o r r e c t s e t - u p o f i n j e c t i o n p u m p .

C o r r e c t t h e s e t - u p o f t h e p u m p s o t h a t i n -

j e c t i o n o c c u r s a t t h e s p e c i f i e d a n g l e .





A N O M A L Y




T E S T S O R


N O T E

E n g i n e r u n n i n g w i t h a b n o r m a l k n o c k i n g

K n o c k i n

g o f c r a n k s h a f t c a u s i n g e x c e s s i v e

p l a y o n

o n e o r m o r e m a i n o r r o d b e a r i n g s

o r e x c e

s s i v e p l a y o n s h o u l d e r s .

R e

c t i f y t h e p i n s o f t h e c r a n k s h a f t a n d i n -

s t a l l s m a l l e r b e a r i n g s . R e p l a c e t h e t h r u s

t

h a l f - r i n g s .

C r a n k s h a f t u n b a l a n c e d .

C h e c k a l i g n m e n t o f c r a n k s h a f t .

L o o s e n i n g o f s c r e w s s e c u r i n g f l y w h e e l . R e

p l a c e t h e l o o s e n e d s c r e w s a n d t i g h t e n

a l l

t h e s c r e w s t o t h e s p e c i f i e d t o r q u e .

M i s a l i g n

m e n t o f r o d s .

R e

p l a c e t h e r o d s .

N o i s e f r o m p i s t o n j o u r n a l s d u e t o e x c e s s -

i v e p l a y o f p i s t o n h u b s a n d i n t h e r o d

b u s h i n g

.

L o o s e b u s h i n g s i n t h e r o d s e a t i n g s .

R e

p l a c e t h e p i s t o n j o u r n a l a n d / o r t h e p i s -

t o n a n d r o d b u s h i n g .

R e

p l a c e w i t h n e w b u s h i n g s .

N o i s y t i m i n g .

A d j u s t t h e p l a y b e t w e e n c a m s h a f t c a m s

a n d t a p p e t s a n d c h e c k t h a t t h e r e a r e n o

b r o k e n s p r i n g s , t

h a t t h e r e i s n o e x c e s s i v e

p l a y b e t w e e n t h e v a l v e s t e m s a n d t h e

v a l v e g u i d e s , t a p p e t s a n d s e a t i n g s .

T h e e n g i n e s m o k e s a b n o r m a l l y . B l a c k o r

d a r k g r e y s m

o k e .

E x c e s s i v e m a x i m u m p u m p o u t p u t .

D i s c o n n e c t t h e p u m p a n d a d j u s t d e l i v e r y

i n

a c c o r d a n c e w i t h t h e d a t a g i v e n i n t h e

c a l i b r a t i o n t a b l e .


K . S . B . d e v i c e o u t o f c a l i b r a t i o n o r m a l f u n c -

t i o n i n g .

C h e c k o p e r a t i o n b y a t e s t e r a n d a d j u s

t

c o

r r e c t l y a s d e s c r i b e d i n t h e m a n u a l .

T h e r e i s a n e x c e s s i v e d e l a y o n t h e i n j e c -

t i o n p u m p .

C o r r e c t t h e s e t - u p .




x

A N O M A L Y




T E S T S O R


N O T E

T h e e n g i n e s m o k e s a b n o r m a l l y . B l a c k o r

d a r k g r e y s m

o k e .

T h e i n j e c t i o n p u m p h a s a n e x c e s s i v e a d -

v a n c e .

C o r r e c t t h e s e t - u p .

T h e h o

l e s i n t h e a t o m i s e r s ( o r s o m e o f

t h e m ) a r e p a r t i a l l y o r e n t i r e l y b l o c k e d .

R e

p l a c e t h e i n j e c t o r s w i t h a s e r i e s o f n e w

i n j e c t o r s o r c l e a n a n d r e c t i f y t h e o r i g i n a

l

o n

e s u s i n g s u i t a b l e e q u i p m e n t .

A i r c l e a

n e r b l o c k e d o r d e t e r i o r a t e d .

C l e a n o r r e p l a c e t h e f i l t e r e l e m e n t .

L o s s o f

c o m p r e s s i o n i n t h e e n g i n e d u e t o :

s t u c k o r w o r n f l e x i b l e r i n g s ;

w o r n c y l i n d e r l i n e r s ;

v a l v e s d

e t e r i o r a t e d o r b a d l y a d j u s t e d .

O v e r h a u l t h e e n g i n e o r l i m i t t h e i n t e r v e n -

t i o

n s t o t h e r e l a t i v e p a r t s .

U n s u i t a

b l e i n j e c t o r s , d i f f e r e n t t y p e s o f i n -

j e c t o r s o r i n c o r r e c t l y c a l i b r a t e d .

R e

p l a c e o r c a l i b r a t e t h e i n j e c t o r s .

I n j e c t i o n h o s e s w i t h a n u n s u i t a b l e i n t e r n a l

d i a m e t e r , e n d o f h o s e s p i n c h e d d u e t o r e -

p e a t e d

b l o c k i n g .

C h e c k c o n d i t i o n s o f t h e e n d o r u n i o n s

a n d w h e r e n e c e s s a r y r e p l a c e t h e h o s e s .

B l u e , g r e y - b l u e , g r e y s m o k e t e n d i n g t o

w h i t e .

E x c e s s i v e d e l a y i n i n j e c t i o n p u m p .

C o r r e c t t h e s e t - u p o f t h e p u m p .


K . S . B . a u t o m a t i c c o l d a d v a n c e d e v i c e m a l -

f u n c t i o n i n g .



F a u l t y i n j e c t o r .

R e

p l a c e t h e i n j e c t o r .

L e a k i n g

o f o i l f r o m t h e p i s t o n r i n g s c a u s e d

b y g l u e d o r w o r n r i n g s o r w e a r i n g o f c y l i n -

d e r l i n e

r w a l l s .

O v e r h a u l t h e e n g i n e .

E n g i n e

o i l p a s s i n g t h r o u g h t h e i n t a k e

g u i d e s - v a l v e s f o l l o w i n g w e a r i n g o f g u i d e s

o r v a l v e

s t e m s .

R e

c o n d i t i o n t h e c y l i n d e r h e a d .

E n g i n e t o o c o l d ( t h e r m o s t a t b l o c k e d o r

i n e f f i c i e n t ) .

R e

p l a c e t h e t h e r m o s t a t .



PART THREE - TROUBLESHOOTING

(ELECTRONICS ENGINES)





x



Figure 1

CNH -- EST DIAGNOSTIC TOOL

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

88201


Code Description Language

380060157 Italian

380060158 French

380060159 English

380060160 German

380060161agnost c t

Spanish

380060162 Holland

380060163 Danish

380060164 Portuguese




x

FAULT CODES

Failure code Failure description

Vehicle 1 ((Sensors / Consistency tests)

1.1.2 ACCELERATOR PEDAL

1.1.9 PLAUSIBILITY +15

1.1.A PLAUSIBILITY +50

Vehicle 2 (Indicator lamps / Relais / Actuators)

1.2.3 EDC LAMP

1.2.5 MAIN RELAY DEFECT

1.2.6 BATTERY VOLTAGE

1.2.8 MAIN RELAY - SHORT CIRCUIT TO BATTERY

1.2.9 AIR-CONDITIONER COMPRESSOR RELAY

1.2.B THERMOSTARTER RELAY 1 (HEATER)

1.2.E MANAGEMENT SYSTEM PRE/POST-HEATING (ACTIVE)

2.2.5 INTERRUPTED AFTER-RUN

2.2.8 MAIN RELAY - SHORT CIRCUIT TO GROUND

Engine 1 (Temperature and pressure sensors)

1.3.1 COOLANT TEMPERATURE SENSOR

1.3.2 COOLANT TEMPERATURE SENSOR (TEST)

1.3.3 AIR TEMPERATURE SENSOR BOOST AIR

1.3.4 BOOST PRESSURE SENSOR

1.3.5 FUEL TEMPERATURE SENSOR

1.3.6 RAIL PRESSURE SENSOR OR SIGNAL ERROR

1.3.7 DBV VALVE MANAGEMENT (BOOST PRESSURE)

1.3.8 OIL PRESSURE SENSOR

1.3.A OIL TEMPERATURE SENSOR

2.3.2 COOLANT TEMPERATURE SENSOR ABSOLUTE TEST

2.3.6 RAIL PRESSURE SENSOR OFFSET

2.3.8 OIL LOW PRESSURE

2.3.A OIL TEMPERATURE ABOVE NORMAL

Engine 2 (Speed sensors/actuators)

1.4.1 CRANKSHAFT SPEED

1.4.2 ENGINE WORKING ONLY WITH CAMSHAFT SENSOR

1.4.3 CAMSHAFT SENSOR

1.4.4 FAULT BETWEEN FLYWHEEL SENSOR AND CAMSHAFT

Damage information

1.4.D ENGINE OVERSPEED

1.5.B HIGH PRESSURE TEST (DEACTIVATES RAIL PRESS.MONITORING)

1.9.D INDICATES TORQUE LIMITATION DUE TO PERFORMANCE LIMITER

4.9.E INDICATES THE TORQUE LIMITATION DUE TO ENGINE PROTECTION

6.9.E INDICATES TORQUE LIMITATION DUE TO FUEL QUANTITY LIMITATION





Fuel metering

1.5.1 HIGH PRESSURE SYSTEM

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

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

1.5.4 RAIL PRESSURE ERROR: TOO LOW1.5.5 RAIL PRESSURE ERROR: TOO HIGH


1.5.7 ERROR ON THE RAIL PRESSURE (EXCESSIVE DUTY CYCLE)


1.5.9 PRESSURE MPROP REGULATOR ERROR

2.5.9 PRESSURE MPROP REGULATOR ERROR (SHORT CIRCUIT TO POSITIVE)

3.5.9 SHORT CIRCUIT TO GROUND OF METERING UNIT OUTPUT

Injectors 1

1.6.1 INJECTOR CYLINDER 1 / SHORT CIRCUIT






1.6.7 INJECTOR CYLINDER 1 / OPEN CIRCUIT



1.6.A INJECTOR CYLINDER 4 / OPEN CIRCUIT

1.6.B INJECTOR CYLINDER 5 / OPEN CIRCUIT

1.6.C INJECTOR CYLINDER 6 / OPEN CIRCUIT

1.6.E THE MINIMUM NUMBER OF INJECTIONS WAS NOT REACHED: STOP THE ENGINE

Injectors 2

1.7.1 BENCH 1 CC

1.7.3 BENCH 2 CC

1.7.C BENCH 1 INJECTORS CHECK (INTERNAL ECU)

2.7.C BENCH 2 INJECTORS CHECK (INTERNAL ECU)

Boosting system and turbine speed

1.9.E TORQUE REDUCTION DUE TO SMOKE LIMITATION

Interfaces 1 (CAN-Bus)

1.B.1 ERROR ON CAN CONTROLLER A

1.B.3 ERROR ON CAN CONTROLLER C

1.B.4 TIMEOUT CAN MESSAGE BC2EDC1

1.B.5 TIMEOUT CAN MESSAGE VM2EDC

1.B.D TIMEOUT CAN MESSAGE CCVS

2.B.4 TIMEOUT CAN MESSAGE BC2EDC2

Interfaces 2 (CAN line timeout messages)

1.C.6 ERROR MESSAGE CAN TSC1-PE




x


1.C.8 ERROR MESSAGE CAN TSC1-VE

1.C.9 ERROR MESSAGE CAN TF

2.C.6 TIMEOUT OF CAN MESSAGE TSC1-PE PASSIVE

3.C.8 TIMEOUT OF CAN MESSAGE TSC1-VE PASSIVE

ECU 1 (internal checks)1.D.1 ECU OVERRUN MONITORING ERROR

1.D.2 ECU OVERRUN MONITORING ERROR




1.D.6 ECU INTERNAL ERROR (TPU)

1.D.7 INTERNAL ECU ERROR (VARIANT AREA)




3.D.3 ERRORE INTERNO CENTRALINA

ECU 2 (Power supply / Immobilizer / Runaway / Sensor power supply)

1.E.1 ECU: SHORT CIRCUIT OR OPEN CIRCUIT

1.E.3 ERROR FOR ECU INTERNAL MONITORING

1.E.4 ERROR FOR ECU INTERNAL MONITORING

1.E.5 SENSORS POWER SUPPLY FAULT (12V)

1.E.6 SENSOR POWER SUPPLY 1



1.E.9 ECU OVERRUN MONITORING ERROR

1.E.A ECU OVERRUN MONITORING ERROR

1.E.B ATMOSPHERIC PRESSURE SENSOR

2.E.1 SHORT CIRCUIT TO BATT OR GROUND, NO LOAD, EXCESS.TEMP. FOR LOW SIDE POWER STAGE




A

N O M A L Y


( * ) = i f

a v a i l a b l e i n t h e e q u i p m e n t


T E S T S O R


R E M A R K S

L o w p e r f o r m a n

c e a t l o a d r e q u e s t .

P o s s i b l e e x e s s i v

e s m o k e .

P o s s i b l e b l i n k - c o d e 8 . 1

I n s u f f i c i e n t f u e l l e v e l i n t h e t a n k .

C h e c

k f u e l l e v e l .

T h e e x c e s s i v e s m o k e i s d u e t o t h e f a c t

t h a t , i n c a s e o f i n s u f f i c i e n t f u e l f e e d i n g , t h e

e n g i n e c o n t r o l m o d u l e t r i e s t o c o m p e n -

s a t e p r o l o n g i n g t h e i n j e c t o r s w o r k

i n g

t i m e .

F u e l t a n k

d e v i c e p a r t i a l l y o b s t r u c t e d b y

i m p u r i t i e s o r d e f o r m e d b e c a u s e o f o v e r -

h e a t i n g .

C h e c

k i f t h e p r i m i n g p u m p o f t h e p r e - f i l t e r

i s w o

r k i n g c o r r e c t l y .

I f t h e

p u m p p l u n g e r i s p e r m a n e n t l y d e -

p r e s s e d d i s a s s e m b l e a n d c h e c k t h e t a n k

p i c k . - u p t u b e . I f t

h i s i s i n o r d e r , r e p l a c e t h e

p r e - f i l t e r .

O b s t r u c t e d a i r f i l t e r .

R e p l a

c e t h e a i r f i l t e r .

S o l v e t h e c a u s e o f t h e f i l t e r ’ s o b s t r u c t i o n .

E x c e s s i v e

f u e l b l o w - b y f r o m r a i l b o o s t

v a l v e .

C h e c

k t h e O R i n g s a n d t h e c o r r e c t c o n -

n e c t i o n o f t h e p i p e f i t t i n g s u n d e r t h e

f e e d i n g p u m p ( t h e l o c k e r s m u s t s t a y o u t -

s i d e a

n d t h e f i t t i n g s m u s t b e w e l l l o c k e d ) .

V i s u a

l l y c h e c k t h e l o w p r e s s u r e p i p e l i n e

i n t e g r i t y .

U n l e s s t h e l e a k a g e i s s i g n i f i c a n t , n o p

e r -

f o r m a n c e f a i l u r e s w i l l b e d e t e c t e d .

T o v e r i f y O - r i n g s i n t e g r i t y , e x t r a c t f r o m

t h e t a n k t h e f u e l r e c y c l i n g p i p e l i n e , s e a l

t h e e n d a n d a c t i v a t e t h e p r i m i n g p u m p

d r i v i n g t h e l o w p r e s s u r e c i r c u i t .

E x c e s s i v e

f u e l b l o w - b y f r o m r a i l b o o s t

v a l v e .

D i s c o

n n e c t t h e p i p e a n d v i s u a l l y c h e c k i f

t h e r e

a r e a n y s i g n i f i c a n t b l o w - b y f r o m t h e

b o o s t g a u g e v a l v e ; i n s u c h c a s e r e p l a c e

t h e v a l v e .

T h e e n g i n e s u d d e n l y s t o p s ( w i t h n o p r e v i -

o u s p r o b l e m s ) a n d d o e s n o t s t a r t a g a i n .

O b s t r u c t e d f u e l f i l t e r .

R e p l a

c e t h e f u e l f i l t e r .

S o l v e t h e c a u s e o f t h e f i l t e r ’ s o b s t r u c t i o n

( e m p t y a n d c l e a n t h e t a n k a n d t h e p a r t o f

t h e c i r c u i t o v e r t h e f i l t e r , r e f i l l w i t h c l e a n

f u e l ) .

TROUBLESHOOTING




x

A N O M A L Y




T E S T S O R


R E M A R K S

T h e e n g i n e d

i s c o n n e c t s o r d o e s n o t s t a r t .

( * ) E D C ” b

u r n e d ” b y s h o r t c i r c u i t o n t h e w i r -

i n g h a r n e s s o f t h e f r i c t i o n c l u t c h .

E l i m i n a t e t h e s h o r t c i r c u i t a n d r e p l a c e t h e

E D

C .

V e r i f y t h a t t h e w i r e l i n e , c l o s e t o t h e

p e d a l , i s n o t e x p o s e d t o .

D i f f i c u l t s t a r t a n d l o w p e r f o r m a n c e i n a l l

c o n d i t i o n s .

I n e f f i c i e

n t h i g h p r e s s u r e p u m p .

A f t e r h a v i n g e x c l u d e d a n y o t h e r p o s s i b l e

c a u s e , r e p l a c e t h e h i g h p r e s s u r e p u m p .

D i f f i c u l t s t a r t , l o w p e r f o r m a n c e a n d e n -

g i n e r u n n i n g

w i t h o n e c y l i n d e r l e s s .

I n j e c t o r w i t h o b s t r u c t e r o r s o l e n o i d

( m e c h a n i c a l p a r t ) b l o c k e d o p e n .

T h

e n o n - w o r k i n g i n j e c t o r i s e a s i l y r e c o g -

n i s a b l e d e t e c t i n g b y f e e l i n g t h e a b s e n c e o

f

p u

l s i n g w i t h i n t h e r e l e v a n t h i g h p r e s s u r e

p i p e .

I n c a s e o f l o w e n t i t y b l o w - b y , i n f i c i a t i n g

t h e m e c h a n i c a l w o r k i n g o f t h e i n

j e c t o r

b u t n o t i n v o l v i n g f l o w l i m i t e r a c t i v a t i o n ,

t h e r e i s n o e r r o r m e m o r i s a t i o n i n t h e e n -

g i n e c o n t r o l m o d u l e .

I f t h e f l o w l i m i t e r i s a c t i v a t e d . C h e c k

e r r o r

c o d e m e m o r y .

S t a r t i n g r e q u

i r e s i n e x c e s s o f t e n s e c o n d s ,

f o l l o w e d b y

h u g e w h i t e e x h a u s t f u m e s ,

a n d a f u e l s m

e l l .

I n j e c t o r b l o c k e d i n o p e n p o s i t i o n ( w i t h

n o r e t u

r n ) .

T h

e n o n - w o r k i n g i n j e c t o r i s e a s i l y r e c o g -

n i s a b l e d e t e c t i n g b y f e e l i n g t h e a b s e n c e o

f

p u

l s i n g w i t h i n t h e r e l e v a n t h i g h p r e s s u r e

p i p e .

U s u a l l y , w

h e t h e r s u c h s y m p t o m s a p p e a r ,

i t i s i n s t i n c t i v e t o g i v e u p e n g i n e s t a r t .

H o w e v e r , b y

i n s i s t i n g , i t i s p o s s i b l e t o s t a r t

t h e e n g i n e .

A s a m a t t e r o f f a c t s , b y i n s i s t i n g , i f w i t h i n

t h e r a i l t h e p r e s s u r e m a k e s t h e f l o w l i -

m i t e r c l o s e u p , t

h e e n g i n e s t a r t s w i t h o n e

c y l i n d e r l e s s a n d g r a d u a l l y t h e g r a

d e o f

f u m e s r e d u c e s a n d d i s a p p e a r s .

B r e a k i n g o f h i g h p r e s s u r e p i p e l i n e f r o m

p u m p t o r a i l .

S t r a n g e

v i b r a t i o n s p r o v o k e d b y s l a c k o f

p i p e b r a c k e t .

R e

p l a c e t h e p i p e l i n e e n s u r i n g t h e c o r r e c

t

t i g h t e n i n g o f t h e a n t i - v i b r a t i o n b r a c k e

t

s c r e w s .

I t i s v e r y i m p o r t a n t , i n a d d i t i o n t o c o r r e c t

b l o c k i n g , t o k e e p t h e b r a c k e t s i n t h e o r i g -

i n a l p o s i t i o n .

T h e e n g i n e w o r k s w i t h o n e c y l i n d e r l e s s ,

w i t h o u t m e m

o r i s i n g f a i l u r e b l i n k c o d e s i n

t h e e n g i n e c o n t r o l m o d u l e .

I n j e c t o r b l o c k e d i n c l o s e d p o s i t i o n .

I d e n t i f y t h e i n j e c t o r t h a t i s n o t w o r k i n g

a n y m o r e a n d t h e r e l a t i n g h i g h p r e s s u r e

f i l l e r .

T h e n o n - w o r k i n g i n j e c t o r i s e a s i l y r e c o g -

n i s a b l e d e t e c t i n g b y f e e l i n g t h e a b s e n c e o f

p u l s i n g w i t h i n t h e r e l e v a n t h i g h p r e s s u r e

p i p e .



PART FOUR - MAINTENANCE PLANNING




Check of fuel system

The check must be executed both when the enginedisconnected and when it is running.The check operation consists in examining the fuel pipelinesrunning from the tank to the pre-filter (if provided in thespecific equipment), to the filter, to the injection pump and to

the injectors.

Cooling system check

The check must be executed both when the enginedisconnected and when it is running.

Check the pipelines from the engine to the radiator, from theexpansion tank and vice-versa. Findout any blow-by, verify thestatus of the pipes specially close to the holding strips.

Verify that the radiator is clean, the correct working of the fanflywheels, the presence of any leakage from the connectors,from the manifold and from the radiating unit.

Due to the high temperatures achieved by thesystem, do not operate immediately after the engine’sdisconnection, but wait for the time deemednecessary for the cooling.Protect the eyes and the skin from any eventual highpressure jet of cooling liquid.

Lubricating system check

The check must be executed both when the enginedisconnected and when it is running.

Verify the presence of any oil leakage or blow-by from thehead, from the engine pan of from the heat exchanger.

The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water and detergent.

Adequately protect the skin and the eyes, operate infull compliance with safety regulations.

Disposal must be carried out properly, and in fullcompliance with the law and regulations in force.

Check of water presence within fuel filter or pre-filter

The components of the system can be damagedvery quickly in presence of water or impurity within

the fuel.

Timely proceed operating on the pre-filter (notavailable on the engine block) to carry out thedrainage of the water within the feed circuit.

The density of the cooling liquid must be checked any how

every year before winter season and be replaced in any caseevery two year.

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

If bleeding of the system is not carried out, seriousinconvenience might be caused to the engine due

to the presence of air pockets in the engine’s head.

Fuel filter is equipped with pump screw-valve to drain thewater eventually mixed with fuel (some applications of 6cylinders engines will be equipped with two fuel filters, bothprovided with drainage.

Place a container underneath the filter and slightly loosen thescrew. Drain the water eventually contained in the filter’sbottom.

Lock the screw (max 0.5 Nm locking couple) as soon as fuelstarts bleeding.

NOTE

NOTE





x

Check of drive belt tensioning

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

Check of belt’s tear and wear status

Carefully verify the belt’s surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing;

check end and surface grinding.

Adjust clearance between rockers and valves using setscrewwrench (1), box wrench (3) and feeler gauge (2).

Working clearance shall be as follows:- intake valves 0.25 ± 0.05 mm- exhaust valves 0.51 ± 0.05 mm.

Check and setting of tappet clearance

Figure 4

2 1

3

75806

Danger: if the engine is switched off but is still hot,unexpected motion of the belt may occur.

Wait for engine temperature cooling as a precautionin order to avoid serious danger injury.

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

NOTE

Oil motor and filter replacement

Due to the several applications, the pan shape and the oilquantity can change slightly. However, the following oper-ations are valid for all applications.

We recommend to carry out the oil drainage when the motor is hot.

- Place a proper container for the oil collecting under thepan connected with the drain plug.

- Unscrew the plug and then take out the control dipsick and the inserting plug toeasethe downflow of the lubrica-

tion oil.

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

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

The oil motor is very pollutant and harmful.

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

Protect properly skin and eyes: operate according tosafety rules.

Dispose of the residual properly following the rules.

- After the complete drainage, screwthe plug and carryout the clean oil filling.

!Use only the recommended oil or oil having the re-quested features for the corrrect motor functioning.

In case of topping up, don’t mix oils having differentfeatures.

If you don’t comply with theses rules, the service war-ranty is no more valid.

- Check the level through the dipsick until when the fillingis next to the maximum level notch indicated on the dip-sick.



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

According to the application the filter can be located in differ-ent positions: the following procedure is a valid guide for allapplications.

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

380000670-tool.

Warning: the oi l fil ter contains inside a quantity of oilof about 1 kg.

Place properly a container for the liquid.

Warning: avoid the contact of skin with the motor oil:in case of contact wash the skin with running water.

The motor oil is very pollutant: it must be disposedof according to the rules.

- Replace the filtering cartidge with a new one and screwmanually until when the gasket is in contact with the sup-port.

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

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

Fuel filter replacement

According to the applications the filters position and the quantity can change.

However the following operationsare valid for all applications.

- Drain the fuel inside the filter by operating the water re-lease screw. Collect the fuel in a container without impu-rities.

- Unscrew the cartridge by using the 380000670-tool.

- Collect the eventual fuel inside the filtering cartridge.

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

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

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

During this operation don’t smoke and don’t use freeflames.

Avoid to breathe the vapors coming from filter.

!After filters replacement the supply equipmentdeaeration must be carried out.




Alternator belt replacement

Due to several applications the beltrun can change very much.

We describe the replacement of a belt mounted on a 4-cylin-ders motor with traditional belt tension.

Warning: with switched off motor (but still hot) thebelt can operate without advance notice.

Wait for the motor temperature lowering to avoidvery serious accidents.

Figure 5

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

- Loosen the bolt that fixes the alternator to the support.

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

- Stretch POLY-V belt (2).

- Lock screw(1) and the bolt that fixes the alternator tothesupport

- Run the engine for a few hours and check proper beltstretching.

88089


CNH

PARTS


x



SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1NEF ENGINES

SECTION 4

Overhaul and technical specifications

Page

GENERAL SPECIFICATIONS 5. . . . . . . . . . . . . . .

CLEARANCE DATA 6. . . . . . . . . . . . . . . . . . . . .

TABLE OF PRE-DELIVERY VALUES FOR BOSCHINJECTION PUMPS 12. . . . . . . . . . . . . . . . . . . .

MECHANICALS ENGINES OVERHAUL 13. . . . . .

ENGINE REMOVAL AT THE BENCH 13. . . . . . . .

REPAIR OPERATIONS 14. . . . . . . . . . . . . . . . . . . .

CYLINDER UNIT 14. . . . . . . . . . . . . . . . . . . . . . . .

- Checks and measurements 14. . . . . . . . . . . . . . .

- Checking head supporting surface on cylinder unit 15

TIMING SYSTEM 16. . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking cam lift and pin alignment 171. . . . . . . .

BUSHES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Bush replacement 18. . . . . . . . . . . . . . . . . . . . . .

- Tappets 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting tappets — camshaft 18. . . . . . . . . . . . . . . .

OUTPUT SHAFT 19. . . . . . . . . . . . . . . . . . . . . . . .

- Measuring journals and crankpins (4 cylinders) 19

- Replacing oil pump control gear 21. . . . . . . . . . .

- Fitting main bearings 21. . . . . . . . . . . . . . . . . . . .

- Finding journal clearance 21. . . . . . . . . . . . . . . . .

- Checking output shaft shoulder clearance 22. . .

CONNECTING ROD — PISTON ASSEMBLY 22. .



2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS NEF ENGINES

Page

- Pistons 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring piston diameter 23. . . . . . . . . . . . . . . .

- Piston pins 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Conditions for proper pin-piston coupling 24. . . .

- Split rings 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Connecting rods 25. . . . . . . . . . . . . . . . . . . . . . .

- Bushes 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod-piston assembly 26. . . . . .

- Connecting rod-piston coupling 26. . . . . . . . . . . .

- Fitting split rings 26. . . . . . . . . . . . . . . . . . . . . . . .

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

- Finding crankpin clearance 27. . . . . . . . . . . . . . . .

- Checking piston protrusion 28. . . . . . . . . . . . . . .

CYLINDER HEAD 29. . . . . . . . . . . . . . . . . . . . . . . .

- Removing the valves 29. . . . . . . . . . . . . . . . . . . .

- Checking cylinder head wet seal 30. . . . . . . . . . .

- Checking cylinder head supporting surface 30. . .

VALVES 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing carbon deposits, checking and grindingvalves 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking clearance between valve stem and valveguide and valve centering 31. . . . . . . . . . . . . . . . .

VALVE GUIDE 32. . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE SEATS 32. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Regrinding — replacing the valve seats 32. . . . . . .

VALVE SPRINGS 33. . . . . . . . . . . . . . . . . . . . . . . . .

Page

FITTING CYLINDER HEAD 33. . . . . . . . . . . . . . . .

- Refitting the cylinder head 34. . . . . . . . . . . . . . . .

TIGHTENING TORQUE 35. . . . . . . . . . . . . . . . . .

ELECTRONICS ENGINES OVERHAUL 37. . . . . . .

ENGINE REMOVAL AT THE BENCH 37. . . . . . . .

REPAIR OPERATIONS 38. . . . . . . . . . . . . . . . . . . .

CYLINDER UNIT 38. . . . . . . . . . . . . . . . . . . . . . . .

- Checks and measurements 38. . . . . . . . . . . . . . .

- Checking head supporting surface on cylinder unit 39

TIMING SYSTEM 40. . . . . . . . . . . . . . . . . . . . . . . . .

- Camshaft 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking cam lift and pin alignment 41. . . . . . . . .

BUSHES 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Bush replacement 42. . . . . . . . . . . . . . . . . . . . . .

- Tappets 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting tappets — camshaft 43. . . . . . . . . . . . . . . .

OUTPUT SHAFT 44. . . . . . . . . . . . . . . . . . . . . . . .

- Measuring journals and crankpins (4 cylinders) 46

- Replacing oil pump control gear 48. . . . . . . . . . .

- Fitting main bearings 48. . . . . . . . . . . . . . . . . . . .

- Finding journal clearance 48. . . . . . . . . . . . . . . . .

- Checking output shaft shoulder clearance 49. . . .

CONNECTING ROD — PISTON ASSEMBLY 49. .

- Pistons 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Measuring piston diameter 50. . . . . . . . . . . . . . . .

- Piston pins 51. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Conditions for proper pin-piston coupling 51. . . .




Page

- Connecting rods 52. . . . . . . . . . . . . . . . . . . . . . .

- Bushes 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod-piston assembly 53. . . . . .

- Connecting rod-piston coupling 53. . . . . . . . . . . .

- Fitting split rings 54. . . . . . . . . . . . . . . . . . . . . . . .

- Fitting connecting rod-piston assembly into cylinder barrels 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Finding crankpin clearance 55. . . . . . . . . . . . . . . .

- Checking piston protrusion 56. . . . . . . . . . . . . . .

CYLINDER HEAD 57. . . . . . . . . . . . . . . . . . . . . . . .

- Removing the valves 57. . . . . . . . . . . . . . . . . . . .

- Checking cylinder head wet seal 58. . . . . . . . . . .

Page

- Checking cylinder head supporting surface 58. . .

VALVES 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Removing carbon deposits, checking and grinding

valves 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Checking clearance between valve stem and valveguide and valve centering 59. . . . . . . . . . . . . . . . .

VALVE GUIDE 60. . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE SEATS 60. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Regrinding — replacing the valve seats 60. . . . . . .

VALVE SPRINGS 62. . . . . . . . . . . . . . . . . . . . . . . . .

FITTING CYLINDER HEAD 62. . . . . . . . . . . . . . . .

- Refitting the cylinder head 63. . . . . . . . . . . . . . . .

TIGHTENING TORQUE 64. . . . . . . . . . . . . . . . . .




GENERAL SPECIFICATIONS

Type 4 CYLINDERS

Cycle Four-stroke diesel engine

Power See properties described in Section 3

Injection Direct

Number of cylinders 4 in-line

∅

Bore mm 104

Stroke mm 132

+ + +.. = Total displacement cm3 4485

TIMING

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

--

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

--

X

Checking timingmm

Xmm

Checking operationmm

Xmm

-

-

0.25 to 0.05

0.50 to 0.05

FUEL FEED

InjectionType: Bosch VE 4/12 F

Nozzle type -

Injection sequence 1 - 3 - 4 - 2




CLEARANCE DATA

Type 4 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅1

X

Cylinder barrels ∅1 104.000 to 104.024

0.4

∅1

X

∅ 2

Spare pistons type:Size XOutside diameter ∅ 1Pin housing ∅ 2

55.9103.714 to 103.732

38.010 to 38.016

Piston — cylinder barrels 0.268 to 0.310

CNH

PARTSPiston diameter ∅ 1 0.4

X

Piston protrusion X 0.28 to 0.52

3∅ Piston pin ∅ 3 37.994 to 38.000

Piston pin — pin housing 0.010 to 0.022




Type 4 CYLINDERS


X

1

32

X

X

X1*Split ring slots X 2

X 3* measured on a ∅ of

99.00 mm

2.705 to 2.7352.440 to 2.460

4.030 to 4.050

1

3

2S

S

S S 1*

Split rings S 2S 3

2.560 to 2.6052.350 to 2.3803.970 to 3.990

1Split rings - slots 2

3

0.100 to 0.1750.060 to 0.1100.040 to 0.080

CNH

PARTSSplit rings 0.4

X 1

3

2X

X

Split ring end openingin cylinder barrel:

X 1X 2X 3

0.30 to 0.400.60 to 0.800.30 to 0.55

1∅

∅ 2

Small end bushhousing ∅ 1Big end bearinghousing ∅ 2

40.987 to 41.013

72.987 to 73.013

∅

S

3Small end bush diameter Outside ∅ 4Inside ∅ 3Spare big end half bearings S

38.019 to 38.033

1.955 to 1.968

Piston pin — bush 0.019 to 0.039

CNH

PARTSBig end half bearings 0.250 to 0.500




Type 4 CYLINDERS


X

Size X

Max. toleranceon connecting rodaxis alignment

-

-

Journals ∅ 1Crankpins ∅ 2

82.99 to 83.0168.987 to 69.013

1 2∅∅

S 1 S 2

Main half bearings S 1

Big end half bearings S 2

2.456 to 2.464

1.955 to 1.968

3∅

Main bearingsNo. 1 — 5 ∅ 3No. 2 — 3 — 4 ∅ 3

87.982 to 88.00887.977 to 88.013

Half bearings — JournalsNo. 1 — 5No. 2 — 3 — 4

0.022 to 0..0530.019 to 0.055

Half bearings - Crankpins 0.019 to 0.058

CNH

PARTS

Main half bearingsBig end half bearings

0.250 to 0.500

1X

Shoulder journal X 1 37.475 to 37.550

X 2

Shoulder main bearing X 2 32.180 to 32.280

X 3Shoulder half-rings X 3 37.28 to 37.38

Output shaft shoulder 0.095 to 0.270




Type 4 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

∅ 1

Valve guide seats oncylinder head ∅ 1 8.019 to 8.039

∅

α

4 Valves:

∅ 4α

∅ 4α

7.960 to 7.98060º

7.960 to 7.98045º

Valve stem and guide 0.059 to 0.086

∅ 1

Housing on head for valve seat:

∅1

∅1

46.987 to 47.013

43.637 to 43.663

α

2∅

Valve seat outside diameter;valve seat angle on cylinder head:

∅ 2α

∅ 2α

47.063 to 47.08960º

43.713 to 43.73945º

X

X

Sinking X

1 to 1.52

1 to 1.52

Between valve seatand head

0.050 to 0.102

0.050 to 0.102

CNH

PARTS Valve seats -



70159

70158

70160

70161

70162

Figure 1

Figure 2

Figure 3

Figure 4

Remove the screws (1) fastening the connecting rod caps (2)and remove them.

Withdraw the pistons including the connecting rods from the

top of the engine block.

Remove the screws (1) and the main bearing caps (2).

The second last main bearing cap (1) and the relevantsupport are fitted with shoulder half-bearing (2).

Use tool 380000362 (1) and hoist to remove the outputshaft (2) from the block.

Remove the main half-bearings (1).Remove the screws (2) and remove the oil nozzles (3).

Keep the half-bearings into their housings since incase of use they shall be fitted in the same positionfound at removal.

Take note of lower and upper half-bearing

assembling positions since in case of reuse they shall be fitted in the same position found atremoval.

Figure 5

MECHANICALS ENGINES OVERHAULENGINE REMOVAL AT THE BENCH

The following instructions are prescribed on theunderstanding that the engine has previously been placed on the rotating bench and that removal of all specificcomponents of the equipment have been already removedas well. (See Section 3 of the manual herein).

The section illustrates therefore all the most importantengine overhaul procedures.

The following operations are relating to the 4 cylindersengine but are analogously applicable for the 6 cylinders.

NOTE

NOTE




70163

70165

70164

70166

70167

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Removethe screws (1) and disconnect camshaft (3)retainingplate (2).

Withdraw carefully the camshaft (1) from the engine block.

Withdraw the tappets (1) from the engine block.

Once engine is disassembled, clean accurately thecylinder-block assembly.

Use the proper rings to handle the cylinder unit.The engine block shall not show cracks.

Check operating plug conditions and replace them in case of uncertain seal or if rusted.

Inspect cylinder barrel surfaces; they shall be free from seizing,scores, ovalisation, taper or excessive wear.

Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1)fitted with the dial gauge previously set to zero on the ringgauge (2) of the cylinder barrel diameter.

Measurements shall be performed on each cylinder, at threedifferent heights in the barrel and on two planesperpendicular with each other: one parallel to thelongitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane(B) in correspondence with the first measurement.

Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall beperformed according to the spare piston diameter oversizedby 0.5 mm and to the specified assembling clearance.

Take note of plate (2) assembling position.

REPAIR OPERATIONSCYLINDER UNITChecks and measurements

Should the ring gauge be not available, use amicrometer for zero-setting.

s

NOTE

NOTE


zs



70169

Figure 12

TIMING SYSTEMCamshaft

CAMSHAFT MAIN DATA (4 CYL.)Specified data refer to pin standard diameter

70512

Figure 13

MAIN DATA ABOUT CAMSHAFT PINS (6 CYL.)

Camshaft pin and cam surfaces shall be absolutely smooth;if they show any traces of seizing or scoring replace the

camshaft and the bushes.




70171

70172

Figure 14

Figure 15

Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.

Camshaft bush (2) shall be pressed into its housing.Internal surface must not show seizing or wear.Use bore dial gauge (3) to measure camshaft bush (2) andintermediate housing (1) diameter.Measurements shall be performed on two perpendicular axes.

BUSHESChecking cam lift and pin alignment

Set the camshaft on the tailstock and using a 1/100 gauge seton the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft.

Figure 16

MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (4-cylinder engines)* Value to be obtained after driving the bushes.

107399

Sec. A-A




70174

84053

70176

70164

70238

Figure 17

To replace the bearing (1) use tool 380000667 (2) and

handle 380000668 (3) to remove and install it.

MAIN DATA CONCERNING THE TAPPETS AND THERELEVANT HOUSINGS ON THE ENGINE BLOCK

Lubricate the tappets (1) and fit them into the relevanthousings on the engine block.

Lubricate the camshaft support bearing and install thecamshaft (1) being careful to ensure that the bearing or theshaft support seats are not damaged during the operation.

Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator,

then tighten the screws (2) to the specified torque.

Bush replacement Fitting tappets — camshaft

CNH

PARTS

When installing the bearing (1) it must be orientedso that the lubrication holes are aligned with thoseon the seats of the crankcase

Tappets

Figure 18

Figure 19

Figure 20

Figure 21

NOTE




70179

70180

70182

Figure 22

Figure 23

Figure 24

Figure 25

Check camshaft end float (1).It shall be 0.23 ± 0.13 mm.

Fit nozzles (2) and tighten the fastening screws (1) to thespecified torque.

Grind journals and crankpins if seizing, scoring or excessiveovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to

which the pins are to be ground.

It is recommended to insert the found values in theproper table.See Figure 25.

Undersize classes are:

Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be markedon the side of the crank arm No.1.For undersized crankpins: letter MFor undersized journals: letter BFor undersized crankpins and journals: letters MB

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES

*Rated value

OUTPUT SHAFTMeasuring journals and crankpins

108487

NOTE

NOTE





TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness SHAPE

Cilindricity //

Parallelism //

DIRECTION Verticality

Straightness

POSITION Concentricity or coaxiality Circular oscillation

OSCILLATIONTotal oscillation

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ©

IMPORTANT ⊕

SECONDARY ⊝

70183

Figure 26

OUTPUT SHAFT MAIN TOLERANCES

70237

MAIN BEARING ON TIMINGSYSTEM CONTROL SIDE

INTERMEDIATE MAINBEARINGS

FIRST MAIN BEARINGON FRONT SIDE

measured on > 45.5 mm radius

between adjacent journals



70184

70185

Figure 27

Figure 28

Figure 29

Figure 30

Refit the output shaft (2).

Check the backlash between output shaft main journals and the relevant bearings as follows:

Refit the main bearings that have not beenreplaced, in the same position found at removal.

CNH

PARTS

Fitting main bearings

CNH

PARTS

Do not try to adapt the bearings.

Main bearings (1) are supplied spare with 0.250 — 0.500 mmundersize on the internal diameter.

Clean accurately the main half bearings (1) having thelubricating hole and fit them into their housings.

The second last main half bearing (1) is fitted with shoulder half rings.

Check that gear toothing (1) is not damaged or worn,otherwise remove it using the proper puller (3).

When f itting the new gear, heat it to 180°C for 10 minutesin an oven and then key it to the output shaft.

Finding journal clearance

- clean accurately the parts and remove any trace of oil;

- positiona piece of calibrated wire (3) on the output shaftpins (4) so that it is parallel to the longitudinal axis;

- fit caps (1), including the half bearings (2) on the relevantsupports.

70186

70161

Replacing oil pump control gear

NOTE

NOTE

75703

D1D2

NOTE Before using the fixing screws again, measure them

twice as indicated in the picture, checking D1 andD2 diameters:if D1- D2< 0,1 mmthescrewcan beutilised again;if D1 - D2 > 0,1 mm the screw must be replaced.




This check is performed by setting a magnetic-base dial gauge(2) on the output shaft (3) as shown in the figure, standardvalue is 0.068 to 0.41.

If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearancecheck between output shaft pins and main half bearings.

70188

70189

70190

70191

Figure 31

Figure 32

Figure 33

Figure 34

- 3rd stage, with tool 380000304 (1) set as shown in the

figure, tighten the screws (2) with 90° ±

5°

angle.

- Remove caps from supports.

The backlash between the main bearings and the pins isfound by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1)containing the calibrated wire.

The numbers on the scale indicate the backlash in mm.

Replace the half bearings and repeat the check if a differentbacklash value is found. Once the specified backlash isobtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described.

CONNECTING ROD — PISTON ASSEMBLYCOMPONENTS

1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -6. Half bearings - 7. Connecting rod - 8. Bush.

α

Checking output shaft shoulder clearance

Pistons are supplied spare with 0.4 mm oversize.

CONNECTING ROD — PISTON

ASSEMBLY

NOTE

Figure 35

70187

Tighten the pre-lubricated screws (1) in the following threesuccessive stages:- 1st stage, with dynamometric wrench to 50 ± 6 Nm.- 2nd stage, with dynamometric wrench to 80 ± 6 Nm.




32615

32614

32613

70192

87760

Figure 36

Figure 37

Figure 38

Figure 39

Figure 40

Removesplit rings (1) from piston (2) using pliers 380000221(3).

Piston pin (1) split rings (2) are removed using a scriber (3).

Using a micrometer (2), measure the diameter of the piston(1) to determine the assembly clearance.

The clearance between the piston and the cylinder barrel canbechecked also with a feeler gauge (1) as shownin thefigure.

The diameter shall be measuredat 12 mm from the

piston skirt.

MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

PistonsMeasuring piston diameter

NOTE




32619

32620

16552

18857

41104

Figure 41

Figure 42

Figure 43

Figure 44

Figure 45

To measure the piston pin (1) diameter use the micrometer (2).

Conditions for proper pin-piston coupling

Lubricate the pin (1) and its seat on piston hubs with engineoil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.

Use a micrometer (1) to check split ring (2) thickness.

Check the clearance between the sealing rings (3) of the 2nd

and3rd slot and the relevant housings on the piston (2), usinga feeler gauge (1).

DIAGRAM FOR MEASURING THE CLEARANCE XBETWEEN THE FIRST PISTON SLOT AND THE

TRAPEZOIDAL RING

Since the first sealing ring section is trapezoidal, the clearancebetween the slot and the ring shall be measured as follows:make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).

In this position, use a feeler gauge to check the clearance (X)between ring and slot: found value shall be the specified one.

Piston pins

Split rings




70194

88607

Figure 46

Use feeler gauge (1) to measure the clearance between theends of the split rings (2) fitted into the cylinder barrel (3).

The surface of connecting rod and rod cap areknurled to ensure better coupling.Therefore, it is recommended not to smooth theknurls.

Connecting rods

Figure 47

NOTE

Figure 48

80339

Every connecting rod is marked as follows:

- On body and cap with a number showing their coupling and the corresponding cylinder.In case of replacement it is thereforenecessary to mark the new connecting rod with the same

numbers of the replaced one.- On body with a letter showing the weight of

the connecting rod assembled at production:

S V, 1820 to 1860 (yellow marking);

S W, 1861 to 1900 (green marking);

S X, 1901 to 1940 (blue marking);

Spare connecting rods are of the W class with

green marking *.

Material removal is not allowed.

NOTE




70198

Figure 49

Fitting connecting rod-piston assemblyConnecting rod-piston coupling

The piston crown is marked as follows:1. Part number and design modification number;2. Arrow showing piston assembling direction into cylinder

barrel, this arrow shall face the front key of the engineblock;

3. Marking showing 1st slot insert testing;4. Manufacturing date.

Figure 50

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into thecylinder barrel and the numbers (5) marked on theconnecting rod (5) are read as shown in the figure.

70199

Bushes

Check that the bush in the connecting rod small end is freefrom scoring or seizing and that it is not loosen. Otherwisereplace.

Removal and refitting shall be performed using the proper beater.

When refitting take care to make coincide the oil holes set

on the bush with those set on the connecting rod small end.Grind the bush to obtain the specified diameter.

72705

32613

Figure 51

Figure 52

Position the piston (1) on the connecting rod according to the diagram shown in the figure, fit the pin (3) and stop it by the split rings (2).

Fitting split rings

Use pliers 380000221 (3) to fitthe splitrings (1) on thepiston(2).Split rings shall be fitted with the marking “TOP” facingupwards and their openings shall be displaced with eachother by 120°.

Split rings are supplied spare with the followingsizes:

- standard;

- 0.4 mm oversize.

NOTE




70200

70201

Figure 53

Figure 54

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

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside.

Use band 380000220 (2) to fit the connecting rod-pistonassembly (1) into the cylinderbarrels and check thefollowing:

- the number of each connecting rod shall correspond to the cap coupling number.

Fitting connecting rod-piston assembly intocylinder barrels

Refit the main bearings that have not beenreplaced, in the same position found at removal.Do not try to adapt the half bearings.

NOTE

70202

70203

Figure 55

Figure 56

DIAGRAM FOR CONNECTING ROD-PISTONASSEMBLY FITTING INTO BARREL

- Split ring openings shall be displaced with each other by 120°;

- connecting rod-piston assemblies shall have the sameweight;

- thearrow markedon thepiston crown shall befacing thefront side of the engine block or theslot obtained on thepiston skirt shall be corresponding to the oil nozzleposition.

Finding crankpin clearance

To measure the clearance proceed as follows:

- clean the parts accurately and remove any trace of oil;

- set a piece of calibrated wire (2) on the output shaft pins

(1);- fit the connecting rod caps (3) with the relevant half

bearings (4).

75703

D1D2

NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 andD2 diameters:if D1- D2< 0,1 mmthescrewcan beutilised again;if D1 - D2 > 0,1 mm the screw must be replaced.




70204

70205

70206

Figure 57

Figure 58

Figure 59

- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometricwrench (2).

- Apply tool 380000304 (1) to the socket wrench and tighten screws (2) of 60°.

- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale

on the wire envelope (2).

α

α

70207

Figure 60

If a different clearance value is found, replacethe half bearingsand repeat the check.

Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening theconnecting rod cap fastening screws to the specified torque.

Check manually that the connecting rods (1) are slidingaxially on the output shaft pins and that their end float,measured with feeler gauge (2) is 0.250 to 0.275 mm.

70208

Figure 61

Once connecting rod-piston assemblies refitting is over, usedial gauge 39395603 (1) fitted with base 380000364 (2) tocheck piston (3) protrusion at T.D.C. with respect to the topof the engine block.

Protrusion shall be 0.28 to 0.52 mm.

Checking piston protrusion




75750

Figure 62

Intake (1) and exhaust (2) valves have heads with the samediameter.

The central notch (→) of the exhaust valve (2) headdistinguishes it from the intake valve.

Should cylinder head valves be not replaced,number them before removing in order to refit them in the same position.

A = intake side — S = exhaust side

CYLINDER HEADRemoving the valves

Valve removal shall be performed using tool 380000302 (1)and pressing the cap (3) so that when compressing thesprings (4) the cotters (2) can be removed. Then remove thecap (3) and the springs (4).

Repeat this operation for all the valves.

Overturn the cylinder head and withdraw the valves (5).

75751

75752

Figure 63

Figure 64

Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

1

2

A

1 2

3

4

5

6

2

1

NOTE

NOTE




18625

18882

75757

Figure 67

Figure 68

Figure 69

Figure 70

VALVES

INTAKE AND EXHAUST VALVE MAIN DATA

Remove carbon deposits from valves using the proper metalbrush.

Check that the valves show no signs of seizing, scoring or cracking.

Regrind the valve seats, if required, using tool 99305018 andremoving as less material as possible.

Check the valve stem (1) using a micrometer (2), it shall be7.960 ± 7.980.

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.056 ± 0.096 mm.

Turn the valve (2) and check that the centering error is notexceeding 0.03 mm.

Removing carbon deposits, checking andgrinding valves

CNH

PARTS

Checking clearance between valve stem andvalve guide and valve centering

2

1

116395

INTAKEVALVE

EXHAUSTVALVE




EXHAUST70328

75754

Figure 71

Figure 72

Use a bore dial gauge to measure the inside diameter of thevalve guides, the read value shall comply with the valueshown in the figure.

Check the valve seats (2). If slight scoring or burnout is found,regrind seats using tool 99305018 (1) according to the angle

values shown in Figure 73.

VALVE SEATSRegrinding — replacing the valve seats

VALVE SEAT MAIN DATA

INTAKE EXHAUST

INTAKE

Figure 73

CNH

PARTS

Should valve seats be not reset just by regrinding, replace them with the spare ones. Use adequate tool to remove asmuch material as possible from the valve seats (take care not to damage the cylinder head) until they can be extractedfrom the cylinder head using a punch.

Heat the cylinder head to 80° - 100°C and using the proper beater, fit the new valve seats, previously cooled, into thecylinder head.

Use adequate tool to regrind the valve seats according to thevalues shown in figure.

1

2

VALVE GUIDE

116356




Check cleanness of cylinder head and engine block couplingsurface.Take care not to foul the cylinder head gasket.Set the cylinder head gasket (1) with the marking “TOP” (1)facing the head.The arrow shows the point where the gasket thickness isgiven.

87759

Figure 78

Refitting the cylinder head

CNH

PARTS

There are two types of head seals, for thethickness (1.25 mmType A and 1.15 mm Type B) take the following measures:

- for each piston detect, as indicated on figure , at adistance of 45 mm from the centre of the pistonoverhandings S1 and S2 in relation to the engine baseupper plane then calculate the average:

For 4 cylinder versions:

Repeat the operation for pistons 2, 3 and 4 and calculate the average value.

88775

Figure 79

Scil1 =S1+ S2

2

CNH

PARTS

S =Scil1+ Scil2+ Scil3+ Scil4

4

75703

D1D2

NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 andD2 diameters:if D1- D2< 0,1 mmthescrewcan beutilised again;if D1 - D2 > 0,1 mm the screw must be replaced.





TIGHTENING TORQUETORQUE

COMPONENTNm kgm

Cooling Nozzles (M8x1.25x10) 15 ± 3 1.5 ± 0.3

Main bearing cap 1st stage2nd stage

50 ± 680 ± 6

5.0 ± 0.68.0 ± 0.6

3rd stage 90º ± 5º

Rear gear housing assembly (M8x1.25x40)(M8x1.25x25)(M10x1.5)

24 ± 424 ± 449 ± 5

2.4 ± 0.42.4 ± 0.44.9 ± 0.5

Oil pump (M8x1.25x30) 8 ± 1 0.8 ± 0.1

Front cover assembly (M8x1.25x45)(M8x1.25x30)

24 ± 424 ± 4

2.4 ± 0.42.4 ± 0.4

Connecting rod bolts (M11x1.25) 1st stage2nd stage

30 ± 360 ± 5

3.0 ± 0.36.0 ± 0.5


Ladder frame assembly (M10x1.25x25) 43 ± 5 4.3 ± 0.5

Oil rifle plugs(M10x1)(M14x1.5)

6 ± 111 ± 2

0.6 ± 0.11.1 ± 0.2

Assemble oil suction tube (M8x1.25x20) 24 ± 4 2.4 ± 0.4

Oil pan assembly (M8x1.25x25)(M18x1.50)

24 ± 460 ± 9

2.4 ± 0.46.0 ± 0.9

Set timing pin 5 ± 1 0.5 ± 0.1

Fuel pump assembly M8 screwM6 screwM6 nut

24 ± 410 ± 110 ± 1

2.4 ± 0.41.0 ± 0.11.0 ± 0.1

M10x1.5 flange head nuts pre-torqueFinal torque 10 - 1550 - 55 1.0 - 1.55.0 - 5.5

Fuel pump gear (drive gear nut) Snug torqueFinal torque

15 - 2085 - 90

1.5 - 2.08.5 - 9.0

Timing pin cap of fuel pump 30 - 35 3.0 - 3.5

Rocker assys (M8) 24 ± 4 2.4 ± 0.4

Cylinder head bolts(M12x70)(M12x140)(M12x180)

50 + 90º40 + 180º70 + 180º

5.0 + 90º4.0 + 180º7.0 + 180º

Assy rocker covers (M8x1.25x25) 24 ± 4 2.4 ± 0.4

Intake manifold (M8x1.25) 24 ± 4 2.4 ± 0.4

Assy air intake connection (M8x1.25) 24 ± 4 2.4 ± 0.4

Oil bypass valve into lube filter head (M22x1.5x10) 80 ± 8 8.0 ± 0.8

Plug (M12x1.5x12) 10 ± 1 1.0 ± 0.1

Exhaust manifold (M10x1.5x65) 43 ± 6 4.3 ± 0.6

Water pump (M8x1.25x25) 24 ± 4 2.4 ± 0.4

Water outlet connection(M8x1.25x35)(M8x1.25x70)

24 ± 424 ± 4

2.4 ± 0.42.4 ± 0.4

Fan support (M10x1.5x20) 33 ± 5 3.3 ± 0.5

Fan pulley (M6)(M10)

10 ± 243 ± 6

1.0 ± 0.24.3 ± 0.6




TORQUE

Nm kgm

Rear lifting bracket (M12x1.75x30) 77 ± 12 7.7 ± 1.2

Crankshaft pulley (M12x1.75x10.9) 110 ± 5 11.0 ± 0.5

Flywheel housing(M12x120)

(M12x80)(M10x80)(M10x40)

85 ± 10

85 ± 1049 ± 549 ± 5

8.5 ± 1.0

8.5 ± 1.04.9 ± 0.54.9 ± 0.5

Flywheel housing (M12x1.25) 1st stage 30 ± 4 3.0 ± 0.4

2nd stage 60º ± 5º

Assy rear cover plate to flywheel housing (M8x1.25x16) 24 ± 4 2.4 ± 0.4

Fuel injectors 60 ± 5 6.0 ± 0.5

Fuel lift pump 24 ± 4 2.4 ± 0.4

Turbocharger to exhaust manifold (M10) 43 ± 6 4.3 ± 0.6

Oil feed to oil filter head 24 ± 4 2.4 ± 0.4

Oil feed to turbocharger (M12x1.5) 35 ± 5 3.5 ± 0.5

Oil drain (M8x1.25x16) 24 ±

4 2.4 ±

0.4Alternator to alternator support (M8x1.25x30) 24 ± 4 2.4 ± 0.4

Alternator to water inlet conn. assy (M8x1.25x30) 24 ± 4 2.4 ± 0.4

Lower alternator mounting (M10x1.25x25) 24 ± 4 2.4 ± 0.4

Alternator upper pivot to support (M10) 49 ± 5 4.9 ± 0.5

Alternator mounting hardware (M12x1.75x120) 43 ± 6 4.3 ± 0.6

Alternator wiring (M6x1.0 nut) 10 ± 2 1.0 ± 0.2

Starter motor to gear case (M10) 49 ± 5 4.9 ± 0.5

Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3

Screw M12 for fastening output shaft caps 1st stage2nd stage

50 ± 680 ± 6

5 ± 0.68 ± 0.6

3rd

stage 90º ± 5ºScrew M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4

Screw M8 for fastening camshaft gear 36 ± 4 3.6 ± 0.4

Screw M11 for fastening connecting rod caps 1st stage 60 ± 5 6 ± 0.5




70159

70158

70160

70161

70162

Figure 1

Figure 2

Figure 3

Figure 4Loosen the fixing screws (1) and remove the rod caps (2).

Withdraw the pistons including the connecting rods from the top of the engine block.

Remove the screws (1) and the main bearing caps (2).

The second last main bearing cap (1) andthe relevant supportare fitted with shoulder half-bearing (2).

Use tool 380000362 (1) and hoist to remove the crankshaft(2) from the block.

Remove the main half-bearings (1).Remove the screws (2) and remove the oil nozzles (3).

Keep the half-bearings into their housings since in

case of use they shall be fitted in the same positionfound at removal.

Take note of lower and upper half-bearingassembling positions since in case of reuse they shall

be fitted in the same position found at removal.

Figure 5

ELECTRONICS ENGINES OVERHAULENGINE REMOVAL AT THE BENCH

The following instructions assume that the engine haspreviously been placed on the rotating bench and thatremoval of all specific components of the Iveco Motorsequipment have been already removed as well. (See Section3 of the manual herein).

The section illustrates therefore all the most important engineoverhaul procedures.

The following operations are relating to the 4 cylinder enginebut are similar and applicable for the 6 cylinder.

NOTE

NOTE




70163

70165

70164

70166

70167

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Remove the screws (1) and disconnect camshaft (3) retainingplate (2).

Withdraw carefully the camshaft (1) from the engine block.

Withdraw the tappets (1) from the engine block.

Once engine is disassembled, clean accurately thecylinder-block assembly.Use the proper rings to handle the cylinder unit.The engine block shall not show cracks.

Check operating plug conditions and replace them in case of uncertain seal or if rusted.Inspect cylinder barrel surfaces; they shall be free from seizing,scores, ovalisation, taper or excessive wear.Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1)fitted with the dial gauge previously set to zero on the ringgauge (2) of the cylinder barrel diameter.

Measurements shall be performed on each cylinder, at threedifferent heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of theengine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the firstmeasurement.

Should ovalisation, taper or wear be found, bore andgrind thecylinder barrels. Cylinder barrel regrinding shall be performedaccording to the spare piston diameter oversized by 0.4 mm

and to the specified assembling clearance.

Take note of plate (2) assembling position.

REPAIR OPERATIONSCYLINDER UNITChecks and measurements

Should the ring gauge be not available, use a

micrometer for zero-setting.

s

NOTE

NOTE


zs



Figure 11

In case of regrinding, all barrels shall have the sameoversize (0.4 mm).

Checking head supporting surface on cylinder unit

When finding the distortion areas, replace the cylinder unit.

Planarity error shall not exceed 0.075 mm.

Check cylinder unit operating plug conditions, replace themin case of uncertain seal or if rusted.

α

Check main bearing housings as follows:

- fit the main bearings caps on the supports withoutbearings;

- tighten the fastening screws to the specified torque;

- use the proper internal gauge to check whether thehousing diameter is falling within the specified value.

Replace if higher value is found.

107804

NOTE




70169

Figure 12

TIMING SYSTEMCamshaft

CAMSHAFT MAIN DATA (4 cyl.)Specified data refer to pin standard diameter

Figure 13

MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders)Specified data refer to pin standard diameter

Camshaft pin and cam surfaces shall be absolutely smooth;if they show any traces of seizing or scoring replace the

camshaft and the bush.

84089




70171

70172

Figure 14

Figure 15

Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.

Camshaft bush (2) shall be pressed into its housing.Internal surface must not show seizing or wear.

Use bore dial gauge (3) to measure camshaft bush (2) andintermediate housing (1) diameter.Measurements shall be performed on two perpendicular axes.

BUSHESChecking cam lift and pin alignmentSet the camshaft on the tailstock and using a 1/100 gauge seton the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft.Check cam lift; found values shall be: 6.045 mm for exhaustcams and 7.582mm for intake cams, in case of different valuesreplace the camshaft.

Figure 16

CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.)* Value to be obtained after driving the bush.

107399

Sec. A-A




Figure 17

Figure 18

MAIN DATA ABOUT CAMSHAFT BUSHES AND RELATED HOUSINGS

*Height to be obtained after driving the bush.

70174

To replace bush (1), remove and refit them using the beater 380000367 (2) and the handgrip 380000368 (3).

Bush replacement

CNH

PARTS

When refitting the bush (1), direct them to make the lubricating holes (2) coincide with the holes on

the block housing.

MAIN DATA CONCERNING THE TAPPETS AND THERELEVANT HOUSINGS ON THE ENGINE BLOCK

Tappets

Figure 19

107268

sec. A-A

NOTE

112890




70176

70164

70238

Lubricate the tappets (1) and fit them into the relevant

housings on the engine block.

Lubricate the camshaft bush and fit the camshaft (1) takingcare not to damage the bush or the housings.

Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque.

Fitting tappets — camshaft

Figure 20

Figure 21

Figure 22

Figure 23

70179

70180

Check camshaft end float (1).It shall be 0.23 ± 0.13 mm.

Fit nozzles (2) and tighten the fastening screws (1) to thespecified torque.

Figure 24




70182

Figure 25

Figure 26

Grind journals and crankpins if seizing, scoring or excessiveovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter towhich the pins are to be ground.

It is recommended to insert thefound values in theproper table.See Figure 26.

Undersize classes are:

Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be markedon the side of the crank arm No.1.For undersized crankpins: letter MFor undersized journals: letter BFor undersized crankpins and journals: letters MB.

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.)

*Rated value

OUTPUT SHAFTMeasuring journals and crankpins

108487

NOTE

NOTE




Figure 28

FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES

*Rated value

Figure 29

MAIN OUTPUT SHAFT TOLERANCES

* Measured on a radius greater than 45.5 mm** 0.500 between adjacent main journals

70577

Measuring journals and crankpins (6 cyl.)

107269




70237

MAIN BEARING ON TIMINGSYSTEM CONTROL SIDE

INTERMEDIATE MAINBEARINGS

FIRST MAIN BEARING ONFRONT SIDE

Figure 30


TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness SHAPE Cilindricity //

Parallelism //

DIRECTION Verticality

Straightness

POSITION Concentricity or coaxial ity

Circular oscillationOSCILLATION

Total oscillation

LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ©

IMPORTANT ⊕

SECONDARY ⊝



70184

70185

Figure 31

Figure 32

Figure 33

Figure 34

Refit the crankshaft (2).

Check the backlash between crankshaf main journals and therelevant bearings as follows:

Refit the main bearings that have not beenreplaced, in the same position found at removal.

CNH

PARTS

Fitting main bearings

CNH

PARTS

Do not try to adapt the bearings.

Main bearings (1) are supplied spare with 0.250 — 0.500 mmundersize on the internal diameter.

Clean accurately the main half bearings (1) having thelubricating hole and fit them into their housings.

The second last main half bearing (1) is fitted with shoulder half rings.

Check that gear toothing (1) is not damaged or worn,otherwise remove it using the proper puller (3).

When fitting the new gear, heat it to 180°C for 10 minutesin an oven and then key it to the crankshaft.

- clean accurately the parts and remove any trace of oil;

- position a piece of calibrated wire (3) on the crankshaftpins (4) so that it is parallel to the longitudinal axis;

- fit caps (1), including the half bearings (2) on the relevantsupports.

70186

70161

Replacing oil pump control gear Finding journal clearance

NOTE

NOTE

75703

D1D2

NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 andD2 diameters:

if D1- D2< 0,1 mmthescrewcan beutilised again;if D1 - D2 > 0,1 mm the screw must be replaced.

Revi - February 2007




This check is performed by setting a magnetic-base dial gauge(2) on the crankshaft (3) as shown in the figure, standardvalue is 0.068 to 0.41.

If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearancecheck between crankshaft pins and main half bearings.

70188

70189

70190

70191

Figure 35

Figure 36

Figure 37

Figure 38

- 3rd stage, with tool 380000304 (1) set as shown in the

figure, tighten the screws (2) with 90 ±

5°

angle.

- Remove caps from supports.

The backlash between the main bearings and the pins isfound by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1)containing the calibrated wire.

The numbers on the scale indicate the backlash in mm.

Replace the half bearings and repeat the check if a differentbacklash value is found. Once the specified backlash isobtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described.

CONNECTING ROD — PISTON ASSEMBLYCOMPONENTS

1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -6. Half bearings - 7. Connecting rod - 8. Bush.

α

Checking crankshaft shoulder clearance

The pistons are supplied spare with the followingsizes:

- standard;- 0.4 mm oversize.

CONNECTING ROD — PISTON ASSEMBLY

NOTE

70187

Tighten the pre-lubricated screws (1) in the following threesuccessive stages:- 1st stage, with torque wrench to 50 ± 6 Nm.- 2nd stage, with torque wrench to 80 ± 6 Nm.

Figure 39





32620

16552

32619

18857

Figure 45

Figure 46

Figure 47

Figure 48

To measure the piston pin (1) diameter use the micrometer (2).

Lubricate the pin (1) and its seat on piston hubs with engineoil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.


Check the clearance between the sealing rings (3) of the 2 nd

and 3rd slot and the relevant housings on the piston (2), usinga feeler gauge (1).

Piston pins

Figure 49

MAIN DATA OF THE PISTON WITHOUT PIN TUNNEL AND PLASTIC RINGS

* Value measured on 101 mm diameter

Conditions for proper pin-piston coupling

114798




41104

Figure 50

Figure 51

Figure 52


DIAGRAM FOR MEASURING THE CLEARANCE XBETWEEN THE FIRST PISTON SLOT AND THE

TRAPEZOIDAL RING

Since the first sealing ring section is trapezoidal, the clearancebetween the slot and the ring shall be measured as follows:make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).

In this position, use a feeler gauge to check the clearance (X)between ring and slot: found value shall be the specified one.

70194

Use feeler gauge (1) to measure the clearance between theends of the split rings (2) fitted into the cylinder barrel (3).

MAIN DATA FOR CONNECTING ROD, BUSH, PISTONPIN AND HALF BEARINGS

Connecting rods

* Value for inside diameter to be obtained after driving inconnecting rod small end and grinding.

The surface of connecting rod and rod cap areknurled to ensure better coupling.Therefore, it is recommended not to smooth theknurls.

88607

NOTE




70196

Figure 53 BushesCheck that the bush in the connecting rod small end is freefrom scoring or seizing and that it is not loosen. Otherwisereplace.

Removal and refitting shall be performed using the proper beater.

When refitting take care to make coincide the oil holes set

on the bush with those set on the connecting rod small end.Grind the bush to obtain the specified diameter.

Every connecting rod is marked as follows:

- On body and cap with a number showingtheir coupling and the corresponding cylinder.In case of replacement it is therefore necessary

to mark the new connecting rod with the samenumbers of the replaced one.

- On body with a letter showing the weight of the connecting rod assembled at production:

S V, 1820 to 1860 (yellow marking);

S W, 1861 to 1900 (green marking);

S X, 1901 to 1940 (blue marking);

Spare connecting rods are of the W class withgreen marking *.

Material removal is not allowed.

*

CONNECTING ROD BODY

CONNECT-ING RODBODY

CONNECT-ING RODBODY

CONNECT-ING RODBODY

CONNECT-ING RODBODY

CONNECTING RODBODY

CONNECTING ROD BODY

NOTE70198

Figure 54

Fitting connecting rod-piston assemblyConnecting rod-piston coupling

The piston crown is marked as follows:1. Part number and design modification number;2. Arrow showing piston assembling direction into cylinder

barrel, this arrow shall face the front key of the engine

block;3. Manufacturing date.4. Marking showing 1st slot insert testing;

Figure 55

Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into thecylinder barrel and the numbers (5) marked on the

connecting rod (5) are read as shown in the figure.

108597




72705

32613

70200

70201

Figure 56

Figure 57

Figure 58

Figure 59

Position the piston (1) on the connecting rod according to the diagram shown in the figure, fit the pin (3) and stop it by the split rings (2).

Fitting split rings

Use pliers 380000221 (3) to fitthe splitrings (1) on thepiston(2).Split rings shall be fitted with the marking “TOP” facingupwards and their openings shall be displaced with eachother by 120°.

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

Lubricate accurately the pistons, including the split rings and the cylinder barrel inside.

Use band 380000220 (2) to fit the connecting rod-pistonassembly (1) into the cylinder barrels and check thefollowing:

- the number of each connecting rod shall correspond to

the cap coupling number.

Split rings are supplied spare with the followingsizes:

- standard, yellow marking;

- 0.4 mm oversize, yellow/green marking;

Fitting connecting rod-piston assembly intocylinder barrels

Refit the main bearings that have not beenreplaced, in the same position found at removal.Do not try to adapt the half bearings.

NOTE

NOTE




70203

70204

70205

70206

Figure 60

Figure 61

Figure 62

Figure 63

Figure 64

DIAGRAM FOR CONNECTING ROD-PISTONASSEMBLY FITTING INTO BARREL

- Split ring openings shall be displaced with each other by 120°;

- connecting rod-piston assemblies shall have the same

weight;- thearrow markedon thepiston crown shall befacing the

front side of the engine block or the slot obtained on thepiston skirt shall be corresponding to the oil nozzleposition.

Finding crankpin clearance

To measure the clearance proceed as follows:- clean the parts accurately and remove any trace of oil;

- set a piece of calibrated wire (2) on the output shaft pins(1);

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

- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench(2).

- Apply tool 380000304 (1) to the socket wrench and tighten screws (2) of 60°.

- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale

on the wire envelope (2).

α

α

108596

Before the final fitting of the connecting rod capfastening screws, check that their diameter measured at the centre of the thread length is not< 0.1 mm than the diameter measured at approx.

10 mm from screw end.

NOTE





70207

70208

Figure 65

If a different clearance value is found, replacethe half bearingsand repeat the check.

Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening theconnecting rod cap fastening screws to the specified torque.

Once connecting rod-piston assemblies refitting is over, usedial gauge 380000228 (1) fitted with base 380000364 (2) tocheck piston (3) protrusion at T.D.C. with respect to the top

of the engine block.

Protrusion shall be 0.28 to 0.52 mm.

Checking piston protrusion

Figure 66





70319

Figure 67

Intake (1) and exhaust (2) valves have heads with the samediameter.

The central notch (→) of the exhaust valve (2) headdistinguishes it from the intake valve.

Should cylinder head valves be not replaced,number them before removing in order to refit them in the same position.

A = intake side — S = exhaust side

CYLINDER HEADRemoving the valves

Valve removal shall be performed using tool 380000302 (1)and pressing the cap (3) so that when compressing thesprings (4) the cotters (2) can be removed. Then remove thecap (3) and the springs (4).

Repeat this operation for all the valves.

Overturn the cylinder head and withdraw the valves (5).

70321

70322

Figure 68

Figure 69

Remove sealing rings (1 and 2) from the valve guide.

Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

NOTE

NOTE




70323

Figure 70

Figure 71

This check shall be performed using the proper tools.

Use a pump to fill with water heated to approx. 90°C and 2 to 3 bar pressure.

Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting.

Replace the cylinder head if leaks are found.

Distortion found along the whole cylinder head shall notexceed 0.20 mm.

If higher values are found grind the cylinder head according to values and indications shown in the following figure.

Checking cylinder head wet seal

Before refitting, smear the plug surfaces withwater-repellent sealant.

Checking cylinder head supporting surface

70325

The ratedthickness A for the cylinder headis 105 ± 0.25 mm,max. metal removal shall not exceed thickness B by 1 mm.

After grinding, check valve sinking. Regrind thevalve seats, if required,to obtain the specified value.

NOTE

NOTE




18625

18882

70327

Figure 72

Figure 73

Figure 74

Figure 75

VALVES

INTAKE AND EXHAUST VALVE MAIN DATA

Remove carbon deposits from valves using the proper metalbrush.

Check that the valves show no signs of seizing, scoring or cracking.

If necessary, rectify the valve seats, taking away the least

amount of material possible.

Check the valve stem (1) using a micrometer (2), it shall be6.970 ÷ 6.990.

Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 ÷ 0.092 mm.

Turn the valve (2) and check that the centering error is notexceeding 0.03 mm.

Removing carbon deposits, checking andgrinding valves

CNH

PARTS

Checking clearance between valve stem andvalve guide and valve centering

INTAKEVALVE

EXHAUSTVALVE

107280




EXHAUST 79457

70330

70331

Figure 76

Figure 77

Use a bore dial gauge to measure the inside diameter of thevalve guides, the read value shall comply with the valueshown in the figure.

Should slight scratches or burns be found, go over with theadequate tool (1) according to the inclination valuesindicated in the Figure 78.

VALVE SEATSRegrinding — replacing the valve seats

VALVE SEAT MAIN DATA (4 CYL.)

INTAKE EXHAUST

INTAKE

Figure 78

VALVE GUIDE




70332

Figure 79

Should valve seats be not reset just by regrinding, replace them with the spare ones. Using a suitable tool, remove asmuch material as possible from the valve seats (take care not to damage the cylinder head) until they can be extractedfrom the cylinder head using a punch.

Heat the cylinder head to 80° - 100°C and using the proper punch, fit the new valve seats, previously cooled, into thecylinder head.

Therefore, with an adequate tool, go over the valve seatsaccording to the values stated in the Figure 78.

MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD

EXHAUST INTAKE

Figure 80

70333

After regrinding, check that valve (3) sinking value is thespecified one by using the base 380000364 (2) and the dialgauge 380000228 (1).




50676

70334

770321

Figure 81 Figure 82

MAIN DATA TO CHECK INTAKE AND EXHAUSTVALVE SPRINGS

Before refitting use tool to check spring flexibility. Compareload and elastic deformation data with those of the newsprings shown in the following table.

FITTING CYLINDER HEAD

Lubricate the valve stems (1) and fit them into the relevantvalve guides according to the position marked at removal.

Fit the sealing rings (2 and 3) on the valve guide.

Position on the cylinder head: the spring (4), the upper cap(3); use tool 380000302 (1) to compress the spring (4) andlock the parts to the valve (5) by the cotters (2).

Sealing rings (2) for intake valves are yellow andsealing rings (3) for exhaust valves are green.

CNH

PARTS

VALVE SPRINGS

Figure 83

NOTE


Height Under a load of

mm N

H 47.75 Free

H1 35.33 P 339.8 ± 19 N

H2 25.2 P1 741 ± 39 N



Check cleanness of cylinder head and engine block couplingsurface.Take care not to foul the cylinder head gasket.

Set the cylinder head gasket (1) with the marking “TOP” (1)facing the head.The arrow shows the point where the gasket thickness isgiven.

70335

Figure 84

Refitting the cylinder head

CNH

PARTS

88775

Figure 85

CNH

PARTS

There are twotypes of head seals,for thethickness (1.25 mmType A and 1.15 mm Type B) take the following measures:

- for each piston detect, as indicated on Figure 85, at adistance of 45 mm from the centre of the pistonoverhandings S1 and S2 in relation to the engine baseupper plane then calculate the average:


Repeat the operation for pistons 2, 3 and 4 and calculate theaverage value.


Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.

If S is > 0,40 mm use seal type A.If S is < 0,40 mm use seal type B.

S =Scil1+ Scil2+ Scil3+ Scil4+ Scil5+ Scil6

6

Scil1 =S1+ S2

2

S =Scil1+ Scil2+ Scil3+ Scil4

4

75703

D1D2

NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 andD2 diameters:

if D1- D2< 0,1 mmthescrewcan beutilised again;if D1 - D2 > 0,1 mm the screw must be replaced.






TIGHTENING TORQUETORQUE

Nm kgm

Studs M6 for camshaft sensors 8 ± 2 0.8 ± 0.2

Studs M8 for feed pump 12 ± 2 1.2 ± 0.2

Screw M12 for fastening rear gear case

Screw M10 for fastening rear gear caseScrew M8 for fastening rear gear case

77 ± 12

47 ± 524 ± 4

7.7 ± 1.2

4.7 ± 0.52.4 ± 0.4

Nut M6 for fastening camshaft sensor 10 ± 2 1 ± 0.2

Screw M8 for fastening oil pump 1st stage

2nd stage8 ± 1

24 ± 40.8 ± 0.12.4 ± 0.4

Screw M8 for fastening front cover 24 ± 4 2.4 ± 0.4

Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4


Screw M10 for fastening crankcase plate 43 ± 5 4.3 ± 0.4

Nut M18 for fastening high pressure pump gear 105 ± 5 10.5 ± 0.5

Nuts M8 for fastening fuel pump 24 ± 4 2.4 ± 0.4

½ inch plug on cylinder head

¼ inch plug on cylinder head¾ inch plug on cylinder head

24 ± 4

36 ± 512 ± 2

2.4 ± 0.43.6 ± 0.51.2 ± 0.2

1st stage 8.5 ± 0.35 0.85 ± 0.035Screw M6 for fastening injectors


Nut fastening for injector feed connector 50 ± 5 5 ± 0.5

Nut M6 for flame start grille on intake manifold 8 ± 2 0.8 ± 0.2

Screw M8 for fastening intake manifold 24 ± 4 2.4 ± 0.4

Screw M12 for fastening rear brackets for engine lifting 77 ± 12 7.7 ± 1.2

Screws M8 for fastening Common Rail 24 ± 4 2.4 ± 0.4

Connectors M14 for high pressure fuel pipes 20 ± 2 2 ± 0.2

Screw M12 (12 x 1.75 x 130) for fastening cylinder headst

35 ± 5 3.5 ± 0.5

Screw M12 (12 x 1.75 x 150) for fastening cylinder head 1s

stage 55 ± 5 5.5 ± 0.52nd stage 90º ± 5º


Screw for fastening rocker bracket 36 ± 5 3.6 ± 0.5

Valve clearance adjusting nuts 24 ± 4 2.4 ± 0.4

Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail 20 ± 2 2 ± 0.2

Screw M8 for fastening high pressure pipe connector 24 ± 4 2.4 ± 0.4

Screw M6 for fastening wiring bulkhead 10 ± 2 1 ± 0.2

Screw M8 for fastening electric wiring support for injector feed 24 ± 4 2.4 ± 0.4

Nuts for fastening wiring on each injector 1.5 ± 0.25 0.15 ± 0.025

Screw M12 for fastening fuel filter bracket 77 ± 8 7.7 ± 0.8

Screw M8 for fastening fuel filter holder 24 ± 4 2.4 ± 0.4Fuel filter contact + ¾ turn

Screw M22 for fastening oil pressure relief valve on oil fi lter support 80 ± 8 8 ± 0.8

Screw M8 for radiator seal and oil filter support 24 ± 4 2.4 ± 0.4

Oil filter contact + ¾ turn

11/8 inch connection on filter support for turbine lubrication 24 ± 4 2.4 ± 0.4

Nut M12 for fastening turbine lubrication pipe 10 ± 2 1 ± 0.2

Screw M10 for fastening engine coolant inlet connection 43 ± 6 4.3 ± 0.6

90° elbow fastening (if required) to engine coolant inlet connection 24 ± 4 2.4 ± 0.4

Pipe on cylinder head for compressor cooling 22 ± 2 2.2 ± 0.2




TORQUE

Nm kgm

Screw M6 for fastening engine coolant drain connector 10 ± 2 1 ± 0.2

Pin fastening on engine block for exhaust manifold 10 ± 2 1 ± 0.2

Screw M10 for fastening exhaust manifold on cylinder head 53 ± 5 5.3 ± 0.5

Screw M12 for fastening damper adapter 1st stage 50 ± 5 5 ± 0.5

and damper on output shaft 2nd stage 90º

Screw M10 for fastening pulley on output shaft 68 ± 7 6.8 ± 0.7

Screw M8 for fastening water pump 24 ± 4 2.4 ± 0.4

Screw M10 for fastening auxiliary component control belt tensioners 43 ± 6 4.3 ± 0.6

Screw M10 for fastening fixed pulleys for auxiliary component control belt 43 ± 6 4.3 ± 0.6

Screw M10 for fastening flywheel housingScrew M12 for fastening flywheel housing

85 ± 10

49 ± 58.5 ± 1

4.9 ± 0.5

Screw M6 for fastening heat exchanger for control unitScrew M8 for fastening heat exchanger for control unit

10 ± 2

24 ± 41 ± 0.2

2.4 ± 0.4

Connection M12 for fuel inlet-outlet on heat exchanger 12 ± 2 1.2 ± 0.2

Nut M8 for fastening valve cover 24 ± 4 2.4 ± 0.4

Screw M6 for fastening camshaft sensor 8 ± 2 0.8 ± 0.2Screw M6 for fastening output shaft sensor 8 ± 2 0.8 ± 0.2

Screw M14 for fastening coolant temperature sensor 20 ± 3 2 ± 0.3

Screw M5 for fastening oil pressure/temperature sensor 6 ± 1 0.6 ± 0.1

Screw for fastening fuel pressure sensor 35 ± 5 3.5 ± 0.5

Screw M14 for fastening fuel temperature sensor 20 ± 3 2 ± 0.3

Screw for fastening air temperature/pressure sensor on intake manifold 6 ± 1 0.6 ± 0.1

Screw M12 for fastening engine oil level sensor 12 ± 2 1.2 ± 0.2

pins M86-c l.

7 ± 1 0.7 ± 0.1

Turbine fixing to exhaust manifoldnu ts M8

- .

ins M8

43 ± 6 4.3 ± 0.6

4-cyl. nuts M8±

24 ±

4

. ± .

2.4 ±

0.4Adapter M12 on turbine for lubricant oil pipes (inlet) 35 ± 5 3.5 ± 0.5

Pipe fixing on adapter M10 for turbine lubrication 35 ± 5 3.5 ± 0.5

Oil pipe fixing on adapter M10 for turbine lubrication to block 43 ± 6 4.3 ± 0.6

Oil drain pipe fixing M8 on turbine 24 ± 4 2.4 ± 0.4

Connector fixing M6 for oil return from cylinder head to flywheel housing 10 ± 2 1 ± 0.2

Screw M12 for fastening engine flywheel 1st stage 30 ± 4 3 ± 0.4


Screw M8 for fastening front bracket for engine lifting 24 ± 4 2.4 ± 0.4

Screw for fastening engine oil sump 24 ± 4 2.4 ± 0.4

Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3

Screw M12 for fastening output shaft caps 1st

stage2nd stage 50 ±

680 ± 6 5 ±

0.68 ± 0.6


Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4


Screw M11 for fastening connecting rod caps 1st stage 60 ± 5 6 ± 0.5


Alternator

M10 Screw, Bracket fixing on water feed pipefitting 43 ± 6 4.3 ± 0.6

M10 Screw, alternator locking 43 ± 6 4.3 ± 0.6

Starter

Starter fixing screw 43 ± 6 4.3 ± 0.6



SECTION 5 - TOOLS 1NEF ENGINES

SECTION 5

Tools

Page

TOOLS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



2 SECTION 5 - TOOLS NEF ENGINES




TOOLS

TOOL NO. DESCRIPTION

380000144 Tool for flywheel holding

380000216 Lifting rig for engine removal/refitting

380000220 Band for fitting piston into cylinder barrel (60 — 125 mm)

380000221 Pliers for removing/refitting piston rings (65 — 110 mm)

380000228 Dial gauge (0 — 5 mm)

380000229 Dial gauge holder for rotary injection pump timing (use with

380000228)





380000661 Brackets for fastening engine to revolving stand 99322205

380000663 Tool to remove output shaft rear gasket

380000664 Tool for fitting output shaft rear gasket

380000665 Tool to remove output shaft front gasket

380000666 Tool for fitting output shaft rear gasket

380000667 Beater for removing/refitting camshaft bushes (to be used with

380000668)




v


380000668 Interchangeable willow handgrip

380000669 Tool to remove gaskets

380000670 Tool to remove oil filter (engine)

380000671 Tool to remove injectors

380000988 Tool for stopping the engine flywheel

380000989 Adapter, cylinder compression test (use with 380001006)





380000997 Gauge base for different measurements (to be used with 380001005)

380001005 Dial gauge (0 — 10 mm)

380001006 Diesel fuel engine cylinder compression control device

380002385 Flywheel crank handle

3800002729 Band for fitting piston into cylinder barrel (60 — 125 mm)



SECTION 6 - ENGINES FEATURES F4CE - F4DE - F4GE - F4HE 1NEF ENGINES

SECTION 6

Engines featuresF4CE - F4DE - F4GE - F4HE

Page

ENGINES F4CE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

- General characteristics 3. . . . . . . . . . . . . . . . . .

- Clearance data 9. . . . . . . . . . . . . . . . . . . . . . . .

ENGINES F4DE 15. . . . . . . . . . . . . . . . . . . . . . . . . . .


- Clearance data 19. . . . . . . . . . . . . . . . . . . . . . . .

ENGINES F4GE 25. . . . . . . . . . . . . . . . . . . . . . . . . . .


- Clearance data 27. . . . . . . . . . . . . . . . . . . . . . . .

ENGINES F4HE 35. . . . . . . . . . . . . . . . . . . . . . . . . . .


- Clearance data 37. . . . . . . . . . . . . . . . . . . . . . . .




F4CE ENGINESGeneral characteristics

Type F4CE9484


Power Supercharged with intercooler

Injection Direct


∅

Bore mm 104

Stroke mm 132


TIMING


--


--

X

Checking timingmm

Xmm


Xmm

-

-

0.25 to 0.05

0.50 to 0.05

FUEL FEED

Injection

Type: Bosch VE 4/12 F

Nozzle type -


bar

Injection pressure bar -



Data, features and performances are valid only if the setter fully complies with all the installation prescriptions providedby FPT.

Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns

based on which the engine has been designed.

NOTE

4 SECTION 6 - ENGINES FEATURES F4CE - F4DE - F4GE - F4HE NEF ENGINES

Type F4CE9484A*J600

ρ Compression ratio 16.5:1

Max. output kW

(HP)rpm

56(76)

2300

Max. torque Nm(kgm)rpm

340(34.7)

1300

Loadless engineidling rpm

-

Loadless enginepeak rpm rpm

-

Bore x stroke mmDisplacement cm3

104 x 1324485

SUPERCHARGING with intercooler

Turbocharger type -

bar

LUBRICATION

Oil pressure(warm engine)

- idling bar

- peak rpm bar

Forced by gear pump, relief valve single actionoil filter

-

-

COOLING

Water pump controlThermostat- start of opening ºC

Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING

- engine sump*liters

engine sump + filter liters

-

-






NOTE


Type F4CE9484D*J600


Max. output kW(HP)

rpm

82(111)

2200

Max. torque Nm(kgm)

rpm

455(46.4)

14000

Loadless engineidling

rpm -

Loadless enginepeak rpm

rpm -

Bore x stroke mmDisplacement cm3 104 x 132

4485


Turbocharger type HOLSET HX25

bar

LUBRICATION


- idling bar - peak rpm bar


-

-

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4CE9484L*J600


Max. output kW(HP)

rpm

78(106)

2300

Max. torque Nm(kgm)

rpm

448(45.7)

1300


rpm -

Loadless enginepeak

rpm -


4485


Turbocharger type -

bar

LUBRICATION




--

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4CE9484M*J601


Max. output kW(HP)

rpm

71(97)

2300

Max. torque Nm(kgm)

rpm

418(42,6)

1300


rpm -

Loadless enginepeak

rpm -


4485


Turbocharger type -

bar

LUBRICATION




--

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4CE9484N*J601


Max. output kW(HP)

rpm

63(86)

2300

Max. torque Nm(kgm)

rpm

370(37.7)

1300


rpm -

Loadless enginepeak

rpm -


4485


Turbocharger type -

bar

LUBRICATION




--

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-




Clearance data

Type F4CE9484


∅1

X


0.4

∅1

X

∅ 2

Pistons

Size XOutside diameter ∅ 1Pin housing ∅ 2

55.9103.714 to 103.732

38.010 to 38.016


CNH


X

Piston protrusion X -

3∅ Piston pin ∅ 3 37.994 to 38.000





Type F4CE9484


X

1

3

2

X

X


X 3* measured on 101 mm ∅

2.705 to 2.735*2.440 to 2.460

4.030 to 4.050

1

3

2S

S

SS 1*

Split rings S 2S 3

2.560 to 2.6052.350 to 2.3803.970 to 3.990


3

0.100 to 0.1750.060 to 0.1100.040 to 0.080

CNH


X 1

3

2X

X


X 1X 2X 3

0.30 to 0.400.60 to 0.800.30 to 0.55

1∅

∅ 2


40.987 to 41.013

72.987 to 73.013

∅

S


38.019 to 38.033

1.955 to 1.968


CNH





Type F4CE9484


X

Size X


-

-


82.990 to 83.01068.987 to 69.013

1 2∅∅

S 1 S 2

Main half bearings S 1

Big end half bearings S 2

2.456 to 2.464

1.955 to 1.968

3∅


87.982 to 88.00887.977 to 88.013

Half bearings — JournalsNo. 1 — 5No. 2 — 3 — 4

0.064 to 0.0950.059 to 0.100


CNH

PARTS


0.250 to 0.500

1X


X 2







Type F4CE9484


∅ 1


∅

α

4 Valves:

∅ 4α

∅ 4α

7.960 to 7.98060°

7.960 to 7.98045°


∅ 1


∅1

∅1

46.987 to 47.013

43.637 to 43.663

α

2∅


∅ 2α

∅ 2α

47.063 to 47.08960o

43.713 to 43.73945o

X

X

Sinking X

1 to 1.52

1.05 to 1.52


0.050 to 0.102

0.050 to 0.102

CNH

PARTS Valve seats -




Type F4CE9484


H H 1H 2

Valve spring height:

free spring H

under a load equal to:339.8 ± 9 N H1741 ± 39 N H2

63.50

49.0238.20

X

Injector protrusion X not adjustable

∅∅∅

1 2 3 4 5

Camshaft bushhousings No. 1-5

Camshaft housingsNo. 2-3-4

59.222 to 59.248

54.089 to 54.139

∅

∅

∅1

2

3

Camshaft journals:1 ⇒ 5 ∅ 53.995 to 54.045

∅ Bush inside

diameter ∅ 54.083 to 54.147

Bushes and journals

Housings and journals

0.038 to 0.162

0.044 to 0.144

H

Cam lift:

H

H

11.02

10.74




F4DE ENGINESGeneral characteristics

Type F4DE9484


Power Supercharged with intercooler

Injection Direct


∅

Bore mm 104

Stroke mm 132


TIMING


--


--

X

Checking timingmm

Xmm


Xmm

-

-

0.20 to 0.30

0.45 to 0.55

FUEL FEED

InjectionType: Bosch high pressure common rail

EDC7 ECU

Injectors CRIN 2

Nozzle type DSLA and DLLA


bar

Injection pressure bar 0.250 - 1600






NOTE


Type F4DE9464B*J101


Max. output kW(HP)

rpm

97(132)

2200

Max. torque Nm(kgm)

rpm

534(54.4)

1400


-

Loadless enginepeak rpm rpm

-

2500


104 x 1324485


Turbocharger type -

bar

LUBRICATION

Oil pressure

(warm engine)



--

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4DE9484D*J101


Max. output kW(HP)

rpm

89(121)

2200

Max. torque Nm(kgm)

rpm

563(57.4)

14000


rpm -


rpm -


4485


Turbocharger type -

bar

LUBRICATION




--

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-




Clearance data

Type F4DE9484


∅1

X


0.4

∅1

X

∅ 2


55.9103.714 to 103.732

38.010 to 38.016


CNH


X

Piston protrusion X -

3∅ Piston pin ∅ 3 37.994 to 38.000





Type F4DE9484


X

1

3

2

X

X

X1*

Split ring slots X 2X 3

2.705 to 2.735

2.440 to 2.4604.030 to 4.050

1

3

2S

S

SS 1*

Split rings S 2S 3

* measured on 98 mm ∅

2.560 to 2.6052.350 to 2.3803.970 to 3.990


3

0.100 to 0.1750.060 to 0.1100.040 to 0.080

CNH


X 1

3

2X

X


X 1X 2X 3

0.30 to 0.400.60 to 0.800.30 to 0.55

1∅

∅ 2


42.987 to 43.553

72.987 to 73.013

∅

S


38.019 to 38.033

1.955 to 1.968


CNH





Type F4DE9484


1 2∅∅

S 1 S 2

Journals ∅ 1

Crankpins ∅ 2

Main half bearings S 1Big end half bearings S 2

*provided as spare part

82.99 to 83.01

68.99 to 69.01

2.456 to 2.4641.955 to 1.968

3∅


87.982 to 88.00887.977 to 88.013

Half bearings — JournalsNo. 1 — 5

No. 2 — 3 — 4

0.041 to 0.119

0.041 to 0.103Half bearings - Crankpins 0.033 to 0.041

CNH

PARTS


0.250 to 0.500

1X


X 2







Type F4DE9484


∅ 1


2∅

∅ 3

∅ 2Valve guides

∅ 3

-

-

Valve guides and seats on head -

CNH

PARTSValve guides -

∅

α

4 Valves:

∅ 4α

∅ 4α

6.970 to 6.99960o ± 0.25o

6.970 to 6.99945o ± 0.25o


∅ 1


∅1

∅1

34.837 to 34.863

34.837 to 34.863

α

2∅


∅ 2α

∅ 2α

34.917 to 34.93160o

34.917 to 34.93145o

X

X

Sinking X

0.59 to 1.11

0.96 to 1.48


0.054 to 0.094

0.054 to 0.094

CNH

PARTSValve seats -




Type F4DE9484


H H 1H 2


free spring H


47.75

35.3325.2

X

Injector protrusion X -

∅∅∅

1 2 3 4 5

Camshaft bushhousings No. 1-5

Camshaft housingsNo. 2-3-4

59.222 to 59.248

54.089 to 54.139

∅

∅

∅1

2

3


∅ Bush inside

diameter ∅ 54.083 to 54.147

Bushes and journals 0.038 to 0.162

H

Cam lift:

H

H

6.045

7.582




Type F4DE9484


∅ 1Tappet cap housing

on block ∅ 1 16.000 to 16.030

∅ 23

∅

∅

2

Tappet cap outsidediameter: ∅ 2

∅ 315.924 to 15.95415.960 to 15.975

Between tappets and housings 0.025 to 0.070

CNH

PARTSTappets -

∅ 1

Rocker shaft ∅ 1 21.965 to 21.977

∅ 2

Rockers ∅ 2 22.001 to 22.027

Between rockers and shaft 0.024 to 0.162



Data, features and performances are valid only if the setter fully complies with all the installation prescriptions providedby CNH.



NOTE


F4GE ENGINEGeneral characteristics

Type F4CE9454C*J602


Max. output kW(HP)

rpm

67(91)

2300

Max. torque Nm(kgm)

rpm

372(38)

1300


1150


rpm 2530Bore x stroke mmDisplacement cm3

104 x 1324485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING

- engine sump

liters


13

14






NOTE


Type F4GE9484D*J600


Max. output kW(HP)

rpm

93(126)

2200


510(52)

1250


rpm -


rpm -


4485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING

- engine sump

liters


-

-






NOTE


Clearance data

Type F4GE9484E*J600


Max. output kW

(HP)

rpm

90

(122)

2000


525(53.5)

1200


rpm-

Loadless engine

peak rpmrpm -


104 x 1324485



bar

LUBRICATION

Oil pressure

(warm engine)



0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING

- engine sumpliters


-

-






NOTE


Type F4GE9484H*J600


Max. output kW(HP)

rpm

84(114)

2000

Max. torque Nm(kgm)

rpm

495(50.5)

1200


rpm -


rpm -


4485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4GE9484J*J600


Max. output kW(HP)

rpm

88(120)

2200


515(52.5)

1250


rpm -


rpm -


4485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4GE9484A*J601


Max. output kW(HP)

rpm

94(128)

2300


1300

515(52.5)


rpm -


rpm -


4485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4GE9484K*J601


Max. output kW

(HP)rpm

74(101)

2300

Max. torque Nm(kgm)

rpm

-(-)

-


rpm -


rpm -


4485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


TypeType

F4GE9484A*J602

F4GE06


Max. output kW

(HP)rpm

94(128)

2300


515(52.5)

1300


rpm -


rpm -


4485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING



-

-






NOTE


Type F4GE9484D*J603


Max. output kW

(HP)rpm

93(126)

2200

Max. torque Nm(kgm)

rpm

510(52)

1250


rpm-


rpm -Bore x stroke mmDisplacement cm3

104 x 1324485



bar

LUBRICATION




0.703.50

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING

- engine sump*

liters


-

-




F4HE ENGINESGeneral characteristics

Type F4HE9484


Power Turbocharged with intercooler Injection Direct

Number of cylinders 4

∅

Bore mm 104

Stroke mm 132


TIMING


18.5º29.5º


67º35º

X

Checking timingmm

Xmm


Xmm

-

-

0.20 to 0.30

0.45 to 0.55

FUEL FEED

InjectionType: Bosch

high pressure common railEDC7 ECU

Injector CRIN 2

Nozzle type DSLA and DLLA


bar

Injection pressure bar 250 - 1600






NOTE


Type F4HE9484C*J102


Max. output kW(HP)

rpm

82(111)

2200

Max. torque Nm(kgm)

rpm

1400

516(52.6)


rpm 950


rpm 2430


4485


Turbocharger type -

bar

LUBRICATION




--

COOLING


Liquid

Through belt

81 ± 2

15W40 ACEA E3

FILLING

- engine sumpliters


-

-




Clearance data

Type F4HE9484


∅1

X

Cylinder barrels ∅1

∅1

104.000 to 104.024

0.4

∅1

X

∅ 2


55.9103.714 to 103.732

38.010 to 38.016

CNH


X

Piston protrusion X 0.28 to 0.52

3∅ Piston pin ∅ 3 37.994 to 38.000





Type F4HE9484


X

1

32

X

X


X 3

* measured on 101 mm

2.705 to 2.7352.440 to 2.460

4.030 to 4.050

1

3

2S

S

SS 1*

Split rings S 2S 3

2.560 to 2.6052.350 to 2.3803.970 to 3.990


3

0.100 to 0.1750.060 to 0.1100.040 to 0.080

CNH


X 1

3

2X

X

Split ring end openingX 1X 2X 3

0.30 to 0.400.60 to 0.800.30 to 0.55

1∅

∅ 2


40.987 to 41.013

72.987 to 73.013

∅

S

3 Small end bush diameter

Inside ∅ 3Big end half bearings S

38.019 to 38.033

1.955 to 1.968


CNH

PARTSBig end half bearings 0.250 ; 0.500




Type F4HE9484


X

Size X


-

-

1 2∅∅

S 1 S 2


Main half bearings S 1Big end half bearings S 2

82.99 to 83.0168.987 to 69.013

2.456 to 2.4641.955 to 1.968

3∅

Main bearingsNo. 1 — 5 / 1- 7 ∅ 3No. 2 — 3 — 4 ∅ 3

87.982 to 88.00887.977 to 88.013

Half bearings — JournalsNo. 1—5 / 1-7No. 2—3—4 / 2-3-4-5-6

0.041 to 0.1190.041 to 0.103


CNH

PARTS


0.250 to 0.500

1X


X 2







Type F4HE9484


∅ 1


∅

α

4 Valves:

∅ 4α

∅ 4α

6.970 to 6.99060o ± 0.25o

6.970 to 6.99045o ± 0.25o


∅ 1


∅1

∅1

34.837 to 34.863

34.837 to 34.863

α

2∅


∅ 2α

∅ 2α

34.917 to 34.93160o

34.917 to 34.93145o

X

X

Sinking X

0.59 to 1.11

0.96 to 1.48


0.054 to 0.094

0.054 to 0.094

CNH

PARTS Valve seats -




Type F4HE9484


H H 1H 2


free spring H


47.75

35.3325.2

X

Injector protrusion X -

∅∅∅

1 2 3 4 5

Camshaft bushhousings No. 1(flywheel side)

Camshaft housingsNo. 2-3-4-5/2-3-4-5-6-7 ∅

59.222 to 59.248

54.089 to 54.139

∅

∅

∅1

2

3


∅ Bush inside

diameter ∅ 54.083 to 54.147

Bushes and journals 0.038 to 0.162

H

Cam lift:

H

H

6.045

7.582




Type F4HE9484


∅ 1Tappet cap housing

on block ∅ 1 16.000 to 16.030

∅ 23

∅

∅

2

Tappet cap outsidediameter: ∅ 2

∅ 315.924 to 15.95415.960 to 15.975

Between tappets and housings 0.025 to 0.070

CNH

PARTSTappets -

∅ 1

Rocker shaft ∅ 1 21.965 to 21.977

∅ 2

Rockers ∅ 2 22.001 to 22.027

Between rockers and shaft 0.024 to 0.162



APPENDIX 1NEF ENGINES

Appendix

Page

SAFETY PRESCRIPTIONS 3. . . . . . . . . . . . . . . . .



2 APPENDIX NEF ENGINES



Particular attention shall be drawn on some precautions thatmust be followed absolutely in a standard working area andwhose non fulfillment will make any other measure uselessor not sufficient to ensure safety to the personnel in-chargeof maintenance.

Be informed and inform personnel as well of the laws in forceregulating safety, providing information documentationavailable for consultation.

- Keep working areas as clean as possible, ensuringadequate aeration.

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

- Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnelmust be trained on intervention methods and priorities.

- Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequateindications of the emergency exit lines.

- Smoking in working areas subject to fire danger must bestrictly prohibited.

- Provide Warnings throughout adequate boards signalingdanger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.

- Do not execute any intervention if not provided withnecessary instructions.

- Do not use any tool or equipment for any differentoperation from the ones they’ve been designed andprovided for: serious injury may occur.

- In case of test or calibration operations requiring enginerunning, ensure that the area is sufficiently aerated or

utilize specific vacuum equipment to eliminate exhaustgas. Danger: poisoning and death.

SAFETY PRESCRIPTIONSStandard safety prescriptions

Prevention of injury

- Do not wear unsuitable cloths for work, with flutteringends, nor jewels such as rings and chains when workingclose to engines and equipment in motion.

- Wear safety gloves and goggles when performing thefollowing operations:- filling inhibitors or anti-frost- lubrication oil topping or replacement- utilization of compressed air or liquids under pressure

(pressure allowed: ≤ 2 bar)

- Wear safety helmet when working close to hangingloads or equipment working at head height level.

- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.

- Use protection cream for hands.

- Change wet cloths as soon as possible

- In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections.Ensure that hands and feet are dry and execute workingoperations utilizing isolating foot-boards. Do not carry out working operations if not trained for.

- Do not smoke nor light up flames close to batteries and to any fuel material.

- Put the dirty rags with oil, diesel fuel or solvents inanti-fire specially provided containers.

During maintenance

- Never open filler cap of cooling circuit when the engineis hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Waitunit the temperature decreases under 50ºC.

- Never top up an overheated engine with cooler andutilize only appropriate liquids.

- Always operate when the engine is turned off: whether

particular circumstances require maintenanceintervention on running engine, be aware of all risksinvolved with such operation.

- Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil.

- Keep the engine clean from oil tangles, diesel fuel and or chemical solvents.

- Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areasaerated. Whenever necessary wear safety mask.

- Do not leave rags impregnated with flammablesubstances close to the engine.

- Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate.

- Do not utilize fast screw-tightening tools.

- Never disconnect batteries when the engine is running.

- Disconnect batteries before any intervention on theelectrical system.

- Disconnect batteries from system aboard to load themwith the battery loader.

- After every intervention, verify that battery clamp

polarity is correct and that the clamps are tight and safefrom accidental short circuit and oxidation.

- Do not disconnect and connect electrical connectionsin presence of electrical feed.

- Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes)verifypresence of liquidor air under pressure. Take all necessary precautionsbleeding and draining residual pressure or closing dumpvalves. Always wear adequate safety mask or goggles.Non fulfillment of these prescriptions may cause seriousinjury and poisoning.

APPENDIX 3NEF ENGINES



- Respect of the Environment shall be of primary importance: all necessary precautions to ensurepersonnel’s safety and health shall be adopted.

- Be informed and inform the personnel as well of laws in

Respect of the Environment- Avoid incorrect tightening or out of couple. Danger:incorrect tightening may seriously damage engine’scomponents, affecting engine’s duration.

- Avoid priming from fuel tanks made out of copper alloysand/or with ducts not being provided with filters.

4 APPENDIX NEF ENGINES

case new holland kobelco iveco komatsu f4ce f4de f4ge f4he service repair manual for engine overhaul...

Documents