N TIER 3 SERIES Industrial application
N45 N45 ENT.X - N45 MSS.X - N45 MNS.X N45 MRT.X - N45 MST.X - N45 MNT.X
N67 N67 ENT.X - N67 ERT.X N67 MST.X - N67 MRT.X - N67 MNT.X
Technical and Repair manual
This publication contains data, features, instructions and methods for performing repair interventions on the assembly and its components. This publication is addressed to qualified, specialised personnel. Check that you have the publication related to the assembly on which you are about to work available before you start. Make sure that you have all the necessary safety apparatuses, such as, for example, protective eyewear, helmet, gloves, footwear, etc. Check that the working, lifting and transport equipment etc. is available and in working order. Make sure that the group is prepared and secured. Proceed by carefully observing the instructions contained herein and use the indicated specific tools to ensure correct repair procedures, observance of time schedules and safety of operators. All repair interventions are aimed at restoring the conditions of operation, efficiency and safety contemplated by FPT. All on-group interventions, aimed at implementing changes, alterations or other not authorised by FPT will relieve FPT from responsibility. Specifically, the warranty (where applicable) will be immediately cancelled. FPT cannot be held responsible for repair interventions. FPT is available to provide any additional information needed for performing the inventions and indications in the cases and situations not contemplated in this publication. The data contained in this publication may not be up-to-date if changes are made by the manufacturer at any time for technical or commercial reasons or if required to meet legal requirements of countries worldwide. Contact a FPT dealership before proceeding in the event of differences between the contents of this publication and the actual assembly. Reproduction, even partial, of this text and the illustrations contained herein is prohibited.
Publication edited by FPT Industrial S.p.A Via Puglia 15, 10156 Torino, Italia www.fptindustrial.com Print P2D32N003 E - 3a Ed. 05.2010 1st Updating 09.2012
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N TIER 3 SERIES
N TIER 3 ENGINES
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N F4HE engines
Part 1
N F4CE engines
Part 2
N F4DE engines
Part 3
N F4GE engines
Part 4
PT-BOX Instructions
Part 5
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N TIER 3 SERIES
INTRODUCTION
1
Introduction Page
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PREFACE TO USER’S GUIDELINE MANUAL . . . .
3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Service operations . . . . . . . . . . . . . . . . . . . . . .
3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . .
5
GENERAL WARNINGS ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . . .
7
- Bonding and screening . . . . . . . . . . . . . . . . . . .
8
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES . . . . . . . . . . . . . . . . . . . . .
10
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INTRODUCTION
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INTRODUCTION
3
PREFACE TO USER’S GUIDELINE MANUAL Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules. The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the control units peculiar to the electric system. Section 1 describes the engine illustrating its features and working in general. Section 2 describes the type of fuel feed. Section 3 relates to the specific duty and is divided in four separate parts: 1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating specific duty. 2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating specific duty. 3. Maintenance planning and specific overhaul. 4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct instructions to identify the cause of the major inconveniences. Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such operations. The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order to prevent serious accidents taking place. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - Warnings Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Danger of serious damage for the assembly Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may sometimes cause the warranty to become null and void.
!
General danger It includes the dangers of above described signals.
Environment protection Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect the environment as much as possible. NOTE
It indicates an additional explanation for a piece of information.
Service operations Example ∅1
Ø 1 = housing for connecting rod small end bush α
Tighten to torque Tighten to torque + angular value
∅ 2 Ø 2 = housing for connecting rod bearings
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INTRODUCTION
Removal Disconnection
Intake
Refitting Connection
Exhaust
Removal Disassembly
Operation
Fitting in place Assembly
α
!
N TIER 3 SERIES
ρ
Compression ratio
Tighten to torque
Tolerance Weight difference
Tighten to torque + angle value
Rolling torque
Press or caulk
Rotation
Regulation Adjustment
Angle Angular value
Warning Note
Preload
Visual inspection Fitting position check
Number of revolutions
Measurement Value to find Check
Temperature
Equipment
bar
Pressure
Surface for machining Machine finish
Oversized Higher than…. Maximum, peak
Interference Strained assembly
Undersized Less than…. Minimum
Thickness Clearance
Selection Classes Oversizing
Lubrication Damp Grease
Temperature < 0 °C Cold Winter
Sealant Adhesive
Temperature > 0 °C Hot Summer
Air bleeding
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INTRODUCTION
5
GENERAL WARNINGS
!
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check. The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path. Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it. In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel. Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position. Keep personnel not authorised to operations clear of working area. 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 supporting stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist. When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document, as well as all the specific safety standards provided for. Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful materials 12-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers. Worn out, damaged or consumable parts must be replaced by original spares. During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
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INTRODUCTION
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Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside. Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present. Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers. Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking nuts with an insert made of nylon must always be replaced. 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; FPT commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document. Before welding: - Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding) and detach connectors. - 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 materials flow which may catch fire easily on welding. Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
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INTRODUCTION
7
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
!
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated. Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals. Do not cause sparks to be generated in checking if the circuit is energised. Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses. Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with FPT 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 avoid the danger of causing a short circuit, as well as of damaging plugged connections, which would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only 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.
NOTE
Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable side.
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INTRODUCTION
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Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: -
Electronic central units must be connected to system bonding when they are provided with a metallic shell.
-
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.
Figure 1
1.
NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2.
SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE ! 0
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INTRODUCTION
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power 1 kW 1 kW 1 metric HP 1 metric HP 1 HP 1 HP
= = = = = =
1.36 metric HP 1.34 HP 0.736 kW 0.986 HP 0.746 kW 1.014 metric HP
Torque 1 Nm 1 kgm
= =
0.1019 kgm 9.81 Nm
OF
9
THE
Revolutions per time unit 1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602 Pressure 1 bar 1 kg/cm2 1 bar
= = =
1.02 kg/cm2 0.981 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° F 1° C = (1 x 1.8 + 32) ° F
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INTRODUCTION
N TIER 3 SERIES
KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of vehicle
Printout number
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Section title
Language Publication
Basic edition referred to month - year editorial phase closing
Page number
When month - year update is present (revi) to the basic edition
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1
F4HE N ENGINES
Part 1 F4HE N SERIES Section General specifications
1
Fuel
2
Industrial application
3
Overhaul and technical specifications
4
Tools
5
Safety prescriptions
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Appendix
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UPDATING Section 3
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Description
Page
Date of revision
Industrial application
19
Revi-September 2012
Base - May 2010 Revi - September 2012
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SECTION 1 - GENERAL SPECIFICATIONS
1
SECTION 1 General specifications
Page
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CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE . . . . . . .
3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
4
- 4-cylinder engine version . . . . . . . . . . . . . . . . .
4
- 6-cylinder engine version . . . . . . . . . . . . . . . . .
5
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . .
6
- Version with blow-by filter . . . . . . . . . . . . . . . .
6
- Version without blow-by filter . . . . . . . . . . . . .
7
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
8
- 4-cylinder engine version . . . . . . . . . . . . . . . . .
8
- 6-cylinder engine version . . . . . . . . . . . . . . . . .
9
AIR INDUCTION - BOOST DIAGRAM . . . . . . .
10
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) . . . . . . . . . . . . . . . . . . . . . . . .
11
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SECTION 1 - GENERAL SPECIFICATIONS
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CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code F4HE9484A*J101 F4HE9484A*J105 F4HE9684P*J101 F4HE9687B*J101 F4HE9687E*J101 F4HE9687X*J101 F4HE9684A*J100 F4HE9684Q*J100 F4HE9684W*J100 F4HE9687P*J100 F4HE9687A*J100
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Commercial Code N45 ENT.X
N67 ENT.X
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SECTION 1 - GENERAL SPECIFICATIONS
F4HE N ENGINES
LUBRICATION Lubrication by forced circulation is achieved through oil rotary expansion pump (1), placed in the front part of the basement, driven by the straight-tooth gear splined to the shaft’s bar hold.
Lubrication involves the heat exchanger as well, the turbo-blower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.
From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.
4-cylinder engine version Figure 1
(Demonstration)
Oil recover from the turbo-blower
To the exchanger and to the turbo-blower
Routing of oil return by gravity to sump
108511
Routing of oil return by gravity to sump Introduction of oil
LUBRICATION SYSTEM LAYOUT (4-cylinder engines)
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SECTION 1 - GENERAL SPECIFICATIONS
6-cylinder engine version Even for the 6 cylinders version lubrication is obtained by forced circulation and achieved through an oil rotary expansion pump similar to the 4 cylinders’ one.
Figure 2
5
Also in this case, the components such as the oil exchanger, the turbo-blower and the eventual compressor are specifically studied and made out to suit the equipment or the duty for which the engine has been developed.
(Demonstration)
Oil recover from the turbo-blower
To the exchanger and to the turbo-blower
Routing of oil under pressure 108512
Routing of oil return by gravity to sump Introduction of oil
LUBRICATION SYSTEM LAYOUT (6-cylinder engines) Print P2D32N003 E
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SECTION 1 - GENERAL SPECIFICATIONS
F4HE N ENGINES
OIL VAPOUR RECYCLING Version with blow-by filter Figure 3
70484
Oil condensate Oil vapours 1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine. The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and condenses a part of vapours at the same time. Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3). In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again through pipe (2).
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SECTION 1 - GENERAL SPECIFICATIONS
Version without blow-by filter Figure 4
Oil condensate Oil vapours
109903
1. Pre-separator - 2. Bleeder on side. The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and condenses a part of vapours at the same time. The condensed oil returns to the oil sump, whereas the residual vapour is conveyed, collected and discharged into the open air through the bleeder on the side (2). Print P2D32N003 E
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SECTION 1 - GENERAL SPECIFICATIONS
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COOLING SYSTEM The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment. - Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.
- Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment. - Centrifugal water pump, placed in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.
- Viscous pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development.
4-cylinder engine version Figure 5
Expansion tank
(Demonstration)
Expansion tank
Heater (optional)
Radiator
Radiator
Water coming out from thermostat Water recirculating in engine Water coming into pump 74194
COOLING SYSTEM LAYOUT 4-cylinder engines Base - May 2010
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9
6-cylinder engine version The engine cooling system, closed circuit forced circulation type, is of a similar design as the 4 cylinders engine. It incorporates necessary components such as the radiator, the heat exchanger, the expansion tank and some ancillary components such as the heater or the compressor for the compressed air. Such components always vary according to the engine’s equipment and duty.
Figure 6
(Demonstration) Expansion tank
Expansion tank
Heater (optional)
Radiator
Radiator
Water coming out from thermostat Water recirculating in engine Water coming into pump 108513
COOLING SYSTEM LAYOUT 6-cylinder engines Print P2D32N003 E
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SECTION 1 - GENERAL SPECIFICATIONS
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AIR INDUCTION - BOOST DIAGRAM Figure 7
4 Cylinders version
TURBOCHARGER
AIR FILTRE
EXHAUST
RADIATOR
6 Cylinders version
TURBOCHARGER
AIR FILTRE
EXHAUST
RADIATOR 74195
Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emissions flow through the body of the turbine, causing 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 drawn air through the air filter.
The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s funchon is to restrict the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
The above mentioned air is then cooled by the radiator and flown through the piston induction collector.
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SECTION 1 - GENERAL SPECIFICATIONS
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) In the TIER 3 version, the profile of the exhaust cam has been modified in order to allow the partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders. The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitric acid (NOx). The exhaust gas re-circulation system (EGR), reducing the combustion temperature by means of the diminishing of the concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission of NOx .
11
The internal EGR system is not equipped with any electronically controlled elements: the system is always active. Its configuration does not need additional elements i.e.checking valves, piping or heat exchangers. The exhaust cam (B) has another lobe apart from the major lobe (see Section. A-A fig.) with respects to the configuration without EGR. The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the aspiration phase inside the cylinder.
Figure 8
114789
A. Aspiration valve control - B. Exhaust valve control. Print P2D32N003 E
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SECTION 1 - GENERAL SPECIFICATIONS
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SECTION 2 - FUEL
1
SECTION 2 Fuel
Page
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HIGH PRESSURE ELECTRONIC INJECTION SYSTEM (COMMON RAIL) . . . . . . . . . . . . . . . . . . . . .
3
- Introduction . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Description of system . . . . . . . . . . . . . . . . .
3
- Electrical system . . . . . . . . . . . . . . . . . . . . . .
3
EDC 7 OPERATION . . . . . . . . . . . . . . . . . . . . .
5
WORKING PROCESS . . . . . . . . . . . . . . . . . . . .
6
FUEL SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . .
8
MECHANICAL FEEDING PUMP . . . . . . . . . . . .
10
- Ordinary working condition . . . . . . . . . . . . .
10
- Overpressure condition in Exhaust unit . . . .
10
- Jettison condition . . . . . . . . . . . . . . . . . . . . .
10
CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . .
11
- High pressure pump-inside structure . . . . . .
12
- Working principle . . . . . . . . . . . . . . . . . . . .
13
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . .
15
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . .
16
- Injector in rest position . . . . . . . . . . . . . . . .
16
- Injection start . . . . . . . . . . . . . . . . . . . . . . . .
16
- Injection end . . . . . . . . . . . . . . . . . . . . . . . .
16
PRESSURE LIMITER FOR FUEL RETURN . . . . . .
17
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SECTION 2 - FUEL
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HIGH PRESSURE ELECTRONIC INJECTION SYSTEM (COMMON RAIL) Introduction Extremely high injection pressures are necessary in order to reduce PARTICULATE emissions. The common rail system makes it possible to inject fuel at pressures of up to 1450 - 1600 bar, while the injection precision obtained by electronic control of the system serves to optimise operation of the engine while limiting emissions and fuel consumption.
SECTION 2 - FUEL
3
For engines more powerful than 152 kW, the CRIN2 injectors have DLLA nozzles that work up to a pressure of 1600 bar, whilst for engines less powerful than 152 kW, DSLA nozzles are fitted which work a pressures up to 1450 bar. Description of system The injection system is composed of an electrical part and a hydraulic part. Electrical system The electronic control unit monitors engine control parameters by means of the various sensors on the engine.
4 cylinders version Figure 1
108501
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.
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Base - May 2010
4
SECTION 2 - FUEL
F4HE N ENGINES
6 cylinders version Figure 2
107851
1. Connection to Electro-injectors - 2. Sensor monitoring temperature of engine’s cooling liquid - 3. Fuel pressure sensor cable - 4. Sensor of engine’s oil temperature and pressure - 5. Driving shaft sensor - 6. Electro-injector - 7. Temperature and air pressure sensor - 8. Camshaft sensor - 9. Fuel heater cable and fuel temperature sensor - 10. Pressure gauge cabling 11. EDC 7 gearbox.
Base - May 2010
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F4HE N ENGINES
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 be injected is determined at the time of starting. Injection control On the basis of information transmitted by the sensors, the control unit administrates the pressure regulator and modifies the pre-injection and main injection mode. On F4 engines pre-injection is activated at all engine speeds. Injection pressure closed loop control On the basis of the engine load, as determined by processing of data transmitted by the various sensors, the control unit administrates the regulator to maintain injection pressure at constantly optimal values. Pilot and main injection advance control On the basis of signals transmitted by the various sensors, the control unit determines the optimum injection point on the basis of internal mapping. Idle speed control The control unit processes signals transmitted by the various sensors and adjusts the quantity of fuel injected. It also controls the pressure regulator and modulates injection duration of the electro-injectors. Within specific limits, the control unit also monitors battery voltage. Overheating protection If the water temperature reaches 110 °C, the control unit reduces engine performance. When the temperature returns below 100 °C, the engine resumes normal operation, (in some applications, the over boosting temperature is the reference temperature). Maximum engine speed limiting Depending on the application, the control unit memory can contain appropriate engine speed limits. When the engine speed surpasses these limits the control unit activates power reduction strategies by controlling energization time of the electro-injectors. In some applications the maximum limiting response consists in stopping the engine. Cut Off Fuel cut-off in release phases is managed by the control unit with the following logical interventions:
SECTION 2 - FUEL
5
Smoke control under acceleration With intense load demands, in accordance with signals received from the air inlet meter and the engine speed sensor, the control unit manages the pressure regulator and modulates the activation time of the electro-injectors to prevent the emission of smoke from the exhaust. After Run After the engine is stopped, the control unit microprocessor saves various parameters to the EEPROM memory, including the faults log so that they will be available the next time the engine is started. Control of working speed in normal operating conditions Each time work load varies, the control unit adjusts torque so as to maintain the engine in maximum power conditions. If the load causes a reduction in power, the control unit increases torque i.e. it increases the amount of fuel injected in order to restore the engine to maximum power. Recovery strategies Recovery strategies are characterized by certain differences as application varies, i.e. - Control of fuel leaks In the case of fuel supply problems, the system controls the engine with suitable constant power values obtained with a low number of revs and high torque values in order to inject the maximum quantity of fuel. - Control of pressure in the rail When the pressure in the rail exceeds safety values, the engine reduces power. - Synchronism problems In the case of synchronism problems, faulty rev sensors, the system controls the engine by increasing the number of revs in order to improve interpretation of the signals. - Power restrictions as operating temperature increases When the temperature of the supercharging air rises above 88 °C, power reduction is started; when a temperature of 120 °C is reached, performance is further reduced and is comparable to that of the same engine if it were aspirated. - Reduction of power as reference temperature varies In normal operating conditions, the system knows the supercharging air, oil and water temperatures. If the temperature of the engine water is not available, the system takes the temperature of the oil as reference and when this reaches the threshold of 103 °C, it starts to reduce the power available. On reaching 113 °C, power is reduced to 50%.
- disactivation of the electro-injectors; - reactivation of electro-injectors immediately prior to arrival at idle speed; - control of fuel pressure regulator.
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6
SECTION 2 - FUEL
F4HE N ENGINES
WORKING PROCESS 4 Cylinders version Figure 3
High Pressure Low Pressure Fuel outlet 158007
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 and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors. Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet. When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place in the related cylinder. The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit. The high-pressure circuit is composed of the following pipings: - piping connecting high-pressure pump outlet to rail; - pipings supplying injectors from rail. The low-pressure circuit is composed of the following pipings: - fuel suction piping from tank to prefilter; - pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter; - pipings supplying the high-pressure pump through the fuel filter. The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
Base - May 2010
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F4HE N ENGINES
SECTION 2 - FUEL
7
6 cylinders version Figure 4
High Pressure Low Pressure Fuel outlet 158008
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 and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors. Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet. When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place in the related cylinder. The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit. The high-pressure circuit is composed of the following pipings: - piping connecting high-pressure pump outlet to rail; - pipings supplying injectors from rail. The low-pressure circuit is composed of the following pipings: - fuel suction piping from tank to prefilter; - pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter; - pipings supplying the high-pressure pump through the fuel filter. The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
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8
SECTION 2 - FUEL
FUEL SYSTEM LAYOUT This fuel system is a Common Rail injection with CP3 high pressure pump and this layout is for 4 cylinder version. The pressure regulator, placed upstream of the high-pressure pump, adjusts the fuel flow that is necessary on the low-pressure system. Afterwards, the high-pressure pump takes care of supplying the rail properly. This arrangement, by pressurising the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system. Function of the pressure relief valve (2), assembled on the high-pressure pump, is keeping the pressure, at the pressure regulator inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream.
F4HE N ENGINES
The pressure relief valve (2) intervention brings about a fuel flow increase in the high-pressure pump cooling circuit, through inlet and drain piping (16) from piping (8). The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 to 2 bars. Two by-pass valves are placed in parallel with the mechanical supply pump. The by-pass valve (18) allows fuel to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value. The by-pass valve (17) allows filling the supply system through the manual priming pump (10).
4 cylinders version Figure 5
EXHAUST SUCTION (LOW PRESSURE) HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE) HIGH PRESSURE
114545
1. High-pressure pump. — 2. Pressure relief valve on high-pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars. — 4. Rail overpressure valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. — 8. Return piping. — 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. — 12. Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High-pressure pump cooling piping. — 17. By-pass valve. — 18. By-pass valve.
Base - May 2010
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F4HE N ENGINES
SECTION 2 - FUEL
9
FUEL SYSTEM LAYOUT The 6 cylinder version is similar design.
6 Cylinders version Figure 6
EXHAUST INTAKE (LOW PRESSURE) HIGH--PRESSURE PUMP SUPPLY (LOW PRESSURE) HIGH PRESSURE
114545
1. High-pressure pump. — 2. Pressure relief valve on high-pressure pump, 5 bars. — 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars. — 4. Rail overpressure valve. — 5. Common Rail. — 6. Pressure sensor. — 7. Injector. — 8. Return piping. — 9. Control unit heat exchanger. — 10. Mechanical priming pump. — 11. Prefilter assembled on chassis. — 12. Fuel tank. — 13. Mechanical supply pump. — 14. Fuel filter. — 15. Pressure regulator. — 16. High-pressure pump cooling piping. — 17. By-pass valve. — 18. By-pass valve.
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10
SECTION 2 - FUEL
F4HE N ENGINES
MECHANICAL FEEDING PUMP
Jettison condition
Gear pump, placed on rear part of the high pressure pump, whose function is to feed the high pressure pump. It is driven by the high pressure pump’s shaft.
Figure 9
Ordinary working condition Figure 7
72594
72592
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, I - 2 By-pass valves in close position.
The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system through the priming pump. In this condition the by pass valve (I) keeps closed while the dump by-pass valve (2) opens up due to the pressure effect on the entry unit so the fuel flows to the exhaust unit B. NOTE The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the high pressure pump.
Overpressure condition in Exhaust unit Figure 8
72593
The by-pass valve (I) is activated in case of overpressure on B Exhaust unit. The actual pressure, overcoming the resistance of the valve’s spring (I), connects the exhaust with the entry through the gallery (2).
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F4HE N ENGINES
SECTION 2 - FUEL
11
CP3 HIGH PRESSURE PUMP Pump provided with 3 radial pumping elements driven by the timing system gear, no need of timing. The mechanical feeding pump driven by the high pressure pump’s shaft is assembled to the rear side of the high pressure pump.
NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither the fixing screws must be tampered. The only allowed interventions concern control gear and pressure regulator replacement.
Figure 10
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.
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12
SECTION 2 - FUEL
F4HE N ENGINES
High pressure pump-inside structure Figure 11
Sec. B-B
Sec. C-C
70498
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — 7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.
Every pumping unit is composed of: - a piston (5) actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), being floating on a misaligned part of the shaft (6), when the shaft rotates, does not rotate therewith but is only translated in a circular movement along a wider radius, with the resulting alternate actuation of the three pumping elements;
Base - May 2010
- cap intake valve (3); - ball delivery valve (4).
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F4HE N ENGINES
SECTION 2 - FUEL
13
Working principle Figure 12
Sec. B-B
Sec. D-D
72597
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.
The pumping element (3) is orientated towards the pump’s camshaft (4). During the intake phase, the pumping element is fed through the feeding line (5). The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge (7). The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element. Print P2D32N003 E
During compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to common rail (2), feeding it through the exhaust unit (I).
Base - May 2010
14
SECTION 2 - FUEL
F4HE N ENGINES
Figure 13
Sec. C - C
Figure 14
72598
72601
Sec. A - A
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.
1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel exhaust flowing from pump with connector to high pressure pipe for common rail.
Figure 13 shows the fuel runs at low pressure inside the pump; the following elements are clearly visible: the main feeding line to the pumping elements (4); the feeding lines to the pumping elements (1-3-6), the duct lines run for the pump lubrication (2), the pressure gauge (5), the flow limiting valve to 5 bar (8) and the fuel exhaust flue (7).
Figure 14 shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.
The pump shaft is lubricated by the fuel through the feeding and recovery lines. The pressure gauge (5) determines the quantity of fuel to feed the pumping elements: the fuel in excess flows through the exhaust gallery (9). The limiting valve to 5 bar, in addition to recovering fuel exhaust as a collector has also function to keep the pressure constant to 5 bar limit at gauge entry.
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F4HE N ENGINES
Operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements (about 2 bars).
SECTION 2 - FUEL
15
RAIL Figure 15
The amount of fuel supplying the high-pressure pump is metered by the pressure regulator, placed on the low-pressure system; the pressure regulator is controlled by the EDC7 control unit through a PWM signal. When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, not being able to come out, is compressed above the supply pressure value existing in the rail. The thereby-generated pressure makes the exhaust valve open and the compressed fuel reaches the high-pressure circuit. The pumping element compresses the fuel till the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed. The pumping element piston goes back towards the bottom dead center and the remaining fuel is decompressed. When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated. The delivery valves must always be free in their movements, free from impurities and oxidation.
108609
1. Rail — 2. Fuel inlet from high-pressure pump — 3. Overpressure valve - 4. Pressure sensor. The rail volume is comparatively small to allow a quick pressurisation at startup, at idle and in case of high flow-rates. It anyway has enough volume as to minimise system spikes and the use of plenum chambers caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump. A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.
The rail delivery pressure is modulated between 250 and 1600 bars by the electronic control unit, through the pressure 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 traditional injection pumps, because it does not require setting. If the pipe between fuel filter and high-pressure pump is to be removed-refitted, be sure that hands and components are absolutely clean.
RELIEF VALVE Mounted on the end of the rail, it has the function of protecting the system’s components in case the failure of the rail pressure sensor or the pressure regulator of pump CP3 causes an excessive pressure increase in the high-pressure plant. When the rail pressure reaches 1800 bars, the valve initially intervenes in order to allow the fuel to flow and subsequently to reduce the pressure within safety limits and then it mechanically regulates the rail pressure to approx. 800 bars. This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of the fuel preserving the return pipes to the tank.
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16
SECTION 2 - FUEL
F4HE N ENGINES
ELECTRO-INJECTOR
Injection start
As for NEF TIER 3 engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power developed by the engine. Jet
Powers kW
Pressures bar
DLLA
Up to 152
250 ÷ 1600 bar
DSLA
Lower to 152
250 ÷ 1450 bar
Figure 17
15
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 Figure 16 70506
When coil (4) is energised, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, with following fuel injection into the cylinder.
Injection end When coil (4) is de-energised, shutter (6) goes back to its closing position, in order to re-create such a force balance as to make plunger (2) go back to its closing position and end the injection.
15
NOTE The injector cannot be overhauled and therefore it must not be disassembled.
70505
1. Pressure rod — 2. Plunger — 3. Nozzle — 4. Coil — 5. Pilot valve — 6. Ball shutter — 7. Control area — 8. Pressure chamber — 9. Control volume — 10. Control duct — 11. Supply duct — 12. Control fuel outlet — 13. Electric connection — 14. Spring — 15. High-pressure fuel inlet.
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F4HE N ENGINES
SECTION 2 - FUEL
17
PRESSURE LIMITER FOR FUEL RETURN It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at a pressure 1.3 and 2 bars. By guaranteeing this pressure to the return fuel, the fuel vapours formation inside injectors is avoided, optimising fuel spraying and combustion.
Figure 18
70507
A
To tank — B From injectors
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18
SECTION 2 - FUEL
Base - May 2010
F4HE N ENGINES
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F4HE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
1
SECTION 3 Duty-industrial application
Page
Print P2D32N003 E
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . .
3
- Section pictures of complete engine common rail version . . . . . . . . . . . . . . . . . . . .
3
- Clearance data - 4 cyl. . . . . . . . . . . . . . . . . . . .
4
- Clearance data - 6 cyl. . . . . . . . . . . . . . . . . . . .
5
PART ONE MECHANICAL COMPONENTS . . . . . . . . . . .
7
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . .
9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . .
9
- Disassembly of application components . . . . .
10
- Assembly of application components . . . . . . .
17
- Completion of the engine . . . . . . . . . . . . . . . .
29
- Checks and inspections . . . . . . . . . . . . . . . . . .
30
PART TWO ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . .
31
LOCATION OF THE MAIN ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . .
33
- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
- Cable on engine . . . . . . . . . . . . . . . . . . . . . . .
35
- Injectors connector (A) . . . . . . . . . . . . . . . . . .
36
- Sensors connector (C) . . . . . . . . . . . . . . . . . .
36
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . .
37
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . .
37
- Supercharging air pressure - temperature sensor
38
- Engine oil temperature-pressure sensor . . . . .
38
Base - May 2010
2
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4HE N ENGINES
Page
Page - Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . . .
58
MAINTENANCE PROCEDURES . . . . . . . . . . . . . .
58
41
- Checks and inspections . . . . . . . . . . . . . . . . . .
58
- Coolant temperature sensor . . . . . . . . . . . . . .
42
- Engine oil level check . . . . . . . . . . . . . . . .
58
- Fuel temperature sensor . . . . . . . . . . . . . . . . .
43
- Combustion system inspection . . . . . . . .
59
- High pressure pump - pressure regulator . . . .
44
- Cooling system inspection . . . . . . . . . . . .
59
PART THREE - TESTS - TROUBLESHOOTING .
45
- Lubricating system inspection . . . . . . . . .
59
- PT-BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
- Inspection of water presence within fuel filter or pre-filter . . . . . . . . . . . . . . . .
59
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48 - Inspection/replacement of blow-by filter .
60
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 - Inspection of drive belt tensioning . . . . . .
60
- Fuel temperature and pressure sensor . . . . . . .
39
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . .
40
- Pre-post heating resistance and contactor . . . .
PART FOUR MAINTENANCE PLANNING . . . . . . . . . . . . .
55
- Inspection and setting of tappet clearance
60
MAINTENANCE PLANNING . . . . . . . . . . . . . . . .
57
- Oil motor and filter replacement . . . . . . .
61
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
- Fuel filter replacement . . . . . . . . . . . . . . .
62
- Regular maintenance and inspection planning .
57
- Alternator belt replacement . . . . . . . . . . .
62
Base - May 2010
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F4HE N ENGINES
3
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
GENERAL SPECIFICATIONS Section pictures of complete engine - common rail version Figure 1
108540
The NEF F4HE engines are characterised by four-stroke diesel cycles supercharged with 4 or 6 cylinders with 4 valves per cylinder. They have high pressure injection fuelling (common rail) and are entirely electronically driven in order to optimise the working process in accordance to the operation, limiting as much as possible the pollution emissions and consumption.
The section herein described is composed or four sections: - Section of mechanical overhaul prescribed in accordance to the engine’s specific duty, illustrating all necessary operation to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover; - Electrical section, describing the connections to the different components of the engine control module and of the sensors assembled to the engine; - Diagnosis section; - Section of preventive maintenance operations, providing instructions for the execution of the main operations.
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by 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.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4HE N ENGINES
Clearance data - 4 cyl.
F4HE9484A *J101
Type
ρ
Compression ratio Max. output
Max. torque
Loadless engine idling Loadless engine peak Bore x stroke Displacement
16.5 : 1 kW (HP)
104 141
rpm Nm (kgm)
2200 608 60.8
rpm
1600
rpm
-
rpm
-
cm3
104 x 132 4485
TURBOCHARGING
with intercooler
Turbocharger type z
*J105
HOLSET HX27W Forced by gear pump, relief valve single action oil filter
LUBRICATION
bar
Oil pressure (warm engine) - idling
bar
0.7
- peak rpm
bar
4.0 By liquid
COOLING Water pump control
Through belt
Thermostat - start of opening FILLING
°C
engine sump
liters
5.3
engine sump + filter
liters
6.3
15W40 ACEA E3
!
81 ± 2
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements provided by FPT. Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for which the engine has been designed.
Base - May 2010
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F4HE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
5
Clearance data - 6 cyl.
F4HE9684 P*J101 A*J100 Q*J100 W*J100
Type
ρ
Compression ratio Max. output
Max. torque
17.5 : 1 kW (HP)
175 238
154 210
143 195
134 180
rpm
2200
2200
2200
2200
Nm (kgm)
1020 102
950 95
850 85
800 80
rpm
1500
1400
1400
1400
Loadless engine idling
rpm
Loadless engine peak rpm
rpm
Bore x stroke Displacement
cm3
-
104 x 132 6728
TURBOCHARGING
with intercooler
Turbocharger type
HOLSET HX35
LUBRICATION Oil pressure (warm engine) bar
- idling
bar
- peak rpm
bar
COOLING
Forced by gear pump, relief valve single action oil filter 0.7 3.5 By liquid
Water pump control
Through belt
Thermostat
15W40 ACEA E3
!
81 ± 2
- start of opening FILLING
ºC
engine sump
liters
15
engine sump + filter
liters
15 + 1
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements provided by FPT. Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for which the engine has been designed.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4HE N ENGINES
F4HE9684 B*J101 E*J101 P*J101 A*J100 X*J101
Type
ρ
Compression ratio Max. output
Max. torque
17.5 : 1 kW (HP)
129 175
123 170
175 240
154 210
112 150
rpm
2200
2200
2200
2200
2200
Nm (kgm)
753 75,3
747 74,7
1020 102
950 95
705 70,5
rpm
1400
1400
1500
1400
1400
Loadless engine idling
rpm
-
Loadless engine peak rpm
rpm
-
Bore x stroke Displacement
104 x 132 cm3
6728
TURBOCHARGING
with intercooler
Turbocharger type
HOLSET HX35
LUBRICATION
Forced by gear pump, relief valve single action oil filter
Oil pressure (warm engine) bar
- idling
bar
- peak rpm
bar
0.7 3.5 By liquid
COOLING Water pump control
Through belt
Thermostat - start of opening
ºC
81 ± 2
FILLING 15W40 ACEA E3
!
engine sump
liters
15
engine sump + filter
liters
15 + 1
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements provided by FPT. Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for which the engine has been designed. Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
7
DIAGNOSI
PART ONE MECHANICAL COMPONENTS
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
ENGINE OVERHAUL Preface Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well.
NOTE With regard to the engine disassembly operations from the machine, please apply for Information consulting the specific manual. All operations of Engine disassembly operations as well as overhaul operations must be executed by qualified technicians provided with the specific tooling and equipment required. The following information relates to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties. In section ”General overhaul”, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.
9
- disconnect the high pressure fuel pipeline from the rail diffuser and from the high pressure pump and disassemble it from the engine block removing the fixing clamps. - disconnect the pipeline feeding the mechanic pump that is combined to the high pressure pump through the exchanger of the engine control module; - disassemble the oil introduction tube (if present) by undoing and removing the fixing screws. Remove the O-ring from the tube. NOTE Because of the high pressure in the pipelines running from the high pressure pump to the rail and from this last one to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working; - re-use the disassembled pipelines.
Figure 3
Engine setting operations for the assembly on turning stand Figure 2
116237
To disconnect the low pressure fuel pipe from the relevant connecting joint, you need to hold the clasp (1) pressed, and release the quick fitting joint (2). 108541
In order to apply the brackets 99361037 to the engine block to fix it on to the stand for the overhaul, it is necessary to perform the following operations on the left hand side of the engine: - using the tool 99360073 disassembly the fuel filter and remove it from the support; - disconnect the electrical connection from the support and the heater’s one (placed on the filter support as well); - disconnect the fuel low pressure pipelines from the support; - disconnect pipeline from the support; - remove the sustaining support bracket from the block; Print P2D32N003 E
To connect the low pressure fuel pipe to the connecting joint, insert the quick fitting joint (2) into the connecting joint, and push until the clip (3) is fastened.
Base - May 2010
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Figure 5
On the right hand side of the engine:
1
Figure 4
2 74166
Remove the starter (2) from the flywheel housing (1).
114790
Remove the screws and remove the oil pipe (1) from the turbocharger pipe (2) and from the engine block.
Apply brackets 99361037 to engine block and use them to secure the engine to the revolving stand 99322205. Remove sump cap and drain out oil. Remove the fan from the output shaft pulley.
Collect and dispose of engine oil according to rules in force.
Disassembly of application components Figure 6
107246
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. EDC 7 gearbox - 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. Electro-injector. Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Disconnect the engine’s cable from the connectors wiring harness to Electro-injectors (1); (10) air pressure/temperature sensor; (3) fuel pressure sensor; (6) engine control module; (9) timing system sensor; (2) Thermostat sensor of engine cooling liquid’s temperature; (5) sensor of engine’s revolutions.
Figure 8
1
6 2
5 4
Figure 7
3
74170
Disconnect the pipeline (2) from the fuel recover pressure-limiter, working on the connections as described in Figure 3. Unscrew the nut and loosen the clamp tightening the oil vapour pipe. Remove the pipe (6). Undo the screws (3) and, if present, disassemble the blow-by filter (4). Remove on the nuts and tappet cover. 108543
Disconnect from the rail (2): the fuel pipe (7) according to procedures described in Figure 3. Disconnect fuel pipes (5) from rail (2) and injector manifolds (6).
Figure 9
NOTE When releasing pipe (6) connections (4) to rail (2), use the proper wrench to avoid rotation of flow limiters (3).
Remove the screws (1) and disconnect the rail (2).
74744
Remove nuts (7) and disconnect the electrical cables from injectors (8). Remove screws (1) and disconnect injector wiring support (2) including the gasket. Remove screws (5), disconnect air pressure/temperature sensor (6). Remove nuts (3) and remove fuel manifolds (4).
NOTE Disassembled fuel manifolds (4) must not be used again, replace with new ones during reassembly.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 10
Figure 12
70132
Loosen tappet adjustment fastening nuts (1) and unscrew the adjusters. Remove the screws (2), remove the rocker assembly (3), consisting of: bracket (6), rockers (4), shafts (5) and remove jumpers (7) from valves. Remove rods (8). Figure 11
108545
Release on the drive belt tensioner (1) and extract the belt (2) from the belt pulleys from the water pump ones and from the belt rebound pulleys; Disassemble the belt tensioner (1). Loosen the screws fixing the alternator to the support and disassemble it.
Figure 13
70133
Remove injector fastening screws. Use tool 99342101 (1) to remove injectors (2) from the cylinder head.
108546
Disconnect the oil pipeline (3) from the supports of the heat exchanger / oil filter and from the pipe fitting (4) to the turbine. Remove the fixing nuts and disassemble the turbocharger (1) from the exhaust collector (2). Loosen the screws and disassemble the exhaust collector (2) from the cylinder head.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
13
Figure 17
Figure 14
108547
On the opposite side, loosen the fixing screws of the inlet manifold (1) and disassemble the joint to the air heater (2) for the cold start.
108580
Remove the screws (4) and disconnect temperature/pressure sensor (3).
the oil
Remove the screws (1) and then remove: heat exchanger/oil filter support (2), intermediate plate (6) and relevant gaskets. Remove the oil level sensor (5).
Figure 15 Figure 18
1
2
74174
74779
Hook brackets (1) with suitable lifting chains and remove cylinder head (2) from block using hoist.
Remove the screws (1) and disconnect the ECU (2) including the heat exchanger. Figure 19
Figure 16
1
4
3
2
108549
Remove the screws (2) and disconnect the alternator support (3). Use tool 99360076 to remove the oil filter (1). Print P2D32N003 E
74176
Unloose the screws (3) and remove the cap (1). Keep the gasket (4), the power take-off (2) and the second gasket (4). Base - May 2010
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Figure 23
Figure 20
116241
70145
Remove the nut (1) and disconnect the timing sensor (2). Remove the nuts (3) and disconnect the high pressure pump (4) including the feed pump (5).
Remove the screws (1) and disconnect the water pump (2). Remove the screw (3) and the roller (4). Remove the screw (5) and disconnect the engine speed sensor (6). Figure 24
Figure 21
00900t
70146
Fit tool 99360339 (2) to the flywheel housing (1) to stop flywheel (3) rotation. Loosen the screws (4).
Remove the ring sealing the engine’s driving shaft from the front cover. Use the tool 99340055 (4) to operate on the front bar hold of the driving shaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool to the ring tightening the 6 screws provided with the equipment. Then proceed removing the ring (2) by tightening the screw (3).
Figure 22 Figure 25
108548
Remove the screws (3) and disassemble the damping flywheel (2) and the pulley (1).
00904t
Using the specific tie rod (3) of the tool 99363204 and the ancillary lever (4), remove the external holding ring (2) from the front cover (1). Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 26
15
Figure 29
70152 116242
Remove the screws (1 and 3) and take out the front cover (2). NOTE Take note of screw (1) assembling positions since they have different lengths.
Tighten two screws of medium length into the holes (4) to sling the flywheel with the hoist. Throughout the two guide pins (2) previously screw into the driving shaft holes (3) withdraw the engine flywheel (1) after slinging it with the hoist. Figure 30
Figure 27
Remove the screws (1) and disconnect the oil pump (2). 00903t
Figure 28
Remove the holding ring of the flywheel cover box using the tool 99340056 (3) to operate on the driving shaft’s back bar hold (5). Through the steering holes of the tool, perforate the inside holding ring with a straight way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool 99340056 (3) to the ring tightening the 6 screws provided with the equipment.(4) Then proceed removing the ring (1) by tightening the screw (2). Using a specific tie rod of the tool 99363204 and an ancillary lever, remove the external holding ring (2) from the front cover.
70151
Remove two opposite screws (1) from the area where the withdrawal pins will be introduced (2, Figure 29). Loosen the remaining flywheel fixing screws (3) from the driving shaft (4). Remove the flywheel locking tool 99360351. Print P2D32N003 E
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 31
Figure 33
70153
Remove the screws (2) and take out the rear cover (1). NOTE Take note of screw (2) assembling positions since they have different sizes.
86516
Remove the screws (1 and 4) and disassemble the oil suction tube (5). Remove the screws (2) and disassemble the stiffening plate (3). NOTE For engines the stiffening plate (4) has a single element.
Figure 32
Figure 34
74775
Overturn the engine. Remove the screws (2), disassemble the plate (3) and disconnect the oil sump (1). NOTE The shape and the dimensions of the oil pan and of the suction tube may vary according to the duty of the engine. The relevant pictures of the instructions are therefore providing an outline of the intervention to be executed.
70156
Remove the screws (1) and remove the gear (3) from the camshaft (2). Figure 35
However the procedures described are still applicable.
70157
Remove the screws (2) and disconnect the timing gear case (1). NOTE Take note of screw (2) assembling positions since they have different sizes.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Assembly of application components
17
Figure 37
Figure 36
70210 70209
LOCTITE 5205 SEALANT APPLICATION AREAS Clean accurately the timing gear case (1) and the engine block.
NOTE Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).
DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR CASE FASTENING SCREWS Refit the case (1) to the engine block. Screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 65 to 89 Nm Screws M8 20 to 28 Nm Screws M10 42 to 52 Nm NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 38
70211
With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the side surface of which a groove has been created for the ignition timing.
NOTE Fasten screwing of the two pins to facilitate the operation of engine driving shaft rotation.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 39
NOTE Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).
114791
Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).
Figure 42
Figure 40
70215
70213
Tighten the screws (1) fastening gear (2) to camshaft (3) to the specified torque. Figure 41
SEQUENCE FOR TIGHTENING THE FLYWHEEL HOUSING FASTENING SCREWS Refit the housing (1) to the engine block and screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 75 to 95 Nm Screws M10 44 to 53 Nm
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 43
19
Figure 45
70152
0901t
Apply tool 99346253 part (6) to the rear output shaft tang (5), secure it by screws (4) and fit the new sealing ring (3). Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into flywheel housing (7).
Screw two pins (2) having suitable length into shaft holes (3) and remove the engine flywheel (1) using proper sling and hoister. Figure 46
Figure 44
Apply tool 99360339 (2) to the flywheel housing to stop engine flywheel (3) rotation. Tighten the screws (1) fastening the engine flywheel (3) to the output shaft. Figure 47 α 70217
Check the supporting surface (1) of the clutch plate and if it is scratched, it is necessary to carry out turning. 70219
Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1, Figure 43) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.
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Tighten engine flywheel (2) fastening screws (1) in two stages: - 1st stage, tightening to 30 ± 4 Nm torque with dynamometric wrench; - 2nd stage, tightening to 60 ± 5° angle. NOTE Tightening to angle is performed using tool 99395216. Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Base - May 2010 Revi - September 2012
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 48
Figure 51
106549 70220
Fit the oil pump (1). Tighten the fastening screws (2) to the specified torque.
Remove the sealing ring (2) from the front cover (1), clean accurately the coupling surfaces and smear them with LOCTITE 5205. Figure 52
Figure 49
106550 70221
Clean accurately the front cover (2) surface and refit it. Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1). Figure 53 Figure 50
00902t 70222
Fit the water pump (1). Tighten the screws (2) to the specified torque.
Base - May 2010
Apply tool 99346252 part (4) to the front output shaft tang (6), secure it by screws (5) and fit the new sealing ring (7). Position part (2) on part (4), screw nut (3) until completing sealing ring (7) fitting into front cover (1).
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 54
21
Figure 57
108548
108553
Fit the plate (1), the oil pick up tube (2) and tighten the fastening screws (3) to the specified torque. Figure 55
Assemble the pulley (1) and the damping flywheel (2) to the driving shaft. Tighten the fixing screws (3) and clamp them to the couple 68 ± 7 Nm. Figure 58
116245
Set the gasket (1) on the oil sump (2).
Fit a new sealing ring on the speed sensor (3).
NOTE The pictures of the instructions relating to the oil pan and to thesuction rose may not reflect the actual shape and dimensions of your engine equipment. However the procedures described are still applicable.
Fit the speed sensor (3) on the front cover (1) and tighten the screw (2) to the specified torque. Figure 59
Figure 56
108576 74775
Fit the oil sump (1) and apply the plate (3) to it. Tighten the screws (2) to the specified torque. NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Print P2D32N003 E
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. NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Base - May 2010
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Figure 60
Figure 62
114792
108578
Refit the alternator (1). Lubricate the sealing ring (2) with engine oil and set it on the oil filter (3). Screw manually to seat the oil filter (3) on the support connection (1) and then screw again the oil filter (3) by ¾ turn.
Tighten the screw (2) to the specified torque. Figure 63
Apply a new sealing ring on the oil temperature/pressure sensor (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.
Figure 61 114793
Refit the automatic belt tensioner (2). Tighten the screw (3) to the specified torque using a wrench, turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers. Figure 64
70234
Position the alternator support (1) so that pins (3 and 4) are set against the engine block. Tighten the screws (2) to the specified torque.
70145
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Base - May 2010
Refit the high pressure pump (6) including the feed pump (5) and tighten the nuts (3) to the specified torque. Fit the support (4) with a new sealing ring, the timing sensor (2) with a new sealing ring and tighten the relevant fastening nut (1) to the specified torque.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 65
1
3
4
23
For 6 cylinder engines Figure 68
2 74176
Insert the power take-off (2) equipped with the gasket (4), the cover (I) and its gasket (4). Tighten the screws (3) to the prescribed matching couple. Figure 66
76152
- Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block. Figure 69
1
2
74174
Assemble the electronic gearbox (2) equipped with the exchanger to the engine, fixing it with the screws (1). In case the rubber buffers are cracked or excessively deformed, provide replacing them.
α 70336
Assemble cylinder head (1), tighten the screws (2) in three following steps, following order and mode shown in the figure below.
For 4 cylinder engines NOTE The angle tightening is carried out through tool 99395216 (3).
Figure 67 1 2
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
3 NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
4 75688
- Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block. Print P2D32N003 E
D2
D1 75703
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 70
Figure 73
α
A
6-cylinder engine
70476
Tightening order layout for cylinder head fastening screws: - 1st step pre-tightening with dynamometric wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm
70339
- 2nd step tightening with a 90 ± 5° angle
Fit injectors (1) on the cylinder head seats, directed so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
- 3rd step tightening with a 90 ± 5° angle A = Front side NOTE
Between the phases, wait a few minutes for settling
Figure 74
Figure 71
α
4-cylinder engine
A 70337
Cylinder head fastening screws tightening sequence: 70133
- 1st stage pre-tightening, with a torque wrench:: • Screw 12x1.75x130 ( ) 35 ± 5 Nm • Screw12x1.75 x 150 ( ) 55 ± 5 Nm A = Lato anteriore
Use tool 99342101 (1) to fit the injector (2) into its seat. Screw injector fastening screws without tightening them.
- 2nd stage tightening with angle 90 ± 5° - 3rd stage tightening with angle 90 ± 5° NOTE
Between the phases, wait a few minutes for settling
Figure 72
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and a new sealing washer (3) on injector (1). Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 75
25
Figure 77
70343
91572
Fit a new sealing ring (3) lubricated with petroleum jelly on the fuel manifold (2) and fit it into the cylinder head seat so that the positioning ball (5) is coinciding with the relevant housing (4).
ROCKER ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers. Figure 78
NOTE Disassembled fuel manifolds (2) must not be used again. Replace with new items. The fuel manifolds (2) for engines have 2 positioning spheres. Screw the fastening nuts (2, Figure 76) without locking them. NOTE During this operation, the injector (1) shall be moved so that the manifold (2, Figure 72) is properly inserted into the fuel inlet hole (2, Figure 75). SHAFT-ROCKER MAIN DATA Check that shaft/rocker coupling surfaces are not showing excessive wear or damages.
Figure 76
Figure 79
32655 70342
Use the torque wrench to tighten gradually and alternately the injector fastening screws (1) to 8.5 ± 0.8 Nm torque. Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm torque.
Rocker control rods shall not be distorted; the ball seats in touch with the rocker adjusting screw and with tappets (arrows) shall not show seizing or wear; otherwise replace them. Intake and exhaust valve control rods are identical and are therefore interchangeable.
Carry out the assembly of the equalisers’ unit , after previous check of the components.
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On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
Figure 80
To place the cylinder at top dead centre, the end of the compression stroke, position tool 99395097 in the injector seat of the cylinder whose valves you wish to balance. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed. 70345
Fit the rods (2). Position jumpers (1) on valves with marks (→) facing the exhaust manifold. Figure 81
Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Correct slack is: - suction valves 0.25 0.05 mm - exhaust valves 0.50 0.05 mm. 4 cylinder engines IGNITION SEQUENCE: 1 — 3 — 4 - 2 Engine shaft starting and rotation
Bilance valves cylinder n°
Adjust intake and exhaust valves clearance cylinder n°
1° al PMS
1
1
180°
3
3
180°
4
4
180°
2
2
6 cylinder engines 70346
Check that tappet adjusters (1) are loose to prevent their balking on the rods (2, Figure 80) when refitting the rocker assembly. Then refit the rocker assembly consisting of: bracket (5), rockers (3), shafts (4) and secure them to the cylinder head by tightening the fastening screws (2) to 36 Nm torque. Figure 82
IGNITION SEQUENCE: 1 - 5 - 3 - 6 - 2 - 4 Engine shaft starting and rotation
Bilance valves cylinder n°
Adjust intake and exhaust valves clearance cylinder n°
1° al PMS
1
1
120°
5
5
120°
3
3
120°
6
6
120°
2
2
120°
4
4
70520
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 83
27
Figure 86
108547
Apply to the coupling surface of the intake manifold (1) equipped with heater (2) a sufficient coat of LOCTITE 5999 and provide tightening the screws to the prescribed matching couple. Figure 84
108569
NOTE Pipe (7) connections shall be tightened to 20 Nm torque, using the proper wrench (5) and the torque wrench 99389829 (4). Connections (6) shall be tightened by holding the flow limiting valve hexagon (1) with the proper wrench.
Connect the fuel pipe (3) to the rail (2) following the procedure shown in the following figure. Figure 87
108567
Fit the rail (2) and tighten the screws (1) to the specified torque, connect the ground cable (3) to the intake manifold (4) and tighten the fastening nut to the specified torque. Figure 85 116237
In order to connect the low-pressure fuel pipes to the connection joint, insert the rapid fitting joint into the latter, (2) and press until the clip fastens securely (3).
NOTE Check proper fuel pipe connection.
108568
Connect new fuel pipes (1) to rail (3) and injector manifolds (2). Print P2D32N003 E
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Connect the electrical cables (1) to the injectors (3) and use the torque wrench 99389834 (4) to tighten the fastening nuts (2) to the specified torque.
Figure 88
Figure 91
70352
Check electrical cable (5) conditions, replace if damaged by cutting the support (2) clamps and removing the screws (4) that secure it to connections (3). Fit a new gasket (1) on the support (2).
70355
Fit a new gasket (2) on the tappet cover (1). Figure 89
Place the tappet cover on, install the bolts in the correct position and tighten.
Figure 92 108570
Fit the wiring support (2) and tighten the screws (1) to the specified torque. NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 90
108572
Reconnect the exhaust manifold (2) with new gaskets. Tighten the fastening screws (1) to the specified torque. Sling the turbocharger (1) and place it over the manifold after having first inserted a new gasket. Connect the oil pipeline (3) to the support of the heat exchanger /oil filter. Fix the pipe (3) to the pipe fitting on the turbocharger. 108571
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 93
29
Figure 95
1
6 2
5 4
3
74170
If present, insert blow-by filter (4) and tighten the screws (3). Connect the pipeline (6) and fix the oil vapour recover pipe through the clamp (5); lock up the nut fixing it to the upper edge. Connect the pipeline (2) to the pressure- limiter (1).
Completion of the engine Properly handle the engine holding it by a lifter, remove it from the rotating shaft, remove the brackets 99341009 and place it on proper suitable support to carry out the completion.
108541
Assemble the bracket and the support of the fuel filter. Proceed connecting the pipelines (9,3,4 and 5) of the support to the high pressure pump. Connect the pipeline from the high pressure pump to the engine control module heat exchanger. Connect the pipeline from the high pressure pump to the rail diffuser. Figure 96
Proceed assembling the oil filter. Figure 94
1
116237
All the low-pressure fuel pipes are fastened with clips shown in the picture.
2
In order to connect the low-pressure fuel pipes to the connection joint, insert the rapid fitting joint into the latter, (2) and press until the clip fastens securely (3).
Assemble the starter (2) to the internal part of the flywheel cover. Assemble the oil feeding pipe using a new O-ring. Fix with three M12x25 screws.
NOTE In case the pipes are re-employed, they must keep the sealing tops at the edges. Make sure that the fuel pipeline is correctly connected.
Reconnect the engine harness to all the sensors, the engine control module and the rail diffuser (see Figure 6, page 10). Print P2D32N003 E
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Checks and inspections NOTE The following checking inspections must be carried out after the engine assembly on the vehicle .
Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check:
- that there are no water leaks from the connecting sleeves of engine cooling circuit pipes and cab internal heating pipes, tighten the clamping collars if required; - check carefully the connection between the low pressure fuel pipes and the relevant connectors; - that there are no oil leaks between the cover and the cylinder head, between oil sump and engine block, between heat exchanger oil filter and the relevant housings and between the different pipes in the lubricating circuit; - that there are no fuel leaks from the fuel pipes; - that there are no air leaks from pneumatic pipes (if fitted); - check also proper operation of the warning lights set on the instrument panel and of the equipment disconnected when engine was removed. - Carefully check and bleed the engine cooling equipment by repeated draining operations.
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PART TWO ELECTRICAL EQUIPMENT
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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LOCATION OF THE MAIN ELECTRICAL COMPONENTS Figure 97
(Demonstration)
108641
The NEF F4HE engines are fully driven by the electronic engine control module, which is assembled directly to the engine by means of a heat exchanger enabling its cooling, utilising rubber buffers to reduce vibration originated by the engine.
The electrical and electronic components of the engine are listed here following:
Through the engine control module it is possible to verify the correct working of the engine. (See part three of the hereby user’s guide specifically dedicated to diagnostic).
3. RAIL pressure sensor.
1. Coolant temperature sensor. 2. Electro-injector. 4. Air temperature/pressure sensor. 6. Timing sensor. 7. Solenoid valve for pressure regulator. 8. Fuel temperature sensor. 9. EDC electronic control unit. 10. Crankshaft sensor. 11. Engine oil pressure/temperature sensor. 12. Heating element for pre-post heating.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4HE N ENGINES
EDC7 ECU Figure 98
01525t
A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled); C - Connector to sensors.
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Cable on engine All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary version, in other words at the approval stage.
Figure 99
0051064t
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor 5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor 8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Rail temperature and pressure sensor 11. Pressure regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Injectors connector (A)
ECU PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FUNCTION Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Pressure regulator Pressure regulator Cylinder 2 injector Cylinder 3 injector Cylinder 1 injector Cylinder 4 injector Cylinder 6 injector Cylinder 5 injector
F4HE N ENGINES
Sensors connector (C)
ECU PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
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ECU PIN Timing sensor Timing sensor Negative for rail temperature and pressure sensor Positive for rail temperature and pressure sensor Signal from rail temperature and pressure sensor Coolant temperature sensor Signal from fuel temperature sensor Engine rpm sensor Engine rpm sensor Negative for engine oil pressure and temperature sensor Negative for air temperature and pressure sensor Coolant temperature sensor Signal from engine oil pressure sensor Signal from engine oil temperature sensor Positive for engine oil pressure and temperature sensor Positive for air temperature and pressure sensor Signal from air pressure sensor Negative for fuel temperature sensor Signal from air temperature sensor
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Crankshaft sensor This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft. The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is ∼900 Ω. Figure 100
50319
Crankshaft sensor
Timing sensor This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal. Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape. The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance is ∼900 Ω. Figure 101
50320
Timing sensor 3
2
1
50342
50288
Connector Ref. 1 2 3
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Wiring diagram Description
Signal Signal Shield
ECU pin Camshaft sensor 19C 23C
Timing sensor 10C 9C
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Supercharging air pressure - temperature sensor This component incorporates a temperature sensor and a pressure sensor. Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle. The sensor is connected to the control unit on pins 25C - 36C - 33C - 34C. The power supply is 5 volt Voltage at the sensor output is proportional to the detected pressure or temperature. Pin 25C - 36C Pin 33C - 34C
Temperature Pressure
Engine oil temperature-pressure sensor This component is analogous to the air temperature-pressure sensor. The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position. This sensor measures the engine oil temperature and pressure. The sensor is connected to the control unit on pins 24C - 28C - 32C - 27C. The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light). The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit. Pin 24C - 28C Pin 32C - 27C
Temperature Pressure
Figure 102
50324
50344
Wiring diagram
Ref. 1 2 3 4
Base - May 2010
Description Ground NTC signal (temperature) +5 V power input Signal (pressure)
ECU Pin Oil 24C 28C 32C 27C
Air 25C 36C 34C 34C
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Fuel temperature and pressure sensor Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command. This sensor is connected to the control unit on pins 12C - 14C- 13C. The power supply is 5 Volt.
Figure 103
0051065t
Fuel pressure sensor connector
Ref. 1 2 3
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Description Ground Signal Power supply
ECU pin 12C 14C 13C
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Electro-injectors The electro-injectors are effectively N.O. solenoid valves. Each injector is connected to the EDC control unit on connector A. The impedance of the coil of each injector is 0.56 - 0.57 Ω.
Ref. CONNECTOR 1
CONNECTOR 2
CONNECTOR 3
Description 1 2 3 4 1 2 3 4 1 2 3 4
Cylinder 2 injector Cylinder 2 injector Cylinder 1 injector Cylinder 1 injector Cylinder 4 injector Cylinder 4 injector Cylinder 3 injector Cylinder 3 injector Cylinder 6 injector Cylinder 6 injector Cylinder 5 injector Cylinder 5 injector
ECU pin 11 A 6A 13 A 4A 14 A 3A 12 A 5A 15 A 2A 1A 16 A
Figure 104
50343
Figure 105
50349
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Pre-post heating resistance and contactor The pre-post heating resistance is located on the intake manifold. The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor. The resistance impedance is approximately 0.5 Ω.
Figure 106 B
A
108909
A. - B. Connection terminals
Figure 107
002371t
A. Control contactor
The control contactor is connected to the control unit B connector. The contactor is tripped with water and/or fuel temperature below 5 °C. The contactor impedance is approximately 15 Ω.
Do not use flammable gases or liquids to provoke the engine ignition. These substances in contact with the resistance could easily become inflamed creating situations of serious danger.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Coolant temperature sensor This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine. The same signal is utilized by the control unit to drive an instrument panel gauge, if present. This sensor is connected to the control unit on pins 15C - 26C. The impedance of the coolant temperature sensor at 20 °C is approximately 2.50 Ω.
Figure 108
107471
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Fuel temperature sensor This sensor is identical to the coolant temperature sensor. This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel. The fuel temperature sensor is connected to the control unit on pins 35C -18C. The sensor impedance at 20 °C is approximately 2.50 Ω. Figure 109
0051140t
1. Fuel temperature sensor - 2. Filter heating resistance.
The ECU drives the filter heater contactor at fuel temperature ≤ 5 °C.
107799
107798
Connector
Ref. 1 2
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Description Ground Temperature signal
ECU Pin Coolant 15C 26C
Fuel 35C 18C
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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High pressure pump - pressure regulator Figure 110
000912t
A. Pressure regulator.
The quantity of fuel supplied to the high pressure pump is metered by the pressure regulator on the low pressure system; the pressure regulator is managed by the EDC7 control unit. Delivery pressure to the rail is modulated between 250 and 1450 bar by the electronic control unit by controlling the pressure regulator solenoid valve. - This component is a N.O. solenoid valve. - The solenoid is connected to the control unit on pins 9A - 10A. - The solenoid valve impedance is approximately 3.2 Ω.
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PART THREE TROUBLESHOOTING
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
PT - BOX PT - BOX is a test tool to be connected to a Laptop.
Figure 111
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator - 5. Serial port indicator 6. ”Error” indicator - 7. CAN line indicator - 8. Line K indicator for automatic management PT-BOX functions: - ECU ID reading; - Failure memory reading; - Flight recorder reading; - Parameters reading; - Failure memory cleaning; - Active diagnosis: actuators activation/testing; - Programming of repalced components and parameters/second level; - Acquisition/Saving of parameters
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
PREFACE A successful troubleshooting is carried out with the competence acquired by years of experience and attending training courses. When the user complains for bad efficiency or working anomaly, his indications must be kept into proper consideration using them to acquire any useful information to focus the intervention.
F4HE N ENGINES
Every time there is a breakdown claim and this breakdown is actually detected, it is necessary to proceed inquiring the electronic unit in one of the ways indicated and then proceed with the diagnostic research making trials and tests in order to have a picture of the working conditions and identify the root causes of the anomaly. In case the electronic device is not providing any indication, it will be necessary to proceed relying on the experience, adopting traditional diagnosis procedures.
Using FPT processing instruments, it is also possible to establish a bi-directional connection with the central unit, by which not only to decoding the failure codes but also input an enquiry relying on memory files, in order to achieve any further necessary information to identify the origin of the anomaly. NOTE Any kind of operation on the electronic center unit must be executed by qualified personnel, duly authorized by FPT. Any unauthorized tamper will involve decay of after-sales service in warranty.
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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
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Failure code
Failure description Fuel metering
1.5.1
HIGH PRESSURE SYSTEM
1.5.2
FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (POSITIVE DEVIATION)
1.5.3
FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (NEGATIVE DEVIATION)
1.5.4
RAIL PRESSURE ERROR: TOO LOW
1.5.5
RAIL PRESSURE ERROR: TOO HIGH
1.5.6
HIGH PRESSURE SYSTEM
1.5.7
ERROR ON THE RAIL PRESSURE (EXCESSIVE DUTY CYCLE)
1.5.8
HIGH PRESSURE SYSTEM
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
1.6.2
INJECTOR CYLINDER 2 / SHORT CIRCUIT
1.6.3
INJECTOR CYLINDER 3 / SHORT CIRCUIT
1.6.4
INJECTOR CYLINDER 4 / SHORT CIRCUIT
1.6.5
INJECTOR CYLINDER 5 / SHORT CIRCUIT
1.6.6
INJECTOR CYLINDER 6 / SHORT CIRCUIT
1.6.7
INJECTOR CYLINDER 1 / OPEN CIRCUIT
1.6.8
INJECTOR CYLINDER 2 / OPEN CIRCUIT
1.6.9
INJECTOR CYLINDER 3 / 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 Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Failure code
51
Failure description
1.C.8
ERROR MESSAGE CAN TSC1-VE
1.C.9
ERROR MESSAGE CAN TF
2.C.6
TIMEOUT OF CAN MESSAGE TSC1-PE PASSIVE
3.C.8
TIMEOUT OF CAN MESSAGE TSC1-VE PASSIVE ECU 1 (internal checks)
1.D.1
ECU OVERRUN MONITORING ERROR
1.D.2
ECU OVERRUN MONITORING ERROR
1.D.3
ECU OVERRUN MONITORING ERROR
1.D.4
ECU OVERRUN MONITORING ERROR
1.D.5
ECU OVERRUN MONITORING ERROR
1.D.6
ECU INTERNAL ERROR (TPU)
1.D.7
INTERNAL ECU ERROR (VARIANT AREA)
1.D.8
ECU OVERRUN MONITORING ERROR
1.D.9
ECU OVERRUN MONITORING ERROR
2.D.3
ECU OVERRUN MONITORING ERROR
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.7
SENSOR POWER SUPPLY 2
1.E.8
SENSOR POWER SUPPLY 3
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
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Low performance at load request.
POSSIBLE CAUSE (*) = if available in the equipment Insufficient fuel level in the tank.
RECOMMENDED TESTS OR INTERVENTION Check fuel level.
Possible exessive smoke. Possible blink-code 8.1
REMARKS The excessive smoke is due to the fact that, in case of insufficient fuel feeding, the engine control module tries to compensate prolonging the injectors working time.
F4HE N ENGINES
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ANOMALY
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter impurities or deformed because of over- is working correctly. heating. If the pump plunger is permanently depressed disassemble and check the tank pick.-up tube. If this is in order, replace the pre-filter. Obstructed air filter.
Replace the air filter.
Excessive fuel blow-by from rail boost Check the O Rings and the correct convalve. nection of the pipe fittings under the feeding pump (the lockers must stay outside and the fittings must be well locked). Visually check the low pressure pipeline integrity.
Solve the cause of the filter’s obstruction. Unless the leakage is significant, no performance failures will be detected. To verify O-rings integrity, extract from the tank the fuel recycling pipeline, seal the end and activate the priming pump driving the low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if valve. there are any significant blow-by from the boost gauge valve; in such case replace the valve. Obstructed fuel filter.
Replace the fuel filter.
Solve the cause of the filter’s obstruction (empty and clean the tank and the part of the circuit over the filter, refill with clean fuel).
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The engine suddenly stops(with no previous problems) and does not start again.
REMARKS
Eliminate the short circuit and replace the Verify that the wire line, close to the EDC. pedal, is not exposed to.
EDC ”burned” by short circuit on the wiring harness of the friction clutch. Difficult start and low performance in all Inefficient high pressure pump. conditions.
After having excluded any other possible cause, replace the high pressure pump.
Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recoggine running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of pulsing within the relevant high pressure pipe.
In case of low entity blow-by, inficiating the mechanical working of the injector but not involving flow limiter activation, there is no error memorisation in the engine control module. If the flow limiter is activated. Check error code memory.
Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recogfollowed by huge white exhaust fumes, no return). nisable detecting by feeling the absence of and a fuel smell. pulsing within the relevant high pressure pipe.
Usually, whether such symptoms appear, it is instinctive to give up engine start. However, by insisting, it is possible to start the engine. As a matter of facts, by insisting, if within the rail the pressure makes the flow limiter close up, the engine starts with one cylinder less and gradually the grade of fumes reduces and disappears.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
The engine disconnects or does not start. (*)
RECOMMENDED TESTS OR INTERVENTION
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POSSIBLE CAUSE (*) = if available in the equipment
ANOMALY
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the origscrews. inal position. The engine works with one cylinder less, Injector blocked in closed position. without memorising failure blink codes in the engine control module.
Identify the injector that is not working The non-working injector is easily recogany more and the relating high pressure nisable detecting by feeling the absence of filler. pulsing within the relevant high pressure pipe.
F4HE N ENGINES
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PART FOUR MAINTENANCE PLANNING
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MAINTENANCE PLANNING Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run.
Regular maintenance and inspection planning
Checks and periodical inspections Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . Inspection blow-by filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of blow by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency (hours) Daily Daily 4000 When anomaly occurs 500 1000 500 500 1500
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by 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.
Print P2D32N003 E
Base - May 2010
58
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4HE N ENGINES
Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers. - Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits. - Notify the maintenance if any inconvenience is detected of if any filling is necessary. After engine start and while engine is running, proceed with the following checks and controls: - check presence of any eventual leakage from the fuel, cooling and lubricating circuits. - Verify absence of noise or unusual rattle during engine working. - Verify, using the vehicle devices, the prescribed pressure temperature and other parameters. - Visual check of fumes (colour of exhaust emissions) - Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES Checks and inspections Engine oil level check The check must be executed when the engine is disconnected and possibly cool.
Figure 113
The check can be made using the specially provided flexible rod (1) placed on the right hand side of the EDC.
Figure 112
1
108540
2 74174
To provide filling, operate through the upper top or through the lateral top (2, Figure 112). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier”.
Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level. Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level. In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine’s components.
Base - May 2010
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Print P2D32N003 E
F4HE N ENGINES
Combustion system inspection The check must be executed both when the engine disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head. Special attention must be paid to the connections on the high pressure pipelines. Due to the high pressure within the pipelines running from the high-pressure pump to the rail diffuser and from this last one to the electro-injectors, special attention must be aid also in checking presence of any leakage or blow-by. Protect the eyes and the skin from any eventual high pressure jet: these may deeply penetrate under the skin surface provoking serious poisoning.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
59
Lubricating system inspection The check must be executed both when the engine disconnected and when it is running. Verify the presence of any oil leakage or blow-by from the head, from the engine pan of from the heat exchanger.
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Inspection of water presence within fuel filter or pre-filter
Cooling system inspection The check must be executed both when the engine disconnected and when it is running. Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips.
NOTE The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel. Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.
Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.
Due to the high temperatures achieved by the system, do not operate immediately after the engine’s disconnection, but wait for the time deemed necessary for the cooling. Protect the eyes and the skin from any eventual high pressure jet of cooling liquid.
The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two year. NOTE In case of new filling, proceed bleeding system, through the bleeds on the engine. If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.
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Base - May 2010
60
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4HE N ENGINES
Inspection/replacement of blow-by filter The filter in subject has been developed and equipped for the collection, filtering and condense of the lubricating oil vapours. Within the filter unit (1) two cartridge filters are included (2). Figure 114
1
NOTE On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
2 74188
The check of the filtering element is carried out by removing the cover and drawing off the cartridges (2).
Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.
Inspection and setting of tappet clearance Figure 115
70520
Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
Oil motor and filter replacement
Warning: We recommend to wear proper protections because of high motor service temperature. The motor oil reaches very high temperature: you must always wear protection gloves.
Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
61
Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications. - The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the 9936076-tool.
Warning: the oil filter contains inside a quantity of oil of about 1 kg. Place properly a container for the liquid.
We recommend to carry out the oil drainage when the motor is hot.
Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the pan connected with the drain plug.
The motor oil is very pollutant: it must be disposed of according to the rules.
- Unscrew the plug and then take out the control dipsick and the inserting plug to ease the downflow of the lubrication oil.
The oil motor is very pollutant and harmful.
- Replace the filtering cartidge with a new one and screw manually until when the gasket is in contact with the support.
In case of contact with the skin, wash with much water and detergent.
- Tigthen by means of the 99360076-tool of three fourth turn.
Protect properly skin and eyes: operate according to safety rules.
- Operate the motor for some minutes and check the level through the dipsick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.
Dispose of the residual properly following the rules.
- After the complete drainage, screw the plug and carry out the clean oil filling.
!
Use only the recommended oil or oil having the requested features for the corrrect motor functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with theses rules, the service warranty is no more valid.
- Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dipsick.
Print P2D32N003 E
Base - May 2010
62
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Fuel filter replacement
F4HE N ENGINES
Alternator belt replacement Due to several applications the belt run can change very much.
During this operation don’t smoke and don’t use free flames. Avoid to breathe the vapors coming from filter. Warning: with switched off motor (but still hot) the belt can operate without advance notice. According to the applications the filters position and the quantity can change.
Wait for the motor temperature lowering to avoid very serious accidents.
However the following operations are valid for all applications. - Drain the fuel inside the filter by operating the water release screw. Collect the fuel in a container without impurities. - Unscrew the cartridge by using the 99360076-tool. - Collect the eventual fuel inside the filtering cartridge. - Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.
For applications with automatic belt stretcher, the procedure is the following: Figure 116
- Screw manually the new filtering cartdrige until when the gasket is completely on its seat. - Tigthen through the 99360076-tool at 10-15 Nm torque.
108545
- Operate on the tightener (1) and withdraw the belt (2) from the alternator and water pumps from pulleys and from the returns pumps. - Replace the worn belt with a new one. - Place the belt on the pulleys and the guide rollers. - Place the automatic tightener in order to key the belt in the functioning position. - Further adjustments are not required.
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
1
SECTION 4 Overhaul and technical specifications
Page
Print P2D32N003 E
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .
4
4 AND 6 ENGINE OVERHAUL . . . . . . . . . . . . .
11
ENGINE REMOVAL AT THE BENCH . . . . . . . .
11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .
12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . .
12
- Checks and measurements . . . . . . . . . . . . . . .
12
- Checking head supporting surface on cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Checking cam lift and pin alignment . . . . . . . .
15
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Bush replacement . . . . . . . . . . . . . . . . . . . . . .
16
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
- Fitting tappets — camshaft . . . . . . . . . . . . . . . .
17
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
18
- Measuring journals and crankpins . . . . . . . . . .
18
- Measuring journals and crankpins (6 cyl.) . . . .
20
- Replacing oil pump control gear . . . . . . . . . . .
22
- Fitting main bearings . . . . . . . . . . . . . . . . . . . .
22
- Finding journal clearance . . . . . . . . . . . . . . . . .
22
- Checking crankshaft shoulder clearance . . . . .
23
CONNECTING ROD — PISTON ASSEMBLY . .
23
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
Base - May 2010
2
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
Page
Page
- Measuring piston diameter . . . . . . . . . . . . . . . . - Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing the valves . . . . . . . . . . . . . . . . . . . .
31
- Checking cylinder head wet seal . . . . . . . . . . .
32
- Checking cylinder head supporting surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . .
33
24 25
- Conditions for proper pin-piston coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .
26
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Fitting connecting rod-piston assembly . . . . . .
27
- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . .
33
- Connecting rod-piston coupling . . . . . . . . . . . .
27
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .
28
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .
34
- Regrinding — replacing the valve seats . . . . . . .
34
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
36
- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . .
28
- Finding crankpin clearance . . . . . . . . . . . . . . . .
29
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . .
36
- Checking piston protrusion . . . . . . . . . . . . . . .
30
- Refitting the cylinder head . . . . . . . . . . . . . . . .
37
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .
31
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
38
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
3
GENERAL SPECIFICATIONS Type
4 CYLINDERS
6 CYLINDERS
Cycle
Four-stroke diesel engine
Power
Turbocharged with intercooler
Injection
Direct
Number of cylinders
4
6
∅
+
+
Bore
mm
104
Stroke
mm
132
+.. = Total displacement
cm3
4485
6728
TIMING start before T.D.C. end after B.D.C.
A B
18.5º 29.5º
start before B.D.C. end after T.D.C.
D C
67º 35º
Checking timing mm
0.20 to 0.30
mm
0.45 to 0.55
Bosch
high pressure common rail EDC7 ECU
X
X
FUEL FEED Injection Type:
Injector
CRIU 2
Nozzle type
DSLA and DLLA
Injection sequence
1-3-4-2
1-5-3-6-2 -4
bar
Injection pressure
Print P2D32N003 E
bar
250 - 1600
Base - May 2010
4
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
CLEARANCE DATA
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1 Cylinder barrels X ∅1 X
mm
∅1
102.009 to 102.031
∅1
0.4
X ∅1 ∅2
55.9 / 49.5 (•) 103.714 to 103.732 / 103.759 to 103.777 (•) 38.010 to 38.016
Pistons Size Outside diameter Pin housing
∅2
6 CYLINDERS
Piston diameter
∅1
Piston protrusion
X
0.4
X
∅ 3
Piston pin Piston pin — pin housing
(•) Valid for engines
Base - May 2010
0.28 to 0.52
∅3
37.994 to 38.000 0.01 to 0.022
F4HE9684P F4HE9684A F4HE9687P F4HE9687A
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S 2 S 3
X1* X2 X3
Split ring slots
X2
Split rings
S1 S2 S3
Split rings - slots
1 2 3
∅ 2
Small end bush housing Big end bearing housing
2.560 to 2.605 2.350 to 2.380 3.970 to 3.990 0.100 to 0.175 0.060 to 0.110 / 0.040 to 0.090 (•) 0.040 to 0.080
X1 X2 X3
0.30 to 0.40 0.60 to 0.80 0.30 to 0.55
∅1
40.987 to 41.013
∅2
72.987 to 73.013
Small end bush diameter
S
Inside Big end half bearings
Big end half bearings
Print P2D32N003 E
2.705 to 2.735 2.440 to 2.460 / 2.420 to 2.440 (•) 4.030 to 4.050
0.4
∅ 3
Piston pin — bush
(•) Valid for engines
mm
Split ring end opening
X3
∅1
6 CYLINDERS
* measured on 101 mm
Split rings X1
5
∅3 S
38.019 to 38.033 1.955 to 1.968 0.019 to 0.039 0.250 ; 0.500
F4HE9684P F4HE9684A F4HE9687P F4HE9687A
Base - May 2010
6
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4HE N ENGINES
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
6 CYLINDERS mm
X Size
X
Max. tolerance on connecting rod axis alignment
-
-
∅2
∅1
S 1
S 2
∅ 3
Journals Crankpins
∅1 ∅2
82.99 to 83.01 68.987 to 69.013
Main half bearings Big end half bearings
S1 S2
2.456 to 2.464 1.955 to 1.968
Main bearings No. 1 — 5 / 1- 7 No. 2 — 3 — 4
∅ 3 ∅3
87.982 to 88.008 87.977 to 88.013
Half bearings — Journals No. 1—5 / 1-7 No. 2—3—4 / 2-3-4-5-6
0.041 to 0.119 0.041 to 0.103
Half bearings - Crankpins
0.033 to 0.041
Main half bearings Big end half bearings
0.250 to 0.500
Shoulder journal
X1
37.475 to 37.545
Shoulder main bearing
X2
32.180 to 32.280
Shoulder half-rings
X3
37.28 to 37.38
X 1
X 2 X 3
Output shaft shoulder
Base - May 2010
0.095 to 0.265
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM ∅ 1
6 CYLINDERS mm
Valve guide seats on cylinder head
∅ 4
7
∅1
7.042 to 7.062
∅4 α
6.970 to 6.990 60o ± 0.25o
∅4 α
6.970 to 6.990 45o ± 0.25o
Valves:
α Valve stem and guide
0.052 to 0.092
Housing on head for valve seat:
∅ 1
34.837 to 34.863
∅1
34.837 to 34.863
Valve seat outside diameter; valve seat angle on cylinder head: ∅2 α
∅ 2
∅2 α
α
X
Sinking Between valve seat and head Valve seats
Print P2D32N003 E
∅1
34.917 to 34.931 60o 34.917 to 34.931 45o
X
0.59 to 1.11
X
0.96 to 1.48 0.054 to 0.094 0.054 to 0.094 -
Base - May 2010
8
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4HE N ENGINES
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
6 CYLINDERS mm
Valve spring height: free spring H
H1
H 2 under a load equal to: 339.8 ± 9 N 741 ± 39 N Injector protrusion
H
47.75
H1 H2
35.33 25.2
X
-
X
∅ ∅ ∅ 1 23 4 5 ∅ 2
Camshaft bush housings No. 1 (flywheel side)
59.222 to 59.248
Camshaft housings No. 2-3-4-5/2-3-4-5-6-7 ∅
54.089 to 54.139
Camshaft journals: 1⇒5 1⇒7 ∅ 1
∅
53.995 to 54.045
∅
54.083 to 54.147
∅ 3 ∅
Bush inside diameter Bushes and journals
0.038 to 0.162
Cam lift: H
Base - May 2010
H
6.045
H
7.582
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
9
6 CYLINDERS mm
∅1 Tappet cap housing on block ∅2 ∅ 3
Tappet cap outside diameter:
∅2
∅1
16.000 to 16.030
∅2 ∅3
15.924 to 15.954 15.960 to 15.975
Between tappets and housings Tappets
0.025 to 0.070 -
∅ 1 Rocker shaft
∅1
21.965 to 21.977
Rockers
∅2
22.001 to 22.027
∅ 2 Between rockers and shaft
Print P2D32N003 E
0.024 to 0.162
Base - May 2010
10
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Base - May 2010
F4HE N ENGINES
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
4 AND 6 ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH
11
Figure 3
The following instructions assume that the engine has previously been placed on the rotating bench and that removal of all specific components of the FPT equipment have been already removed as well. (See Section 3 of the manual herein). The section illustrates therefore all the most important engine overhaul procedures. The following operations are relating to the 4 cylinder engine but are similar and applicable for the 6 cylinder. Figure 1 70160
The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2). NOTE Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.
70158
Figure 4 Loosen the fixing screws (1) and remove the rod caps (2). Withdraw the pistons including the connecting rods from the top of the engine block. NOTE Keep the half-bearings into their housings since in case of use they shall be fitted in the same position found at removal.
70161
Use tool 99360500 (1) and hoist to remove the crankshaft (2) from the block. Figure 2 Figure 5
70159
Remove the screws (1) and the main bearing caps (2).
Print P2D32N003 E
Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3).
70162
Base - May 2010
12
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
zs
REPAIR OPERATIONS CYLINDER UNIT Checks and measurements
Figure 6
Figure 9
s
70163
Remove the screws (1) and disconnect camshaft (3) retaining plate (2). 70166
Once engine is disassembled, clean accurately the cylinder-block assembly. Use the proper rings to handle the cylinder unit. The engine block shall not show cracks. Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear. Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter.
NOTE Take note of plate (2) assembling position.
Figure 7
NOTE Should the ring gauge be not available, use a micrometer for zero-setting. 70164
Figure 10 Withdraw carefully the camshaft (1) from the engine block.
Figure 8
70167
Measurements shall be performed on each cylinder, at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement.
70165
Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.4 mm and to the specified assembling clearance.
Withdraw the tappets (1) from the engine block. Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
13
Check main bearing housings as follows:
Figure 11
- fit the main bearings caps on the supports without bearings; - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value.
α
Replace if higher value is found.
Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit. Planarity error shall not exceed 0.075 mm. Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.
107804
NOTE In case of regrinding, all barrels shall have the same oversize (0.4 mm).
Print P2D32N003 E
Base - May 2010
14
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
TIMING SYSTEM Camshaft Figure 12
70169
CAMSHAFT MAIN DATA (4 cyl.) Specified data refer to pin standard diameter
Figure 13
84089
MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders) Specified data refer to pin standard diameter
Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the Base - May 2010
camshaft and the bush. Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cam lift and pin alignment
15
BUSHES
Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft. Check cam lift; found values shall be: 6.045 mm for exhaust cams and 7.582 mm for intake cams, in case of different values replace the camshaft.
Figure 15
Figure 14
70172
70171
Camshaft bush (2) shall be pressed into its housing. Internal surface must not show seizing or wear. Use bore dial gauge (3) to measure camshaft bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.
Figure 16
Sec. A-A
107399
CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.) * Value to be obtained after driving the bush. Print P2D32N003 E
Base - May 2010
16
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
Figure 17 sec. A-A
107268
MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING *Height to be obtained after driving the bush.
Bush replacement
Tappets
Figure 18
Figure 19
70174 112890
To replace bush (1), remove and refit it using the beater 99360362 (2) and the handgrip 99370006 (3). MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK NOTE When refitting the bush (1), direct it to make the lubricating holes (2) coincide with the holes on the block housing.
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Fitting tappets — camshaft
17
Figure 22
Figure 20
70238
Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque. 70176
Lubricate the tappets (1) and fit them into the relevant housings on the engine block. Figure 23
70179
Check camshaft end float (1). It shall be 0.23 ± 0.13 mm.
Figure 21
Figure 24
70164 70180
Lubricate the camshaft bush and fit the camshaft (1) taking care not to damage the bush or the housings. Fit nozzles (2) and tighten the fastening screws (1) to the specified torque. Print P2D32N003 E
Base - May 2010
18
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
OUTPUT SHAFT Measuring journals and crankpins
F4HE N ENGINES
NOTE It is recommended to insert the found values in the proper table. See Figure 26.
Figure 25
Undersize classes are:
NOTE Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB. 70182
Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.
Figure 26
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.) *Rated value
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
19
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 27
measured on > 45.5 mm radius between adjacent journals
70183
OUTPUT SHAFT MAIN TOLERANCES
TOLERANCES
TOLERANCE CHARACTERISTIC Roundness
SHAPE
DIRECTION POSITION OSCILLATION
Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL ○ /○/ //
GRAPHIC SYMBOL
CRITICAL
©
IMPORTANT
⊕
SECONDARY
⊝
MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
INTERMEDIATE MAIN BEARINGS
FIRST MAIN BEARING ON FRONT SIDE
70237
Print P2D32N003 E
Base - May 2010
20
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
Measuring journals and crankpins (6 cyl.) Figure 28
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value
Figure 29
* **
Measured on a radius greater than 45.5 mm ↗ 0.500
between adjacent main journals
70577
MAIN OUTPUT SHAFT TOLERANCES
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
21
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 30
INTERMEDIATE MAIN BEARINGS
MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
FIRST MAIN BEARING ON FRONT SIDE
70237
TOLERANCES
TOLERANCE CHARACTERISTIC Roundness
SHAPE
DIRECTION POSITION OSCILLATION
Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL ○ /○/ //
GRAPHIC SYMBOL
CRITICAL
©
IMPORTANT
⊕
SECONDARY
⊝
Print P2D32N003 E
Base - May 2010
22
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Replacing oil pump control gear
F4HE N ENGINES
Finding journal clearance Figure 33
Figure 31
70161
70184
Refit the crankshaft (2). Check the backlash between crankshaf main journals and the relevant bearings as follows:
Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3). When fitting the new gear, heat it to 180°C for 10 minutes in an oven and then key it to the crankshaft.
Figure 34
Fitting main bearings Figure 32
70186
70185
NOTE Refit the main bearings that have not been replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter.
- clean accurately the parts and remove any trace of oil; - position a piece of calibrated wire (3) on the crankshaft pins (4) so that it is parallel to the longitudinal axis; - fit caps (1), including the half bearings (2) on the relevant supports.
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
NOTE Do not try to adapt the bearings. 75703
Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings. The second last main half bearing (1) is fitted with shoulder half rings. Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
23
Checking crankshaft shoulder clearance
Figure 35
Figure 38
70187
Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, with torque wrench to 50 ± 6 Nm. - 2nd stage, with torque wrench to 80 ± 6 Nm. Figure 36
70190
This check is performed by setting a magnetic-base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 to 0.41. If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft pins and main half bearings.
α
CONNECTING ROD — PISTON ASSEMBLY 70188
- 3rd stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90 ± 5° angle.
Figure 39
Figure 37
70191
70189
- Remove caps from supports. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire. The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described. Print P2D32N003 E
CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE The pistons are supplied spare with the following sizes: - standard; - 0.4 mm oversize. Base - May 2010
24
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
Pistons Measuring piston diameter
Figure 40
Figure 43
32613
Remove split rings (1) from piston (2) using pliers 99360183 (3).
32615
Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.
Figure 41
Figure 44
32614
Piston pin (1) split rings (2) are removed using a scriber (3). 70192
The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure. Figure 42 1.5
*
2.560 2.605
2.350 2.380
3.970 3.990
2.705 2.735
2.420 2.440
2°±20’
38.010 38.016
37.994 38.000 114797
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS * Value measured on 101 mm diameter Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
25
Figure 45
114798
MAIN DATA OF THE PISTON WITHOUT PIN TUNNEL AND PLASTIC RINGS * Value measured on 101 mm diameter
Piston pins Figure 46 Figure 48
18857
To measure the piston pin (1) diameter use the micrometer (2).
16552
Use a micrometer (1) to check split ring (2) thickness.
Conditions for proper pin-piston coupling Figure 47
Figure 49
32619
Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.
Print P2D32N003 E
32620
Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1). Base - May 2010
26
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
Connecting rods
Figure 50
Figure 52
41104
DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3). In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.
88607
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS * Value for inside diameter to be obtained after driving in connecting rod small end and grinding.
Figure 51
NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls.
70194
Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).
Use a micrometer (1) to check split ring (2) thickness.
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
27
Bushes
Figure 53
Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.
CONNECTING ROD BODY CONNECT- CONNECTING ROD ING ROD BODY BODY
*
Fitting connecting rod-piston assembly Connecting rod-piston coupling Figure 54
CONNECTING ROD BODY CONNECTING ROD BODY
CONNECTING ROD BODY
CONNECTING ROD BODY
70196
70198
NOTE Every connecting rod is marked as follows: - On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one. - 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);
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
Spare connecting rods are of the W class with green marking *. Material removal is not allowed.
108597
Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure. Print P2D32N003 E
Base - May 2010
28
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 56
F4HE N ENGINES
Figure 58
72705 70200
Position the piston (1) on the connecting rod according to the diagram shown in the figure, fit the pin (3) and stop it by the split rings (2).
Fit half bearings (1) on connecting rod and cap.
Fitting split rings NOTE Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings.
Figure 57
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°.
Fitting connecting rod-piston assembly into cylinder barrels Figure 59
NOTE Split rings are supplied spare with the following sizes: -
standard;
-
0.4 mm oversize.
70201
Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 99360605 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number.
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 60
29
Figure 62
α
108596 70204
DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL - Split ring openings shall be displaced with each other by 120°; - connecting rod-piston assemblies shall have the same weight; - the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.
- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench (2). Figure 63 α
Finding crankpin clearance Figure 61
70205
- Apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60°.
Figure 64
70203
To measure the clearance proceed as follows: - clean the parts accurately and remove any trace of oil; - set a piece of calibrated wire (2) on the output shaft pins (1); - fit the connecting rod caps (3) with the relevant half bearings (4). NOTE Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the centre of the thread length is not < 0.1 mm than the diameter measured at approx. 10 mm from screw end.
Print P2D32N003 E
70206
- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).
Base - May 2010
30
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
Checking piston protrusion
Figure 65
Figure 66
70207
If a different clearance value is found, replace the half bearings and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.
70208
Once connecting rod-piston assemblies refitting is over, use dial gauge 99395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm.
Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.10 to 0.33 mm.
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
31
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
CYLINDER HEAD Removing the valves
Figure 68
Figure 67
70321
70319
Intake (1) and exhaust (2) valves have heads with the same diameter. The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.
Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Repeat this operation for all the valves. Overturn the cylinder head and withdraw the valves (5). Figure 69
NOTE 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
70322
Remove sealing rings (1 and 2) from the valve guide.
NOTE Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.
Print P2D32N003 E
Base - May 2010
32
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cylinder head wet seal
F4HE N ENGINES
Figure 71
Figure 70
70323
70325
This check shall be performed using the proper tools. Use a pump to fill with water heated to approx. 90°C and 2 to 3 bar pressure.
The rated thickness A for the cylinder head is 105 ± 0.25 mm, max. metal removal shall not exceed thickness B by 1 mm.
Replace the core plugs (1) if leaks are found, use the proper punch for their removal/refitting. NOTE Before refitting, smear the plug surfaces with water-repellent sealant.
NOTE After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure.
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVES
33
Figure 74
Figure 72 EXHAUST VALVE
INTAKE VALVE
18882
Check the valve stem (1) using a micrometer (2), it shall be 6.970 ÷ 6.990. 107280
INTAKE AND EXHAUST VALVE MAIN DATA
Removing carbon deposits, checking and grinding valves Figure 73
Checking clearance between valve stem and valve guide and valve centering Figure 75
18625
Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. If necessary, rectify the valve seats, taking away the least amount of material possible.
Print P2D32N003 E
70327
Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 ÷ 0.092 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. Base - May 2010
34
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVE GUIDE
F4HE N ENGINES
VALVE SEATS Regrinding — replacing the valve seats
Figure 76 Figure 77
70330
INTAKE
EXHAUST
79457
Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.
Should slight scratches or burns be found, go over with the adequate tool (1) according to the inclination values indicated in the Figure 78.
Figure 78
INTAKE
EXHAUST
70331
VALVE SEAT MAIN DATA (4 CYL.)
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Should valve seats be not reset just by regrinding, replace them with the spare ones. Using a suitable tool, remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.
35
Heat the cylinder head to 80° - 100°C and using the proper punch, fit the new valve seats, previously cooled, into the cylinder head. Therefore, with an adequate tool, go over the valve seats according to the values stated in the Figure 78.
Figure 79
EXHAUST
INTAKE
70332
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD
After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial gauge 99395603 (1).
Figure 80
70333
Print P2D32N003 E
Base - May 2010
36
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVE SPRINGS
F4HE N ENGINES
FITTING CYLINDER HEAD
Figure 81
Figure 82
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before refitting use tool to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table.
70334
Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal. Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green. 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
Figure 83
770321
Position on the cylinder head: the spring (4), the upper cap (3); use tool 99360268 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2). Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
37
There are two types of head seals, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on Figure 85, at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average:
Refitting the cylinder head Figure 84
S cil1 = S1 + S2 2 For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value.
70335
Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “TOP” (1) facing the head. The arrow shows the point where the gasket thickness is given.
S=
S cil1 + S cil2 + S cil3 + S cil4 4
For 6 cylinder versions: Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.
S=
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6 6
If S is > 0,40 mm use seal type A. If S is < 0,40 mm use seal type B. Figure 85 NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
88775
Print P2D32N003 E
Base - May 2010
38
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4HE N ENGINES
TIGHTENING TORQUE TORQUE
COMPONENT
Nm 8±2 12 ± 2 77 ± 12 47 ± 5 24 ± 4 10 ± 2 8±1 24 ± 4 24 ± 4 24 ± 4 36 ± 4 43 ± 5 105 ± 5 24 ± 4 24 ± 4 36 ± 5 12 ± 2 8.5 ± 0.35
Studs M6 for camshaft sensors Studs M8 for feed pump Screw M12 for fastening rear gear case Screw M10 for fastening rear gear case Screw M8 for fastening rear gear case Nut M6 for fastening camshaft sensor Screw M8 for fastening oil pump
1st stage 2nd stage
Screw M8 for fastening front cover Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M10 for fastening crankcase plate Nut M18 for fastening high pressure pump gear Nuts M8 for fastening fuel pump ½ inch plug on cylinder head ¼ inch plug on cylinder head ¾ inch plug on cylinder head Screw M6 for fastening injectors Nut fastening for injector feed connector Nut M6 for flame start grille on intake manifold Screw M8 for fastening intake manifold Screw M12 for fastening rear brackets for engine lifting Screws M8 for fastening Common Rail Connectors M14 for high pressure fuel pipes Screw M12 (12 x 1.75 x 130) for fastening cylinder head Screw M12 (12 x 1.75 x 150) for fastening cylinder head
1st stage 2nd stage
}1
st
75º ± 5º
stage
2nd stage 3rd stage Screw for fastening rocker bracket Valve clearance adjusting nuts Nuts M14 for fastening fuel pipes from high pressure pump to Common Rail Screw M8 for fastening high pressure pipe connector Screw M6 for fastening wiring bulkhead Screw M8 for fastening electric wiring support for injector feed Nuts for fastening wiring on each injector Screw M12 for fastening fuel filter bracket Screw M8 for fastening fuel filter holder Fuel filter Screw M22 for fastening oil pressure relief valve on oil filter support Screw M8 for radiator seal and oil filter support Oil filter 11/8 inch connection on filter support for turbine lubrication Nut M12 for fastening turbine lubrication pipe Screw M10 for fastening engine coolant inlet connection 90° elbow fastening (if required) to engine coolant inlet connection Pipe on cylinder head for compressor cooling
Base - May 2010
kgm 0.8 ± 0.2 1.2 ± 0.2 7.7 ± 1.2 4.7 ± 0.5 2.4 ± 0.4 1 ± 0.2 0.8 ± 0.1 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 3.6 ± 0.4 4.3 ± 0.4 10.5 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 3.6 ± 0.5 1.2 ± 0.2 0.85 ± 0.035
50 ± 5 8±2 24 ± 4 77 ± 12 24 ± 4 20 ± 2 35 ± 5
5 ± 0.5 0.8 ± 0.2 2.4 ± 0.4 7.7 ± 1.2 2.4 ± 0.4 2 ± 0.2 3.5 ± 0.5
55 ± 5
5.5 ± 0.5 90º ± 5º 90º ± 5º
36 ± 5 3.6 ± 0.5 24 ± 4 2.4 ± 0.4 20 ± 2 2 ± 0.2 24 ± 4 2.4 ± 0.4 10 ± 2 1 ± 0.2 24 ± 4 2.4 ± 0.4 1.5 ± 0.25 0.15 ± 0.025 77 ± 8 7.7 ± 0.8 24 ± 4 2.4 ± 0.4 contact + ¾ turn 80 ± 8 8 ± 0.8 24 ± 4 2.4 ± 0.4 contact + ¾ turn 24 ± 4 2.4 ± 0.4 10 ± 2 1 ± 0.2 43 ± 6 4.3 ± 0.6 24 ± 4 2.4 ± 0.4 22 ± 2 2.2 ± 0.2
Print P2D32N003 E
F4HE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
TORQUE
COMPONENT Screw M6 for fastening engine coolant drain connector Pin fastening on engine block for exhaust manifold Screw M10 for fastening exhaust manifold on cylinder head Screw M12 for fastening damper adapter 1st stage and damper on output shaft 2nd stage Screw M10 for fastening pulley on output shaft Screw M8 for fastening water pump Screw M10 for fastening auxiliary component control belt tensioners Screw M10 for fastening fixed pulleys for auxiliary component control belt Screw M10 for fastening flywheel housing Screw M12 for fastening flywheel housing Screw M6 for fastening heat exchanger for control unit Screw M8 for fastening heat exchanger for control unit Connection M12 for fuel inlet-outlet on heat exchanger Nut M8 for fastening valve cover Screw M6 for fastening camshaft sensor Screw M6 for fastening output shaft sensor Screw M14 for fastening coolant temperature sensor Screw M5 for fastening oil pressure/temperature sensor Screw for fastening fuel pressure sensor Screw M14 for fastening fuel temperature sensor Screw for fastening air temperature/pressure sensor on intake manifold Screw M12 for fastening engine oil level sensor 6-cyl. Turbine fixing to exhaust manifold 4-cyl.
{ pins nuts { pins nuts
M8 M8 M8 M8
Adapter M12 on turbine for lubricant oil pipes (inlet) Pipe fixing on adapter M10 for turbine lubrication Oil pipe fixing on adapter M10 for turbine lubrication to block Oil drain pipe fixing M8 on turbine Connector fixing M6 for oil return from cylinder head to flywheel housing Screw M12 for fastening engine flywheel 1st stage 2nd stage Screw M8 for fastening front bracket for engine lifting Screw for fastening engine oil sump Screw M8 for fastening cylinder barrel lubricating nozzles Screw M12 for fastening output shaft caps
1st stage 2nd stage 3rd stage
Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M10 for fastening connecting rod caps 1st stage 2nd stage Alternator M10 Screw, Bracket fixing on water feed pipefitting M10 Screw, alternator locking Starter Starter fixing screw
Print P2D32N003 E
39
Nm 10 ± 2 10 ± 2 53 ± 5 50 ± 5
kgm 1 ± 0.2 1 ± 0.2 5.3 ± 0.5 5 ± 0.5 90º
68 ± 7 24 ± 4 43 ± 6 43 ± 6 85 ± 10 49 ± 5 10 ± 2 24 ± 4 12 ± 2 24 ± 4 8±2 8±2 20 ± 3 6±1 35 ± 5 20 ± 3 6±1 12 ± 2 7±1 43 ± 6 7±1 24 ± 4 35 ± 5 35 ± 5 43 ± 6 24 ± 4 10 ± 2 30 ± 4
6.8 ± 0.7 2.4 ± 0.4 4.3 ± 0.6 4.3 ± 0.6 8.5 ± 1 4.9 ± 0.5 1 ± 0.2 2.4 ± 0.4 1.2 ± 0.2 2.4 ± 0.4 0.8 ± 0.2 0.8 ± 0.2 2 ± 0.3 0.6 ± 0.1 3.5 ± 0.5 2 ± 0.3 0.6 ± 0.1 1.2 ± 0.2 0.7 ± 0.1 4.3 ± 0.6 0.7 ± 0.1 2.4 ± 0.4 3.5 ± 0.5 3.5 ± 0.5 4.3 ± 0.6 2.4 ± 0.4 1 ± 0.2 3 ± 0.4 60º ± 5º
24 ± 4 24 ± 4 15 ± 3 50 ± 6 80 ± 6
2.4 ± 0.4 2.4 ± 0.4 1.5 ± 0.3 5 ± 0.6 8 ± 0.6 90º ± 5º
24 ± 4 36 ± 4 60 ± 5
2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60º ± 5º
43 ± 6 43 ± 6
4.3 ± 0.6 4.3 ± 0.6
43 ± 6
4.3 ± 0.6
Base - May 2010
40
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Base - May 2010
F4HE N ENGINES
Print P2D32N003 E
F4HE N ENGINES
SECTION 5 - TOOLS
1
SECTION 5 Tools
Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3
Base - May 2010
2
SECTION 5 - TOOLS
Base - May 2010
F4HE N ENGINES
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F4HE N ENGINES
SECTION 5 - TOOLS
3
TOOLS TOOL NO.
DESCRIPTION
99327281
Tester PT-BOX
99317915
Set of 3 pin wrenches (14 - 17 - 19 mm)
99322205
Revolving stand for overhauling units (700 daN/m capacity, 120 daN/m torque)
99340055
Tool to remove output shaft front gasket
99340056
Tool to remove output shaft rear gasket
99341001
Double acting puller
Print P2D32N003 E
Base - May 2010
4
SECTION 5 - TOOLS
F4HE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99341009
Pair of brackets
99341015
Press
99342101
Tool to remove injectors
99346252
Tool for fitting output shaft front gasket
99346253
Tool for fitting output shaft rear gasket
99360076
Tool to remove oil filter (engine)
Base - May 2010
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F4HE N ENGINES
SECTION 5 - TOOLS
5
TOOLS TOOL NO.
DESCRIPTION
99360183
Pliers for removing/refitting piston rings (65 — 110 mm)
99360268
Tool for removing/refitting engine valves
99360339
Tool for rotating/stopping the engine flywheel
99360351
Equipment for flywheel holding
99360362
Beater for removing/refitting camshaft bushes (to be used with 993700069)
99360500
Tool for lifting the output shaft
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Base - May 2010
6
SECTION 5 - TOOLS
F4HE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99360595
Lifting rig for engine removal/refitting
99360605
Band for fitting piston into cylinder barrel (60 — 125 mm)
99361037
Brackets for fastening engine to revolving stand 99322205
99363204
Tool to remove gaskets
99370006
Handgrip for interchangeable beaters
99370415
Gauge base for different measurements (to be used with 99395603)
Base - May 2010
Print P2D32N003 E
F4HE N ENGINES
SECTION 5 - TOOLS
7
TOOLS TOOL NO.
DESCRIPTION
99389829
Dog type dynamometric wrench 9x12 (5-60 Nm)
99389834
Torque screwdriver for injector solenoid valve connector stop nut setting
99395216
Pair of gauges with ½” and ¾” square head for angle tightening
99395603
Dial gauge (0 — 5 mm)
Print P2D32N003 E
Base - May 2010
8
SECTION 5 - TOOLS
Base - May 2010
F4HE N ENGINES
Print P2D32N003 E
F4HE N ENGINES
APPENDIX
1
Appendix
Page
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SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . .
3
- Standard safety prescriptions . . . . . . . . . . . . . .
3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . .
3
- During maintenance . . . . . . . . . . . . . . . . . . . .
3
- Respect of the Environment . . . . . . . . . . . . . .
4
Base - May 2010
2
APPENDIX
Base - May 2010
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F4HE N ENGINES
APPENDIX
3
SAFETY PRESCRIPTIONS Standard safety prescriptions
- Do not execute any intervention if not provided with necessary instructions.
Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance. Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation. - Keep working areas as clean as possible, ensuring adequate aeration. - Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. - Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities. - Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines. - Smoking in working areas subject to fire danger must be strictly prohibited. - Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.
- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur.
Prevention of injury
- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.
During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50 °C. - Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. - 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 areas aerated. Whenever necessary wear safety mask.
- Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion.
- Do not leave rags impregnated with flammable substances close to the engine.
- Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed: ≤ 2 bar)
- Do not utilize fast screw-tightening tools.
- Wear safety helmet when working close to hanging loads 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 working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material. - Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.
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- Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate. - Never disconnect batteries when the engine is running. - Disconnect batteries before any intervention on the electrical system. - Disconnect batteries from system aboard to load them with the battery loader. - After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. - Do not disconnect and connect electrical connections in presence of electrical feed. - Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning.
Base - May 2010
4
APPENDIX
- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved by Iveco. - Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80 °C temperature.
F4HE N ENGINES
Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted. - Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger. - Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.
- Do not paint the components and the electronic connections. - Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.
Base - May 2010
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1
F4CE N ENGINES
Part 2 F4CE N SERIES Section General specifications
1
Fuel
2
Industrial application
3
Overhaul and technical specifications
4
Tools
5
Safety prescriptions
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Appendix
Base - May 2010
2
Base - May 2010
F4CE N ENGINES
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3
F4CE N ENGINES
UPDATING Section
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Description
Page
Date of revision
Base - May 2010
4
Base - May 2010
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F4CE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
1
SECTION 1 General specifications
Page
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CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE . . . . . . .
3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
4
- 4-cylinder engine version . . . . . . . . . . . . . . .
4
- 6-cylinder engine version . . . . . . . . . . . . . . .
5
OIL VAPOUR RECIRCULATING SYSTEM . . . . .
6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
7
- 4-cylinder engine version . . . . . . . . . . . . . . .
7
- 6-cylinder engine version . . . . . . . . . . . . . . .
8
AIR INDUCTION - BOOST DIAGRAM . . . . . . .
9
- Description . . . . . . . . . . . . . . . . . . . . . . . . .
9
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) . . . . . . . . . . . . . . . . . . . . . . . .
10
Base - May 2010
2
SECTION 1 - GENERAL SPECIFICATIONS
Base - May 2010
F4CE N ENGINES
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F4CE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
3
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Print P2D32N003 E
Technical Code
Commercial Code
F4CE9484F*J600 F4CE9684L*J602 F4CE9684N*J600
N45 MRT.X N67 MRT.X
Base - May 2010
4
SECTION 1 - GENERAL SPECIFICATIONS
LUBRICATION Forced-circulation lubrication, is obtained by means of the oil lobe pump fitted in the front part of the basement, driven by the splined bush, keyed on the hold of the engine drive shaft. From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.
F4CE N ENGINES
Lubrication circle also includes the heat exchanger, the turbo-blower for the turbo-compressed version and eventually the compressor for the compressed air system. These components may often vary according to the specific duty.
4- cylinder engine version Figure 1
(Demonstration)
Routing of oil return by gravity to sump Introduction of oil
88203
LUBRICATION SYSTEM LAYOUT (Engines with 4 cylinders) 1. Lubrication oil pipe to supercharger - 2. Oil filter - 3. Heat exchanger body - 4. Heat exchanger 5. Oil rotary expansion pump.
Base - May 2010
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F4CE N ENGINES
5
SECTION 1 - GENERAL SPECIFICATIONS
6- cylinder engine version Even for the 6 cylinders version lubrication is obtained by forced circulation and achieved through an oil rotary expansion pump similar to the 4 cylinders’ one.
Also in this case, the components such as the oil exchanger, the turbo-blower and the eventual compressor are specifically studied and made out to suit the equipment or the duty for which the engine has been developed.
Figure 2
Routing of oil return by gravity to sump
88205
Introduction of oil LUBRICATION SYSTEM LAYOUT (6-cylinder engines) 1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine - 5. Oil pump
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Base - May 2010
6
SECTION 1 - GENERAL SPECIFICATIONS
F4CE N ENGINES
OIL VAPOUR RECIRCULATING SYSTEM Figure 3
1
2
3
3240t
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 (connection towards these vapours shall be designed by the Engineer).
Base - May 2010
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F4CE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
COOLING SYSTEM The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment. - Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.
7
- Visc pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development. - Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment. - Centrifugal water pump, placed in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.
4- cylinder engine version Figure 4
(Demonstration) TO RADIATOR
FROM RADIATOR
117592
Water coming out from thermostat Water recirculating in engine Water coming into pump
COOLING SYSTEM LAYOUT (4-cylinder engines) Print P2D32N003 E
Base - May 2010
8
SECTION 1 - GENERAL SPECIFICATIONS
F4CE N ENGINES
6- cylinder engine version The engine cooling system, closed circuit forced circulation type, is of a similar design as the 4 cylinders engine. It incorporates necessary components such as the radiator, the heat exchanger, the expansion tank and some ancillary components such as the heater or the compressor for the compressed air. Such components always vary according to the engine’s equipment and duty.
Figure 5
(Demonstration)
117592
Water coming out from thermostat Water recirculating in engine Water coming into pump
COOLING SYSTEM LAYOUT (6-cylinder engines)
Base - May 2010
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F4CE N ENGINES
9
SECTION 1 - GENERAL SPECIFICATIONS
AIR INDUCTION - BOOST DIAGRAM Figure 6
4 Cylinders version
TURBOCHARGER
AIR FILTRE
EXHAUST
RADIATOR
6 Cylinders version
TURBOCHARGER
AIR FILTRE
EXHAUST
RADIATOR 74195
Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emissions flow through the body of the turbine, causing 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 drawn air through the air filter.
The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s funchon is to restrict the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
The above mentioned air is then cooled by the radiator and flown through the piston induction collector.
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Base - May 2010
10
SECTION 1 - GENERAL SPECIFICATIONS
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) In the TIER 3 version, the profile of the exhaust cam has been modified in order to allow the partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders. The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitric acid (NOx). The exhaust gas re-circulation system (EGR), reducing the combustion temperature by means of the diminishing of the concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission of NOx .
F4CE N ENGINES
The internal EGR system is not equipped with any electronically controlled elements: the system is always active. Its configuration does not need additional elements i.e.checking valves, piping or heat exchangers. The exhaust cam (B) has another lobe apart from the major lobe (see Section. A-A fig.) with respects to the configuration without EGR. The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the aspiration phase inside the cylinder.
Figure 7
114789
A. Aspiration valve control - B. Exhaust valve control. Base - May 2010
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F4CE N ENGINES
SECTION 2 - FUEL
1
SECTION 2 Fuel Page
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4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP . . . . . . . . . . . .
3
- General information . . . . . . . . . . . . . . . . . . . .
3
- Description of working principles . . . . . . . . . . .
4
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Example of identification . . . . . . . . . . . . . . . . .
5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
6-CYLINDER ENGINES WITH BOSCH VE 6/12 F ROTARY MECHANICAL PUMP . . . . . . . . . . . .
8
- General information . . . . . . . . . . . . . . . . . . . .
8
- Description of working principles . . . . . . . . . . .
9
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Base - May 2010
2
SECTION 2 - FUEL
Base - May 2010
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F4CE N ENGINES
3
SECTION 2 - FUEL
4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) - Priming pump, assembled to the engine and driven by the camshaft - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed rotary pump - Injector feed pipeline (from fuel feed pump to injectors) - Injectors
Figure 1
2 1 4
7
5 3 6
74168
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.
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Base - May 2010
4
SECTION 2 - FUEL
F4CE N ENGINES
Figure 2
116385
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Description of working principles Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft. Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For applications to be equipped in cold climate areas, the fuel filter is provided with heater).
The fuel arrives therefore to the valve gauging the pressure inside feed pump. The distribution plunger further increases this pressure and delivers fuel throughout the delivery pipe fitting to the injectors. The fuel drawing from the injectors is recovered and delivered to the tank again.
Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.
Base - May 2010
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F4CE N ENGINES
5
SECTION 2 - FUEL
FEED PUMP The rotary type pump is driven by a gear mating the camshaft’s one.
Example of identification V
=
Distribution rotary plunger
E
=
Pump dimensions
4
=
4 cylinders engine
12 =
Distribution plunger in mm.
1150
=
LV =
Left direction of rotation
N°. of pump revolutions per minute
Figure 3
1 15 2 14 3 4
5 13 12 6
7 8
9 11 10
30454
Injection pump longitudinal section 1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk 9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate 14. Gauge pin - 15. Counteracting spring. Print P2D32N003 E
Base - May 2010
6
SECTION 2 - FUEL
F4CE N ENGINES
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 4
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.
Base - May 2010
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F4CE N ENGINES
SECTION 2 - FUEL
7
FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperature sensor. On some versions, a water presence sensor is present at filtering cartridge base.
Figure 5
88210
1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.
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Base - May 2010
8
SECTION 2 - FUEL
F4CE N ENGINES
6-CYLINDER ENGINES WITH BOSCH VE 6/12 F ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed pump - Injector feed pipeline (from fuel feed pump to injectors) - Injectors
Figure 6
9
86495
1. Injector fuel pipe 1 - 2. Injector fuel pipe 2 - 3. Injector fuel pipe 3 - 4. Injector fuel pipe 4 - 5. Injector fuel pipe 6. Injector fuel pipe 5 - 7. Injector fuel pipe 6 - 7. Injector fuel pipe 6 - 8. Injection pump - 9. Injector.
Base - May 2010
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F4CE N ENGINES
SECTION 2 - FUEL
9
Figure 7
114799
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Description of working principles Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft. Throughout the filter/s, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For applications to be equipped in cold climate areas, the fuel filter is provided with heater).
Fuel is delivered to the pressure gauge valve within feed pump. Timing plungers further increase the pressure and deliver fuel to the injectors throughout the delivery pipe fittings. Fuel bleeding from the injectors is recovered and piped back to the pump.
Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.
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Base - May 2010
10
SECTION 2 - FUEL
F4CE N ENGINES
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 8
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.
Base - May 2010
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F4CE N ENGINES
SECTION 2 - FUEL
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 and separation of water from fuel. On the filter cartridge base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a temperature sensor (5).
Figure 9
88210
1. Fuel filter bearing - 2. Filter cartridge - 3. Bleender vent screw.
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Base - May 2010
12
SECTION 2 - FUEL
Base - May 2010
F4CE N ENGINES
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F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
1
SECTION 3 Industrial application
Page
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GENERAL INFORMATION . . . . . . . . . . . . . . . . . .
3
- Version equipped with mechanical feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
F4CE ENGINE CHARACTERISTICS . . . . . . . . . . .
4
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . .
4
- 6-cylinder engines . . . . . . . . . . . . . . . . . . . . . .
5
PART ONE - MECHANICAL COMPONENTS . .
7
OVERHAUL OF THE ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP . . . . . .
9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . .
9
- Disassembly of application components . . . . .
10
- Installation of application components . . . . . .
17
- Completion of the engine . . . . . . . . . . . . . . . .
28
- Rotary feed pump disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
- Feed system bleed procedure . . . . . . . . . . . . .
32
- Power takeoff . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Checks and inspections . . . . . . . . . . . . . . . . . .
32
PART TWO ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . .
33
ELECTRICAL COMPONET LAYOUT . . . . . . . . . .
35
- Cooling liquid temperature sensor . . . . . . . . .
36
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
- Pre-post heating resistor . . . . . . . . . . . . . . . . .
36
- Pre-post heating unit . . . . . . . . . . . . . . . . . . . .
37
- KSB Water temperature sensor . . . . . . . . . . .
37
Base - May 2010
2
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Page - Electromagnets assembled to feed pump . . . .
38
- Oil pressure switch . . . . . . . . . . . . . . . . . . . . .
38
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
- Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . .
39
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
PART THREE - TROUBLESHOOTING . . . . . . . .
41
PART FOUR - MAINTENANCE PLANNING . . .
49
MAINTENANCE PLANNING . . . . . . . . . . . . . . . .
51
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
- Planning of controls and periodical intervention . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
- Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . . .
52
MAINTENANCE PROCEDURES . . . . . . . . . . . . . .
52
- Checks and controls . . . . . . . . . . . . . . . . . . . .
52
Base - May 2010
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F4CE N ENGINES
3
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
GENERAL INFORMATION Version equipped with mechanical feed pump Figure 1
114800
NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment in general. They are featured by 4 stroke diesel cycle having 4 cylinder boost with 2 valves per cylinder. Feed is provided by rotary mechanical pump or on line according to the equipment application. It differs from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine.
NOTE The picture shows application designed for 4 cylinders version, 2 valves per cylinder, having fuel feed mechanical pump.
Print P2D32N003 E
NOTE Data, technical specifications and performances granted shall be valid only if the Setter will follow and comply with all installation prescriptions provided by FPT. Furthermore, the expanders assembled by the Setter must always comply with couple, power and number of revolutions based on which the engine has been designed. The section herein described is composed or four directories: - directory of mechanical overhaul prescribed in accordance to the engine’s specific duty, illustrating all necessary operations to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover; - electrical directory, describing the connections of the different components, of the pre-post heating gearbox (only for some versions) and of the sensors assembled to the engine; - troubleshooting directory; - directory of preventive and regular maintenance operations, providing instructions for the execution of the main operations. Base - May 2010
4
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
F4CE ENGINE CHARACTERISTICS 4-cylinder engines
F4CE9484F*J600 Type
ρ
Compression ratio Max. output
Max. torque
17.5 : 1 kW (HP)
74 (101)
rpm Nm (kgm)
2200 430 (44)
rpm
1250
Loadless engine idling
rpm
-
Loadless engine peak
rpm
-
Bore x stroke Displacement
mm cm3
104 x 132 4485 with intercooler
SUPERCHARGING
HOLSET HX35W
Turbocharger type LUBRICATION
bar
Forced-circulation by means of lobe pump. Pressure control valve, oil filter
Oil pressure (warm engine) - idling
bar
0.8
- peak rpm
bar
3.5
COOLING
Liquid
Water pump control Thermostat - start of opening
Through belt ºC
81 ± 2
FILLING engine sump* 15W40 ACEA E3
liters
16
liters
17
engine sump + filter* * First filling
NOTE Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
5
6-cylinder engines
F4CE9684
ρ
L*J602
N*J600
kW (HP)
17,5 : 1 86 (117)
17,5 : 1 126 (170)
rpm Nm (kgm)
2200 522 (52,2)
2200 720 (72)
rpm
1250
1250
Type Compression ratio Max. output
Max. torque
Loadless engine idling Loadless engine peak rpm Loadless engine peak rpm
rpm
-
rpm
104 x 132 6728 with intercooler
rpm
SUPERCHARGING
HOLSET HX35W
Turbocharger type LUBRICATION
bar
Forced-circulation by means of lobe pump. Pressure control valve, oil filter
Oil pressure (warm engine) - idling
bar
0.8
- peak rpm
bar
3.5
COOLING
Liquid
Water pump control Thermostat - start of opening
Through belt ºC
81 ± 2
FILLING engine sump* 15W40 ACEA E3
liters
16
liters
17
engine sump + filter* * First filling
NOTE Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed. Print P2D32N003 E
Base - May 2010
6
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Base - May 2010
F4CE N ENGINES
Print P2D32N003 E
F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
7
DIAGNOSI
PART ONE MECHANICAL COMPONENTS
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Base - May 2010
8
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
DIAGNOSI
Base - May 2010
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F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
OVERHAUL OF THE ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface
9
Figure 3
Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well. NOTE With regard to the engine disassembly operations, please apply for information consulting the specific manual. All operations of engine disassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. 87712
The following information relate to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties. NOTE For specific application exigencies, some units can be assembled to the engine in different positions. Within ”General overhaul” section, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.
- Disassemble the starter; Properly hold the starter (2) and loosen the two fixing screws (1); assemble the supporting bracket 99361037 using the threaded ports on the basement.
Figure 4
Engine setting operations for the assembly on turning stand Figure 2
88216
88215
On the left hand side:
In order to apply the brackets 99361037 to the engine block to fix it on to the stand 99322205 for the overhaul, it is necessary to perform the following operations: On the right hand side: - disassemble lubrication oil exhaust pipe (2) from the turbo-blower: Underneath the turbo-blower loosen the screws (1);; finally loosen and remove the union (5) from the block; plug the pipe ends and the exhaust of the turbo-blower. - oil level rod (4); - oil filter (3).
- assemble the second bracket 99361037 throughout the screw-threaded ports (1).
Provide for oil recovery and disposal in compliance with the law and regulations in force.
Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.
Print P2D32N003 E
- Lift the engine using the rocker arm 99360595 and put it on the turning stand 99322205. - Drain the oil through the cap underneath the plug.
Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water.
Base - May 2010
10
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Figure 7
Disassembly of application components Figure 5 1
75675
Proceed disassembling the supercharger:
70126
- loosen the fixing nut (1) and remove the lubrication pipe from the supercharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger. - Loosen the fixing screw (3) and remove the exaust lubrication pipe from the supercharger. - Hold up the supercharger and after lifting it remove the gasket.
NOTE To disconnect fuel pipelines (2 and 3, Figure 6), in low pressure from the relating pipe fittings, it is Necessary to press the locking fastener (1) as shown in picture B. After having disconnected the pipeline, reset the locking fastener (1) in lock position as shown in. picture A, to avoid any possible deformation of the fastener itself.
Figure 6
4 3 2 Figure 8
1
1
87404
NOTE In some versions, the fuel filter has the sensor detecting water on the basis of the filtering cartridge and/or a heater interposed between filter support and filtering cartridge. For the versions requiring it, disconnect the electrical connections of such electrical components before removing the fuel filter. - Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. Carry out complete drainage of the fuel contained therein. - Screw out completely the faucet and, using equipment 99360076 disassemble fuel filter (1). - Disconnect fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump. - Remove the fuel filter bearing from the bracket fixed to the engine head. Base - May 2010
87405
- Disconnect the LDA pipe (1) from the head and from the feed pump. - Pipe the ends of the pipelines as well as the feed pump and the engine head.
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F4CE N ENGINES
11
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 9
88311
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. Bracket fixing screw to injection pump side- 6. Bracket fixing screw to injection pump side- - 7. Front bracket fixing screw (on suction collector plate) - 8. Injector.
Figure 10
Figure 11
88218
88102
- Disconnect the pipelines (1) and (2) that provide feed and fuel recovery between pump and injectors; screw out the nuts fixing the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery pipeline; loosen the screws holding the fixing brackets of such pipelines (1, 5, 6, and 7, Figure 9); pipe the pipeline ends.
- Loosen the two fixing screws (2) and disassemble priming pump (1).
- Disassemble the injectors and remove them from their slot: remove the gaskets.
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Base - May 2010
12
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Figure 12
Figure 14 2
1 76149
- Remove tappet caps: Loosen the fixing screws (1) and lift the caps (2); remove the gaskets. NOTE On the central cap there is a blow-by valve for the lubrication oil vapours. All the gaskets shall always be replaced during assembly.
75683
- Disassemble rocker arm bearings; loosen the two fixing screws (2) and remove the complete rocker arm bearing; withdraw tappet rods. Repeat the operation for all the remaining rocker arm bearings. - Disassemble water temperature transmitter (1). Figure 15
(Demonstration)
Figure 13
88305
- Using the square wrench with suitable dimensions, work on the A point shown in the picture, release the pressure and withdraw the Poli-V belt (3) from the transmission and drive pulleys. - Proceed disconnecting the automatic tightening device (1) and the relevant support (2). Figure 16 87409
- Disassemble suction and exhaust manifolds: loosen the screws (1) fixing the suction manifold plate to the cylinder head. - From the exhaust manifold side loosen the (2) fixing screws; remove the gaskets.
87413
- Duly hold the alternator (2) removing it from its support by loosening the screw (3) and from the bracket by loosening the screw (1); recover nuts and washers. Base - May 2010
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F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 17
13
Figure 19
88219
117593
- Disassemble thermostat unit; loosen the three fixing screws (1), disassemble the thermostat unit (2). Remove the gasket (3) and the thermostat (4).
- Loosen the fastening screws (4) and remove the oil filter support (5), together with the sheaths (1) and (3) and the heat exchanger (2). - Disassemble the ignition pump (see the specific procedure) and the power takeoff underneath (if available).
Figure 18
Figure 20
88231
88306
- Loosen the screws (1) and withdraw the alternator bearing (2).
- Loosen the fastening screws (3) and remove the pulley controlling the fan (2). - Proceed detaching the support (1). - Remove the transmission pulley (4).
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Base - May 2010
14
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
For 4 cylinder engines
Figure 24
Figure 21
1
2
4
3
1 2
3
4
75688
- Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block. - F4HE9484A*J105 For 6 cylinder engines Figure 22
75689
- Loosen the screws (1) and withdraw water pump (2). - Loosen the screws (3) and remove the pulley (4).
76152
- Proceed disconnecting the cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.
Figure 25
- Remove the gasket (4). Figure 23
00900t
87747
- Use the tool 99360339 to operate on the flywheel cover box (1) in order to block flywheel rotation (2). (Utilise starter holding down studs and fixing screw nuts). - Loosen the flywheel fixing screws (3) to engine drive shaft. Base - May 2010
- Remove the engine drive shaft fixing ring from the front cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3). Print P2D32N003 E
F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
15
Figure 28
Figure 26
88214
- Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring (1) from the front cover (2).
87420
- Screw out the opposite screws (1) from the ports and introduce the withdrawal pins (see picture following). - Loosen remaining flywheel fixing screws (3) to the engine drive shaft (2). - Remove the flywheel block tool (2).
Figure 27
Figure 29
87419
- Loosen the screws (2) and remove the front cover (1). - Remove the gasket.
NOTE Take note of the screw (2) assembly position, since the screws have different length.
Print P2D32N003 E
87421
- Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.
Base - May 2010
16
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Figure 30
Figure 32
88307
00903t
- Remove the flywheel cover box fixing ring using the tool 99340056 (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.
- Turn the engine upside-down. - Loosen the screws (2), remove the oil pan(1) recovering the gasket. Figure 33
- Fix the tool 99340056 (3) to the ring (1) tightening the screws specially provided (4). - Proceed with drawing the ring (1) tightening the screw (2). - Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring of the flywheel cover box.
Figure 31
87655
- Remove the gear (1) transmitting motion to the ignition pump and the relevant support. Figure 34
87422
- Loosen the screws (2) and remove the flywheel cover box (1). NOTE Take note of the screw (1) assembly position, since the screws have different length.
Base - May 2010
87424
- Remove the screws (1) and disassemble the gears (3) and (4) from the camshaft (2). Print P2D32N003 E
F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Installation of application components
17
Figure 37
Figure 35
87653
70211
- With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the side surface of which a groove has been created for the ignition timing.
- Place the dial gauge (1) on the timing gear (2) and check that the slack between the gears (2) and (3) is included in the range between 0,076 ÷ 0,280 mm. Figure 38
NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.
Figure 36
87654
- Fit the screws (1) fastening the gears (2) to the camshaft (3) and tighten them to the prescribed pair. Figure 39
116355
- Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).
87655
- Spline the gear (1) transferring motion to the ignition pump. Print P2D32N003 E
Base - May 2010
18
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Figure 40
Figure 42
87656
- Fit the power take-off gear (2) (if available) into the specially provided housing and fasten the screws (1),
87658
- Re-assemble the box (1) to the engine basement. - Tighten the fastening screws (2) to the same position detected before disassembly.
Figure 41 NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Figure 43
87657
DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. After having completed seal application, the joints must be immediately assembled (10-20 minutes time).
Base - May 2010
87659
- Apply to the rear tongs hold (3) of the engine drive shaft the part (6) of the tool 99346253, fix it with the screws (1) and spline the new tight ring to it (2). - Place the part (5) on the part (6), tighten the nut (4) until tight ring assembly (2) into the flywheel box is completed.
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F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 44
19
Figure 47
α
87663 87660
- Check the laying surface (1) of the clutch disk: if it is scratched proceed with facing. - Check the tooth conditions of the toothed rim (2), replace it in case of broken tooth or excessive wear. Fit the new one, previously heated at the temperature of 150 °C for 15’÷20’. Figure 45
Tighten the engine flywheel (1) fixing screws (2) in two phases: - 1st phase; tightening by means of dynamometric wrench to couple 30 ± 4 Nm; - 2nd phase, 60º ± 5º angle dwell. NOTE Angle dwell shall always be performed using 99395216 tool. Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Figure 48
87661
- Screw tighten two pins (2) of appropriate length into the ports of the engine drive shaft (3) and assemble the engine flywheel (1) using the specially provided sling.
- Fit the sheath.
87664
- Assemble the oil pump (1). - Fit the fastening screws (2) and tighten them.
Figure 46
Figure 49
87662
- Spline the flywheel (1) on the engine drive shaft by tightening the screws (2) manually. - Duly lock the flywheel before proceeding with tightening the relevant screws to the prescribed pair. Print P2D32N003 E
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. Base - May 2010
20
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Figure 50
Figure 53
87666
- Fit part (4) of the tool 99346252 on the front tang (3) of the engine drive shaft; fasten it with the screws (5) and spline the new tight ring on it (6). - Fit part (1) on part (4), screw-tighten the nut (7) until the assembly of the tight ring (6) into the front cover (2) is completed.
- Assemble the water pump (1).
87668
- Tighten the screws (2) and lock them to the prescribed couple. Figure 54
Figure 51
88219
- Assemble the following elements to the block: new gasket (1), heat exchanger (2), new gasket (3), oil filter bearing (5). - Tighten the screws (1) and lock them to the prescribed couple. 88225
- Spline the pulley (2) on the engine drive shaft and tighten the screws to the prescribed pair and angle (1).
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Figure 55
Figure 52
70221 88231
- Apply to the water pump (1) a new fixing ring (2). Base - May 2010
- Fit the alternator support (1) and tighten the screws (2) fastening them to the prescribed pair. Print P2D32N003 E
F4CE N ENGINES
21
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
4-cylinder engine
Figure 56
Figure 58 1 2
3
4
87676
- Fit the bracket (1) back to fix the alternator (2) to the engine basement. Tighten the screws (3) fastening the alternator to the support.
75688
- Place the head (3) over the block and insert screws (1) and (2). NOTE If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.
Figure 57
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703 87670
- Place the gasket (1) over the block.
Figure 59
Do not grease the gasket. It is recommended to keep the gasket inside packaging until assembly to the cylinder head. Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture.
4
10
NOTE Verify that the engine block stand is clean. α
1
9
8
2
7
13
3
11
5
6
14 12 76115
- Lubricate cylinder head bolts and install to head. - Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. - 1st phase of pre-tightening. Screws 70 mm: 60 ± 5 N. Screws 140 mm: 40 ± 5 N. Screws 180 mm: 70 ± 5 N. - 2nd phase of angle tightening for all screws: 90° ± 5° - 3rd phase of angle tightening solo per le viti da 140 e da 180 mm: 90° ± 5° NOTE If not faulty the gasket can be reused.
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Base - May 2010
22
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
6-cylinder engine
Figure 62
Figure 60 4 1 3 2 2 3
1
75705 76152
- Place the head (3) over the block and insert screws (1) and (2). NOTE If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.
ROCKER ARM UNIT COMPONENTS: 1. Elastic ring - 2. Spacer- 3. Rocker arms4. Support. - Carry out the assembly of the rocker arms after previous check of the components. Figure 63
18.975 18.963
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
19.000 19.026
19.000 19.026
Figure 61
75704
SHAFT AND ROCKER ARM BASIC DATA Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary.
α 76214
- Lubricate cylinder head bolts and install to head. - Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. - 1st phase of pre-tightening. Screws 70 mm: 60 ± 5 N. Screws 140 mm: 40 ± 5 N. Screws 180 mm: 70 ± 5 N. - 2nd phase of angle tightening for all screws: 90° ± 5° - 3rd phase of angle tightening solo per le viti da 140 e da 180 mm: 90° ± 5° NOTE If not faulty the gasket can be reused. Base - May 2010
Figure 64
13.00 11.00 116391
ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the i 4 - 6 Nm couple. Print P2D32N003 E
F4CE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 65
23
Figure 68 2
1 3
75806 32655
Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable. Figure 66
D2
D1
Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Correct slack is: - suction valves 0.25 0.05 mm - exhaust valves 0.50 0.05 mm.
NOTE In TIER 3 engines, due to the presence of a supplementary lobe, as regards the INTERNAL E.G.R. the procedure of the regulation of the valve clearance, which foresees the enforcement of the clearance regulation of all valves by using only 2 movements of the engine shaft, cannot be used. Each cylinder must be checked by bringing it up to the U.D.C. (upper dead centre) at the end of compression and by regulating the clearance of both valves exclusively on the cylinder in question.
75703
- Insert the tappet driving rods and the Rocker Arm unit. Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced; Figure 67 2
1 75683
- Tighten the screws (2) to the prescribed couple and assemble water temperature sensor (1). Print P2D32N003 E
Base - May 2010
24
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Figure 69
Figure 71
1 75707 117588
- Assemble injectors after having replaced the sealing gasket (1). NOTE During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing.
- Assemble thermostat unit (2) including thermostat (5) and gasket (4). - Tighten the screws to the prescribed couple.
NOTE The screws (1) have been have been utilised to fix the bracket (3) (if available). Figure 70
The gasket (4) must be new.
Figure 72
87409
- Tighten the fastening screws (2) and assemble the exhaust collector with new sheaths. - Apply the sheath to the assembly surface of the induction collector plate and provide tightening the screws (1) to the prescribed pair. - If the duct from the suction collector has been disassembled, re-assemble it after having fitted the sheaths and the heater.
76149
- Assemble cylinder covers (2) with the respective gaskets; - Fit the seal nods and tighten the screws (1) fixing them to the prescribed couple. NOTE Always replace the gaskets using new ones. Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. In such case provide for replacement with new nods.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 73
25
Figure 76
87677 88309
- Assemble the ignition pump unit (1) into the gearbox housing (2) and fix it, without tightening, throughout the screws (3). Figure 74
- Assemble the support (3) of the automatic tightening device by fastening the relevant screws. - Tighten the fastening screw (1) and assemble the automatic tightening device (2). Figure 77
88308
- Assemble the support (1) of the fan pulley throughout the screws (2) ) tightening them to the prescribed pair. Figure 75
88310
- Assemble the Poli-V belt (4) on the pulley of the engine drive shaft, on the water pump (5), on the alternator (1), on the fan pulley (2) and on the transmission pulley (3).
NOTE Execute belt tightening operation working on the belt tightening pulley (5). In case the previously disassembled belt is going to be reassembled, it is necessary to examine it carefully first in order to detect any incision or evidence of stress decay.
88306
- Assemble the fan pulley (2) to the support (1) throughout the screws (3) tightening them to the pair. - Assemble the transmission pulley (4). Print P2D32N003 E
Base - May 2010
26
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 78
Figure 80
88102
- Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple.
88218
- Assemble the fastening brackets of the fuel pipes. - Assemble the pipes (1) and (2) providing fuel feed and recovery between pump and injectors; Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold; fix the pipes to the injectors throughout the brackets previously assembled.
Figure 79
88311
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. Bracket fixing screw to injection pump side- 6. Bracket fixing screw to injection pump side- - 7. Front bracket fixing screw (on suction collector plate) - 8. Injector. Base - May 2010
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27
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 81
Figure 83
1
70126
87405
- Fix the LDA pipeline (1) to the engine head and to the feed pump.
NOTE To connect fuel pipelines (2 and 3, Figure 82) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B. After having connected the pipeline, reset the fastener (1) into block position as shown in picture A.
Figure 82
4
Figure 84
3
1
2 1
75675
87404
- Assemble the fuel filter bearing (4) to the bracket fixed to the engine head. - Connect the fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to feed pump. - Using 99360076 equipment assemble fuel filter (1). NOTE The filter shall be priory filled with fuel to facilitate feed system bleed operations. For the versions requiring it, connect the electrical connections of the sensor detecting presence of water, and of the heater.
Proceed assembling the turbocharger: - Hold the turbocharger and place it on the exhaust manifold after having interposed the gasket. - Screw up the fixing nuts of the turbocharger to the exhaust manifold tightening them to the prescribed couple. - Tighten the lubrication pipe fixing ring. Operate in the same way on the other end of the pipe. Connect it to the upper part of the heat exchanger. To complete engine assembly it is necessary to remove it from the turning stand. - Using rocker arm 99360595 hold the engine and loosen the screws fixing the brackets to the turning stand 99322205. - Disassemble the brackets from the engine after having properly put it on a wooden bearing.
Print P2D32N003 E
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Completion of the engine
Figure 86
Figure 85
88215
87712
On the right hand side: - reassemble the lubrication oil exhaust pipeline (2) from the turbocharger; from underneath the turbocharger tighten the screws (1). Tighten the union (5) to the block.
- Reassemble the starter; properly hold the starter (2) and tighten the fixing screws (1) to the prescribed couple.
- The oil level rod (4).
- Fill up engine oil. - Install the engine on the machine (for installation operations please apply to specific issue).
- Oil filter (3).
Base - May 2010
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29
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Rotary feed pump disassembly and assembly procedure
Search for top dead center throughout tool 99360339 Figure 88
NOTE This procedure prescribes that: - The fuel pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump) shall all be disassembled. - Electrical connection to feed pump shall be disconnected. - Accelerator cable shall be disconnected.
In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part.
88232
On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine and disassemble it only afterwards.
- Fit the racket of the tool 99360339 (1) holding the flywheel provided with the rotation coil (2).
The following procedure analyses this second hypothesis since it is the more complex.
- Rotate the flywheel until the pin (4) provided with the tool 99360339 engages in the notch of the flywheel (3).
- Carefully rotate the flywheel in its rotation director to annul the gear slacks.
Search for top dead center throughout tool 99395097 False injector
Figure 87
Figure 89
87712
- Disassemble the starter (2) removing the screws (1). 88101
Remove the first injector, fit the tool 99395097 (2) and the relevant dial gauge 99395604 (1) and remove the tappet cover. Apply tool 99360339 (see Figure 88) in order to make the engine shaft rotate. The condition of 1st cylinder to TDC at end of compression phase is obtained when the dial gauge pointer reaches maximum value and suction and exhaust valves are both closed and not balancing. Once PMS has been obtained, lock the flywheel by means of tool 99360339 (Figure 88). Print P2D32N003 E
Base - May 2010
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Figure 90
Figure 93
88102
- After having disconnected fuel pipes of the priming pump, loosen the fastening screws (2) and remove the pump (1) from the basement (3). Figure 91
87717
- On timing system side, take cover off gear box to access pump control gear securing nut. - Remove nut securing injection pump gear. - Remove the three nuts (2), (3), (5) fastening the ignition pump (1) to the basement (4) and withdraw it from their own housing. - Reattach the ignition pump following the same order followed to execute disassembly, in reverse. Figure 94
87715
- Check, through the priming pump housing, that the camshaft (1) is in (TDC) end of compression phase, throughout the notches (2) on said shaft. If the notches are not visible, unlock the flywheel and rotate the engine of 360_ until the notches are visible. Lock the flywheel. Figure 92
87718
- At the time of assembling the feed pump to the engine it is necessary to ensure T.D.C. conditions to the cylinder no.1 in phase of compression, as described previously (Figure 84 or 85). - Assemble the ignition pump unit (1), preset , into the gearbox housing (2) and fasten it, without tightening it, throughout the screws (3). 87716
- Loosen the screw (2), remove the “L” spacer (1) and lock the screw (2) to keep the pump timed with the engine flywheel. - Duly keep the “L” spacer with the pump unit. Base - May 2010
NOTE The gasket removed during pump disassembly shall not be utilised again. Always use original spare parts. Print P2D32N003 E
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 95
31
Figure 97
2
1
88148
88102
- Loosen screw (1) that prevents pump shaft rotation and insert spacer (2). Tighten screw (1)so that it locks spacer (2): in this way the supplì pump shaft will be able to rotate freely.
- Assemble the priming pump (1) to the basement (3) and tighten the fastening screws (2) to the prescribed pair.
- Unlock the engine flywheel. - Remove the flywheel rotation locking tool 99360339; place the starter into its housing.
Ignition pump control and timing
- Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump). - Connect electrical connections to electro-magnets on the hydraulic head and on KSB. NOTE In case pump removal has been carried out while the engine was assembled, connect acceleration cable.
Figure 96
88312
- With the ignition pump fitting into its housing and with loosened fastening screws, remove the closure cap placed over the pump cover. - Fit the dial gauge 99395603 (2) and the relevant tool 99395100 (1), pre-loading the rod by 2,5 mm. - Rotate the engine derive shaft to shift from the condition of the first cylinder to TDC end of compression phase. Reset the dial gauges and rotate the engine drive shaft into the opposite direction until recovering the condition of the 1st cylinder to TDC in phase of compression (see Figure 84 or 85). From this position on the comparator applied on the pump it must be possible to read the value listed on the pumping element pre-lift table. Section 4. - Rotate the pump in anti-clockwise direction if the stroke is shorter or in clockwise direction if the stroke is longer, until obtaining the stroke prescribed. - Checking these conditions, lock the pump by tightening the relevant nuts to the prescribed pair. Print P2D32N003 E
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Feed system bleed procedure
Checks and inspections
Figure 98
NOTE The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.
Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:
88304
In case any operation has been executed on the components of the feed circuit, it is necessary to execute bleeding of air within the system. - Disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the priming pump. - Continue the operation until when fuel outflows.
- there is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings. - Carefully check the fuel connection pipes to the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and. - Cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings.
- Connect the (1) to the filter.
- 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 the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection.
Power takeoff Figure 99
- Check and blow by with care the engine cooling system, carrying out frequent drainage.
88230
For the engines with power takeoff, operate as follows: - loosen the 2 fastening screws (1) and remove the cover (2). - Insert the device utilizing the fastening points available.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
33
PART TWO ELECTRICAL EQUIPMENT
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34
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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35
ELECTRICAL COMPONET LAYOUT Figure 100
88320
The electrical components available on the 6-cylinder NEF engines are listed here following. 1. Cooling liquid temperature sensor; 2. Starter; 3. Resistor for cold start; 4. KSB Water temperature sensor; 5. Electromagnets assembled to feed pump: (A) on hydraulic head unit (B) on KSB; 6. Oil pressure switch; 7. Fuel heater (C) and water detecting sensor (D) (where available); 8. Speed sensor; 9. Alternator.
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36
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Cooling liquid temperature sensor
Starter
Figure 101
Figure 102
88314
Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch assembled to the starter itself.
C
Specifications:
A B
A
B
BOSCH 3 kW - 12V
C
75718
Pre-post heating resistor Figure 103
It is a component integrating a temperature sensor. It is assembled to the engine head close to the thermostat unit and its duty is to detect engine cooling liquid temperature. Specifications: Range of working temperatures: Connection side
-40 ÷ 130 °C/(+150 °C for < 10 min.)
Bulb side on engine:
-40 ÷ 140 °C
Working tensions:
6 ÷ 28 V
Settings: 80 °C
0.304 ÷ 0.342 kΩ
20 °C
2.262 ÷ 2.760 kΩ
-10 °C
8.244 ÷ 10.661 kΩ
75723
It is a resistor assembled to the suction collector and is utilised to heat the air during pre-post heating operations. It is fed by a tele-switch usually placed very close to the engine. Specifications: Working tensions: Maximum possible Air flow:
Base - May 2010
12 V 2 cc / min (pressure 138 kPa)
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Pre-post heating unit
KSB Water temperature sensor
Figure 104
Figure 105
30
+0
F 30 N31
37
15
7
50 NTC 31
5 10
4
6
GH
F
T
GHC
8 3
1
FB
R
1.2W
75719
88153
Legend F= R= T= GHC =
Fuse Pre-post heating resistance Remote control switch Pre-post heating unit
Electrical diagram pin out
PIN
Description
1
Output for “cold start” warning light
2
Not connected
3
Feedback signal input from pre-post heating resistance (FB)
4
Started engine signal input (D)
5
Start-up signal input (50)
6
Pre-post heating resistance supply remote control switch output (GH)
7
Supply positive (15)
8
Supply negative (31)
9
Not connected
10
Temperature analogue signal input (NTC)
It is assembled to the cylinder head on the engine left hand side. Specifications: Working tensions:
12 ÷ 24 V
Electrical Power load:
2.5 A (induction) 5.0 A (resistance)
Setting:
63±3°C Contact opening upon increasing temperature 53±3 °C Contact closure upon decreasing temperature
This unit operates, by means of the remote control switch, the pre-post heating resistance according to the engine coolant temperature. Features: Working tensions: Operating voltage: Operating temperature: Maximum current in the GH line: Print P2D32N003 E
12 V 7 V ÷ 16V -40°C ÷ 85°C 0.3A Base - May 2010
38
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Electromagnets assembled to feed pump
Fuel filter
Figure 106
Figure 107
88321
1 - Hydraulic head Electro-magnet; 2 - KSB Electro-magnet
Oil pressure switch 88319
Figure 108 1. Heater - 2. Water detecting sensor. On the basis of the fuel filter there is a sensor detecting the presence of water. For the use requiring it ( use in cold climate conditions) a heater provided with connector for heat resistance of the fuel filter may be interposed between the filter support and the filtering cartridge.
75722
It is assembled to the block on the engine’s left hand side. Specifications: Working tensions:
12 ÷ 24 V
Contact closure upon lower pressure:
0.6 bar
Contact opening upon higher pressure:
0.9 bar
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Speed sensor
39
Alternator
It is an induction type sensor and it is placed on the front part of the engine. It generates signals obtained from magnetic flow lines.
Figure 111
Figure 109
88315
75725
Figure 110
It is place front view on the right hand side of the engine, and is driven by tooth belt. Specifications: Working tension:
12 V
Current delivered:
90A (at 6000 rpm)
Absorption in stand-by:
≤ 1mA
Sense of rotation:
clockwices
88316
Pin out PIN
Description
1
Signal
2
Signal
3
Screening
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
41
PART THREE TROUBLESHOOTING
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42
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Base - May 2010
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The engine does not start
POSSIBLE CAUSE Battery flat or faulty.
REMEDY
NOTE
Check and recharge battery. Replace battery if necessary.
Connections to battery terminals cor- Clean, examine and tighten the nuts on roded or loose. the battery terminals. Replace the cable terminals and the nuts if excessively corroded. Incorrect timing of injection pump.
Check and correctly time the injection See your Iveco dealer. pump.
Deposits or water in the fuel tank.
Disconnect the hoses and clean them Drain feed system. using a jet of compressed air. Dismantle and clean the injection pump. Remove water from tank and refuel.
No fuel in tank.
Refuel.
No power supply.
Overhaul or replace the fuel or transfer pump.
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ANOMALY
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in pump. fact present and also check the fuel pump. Eliminate the air from the injection pump by unscrewing the cap and working the fuel pump by hand. Faulty starter motor.
Repair or replace the starter motor. SECTION 3 - DUTY-INDUSTRIAL APPLICATION
43
Base - May 2010
POSSIBLE CAUSE
REMEDY
NOTE
K.S.B. device for cold spark advance con- Check or replace the injection pump. trol operating incorrectly. The engine cuts out.
See your Iveco dealer.
Idle rpm too low.
Adjust with adjustment screw.
Irregular flow of injection pump.
Adjust flow.
Impurities or water in the fuel lines.
Disconnect the hoses and clean them Drain feed system. using a jet of compressed air. Dismantle and clean the injection pump. Remove water from fuel tank and refuel.
Clogged fuel filter.
Dismantle and replace if necessary.
See your Iveco dealer.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use peratures forming due to the use of unsuitable fuel. at low temperatures. Replace the fuel filters.
44
Base - May 2010
ANOMALY
Presence of air in the fuel and injection Check that the hoses are not cracked or system. the unions loose. Replace worn parts, remove the air from the hoses and deaerate the injection pump and fuel filter by unscrewing the caps and working the primer pump by hand. Broken injection pump controls.
Replace the faulty parts.
Abnormal clearance between camshaft Adjust clearance by replacing shims. cams and tappets. Burnt, corroded or chalky valves.
Replace the valves, rectify or replace the cylinder head seatings.
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The engine overheats
POSSIBLE CAUSE
REMEDY
Faulty water pump.
Check the unit and replace if necessary. Replace the gasket.
Malfunctioning thermostat.
Replace the thermostat.
NOTE
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ANOMALY
Fouling in coolant openings in the cylinder Wash following the standards specified head and cylinder groups. for the type of descaling product used.
Engine operation is irregular and lacks power
Water pump drive belt slack.
Check and adjust the tightness of the belt. On applications provided with automatic tensioner, check corret worching of such device.
Coolant level too low.
Top-up radiator with coolant.
Incorrect engine timing.
Check timing and tune correctly.
Incorrect calibration of injection pump.
Correct the delivery rate of the pump on See your Iveco dealer. a bench so that the injection is at the specified rate.
Dry air cleaner blocked.
Clean the air filter or replace if necessary.
Incorrect timing of injection pump.
Check timing and correctly set pump.
K.S.B. automatic cold advance device mal- Check or replace injection pump. functioning. Excessive piston wear.
Check or replace injection pump.
Incorrect calibration of speed regulator.
Check and correctly calibrate the regula- See your Iveco dealer. tor. SECTION 3 - DUTY-INDUSTRIAL APPLICATION
45
Base - May 2010
REMEDY
NOTE
Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using ation of injectors. the appropriate tools and completely overhaul the injectors. Impurities or water in the fuel and injec- Carefully clean the system and refuel. tion system.
If necessary drain feed system.
Incorrect play between camshaft cams Check and correct play and tappets. Faulty turbocharger.
Replace complete unit.
Air cleaner blocked.
Clean or replace air cleaner.
Faulty operation of L.D.A. device
Check that the diaphragm is not perfor- See your Iveco dealer. ated, that the counter spring is suitable and that it has the correct loading (check on test bench). Check that there is adequate air pressure inside the intake manifold in relation to the engine rpm under full-load conditions.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Engine operation is irregular and lacks power
POSSIBLE CAUSE
46
Base - May 2010
ANOMALY
Tie rods between accelerator pedal and Adjust the tie-rods so that the command regulation lever incorrectly adjusted. lever can be moved to the full delivery position. Engine running with abnormal knocking
Faulty operation of injectors.
Replace all injectors.
Fuel lines blocked.
Dismantle the hoses, clean them and replace those that are seriously dented.
Incorrect set-up of injection pump.
Correct the set-up of the pump so that in- See your Iveco dealer. jection occurs at the specified angle.
F4CE N ENGINES
Print P2D32N003 E
Engine running with abnormal knocking
POSSIBLE CAUSE
REMEDY
NOTE
Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and inplay on one or more main or rod bearings stall smaller bearings. Replace the thrust or excessive play on shoulders. half-rings. Crankshaft unbalanced.
Check alignment of crankshaft.
Loosening of screws securing flywheel.
Replace the loosened screws and tighten all the screws to the specified torque.
Misalignment of rods.
Replace the rods.
F4CE N ENGINES
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ANOMALY
Noise from piston journals due to excess- Replace the piston journal and/or the pisive play of piston hubs and in the rod ton and rod bushing. bushing. Loose bushings in the rod seatings. Replace with new bushings. Noisy timing.
The engine smokes abnormally. Black or Excessive maximum pump output. dark grey smoke.
Adjust the play between camshaft cams and tappets and check that there are no broken springs, that there is no excessive play between the valve stems and the valve guides, tappets and seatings. Disconnect the pump and adjust delivery See your Iveco dealer. in accordance with the data given in the calibration table.
K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust tioning. correctly as described in the manual.
47
Base - May 2010
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
There is an excessive delay on the injec- Correct the set-up. tion pump.
POSSIBLE CAUSE
REMEDY
NOTE
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up. dark grey smoke. vance. The holes in the atomisers (or some of Replace the injectors with a series of new them) are partially or entirely blocked. injectors or clean and rectify the original ones using suitable equipment. Air cleaner blocked or deteriorated.
48
Base - May 2010
ANOMALY
Clean or replace the filter element.
Loss of compression in the engine due to: Overhaul the engine or limit the interventions to the relative parts. stuck or worn flexible rings; worn cylinder liners; valves deteriorated or badly adjusted. Unsuitable injectors, different types of in- Replace or calibrate the injectors. jectors or incorrectly calibrated. Injection hoses with an unsuitable internal Check conditions of the end or unions diameter, end of hoses pinched due to re- and where necessary replace the hoses. peated blocking. Blue, grey-blue, grey smoke tending to Excessive delay in injection pump. white.
Correct the set-up of the pump.
K.S.B. automatic cold advance device mal- Check or replace injection pump. functioning. Faulty injector.
See your Iveco dealer. See your Iveco dealer.
Replace the injector.
Leaking of oil from the piston rings caused Overhaul the engine. by glued or worn rings or wearing of cylinder liner walls. Engine oil passing through the intake Recondition the cylinder head. guides-valves following wearing of guides or valve stems. Engine too cold (thermostat blocked or Replace the thermostat. inefficient).
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49
PART FOUR MAINTENANCE PLANNING
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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51
MAINTENANCE PLANNING Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run.
Planning of controls and periodical intervention
Controls and periodical intervention Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency (hours) Daily Daily 4000 500 1000 500 1500
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by 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.
Print P2D32N003 E
Base - May 2010
52
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4CE N ENGINES
Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers. - Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits. - Notify the maintenance if any inconvenience is detected of if any filling is necessary. After engine start and while engine is running, proceed with the following checks and controls: - check presence of any eventual leakage from the fuel, cooling and lubricating circuits. - Verify absence of noise or unusual rattle during engine working. - Verify, using the vehicle devices, the prescribed pressure temperature and other parameters. - Visual check of fumes (colour of exhaust emissions) - Visual check of cooling liquid level, in the expansion tank.
Figure 113
MAINTENANCE PROCEDURES Checks and controls Engine oil level check. The check must be executed when the engine is disconnected and possibly cool. The check can be made using the specially provided flexible rod (1). Figure 112
87757
To provide filling, operate through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier”. 87756
Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level. Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level. In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine’s components.
Base - May 2010
Some applications are equipped with a level transmitter alerting dashboard instruments in case of insufficient lubrication oil within the pan. The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Print P2D32N003 E
F4CE N ENGINES
Check of fuel system The check must be executed both when the engine disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the injection pump and to the injectors.
Cooling system check The check must be executed both when the engine disconnected and when it is running. Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips. Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.
Due to the high temperatures achieved by the system, do not operate immediately after the engine’s disconnection, but wait for the time deemed necessary for the cooling. Protect the eyes and the skin from any eventual high pressure jet of cooling liquid.
The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two year.
NOTE In case of new filling, proceed bleeding system, through the bleeds on the engine. If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
53
Lubricating system check The check must be executed both when the engine disconnected and when it is running. Verify the presence of any oil leakage or blow-by from the head, from the engine pan of from the heat exchanger.
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Check of water presence within fuel filter or pre-filter NOTE The components of the system can be damaged very quickly in presence of water or impurity within the fuel. Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.
Fuel filter is equipped with pump screw-valve to drain the water eventually mixed with fuel (some applications of 6 cylinders engines will be equipped with two fuel filters, both provided with drainage. Place a container underneath the filter and slightly loosen the screw. Drain the water eventually contained in the filter’s bottom. Lock the screw (max 0.5 Nm locking couple) as soon as fuel starts bleeding.
Base - May 2010
54
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Check of drive belt tensioning Some applications are equipped with an automatic tensioner that provides correcting belt tensioning.
F4CE N ENGINES
Check and setting of tappet clearance Figure 114
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.
Danger: if the engine is switched off but is still hot, unexpected motion of the belt may occur. Wait for engine temperature cooling as a precaution in order to avoid serious danger injury.
87673
Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.
NOTE In TIER 3 engines, due to the presence of a supplementary lobe, as regards the INTERNAL E.G.R. the procedure of the regulation of the valve clearance, which foresees the enforcement of the clearance regulation of all valves by using only 2 movements of the engine shaft, cannot be used. Each cylinder must be checked by bringing it up to the U.D.C. (upper dead centre) at the end of compression and by regulating the clearance of both valves exclusively on the cylinder in question.
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
Oil motor and filter replacement
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
55
Whereas you replace the lubrication oil, it is necessary to replace the filter.
Warning: We recommend to wear proper protections because of high motor service temperature.
According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.
The motor oil reaches very high temperature: you must always wear protection gloves.
- The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the 9936076-tool.
Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.
Warning: the oil filter contains inside a quantity of oil of about 1 kg.
We recommend to carry out the oil drainage when the motor is hot. - Place a proper container for the oil collecting under the pan connected with the drain plug. - Unscrew the plug and then take out the control dipsick and the inserting plug to ease the downflow of the lubrication oil.
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 to safety rules. Dispose of the residual properly following the rules.
Place properly a container for the liquid. Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water. The motor oil is very pollutant: it must be disposed of according to the rules.
- Replace the filtering cartidge with a new one and screw manually until when the gasket is in contact with the support. - Tigthen by means of the 99360076-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 topping up to compensate the quantity of oil used for the filling of the filtering cartridge.
- After the complete drainage, screw the plug and carry out the clean oil filling.
!
Use only the recommended oil or oil having the requested features for the corrrect motor functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with theses rules, the service warranty is no more valid.
- Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dipsick.
Print P2D32N003 E
Base - May 2010
56
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Fuel filter replacement
F4CE N ENGINES
Alternator belt - water pump replacement Figure 115
!
(Demonstration)
During this operation don’t smoke and don’t use free flames. Avoid to breathe the vapors coming from filter.
NOTE After filters replacement the supply equipment deaeration must be carried out.
According to the applications the filters position and the quantity can change. However the following operations are valid for all applications. - Drain the fuel inside the filter by operating the water release screw. Collect the fuel in a container without impurities. - Unscrew the cartridge by using the 99360076-tool. - Collect the eventual fuel inside the filtering cartridge. - Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.
88305
- Using a suitably-sized square-head wrench, work on point A indicated in the illustration, lower the pressure and unthread the Poly-V belt (3) from the control and guide pulleys. - Assemble the Poly-V belt (3) on the engine shaft pulley, on the water pump, on the alternator (1), on the ventilator and drawback pulleys.
- Screw manually the new filtering cartdrige until when the gasket is completely on its seat. - Tigthen through the 99360076-tool at 10-15 Nm torque.
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
1
SECTION 4 Overhaul and technical specifications
Page
Print P2D32N003 E
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . .
3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . .
4
INJECTION PUMP PUMPING ELEMENT PRE-LIFT TABLE . . . . . . . . . . . . . . . . . . . . . . . . .
10
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . .
11
ENGINE REMOVAL AT THE BENCH . . . . . . . . . .
11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . .
12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . .
12
- Checks and measurements . . . . . . . . . . . . . . .
12
- Checking head supporting surface on cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Checking cam lift and pin alignment . . . . . . . .
14
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Bush replacement . . . . . . . . . . . . . . . . . . . . . .
15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Fitting tappets — camshaft . . . . . . . . . . . . . . . .
15
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .
16
- Measuring journals and crankpins . . . . . . . . . .
16
- Replacing oil pump control gear . . . . . . . . . . .
19
- Fitting main bearings . . . . . . . . . . . . . . . . . . . .
19
- Finding journal clearance . . . . . . . . . . . . . . . . .
19
- Checking output shaft shoulder clearance . . .
20
CONNECTING ROD — PISTON ASSEMBLY . . . .
20
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
Base - May 2010
2
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
Page
Page CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . .
28
- Removing the valves . . . . . . . . . . . . . . . . . . . .
28
- Checking cylinder head wet seal . . . . . . . . . . .
29
- Checking cylinder head supporting surface . . .
29
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
23
- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . .
30
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . .
30
- Fitting connecting rod-piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Connecting rod-piston coupling . . . . . . . . . . . .
25
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .
25
- Regrinding — replacing the valve seats . . . . . . .
31
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Measuring piston diameter . . . . . . . . . . . . . . . .
21
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
- Conditions for proper pin-piston coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .
- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . .
26
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . . .
33
- Finding crankpin clearance . . . . . . . . . . . . . . . .
26
- Refitting the cylinder head . . . . . . . . . . . . . . . .
33
- Checking piston protrusion . . . . . . . . . . . . . . .
27
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . .
34
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
3
GENERAL SPECIFICATIONS Type
4 CYLINDERS
6 CYLINDERS
Cycle
Four-stroke diesel engine
Power
Turbocharged with intercooler
Injection
Direct
Number of cylinders
4
6
∅
+
+
Bore
mm
104
Stroke
mm
132
+.. = Total displacement
cm3
4485
6728
TIMING start before T.D.C. end after B.D.C.
A B
15° 35°
start before B.D.C. end after T.D.C.
D C
69° 21°
Checking timing mm
0.25 ± 0.05
mm
0.50 ± 0.05
Bosch
VE 6/12F
X
X
FUEL FEED Injection Type: Nozzle type
Injection sequence
DSLA 145 P
1-3-4-2
1-5-3-6-2 -4
bar
Injection pressure bar
Print P2D32N003 E
-
Base - May 2010
4
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
CLEARANCE DATA
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1
104.000 to 104.024
∅1
0.4
Size Outside diameter Pin housing
X ∅1 ∅2
55.9 103.714 to 103.732 38.010 to 38.016
Piston diameter
∅1
0.4
Piston protrusion
X
Piston pin
∅3
X X ∅2
mm
∅1
Cylinder barrels
∅1
6 CYLINDERS
Pistons
X
∅3
Piston pin — pin housing
Base - May 2010
0.28 to 0.52
37.994 to 38.000 0.010 to 0.022
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S2 S3
X 1* X2 X3
Split ring slots
X2
∅2 ∅3 S
2.705 to 2.735* 2.440 to 2.460 4.030 to 4.050
S1 S2 S3
2.560 to 2.605 2.350 to 2.380 3.970 to 3.990
Split rings - slots
1 2 3
0.100 to 0.175 0.060 to 0.110 0.040 to 0.080 0.4
Split ring end opening in cylinder barrel:
Small end bush housing Big end bearing housing
X1 X2 X3
0.30 to 0.40 0.60 to 0.80 0.30 to 0.55
∅1
40.987 to 41.013
∅2
72.987 to 73.013
Small end bush diameter Inside
∅3
Big end half bearings
S
Piston pin — bush Big end half bearings
Print P2D32N003 E
mm
Split rings
X3
∅1
6 CYLINDERS
* measured on 101 mm ∅
Split rings X1
5
38.019 to 38.033 1.955 to 1.968 0.019 to 0.039 0.250 ; 0.500
Base - May 2010
6
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4CE N ENGINES
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
6 CYLINDERS mm
X Size
X
Max. tolerance on connecting rod axis alignment ∅2
∅1
S1
S 2
∅ 3
-
-
Journals Crankpins
∅1 ∅2
82,990 to 83,010 68,987 to 69,013
Main half bearings Big end half bearings
S1 S2
2.456 to 2.464 1.955 to 1.968
Main bearings No. 1 - 7 / 1 - 5 No. 2-3-4-5-6 / 2-3-4
∅3 ∅3
87.982 to 88.008 87.977 to 88.013
Half bearings — Journals No. 1-7 / 1-5 No. 2-3-4-5-6 / 2-3-4
0.041 to 0.119 0.041 to 0.103
Half bearings - Crankpins
0.033 to 0.041
Main half bearings Big end half bearings
0.250 ; 0.500
Shoulder journal
X1
37.475 to 37.545
Shoulder main bearing
X2
32.180 to 32.280
Shoulder half-rings
X3
37.28 to 37.38
X1
X2 X3
Output shaft shoulder
Base - May 2010
0.095 to 0.265
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM ∅1
6 CYLINDERS mm
Valve guide seats on cylinder head
∅4
7
∅1
8.019 to 8.039
∅4 α
7.960 to 7.980 60°
∅4 α
7.960 to 7.980 45°
Valves:
α Valve stem and guide
0.039 to 0.079
Housing on head for valve seat:
∅1
∅1
46.987 to 47.013
∅1
43.637 to 43.663
Valve seat outside diameter; valve seat angle on cylinder head: ∅2 α
∅ 2
∅2 α
α
47.063 to 47.089 60o 43.713 to 43.739 45o
X
1 to 1.52
X
1.05 to 1.52
Sinking X Between valve seat and head Valve seats
Print P2D32N003 E
0.050 to 0.102 0.050 to 0.102 -
Base - May 2010
8
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4CE N ENGINES
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
6 CYLINDERS mm
Valve spring height:
H
H1
H2
free spring
H
63.50
under a load equal to: 329 N 641 N
H1 H2
49.02 38.20
Injector protrusion
X
not adjustable
X
∅ ∅ ∅ 1 23 4 5 ∅ 2
Camshaft bush housings No. 1-5
59.222 to 59.248
Camshaft housings No. 2-3-4-5 / 2-3-4-5-6-7
54.089 to 54.139
Camshaft journals: 1⇒5 1⇒7 ∅ 1
53.995 to 54.045
∅ 3 ∅
Bush inside diameter
∅
Bushes and journals
54.083 to 54.147 0.038 to 0.152 0.044 to 0.144
Housings and journals Cam lift: H
Base - May 2010
H
11.02
H
10.74
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
9
6 CYLINDERS mm
∅1 Tappet cap housing on block ∅2 ∅3
Tappet cap outside diameter:
∅2
∅1
16.000 to 16.030
∅2 ∅3
15.929 to 15.959 15.965 to 15.980
Between tappets and housings Tappets
0.020 to 0.065 -
∅ 1 Rocker shaft
∅1
18.963 to 18.975
Rockers
∅2
19.000 to 19.026
∅2 Between rockers and shaft
Print P2D32N003 E
0.025 to 0.063
Base - May 2010
10
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
INJECTION PUMP PUMPING ELEMENT PRE-LIFT TABLE
4-CYLINDER ENGINES 6-CYLINDER ENGINES
NOTE
Technical Code
Commercial Code
Pre-lift (mm)
F4CE9484F*J600
N45 MRT.X
0.80 ± 0.05
F4CE9684N*J6..
N67 MRT.X
1 ± 0.05
F4CE9684L*J6..
N67 MRT.X
1 ± 0.05
INJECTION PUMP CALIBRATION Overhaul and calibration interventions are up to BOSCH assistance network. The contract technical specification containing the data to calibrate the pump at the bench is identified by the code shown on injection pump body and is available at BOSCH technical assistance network. Otherwise, refer to FPT Technical Assistance Service.
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH
11
Figure 3
The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well. (See Section 3 of the manual herein). The section illustrates therefore all the most important engine overhaul procedures.
70160
The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).
Figure 1
NOTE Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal. Figure 4
70158
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. NOTE Keep the half-bearings into their housings since in case of use they shall be fitted in the same position found at removal.
74774
With tool 99360500 (1) and hoist, remove the engine shaft from the (2) engine crankcase.
Figure 5 Figure 2
87754 70159
Remove the screws (1) and the main bearing caps (2).
Print P2D32N003 E
Disassemble the bench half-bearings (1). For the supercharged engines, withdraw the screws (2) and disassemble the oil sprayers (3). If present, remove nozzles from the (4) workbench supports. Base - May 2010
12
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
zs
REPAIR OPERATIONS CYLINDER UNIT Checks and measurements
Figure 6
Figure 9
s
70163
Remove the screws (1) and disconnect camshaft (3) retaining plate (2). NOTE Take note of plate (2) assembling position.
70166
Once engine is disassembled, clean accurately the cylinder-block assembly. Use the proper rings to handle the cylinder unit. The engine block shall not show cracks. Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear. Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter.
Figure 7
NOTE Should the ring gauge be not available, use a micrometer for zero-setting. 70164
Figure 10 Withdraw carefully the camshaft (1) from the engine block.
Figure 8
70167
Measurements shall be performed on each cylinder, at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement. 70165
Withdraw the tappets (1) from the engine block. Base - May 2010
Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.5 mm and to the specified assembling clearance. Print P2D32N003 E
F4CE N ENGINES
13
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Check main bearing housings as follows:
Figure 11
- fit the main bearings caps on the supports without bearings; - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value. Replace if higher value is found.
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 them in case of uncertain seal or if rusted.
α
107804
NOTE In case of regrinding, all barrels shall have the same oversize (0.4 mm).
TIMING SYSTEM Camshaft Figure 12
70512
CAMSHAFT MAIN DATA (6 cyl.) The data reported refer to standard diameter (dimensions in mm) of pins
Print P2D32N003 E
Base - May 2010
14
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cam lift and pin alignment
F4CE N ENGINES
BUSHES
Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft.
Figure 14
Figure 13
70172
70171
Camshaft bush (2) shall be pressed into its housing. Internal surface must not show seizing or wear. Use bore dial gauge (3) to measure camshaft front and rear bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.
Figure 15
sec. A-A
107268
CAMSHAFT BUSH AND HOUSING MAIN DATA (6 cyl.) * Value to be obtained after driving the bush (dimensions in mm).
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Bush replacement
15
Fitting tappets — camshaft
Figure 16
Figure 18
70176
70174
To replace front and rear bushes (1), remove and refit them using the beater 99360362 (2) and the handgrip 99370006 (3).
Lubricate the tappets (1) and fit them into the relevant housings on the engine block. Figure 19
NOTE When refitting the bushes (1), direct them to make the lubricating holes (2) coincide with the holes on the block housings.
Tappets Figure 17
70164
Lubricate the camshaft bush and fit the camshaft (1) taking care not to damage the bush or its housing.
Figure 20
84053
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK (dimensions in mm).
Print P2D32N003 E
70238
Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque.
Base - May 2010
16
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 21
F4CE N ENGINES
OUTPUT SHAFT Measuring journals and crankpins Figure 23
70179 70182
Check camshaft end float (1). It shall be 0.23 ± 0.13 mm.
Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.
Figure 22
Undersize classes are: 0.250 - 0.500 mm.
87755
For supercharged engines: Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.
NOTE Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB
Fit (if disassembled) the nozzles (3) into the bench supports.
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
17
Measuring journals and crankpins Figure 24
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value (dimensions in mm)
Figure 25
K
* **
Measured on a radius greater than 45.5 mm ↗ 0.500
between adjacent main journals
70577
MAIN OUTPUT SHAFT TOLERANCES Print P2D32N003 E
Base - May 2010
18
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
Figure 26
INTERMEDIATE MAIN BEARINGS
MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
FIRST MAIN BEARING ON FRONT SIDE
70237
TOLERANCES
TOLERANCE CHARACTERISTIC Roundness
SHAPE
DIRECTION POSITION OSCILLATION
Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL ○ /○/ //
GRAPHIC SYMBOL
CRITICAL
©
IMPORTANT
⊕
SECONDARY
⊝
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Replacing oil pump control gear
19
Finding journal clearance Figure 29
Figure 27
74774
87741
Check that the toothing of the threaded bush (1) splined on the engine drive shaft (2) has no damage neither wear and in case it has, provide executing two diametrically opposite radial grooves on the bush (1) and proceed with extraction using the specially provided grab.
With tool 99360500 (1) and hoist, re-assemble the engine shaft inside the engine crankcase (2). Check the backlash between output shaft main journals and the relevant bearings as follows:
Figure 30
In phase of assembly of the new grooved bush, it is necessary to heat the latter into an oven, for maximum 60’ , at constant temperature of 160 °C, then spline it on the engine drive shaft.
Fitting main bearings Figure 28
70186
- clean accurately the parts and remove any trace of oil; - position a piece of calibrated wire (3) on the output shaft pins (4) so that it is parallel to the longitudinal axis; - fit caps (1), including the half bearings (2) on the relevant supports. 70185
NOTE Refit the main bearings that have not been replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter.
NOTE Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings. The second last main half bearing (1) is fitted with shoulder half rings. Print P2D32N003 E
Figure 31
D2
D1
75703
- At final assembly, before re-using the bench support fastening screws, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced;
Base - May 2010
20
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
Checking output shaft shoulder clearance
Figure 32
Figure 35
70187
Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, with dynamometric wrench to 50 ± 6 Nm. - 2nd stage, with dynamometric wrench to 80 ± 6 Nm. Figure 33
70190
This check is performed by setting a magnetic-base dial gauge (2) on the output shaft (3) as shown in the figure, standard value is 0.068 to 0.41. If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between output shaft pins and main half bearings.
α
CONNECTING ROD — PISTON ASSEMBLY 70188
- 3rd stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90° ± 6° angle. Figure 34
Figure 36
70191 70189
- Remove caps from supports. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire. The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described. Base - May 2010
CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush. NOTE The pistons are supplied spare with the following sizes: - standard; - 0.4 mm oversize. Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
21
Pistons Measuring piston diameter
Figure 37
Figure 39
32613
Remove split rings (1) from piston (2) using pliers 99360183 (3).
32615
Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.
NOTE The diameter shall be measured at 55.9 mm from the piston skirt.
Figure 40 Figure 38
70192 32614
Piston pin (1) split rings (2) are removed using a scriber (3).
Print P2D32N003 E
The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.
Base - May 2010
22
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
Figure 41
87730
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS (dimensions in mm)
Piston pins
Split rings
Figure 42
Figure 44
18857
To measure the piston pin (1) diameter use the micrometer (2).
16552
Use a micrometer (1) to check split ring (2) thickness.
Conditions for proper pin-piston coupling Figure 43
Figure 45
32619
32620
Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.
Check the clearance between the sealing rings (3) of the 1st slot (only for pistons of supercharged engines), of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1).
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
23
Connecting rods
Figure 46
Figure 48
41104
DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING (supercharged engines only) Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3). In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.
88607
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS * Value for inside diameter to be obtained after driving in connecting rod small end and grinding. Figure 47 NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls.
70194
Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).
Print P2D32N003 E
Base - May 2010
24
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
Figure 49
CONNECTING ROD CAP YEAR
DAY
CONN. ROD BODY CONN. WEIGHT ROD No.
CONNECTING ROD CAP CONNECTING ROD No.
87742
Bushes NOTE Every connecting rod is marked as follows: - On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one. - On the body and on the top by numbers indicating number of connecting rod and date of production and by a coloured identification mark.
Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.
- On body with a letter showing the weight of the connecting rod assembled at production:
S
V, 1600 to 1640 g (yellow marking);
S
W, 1641 to 1680 g (green marking);
S
X, 1681 to 1720 g (blue marking);
Spare connecting rods are of the W class with green marking *. Material removal is not allowed.
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Fitting connecting rod-piston assembly Connecting rod-piston coupling
25
Figure 52
Figure 50
72705
87731
The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block; 3. Marking showing 1st slot insert testing; 4. Manufacturing date.
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 Figure 53
Figure 51
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°.
87732
Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure.
Print P2D32N003 E
NOTE Split rings are supplied spare with the following sizes: -
standard; 0.4 mm oversize.
Base - May 2010
26
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 54
F4CE N ENGINES
Figure 56
87733
DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL 70200
- Split ring openings shall be displaced with each other by 120°; - connecting rod-piston assemblies shall have the same weight;
Fit half bearings (1) on connecting rod and cap.
NOTE Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings.
- the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.
Finding crankpin clearance Figure 57
Fitting connecting rod-piston assembly into cylinder barrels Figure 55 70203
To measure the clearance proceed as follows: - clean the parts accurately and remove any trace of oil; - set a piece of calibrated wire (2) on the output shaft pins (1); - fit the connecting rod caps (3) with the relevant half bearings (4).
70201
Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 99360605 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number. Base - May 2010 Revi - February 2007
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 58
27
Figure 61
α
70204
- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometric wrench (2). (60 to 5 Nm)
70207
If a different clearance value is found, replace the half bearings and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.
Figure 59
NOTE Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the centre of the thread length is not < 0.1 mm than the diameter measured at approx. 10 mm from screw end.
α
Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.10 to 0.33 mm. 70205
- Apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60°.
Checking piston protrusion Figure 62
Figure 60
70208
70206
- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2). Print P2D32N003 E
Once connecting rod-piston assemblies refitting is over, use dial gauge 39395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm. Base - May 2010
28
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
CYLINDER HEAD Removing the valves
F4CE N ENGINES
Figure 64
1
2 3
Figure 63
4
1 2
6
5 A
75751
75750
Intake (1) and exhaust (2) valves have heads with the same diameter.
Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Repeat this operation for all the valves. Overturn the cylinder head and withdraw the valves (5). Figure 65
NOTE Should cylinder head valves be not replaced, number them before removing in order to refit them in the same position.
2
A = intake side
1 75752
Remove sealing rings (1 and 2) from the valve guide.
Base - May 2010
Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cylinder head wet seal
29
Figure 67
Figure 66
A
B
87735
116357
The rated thickness A for the cylinder head is 95 ± 0.25 mm, max. metal removal shall not exceed thickness B by 0.13 mm.
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 cup plugs (1) if leaks are found, use the proper beater for their removal/refitting.
NOTE After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure.
Print P2D32N003 E
Base - May 2010
30
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVES
F4CE N ENGINES
Figure 70
Figure 68 EXHAUST VALVE
INTAKE VALVE
18882
116395
Check the valve stem (1) using a micrometer (2), it shall be 7.960 ± 7.980.
INTAKE AND EXHAUST VALVE MAIN DATA
Removing carbon deposits, checking and grinding valves Figure 69
Checking clearance between valve stem and valve guide and valve centering Figure 71
18625
Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Regrind the valve seat, if required, removing as less material as possible. Base - May 2010
87738
Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 ± 0.092 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVE GUIDE
31
VALVE SEATS Regrinding — replacing the valve seats
Figure 72
Figure 73
1 2
75754
Check the valve seats (2). If slight scoring or burnout is found, regrind seats using adequate tool (1) according to the angle values shown in Figure 74. INTAKE
EXHAUST 84046
Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure. Figure 74
88368
VALVE SEAT MAIN DATA (dimensions in mm) A = exhaust valve B = intake valve Print P2D32N003 E
Base - May 2010
32
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
Figure 75
116356
VALVE SEAT HOUSING MAIN DATA (dimensions in mm) A = exhaust valve B = intake valve Should valve seats be not reset just by regrinding, replace them with the spare ones. Use adequate tool to remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.
Heat the cylinder head to 80° - 100°C and using the proper beater, fit the new valve seats, previously cooled, into the cylinder head. Use adequate tool to regrind the valve seats according to the values shown in Figure 74.
VALVE SPRINGS Figure 77 Figure 76
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before refitting use adequate tool to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table.
87740
After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial gauge 99395603 (1). Base - May 2010
Height
Under a load of
mm
N
H (free)
63,50
no load
H1
49,02
P1
329
H2
38,20
P2
641 Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
FITTING CYLINDER HEAD
Refitting the cylinder head Figure 80
Figure 78
3
33
1
1 2 75759
Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal. Fit the sealing rings (2 and 3) on the valve guide.
70335
Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “TOP” (1) facing the head. The arrow shows the point where the gasket thickness is given. Figure 81
Figure 79
1
2 3 4
6
5 75751
Position on the cylinder head: the protection cap (5), the spring (4), the upper cap (3); use tool 99360268 (1) to compress the spring (4) and lock the parts to the valve (6) by the cotters (2).
88775
There are two types of head seals for F4AE04.., F4AE06.. and F4HE06.. engines, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on Figure 81, at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average: S cil1 = S1 + S2 2 Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value. S + S cil2 + S cil3 + S cil4 + S cil5 + S cil6 S = cil1 6 If S is > 0,40 mm use seal type A. If S is < 0,40 mm use seal type B. NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
Print P2D32N003 E
Base - May 2010 Revi - February 2007
34
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4CE N ENGINES
TIGHTENING TORQUE TORQUE
COMPONENT Cooling Nozzles (M8x1.25x10) Main bearing cap
1st stage 2nd stage 3rd stage
Rear gear housing assembly (M8x1.25x40) (M8x1.25x25) (M10x1.5) Front cover assembly - Oil pump (M8x1.25x45) (M8x1.25x30) Connecting rod bolts(M11x1.25)
1st stage 2nd stage 3rd stage
Ladder frame assembly (M10x1.25x25) Oil rifle plugs (M10x1) (M14x1.5) Assemble oil suction tube (M8x1.25x20) Oil pan assembly (M8x1.25x25) (M18x1.50) Set timing pin Fuel pump assembly M8 screw M6 screw M6 nut M10x1.5 flange head nuts Fuel pump gear (drive gear nut) Timing pin cap of fuel pump Equalizer fastening to cylinder head (M8) Cylinder head bolts (M12x70) (M12x140) (M12x180) Assy rocker covers (M8x1.25x25) Intake manifold (M8x1.25) Assy air intake connection (M8x1.25) Oil bypass valve into lube filter head (M22x1.5x10) Plug (M12x1.5x12) Exhaust manifold (M10x1.5x65) Water pump (M8x1.25x25) Water outlet connection (M8x1.25x35) (M8x1.25x70) Fan support (M10x1.5x20) Fan pulley (M6) (M10) Base - May 2010
pre-torque Final torque Snug torque Final torque
Nm 15 ± 3 50 ± 6 80 ± 6
kgm 1.5 ± 0.3 5.0 ± 0.6 8.0 ± 0.6 90° ± 5°
24 ± 4 24 ± 4 49 ± 5
2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5
24 ± 4 24 ± 4 30 ± 3 60 ± 5
2.4 ± 0.4 2.4 ± 0.4 3.0 ± 0.3 6.0 ± 0.5 60° ± 5°
43 ± 5
4.3 ± 0.5
6±1 11 ± 2 24 ± 4
0.6 ± 0.1 1.1 ± 0.2 2.4 ± 0.4
24 ± 4 60 ± 9 5±1
2.4 ± 0.4 6.0 ± 0.9 0.5 ± 0.1
24 ± 4 10 ± 1 10 ± 1 10 - 15 50 - 55 15 - 20 85 - 90 30 - 35 24 ± 4
2.4 ± 0.4 1.0 ± 0.1 1.0 ± 0.1 1.0 - 1.5 5.0 - 5.5 1.5 - 2.0 8.5 - 9.0 3.0 - 3.5 2.4 ± 0.4
50 + 90° 40 + 180° 70 + 180° 24 ± 4 24 ± 4 24 ± 4 80 ± 8 10 ± 1 43 ± 6 24 ± 4
5.0 + 90° 4.0 + 180° 7.0 + 180° 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 8.0 ± 0.8 2.4 ± 0.4 4.3 ± 0.6 2.4 ± 0.4
24 ± 4 24 ± 4 33 ± 5
2.4 ± 0.4 2.4 ± 0.4 3.3 ± 0.5
10 ± 2 43 ± 6
1.0 ± 0.2 4.3 ± 0.6 Print P2D32N003 E
F4CE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
TORQUE
COMPONENT Rear lifting bracket (M12x1.75x30) Crankshaft pulley (M12x1.75x10.9) Flywheel housing (M12x120) (M12x80) (M10x80) (M10x40) Flywheel housing (M12x1.25)
1st stage 2nd stage
Assy rear cover plate to flywheel housing (M8x1.25x16) Fuel injectors Fuel lift pump Turbocharger to exhaust manifold (M10) Oil feed to oil filter head Oil feed to turbocharger (M12x1.5) Oil drain (M8x1.25x16) Alternator to alternator support (M8x1.25x30) Alternator to water inlet conn. assy (M8x1.25x30) Lower alternator mounting (M10x1.25x25) Alternator upper pivot to support (M10) Alternator mounting hardware (M12x1.75x120) Alternator wiring (M6x1.0 nut) Starter motor to gear case (M10) Screw M12 for fastening output shaft caps
1st stage 2nd stage 3rd stage
Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M10 for fastening connecting rod caps 1st stage 2nd stage
Print P2D32N003 E
35
Nm 77 ± 12 110 ± 5
kgm 7.7 ± 1.2 11 ± 0.5
85 ± 10 85 ± 10 49 ± 5 49 ± 5 30 ± 4
8.5 ± 1.0 8.5 ± 1.0 4.9 ± 0.5 4.9 ± 0.5 3.0 ± 0.4 60° ± 5°
24 ± 4 60 ± 5 24 ± 4 43 ± 6 24 ± 4 35 ± 5 24 ± 4 24 ± 4 24 ± 4 24 ± 4 49 ± 5 43 ± 6 10 ± 2 49 ± 5 50 ± 6 80 ± 6
2.4 ± 0.4 60 ± 0.5 24 ± 0.4 4.3 ± 0.6 2.4 ± 0.4 3.5 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5 4.3 ± 0.6 1.0 ± 0.2 4.9 ± 0.5 5 ± 0.6 8 ± 0.6 90° ± 5°
24 ± 4 36 ± 4 60 ± 5
2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60° ± 5°
Base - May 2010
36
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Base - May 2010
F4CE N ENGINES
Print P2D32N003 E
F4CE N ENGINES
SECTION 5 - TOOLS
1
SECTION 5 Tools Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print P2D32N003 E
3
Base - May 2010
2
SECTION 5 - TOOLS
Base - May 2010
F4CE N ENGINES
Print P2D32N003 E
F4CE N ENGINES
SECTION 5 - TOOLS
3
TOOLS TOOL NO.
DESCRIPTION
99322205
Revolving stand for overhauling units (700 daN/m capacity, 120 daNm torque)
99340055
Tool to remove output shaft front gasket
99340056
Tool to remove output shaft rear gasket
99340205
Tool to remove injectors
99346252
Tool for fitting output shaft front gasket
99346253
Tool for fitting output shaft rear gasket
Print P2D32N003 E
Base - May 2010
4
SECTION 5 - TOOLS
F4CE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99360076
Tool to remove oil filter (engine)
99360183
Pliers for removing/refitting piston rings (65 — 110 mm)
99360268
Tool for removing/refitting engine valves
99360339
Tool for stopping the engine flywheel
99360344
Union to control compression within cylinders (use with 99395682)
99360362
Beater for removing/refitting camshaft bushes (to be used with 993700069)
Base - May 2010
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F4CE N ENGINES
SECTION 5 - TOOLS
5
TOOLS TOOL NO.
DESCRIPTION
99360500
Tool for lifting the output shaft
99360595
Lifting rig for engine removal/refitting
99360605
Band for fitting piston into cylinder barrel (60 — 125 mm)
99361037
Brackets for fastening engine to revolving stand 99322205
99363204
Tool to extract sheaths A
99370006
Handgrip for interchangeable beaters
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Base - May 2010
6
SECTION 5 - TOOLS
F4CE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99370415
Gauge base for different measurements (to be used with 99395603)
99395097
Tool to control Top Dead Center (use with 99395604)
99395100
Dial gauge holding tool for rotating ignition pump timing (use with 99395603)
99395216
Pair of gauges with ½” and ¾” square head for angle tightening
99395603
Dial gauge (0 — 5 mm)
99395604
Dial gauge (0 — 10 mm)
Base - May 2010
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F4CE N ENGINES
SECTION 5 - TOOLS
7
TOOLS TOOL NO.
DESCRIPTION
99395682
Device controlling diesel engine compression cylinders
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Base - May 2010
8
SECTION 5 - TOOLS
Base - May 2010
F4CE N ENGINES
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F4CE N ENGINES
APPENDIX
1
Appendix
Page
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SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . .
3
- Standard safety prescriptions . . . . . . . . . . . . . .
3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . .
3
- During maintenance . . . . . . . . . . . . . . . . . . . .
3
- Respect of the Environment . . . . . . . . . . . . . .
4
Base - May 2010
2
APPENDIX
Base - May 2010
F4CE N ENGINES
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F4CE N ENGINES
SAFETY PRESCRIPTIONS Standard safety prescriptions Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance. Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation. - Keep working areas as clean as possible, ensuring adequate aeration. - Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. - Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities. - Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines. - Smoking in working areas subject to fire danger must be strictly prohibited. - Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.
Prevention of injury - Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion. - Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed: ≤ 2 bar) - Wear safety helmet when working close to hanging loads 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 working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material. - Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.
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APPENDIX
3
- Do not execute any intervention if not provided with necessary instructions. - Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur. - In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.
During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. - 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 areas aerated. Whenever necessary wear safety mask. - Do not leave rags impregnated with flammable substances close to the engine. - Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate. - Do not utilize fast screw-tightening tools. - Never disconnect batteries when the engine is running. - Disconnect batteries before any intervention on the electrical system. - Disconnect batteries from system aboard to load them with the battery loader. - After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. - Do not disconnect and connect electrical connections in presence of electrical feed. - Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning.
Base - May 2010
4
APPENDIX
F4CE N ENGINES
GENERALMANUTENZIONE
- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved by Iveco. - Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80ºC temperature.
Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted. - Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger. - Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.
- Do not paint the components and the electronic connections. - Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.
Base - May 2010
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1
F4DE N ENGINES
Part 3 F4DE N SERIES Section General specifications
1
Fuel
2
G-DRIVE applications
3
Overhaul and technical specifications
4
Tools
5
Safety prescriptions
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Appendix
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2
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3
F4DE N ENGINES
UPDATING Section
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Description
Page
Date of revision
Base - May 2010
4
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1
SECTION 1 - GENERAL SPECIFICATIONS
SECTION 1 General specifications
Page
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CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE . . . . . . . . . . . . .
3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
5
AIR INDUCTION BOOST DIAGRAM . . . . . . . .
6
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR)
7
Base - May 2010
2
SECTION 1 - GENERAL SPECIFICATIONS
Base - May 2010
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SECTION 1 - GENERAL SPECIFICATIONS
3
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code F4DE9684A*J100 F4DE9684Q*J100 F4DE9684W*J100 F4DE9684E*J103 F4DE9684X*J102 F4DE9687B*J100
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Commercial Code
N67 ERT.X
Base - May 2010
4
SECTION 1 - GENERAL SPECIFICATIONS
F4DE N ENGINES
LUBRICATION Lubrication by forced circulation is achieved through oil pump, placed in the front part of the basement. From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive.
Lubrication involves the heat exchanger as well, the turbo-blower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.
Figure 1
Oil under pressure Oil return by gravity to sump
116358
LUBRICATION SYSTEM LAYOUT Base - May 2010
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F4DE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
COOLING SYSTEM The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment. - Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.
5
- Viscous pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development. - Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment. - Centrifugal water pump, placed in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.
Figure 2
116359
A = TO RADIATOR B = FROM RADIATOR
COOLING SYSTEM LAYOUT Print P2D32N003 E
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SECTION 1 - GENERAL SPECIFICATIONS
F4DE N ENGINES
AIR INDUCTION BOOST DIAGRAM Figure 3
6 Cylinders version
TURBOCHARGER
AIR FILTRE
EXHAUST
RADIATOR 74195
Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emissions flow through the body of the turbine, causing 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 drawn air through the air filter. The above mentioned air is then cooled by the radiator and flown through the piston induction collector. Base - May 2010
The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s funchon is to restrict the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
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F4DE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) In the TIER 3 version, the profile of the exhaust cam has been modified in order to allow the partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders. The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitric acid (NOx). The exhaust gas re-circulation system (EGR), reducing the combustion temperature by means of the diminishing of the concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission of NOx .
7
The internal EGR system is not equipped with any electronically controlled elements: the system is always active. Its configuration does not need additional elements i.e.checking valves, piping or heat exchangers. The exhaust cam (B) has another lobe apart from the major lobe (see Section. A-A fig.) with respects to the configuration without EGR. The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the aspiration phase inside the cylinder.
Figure 4
114789
A. Aspiration valve control - B. Exhaust valve control. Print P2D32N003 E
Base - May 2010
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SECTION 1 - GENERAL SPECIFICATIONS
Base - May 2010
F4DE N ENGINES
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F4DE N ENGINES
SECTION 2 - FUEL
1
SECTION 2 Fuel
Page
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COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . .
3
WORKING PROCESS . . . . . . . . . . . . . . . . . . . .
5
FUEL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . .
6
MECHANICAL FEEDING PUMP . . . . . . . . . . . .
7
CP3 HIGH PRESSURE PUMP . . . . . . . . . . . . . . .
8
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
ELECTRO-INJECTOR . . . . . . . . . . . . . . . . . . . . .
13
PRESSURE LIMITER FOR FUEL RETURN . . . . . .
14
Base - May 2010
2
SECTION 2 - FUEL
Base - May 2010
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SECTION 2 - FUEL
3
COMMON RAIL General Specifications In order to reduce PARTICULATES emissions, very high injection pressures are required. The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision, obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description Electric system Figure 1
116360
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. Through the sensors, present on the engine, the ECU controls the engine operation.
The outlet voltage is proportional to the pressure or temperature obtained by the sensor.
Air pressure/temperature sensor
Engine oil temperature and pressure sensor
It is a component integrating a temperature sensor and a pressure sensor.
Same as air pressure/temperature sensor, it is fitted on the engine oil filter, in a horizontal position.
Fitted on the intake manifold, it measures the max. inlet air capacity to calculate precisely the fuel quantity to inject at every cycle.
It measures engine oil temperature and pressure.
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4
SECTION 2 - FUEL
Fuel pressure sensor Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The injection pressure value is used to control the pressure and to determine the electric injection control length. Fuel temperature sensor It is a sensor that is equal to the previous one. It measures fuel temperature to provide the control unit with an index of the diesel fuel thermal state. Coolant temperature sensor It is a variable-resistance sensor suitable to measure the coolant temperature to provide the control unit with an index of the engine thermal state. Output shaft sensor It is an inductive sensor placed on the front engine part. Signals generated through the magnetic flow that is closed on the phonic wheel, change their frequencies depending on output shaft rotation speed. Timing sensor It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape. System functionality Self-diagnosis The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data. IVECO Code recognition The EDC7 control unit communicates with the Immobilizer control unit (if fitted) to obtain the startup consent. Engine pre-heating resistance check The pre-post heating is activated when even only one of the water, air or fuel temperature sensors signals a temperature that is less than 5 °C. Phase recognition By means of signals coming from camshaft sensor and flywheel sensor, the cylinder on which fuel must be injected is recognised upon startup.
Base - May 2010
F4DE N ENGINES
Injection control The control unit, depending on information coming from sensors, controls the pressure regulator, and changes pre-injection and main injection modes. Closed-loop control for injection pressure Depending on engine load, measured by processing signals coming from various sensors, the control unit controls the regulator in order to always have the optimum pressure. Pilot and main injection spark advance control The control unit, depending on signals coming from various sensors, computes the optimum injection point according to an internal mapping. Idle speed control The control unit processes signals coming from various sensors and adjusts the amount of injected fuel. It controls the pressure regulator and changes the injection time of injectors. Within certain thresholds, it also takes into account the battery voltage. Maximum speed limiting At 2700 rpm, the controlunit limits fuel flow-rate by reducing the injectors opening time. Over 3000 rpm it deactivates the injectors. Cut Off Fuel cut off upon release is controlled by the control unit performing the following logics: - it cuts off injectors supply; - it re-activates the injectors shortly before idle speed is reached; - it controls fuel pressure regulator. Smoke control upon acceleration With strong load requests, the control unit, depending on signals received by air inlet meter and engine speed sensor, controls the pressure regulator and changes the injectors actuation time, in order to avoid exhaust smoke. Fuel temperature control When the fuel temperature exceeds 75 °C (measured by the sensor placed on fuel filter) the control unit intervenes by reducing injection pressure. If the temperature exceeds 90 °C, the power is reduced to 60%. AC compressor engagement control (if fitted) The control unit is able to drive engagement and disengagement of the electromagnetic compressor clutch depending on coolant temperature. If the coolant temperature reaches about 105 °C, it disengages the clutch. After Run The control unit microprocessor allows storing certain EPROM data, among which failure memory and Immobilizer information, in order to make them available upon the following startup.
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5
SECTION 2 - FUEL
WORKING PROCESS Figure 2
High Pressure Low Pressure
116361
1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter. The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors. Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet. When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place in the related cylinder. The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit. The high-pressure circuit is composed of the following pipings: - piping connecting high-pressure pump outlet to rail; - pipings supplying injectors from rail. The low-pressure circuit is composed of the following pipings: - fuel suction piping from tank to prefilter; - pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter; - pipings supplying the high-pressure pump through the fuel filter. The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
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6
SECTION 2 - FUEL
FUEL SYSTEM DIAGRAM The following figure outlines the common rail injection system with pump CP3. The pressure regulator, located upstream from the high-pressure pump, governs the necessary flow of fuel on the low-pressure system. Then the high-pressure pump supplies the rail correctly. This solution, pressurizing only the necessary amount of fuel, improves energy efficiency and limits fuel heating in the system. The pressure relief valve (2), fitted on the high-pressure pump, has the function of keeping the regulator inlet pressure constant at 5 bar, irrespective of the efficiency of the fuel filter and of the system upstream.
F4DE N ENGINES
The pressure relief valve housed on the cylinder head, fitted on the return of the electro-injectors (3), limits the fuel return flow from the electro-injectors to a pressure of 1.3 ÷2 bar. In parallel with the mechanical supply pump there are two by-pass valves. The by-pass valve (18) is used to run off the fuel from the outlet of the mechanical pump at its inlet when the pressure at the inlet of the fuel filter exceeds the allowed limit. The by-pass valve (17) is used to fill the fuel system through the manual priming pump (10).
The action of the pressure relief valve (2) causes an increase in the flow of fuel in the cooling circuit of the high-pressure pump through the pipe (16) for the intake and exhaust from the pipe (8).
Figure 3
EXHAUST INTAKE (LOW PRESSURE) HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE) HIGH PRESSURE
74786
1. High-pressure pump - 2. Pressure relief valve on the high-pressure pump, 5 bar. - 3. Pressure relief valve fitted on the fuel return from the electro-injectors, from 1.3 to 2 bar. - 4. Rail pressure relief valve. - 5. Common Rail.- 6. Pressure sensor. 7. Electro-injector. - 8. Return feed line. - 9. Heat exchanger of the control unit. - 10. Mechanical priming pump. 11. Prefilter fitted on the chassis (if applicable)- 12. Fuel tank - 13. Mechanical fuel pump. - 14. Fuel filter. - 15. Pressure regulator. - 16. Pipe for cooling high-pressure pump. - 17. By-pass valve. - 18. By-pass valve.
Base - May 2010
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F4DE N ENGINES
SECTION 2 - FUEL
MECHANICAL FEEDING PUMP
7
Jettison condition
Gear pump, placed on rear part of the high pressure pump, whose function is to feed the high pressure pump. It is driven by the high pressure pump’s shaft.
Figure 6
Ordinary working condition Figure 4
72594
72592
A- Fuel entry flowing from the tank. B- Fuel exhaust to filter, I - 2 By-pass valves in close position.
The dump by-pass valve (2) is activated in case, when the engine is off, it is necessary to fill the feeding system through the priming pump. In this condition the by pass valve (I) keeps closed while the dump by-pass valve (2) opens up due to the pressure effect on the entry unit so the fuel flows to the exhaust unit B.
Overpressure condition in Exhaust unit NOTE The mechanical feeding pump cannot be replaced separately, therefore it must not be disassembled from the high pressure pump.
Figure 5
72593
The by-pass valve (I) is activated in case of overpressure on B Exhaust unit. The actual pressure, overcoming the resistance of the valve’s spring (I), connects the exhaust with the entry through the gallery (2).
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SECTION 2 - FUEL
F4DE N ENGINES
CP3 HIGH PRESSURE PUMP Pump provided with 3 radial pumping elements driven by the timing system gear, no need of timing. The mechanical feeding pump driven by the high pressure pump’s shaft is assembled to the rear side of the high pressure pump.
NOTE The high pressure pump unit - feeding pump is not subject to overhaul , therefore it must not be disassembled neither the fixing screws must be tampered. The only allowed interventions concern control gear and pressure regulator replacement.
Figure 7
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.
Base - May 2010
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F4DE N ENGINES
SECTION 2 - FUEL
9
High pressure pump-inside structure Figure 8
Sec. B-B
Sec. C-C
70498
1. Cylinder. — 2. Three-lobe element. — 3. Cap intake valve. — 4. Ball delivery valve. — 5. Piston. — 6- Pump shaft. — 7. Low-pressure fuel inlet. — 8. Pumping elements supplying fuel ducts.
Every pumping unit is composed of: - a piston (5) actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), being floating on a misaligned part of the shaft (6), when the shaft rotates, does not rotate therewith but is only translated in a circular movement along a wider radius, with the resulting alternate actuation of the three pumping elements;
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- cap intake valve (3); - ball delivery valve (4).
Base - May 2010
10
SECTION 2 - FUEL
F4DE N ENGINES
Working principle Figure 9
Sec. B - B
Sec. D - D
72597
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. The pumping element (3) is orientated towards the pump’s camshaft (4). During the intake phase, the pumping element is fed through the feeding line (5). The quantity of fuel to flow to the pumping element is determined by the pressure regulating gauge (7). The pressure regulating gauge, according to the PWM command received by the engine control module, stops the fuel flow to the pumping element. Base - May 2010
During compression phase of the pumping element, the fuel achieves the level of pressure determining the opening of the by-pass valve to common rail (2), feeding it through the exhaust unit (I).
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F4DE N ENGINES
SECTION 2 - FUEL
Figure 10
11
Figure 11
72601
72598
Sec. C - C
Sec. A - A
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.
1. Fuel exhaust flue - 2. Fuel exhaust gallery - 3 Fuel exhaust flowing from pump with connector to high pressure pipe for common rail.
Picture 10 shows the fuel runs at low pressure inside the pump; the following elements are clearly visible: the main feeding line to the pumping elements (4); the feeding lines to the pumping elements (1-3-6), the duct lines run for the pump lubrication (2), the pressure gauge (5), the flow limiting valve to 5 bar (8) and the fuel exhaust flue (7).
Picture 11 shows the fuel flow under high pressure running through the exhaust galleries of the pumping elements.
The pump shaft is lubricated by the fuel through the feeding and recovery lines. The pressure gauge (5) determines the quantity of fuel to feed the pumping elements: the fuel in excess flows through the exhaust gallery (9). The limiting valve to 5 bar, in addition to recovering fuel exhaust as a collector has also function to keep the pressure constant to 5 bar limit at gauge entry.
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Base - May 2010
12
SECTION 2 - FUEL
Operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements (about 2 bars).
F4DE N ENGINES
RAIL Figure 12
The amount of fuel supplying the high-pressure pump is metered by the pressure regulator, placed on the low-pressure system; the pressure regulator is controlled by the EDC7 control unit through a PWM signal. When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber, not being able to come out, is compressed above the supply pressure value existing in the rail. The thereby-generated pressure makes the exhaust valve open and the compressed fuel reaches the high-pressure circuit. The pumping element compresses the fuel till the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed. The pumping element piston goes back towards the bottom dead center and the remaining fuel is decompressed. When the pumping element chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated. The delivery valves must always be free in their movements, free from impurities and oxidation.
108609
1. Rail — 2. Fuel inlet from high-pressure pump — 3. Overpressure valve - 4. Pressure sensor. The rail volume is comparatively small to allow a quick pressurisation at startup, at idle and in case of high flow-rates. It anyway has enough volume as to minimise system spikes and the use of plenum chambers caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump. A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.
The rail delivery pressure is modulated between 250 and 1600 bars by the electronic control unit, through the pressure 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 traditional injection pumps, because it does not require setting. If the pipe between fuel filter and high-pressure pump is to be removed-refitted, be sure that hands and components are absolutely clean.
RELIEF VALVE Mounted on the end of the rail, it has the function of protecting the system’s components in case the failure of the rail pressure sensor or the pressure regulator of pump CP3 causes an excessive pressure increase in the high-pressure plant. When the rail pressure reaches 1800 bars, the valve initially intervenes in order to allow the fuel to flow and subsequently to reduce the pressure within safety limits and then it mechanically regulates the rail pressure to approx. 800 bars. This valve allows the engine to work for long periods at a limited efficiency and avoids the excessive overheating of the fuel preserving the return pipes to the tank.
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 2 - FUEL
ELECTRO-INJECTOR
13
Injection start
As for NEF TIER 3 engines, BOSCH - CRIN2 electro-injectors with different injection tubes are used working on power developed by the engine. Jet
Powers kW
Pressures bar
DLLA
Up to 152
250 ÷ 1600 bar
DSLA
Lower to 152
250 ÷ 1400 bar
Figure 14
15
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 Figure 13 70506
When coil (4) is energised, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, with following fuel injection into the cylinder.
Injection end When coil (4) is de-energised, shutter (6) goes back to its closing position, in order to re-create such a force balance as to make plunger (2) go back to its closing position and end the injection.
15
NOTE The injector cannot be overhauled and therefore it must not be disassembled.
70505
1. Pressure rod — 2. Plunger — 3. Nozzle — 4. Coil — 5. Pilot valve — 6. Ball shutter — 7. Control area — 8. Pressure chamber — 9. Control volume — 10. Control duct — 11. Supply duct — 12. Control fuel outlet — 13. Electric connection — 14. Spring — 15. High-pressure fuel inlet.
Print P2D32N003 E
Base - May 2010
14
SECTION 2 - FUEL
F4DE N ENGINES
PRESSURE LIMITER FOR FUEL RETURN It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at a pressure 1.3 and 2 bars. By guaranteeing this pressure to the return fuel, the fuel vapours formation inside injectors is avoided, optimising fuel spraying and combustion.
Figure 15
70507
A
To tank — B From injectors
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
1
SECTION 3 - INDUSTRIAL APPLICATION
SECTION 3 Industrial application
Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
3
- Section pictures of complete engine - common rail version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Clearance data - 6 cyl. . . . . . . . . . . . . . . . . . . .
4
PART ONE - MECHANICAL COMPONENTS .
5
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . .
7
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - Disassembly of application components . . . . .
9
- Assembly of application components . . . . . . .
16
- Completion of the engine . . . . . . . . . . . . . . . .
26
- Checks and inspections . . . . . . . . . . . . . . . . . .
27
PART TWO - ELECTRICAL EQUIPMENT . . . .
29
LOCATION OF MAIN ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .
31
- EDC7 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Connector to injectors (A) . . . . . . . . . . . . . . .
33
- Feed connector (B) to components and to functions of the specific equipment . . . . . . . . . . . . . . . . 34
Print P2D32N003 E
- Connector to sensors (C) . . . . . . . . . . . . . . . .
35
- Temperature and air-pressure sensor . . . . . . .
36
- Sensor of engine’s oil temperature and pressure
36
- Driving shaft sensor . . . . . . . . . . . . . . . . . . . . .
36
- Timing system sensor . . . . . . . . . . . . . . . . . . .
36
- Fuel pressure sensor . . . . . . . . . . . . . . . . . . . .
37
Base - May 2010
2
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Page
Page - Fuel temperature sensor . . . . . . . . . . . . . . . . .
37
- Resistor pre-post heating . . . . . . . . . . . . . . . . .
37
- Cooling liquid temperature sensor . . . . . . . . . .
37
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE PROCEDURES . . . . . . . . . . . .
52
- Checks and inspections . . . . . . . . . . . . . . . . . .
52
38
- Engine oil level check . . . . . . . . . . . . . . . .
52
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . . .
38
- Combustion system inspection . . . . . . . .
53
PART THREE - TROUBLESHOOTING . . . . . .
39
- Cooling system inspection . . . . . . . . . . . .
53
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
- Lubricating system inspection . . . . . . . . .
53
PT - BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . .
43
PART FOUR - MAINTENANCE PLANNING .
49
- Inspection of drive belt tensioning . . . . . .
53
MAINTENANCE PLANNING . . . . . . . . . . . . . .
51
- Inspection and setting of tappet clearance
54
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
- Oil motor and filter replacement . . . . . . .
54
- Regular maintenance and inspection planning .
51
- Fuel filter replacement . . . . . . . . . . . . . . .
55
- Alternator belt replacement . . . . . . . . . . .
55
- Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Base - May 2010
- Inspection of water presence within fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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F4DE N ENGINES
3
SECTION 3 - INDUSTRIAL APPLICATION
GENERAL SPECIFICATIONS Section pictures of complete engine - common rail version Figure 1
116362
The and F4DE9684 engines are turbocharged a 4-stroke diesel engines with 6 cylinders, with 4 valves per cylinder. They have high pressure injection fuelling (common rail) and are entirely electronically driven in order to optimise the working process in accordance to the operation, limiting as much as possible the pollution emissions and consumption.
The section herein described is composed or four sections: - Section of mechanical overhaul prescribed in accordance to the engine’s specific duty, illustrating all necessary operation to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover; - Electrical section, describing the connections to the different components of the engine control module and of the sensors assembled to the engine; - Diagnosis section; - Section of preventive maintenance operations, providing instructions for the execution of the main operations.
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by 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.
Print P2D32N003 E
Base - May 2010
4
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Clearance data - 6 cyl.
F4DE9684
ρ
Type
A*J100
Q*J100
W*J100
X*J102
B*J100
kW (HP)
154 (210)
143 (195)
134 (180)
123 (170)
112 (150)
129 (175)
rpm
2200
2200
2200
2200
2200
2200
Nm (kgm)
950 (95)
850 (85)
800 (80)
747 (74.7)
705 (70.5)
753 (75.3)
rpm
1400
1400
1400
1400
1400
1400
Compression ratio Max. output
Max. torque
E*J103
17.5 : 1
Loadless engine idling
rpm
-
Loadless engine peak
rpm
Bore x stroke
104 x 132
Displacement
4485
TURBOCHARGING
with intercooler
Turbocharger type
HOLSET HX35W Forced by means of a lobe pump, pressure relief valve, oil filter
LUBRICATION Oil pressure (warm engine)
bar
- idling
bar
0.8
- peak rpm
bar
3.5
COOLING
By liquid
Water pump control
Through belt
Thermostat 81 ± 2
- start of opening FILLING
ºC
engine sump*
{ max
min
15W40
liters
engine sump + filter*
liters
12 15 15 + 1
* first filling
!
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE Data, features and performances are valid only if the technician fully complies with all the installation requirements provided by FPT. Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for which the engine has been designed. Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
5
PART ONE - MECHANICAL COMPONENTS
Print P2D32N003 E
Base - May 2010
6
SECTION 3 - INDUSTRIAL APPLICATION
Base - May 2010
F4DE N ENGINES
Print P2D32N003 E
F4DE N ENGINES
7
SECTION 3 - INDUSTRIAL APPLICATION
ENGINE OVERHAUL Preface
Figure 3
Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well. NOTE With regard to the engine disassembly operations from the machine, please apply for Information consulting the specific manual. All operations of Engine disassembly operations as well as overhaul operations must be executed by qualified technicians provided with the specific tooling and equipment required.
The following information relates to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties. In section 4, ”General overhaul”, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.
A Connector properly locked B Connector released for removal-refitting
70126
NOTE Press clamp (1), as shown in Figure B, to disconnect the low pressure fuel pipes (3 — 4 — 5, Figure 2) from the corresponding connections. After disconnecting the pipe, reset the clamp (1) in locking position (Figure A) to prevent distortions.
Engine setting operations for the assembly on turning stand Disconnect the high pressure fuel pipeline (7, Figure 2) from the rail diffuser and from the high pressure pump (8) and disassemble it from the engine block removing the fixing clamps.
Figure 2
Disconnect the pipeline (9) from the high pressure pump.
NOTE Because of the high pressure in the pipelines running from the high pressure pump to the rail and from this last one to the electro-injectors, it is absolutely required NOT to: - disconnect the pipelines when the engine is working; - re-use the disassembled pipelines. 116364
In order to apply the brackets 99361037 to the engine block to fix it on to the stand for the overhaul, it is necessary to perform the following operations on the left hand side of the engine: - Using the tool 99360076 disassembly the fuel filter (6) and remove it from the support (1); - Disconnect the electrical connection (2) from the support (1) and the heater’s one (placed on the filter support as well); - Disconnect the fuel low pressure pipelines (3-4-5) from the support (1); - Disconnect pipeline (9) from the support (1); - Remove the sustaining support bracket (1) from the block. Print P2D32N003 E
Base - May 2010
8
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
On the right side of the engine
Figure 5
Figure 4
116366
Disconnect the lubricating pipe (2) from the upper side of the heat exchanger on the turbo blower (1). Undo the fastening screws (4) and remove the support (3). Disassemble the thermostat body including the seal. 116365
Figure 6 Disconnect the oil filling pipe (1). Unscrew the fixing screws and disconnect the starting motor (2) from its seat.
116367
Make holes (1) and (2) on both sides of the engine base, brackets 99361037 and then fix by means of the later, the engine to revolving stand 99322205. Empty the engine oil by removing the cap of the sump.
Collect and dispose of the engine oil according to enforced regulations.
Base - May 2010
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F4DE N ENGINES
9
SECTION 3 - INDUSTRIAL APPLICATION
Disassembly of application components Figure 7
116360
1. Connections for Electro-injectors - 2. Engine cooling liquid temperature’s sensor - 2. Cable of the fuel pressure sensor 4. Sensor of engine’s oil temperature and pressure - 5. Driving shaft sensor 6. Electro-injector - 7. Temperature - air pressure sensor - 8. Timing system sensor - 9. Cable of fuel heater and fuel temperature’s sensor - 10. Cable of pressure regulating gauge - 11. EDC 7 electronic module.
Disconnect the engine’s cable from the connectors (1, Figure 7) wiring harness to Electro-injectors (6); (7) air pressure/temperature sensor; (3) fuel pressure sensor; (11) engine control module; (10) high pressure pump sensor; (8) timing system sensor; (2) Thermostat sensor of engine cooling liquid’s temperature; (5) sensor of engine’s revolutions. Print P2D32N003 E
Disassemble the engine from the engine block removing the fixing clamps.
Base - May 2010
10
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Figure 8
Figure 10
116370 116368
Disconnect from the rail (1): the fuel pipe (3) according to procedures described in Figure 3. Disconnect fuel pipes (5) from rail (1) and injector manifolds (4).
Now disassemble the supercharger: Unscrew fixing nuts (3) of the turbo-blower (4) on exhaust manifold (4). Hold up turbo-blower (4) and get the seal. Undo the fastening screws (1) and detach the exhaust manifold (2).
Remove the screws (2) and disconnect the rail (1).
Figure 11 Figure 9
116371 116369
Disconnect the fuel return pressure limiter (1), the pipeline by acting on the connections as described on Figure 3. Remove the external vent pipe (2).
On the opposite side, loosen the fixing screws (2) of the inlet manifold (1) and disassemble the joint to the air heater for the cold start. Remove the pressure-air temperature sensor from the induction manifold (1).
Loosen the nuts (3) and disconnect the tappet cap (4). Base - May 2010
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F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
Figure 12
11
Figure 14
116372
Remove nuts (3) and remove fuel manifolds (4). Remove nuts (6) and disconnect the electrical cables from injectors (5). 116378
Undo the fastening screws and remove the belt tightener (2). Undo the fastening screws and remove the drawback pulley (3 and 5). Undo the fastening screws and remove the belt tightener (7). Undo the fastening screws on the cylinder head and remove the support (6). Undo the fastening screws and remove the ventilator support (1).
Remove screws (1) and disconnect injector wiring support (2) including the gasket.
NOTE Disassembled fuel manifolds (4) must not be used again, but however replaced with other new ones.
Figure 13 Figure 15
70132
70133
Remove injector fastening screws. Use tool 99342101 (1) to remove injectors (2) from the cylinder head.
Print P2D32N003 E
Loosen tappet adjustment fastening nuts (1) and unscrew the adjusters. Remove the screws (2), remove the rocker assembly (3), consisting of: bracket (6), rockers (4), shafts (5) and remove jumpers (7) from valves. Remove rods (8). Base - May 2010
12
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Figure 16
Figure 18
116377
Use tool 99360076 to remove the oil filter (1).
116373
Remove the fastening screws (1) from the cylinder head (2). Figure 19 NOTE The highlighted screws are shorter.
Figure 17
88555
Unscrew the fixing screws (1) and disassemble the pipeline union (2).
116374
Fix suitable clips (1) to the cylinder head (2). By means of opportune metal cables and a hoist, detach the cylinder head (2) from the engine crankcase. Base - May 2010
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F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
Figure 20
13
Figure 22
88558
88556
Disconnect connector (1) from the oil temperature pressure sensor.
Apply the tool (1) to stop flywheel rotation (2) through the hole (3) made on the base. Tool (1) positioned in hole (3) is to be inserted in the groove made on the flywheel blocking its rotation. Loosen the engine shaft flywheel fixing screws.
Unscrew screws (2) and disconnect oil temperature pressure sensor (3). Unscrew screws(4) and disconnect oil filter support (5) from the base, and remove the relevant seals. Remove the heat exchanger from its seat.
Figure 23
Figure 21
116376
Undo the screws (1), disassemble the silencer (2) and the pulley (3). 88557
The blocking tool of the engine flywheel can facilitate disassembly of dampening flywheel (2) assembled on pulley (3).
Remove nuts (1) and disconnect high pressure pump (2) along with the fuel pump (3). Print P2D32N003 E
Base - May 2010
14
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Figure 24
Figure 26
1
2
88560
00900t
Remove the ring sealing the engine’s driving shaft from the front cover. Use the tool 99340055 (4) to operate on the front bar hold of the driving shaft. Through the steering holes of the tool, perforate the inside holding ring (1) with a straight way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool to the ring tightening the 6 screws provided with the equipment. Then proceed removing the ring (2) by tightening the screw (3).
Remove the screws (1) and take out the front cover (2).
NOTE Take note of screw (1) assembling positions since they have different lengths.
Figure 27
Figure 25
88561 00904t
Using the specific tie rod (3) of the tool 99363204 and the ancillary lever (4), remove the external holding ring (2) from the front cover (1).
Remove two opposite screws (1) from the area where the withdrawal pins will be introduced (2, Figure 28). Loosen the remaining flywheel fixing screws (3) from the driving shaft (2). Remove the flywheel locking tool (4).
Base - May 2010
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F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
Figure 28
15
Figure 30
88307 88562
Tighten two screws of medium length into the holes (4) to sling the flywheel with the hoist. Throughout the two guide pins (2) previously screw into the driving shaft holes (3) withdraw the engine flywheel (1) after slinging it with the hoist.
Turn the engine upside down. Remove screws (2) and disconnect oil sump (1). Disconnect the high pressure pump stroke sensor. Unscrew the screws(3) and remove timing gear distribution box (4) from the base.
Figure 29
Figure 31
00903t
Remove the holding ring of the flywheel cover box using the tool 99340056 (3) to operate on the driving shaft’s back bar hold (5). Through the steering holes of the tool, perforate the inside holding ring with a straight way drill (diam. 3,5mm) for the depth of 5mm. Fix the tool 99340056 (3) to the ring (1) tightening the 6 screws provided with the equipment (4). Then proceed removing the ring (1) by tightening the screw (2). Using a specific tie rod of the tool 99363204 and an ancillary lever, remove the external holding ring (2) from the front cover. Print P2D32N003 E
88564
Undo the screws (1) and remove the bevel gear (3) from the distribution shaft (2).
Base - May 2010
16
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Figure 34
Assembly of application components Figure 32
88567
Tighten the screws (1) fastening gear (2) to camshaft (3) to the specified torque (36 Nm ± 4 Nm). 70211
With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) on the upright surface where a groove has been created for the ignition timing.
Figure 35
NOTE Fasten screwing of the two pins to facilitate the operation of engine driving shaft rotation.
Figure 33
70214
LOCTITE 5205 SEALANT APPLICATION AREAS Clean accurately the timing gear case and the engine block.
116375
Turn the engine shaft and the distribution shaft so that, by mounting the bevel gear on the latter, the tooth with the gear groove of the engine shaft coincides between the two marks created on the bevel gear (1).
Base - May 2010
NOTE Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5205 to obtain a bead (1) of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).
Print P2D32N003 E
F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
Figure 36
17
Figure 38
88569 88571
GEARCASE FIXING SCREW TIGHTENING DIAGRAM
Put a new seal ring on the water pump.
Reassemble box (1) on the engine.
Assemble water pump (1); tighten the screws (2) up to the prescribed torque.
Tighten fixing screws (2) on the same position from where they had been removed up to the tightening torque indicated below. Screws M8 20 ÷ 28 Nm Screws M10 42 ÷ 52 Nm
Figure 39
Reconnect stroke sensor (3) of the high pressure pump.
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 37 88572
Disassemble seal ring (2) from the front cap (1), clean the coupling surface accurately. Figure 40
88570
Apply tool 99346253 part (6) to the rear output shaft tang (5), secure it by screws (4) and fit the new sealing ring (3). Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into housing.
88573
Accurately clean the contact surface on the engine block and position seal (1) on the base. Print P2D32N003 E
Base - May 2010
18
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Figure 41
Figure 44
88574
Assemble oil pump (1) on the block and tighten the screws up to the prescribed torque. Figure 42
88307
Fit the new sheath on the basement. Assemble the oil pan (1). Fit the screws (2) and tighten them to the prescribed pair. Tighten the exhaust caps to the prescribed pair. NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
88575
Apply tool 99346252 part (4) to the front output shaft tang (6), secure it by screws (5) and fit the new sealing ring (7). Position part (2) on part (4), screw nut (3) until completing sealing ring (7) fitting into front cover (1).
Figure 45
Figure 43
88581
116376
Adjust the pulley (3), and the silencer (1) on the engine shaft. Tighten screws (1) up to torque 68 ± 7 Nm. Assemble a new seal ring on the revolution sensor. Assemble the revolution sensor in the front cap and tighten the fixing screws up to the prescribed torque.
Base - May 2010
Check the contact surface (1) of the clutch plate and if it is scratched, proceed with turning. Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.
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F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
Figure 46
19
Figure 49
88582 80359
Screw two manoeuvring hooks or lunettes on flywheel (1) using holes (4). With the help of a hoist bring the flywheel closer to its seat inside the flywheel housing box. Screw two pins (2) with proper length for shaft holes (3) and use them as guides, assemble engine flywheel (1) by arranging it properly in the flywheel housing box. Figure 47
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.
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 50
88583
Screw engine flywheel (3) fixing screws (4) on the engine shaft. Put the tool in the proper hole (2) in order to block engine flywheel rotation. Figure 48 α 88586
Lubricate the sealing ring (2) with engine oil and set it on the oil filter (3).
88584
Tighten engine flywheel (1) fastening screws (2).
Screw manually to seat the oil filter (3) on the support connection (1) and then screw again the oil filter (3) by ¾ turn. Apply a new sealing ring on the oil temperature/pressure sensor (4) and fit it on the support (1). Tighten the screws (5) to the specified torque.
NOTE Tightening to angle is performed using tool 99395216. Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Print P2D32N003 E
Fit a new sealing ring (6) in the engine block seat.
Base - May 2010
20
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Figure 51
Figure 53
88590 88587
Assemble pipeline union (1) and tighten screws (2) up to the prescribed torque.
Refit the high pressure pump (2) including the feed pump (3) and tighten the nuts (1) to the specified torque.
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 54
Figure 52
116378
116374
Apply a new gasket to the engine block and then place the cylinder head (2) slung by the hanger brackets (1).
Base - May 2010
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). Print P2D32N003 E
F4DE N ENGINES
21
SECTION 3 - INDUSTRIAL APPLICATION
Figure 57
Figure 55
α 70338
70336
Assemble cylinder head (1), tighten the screws (2) in three following steps, following order and mode shown in the figure below.
Fit a new sealing ring (2) lubricated with petroleum jelly and a new sealing washer (3) on injector (1).
Figure 58
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
NOTE The angle tightening is carried out through tool 99395216 (3).
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 56 Figure 59
α
A 6-cylinder engine 70476
Tightening order layout for cylinder head fastening screws: - 1st step pre-tightening with dynamometric wrench: • Screw 12x1.75x130 ( ) 35 ± 5 Nm A • Screw 12x1.75 x 150 ( ) 55 ± 5 Nm - 2nd step tightening with a 90° ± 5° angle
70133
- 3rd step tightening with a 90° ± 5° angle A = Front side
Use tool 99342101 (1) to fit the injector (2) into its seat. Screw injector fastening screws without tightening them.
Print P2D32N003 E
Base - May 2010 Revi - February 2007
22
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Figure 60
Figure 62
70343
70341
Fit a new sealing ring (3) lubricated with vaseline on the fuel manifold (2) and fit it into the cylinder head seat so that the positioning ball (5) is coinciding with the relevant housing (4).
ROCKER ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers. Figure 63
NOTE Disassembled fuel manifolds (2) must not be used again, but however replaced with other new ones.
Screw the fastening nuts (2, Figure 61) without locking them. NOTE During this operation, the injector (1) shall be moved so that the manifold (2, Figure 58) is properly inserted into the fuel inlet hole (2, Figure 60).
SHAFT-ROCKER MAIN DATA Check that shaft/rocker coupling surfaces are not showing excessive wear or damages.
Figure 61 Figure 64
70342
Use the torque wrench to tighten gradually and alternately the injector fastening screws (1) to 8.5 ± 0.8 Nm torque. Tighten the fuel manifold (3) fastening nuts (2) to 50 Nm torque. Carry out the assembly of the equalisers’ unit , after previous check of the components. Base - May 2010
32655
Rocker control rods shall not be distorted; the ball seats in touch with the rocker adjusting screw and with tappets (arrows) shall not show seizing or wear; otherwise replace them. Intake and exhaust valve control rods are identical and are therefore interchangeable.
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F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
Figure 65
23
Figure 67
70520 70345
Fit the rods (2). Position jumpers (1) on valves with marks (→) facing the exhaust manifold.
Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.
Figure 66 NOTE On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
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 head by tightening the fastening screws (2) to 36 Nm torque.
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Figure 68
Figure 70
116371
Apply to the coupling surface of the intake manifold (1) equipped with heater a sufficient coat of LOCTITE 5999 and provide tightening the screws (2) to the prescribed matching couple. Fit temperature and air pressure sensor.
116379
Fit the wiring support (2) and tighten the screws (1) to the specified torque. NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Connect the electric cables to the electro-injectors (3) and with dynamometric wrench 99389834, fasten fixing nuts to the prescribed (4) torque.
Figure 71
Figure 69
70352 70355
Check electrical cable (5) conditions, replace if damaged by cutting the support (2) clamps and removing the screws (5) that secure it to connections (3). Fit a new gasket (1) on the support (2).
Base - May 2010
Fit a new gasket (2) on the tappet cover (1). Place the tappet cover on, install the bolts in the correct position and tighten.
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SECTION 3 - INDUSTRIAL APPLICATION
Figure 72
25
Figure 74
116370 116380
Assemble the rail (2) and fasten the fixing screws (1) to the prescribed torque. Connect new fuel pipes (6) to the rail (2) and to the manifold for electro-injectors (5).
Reconnect the exhaust manifold (2) with new gaskets. Tighten the fastening screws (1) to the specified torque. Sling the turbocharger (4) and place it over the manifold after having first inserted a new gasket, tighten the fastening screws (3) to the specified torque.
NOTE The pipe joints (3) must be fastened to the 20 Nm torque.
Connect the fuel pipe (4) to the rail based on the procedure described in the following illustration.
Figure 73
Figure 75
70126
Press the clamp (1) in arrow direction (Figure B) and connect the pipe to the rail, reset the clamp to the initial locking position “A”. 116366
NOTE Check proper fuel pipe connection.
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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). Base - May 2010
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Figure 76
Figure 78
116381
Connect the piping (2) to the fuel return pressure limiting device (1). Connect the external vent pipe (3) to the head cover and to the crankcase.
Completion of the engine Properly handle the engine holding it by a lifter, remove it from the rotating shaft, remove the brackets 99361037 and place it on proper suitable support to carry out the completion. Figure 77
116364
Assemble the bracket and the support (1) of the fuel filter (6). Proceed connecting in sequence the pipelines (9,3,4 and 5) of the support (1) to the high pressure pump (8). Connect the pipeline (7) from the high pressure pump to the rail diffuser.
Figure 79
70126
All the fuel pipelines are fixed using the clamps shown in the picture. For the connection of the pipes, press the clamp (I) following the arrow’s direction (Figure B) and connect the pipe to the clamp on the high pressure pump or on the support of the fuel filter. Reset the clamp in the initial locking ”A” position.
116365
Assemble oil filling pipe (1). Screw fixing screws and assemble starting motor (2) in place.
Base - May 2010
NOTE In case the pipes are re-employed, they must keep the sealing tops at the edges. Make sure that the fuel pipeline is correctly connected. Reconnect the engine harness to all the sensors, the engine control module and the rail diffuser. Print P2D32N003 E
F4DE N ENGINES
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27
Checks and inspections NOTE The following checking inspections must be carried out after the engine assembly on the vehicle .
Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check:
- that there are no water leaks from the connecting sleeves of engine cooling circuit pipes and cab internal heating pipes, tighten the clamping collars if required; - check carefully the connection between the low pressure fuel pipes and the relevant connectors; - that there are no oil leaks between the cover and the cylinder head, between oil sump and engine block, between heat exchanger oil filter and the relevant housings and between the different pipes in the lubricating circuit; - that there are no fuel leaks from the fuel pipes; - that there are no air leaks from pneumatic pipes (if fitted); - check also proper operation of the warning lights set on the instrument panel and of the equipment disconnected when engine was removed. - Carefully check and bleed the engine cooling equipment by repeated draining operations.
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SECTION 3 - INDUSTRIAL APPLICATION
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F4DE N ENGINES
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29
PART TWO - ELECTRICAL EQUIPMENT
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SECTION 3 - INDUSTRIAL APPLICATION
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SECTION 3 - INDUSTRIAL APPLICATION
LOCATION OF MAIN ELECTRICAL COMPONENTS Figure 80
116382
The and F4DE9684 engines are fully driven by the electronic engine control module.
The electrical and electronic components of the engine are listed here following:
Through the engine control module it is possible to verify the correct working of the engine. (See part three of the hereby user’s guide specifically dedicated to diagnostic).
1.
Temperature sensor of cooling liquid;
2.
Electro-injector;
3.
Starter;
4.
Pressure sensor assembled to rail diffuser;
5.
Temperature and air pressure sensor;
6.
Timing system sensor;
7.
Fuel temperature sensor;
8.
EDC7 electronic module (not positioned on engine);
9.
Driving shaft sensor;
10. Sensor of engine’s oil temperature and pressure; 11. Pre-post heating resistor. Print P2D32N003 E
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EDC7 ECU Figure 81
01525t
A - Connector to injectors; B - Connector to chassis (Provide reference of the vehicle to which the engine is assembled); C - Connector to sensors.
Base - May 2010
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33
Connector to injectors (A) Figure 82 12
16
6
11
1
PIN ECU 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Colour legend C A B L G H M N W S R V Z
CABLE COLOUR MN MV VB HR MB VN VG HN HG CN CB CL
5
50350
FUNCTION Injector cylinder 2 (**) Injector cylinder 3 (**) / Injector cylinder 4 (*) Injector cylinder 4 (**) Injector cylinder 2 (**) Earth Injector cylinder Injector cylinder 1 (*) / (**) Injector cylinder 6 (**) / Injector cylinder 2 (*) Injector cylinder 5 (**) / Injector cylinder 3 (*) Injector cylinder 3 (**) / Injector cylinder 4 (*) Injector cylinder 1 (*) / (**) Injector cylinder 4 (**) Injector cylinder 6 (**) / Injector cylinder 2 (*) Injector cylinder 5 (**) / Injector cylinder 3 (*) (*) Only for 4 cyl. versions (**) Only for 6 cyl. versions
ORANGE SKY BLUE WHITE BLUE YELLOW GREY BROWN BLACK LIGHT BROWN PINK RED GREEN PURPLE
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Feed connector (B) to components and to functions of the specific equipment 72 54 6
89
Figure 83
1
71
11
53
7 35
18
12
36 17
03210t
PIN ECU
CABLE COLOUR
FUNCTION
1
8150
Positive driven by battery
2
0087
Negative for switch of fuel filter heater/starter
3
0000
Earth
4
8885/0159
7
8150
Positive driven by battery
8
7777
Positive for blink-code button/ oil low pressure led/ pre-heating led/
9
0000
Earth
12/13
8150
Positive driven by battery
14/15
0000
Earth
16
0094
Negative for post-heating resistor
19
0150
Negative start-stop push buttons from eng./accelerator pressed
20
8153
Positive from change over switch to key in starting phase (+50)
27
0156
Positive from blink-code button
28
5535
Positive for EDC diagnostic led
31
2298
K Line for diagnosis connector, 30 poles (2 pin)
32
-
36
8837
Positive for fuel filter heating switch
37
8888
Positive for starter
39
8051
Positive from key switch/ L line for diagnosis connector 30 poles (pin 11)
44
9905
Negative from starter push button from engine
45
9906
Negative from engine stop push button from engine
46
5553
Negative for pre-heating led in on position
49
5584
Diagnosis connector (pin 28)
50
0158
Negative from accelerator push button pressed
52
6109
CAN Line (whether equipped), diagnosis connector (pin 22)
53
6108
CAN Line (whether equipped), diagnosis connector (pin 22)
55
5158
Positive for sensor of foot accelerator pedal pos. / Earth multi-switch
62
0160
Negative for clutch sensor
63
5503
Negative for engine oil low pressure led
64
0535
Negative for EDC diagnosis led
72
0159
Positive from pressed accelerator push button / multi-switch signal
73
0159
Positive redundant from pressed accelerator push button
78
8162
Positive air conditioner device (whether equipped)
81
0157
Negative sensor of foot accelerator pedal pos. / Earth multi-switch
83
5157
Signal from sensor of foot accelerator pedal pos. / Signal multi-switch
87
-
Positive for pre-post heating resistor
Air conditioner switch (if available) / EDC
Base - May 2010
Negative for multi-switch couple-limiter
Positive for couple multi-switch limiter Print P2D32N003 E
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35
Connector to sensors (C) Figure 84
Colour legend 8
6
16
9
15
5
22
4
29
1 3
23
PIN ECU
CABLE COLOUR
5 7 9 10 12 17 18 19 20 21 23 24 25 27 28 29 30 33 34 35 36
C V MN CR HN BL CV GV BZ GN R B R RV LN BH
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B
GR CN NS BG
30
36
03211t
C A B L G H M N W S R V Z
ORANGE SKY BLUE WHITE BLUE YELLOW GREY BROWN BLACK LIGHT BROWN PINK RED GREEN PURPLE
FUNCTION Earth for pressure regulator Pressure regulating drive Feed for engine oil temperature/pressure sensor Feed for air pressure and temperature sensor Feed for rail pressure sensor Earth for fuel temperature sensor Earth for cooling liquid temperature sensor Earth for engine oil temperature pressure Feed for rail pressure sensor Feed for air pressure - temperature sensor Timing system sensor Driving shaft sensor Driving shaft sensor Signal from rail pressure sensor Signal from air pressure sensor Signal from air temperature sensor Earth for timing system sensor Signal from engine oil temperature sensor Signal from fuel temperature sensor Signal from engine oil pressure Signal from cooling oil temperature
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Temperature and air-pressure sensor
Driving shaft sensor
Figure 85
Figure 86
3 2 1
50319
50342
It is an inductive type sensor and it is placed on the front part of the engine.
88438
It is a component integrating one temperature sensor and a pressure one. It is assembled to the suction inlet manifold and measures the maximum capacity of air introduced, in order to provide to the engine control module the necessary data to calculate the quantity of fuel to be injected per each cycle. It is connected to the engine control module by 21C and 29C pin (temperature), 10C and 28C (pressure) and has a 5 volt feeding.
It generates some signals originated by the magnetic flow lines that close up through the openings of a phonic wheel splined to the driving shaft. The same signal is utilised to control the eventual electronic engine speed indicator placed on the vehicle instrument board. 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.
Timing system sensor Figure 87
21C Earth 29C NTC signal (temperature) 10C +5V feed 28C Signal (pressure) 50320
3 2 1
Sensor of engine’s oil temperature and pressure It is a component integrating one temperature sensor and a pressure one. It is assembled on the engine oil filter support. It measures the temperature and the pressure of the engine’s oil. It is connected to the engine control module by 19C and 33C, 9C and 35C. 19C Earth 33C NTC signal (temperature) 9C
+5V feed
35C Signal (pressure) Base - May 2010
50342
It is an inductive type sensor and it is placed on the back left part of the engine. It generates some signals originated by the magnetic flow lines that close up through the ports drilled on the gear splined to the camshaft. The signal generated by this sensor is utilised by the electronic engine control module as signal of injection phase. Even being equal to the flywheel sensor it is not interchangeable since the external shape is different. It is connected to the engine control module by pin 23C (signal) and 30C (signal). The third pin is for screening. The resistance value of the sensor is of about 900 Ω. Print P2D32N003 E
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Fuel pressure sensor
37
Resistor pre-post heating
Figure 88
Figure 90
116384 116383
It is a resistor placed on the suction inlet manifold and is utilised to heat the air during the heating pre-post operations.
1 - Earth; 2- Signal; 3- Feed. It is a sensor assembled to one end of the rail and measures the pressure of the fuel available in order to determine the injection pressure. The value of the injection pressure is utilised to control the pressure itself and to determine the duration of the electronic injection 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 fed by a tele-switch usually placed very close to the engine.
Cooling liquid temperature sensor It is a sensor with variable resistor, able to detect the cooling liquid temperature to provide to the engine control module an index of the engine thermal status. Usually, the same signal is driven by the engine control module to the temperature device placed within the vehicle’s dashboard.
Fuel temperature sensor
It is connected to the engine control module by pin 18C (Earth) and 36C (temperature signal).
Figure 89
The resistor to 20 ºC = 2,5 kΩ.
88440
1 - Fuel temperature sensor It is a sensor with variable resistor, able to detect the fuel temperature to provide to the engine control module an index of the fuel thermal status. It is connected to the engine control module by pin 17C (Earth) and 34C (temperature signal). The resistor to 20 ºC = 2,5 kΩ. Print P2D32N003 E
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Figure 91
Starter The starter is usually driven by the starting block assembled to the vehicle’s dashboard and provides positive voltage to pin B20 of the EDC.
Electro-injectors This is a N.A. type solenoid valves They are individually connected to the EDC gearcase on connector A. The resistance of each injector coil is 0.56 ÷ 0.57 Ω.
88314
1. Feeding relay of the starter
6 cylinder engines REFERENCE
DESCRIPTION
PIN EDC
CONNECTOR 1
1 2 3 4
Injector cylinder 2 Injector cylinder 2 Injector cylinder 1 Injector cylinder 1
3A 6A 13 A 9A
CONNECTOR 2
1 2 3 4
Injector cylinder 4 Injector cylinder 4 Injector cylinder 3 Injector cylinder 3
5A 14 A 12 A 4A
CONNECTOR 3
1 2 3 4
Injector cylinder 6 Injector cylinder 6 Injector cylinder 5 Injector cylinder 5
10 A 15 A 16 A 11 A
Figure 92
50343
50349
Base - May 2010
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39
PART THREE - TROUBLESHOOTING
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F4DE N ENGINES
PREFACE A successful troubleshooting is carried out with the competence acquired by years of experience and attending training courses. When the user complains for bad efficiency or working anomaly, his indications must be kept into proper consideration using them to acquire any useful information to focus the intervention.
SECTION 3 - INDUSTRIAL APPLICATION
41
Every time there is a breakdown claim and this breakdown is actually detected, it is necessary to proceed inquiring the electronic unit in one of the ways indicated and then proceed with the diagnostic research making trials and tests in order to have a picture of the working conditions and identify the root causes of the anomaly. In case the electronic device is not providing any indication, it will be necessary to proceed relying on the experience, adopting traditional diagnosis procedures.
Using FPT processing instruments, it is also possible to establish a bi-directional connection with the central unit, by which not only to decoding the failure codes but also input an enquiry relying on memory files, in order to achieve any further necessary information to identify the origin of the anomaly. NOTE Any kind of operation on the electronic center unit must be executed by qualified personnel, duly authorized by FPT. Any unauthorized tamper will involve decay of after-sales service in warranty.
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PT - BOX PT - BOX is a test tool to be connected to a Laptop.
Figure 93
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator 4. Operation indicator - 5. Serial port indicator - 6. ”Error” indicator - 7. CAN line indicator - 8. Line K indicator for automatic management PT-BOX functions: -
ECU ID reading;
-
Failure memory reading;
-
Flight recorder reading;
-
Parameters reading;
-
Failure memory cleaning;
-
Active diagnosis: actuators activation/testing;
-
Programming of repalced components and parameters/second level;
-
Acquisition/Saving of parameters
Base - May 2010
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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
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Failure code
Failure description Fuel metering
1.5.1
HIGH PRESSURE SYSTEM
1.5.2
FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (POSITIVE DEVIATION)
1.5.3
FAULT ON THE FUEL PRESSURE CONTROL OF THE RAIL (NEGATIVE DEVIATION)
1.5.4
RAIL PRESSURE ERROR: TOO LOW
1.5.5
RAIL PRESSURE ERROR: TOO HIGH
1.5.6
HIGH PRESSURE SYSTEM
1.5.7
ERROR ON THE RAIL PRESSURE (EXCESSIVE DUTY CYCLE)
1.5.8
HIGH PRESSURE SYSTEM
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
1.6.2
INJECTOR CYLINDER 2 / SHORT CIRCUIT
1.6.3
INJECTOR CYLINDER 3 / SHORT CIRCUIT
1.6.4
INJECTOR CYLINDER 4 / SHORT CIRCUIT
1.6.5
INJECTOR CYLINDER 5 / SHORT CIRCUIT
1.6.6
INJECTOR CYLINDER 6 / SHORT CIRCUIT
1.6.7
INJECTOR CYLINDER 1 / OPEN CIRCUIT
1.6.8
INJECTOR CYLINDER 2 / OPEN CIRCUIT
1.6.9
INJECTOR CYLINDER 3 / 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 Base - May 2010
ERROR MESSAGE CAN TSC1-PE Print P2D32N003 E
F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
Failure code
45
Failure description
1.C.8
ERROR MESSAGE CAN TSC1-VE
1.C.9
ERROR MESSAGE CAN TF
2.C.6
TIMEOUT OF CAN MESSAGE TSC1-PE PASSIVE
3.C.8
TIMEOUT OF CAN MESSAGE TSC1-VE PASSIVE ECU 1 (internal checks)
1.D.1
ECU OVERRUN MONITORING ERROR
1.D.2
ECU OVERRUN MONITORING ERROR
1.D.3
ECU OVERRUN MONITORING ERROR
1.D.4
ECU OVERRUN MONITORING ERROR
1.D.5
ECU OVERRUN MONITORING ERROR
1.D.6
ECU INTERNAL ERROR (TPU)
1.D.7
INTERNAL ECU ERROR (VARIANT AREA)
1.D.8
ECU OVERRUN MONITORING ERROR
1.D.9
ECU OVERRUN MONITORING ERROR
2.D.3
ECU OVERRUN MONITORING ERROR
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.7
SENSOR POWER SUPPLY 2
1.E.8
SENSOR POWER SUPPLY 3
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
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Low performance at load request.
POSSIBLE CAUSE (*) = if available in the equipment Insufficient fuel level in the tank.
RECOMMENDED TESTS OR INTERVENTION Check fuel level.
Possible exessive smoke. Possible blink-code 8.1
REMARKS The excessive smoke is due to the fact that, in case of insufficient fuel feeding, the engine control module tries to compensate prolonging the injectors working time.
F4DE N ENGINES
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ANOMALY
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter impurities or deformed because of over- is working correctly. heating. If the pump plunger is permanently depressed disassemble and check the tank pick.-up tube. If this is in order, replace the pre-filter. Obstructed air filter.
Replace the air filter.
Excessive fuel blow-by from rail boost Check the O Rings and the correct convalve. nection of the pipe fittings under the feeding pump (the lockers must stay outside and the fittings must be well locked). Visually check the low pressure pipeline integrity.
Solve the cause of the filter’s obstruction. Unless the leakage is significant, no performance failures will be detected. To verify O-rings integrity, extract from the tank the fuel recycling pipeline, seal the end and activate the priming pump driving the low pressure circuit.
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if valve. there are any significant blow-by from the boost gauge valve; in such case replace the valve. The engine suddenly stops(with no previous problems) and does not start again.
Obstructed fuel filter.
Replace the fuel filter.
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Base - May 2010
SECTION 3 - INDUSTRIAL APPLICATION
Solve the cause of the filter’s obstruction (empty and clean the tank and the part of the circuit over the filter, refill with clean fuel).
REMARKS
Eliminate the short circuit and replace the Verify that the wire line, close to the EDC. pedal, is not exposed to.
EDC ”burned” by short circuit on the wiring harness of the friction clutch. Difficult start and low performance in all Inefficient high pressure pump. conditions.
After having excluded any other possible cause, replace the high pressure pump.
Difficult start, low performance and en- Injector with obstructer or solenoid The non-working injector is easily recoggine running with one cylinder less. (mechanical part) blocked open. nisable detecting by feeling the absence of pulsing within the relevant high pressure pipe.
In case of low entity blow-by, inficiating the mechanical working of the injector but not involving flow limiter activation, there is no error memorisation in the engine control module. If the flow limiter is activated. Check error code memory.
Starting requires in excess of ten seconds, Injector blocked in open position (with The non-working injector is easily recogfollowed by huge white exhaust fumes, no return). nisable detecting by feeling the absence of and a fuel smell. pulsing within the relevant high pressure pipe.
Usually, whether such symptoms appear, it is instinctive to give up engine start. However, by insisting, it is possible to start the engine. As a matter of facts, by insisting, if within the rail the pressure makes the flow limiter close up, the engine starts with one cylinder less and gradually the grade of fumes reduces and disappears.
SECTION 3 - INDUSTRIAL APPLICATION
The engine disconnects or does not start. (*)
RECOMMENDED TESTS OR INTERVENTION
48
Base - May 2010
POSSIBLE CAUSE (*) = if available in the equipment
ANOMALY
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the origscrews. inal position. The engine works with one cylinder less, Injector blocked in closed position. without memorising failure blink codes in the engine control module.
Identify the injector that is not working The non-working injector is easily recogany more and the relating high pressure nisable detecting by feeling the absence of filler. pulsing within the relevant high pressure pipe.
F4DE N ENGINES
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F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
49
PART FOUR - MAINTENANCE PLANNING
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Base - May 2010
50
SECTION 3 - INDUSTRIAL APPLICATION
Base - May 2010
F4DE N ENGINES
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F4DE N ENGINES
SECTION 3 - INDUSTRIAL APPLICATION
51
MAINTENANCE PLANNING Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run.
Regular maintenance and inspection planning
Checks and periodical inspections Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . Inspection of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequency (hours) Daily Daily 4000 500 1000 500 1500
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by 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.
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SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers. - Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits. - Notify the maintenance if any inconvenience is detected of if any filling is necessary. After engine start and while engine is running, proceed with the following checks and controls: z - check presence of any eventual leakage from the fuel, cooling and lubricating circuits. - Verify absence of noise or unusual rattle during engine working. - Verify, using the vehicle devices, the prescribed pressure temperature and other parameters. - Visual check of fumes (colour of exhaust emissions) - Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES Checks and inspections Engine oil level check The check must be executed when the engine is disconnected and possibly cool.
Figure 95
The check can be made using the specially provided rod (1).
Figure 94
88543
To provide filling, operate through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed in order to make the oil flow easier. 88542
Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level.
The engine oil is highly polluting and harmful.
Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level.
In case of contact with the skin, rinse well with water and detergent.
In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine’s components.
Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Base - May 2010
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F4DE N ENGINES
Combustion system inspection The check must be executed both when the engine disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head. Special attention must be paid to the connections on the high pressure pipelines.
SECTION 3 - INDUSTRIAL APPLICATION
53
Lubricating system inspection The check must be executed both when the engine disconnected and when it is running. Verify the presence of any oil leakage or blow-by from the head, from the engine pan of from the heat exchanger.
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent.
Due to the high pressure within the pipelines running from the high-pressure pump to the rail diffuser and from this last one to the electro-injectors, special attention must be aid also in checking presence of any leakage or blow-by.
Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Protect the eyes and the skin from any eventual high pressure jet: these may deeply penetrate under the skin surface provoking serious poisoning. Inspection of water presence within fuel filter or pre-filter Cooling system inspection The check must be executed both when the engine disconnected and when it is running. Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips. Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.
NOTE The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel. Timely proceed operating on the pre-filter to carry out the drainage of the water within the feed circuit.
Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.
Due to the high temperatures achieved by the system, do not operate immediately after the engine’s disconnection, but wait for the time deemed necessary for the cooling. Protect the eyes and the skin from any eventual high pressure jet of cooling liquid.
The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two year.
!
In case of new filling, proceed bleeding system, through the bleeds on the engine. If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.
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Base - May 2010
54
SECTION 3 - INDUSTRIAL APPLICATION
F4DE N ENGINES
Oil motor and filter replacement
Inspection and setting of tappet clearance Figure 96
Warning: We recommend to wear proper protections because of high motor service temperature. The motor oil reaches very high temperature: you must always wear protection gloves.
Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications. We recommend to carry out the oil drainage when the motor is hot. 70520
Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.
- Place a proper container for the oil collecting under the pan connected with the drain plug. - Unscrew the plug and then take out the control dipsick and the inserting plug to ease the downflow of the lubrication oil.
The oil motor is very pollutant and harmful. In case of contact with the skin, wash with much water and detergent.
NOTE On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
Protect properly skin and eyes: operate according to safety rules. Dispose of the residual properly following the rules.
- After the complete drainage, screw the plug and carry out the clean oil filling.
!
Use only the recommended oil or oil having the requested features for the corrrect motor functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with theses rules, the service warranty is no more valid.
- Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dipsick.
Base - May 2010
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F4DE N ENGINES
Whereas you replace the lubrication oil, it is necessary to replace the filter.
SECTION 3 - INDUSTRIAL APPLICATION
55
Alternator belt replacement Due to several applications the belt run can change very much.
According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications. - The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the 9936076-tool.
Warning: with switched off motor (but still hot) the belt can operate without advance notice. Wait for the motor temperature lowering to avoid very serious accidents.
Warning: the oil filter contains inside a quantity of oil of 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 disposed of according to the rules.
For applications with automatic belt stretcher, the procedure is the following: Figure 97
(Demonstration)
- Replace the filtering cartidge with a new one and screw manually until when the gasket is in contact with the support. - Tigthen by means of the 99360076-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 topping up to compensate the quantity of oil used for the filling of the filtering cartridge.
Fuel filter replacement 88544
During this operation don’t smoke and don’t use free flames. Avoid to breathe the vapors coming from filter.
- By means of a square wrench of proper size act on point A, indicated on the figure, of the automatic belt tightener (1) and release the pressure. - Remove the control belt (2) from the driven and intermediate pulleys.
According to the applications the filters position and the quantity can change. However the following operations are valid for all applications. - Drain the fuel inside the filter by operating the water release screw. Collect the fuel in a container without impurities.
- Replace the worn belt with a new one. - Place the belt on the pulleys and the guide rollers. - Place the automatic tightener in order to key the belt in the functioning position. - Check proper position in the races of the pulleys.
- Unscrew the cartridge by using the 99360076-tool. - Collect the eventual fuel inside the filtering cartridge. - Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge. - Screw manually the new filtering cartdrige until when the gasket is completely on its seat. - Tigthen through the 99360076-tool at 10-15 Nm torque.
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Base - May 2010
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SECTION 3 - INDUSTRIAL APPLICATION
Base - May 2010
F4DE N ENGINES
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F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
1
SECTION 4 Overhaul and technical specifications Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .
4
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . .
11
ENGINE REMOVAL AT THE BENCH . . . . . . . .
11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .
12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . .
12
- Checks and measurements . . . . . . . . . . . . . . .
12
- Checking head supporting surface on cylinder unit 13
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TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Checking cam lift and pin alignment . . . . . . . .
14
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Bush replacement . . . . . . . . . . . . . . . . . . . . . .
15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Fitting tappets — camshaft . . . . . . . . . . . . . . . .
15
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
16
- Measuring journals and crankpins . . . . . . . . . .
16
- Replacing oil pump control gear . . . . . . . . . . .
19
- Fitting main bearings . . . . . . . . . . . . . . . . . . . .
19
- Finding journal clearance . . . . . . . . . . . . . . . . .
19
- Checking output shaft shoulder clearance . . .
20
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
- Measuring piston diameter . . . . . . . . . . . . . . .
21
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
Page
Page - Checking cylinder head wet seal . . . . . . . . . . .
29
- Checking cylinder head supporting surface . . .
29
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . .
30
- Conditions for proper pin-piston coupling . . . .
22
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .
23
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
- Fitting connecting rod-piston assembly . . . . . .
24
- Connecting rod-piston coupling . . . . . . . . . . . .
24
- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . . . . . . . 30
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .
25
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Regrinding — replacing the valve seats . . . . . . .
31
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
33
- Finding crankpin clearance . . . . . . . . . . . . . . . .
26
- Checking piston protrusion . . . . . . . . . . . . . . .
27
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . .
33
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .
28
- Refitting the cylinder head . . . . . . . . . . . . . . . .
34
- Removing the valves . . . . . . . . . . . . . . . . . . . .
28
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
35
Base - May 2010
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F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
3
GENERAL SPECIFICATIONS Type
6 CYLINDERS
Cycle
Four-stroke diesel engine
Power
Turbocharged with intercooler
Injection
Direct
Number of cylinders
6
∅
+
+
Bore
mm
104
Stroke
mm
132
cm3
6728
start before T.D.C. end after B.D.C.
A B
18.5º 29.5º
start before B.D.C. end after T.D.C.
D C
67º 35º
+.. = Total displacement TIMING
Checking timing X
mm
0.20 to 0.30
mm
0.45 to 0.55
Bosch
high pressure common rail EDC7 ECU
X
FUEL FEED Injection Type:
Nozzle type
Injectors
Injection sequence
ba r
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Injection pressure
1-5-3-6-2-4
bar
250 - 1600
Base - May 2010
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
CLEARANCE DATA Type
6 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1 Cylinder barrels X ∅1 X
∅1
104.00 to 104.024
∅1
0.4
X ∅1 ∅2
55.9 / 49.5 (•) 103.714 to 103.732 / 103.759 to 103.777 (•) 38.010 to 38.016
Pistons Size Outside diameter Pin housing
∅2
mm
Piston — cylinder barrels
0.252 to 0.294
Piston diameter
∅1
Piston protrusion
X
0.4
X
∅ 3
Piston pin Piston pin — pin housing
0.28 to 0.42
∅3
37.994 to 38.000 0.010 to 0.022
(•) Valid for engines F4DE9684A
Base - May 2010
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F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
6 CYLINDER
CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S 2 S 3
X1* X2 X3 * measured on 101 mm ∅ Split ring slots
Split rings
S1 S2 S3
Split rings - slots
1 2 3
Split rings X1 X2
∅ 2 ∅ 3 S
mm 2.705 to 2.735 2.440 to 2.460 / 2.420 to 2.440 (•) 4.030 to 4.050
2.560 to 2.605 2.350 to 2.380 3.970 to 3.990 0.100 to 0.175 0,.060 to 0,110 / 0.040 to 0.090 (•) 0.040 to 0.080 0.4
Split ring end opening in cylinder barrel:
X3
∅1
5
Small end bush housing Big end bearing housing
X1 X2 X3
0.30 to 0.40 0.60 to 0.80 0.30 to 0.55
∅1
40.987 to 41.013
∅2
72.987 to 73.013
Small end bush diameter Inside
∅3
Big end half bearings
S
Piston pin — bush Big end half bearings
38.019 to 38.033 1.955 to 1.968 0.019 to 0.033 0.250 ; 0.500
(•) Valid for engines F4DE9684A
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Base - May 2010
6
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4DE N ENGINES
6 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
mm
X Size
X
Max. tolerance on connecting rod axis alignment ∅2
∅1
S 1
-
-
Journals Crankpins
∅1 ∅2
82.990 to 83.010 68.987 to 69.013
Main half bearings Big end half bearings
S1 S2
2.456 to 2.464 1.955 to 1.968
Main bearings No. 1 - 7 No. 2-3-4-5-6
∅3 ∅3
87.982 to 88.008 87.977 to 88.013
S 2
∅ 3
Half bearings — Journals No. 1-7 No. 2-3-4-5-6
0.041 to 0.119 0.041 to 0.103
Half bearings - Crankpins
0.033 to 0.041
Main half bearings Big end half bearings
0.250 ; 0.500
Shoulder journal
X1
37.475 to 37.545
Shoulder main bearing
X2
32.180 to 32.280
Shoulder half-rings
X3
37.28 to 37.38
X 1
X 2 X 3
Output shaft shoulder
Base - May 2010
0.095 to 0.265
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F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
6 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM ∅ 1
mm
Valve guide seats on cylinder head
∅1
Valve guides and seats on head ∅ 4
7
7.042 to 7.062
-
Valves:
α
∅4 α
6.970 to 6.990 60º ± 0.25º
∅4 α
6.970 to 6.990 45º ± 0.25º
Valve stem and guide
0.052 to 0.092
Housing on head for valve seat:
∅ 1
∅1
34.837 to 34.863
∅1
34.837 to 34.863
Valve seat outside diameter; valve seat angle on cylinder head: ∅2 α
∅ 2
∅2 α
α
34.917 to 34.931 60º 34.917 to 34.931 45º
X
0.59 to 1.11
X
0.96 to 1.48
Sinking X Between valve seat and head Valve seats
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0.054 to 0.094 0.054 to 0.094 -
Base - May 2010
8
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4DE N ENGINES
6 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
mm
Valve spring height: free spring H
H1
H 2 under a load equal to: 339.8 ± 19 N 741 ± 39 N Injector protrusion
H
47.75
H1 H2
35.33 25.2
X
-
X
∅ ∅ ∅ 1 23 4 5
Camshaft bush housings No. 1 (flywheel side)
59.222 to 59.248
Camshaft housings No. 2-3-4-5-6-7
54.089 to 54.139
∅ 2
∅ 1
Camshaft journals: 1⇒7
∅
53.995 to 54.045
Bush inside diameter
∅
54.083 to 54.147
∅ 3 ∅
Bushes and journals
0.038 to 0.162
Cam lift: H
Base - May 2010
H
6.045
H
7.582
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F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
9
6 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
mm
∅1 Tappet cap housing on block ∅2 ∅ 3
Tappet cap outside diameter:
∅2
∅1
16.000 to 16.030
∅2 ∅3
15.924 to 15.954 15.960 to 15.975
Between tappets and housings Tappets
0.025 to 0.070 -
∅ 1 Rocker shaft
∅1
21.965 to 21.977
Rockers
∅2
22.001 to 22.027
∅ 2 Between rockers and shaft
Print P2D32N003 E
0.024 to 0.162
Base - May 2010
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Base - May 2010
F4DE N ENGINES
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F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH
11
Figure 3
The following instructions assume that the engine has previously been placed on the rotating bench and that removal of all specific components of the FPT equipment have been already removed as well. (See Section 3 of the manual herein). The section illustrates therefore all the most important engine overhaul procedures.
Figure 1
70160
The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).
NOTE Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.
Figure 4 70158
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. NOTE Keep the half-bearings into their housings since in case of use they shall be fitted in the same position found at removal. 74774
Use tool 99360500 (1) and hoist to remove the crankshaft (2) from the block.
Figure 2 Figure 5
70159
Remove the screws (1) and the main bearing caps (2).
70162
Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3). Print P2D32N003 E
Base - May 2010
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
zs
REPAIR OPERATIONS CYLINDER UNIT Checks and measurements
Figure 6
Figure 9
70163
s
Remove the screws (1) and disconnect camshaft (3) retaining plate (2). NOTE Take note of plate (2) assembling position. 70166
Once engine is disassembled, clean accurately the cylinder-block assembly. Use the proper rings to handle the cylinder unit. The engine block shall not show cracks. Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear. Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter.
Figure 7
NOTE Should the ring gauge be not available, use a micrometer for zero-setting. 70164
Withdraw carefully the camshaft (1) from the engine block.
Figure 10
Figure 8
70167
Measurements shall be performed on each cylinder, at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement. 70165
Withdraw the tappets (1) from the engine block. Base - May 2010
Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.5 mm and to the specified assembling clearance. Print P2D32N003 E
F4DE N ENGINES
13
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Check main bearing housings as follows:
Figure 11
- fit the main bearings caps on the supports without bearings; - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value. Replace if higher value is found.
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 (1) conditions, replace them in case of uncertain seal or if rusted. α
107804
NOTE In case of regrinding, all barrels shall have the same oversize (0.4 mm).
TIMING SYSTEM Camshaft Figure 12
88595
CAMSHAFT MAIN DATA (6-cyl.) 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 Print P2D32N003 E
camshaft and the bushes.
Base - May 2010
14
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cam lift and pin alignment
F4DE N ENGINES
BUSHES
Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft. Check cam lift; found values shall be: 6.045 mm for exhaust cams and 7.582 mm for intake cams, in case of different values replace the camshaft.
Figure 14
Figure 13
88596
70171
Camshaft bush (2) shall be pressed into its housing. Internal surface must not show seizing or wear. Use bore dial gauge (3) to measure camshaft bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.
Figure 15
116363
MAIN DATA ABOUT CAMSHAFT BUSH AND RELATED HOUSING (6-cyl.) *Height to be obtained after driving the bush.
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Bush replacement
15
Fitting tappets — camshaft Figure 18
Figure 16
88600 88599
To replace bush (1), remove and refit it using the beater 99360362 (2) and the handgrip 99370006 (3).
Lubricate the tappets (1) and fit them into the relevant housings on the engine block. Figure 19
NOTE When refitting the bush (1), direct them to make the lubricating holes (2) coincide with the holes on the block housing.
88601
Lubricate the camshaft bush and fit the camshaft (1) taking care not to damage the bush or the housing.
Tappets Figure 17
Figure 20
88602 88612
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK
Print P2D32N003 E
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.
Base - May 2010
16
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
OUTPUT SHAFT Measuring journals and crankpins
Figure 21
Figure 23
88605
70182
Check camshaft end float (1). It shall be 0.23 ± 0.13 mm.
Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.
NOTE It is recommended to insert the found values in the proper table. See Figure 24. Undersize classes are: 0.250; 0.500 mm
NOTE Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB
Figure 22
70180
Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
17
Figure 24
88604
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value
Figure 25
* **
Measured on a radius greater than 45.5 mm ↗ 0.500
between adjacent main journals
70577
MAIN OUTPUT SHAFT TOLERANCES
Print P2D32N003 E
Base - May 2010
18
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
Figure 26
INTERMEDIATE MAIN BEARINGS
MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
FIRST MAIN BEARING ON FRONT SIDE
70237
TOLERANCES SHAPE
DIRECTION POSITION OSCILLATION
TOLERANCE CHARACTERISTIC
GRAPHIC SYMBOL
Roundness
○
Cilindricity
/○/ //
Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL
CRITICAL
©
IMPORTANT
⊕
SECONDARY
⊝
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
19
Finding journal clearance
Replacing oil pump control gear
Figure 29 Figure 27
74774
70184
Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3). When fitting the new gear, heat it to 180°C for 10 minutes in an oven and then key it to the output shaft.
With tool 99360500 (1) and hoist, re-assemble the engine shaft inside the engine crankcase (2). Check the backlash between output shaft main journals and the relevant bearings as follows:
Figure 30
Fitting main bearings Figure 28
70186
- clean accurately the parts and remove any trace of oil; 70185
- position a piece of calibrated wire (3) on the output shaft pins (4) so that it is parallel to the longitudinal axis;
NOTE Refit the main bearings that have not been replaced, in the same position found at removal.
- fit caps (1), including the half bearings (2) on the relevant supports.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter.
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
NOTE Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings.
D2
D1
75703
The second last main half bearing (1) is fitted with shoulder half rings. Print P2D32N003 E
Base - May 2010
20
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
Checking output shaft shoulder clearance
Figure 31
Figure 34
70187
Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, with dynamometric wrench to 50 ± 6 Nm. - 2nd stage, with dynamometric wrench to 80 ± 6 Nm. Figure 32
70190
This check is performed by setting a magnetic-base dial gauge (2) on the output shaft (3) as shown in the figure, standard value is 0.068 to 0.41. If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between output shaft pins and main half bearings.
α
CONNECTING ROD — PISTON ASSEMBLY 70188
-
Figure 35
3rd
stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90° ± 5° angle. Figure 33
70191
70189
- Remove caps from supports. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire. The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described. Base - May 2010
CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE The pistons are supplied spare with the following sizes: - standard; - 0.4 mm oversize. Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
21
Pistons Measuring piston diameter
Figure 36
Figure 39
32613
Remove split rings (1) from piston (2) using pliers 99360183 (3).
32615
Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.
Figure 37
Figure 40
32614
Piston pin (1) split rings (2) are removed using a scriber (3). 70192
The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure. Figure 38 1.5
*
2.560 2.605
2.350 2.380
3.970 3.990
2.705 2.735
2.420 2.440
2°±20’
38.010 38.016
37.994 38.000
114797
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS * Value measured on 101 mm diameter Print P2D32N003 E
Base - May 2010
22
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
Figure 41
114798
MAIN DATA CONCERNING MONDIAL MAHLE PISTON, PINS AND SPLIT RINGS * Value measured on 101 mm diameter
Piston pins Figure 42 Figure 44
18857
To measure the piston pin (1) diameter use the micrometer (2).
16552
Use a micrometer (1) to check split ring (2) thickness.
Conditions for proper pin-piston coupling Figure 43
Figure 45
32619
Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.
Base - May 2010
32620
Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1). Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
23
Connecting rods
Figure 46
Figure 48
41104
DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3). In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.
88607
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS * Value for inside diameter to be obtained after driving in connecting rod small end and grinding.
Figure 47
NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls.
70194
Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).
Use a micrometer (1) to check split ring (2) thickness.
Print P2D32N003 E
Base - May 2010
24
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 49
F4DE N ENGINES
Bushes Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.
Fitting connecting rod-piston assembly Connecting rod-piston coupling Figure 50
80339
NOTE Every connecting rod is marked as follows: - On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one. - On body with a letter showing the weight of the connecting rod assembled at production:
S
V, 1600 to 1640 (yellow marking);
S
W, 1641 to 1680 (green marking);
S
X, 1681 to 1720 (blue marking);
88608
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 51
Spare connecting rods are of the W class with green marking *. Material removal is not allowed.
88609
Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (4) are read as shown in the figure. Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 52
25
Figure 54
72705
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).
70200
Fit half bearings (1) on connecting rod and cap. NOTE Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings.
Fitting split rings Figure 53
Fitting connecting rod-piston assembly into cylinder barrels Figure 55
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°. NOTE Split rings are supplied spare with the following sizes: -
standard;
-
0.4 mm oversize.
Print P2D32N003 E
70201
Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 99360605 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number. Base - May 2010
26
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 56
F4DE N ENGINES
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
88610
Figure 58 DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL - Split ring openings shall be displaced with each other by 120°; - connecting rod-piston assemblies shall have the same weight; - the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.
α
70204
Finding crankpin clearance
- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometric wrench (2).
Figure 57
Figure 59 α 70203
To measure the clearance proceed as follows: - clean the parts accurately and remove any trace of oil; - set a piece of calibrated wire (2) on the output shaft pins (1); - fit the connecting rod caps (3) with the relevant half bearings (4).
70205
- Apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60°. Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
27
Checking piston protrusion
Figure 60
Figure 62
70206
- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).
70208
Once connecting rod-piston assemblies refitting is over, use dial gauge 39395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm.
Figure 61
70207
If a different clearance value is found, replace the half bearings and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque. Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.10 to 0.33 mm.
Print P2D32N003 E
Base - May 2010
28
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4DE N ENGINES
Figure 64
CYLINDER HEAD Removing the valves Figure 63
70321
70319
Intake (1) and exhaust (2) valves have heads with the same diameter. The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.
Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Repeat this operation for all the valves. Overturn the cylinder head and withdraw the valves (5). Figure 65
NOTE 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
70322
Remove sealing rings (1 and 2) from the valve guide. NOTE Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cylinder head wet seal
29
Figure 67
Figure 66
70323
70325
This check shall be performed using the proper tools. Use a pump to fill with water heated to approx. 90°C and 2 to 3 bar pressure.
The rated thickness A for the cylinder head is 105 ± 0.25 mm, max. metal removal shall not exceed thickness B by 1 mm.
Replace the cup plugs (1) if leaks are found, use the proper beater for their removal/refitting. NOTE After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value. NOTE Before refitting, smear the plug surfaces with water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface Use a rule (2) and a feeler gauge (3) to check the cylinder head (1) supporting surface. Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure.
Print P2D32N003 E
Base - May 2010
30
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVES
F4DE N ENGINES
Figure 70
Figure 68 EXHAUST VALVE
INTAKE VALVE
18882
Check the valve stem (1) using a micrometer (2), it shall be 6.970 ± 6.990.
107280
INTAKE AND EXHAUST VALVE MAIN DATA
Removing carbon deposits, checking and grinding valves Figure 69
Checking clearance between valve stem and valve guide and valve centering Figure 71
18625
Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Regrind the valve seats, if required, removing as less material as possible.
Base - May 2010
70327
Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.052 ± 0.092 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVE GUIDE
31
VALVE SEATS Regrinding — replacing the valve seats
Figure 72 Figure 73
INTAKE
EXHAUST
70330 70328
Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.
Check the valve seats (2). If slight scoring or burnout is found, regrind seats using adequate tool (1) according to the angle values shown in Figure 74.
Figure 74
INTAKE
EXHAUST 70331
VALVE SEAT MAIN DATA (6 CYL.)
Print P2D32N003 E
Base - May 2010
32
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Should valve seats be not reset just by regrinding, replace them with the spare ones. Use adequate tool to remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.
F4DE N ENGINES
Heat the cylinder head to 80° - 100°C and using the proper beater, fit the new valve seats, previously cooled, into the cylinder head. Use adequate tool to regrind the valve seats according to the values shown in Figure 74.
Figure 75
EXHAUST
INTAKE
70332
MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD (6-CYL.)
After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial gauge 99395603 (1).
Figure 76
70333
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVE SPRINGS
33
FITTING CYLINDER HEAD
Figure 77
Figure 78
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before refitting use tool 99305047 to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table.
70334
Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal. Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green. Height
Under a load of
mm
kg
H
47,75
Free
H1
35,33
P
339,8 ± 19 N
H2
25,2
P1
741 ± 39 N
Figure 79
770321
Position on the cylinder head: the spring (4), the upper cap (3); use tool 99360268 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2). Print P2D32N003 E
Base - May 2010
34
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Refitting the cylinder head
F4DE N ENGINES
Figure 81
Figure 80
88775
70335
Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “TOP” (1) facing the head. The arrow shows the point where the gasket thickness is given.
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
There are two types of head seals, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on Figure 81, at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average:
S cil1 = S1 + S2 2 For 6 cylinder versions: Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value. S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6 6 If S is > 0,40 mm use seal type A. If S is < 0,40 mm use seal type B. S=
75703
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
35
TIGHTENING TORQUE TORQUE
COMPONENT Bench fixing screws:
Connecting rod cap:
Engine cover fixing nuts (M8x125) Engine flywheel fixing screws: Pulleys and dampener fixing screws Screws used to fix the injectors on the cylinder heads P.A.P. gear fixing nut: Compressor gear fixing nut: Distribution gear fixing screws: Piston lubricating nozzle fixing unions: Distribution box fixing screws M8 1.25x40 M10 1.5x30 Front cover fixing screws M10 1.5x30 Bench cap fixing screws M12x1.50
Ladder Frame fixing screws M10 1.5x25 Hoisting bracket fixing screws: M12 1.75x25 M10 Heat exchanger fixing screws M8 1.25x35 M8 1.25x100 M12 Connector M8 valve cap fixing screws Engine exhaust fixing (Ccv) M8 1.25x45 M8 1.25x35 Oil sump fixing screws Screws No. 26-23 M10 1.5x45 Screws No. 3÷10; 13÷20; 24-25 M10 1.5x90 Screws No. 1-2-21-22 M10 1.5x125 Screws No. 11-12 M10 15x190 Screws / Caps on Head 1/2” Nptf 3/4” Nptf 1/4 Inch Nptf Cylinder head fixing screws Screws No. 16-15-8-7-1-2-9-10-17-18 M12 1.75x150 Screws No. 12-11-4-3-5-6-13-14 M12 1.75x130
1st step 2nd step 3rd step 1st step 2nd step 3rd step 1st step 2nd step
1st step 2nd step 3rd step
Nm 50 ± 6 80 ± 6 90_ ± 5_ 30 ± 3 60 ± 5
Print P2D32N003 E
3 ± 0.3 6 ± 0.5 60_ ± 5_
25 ± 5 30 ± 4
2.5 ± 0.5 3 ± 0.4 60_ ± 5_
110 ± 5 110 ± 5 105 ± 7 125 ± 19 36 ± 4 15 ± 3
11 ± 0.5 11 ± 0.5 10.5 ± 0.7 12.5 ± 1.9 3.6 ± 0.4 1.5 ± 0.3
24 ± 4 47 ± 5
2.4 ± 0.4 4.7 ± 0.5
24 ± 4 50 ± 6 80 ± 6
2.4 ± 0.4 5.0 ± 0.6 8.0 ± 0.6 + 90_ ± 5_
43 ± 5
4.3 ± 0.5
70 ± 12 43 ± 5
7 ± 1.2 4.3 ± 0.5
25 ± 5 25 ± 5 25 ± 5
2.5 ± 0.5 2.5 ± 0.5 2.5 ± 0.5
24 ± 4
2.4 ± 0.4
24 ± 4 24 ± 4
2.4 ± 0.4 24 ± 0.4
50 ± 5 70 ± 5 70 ± 5 70 ± 5
5 ± 0.5 7 ± 0.5 7 ± 0.5 7 ± 0.5
24 ± 4 36 ± 5 12 ± 2
2.4 ± 0.4 3.6 ± 0.5 1.2 ± 0.2
55 ± 5 35 ± 5
5.5 ± 0.5 3.5 ± 0.5 + 90_ ± 5_ + 180_ ± 5_
Angle closure M6 heater grid fixing screws Intake manifold fixing screws: M8 1.25x25 M8 1.25x60
kgm 5 ± 0.6 8 ± 0.6
10 ± 2
1.0 ± 2
25 ± 5 25 ± 5
2.5 ± 0.5 2.5 ± 0.5
Base - May 2010
36
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
TORQUE
COMPONENT Screws used to fix the exhaust manifold on the head: M8x1.25x25 mm M8x1.25x14 mm M11x1.25 connection rod cap fixing screws
1st step 2nd step 3rd step
Flywheel fixing screws M12 M10 M8x1.25x25 distribution shaft should plate fixing screws M8x1.25x20 distribution shaft gear fixing screws Rocker arm fixing screws 3/8 rocker arm register fixing screws Rocker arm box fixing screws M12x1.25 phonic wheel fixing screws Head side fuel connector fixing Common Rail side fuel connector fixing Common Rail fixing M8 1.25x10 M8 1.25x50 M8 1.25x90 Fixing of high pressure pipe between Common Rail and M14x1.5 cylinder head Fixing of fuel combustion filter support on M12x1.75x25 base Fixing of turbine on the M8x1.25 exhaust manifold M12x1.5 oil delivery and return pipeline fixing Oil level rod fixing M8x1.25x30 oil pump fixing screws Principal oil delivery screws (caps) M10 — 1 M14 — 1.5 Fixing between oil cooler with oil filter assembly Fixing of the water pump on the base: M8x1.25x25 Belt tightener fixing M10x1.5x60 M10 fan support fixing Fan pulley fixing Fan spacer or accessory pulley fixing (on request) M6 M10 M12
Base - May 2010
F4DE N ENGINES
Nm
kgm
25 ± 5 25 ± 5 30 ± 3 60 ± 5
2.5 ± 0.5 2.5 ± 0.5 3.0 ± 0.3 6.0 ± 0.5 + 90_ ± 5_
85 ± 10 49 ± 5 24 ± 4 36 ± 4 36 ± 5 24 ± 4 24 ± 4 110 ± 5 50 ± 5 20 ± 2
8.5 ± 1.0 4.9 ± 0.5 2.4 ± 0.4 3.6 ± 0.4 3.6 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 11.0 ± 0.5 5.0 ± 0.5 2.0 ± 0.2
24 ± 4
2.4 ± 0.4
20 ± 2 77 ± 8 25 ± 5 35 ± 5 24 ± 4 8±1 24 ± 4
2.0 ± 0.2 7.7 ± 0.8 2.5 ± 0.5 3.5 ± 0.5 2.4 ± 0.4 0.8 ± 0.1 2.4 ± 0.4
6±1 11 ± 2 24 ± 4 24 ± 4 43 ± 6
0.6 ± 0.1 1.1 ± 0.2 2.4 ± 0.4 2.4 ± 0.4 4.3 ± 0.6
– 33 ± 5 –
– 3.3 ± 0.5 –
10 ± 2 43 ± 6 77 ± 12
1.0 ± 0.2 4.3 ± 0.6 7.7 ± 1.2
Print P2D32N003 E
F4DE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
TORQUE
COMPONENT
Nm
kgm
Stud fixing for M8 fuel pump assembly
12 ± 2
1.2 ± 0.2
M8x1.5 injection pump fixing screws
24 ± 4
2.4 ± 0.4
M18x1.5 injection pump gear fixing nut closure
105 ± 5
10.5 ± 0.5
Fixing of the unions between the injection pump and the M12x15 Common Rail
20 ± 2
2.0 ± 0.2
Injector fixing screws
3.5 ± 0.35
0.35 ± 0..35
Injector connector fixing screws
1.5 ± 0.25
0.15 ± 0..25
Oil pressure regulator sensor fixing
8±2
0.8 ± 0.2
Fixing of distribution shaft sensor in the M6 gear box
8±2
0.8 ± 0.2
Fixing of engine shaft speed sensor on the M6 front cap
8±2
0.8 ± 0.2
Fixing of the temperature sensor on the M14x1.5x12 cylinder heads
20 ± 3
2.0 ± 0.3
Fixing of the air temperature sensor on the M6x1x20 intake manifold
3±1
0.3 ± 0.1
Fixing of the air pressure and temperature sensor on the intake manifold M5
3±1
0.3 ± 0.1
Fuel pressure sensor fixing
35 ± 5
3.5 ± 0.5
M14x1.5x12 fuel temperature sensor fixing
20 ± 3
2.0 ± 0.3
125 ± 19
12.5 ± 1.9
81 ± 12 50 ± 6 80 ± 6
8.1 ± 1.2 5 ± 0.6 8 ± 0.6
Fixing of gear on the 5/8 air compressor Air compressor fixing on the M12 base Screw M12 for fastening output shaft caps
1st stage 2nd stage 3rd stage
Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M10 for fastening connecting rod caps 1st stage 2nd stage
Print P2D32N003 E
37
90º ± 5º 24 ± 4 36 ± 4 60 ± 5
2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60º ± 5º
Base - May 2010
38
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Base - May 2010
F4DE N ENGINES
Print P2D32N003 E
F4DE N ENGINES
SECTION 5 - TOOLS
1
SECTION 5 Tools
Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print P2D32N003 E
3
Base - May 2010
2
SECTION 5 - TOOLS
Base - May 2010
F4DE N ENGINES
Print P2D32N003 E
F4DE N ENGINES
SECTION 5 - TOOLS
3
TOOLS TOOL NO.
DESCRIPTION
99317915
Set of 3 pin wrenches (14 - 17 - 19 mm)
99322205
Revolving stand for overhauling units (700 daN/m capacity, 120 daN/m torque)
99327281
Tester PT-BOX
99340055
Tool to remove output shaft front gasket
99340056
Tool to remove output shaft rear gasket
99341001
Double acting puller
Print P2D32N003 E
Base - May 2010
4
SECTION 5 - TOOLS
F4DE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99341009
Pair of brackets
99341015
Press
99342101
Tool to remove injectors
99346252
Tool for fitting output shaft front gasket
99346253
Tool for fitting output shaft rear gasket
99360076
Tool to remove oil filter (engine)
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 5 - TOOLS
5
TOOLS TOOL NO.
DESCRIPTION
99360183
Pliers for removing/refitting piston rings (65 — 110 mm)
99360268
Tool for removing/refitting engine valves
99360339
Tool for rotating/stopping the engine flywheel
99360362
Beater for removing/refitting camshaft bushes (to be used with 993700069)
99360500
Tool for lifting the output shaft
99360595
Lifting rig for engine removal/refitting
Print P2D32N003 E
Base - May 2010
6
SECTION 5 - TOOLS
F4DE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99360605
Band for fitting piston into cylinder barrel (60 — 125 mm)
99361037
Brackets for fastening engine to revolving stand 99322205
99363204
Tool to remove gaskets
99370006
Handgrip for interchangeable beaters
99370415
Gauge base for different measurements (to be used with 99395603)
99389829
Dog type dynamometric wrench 9x12 (5-60 Nm)
Base - May 2010
Print P2D32N003 E
F4DE N ENGINES
SECTION 5 - TOOLS
7
TOOLS TOOL NO.
DESCRIPTION
99389834
Torque screwdriver for injector solenoid valve connector stop nut setting
99395216
Pair of gauges with ½” and ¾” square head for angle tightening
99395603
Dial gauge (0 — 5 mm)
Print P2D32N003 E
Base - May 2010
8
SECTION 5 - TOOLS
Base - May 2010
F4DE N ENGINES
Print P2D32N003 E
F4DE N ENGINES
APPENDIX
1
Appendix
Page
Print P2D32N003 E
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . .
3
- Standard safety prescriptions . . . . . . . . . . . . . .
3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . .
3
- During maintenance . . . . . . . . . . . . . . . . . . . .
3
- Respect of the Environment . . . . . . . . . . . . . .
4
Base - May 2010
2
APPENDIX
Base - May 2010
F4DE N ENGINES
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F4DE N ENGINES
APPENDIX
3
SAFETY PRESCRIPTIONS Standard safety prescriptions
- Do not execute any intervention if not provided with necessary instructions.
Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.
- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur.
Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation.
- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.
- Keep working areas as clean as possible, ensuring adequate aeration. - Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. - Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities. - Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines. - Smoking in working areas subject to fire danger must be strictly prohibited. - Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.
During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. - 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.
Prevention of injury
- Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas aerated. Whenever necessary wear safety mask.
- Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion.
- Do not leave rags impregnated with flammable substances close to the engine.
- Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed: ≤ 2 bar)
- Do not utilize fast screw-tightening tools.
- Wear safety helmet when working close to hanging loads 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 working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material. - Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers. Print P2D32N003 E
- Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate. - Never disconnect batteries when the engine is running. - Disconnect batteries before any intervention on the electrical system. - Disconnect batteries from system aboard to load them with the battery loader. - After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. - Do not disconnect and connect electrical connections in presence of electrical feed. - Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning.
Base - May 2010
4
APPENDIX
- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved by Iveco. - Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80ºC temperature.
F4DE N ENGINES
Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted. - Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger. - Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.
- Do not paint the components and the electronic connections. - Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.
Base - May 2010
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1
F4GE N ENGINES
Part 4 F4GE N ENGINES Sezione General specifications
1
Fuel
2
Duty - Industrial application
3
Overhaul and technical specifications
4
Tools
5
Safety prescriptions
Print P2D32N003 E
Appendix
Base - May 2010
2
Base - May 2010
F4GE N ENGINES
Print P2D32N003 E
3
F4GE N ENGINES
SPECIAL REMARKS Where possible, the same sequence of procedures has been followed for easy reference. Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures.
Example ∅1
Ø 1 = housing for connecting rod small end bush α
∅2
Print P2D32N003 E
Tighten to torque Tighten to torque + angular value
Ø 2 = housing for connecting rod bearings
Base - May 2010
4
F4GE N ENGINES
SYMBOLS - ASSISTANCE OPERATIONS Removal Disconnection
Intake
Refitting Connection
Exhaust
Removal Disassembly
Operation
Fitting in place Assembly
α
Compression ratio
Tighten to torque
Tolerance Weight difference
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 Sealant Adhesive Air bleeding
Base - May 2010
ρ
Selection Classes Oversizing Temperature < 0 °C Cold Winter Temperature > 0 °C Hot Summer
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5
F4GE N ENGINES
UPDATING Section 3
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Description
Page
Date of revision
Industrial application
25 - 55
Revi-September 2012
Base - May 2010 Revi - September 2012
6
Base - May 2010
F4GE N ENGINES
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F4GE N ENGINES
1
SECTION 1 - GENERAL SPECIFICATIONS
SECTION 1 General specifications Page
Print P2D32N003 E
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE . . . . . . . . . . . . .
3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
4
OIL VAPOUR RECIRCULATING SYSTEM . . . . .
6
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
7
AIR INDUCTION BOOST DIAGRAM . . . . . . . .
9
- Boosting version engines . . . . . . . . . . . . . . . . .
9
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
AIR INDUCTION BOOST DIAGRAM . . . . . . . .
10
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR)
11
Base - May 2010
2
SECTION 1 - GENERAL SPECIFICATIONS
Base - May 2010
F4GE N ENGINES
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F4GE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
3
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code F4GE9454H*J601 F4GE9454J*J600 F4GE9454H*J600 F4GE9454H*J603 F4GE9454H*J605 F4GE9454H*J602 F4GE9454J*J601 F4GE9484D*J601 F4GE9484F*J603 F4GE9484D*J602 F4GE9484D*J609 F4GE9484D*J612 F4GE9484D*J613 F4GE9484D*J610 F4GE9484D*J614 F4GE9484J*J602 F4GE9484F*J604 F4GE9484F*J607 F4GE9484F*J611 F4GE9684P*J601 F4GE9684P*J602 F4GE9684A*J602
Print P2D32N003 E
Commercial Code
N45 MSS.X
N45 MNS.X N45 MST.X
N45 MNT.X
N67 MST.X N67 MNT.X
Base - May 2010
4
SECTION 1 - GENERAL SPECIFICATIONS
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.
F4GE N ENGINES
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 specific duty.
Figure 1
Routing of oil under pressure Routing of oil return by gravity to sump Introduction of oil
116396
LUBRICATION SYSTEM LAYOUT (4 cylinder engine) 1. Heat exchanger body - 2. Lubrication oil pipe to supercharger - 3. Oil filter - 4. Heat exchanger 5. Oil rotary expansion pump.
Base - May 2010
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F4GE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
5
Figure 2
112886
LUBRICATION SYSTEM LAYOUT (6 cylinder engines) 1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger - 4. Oil rotary expansion pump 5. Oil filter.
Print P2D32N003 E
Base - May 2010
6
SECTION 1 - GENERAL SPECIFICATIONS
F4GE N ENGINES
OIL VAPOUR RECIRCULATING SYSTEM Figure 3
1
2
3
003240t
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 (connection towards these vapours shall be designed by the Engineer).
Base - May 2010
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F4GE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
COOLING SYSTEM The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment. - Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.
7
- Heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment. - Centrifugal water pump, placed in the front part of the engine block. - Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.
- Visc pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development. 6 cylinders version Figure 4
TO RADIATOR
FROM RADIATOR
Water coming out from thermostat
117586
Water recirculating in engine Water coming into pump COOLING SYSTEM LAYOUT (4 cyl. engines) Print P2D32N003 E
Base - May 2010
8
SECTION 1 - GENERAL SPECIFICATIONS
F4GE N ENGINES
6 cylinders version Figure 5 TO RADIATOR
FROM RADIATOR
117587
Water coming out from thermostat Water recirculating in engine Water coming into pump
COOLING SYSTEM LAYOUT (6 cyl. engines)
Base - May 2010
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F4GE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
9
AIR INDUCTION BOOST DIAGRAM Boosting version engines Figure 6
TURBOCHARGER
AIR FILTER
EXHAUST
4 cylinders version
TURBOCHARGER
AIR FILTER
EXHAUST
6 cylinders version 88208
Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation. The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter. The air coming out of the compressor is sent via the intake manifold directly to the pistons.
Print P2D32N003 E
The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s duty is to choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
Base - May 2010
10
SECTION 1 - GENERAL SPECIFICATIONS
F4GE N ENGINES
AIR INDUCTION BOOST DIAGRAM Inter-cooled engine version Figure 7
TURBOCHARGER
AIR FILTER
EXHAUST
RADIATOR 74195
4 cylinders version
TURBOCHARGER
AIR FILTER
EXHAUST
RADIATOR 74195
6 cylinders version
Description The turbocharger is composed by the following main parts: one turbine, one transforming valve to regulate the boost feeding pressure , one main body and one compressor. During engine working process, the exhaust emission flow through the body of the turbine, provoking the turbine disk wheel’s rotation. The compressor rotor, being connected by shaft to the turbine disk wheel, rotates as long as this last one rotates, compressing the sucked air through the air filter. The above mentioned air is then cooled by the radiator and flown through the piston induction collector. Base - May 2010
The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction collector. It’s duty is to choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value. The cooling process and the lubrication of the turbocharger and of the bearings is made by the oil of the engine.
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F4GE N ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) In the TIER 3 version, the profile of the exhaust cam has been modified in order to allow the partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders. The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitric acid (NOx). The exhaust gas re-circulation system (EGR), reducing the combustion temperature by means of the diminishing of the concentration of oxygen in the combustion chamber, represents therefore an efficient control system of the emission of NOx .
11
The internal EGR system is not equipped with any electronically controlled elements: the system is always active. Its configuration does not need additional elements i.e.checking valves, piping or heat exchangers. The exhaust cam (B) has another lobe apart from the major lobe (see Section. A-A fig.) with respects to the configuration without EGR. The additional lobe, during the aspiration phase in the cylinder in question, allows a brief opening of the exhaust valve generating re-circulation due to the intake of the exhaust gases caused by depression which is created in the aspiration phase inside the cylinder.
Figure 8
114789
A. Aspiration valve control - B. Exhaust valve control. Print P2D32N003 E
Base - May 2010
12
SECTION 1 - GENERAL SPECIFICATIONS
Base - May 2010
F4GE N ENGINES
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F4GE N ENGINES
SECTION 2 - FUEL
1
SECTION 2 Fuel Page 4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP . . . . . . . . . . . . . . . 3 - General information . . . . . . . . . . . . . . . . . . . .
3
- Description of working principles . . . . . . . . . . .
4
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Example of identification . . . . . . . . . . . . . . . . .
5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
6-CYLINDER ENGINES WITH BOSCH VE 6/12 F ROTARY MECHANICAL PUMP . . . . . . . . . . . . . . . 8
Print P2D32N003 E
- General information . . . . . . . . . . . . . . . . . . . .
8
- Description of working principles . . . . . . . . . . .
9
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
10
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4-CYLINDER ENGINES WITH DELPHI ROTARY MECHANICAL PUMP . . . . . . . . . . . . . . . . . .
12
- General information . . . . . . . . . . . . . . . . . . . .
12
- Description of working principles . . . . . . . . . . .
13
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
14
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Base - May 2010
2
SECTION 2 - FUEL
Base - May 2010
F4GE N ENGINES
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F4GE N ENGINES
3
SECTION 2 - FUEL
4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) - Priming pump, assembled to the engine and driven by the camshaft - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed rotary pump - Injector feed pipeline (from fuel feed pump to injectors) - Injectors
Figure 1
2 1 4
7
5 3 6
74168
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.
Print P2D32N003 E
Base - May 2010
4
SECTION 2 - FUEL
F4GE N ENGINES
Figure 2
116385
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Description of working principles Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft. Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For applications to be equipped in cold climate areas, the fuel filter is provided with heater).
The fuel arrives therefore to the valve gauging the pressure inside feed pump. The distribution plunger further increases this pressure and delivers fuel throughout the delivery pipe fitting to the injectors. The fuel drawing from the injectors is recovered and delivered to the tank again.
Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.
Base - May 2010
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F4GE N ENGINES
5
SECTION 2 - FUEL
FEED PUMP The rotary type pump is driven by a gear mating the camshaft’s one.
Example of identification V
=
Distribution rotary plunger
E
=
Pump dimensions
4
=
4 cylinders engine
12 =
Distribution plunger in mm.
1150
=
LV =
Left direction of rotation
N°. of pump revolutions per minute
Figure 3
1 15 2 14 3 4
5 13 12 6
7 8
9 11 10
30454
Injection pump longitudinal section 1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk 9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate 14. Gauge pin - 15. Counteracting spring. Print P2D32N003 E
Base - May 2010
6
SECTION 2 - FUEL
F4GE N ENGINES
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 4
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.
Base - May 2010
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F4GE N ENGINES
SECTION 2 - FUEL
7
FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperature sensor. On some versions, a water presence sensor is present at filtering cartridge base.
Figure 5
88210
1. Fuel filter bearing- - 2. Filter cartridge - 3. Water dump screw.
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8
SECTION 2 - FUEL
F4GE N ENGINES
6-CYLINDER ENGINES WITH BOSCH VE 6/12 F ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed pump - Injector feed pipeline (from fuel feed pump to injectors) - Injectors
Figure 6
9
86495
1. Injector fuel pipe 1 - 2. Injector fuel pipe 2 - 3. Injector fuel pipe 3 - 4. Injector fuel pipe 4 - 5. Injector fuel pipe 6. Injector fuel pipe 5 - 7. Injector fuel pipe 6 - 7. Injector fuel pipe 6 - 8. Injection pump - 9. Injector.
Base - May 2010
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F4GE N ENGINES
SECTION 2 - FUEL
9
Figure 7
114799
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Description of working principles Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft. Throughout the filter/s, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For applications to be equipped in cold climate areas, the fuel filter is provided with heater).
Fuel is delivered to the pressure gauge valve within feed pump. Timing plungers further increase the pressure and deliver fuel to the injectors throughout the delivery pipe fittings. Fuel bleeding from the injectors is recovered and piped back to the pump.
Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.
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10
SECTION 2 - FUEL
F4GE N ENGINES
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 8
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.
Base - May 2010
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F4GE N ENGINES
SECTION 2 - FUEL
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 and separation of water from fuel. On the filter cartridge base (4) there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing (1) for those equipment applications requiring it (cold climate areas), there can be a heater assembled to (2) and a temperature sensor (5).
Figure 9
88210
1. Fuel filter bearing - 2. Filter cartridge - 3. Bleender vent screw.
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12
SECTION 2 - FUEL
F4GE N ENGINES
4-CYLINDER ENGINES WITH DELPHI ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) - Priming pump, assembled to the engine and driven by the camshaft - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed rotary pump - Injector feed pipeline (from fuel feed pump to injectors) - Injectors
Figure 10
127132
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Connector for LDA pressure gauge pipe within suction collector - 4. Fuel feed rotary pump - 5. Electro-valve - 6. KSB thermal bulb - 7. KSB Sensor - 8. Injector.
Base - May 2010
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F4GE N ENGINES
SECTION 2 - FUEL
13
Figure 11
127134
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Description of working principles Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft. Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the transfer pump. (For applications to be equipped in cold climate areas, the fuel filter is provided with heater).
The fuel arrives therefore to the valve gauging the pressure inside feed pump. The distribution plunger further increases this pressure and delivers fuel throughout the delivery pipe fitting to the injectors. The fuel drawing from the injectors is recovered and delivered to the tank again.
Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase fuel pressure in correspondence with the increase of the number of revolutions.
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14
SECTION 2 - FUEL
F4GE N ENGINES
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 12
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.
Base - May 2010
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F4GE N ENGINES
SECTION 2 - FUEL
15
FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage.
Figure 13
127131
1. Bleed screw - 2. Fuel filter bearing- - 3. Filter cartridge - 4. Water dump screw.
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Base - May 2010
16
SECTION 2 - FUEL
Base - May 2010
F4GE N ENGINES
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
1
SECTION 3 Industrial application Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . .
5
F4GE ENGINE CHARACTERISTICS . . . . . . . . . . . .
6
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . .
6
F4GE ENGINE CHARACTERISTICS . . . . . . . . . . . .
7
- 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . . .
7
- 6-cylinder engines . . . . . . . . . . . . . . . . . . . . . . .
9
PART ONE - MECHANICAL COMPONENTS . . .
11
OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP . . . . . . 13 - Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 - Disassembly of application components . . . . . .
14
- Installation of rear components . . . . . . . . . . . .
23
- Installation of rear components with reduced distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
- Flywheel installation . . . . . . . . . . . . . . . . . . . . .
28
- Installation of front components . . . . . . . . . . . .
28
- Timing of additional masses . . . . . . . . . . . . . . .
30
- Assembly of additional masses . . . . . . . . . . . . .
30
- Completion of engine re-assembly . . . . . . . . . .
39
- Rotary feed pump disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
- Power take-off disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
- Feed system bleed procedure . . . . . . . . . . . . . .
43
- Checks and controls . . . . . . . . . . . . . . . . . . . . .
44
OVERHAUL OF THE 6 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP . . . . . . 45 - Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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Base - May 2010
2
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Page
Page
- Removing components from application . . . . .
46
- Flywheel installation . . . . . . . . . . . . . . . . . . . . .
55
- Installation of front components . . . . . . . . . . . .
56
ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES WITH ROTARY PUMP) . . . . . . . . . . . . . . . . . . 105
- Completion of engine re-assembly . . . . . . . . . .
66
- Cooling liquid temperature sensor . . . . . . . . . .
106
- Checks and inspections . . . . . . . . . . . . . . . . . . .
66
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
- Rotary feed pump disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- KSB Water temperature sensor . . . . . . . . . . . .
106
67
- Feed system bleed procedure . . . . . . . . . . . . . .
- Electromagnets assembled to feed pump . . . . .
107
70 - Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . .
107
PART TWO ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . .
103
- Power take-off disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107
- Checks and controls . . . . . . . . . . . . . . . . . . . . .
71
- Pre-post heating resistor . . . . . . . . . . . . . . . . . .
107
REVIEW OF 4-CYLINDER ENGINE WITH DELPHI PUMP . . . . . . . . . . . . . . . . . . . . . . . . .
72
ELECTRICAL COMPONENT LAYOUT (6 CYL. ENGINES WITH ROTARY PUMP) . . . . . . . . .
108
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
- Cooling liquid temperature sensor . . . . . . . . . .
109
- Engine setting operations for the assembly on turning stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
- KSB Water temperature sensor . . . . . . . . . . . .
109
- Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . .
110
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110
- Pre-post heating resistor . . . . . . . . . . . . . . . . . .
110
ELECTRICAL COMPONENT LAYOUT . . . . . . . . .
111
4 CYLINDER ENGINE WITH DELPHI PUMP . . . .
111
- Cooling liquid temperature sensor . . . . . . . . . .
112
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
- Cooling liquid temperature sensor . . . . . . . . . .
112
- Electromagnets assembled to feed pump . . . . .
113
- Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . .
113
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
PART THREE - TROUBLESHOOTING . . . . . . . . .
115
- Disassembly of application components . . . . . .
73
- Installation of rear components . . . . . . . . . . . .
81
- Flywheel installation . . . . . . . . . . . . . . . . . . . . .
84
- Installation of front components . . . . . . . . . . . .
85
- Assembly of additional masses . . . . . . . . . . . . .
86
- Timing of additional masses . . . . . . . . . . . . . . .
87
- Completion of engine re-assembly . . . . . . . . . .
96
- Rotary feed pump disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
- Power take-off disassembly and assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100
- Feed system bleed procedure . . . . . . . . . . . . . .
100
- Checks and controls . . . . . . . . . . . . . . . . . . . . .
101
Base - May 2010
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
3
Page PART FOUR - MAINTENANCE PLANNING . . . .
123
MAINTENANCE PLANNING . . . . . . . . . . . . . . . .
125
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125
- Planning of controls and periodical intervention
125
- Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 MAINTENANCE PROCEDURES . . . . . . . . . . . . . .
125
- Checks and controls . . . . . . . . . . . . . . . . . . . . .
126
- Engine oil level check . . . . . . . . . . . . . . . .
126
- Check of fuel system . . . . . . . . . . . . . . . .
127
- Cooling system check . . . . . . . . . . . . . . .
127
- Lubricating system check . . . . . . . . . . . . .
127
- Check of water presence within fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . .
127
- Check of drive belt tensioning . . . . . . . . .
128
- Check of belt’s tear and wear status . . . .
128
- Check and setting of tappet clearance . . .
128
- Oil motor and filter replacement . . . . . . .
128
- Fuel filter replacement . . . . . . . . . . . . . . .
129
- Alternator belt replacement . . . . . . . . . . .
130
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Base - May 2010
F4GE N ENGINES
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
5
GENERAL INFORMATION Figure 1
116390
NEF engines have been designed and developed by FPT specifically for transportation by land and farming equipment in general. They are characteristed by diesel cycle 4 stroke atmospheric or supercharged 4 and 6 cylinders each with 2 valves. Feed is provided by rotary mechanical pump or on line according to the equipment application. It differs from other applications because of the provision of different power, power take-off for the different collector configuration, priming pump, oil pan and boost turbine.
NOTE The picture shows application designed for 6 cylinders version, 2 valves per cylinder, having fuel feed mechanical pump.
NOTE Data, technical specifications and performances granted shall be valid only if the Setter will follow and comply with all installation prescriptions provided by FTP. Furthermore, the expanders assembled by the Setter must always comply with couple, power and number of revolutions based on which the engine has been designed. The section herein described is composed or four directories: - directory of mechanical overhaul prescribed in accordance to the engine’s specific duty, illustrating all necessary operations to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover; - electrical directory, describing the connections of the different components, of the pre-post heating gearbox (only for some versions) and of the sensors assembled to the engine; - troubleshooting directory; - directory of preventive and regular maintenance operations, providing instructions for the execution of the main operations.
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6
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
F4GE ENGINE CHARACTERISTICS 4-cylinder engines
F4GE9454H* Type
J601
ρ
Compression ratio
J600
J603
J605
17.5:1
Max. output
kW (HP) rpm
Max. torque
Nm (kgm) rpm
74 (100) 2000 400 (40) 1250
410 (43) 1400
Loadless engine idling
rpm
-
-
Loadless engine peak rpm
rpm
-
-
Bore x stroke Displacement
mm cm3
SUPERCHARGING Turbocharger type LUBRICATION
bar
J602
104 X 132 6728 without intercooler HOLSET HX25 Forced by gear pump, relief valve single action oil filter
Oil pressure (warm engine) - idling - peak rpm
bar bar
COOLING Water pump control Thermostat - start of opening ºC
0.70 3.50 By centrifugal pump, regulating thermostat, heat exchanger, intercooler Through belt 81 ± 2
FILLING 15W40 ACEA E3
!
NOTE
engine sump* liters engine sump + filter* liters * First filling operation
13 14
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.
Base - May 2010
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
7
F4GE ENGINE CHARACTERISTICS 4-cylinder engines
Type
ρ
F4GE9454J*J6
Compression ratio
17.5:1
Max. output
kW (HP) rpm
66 (90) 2000
Max. torque
Nm (kgm) rpm
375 (37,5) 1250
Loadless engine idling
rpm
-
-
Loadless engine peak rpm
rpm
-
-
Bore x stroke Displacement
mm cm3
SUPERCHARGING Turbocharger type LUBRICATION
104 X 132 6728 without intercooler HOLSET HX25 Forced by gear pump, relief valve single action oil filter
Oil pressure (warm engine)
b ar
- idling - peak rpm
bar bar
COOLING Water pump control Thermostat - start of opening ºC
0.70 3.50 By centrifugal pump, regulating thermostat, heat exchanger, intercooler Through belt 81 ± 2
FILLING 15W40 ACEA E3
!
NOTE
engine sump* liters engine sump + filter* liters * First filling operation
13 14
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.
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8
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Type
ρ
F4GE9484 J*J602
Compression ratio
D*J6 17.5:1
Max. output
kW (HP) rpm
88 (120) 2200
93 (126) 2200
Max. torque
Nm (kgm) rpm
515 (52,5) 1250
525 (51,0) 1250
Loadless engine idling
rpm
-
Loadless engine peak rpm
rpm
-
Bore x stroke Displacement
mm cm3
SUPERCHARGING
Turbocharger type LUBRICATION
104 X 132 4485 with intercooler HOLSET HX25 Forced by gear pump, relief valve single action oil filter
Oil pressure (warm engine)
ba r
- idling - peak rpm
bar bar
COOLING Water pump control Thermostat - start of opening ºC
0.70 3.50 By centrifugal pump, regulating thermostat, heat exchanger, intercooler Through belt 81 ± 2
FILLING 15W40 ACEA E3
!
NOTE
engine sump engine sump + filter
liters
-
liters
-
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.
Base - May 2010
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
9
6-cylinder engines
F4GE9684 Type
A*J6
ρ
Compression ratio
17.5:1
Max. output
kW (HP) rpm
129 (175) 2200
Max. torque
Nm (kgm) rpm
770 (77) 1250
Loadless engine idling
rpm
-
Loadless engine peak rpm
rpm
-
Bore x stroke Displacement
mm cm3
104 X 132 6728
SUPERCHARGING
with intercooler
Turbocharger type
HOLSET HX35
LUBRICATION
bar
Forced by gear pump, relief valve single action oil filter
Oil pressure (warm engine) - idling - peak rpm
bar bar
COOLING Water pump control Thermostat - start of opening ºC
0.70 3.50 By centrifugal pump, regulating thermostat, heat exchanger, intercooler Through belt 81 ± 2
FILLING 15W40 ACEA E3
!
NOTE
engine sump* liters engine sump + filter* liters * First filling operation
15 16
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.
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Base - May 2010
10
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
F4GE9684P* Type
J601
ρ
Compression ratio
J602 17.5:1
Max. output
kW (HP) rpm
98 (133) 2200
Max. torque
Nm (kgm) rpm
590 (60) 1250
Loadless engine idling
rpm
-
Loadless engine peak rpm
rpm
-
Bore x stroke Displacement
mm cm3
104 X 132 6728
SUPERCHARGING
with intercooler
Turbocharger type
HOLSET HX35
LUBRICATION
Forced by gear pump, relief valve single action oil filter
Oil pressure (warm engine)
b a r
- idling - peak rpm
bar bar
COOLING Water pump control Thermostat - start of opening ºC
0.70 3.50 By centrifugal pump, regulating thermostat, heat exchanger, intercooler Through belt 81 ± 2
FILLING 15W40 ACEA E3
!
engine sump* liters engine sump + filter* liters * First filling operation
15 16
Use STANDARD fuel compliant to the EN 590 (2005/55 - 2005/78). Refuelling from drums or tanksmay result in pollution of the diesel fuel, with the risk of damage to the injection system; if necessary, filter the fuel in a suitable manner or allow sedimentation of the impurities before refuelling.
NOTE
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.
Base - May 2010
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
11
PART ONE - MECHANICAL COMPONENTS
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
OVERHAUL OF THE 4 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface
13
Figure 3
Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well. NOTE With regard to the engine disassembly operations, please apply for information consulting the specific manual. All operations of engine disassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. The following information relate to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties. NOTE For specific application exigencies, some units can be assembled to the engine in different positions. Within ”General overhaul” section, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.
Engine setting operations for the assembly on turning stand
164006
- disassemble lubrication oil exhaust pipe from the turbo-blower: Underneath the turbo-blower loosen the two screws (1), loosen the screw (2) fixing the pipe throughout the stop collar (3) fixing the block; finally loosen and remove the union (5) from the block; plug the pipe ends and the exhaust of the turbo-blower.
Figure 2
Figure 4
3
164007
In order to apply the brackets 99361037 to the engine block to fix it on to the stand 99322205 for the overhaul, it is necessary to perform the following operations: On the right hand side: - disassemble the oil filter (1) from the support using tool 99360076; 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.
2
1 75672
- Disassemble the starter; Properly hold the starter (1) and loosen the fixing screws (2); - assemble the bracket bearing 99361037 using the four screw threaded ports (3).
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14
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 5
Figure 7
1
75674
From the left-hand side: - Assemble the second bracket 99361037 throughout the screw-threaded ports (1). - Lift the engine using the rocker arm 99360595 and put it on the turning stand 99322205. - Drain the oil through the cap underneath the plug.
116387
- Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. Carry out complete drainage of the fuel contained therein. - Screw out completely the faucet and, using equipment 99360076 disassemble oil filter (2).
Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.
Disassembly of application components
- Disconnect fuel pipelines (4 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump. - Remove the fuel filter bearing (1) from the bracket fixed to the engine head.
Figure 8
Figure 6 1
75675 70126
Proceed disassembling the supercharger: - loosen the fixing nut (1) and remove the lubrication pipe from the supercharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger. - Loosen the screw nuts fixing the supercharger on the exhaust manifold. - Hold up the supercharger and after lifting it remove the gasket.
Base - May 2010
NOTE To disconnect fuel pipelines (2 and 3, Figure 7), in low pressure from the relating pipe fittings, it is Necessary to press the locking fastener (1) as shown in picture B. After having disconnected the pipeline, reset the locking fastener (1) in lock position as shown in. picture A, to avoid any possible deformation of the fastener itself. Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
BOSCH VE 4/12 F Pump
15
Figure 10
Figure 9 1
1
2 1
75679 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.
- Disconnect the pipelines (1) and (2) that provide feed and fuel recovery between pump and injectors; screw out the nuts fixing the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery pipeline; loosen the screws holding the fixing brackets of such pipelines (1,6, and 7, Figure 11); pipe the pipeline ends. - Disassemble the injectors and remove them from their slot: remove the gaskets.
Figure 11
1
2 3 7
4 6
5
75680
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). Print P2D32N003 E
Base - May 2010
16
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 12
Figure 14
87409 88102
- Loosen the two fixing screws (2) and disassemble priming pump (1).
- Disassemble suction and exhaust manifolds: loosen the 8 screws (1) fixing the suction manifold plate to the cylinder head (two of them have already been screwed-out since fixing the pipe brackets to the injectors); from the exhaust manifold side; loosen the (2) fixing screws; remove the gaskets.
Figure 13
Figure 15 2
87406
- Remove tappet caps: Loosen the four fixing screws (1) and lift the caps (2); remove the gaskets.
1 75683
NOTE On the central cap there is a blow-by valve for the lubrication oil vapours. All the gaskets shall always be replaced during assembly.
- Disassemble rocker arm bearings; loosen the two fixing screws (2) and remove the complete rocker arm bearing; withdraw tappet rods. Repeat the operation for all the remaining rocker arm bearings. - Disassemble water temperature transmitter (1).
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
17
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 16
Figure 18
1
2
117588
- Disassemble thermostat unit; loosen the three fixing screws (1) and disassemble the thermostat unit (2) together with the bracket (3); remove the gasket (4) and the thermostat (5). - Assemble the bracket in the original position fixing it with the screws of the thermostat unit.
75686
- Properly hold the alternator (1) separating it from its bearing by loosening the screw (2); remove screw nut and washer.
Figure 19 Figure 17
88091 88089
- Loosen screw (1) and relevant nut on belt stretcher bracket (3). - Loosen screw (2, Figure 18) in order to slide out POLY-V belt (2). - Remove the belt stretcher bracket (3). - Disassemble the driven pulleys and the guide rollers.
Print P2D32N003 E
- Loosen the screws (1) and withdraw the alternator bearing (2).
NOTE The shape and the dimensions of the support of the alternator vary according to the use of the engine. The relevant pictures provide a general trace of the intervention that is to be carried out. The procedures described are always applicable.
Base - May 2010
18
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 20
Figure 22 2
1
3 4
75692
75810
- Loosen the screws (4) and disassemble the oil pressure/temperature sensor (3) (if fitted). - Loosen the screws (1) and disassemble the oil filter/heat exchanger bearing (2), interlayer plate (6) and relating gaskets.
- Use the tool 99360339 (2) to operate on the flywheel cover box (1) in order to block flywheel rotation (3). (Utilise starter holding down studs and fixing screw nuts). - Loosen the flywheel fixing screws (4) to engine drive shaft.
- Disassemble oil level sensor (5) (whether provided). - Disassemble injection pump (see specific procedure) and the power take-off underneath.
NOTE In some versions there is provided 99360351 tool checking the flywheel.
Figure 21 1 2
3
Figure 23
4 75688
- Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.
90504
- Loosen the screws (1) and disassemble the pulley (2). Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
19
Figure 26
Figure 24
116242
- Loosen the screws (1 and 3) and remove the front cover (2). 78256
- Remove the engine drive shaft fixing ring from the front cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3).
NOTE Take note of the screw (1 and 3) assembly position, since the screws have different length.
Figure 27
75811
Figure 25
- Loosen the screws (1) and remove oil pump (2). Figure 28 1
2
4 3 75691
00904t
- Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1). Print P2D32N003 E
- Screw out the opposite screws (1) from the ports where the withdrawal pins shall be introduced (see picture following). - Loosen remaining flywheel fixing screws (3) to the engine drive shaft (4). - Remove the flywheel block tool (2). Base - May 2010
20
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 29 1
Figure 31 4
2
3 70153
75690
- Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.
- Loosen the screws (2) and remove the flywheel cover box (1). NOTE Take note of the screw (1) assembly position, since the screws have different length. Figure 32
Figure 30
00903t
- Remove the flywheel cover box fixing ring using the tool 99340056 (3) to operate on the back tang (5) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring using Ø 3,5 mm drill for a 5mm depth. - Fix the tool 99340056 (3) to the ring (1) tightening the 6 screws specially provided (4). - Proceed with drawing the ring (1) tightening the screw (2). - Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring of the flywheel cover box.
Base - May 2010
88046
- Turn the engine upside-down. - Loosen the screws (2), disassemble the plate (3) and remove the oil pan (1). NOTE The shape and dimensions of the pan and of the rose pipe may vary according to the engine application. The relating illustrations provide general guidelines of the operation to be performed. The procedures described are applicable anyway. Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Version with suction rose type A
21
Figure 36
Figure 33
99222
- Loosen the screws (1) and disassemble the oil suction rose pipe (3). - Loosen the screws (2) and remove the stiffening plate (4). Version with suction rose type B Figure 34
90505
- Loosen the screws (1) and disassemble the gear from the camshaft (2).
86601
Figure 37
- Remove the screws (1) and (4) and disassembled the suction rose (5). - Remove the screws (2) and disassemble the stiffening plate (3) Version with additional masses Figure 35
70157
- Loosen the screws (2) and disassemble the timing gearbox (1).
86578
By means of pin (1) lock the additional masses (2) in the P.M.S. Loosen the fixing screws (3) and remove the additional masses (2). Print P2D32N003 E
NOTE Take note of the screw (2) assembly position, since the screws have different length.
Base - May 2010
22
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Version with reduced distribution
Figure 40
Figure 38
87424
87422
- Loosen the screws (2) and remove the flywheel cover box (1).
- Remove the screws (1) and disassemble the gears (3) and (4) from the camshaft (2).
NOTE Take note of the screw (2) assembly position, since the screws have different length.
Figure 39
87655
- Remove the gear (1) transmitting motion to the ignition pump and the relevant support.
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Installation of rear components
Figure 42 1
Figure 41
9
10
6 4
8
3
2
1 7
5
1
75711 75712
DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION WITHIN GEARBOX AREAS - Accurately clean the timing gearbox (1) and the engine block.
!
23
It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones.
DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX - 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 locking couples listed here below, following the order as shown in the picture. Screws M12 Screws M8 Screws M10
65 ÷ 89 Nm 20 ÷ 28 Nm 42 ÷ 52 Nm
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages.
Figure 43
Couplings must be assembled within 10 minutes after completing the sealing operation.
70211
- With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the upright surface on which a groove has been created for the ignition timing. NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.
Print P2D32N003 E
Base - May 2010
24
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 44
Figure 46
90508 90506
- Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).
- Tighten the screws (1) fixing the gear to the camshaft (3) and lock them to the prescribed couple.
Figure 47
Figure 45
90507
1 75708
- Position comparator (1) on timing system gear (2) and check that the clearance between gears (2) and (3) is within 0.076 ÷ 0.280 mm range. Base - May 2010
DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION. Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal.
25
Figure 49
Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. Couplings must be assembled within 10 minutes after completing the sealing operation.
0901t
- Apply to engine drive shaft rear tang (6), the detail (5) of the tool 99346253, 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 the flywheel cover box (7). Figure 48 1 16
Figure 50
15 14
8
17
7 1
6 18
2
13 5
12
19 20
11 1
2 21 4
9
10
3 75709
DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX. - Reassemble the box (1) to the engine block, tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below, following the order as shown in the picture. Screws M12
75 ÷ 95 Nm
Screws M10
44 ÷ 53 Nm
!
75696
- Check the contact surface (1) of the clutch plate and if it is scratched, proceed with turning. - Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.
Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Print P2D32N003 E
Base - May 2010 Revi - September 2012
26
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Installation of rear components with reduced distribution
Figure 53
Figure 51
87653
70211
- With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the upright surface on which a groove (3) has been created for the ignition timing.
- Place the dial gauge (1) on the timing gear (2) and check that the slack between the gears (2) and (3) is included in the range between 0,076 ÷ 0,280 mm. Figure 54
NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.
Figure 52
87654
- Fit the screws (1) fastening the gears (2) to the camshaft (3) and tighten them to the prescribed pair. Figure 55
116375
- Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).
87655
- Spline the gear (1) transferring motion to the ignition pump. Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 56
27
Figure 58
87656
- Fit the power take-off gear (2) (if available) into the specially provided housing and fasten the screws (1),
87658
- Re-assemble the box (1) to the engine basement. - Tighten the fastening screws (2) to the same position detected before disassembly.
Figure 57 NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Figure 59
87657
DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. Couplings must be assembled within 10 minutes after completing the sealing operation.
Print P2D32N003 E
87659
- Apply to the rear tongs hold (3) of the engine drive shaft the part (6) of the tool 99346253, fix it with the screws (1) and spline the new tight ring to it (2). - Place the part (5) on the part (6), tighten the nut (4) until tight ring assembly (2) into the flywheel box is completed.
Base - May 2010
28
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Flywheel installation
Installation of front components
Figure 60 1
Figure 63 4
2
3 75690
- Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling . - Using a hoist, handle the flywheel to place it in its housing inside the flywheel cover box. - Screw up to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine flywheel (1) properly placing it inside the flywheel cover box. Figure 61 2
70220
- Assemble oil pump (1). - Tighten fixing screws (2) and lock them to the prescribed couple. Figure 64
1
3 4
75692
- Tighten the screws (4) fixing the engine flywheel (3) to the engine shaft. Use tool 99360339 (2) to operate on the flywheel cover box (1) to block engine flywheel rotation. Figure 62 1
70221
- Apply to the water pump (1) a new fixing ring (2).
Figure 65
α 2
75695
Tighten the engine flywheel (1) fixing screws (2) in two phases: - 1st phase; tightening by means of dynamometric wrench to couple 30 ± 4 Nm; - 2nd phase, 60º ± 5º angle dwell with tool 99395216. NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Base - May 2010
76112
- Assemble the water pump (1). - Tighten the screws (2) and lock them to the prescribed couple. Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 66
29
Figure 69
106549
- Remove the fixing ring (2) from the front cover (1), accurately clean the plug surface. Figure 67
00902t
- Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252, 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. Figure 70
87260
75710
- Accurately clean the contact surface of engine block and apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs.
- Assemble the plate (1), the rose pipe (2), tighten the fixing screws (3) and fix them to the prescribed couple. Figure 71
Figure 68
86601 106550
- Assemble the front cover (2) to the block and tighten the screws (1) fixing them to the prescribed couple. Print P2D32N003 E
- Assemble the plate (3), the suction rose (5) and tighten the fixing screws (1, 2 and 4) to the prescribed torque. Base - May 2010
30
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Fit the additional masses (2) and tighten the screws (3) on the engine block.
Assembly of additional masses Figure 72
Remove the lock pin (1) of the additional masses.
86578
Timing of additional masses Version with reduced distribution Match the signs (A) engraved on the gears for timing, insert the pin in the hole (B) on the balancing mass. Figure 73
86614
1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) 4. Additional masses. Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
31
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
zs
Figure 74
Figure 76
- Provide for new gasket replacement (1) of the oil pan (2).
3
NOTE The pictures illustrating the pan and of the rose pipe may not correspond to the ones of your model. However the procedures described are applicable anyway. Figure 75
1
2 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
75814
- Assemble oil pan (1), apply the plate over it (2). Tighten the screws (2) and lock them to the prescribed couple.
- Assemble the following elements to the block: new gasket (1), heat exchanger (2), new gasket (3), oil filter bearing (4). Tighten the screws (5) and lock them to the prescribed couple.
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
88046
Print P2D32N003 E
Base - May 2010
32
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
zs
Figure 78
Figure 80
1
2
76113
- Lubricate the fixing ring (2) using engine oil and place it on 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.
75686
- Connect the alternator (1) to the support. - Tighten the screw without locking it (2).
- 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 the bearing (1) tightening the fixing screws to the prescribed couple. Figure 79 Figure 81
76114
- Assemble the alternator bearing (1) ensuring that the pins (3 and 4) are against the engine block. - Tighten the screws (2) and lock them to the prescribed couple. NOTE The shape and the dimensions of the alternator support vary according to the use of the engine. Therefore the relevant pictures provide a general guideline of the intervention that is to be carried out. However the procedures described are applicable.
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Base - May 2010
87759
- Place the gasket (1) over the block. The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface.
NOTE Verify that the engine block stand is clean. Do not grease the gasket. It is recommended to keep the gasket inside packaging until assembly to the cylinder head. Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture.
Print P2D32N003 E
F4GE N ENGINES
33
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 82
Figure 84
1
4
2
1 3
3
2 2 3
1
75705
4 75688
- Place the head (3) over the block and insert screws (1) and (2).
- Carry out the assembly of the rocker arms after previous check of the components.
NOTE If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.
ROCKER ARM UNIT COMPONENTS: 1. Elastic ring - 2. Spacer- 3. Rocker arms4. Support.
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
Figure 85
18.975 18.963
D1
75703
19.000 19.026
Figure 83
19.000 19.026 75704
SHAFT AND ROCKER ARM BASIC DATA 10
4
1
5
13
7
2
8
11
Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary.
α 9
3
6
14
Figure 86
12
1 76115
- Lubricate cylinder head bolts and install to head. - Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. Then a further 90 degrees for the M12 x 140 and M12 x 180. M12 x 70 M12 x 140 M12 x 180 Print P2D32N003 E
50 Nm + 90 deg’s 40 Nm + 180 deg’s 70 Nm + 180 deg’s
19.00 16.00 75702
ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the i 0.4 - 0.6 Nm couple. Base - May 2010
34
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 87
Figure 89
2
1
32655
75683
Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable.
- Tighten the screws (2) to the prescribed couple and assemble water temperature sensor (1). Figure 90
2
1 3
Figure 88
D2
D1
75703
- Insert the tappet driving rods and the Rocker Arm unit. Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced;
75806
Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Correct slack is: - suction valves 0.25 0.05 mm - exhaust valves 0.50 0.05 mm. NOTE On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 91
35
Figure 93
1
2 1 75808
75707
- Assemble injectors after having replaced the sealing gasket (1). NOTE During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing.
- Assemble exhaust manifold (1) providing new gaskets (2). NOTE The illustration of exhaust manifold may be not matching your model. Anyhow, described procedure is applicable.
Figure 92
Figure 94
117588 87406
- Assemble cylinder covers (2) with the respective gaskets; - Fit the seal nods and tighten the screws fixing them to the prescribed couple.
NOTE Always replace the gaskets using new ones.
- Assemble thermostat unit (2) including thermostat (5) and gasket (4). - Tighten the screws to the prescribed couple.
NOTE The screws (1) have been have been utilised to fix the bracket (3).
Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit.
Disassemble the bracket and reassemble components from 1 to 5 as shown in the picture.
Seal nods shall have no visible deformation. In such case provide for replacement with new nods.
The gasket must be new.
Print P2D32N003 E
Base - May 2010
36
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 95
Figure 96 2
3
88090
1
- Tighten the control belt turning the alternator as illustrated. - Tighten the screws (1) and the alternator fixing bolt to the support.
75687
Figure 97 - Assemble the pulley fan bearing tightening the screws to the prescribed couple.
1
- Assemble the alternator tensioning bracket.
2
7
- Mount pulley (3) and secure it to support through screws (2).
6
- Assemble the transmission pulley (1).
5
- Fit the new belt onto the pulleys and guide rollers.
4 3
NOTE If the old belt is to be reassembled examine it carefully in order to see if there may be incisions or evident signs of yielding.
75701
- Apply on the surface joining the suction manifold plate (1) a sufficient coat of Loctite 5999 and provide. fixing the screws to the prescribed couple. - If the pipe (6) of the suction manifold plate (1) has been removed, reassemble it after having fit a new gasket (5). - Tighten the screws (7) to the prescribed couple.
NOTE For the versions provided with heater, also assemble components (3) and (4).
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 98
37
Figure 99
2 1
88102
- Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple. - Also assemble feed pump (see specific procedure) and the power take-off underneath.
NOTE Pump mounting requires specific procedure contained in this section. 75700
- Assemble the brackets (1) fixing the fuel pipelines to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture. BOSCH VE 4/12 F pump Figure 100
1
2 3 7
4 6
5
75680
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). Print P2D32N003 E
Base - May 2010
38
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 101
1
Figure 103
1
2
75679
- Assemble the pipes (1) and (2) providing fuel feed and recovery between pump and injectors; Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold; fix the pipes to the injectors throughout the brackets previously assembled.
116387
- Assemble the fuel filter bearing (1) to the bracket fixed to the engine head. - Connect the fuel pipelines (4 and 3) respectively from priming pump to filter bearing and from this last one to feed pump. - Using 99360076 equipment assemble fuel filter (2). NOTE The filter shall be priory filled with fuel to facilitate feed system bleed operations.
Figure 104 Figure 102
1
70126
75677
- Fix the LDA pipeline (1) to the engine head and to the feed pump.
Base - May 2010
NOTE To connect fuel pipelines (3 and 4, Figure 103) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B. After having connected the pipeline, reset the fastener (1) into block position as shown in picture A.
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
39
Completion of engine re-assembly
Figure 105
Figure 106
1
75675
Proceed assembling the turbocharger: - Hold the turbocharger and place it on the exhaust manifold after having interposed the gasket. - Screw up the fixing nuts of the turbocharger to the exhaust manifold tightening them to the prescribed couple. - Tighten the lubrication pipe fixing ring. Operate in the same way on the other end of the pipe. Connect it to the upper part of the heat exchanger. To complete engine assembly it is necessary to remove it from the turning stand. - Using rocker arm 99360595 hold the engine and loosen the screws fixing the brackets to the turning stand 99322205. - Disassemble the brackets 99361037 from the engine after having properly put it on a wooden bearing.
164004
From the right-hand side: - Re-assemble the lubrifying oil discharge pipe (6) from the turbo-blower by inserting the joint (5) into the engine crankcase and tightening the two fastening (1) screws underneath the turbo blower; - Tighten the screw (2) which holds the piping to the (6) monoblock by means of the cylinder bracket (3); - Re-assemble the oil filter (4) onto the heat exchanger with tool 99360076;
Figure 107
1
75717
- re-assemble the starting engine (1); opportunely support the starting engine (1) and tighten the two fastening screws to the prescribed torque.
Print P2D32N003 E
Base - May 2010
40
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Rotary feed pump disassembly and assembly procedure
In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part.
NOTE This procedure prescribes that:
On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine and disassemble it only afterwards.
- the fuel pipes (from the pumping elements to the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed; - the electrical disconnected.
connections
have
been
- Accelerator cable shall be disconnected.
The following procedure analyses this second hypothesis since it is the more complex. Find the top dead centre with the tool (99395097) - False injector Figure 110
Engine versions with tool (99360330) Figure 108
1 88141
1
88140
Disassemble the starter from the flywheel box and use tool 99360330 to rotate the flywheel. Engine versions with tool (99360339)
Remove the rocker covers of the 1st cylinder; remove the 1st injector and place the tool (1) to set the 1st cylinder top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed. Once PMS has been obtained, lock the flywheel by means of tool 99360339 (Figure 109). Searching for the top dead centre with timing gear blocking pin Figure 111
Figure 109
2
1
75714 84071
Disassemble the starter from the flywheel box (1) and use tool 99360339 (2) to rotate the flywheel. Base - May 2010
Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2) obtaining the TDC of the 1° cylinder. Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
41
zs
BOSCH VE 4/12 F Pump
Figure 114
Figure 112
1
2
1
75694 75721
- Unscrew the side screw that locks the pump shaft partially (1) and remove spacer (2). This must be kept on a side (we recommend to fix it on the pump with a wire or a clip). - Tighten the lateral screw (1) blocking rotation of the pump shaft. Figure 113
1
- From the pump side, loosen the fixing nuts (1) without removing them in order to enable moving the pump backwards using 99340035 extractor. - Assemble the 99340035 extractor throughout the two threaded ports (4, Figure 113) and withdraw the gear from the pump shaft. - Properly hold the feed pump and loosen completely the fixing nuts. - Withdraw the pump from the studs, together with the gasket.
4
When the supply pump is to be assembled on the engine the P.M.S. conditions at compression end stage cylinder No. 1 must be carried out.
NOTE Hold the pump driving gear to avoid interference or crawling during timing gear rotation.
2
3 75693
- From timing side, remove the cover (2) loosening the screws (1) in order to have access to the union fixing nut (3) to the pump driving gear. - Loosen the fixing nut (3) and remove the relating washer.
Print P2D32N003 E
Base - May 2010
42
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
zs
Figure 115
Figure 117
1
1
2
75721
75694
- Assemble the pump pre-set in its housing on the engine, fitting the shaft into the gear port (not provided with wrench). - Tighten the fixing nuts (1) locking the pump flange in the slot centre.
NOTE The gasket removed during pump disassembly shall not be utilised again. Always use original spare parts.
- Loosen screw (1) that prevents pump shaft rotation and insert spacer (2). Tighten screw (1)so that it locks spacer (2): in this way the supply pump shaft will be able to rotate freely. - Assemble the cover (2, Figure 116) including gasket and tighten the screws (1, Figure 116). - Disassemble the flywheel rotation/locking tool 99360339 or 99360330; arrange the starting motor in its seat. - Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump). - Connect electrical connections to electro-magnets on the hydraulic head and on KSB. NOTE If the pump has been removed with the engine mounted, connect the accelerator cable, if present in the application. Ignition pump control and timing Figure 118
Figure 116
1
4
2
3 75715
- On the timing side, throughout the specially appointed port, fit the washer and screw up the fixing nut (3) to the pump shaft. Lock the nut to the 90-95 Nm couple.
Base - May 2010
(Demonstration)
87720
- With the injection pump inserted in relating seat and securing screws loosened, mount comparator 99395603 (2) and 99395100 gauge tool (1), preloading the rod by 2.5 mm. - Rotate the engine derive shaft to shift from the condition of the first cylinder to TDC end of compression phase. Reset the dial gauges and rotate the engine drive shaft into the opposite direction until recovering the condition of the 1st cylinder to TDC in phase of compression (see Figure 111). From this position on the comparator applied on the pump it must be possible to read the value listed on the pumping element pre-lift table. Section 4. - Rotate the pump in anti-clockwise direction if the stroke is shorter or in clockwise direction if the stroke is longer, until obtaining the stroke prescribed. - Checking these conditions, lock the pump by tightening the relevant nuts to the prescribed pair. Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Feed system bleed procedure
Power take-off disassembly and assembly procedure
Version with B type fuel filter Figure 119
43
Figure 120
(Demonstration)
1
2
87751
4
3
75720
Where designed, there is a power take-off able to transmit motion to different auxiliary parts.
- Disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the priming pump.
Disassembly of such mechanism shall be executed as following:
- Continue the operation until when fuel outflows.
- Loosen the two screws (3) and after having removed the cover (1) with a specially provided extractor, withdraw the power take-off (2).
- Connect the (1) to the filter.
- The two gaskets (4) shall be replaced in phase of reassemble. - Vary out the assembly fitting the power take-off in its housing, providing new gasket and checking the sprocket gear meshing. - Assemble cover and gasket and tighten the screws to the prescribed couple.
Print P2D32N003 E
Base - May 2010
44
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Checks and controls
!
The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.
Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:
- There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings. - Carefully check the fuel connection pipes to the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings. - 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 the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection. - Check and blow by with care the engine cooling system, carrying out frequent drainage.
Base - May 2010
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F4GE N ENGINES
45
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
OVERHAUL OF THE 6 CYLINDER ENGINE PROVIDED WITH MECHANICAL ROTARY PUMP Preface
Figure 122
Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well. NOTE With regard to the engine disassembly operations, please apply for information consulting the specific manual. All operations of engine disassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. The following information relate to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties. NOTE For specific application exigencies, some units can be assembled to the engine in different positions.
Within ”General overhaul” section, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described.
76147
- Assemble the bracket bearing 99361037 using the four screw threaded ports (1).
Figure 123
Engine setting operations for the assembly on turning stand Figure 121
76145
- Assemble the second bracket 99361037 throughout the screw-threaded ports (1). - Lift the engine using the rocker arm 99360595 and put it on the turning stand 99322205. 76146
In order to apply to the engine crankcase, the engine fixing brackets 99361037 to trestle 99322205 and to carry out an adequate revision, proceed in the following manner. From the left-hand side: - Disassemble the starting engine (1); opportunely support the starting engine (1) and unscrew the fastening screws (2).
Print P2D32N003 E
- Drain the oil through the cap underneath the plug.
Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.
Base - May 2010
46
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 125
Removing components from application Figure 124
116389
- Loosen the fixing nut (1) and remove the lubrication pipe from the supercharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger. - Loosen the screw nuts (2) fixing the supercharger on the exhaust manifold. - Hold up the supercharger and after lifting it remove the gasket. 164004
- Undo the screw (2) which holds the lubrifying oil discharge pipe (6) from the turbo-blower to the monoblock by means of the cylinder bracket (3).
Figure 126
- Undo the two fastening screws (1) of the piping (6) leading to the turbo-blower. - Remove the lubrifying (6) oil discharge pipe from the turbo-blower by undoing the junction from the (5) engine crankcase and blocking the tube ends and the turbo-blower exhaust. - Remove the oil filter by (4) using tool 99360076.
116387
Warning: the oil filter contains inside aprx. 1 kg. of engine oil. Provide tank with sufficient capacity to contain the liquid. Warning: avoid contact of engine oil with the skin: in case of skin contamination rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.
- Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. Carry out complete drainage of the fuel contained therein. - Screw out completely the faucet and, using equipment 99360076 disassemble oil filter (2). - Disconnect fuel pipelines (4 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump. - Remove the fuel filter bearing (1) from the bracket fixed to the engine head.
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 127
47
Figure 129
70126
NOTE To disconnect fuel pipelines (3 and 4, Figure 126), in low pressure from the relating pipe fittings, it is Necessary to press the locking fastener (1) as shown in picture B. After having disconnected the pipeline, reset the locking fastener (1) in lock position as shown in. picture A, to avoid any possible deformation of the fastener itself.
88143
- Disconnect the supply pipe unit from the injectors (1). - Remove fuel exhaust pipe (2) from the injectors by removing screw (4) and seal (3). Figure 130
BOSCH VE 6/12 F Pump Figure 128
76148
Figure 131
88142
- 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. - Disassemble the pipes (2) that constitute the fuel recovery and supply between the pump and the injectors.
76150
- Loosen the screws (1, Figure 130 and Figure 131) holding the fixing brackets of such pipelines; pipe the pipeline ends. Print P2D32N003 E
Base - May 2010
48
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 132
Figure 134
76149 76151
- Remove tappet caps: Loosen the fixing screws (1) and lift the caps (2); remove the gaskets. NOTE On the tappet cap there is a blow-by valve for the lubrication oil vapours. All the gaskets shall always be replaced during assembly.
- Disassemble suction and exhaust manifolds: loosen the screws (1) fixing the suction manifold plate to the cylinder head (some of them have already been screwed-out since fixing the pipe brackets to the injectors); from the exhaust manifold side loosen the (2) fixing screws; remove the gaskets.
Figure 135 2
Figure 133
1 75683
84082
- Disassemble rocker arm bearings; loosen the two fixing screws (2) and remove the complete rocker arm bearing; withdraw tappet rods. Repeat the operation for all the remaining rocker arm bearings. - Disassemble water temperature transmitter (1).
- Remove injectors (2) with tool 99340205 (1) and take out the cylinder head.
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 136
49
Figure 138
1
2
75686 88089
- Loosen screw (1) and relevant nut on belt stretcher bracket (3).
- Properly hold the alternator (1) separating it from its bearing by loosening the screw (2); remove screw nut and washer.
- Loosen screw (2, Figure 138 page 45) in order to slide out POLY-V belt (2). - Remove belt stretcher bracket (3). - Disassemble the control pipe pulleys and the guide rollers.
Figure 139 Figure 137
117588 88091
- Disassemble thermostat unit; loosen the three fixing screws (1) and disassemble the thermostat unit (2) together with the bracket (3); remove the gasket (4) and the thermostat (5). - In order to facilitate head overhauling operations at the test bench keep bracket (3) assembled on it by fixing it with the thermostat unit screws.
Print P2D32N003 E
- Loosen the screws (1) and withdraw the alternator bearing (2). NOTE The shape and the dimensions of the support of the alternator vary according to the use of the engine. The relevant pictures provide a general trace of the intervention that is to be carried out. The procedures described are always applicable.
Base - May 2010
50
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 140
Figure 142
2
1
3 70141
- Loosen the screws (4) and disassemble the oil pressure/temperature sensor (3) (if fitted). - Loosen the screws (1) and disassemble the oil filter/heat exchanger bearing (2), interlayer plate (6) and relating gaskets.
4
75692
- Apply the suitable tool (2) on the flywheel covering box (1) in order to lock flywheel (3) rotation. (use the starting motor fixing nuts and studs). - Loosen the flywheel fixing screws (4) to engine drive shaft.
- Disassemble oil level sensor (5) (whether provided). - Disassemble injection pump (see specific procedure). Figure 143
1 2 Figure 141
3
74175
- Unloose the screws (3) and disassemble the damping flywheel (2) and the pulley (1).
76152
- Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.
Base - May 2010
NOTE In some versions, the phonic wheel mounted on pulley (1) may be not present and pulley (1) can be different from the pulley shown in Figure 143.
Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 144
51
Figure 146
70148
- Remove the screws (1) and disconnect the water pump (2). - Remove the screw (3) and the roller (4). - Remove the screw (5) and disconnect the engine speed sensor (6).
00904t
- Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1).
Figure 147
Figure 145
116242
00900t
- Remove the engine drive shaft fixing ring from the front cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3).
Print P2D32N003 E
- Loosen the screws (1 and 3) and remove the front cover (2).
NOTE Take note of the screw (1 and 3) assembly position, since the screws have different length.
Base - May 2010
52
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 148
Figure 150
1
4
2
3 75811 75690
- Loosen the screws (1) and remove oil pump (2).
- Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.
Figure 149 1
2
Figure 151
4 3 75691
- Screw out the opposite screws (1) from the ports where the withdrawal pins shall be introduced (see picture following). - Loosen remaining flywheel fixing screws (3) to the engine drive shaft (4). - Remove the flywheel block tool (2).
00903t
- Remove the flywheel cover box fixing ring using the tool 99340056 (3) to operate on the back tang (5) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring using Ø 3,5 mm drill for a 5mm depth. - Fix the tool 99340056 (3) to the ring (1) tightening the 6 screws specially provided (4). - Proceed with drawing the ring (1) tightening the screw (2). - Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring of the flywheel cover box. Base - May 2010
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 152
53
Figure 154
1 9
10
6 4
8
3
2
1 7
5
75711
DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX - 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 locking couples listed here below, following the order as shown in the picture. Screws M12 65 ÷ 89 Nm Screws M8 20 ÷ 28 Nm Screws M10 42 ÷ 52 Nm NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
90506
- Orient engine drive shaft (3) and camshaft (4) taking care that in phase of assembly of the driving gear (2) to the camshaft, the notches marked on the gears (1 and 2) shall match.
Figure 153
Figure 155
70211
- With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the upright surface on which a groove (3) has been created for the ignition timing. NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.
Print P2D32N003 E
90507
- Position comparator (1) on timing system gear (2) and check that the clearance between gears (2) and (3) is within 0.076 ÷ 0.280 mm range.
Base - May 2010
54
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 156
NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. Couplings must be assembled within 10 minutes after completing the sealing operation.
Figure 158
90508
- Tighten the screws (1) fixing the gear to the camshaft (3) and lock them to the prescribed couple.
1 16
15 14
8
17
7
6 18
13 5
12
19 20
Figure 157
11 1
2 21 4
9
10
3 75709
DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX. - Reassemble the box (1) to the engine block, tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below, following the order as shown in the picture.
1 75708
DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION. Base - May 2010
Screws M12
75 ÷ 95 Nm
Screws M10
44 ÷ 53 Nm
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt. Print P2D32N003 E
F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
55
Flywheel installation
Figure 159
Figure 161
1
4
2
3 75690
0901t
- Apply to engine drive shaft rear tang (6), the detail (5) of the tool 99346253, 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 the flywheel cover box (7).
- Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling . - Using a hoist, handle the flywheel to place it in its housing inside the flywheel cover box. - Screw up to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine flywheel (1) properly placing it inside the flywheel cover box.
Figure 160 1
2
Figure 162
2
1
75696
- Check the contact surface (1) of the clutch plate and if it is scratched, proceed with turning. - Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1) using a suitable hammer and fit the new one, previously heated to 150°C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.
Print P2D32N003 E
3 4
75692
- Tighten the screws (4) fixing the engine flywheel (3) to the engine shaft. Use tool 99360339 (2) to operate on the flywheel cover box (1) to block engine flywheel rotation.
Base - May 2010 Revi - September 2012
56
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 163 α
Figure 165
1
2
75695
70221
- Apply to the water pump (1) a new fixing ring (2). Tighten the engine flywheel (1) fixing screws (2) in two phases: - 1st phase; tightening by means of dynamometric wrench to couple 30 ± 4 Nm;
Figure 166
- 2nd phase, 60º ± 5º angle dwell. NOTE Angle dwell shall always be performed using 99395216 tool. Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
76112
Installation of front components
- Assemble the water pump (1). - Tighten the screws (2) and lock them to the prescribed couple.
Figure 164
Figure 167
70220
106549
- Assemble oil pump (1). - Tighten fixing screws (2) and lock them to the prescribed couple.
Base - May 2010
- Remove the fixing ring (2) from the front cover (1), accurately clean the plug surface.
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 168
57
Figure 170
00902t
- Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252, fix it with the screws (5) and key the new holding ring on it (7).
75710
- 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.
- Accurately clean the contact surface of engine block and apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs.
Figure 171
Figure 169
106550
86516
- Assemble the front cover (2) to the block and tighten the screws (1) fixing them to the prescribed couple. Print P2D32N003 E
- Assemble the plate (3), the rose pipe (5), tighten the fixing screws (1, 2 and 4) and fix them to the prescribed couple. Base - May 2010
58
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 172
Figure 174 1 2
3 74175 - Assemble the pulley (1) and the dumping flywheel (2) to the driving shaft. 88075
- Provide for new gasket replacement (1) of the oil pan (2).
- Tighten the fixing screws (3) and clamp them to the couple 68 ± 7 Nm. Figure 175
NOTE The pictures illustrating the pan and of the rose pipe may not correspond to the ones of your model. However the procedures described are applicable anyway.
70230
- Fit a new sealing ring on the speed sensor (3) (if fitted). - Fit the speed sensor (3) on the front cover (1) and tighten the screw (2) to the specified torque (if fitted).
Figure 173
Figure 176
70231 88076
- Assemble oil pan (1), apply the plate over it (2). Tighten the screws (2) and lock them to the prescribed couple.
- Assemble the following elements to the block: new gasket (1), heat exchanger (2), new gasket (3), oil filter bearing (4). Tighten the screws (5) and lock them to the prescribed couple.
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Base - May 2010
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F4GE N ENGINES
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 177
59
Figure 179 1
2
76113
- Lubricate the fixing ring (2) using engine oil and place it on 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.
75686
- Connect the alternator (1) to the support. - Tighten without locking the screw (2).
- Apply, (if needed) new fixing ring on the oil temperature/pressure sensor (4) and assemble it to the bearing (1) tightening the fixing screws to the prescribed couple. - Place a new fixing ring on the block housing (6). - Tighten the screw (5) and lock it to the prescribed couple. Figure 180
Figure 178
70234
- Assemble the alternator bearing (1) ensuring that the pins (3 and 4) are against the engine block. - Tighten the screws (2) and lock them to the prescribed couple. NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
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88090
- Fit the new belt onto pulleys and guide rollers. - Tighten the control belt by turning the alternator as illustrated. - Fix the screw (1) and the alternator fixing bolt (2, Figure 179) to the support. NOTE In case the same belt priory removed is assembled again, proceed examining it carefully to check there
Base - May 2010
60
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
F4GE N ENGINES
Figure 181
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
1
D2
D1
75703
88092
- Place the gasket (1) over the block. The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface.
Figure 183
α
NOTE Verify that the engine block stand is clean. Do not grease the gasket. It is recommended to keep the gasket inside packaging until assembly to the cylinder head.
76214
- Lubricate cylinder head bolts and install to head. - Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. Then a further 90 degrees for the M12 x 140 and M12 x 180. M12 x 70 M12 x 140 M12 x 180
Figure 182
50 Nm + 90 deg’s 40 Nm + 180 deg’s 70 Nm + 180 deg’s
Figure 184
4 1 3 2 76152
2
- Place the head (3) over the block and insert screws (1) and (2).
1
NOTE If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.
Base - May 2010
3 75705
ROCKER ARM UNIT COMPONENTS: 1. Elastic ring - 2. Spacer- 3. Rocker arms4. Support. - Carry out the assembly of the rocker arms after previous check of the components. Print P2D32N003 E
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 185
61
Figure 188
18.975 18.963 D2
D1
75703
19.000 19.026
19.000 19.026 75704
SHAFT AND ROCKER ARM BASIC DATA
- Insert the tappet driving rods and the Rocker Arm unit. Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced;
Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary. Figure 186
Figure 189
13.00 11.00
2 116391
ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the i 4 - 6 Nm couple. Figure 187 1 75683
- Tighten the screws (2) to the prescribed couple and assemble water temperature sensor (1).
32655
Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable. Print P2D32N003 E
Base - May 2010
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Figure 191
Figure 190 2
1 3
75806
1
Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Correct slack is: - suction valves 0.25 0.05 mm - exhaust valves 0.50 0.05 mm.
NOTE On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
75707
- Assemble injectors after having replaced the sealing gasket (1). NOTE During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing.
Figure 192
76149
- Assemble cylinder covers (2) with the respective gaskets; - Fit the seal nods and tighten the screws (1) fixing them to the prescribed couple.
NOTE Always replace the gaskets using new ones. Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. In such case provide for replacement with new nods.
Base - May 2010
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Figure 193
63
Figure 195
76207
76206
- Assemble exhaust manifold (1) providing new gaskets (2).
- Apply on the surface joining the suction manifold plate (1) the gasket (3) and provide. Fixing the screws (2) to the prescribed couple. - If the pipe (7) of the suction manifold plate (1) has been removed, reassemble it after having fit a new gasket (6).
NOTE The illustration of exhaust manifold may be not matching your model. Anyhow, described procedure is applicable.
- Tighten the screws (8) to the prescribed couple.
NOTE For the versions provided with heater, also assemble components (4) and (5). Figure 194
Figure 196
2 1
117588 76208
- Assemble thermostat unit (2) including thermostat (5) and gasket (4). - Tighten the screws to the prescribed couple.
- Also assemble the brackets (1) fixing the fuel pipelines to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture. - Also assemble feed pump (see specific procedure).
NOTE The screws (1) have been have been utilised to fix the bracket (3). Disassemble the bracket (3) and reassemble components from 1 to 5 as shown in the picture. The gasket (4) must be new.
Print P2D32N003 E
NOTE Pump mounting requires specific procedure contained in this section.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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BOSCH VE 6/12 F Pump
Figure 200
Figure 197
1
1 88144
- Assemble the supply pump supply pipes (1). Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold.
88146
- Assemble the supply pump pipes (1).
Figure 201 Figure 198
1
76148
88145
Figure 199 - Fix the LDA pipeline (1) to the engine head and to the feed pump.
76150
- Fix the pipes to the injectors throughout the brackets previously assembled (1). Base - May 2010
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Figure 202
65
Figure 204
116389 116387
- Assemble the fuel filter bearing (1) to the bracket fixed to the engine head. - Connect the fuel pipelines (4 and 3) respectively from priming pump to filter bearing and from this last one to feed pump. - Using 99360076 equipment assemble fuel filter (2).
- Hold the turbocharger and place it on the exhaust manifold after having interposed the gasket. - Screw up the fixing nuts (2) of the turbocharger to the exhaust manifold tightening them to the prescribed couple. - Tighten the lubrication pipe fixing ring (1). Operate in the same way on the other end of the pipe. Connect it to the upper part of the heat exchanger. Figure 205
NOTE The filter shall be priory filled with fuel to facilitate feed system bleed operations.
Figure 203
70126 164006
NOTE To connect fuel pipelines (3 and 4, Figure 202) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B. After having connected the pipeline, reset the fastener (1) into block position as shown in picture A.
Assemble the lubrifying oil discharge pipe (6) coming from the turbo-blower: - Insert the junction (5) into the engine crankcase; - Tighten the two turbo-blower;
screws
(1)
underneath
the
- Tighten the screw (2) which holds the piping to the monoblock by means of the cylinder bracket (3). - Assemble the oil filter using tool 99360076 (4).
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Base - May 2010
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Checks and inspections
Completion of engine re-assembly In order to complete the re-assembly of the engine, it is necessary to remove it from the rotating trestle. - With the aid of lifting beam 99360595, hold the engine and undo the screws which limit the brackets to the rotating trestle 99322205.
NOTE The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.
- Dissemble the brackets from the engine after having opportunely placed them on a wooden support. Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:
Figure 206
- There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings. - Carefully check the fuel connection pipes to the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and. 1 75717
- Cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings. - There is no fuel leakage from fuel pipelines. - There is no blow-by from pneumatic pipes (if provided).
From the right: - Assemble the starting engine (1); opportunely support the starting engine (1) and tighten the fastening screws to the prescribed torque. Finally: - carry out the loading of engine oil.
- Verify correct working of the lighting leds of the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection. - Check and blow by with care the engine cooling system, carrying out frequent drainage.
- Install onto the car (for installation procedures, please refer to specific literature).
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Rotary feed pump disassembly and assembly procedure
In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part.
NOTE This procedure prescribes that:
On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine and disassemble it only afterwards.
- the fuel pipes (from the pumping elements to the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed; - the electrical disconnected.
connections
have
been
- Accelerator cable shall be disconnected.
The following procedure analyses this second hypothesis since it is the more complex. Find the top dead centre with the tool (99395097) - False injector Figure 209
Engine versions with tool (99360330) Figure 207
1 88141
1
88140
Disassemble the starter from the flywheel box and use tool 99360330 to rotate the flywheel. Engine versions with tool (99360339)
Remove the rocker covers of the 1st cylinder; remove the 1st injector and place the tool (1) to set the 1st cylinder top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed. Once PMS has been obtained, lock the flywheel by means of tool 99360339 (Figure 208). Searching for the top dead centre with timing gear blocking pin Figure 210
Figure 208
2
1
75714 84071
Disassemble the starter from the flywheel box (1) and use tool 99360339 (2) to rotate the flywheel. Print P2D32N003 E
Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2) obtaining the TDC of the 1° cylinder. Base - May 2010
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zs
BOSCH VE 6/12 F Pump
Figure 213
Figure 211
1
2
1
88149
88148
- Unscrew the side screw that locks the pump shaft partially (1) and remove spacer (2). This must be kept on a side (we recommend to fix it on the pump with a wire or a clip). - Tighten the lateral screw (1) blocking rotation of the pump shaft.
- From the pump side, loosen the fixing nuts (1) without removing them in order to enable moving the pump backwards using 99340035 extractor. - Assemble the 99340035 extractor throughout the two threaded ports (4, Figure 212) and withdraw the gear from the pump shaft. - Properly hold the feed pump and loosen completely the fixing nuts. - Withdraw the pump from the studs, together with the gasket. When the supply pump is to be assembled on the engine the P.M.S. conditions at compression end stage cylinder No. 1 must be carried out.
Figure 212
1
4
2
3
NOTE Hold the pump driving gear to avoid interference or crawling during timing gear rotation.
75693
- From timing side, remove the cover (2) loosening the screws (1) in order to have access to the union fixing nut (3) to the pump driving gear. - Loosen the fixing nut (3) and remove the relating washer.
Base - May 2010
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69
zs
Figure 214
Figure 216
1 2
1
88148
88149
- Assemble the pump pre-set in its housing on the engine, fitting the shaft into the gear port (not provided with wrench). - Tighten the fixing nuts (1) locking the pump flange in the slot centre.
NOTE The gasket removed during pump disassembly shall not be utilised again. Always use original spare parts.
- Loosen screw (1) that prevents pump shaft rotation and insert spacer (2). Tighten screw (1)so that it locks spacer (2): in this way the supply pump shaft will be able to rotate freely. - Assemble the cover (2, Figure 215) including gasket and tighten the screws (1, Figure 215). - Disassemble the flywheel rotation/locking tool 99360339 or 99360330; arrange the starting motor in its seat. - Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump). - Connect electrical connections to electro-magnets on the hydraulic head and on KSB. NOTE If the pump has been removed with the engine mounted, connect the accelerator cable, if present in the application. Ignition pump control and timing Figure 217
(Demonstration)
Figure 215
1
4
2
3 75715
- On the timing side, throughout the specially appointed port, fit the washer and screw up the fixing nut (3) to the pump shaft. Lock the nut to the 90-95 Nm couple.
Print P2D32N003 E
87720
- With the injection pump inserted in relating seat and securing screws loosened, mount comparator 99395605 (2) and 99395100 gauge tool (1), preloading the rod by 2.5 mm. - Rotate the engine derive shaft to shift from the condition of the first cylinder to TDC end of compression phase. Reset the dial gauges and rotate the engine drive shaft into the opposite direction until recovering the condition of the 1st cylinder to TDC in phase of compression (see Figure 209). From this position on the comparator applied on the pump it must be possible to read the value listed on the pumping element pre-lift table. Section 4. - Rotate the pump in anti-clockwise direction if the stroke is shorter or in clockwise direction if the stroke is longer, until obtaining the stroke prescribed. - Checking these conditions, lock the pump by tightening the relevant nuts to the prescribed pair. Base - May 2010
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Feed system bleed procedure
Power take-off disassembly and assembly procedure
Version with B type fuel filter Figure 218
Figure 219
(Demonstration)
87751
76137
- Disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the priming pump.
Where designed, there is a power take-off able to transmit motion to different auxiliary parts.
- Continue the operation until when fuel outflows.
Disassembly of such mechanism shall be executed as following:
- Connect the (1) to the filter.
- Loosen the two screws (3) and after having removed the cover (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 its housing, providing new gasket and checking the sprocket gear meshing. - Assemble cover and gasket and tighten the screws to the prescribed couple.
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71
Checks and controls NOTE The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.
Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:
- There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings. - Carefully check the fuel connection pipes to the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings. - 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 the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection. - Check and blow by with care the engine cooling system, carrying out frequent drainage.
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Base - May 2010
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REVIEW OF 4-CYLINDER ENGINE WITH DELPHI PUMP Preface
Figure 221
Part of the operations illustrated within this section can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well. NOTE With regard to the engine disassembly operations, please apply for information consulting the specific manual. All operations of engine disassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. The following information relate to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties. NOTE For specific application exigencies, some units can be assembled to the engine in different positions.
Within ”General overhaul” section, all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described. 164006
Engine setting operations for the assembly on turning stand - Remove the wiring harness from all components indicated in part II, electrical equipment. Figure 220
- disassemble lubrication oil exhaust pipe from the turbo-blower: Underneath the turbo-blower loosen the two screws (1), loosen the screw (2) fixing the pipe throughout the stop collar (3) fixing the block; finally loosen and remove the union (5) from the block; plug the pipe ends and the exhaust of the turbo-blower.
Figure 222
164007
In order to apply the brackets 99361037 to the engine block to fix it on to the stand 99322205 for the overhaul, it is necessary to perform the following operations: On the right hand side: - disassemble the oil filter (1) from the support using tool 99360076; 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.
87712
- Disassemble the starter; Properly hold the starter (1) and loosen the fixing screws (2); - assemble the supporting bracket 99361037 using the threaded ports on the basement.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Disassembly of application components
Figure 223
Figure 225
1
75674
From the left-hand side: - Assemble the second bracket 99361037 throughout the screw-threaded ports (1). - Lift the engine using the rocker arm 99360595 and put it on the turning stand 99322205. - Drain the oil through the cap underneath the plug.
Warning: avoid contact of engine oil with the skin: in case of skin contamination, rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force.
116389
Proceed disassembling the supercharger: - loosen the fixing nut (1) and remove the lubrication pipe from the supercharger. Analogously carry out the same operation on the other end of the pipe and remove it from the upper part of the heat exchanger. - Loosen the screw nuts fixing (2) the supercharger on the exhaust manifold. - Hold up the supercharger and after lifting it remove the gasket.
Figure 226 Figure 224
x
116387 127121
Loosen the screws (2), remove the duct (3) and the heater (1)
- Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. Carry out complete drainage of the fuel contained therein. - Screw out completely the faucet and, using equipment 99360076 disassemble oil filter (2). - Disconnect fuel pipelines (4 and 3) respectively from priming pump to filter bearing and from this last one to the feed pump. - Remove the fuel filter bearing (1) from the bracket fixed to the engine head.
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DELPHI Pump
Figure 227
Figure 229
70126
NOTE To disconnect fuel pipelines (3 and 4, Figure 226), in low pressure from the relating pipe fittings, it is Necessary to press the locking fastener (1) as shown in picture B. After having disconnected the pipeline, reset the locking fastener (1) in lock position as shown in. picture A, to avoid any possible deformation of the fastener itself.
127119
- 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. Figure 230
Figure 228
127133 87406
- Remove tappet caps: Loosen the four fixing screws (1) and lift the caps (2); remove the gaskets.
NOTE On the cap there is a blow-by valve for the lubrication oil vapours. All the gaskets shall always be replaced during assembly.
Base - May 2010
- Disconnect the pipelines (1) and (3) that provide feed and fuel recovery between pump and injectors; screw out the nuts fixing the pipes to the pumping elements; loosen the fuel recovery pipe collar on the injection pump; operate on the nuts assembled to the injectors and loosen the screws fixing the fuel recovery pipeline; loosen the screws holding the fixing brackets of such pipelines (2); pipe the pipeline ends. - Disassemble the injectors and remove them from their slot: remove the gaskets.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 231
75
Figure 233
125114 88102
- Loosen the two fixing screws (2) and disassemble priming pump (1).
- Disassemble rocker arm bearings; loosen the two fixing screws (2) and remove the complete rocker arm bearing; withdraw tappet rods. Repeat the operation for all the remaining rocker arm bearings. - Disassemble water temperature transmitter (1).
Figure 232
Figure 234
87409
- Disassemble suction and exhaust manifolds: loosen the 8 screws (1) fixing the suction manifold plate to the cylinder head (two of them have already been screwed-out since fixing the pipe brackets to the injectors); from the exhaust manifold side; loosen the (2) fixing screws; remove the gaskets.
127122
- Disassemble thermostat unit; loosen the three fixing screws (1) and disassemble the thermostat unit (2) together with the bracket (4); remove the gasket (3) and the thermostat (5). - Assemble the bracket in the original position fixing it with the screws of the thermostat unit.
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Figure 235
Figure 237
88555
Unscrew the fixing screws (1) and disassemble the pipeline union (2).
127123
Figure 238
- Loosen the screw nut (5) and the screw (2) - Loosen the screw (2, figure 18) - Reduce belt tension operating on the screw (4) - Loosen the screw (2) on the belt tensioning bracket (3) - Withdraw the POLY-V belt - Remove the belt tensioning bracket loosening the screw (1) - Disassemble the pulleys and the guide rollers.
Figure 236 1
107275
2
- Loosen the screws (5) and disassemble the oil (2) filter/heat exchanger bearing (4), interlayer plate (3) and relating gaskets (1). - Disassemble injection pump (see specific procedure) and the power take-off underneath.
88089
- Properly hold the alternator (1) separating it from its bearing by loosening the screw (2); remove screw nut and washer.
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Figure 239
77
Figure 242 1 2
3
4
90504 75688
- Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block.
- Loosen the screws (1) and disassemble the pulley (2).
Figure 240 Figure 243
1 88140
Fit tool 99360330 (2) in the starter motor housing to be able to rotate the flywheel. Figure 241
78256
- Remove the engine drive shaft fixing ring from the front cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3).
84071
Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2). Print P2D32N003 E
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Figure 246
Figure 244
75811 00904t
- Loosen the screws (1 and 3) and remove the front cover (2).
- Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1).
Figure 245
Figure 247 1
2
75695
116242
- Loosen the screws (1 and 3) and remove the front cover (2).
NOTE Take note of the screw (1 and 3) assembly position, since the screws have different length.
Base - May 2010
- Screw out the opposite screws from the ports where the withdrawal pins shall be introduced (see picture following). - Loosen remaining (2) flywheel fixing screws (1) to the engine drive shaft. - Remove the flywheel block tool (2).
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 248 1
79
Figure 250 4
2
3
75690
- Screw up two medium length screws in the ports (4) to sling the flywheel with a hoist. Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist.
84077
- Loosen the screws (2) and remove the flywheel cover box (1). NOTE Take note of the screw (1) assembly position, since the screws have different length.
Figure 249
Figure 251
127124 00903t
- Remove the flywheel cover box fixing ring using the tool 99340056 (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.
- Turn the engine upside-down. - Loosen the screws (2) and remove the oil pan (1).
- Fix the tool 99340056 (3) to the ring (1) tightening the 6 screws specially provided (4). - Proceed with drawing the ring (1) tightening the screw (2). - Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring of the flywheel cover box.
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Figure 252
Figure 254
87656
127125
- Loosen the screws (1) e (3) and disassemble the oil suction rose pipe (2).
- Loosen the screws (1) and remove the power take-off gear (2) (if available).
Figure 255
Figure 253
88221 87655
By means of pin (1) lock the additional masses (2) in the P.M.S. Loosen the fixing screws (3) and remove the additional masses (2).
Base - May 2010
- Remove the gear (1) transmitting motion to the ignition pump and the relevant support.
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Installation of rear components
Figure 256
Figure 258
(Demonstration)
87424
70210
DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX - 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 locking couples listed here below, following the order as shown in the picture.
Figure 257
Screws M8 Screws M10
!
20 ÷ 28 Nm 44 ÷ 54 Nm
It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal.
70157
- Loosen the screws (2) and disassemble the timing gearbox (1).
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
NOTE Take note of the screw (2) assembly position, since the screws have different length.
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Figure 259
Figure 261
87653
70211
- With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the upright surface on which a groove (3) has been created for the ignition timing.
- Place the dial gauge (1) on the timing gear (2) and check that the slack between the gears (2) and (3) is included in the range between 0,076 ÷ 0,280 mm. Figure 262
NOTE Screw up two pins to facilitate operation of engine drive shaft rotation.
Figure 260
87654
- Fit the screws (1) fastening the gears (2) to the camshaft (3) and tighten them to the prescribed pair. Figure 263
116355
- Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).
87655
- Spline the gear (1) transferring motion to the ignition pump. Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 264
83
Figure 266
87656
- Fit the power take-off gear (2) (if available) into the specially provided housing and fasten the screws (1),
84077
- Re-assemble the box (1) to the engine basement. - Tighten the fastening screws (2) to the same position detected before disassembly.
Figure 265 NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Figure 267
122588
DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing LOCTITE 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no crumbs), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. Couplings must be assembled within 10 minutes after completing the sealing operation.
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87659
- Apply to the rear tongs hold (3) of the engine drive shaft the part (6) of the tool 99346253, fix it with the screws (1) and spline the new tight ring to it (2). - Place the part (5) on the part (6), tighten the nut (4) until tight ring assembly (2) into the flywheel box is completed.
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Flywheel installation
Figure 270
Figure 268 1
4
2
3
75690
- Screw up two hooks or trail rings in the flywheel (1) threaded ports (4) for handling . - Using a hoist, handle the flywheel to place it in its housing inside the flywheel cover box.
84071
Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2).
- Screw up to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine flywheel (1) properly placing it inside the flywheel cover box. - Tighten the screws (4) fixing the engine flywheel (3) to the engine shaft.
Figure 271
Figure 269
α
1
2
75695
1
88140
Fit tool 99360330 (2) in the starter motor housing to be able to rotate the flywheel.
Tighten the engine flywheel (1) fixing screws (2) in two phases: - 1st phase; tightening by means of dynamometric wrench to couple 30 ± 4 Nm; - 2nd phase, 60º ± 5º angle dwell with tool 99395216. NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Installation of front components
85
Figure 274
Figure 272
76112
70220
- Assemble oil pump (1). - Tighten fixing screws (2) and lock them to the prescribed couple.
Figure 273
Apply a new sealing ring (2) to the water pump (1).
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- Tighten the screws (2) and lock them to the prescribed couple.
Figure 275
70221
- Apply to the water pump (1) a new fixing ring (2).
- Assemble the water pump (1).
106549
- Remove the fixing ring (2) from the front cover (1), accurately clean the plug surface.
Base - May 2010
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Figure 276
Figure 278
00902t
- Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252, fix it with the screws (5) and key the new holding ring on it (7).
75710
- 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.
- Accurately clean the contact surface of engine block and apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs.
Assembly of additional masses Figure 279
Figure 277
88221
Fit the additional masses (2) and tighten the screws (3) on the engine block. Remove the lock pin (1) of the additional masses. 106550
- Assemble the front cover (2) to the block and tighten the screws (1) fixing them to the prescribed couple.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
87
Timing of additional masses Match the signs (A) engraved on the gears for timing, insert the pin in the hole (B) on the balancing mass. Figure 280
86614
1. Injection pump gear - 2. Camshaft control gear - 3. Injection pump control gear (reduced distribution) 4. Additional masses. - Assemble, the suction rose (2) and tighten the fixing screws (1 and 3) to the prescribed torque.
Figure 281
127125
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 282
Figure 284
3
119123
- Provide for new gasket replacement (1) of the oil pan (2).
1
2 75697
Figure 283
- 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 285
127124
- Assemble oil pan (1). Tighten the screws (2) and lock them to the prescribed couple.
NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
107275
- Assemble the following elements to the block: new gasket (1), heat exchanger (2), new gasket (3), oil filter bearing (4). Tighten the screws (5) and lock them to the prescribed couple. NOTE Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 286
89
Figure 288 1
2
75686
122589
- Lubricate the fixing ring (4) using engine oil and place it on the oil filter (2). - Manually start the oil filter (2) on the bearing union (1) until counter-boring, further screw up the oil filter (2) by 3/4 turn.
- Connect the alternator (1) to the support. - Tighten the screw without locking it (2).
- Place a new fixing ring on the block housing (3).
Figure 289 Figure 287
87759 88587
Assemble pipeline union (1) and tighten screws (2) up to the prescribed torque.
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
- Place the gasket (1) over the block. The choice of the gasket’s thickness shall be made in consideration of the cylinder protrusion measured with respect to the block’s upper surface.
NOTE Verify that the engine block stand is clean. Do not grease the gasket. It is recommended to keep the gasket inside packaging until assembly to the cylinder head. Gasket assembly shall be made following the direction of wording printed on the gasket itself so that this will be readable as indicated in the picture.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Figure 290
Figure 292 1
4
2 1 3 3 2 2 3
1 4
75705 75688
- Place the head (3) over the block and insert screws (1) and (2).
NOTE If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block.
- Carry out the assembly of the rocker arms after previous check of the components. ROCKER ARM UNIT COMPONENTS: 1. Elastic ring - 2. Spacer- 3. Rocker arms4. Support. Figure 293
18.975 18.963
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1 19.000 19.026
75703
19.000 19.026 75704
SHAFT AND ROCKER ARM BASIC DATA
Figure 291
α
10
4
1
5
11
13
7
2
8
14
9
3
6
Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary. Figure 294
12 76115
- Lubricate cylinder head bolts and install to head. - Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. Then a further 90 degrees for the M12 x 140 and M12 x 180. M12 x 70 M12 x 140 M12 x 180
Base - May 2010
50 Nm + 90 deg’s 40 Nm + 180 deg’s 70 Nm + 180 deg’s
13.00 11.00
116391
ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the i 4 ÷ 6 Nm couple.
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91
Figure 298
Figure 295
2
1 3
122587
Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in contact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable.
Figure 296
D2
D1
75703
- Insert the tappet driving rods and the Rocker Arm unit. Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced;
75806
On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question. Place the tool 99395097(see Figure 98) to set the cylinder top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed. Adjust the slack between rocker arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2). Correct slack is: - suction valves 0.25 0.05 mm - exhaust valves 0.50 0.05 mm.
IGNITION SEQUENCE: 1 — 3 — 4 - 2
Figure 297
Engine shaft starting and rotation
Bilance valves cylinder n°
Adjust intake and exhaust valves clearance cylinder n°
1° al PMS
1
1
180°
3
3
180°
4
4
180°
2
2
125114
- Tighten the screws (2) to the prescribed couple and assemble water temperature sensor (1).
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Figure 299
Figure 301
1 75707 127122
- Assemble injectors after having replaced the sealing gasket (1).
- Assemble thermostat unit (2) including thermostat (5) and gasket (3). - Tighten the screws to the prescribed couple.
NOTE During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing. NOTE The screws (1) have been have been utilised to fix the bracket (4). Disassemble the bracket and reassemble components from 1 to 5 as shown in the picture. The gasket (3) must be new.
Figure 300
123025
- Assemble exhaust manifold (1) providing new gaskets (2).
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 302
93
Figure 303 2
3
1
127123
- Tighten the screw (2), the screwnut (5) and the screwnut fastening the alternator to the support. - Assemble the alternator tensioning bracket (3) and secure it through screw (1) 75687
- Tighten the screw (2) without locking it - Tension drive belt operating on the screw (4)
- Assemble the pulley fan bearing tightening the screws to the prescribed couple. - Mount pulley (3) and secure it to support through screws (2).
Figure 304
- Assemble the transmission pulley (1). - Fit the new belt onto the pulleys and guide rollers.
NOTE If not faulty the gasket can be reused.
127127
- Apply on the surface joining the suction manifold plate (1) a sufficient coat of Loctite 5999 and provide. fixing the screws (2) to the prescribed couple.
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Figure 305
Figure 307
2 1
127120
75700
- Assemble the brackets (1) fixing the fuel pipelines to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture.
- Assemble the pipes (1) and (2) providing fuel feed and recovery between pump and injectors; Screw up the locking nuts and tighten the screws fixing the fuel recovery manifold; fix the pipes to the injectors throughout the brackets previously assembled.
Figure 306 Figure 308
88102 87406
- Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple. - Also assemble feed pump (see specific procedure) and the power take-off underneath.
NOTE Pump mounting requires specific procedure contained in this section.
Base - May 2010
- Assemble cylinder covers (2) with the respective gaskets; - Fit the seal nods and tighten the screws fixing them to the prescribed couple. NOTE Always replace the gaskets using new ones. Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. In such case provide for replacement with new nods. If not faulty the gasket can be reused.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 309
Figure 311
116387
- Assemble the fuel filter bearing (1) to the bracket fixed to the engine head. - Connect the fuel pipelines (4 and 3) respectively from priming pump to filter bearing and from this last one to feed pump. - Using 99360076 equipment assemble fuel filter (2). 127119
- Fix the LDA pipeline (1) to the engine head and to the feed pump.
NOTE Pump mounting requires specific procedure contained in this section.
Figure 312 Figure 310
70126
127121
- Refit the duct (3) and thje heater (1), after having fitted new gaskets, and thighten the screws (2).
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NOTE To connect fuel pipelines (3 and 4, Figure 311) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as shown in picture B. After having connected the pipeline, reset the fastener (1) into block position as shown in picture A.
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Completion of engine re-assembly
Figure 313
Figure 314
116389
Proceed assembling the turbocharger: - Hold the turbocharger and place it on the exhaust manifold after having interposed the gasket. - Screw up the fixing (2) nuts of the turbocharger to the exhaust manifold tightening them to the prescribed couple. - Tighten the lubrication pipe fixing ring. Operate in the same way on the other end of the pipe. Connect it to the upper part of the heat exchanger. To complete engine assembly it is necessary to remove it from the turning stand. - Using rocker arm 99360595 hold the engine and loosen the screws fixing the brackets to the turning stand 99322205. - Disassemble the brackets 99361037 from the engine after having properly put it on a wooden bearing.
164004
From the right-hand side: - Re-assemble the lubrifying oil discharge pipe (6) from the turbo-blower by inserting the joint (5) into the engine crankcase and tightening the two fastening (1) screws underneath the turbo blower; - Tighten the screw (2) which holds the piping to the (6) monoblock by means of the cylinder bracket (3); - Re-assemble the oil filter (4) onto the heat exchanger with tool 99360076; Figure 315
87712
- re-assemble the starting engine (2); opportunely support the starting engine (2) and tighten the fastening screws to the prescribed torque. - Refit and connect the wiring harness Base - May 2010
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97
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Rotary feed pump disassembly and assembly procedure
Find the top dead centre with the tool (99395097) - False injector Figure 317
NOTE This procedure prescribes that: - the fuel pipes (from the pumping elements to the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed; - the electrical disconnected.
connections
have
been
- Accelerator cable shall be disconnected.
1
Figure 316
88141
Remove the rocker covers of the 1st cylinder; remove the 1st injector and place the tool (1) to set the 1st cylinder top dead centre position (end-of-compression phase). Pre-load the gauge. The searched condition is obtained by rotating the engine shaft properly until you find the maximum value on the comparator and then checking that the intake and exhaust valves are both closed.
1
Figure 318
88140
Disassemble the starter from the flywheel box and use tool 99360330 to rotate the flywheel. In case feed pump replacement is necessary, this shall be supplied pre-set already as spare part. On the other hand, in case the pump shall be disassembled and reassembled later on without being repaired it will be necessary to pr-set it while it is still assembled to the engine and disassemble it only afterwards. The following procedure analyses this second hypothesis since it is the more complex. 84071
Turn the flywheel until, when pushing the pin 99360616 (1), it blocks the gear (2) obtaining the TDC of the 1° cylinder.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Pump DELPHI
Figure 321
Figure 319
1
75694
127693
- Unscrew the side screw that locks the pump shaft partially (1) and move spacer (2) from position (A) to position (B) - Tighten the lateral screw (1) blocking rotation of the pump shaft.
- From the pump side, loosen the fixing nuts (1) without removing them in order to enable moving the pump backwards using 99340035 extractor. - Assemble the 99340035 extractor throughout the two threaded ports (4, Figure 320) and withdraw the gear from the pump shaft. - Properly hold the feed pump and loosen completely the fixing nuts. - Withdraw the pump from the studs, together with the gasket. When the supply pump is to be assembled on the engine the P.M.S. conditions at compression end stage cylinder No. 1 must be carried out.
Figure 320 1
4
2
3
NOTE Hold the pump driving gear to avoid interference or crawling during timing gear rotation.
75693
- From timing side, remove the cover (2) loosening the screws (1) in order to have access to the union fixing nut (3) to the pump driving gear. - Loosen the fixing nut (3) and remove the relating washer.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Figure 322
99
Figure 324 1
75694
- Assemble the pump pre-set in its housing on the engine, fitting the shaft into the gear port (not provided with wrench). - Tighten the fixing nuts (1) locking the pump flange in the slot centre, to the pair 24 Nn.
NOTE The gasket removed during pump disassembly shall not be utilised again. Always use original spare parts.
127693
- Loosen screw (1) that prevents pump shaft rotation and move spacer (2) from position (B) to position (A). Tighten screw (1) so that it locks spacer (2): in this way the supply pump shaft will be able to rotate freely. - Assemble the cover (2, Figure 323) including gasket and tighten the screws (1, Figure 323). - Disassemble the flywheel rotation/locking tool 99360339 or 99360330; arrange the starting motor in its seat. - Connect all pipelines (from pumping elements to injectors, bleeding recovery pipes from injectors to pump, LDA pipeline and feed provided by priming pump). - Connect electrical connections to electro-magnets on the hydraulic head and on KSB.
Figure 323
1
4 NOTE If the pump has been removed with the engine mounted, connect the accelerator cable, if present in the application.
2
3 75693
- On the timing side, throughout the specially appointed port, fit the washer and screw up the fixing nut (3) to the pump shaft. Lock the nut to the prescribed pair.
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Feed system bleed procedure
Power take-off disassembly and assembly procedure
Figure 325
Figure 326 1
2
4
3
75720
127694
- Disconnect the fuel pipe (1) of the filter and repeat working on the drain lever (2) of the priming pump. - Continue the operation until when fuel outflows. - Connect the (1) to the filter.
Where designed, there is a power take-off able to transmit motion to different auxiliary parts. Disassembly of such mechanism shall be executed as following: - Loosen the two screws (3) and after having removed the cover (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 its housing, providing new gasket and checking the sprocket gear meshing. - Assemble cover and gasket and tighten the screws to the prescribed couple.
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101
Checks and controls NOTE The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored.
Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:
- There is no water bleeding from the manifolds connecting engine cooling circuit pipelines and cabin internal heating, eventually providing to further tighten the locking rings. - Carefully check the fuel connection pipes to the respective unions. - There is no oil leakage from the lubrication circuit of the various pipelines connecting cover and cylinder head, oil pan and bearing, oil filter and heat exchanger as well as relating housings. - 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 the dashboard containing the tools as well as of the equipment that was disconnected during engine disconnection. - Check and blow by with care the engine cooling system, carrying out frequent drainage.
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103
PART TWO ELECTRICAL EQUIPMENT
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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105
ELECTRICAL COMPONENT LAYOUT (4 CYL. ENGINES WITH ROTARY PUMP) Figure 327
A
B
116392
Below there are listed the electric components which are present on F4GE94--- engines*. 1.
Cooling liquid temperature sensor;
2.
Starter;
3.
KSB Water temperature sensor;
4.
Electromagnets assembled to feed pump: (A) on hydraulic head unit (B) on KSB;
5.
Oil pressure sensor;
6.
Resistance for cold start up (where provided for);
7.
Alternator;
*
Excluding motor F4GE9454H*J600, F4GE9454H*J603 and F4GE9454H*J605.
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Cooling liquid temperature sensor
Starter
Figure 328
Figure 329
1 75717
Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch assembled to the starter itself.
C
Specifications:
A B
A
B
BOSCH 3 kW - 12V
C 75718
KSB Water temperature sensor Figure 330
It is a component integrating a temperature sensor. It is assembled to the engine head close to the thermostat unit and its duty is to detect engine cooling liquid temperature. Specifications: Range of working temperatures: 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 kΩ
20 ºC
2.262 ÷ 2.760 kΩ
-10 ºC
8.244 ÷ 10.661 kΩ
75719
It is assembled to the cylinder head on the engine left hand side. Specifications: Working tensions:12 ÷ 24 V
Base - May 2010
Electrical Power load:
2.5 A (induction) 5.0 A (resistance)
Setting:
63±3 ºC Contact opening upon increasing temperature 53±3 ºC Contact closure upon decreasing temperature Print P2D32N003 E
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Electromagnets assembled to feed pump
107
Alternator
Figure 331
Figure 333
1
2
75724a 75725
1 - Hydraulic head Electro-magnet; 2 - KSB Electro-magnet
It is place front view on the right hand side of the engine, and is driven by tooth belt. Specifications:
Oil pressure sensor Figure 332
Working tension:
12 V
Current delivered:
90A (at 6000 rpm)
Absorption in stand-by:
≤ 1mA
Sense of rotation:
clockwices
Pre-post heating resistor Figure 334
75722
It is assembled to the block on the engine’s left hand side. Specifications:
75723
Working tensions:
12 ÷ 24 V
Contact closure upon lower pressure:
0.2 bar
Contact opening upon higher pressure:
0.9 bar
It is a resistor assembled to the suction collector and is utilised to heat the air during pre-post heating operations. It is fed by a tele-switch usually placed very close to the engine. Specifications: Working tension: Maximum possible air flow:
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12 V 2 cc / min (pressure 138 kPa)
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108
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ELECTRICAL COMPONENT LAYOUT (6 CYL. ENGINES WITH ROTARY PUMP) Figure 335
A
B
116393
Below there are listed the electric components which are present on F4GE06--- engines. 1.
Cooling liquid temperature sensor;
2.
Alternator;
3.
Starter;
4.
Magnets mounted on feed pump: (A) on hydraulic head body; (B) on KSB;
5.
Oil pressure sensor;
6.
KSB Water temperature sensor;
7.
Resistance for cold start up (where provided for).
Base - May 2010
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Cooling liquid temperature sensor
109
Starter
Figure 336
Figure 337
1 75717
Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch assembled to the starter itself.
C
Specifications:
A A
B
B
BOSCH 4 kW - 24V
C 75718
KSB Water temperature sensor Figure 338
It is a component integrating a temperature sensor. It is assembled to the engine head close to the thermostat unit and its duty is to detect engine cooling liquid temperature. Specifications: Range of working temperatures: 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 kΩ
20 ºC
2.262 ÷ 2.760 kΩ
-10 ºC
8.244 ÷ 10.661 kΩ
75719
It is assembled to the cylinder head on the engine left hand side. Specifications: Working tensions:12 ÷ 24 V
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Electrical Power load:
2.5 A (induction) 5.0 A (resistance)
Setting:
63±3 ºC Contact opening upon increasing temperature 53±3 ºC Contact closure upon decreasing temperature Base - May 2010
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Oil pressure sensor
Pre-post heating resistor
Figure 339
Figure 341
75723 75722
It is assembled to the block on the engine’s left hand side. Specifications:
It is a resistor assembled to the suction collector and is utilised to heat the air during pre-post heating operations.
Working tensions:12 ÷ 24 V
It is fed by a tele-switch usually placed very close to the engine.
Contact closure upon lower pressure:
Specifications: 0.2 bar
Contact opening upon higher pressure:
0.9 bar
Working tension: Maximum possible air flow:
24 V 2 cc / min (pressure 138 kPa)
Alternator Figure 340
75725
It is place front view on the right hand side of the engine, and is driven by tooth belt. Specifications: Rated tensions:
24 V
Current delivered:
90A (at 6000 rpm)
Absorption in stand-by:
≤ 1mA
Sense of rotation:
clockwices
Base - May 2010
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111
ELECTRICAL COMPONENT LAYOUT 4 CYLINDER ENGINE WITH DELPHI PUMP Figure 342
127135
Below there are listed the electric components which are present on F4GE9454H*J600, F4GE9454H*J603, F4GE9454H*J605 engine. 1A. KSB Water temperature sensor; 1B. KSB Electro-magnet; 1C. Pump stop connection; 1D. Engine stop solenoid; 2.
Cooling liquid temperature sensor;
3.
Alternator;
4.
Starter;
5.
Oil pressure sensor.
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Cooling liquid temperature sensor
Starter
Figure 343
Figure 344
1 75717
Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch assembled to the starter itself.
C A A
B
B
Specifications: BOSCH 3 kW - 12V
C
Cooling liquid temperature sensor 75718
Figure 345 It is a component integrating a temperature sensor. It is assembled to the engine head close to the thermostat unit and its duty is to detect engine cooling liquid temperature. Specifications: Range of working temperatures: 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 kΩ
20 ºC
2.262 ÷ 2.760 kΩ
-10 ºC
8.244 ÷ 10.661 kΩ
75719
It is assembled to the cylinder head on the engine left hand side. Specifications:
Base - May 2010
Working tensions:
12 ÷ 24 V
Electrical Power load:
2.5 A (induction) 5.0 A (resistance)
Setting:
63±3 ºC Contact opening upon increasing temperature 53±3 ºC Contact closure upon decreasing temperature
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Electromagnets assembled to feed pump
113
Alternator
Figure 346
Figure 348
2
1
75725
4
3 127136
1. KSB Water temperature sensor - 2. KSB Electro-magnet - 3. Pump stop connection 4. 1D. Engine stop solenoid;
It is place front view on the right hand side of the engine, and is driven by tooth belt. Specifications: Working tension:
12 V
Current delivered:
90A (at 6000 rpm)
Absorption in stand-by:
≤ 1mA
Sense of rotation:
clockwices
Oil pressure sensor Figure 347
75722
It is assembled to the block on the engine’s left hand side. Specifications: Working tensions:
12 ÷ 24 V
Contact closure upon lower pressure:
0.6 bar
Contact opening upon higher pressure:
0.9 bar
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
115
PART THREE - TROUBLESHOOTING
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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F4GE N ENGINES
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The engine does not start
POSSIBLE CAUSE Battery flat or faulty.
REMEDY
NOTE
Check and recharge battery. Replace battery if necessary.
Connections to battery terminals cor- Clean, examine and tighten the nuts on roded or loose. the battery terminals. Replace the cable terminals and the nuts if excessively corroded. Incorrect timing of injection pump.
Check and correctly time the injection See your Iveco dealer. pump.
Deposits or water in the fuel tank.
Disconnect the hoses and clean them Drain feed system. using a jet of compressed air. Dismantle and clean the injection pump. Remove water from tank and refuel.
No fuel in tank.
Refuel.
No power supply.
Overhaul or replace the fuel or transfer pump.
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ANOMALY
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in pump. fact present and also check the fuel pump. Eliminate the air from the injection pump by unscrewing the cap and working the fuel pump by hand. Faulty starter motor.
Repair or replace the starter motor. SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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POSSIBLE CAUSE
REMEDY
NOTE
K.S.B. device for cold spark advance con- Check or replace the injection pump. trol operating incorrectly. The engine cuts out.
See your Iveco dealer.
Idle rpm too low.
Adjust with adjustment screw.
Irregular flow of injection pump.
Adjust flow.
Impurities or water in the fuel lines.
Disconnect the hoses and clean them Drain feed system. using a jet of compressed air. Dismantle and clean the injection pump. Remove water from fuel tank and refuel.
Clogged fuel filter.
Dismantle and replace if necessary.
See your Iveco dealer.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use peratures forming due to the use of unsuitable fuel. at low temperatures. Replace the fuel filters.
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ANOMALY
Presence of air in the fuel and injection Check that the hoses are not cracked or system. the unions loose. Replace worn parts, remove the air from the hoses and deaerate the injection pump and fuel filter by unscrewing the caps and working the primer pump by hand. Broken injection pump controls.
Replace the faulty parts.
Abnormal clearance between camshaft Adjust clearance by replacing shims. cams and tappets. Burnt, corroded or chalky valves.
Replace the valves, rectify or replace the cylinder head seatings.
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The engine overheats
POSSIBLE CAUSE
REMEDY
Faulty water pump.
Check the unit and replace if necessary. Replace the gasket.
Malfunctioning thermostat.
Replace the thermostat.
NOTE
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ANOMALY
Fouling in coolant openings in the cylinder Wash following the standards specified head and cylinder groups. for the type of descaling product used.
Engine operation is irregular and lacks power
Water pump drive belt slack.
Check and adjust the tightness of the belt. On applications provided with automatic tensioner, check corret worching of such device.
Coolant level too low.
Top-up radiator with coolant.
Incorrect engine timing.
Check timing and tune correctly.
Incorrect calibration of injection pump.
Correct the delivery rate of the pump on See your Iveco dealer. a bench so that the injection is at the specified rate.
Dry air cleaner blocked.
Clean the air filter or replace if necessary.
Incorrect timing of injection pump.
Check timing and correctly set pump.
K.S.B. automatic cold advance device mal- Check or replace injection pump. functioning. Excessive piston wear.
Check or replace injection pump.
Incorrect calibration of speed regulator.
Check and correctly calibrate the regula- See your Iveco dealer. tor. SECTION 3 - DUTY-INDUSTRIAL APPLICATION
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Base - May 2010
REMEDY
NOTE
Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using ation of injectors. the appropriate tools and completely overhaul the injectors. Impurities or water in the fuel and injec- Carefully clean the system and refuel. tion system.
If necessary drain feed system.
Incorrect play between camshaft cams Check and correct play and tappets. Faulty turbocharger.
Replace complete unit.
Air cleaner blocked.
Clean or replace air cleaner.
Faulty operation of L.D.A. device
Check that the diaphragm is not perfor- See your Iveco dealer. ated, that the counter spring is suitable and that it has the correct loading (check on test bench). Check that there is adequate air pressure inside the intake manifold in relation to the engine rpm under full-load conditions.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Engine operation is irregular and lacks power
POSSIBLE CAUSE
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ANOMALY
Tie rods between accelerator pedal and Adjust the tie-rods so that the command regulation lever incorrectly adjusted. lever can be moved to the full delivery position. Engine running with abnormal knocking
Faulty operation of injectors.
Replace all injectors.
Fuel lines blocked.
Dismantle the hoses, clean them and replace those that are seriously dented.
Incorrect set-up of injection pump.
Correct the set-up of the pump so that in- See your Iveco dealer. jection occurs at the specified angle.
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Engine running with abnormal knocking
POSSIBLE CAUSE
REMEDY
NOTE
Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and inplay on one or more main or rod bearings stall smaller bearings. Replace the thrust or excessive play on shoulders. half-rings. Crankshaft unbalanced.
Check alignment of crankshaft.
Loosening of screws securing flywheel.
Replace the loosened screws and tighten all the screws to the specified torque.
Misalignment of rods.
Replace the rods.
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ANOMALY
Noise from piston journals due to excess- Replace the piston journal and/or the pisive play of piston hubs and in the rod ton and rod bushing. bushing. Loose bushings in the rod seatings. Replace with new bushings. Noisy timing.
The engine smokes abnormally. Black or Excessive maximum pump output. dark grey smoke.
Adjust the play between camshaft cams and tappets and check that there are no broken springs, that there is no excessive play between the valve stems and the valve guides, tappets and seatings. Disconnect the pump and adjust delivery See your Iveco dealer. in accordance with the data given in the calibration table.
K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust tioning. correctly as described in the manual.
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
There is an excessive delay on the injec- Correct the set-up. tion pump.
POSSIBLE CAUSE
REMEDY
NOTE
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up. dark grey smoke. vance. The holes in the atomisers (or some of Replace the injectors with a series of new them) are partially or entirely blocked. injectors or clean and rectify the original ones using suitable equipment. Air cleaner blocked or deteriorated.
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ANOMALY
Clean or replace the filter element.
Loss of compression in the engine due to: Overhaul the engine or limit the interventions to the relative parts. stuck or worn flexible rings; worn cylinder liners; valves deteriorated or badly adjusted. Unsuitable injectors, different types of in- Replace or calibrate the injectors. jectors or incorrectly calibrated. Injection hoses with an unsuitable internal Check conditions of the end or unions diameter, end of hoses pinched due to re- and where necessary replace the hoses. peated blocking. Blue, grey-blue, grey smoke tending to Excessive delay in injection pump. white.
Correct the set-up of the pump.
K.S.B. automatic cold advance device mal- Check or replace injection pump. functioning. Faulty injector.
See your Iveco dealer. See your Iveco dealer.
Replace the injector.
Leaking of oil from the piston rings caused Overhaul the engine. by glued or worn rings or wearing of cylinder liner walls. Engine oil passing through the intake Recondition the cylinder head. guides-valves following wearing of guides or valve stems. Engine too cold (thermostat blocked or Replace the thermostat. inefficient).
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SECTION 3 - DUTY-INDUSTRIAL APPLICATION
123
PART FOUR - MAINTENANCE PLANNING
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125
MAINTENANCE PLANNING Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run.
Planning of controls and periodical intervention Controls and periodical intervention Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*
Frequency (hours) Daily Daily 4000 500* 1000 500 1500
600 hours for engines F4GE9454H*J600, F4GE9454H*J603 and F4GE9454H*J605
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by 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.
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Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers. - Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits. - Notify the maintenance if any inconvenience is detected of if any filling is necessary. After engine start and while engine is running, proceed with the following checks and controls: - check presence of any eventual leakage from the fuel, cooling and lubricating circuits. - Verify absence of noise or unusual rattle during engine working. - Verify, using the vehicle devices, the prescribed pressure temperature and other parameters. - Visual check of fumes (colour of exhaust emissions) - Visual check of cooling liquid level, in the expansion tank.
Figure 350
MAINTENANCE PROCEDURES Checks and controls Engine oil level check The check must be executed when the engine is disconnected and possibly cool.
(Demonstration)
1
The check can be made using the specially provided flexible rod (1).
Figure 349
(Demonstration)
MAX 2 75749
MIN To provide filling, operate through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier”.
1
Some applications are equipped with a level transmitter alerting dashboard instruments in case of insufficient lubrication oil within the pan. 75748
The engine oil is highly polluting and harmful.
Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level.
In case of contact with the skin, rinse well with water and detergent.
Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level.
Adequately protect the skin and the eyes, operate in full compliance with safety regulations.
In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine’s components.
Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Base - May 2010
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F4GE N ENGINES
Check of fuel system The check must be executed both when the engine disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the injection pump and to the injectors.
Cooling system check The check must be executed both when the engine disconnected and when it is running. Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips. Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.
Due to the high temperatures achieved by the system, do not operate immediately after the engine’s disconnection, but wait for the time deemed necessary for the cooling. Protect the eyes and the skin from any eventual high pressure jet of cooling liquid.
The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two year.
NOTE In case of new filling, proceed bleeding system, through the bleeds on the engine. If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine’s head.
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127
Lubricating system check The check must be executed both when the engine disconnected and when it is running. Verify the presence of any oil leakage or blow-by from the head, from the engine pan of from the heat exchanger.
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Check of water presence within fuel filter or pre-filter
NOTE The components of the system can be damaged very quickly in presence of water or impurity within the fuel. Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.
Fuel filter is equipped with pump screw-valve to drain the water eventually mixed with fuel (some applications of 6 cylinders engines will be equipped with two fuel filters, both provided with drainage. Place a container underneath the filter and slightly loosen the screw. Drain the water eventually contained in the filter’s bottom. Lock the screw (max 0.5 Nm locking couple) as soon as fuel starts bleeding.
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Oil motor and filter replacement
Check of drive belt tensioning Some applications are equipped with an automatic tensioner that provides correcting belt tensioning.
Warning: We recommend to wear proper protections because of high motor service temperature.
Check of belt’s tear and wear status Carefully verify the belt’s surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing; check end and surface grinding.
Danger: if the engine is switched off but is still hot, unexpected motion of the belt may occur. Wait for engine temperature cooling as a precaution in order to avoid serious danger injury.
The motor oil reaches very high temperature: you must always wear protection gloves. Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications. We recommend to carry out the oil drainage when the motor is hot. - Place a proper container for the oil collecting under the pan connected with the drain plug. - Unscrew the plug and then take out the control dipsick and the inserting plug to ease the downflow of the lubrication oil.
Check and setting of tappet clearance Figure 351
2
The oil motor is very pollutant and harmful.
1
In case of contact with the skin, wash with much water and detergent.
3
Protect properly skin and eyes: operate according to safety rules. Dispose of the residual properly following the rules.
- After the complete drainage, screw the plug and carry out the clean oil filling.
75806
Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Clearance shall be as follows: - intake valves 0.25 ± 0.05 mm - exhaust valves 0.50 ± 0.05 mm.
NOTE On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearance adjustment procedure that requires adjusting the clearance of all the valves by positioning the crankshaft 2 times only. Each cylinder must be checked by taking it to the T.D.C. (top dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
Base - May 2010
!
Use only the recommended oil or oil having the requested features for the corrrect motor functioning. In case of topping up, don’t mix oils having different features. If you don’t comply with theses rules, the service warranty is no more valid.
- Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dipsick.
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Whereas you replace the lubrication oil, it is necessary to replace the filter.
SECTION 3 - DUTY-INDUSTRIAL APPLICATION
Fuel filter replacement
According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications.
During this operation don’t smoke and don’t use free flames. Avoid to breathe the vapors coming from filter.
- The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the 9936076-tool.
Warning: the oil filter contains inside a quantity of oil of about 1 kg.
129
!
After filters replacement the supply equipment deaeration must be carried out.
Place properly a container for the liquid. Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water. The motor oil is very pollutant: it must be disposed of according to the rules.
According to the applications the filters position and the quantity can change. However the following operations are valid for all applications.
- Replace the filtering cartidge with a new one and screw manually until when the gasket is in contact with the support. - Tigthen by means of the 99360076-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 topping up to compensate the quantity of oil used for the filling of the filtering cartridge.
- Drain the fuel inside the filter by operating the water release screw. Collect the fuel in a container without impurities. - Unscrew the cartridge by using the 99360076-tool. - Collect the eventual fuel inside the filtering cartridge. - Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge. - Screw manually the new filtering cartdrige until when the gasket is completely on its seat. - Tigthen through the 99360076-tool at 10-5 Nm torque.
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Alternator belt replacement Due to several applications the belt run can change very much. We describe the replacement of a belt mounted on a 4-cylinders motor with traditional belt tension.
Warning: with switched off motor (but still hot) the belt can operate without advance notice. Wait for the motor temperature lowering to avoid very serious accidents.
For applications with traditional belt stretcher Figure 352
88089
- Loosen screw (1) and the relevant nut on belt stretching bracket (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 to the support - Run the engine for a few hours and check proper belt stretching.
Base - May 2010
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
1
SECTION 4 Overhaul and technical specifications
Page GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .
4
TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F - VE 6/12 F . .
10
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . .
11
ENGINE REMOVAL AT THE BENCH . . . . . . . .
11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .
12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . .
12
- Checks and measurements . . . . . . . . . . . . . . .
12
- Checking head supporting surface on cylinder unit 13
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TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Checking cam lift and pin alignment . . . . . . . .
15
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Bush replacement . . . . . . . . . . . . . . . . . . . . . .
17
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
- Fitting tappets — camshaft . . . . . . . . . . . . . . . .
17
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
18
- Measuring journals and crankpins (4 cylinders)
18
- Measuring journals and crankpins (6 cylinders)
20
- Replacing oil pump control gear . . . . . . . . . . .
22
- Fitting main bearings . . . . . . . . . . . . . . . . . . . .
22
- Finding journal clearance . . . . . . . . . . . . . . . . .
22
- Checking output shaft shoulder clearance . . .
23
CONNECTING ROD — PISTON ASSEMBLY . .
23
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Page
Page CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .
30
- Removing the valves . . . . . . . . . . . . . . . . . . . .
30
- Checking cylinder head wet seal . . . . . . . . . . .
31
- Checking cylinder head supporting surface . . .
31
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
- Measuring piston diameter . . . . . . . . . . . . . . . .
24
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Conditions for proper pin-piston coupling . . . .
25
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .
26
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . . . . . . . . . 32
- Fitting connecting rod-piston assembly . . . . . .
27
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . .
33
- Connecting rod-piston coupling . . . . . . . . . . . .
27
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . .
27
- Regrinding — replacing the valve seats . . . . . . .
33
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
34
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . .
34
- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Finding crankpin clearance . . . . . . . . . . . . . . . .
28
- Refitting the cylinder head . . . . . . . . . . . . . . . .
35
- Checking piston protrusion . . . . . . . . . . . . . . .
29
TIGHTENING TORQUE (FOR 4 AND 6 CYL.)
36
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
3
GENERAL SPECIFICATIONS Type
4 CYLINDERS
6 CYLINDERS
Cycle
Four-stroke diesel engine
Power
See properties described in Section 3
Injection
Direct
Number of cylinders
4 in-line
6 in-line
∅
+
+
Bore
mm
104
Stroke
mm
132
+.. = Total displacement
cm3
4485
6728
TIMING start before T.D.C. end after B.D.C.
A B
-
start before B.D.C. end after T.D.C.
D C
-
Checking timing mm
0.25 ± 0.05
mm
0.50 ± 0.05
X
X
FUEL FEED Type:
Bosch* VE 4/12 F
rotary
Nozzle type
Bosch VE 6/12 F
-
Injection sequence
1-3-4-2
1-5-3-6-2-4
bar
Injection pressure
*
bar
-
Excluding motor F4GE9454H*J600, F4GE9454H*J603 and F4GE9454H*J605.
Print P2D32N003 E
Base - May 2010
4
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
CLEARANCE DATA
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅1 Cylinder barrels X ∅1 X
mm
∅1
104.000 to 104.024
∅1
0.4
X ∅1 ∅2
55.9 103.714 to 103.732 38.010 to 38.016
Pistons Size Outside diameter Pin housing
∅2
6 CYLINDERS
Piston — cylinder barrels
0.252 to 0.294
Piston diameter
∅1
Piston protrusion
X
0.4
X
∅ 3
Piston pin Piston pin — pin housing
Base - May 2010
0.28 to 0.52
∅3
37.994 to 38.000 0.010 to 0.022
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X1 Split ring slots X2 X3 X2 X3 * measured on a ∅ of 99.00 mm S 1 S 2 S 3
X1 X2
∅ 2 ∅ 3 S
2,705 to 2,735 2,440 to 2,460 4,030 to 4,050
2.560 to 2.605 2.350 to 2.380 3.970 to 3.990
Split rings - slots
1 2 3
0.100 to 0.175 0.060 to 0.110 0.040 to 0.080 0.4
Split ring end opening in cylinder barrel:
Small end bush housing Big end bearing housing
X1 X2 X3
0.30 to 0.40 0.60 to 0.80 0.30 to 0.55
∅1
40.987 to 41.013
∅2
72.987 to 73.013
Small end bush diameter Inside
∅3
Big end half bearings
S
Piston pin — bush Big end half bearings
Print P2D32N003 E
mm
S1 S2 S3
X3
∅1
6 CYLINDER
Split rings
Split rings
5
38.019 to 38.033 1.955 to 1.968 0.019 to 0.039 0.250 ; 0.500
Base - May 2010
6
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4GE N ENGINES
4 CYLINDERS
6 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
mm
X Size
-
X
Max. tolerance on connecting rod axis alignment
-
Journals Crankpins
∅1 ∅2
82.99 to 83.01 68.987 to 69.013
Main half bearings Big end half bearings
S1 S2
2.456 to 2.464 1.955 to 1.968
Main bearings No. 1 — 5 No. 2 — 3 — 4
∅3 ∅3
87.982 to 88.008 87.977 to 88.013
∅2
∅1
S 1
S 2
∅ 3
Half bearings — Journals No. 1—5 / 1-7 No. 2—3—4 / 2-3-4-5-6
0.064 to 0.095 0.059 to 0.100
Half bearings - Crankpins
0.064 to 0.090
Main half bearings Big end half bearings
0.250 to 0.500
Shoulder journal
X1
37.475 to 37.550
37.475 to 37.545
Shoulder main bearing
X2
32.180 to 32.280
Shoulder half-rings
X3
37.28 to 37.38
X 1
X 2 X 3
Output shaft shoulder
Base - May 2010
0.095 to 0.270
0.095 to 0.265
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM ∅ 1
6 CYLINDERS mm
Valve guide seats on cylinder head
∅ 4
7
∅1
8.019 to 8.039
∅4 α
7.960 to 7.980 60º
∅4 α
7.960 to 7.980 45º
Valves:
α Valve stem and guide
0.059 to 0.086
Housing on head for valve seat:
∅ 1
46.987 to 47.013
∅1
43.637 to 43.663
Valve seat outside diameter; valve seat angle on cylinder head: ∅2 α
∅ 2
∅2 α
α
X
Sinking Between valve seat and head Valve seats
Print P2D32N003 E
∅1
47.063 to 47.089 60º 43.713 to 43.739 45º
X
1 to 1.52
X
1 to 1.52 0.050 to 0.102 0.050 to 0.102 -
Base - May 2010
8
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
F4GE N ENGINES
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
6 CYLINDERS mm
Valve spring height: free spring H
H1
H 2 under a load equal to: 329 N 641 N Injector protrusion
H
63.50
H1 H2
49.02 38.20
X
-
X Camshaft bush housings No. 1 (flywheel side) ∅ ∅ ∅ 1 23 4 5 ∅ 2
∅ 1
59.222 to 59.248
Camshaft housings No. 2-3-4-5 / 2-3-4-5-6-7
54.089 to 54.139
Camshaft journals: 1⇒5 1⇒7
∅ ∅
53.995 to 54.045
Bush inside diameter
∅
54.083 to 54.147
∅ 3 ∅
Bushes and journals
0.038 to 0.162
Cam lift: H
Base - May 2010
H
-
H
-
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
9
6 CYLINDERS mm
∅1 Tappet cap housing on block ∅2 ∅ 3
Tappet cap outside diameter:
∅2
∅1
16.000 to 16.030
∅2 ∅3
15.924 to 15.954 15.965 to 15.980
Between tappets and housings
-
Tappets
-
∅ 1 Rocker shaft
∅1
18.963 to 18.975
Rockers
∅2
19.000 to 19.026
∅ 2 Between rockers and shaft
Print P2D32N003 E
0.025 to 0.063
Base - May 2010
10
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F - VE 6/12 F
4-CYLINDER ENGINES
6-CYLINDER ENGINES
NOTE
Technical Code
Commercial Code
Pre-lift (mm)
F4GE9454H*J601 F4GE9454J*J600
N45 MSS.X
1.00 ± 0.05 0.70 ± 0.05
F4GE9454H*J602 F4GE9454J*J601
N45 MNS.X
1.00 ± 0.05 0.70 ± 0.05
F4GE9484D*J601 F4GE9484F*J603
N45 MST.X
0.75 ± 0.05 0.80 ± 0.05
N45 MNT.X
0.80 ± 0.05 0.80 ± 0.05 0.80 ± 0.05 0.80 ± 0.05 0.75 ± 0.05 0.75 ± 0.05 0.75 ± 0.05 0.75 ± 0.05 0.75 ± 0.05 0.75 ± 0.05 1.00 ± 0.05
N67 MST.X
0.70 ± 0.05 0.70 ± 0.05
F4GE9484F*J611 F4GE9484J*J602 F4GE9484F*J604 F4GE9484F*J607 F4GE9484D*J602 F4GE9484D*J612 F4GE9484D*J613 F4GE9484D*J614 F4GE9484D*J610 F4GE9484D*J609 F4GE9484D*J602 F4GE9684A*J602 F4GE9684P*J601 F4GE9684P*J602
INJECTION PUMP CALIBRATION Overhaul and calibration interventions are up to BOSCH assistance network. The contract technical specification containing the data to calibrate the pump at the bench is identified by the code shown on injection pump body and is available at BOSCH technical assistance network. Otherwise, refer to FPT Technical Assistance Service.
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH
11
Figure 3
The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well. (See Section 3 of the manual herein). The section illustrates therefore all the most important engine overhaul procedures. The following operations are relating to the 4 cylinders engine but are analogously applicable for the 6 cylinders. 70160
The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).
Figure 1
NOTE Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.
Figure 4
70158
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. NOTE Keep the half-bearings into their housings since in case of use they shall be fitted in the same position found at removal.
70161
Use tool 99360500 (1) and hoist to remove the output shaft (2) from the block. Figure 2 Figure 5
70159
Remove the screws (1) and the main bearing caps (2).
70162
Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3). Print P2D32N003 E
Base - May 2010
12
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
zs
REPAIR OPERATIONS CYLINDER UNIT Checks and measurements
Figure 6
Figure 9
70163
s
Remove the screws (1) and disconnect camshaft (3) retaining plate (2). NOTE Take note of plate (2) assembling position.
70166
Once engine is disassembled, clean accurately the cylinder-block assembly. Use the proper rings to handle the cylinder unit. Figure 7
The engine block shall not show cracks. Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear. Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter. NOTE Should the ring gauge be not available, use a micrometer for zero-setting. 70164
Withdraw carefully the camshaft (1) from the engine block.
Figure 10
Figure 8
70167
Measurements shall be performed on each cylinder, at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement. 70165
Withdraw the tappets (1) from the engine block. Base - May 2010
Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.5 mm and to the specified assembling clearance. Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
13
Check main bearing housings as follows:
Figure 11
- fit the main bearings caps on the supports without bearings; - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value.
α
Replace if higher value is found.
Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit. Planarity error shall not exceed 0.075 mm. Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.
107804
NOTE In case of regrinding, all barrels shall have the same oversize (0.4 mm).
Print P2D32N003 E
Base - May 2010
14
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
TIMING SYSTEM Camshaft Figure 12
70169
CAMSHAFT MAIN DATA (4 CYL.) Specified data refer to pin standard diameter
Figure 13
70512
MAIN DATA ABOUT CAMSHAFT PINS (6 CYL.)
Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the
Base - May 2010
camshaft and the bushes.
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cam lift and pin alignment
15
BUSHES
Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft.
Figure 15
Figure 14
70172
70171
Camshaft bush (2) shall be pressed into its housing. Internal surface must not show seizing or wear. Use bore dial gauge (3) to measure camshaft bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.
Print P2D32N003 E
Base - May 2010
16
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
Figure 16 sec. A-A
107399
MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (4-cylinder engines) * Dimension to be measured after inserting the bearing bush.
Figure 17
sec. A-A
107268
MAIN SPECIFICATIONS OF THE CAMSHAFT BEARING BUSH AND ITS SEAT (6-cylinder engines) * Dimension to be measured after inserting the bearing bush. Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Bush replacement
17
Fitting tappets — camshaft Figure 20
Figure 18
70176 70174
To replace the bearing (1) use tool 99360362 (2) and handle 99370006 (3) to remove and install it.
Lubricate the tappets (1) and fit them into the relevant housings on the engine block. Figure 21
NOTE When installing the bearing (1) it must be oriented so that the lubrication holes are aligned with those on the seats of the crankcase.
70164
Lubricate the camshaft support bearing and install the camshaft (1) being careful to ensure that the bearing or the shaft support seats are not damaged during the operation.
Tappets Figure 22
Figure 19
70238 84053
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK Print P2D32N003 E
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.
Base - May 2010
18
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
OUTPUT SHAFT Measuring journals and crankpins (4 cylinders)
Figure 23
Figure 25
70179
Check camshaft end float (1). It shall be 0.23 ± 0.13 mm.
70182
Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.
Figure 24
NOTE It is recommended to insert the found values in the proper table. See Figure 26. Undersize classes are:
70180
Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.
NOTE Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB
Figure 26
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
19
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 27
measured on > 45.5 mm radius between adjacent journals
70183
OUTPUT SHAFT MAIN TOLERANCES
TOLERANCES
TOLERANCE CHARACTERISTIC Roundness
SHAPE
DIRECTION POSITION OSCILLATION
Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL ○ /○/ //
GRAPHIC SYMBOL
CRITICAL
©
IMPORTANT
⊕
SECONDARY
⊝
MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
INTERMEDIATE MAIN BEARINGS
FIRST MAIN BEARING ON FRONT SIDE
70237
Print P2D32N003 E
Base - May 2010
20
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
Measuring journals and crankpins (6 cylinders) Figure 28
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value
Figure 29
K
* **
Measured on a radius greater than 45.5 mm ↗ 0.500
between adjacent main journals
70577
MAIN OUTPUT SHAFT TOLERANCES
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
21
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 30
INTERMEDIATE MAIN BEARINGS
MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
FIRST MAIN BEARING ON FRONT SIDE
70237
TOLERANCES
TOLERANCE CHARACTERISTIC Roundness
SHAPE
DIRECTION POSITION OSCILLATION
Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL ○ /○/ //
GRAPHIC SYMBOL
CRITICAL
©
IMPORTANT
⊕
SECONDARY
⊝
Print P2D32N003 E
Base - May 2010
22
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
Finding journal clearance
Replacing oil pump control gear
Figure 33 Figure 31
70161
Refit the output shaft (2). Check the backlash between output shaft main journals and the relevant bearings as follows: 70184
Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3). When fitting the new gear, heat it to 180°C for 10 minutes in an oven and then key it to the output shaft. Figure 34
Fitting main bearings Figure 32
70186
- clean accurately the parts and remove any trace of oil; 70185
NOTE Refit the main bearings that have not been replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter. NOTE Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings.
- position a piece of calibrated wire (3) on the output shaft pins (4) so that it is parallel to the longitudinal axis; - fit caps (1), including the half bearings (2) on the relevant supports.
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
The second last main half bearing (1) is fitted with shoulder half rings. Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
23
Checking output shaft shoulder clearance
Figure 35
Figure 38
70187
Tighten the pre-lubricated screws (1) in the following three successive stages: - 1st stage, with dynamometric wrench to 50 ± 6 Nm. - 2nd stage, with dynamometric wrench to 80 ± 6 Nm. Figure 36
70190
This check is performed by setting a magnetic-base dial gauge (2) on the output shaft (3) as shown in the figure, standard value is 0.068 to 0.41. If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between output shaft pins and main half bearings.
α
CONNECTING ROD — PISTON ASSEMBLY 70188
- 3rd stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90° ± 5° angle.
Figure 39
Figure 37
70191 70189
- Remove caps from supports. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire. The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described. Print P2D32N003 E
CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush. NOTE The pistons are supplied spare with the following sizes: - standard; - 0.4 mm oversize. Base - May 2010
24
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
Pistons Measuring piston diameter
Figure 40
Figure 43
32613
Remove split rings (1) from piston (2) using pliers 99360183 (3).
32615
Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance. NOTE The diameter shall be measured at 55.9 mm from the piston skirt.
Figure 41
Figure 44
32614
Piston pin (1) split rings (2) are removed using a scriber (3). 70192
Figure 42
The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.
87760
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
25
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Piston pins
Figure 48
Figure 45
18857
32620
To measure the piston pin (1) diameter use the micrometer (2).
Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1).
Conditions for proper pin-piston coupling Figure 46
Figure 49
32619
Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.
41104
DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).
Split rings Figure 47
In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.
16552
Use a micrometer (1) to check split ring (2) thickness.
Print P2D32N003 E
Base - May 2010
26
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 50
F4GE N ENGINES
Figure 52
70194
Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).
Connecting rods Figure 51
80339
NOTE Every connecting rod is marked as follows: - On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one. - On body with a letter showing the weight of the connecting rod assembled at production:
S
V, 1820 to 1860 (yellow marking);
S
W, 1861 to 1900 (green marking);
S
X, 1901 to 1940 (blue marking);
Spare connecting rods are of the W class with green marking *. Material removal is not allowed. 88607
NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls.
Base - May 2010
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Bushes
27
Figure 55
Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.
Fitting connecting rod-piston assembly Connecting rod-piston coupling 72705
Figure 53
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 Figure 56
70198
The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block; 3. Marking showing 1st slot insert testing; 4. Manufacturing date. 32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°.
Figure 54
NOTE Split rings are supplied spare with the following sizes: -
standard;
-
0.4 mm oversize.
70199
Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure. Print P2D32N003 E
Base - May 2010
28
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 57
F4GE N ENGINES
Figure 59
70202
70200
Fit half bearings (1) on connecting rod and cap. NOTE Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings.
DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL - Split ring openings shall be displaced with each other by 120°; - connecting rod-piston assemblies shall have the same weight; - the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.
Finding crankpin clearance Figure 60
Fitting connecting rod-piston assembly into cylinder barrels Figure 58 70203
To measure the clearance proceed as follows: - clean the parts accurately and remove any trace of oil; - set a piece of calibrated wire (2) on the output shaft pins (1); - fit the connecting rod caps (3) with the relevant half bearings (4).
70201
Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 99360605 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number. Base - May 2010
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Figure 61
29
Figure 64
α
70204
- Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometric wrench (2).
70207
If a different clearance value is found, replace the half bearings and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque.
Figure 62 α
Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.250 to 0.275 mm.
70205
- Apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60°.
Checking piston protrusion Figure 65
Figure 63
70208
70206
- Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2).
Print P2D32N003 E
Once connecting rod-piston assemblies refitting is over, use dial gauge 39395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm. Base - May 2010
30
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
CYLINDER HEAD Removing the valves
F4GE N ENGINES
Figure 67
1
2 3
Figure 66
4
1 2
6
5 A
75751
75750
Intake (1) and exhaust (2) valves have heads with the same diameter. The central notch (→) of the exhaust valve (2) head distinguishes it from the intake valve.
Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Repeat this operation for all the valves. Overturn the cylinder head and withdraw the valves (5). Figure 68
NOTE
Should cylinder head valves be not replaced, number them before removing in order to refit them in the same position.
2
A = intake side — S = exhaust side
1
75752
NOTE Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.
Base - May 2010
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F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Checking cylinder head wet seal
31
Figure 70
Figure 69 D
1
0,4 C 0,025 / ¯ 25,4
A
B
0,4 TOTAL 0,01 / ¯ 50
75753
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 cup plugs (1) if leaks are found, use the proper beater for their removal/refitting.
C
75756
The rated thickness A for the cylinder head is 95 ± 0.25 mm, max. metal removal shall not exceed thickness B by 1 mm. NOTE After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with water-repellent sealant. Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface
Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure.
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Base - May 2010
32
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVES
F4GE N ENGINES
Figure 73
Figure 71 EXHAUST VALVE
INTAKE VALVE
18882
Check the valve stem (1) using a micrometer (2), it shall be 7.943 to 7.963.
116395
INTAKE AND EXHAUST VALVE MAIN DATA
Removing carbon deposits, checking and grinding valves Figure 72
Checking clearance between valve stem and valve guide and valve centering Figure 74
1 2
18625
Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Regrind the valve seats, if required, removing as less material as possible. Base - May 2010
75757
Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.056 ± 0.096 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. Print P2D32N003 E
F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
VALVE GUIDE
33
VALVE SEATS Regrinding — replacing the valve seats
Figure 75
Figure 76
1 2
75754
INTAKE
EXHAUST 84046
Check the valve seats (2). If slight scoring or burnout is found, regrind seats using adequate tool (1) according to the angle values shown in Figure 77.
Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.
Figure 77
116356
INTAKE
EXHAUST VALVE SEAT MAIN DATA
Should valve seats be not reset just by regrinding, replace them with the spare ones. Use adequate tool to remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch.
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Heat the cylinder head to 80° - 100°C and using the proper beater, fit the new valve seats, previously cooled, into the cylinder head. Use adequate tool to regrind the valve seats according to the values shown in Figure 77.
Base - May 2010
34
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
FITTING CYLINDER HEAD
Figure 78
Figure 80
1 3
1
2 3
1 2 75758 75759
After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial gauge 99395603 (1).
Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal. Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green.
VALVE SPRINGS Figure 79
50676
Figure 81
1 MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Before refitting use adequate tool to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table.
2 3 4
6 Height
Under a load of
mm
N
H (free)
63.50
0
H1
49.02
329
H2
38.20
641
5 75751
Position on the cylinder head: the spring (4), the upper cap (3); use tool 99360268 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2). Base - May 2010
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F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
35
For 6 cylinder versions:
Refitting the cylinder head
Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value.
Figure 82
S=
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6 6
If S is > 0,40 mm use seal type A. If S is < 0,40 mm use seal type B.
87759
Check cleanness of cylinder head and engine block coupling surface. Take care not to foul the cylinder head gasket. Set the cylinder head gasket (1) with the marking “N. of component” (1) facing the head. The arrow shows the point where the gasket thickness is given. Figure 83
NOTE Before using the fixing screws again, measure them twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 > 0,1 mm the screw must be replaced.
D2
D1
75703
88775
There are two types of head seals, for the thickness (1.25 mm Type A and 1.15 mm Type B) take the following measures: - for each piston detect, as indicated on Figure 83, at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average: S cil1 = S1 + S2 2 For 4 cylinder versions: Repeat the operation for pistons 2, 3 and 4 and calculate the average value. S=
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S cil1 + S cil2 + S cil3 + S cil4 4
Base - May 2010
36
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
F4GE N ENGINES
TIGHTENING TORQUE (FOR 4 AND 6 CYL.) TORQUE
COMPONENT Cooling Nozzles (M8x1.25x10) Main bearing cap
Rear gear housing assembly (M8x1.25x40) (M8x1.25x25) (M10x1.5) Oil pump (M8x1.25x30) Front cover assembly (M8x1.25x45) (M8x1.25x30) Connecting rod bolts (M11x1.25)
1st stage 2nd stage 3rd stage
kgm 1.5 ± 0.3 5.0 ± 0.6 8.0 ± 0.6 90º ± 5º 2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5
24 ± 4 24 ± 4 49 ± 5 8±1
1st stage 2nd stage 3rd stage
Ladder frame assembly (M10x1.25x25) Oil rifle plugs (M10x1) (M14x1.5) Assemble oil suction tube (M8x1.25x20) Oil pan assembly (M8x1.25x25) (M18x1.50) Set timing pin Fuel pump assembly M8 screw M6 screw M6 nut M10x1.5 flange head nuts pre-torque Final torque Fuel pump gear (drive gear nut) Snug torque Final torque Timing pin cap of fuel pump Rocker assys (M8) Cylinder head bolts (M12x70) (M12x140) (M12x180) Assy rocker covers (M8x1.25x25) Intake manifold (M8x1.25) Assy air intake connection (M8x1.25) Oil bypass valve into lube filter head (M22x1.5x10) Plug (M12x1.5x12) Exhaust manifold (M10x1.5x65) Water pump (M8x1.25x25) Water outlet connection (M8x1.25x35) (M8x1.25x70) Fan support (M10x1.5x20) Fan pulley (M6) (M10)
Base - May 2010
Nm 15 ± 3 50 ± 6 80 ± 6
0.8 ± 0.1
24 ± 4 24 ± 4 30 ± 3 60 ± 5
2.4 ± 0.4 2.4 ± 0.4 3.0 ± 0.3 6.0 ± 0.5 60º ± 5º
43 ± 5
4.3 ± 0.5
6±1 11 ± 2 24 ± 4
0.6 ± 0.1 1.1 ± 0.2 2.4 ± 0.4
24 ± 4 60 ± 9 5±1
2.4 ± 0.4 6.0 ± 0.9 0.5 ± 0.1
24 ± 4 10 ± 1 10 ± 1 10 - 15 50 - 55 15 - 20 85 - 90 30 - 35 24 ± 4
2.4 ± 0.4 1.0 ± 0.1 1.0 ± 0.1 1.0 - 1.5 5.0 - 5.5 1.5 - 2.0 8.5 - 9.0 3.0 - 3.5 2.4 ± 0.4
50 + 90º 40 + 180º 70 + 180º 24 ± 4 24 ± 4 24 ± 4 80 ± 8 10 ± 1 43 ± 6 24 ± 4
5.0 + 90º 4.0 + 180º 7.0 + 180º 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 8.0 ± 0.8 1.0 ± 0.1 4.3 ± 0.6 2.4 ± 0.4
24 ± 4 24 ± 4 33 ± 5
2.4 ± 0.4 2.4 ± 0.4 3.3 ± 0.5
10 ± 2 43 ± 6
1.0 ± 0.2 4.3 ± 0.6
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F4GE N ENGINES
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
TORQUE
COMPONENT Rear lifting bracket (M12x1.75x30) Crankshaft pulley (M12x1.75x10.9) Flywheel housing (M12x120) (M12x80) (M10x80) (M10x40) Flywheel housing (M12x1.25)
1st stage 2nd stage Assy rear cover plate to flywheel housing (M8x1.25x16) Fuel injectors Fuel lift pump Turbocharger to exhaust manifold (M10) Oil feed to oil filter head Oil feed to turbocharger (M12x1.5) Oil drain (M8x1.25x16) Alternator to alternator support (M8x1.25x30) Alternator to water inlet conn. assy (M8x1.25x30) Lower alternator mounting (M10x1.25x25) Alternator upper pivot to support (M10) Alternator mounting hardware (M12x1.75x120) Alternator wiring (M6x1.0 nut) Starter motor to gear case (M10) Screw M8 for fastening cylinder barrel lubricating nozzles Screw M12 for fastening output shaft caps
Nm 77 ± 12 110 ± 5
kgm 7.7 ± 1.2 11.0 ± 0.5
85 ± 10 85 ± 10 49 ± 5 49 ± 5 30 ± 4
8.5 ± 1.0 8.5 ± 1.0 4.9 ± 0.5 4.9 ± 0.5 3.0 ± 0.4 60º ± 5º
1st stage 2nd stage 3rd stage
Screw M8 for fastening camshaft longitudinal retaining plate Screw M8 for fastening camshaft gear Screw M10 for fastening connecting rod caps 1st stage 2nd stage
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37
24 ± 4 60 ± 5 24 ± 4 43 ± 6 24 ± 4 35 ± 5 24 ± 4 24 ± 4 24 ± 4 24 ± 4 49 ± 5 43 ± 6 10 ± 2 49 ± 5 15 ± 3 50 ± 6 80 ± 6
2.4 ± 0.4 6.0 ± 0.5 2.4 ± 0.4 4.3 ± 0.6 2.4 ± 0.4 3.5 ± 0.5 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5 4.3 ± 0.6 1.0 ± 0.2 4.9 ± 0.5 1.5 ± 0.3 5 ± 0.6 8 ± 0.6 90º ± 5º
24 ± 4 36 ± 4 60 ± 5
2.4 ± 0.4 3.6 ± 0.4 6 ± 0.5 60º ± 5º
Base - May 2010
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SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS
Base - May 2010
F4GE N ENGINES
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F4GE N ENGINES
SECTION 5 - TOOLS
1
SECTION 5 Tools Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3
Base - May 2010
2
SECTION 5 - TOOLS
Base - May 2010
F4GE N ENGINES
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F4GE N ENGINES
SECTION 5 - TOOLS
3
TOOLS TOOL NO.
DESCRIPTION
99322205
Revolving stand for overhauling units (700 daN/m capacity, 120 daN/m torque)
99340035
Injection pump gear extractor.
99340055
Tool to remove output shaft front gasket
99340056
Tool to remove output shaft rear gasket
99340205
Tool to remove injectors
99346252
Tool for fitting output shaft front gasket
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Base - May 2010
4
SECTION 5 - TOOLS
F4GE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99346253
Tool for fitting output shaft rear gasket
99360076
Tool to remove oil filter (engine)
99360183
Pliers for removing/refitting piston rings (65 — 110 mm)
99360268
Tool for removing/refitting engine valves
99360330
Flywheel crank handle
99360339
Tool for stopping the engine flywheel
Base - May 2010
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F4GE N ENGINES
SECTION 5 - TOOLS
5
TOOLS TOOL NO.
DESCRIPTION
99360344
Adapter, cylinder compression test (use with 99395682)
99360351
Tool for flywheel holding
99360362
Beater for removing/refitting camshaft bushes (to be used with 993700069)
99360500
Tool for lifting the output shaft
99360595
Lifting rig for engine removal/refitting
99360605
Band for fitting piston into cylinder barrel (60 — 125 mm)
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Base - May 2010
6
SECTION 5 - TOOLS
F4GE N ENGINES
TOOLS TOOL NO.
DESCRIPTION
99360616
Engine TDC positioning tool
99361037
Brackets for fastening engine to revolving stand 99322205
99363204
Tool to remove gaskets
99370006
Interchangeable willow handgrip
99370415
Gauge base for different measurements (to be used with 99395603)
99395097
Tool to check top dead centre (use with 99395604)
Base - May 2010
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F4GE N ENGINES
SECTION 5 - TOOLS
7
TOOLS TOOL NO.
DESCRIPTION
99395100
Dial gauge holder for rotary injection pump timing (use with 99395603)
99395216
Pair of gauges with ½” and ¾” square head for angle tightening
99395603
Dial gauge (0 — 5 mm)
99395604
Dial gauge (0 — 10 mm)
99395682
Diesel fuel engine cylinder compression control device
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Base - May 2010
8
SECTION 5 - TOOLS
Base - May 2010
F4GE N ENGINES
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1
PT-BOX ISTRUCTIONS
Part 5 PT-BOX ISTRUCTIONS Section PT-BOX istructions
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Base - May 2010
2
Base - May 2010
PT-BOX ISTRUCTIONS
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3
PT-BOX ISTRUCTIONS
PT-BOX INSTRUCTIONS Hardware installation
!
This Sw may cause engine start-up. Be extremely careful. The user is responsible for the correct use of the PT-DIAGNOSIS software so as not to any cause injury to people or damage to items. The user is also responsible for complying with all the rules relating to security for activities on the industrial applications (engine, pump, generating set…) carried out in the workshop. Carefully read the user manual before using the diagnostic tool and follow the instructions displayed on the screen.
Select your user configuration type and then follow the relevant information. 1. PT-PLUS configuration - PC Panasonic user - PT-BOX module - PT-DIAGNOSIS sw 2. PT-DIAGNOSIS configuration - user with own PC - PT-BOX module - PT-DIAGNOSIS sw The PT-BOX module (Electronic Communication Interface) PT-BOX is an interface module allowing the communication between the engine ecu’s and the PC. - Weight: 500 g; - Dimension: 175x75x30mm;
General rules for use
- Flash memory: 4Mb - RAM 1Mb;
The following instructions should always be strictly followed:
- Thermal tolerance: 0-50°C;
-
- Power supply: 6-32V;
all instruments ensuring the security must be applied as indicated in the application;
-
ensure that the PT-BOX module is connected to the diagnostic socket of the engine on which work is to be carried out;
-
in case of emergency, disconnect the PT-BOX module from the engine or disconnect the USB cable;
-
ensure that while using the software, there is nobody near the engine/vehicle you are working on;
-
if it is necessary for more than one person to be working on or near the engine/vehicle, they are all responsible for complying with security regulations of the workshop;
-
we strongly suggest that the PT-BOX modules be visibly and uniquely identified (for example by using coloured adhesive tape, labels with names, etc…).
!
By only accepting the use disposal it is possible to access PT-DIAGNOSIS (the green tick icon becomes active).
The diagnosis system consists of: -
a PC (Panasonic / your PC + Microsoft Windows 2000 or Windows XP Professional);
-
an instrument used as interface between engines/vehicles and PC (PT-BOX tester);
-
a SW program (PT-DIAGNOSIS) to process data.
By combinating the above indicated components 2 different configuration are possible.
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- Connection interfaces: USB and RS232 standard Bluetooth optional; - Interface for engine electronic systems: 9 KL ISO 9141 lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O PWM. The led indicators on the front view allow to check the communication lines activity with the engine and with the PC to which the instrument is connected. Figure 1
156133
1. Led indicators to display the activity of the communication lines K/L. - 2. The upper led display the ECU’s communication activity. - 3. The lower led indicators display the CAN lines activity. - 4. The three upper led indicators show the activity of the K/L communication lines. - 5. The lower led indicator (fault) shows the presence of errors on the K/L lines. - 6. The upper led indicator shows that the PT-BOX is power-supplied. - 7. When blinking the lower led indicator (run) shows that the PT-BOX module is correctly working. - 8. Led indicators to display the USB ports (upper led). - 9. Led indicators to display the serial ports (lower led).
Base - May 2010
4
PT-BOX ISTRUCTIONS
Pt-box - engine/vehicle connection
Connect the pt-box module On the PT-BOX module there are the communication ports for the connection to the PC and to the engine / vehicle.
Figure 5
Communication ports for the connection to the PC Figure 2
156138
-
connect the module to the engine/vehicle by using the specific connection cable.
156135
1. serial port - 2. USB port
NOTE
Figure 3
The module is power-supplied by the diagnostic cable; for this reason to work correctly it must be connected to the engine.
System requirements Minimum -
Processor: 300 MHz Pentium-II CPU;
-
Hard disk space: 3 GB available;
-
Ram: 256 MB;
-
Display: 800 x 600 video adapter and monitor;
-
Internet connection only needed for rss and pt-diagnosis software update (eaus): modem;
-
External ports: USB connector;
-
External reader: DVD-ROM reader;
-
Os: Microsoft WindowsTM XP Professional Service Pack 2 - Microsoft Windows 2000 Service Pack 4 plus Windows 2000-KB835732-x86-ENU.EXE (login with administrator privileges);
-
Browser: Internet Explorer 5.5.
156136
Connector for the connection of the engine communication cable. Pt-box - pc connection Figure 4
Recommended -
Processor: 1 GHz Pentium IV - Centrino CPU;
-
Hard disk space: 5 GB available;
-
Ram: 512 MB;
-
Display: 1024 x 768 high colour video adapter and monitor;
-
Internet connection only needed for rss and pt-diagnosis software update (eaus): high-speed e.g. ADSL;
connect the USB cable (PT-BOX side marked) to the PT-BOX module (remove the holding screws from the PT-BOX module, where present);
-
External ports: 2 USB 2.0 connectors, Bluetooth;
-
External reader: DVD-ROM reader;
-
connect the USB cable to the PC;
-
-
turn the PC on.
Os: Microsoft WindowsTM XP Professional - Service Pack 3 (login with administrator privileges);
-
Browser: Internet Explorer 6.0.
156137
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5
PT-BOX ISTRUCTIONS
Software installation Registration Before using the PT-Diagnosis system you have to carry out the registration of the system being used. This procedure allows you to obtain the activation code. The registration procedure is carried out on-line and it is different according to the user type: - OEM users - Dealer users
NOTE
For both configurations (PT-PLUS and PT-DIAGNOSIS) the SW installation is the same. -
A fill-in form is displayed.
Registration>OEM users
!
Before using the PT-Diagnosis system you have to carry out the registration of the system being used. This procedure allows you to obtain the activation code. For this reason: -
Check that the registration card has been delivered together with the kit.
-
Select www.eltrac.it/ivecomotors/default.asp.
-
From the starting page, select the language.
-
Select pt users registration.
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The activation code received will be requested the first time you run the PT-DIAGNOSIS software.
Registration form (OEM user) The Registration allows you to download the EVCA SYNC WEB application which allows you to obtain the activation code:
In the registration form: 1.
Enter the Customer PIN: it is the customer authentication code; it is an alphanumeric code sent by e-mail to the user after having bought the PT-DIAGNOSIS system.
2.
Select the send key: the identification data and the Network characteristics areautomatically entered.
3.
Enter the serial number of the PT-BOX instrument.
Base - May 2010
6
PT-BOX ISTRUCTIONS
Figure 6
NOTE
Before carrying out the registration we suggest to install the PT-Diagnosis SW.
Installing the EVCA SYNC WEB (OEM users) application To obtain the activation code it is necessary to install the EVCA SYNC WEW application, after saving it on the desired directory:
156139
The serial number is type PB-#####-##-##-##; to be found on the back of the PT-BOX module 4.
Read the note in compliance with art. 13 of Italian Legislative Degree 196 dated 30 June 2003 about the processing of personal data Informative
5.
Select the send key (only once!) wait…
After sending a summary window is displayed waiting for the end of the registration procedure.
1.
Unzip the evcasyncweb1.2.6.zip (for example using WinZip: www.winzip.com/downwz.htm).
2.
Open the EVCASyncWeb1.2.6 EVCASyncWeb15-09-10 (Rel1.2.6).
3.
Run setup.exe and continue with the installation of the guided application.
NOTE
and
then
For further information about the installation of EVCASyncWeb it is possible to read the detailed guide EVCASyncWeb Setup.pdf in the directory EVCASyncWeb1.2.6.
Then a link is available to download the EVCA SYNC WEB application. It will be used to obtain the activation code: 6.
Select the print key for printing a summary report (registration data and number of registered instrument).
7.
Select the link to download and then select the save key, to save the application on the PC.
Base - May 2010
4.
At the end of the installation, the icon of the EVCASyncWeb application is displayed on the desktop of the PC.
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7
PT-BOX ISTRUCTIONS
Running the EVCA SYNC WEB (OEM user) application
1.
3.
Enter the PT-BOX serial number of and the Customer PIN.
4.
To continue, select the confirm key.
5.
Enter the alpha code supplied with the Registration Card (scrap the card).
6.
To continue, select the confirm key.
Double click on the icon EVCASyncWeb application.
At the start up of the application choose the Internet connection mode: - by means of the Proxy Server; it is necessary to enter the connection parameters; at the end select the okey. It is possible to pre-set the connection parameters: read the EVCASyncWeb manual; - without Proxy Server; select the okey.
The starting page EVCASyncWeb is displayed; some functions are available (for more information read the manual EVCASyncWeb). 2.
Select the applications key for pc.
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Base - May 2010
8
PT-BOX ISTRUCTIONS
Summary of the selected choices (OEM user) At the end of the activation procedure, the summary of the selected choices is available. The following data are displayed:
Contract Activation (OEM User) 7.
Select a contract type.
The contract types available for the OEM users are indicated below: - Fee (annually): the duration of the contract is for one year, starting from the activation date of the contract. During this phase it is only possible to associate one instrument to the contract. - Token (to be deducted): it is the payment for a single download of an application; it is possible to associate to the contract to 4 instruments. 8.
To continue, select the confirm key.
- The type of selected contract. - The list of instruments (PT/PB) associated to the contract with the generated activation codes - The expire date of the contract (in case of yearly fee) or residual credit (coins): 1.
We suggest you to print and keep the summary data: select the key print selections recap.
2.
Show and download the list of the available applications belonging to your profile (FPT activation): select the applications download key.
The window containing the activation codes is displayed. 9.
Print/copy the activation codes and keep them together with the instruments they are associated to.
10. Select the okey to end.
Base - May 2010
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9
PT-BOX ISTRUCTIONS
Download the applications
Registration>Dealer users Before using the PT-DIAGNOSIS diagnosis system you must register on the FPT web site.
The following information for each one of the available applications for downloading is displayed: ECU, license, file name, Release Date, Release Type and short description.
1.
Connect to http://www.fptpowertrain.com/index_main.htm.
2.
Select the language.
3.
Select Fiat Powertrain Technologies and then Partner Area.
4.
Connect to the web site by selecting Click here.
Each option can be used to sort the list: to sort the list in ascending/descending order according to a given key, select the title of the corresponding column. 1.
Select the application to be downloaded; the selected line is highlighted in red.
2.
Select the download the selected application key and follow the system instructions.
3.
Identify the path where the packets have been downloaded.
4.
At the end of the download install the packets (double click) one by one.
NOTE
The packets must be downloaded/installed one by one.
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10
5.
PT-BOX ISTRUCTIONS
Fill in the fields for the login procedure.
7. NOTE
For the new customers: request username and password
[email protected].
Go to the registration web page; select pt users registration a fill-in form is displayed (on-line registration form).
to
For the customers already registered: use username and password received by e-mail.
Registration form (Dealer user) The Registration allows you to download the EVCA SYNC WEB application which allows you to obtain the activation code.
In the registration form:
6.
Please follow the indicated instructions After Sales>Various>Diagnostic Instruments>Diagnostic Tools
Base - May 2010
1.
Enter the Customer PIN: it is the customer authentication code; it is an alphanumeric code sent by e-mail to the user after having bought the PT-DIAGNOSIS system.
2.
Select the send key: the identification data and the Network characteristics are automatically entered.
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11
PT-BOX ISTRUCTIONS
3.
Fill in the yellow field by entering the alpha code supplied with the Registration Card (scrap the area on the card).
4.
Enter the serial number of the pt-box instrument.
6.
Select the send key (only once!) wait…
After sending a summary window is displayed waiting for the end of the registration procedure. Wait for the following window: - the activation code; - the link to download the EAUS application (EAsy Update Software). 7.
Print the activation codes (print key) and keep them together.
8.
Select the link to download the EAUS application.
Installation of EAUS application (Dealer user) The EAUS application is an update utility to automatically download all SW Updates for all ECU’s activated for FPT. After having selected the link for downloading the EAUS application, the system asks you to select the file or to directly run it.
Figure 7
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The serial number is type PB-#####-##-##-##; to be found on the back of the PT-BOX module. 5.
Read the note in compliance with art. 13 of Italian Legislative Degree 196 dated 30 June 2003 about the processing of personal data Informative.
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1.
Select the run key: the system automatically downloads first and then installs the EAUS application; run the operation required by the system and wait for the end of operation.
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PT-BOX ISTRUCTIONS
Connection Figure 8
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2.
Select the end key to exit the installation.
NOTE
1.
Connect the PT-BOX module to the engine/vehicle using the diagnosis cable.
2.
Connect the PT-BOX module to the PC, using one of the two USB cables provided with the module.
Before carrying out the registration we suggest to install the PT-Diagnosis SW.
!
The PT-BOX module is supplied by the diagnosis cable; therefore it must be connected to the engine/vehicle to be able to work. Figure 9
Run the EAUS (Dealer user) application
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3.
Switch the PC on.
PT-BOX module USB driver set-up (only for the PT-DIAGNOSIS configuration) This operation is required only if the PC in use has never been connected to an PT-BOX module:
1.
It is now possible to download the update by using the Automatic Update Function (tools>software update key).
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1.
Check that the PT-BOX module is correctly connected to the PC via the USB cable.
2.
The PC acknowledges the presence of a new hardware component; press the cross button to continue.
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PT-BOX ISTRUCTIONS
3.
4.
5.
Select the have disk…> button to continue.
6.
Enter the path: ProgramFiles\EltracECI\Driver\PT-BOX.sys; select the ok button.
7.
Select the next> button to continue.
Automatically (Windows XP) the procedure starts to set-up the driver; select the Install from a list or specific location option; select the next> button to continue.
Select the Don’t search. I will choose the driver to install; select the next> button to continue.
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PT-BOX ISTRUCTIONS
8.
Driver set-up begins… wait.
9.
The procedure is completed; press the finish button.
4.
The system asks you to enter the activation code received from Field Service; select the tick button.
5.
Enter the activation code sent via Web.
6.
Select the register button; a message confirms that registration has taken place.
7.
Select the cross button to close the Activation Code window and go back to the PT-DIAGNOSIS screen.
8.
Select the stop button and restart PT-DIAGNOSIS.
10. The system informs that the new hardware has been correctly installed; select the cross button to continue. 11. Re-start the PC.
Activation - first time of use of PT-DIAGNOSIS sw + PT-BOX module The first time the PT-DIAGNOSIS Diagnosis System is used, it is necessary to follow the procedure described below: 1.
Make sure you possess the activation codes (Web access).
2.
Connect the PT-BOX module to the Panasonic PC and to the engine/vehicle using the USB/BT module.
3.
Start the Panasonic PC.
Now all the software functions are available.
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PT-BOX ISTRUCTIONS
Activating - new PT-BOX module The activation procedure is necessary every time you want to use an PT-BOX module that has not yet been paired to the PT-DIAGNOSIS diagnosis system in use; follow the operations described below:
1.
Make sure you have requested and obtained the activating code for the PT-BOX module.
2.
Connect the PT-BOX module to the Panasonic PC and to the engine/vehicle using the USB cable.
3.
Start the PT-DIAGNOSIS software: double click on the EASY icon (PT-DIAGNOSIS) placed on the desktop of PC.
4.
Select the tools>activations button.
5.
Select the entry button.
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6.
Enter the activation code received from Field Service.
7.
Select the register button; …a message confirms that registration has taken place.
8.
Select the cross button to end activation.
9.
Re-start the PT-DIAGNOSIS (E.A.SY. icon).
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PT-BOX ISTRUCTIONS
Software Interface The PT-DIAGNOSIS software interface is designed to facilitate access to tools, view functions and make diagnostic procedures clear and adaptable to various needs. All windows follow the same design with additional features which depend on the specific working environments. Each window presents three main areas to which specific functions are univocally associated: - Keys Area - Title Area - Operative Area
The Title area shows the selected function under test and previous choices by which you arrived.
The Keys area contains Keys for accessing the operative environments and the functions to which they are associated.
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The Operative area contains available system and function list referred to the intervention area.
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PT-BOX ISTRUCTIONS
To go from one environment to another
1.
3.
Select the Class and the System under test to which the engine/ vehicle belongs; then press the navigation key (is active - green) to continue.
4.
The window Choose Activity appears; it is here possible to choose from four lists.
The Start Window shows the family.
Start Window - It is possible to select a new family or to choose a family from the database; - green identifies a pull-down menu.
Window Choose Activity It is now possible to choose: - diagnosis; - test; - programming; - specific functions. Navigation keys 2.
Select the fami ly of the engine/vehicle under diagnosis; then press the navigation key (is active - green) to continue.
Family Choice Window
They allow you to go from one environment to another. Enabled keys are displayed in green and disabled keys are displayed in grey. navigation key forward disabled
- Yellow identifies a selected item in a pull-down menu; - a paged list is used to display a large amount of information one page at a time; navigation tools are available to navigate from page to page.
navigation key forward enabled navigation key back enabled Database key It allows you to access the Database environment.
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PT-BOX ISTRUCTIONS
Browse key To scroll long lists which cannot be contained in a single window.
ignition key
Detail of Keys area In the Start Window the Keys area contains the Keys for accessing the functions which are always available:
For the equipped engines, it allows you to operate engine ignition directly via the diagnostic tool. Two positions (stop and mar) and three states (enabled stop, disabled stop, enabled mar) are possible.
communication panel It indicates that the communication with the ECU is active or that the ECU is not present (no ecu). The lower leds indicate the communication state of the electronic system as shown below: Square LEDs: two states (green/red); green indicates that communication with the electronic system has been initialised; if red indicates the communication has been interrupted. Rectangular LEDs: blinking indicate that data exchange between electronic system and diagnostic system is in progress. Utilities key
stop key To quit PT-DIAGNOSIS application at any time.
engine/vehicle key It allows you to return to the Family Choice Window.
utilities key When selected the Key background will be yellow and allows you to access a menu.
guide to diagnosis key It allows you to access the environment Guide to Diagnosis (only available for some ranges). It is available in the Electrical Control Units environment.
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PT-BOX ISTRUCTIONS
Teleservices key It allows you to access the remote connections services. Activations key It allows you to access the management function of the activation codes. Select the measure unit key It allows you to choose the measure unit system.
Electronic control units key It allows you to access the Electronic Ecu’s environment. The key appears on a yellow background (default status, environment Electronic Control Units enabled) or on a grey background (environment Electronic Control Units disabled). If you want to work at the same time with more Ecu’s, select the key environment electronic ecu’s>add ecu.
Electrical diagrams key The Metric System (SI), the international standard one, is based on the meter, kilogram and second. The British System (fps) is based on the foot, pound and second. Select language key
It refers to a CLASSES list for which an electrical diagram is available. The key appears on a yellow background (environment Electrical Diagrams enabled) or on a grey background (environment Electrical Diagrams disabled). To enter the Electrical Diagrams environment select the key electrical diagrams area.
To change the language; restart the application to make the setting operational. Software update key It allows you to carry out the automatic update of the PT-DIAGNOSIS software. Eci management key It allows you to manage the connection (usb or Bluetooth) PT-DIAGNOSIS - PT-BOX module.
Report key It allows you to access the Report environment. The key appears on a yellow background (environment Report enabled) or on a grey background (environment Report disabled). To access the Report environment select the report key.
On/Off-line key
In the Start Window select the fami ly; by pressing the navigation key forward it is possible to access the next window. New icons appear in the Keys area for accessing specific functions:
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It can be on-line or off-line. The on-line key indicates that the PT-Diagnosis SW uses the PT-BOX/PC module connection. The off-line key indicates the PT-Diagnosis SW is working in simulated mode. To change the status select the key.
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PT-BOX ISTRUCTIONS
Acceptance key search
Environment DataBase From the PT-DIAGNOSIS start window it is possible to select a new engine or to select one from the database.
It allows you to search an engine by applying a filter (DATE, engine mode l, CUSTOMER or NUMBER PLATE).
key delete search It cancel the filter; it is active only after a search.
key order It orders the list according to the selected ordering criterion.
key report It gives access to the summary environment; enabled after selecting an engine.
1.
2.
Select the database button: you access the DataBase environment (it contains the list of accepted engines).
The list of accepted engines is available. They can be search by means of the following keys:
key delete It deletes the selected engine from the database; it is active only after selecting an engine.
- DATE
3.
Select an engine from the list (the background is yellow); it is possible:
- ENGINE MODEL
-
to analyse engine data (report button);
- CUSTOMER
-
to start again the diagnosis procedure on the engine (navigation button forward);
-
to return to the start window (navigation button back).
- NUMBER PLATE
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PT-BOX ISTRUCTIONS
How to order the engines list
3.
If required, enter the word or the code to be searched and confirm by selecting the tick icon.
To cancel the search and display all elements from the archive select the cancel search key.
For the selection of a new engine see ECU Diagnosis.
!
1.
Select the order key.
2.
Select the order method. - DATE - ENGINE MODEL - CUSTOMER - NUMBER PLATE
Environment Report How to search for an engine from the database
When the engine sheet of the engine under test has been saved in the Report Environment, the engine has been accepted. You access the Report environment in the following ways:
1.
Select the search key.
2.
Select the search method. - DATE - ENGINE MODEL - CUSTOMER - NUMBER PLATE
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- from the Buttons area at any time by selecting the corresponding button; - from the DataBase environment by selecting the required engine and the report button.
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PT-BOX ISTRUCTIONS
Environment Report
ENGINE DATA KEY: engine identification data; the fields can be always changed (with the exception of the engine model and the date) can be always changed
SAVE KEY: it allows you to save the engine sheet (to accept it)
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DIAGNOSIS REPORT LIST KEY: summary of all performed diagnosis operations
PROGRAMMING REPORT LIST KEY: summary of all performed programming operations
AUTOMATIC ACCEPTANCE KEY: (enabled only if the communication is active)
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PT-BOX ISTRUCTIONS
Acceptance The acceptance (sheet saving) is mandatory when important operations are performed on the engine (read or cancel faults memory, programming).
1.
Read or cancel the faults memory or carry out a programming and then select from the corresponding environment the report button; you enter the Report environment.
2.
Enter data.
3.
Save the sheet by selecting the save button.
4.
From the Buttons area select the button of the operation you want to perform.
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When you read or cancel the faults memory or carry out a programming it is not possible to return directly to the window Family Choice; by selecting the engine button the following windows are displayed:
1.
Before continuing it is necessary to save the data of the performed activity; select the tick icon; the Report environment appears.
2.
Enter data.
3.
Save the sheet by selecting the save button.
It is now possible to return to the Family Choice window.
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PT-BOX ISTRUCTIONS
Automatic acceptance From the Report environment it is also possible to accept the engine automatically.
! 1.
This operation is only possible if the communication with the system has been activated.
Read or cancel the faults memory or carry out a programming and then select from the corresponding environment the report button.
5.
The automatic information:
acceptance
reads
the
following
- Engine Model (engine type + engine serial number) - PIC - Engine type - Engine Serial Number 6.
2.
You enter the Report environment.
3.
Select the button automatic acceptance.
4.
At the select the save key.
ECU diagnosis
1.
Sselect the Family, the Class and then the System of engine under diagnosis.
2.
Press the navigation button forward (enabled - green) to continue.
By means of the automatic acceptance the system tries to communicate with the engine ECU: confirm the displayed message by pressing the tick icon; wait until the ECU is ready.
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PT-BOX ISTRUCTIONS
3.
The window Choose Activity appears; it is here possible to choose from four lists:
2.
Window Choose Activity - diagnosis - test - programming - specific functions
4.
PT-DIAGNOSIS system presents a pop-up window where to select the automatic or the manual activation of the ignition key; select the required mode; the key button is disabled.
Under the automatic mode all activation of the ignition key are controlled by the diagnosis instrument (key button working). Under the manual mode all activation of the ignition key are controlled by the operator on the engine.
The present Repair Guide describes the diagnosis environment and the specific functions to which it is associated: - Identification Code Reading - Faults Memory Reading - Parameters Reading
Identification code reading 3.
1.
Confirm the new message by pressing the tick icon.
To access the Read Identification environment select the item Identification Code Reading from the Diagnosis list and then press the navigation button forward.
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PT-BOX ISTRUCTIONS
Multitasking option report key Shows the Diagnosis Report List (and allows you to print each report).
print key Prints the summary page of Identification Parameters.
4.
PT-DIAGNOSIS introduces a very important news: it is possible to associate more ECU’s to the family of engine under test. Add an ecu It is possible to interrupt the diagnosis with an ECU and to start the procedure with another one.
Wait until the ECU is ready; the general information about the electronic system under test is read: - identification code - HW version - SW version
1.
- production date - … After identification code reading it is possible to carry out other activities (step 5) or to return to the window Choose engine (step 6).
Select the button ecu’s area>add ecu; the Choose Vehicle window will appear, where you can select the desired ECU.
Managing more ecu’s It is possible to operate with two or more connected ECU’s at the same time.
1.
Select the button ecu’s area>desired ecu.
The activity remains interrupted for the not selected ECU’s and can be started again at any time. Cancel an ecu 5.
To access the other activities from the environment Identification Code Reading, select the choose activities buttons: choose an activity; the system automatically access the selected activity.
It is possible to stop the activity on one of the connected ECU’s.
The choose activities buttons are shown in yellow when selected.
6.
To exit the diagnosis of the engine under test select the button ecu’s area>ecu under test>cancel.
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1.
Slect the button ecu’s area>required ecu>cancel.
2.
Select the required ECU.
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PT-BOX ISTRUCTIONS
Ignition Key Button Modes - on line/off line
Read faults memory
At the system start up the on/off button is on-line if the PT-BOX module is activated and connected to the PC, otherwise is disabled (off-line). On line mode The function “Ignition Key” is active; it can be managed in automatic or manual mode; the ”ignition key” screen appears only after the selection of a function that requires it (e.g. diagnosis functions). In automatic mode all ignition key activations are managed by the diagnosis instrument. In manual mode all ignition key activations are managed by the operator on the engine. The automatic activation depends on the type of engine; make sure the engine supports the function before selecting automatic mode.
1.
After selecting the automatic mode a test procedure is carried out.
2.
Switch the ignition off.
3.
The engine chassis may move.
1.
To access the Read Faults Memory environment select the item Faults Memory Reading from the list Diagnosis and then press the navigation button forward.
2.
PT-DIAGNOSIS system presents a pop-up window where to select the automatic or the manual activation of the ignition key; select the required mode; the key button is disabled.
3.
Confirm the new message by pressing the tick icon.
The PT-DIAGNOSIS SW activates the ignition key and displays a screen page in which it asks to check the dashboard; if it is turned ”on” the diagnosis procedure can be continued; otherwise the system asks for position of the key to ON in manual mode. Both in manual and in automatic mode: 1.
Before ignition key activation a message is always displayed: request (manual mode) or warning (automatic).
2.
When the ECU is cancelled a message indicates that it is necessary to interrupt the communication and then to confirm the operation.
3.
The chosen mode remains until the engine under test is changed.
Off line mode The basis diagnosis is simulated and it is possible to read some information about the electronic system under test.
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PT-BOX ISTRUCTIONS
cancel faults memory key It cancels the faults selected in the list; it is possible to cancel a fault at a time; the cancel operation will be effective when you confirm it by pressing the tick icon displayed in the next pop-up-window.
faults key It allows you to access the Faults environment; it can be yellow (the faults list is displayed) or gray (environment Faults disabled). 4.
Wait until the ECU is ready; the list and faults type occurred during the working are displayed. There are two types of failures: - failures present during the reading procedure (red); - intermittent failures not present during the reading operation but which occurred at least once before (black).
Detail of Buttons area of the Faults Memory area New icons appear in the window Read Faults Memory for accessing specific functions:
On line Mode Faults Memory Reading Icons environmental condi tions key Active when the communication with the ECU has been interrupted this is used to examine environmental conditions when the failure occurred. It can be gray (default status) or yellow (when selected).
repair guide key On line Mode Faults Memory Reading Icons
Active when the communication with the ECU has been interrupted it gives an analysis of the fault selected from the list; in particular other information (blink code, failure code and fault mode) is available it can be gray (default status) or yellow (when selected).
on key The communication between the system and the ECU is active: it performs again the Faults Reading; it updates the ECU communication. Select the button to interrupt the reading. off key The communication with the ECU has been interrupted. Select the button to start again the electronic system reading.
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report key It allows you to save the report of carried out operations see Report environment > button diagnosis report.
print key It allows you to print the displayed window.
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PT-BOX ISTRUCTIONS
Off line Mode
2.
Select the button environmental conditions.
Faults Memory Reading Icons
It examines the present environmental conditions at time of the fault.
blink code search key Appears only if the communication with the ECU interrupted is (under OFF LINE Mode) recognize the fault where blink code or required word appear. To go from one function to another (faults, environmental conditions, troubleshooting) select the corresponding button. Operations like Read and Cancel Faults Memory are very important: they are automatically stored and need the engine acceptance. How to get information about a fault 1.
Interrupt the communication with the ECU (button on/off) and select an item from the faults list: the fault is described in the below blank area; in particular the following information is available:
3.
Select the repair guide button; the following information is available: - the blink code - the failure code (DTC) - the failure mode (FMI)
Appears a new icon, the measures key measures key The Measurements pop-up window opens with a list of possible measurements and the relevant operating suggestions. - the fault - the signal type - the repetition type The button faults appears on yellow background because it is selected. Print P2D32N003 E
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PT-BOX ISTRUCTIONS
Parameters reading
3.
The read parameters are shown and the values assumed
4.
Select the groups key.
The groups key allows you to access the groups management functions (see group Management).
Detail of parameters buttons area New icons appears on the window Parameters Reading for accessing specific functions:
1.
To access the Parameters Reading environment select the item Parameters Reading from the Diagnosis List and then press the navigation button forward.
on key The communication between the system and the ECU is active: select the button to interrupt the reading. off key The communication with the ECU has been interrupted; select the button to start again the electronic system reading. 2.
PT-DIAGNOSIS system presents a pop-up window where to select the automatic or the manual activation of the ignition key; select the required mode; the key button is disabled.
groups key It opens the GROUPS window showing the list of created group (A) and the keys to create/modify the groups (B).
Pay close attention to the displayed messages and wait until the ECU is ready.
parameters acquisition key It allows to record the trend in time of the measurable parameters. report key It allows you to save the report of carried out operations. print key It allows you to print the displayed window. Base - May 2010
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PT-BOX ISTRUCTIONS
Groups Management
9.
From the drop down menu (above on the left), select one of the available parameter groups, excluding the parameter you are changing.
10. On the left-hand list the parameters of the selected group are shown; on the right-hand list the parameter of the group you are changing are shown. The parameters with a gray background on the left-hand list are parameters that have already been added and can not be selected.
5.
The Groups window opens.
The pre-defined parameter groups are first displayed then the customized ones; the pre-defined parameters (measurable and status) can not be modified.
11. To a parameter to the right-hand group, select it and confirm by pressing the right arrow key ( ). 12. To remove a parameter (from the right-hand list select it and confirm by pressing the left hand arrow key ( ). Select the save key to save and exit the groups management environment.
Create a new parameters group 6.
Select create.
7.
Enter the name of the group you want to create.
8.
Confirm by selecting the green tick icon.
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Modify a parameters group
1.
Select a customized parameters group.
2.
Select modify; the window for parameters groups management opens.
3.
Select the group you want to change and continue with step 9 (link).
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PT-BOX ISTRUCTIONS
Cancel a parameters group
1.
Select a group of customized parameters
2.
Select delete; confirm or cancel the request.
Window Store Parameter
2.
Select the sample time by using the arrows on the Sampling active area.
3.
Select the duration of registration by using the arrows key on the active area Duration.
4.
Select the key start/stop to start the registration (a new window open Notes where you can add a comment).
5.
Close the Notes window, the registration starts.
6.
Wait for the end of registration procedure (it is also possible to interrupt the registration, by using the stop key).
7.
Select the archive key: the Archive window open showing the list of available registration in the archive.
Appendix parameter acquisition key
1.
Select the parameters acquisition key; the window Store Parameter opens. The key is only active under on line mode.
Parameters reading
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PT-BOX ISTRUCTIONS
Archive window
- To display tables (horizontal or vertical). - To colour display the area indicated by the diagram. - Print. - To go back
Programming The consultation can be started To access the programming area of the ECU under test proceed as follows: 1.
From the Archive windows, select a registration; it is possible: - to cancel it (cancel key) - to read data (report key) - to show data (show key, opens the Data Reading window) - to print data (print key) - to save data in text format (save as key) - to go back (cross key)
Data Reading window
2.
1.
Select the Engine Family under diagnosis.
2.
Press the navigation button forward (enabled - green) to continue.
3.
Select the Class and the System under test to which the engine belongs; select the forward navigation key (enabled - green) to continue.
From the Archive window, select a registration and the show key; the Data Reading window opens; it is possible: - To select all parameters (fast selection key). - Deselect all parameters (fast deselection key). - To show the diagram with full-screen. - Increase, reduce or to bring back to the original display the time range (x-axle, seconds).
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PT-BOX ISTRUCTIONS
4.
Select the programming option from the Programming list; select the forward navigation key (enabled - green).
7.
Read the displayed messages and select the green tick icon to continue.
5.
If required, enter the required data, by following the indicated procedure.
8.
At the end the system permits access to the Programming environment; the components list is displayed, on which tests can be carried out.
!
It is possible to carry out a programming only in online mode. In case of error check the connections ECU/PT-BOX/PT-DIAGNOSIS.
!
During the programming do not disconnect the USB cable. Before carrying out the ECU programming verify the charge left in the computer’s battery. It is recommended to plug the PC in (connect it to the engine/vehicle or to the mains supply).
Programming environment It is possible to use specific functions, by selecting the corresponding key:
6.
Select the ignition key management (automatic/manual): if the electronic system engine under test is fitted with this function, select the automatic key.
- Data Reading
- PT-DIAGNOSIS shows the running activities.
- Programming
- The ignition key ON is automatically activated.
- PTO (only for the PT-DIAGNOSIS full version SW)
- Change the configuration
- The connection to the ECU starts.
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PT-BOX ISTRUCTIONS
The available function types are determined according to the type of ECU under test. The Keys area contains the buttons for accessing the functions specific for the Programming environment.
Data Reading This is used to view the data concerning the ECU and the respective programming state; tampering attempts are shown.
The following are indicated: print key If enabled, select to print a report.
- station type and number; - programming date; - ECU software release.
cancel key If enabled, select to re-establish a configuration.
navigation keys If enabled, select to move between different environments.
cross key If enabled, select to cancel an operation. The system views the following data classes: - supplying data; - factory data (never updated); - service data (updated after each programming event).
scroll keys If enabled, select to scroll the list step by step.
fast scroll keys If enabled, select to scroll the list step by step.
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PT-BOX ISTRUCTIONS
Active diagnosis To start the Active Diagnosis
1.
Select the Engine Family under diagnosis.
2.
Press the navigation button forward (enabled - green) to continue.
!
5.
It is possible to carry out an active diagnosis only in online mode. In case of error check the following connections ECU/PT-BOX/PT-DIAGNOSIS.
Select the ignition key management (automatic/manual): if the electronic system engine under test is fitted with this function, select the automatic key. - PT-DIAGNOSIS displays some information about the activity in progress. - The ignition key ON is automatically activated. - The ECU connection starts.
3.
4.
6.
Read the displayed messages and select the green tick icon to continue.
7.
At the end the system permits access to the Active Diagnosis environment; the components list is displayed, on which tests can be carried out.
Select the Class and the System under test to which the engine belongs; select the forward navigation key (enabled - green) to continue.
From the Test list select the option acti ve diagnosis; select the forward navigation key (it is active, in green displayed).
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PT-BOX ISTRUCTIONS
Active Diagnosis environment The components of the selected electronic system are indicated in a list; use the browse keys to display all the elements of the list. 1.
Select the component on which the test will be carried out.
2.
Select the forward navigation key to continue and carry out the test.
Help key if selected it shows information about the electronic system under test; information about the guide to the diagnosis are not provided.
Components: selectable list
Browse key
Forward navigation key
Back navigation key It allows you to move one step back; if selected at this level it allows you to exit the Active Diagnosis environment.
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PT-BOX ISTRUCTIONS
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APPENDIX
1
Appendix Page
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SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . .
3
- Standard safety prescriptions . . . . . . . . . . . . . .
3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . .
3
- During maintenance . . . . . . . . . . . . . . . . . . . .
3
- Respect of the Environment . . . . . . . . . . . . . .
4
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APPENDIX
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APPENDIX
3
SAFETY PRESCRIPTIONS Standard safety prescriptions
- Do not execute any intervention if not provided with necessary instructions.
Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.
- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur.
Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation.
- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.
- Keep working areas as clean as possible, ensuring adequate aeration. - Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. - Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities. - Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines. - Smoking in working areas subject to fire danger must be strictly prohibited. - Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.
Prevention of injury - Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion. - Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed: ≤ 2 bar) - Wear safety helmet when working close to hanging loads 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 working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material. - Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers. Print P2D32N003 E
During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. - 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 areas aerated. Whenever necessary wear safety mask. - Do not leave rags impregnated with flammable substances close to the engine. - Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate. - Do not utilize fast screw-tightening tools. - Never disconnect batteries when the engine is running. - Disconnect batteries before any intervention on the electrical system. - Disconnect batteries from system aboard to load them with the battery loader. - After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. - Do not disconnect and connect electrical connections in presence of electrical feed. - Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning. Base - May 2010
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APPENDIX
GENERALMANUTENZIONE
- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine’s components, affecting engine’s duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved by Iveco. - Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80ºC temperature.
Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted. - Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger. - Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.
- Do not paint the components and the electronic connections. - Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.
Base - May 2010
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