iveco F4GE9484F, F4GE9454 Repair manual

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NSERIES

F4G TIER 3

Agricultural applications (Hyundai)

F4GE9484F*J608

F4GE9454J*J604

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, suchas,forexample,protectiveeyewear,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 proceedingin 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 FIAT Powertrain Technologies Mkt. Advertising & Promotion Viale dell’Industria, 15/17 20010 Pregnana Milanese Milano (Italy) Print P2D32N010 E -1

Ed. 02.2009

Produced by:

B.U. TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio, 15/19 10156 Turin - Italy

F4GE N SERIES

F4GE N Series Part 1

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INTRODUCTION 1

Introduction

Page

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

INTRODUCTION

F4GE N SERIES

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

∅

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

∅

Tighten to torque Tighten to torque + angular value

INTRODUCTION

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Removal Disconnection

Refitting Connection

Removal Disassembly

Fitting in place Assembly

Tighten to torque

Intake

Exhaust

Operation

Compression ratio

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

Number of revolutions

Check

Equipment Temperature

Surface for machining Machine finish

Interference Strained assembly

Thickness Clearance

Lubrication Damp Grease

Sealant Adhesive

bar

Pressure

Oversized Higher than…. Maximum, peak

Undersized Less than…. Minimum

Selection Classes Oversizing

Temperature < 0 °C Cold Winter

Temperature > 0 °C

Air bleeding

Hot Summer

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GENERAL WARNINGS

Warnings shown cannot be representative of all danger situationspossibly 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.

INTRODUCTION 5

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 c ards. 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 workshopactivity, 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 r epair interventions must meet safety rules.

INTRODUCTION

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

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

Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct c ontact 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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GENERALWARNINGS O N 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.

INTRODUCTION 7

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.

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

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

88039

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INTRODUCTION 9

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

Power

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

Torque

1 Nm = 0.1019 kgm 1 kgm = 9.81 Nm

Revolutions per time unit

1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602

Pressure

according to ratio 1:1

1 bar = 1.02 kg/cm 1 kg/cm 1bar = 10

= 0.981 bar

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/cm

1 kg/cm

=1bar.

Temperature

0° C=32° F 1° C = (1 x 1.8 + 32) ° F

INTRODUCTION

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

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Type of

vehicle

Section

title

Page

number

Printout number

Language

Publication

Basic edition referred to

month - year editorial

phase closing

When month - year update

is present (revi) to the

basic edition

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Part 1 F4GE N SERIES

Section

General specifications

Fuel 2

Agricultural applications 3

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

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UPDATING

Section Description Page Date of revision

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SECTION 1 - GENERAL SPECIFICATIONS 1

SECTION 1

General Specifications

Page

LUBRICATION 3............................

OIL VAPOUR RECIRCULATING SYSTEM 4.......

COOLING SYSTEM 5........................

AIR INDUCTION BOOST DIAGRAM 6..........

- Boosting version engines 6.................

- Description 6...........................

- Inter-cooled engine version 7...............

- Description 7...........................

EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) 8

SECTION 1 - GENERAL SPECIFICATIONS

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SECTION 1 - GENERAL SPECIFICATIONS 3

LUBRICATION

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

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

Figure 1

Lubrication involves the heat exchanger and the turboblower.

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

Routing of oil under pressure

Routing of oil return by gravity to sump

Introduction of oil

LUBRICATION SYSTEM LAYOUT

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

132102

SECTION 1 - GENERAL SPECIFICATIONS

OIL VAPOUR RECIRCULATING SYSTEM

Figure 2

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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).

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SECTION 1 - GENERAL SPECIFICATIONS 5

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.

- Visc pusher fan, having the duty to increase the heat

dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development.

Figure 3

TO RADIATOR

- 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.

FROM RADIATOR

Water coming out from thermostat

Water recirculating in engine

Water coming into pump

127129

COOLING SYSTEM LAYOUT

SECTION 1 - GENERAL SPECIFICATIONS

AIRINDUCTION BOOST DIAGRAM Boosting version engines

Figure 4

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AIR FILTER

TURBOCHARGER

EXHAUST

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.

The turbocharger is equipped with a transforming valve to regulate the pressure , that is l ocated 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 exhau st tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value.

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

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Inter-cooled engine version

Figure 5

SECTION 1 - GENERAL SPECIFICATIONS 7

AIR FILTER

TURBOCHARGER

EXHAUST

RADIATOR

74195

4 cylinders version

Description

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

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

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

The above mentioned air is then cooled by the radiator and flown through the piston induction collector.

The turbocharger is equipped with a transforming valve to regulate the pressure , that is l ocated 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 exhau st 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.

SECTION 1 - GENERAL SPECIFICATIONS

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EXHAUST GAS RE-CIRCULATION SYSTEM (EGR)

In the TIER 3 version, the profile of the exhaust cam has been modified in order to allow the partial opening of the relative valve during the aspiration phase (re-circulation of EGR exhaust gas) with the subsequent re-introduction of part of the exhaust gas into the engine cylinders. The exhaust gases can partially be re-directed into the cylinders so as to reduce the maximum combustion temperature values responsible for the production of nitric acid (NO 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 NO

Figure 6

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 configur ation 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.

114789

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

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

SECTION 2 - FUEL

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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 ac cording to equipment application and duty)

- Fuel feed rotary pump

- Injec t or feed pipeline (from fuel feed pump to injectors)

- Injectors

Figure 1

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 c ollector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.

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Figure 2

SECTION 2 - FUEL

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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 c hamber of the transfer pump. (For applications to be equipped in cold climate areas, the fuel filter is provided with heater).

Transfer pump is placed inside the feed pump, and is bladed type; its duty is to increase fuel pressure in c orrespondence with the increase of the number of revolutions.

The fuel arrives therefore to the valve gauging the pressure inside feed pump.

The distribution plunger further increases this pressure and delivers fuel throughout the delivery pipe fitting to the injectors.

The fuel drawing from the injectors is recovered and delivered to the tank again.

75807

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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 cy linders engine

12 = Distribution plunger in mm.

1150 = N°. of pump revolutions per minute

LV = L eft direction of rotation

Figure 3

SECTION 2 - FUEL

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.

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SECTION 2 - FUEL

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PRIMING PUMP

This pump h as the specific duty to prime th e fuel available in the tank and convey it to t he feed pump inlet. It is assembled to the engine basement and driven by the camshaft.

Figure 4

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

88209

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SECTION 2 - FUEL

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 wat er 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

3243t

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

5. Temperature sensor.

3244t

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SECTION 2 - FUEL

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SECTION 3 - AGRICULTURAL APPLICATION

SECTION 3

Agricultural application

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

CLEARANCE DATA 4.......................

PART ONE -

MECHANICAL COMPONENTS 7...........

OVERHAUL OF THE ENGINE 9...............

- Preface 9..............................

- Engine setting operations for the assembly on

turning stand 9..........................

- Disassembly of application components 11.....

Page

- Installation of rear components 19............

- Flywheel installation 22.....................

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

- Completion of engine 33...................

- Rotary feed pump disassembly and assembly pro-

cedure 35...............................

- Power take-off disassembly and assembly

procedure 38............................

- Feed system bleed procedure 38.............

- Checks and inspections 39..................

PART TWO -

ELECTRICAL EQUIPMENT 41...............

ELECTRICAL COMPONENT LAYOUT 43........

- Cooling liquid temperature sensor 44.........

- Starter 44...............................

- KSB Water temperature sensor 44...........

- Electromagnets assembled to feed pump 45....

- Oil pressure sen sor 45.....................

- Alternator 45............................

- Pre-post heating resistor 45.................

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SECTION 3 - AGRICULTURAL APPLICATION

PART THREE - TROUBLESHOOTING 47........

PART FOUR -

MAINTENANCE PLANNING 55.............

MAINTENANCE SCHEDULE 57.................

- Checks not included in maintenance planning-daily

checks 58...............................

MAINTENANCE PROCEDURES 58..............

- Chec ks and controls 58....................

- Engine oil level check 58................

- Check of fuel system 59................

- Cooling system check 59...............

- Lubricating system ch eck 59.............

- Check of water presence within fuel filter or

pre-filter 59..........................

F4GE N SERIES

Page

- Check of drive belt tensioning 60.........

- Check of belt’s tear and wear status 60....

- Check and setting of tappet clearance 60...

- Oil motor and filter replacement 60.......

- Fuel filter replacement 61...............

- Alternator belt replacement 62...........

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GENERAL INFORMATION

Figure 1

SECTION 3 - AGRICULTURAL APPLICATION 3

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 differ 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.

132103

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 accordan-

ce 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 opera-

tions, providing instructions for the execution of the main operations.

SECTION 3 - AGRICULTURAL APPLICATION

CLEARANCE DATA

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bar

Type

Compression ratio 17.5:1

Max. output kW

(HP) rpm

Max. torque Nm

(kgm) rpm

Loadless engine idling rpm

Loadless engine peak rpm rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type

LUBRICATION

Oil pressure (warm engine)

Forced by gear pump, relief valve single action

F4GE9454J*604

(90)

2200

400

(40.0)

1250

950

2430

104 X 132

4485

without intercooler

Direct injection

HOLSET HX25

oil filter

ACEA: E3, E5, E7 URANIA LD7

20W40: 0°C to 40°C (Very hot countries, heavy mission)

15W40: -10°C to 40°C (Europa/Nord American mission)

10W30: -28°C to 35°C (Cold mission)

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.

- idling bar

- peak rpm bar

COOLING

Water pump control Thermostat

- start of opening ºC

FILLING

engine sump*

liters

engine sump + filter*

liters

* First filling operation

>0.70

3.1

By centrifugal pump, regulating thermostat, heat

exchanger, intercooler

Through belt

81 ± 2

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SECTION 3 - AGRICULTURAL APPLICATION 5

Type

Compression ratio 17.5:1

Max. output kW

(HP)

rpm

Max. torque Nm

(kgm)

rpm

Loadless engine

idling rpm

Loadless engine peak rpm rpm

Borexstroke mm Displacement cm

SUPERCHARGING With intercooler

Turbocharger type HOLSET HX25

F4GE9484F*J608

(101)

2200

430

(43.0)

1250

800

2430

104 X 132

4485

bar

ACEA: E3, E5, E7 URANIA LD7

20W40: 0°C to 40°C (Very hot countries, heavy mission)

15W40: -10°C to 40°C (Europa/Nord American mission)

10W30: -28°C to 35°C (Cold mission)

LUBRICATION

Oil pressure (warm engine)

- idling bar

- peak rpm bar

COOLING

Water pump control Thermostat

- start of opening ºC

FILLING

engine sump*

liters

engine sump + filter*

liters

* First filling operation

Forced by gear pump, relief valve single action

oil filter

>0.70

3.1

By centrifugal pump, regulating thermostat, heat

exchanger, intercooler

Through belt

81 ± 2

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.

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 7

PART ONE - MECHANICAL COMPONENTS

SECTION 3 - AGRICULTURAL APPLICATION

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SECTION 3 - AGRICULTURAL APPLICATION

OVERHAUL OF THE ENGINE

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

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

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.

With regard to the engine disassembly operations, please apply for information consultin g th e 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.

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

Figure 3

Engine setting operations for the assembly on turning stand

Figure 2

116386

In order t o 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 pipes (1) from the union (2) fitting the

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

75671

- disassemble lubrication o il exhaust pipe from the

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

Figure 4

NOTE

For some versions, th e oil filter (3) is directly

75672

assembled on to the heat exchanger:in such case it shall be disassembled using tool 99360076. Warning: the oil filter c o ntains inside aprx. 1 kg. of engine oil. Provide for oil recovery and disposal in compliance with the law and regulations in force.

- Disassemble th e starter;

Properly h old the starter (2) and loosen the fixing screws (1); assemble the supporting bracket (99361037) using the threaded ports on the basement.

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Figure 5

75673

On the left hand side:

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

with engine oil filter not directly assembled on to t h e exchanger); Using tool 99360076 operate on oil filter; Loosen the screws (3) removing the bracket together with the filter bearing (4 and 5).

Figure 6

75674

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

Warning: avoid co ntact 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.

- The plug and the oil filler pipe (for versions with the

engine oil filter fitted directly on the heat exchanger).

- Seal the opening to prevent foreign bodies from

entering.

- Remove the oil level rod together with guide pipe (2);

(loosen the guide pipe disassembling from the block); properly pipe the screw-threaded port to avoid inlet of foreign matters.

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

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

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Disassembly of application components

Figure 7

75675

Proceed disassembling the supercharger:

- loosen the fixing nut (1) and removethe 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.

- Place a container under the fuel filter and screw out the

condense drain faucet underneath said filt er. Carry out complete drainage of the fuel contained therein.

- Screw out completely the faucet and, using equipment

99360076 disassemble oil filter (1).

- Disconnect fuel pipelines (2 and 3) respectively from

priming pump to filter bearing and from this last one to the feed pump.

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

to the engine head.

Figure 9

Figure 8

NOTE

123024

In some versions, the fuel filter has a heater interposed between filter support an d filtering cartridge. For the versions requiring it, disconnect the electrical connections of such electrical component before removing the fuel filter.

NOTE

70126

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

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.

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BOSCHVE4/12FPump

Figure 10

75677

- Disconnect the LDA pipe (1) from the head and from

the feed pump. Pipe the ends of the pipelines as well as the feed pump and the engine head.

Figure 11

75679

- 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 12); pipe the pipeline ends.

- Disassemble the injectors and remove them from their

slot: remove the gaskets.

Figure 12

75680

1. Rear bracket fixing sc rew (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).

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 13

88102

- Loosen the two fixing screws (2) and disassemble

priming pump (1).

Figure 15

87409

- Disassemble su ction 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 t o the injectors); from the exhaust manifold side; loosen the (2) fixing screws; remove the gaskets.

Figure 14

- Remove tappet caps:

Loosen the four fixing screws (1) and lift the c aps (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.

Figure 16

87406

125114

- 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).

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Figure 17

123023

- Disassemble thermostat unit; loosen the three fixing

screws (1) and disassemble the thermostat unit (2) together with the bracket (5); remove the gasket (3) and the thermostat (4).

- Assemble the bracket in the original position fixing it with

the screws of the thermostat unit.

NOTE

The shape and the size of the thermostat c asing vary according to the usage of the engine. The illustrations therefore provide a general guideline for the operation to be carried out. The procedures described are therefore applicable.

Figure 19

75686

- Properly hold th e alternator (1) separating it from its

bearing by loosening the screw (2); remove screw nut and washer.

Figure 18

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 20

88555

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

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Figure 21

107275

- Loosen the screws (5) and disassemble the oil filter/heat

(2) exchanger bearing (4), interlayer plate (3) and relating gasket s (1).

- Disassemble injection pump (see specific procedure)

and the power take-off underneath.

Figure 23

88140

Fit tool 99360330 (2) in the starter motor housing to be a ble to rotate the flywheel.

Figure 24

Figure 22

- 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 h ead from the block.

84071

Turn the flywheel unt il, when pushing the pin 99360616 (1), it blocks the gear (2).

Figure 25

75688

90504

- Loosen the sc rews (1) and disassemble the pulley (2).

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SECTION 3 - AGRICULTURAL APPLICATION

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Figure 26

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).

Figure 28

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.

Figure 29

Figure 27

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

75811

Figure 30

75695

- Screw out the opposite screws (2) from the ports where

00904t

the withdrawal pins shall be introduced (see picture following).

- 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).

- Loosen remaining flywheel fixing screws (1) to the

engine drive shaft.

- Remove the flywheel block tool (2).

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 31

(Demonstrative)

75690

- Screw up two medium length screws in the ports (4) to

slingtheflywheelwithahoist. 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 33

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 34

Figure 32

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 th e specially provided tie rod (3) for the tool

99363204 an d the lever (4), withdraw the external holding ring of the flywheel cover box.

132104

- Turntheengineupside-down.

- Loosen the screws (2), disassemble the plate (3) and

remove the oil pan (1).

NOTE

The shape and the size of the sump vary according to the usage of the engine.

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Figure 35

99222

- Loosen the screws (1) and disassemble the oil suction

rose pipe (3).

- Loosen the screws (2) and remove the stiffening

plate (4).

Figure 36

87655

- Remove the gear (1) transmitting motion to the ignition

pump and t he relevant support.

Figure 37

87424

- Remove the screws (1) and disassemble the gears (3)

and (4) from the camshaft (2).

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 38

70157

- Loosen the screws (2) and disassemble the timing

gearbox (1).

NOTE

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

Installation of rear components

Figure 39

70210

DIAGRAM SHOWING SCREW

TIGHTENING TO FIX REAR GEARBOX

- Accurately clean the timing gearbox (1) and the engine

block.

- 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 M8 20 ÷ 28 Nm Screws M10 44 ÷ 54 Nm

NOTE

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

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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Figure 40

70211

- Use a felt pen to mark the driving gear (1) tooth fitted

on the output shaft (2) having the mark (→)fortiming onthesidesurface.

NOTE

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

Figure 42

87653

- Place the dial gauge (1) on the ti min g 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 43

87654

- Fit the screws (1) fastening the gears (2) to the camshaft

Figure 41

(3) and tighten them to the prescribed pair.

Figure 44

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).

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

pump.

87655

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 45

DIAGRAM SHOWING SEALING LOCTITE 5205

APPLICATION

NOTE

It is necessary and essential to c lean 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.

122588

Figure 46

84077

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

- Tighten the fastening screws (2) to the same position

detected before disassembly.

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 t he joint and obstruct lubricant passages.

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

Figure 47

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 48

- 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 fly wh eel 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.

- Tighten the screws (4) fixing the engine flywheel (3) to

theengineshaft.

(Demonstration)

75690

Figure 50

84071

Turn the flywheel unt il, when pushing the pin 99360616 (1), it blocks the gear (2).

Figure 49

88140

Fit tool 99360330 (2) in the starter motor housing to be a ble to rotate the flywheel.

Figure 51

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;

- 2n d 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.

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Installation of front components

Figure 52

70220

- Assemble oil pump (1).

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

couple.

Figure 53

Figure 55

106549

- Remove the fixing ring (2) from the front cover (1),

accurately clean the plug surface.

70221

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

Figure 54

- Assemble the water pump (1).

76112

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

couple.

Figure 56

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.

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Figure 57

106550

- Assemble the front cover (2) to the block and tighten

the screws (1) fixing them to the prescribed couple.

Figure 59

99222

- Assemble the plate (4), the rose pipe (3), tighten the

fixing screws (1, 2 and 4) and fix them to the prescribed couple.

Figure 58

00902t

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 60

Set the gasket (1) on the oil sump (2).

NOTE

The shape and the size of the sump vary according to the usage of the engine.

119123

Figure 62

Figure 61

132104

- Assemble oil pan (1), apply t he plate over it (2). Tighten

the screws (2) and lock them to the prescribed couple.

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 110

± 5Nmcouple.

Figure 63

107275

- Assemble the following elements to the block: new

gasket (1), heat exchanger (2), n ew 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

NOTE

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

PrintP2D32N010E B

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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SECTION 3 - AGRICULTURAL APPLICATION

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Figure 64

122589

- Lubricate the fixing ring (4) using engine oil and place it

on the oil filter (2).

- Tighten the oil filter (2) manually on the connector for

the support (1) until it is in the end of travel position, tighten the oil filter (2) a further ¾ of a turn (for versions with the engine oil filter fitted directly o n the heat exchanger).

- Place a new fixing ring on the block housing (3).

Figure 66

75686

- Connect the alternator (1) to the support.

- Tighten the screw without locking it (2).

Figure 67

Figure 65

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 t he 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 engin e block stand is clean.

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

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

87759

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Figure 68

75688

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

and (2).

NOTE

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

NOTE Before using the fixing screws again, measure them

twice as indicated in the picture, ch ec king D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1-D2>0,1mmthescrewmustbereplaced.

Figure 70

75705

- 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 arms-

4. Support.

Figure 71

18.975

18.963

D1D2

75703

Figure 69

13 14

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

76115

19.000

19.026

19.000

19.026

75704

SHAFT AND ROCKER ARM BASIC DATA

Check the coupling surfacesof bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary.

Figure 72

13.00

11.00

116391

ROCKER ARM ADJUSTMENT SCREW

If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the i 4 ÷ 6Nmcouple.

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Figure 73

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 evidenceof seizure or wear: in case of detection proceed replacing them. The rods driving the suction and exhaust valves are identical and therefore interchangeable.

Figure 74

D1D2

75703

- Insert the tappet driving rods and the Rocker Arm unit.

Before using th e 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>0,1mmthescrewmustbereplaced;

Figure 76

75806

On TIER 3 engines, due to the additional lobe for the INTERNAL E.G.R., it is not possible to use the valve clearan ce 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.

Remove the rocker covers of the cylinder; remove the injector and 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 th en checking that the intake and exhaust valves are both cl osed.

Adjust the slack between rock er arms and valves using socket wrench (1), point wrench (3) and feeler gauge (2).

Correct slack is:

- suction valves 0.25  0.05 mm

- exh aust valves 0.50  0.05 mm.

Figure 75

IGNITION SEQUENCE: 1 - 3 - 4 -

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 77

75707

- Assemble in jec t ors 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 79

123025

- Assemble exhaust manifold (1) providing new gaskets

(2).

NOTE

The illustration of exhaust manifold may be n ot matching your model. Anyhow, described procedure is applicable.

Figure 78

(Demonstrative)

87406

- Assemble cylinder covers (2) with the respective gaskets;

- Fit the seal nods and tighten the screws fixing them to

the prescribed couple.

Figure 80

123023

- Assemble thermostat unit (2) including thermostat (4)

and gasket (3).

- Tighten the screws to the prescribed couple.

NOTE

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

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

The gasket must be new.

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.

NOTE

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Figure 81

86571

- Assemble the pulley fan bearing(8) tightening the screws

to the prescribed couple.

- Assemble the alternator (1) tensioning bracket.

- Mount pulley (5) and secure it to support through

screws.

- Assemble th e transmission pulley (7).

- Refit the automatic belt tensioner (2), tightening the

fixing bolt to the recommended torque.

- Assemble belt Poli-V (4) on the pulley (5) of the engine

shaft, on the jockey pulley, on the water pump (6) and on the alternator (3), tighten (syn.: tension) the belt by means of the automatic belt tensioner (2).

Figure 82

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 duct (6) from the intake manifold plate (1) has been

removed, refit it after having fitted a new gasket (5) and components (3) and (4).

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

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.

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F4GE N SERIES

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 83

75700

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

injectors: u se the same screws (2) fixing the manifold plateasshowninthepicture.

Figure 84

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.

BOSCHVE4/12Fpump

Figure 85

75680

1. Rear bracket fixing sc rew (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).

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SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

Figure 86

1 1

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.

Figure 88

123024

- Assemble th e 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).

Figure 87

NOTE

Figure 89

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

70126

75677

NOTE

To connect fuel pipelines (3 and 4, Figure 89) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as

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

feed pump.

showninpictureB.

After having connected the pipeline, reset the fastener (1) into block position as shown in pictur A.

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F4GE N SERIES

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 90

75675

Proceed assembling the turbocharger:

- Hold t he turbocharger and place it on the exhaust

manifold after having int erposed the gasket.

- Screw u p the fixing nuts of the turbocharger to the

exhaust manifold tightening them to the prescribed couple.

- Tighten the lubrication pipe fixing ring. Operate in th e

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.

Completion of engine

Figure 91

On the right hand side:

- reassemble the pipes (1) from the union (2) to the

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

NOTE

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

Figure 92

116386

75671

- Reassemble the lubrication oil exhaust pipeline (1) from

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

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SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

Figure 93

- Reassemble the starter;

properlyhold the starter (2) and tighten the fixing screws (1) to the prescribed couple.

87712

Figure 94

75673

On the left hand side:

- Assemble oil filter (1) together with bracket (for the

versions with engine oil filter not directly assembled to the exchanger); tighten the screws (3) assembling the bracket (4) including filter bearing (5). Using tool 99360076 screw up oil filt er;

- The plug and the oil filler pipe (for versions with the

engine oil filter fitted directly on the heat exchanger);

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

- Fill up engine oil.

- Install the engine on the machine (for installation

operations please apply to specific issue).

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F4GE N SERIES

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SECTION 3 - AGRICULTURAL APPLICATION

Rotary feed pump disassembly and assembly procedure

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 connections have been

disconnected.

- Accelerator cable shall be disconnected.

Figure 95

Find the top dead centre with the tool (99395097) - False injector

Figure 96

88141

Remove the rocker covers of the 1stcylinder; remove the 1 injector and place the tool (1) to set the 1stcylinder 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 th en checking that the intake and exhaust valves are both cl osed.

88140

Disassemblethestarterfromtheflywheelboxandusetool 99360330 to rotate the flyw heel.

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.

Figure 97

84071

Turn the flywheel unt il, when pushing the pin 99360616 (1), it blocks the gear (2) obtaining the TDC of the 1° cylinder.

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SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

BOSCHVE4/12FPump

Figure 98

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 99

Figure 100

75694

- From the pump side, loosen the fixing n u t s (1) withou t

removing them in order to enable moving the pump backwards usin g 99340035 extractor.

- Assemble the 99340035 extractor throughout the two

threaded ports (4, Figure 99) 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 cylin der No. 1 must be carried out.

75693

- From timing side, remove the c over (2) loosening the

screws (1) in order to have access to the union fixing nut (3) to the pump driving gear.

- Loosen the fixing nu t (3) and remove the relating

washer.

NOTE

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

P2D32N010E

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SECTION 3 - AGRICULTURAL APPLICATION

Figure 101

75694

- Assemble the pump pre-set in its housing on th e 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 u se original spare parts.

Figure 103

75721

- 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 102) including gasket and

tighten the screws (1, Figure 102).

- Disassemble the flywheel rotation/locking tool 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 en gine mounted, connect the accelerator cable, if present in the application.

Figure 102

75693

- On the timing side, throu ghout 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.

Ignition pump control and timing

Figure 104

(Demonstration)

87720

- With the injection pump inserted in relating seat and secur-

ing 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 97). 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.

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SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

Feed system bleed procedure

Power take-off disassembly and assembly procedure

Figure 105 Figure 106

76211

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

- Loosen the air bleed screw (3) on the fuel filter (1) and

operate the bleed lever for the priming pump (2) repeatedly.

- Continue executing this operation until when fuel drains

from the bleeder vent screw.

- Tigh ten the air bleed screw (3) to a torque of 7 ÷ 9 Nm.

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.

(Demonstration)

75720

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F4GE N SERIES

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Checks and inspections

SECTION 3 - AGRICULTURAL APPLICATION

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 an d 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 cylin der head, oil pan and bearing, oil filter and heat exchanger as well as relating housings.

- Th ere 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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SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

P2D32N010E

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 41

PART TWO -

ELECTRICAL EQUIPMENT

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

ELECTRICAL COMPONENT LAYOUT

Figure 107

SECTION 3 - AGRICULTURAL APPLICATION 43

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

1. Cooling liquid temperature sensor;

2. Alternator;

3. Starter;

4. (A) Engine STOP solenoid, (B) KSB electromagnet;

5. Oil pressure sensor;

6. Fuel heater (where provided for);

7. KSB Water temperature sensor;

8. Resistance for cold start up;

132105

SECTION 3 - AGRICULTURAL APPLICATION

Cooling liquid temperature sensor Starter

F4GE N SERIES

Figure 108

Figure 109

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.

Specifications:

BOSCH 3 kW - 12V

KSB Water temperature sensor

75718

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 °Cfor

<10min.)

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

Figure 110

75719

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 ºC Contact opening

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

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 45

Electromagnets assembled to feed pump

Figure 111

1 - Engine STOP solenoid;

2 - KSB Electro-magnet

75724a

Alternator

Figure 113

75725

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 112

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

Pre-post heating resistor

Figure 114

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 tension: 12 V Maximum possible air flow: 2 cc / min

(pressure 138 kPa)

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 47

PART THREE - TROUBLESHOOTING

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION

See your FPT dealer.

Drain feed system.

tery if necessary.

Clean, examine and tighten the nuts on

the battery terminals. Replace the cable

terminals and the nuts if excessively cor-

roded.

pump.

using a jet of compressed air.

Dismantle and clean the injection pump.

Remove water from tank and refuel.

Connections to battery terminals cor-

roded or loose.

Incorrect timing of injection pump. Check and correctly time the injection

Deposits or water in the fuel tank. Disconnect the hoses and clean them

No fuel in tank. Refuel.

pump.

Check the hoses to ensure that air is in

fact present and also check the fuel pump.

Eliminate the air from the in jec t ion pump

by unscrewing the cap and working the

fuel pump by hand.

No power supply. Overhaul or replace the fuel or transfer

Air bubbles in th e fuel lines or injection

pump.

Faulty starter motor. Repair or replace the starter motor.

ANOMALY POSSIBLE CAUSE REMEDY NOTE

Theenginedoesnotstart Battery flat or faulty. Check and recharge battery. Replace bat-

PrintP2D32N010 E Base - Februa

2009

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

Drain feed system.

Replace the fuel with fuel su itable for use

at low temperatures. Replace the fuel fil-

ters.

Fuel system clogged with paraffin crystals

Check or replace the injection pump. See your FPT dealer.

forming due to the use of unsuitable fuel.

K.S.B. device for cold spark advance co n-

trol operating incorrectly.

using a jet of compressed air. Dismantle

and clean the injection pump. Remove

water from fuel tank and refuel.

Irregular flow of injection pump. Adjust flow. See your FPT dealer.

Impurities or water in the fuel lines. Disconnect the hoses and clean them

Check that the hoses are not cracked or

the unions loose. Replace worn parts, re-

move the a ir from the hoses and deaerate

the injection pump and fuel filter by un-

screwing the caps and working the primer

pump by hand.

Clogged fuel filt er. Dismantle and replace if necessary.

Presence of air in the fuel and injection

system.

Adjust clearance by replacing shims.

Broken injection pump controls. Replace the faulty parts.

Abnormal clearance between camshaft

cylinder head seatings .

cams and tappets.

Burnt, corroded or chalky valves. Replace the valves, rectify or replace the

ANOMALY POSSIBLE CAUSE REMEDY NOTE

The engine does not start at low tem-

peratures

Base - Februa

2009 PrintP2D32N010 E

The engine cuts out. Idle rpm too low. Adjust with adjustment screw.

F4GE N SERIES

tensioner, check corret worching of such

SECTION 3 - AGRICULTURAL APPLICATION

device.

See your FPT dealer.

See your FPT Dealer

Replace the gasket.

Wash following the standards specified

for the type of descaling product used.

Malfunctioning thermostat. Replace the thermostat.

Fouling in coolant openingsin the cylinder

head and cylinder groups.

Water pump drive belt slack. Check and adjust the tightness of the belt. On applications provided with automatic

Coolant level too low. Top-up radiator with coolant.

a bench so that the injection is at the

specified rate.

Incorrect engine timing. Check timing and tune correctly.

Incorrect calibration of injection pump. Correctthedeliveryrateofthepumpon

Dry air cleaner blocked. Clean the air filter or replace if necessary.

Incorrect timing of injection pump. Check timing and correctly set pump.

setup; if values found do not correspond

to requirements, change variator spring.

Check or replace injection pump.

Faulty automatic advance variator Check operation on injection pump test

K.S.B. automatic cold advance device mal-

functioning.

tor.

Excessive piston wear. Check or replace injection pump.

Incorrect calibration of speed regulator. Check and correctly calibrate the regula-

ANOMALY POSSIBLE CAUSE REMEDY NOTE

Theengineoverheats Faulty water pump. Check the unit and replace if necessary.

PrintP2D32N010 E Base - Februa

Engine operation is irregular and lacks

power

2009

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

See your FPT dealer.

Clean the nozzles of the atomisers using

the appropriate tools and completely

overhaul the injectors.

Carefully clean the system and refuel. If necessary drain feed system.

Check and correct play

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.

Adjust the tie-rods so that the command

lever can be moved to the full delivery

position.

See your FPT dealer.

place those that are seriously dented.

jection occurs at the specified angle.

Partial blockage of nozzles or faulty oper-

ation of injectors.

Impurities or water in the fuel and injec-

tion system.

Incorrect play between camshaft cams

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-

Tie rods between accelerator pedal and

regulation lever incorrectly adjusted.

Fuel lines blocked. Dismantle the hoses, clean them and re-

Incorrect set-up of injection pump. Correct the set-up of the pumpso that in-

ANOMALY POSSIBLE CAUSE REMEDY NOTE

Engine operation is irregular and lacks

power

Base - Februa

2009 PrintP2D32N010 E

Engine running with abnormal knocking Faulty operation of injectors. Replace all injectors.

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION

See your FPT dealer.

Rectify the pins of the crankshaft and in-

stall smaller bearings. Replace the thrust

play on one or more main or rod bearings

half-rings.

or excessive play on shoulders.

all the screws to the specified torque.

Crankshaft unbalanced. Check alignment of crankshaft.

Loosening of screws securing flywheel. Replace the loosened screws and tighten

Replace the piston journal and/or the pis-

ton and rod bushing.

Replace with new bushings.

and tappets and c heck that there are no

broken springs, that there is no excessive

play between t he valve stems and the

valve guides, tappets and seati ngs.

in accordance with the data given in the

calibration table.

Check operation by a tester and adjust

correctly as described in the manual.

Correct the set-up.

Misalignment of rods. Replace the rods.

Noise from piston journals due to excess-

ive play of piston h u bs and in the rod

bushing.

Loose bushings in the rod seatings.

Noisy timing. Adjust the play between camshaft cams

Excessive maximum pump output. Disconnect the pump and adjust delivery

K.S.B.device out of calibration or malfunc-

tioning.

There is an excessive delay on the injec-

tion pump.

ANOMALY POSSIBLE CAUSE REMEDY NOTE

Engine running with abnormal knocking Knocking of crankshaft causing excessive

PrintP2D32N010 E Base - Februa

The engine smokes abnormally. Black or

dark grey smoke.

2009

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

Correct the set-up.

Replace the injectors with a series of new

injectors or clean and rectify the original

ones using suitable equipment.

The injection pump has an excessive ad-

vance.

Theholesintheatomisers(orsomeof

them) are partially or entirely blocked.

Overhaul the engine or limit the interven-

tions to the relative parts.

Air cleaner blocked or deteriorated. Clean or replace the filter element.

Loss of compression in the engine due to:

stuck or worn flexible rings;

Replace or calibrate the injectors.

Check conditions of the end or unions

and where necessary replace the hoses.

worn cylinder liners;

valves deteriorated or badly adjusted.

Unsuitable injectors, different types of in-

jectors or incorrectly calibrated.

Injection hoses with an unsuitable internal

diameter, end of hoses pinched due to re-

peated blocking.

Excessive delay in injection pump. Correct the set-up of the pump. See your Iveco dealer.

Check or replace injection pump. See your Iveco dealer.

K.S.B. automatic cold advance device mal-

Overhaul the engine.

functioning.

Faulty injector. Replace the injector.

Leaking of oil from the piston rings caused

by glued or worn rings or wearing of cylin-

der liner walls.

Recondition the cylinder head.

Engine oil passing through the intake

Replace the thermostat.

guides-valves following wearing of guides

or valve stems.

Engine too c old (th ermostat blocked or

inefficient).

ANOMALY POSSIBLE CAUSE REMEDY NOTE

The engine smokes abnormally. Black or

dark grey smoke.

Base - Februa

2009 PrintP2D32N010 E

Blue, grey-blue, grey smoke tending to

white.

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 55

PART FOUR - MAINTENANCE PLANNING

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 57

MAINTENANCE SCHEDULE

On purpose to guarantee the right engine use please follow the below indicated maintenance schedule.

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.

Maintenance operations

Visualcheckofengine .............................................

Checkpresenceofwaterinfuelfilterorpre-filter.........................

Checkofbeltwearstatus ...........................................

Checkandsettingoftappetclearance..................................

Oil and filter replacement .

Fuelfilterandprefilterreplacement....................................

Beltreplacement ..................................................

Frequency (hours)

Daily

3600

600

1800

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

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 controls

Engine oil level check

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

Thecheckcanbemadeusingthespeciallyprovidedflexible rod (1).

Figure 115

(Demonstration)

MAX

MIN

Figure 116

132106

To provide filling, operate through the upper top (1) or through the lateral top (2). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier”.

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

75748

Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum l evel.

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.

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.

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 59

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 c lean, 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 coolant should be checked every year before the winter, assessingthe density and it should be changed every two years.

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.

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.

There is a bleed screw at the base of the fuel filter for draining any water in the filter.

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.

SECTION 3 - AGRICULTURAL APPLICATION

F4GE N SERIES

Check of drive belt tensioning

There is an automatic tensioner which corrects the belt tension.

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.

Check and setting of tappet clearance

Figure 117

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 -

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

Oil motor and filter replacement

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.

Remove the rocker covers of the cylinder; remove the injector and 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.

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.

- 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.

F4GE N SERIES

SECTION 3 - AGRICULTURAL APPLICATION 61

- 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.

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.

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.

Fuel filter replacement

During this operation don’t smoke and don’t use free flames.

Avoid to breathe the vapors coming from filter.

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

According to the applicationsthe 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 re-

lease 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.

- 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.

SECTION 3 - AGRICULTURAL APPLICATION

Alternator belt replacement

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.

Figure 118

F4GE N SERIES

88544

- By means of a square wrench of proper size act on point

A, indi cated on the figure, of the automatic belt tightener (1) and release the pressure.

- Remove the control belt (2) from the driven and inter-

mediate pulleys.

- 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.

F4GE N SERIES

ase-February2009

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

SECTION 4

Overhaul and technical specifications

GENERAL SPECIFICATIONS 3.................

CLEARANCE DATA 4.......................

TABLE OF PRE-DELIVERY VALUES FOR BOSCH

INJECTION PUMPS VE 4/12 F 10..............

ENGINE OVERHAUL 11.......................

ENGINE REMOVAL AT THE BENCH 11..........

REPAIR OPERATIONS 12......................

CYLINDER UNIT 12..........................

- Checks and measurements 12...............

Page

- Checking head supporting surface on cylinder unit 13

TIMING SYSTEM 14..........................

- Camshaft 14.............................

- Checking cam lift and pin alignment 14........

BUSHES 14.................................

- Bush replacement 16......................

- Tappets 16..............................

- Fitting tappets — camshaft 16................

OUTPUT SHAFT 17..........................

- Measuring journals and crankpins 17..........

- 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....

PrintP2D32N010E B

ase-February2009Print

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4GE N SERIES

- Piston pins 22............................

- Conditions for proper pin-piston coupling 22....

- Split rings 22.............................

- Connecting rods 23.......................

- Bushes 24...............................

- Fitting connecting rod-piston assembly 24......

- Connectin g rod-piston coupling 24............

- Fitting split rings 24........................

- Fitting connecting rod-piston assembly into cylinder

barrels 25...............................

- Finding crankpin clearance 25................

Page

CYLINDER HEAD 27..........................

- Removing the valves 27....................

- Checking cylinder head wet seal 28...........

- Checking cylinder head supporting surface 28...

VALVES 29..................................

- Removing carbon deposits, checking and grinding

valves 29................................

- Checking clearance between valve stem and valve

guide and valve centering 29.................

VALVE GUIDE 30............................

VALVE SEATS 30.............................

- Regrinding — replacing the valve seats 30.......

VALVE SPRINGS 31...........................

FITTING CYLINDER HEAD 31..................

- Refitting the cylinder head 32................

- Checking piston protrusion 26...............

TIGHTENING TORQUE 33....................

P2D32N010E

F4GE N SERIES

GENERAL SPECIFICATIONS

Type 4CYLINDERS

Cycle Four-stroke diesel engine

Power See properties described in Section 3

Injection Direct

Number of cylinders 4

∅

Bore mm 104

Stroke mm 132

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 3

+++..=

Total displacement cm

TIMING

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

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

Checking timing

FUEL FEED

Injection Type: Bosch

4485

18.5

29.5

67 35

0.25 to 0.05

0.50 to 0.05

VE 4/12 F

Nozzle type DSLA 145 P

Injection sequence 1-3-4-2

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

CLEARANCE DATA

Type 4CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅

Cylinder barrels ∅1

104.000 to 104.024

F4GE N SERIES

0.4

∅

Spare pistons type: Size X Outside diameter ∅ 1 Pin housing ∅ 2

55.9

103.714 to 103.732

38.010 to 38.016

Piston — cylinder barrels 0.268 to 0.310

Piston diameter ∅ 1 0.4

Piston protrusion X 0.28 to 0.52

∅

Piston pin ∅ 3 37.994 to 38.000

Piston pin — pin housing 0.010 to 0.022

iveco F4GE9484F, F4GE9454 Repair manual

Specifications and Main Features

Frequently Asked Questions

User Manual